ENGLISH

GTE 500 GTE 500 K GTE 500 DIEMATIC-m Delta

Fuel oil/gas boilers

Assembling, Installation and maintenance instructions

04/07/03 - 94862872 - 8555-4209A

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

1.1 Technical specifications

Maximum operating pressure : Maximum operating temperature : Maximum safety temperature of boiler : (as per TRD 702)
TYPE OF BOILER Useful efficiency

6 bar 100C 120C

Boiler thermostat setting : Safety thermostat setting :

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

Power input Number of sections Water capacity

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

1019 1057 1095

Water T=10K mbar 18 resistance T=15K mbar 8

(1)

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

T=20K mbar 4.5 mbar 1.7

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

208 Flow detector D E R A Min. height for sweeping = 850

GTE 500

208

1.2 Main dimensions

616 K 1080 T F Burner centre line 370

100 223

17,5 240 140 Max. 500 Max. 700

S C 741 U 815 300 565 E 200 791

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

The sizes are given in mm

8555N045-GB

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

(1) For China : E = 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

DIEMATIC + K 355 P (mm) Standard 130

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

2. INSTALLING THE BOILER

2.1 Boiler location
For the assembly and because of their design, GTE 500 boilers require no special base or stand and their closed furnace system means that the floor need not have refractory properties. All you have to ensure is that the floor can support the weight of the boiler when it is fitted for operation.If the boiler location is not determined precisely, leave enough space around the boiler to facilitate monitoring and maintenance operations.

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. Straight connection (not supplied) 2. Angled connection (not supplied)

(1) In

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

GTE L M C min. D min.

507 1305 248 300 -

508 1445 265 300 -

509 1555 319 300 -

510 1645 243 300 -

511 1755 297 300 -

512 1845 221 300 -

513

514

515 2245 324 436 136

1955 2105 275 300 259 300 -

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

Draining outlet 3/4 tap

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

GTE C (mm) D (mm) H (mm)

507 1488 240 21

508 1488 211 -8

509 1488 212 -7

510 1488 233 14

511 1488 234 15

512 1488 255 36

513

514

515 1488 188 -31

516 1488 189 -30

517 1488 210 -9

518 1504 236 -8

1488 1488 256 37 217 -2

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.

4.3 Filling the system

Filling shall be performed with a low flow rate from a low point in the boiler room in order to ensure that all the air in the boiler is bled from the high point of the system. Always stop the pump before filling. VERY IMPORTANT : Instructions for starting up the boiler for the first time after the system is fully or partly drained : If all the air is not bled naturally to an expansion vessel which opens out onto the air, the system must include manual bleeder valves, in addition to automatic 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 filled system is free of air before the burner is turned on.

4.4 Sludge removal

A tapped 2" hole with a plug has been provided on the bottom of the front of the boiler. Fit a quarter-turn valve on the opening to remove the sludge. Sludge removal leads to the draining of large quantities of water, so remember to refill the system after the operation.
Note : never replace a boiler in an existing system without carefully rinsing the system first. Install a sludge decanting pot on the return pipe, very close to the boiler.

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.

5.1 Flue size

Refer to applicable regulations while determining the size of the flue. Please note that GTE 500 boilers have pressurised and tight furnaces and that the pressure at the nozzle must not exceed 0 mbar, unless special sealing precautions have been taken, for instance in order to connect a static condenser/regenerator.

5.2 Connecting to the flue

The connection shall be removable, and offer minimum load losses, i.e. it must be as short as possible with no sudden change in section. Its diameter shall always be at least equal to that of the boiler outlet, i.e. : - 300 mm for 7-9 sections - 350 mm for 10-13 sections - 400 mm for 14-20 sections. - Boilers with 21-25 sections are supplied with a plain plate. The maximum cut-out dimensions are 500 x 700 mm. 815mm Fit a measuring point ( 10 mm hole) on the flue, in order to adjust the burner (combustion check).
K

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

515 400 -19

516 400 -18

517 400 3

518 400 4

519 400 25

520 400 -24

521 plain plate -23*

522 plain plate -2*

523 plain plate -1*

524 plain plate 20*

525 plain plate 21*

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.

6. FUEL-OIL OR GAS CONNECTIONS

Refer to the instructions supplied with the burner.

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

8.2 Cleaning the casing material

Use a soapy solution and a sponge only. Rinse with clean water and dry with chamois leather or a soft cloth.

8.3 Precautions required in the case of long boiler stops

(one or several years) The boiler and the chimney must be swept carefully. Close all the doors of the boiler to prevent air from circulating inside the boiler. We advise removing the pipe which connects the boiler to the chimney and to close off the nozzle with a cover.

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. SYSTEM MAINTENANCE

10.1 Water level
Regularly check the level of water in the system and top up if required, taking care that cold water is not added suddenly into the boiler when it is hot. This operation should be required only a few times in each heating season, with very low quantities of water. Otherwise, look for the leak and repair it.

10.2 Draining
We advise you against draining the system unless it is absolutely necessary.

11

11. IDENTIFICATION PLATE

The identification plate fixed on the side of the boiler during installation is used to identify the boiler correctly. It also provides the main specifications of the boiler. (1) 09 = 1999, 00 = 2000, ... Type of boiler year week
(1)

XX - XX Date of manufacture

F 67110 NIEDERBRONN

Unit serial no.

8555N156

12. SPARE PARTS

Refer to the following page.

12

8555-4017A

Spare parts

GTE 500 - GTE 500 K GTE 500 DIEMATIC-m Delta

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

GTE 500 - GTE 500 K GTE 500 DIEMATIC-m Delta

INSULATION

70

71

8555N198

2/6

GTE 500 - GTE 500 K GTE 500 DIEMATIC-m Delta

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

GTE 500 / GTE 500 K / GTE 500 DIEMATIC-m Delta

Ref. Code no. DESCRIPTION BOILER BODY + ACCESSORIES Frame 1 1 1 1 1 1 1 1 1 1 8259-8953 8259-8954 8259-8955 8259-8956 8259-8957 8259-8958 8259-8959 8259-8960 8259-8961 8259-8962 Complete frame, 7 sections Complete frame, 8, 9 sections Complete frame, 10, 11 sections Complete frame, 12, 13 sections Complete frame, 14, 15 sections Complete frame, 16, 17 sections Complete frame, 18, 19 sections Complete frame, 20, 21 sections Complete frame, 22, 23 sections Complete frame, 24, 25 sections Body + accessories 2 3 4 5 6 7 8 9 10 11 12 13 14 14 14 14 15 16 17 18 18 18 18 18 18 18 18 18 18 18 18 18 8555-5505 9495-0140 8259-8948 8259-8949 9495-0110 8500-0027 9758-1286 8259-8950 8006-0212 9430-5027 9508-6032 9428-5095 8015-8927 8015-8928 8015-8929 8015-8930 9754-0120 8015-8902 8015-7700 8015-8907 8015-8908 8015-8909 8015-8910 8015-8911 8015-8912 8015-8913 8015-8914 8015-8915 8015-8916 8015-8917 8015-8918 8015-8919 Complete rear section 3/4" plug, no. 290 Normal intermediate section Special intermediate section 1/2" plug, no. 290 1/2" pocket Spring for pocket Complete front section Painted nipple 148.62 Putty for nipple (300 g) Silicone-coated fibreglass seal Silicone filler tube (310 ml) Assembly rod, 12 - 300 long Assembly rod, 12 - 385 long Assembly rod, 12 - 420 long Assembly rod, 12 - 520 long Spring for assembly rod Complete indicator with frame Sight glass + gaskets Assembly rod, 14 - 910 long, 7 sections Assembly rod, 14 - 1006 long, 8 sections Assembly rod, 14 - 1117 long, 9 sections Assembly rod, 14 - 1228 long, 10 sections Assembly rod, 14 - 1339 long, 11 sections Assembly rod, 14 - 1450 long, 12 sections Assembly rod, 14 - 1571 long, 13 sections Assembly rod, 14 - 1683 long, 14 sections Assembly rod, 14 - 1796 long, 15 sections Assembly rod, 14 - 1908 long, 16 sections Assembly rod, 14 - 2021 long, 17 sections Assembly rod, 14 - 2133 long, 18 sections Assembly rod, 14 - 2246 long, 19 sections 27 28 29 30 31 8008-8924 8228-8905 9757-0424 9755-0235 9755-0236 26 8008-8909 24 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 26 8008-8922 8802-4731 8802-4734 8802-4736 8802-4738 8802-4740 8802-4742 8802-4743 8802-4745 8802-4746 8802-4752 8802-4739 8802-4753 8802-4740 8802-4754 8802-4741 8802-4755 8802-4742 8802-4756 8802-4757 8802-4758 8802-4759 8008-8908 23 8008-8905 Ref. 18 18 18 18 18 18 19 20 21 22 23 Code no. 8015-8920 8015-8921 8015-8922 8015-8923 8015-8924 8015-8925 8006-8906 8006-8907 9501-4155 8112-0028 8008-8904 DESCRIPTION Assembly rod, 14 - 2398 long, 20 sections Assembly rod, 14 - 2511 long, 21 sections Assembly rod, 14 - 2623 long, 22 sections Assembly rod, 14 - 2736 long, 23 sections Assembly rod, 14 - 2848 long, 24 sections Assembly rod, 14 - 2960 long, 25 sections Plain square flange + gasket Square flange with 2" tapped hole + gasket 222 x 170 x 4 gasket 2" plug Flange with outlet piece + gasket for 7 - 17 sections (Export) and 7 - 21 sections (China) Flange with outlet piece + gasket for 18 - 25 sections (Export) Nozzle + gasket Flow switch 7 sections Flow switch 8 sections Flow switch 9 - 16 sections Flow switch 10 - 17 sections Flow switch 11 sections Flow switch 12 sections Flow switch 13 sections Flow switch 14 sections Flow switch 15 sections Flow switch 18 sections (Export) Flow switch 18 sections (China) Flow switch 19 sections (Export) Flow switch 19 sections (China) Flow switch 20 sections (Export) Flow switch 20 sections (China) Flow switch 21 sections (Export) Flow switch 21 sections (China) Flow switch 22 sections (Export) Flow switch 23 sections (Export) Flow switch 24 sections (Export) Flow switch 25 sections (Export) Flange with return piece + gasket for 7 - 17 sections (Export) and 7 - 21 sections (China) Flange with return piece + gasket for 18 to 25 sections (Export) Diaphragm + gasket Complete articulation of furnace plate Plain furnace door Furnace door guard Furnace door insulation

4/6

GTE 500 / GTE 500 K / GTE 500 DIEMATIC-m Delta

Ref. 32 33 34 35 36 37 37 37 37 38 39 40 41 42 43 44 45 46 47 48 49 49 49 49 49 52 52 Code no. 8008-8915 8555-8592 8555-5528 8208-0010 9504-6115 8555-5508 8555-5506 8555-5507 8555-5509 9508-6041 8555-5514 8555-5541 8555-5510 8555-5511 8555-5512 8555-5513 8555-8593 9508-6032 8555-5515 8259-0010 8008-8910 8008-8911 8555-5502 8555-5503 8555-5504 9434-5102 9434-5104 DESCRIPTION Furnace plate hinge Bag of screws for furnace door Flue gas outlet + braid Cast-iron cleaning cover 15 Thermocord gasket 400 connection plate + gasket 300 connection plate + gasket 350 connection plate + gasket Plain connection plate +gasket 15 x 9 adhesive gasket Left-hand sweeping door + braid Right-hand sweeping door + braid N1 sweeping cover + braid N2 sweeping cover + braid N3 sweeping cover + braid N4 sweeping cover + braid Bag of screws for sweeping door Silicone-coated fibreglass seal Complete lock Upper baffle Distributing tube + gasket for 15 and 16 sections Distributing tube + gasket for 17 to 19 sections Distributing tube + gasket for 20 to 22 sections Distributing tube + gasket for 23 and 24 sections Distributing tube + gasket for 25 sections Retouching spray paint - anthracite grey Retouching spray paint - ivory Cleaning tools 60 61 61 62 62 63 63 63 9696-8026 8013-8703 8013-8704 8015-8716 8015-8723 9750-5103 9750-5106 9750-5108 Brush for plate Metal brush + 1300 long rod for 7 to 10 sections Metal brush + 1800 long rod for 11 to 15 sections Metal brush + 1300 long rod + extension for 16 to 22 sections Metal brush + 1800 long rod + extension for 23 to 25 sections 1200 long scraper 1500 long scraper 1800 long scraper 80 80 80 80 80 80 80 80 80 80 80 81 82 82 82 82 INSULATING MATERIAL Insulating material for body 70 70 70 70 70 70 8555-5516 8555-5517 8555-5518 8555-5519 8555-5520 8555-5521 Complete insulating material for body, 7 sections Complete insulating material for body, 8 and 9 sections Complete insulating material for body, 10 sections Complete insulating material for body, 11 and 12 sections Complete insulating material for body, 13 and 14 sections Complete insulating material for body, 15 sections 82 82 82 82 82 82 82 83 8555-8008 8555-8009 8555-8010 8555-8011 8555-8012 8555-8013 8555-8014 8555-8015 8555-8016 8555-8017 8555-8018 8555-8021 8555-8035 8555-8036 8555-8037 8555-8038 8555-8039 8555-8040 8555-8041 8555-8042 8555-8043 8555-8044 8555-8045 8555-8048 BOILER CASING 1225 long rail 1365 long rail 1475 long rail 1565 long rail 1675 long rail 1765 long rail 1875 long rail 2025 long rail 2165 long rail 2275 long rail 2365 long rail 1246 long supplementary rail 1260 long left-hand cable channel 1400 long left-hand cable channel 1510 long left-hand cable channel 1600 long left-hand cable channel 1710 long left-hand cable channel 1800 long left-hand cable channel 1910 long left-hand cable channel 2060 long left-hand cable channel 2200 long left-hand cable channel 2310 long left-hand cable channel 2400 long left-hand cable channel 1260 long right-hand cable channel 71 71 71 71 71 71 71 71 71 71 71 71 8555-5529 8555-5530 8555-5531 8555-5532 8555-5533 8555-5534 8555-5535 8555-5536 8555-5537 8555-5538 8555-5539 8555-5540 Ref. 70 70 70 70 70 70 Code no. 8555-5522 8555-5523 8555-5524 8555-5525 8555-5526 8555-5527 DESCRIPTION Complete insulating material for body, 16 and 17 sections Complete insulating material for body, 18 and 19 sections Complete insulating material for body, 20 sections Complete insulating material for body, 21 and 22 sections Complete insulating material for body, 23 and 24 sections Complete insulating material for body, 25 sections Insulating material for sweeping covers Complete insulating material for sweeping covers, 7 sections Complete insulating material for sweeping covers, 8 and 9 sections Complete insulating material for sweeping covers, 10 sections Complete insulating material for sweeping covers, 11 and 12 sections Complete insulating material for sweeping covers, 13 and 14 sections Complete insulating material for sweeping covers, 15 sections Complete insulating material for sweeping covers, 16 and 17 sections Complete insulating material for sweeping covers, 18 and 19 sections Complete insulating material for sweeping covers, 20 sectionss Complete insulating material for sweeping covers, 20 and 21 sections Complete insulating material for sweeping covers, 23 and 24 sections Complete insulating material for sweeping covers, 25 sections

5/6

GTE 500 / GTE 500 K / GTE 500 DIEMATIC-m Delta

Ref. 83 83 83 83 83 83 83 83 83 83 84 85 85 85 85 85 85 85 85 85 85 85 86 Code no. 8555-8049 8555-8050 8555-8051 8555-8052 8555-8053 8555-8054 8555-8055 8555-8056 8555-8057 8555-8058 8555-8080 8555-8066 8555-8067 8555-8068 8555-8069 8555-8070 8555-8071 8555-8072 8555-8073 8555-8074 8555-8075 8555-8076 8555-8079 DESCRIPTION 1400 long right-hand cable channel 1510 long right-hand cable channel 1600 long right-hand cable channel 1710 long right-hand cable channel 1800 long right-hand cable channel 1910 long right-hand cable channel 2060 long right-hand cable channel 2200 long right-hand cable channe 2310 long right-hand cable channel 2400 long right-hand cable channel 1196 long additional cable channel 1131 long central upper plate 1271 long central upper plate 1381 long central upper plate 1471 long central upper plate 1581 long central upper plate 1671 long central upper plate 1781 long central upper plate 1931 long central upper plate 2071 long central upper plate 2181 long central upper plate 2271 long central upper plate 1196 long additional central plate Common parts 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 8259-8014 8555-8515 8259-8818 8555-8516 8555-8517 8555-8518 8259-8021 8259-8022 8259-0518 8555-8519 8555-8520 8555-8521 8259-8055 8555-8522 8555-8526 8555-8082 8555-8523 8555-8022 8555-0526 9532-0780 9775-8859 Lower front crosspiece Fastening bracket for front side pane Complete lower front side panel Complete upper front panel Complete lower front panel Upper rear panel Lower left-hand rear panel Lower right-hand rear panel Panel for furnace door Control panel trim Rear cover for standard control panel Control panel bracket Lower rear crosspiece Upper crosspiece Intermediate upper crosspiece Joining central plate Lower tab of rail Upper bracket Upper front crosspiece Ring Rapid nut 200 201 9536-2215 9536-5186 OPTIONAL FEATURES 135 mm long dip sensor, BP 42 R 1/2 pocket, 120 mm long Diematic-m Delta CONTROL PANEL - FA 1 Refer to the specific list under "Fuel-fired boilers" in the Spare Parts catalogue K CONTROL PANEL - FA2 Refer to the specific list under "Fuel-fired boilers" in the Spare Parts catalogue STANDARD CONTROL PANEL - FA3 Refer to the specific list under "Fuel-fired boilers" in the Spare Parts catalogue 114 114 115 116 116 8555-8500 8555-8501 8555-8513 8555-8505 8555-8506 110 110 110 111 112 112 112 112 113 113 8555-8502 8555-8503 8555-8504 8555-8514 8555-8507 8555-8508 8555-8509 8555-8510 8555-8511 8555-8512 Ref. 108 Code no. 8555-8525 DESCRIPTION Fasteners for common parts Front side casing 800 long front side panel 940 long front side panel 1050 long front side panel Fasteners for front side panel 800 long right-hand upper front plate for sweeping 940 long right-hand upper front plate for sweeping 1050 long right-hand upper front plate for sweeping 800 long left-hand upper front plate for sweeping 940 long left-hand upper front plate for sweeping 1050 long left-hand upper front plate for sweeping Rear side casing 400 long rear side panel 600 long rear side panel Fasteners for rear side panel 400 long upper rear plate for sweeping 600 long upper rear plate for sweeping

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

ASSEMBLY OF GTE 500 BOILERS

Important : Assemble the boiler in the order given by the numbers of each figure, in compliance with all the instructions.

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.

Boiler body + accessories

- Boilers supplied with an assembled body :

GTE 500 boiler Number of sections Assembled boiler body (contents depend upon model) Cleaning tool kit (contents depend upon model) 7 1 1 8 1 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 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

- Boilers supplied with an unassembled body :

GTE 500 boiler Number of sections Frame (dimensions depend upon model) Rear section Normal intermediate section Special intermediate section Front section Set of assembly rods + cleaning tools
(contents depend upon model)

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

Standard accessory kit

(contents depend upon model)

1 package (Export) 1 package (China)

Additional accessory kit

(contents depend upon model)

1 package 300 350 400

Plain furnace plate Flue gas connection plate with opening Plain flue gas connection plate Flue gas box Distributing tube fitting *

FA FA FA FA FA FA FA FA FA 47 48 49 50*51*52*53*54* 55 FA FA FA FA FA FA FA FA FA 47 48 49 50*51*52*84*85* 86 FA FA FA FA FA FA FA FA FA 66 67** 68** 69 70 71 72 73 74 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

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

GTE 500 boiler Baffle plates

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

GTE 500 boiler Box with technical documents

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

GTE 500 boiler Casing fittings

Variable casing parts

Number of sections Package FA 16 Package FA 17 Package FA 18 Package FA 19 Package FA 20 Package FA 21 Package FA 22 Package FA 23 Package FA 24 Package FA 25 Package FA 26 Package FA 27 7 1 1 8 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 1 1 1 1 1 1 1 1 1

GTE 500 boiler

Body insulating material

Number of sections Package FA 30 Package FA 31 Package FA 32 Package FA 33 Package FA 34 Package FA 35 Package FA 36 Package FA 37 Package FA 38 Package FA 39 Package FA 40 Package FA 41 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 1

GTE 500 boiler

Body insulating material

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

GTE 500 boiler

Standard control panel K control panel Diematic-m control panel

Accessories available as an option *

Number of sections 7 1 1 8208-7757 8208-7758 8208-7759 8208-7760 1 8 1 1 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 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

GTE 500 boiler

Furnace plate with 165, 186, 210, 240, or 295 hole Connecting plate with 300 opening or plain connecting plate Set of anti-vibration studs

* 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.

The number of sections of each type is provided in the table below :

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

7, 8, 10, 12, 14, 16, 18, 20, 22, 24 sections :

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

9, 11, 13, 15, 17, 19 21, 23, 25 sections :

FRONT

VORN AVANT

TOP BOTTOM
S O B N E U

8555N001

DE SS US N BE -O OP -T

P O T

FRONT N VOR ANT AV

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 Gently push in the two nipples.

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

Assembling the side assembly rods

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

Assembling the baffle plates

GTE 507 - 509 GTE 510 - 514 GTE 515 - 519 GTE 520 - 525

Boiler Total number of baffle plates Package no.

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

Assembling the sweeping covers

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

Number of sweeping covers per type FRONT REAR 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 4 2 6 4 4 6 2 6 6 8 6 6 8 10 2 2 6 2 2 2 4 2 2 2

REAR

2 Handles turned outward 3

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

Putting in place the lower trap doors

Front and rear

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

Rigid refractory plate

18
7

Installing the hinge of the furnace door

Two 3.94 x 25.4 SIM screws

Two 3.94 x 25.4 SIM screws

8259N023

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 Place the furnace door on the floor and fasten the

articulation onto the door with three HM 12 screws.

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

G Fit the door onto the hinge by inserting the pin

.
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

Flame inspection window

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

Assembling the return flange on boilers GTE 507 - 525

Boiler type L (mm)

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

GTE 515 - GTE 525 (Export) Package FA 50 to FA 60

GTE 515 - GTE 521 (China) Package 50, 51, 52 or FA 84 to FA 87

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

Fitting the boiler outlet flange

GTE 507 - GTE 515
Package FA 42 to FA 50

24

Fitting the boiler outlet flange

GTE 516 - GTE 525 (Export)

Package FA 51 to FA 60

GTE 516 - GTE 525 (China)

Package FA 51, 52 or FA 84 to FA 87

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

Assembling the flow switch

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.

Boiler Total number of baffle plates Package no.

GTE 507 - 509

GTE 510 - 514 GTE 515 - 519 GTE 520 - 525

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

Assembling the upper crosspieces (package FA 5 or FA 6)

31

Assembling the pocket GTE 507 - 519 Front

(for boilers supplied with an assembled body only)

In boilers supplied with an unassembled body, the crosspieces are already in place (see figure 12)

REAR

FRONT

2mm 2mm

GTE 520 - 525 Front

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

Assembling the cable channels (7 -17 sections)

33

Assembling the top insulating material (7 - 17 sections)

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.

No. of 7, 8, 9 sections Length 1200 (mm)

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.

34 Assembling the cable channels and

crosspieces (18 - 25 sections)

35

Assembling the additional cable channels (18 - 25 sections)

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

Assembling the top insulating material (18 - 25 sections)

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

Assembling the lower rail support brackets

Example : GTE 507

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

Rail support brackets

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

11, 13, 15, 17 sections

Right-hand side Rail support brackets

12, 14, 16 sections

Right-hand side

Rear

Frame

Front

Rear

Frame

Front

Left-hand side

Rail support brackets

m22

Left-hand side
8555N182-GB

38c
18, 20 sections
Right-hand side

Rear

Frame

Front

Rail support brackets

Left-hand side

19, 21 sections
Rail support brackets Right-hand side

Rear

Frame

Front

Rail support brackets

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

Rail support brackets

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

Installing the insulating material

REAR Side insulating material (length in mm)

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

400 600 600

2
600

400 1200 1200 1200 1200 400

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

Example : GTE 516

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

Assembling the side casing panels

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

400 400 400 400

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

Assembling the furnace door and lower crosspiece panels

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

Assembling the control panel bracket (all control panels)

2

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

Standard Control Panel

(Go directly to figure 50 for the DIEMATIC-m Delta control panel or K control panel)

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

47 Installing the standard control panel

48

Standard control panel

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

Standard control panel

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

DIEMATIC-m Delta or K control panel

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

Fitting the DIEMATIC-m Delta or K control panel

52 DIEMATIC-m Delta and K control panel

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

G Put in place the insulating material as shown above.

m30

57

Section A-A
Rapid nut Cable channel Control panel bracket

58

Serrated washer Mounted screw

Front crosspiece

Control panel trim

A
8555N160 8555N185

G Unfasten the screws

(mounted in fig. 50). along the screws .

G Fix the trim to the control panel using two tapping screws and serrated washers.

G Slide the control panel trim G Fasten the screws

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

Assembling the central plate for 7 - 17 sections

66

Assembling the central plate for 18 - 25 sections

2 3 1

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

400 400 400 600 600 400 400 600 600

400 400 400 400

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)

year week Type of boiler

XX - XX Date of manufacture

F 67110 NIEDERBRONN

Unit serial no.

8555N156

G Glue the identification plate and CE marking on the casing of the boiler in an easily visible location.

(1) 09 = 1999, 00 = 2000,

m34

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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