CTC Union GIERSCH RG1-L-Na Manual

Technical Information • Installation Instructions
Gas
Edition August 2019
Right reserved to effect techn. modifica-
tions in the interest of product improvement.
RG1
GB

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Contents
Overview ........................................................................................................... 3
General information / safety information .................................................................................... 3
Checking scope of delivery and connection data....................................................................... 3
Operating instructions ................................................................................................................ 4
Instruction of operating personnel.............................................................................................. 4
Maintenance and customer service ........................................................................................... 4
Key for code designation ........................................................................................................... 4
Technical specifications ............................................................................................................. 4
Installation ......................................................................................................... 5
Installing flange and burner........................................................................................................ 5
Installing gas assembly.............................................................................................................. 5
Service position.......................................................................................................................... 5
Dimensions for checking the mixer unit ..................................................................................... 5
Establishing electrical connections ............................................................................................ 6
Function ............................................................................................................. 7
Control box LME ........................................................................................................................ 7
Air flow setting, measurement "A".............................................................................................. 10
Air flap positioning motor .......................................................................................................... 10
Compact gas unit ....................................................................................................................... 11
Adjustable gas pressure switch (only on version KE 15) ........................................................... 11
Start-up .............................................................................................................. 12
Adjustment tables ..................................................................................................................... 12
Adjusting gas burner and boiler ................................................................................................. 13
Calculation principle for gas burner adjustment ......................................................................... 15
Design ............................................................................................................... 17
Exploded view and parts list ...................................................................................................... 17
Service instructions/dimensions ........................................................................ 18
Measuring ionisation current ..................................................................................................... 18
Servicing air pressure monitor ................................................................................................... 18
Declaration of conformity ........................................................................................................... 19
Burner overall dimensions / boiler connection dimensions ........................................................ 20
Working ranges .......................................................................................................................... 20

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Overview
Overview
General information / safety information
The installation of a gas-fired system must conform to extensive regulations and requirements. It is there-
fore the duty of the installer to be familiar with all applicable regulations and requirements. Installation, start-
up and maintenance must be performed with utmost care.
The burner must not be operated in rooms with high levels of air humidity (laundry rooms), dust or corrosive
vapours. The boiler room must be ventilated accordingly with ventilation air.
The GIERSCH RG1 series gas burners are suitable for burning natural gas or liquefied petroleum gas and
comply with the European standard DIN EN 676.
Caution !
Improper installation, adjustment, modification, operation or maintenance may result in physical
injury or damage to property/equipment.
Read the instructions prior to use.
This product must be installed in accordance with the valid regulations (e.g. DIN-VDE, DIN-DVGW).
The design and degree of protection of the burner make it suitable for operation in enclosed rooms.
Checking scope of delivery and connection data
Before installing the GIERSCH gas burner, please check that all items included in the scope of delivery are
present.
Scope of delivery:
Burner, sliding flange and gasket, 4 retaining screws, separate operating instructions,
technical information, one 7-pin connector.
Compact gas unit and gasket (see Overview, Page 9).
The gas pipe must be designed to conform to the flow rate and the available gas flow pressure and routed
with the lowest pressure loss over the shortest distance to the burner. The loss of gas pressure via the com-
pact unit and the burner and the resistance on the fuel gas side of the heat generator must be less than
the connection flow pressure.
Caution !
Observe throughflow direction of compact unit.
Operating instructions
The operating instructions together with this technical information leaflet must be displayed in a clearly
visible position in the boiler room. It is essential to write the address of the nearest customer service centre
in the operating instructions.
Instruction of operating personnel
Faults are often caused by operator error. The operating personnel must be properly instructed in how the
burner works. In the event of recurring faults, Customer Service should be notified.

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Overview
Maintenance and customer service
The complete system should be checked once a year for correct functioning and leaks by a representative
of the manufacturer or other suitably qualified person.
We accept no liability for consequential damage in cases of incorrect installation or repair, the fitting of non-
genuine parts or where the equipment has been used for purposes for which it was not intended.
Key for code designation
Technical specifications
Burner type
Technical data RG1(-L)-Na RG1(-L)-Nb RG1(-L)-Fa RG1(-L)-Fb
Min. burner output in kW
12 25 15 25
Max. burner output in kW
40 61 40 61
Min. boiler output in kW
11 23 14 23
Max. boiler output in kW
37 56 37 56
Gas type
for natural gas LL + E = "-N" / for LPG 3B/P = "-F"
Max. gas pressure in mbar
70
Voltage
1/N/PE ~50 Hz - 230 V
Current consumption
start max. / operation
1.9 A / 0.8 A
Electric motor power in W
90
ignition transformer
1x8 kV / 20 mA
Control box
LME 11
Weight in kg
14
Noise emission in dB(A)
≤59
RG 1-L-N(F)
Natural gas LL+E ="-N" or LPG ="-F"
Air shut-off flap
Size
Series

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Installation
Installation
Installing flange and burner
When installing the sliding flange, only tighten screws
1 and 2 otherwise it will not be possible to secure the
burner pipe with screw 3. Slide in the burner, adjust to
furnace depth and tighten the screws in the following
sequence: 3, 4, 5, raising the housing in the process.
Important: Secure the sliding flange so that the
clamping screw 3 is positioned at the top.
Installing gas assembly
• Remove plastic protective plug.
• Install unions including accompanying seals.
• Observe installation position.
• Check connecting point of gas assembly with
non-corrosive foaming agent for leaks and vent gas
pipe.
• When venting gas, discharge safely to atmosphere
with a hose.
Comply with DVGW-TRGI 1986/96 Section 7,
TRF 1988, DIN 4756 and local regulations.
Service position
Risk of injury by fan wheel during activation in
service position.
• Release quick-release locks and detach base plate.
• Suspend base plate with retaining buttons in cross
recesses of housing.
Dimensions for checking the mixer unit
The ignition electrodes are preset at the factory. The dimensions are specified for checking purposes.
Installation position KE
Centre of gas hole to flow plate
and fully tightened.
There is still slight play at the holder.
Grubscrew determines the position of the holder
Caution:
Ionisation rod.
Red cable
Black cable
Ignition electrode
Electrode to centre of gas hole

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Installation
Establishing electrical connections
• Disconnect system from power supply. Main switch "OFF".
• Check polarity of all connectors.
• Wire connector unit in accordance with connection diagram. Lay flexible control line so that boiler door
can still be swivelled.
• Attach cube connector to gas-pressure monitor connector A (grey) and to solenoid valves B (black)
and secure with screw.
• Check correct wiring of wired connector unit X11 according to connection diagram.
• Attach 7-pin connector unit for boiler control (X11) to black-brown socket unit on burner (X12).
• Supply lead to 7-pin connector unit X11 must be protected with a min. 6.3 A slow-blowing or
max. 10 A quick-blowing fuse.
Connection diagram
Key:
F11 External fuse
F21 Ext. temp. controller, 1st/2nd stages
F3 Ext. safety temperature limiter
Q1 Main heating switch
H11 Ext. pilot lamp
H
13
Ext. fault message lamp
L1 Phase
PE Protective earth
P11 Service hour meter
N Neutral
B4
S3
T2
T1
N
PE
L1
N
PE
L1
N
N
F3
F21
H11
P11
H13
Q1
X11 X12
F11
Female adapter X12
on burner
Male adapter X11
to boiler

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Function
Function
Control unit LME
Testing the control unit for proper functioning
Danger of fatal injury from electric shocks!
Disconnect electrical cable from power supply before
carrying out any work on live parts! Troubleshooting
may only be carried out by authorised and trained per-
sonnel! Unlocking may only be carried out by an autho-
rised specialist.
After startup and after maintenance of the burner, the following controls to perform.
Burner startup with broken lines to the flame detector:
• Disconnect the cable to the flame monitor and restart the burner.
At the end of the safety time the controller makes a lockout
• Reestablish the connection.
Burner operation with simulated loss of flame:
• Pull the compact unit the square plug from the gas pressure switch and jumper the contacts in the
connector.
• Start the burner.
• Connect operation are the ball valve.
After loss of flame, the controller makes a lockout.
• Remove the jumper in the connector and insert it back to the gas pressure switch of the compact unit.
Burner operation with simulated air pressure loss:
• Pull are the operation from the air hose to the "+" input of the air pressure switch.
The controller makes a lockout.
• Insert the air hose back onto the air pressure switch
Safety and switching functions
In the event of a flame failure during operation, the fuel supply is immediately switched off and the control
box goes into fault mode. A restart takes place in all cases following a mains power failure. A fault is trig-
gered immediately if there is flame detection during pre-ventilation. The position of the air pressure monitor
is continuously checked. There can be no start-up if it is not in its neutral position. A fault is triggered if the
working contact fails to close during pre-ventilation, or reopens. In the event of a lack of air during operation,
the air pressure monitor contact opens and the valves close immediately. The device goes into fault mode.

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Function
Operational status indication
Legend:
Steady on
OFF
Red
Yellow
Green
Color code table for multicolor signal lamp (LED)
Status Colore code Color
Waiting time «tw», other waiting states
.................................
OFF
Oil preheater on
.................................
Yellow
Ignition phase, ignition controlled

Flashing yellow
Operation, flame o.k.
.................................
Green
Operation, flame not o.k.

Flashing green
Extraneous light on burner startup

Green-red
Undervoltage

Yellow-red
Fault, alarm
......................................
Red
Error code output
(refer to «Error code table»)

Flashing red
Interface diagnostics

Red flicker light
.........


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Function
Diagnostics of the cause of fault
After lockout, the red signal lamp will remain steady on. In that condition, visual diagnostics of the cause of
fault according to the error code table can be activated by pressing the lockout reset button for more than
3 seconds. Pressing the lockout reset button again for at least 3 seconds, interface diagnostics will be ac-
tivated. Interface diagnostics works only if the lockout reset button extension AGK20… is not fitted. If, by
accident, interface diagnostics has been activated, in which case the slightly red light of the signal lamp
flickers, it can be deactivated by pressing again the lockout reset button for at least 3 seconds. The instant
of switching over is indicated by a yellow light pulse.
Error code table
During the time the cause of fault is diagnosed, the control outputs are deactivated
- Burner remains shut down
- External fault indication remains deactivated
- Fault status signal (alarm) at terminal 10, according to the error code table
The diagnostics of the cause of fault is quit and the burner switched on again by resetting the burner control.
Press the lockout reset button for about 1 second (<3 seconds).
Red blink code of
signal lamp (LED)
Alarm at
term. 10
Possible cause
2 x blinks ON No establishment of flame at the end of safety time
- Faulty or soiled fuel valves
- Faulty or soiled flame detector
- Poor adjustment of burner, no fuel
- Faulty ignition equipment
3 x blinks ON Air pressure switch faulty
- Loss of air pressure signal after specified time
- Air pressure switch welded in normal position
4 x blinks ON Extraneous light when burner is started up
5 x blinks ON Air pressure switch time supervision
- Air pressure switch welded in working position
- Error with valve proving (only in conjunction with LDU11...)
6 x blinks ON Free
7 x blinks ON Too many losses of flame during operation (limitation of repetitions)
- Faulty or soiled fuel valves
- Faulty or soiled flame detector
- Poor adjustment of burner
8 x blinks ON Free
9 x blinks ON Free
10 x blinks OFF Wiring error or internal error, output contacts, other faults
14 x blinks ON CPI contact not closed

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Function
Air flow setting, measurement "A"
1. Distance "A"
2. Locknut for air-restrictor setting
Turn screw (3) clockwise: Air -
Turn screw (3) anticlockwise: Air +
Air flap positioning motor (-L type)
Cooling of furnace avoided during burner standstill.
SA2-F:
Position "OPEN" - "CLOSED" of electric-motor-driven
unit indicated at display lever. When servicing/retrofit-
ting, refer to wiring diagram on Page 17.
Do not turn red positioning lever by hand as
mechanism is destructible.
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