Ideal Boilers Buccaneer GTE 4 Installation And Servicing Manual Download

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Buccaneer GTE -

Installation & Servicing

INSTALLATION

buc5543

3/4"

55 INSTALLING THE FEET

buc5541

Screw the 4 adjustable feet (delivered in the hot water
calorifier instruction pack) on the bottom of the tank.

56 LEVELLING THE TANK

Level the tank by adjusting its feet.

Basic height 35mm, adjustment range 35-40mm.

buc5542

57 ASSEMBLING THE BOILER ON THE HOT WATER CALORIFIER

Locate the boiler on top of the hot water calorifier,
ensuring accuracy of dimension P at the front.

The boiler can be lifted using two 3/4" tubes placed as
shown.

Screw the adjustable boiler feet all the way in to the
minimum position (25mm).

Boiler

GTE 4/L160

Model

GTE 5/L160 - L250

GTE 6/L160

GTE 6/L250

(mm)

256

136

COMBINA

TION BOILERS COMBINA

TION BOILERS

Summary of Contents for Buccaneer GTE 4

Page 1: ......

Page 2: ...rformance It is therefore important that no external control devices e g flue dampers economisers etc are directly connected to these appliances unless covered by these Installation and Servicing Instructions or as otherwise recommended by Caradon Ideal Limited in writing If in doubt please enquire Any direct connection of a control device not approved by Caradon Ideal Limited could invalidate the...

Page 3: ...ation servicing or cleaning of this appliance care should be taken when handling edges of sheet steel components Buccaneer GTE Gas and Fuel Oil PI No 0049 BM 3528 Destination Countries GB IE INTRODUCTION The Buccaneer GTE boilers are fully automatically controlled floor standing boilers designed for connecting to a flue pipe and require a separate automatic fuel oil or gas burner The boilers have ...

Page 4: ...nces BS 5449 Forced circulation hot water central heating systems for domestic premises Note only up to 45kW NOTE TO THE INSTALLER LEAVE THESE INSTRUCTIONS ADJACENT TO THE BOILER BS 5482 Pt1 Domestic butane and propane gas burning installations BS 5546 Installation of gas hot water supplies for domestic purposes BS 5854 Flues and flue structures in buildings BS 5885 Pt2 Gas burners with inputs up ...

Page 5: ...R HOT WATER AND HEATING BOILERS There is a basic need to treat the water contained in all heating and indirect water systems particularly open vented systems It is assumed incorrectly that because boilers are operating in conjunction with what is apparently a closed circuit an open vented system will not under normal circumstances allow damage or loss of efficiency due to hardness salts and corros...

Page 6: ...turn R 1 1 4 3 Drain cock connection for pipe ø int 14 mm 4 4 x M8 on 110 Insulation Cutout 2 BOILER CLEARANCES The minimum dimensions indicated on the following drawing must be respected to ensure good access around the boiler Note To allow the inlet of the combustion air the boiler room must be adequately ventilated the section and the location of which must comply with local recommendations 0 5...

Page 7: ...ilers 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 Minimum vent free area cm2 per kW of boiler rated input positioned at Open flued To room or internal sp...

Page 8: ...gas or water undertakings b The installation should be capable of working with flow temperatures of up to 90o C and a temperature differential of up to 20o C c All components of the system including the heat exchanger of the indirect cylinder must be suitable for a working pressure of 4 bar 60lbf in2 and temperature of 110o C Care should be taken in making all connections so that the risk of leaka...

Page 9: ...lue Gases kg s Natural Gas 9 CO2 Flue Gas Temperature 1 2 Chimney Minimum Recommended Dimensions kW mbar o C Ø min m m Height m GTE4 21 27 0 12 0 014 0 014 180 125 6 5 GTE5 27 33 0 12 0 017 0 017 190 125 7 GTE6 33 39 0 11 0 020 0 020 190 153 7 1 at boiler high power 2 Boiler temperature 80o C ambient temperature 20o C Fuel Oil 12 CO2 The table below contains the minimum dimensions of the flue requ...

Page 10: ...nections to the burner unit MUST comply with the requirements of BS 799 The installation should conform to the recognised standards of good practice in the trade and comply with the relevant Codes of Practice building Regulations and Local Authority Fire and Insurance requirements Piercing Ø of the burner door 300 104 0 10 deflector buc5494 IMPORTANT The burner head deflector must go past the door...

Page 11: ...ons accompanying the options A DHW Sensor Kit AD 212 is available for use with the Buccaneer GTE range 11 BOILER BODY PREPARATION Put a protective piece of cardboard on the floor in front of the boiler body Take the body off the pallet and put it down vertically on the burner door Boiler GTE 4 GTE 5 GTE 6 Boiler FM 2 body FM 3 FM 4 Jacket FM 11 insulation FM 12 FM 13 Control panel FM 126 FM 126 FM...

Page 12: ...n the screw bag making the joint water tight using hemp or sealing paste 5 Put the boiler body back on its feet 13 REVERSE THE DIRECTION OF OPENING OF THE BURNER DOOR IF NECESSARY OPENING AT LEFT 1 2 1 2 buc5500 When the burner leaves the factory the burner door opens towards the right Perform operations in Frames 13 and Frame 14 to open the burner door towards the left if absolutely necessary 1 L...

Page 13: ...ht hand side 3 Remove the 2 screws on the left hand side 4 Reinstall the cast iron hinge pin 2 for the burner door on the left side 15 INSTALLING THE INSULATING MATERIAL 1 Pass the strap between the cast iron body and the base 2 Install the insulation around the body folding the bottom on each side of the boiler inside the base 5 Re install the hinge pins on the left side fixing them by tightening...

Page 14: ...2 The assembly rod 3 The rear section positioning pin 4 Fix it at the front with two M8 flanged nuts 5 Fix the rear section with one M8 x 30 screw and flanged nut on one side and one flanged nut on the assembly rod at the other side Put the rear cross bar into place on the lugs of the rear section facing the outside of the boiler positioning it on 1 The assembly Rod 2 The rear section positioning ...

Page 15: ...x 16 screws and square nuts 4 Replace the control panel display 5 Fix the top part of the control panel using the black screw for plastic supplied for this purpose 6 Fit the earth wire spade connector to the earth tab 21 ROUTING THE BURNER CABLE 1 Put the burner cable in the grommet supplied in the control panel instructions pack 2 Install the grommet and the burner cable into the notch in the con...

Page 16: ...side panel into place engaging the lower notch of the panel in the cross bar of the base 2 Make sure that the lower fold in the panel is correctly positioned under the fold of the cross bar 3 Straighten the side panel and pull it upwards 4 Attach the side panel to the lugs of the control panel support pulling its upper fold upwards such that the upper fold of the side panel is centred and blocked ...

Page 17: ... at the back with two 3 94 x 12 7 self tapping screws and 2 serrated washers Note It may be found suitable to make electrical connections before completing the casing assembly If so refer to Frame 33 34 and 35 2 2 1 1 Fix the two front burner door panels using four M6 x 10 black screws delivered in the screw bag 2 Install the cable clamp on the side panel on the side chosen for installation of the...

Page 18: ...into contact with the side panels and fix it using two black M6 x 10 screws delivered in the casing screw bag 4 2 1 3 3 4 BUC5513 Black screws 28 FINAL LEVELLING OF THE BOILER Level the boiler by adjusting its feet pre installed on the base 1 Basic height 25mm adjustment range 25 40 mm using 19mm spanner 25 mm 1 19 19 25 mm 1 BUC7940 29 NAME PLATE Affix the self adhesive name plate on the side of ...

Page 19: ...hermostat Temperature Resistance Thermostat Temperature Resistance Knob setting in o C in ohm Knob setting in o C in ohm 5 50 3 661 1 10 19 691 6 60 2 535 2 20 12 474 7 70 1 794 3 30 8 080 8 80 1 290 4 40 5 372 9 90 941 32 ELECTRICAL CONNECTIONS WARNING The electrical connections must be made by a qualified professional The electrical wiring has been carefully checked in the factory and the intern...

Page 20: ... on combination mobels Titanium anode optional standard on combination mobels If a titanium anode is not used then the connector supplied in the AD 212 kit with the 22kOhm resistance and a 100nF capacitor must be plugged into terminals 25 and 26 Boiler sensor Heating pump not supplied Zone B DHW pump not supplied Heating pump not supplied Zone A 230V Power supply buc7941 INSTALLATION ...

Page 21: ...ter removal of link zone A Room thermostat at terminals 19 and 20 zone B do not fit link if zone B not used Safety contact to terminals 4 and 5 after removing link Remote alarm to indicate overheat low water pressure etc to terminals 6 and 7 If only one circuit is used connect the room thermostat to circuit A and DO NOT fit link connector TAM B Removeable link Removeable link Safety contact Alarm ...

Page 22: ...RCUIT A DHW LOAD PUMP HEATING PUMP CIRCUIT B BURNER A B B CS DJ4A FA J L N RL BR RL ECS RL PA RL PB S CH S ECS TA TAM A TAM B TS VA ZG ZEH ZT SAFETY CONTACT CIRCUIT BREAKER ANTI PARASITE FILTER PRINTED CIRCUIT CONNECTOR LINE NEUTRAL BURNER CONTROL RELAY DHW LOAD PUMP CONTROL RELAY HEATING PUMP CONTROL RELAY CIRCUIT A HEATING PUMP CONTROL RELAY CIRCUIT B BOILER SENSOR DOMESTIC HOT WATER SENSOR TITA...

Page 23: ...run 1 The potentiometer on the PCB in the boiler is used to adjust the DHW pump overrun The overrun can vary with an adjustment range from 0 to 10 minutes factory setting 4 min Setting the Domestic Hot Water Load Temperature Limiter 2 The potentiometer on the P C B in the boiler is used to adjust the boiler temperature while heating domestic hot water The load temperature setting can vary from 60 ...

Page 24: ... panel clear from the clips and the notches in the top part pulling it towards you 4 Remove the front panel from the notches near the bottom of the side panels 5 Unscrew the attachment screw fastening the front of the control panel 6 Tilt the front panel 7 Remove the shunt bridge 8 Close the control panel and put the front panel back into position using the same procedure as for disassembly in the...

Page 25: ...rmittently operating the DHW load pump and the CH pump This air elimination sequence is de activated if the calorifier temperature is more than 250 C Summer Winter Switch If DHW has been in demand a delay of approx 1 minute will occur for the change from the DHW pump to the CH pump after the changeover to Winter mode MESSAGES ALARMS The display may show the following messages in the case of a malf...

Page 26: ...TRICAL INSTALLATION 1 Checks to ensure electrical safety should be carried out by a competent person 2 ALWAYS carry out the preliminary electrical system checks i e earth continuity polarity resistance to earth and short circuit using a suitable meter WARNING Whilst effecting the required gas soundness test and purging air from the gas installation open all windows and doors extinguish naked light...

Page 27: ...leaning the Casing Material and Control Cover Use a soapy solution and sponge only Rinse with clean water and dry with chamois leather or soft cloth 2 4 3 3 2 1 buc5523 47 CLEANING THE FLUEWAYS 1 Disconnect the burner cable 2 Unfasten the four flanged nuts and flat washers using a 13mm spanner and open the burner door buc5534 2 2 1 only on 3 section boilers buc5535 3 Remove the baffle plates if ne...

Page 28: ...he system hot examine all water connections for soundness Check the gas rate and measure the combustion CO CO2 content Complete the boiler log book Carry out functional checks as appropriate 50 SERVICING SCHEDULE To ensure the continued safe and efficient operation of the appliance it is recommended that it is checked at regular intervals and serviced as necessary The frequency of servicing will d...

Page 29: ...NGS Installation commissioning and maintenance must be carried out by a qualified technician in accordance with installation practices and the instructions in this document Regular maintenance of the equipment is necessary to ensure safe and reliable performance For the guarantee to remain valid no modifications must be made to the domestic hot water tank Central heating water and domestic hot wat...

Page 30: ...d the location of which must comply with local recommendations 61 buc5537 1 4 2 3 355 1011 1181 756 158 285 738 516 286 7 6 5 300 600 C 130 F B 930 160 1306 250 53 82 5 918 4 x M8 on o 150 Burner Plate Cutout o 110 Insulation Cutout o 130 570 600 600 489 35 1488 18 283 GTE 4 160 GTE 5 160 GTE 6 160 163 283 1306 GTE 5 250 GTE 6 250 B C D F 692 819 946 819 946 812 939 1066 939 1066 125 125 153 125 1...

Page 31: ...sleeve in steel cast iron or insulating material must be placed between the hot water outlet of the unit and this pipework so as to avoid any corrosion at the level of the branch pipe Notes The safety unit and its connection to the tank must be at least of the same diameter as the tanks domestic cold water supply pipework minimum 3 4 The safety unit s outlet pipe must have sufficient continuous sl...

Page 32: ...l 54 YA type pressure change health regulations 56 Return circulation loop 57 Domestic hot water outlet 54 PACKAGING The following table shows the box numbers included with the boiler to be installed Boiler GTE 4 160 GTE 5 160 GTE 5 250 GTE 6 160 GTE 6 250 FM 2 Boiler body FM 3 FM 3 FM 4 FM 4 FM 11 Jacket and Insulation FM 12 FM 12 FM 13 FM 13 FM 126 Control Panel FM 126 FM 126 FM 126 FM 126 AD 21...

Page 33: ...feet Basic height 35mm adjustment range 35 40mm 19 buc5542 57 ASSEMBLING THE BOILER ON THE HOT WATER CALORIFIER Locate the boiler on top of the hot water calorifier ensuring accuracy of dimension P at the front The boiler can be lifted using two 3 4 tubes placed as shown Screw the adjustable boiler feet all the way in to the minimum position 25mm Boiler GTE 4 L160 Model GTE 5 L160 L250 GTE 6 L160 ...

Page 34: ...nsor in the attachment lug provided for it on the tank inspection plate Make the electrical connection in accordance with the instructions for the control panel 6 Put the thermal insulation into place sliding it between the cables and the plate 7 Attach the front panel of the hot water calorifier If the DHW kit is being fitted to a remotely located calorifier the sensor lead may be extended using ...

Page 35: ...pump adapter elbow to the tank return pipe 4 Fit the other adapter elbow to the tank flow pipe 5 Plug or fit drain cocks to the bottom outlets at the tank adaptors 1 Fit the pump to the tank adaptor ensure access to speed control and vent screw 2 Fit the flexible pipe from the boiler flow adaptor to the pump 3 Fit the flexible pipe from the tank adaptor to the boiler return adaptor 4 Fit the air v...

Page 36: ...f the tank by pressing the boiler start stop button WARNING Top up the primary circuit with water 5 Put the non return valve into the automatic position A 6 Put the automatic air vent back into place 64 DOMESTIC HOT WATER CIRCUIT SECONDARY CIRCUIT buc5545 A O 1 4 6 3 2 5 0 I Fill the calorifier through the domestic cold water inlet tube Vent the domestic hot water circuit the calorifier and the di...

Page 37: ... the drain position before starting to drain the safety unit and open a hot water tap to allow air to enter Lift up the front panel to remove it Remove the sensor Remove the inspection flange 13mm spanner Remove sludge or scale deposited in the bottom of the tank There is no need to remove scale from the walls Put the inspection trap back into place making sure that the sensor attachment tab is fa...

Page 38: ...38 Buccaneer GTE Installation Servicing NOTES ...

Page 39: ...39 Buccaneer GTE Installation Servicing NOTES ...

Page 40: ...inuing improvement in the design and performance of its products The right is therefore reserved to vary specification without notice The Ideal Boilers Technical Training Centre offers a series of first class training courses for domestic commercial and industrial heating installers engineers and system specifiers For details of courses please ring 01482 498 432 Ideal Installer Technical Helpline ...

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