159180-3.pmd

Buccaneer GTE -

Installation & Servicing

GENERAL

Note.
Fuel rates and flue gas data relate to maximum output ratings.
Gas firing data relates to the use of NATURAL GAS ONLY.
Details for the use of LPG are available on request from Caradon
Ideal Ltd.
Natural gas consumption is calculated using a calorific value of
38.7MJ/m

(1038Btu/ft

) gross or 34.9MJ/m

(935Btu/ft

) nett at

C and 1013.25mbar.

* The value is used in the UK Government's Standard Assessment
Procedure (SAP) for energy rating of dwellings. The test data from
which it has been calculated have been certified by a notified body.

Table 1 Performance Data

Boiler

GTE 4

GTE 5

GTE 6

Number of Sections

Maximum

Heat Output

Btu/hx10

92.1

112.6

133.1

Minimum

Heat Output

Btu/hx10

71.7

92.1

109.2

Hydraulic

mbar

5.3

7.9

10.9

Resistance at 11k

in w.g.

2.1

3.2

4.4

Hydraulic

mbar

1.6

2.4

3.3

Resistance at 20k

in w.g.

0.6

1.0

1.3

Combustion Chamber

mbar

0.23

0.22

Resistance (at zero draught)

in w.g.

0.01

Minimum Draught at Smokehood mbar

0.12

0.11

Outlet (for max. output)

in w.g.

0.048

0.044

HEALTH & SAFETY DOCUMENT NO. 635

The electricity at work regulations, 1989. The manufacturer's
notes must NOT be taken, in any way, as overriding statutory
obligations.
IMPORTANT. These appliances are CE certified for safety and
performance. It is, therefore, important that no external control
devices, e.g. flue dampers, economisers etc., are directly
connected to these appliances unless covered by these
Installation and Servicing Instructions or as otherwise
recommended by Caradon Ideal Limited in writing. If in doubt
please enquire.
Any direct connection of a control device not approved by
Caradon Ideal Limited could invalidate the certification and the
normal appliance warranty. It could also infringe the Gas Safety
Regulations and the above regulations.

Maximum Gross

l/h

3.11

3.80

4.48

Oil Rate

gal/h

0.683

0.836

0.986

Maximum Flue

0.017

0.022

0.025

Gas Volume at 12% CO

/min

Flue Gas CO

/ Temperature

% /

12 / 180

12 / 190

Oil

Maximum

3.10

3.79

4.47

Gas Rate

109.4

133.9

158.0

Maximum Flue

0.019

0.026

0.027

Gas Volume at 9% CO

/min

Flue Gas CO

/ Temperature

% /

9 / 180

9 / 190

Gas

Part Load Efficiency (Gross)

86.0

85.0

84.4

*Seasonal Efficiency (SEDBUK)

[79.9]% Band D

Table 2 General Data

Flow Connection

R 1

Return Connection

R 1

Maximum Operating Pressure

bar

Boiler Thermostat Setting

30 - 90

Safety Thermostat Setting

110

Nominal Flue

m m

125

153

Diameter

in.

Boiler Water

24.5

35.5

Content

gal

5.4

6.6

7.8

Boiler DRY Weight

182

210

237.5

less Burner Unit

401.5

463

523.5

Part Load Efficiency (Gross)

89.5

88.5

87.8

*Seasonal Efficiency (SEDBUK)

[85.7]% Band C

Buccaneer GTE -

Installation & Servicing

GENERAL

CONTENTS

Assembly. ................................................................... 11-18

Boiler Clearances. ............................................................ 6

Burner Connection. ........................................................ 10

Commissioning and Testing. ................................ 25 & 26

Electrical Connections. .................................................. 19

Electrical Supply. .............................................................. 5

Flue Installation. ................................................................ 5

Fluing. ................................................................................ 9

Gas Safety Regulations .................................................... 4

Gas Supply. ........................................................................ 5

Hydraulic Resistance. ...................................................... 2

Initial Lighting. ................................................................. 26

Introduction. ...................................................................... 3

Installation. ........................................................................ 9

Option Kits. ........................................................................ 3

Performance Data. ........................................................... 2

Servicing. ........................................................................ 27

Ventilation. ........................................................................ 7

Water Circulation. ............................................................ 5

Water Connections. ......................................................... 7

Water System Requirements. ......................................... 8

Water Treatment. ............................................................. 5

Wiring Diagrams. ....................................................... 20-22

COMBINATION MODELS ONLY

Assembly. ................................................................... 32-36

Boiler Clearances. .......................................................... 30

Introduction. .................................................................... 29

Servicing. ........................................................................ 37

Start Up. .......................................................................... 36

Technical Data. ...................................................... 29 & 30

Water Connections. ....................................................... 31

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.

Buccaneer GTE

Gas and Fuel Oil
PI No. 0049 BM 3528
Destination Countries: GB, IE

INTRODUCTION

The Buccaneer GTE boilers are fully automatically controlled
floor standing boilers designed for connecting to a flue pipe and
require a separate automatic fuel oil or gas burner.

The boilers have a maximum heat output of 27-39kW.

The boilers are suitable for: combined indirect pumped
domestic hot water and central heating systems; independent
indirect pumped domestic hot water or central heating systems.

Control features include as standard, the ability to control two
heating zones.

Fully pumped systems may be open vented or sealed.

The boilers are NOT suitable for:
1. Gravity DHW systems.
2. Gravity heating systems.
3. Direct domestic hot water supply.

Option
DHW Remote Sensor Kit (AD 212)

buc5487

buc5536

Buccaneer GTE -

Installation & Servicing

GENERAL

SAFETY

Current Gas Safety (Installation and Use) Regulations or
rules in force.

It is law that all gas appliances are installed and serviced by a
CORGI registered installer in accordance with the regulations
below. Failure to install appliances correctly could lead to
prosecution. It is in your own interest, and that of safety, to
ensure the law is complied with.

The following must be conformed with:

Current Building Regulations and Clean Air Act

Water Authority Regulations

Local Authority Regulations and Regional Bylaws

Gas Safety Regulations

Any special regional requirements of local Electricity and Gas
undertaking.

Fire Service and Insurance Company requirements.

In the interests of safety, a competent installer should be
employed to effect the installation of the appliance.
Manufacturer's notes must NOT, in any way, be taken as over
riding statutory obligations.

The installation of the boiler MUST also be in accordance with
the latest I.E.E. (BS7671) Wiring Regulations, local buildings
regulations, bye-laws of the local water authority, the building
regulations and the Building Standards (Scotland) and any
relevant requirements of the local authority.

Detailed recommendations are contained in the following
Codes of Practice:

BS 799 Pt4 & 7 Oil burning equipment.

BS 799 Pt5

Oil storage tanks.

BS 5410 Pt1

Installation for space heating and hot water
supply.

BS 5440

Installation and maintenance of flues and
ventilation for gas appliances of rated input
not exceeding 70kW net (1st, 2nd and 3rd
family gases).

Part 1

Specification for installation of flues

Part 2

Specification for installation and maintenance
of ventilation for gas appliances.

BS 5449

Forced circulation hot water central heating
systems for domestic premises. Note: only
up to 45kW.

NOTE TO THE INSTALLER: LEAVE THESE INSTRUCTIONS ADJACENT TO THE BOILER.

BS 5482 Pt1

Domestic butane and propane gas burning
installations.

BS 5546

Installation of gas hot water supplies for
domestic purposes.

BS 5854

Flues and flue structures in buildings.

BS 5885 Pt2

Gas burners - with inputs up to 60kW.

BS 6798

Installation of gas fired hot water boilers of
rated input not exceeding 60kW.

BS 6891

Installation of low pressure gas pipework of up
to 28mm (R1) in domestic premises (2nd
family gas).

EN 303.1

Heating boilers with forced draught burners.
General requirements.

EN 303.2

Heating boilers with forced draught burners
with atomizing oil burners.

EN 304

Test code for heating boilers for atomizing oil
burners.

73/23 EEC

Low voltage directive. (Relevant standard is
EN60335.1)

89336 EEC

Electromagnetic Compatibility Directive.
(Relevant standards are EN50081.1,
EN50082.1 and EN55014.)

90396 EEC

Gas Devices Directive. (Relevant standards
are EN303.1, EN303.2 and EN304.)

92/42 EEC

HH Efficiency Directive.

IGE/UP1

Soundness testing and purging of industrial
and commercial gas installation.

IGE/UP2

Gas installation pipework, boosters and
compressors on industrial and commercial
premises.

IGE/UP10

Installation of gas appliances in industrial and
commercial premises.

British Gas IM11 Flues for commercial and industrial gas fired

boilers and air heaters.

SAFE HANDLING OF SUBSTANCES

Care should be taken when handling the boiler insulation
panels, which can cause irritation to the skin. No asbestos,
mercury or CFCs are included in any part of the boiler or its
manufacture.

Assembly and Installation Instructions for Ideal Buccaneer GTE heating boilers should be read in conjunction with the general
technical data tables enclosed and any other technical publication supplied with the burner.

Buccaneer GTE -

Installation & Servicing

GENERAL

GAS SUPPLY

The local gas supplier should be consulted, at the installation
planning stage, in order to establish the availability of an
adequate supply of gas. An existing service pipe must NOT be
used without prior consultation with the local gas supplier.

A gas meter can only be connected by the local gas supplier or
by a registered CORGI engineer.

An existing meter should be checked, preferably by the gas
supplier, to ensure that the meter is adequate to deal with the
rate of gas supply required. A minimum working gas pressure
of 17.5mbar MUST be available at the boiler inlet for Natural gas
and 37mbar for Propane.

Do not use pipes of smaller size than the burner inlet gas
connection.

The complete installation MUST be tested for gas soundness
and purged in accordance with the appropriate standards listed
on page 4.

FLUE INSTALLATION

IMPORTANT
It is the responsibility of the installer to ensure, in practice, that
products of combustion discharging from the terminal cannot re-
enter the building or any other adjacent building through
ventilators, windows, doors, other sources of natural air
infiltration, or forced ventilation / air conditioning.

If this should occur the appliance MUST be turned OFF, labelled
as 'unsafe' and corrective action taken.

The flue must be installed in accordance with the appropriate
standards listed on page 4.

WATER CIRCULATION SYSTEM

The system pump MUST be connected to the boiler.

The boiler must NOT be used for direct hot water supply. The
hot water storage cylinder MUST be of the indirect type.

Single feed, indirect cylinders are not recommended and MUST
NOT be used on sealed systems.

The appliances are NOT suitable for gravity central heating nor
are they suitable for the provision of gravity domestic hot water.

The hot water cylinder and ancillary pipework, not forming part of
the useful heating surface, should be lagged to prevent heat
loss and any possible freezing - particularly where pipes run
through roof spaces and ventilated underfloor spaces.

The boiler must be vented.

Draining taps MUST be located in accessible positions, which
permit the draining of the whole system - including the boiler
and hot water storage vessel. They should be at least 1/2" BSP
nominal size and be in accordance with BS. 2879.

The central heating system should be in accordance with the
relevant standards listed on page 4.

Due to the compact nature of the boiler the heat stored within the
castings at the point of shutdown of the burner must be
dissipated in order to avoid overheating. In order to allow pump
operation after burner shutdown the boiler control box
incorporates a pump overrun facility. In order to make use of
this, the pump must be supplied from the terminals inside the
boiler. Note: for pumps requiring greater than 1.0amp current,
they must be connected via a relay.

WATER TREATMENT FOR HOT WATER AND
HEATING BOILERS

There is a basic need to treat the water contained in all heating
and indirect water systems, particularly open vented systems. It
is assumed, incorrectly, that because boilers are operating in
conjunction with what is apparently a closed circuit an open

vented system will not, under normal circumstances, allow

damage or loss of efficiency due to hardness salts and

corrosion once the initial charge of water has been heated up a

few times.

1mm of lime reduces the heat transfer from metal to water by

10%.

In practice the deposition of these salts is liable to cause noises

from the boiler body or even premature boiler failure. Corrosion

and the formation of black iron oxide sludge will ultimately result

in premature radiator failure.

Open vented systems are not completely sealed from the

atmosphere if proper venting and expansion of system water is

to be achieved. The same tank is used to fill the system with

water and it is through the cold feed pipe that system water

expands into the tank when the boiler passes heat into the

system.

Conversely, when the system cools, water previously expelled is

drawn back from the tank into the system together with a quantity

of dissolved oxygen.

Even if leakage from the heating and hot water system is

eliminated there will be evaporation losses from the surface of

the tank which, depending upon ambient temperature, may be

high enough to evaporate a large portion of the system water

capacity over a full heating season.

There will always be corrosion within a heating or hot water

system to a greater or lesser degree, irrespective of water

characteristics, unless the initial fill water from the mains is

treated. Even the water in closed systems will promote

corrosion unless treated. For the reason stated, Caradon Ideal

Limited strongly recommend that when necessary the systems

is thoroughly cleaned, prior to the use of stable inhibitor, which

does not require continual topping up to combat the effects of

hardness salts and corrosion on the heat exchangers of the

boiler and associated systems.

Caradon Ideal Limited advise contact directly with specialists on

water treatment such as:
Betz Dearborn Ltd

Fernox Manufacturing Co. Ltd.

Widnes,

Tandem House, Marlowe Way,

Cheshire,

Croydon, Surrey, CRO 4XS

Tel: 0151 424 5351

Tel: 0870 601 5000

ELECTRICAL SUPPLY

WARNING

This appliance must be earthed.

A 230V - 50Hz mains supply is required, fused at 5amps.

Wiring external to the appliance MUST be in accordance with the
current I.E.E. (BS7671) Wiring Regulations and any local
regulations which apply.

The point of connection to the mains should be readily
accessible and adjacent to the boiler.

LOCATION OF THE BOILER

The boiler must stand on a non-combustible floor (i.e. concrete
or brick) which must be flat, level and of a suitable load bearing
capacity to support the weight of the boiler (when filled with
water) and any ancillary equipment.

If the boiler is mounted on a plinth then the dimensions must
exceed the plan area of the boiler by at least 75mm on each side.

The boiler must not be fitted outside.

Buccaneer GTE -

Installation & Servicing

GENERAL

VENTILATION

The ventilation requirements in the gas fired boiler standard
are also valid for oil fired boilers of the same heat input.

The ventilation requirements of these boilers is dependant on
the type of flue system used, and their heat input. All vents
must be permanent with no means of closing, and positioned
to avoid accidental obstruction by blocking or flooding.
Detail reference should be made to BS 5440 Pt. 2. The
following notes are for general guidance only:
If installed in a room or internal space then a permanent air
vent is required. The sizes for vents directly communicating
with outside air shall have a free area of 5cm

per kW of boiler

rated input in excess of 7kW.
If installed in a compartment, then permanent air vents are
required at high and low level. These vents may
communicate direct to outside air, or to a room/internal space.
If to room/internal space, it must itself be adequately
ventilated as above.

HYDRAULIC CONNECTION

buc5492

355

562

137

Flow
Connection 1

Return
Connection 1

Drain Cock

120

158

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.

Minimum vent free area
(cm

) per kW of boiler

rated input positioned at:

Open-flued

To room or

internal space

Direct to

outside air

High Level

Low Level

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.

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.

General

Recommendations relating to the water system are contained
in BS. 5449 and BS. 6880.

Buccaneer GTE -

Installation & Servicing

GENERAL

SEALED SYSTEM REQUIREMENTS

OPEN VENTED SYSTEM REQUIREMENTS

Detail reference should be made to the appropriate
standards listed on page 4.

The information and guidance given below is not intended to
override any requirements of the above publications or the
requirements of the local authority, gas or water undertakings.

The vertical distance between the pump and feed/expansion
cistern MUST comply with the pump manufacturer's minimum
requirements, to avoid cavitation. Should these conditions
not apply either lower the pump position or raise the cistern
above the minimum requirement specified by Caradon Ideal
Limited. The isolation valves should be fitted as close to the
pump as possible.

The boiler is fitted with an automatic air vent, located in the left
top side of the interior. This air vent must never be shut off, as
this could result in dry firing of the boiler and subsequent
damage to the heat exchanger.

ima5352

Hose unions

Temporary hose

(disconnect after filling)

Additional

stop valve

Double check valve

assembly

(note direction of flow)

Note. The method of filling, refilling, topping up or flushing
sealed primary hot water circuit from the mains via a temporary
hose connection is only allowed if acceptable to the local water
authority.

1. General

a. Detail reference should be made to the appropriate

standards listed on page 4. The information and
guidance given below is not intended to override any
requirements of these publications or the requirements
of the local authority, gas or water undertakings.

b. The installation should be capable of working with flow

temperatures of up to 90

C and a temperature

differential of up to 20

c. All components of the system, including the heat

exchanger of the indirect cylinder, must be suitable for a
working pressure of 4 bar (60lbf/in

) and temperature of

110

C. Care should be taken in making all connections

so that the risk of leakage is minimised.

d. The boiler is fitted with an automatic air vent, located in

the left top side of the interior. This air vent must
never be shut off, as this could result in dry firing
of the boiler and subsequent damage to the
heat exchanger.

2. Safety Valve

A spring loaded safety valve
complying with the relevant
requirements of BS. 6759 Pt. 1
must be fitted in the flow pipe
as close to the boiler as
possible and with no
intervening valve or restriction.
The valve should have the
following features:

a. A non-adjustable preset lift pressure not exceeding 4bar

(60lbf/in

b. A manual testing device.
c. Provision for connection of a discharge pipe. The valve

or discharge pipe should be positioned so that the
discharge of water or steam is visible, but will not cause
hazard to user or plant.

3. Pressure Gauge

A pressure gauge covering at least the range 0-4bar must
be fitted to the system. The gauge should be easily seen
from the filling point and should preferably be connected at
the same point as the expansion vessel.

4. Expansion Vessel

Expansion vessels used must comply with BS. 4814.
Connection to the system must not incorporate an isolating
valve.

Feed/expansion

cistern

500mm
minimum

1500mm
minimum

System
flow to
pump

Inverted cold
feed entry

Cold

Feed

Water

level

(cold)

Open vent

System
return

Connections

to boiler

buc7949

1500

minimum

Buccaneer GTE -

Installation & Servicing

INSTALLATION

FLUING

According to the output, the difference between the
temperature of the flue gas and the ambient temperature can
be as low as 160

C. The installer will have to respect all of the

usual precautions (dilution - piping - T for removal of
condensation) in order to prevent deterioration of the chimney.

30-45

500 minimum

buc5495

Boiler

FLUE SIZE

Refer to applicable regulations while determining the size
and height of the flue. Please note that GTE boilers have
pressurised and sealed combination chambers and that the
pressure at the outlet must not exceed 0 mbar.

Detailed recommendations relating to the design of flues for
GAS fired appliances are quoted in BS. 6644 and British Gas
Publication No. IM11, whilst BS. 5410 Pt. 1 similarly applies to
OIL fired boilers.

Boiler

Power

Required

Draught

Mass Flow of Flue Gases

kg/s

Natural Gas

9% CO

Flue Gas

Temperature

(1) (2)

Chimney:

Minimum Recommended

Dimensions

mbar

Ø min

m m

Height

GTE 4

21-27

0.12

0.014

< 180

125

6.5

GTE 5

27-33

0.12

0.017

< 190

125

GTE 6

33-39

0.11

0.020

< 190

153

(1) : at boiler high power
(2) : Boiler temperature: 80

C (ambient temperature : 20

Fuel Oil

12% CO

The table below contains the minimum dimensions of the flue
required for each boiler model in order to ensure sufficient
draught at the outlet.

However, care must be taken to comply with any applicable
national or local regulations.

285

392

Flue outlet

Boiler Dimension

GTE 4

GTE 5

GTE 6

buc5493

DIMENSIONAL INFORMATION REQUIRED FOR THE FLUE CONNECTION

Connection

The connection must be made in a competent manner with
airtight pipe in a material that is resistant to hot gases from the
combustion and possible acid condensation. This pipe must
be as short as possible, be removable and without any
sudden change in its section.

The diameter must always be at least equal to that of the boiler
outlet.

FLUE OUTLET