De Dietrich GT 530A and GT530AE Series
Assembly,
Installation
and Service
Manual
Product may not be exactly as shown.
www.dedietrichboilers.com
DDR_G30A/AE _ISM_V4.0 03/2014
Oil/Gas-Fired Near-Condensing Hot Water Boiler
DRAFT
Page 1: ...ch GT 530A and GT530AE Series Assembly Installation and Service Manual Product may not be exactly as shown www dedietrichboilers com DDR_G30A AE _ISM_V4 0 03 2014 Oil Gas Fired Near Condensing Hot Wat...
Page 2: ...el carefully before attempting to put the burner into operation Do not store or use gasoline or other flammable liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do no...
Page 3: ...information required 16 2 Recommendations 16 3 Filling 16 4 Ancillaries 17 Assembly and Mounting 18 72 1 Clearances 13 2 Replacement procedures 17 Oil or gas connection 60 Electrical 61 67 Start up p...
Page 4: ...AL ELECTRICAL SOURCE IS UTILIZED THE BOILER WHEN INSTALLED MUST BE ELECTRICALLY BONDED TO GROUND IN ACCORDANCE WITH THE REQUIREMENTS OF THE AUTHORITY HAVING JURISTRICTION OR IN THE ABSENCE OF SUCH REQ...
Page 5: ...l Warranty Professional licensed heating contractor Boiler Documentation Advice for the owner Contaminated air The assembly installation adjustment service and maintenance of this boiler must be perfo...
Page 6: ...e gases leaking into the house can Safety Information Operation cause injury or death Blocked or partially blocked chimneys must have the blockage removed by a qualified heating contractor Check press...
Page 7: ...e technician inspect the heating equipment exhaust vent pipes and chimney flues on a yearly basis In winter inspect the exhaust vents for the dryer furnace wood burning or gas stove fireplace and heat...
Page 8: ...larm is installed on each additional level of the dwelling building or structure served by the side wall horizontal vented gas fueled equipment It shall be the responsibility of the property owner to...
Page 9: ...instructions for the installation of the venting system design or the venting system components and 2 A complete parts list for the venting system design or venting system d MANUFACTURER REQUIREMENTS...
Page 10: ...ld winter conditions then the following steps should be taken Turn off the building s water supply drain the pipes and add some antifreeze for potable water for the toilet tanks and drain traps Have t...
Page 11: ...e with two cleaning traps directly accessible without dismantling the castings Large flueways with fins and turbulators offering high efficiency and easy maintenance Boiler body with 4 pass flueways L...
Page 12: ...0 64 0 78 0 89 0 98 1 10 1 20 1 34 1 45 36 F Ft H2O 0 82 0 27 0 32 0 36 0 44 0 50 0 55 0 62 0 68 0 75 0 82 Combustion chamber Dimensions Diameter equivalent Inch 27 32 mm 694 Depth Inch 62 76 67 13 71...
Page 13: ...28 1 39 Combustion chamber Dimensions Diameter equivalent Inch 27 32 mm 694 Depth Inch 113 97 118 34 122 71 127 08 131 45 135 82 140 19 mm 2 895 3 006 3 117 3 228 3 339 3 450 3 561 Volume Ft 3 38 66 4...
Page 14: ...400 400 400 400 450 450 450 450 450 500 500 500 500 500 500 500 H Inch 1 22 1 18 0 354 0 315 0 512 1 417 1 378 0 551 0 512 0 315 0 354 1 02 2 48 2 44 1 61 5 11 5 07 4 25 mm 31 30 9 8 13 36 35 14 13 8...
Page 15: ...14 57 14 57 25 59 25 59 25 59 38 58 38 58 38 58 60 57 4 56 5 57 4 53 8 55 4 54 7 mm 150 150 370 370 370 650 650 650 980 980 980 1 524 1 457 9 1 435 1 1458 1 366 5 1407 1 1389 3 E In 61 68 61 68 61 68...
Page 16: ...th any of these requirements will result in void of product warranty Particular installation areas and other equipment occupying the same room precautions regarding the combustion air supply and quali...
Page 17: ...498 497 408 429 430 450 452 Installation Specifications DANGER Improper installation adjustment alteration service or maintenance can cause property damage personal injury or loss of life Refer to th...
Page 18: ...one with circulating pumps stopped medium is piped in parallel with the boiler with the appropriate valves to prevent the chilled medium from entering the boiler The boiler piping system of hot water...
Page 19: ...mm The boiler must be connected to a chimney venting system that will safely discharge all flue gases to the outside in an effective manner The boiler breeching and chimney venting must be sized acco...
Page 20: ..._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ GT530A GT530A 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 K In 74 70 0 12 15 98 94 0 90 0 07 032...
Page 21: ...ach type is provided in the table below 1 Rear Section 2 Normal intermediate 3 Special intermediate 3 Fornt section GT 530A 15 1 10 3 1 GT 530A 16 1 11 3 1 GT 530A 17 1 12 3 1 GT 530A 18 1 13 3 1 GT 5...
Page 22: ...learance at the rear of the boiler for water connections and the distributing tube Fit the rear section on the frame behind the fastening brackets see detailed drawing and prop it up Insert the lower...
Page 23: ...traces of rust protective paint with a fine to medium wire wheel so that the surface is perfectly smooth Coat with the nipple coating with the sections A R R I R E D E S S U S O B E N T O P A V A N T...
Page 24: ...6 5 mm diameter 6 1 Rear section 2 Intermediate section Place the first normal intermediate section making sure that it is turned in the right direction i e with the flattening groove against the ther...
Page 25: ...so as to bring together the upper and lower connections evenly and simultaneously Assemble the remaining intermediate sections one by one according to the procedure in step 3 10 First assemble the nor...
Page 26: ...he 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 a...
Page 27: ...and rear lugs For 26 32 sections boilers the provided extension and coupling M14 x 42mm will be required Mount the 2 crosspieces supplied in package MR245 246 with their bends turned backwards and fa...
Page 28: ...E E E C C C C C C C C D D D D D D D D GT 530A 17 F1 F1 F1 R2 R2 R2 GT 530A 15 Place the expansion spring and washer on the rear of each rod Stop tightening the nuts as soon as the gap between the spi...
Page 29: ...m 201 2 520mm 201 2 520mm 201 2 520mm 201 2 520mm 201 2 520mm 201 2 520mm 201 2 520mm 201 2 520mm 201 2 520mm 161 2 420mm 161 2 420mm 161 2 420mm 161 2 420mm 201 2 520mm 201 2 520mm 201 2 520mm 161 2...
Page 30: ...385mm GT 530A 21 B B A A C C C C C C D D D D F2 R1 201 2 520mm 201 2 520mm 201 2 520mm 201 2 520mm 201 2 520mm 201 2 520mm 201 2 520mm 201 2 520mm 153 16 385mm 153 16 385mm 161 2 420mm 161 2 420mm GT...
Page 31: ...0mm GT 530A 24 GT 530AE 26 E E E E B B B B D D D D D D D D D D D D C C C C C C C C C C C C F2 R1 201 2 520mm 201 2 520mm 201 2 520mm 201 2 520mm 201 2 520mm 201 2 520mm 201 2 520mm 201 2 520mm 201 2 5...
Page 32: ...161 2 420mm 201 2 520mm 201 2 520mm 201 2 520mm 201 2 520mm 201 2 520mm 201 2 520mm 201 2 520mm 201 2 520mm 201 2 520mm 201 2 520mm 153 16 385mm 153 16 385mm 161 2 420mm 161 2 420mm 123 5 320mm 123 5...
Page 33: ...01 2 520mm 201 2 520mm 201 2 520mm 201 2 520mm 201 2 520mm 201 2 520mm 201 2 520mm 201 2 520mm 201 2 520mm 201 2 520mm 201 2 520mm 201 2 520mm 201 2 520mm 201 2 520mm 201 2 520mm 201 2 520mm 201 2 520...
Page 34: ...GT 530 15 to GT 530A 19 or the 3 free 1 2 holes for GT 530A 20 to GT 530AE 32 in the special intermediate sections 13 Assembling the pocket and the plugs Fitting the upper and lower front flanges Fit...
Page 35: ...ot less than 60 f 15 C Fit a square flange with hole facing upwards onto the upper flange with outlet piece Fit a blind square flange onto the lower flange with return piece 2 4 3 7 psig 135 0 7 5 8 1...
Page 36: ...GT 530A 20 to 25 Total number of baffles 6 8 Package no CM 22 CM 23 2XCM 23 Boiler GT 530AE 26 to 28 GT 530AE 29 to 32 Total number of baffles 8 10 Package no 2XCM 23 2XCM23 CM22 Put the baffles into...
Page 37: ...her covers evenly Fit the two locks of each cover between the sections 3 Push the cover towards the outside of the boiler to the closed position 4 Fasten the two brass nuts of each cover F2 R1 Rear Fr...
Page 38: ...ocord in the sealing groove on each side and hold it in place with a few drops of silicone filler Insert the thermocord in the sealing groove of the 2 lower flue ways on the rear and front of the boil...
Page 39: ...y felt 3 Rigid refractory plate Put the furnace door insulating material in place and retain it with the 4 screws SIM 3 94x25 4 Place the burner boiler door on the floor and fasten the door hinge onto...
Page 40: ...2013 23 24 1 2 Fit the door onto the hinge by inserting the pin Close the burner door on the 8 studs and fasten with 8 washers and nuts Instal the 2 Cleaning doors of the upper flue ways and fasten w...
Page 41: ...6 X83 4 gasket in between first soak the gasket in warm water Fit the heating return flange with a 170x222 611 16 X83 4 gasket in between first soak the gasket in warm water and fasten it with 4 nuts...
Page 42: ...is turned upward with a 611 16 X83 4 170x222 gasket in between first soak the gasket in warm water and fasten with 4 nuts H18 GT 530A 16 to GT 530AE 32 Assemble the flange with angled piece so that t...
Page 43: ...plied Put in place the thermocord Put the sweeping cover in place and fasten with 2 nuts H10 and 3 8 10mm washers The flue gas outlet is fastened to the rear by means of 6 studs washers and 9 16 12mm...
Page 44: ...e boiler Number of section GT 530A 15 16 GT 530A 17 Length mm 8211 16 2 100 865 8 2 200 2 31 2 80mm 31 2 90mm Place the cable channels so that their bevelled end is at the front Fasten with 2 screws H...
Page 45: ...g material width 600 mm packages FA37 to FA41 on the body of the boiler Push the insulating material under the front and rear crosspieces 26 32 sections Use provided spare insulation and cut to fit th...
Page 46: ...sten with 2 screws H8 x 16 and L8 washers in the third hole starting from the front and opposite the special nut Fasten them to the intermediate piece and the rear crosspieces with 2 screws H8 x 16 an...
Page 47: ...r a GT 530A 1 Fasten the lower rail support brackets using H8 x 16 screws Serrated washer Note For the assembly direction see the following drawings Rail Support brackets Rail Support brackets Right S...
Page 48: ...e Left Side Rear Front Rail Support brackets Right Side Left Side GT 530A 19 and GT 530A 21 GT 530A 18 and GT 530A 20 GT 530A 17 GT 530A 22 and GT 530A 24 Assembly and Set up Base Frame Rear Front Rai...
Page 49: ...t Rail Support brackets Right Side Left Side Base Frame Rear Front Rail Support brackets Right Side Left Side GT 530A 23 and GT 530A 25 GT 530AE 26 27 28 29 32 GT 530AE 30 31 Assembly and Set up Base...
Page 50: ...opposite the holes provided on the lower rail Length required while assembling the 2 piece rails boilers with 18 to 25 sections see fig 12 1 Fix the fastening bracket of the upper rails MR245 or MR24...
Page 51: ...Number of sections 26 27 28 29 30 31 32 Length mm A 133 2 3385 1375 3495 141 9 3605 146 2 3715 150 5 3825 154 9 3935 159 2 4045 A GT 530A 15 to GT 530A 17 Fix the upper rail with H8 x 30 screws and L8...
Page 52: ...AE 27 471 4 1200 153 4 400 153 4 400 471 4 1 200 GT 530AE 28 471 4 1200 153 4 400 153 4 400 471 4 1 200 GT 530AE 29 471 4 1200 153 4 400 153 4 400 471 4 1 200 GT 530AE 30 471 4 1200 153 4 400 153 4 40...
Page 53: ...18 413 8 1050 235 8 600 153 4 400 153 4 400 GT 530A 19 37 940 235 8 600 235 8 600 153 4 400 GT 530A 20 37 940 235 8 600 235 8 600 235 8 600 GT 530A 21 413 8 1050 235 8 600 235 8 600 235 8 600 GT 530A...
Page 54: ...te A 1 8 diameter hole needs to be drilled on each side of the burner mounting plate to accept the 2 self tapping screws On the larger model bolt hole patterns you must clear the boiler door to clear...
Page 55: ...hes 2 Remove the 3 screws 3 Open the control panel 3 screws at the back 4 Secure the control panel 2 self tapping screw 3 94 x 25 Serrated washers 5 Carefully unroll the various temperature sensor bul...
Page 56: ...casing support and down to the burner between the side panel and insulating material v Refer to the control panel instructions to make the electrical connections see the Electrical connections section...
Page 57: ...or 246 52 Installing the front top panel MR245 or MR246 Place the retaining crosspiece on the left and right hand front panels taking care to place the 2 central tabs behind the furnace door panel At...
Page 58: ...e flue gas box insulation and the lower rear insulation If the side crosspieces overlap at the rear by more than 7 8 10mm we advise you to saw them off using a hacksaw 311 2 800mm Attach the 2 rear cr...
Page 59: ...ls 2 Attach the upper rear panel onto the studs and push it up 3 Fasten with 2 screws H8 x 16 and serrated washers 4 Attach the 2 lower rear panels onto the rear crosspieces Front Rear Position the ce...
Page 60: ...the front plate with the round holes towards the front of the boiler Attach 4 screws H8 x 30 and serrated washers 3 Attach the joining plate with the round holes towards the front of the boiler with...
Page 61: ...153 4 400 153 4 400 GT 530A 18 413 8 1050 235 8 600 153 4 400 153 4 400 GT 530A 19 37 940 235 8 600 235 8 600 153 4 400 GT 530A 20 37 940 235 8 600 235 8 600 235 8 600 GT 530A 21 413 8 1050 235 8 600...
Page 62: ...ensate trap control replacement etc The boiler and its gas connection must be leak tested before placing the boiler in operation After placing the boiler in operation the ignition system safety shutof...
Page 63: ...unting bolts attached but the door refractory insulation has not be modified This must be done by the installer Please consult the burner mounting instructions for any special modifications required T...
Page 64: ...ety limit function 8 Aux Switch Optional usage not part of safety circuit consult factory for appropriate use and applications 9 Provisional panel knockout for optional digital control offering consul...
Page 65: ...Modulating Operation All field wiring shown by others Burner terminals Boiler panel terminals WARNING Failure to following these procedures or warning could result in property damage Personal injury i...
Page 66: ...erify the controls are functioning correctly and are adjusted correctly Suitable wire protection and strain relief s are required upstream downstream of the control panel Line voltage wiring and low v...
Page 67: ...with the burner Only if 24v transformer installed OEM digital control option WARNING FAILURE TO FOLLOWING THESE PROCEDURES OR WARNING COULD RESULT IN PROPERTY DAMAGE PERSONAL INJURY INCLUDING DEATH M...
Page 68: ...protection and strain relief s are required upstream downstream of the control panel Line voltage wiring and low voltage sensor wiring must use separate wire conduits LABEL ALL WIRES PRIOR TO DISCONNE...
Page 69: ...equipped with High gas or Pressure switch Burner motor power supply may be from seperate disconnect if power exceed 120V 10 10A 60Hz Or is multi phase WARNING FAILURE TO FOLLOWING THIS WIRING DIAGRAM...
Page 70: ...matic bleeder valves with the capability to bleed the system by themselves when it is operating the manual bleeder valves are used to bleed all the high points of the system and to make sure that the...
Page 71: ...r 316SS Venting Boiler breeching and main chimney De Dietrich GT Series boilers are a high performance boiler The flue gas temperature can be less than 320 F 160 C Special attention is required for t...
Page 72: ...han 140 F 60 C d The flue gas temperature is greater than 252 F 122 C to a maximum of 473 F 245 C e Do not use any barometric draft control on positive vent pressure systems as flue gas spillage will...
Page 73: ...g system or drains Do not install any fittings in the condensation lines The flue gas condensation may require a neutralization system before entering the drain Consult a chemical treatment company fo...
Page 74: ...ensate trap control replacement etc The boiler and its gas connection must be leak tested before placing the boiler in operation After placing the boiler in operation the ignition system safety shutof...
Page 75: ...and to push in or turn the gas control knob Never use tools If the knob will not push in or turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result...
Page 76: ...e hot boiler This operation can only be done a few times a year otherwise look for the leak and remedy it without delay The good performance of the boiler depends on its degree of cleanliness Cleaning...
Page 77: ...um cleaner Remove the left and right hand casing covers Remove the top insulation Unfasten the nuts up to the stop Push in the handles of the cleaning covers Remove the cleaning covers Brush the verti...
Page 78: ...ut back the front casing panels by reversing the removal procedure Remove the lower rear panels Remove the lower rear crosspiece Remove the lower insulation on the rear Unfasten the wing nuts and remo...
Page 79: ..._ _ _ _ _ _ _ _ _ _ Service and maintenance schedule _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _...
Page 80: ...78 GT 530A DDR_G30A AE _IO_V4 0 09 2013 Spare parts GTE 530A BOILER BODY While ordering spare parts do not forget to provide the code number given in the list opposite the part reference...
Page 81: ...79 GT 530A DDR_G30A AE _IO_V4 0 09 2013 Insulation 71 70...
Page 82: ...80 GT 530A DDR_G30A AE _IO_V4 0 09 2013 89 103 91 89 90 95 113 85 97 84 114 110 99 84 100 92 93 116 86 102 96 105 98 88 116 112 110 94 100 101 83 82 88 104 81 80 87 104 103 80 106 114 108 111 115 107...
Page 83: ...81 GT 530A DDR_G30A AE _IO_V4 0 09 2013...
Page 84: ...617 32 25 sections 19 8259 5500 Blind square flange gasket 20 8259 5501 Square flange with 2 tapped hole gasket 21 9501 4155 Gasket 222 x 169 5 mm 22 8249 0011 2 plug 23 8259 1502 Flange with outlet p...
Page 85: ...048 4939 64 long right hand wiring duct 83 8555 8049 551 8 long right hand wiring duct 83 8555 8050 5929 64 long right hand wiring duct 83 8555 8051 63 long right hand wiring duct Ref Code no DESCRIPT...
Page 86: ...114 8555 8501 235 8 long front side panel 115 8555 8513 Fasteners for rear side panel 116 8555 8505 153 4 long upper rear plate 116 8555 8506 235 8 long upper rear plate for cleaning CONTROL PANEL S3N...
