IDEAL INDUSTRIES BUC5034 User's Manual
Contents
1. ZG F 6 3AT L BA Remove bridge LP to benefit LP from the M auo EST heating pump logic N 7 BA A Heating pump RG Control unit ZEH2 Heating pump Summer B Burner TAM Room thermostat Winter switch BA Connection strip TCH Boiler thermostat ZG Main switch CH Time counter TF Flue gas thermostat ZT Test switch cs Safety contact TL Limiting thermostat i Optional F6 3AT Fuse TS Safety thermostat Connecting strip L Phase VA Alarm indicator Connector LP Pump logic V3V Three way valve N Neutral ZEH1 Burner Summer P Filling pump Winter switch BUC5031 4 7 Connecting the Burner The boiler is fitted with a cable with a 7 pin European connecting plug which can be plugged into the socket supplied with the burners see the instructions supplied with the burner Buccaneer GT Falcon GTE Installation Assembly amp Servicing 19 ASSEMBLY 5 COMMISSIONING e g Buccaneer GT BUC5032 Ensure connections are watertight Vent the tank heat exchanger as follows 1 Unscrew the auto vent cap P a few turns 2 Turn the antisyphon valve screw 10 to open position O 3 Close the vent P when water flows continuously 4 Return the antisyphon valve screw 10 to the automatic position A 5 To2. in order to avoid the risk of combustion products condensing on the walls of the boiler 5 2 Commissioning Secondary Circuit If needed flush the sanitary circuit especially if re starting and fill the tank using the sanitary cold water inlet pipe Bleed the secondary circuit tank and distribution system in order to avoid any noise caused by trapped air moving during re heating and drawing off To do this fill it completely with water leaving a hot water tap open close this tap only when the flow of water is continuous and noise free Then bleed in succession all hot water pipes by opening the corresponding taps s Bleed the tank s exchanger circuit using the vent made for the purpose Check all safety units especially the safety valve or group referring to the leaflet supplied with the component WARNING During the heating of domestic hot water some water may escape through the safety valve or group as a result of the expansion of water in the unit There is no cause for concern as this is entirely normal Do no attempt to prevent this from happening Buccaneer GT Falcon GTE Installation Assembly amp Servicing SERVICING 6 MAINTENANCE AND PERIODIC CHECKS Safety valve or group WARNING IMPORTANT The safety unit must be used periodically at least once per month To do this place the safety group in the draining position This allows the evacuation of any deposits wh
3. 2006 156597 A02 5 Ideal Ideal Installer Technical Helpline 01482 498 376 www idealboilers com
4. 250 litre kg 1 Domestic cold water at 10 C Domestic hot water at 45 C Primary at 80 C 2 Storage temperature 60 C 3 Boiler temperature 80 C Ambient temperature Tank Details 425 5 Note With IDEAL boilers the setting limits the temperature of the primary circuit at the beginning to 75 C adjustment is possible from 50 C to 95 C Tank Type MLS 150 III MLS 250 II Primary circuit central heating water Water capacity of coil litres 5 9 7 2 Exchange surface of coil m 0 92 1 2 Secondary circuit sanitary water Water capacity 150 250 Delivery weight 100 Buccaneer GT Falcon GTE Installation Assembly amp Servicing 130 GENERAL 1 2 Main Dimensions 530 1 35 1 thread 1 4 thread N outlet 1 4 Buccaneer GT Combination Boiler ig ia T4 B 2 Optional re delivered a 3 4 dhw loop return burner 1 2 optional tapped draining y outlet gt 3 4 dew inlet F gas nozzle flue 600 1030 4 150 I BUC5000 355 205 lt 560 7214
5. shall be made to the connection strip provided for that purpose outside the volume of the control panel Side Low Voltage Connections Sensor e g Buccaneer G Side 230V o BUC5020 4 4 installation with MB1 Domestic Hot water Priority and Regulation Mode Fitting and Connecting the MB1 Module Fit the MB1 module on the front of the control panel Proceed as follows 1 Remove the cover cut the four fixing studs of the cover with a knife and fold it outward 2 Install and connect the MB1 module as directed on pages 16 18 Buccaneer GT Falcon GTE Installation Assembly amp Servicing il BUC5042 15 ASSEMBLY Install domestic hot water sensor cable A e g for Buccaneer GT as shown and fix it with plastic clips B Insert the sensor in the thimble tube of the tank Connect as directed in the diagram on the following pages Insert the bulb of the limiting thermostat in the thimble tube on the rear of the boiler Tank Sensor Installing the bulb in the tank thimble tube BUC5043 4 5 MB1 Domestic Hot Water Sensor Operating and Installation Package AD127 Boiler Sensor BUC5044 BUC5021 The MB1 module allows for regulation of the storage temperature and ensures priority for the production of hot water for sanitary systems When there is a demand for the sanitary hot water to be reheated the MB 1 module activ
6. vent the pump unscrew the protection cover in the pump head and turn the pump shaft V left and right a few times 6 Leave the pump running with cold water for a few minutes to prime the system Not supplied 5 1 Starting Up Initial starting up shall be performed by a qualified professional Before turning the boiler on make sure that the installation is filled with water Perform the start up operations in the chronological order given below referring to the diagram on page 14 Set boiler thermostat 7 to the selected position move the stop if required WARNING IMPORTANT if the boiler is fitted with a room thermostat set boiler thermostat 7 to the maximum position Set the domestic hot water temperature setting potentiometer to the desired temperature versions with MB1 Check the position of three position switch 5 which must be as follows either set to manual M boilers without room thermostats or set to AUTO automatic boilers with room thermostats 20 s Make sure that safety thermostat 6 is set by unscrewing the hexagonal cap and pressing the reset button with a screwdriver Turn On Off switch 1 to On e Turn burner switch 2 to Winter If the boiler is fitted with an MB1 domestic hot water module this switch is disabled by the optional unit Turn heating pump switch 3 to Winter Note We advise you never to set the boiler thermostat below mark 4 40 C
7. 346 Heating outlet 150 N R1174 flue gas a nozzle Heating OR return 20 _ il 20 _ Tt ct TT Burner Rp 3 4 A Na centre Tine l 4 to be plugged i T 4 ml l 4 R 3 4 outlet l to wa SH X l Optional i 4 1 m R 2 4 dhw loop delivered a i return optional burner ii io a H 3y ML ey 4 i 1 R 4 dow inlet a 9 4 15011030 1501 1274 2501 o 80 600 1180 1501 1424 250 300 300 1 Adjustable feet basic height 10 mm with 9 15 mm adjustment range Rp T apped R T hreaded 5 150 I 4 250 I 5 250 I BUC5025 Buccaneer GT Falcon GTE Installation Assembly amp Servicing INSTALLATION 2 INSTALLING THE BOILER 2 1 Boiler Location Sufficient space shall be left clear around the boiler The figure stated in metres in the drawings below are the minimum recommended dimensions for providing easy access around the boiler Buccaneer GT A T Falcon GTE GTE 4 150 I 5 150 I vent 1424 1587 BUC5001 5 250 BUC5038 2 2 Ventilation WARNING The location of air inlets in relation to the high ventilation openings shall ensure that the air is renewed in the entire volume of the boiler room The ventilation shall comply with any applicable national or local regulations 2 3 Assembly The upper section of the MLS 150 tank only is provided with marks al
8. Bee SSS 22 Fes MSs zng Souk 255 SSE SeS6nS Sa SHE ZEES Sar 25S EH fer782 259 ou ar B20 Suna DnB nS ow wz n iin H Lu niljenunelen AF CS Ta DXA COMMANDE A DISTANCE ALI i TL LP 230V 50Hz TAM T vw Of Om SONDE SONDE SONDE SONDE 13 12 11 10 6 7 8 9 10 11 12 13 1415 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Ogopgogodgotgcogcgcorgogcducgogcdgogcdgogopgcrtgogo Ogogogopgcogogopcogco gcygo BHOOREPOSBRESBHBAGPBHOROREHONERBEERGHBRE BPBHROSBHOROSEHOSarBRg f 3x0 75mm 3x 0 75 mm T 3x 0 75 mm i i BUC5030 Move bridge TL from terminals 1 2 to terminals 1 3 WARNING Remove bridge LP from terminals 4 5 Connect the power supply the heating pump and the tank load pump as shown Connect the tank sensor 18 If the installation includes an MB1 module and no room thermostat TAM set three position switch 5 see page 14 to If the installation includes an MB1 module and a room thermostat TAM set three position switch 5 see page 14 to AUTO Buccaneer GT Falcon GTE Installation Assembly amp Servicing ASSEMBLY 4 6 Heating and Domestic Hot Water Installation with MB1 module WARNING IMPORTANT If the installation includes an MB1 module and no room thermostat TAM set three position switch 5 see page 14 to am If the installation includes an MB1 module and a room thermostat TAM set three position switch 5 see page 14 to AUTO
9. Buccaneer GT Combination Boiler Falcon GTE Combination Boiler Installation Assembly and Servicing Oil or Gas Fired Boilers Assembly and Installation Instructions for Ideal Buccaneer and Falcon Oil or Gas Fired heating combination boilers should be read in conjunction with the Boiler Assembly Instructions enclosed and any other technical publication supplied with the burner CAUTION To avoid the possibility of injury during the installation servicing or cleaning of this appliance care should be taken when handling edges of sheet steel components BUC5034 j Ideal 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 Contents a Ware 7 1 0 21 Wererce EI corre errirerrecerre errr tren 2 1 1 Technical Specifications of Combination Boilers 3 1 2 MENT Dimensions a ea a 4 2dinstaling mhe Bolen 5 POE oea O E eee 5 22 NOME AU OM e re a e e a a eee 5 2D ASSEN E e A E sctpceey pee cenevsesess seeee eee 5 2A levelling eree es ceetceeees ee eva 5 Pek5 NMOL EWING CONIMEXC HONS ne 6 2 6 Connection of the Domestic Hot Water Circuit 6 2 7 Important Recommendations for connecting the Boiler to the Heating Circuit and the drinking Maer Spp E ere 6 28Exampleio
10. Sensor BUC5006 Domestic Hot Water Tank MLS 150 BUC5007 Hydraulic Boiler to Tank Connection Kit BUC5008 See the assembly instruction supplied with burner See the technical instructions for sensor connection The assembly of any optional devices purchased with the boiler is described in the instructions supplied with the relevant device or in the control panel instructions The list of available optional devices is provided in the applicable price list Buccaneer GT Falcon GTE Installation Assembly amp Servicing ASSEMBLY 1 Package IC1 IC2 IC3 BUC5010 BUC5012 Assembling the base and draining tube 1 Lay a sheet of paper in front of the boiler body take the boiler body off the pallet and place it standing on the furnace door Remove the adjustable feet assembled on the base and replace them with the four protective plastic plugs supplied in connection kit package BH 46 BUC5011 BUC5013 Unscrew 2 plastic plug A from the rear section of the boiler body Fit the base onto the feet of the boiler and clip it onto the rear section Screw the draining pipe onto the rear section Make the connection watertight with hemp or filler Set the boiler body on its feet Buccaneer GT Falcon GTE Installation Assembly amp Servicing ASSEMBLY Assembling the boiler onto the tank Place the boiler on the tank so that it is po
11. ake sure that a minimum interval of 10 cm is maintained between them Failure to do so can cause interference and lead to malfunction of the control system and the deterioration of the electronic circuits G Into the boiler pocket o I O I SS O TEMPO i QO M M o T Golo t 0 o BUC5028 Securing the module Mount the module by the front so as to secure it with the help of the two screws located on the front section use a cruciform Phillips screwdriver BUC 5029 Connections Installation with MB1 Module OPTION ZUBEHOR OPTION ZUBEHOR OPTION 5 loprion ZUBEHOR OPTION 2UBEHOR OPTION ZUBEHOR OPTION lt z g sE lg 8 A 4 He Ss 29 BERS y z5 g 283 Z 2 Oe 582a WwW Dea 8 age SES jy 296 Ges PP yi fi Sesje pe ma 28s EG e 3 z a58 PH g A See 8S w eWgidere2 6oco erzl 25 S328 ex 9535 z2 gt aE OFS a wos oLz Wro Ss5g sesass uo od Zee Wgg Se REM B2229 wz z5r S34 Sra2l Seo S5C HEZ SAS 25 u29 FAZ See SSsSEX tee Hee gos woeweoludgs w2eer SHE SHa HS 22s rSn2Z 5o m z4g emie FFACA 22Zz 8
12. ates the burner and the tank charging pump and stops the circulation of the heating system The period during which the heating circulator is switched off depends on the volume of water being pumped round the system the power of the boiler which is connected and the performance values of the sanitary hot water preparation unit 16 A limiter thermostat set at the factory to 80 C regulates the temperature of the boiler during the charging of the sanitary system The timing device of the pump overrun 4 minutes after the burner has been switched off allows for the residual heat accumulated in the body of the heating unit to complete the reheating of the preparation unit Buccaneer GT Falcon GTE Installation Assembly amp Servicing ASSEMBLY 1 Instructions for use Regulating the storage temperature of hot water for sanitary systems The regulating button A allows for the average temperature of stored sanitary hot water to be adjusted between 10 and 80 C with a hard point at 6 about 60 C In the event of prolonged absence In order to ensure that the sanitary hot water tank is protected against frost set the regulating button A to the position 1 this setting corresponds to a temperature of about 10 C 2 Adjusting the timing of the charging pump The timing device for stopping the charging pump allows the pump to keep operating for 4 minutes factory setting after the setting temperature for the sanita
13. awing in section 2 8 Components must conform to the standards and regulations in force A stop valve is installed into the cold water supply WARNING If the distribution pipework is in copper a 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 sanitary cold water supply pipework minimum 3 4 The safety unit s outlet pipe must have sufficient continuous slope and its section must be at least equal to that of the orifice for the safety unit outlet so as to avoid slowing down the water flow when there is an excess of pressure The level of the safety unit must be below that of the cold water inlet so it can be drained If this is not the case install a draining pipe at the lowest point of the tank see drawing in Section 2 8 To ensure hot water as soon as the taps are opened a circulation loop between the mains supply and the re circulation pipes of the unit can be installed 2 7 Important Recommendations for Connecting the Boiler to the Heating Circuit and the Drinking Water Supply The installation shall be made in keeping with applicable regulations and codes of practice and the recommendations contained in these instructions The expansion vessel shall be
14. ce or in the control panel instructions The list of available optional devices is provided in the applicable price list ii Refer to the assembly instructions supplied with the burner Buccaneer GT Falcon GTE Installation Assembly amp Servicing 11 ASSEMBLY 37 Assemble the boiler as instructed in figures 1 16 ba peri Assembling the boiler on the hot water tank Bco Place the boiler on the tank if required with a handling tool if required Assembly the boiler as instructed in figures 17 33 of boiler assembly instructions for Falcon GTE Installing the tubes Connect the tubes between boiler and tank package BH 46 as directed in the instructions on page 13 BUC5018 Assembling the tank front panel Insert the thermometer bulb in the thimble tube of the inspection plug of the tank For 250 litre system separate package BH 47 and fit the tank front panel 12 Buccaneer GT Falcon GTE Installation Assembly amp Servicing ASSEMBLY 3 3 Hydraulic Boiler to Tank Connections Kit BH46 Assembly Buccaneer Buccaneer 12 Lg 1200 mm A Boiler Flow 1 1 4 B Boiler Return 1 1 4 Cc D Tank Inlet 3 4 Sju Tank Outlet 4 BUC5019 P Automatic Air Vent not supplied Connection kit BH46 provides connections from the tank to the IMPORTANT boiler Ensure access to pump speed control and
15. connected to the boiler without any valve or stop valve between the boiler and the expansion vessel 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 As a general rule a check valve shall be fitted on the cold water supply pipe VERY IMPORTANT under safety rules a sealed safety valve calibrated to 7 bar shall be fitted on the cold water intake pipe of the hot water tank We recommend membrane type hydraulic safety devices with the NF mark During normal valve operation some drops of water are lost each time the water is heated This apparent leak is not only normal but is actually a sign that the valve is operating correctly The safety valve shall always be placed on the cold water supply pipe and no valve or tap shall be fitted between the safety valve and the tank In order to ensure the continuous circulation of hot water in the installation and be able to draw hot water as soon as a tap is opened a circulation loop may be installed between the drawing points and the tank recirculation tube A non return valve shall be fitted on this loop 6 Buccaneer GT Falcon GTE Installation Assembly amp Servicing INSTALLATION 2 8 Example of Installation The boiler to tank connection kit is p
16. d 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 water must never come into contact In particular the exchanger must not circulate domestic hot water Buccaneer GT Falcon GTE Installation Assembly amp Servicing 1 1 Technical Specifications of Combination Boilers Boiler Maximum operating pressure 4bar Maximum operating temperature 100 C Maximum safety temperature of boiler as per TRD 702 120 C Boiler thermostat setting 30 85 C Safety thermostat setting 110 C Bucaneer GT Domestic Hot Water Production MLS Calorifier Primary circuit heating water Maximum operating temperature Maximum operating pressure Secondary circuit domestic hot water Maximum operating temperature Maximum operating pressure 95 C 12 bar 95 C 10 bar MLS tank capacity litres Continuous flow rate 1 2 litres h Maximum flow rate over 10mn 1 2 3 litres 10mn Weight Boiler and tank kg Falcon GTE Domestic Hot Water Production 4 150 250 5 150 250 150 250 150 250 780 950 780 950 260 380 260 380 354 395 5 384 20 C MLS tank capacity litres Continuous flow rate 1 2 litres h Maximum flow rate over 10mn 1 2 3 litres 10mn Weight boiler and tank 150 litre kg Weight boiler and tank
17. ertain parts safety valve pumps flap valves Be careful to isolate hydraulically the primary and secondary circuits using stop valves This will facilitate matters during maintenance Inclusion of these valves means that maintenance of the unit and its parts can be carried out without having to empty it They also mean that the tank can be carried out without having to empty it They also mean that the tank can be isolated whilst a watertight pressure test is carried out if the test pressure is above the pressure admitted by the tank 2 6 Connection of the Domestic Hot Water Circuit The domestic hot water units can operate under a maximum service pressure of 10 bar Generally they operate at 7 bar Before connecting the domestic hot water circuit the pipework must be flushed to wash out any metal or other dirt which could damage certain parts safety units pump valves e The connection between the safety valve and the unit must not contain any section parts Also the flow pipe for the safety valve must not be obstructed If the supply pressure exceeds 5 5 bar a pressure reducer must be included upstream of the tank It is advisable to site the pressure reducer downflow of the water meter so as to have the same pressure in all the pipes Include a drain valve in the boiler as well as a syphon funnel for the safety unit Connection to the cold water supply must be carried out according to the dr
18. he maximum position if a room thermostat is used 8 6 3 AT fuse 14 9 Location for MB1 module also refer to the instructions supplied with the device 10 Location for an optional time counter Boilers with the domestic hot water facility A potentiometer for setting the temperature of the domestic hot water is located on the MB1 module casing graduated from 1 8 4 2 Operating Principle Control Panel The boiler temperature is regulated either by the boiler thermostat or any room thermostat The safety of the installation is achieved via the safety thermostat with manual reset Heating Regulation The heating is regulated in different ways manual mixing valve thermostatic valves etc It is up to the fitter to explain to the user how the heating is regulated Domestic Hot Water Regulation Versions with MB1 The presence of a filling pump and an antithermosiphon valve on the primary circuit of the hot water production system means that the domestic hot water temperature is kept correctly regulated The temperature of the domestic hot water is set by means of a potentiometer located on the MB1 When the domestic hot water is reheated the burner and the primary filling pump are started up whilst the heating pump is stopped The boiler temperature is controlled by the limiting thermostat built into the MB1 module the thermostat is factory set to 80 C When the need for hot water is met the burner is turned
19. ich could eventually obstruct the safety group valve Non compliance with this requirement could result in a deterioration of the unit s tank see notice enclosed with the safety unit De scaling in hard water regions it is advisable to ask the installer to carry out an annual de scaling of the tank exchanger so that it will retain its performance Operations to be carried out during the de scaling visual checks and replacement of the magnesium anode Shut off the cold water supply and drain the tank To drain it via the safety unit put the latter into the drainage position and open a hot water tap so that air can enter Take off the front panel and the probes Take off the cover 13 mm spanner If necessary replace the anode Remove all the scaling deposits from the bottom of the tank The exchanger must be de scaled in order to guarantee its proper operation Plastic Spacer Washer _ ov Buccaneer GT Falcon GTE Installation Assembly amp Servicing Magnesium anode The magnesium anode must be checked at least every two years Starting with the first check and taking account of the wear to the anode the frequency of the following checks must be decided The anode can be checked according to one of the following two methods Visual check The anode must be replaced if its diameter is less than 15mm initial diameter 33mm Check by measurement Disconnect the earth wire to the an
20. laced between points A and B between the boiler and the heating circuit Example Buccaneer GT 7 h a aa ae 1 f l i 1 i AL I F m i i Q 32 i j 27 27 l i i B I Domestichot water tank Cold water 1 Heating outlet 30 Sealed safety device calibrated to 7 bar 2 Heating return a Cold water inlet with a non return valve 7 Automatic bleeder valve b Connection to the cold water intake of the tank 9 Valve c Stop valve 17 Draining tap d Safety valve and manual draining tap 24 Exchanger primary input e Draining outlet 25 Exchanger primary output 32 Domestic hot water looping pump optional 26 Hot water filling pump 54 YA type load breaking device health regulations 27 Non return valve 57 Domestic hot water outlet Cra 28 Cold water intake of hot water tank A B Points for connecting to the heating installation 29 Pressure reducer if mains pressure gt 5 5 bar BUC5003 Buccaneer GT Falcon GTE Installation Assembly amp Servicing ASSEMBLY 3 ASSEMBLY 3 1 BUCCANEER GT COMBINATION BOILER Tools required Boiler Body Phillips head screwdriver Packaging the tables below show the numbers of the packages Wide flat screwdriver which make up the boiler The packages are listed in the order in 13mm spanner which they are opened for assembly Jacket Pack BUC5004 Control Panel Standard BUC5005 Domestic Hot Water
21. lowing precise positioning of IDEAL boilers from the Buccaneer GT or Falcon GTE range see leaflet provided with these units 2 4 Levelling Levelling of the unit is carried out using the 4 bolts H 10 x 20 packed in the instruction bag screwed into the base Please note 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 Boilers installed in such locations shall not be covered by the warranty BUC5002 Buccaneer GT Falcon GTE Installation Assembly amp Servicing 5 INSTALLATION 2 5 Hydraulic Connections Installation must be carried out following the regulations in force trade practices and the recommendations contained in this leaflet WARNING There must be no obstructions complete or partial between the boiler and the safety valves WARNING Heating installations must be designed and assembled so that central heating water and any products introduced into it cannot find their way into the drinking water system A removable connection must be installed for filling the heating circuit according to current regulations Before making the hydraulic connections for the central heating circuit it is essential to flush the water system to eliminate any dirt which may damage c
22. med by a qualified professional only Strict compliance with these operating and connecting instructions is a precondition for the correct operation of the boiler BUC5037 On O Off Oswitch 2 Burner switch turning the heating off summer position 3 or on winter position by turning off on the burner and the pump domestic hot water production continues For an MB1 domestic hot water priority module the switch is disabled by the control device 3 Heating pump switch used to turn the heating pump off summer position x or on winter position For an MB1 module it must be set to the winter position 4 Boiler thermometer 5 Three position switch M manual position used when the boiler is not fitted with a room thermostat The boiler temperature is regulated by boiler thermostat 7 This position may be used to test the burner of installations fitted with a room thermostat AUTO automatic position used for normal operation of boilers The boiler temperature is regulated by the connected device TEST STB momentary use to test the safety thermostat Safety thermostat with manual reset factory setting 110 C Boiler thermostat with 30 85 C adjustment range However the built in stop limits the maximum temperature to 75 C The stop may be moved if required The boiler thermostat must necessarily be set to t
23. ninstalatio ne a 7 I ACSC caareccennecerccoecodonaccocencocncoococoeencoreacoccenaeoaceeoacen 8 3 1 Buccaneer GT Combination Boiler 0 00 8 3 2 Falcon GTE Combination Boiler ee 11 3 3 Hydraulic Boiler to Tank Connections Kit BH46 13 4 Electrical Connections and Controls 0 000 14 AI Description a e sys cueve vere Rev eeerarcameeeesere 14 GV 0perating PUMA OS n a e a 14 4ST Eleciical Connec ion eee 15 4 4 Domestic Hot Water Priority Regulation Mode WIA MBI Seana E E E E 15 4 5 MB1 Domestic Hot Water Sensor 00 16 4 6 Heating and Domestic Hot Water Installation 19 AN Tf Connectingithe Burner e 19 Sa COmMM SSO a E A 20 5S1 Starting Up ea e E A E evenneranseeet 20 5 2 Commissioning Secondary Circuit anaa 20 6 Maintenance and Periodic Checks cc0s00 21 1 GENERAL The boilers of the Buccaneer GT and Falcon GTE Combination Boiler are automatic independent hot water boilers designed for connecting to a flue which require a separate fuel oil or gas burner Models available Heating and domestic hot water Buccaneer GT Combination Boiler boiler with an MLS 150 litre domestic hot water tank and a standard control panel which is fitted with an MB1 domestic hot water priority and regulation unit Falcon GTE Combination Boiler boiler with an MLS 150 or 250 litre domestic hot water tank and a standard control panel which is fitted with an MBI d
24. ode Measure the current between the tank and the anode if the current is less than 0 1 mA the anode must be replaced s The outside of the unit can be cleaned with soapy water Replace the inspection cover taking care to place the salt rod at the bottom and refit the washer position the lip seal in the inspection hole being careful to place its tongue outside the tank position the retaining ring around the seal placing the tongue above the ring Refit the cover salt rod at the bottom on the flange tightening the 6 bolts evenly across the diameter of the cover Tongue on the outside BUC5033 21 NOTES 22 Buccaneer GT Falcon GTE Installation Assembly amp Servicing NOTES Buccaneer GT Falcon GTE Installation Assembly amp Servicing 23 Caradon Plumbing Limited P O Box 103 National Ave Kingston upon Hull HU5 4JN Telephone 01482 492 251 Fax 01482 448 858 Registration No London 322 137 oe Caradon Plumbing Limited Technical Training pursues a policy of continuing improvement in the design and performance of its products The right is therefore reserved to vary specification without notice The Caradon Plumbing Limited 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 498432 July
25. off and the filling pump continues to operate for 4 minutes after the burner stops the delay is adjustable from 30 sec to 15 min In this way the residual heat accumulated in the heating elements is used to complete reheating the tank Buccaneer GT Falcon GTE Installation Assembly amp Servicing ASSEMBLY 4 3 Electrical Connections The electrical wiring has been carefully checked in the factory and the internal connections of the control panel must not be modified in any event The electrical connections of the boiler shall be made in compliance with applicable standards and regulations in force The unit shall be powered by a circuit with an omnipole switch with an opening distance greater than 3 mm WARNING Electrical connections shall be carried out by a qualified professional only Refer to Boiler Assembly Instructions for Control Panel Installation The connecting cables may be brought inside the boiler through the cut outs provided in the cover of the boiler which may be used along with purchased cable channels Fasten the cables to the rear plate of the control panel by means of the cable clamps supplied in the instructions bag after mounting them on the plate The pump cable has a connector fitted Discard the connector WARNING VERY IMPORTANT never place sensor cables extra low voltage and 230 V power supply cables in the same cable channel or duct All the connections
26. omestic hot water priority and regulation unit An option of a Correx electric anode AM7 may be fitted to any tank replacing the standard magnesium anode for long life Important Recommendations The boiler tank assembly must be installed in premises free from frost Placing the tank as closely as possible to the water supply will minimise energy losses in the pipework which should be lagged in all cases It is advisable to place the boiler tank assembly on a plinth so that the area can be easily cleaned Description The tanks in high grade steel are lined on the inside with a vitrified enamel at 850 C to food standard quality which protects the tank from corrosion The tank is also protected from corrosion by a magnesium anode which must be checked every two years and replaced if necessary refer to the Maintenance chapter on page 21 The heat exchanger fitted in the tank is constructed of smooth tubing Those surfaces coming into contact with domestic hot water are enamelled MLS tanks are heavily insulated in CFC free polyurethane foam thus reducing heat losses to a minimum The outer casing is in painted sheet metal The tank has a thermometer WARNINGS 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 an
27. rom the boiler control console blue on blue red on red Attach the earthing wire F to an earthing terminal of the control console De Dietrich amp BUC5022 Timer active Oo ojo Timer out of service olo TEMPO MINI MAXI Timer adjustment Meaty O 3 to 6 mins BUC5023 Sorc 30 C 80 C e mO je BUC5024 Main Gs us Terminal 1203 4 5 7203 4 5 Strip al eacatalal BBR e RRS GF GRB HBG it BUC5026 BUC5027 Buccaneer GT Falcon GTE Installation Assembly amp Servicing 17 ASSEMBLY Introduce the bulb G of the limiter thermostat into the boiler pocket Connect the charging pump to the boiler control console ensuring that the terminals live L neutral N and earth are properly attached Connect the probe bulb to the boiler control console Introduce the probe bulb into the pocket of the sanitary hot water tank If the tank is already fitted with a thermostat it will not be used accordingly replace the bulb of this thermostat with the tank probe WARNING IMPORTANT Under no circumstances may the wires of the probe very low voltage and wires carrying 230 V supply feed be placed in the same conduit or cable duct M
28. ry system has been reached This allows the residual heat accumulated in the body of the heating unit to be used to complete the reheating of the sanitary hot water Adjustment This timing device can be adjusted from 3 to 6 minutes with the aid of the potentiometer located on the back of the unit Taking the timing device out of operation To take the timer out of operation remove the bridge unit located on the back of the device as shown in the drawing opposite 3 Adjusting the limiter thermostat It is possible to change the setting of the limiter thermostat over a range from 30 to 90 C the original setting being 80 C To do this Take the module out of the boiler console if applicable Remove the setting button by drawing it towards yourself Unhook the PCB Adjust the limiter thermostat in accordance with the reference settings shown in the diagram opposite with the aid of a flat screwdriver Reassemble the unit by proceeding in the reverse order 4 Installation and Connection For all boilers Remove the TL bridge connected to the terminal strip of the boiler control console with terminals 1 and 2 to terminals 1 and 3 Withdraw the LP bridge at terminals 4 and 5 in order to do away with an ECS priority Remove the panel A from the control console of the boiler refer to the technical instruction plate Connect the connector elements B and C of the module to the connectors D and E coming f
29. sitioned on the first two marks on the front of the tank Assemble the boiler as instructed in views 3 13 of Buccaneer GT boiler Assembly Instructions 3 4 tubes Automatic bleeder D gt not supplied BUC5016 Installing the pipes BUCS01S Assembling the tank front panel Connect the pipes between boiler and tank package Fit the tank front panel after inserting the thermometer bulb BH 46 see the instructions on page13 in the thimble tube of the inspection plug of the tank 10 Buccaneer GT Falcon GTE Installation Assembly amp Servicing ASSEMBLY 3 2 FALCON GTE COMBINATION BOILER Tools required Phillips head screwdriver Packaging the tables below show the numbers of the packages Wide flat screwdriver which make up the boiler The packages are listed in the order in 13mm spanner which they are opened for assembly Boiler GTE 4 150 GTE 5 150 GTE 4 250 GTE 5 250 Boiler Body delivered loose front section intermediate section rear section set of assembly rods accessory package Mounted boiler body with accessories Control Panel Standard BUC5035 Domestic Hot 150 Water Tank 250 BUC5007 Front Panel of tank Hydraulic Connection Kit Domestic Hot Water Sensor The assembly of any optional devices purchased with the boiler is described in the instructions supplied with relevant devi
30. vent screw V Ensure flexible connectors are run to prevent air pockets The 2 plug 11 fitted to Tee 1 can be replaced by a drain cock To ensure best venting of the assembly and continued good operation of the installation an automatic vent P not supplied should be fitted on Tee 9 2 Screw the Tee with union nut 1 and plug 2 on tank outlet D Connecting union 4 Fit the pump 3 to union nut 4 and Tee 1 inserting O rings 5 Tee with union nut 4 Screw Tee 7 to boiler return B Tee 7 Screw Tee with tappings 9 with plug 11 to boiler flow A Screw valve Tee 10 with plug 11 to tank inlet C 3 X Vo plugs 11 Connect elbow flexible 12 1200mm between 7 amp 4 and flexible 3 X 1 1 2 O rings 5 13 1120mm between 9 amp 10 inserting O rings 14 5 X 3 4 O rings 14 Assemble flexible clip 16 and fitting 17 then clip them in the 7 5mm hole E on the boiler rear panel Fit flexible 13 in clip 16 The pump cable allows simple connection to the boiler control box See Electrical section for further information The kit consists of A pump with cable 3 Insulated flexible connector 13 length 1120mm Insulated flexible connector with elbow 12 length 1200mm A bag containing An antisyphon valve 10 Tee with tappings 9 4X plastic plugs 15 Flexible clip 16 with fixing 17 Buccaneer GT Falcon GTE Installation Assembly amp Servicing 13 ASSEMBLY 4 CONTROLS 4 1 Description The boiler connections shall be perfor
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