Beruflich Dokumente
Kultur Dokumente
CONTENTS
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1.2 Main dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2. INSTALLING THE BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2.1 Boiler location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2.2 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 3. ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4. HYDRAULIC CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 Dimensional information required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 Important recommendations for connecting the boiler to the heating circuit 4.3 Filling the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 Sludge removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 5 5 6 6
5. CHIMNEY CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 5.1 Flue size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 5.2 Connecting to the flue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 6. FUEL-OIL OR GAS CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 7. ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 8. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 8.1 Sweeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 8.2 Cleaning the casing material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 8.3 Precautions required in the case of long boiler stops (one or more years) . . . . . . . . . . . . . . . . . . . . . 11 8.4 Precautions required if the heating is stopped when there is a risk of freezing . . . . . . . . . . . . . . . . . . 11 9. BURNER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 10. SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 10.1 Water level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 10.2 Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 11. IDENTIFICATION PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 12. SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CONFORMITY /
MARKING
It will be marketed in the following EEC member states : FR - DE - BE - LU - GB - IR - ES - PT - DK SE - AT - CH - GR - NL with a gas burner of the associated category.
This product complies with the requirements of the following European directives and standards : - 90.396 CEE Gas device Directive Relevant standard : EN 303.1 / EN 303.2 / EN 304. - 73.23 CEE Low voltage Directive Relevant standard : EN 60.335.1. - 89.336 CEE Electromagnetic Compatibility Directive Relevant standard : EN 50.081.1 / EN 50.082.1 / EN 55.014
Warning : The boiler shall be assembled and installed by a qualified professional only. Strict compliance with these assembly, installation and maintenance instructions is a precondition for the correct operation of the boiler.
1. GENERAL
The boilers of the GTE 500 range are pressurised hot water boilers designed for connecting to a flue pipe which require a separate automatic fuel-oil or gas burner. The useful power of GTE 500 boilers is between 348 and 1450 kW.
Models available :
GTE 500 Boiler with standard control panel designed to be connected to the electrical cabinet.
30
I 0
I 0
8555N039
GTE 500 K Boiler with K control panel, which may be fitted with an optional SV-matic control unit for heating only or heating and domestic hot water production or an MB2 domestic hot water priority and regulation module. The GTE 500 K model may also be used as the "end" boiler in cascaded installations with 2 to 10 boilers, one of which is fitted with a DIEMATIC-m Delta control panel. GTE 500 DIEMATIC-m Delta Boiler which is factory fitted with an electronic DIEMATIC-m Delta control unit. GTE 500 DIEMATIC-m Delta boilers are also used as "master" boilers in cascaded installations with 2 to 10 boilers. The other boilers (1-9) must necessarily be fitted with a K control panel.
30
I 0
8555N040
30
I 0
8555N041
30 - 85 C 110 C
GTE GTE GTE GTE GTE GTE GTE GTE GTE GTE GTE GTE GTE GTE GTE GTE GTE GTE GTE 507 508 509 510 511 512 513 514 515 516 517 518 519 520 521 522 523 524 525 kW 348 to 406 kW 387 to 451 7 l 389 406 to 464 451 to 516 8 427 22 9,9 5.5 464 to 522 516 to 580 9 465 522 to 580 580 to 644 10 503 580 to 638 644 to 709 11 541 638 to 696 709 to 773 12 579 696 to 754 773 to 838 13 617 754 to 812 838 to 902 14 655 812 to 870 902 to 967 15 693 870 to 928 928 to 986 986 1044 1102 1160 1218 1276 1334 1392 to to to to to to to to 1044 1102 1160 1218 1276 1334 1392 1450
967 1031 1096 1160 1224 1289 1353 1418 1482 1547 to to to to to to to to to to 1031 1096 1160 1224 1289 1353 1418 1482 1547 1611 16 731 17 769 18 807 19 845 20 905 21 943 22 981 23 24 25
28.4 34.8 42 50 57.6 67.2 77.6 26.2 30.2 35.8 41.4 48.0 53.6 59.2 64.8 71.6 78.4 12.6 15.5 18.7 22.4 25.8 30 34.7 11.7 13.5 14.0 18.5 21.5 24 26.5 29 32 35 7.1 8.7 1.9 10.5 12.5 14.4 16.8 19.4 6.5 2 2.1 2.2 2.3 2.4 2.5 7.6 2.6 9.0 2.7 10.4 12.0 13.4 14.8 16.2 17.9 19.6 2.85 3 3.1 3.2 3.3 3.4 3.5
Pressure in the furnace for nozzle pressure = 0 Flue gas temperature minus room temperature (1)(3)
1.75 1.8
K <190 <190 <190 <190 <190 <190 <190 <190 <190 <190 <190 <190 <190 <190 <190 <190 <190 <190 <190 700 730 614 694 817 770 810 614 694 928 850 890 920 970 1000 1070 1150 1220 1300 1370 1450 1520 1600 1670 1750 1820 1900 1970 1040 1120 1200 1280 1360 1440 1520 1590 1670 1750 1830 1910 1990 2070
Mass flue gas Fuel oil kg/h 620 flow rate (1) (2) Gas kg/h 650 Combustion chamber : - Recorded Diameter mm 614 - Equivalent Diameter mm 694 - Depth mm 706 - Volume
614 614 614 614 614 614 614 614 614 614 614 614 614 614 614 614 694 694 694 694 694 694 694 694 694 694 694 694 694 694 694 694 1039 1150 1261 1372 1483 1594 1705 1816 1927 2038 2189 2300 2411 2522 2633 2744
m3 0.28 0.32 0.36 0.40 0.45 0.49 0.53 0.57 0.61 0.65 0.70 0.74 0.78 0.84 0.88 0.92 0.96 1.00 1.05
Loss on stoppage*T=30K % 0.11 0.10 0.09 0.09 0.08 0.08 0.08 0.08 0.07 0.07 0.07 0.07 0.07 0.07 0.06 0.06 0.06 0.06 0.06 Shipped weight kg 1852 2046 2237 2412 2601 2810 3000 3171 3364 3561 3756 3955 4124 4343 4538 4734 4930 5107 5297
* Loss on stoppage : total heat emission when the burner is off as a percentage of the nominal input power when the difference between the mean boiler temperature and the room temperature is 30 K. (1) Nominal operation (top boiler power) (2) CO2= 13.1 to 13.5% with fuel oil and 9.5% with natural gas. (3) Boiler temperature : 80C Room temperature : 20C
GTE 500
208
1566
370
496
420
543
3/4" H G B L M 610
1172
3
513 514 515 516 517 518 519 520 521 522 523 524 525 256 159(1) 400 370 -8 4 265 355 130 299 355 130 25 13 -36 -24 269 355 130 370 650 400 400 * 650 -35 -23 324 355 130 159(1) 159(1) 159(1) 159 * 650 -14 -2 269 355 130 350 37 49 275 355 130 355 130 355 130 355 130 355 130 259 324 269 321 10 -19 -18 3 -2 -31 -30 -9 150 150 370 400 400 400 400 217 188 189 210 236 257 208 209 230 231 159 * 980 -13 -1 324 355 130 252 159 * 980 8 20 249 355 130 253 159 * 980 9 21 303 355 130
GTE Boiler
507
508
509
510
511
512
A (mm)
897 1008 1119 1230 1341 1452 1563 1674 1785 1896 2007 2118 2229 2380 2491 2602 2713 2824 2935
B (mm)
967 1078 1078 1300 1300 1522 1522 1744 1744 1966 1966 2188 2188 2450 2450 2672 2672 2894 2894
C (mm)
1488 1488 1488 1488 1488 1488 1488 1488 1488 1488 1488 1504 1504 1504 1504 1504 1504 1504 1504
D (mm)
240
211
212
233
234
255
E (weld)
139.7 139.7 139.7 139.7 139.7 139.7 139.7 139.7 139.7 139.7 139.7
F (mm)
300
300
300
350
350
350
G (mm)
H (mm)
21
-8
-7
14
15
36
K** (mm)
33
26
27
48
L (mm)
1305 1445 1555 1645 1755 1845 1955 2105 2245 2355 2445 2555 2645 2845 2955 3045 3155 3245 3355
M (mm)
248
265
319
243
297
221
355 130
355 130
355 130
355 130
355 130
Plain plate, requires cutting. Maximum cut-out 500 x 700 mm G = Length required for clearing the water distributing tube ** Dimension representing the end of the 100 mm long chimney connection Nota : with models 521, 522, 523, 524 and 525, a plain plate which must be cut out is supplied without the 100 mm chimney connection.
DIEMATIC + K 175 175 175 175 175 175 175 175 175 175 175 175 175 175 175 175 175 175 175 R 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 (mm) Standard DIEMATIC + K 1760 1760 1760 1760 1760 1760 1760 1760 1760 1760 1760 1760 1760 1760 1760 1760 1760 1760 1760 S (mm) Standard 1670 1670 1670 1670 1670 1670 1670 1670 1670 1670 1670 1670 1670 1670 1670 1670 1670 1670 1670
T (mm)
706
817
928 1039 1150 1261 1372 1483 1594 1705 1816 1927 2038 2189 2300 2411 2522 2633 2744
U (mm)
1355.5 1466.5 1577.5 1688.5 1799.5 1910.5 2021.5 2132.5 2243.5 2354.5 2465.5 2576.5 2687.5 2838.5 2949.5 3060.5 3171.5 3282.5 3393.5
Boiler body
0,85 m mini
0,195 m
Air outlet
Air inlet
1 300 2 D mini
(1)
8259N004A
1,566 m
0,2
81
M C A L
1,1
72
m
B A'
8555N046
order to facilitate subsequent work on the boiler (replacing the water distributing tube etc.) use a flanged connection from the boiler to the system, making sure you comply with minimum clearance dimension D.
If A = 1.2 m (door opening side), A' = 0.5 m If A = 0.5 m, A' = 1.2 m (door opening side) : adapt the dimensions on the basis of the dimensions of the burner when the door is open. B = 1.5 m : adapt the dimensions on the basis of the dimensions of the burner.
516 2355 269 436 136 517 2445 321 656 356 518 2555 265 656 356 519 2645 299 656 356 520 2845 269 936 636 521 2955 324 936 636 522 3045 269 936 636 523 3155 324 1266 966 524 3245 249 1266 966 525 3355 303 1266 966
513
514
2.2 Ventilation
The ventilation shall comply with applicable regulations, particularly codes of practice. Please note : remember that boilers installed in or close to rooms in which the atmosphere is polluted with chlorine or fluorine compounds may be subject to high corrosion. For example : hairdressing salons, industrial premises (solvents), cooling equipment, etc. Boiler installed in such locations shall not be covered by the warranty.
3. ASSEMBLY
See the separate yellow booklet in the middle of these instructions.
4. HYDRAULIC CONNECTIONS
4.1 Dimensional information required
D
Heating outlet : - 7 to 17 sections : 139.7 - 5 - 18 to 25 sections : 159 -6 - For CHINA : 7 to 21 sections : 139.7 - 5 requires welding
Heating return : - 7 to 17 sections : 139.7 - 5 - 18 to 25 sections : 159 -6 - For CHINA : 7 to 21 sections : 139.7 - 5 requires welding
H*
200 mm
519 1504 257 13
1080mm
* dimension without connection (see figure on page 4, connection 1 or 2)
520 1504 208 -36 521 1504 209 -35 522 1504 230 -14 523 1504 231 -13 524 1504 252 8 525 1504 253 9
8555N047
513
514
4.2 Important recommendations for connecting the boiler to the heating circuit
The installation shall be made in keeping with applicable regulations and codes of practice and the recommendations contained in these instructions. The safety valve shall be connected to the boiler without any valve or stop valve between the boiler and the safety valve. The heating system shall be designed and installed in a way as to prevent the water from the heating circuit and any substances added to it from flowing back into the drinking water circuit located before it. The installation shall not be directly connected to the drinking water system.
58
6m
150mm
2 tapped sludge removal hole
8555N048A
5. CHIMNEY CONNECTION
The high-performance features of modern boilers and their use in specific conditions as a result of the advance in burner technology (e.g. first-stage or low modulation range operation) lead to very low flue gas temperatures (less than 160C). This requires : - the use of flue pipes designed to enable the flow of condensates which may result from such operating modes, in order to prevent damage to the chimney; - the installation of a draining tee at the foot of the chimney. The use of a draught moderator is recommended as well.
F chimney connection
58
6m
58
6m
8555N049
GTE
507
508 300 4
509 300 5
510 350 26
511 350 27
512 350 48
513 350 49
514 400 10
517 400 3
518 400 4
519 400 25
F(mm)300 K (mm) 33
* Dimension representing the end of the 100 mm long chimney connection. Note : with models 521, 522, 523, 524 and 525 a plain plate which requires cutting out is supplied without the 100 mm long chimney connection.
7. ELECTRICAL CONNECTIONS
Refer to the instructions supplied with the control panel of the boiler.
8. MAINTENANCE
The operations described below shall only be performed with the boiler and power supply off.
8.1 Sweeping
The boiler will only operate efficiently if the exchange surfaces are kept clean. The boiler should be cleaned as soon as required and as the chimney, at least once a year or more, depending upon applicable regulations and specific needs.
3 3
8555N173A
8555N172A
- Turn off the power to the boiler. - Remove the upper front panel. - Remove the retaining upper front crosspiece and then the lower left and right-hand front panels. - Remove the lower front panel.
- Unfasten the wing nuts and remove the four sweeping doors.
8555N174
8555N168
- Remove the baffle plates from the upper flue ways. - Carefully sweep the four flue ways with the brush supplied for that purpose. - Brush the baffle plates as well. - If possible, use a vacuum cleaner.
- Remove the left and right-hand casing covers. - Remove the top insulating material.
3 2 1 19
8555N170
8555N169
- Unfasten the nuts up to the stop. - Push in the handles of the sweeping covers. - Remove the sweeping covers.
- Brush the vertical plates. - Put back the sweeping covers, insulating material and casing covers by reversing the procedure above. Note : chemical sweeping is recommended for such boilers. - Put the baffle plates back in place. Interlock them with each other while fitting them into the flue ways. - Close the upper sweeping doors.
9
19
8555N180 8555N175
- Unscrew the eight closing nuts and open the furnace door.
These screws must not be unfastened in any event.
- Brush out the inside of the furnace. - Clean the soot accumulated in the furnace and lower flue ways with a vacuum cleaner. - Close the lower sweeping doors. - Put back the front casing panels by reversing the removal procedure. 10
1 2
8555N171
8555N176
- Remove the lower rear panels. - Remove the lower rear crosspiece. - Remove the lower insulating material on the rear.
- Unfasten the wing nuts and remove the lower left and right-hand sweeping doors. - Remove any soot deposit with a scraper or a vacuum cleaner. - Open the lower sweeping cover of the flue gas box (two H 10 nuts + 10 washers). - Remove the soot. - Put back the sweeping cover and doors. - Put back the lower insulating material, the crosspiece and panels by reversing the removal procedure.
10
8.4 Precautions required if the heating is stopped when there is a risk of freezing
We recommend the use of a correctly dosed antifreeze agent to prevent to the heating circuit from freezing. If this cannot be done, drain the system completely.
9. BURNER MAINTENANCE
Refer to the instructions supplied with the burner.
10.2 Draining
We advise you against draining the system unless it is absolutely necessary.
11
XX - XX Date of manufacture
F 67110 NIEDERBRONN
8555N156
12
8555-4017A
Spare parts
Note : while ordering spare parts, do not forget to provide the code number given in the list opposite the part reference.
BOILER BODY
25 7 23 21 14 37 30a 38 24 15 21 2a 3 26 49 21 34 35 39 4 46 39 27 17 30 39 46 29 11
13
16
8 37 41 39 43 42 38 44 10 12 46 40 21 19 32 47 48 6
36
31 28
52 5 9 18 15
Visserie porte foyre Schraubensatz fr Brennertr Screws for burner door
46 40
22
20
45 62 61 63
Visserie porte ramonage Schraubenset fr Reinigungstr Screws set for cleaning door
33
SONDE A PLONGEUR
60
201
200
8555N192
DE DIETRICH THERMIQUE BP 30 57, rue de la Gare F-67580 MERTZWILLER Tl. : + 33 3 88 80 27 00 Fax : + 33 3 88 80 27 99 N IRC : 347 555 559 RCS STRASBOURG Spare Part Centre 4, rue d'Oberbronn F-67110 REICHSHOFFEN Tel. : + 33 3 88 80 26 50 Fax : + 33 3 88 80 26 98
INSULATION
70
71
8555N198
2/6
CASING
116 116 112 92 94 86 102 93 113 85 110 104 84 100 99 84 100 82 108 114 88 90 96 104 97 88 98 105 103
Visserie pices communes Schraubensatz Screws set main parts
114
106 83 101
80
87
Visserie panneau latral avant Schrauben vordere Seitenplatte Screws front side panel
110 81
Visserie panneau latral arrire Schrauben fr seitliche Hinterplatte Screws for rear side panel
80 115
103 107
89 89 95 91
111
8555N191
3/6
4/6
5/6
6/6
06/99
DE DIETRICH HEIZTECHNIK Rheiner Strasse 151 D-48282 EMSDETTEN www.dedietrich.com info@dedietrich.de Verkaufsbro Emsdetten : Tel. 0 25 72 / 23-179 Fax 0 25 72 / 23-451 Regionalverkaufsbro Berlin : Tel. 030 / 5 65 01-391 Fax 030 / 5 65 01-465 Verkaufsbro Neunkirchen : Tel. 0 68 21 / 98 05-0 Fax 0 68 21 / 98 05-31 Regionalverkaufsbro Erding : Tel. 0 81 22 / 9 93 38-0 Fax 0 81 22 / 9 93 38-19
DE DIETRICH SPINOFF - CENTER Romeinsestraat 10 B-3001 LEUVEN / LOUVAIN Tl. : 016 39 56 40 Fax : 016 39 56 49 www.dedietrich.com DE DIETRICH HEIZTECHNIK Am Concorde Park 1 - B 4 / 28 A-2320 SCHWECHAT / WIEN Tl. : 01 / 706 40 60-0 Fax : 01 / 706 40 60-99 www.dedietrich.com office@dedietrich.at Pour le LUXEMBOURG : les produits sont commercialiss par la socit NEUBERG In LUXEMBURG werden die Produkte durch die Fa. NEUBERG vertrieben NEUBERG SA 39 rue Jacques Stas L - 2010 LUXEMBOURG Tl. : 02 401 401 Fax : 02 402 120 www.dedietrich.com
DE DIETRICH THERMIQUE S.A.S. au capital de 21 686 370 BP 30 57, rue de la Gare F-67580 MERTZWILLER Tl. : (+33) 03 88 80 27 00 Fax : (+33) 03 88 80 27 99 www.dedietrich.com N IRC : 347 555 559 RCS STRASBOURG
In the interest of customers, DE DIETRICH THERMIQUE are continuously endeavouring to make improvements in product quality. All the specifications stated in this document are therefore subject to change without notice.
AD014J
ENGLISH
Packaging :
Before starting to assemble the boiler, refer to the table below to check if you have received all the packages required. G Refer to the applicable price list for any optional features used.
7 1 1 2 3 1 1 FA 42 FA 42 FA 61 1 1
8 1 1 3 3 1 1 FA 43 FA 43 FA 62 1 1
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 1 1 4 3 1 1 FA 44 FA 44 FA 63 1 1 1 1 5 3 1 1 FA 45 FA 45 FA 64 1 1 1 1 6 3 1 1 FA 46 FA 46 FA 65 1 1 1 1 7 3 1 1 1 1 8 3 1 1 1 1 1 1 1 1 9 10 11 3 3 3 1 1 1 1 1 1 1 1 12 3 1 1 1 1 13 3 1 1 1 1 14 3 1 1 1 1 14 4 1 1 1 1 15 4 1 1 FA 56 FA 87 FA 75 1 1 1 16 4 1 1 1 1 17 4 1 1 1 1 18 4 1 1 1 1 19 4 1 1
Plain furnace plate Flue gas connection plate with opening Plain flue gas connection plate Flue gas box Distributing tube fitting *
FA FA FA FA 57 58 59 60
FA FA FA FA 76 77 78 79 1 1 1 1
1 1 1
1 1 1
1 1 1
1 1 1
1 1 1
* The distributing tube fitting for GTE 500 boilers with 15 -19 sections is included in the accessory package. ** The diaphragm fitting for GTE 500 boilers with 13 and 14 sections is included in the additional accessory kit package.
G Baffle
plates
Number of sections Package CM 22 Package CM 23 7 1 8 1 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2
Technical documents
Number of sections 1 Package (Export) 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
8555 -7165 8555 -7166 8555 -7167 8555 -7168 8555 -7169 8555 -7170 8555 -7171 8555 -7172 8555 -7173 8555 -7174 8555 -7175 8555 -7176 8555 -7177 8555 -7178 8555 -7179 8555-7180 8555-7181 8555-7182 8555-7183 8555 -7317 8555 -7318 8555 7319 8555 -7320 8555 -7321 8555 -7322 8555 -7323 8555 -7324 8555 -7325 8555 -7326 8555 -7327 8555 -7328 8555 -7329 8555 -7330 8555 -7331
1 Package (China)
m1
04/07/03 - FM-8555-4209A
Casing fittings
Number of sections Package FA 50 Package FA 60 Package FA 70 Package FA 80 Package FA 90 Package FA 10 Package FA 11 7 1 1 1 1 1 8 1 9 10 11 12 13 14 15 16 17 18 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 1 1 2 2 2 1 1 19 20 21 22 23 24 25 1 1 1 2 1 1 1 3 3 2 2 1 1 1 1 2 2 1 1 1 1 3 1 1 3 1
Control panel
Number of sections Package FA 30 Package FA 20 Package FA 10 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 1
* Refer to the applicable price list for the other optional features (control units etc.) which may be used with these boilers. m2
Tools required :
- JD-TE or JD-TE Plus assembly tool (+ extension for GT 522 or larger) - Flat screwdriver - No. 2 Pozidriv screwdriver - 10, 13, 17 and 19 mm spanners
G 2 mm tubular box spanner 27 mm tubular box spanner electric screwdriver + No. 2 Philips bit Stanley knife Silicone filler (supplied)
If the boiler is supplied with an assembled body, start assembly from figure 29. Assemble the boiler body from the rear to the front :
assemble the rear section, assemble all the normal intermediate sections, assemble all the special intermediate sections, assemble the front section.
104
Section type : Rear
111
151
104
Normal Intermediate
Special Intermediate
Front
8228-0004
GTE 507 GTE 508 GTE 509 GTE 510 GTE 511 GTE 512 GTE 513 GTE 514 GTE 515 GTE 516 GTE 517 GTE 518 GTE 519 GTE 520 GTE 521 GTE 522 GTE 523 GTE 524 GTE 525 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
8228-0001
2 3 4 5 6 7 8 9 10 11 12 13 14 14 15 16 17 18 19
m3
8228-0002
3 3 3 3 3 3 3 3 3 3 3 3 3 4 4 4 4 4 4
8228-0003
8259N003
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1 Boilers with
7, 8, 10, 12, 14, 16, 18, 20, 22 and 24 sections TOP BOTTOM
D E S S U S O B N E
Boilers with 9, 11, 13, 15, 17, 19, 21, 23 and 25 sections
S S E D
G Place the frame on the floor, taking care to note the TOP and FRONT positions. G Fit the fastening brackets as shown, depending on the type of boiler (one 12x40 screw, 19 mm spanner).
DE SS US N BE -O OP -T
P O T
T FRONORN V NT AVA
FRONT
VORN AVANT
TOP BOTTOM
S O B N E U
8555N001
DE SS US N BE -O OP -T
P O T
FRONTN
VOR AVANT
19
8555N042
G Establish the location of the frame on the basis of the opening direction of the furnace door and the length of the burner. Leave enough clearance at the rear of the boiler for water connections (see 4.1 of the instructions) and the distributing tube (see 2 of the instructions and fig. 23 in this booklet). G Fit the rear section on the frame, behind the fastening brackets (see detailed drawing) and prop it up. G Insert the lower assembly rods in the holes of the rear section and the fastening brackets of the frame, in order to position the rear section correctly according to the frame.
8555N076
8555N005 8555N002
G Clean all the openings in the section with a brush. Remove any deposit on the bottom of the section.
G Carefully insert the thermocord in the grooves of the section and retain it in place with a few drops of silicone filler (every 30 cm approximately). Note : do not pull on the seal while inserting it. Otherwise, you may stretch it and reduce its thickness.
m4
7
Rear section
8555N003
G Clean the bores and nipples with diluent. Remove any traces of rustprotective paint so that the surface is per fectly smooth. Coat with the lubricant supplied with the sections.
Intermediate section
8555N005A
8555N004
G Place the first normal intermediate section, making sure that it is turned in the right direction, i.e. with the flattening groove against the thermocord. G For safety, insert a lateral assembly rod (supplied) in the holes of the two sections. G Push the section gently and simultaneously onto both nipples of the rear section with a hammer and a piece of wood positioned in line with the bores.
A R R I R
A R R I R E D E S S U S N E B O P O -T T N VA A
E
D E S S U S N E B O P O T T N A V A
8555N007
8555N006
G Assemble the remaining intermediate sections one by one, to the procedure stated in figures 3, 4, 5, 6, 7 and 8. First assemble the normal intermediate sections, then the special ones (see page 3 of this booklet). Leave the assembly tool in place.
m5
G Put the assembly tool in position. Tighten gradually so as to bring together the upper and lower connections evenly and simultaneously.
10
G Trim off any projecting ends of the thermocords the sweeping covers.
8555N008
11
12
Fitting the upper and lower assembly rods
REAR
FRONT
2mm 2mm
2mm
8555N090 8555N009
G On the lower assembly rods, fit the following at each end in the given order : an expansion spring, a washer and a nut (the holes of the front lugs must be aligned with the holes of the frame brackets as the assembly rods are used to make the boiler body integral with the frame). G Stop tightening as soon as the gap between the spring spires is equal to about 2 mm.
G Put in place the upper assembly rods in the two front and rear lugs. G Mount the two crosspieces (supplied in package FA5 / FA6) with their bends turned backwards and fasten them to the rods with an expansion spring, a nut and a washer. G Remove the assembly tool.
m6
G The side assembly rods must be assembled from the rear to the front. G The rods must be inserted in the holes stated in the diagrams (the lugs of the sections in which the assembly rods are to be inserted have two holes). Rear Front
G Place the expansion spring and washer on the rear of each rod. Stop tightening the nuts as soon as the gap between the spires of the springs is about 1 mm.
C A
lg.420 mm
lg.520 mm
B
1 mm
GTE 507
C A
lg.420 mm lg.520 mm
B
Front Front
E A
lg.420 mm 420 mm
C
385 mm lg.385 mm
lg.385 mm 385 mm
1 mm
C
lg.385 mm
GTE 508
E A
lg.420 mm 420 mm
C
385 mm lg.385 mm
D
Rear Front
1 mm
lg.300 mm 300 mm
C
420 mm lg.420 mm
lg.520 mm 520 mm
GTE 509
1 mm
E A
lg.300mm 300 mm
C
lg.420 mm 420 mm
520 mm lg.520 mm
8555N115A
m7
Rear
Front
A
E
lg.420 mm
C
lg.420 mm
lg.520 mm
1 mm
GTE 510
E
lg.420 mm
C
lg.420 mm
lg.520 mm
Rear
Front
lg.520 mm
C
lg.420 mm
lg.520 mm
1 mm
GTE 511
E
lg.520 mm
C
lg.420 mm
lg.520 mm
Rear
Front
D
1 mm
C A
lg.420 mm
D
lg.420 mm
lg.520 mm
lg.300 mm
GTE 512
C A
lg.420 mm
D
lg.420 mm
C lg.520 mm
1 mm
E A
lg.300 mm
8555N116A
m8
Rear
Front
C A
lg.300 mm
lg.520 mm
lg.520 mm lg.420 mm
GTE 513
C A
lg.300 mm lg.520 mm lg.520 mm lg.420 mm 1 mm
A
B
Rear
Front
B
B
C A
lg.420 mm
lg.520 mm
lg.520 mm lg.420 mm
C
1 mm lg.520 mm
GTE 514
C A
lg.420 mm lg.520 mm
lg.420 mm
Rear
Front
C A
lg.520 mm
lg.520 mm
lg.520 mm lg.420 mm
D
1 mm
GTE 515
A C
lg.520 mm lg.520 mm lg.520 mm lg.420 mm
8555N117A
m9
Rear
Front
lg.300 mm
E D
lg.420 mm
lg.520 mm
C
lg.420 mm
lg.520 mm
GTE 516
E
lg.300 mm
B
C
lg.520 mm
lg.520 mm
lg.420 mm
lg.420 mm
1 mm
Rear Front
C
B
lg.420 mm
C
lg.420 mm
lg.520 mm
C
lg.420 mm
lg.520 mm
GTE 517
E
lg.420 mm
C
lg.420 mm
lg.520 mm
C
lg.420 mm
lg.520 mm
D
1 mm
Rear Front
lg.520 mm
C
lg.420 mm
lg.520 mm
C
lg.420 mm
lg.520 mm
B
1 mm
E A
GTE 518
E
lg.520 mm
C
lg.420 mm
lg.520 mm
C
lg.420 mm
lg.520 mm
8555N118A
m10
C
1 mm
E A
1 mm 1 mm 1 mm
Rear
Front
lg.520 mm
C
lg.520 mm
lg.520 mm
C
lg.420 mm
lg.520 mm
GTE 519
E
lg.520 mm
C
lg.520 mm
lg.520 mm
C
lg.420 mm
lg 520 mm
Rear
Front
C A
lg.420 mm
lg.420 mm
D
lg.520 mm
C lg.520 mm
C lg.520 mm
lg.385 mm
GTE 520
A C
lg.420 mm lg.420 mm
D
lg.520 mm
C lg.520 mm
C lg.520 mm
lg.385 mm
Rear
Front
C A
lg.420 mm
lg.520 mm
D
lg.520 mm
C lg.520 mm
C lg.520 mm
lg.385 mm
GTE 521
A C
lg.420 mm lg.520 mm
D
lg.520 mm
C lg.520 mm
C lg.520 mm
lg.385 mm
8555N119A
m11
C
1 mm
E A
1 mm 1 mm 1 mm
Rear
Front
C A
lg.520 mm
lg.520 mm
C
lg.520 mm
lg.520 mm
C
lg.385 mm
lg.520 mm
GTE 522
C A
lg.520 mm lg.520 mm
C
lg.520 mm
lg.520 mm
C
lg.385 mm
lg.520 mm
Rear
Front
lg.420 mm
C
lg.420 mm
lg.420 mm
C
lg.520 mm
lg.520 mm
C
lg.385 mm
lg.520 mm
GTE 523
E
lg.420 mm
C
lg.420 mm
lg.420 mm
C
lg.520 mm
lg.520 mm
C
lg.385 mm
lg.520 mm
8555N120A
m12
C
1 mm
E A
1 mm 1 mm 1 mm
Rear
Front
lg.420 mm
C
lg.420 mm
lg.520 mm
C
lg.520 mm
lg.520 mm
C
lg.385 mm
lg.520 mm
GTE 524
E
lg.420 mm
C
lg.420 mm
lg.520 mm
C
lg.520 mm
lg.520 mm
C
lg.385 mm
lg.520 mm
Rear
Front
lg.420 mm
C
lg.520 mm
lg.520 mm
C
lg.520 mm
lg.520 mm
C
lg.385 mm
lg.520 mm
GTE 525
E
lg.420 mm
C
lg.520 mm
lg.520 mm
C
lg.520 mm
lg.520 mm
C
lg.385 mm
lg.520 mm
8555N121A
m13
13
2 CM 22
4 CM 23
6 CM 22 + CM 23
8 2xCM 23
G Put the baffle plates into place in the upper front flue ways, taking care to interlock them with each other before fitting them.
8555N011
14
G Clean off the protective varnish on the ground surfaces with diluent. G The covers are numbered from 1 to 4, and must be fitted with a thermocord . The length of the thermocord depends upon the cover and is given below.
Type 1 2 3 4 Thermocord length 1335 mm 1110 mm 890 mm 665 mm
Cover model Type of boiler GTE 507 GTE 508 GTE 509 GTE 510 GTE 511 GTE 512 GTE 513 GTE 514 GTE 515 GTE 516 GTE 517 GTE 518 GTE 519 GTE 520 GTE 521 GTE 522 GTE 523 GTE 524 GTE 525 n 1 n 2 n 3 n 4
REAR
2 4
19
8555N012
G Place the two no. 1 sweeping covers (with the handles turned outward) on either side of the boiler starting from the front. Distribute the other covers evenly. Each cover is fitted with a system whereby it can only be mounted with the handles turned outward.
G Fit the two locks of each cover between the sections. G Push the cover towards the outside of the boiler, to the closed position . G Fasten the two brass nuts of each cover .
m14
15
16
8555N013
8555N014
G Insert the thermocord in the sealing groove on each side and hold it in place with a few drops of silicone filler.
G Insert the thermocord in the sealing groove of the two lower flue ways, on the rear and front of the boiler. G Put the four trap doors on the lower flue ways and fasten with the wing nuts.
17
Refractory felt
18
7
G Put the furnace door insulating material in place and retain it with the four 3.94 x 25.4 SIM screws
8259N022
8555N091
G Fix the furnace door hinge on the right or left-hand side of the front section by means of three H 12 x 25 screws.
m15
19
1
20
8555N101
.
8555N097
2
8555N092
G Close the furnace door on the 8 studs and fasten with 8 washers and nuts .
G Fit the two doors of the upper flue ways (wing nuts). G Fit the plain flange onto the upper connection of the front section (using four H 18 nuts), with the 170 x 222 gasket in between (first soak the gasket in warm water). G Fit the flange with the sludge removal hole onto the lower connection of the front section (hole in the lower part of the flange) using four H 18 nuts, with the gasket in between (soak in warm water first).
21
The flame inspection window is fitted with a 1/4" tapped hole for ventilation (optional) : - if a ventilation system is used, connect the hole to the one provided for that purpose before the burner combustion head.
8555N179A
m16
22
GTE 507 - GTE 512 Package FA 42 to FA 47 Package FA 67 - 13 sections FA 68 - 14 sections GTE 513 - GTE 514 Package FA 48 - 13 sections FA 49 - 14 sections G GTE 507 - GTE 512 : Fit the boiler return flange with a 170 x 222 gasket in between (first soak the gasket in warm water), using four H 18 nuts. G GTE 513 - GTE 514 : Fit the water balancing diaphragm with the notches vertical onto the boiler return with a 170 x 222 gasket in between (first soak the gasket in warm water). Fit the heating return flange with a 170 x 222 gasket in between and fix it with four H 18 nuts.
GTE 515, 516 380 GTE 517 - 519 600 GTE 520 - 522 880 GTE 523 - 525 1210
G GTE 515 - GTE 525 : Fit the water balancing tube onto the boiler return with a 170 x 222 gasket in between (first soak the gasket in warm water), using four H 18 nuts. Fit the heating return flange with a 170 x 222 gasket in between (first soak the gasket in warm water) and fix it with four H 18 nuts.
8555N099A
23
24
8555N103A
G GTE 507 - 515 : Place the nozzle turned outside from the boiler with a 170 x 222 gasket in between (first soak the seal in warm water). Assemble the flange with angled piece so that the angle is turned upward, with a 170 x 222 gasket in between (first soak the gasket in warm water) and fasten with four H 18 nuts. G GTE 516 - 525 : Assemble the flange with angled piece so that the angle is turned upward, with a 170 x 222 gasket in between (first soak the gasket in warm water) and fasten with four H 18 nuts.
8555N162
Carefully insert the 15 gasket in the groove of the rear section and hold it in place with a few drops of silicone.
m17
25
26
Before assembling the flue gas box, grease all bolts, studs and screws with high-temperature grease (not supplied).
8555N163
G Put the flat adhesive seal in place on the flue gas box. G Put the sweeping cover in place and fasten with two H 10 nuts and 10 washers.
8555N164
G The flue gas outlet is fastened to the rear by means of six studs, washers and 12 nuts.
27
28
8555N177 8555N165
Number of sections 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Flow switch codes nos. for Export 8802-4731 8802-4734 8802-4736 8802-4738 8802-4740 8802-4742 8802-4743 8802-4745 8802-4746 8802-4736 8802-4738 8802-4752 8802-4753 8802-4754 8802-4755 8802-4756 8802-4757 8802-4758 8802-4759
Flow switch codes nos. for China 8802-4731 8802-4734 8802-4736 8802-4738 8802-4740 8802-4742 8802-4743 8802-4745 8802-4746 8802-4736 8802-4738 8802-4739 8802-4740 8802-4741 8802-4742
G First adapt the steel connecting plate to the chimney connection flue. Then fasten that plate or the plate with a connecting piece supplied as an option with ten H 10 nuts and 10 washers.
Hydraulic tightness check After assembling the body, the fitter shall run a watertightness check with pressure equal to 1.3 times the operating pressure.
m18
29
Assembling the baffle plates (for boilers supplied with an assembled body only) In boilers supplied with an unassembled body, the baffle plates are already in place.
6 CM 22 + CM 23
CM 22
CM 23
2xCM 23
G Put the baffle plates in place in the upper front flue ways, taking care to interlock them with each other before fitting them.
8555N181A
30
31
In boilers supplied with an unassembled body, the crosspieces are already in place (see figure 12)
REAR
FRONT
2mm 2mm
8555N188
8555N010
G Assemble the pocket for the thermostats and thermometer in : - the third special intermediate section - 150 mm wide, 1/2" hole (GTE 507 - 519) or - the fourth special intermediate section - 150 mm wide, 1/2" hole (GTE 520 - 525). G Plug the two (GTE 507 - 519) or three (GTE 520 525) free 1/2" holes in the special intermediate sections.
G Mount the two crosspieces and fasten them onto the rods with an expansion spring, a nut and a washer.
m19
32
33
REAR
80
90
AVANT
FRONT
8555N108 8555N186
G Place the cable channels so that their bevelled end is to the front. G Fasten with two H 8 x 16 screws + L8 washers in the third hole starting from the front and opposite the special nut. G Fasten at the rear with two H8 x 16 screws + L8 washers opposite the oblong holes and special nut.
10 1500
11, 12 1600
13, 14 1800
15, 16 2100
17 2200
G Put in place the 600 mm wide (packages FA 30 - 36) top insulating material on the body of the boiler.
35
1 3
A
2 2
8555N112
8555N113
G Assemble the intermediate piece on the assembly rods by fitting one slotted side onto one rod and using the flexibility of the other rod. G Place the two cable channels so that their bevelled end is to the front. G Fasten the channels to the front crosspiece with two H 8 x 16 screws + L8 washers in the third hole starting from the front and opposite the special nut. G Fasten the cable channels on the intermediate piece with two H8 x 16 screws + L8 washers.
No. of 18 19 20 21 22 23 24 25 sect. A (mm) 2510 2600 2800 2910 3000 3110 3200 3310
G Align the two additional cable channels with the two others. G Fasten them to the intermediate piece and the rear crosspieces with four H 8 x 16 screws and L8 washers.
m20
36
G Put in place the two 600 mm wide (packages FA 37 - 41) pieces of insulating material on the body of the boiler. G Push the insulating material under the front and rear crosspieces.
80 90
No.of sect.
18
19
20
21
22
23
24
25
8555N187
Length 2 x 2x 2x 2x 2x 2x 2x 2x (mm) 1200 1200 1300 1400 1400 1500 1500 1600
37
Assembling the casing positioning brackets
8555N114
G Fasten the positioning brackets (package FA5 or FA6) onto the right and left-hand upper bosses of the front section with two H 8x16 screws and two serrated washers (13 mm spanner).
m21
38
G Fasten the lower rail support brackets using H8 x 16 screws. Note : for the assembly direction, see the drawings below.
1
Assembly direction of lower rail support brackets
(seen from the top of the frame)
8555N129
38a
7, 8, 10 sections
Right-hand side Rail support brackets
9 sections
Right-hand side
Rear
Frame
Front
Rear
Frame
Front
Left-hand side
Left-hand side
Note : two lower rail support brackets and two upper rail brackets are left unused with 7, 8, 9 and 10 sections.
38b
Rear
Frame
Front
Rear
Frame
Front
Left-hand side
Left-hand side
8555N182-GB
38c
18, 20 sections
Right-hand side
Rear
Frame
Front
Left-hand side
19, 21 sections
Rail support brackets Right-hand side
Rear
Frame
Front
Left-hand side
Note: two lower rail support brackets and two upper rail brackets are left unused with 18, 19, 20 and 21 sections. 22, 24 sections
Rail support brackets Right-hand side
38d
Rear
Frame
Front
Left-hand side
23, 25 sections
Rail support brackets Right-hand side
Rear
Frame
Front
Left-hand side
m23
8555N184-GB
39
G Fasten the lower rail with H 8x30 screws and L8 washers. G The other rail support brackets are fastened opposite the holes provided on the lower rail.
FRONT
Length required while assembling the two-piece rails (boilers with 18 - 25 sections) (see fig. 42)
8555N130
40
Assembling the fastening brackets of the upper and lower rails
Imperative alignment
8555N189
G Fix the fastening bracket of the upper rails (package FA5 or FA6) on the upper lug (these brackets must be vertically aligned with the lower rail support brackets). Fit the bracket onto the stub . G Fasten with H 10x50 screws and serrated washers and H10 nuts .
G Assemble the Rapid nut on the top of the bracket { with the tapped shaft on the inside.
m24
41
Type of boiler FRONT
FRONT
GTE 507 GTE 508 GTE 509 GTE 510 GTE 511 GTE 512 GTE 513 GTE 514 GTE 515 GTE 516 GTE 517 GTE 518 GTE 519 GTE 520 GTE 521 GTE 522 GTE 523 GTE 524 GTE 525
1200 1200 1200 600 1200 1200 1200 1200 1200 1200 1200 1200 1200 1200 1200 1200 1200 1200 1200
1
400 400 600 600 600 400 400 400 1200 1200 400 400 400 600 600 400 400
90 220
2
600
1200
8555N128
G Place the side insulating material against the positioning bracket and cut it so that it is flush with the upper lug on which the rail fastening bracket is fixed, along a 220 mm length . G Push the insulating material in behind the lug and the rail fastening bracket.
G Distribute the insulating material evenly so that you have the same side insulating material on either side of the boiler. G Cut the material similarly along the fastening brackets.
42
REAR
FRONT
Length required while assembling the two-piece rails (boilers with 18 - 25 sections) (see table below). 7 - 17 sections G Fix the upper rail with H8 x 30 screws and L8 washers (the first hole from the front end of the rail must be opposite the first fastening bracket, and similarly with the other brackets). G Push the insulating material behind the lower rail and underneath the boiler. G Join the pieces of insulating material to each other with the clips.
Number of sections A (mm) 18 2500 19 2615 20 2765 21 2875 m25
8555N138 18 - 25 sections G Fix the upper rail with H8 x 30 screws and L8 washers (the first hole from the front end of the rail must be opposite the first fastening bracket, and similarly with the other brackets). G Fix the additional upper and lower rails, making sure you comply with dimension A (see table below). G Push the insulating material behind the lower rail and underneath the boiler. Join the pieces of insulating material to each other with the clips.
22 2965
23 3075
24 3165
25 3275
43
insulation
3
Length and arrangement of panels for the boiler model
Type of boiler GTE 507 GTE 508 GTE 509 GTE 510 GTE 511 GTE 512 GTE 513 GTE 514 GTE 515 GTE 516 GTE 517 GTE 518 GTE 519 GTE 520 GTE 521 GTE 522 GTE 523 GTE 524 GTE 525 800 940 1050 940 1050 940 1050 800 940 1050 940 1050 940 940 1050 940 1050 940 1050 Front Side panels Length in mm 400 400 400 600 600 400 400 600 600 600 600 600 600 600 600 600 600 600 600 Rear
1 2
400 400 600 600 600 400 400 600 600 600 600 600 600 600
4
400 400 400 600 600 400 400 600 600
8555N143
400 mm long panel in Package FA 10 600 mm long panel in Package FA 11 800 mm long panel in Package FA 7 900 mm long panel in Package FA 8 1050 mm long panel in Package FA 9
G First assemble the panels on the front using the as-sembly length table opposite and continue up to the rear section . G Fix the front side panels to the positioning brackets with H 8 x 16 screws and serrated washers . G Push the insulating material into the top of the side panels and fasten the panels to the lower rails by means of the self-drilling screws with the electric screwdriver (2 screws per panel) { . G Fasten the side panels to each other with the clips | .
44
G Put the furnace door panel in place (package FA5 or FA6) and fasten with two 3.94 x 12.7 tapping screws. The furnace door panel may be cut in two at the micro-joints. G Fit two Rapid nuts in the bottom of the front side panels. G Fix the casing support lower crosspiece (package FA5 or FA6) by means of two H 6x20 screws and two serrated washers.
2
m26
8555N149
45
2 1
8555N141
G Fit the four Rapid nuts on the front of the cable channels . G Fit the Rapid nuts in the slots : - 4 Rapid nuts for 7-17 sections,
- 8 Rapid nuts for 18-25 sections. G Fix the control panel bracket (package FA5 or FA6) underneath the two cable channels by means of two H 8x 16 screws and two serrated washers.
46
8555N146
G Place the front crosspiece underneath the control panel bracket and fasten from below with H8 x 30 screws and serrated washers.
G Fix to the side panels with two 3.94 x 12.7 tapping screws and serrated washers.
m27
48
2
REAR
1
3x
FRONT
8555N139
8555N183
G Position the control panel on the rear studs . G Open the control panel (3 screws at the back) .
G Bring the burner cable behind the casing support and down to the burner between the side panel and insulating material.
49
G Fasten the control panel to the panel base with two 3.94 x 25 tapping screws and serrated washers . G Carefully unroll the various bulbs and bring them out of the control panel through the opening designed for that purpose. Cut out the top insulating material and insert the bulbs in the boiler pocket and hold them in place using the spring . G Fasten rear cover H (package FA5 or FA6) to the control panel bracket using two EC CB 4 x 40 screws and serrated washers . G Make the electrical connections to the two terminal blocks provided for this purpose inside of the control panel. See the Electrical Connections section of the instructions supplied with the control panel. G Close the control panel.
8555N161
3 1
3 1
m28
50
180
8555N147
Take the front crosspiece and turn it by 180 in relation to the position for standard control panels (see fig. 46) and fasten it just like the standard control panel.
51
REAR
FRONT
8555N140
8555N144
Position the control panel on the front studs. Open the control panel (two screws on the side).
G Bring the burner cable behind the casing support and down to the burner between the side panel and insulating material.
m29
53
54
Installing the bulbs of DIEMATIC-m Delta and K control panels
8555N145
8555N148
G Fix the control panel to the rear of the control panel bracket using two H 4 x 40 screws and serrated washers. G Carefully unroll the various bulbs and bring them out of the control panel through the opening in the bottom on the panel.
G Cut out the top insulating material to free the boiler pocket. Then, insert the bulbs inside the pocket and maintain them with the spring.
55
56
Putting in place the insulating material for DIEMATIC-m Delta or K control panels
G Make the electrical connections to the terminal blocks provided for this purpose inside of the control panel. See the Electrical Connections section of the instructions supplied with the DIEMATIC-m Delta or K control panel.
8555N142
m30
57
Section A-A
Rapid nut Cable channel Control panel bracket
58
Front crosspiece
A
8555N160 8555N185
59
60
8555N152
8555N150
G Place the insulating material in the lower central front panel (black cloth facing outward). G Fit the lower central front panel (package FA5 or FA6) onto the lower front crosspiece and fix it to the furnace door panel. G Fit the left and right-hand side front panels (package FA5 or FA6) onto the lower front crosspiece and fit them onto the studs of the side panels.
m31
61
62
8555N151
8555N153
G Place the retaining crosspiece (package FA5 or FA6) on the left and right-hand front panels, taking care to place the two central tabs behind the furnace door panel. G Fit the upper front panel (package FA5 or FA6) onto the side panels via the four studs.
G Put in place the insulation of the flue gas box and the lower rear insulating material (package FA5 or FA6).
63
64
1 2
8555N159
8555N155
G Put in place the two rear crosspieces (package FA5 or FA6) behind the bend of the rear side panels and fasten each crosspiece to the side panels using two 3.94 x 12.7 screws.
G Put the two clip-on nuts in place on the side panels . G Fit the upper rear panel (package FA5 or FA6) onto the studs and push it up . Fasten with two H 8x16 screws and serrated washers . G Fit the two lower rear panels (package FA5 or FA6) onto the rear crosspieces { .
m32
65
66
8555N166
8555N167
G Place the central plate on the cable channels with the round holes towards the front of the boiler. G Fasten with H 8x30 screws and serrated washers.
G Place the rear plate, which is 1200 mm long . G Fasten with four H 8x30 screws and serrated washers. G Place the front plate with the round holes towards the front of the boiler y . G Fasten with four H 8 x 30 screws and serrated washers. G Fasten the joining plate with the round holes towards the front of the boiler with four tapping screws and serrated washers.
67
G Put in place the sweeping cover insulating material (packages FA 30 - FA41) : - GTE 507 - 517 : 2 pieces - GTE 518 - 525 : 4 pieces.
8555N158
m33
68
Type of boiler GTE 507 GTE 508 GTE 509 GTE 510 GTE 511 GTE 512 GTE 513 GTE 514 GTE 515 GTE 516 GTE 517 GTE 518 GTE 519 GTE 520 GTE 521 GTE 522 GTE 523 GTE 524 GTE 525 Front Central and side covers (Length in mm) 800 940 1050 940 1050 940 1050 800 940 1050 940 1050 940 940 1050 940 1050 940 1050 400 400 400 600 600 400 400 600 600 600 600 600 600 600 600 600 600 600 600 Rear
8555N157
400 400 600 600 600 400 400 600 600 600 600 600 600 600
Cover packages : 400 mm long panel in Package FA 10 600 mm long panel in Package FA 11 800 mm long panel in Package FA 7 900 mm long panel in Package FA 8 1050 mm long panel in Package FA 9
G Place the side covers (package FA7 to FA11, see table) from the front to rear. They have the same lengths as the side panels.
69
Identification plate and CE marking
(1)
XX - XX Date of manufacture
F 67110 NIEDERBRONN
8555N156
G Glue the identification plate and CE marking on the casing of the boiler in an easily visible location.
m34
DE DIETRICH HEIZTECHNIK Rheiner Strasse 151 D-48282 EMSDETTEN www.dedietrich.com info@dedietrich.de Verkaufsbro Emsdetten : Tel. 0 25 72 / 23-179 Fax 0 25 72 / 23-451 Regionalverkaufsbro Berlin : Tel. 030 / 5 65 01-391 Fax 030 / 5 65 01-465 Verkaufsbro Neunkirchen : Tel. 0 68 21 / 98 05-0 Fax 0 68 21 / 98 05-31 Regionalverkaufsbro Erding : Tel. 0 81 22 / 9 93 38-0 Fax 0 81 22 / 9 93 38-19
DE DIETRICH SPINOFF - CENTER Romeinsestraat 10 B-3001 LEUVEN / LOUVAIN Tl. : 016 39 56 40 Fax : 016 39 56 49 www.dedietrich.com DE DIETRICH HEIZTECHNIK Am Concorde Park 1 - B 4 / 28 A-2320 SCHWECHAT / WIEN Tl. : 01 / 706 40 60-0 Fax : 01 / 706 40 60-99 www.dedietrich.com office@dedietrich.at Pour le LUXEMBOURG : les produits sont commercialiss par la socit NEUBERG In LUXEMBURG werden die Produkte durch die Fa. NEUBERG vertrieben NEUBERG SA 39 rue Jacques Stas L - 2010 LUXEMBOURG Tl. : 02 401 401 Fax : 02 402 120 www.dedietrich.com
DE DIETRICH THERMIQUE S.A.S. au capital de 21 686 370 BP 30 57, rue de la Gare F-67580 MERTZWILLER Tl. : (+33) 03 88 80 27 00 Fax : (+33) 03 88 80 27 99 www.dedietrich.com N IRC : 347 555 559 RCS STRASBOURG
In the interest of customers, DE DIETRICH THERMIQUE are continuously endeavouring to make improvements in product quality. All the specifications stated in this document are therefore subject to change without notice.
AD014J