Giersch GG20-LN Manual

Technical Information • Installation Instructions
Gas
May 2012 edition
In the interests of continuous product
improvement, technical specifications
are subject to change without prior notice!
GG20-LN
GB

2
E.04.99 • G. 09.05.12
Contents
Overview..............................................................................................................3
1. General information/safety instructions.......................................................................................... 3
2. Scope of supply and electrical ratings ........................................................................................... 3
3. Operating instructions .................................................................................................................... 3
4. Instruction ...................................................................................................................................... 3
5. Maintenance and customer service ............................................................................................... 3
6. Key for code designation ............................................................................................................... 4
7. Technical specifications ................................................................................................................. 4
Installation............................................................................................................5
8. Installing flange and burner............................................................................................................ 5
9. Checking the electrode setting........................................................................................................ 5
10. Installing the gas train .................................................................................................................... 5
11. Service position.............................................................................................................................. 6
12. Connecting to power supply.......................................................................................................... 7
Function ...............................................................................................................8
13. Control unit DMG 972 .................................................................................................................... 8
Start-up..............................................................................................................10
14. Air flap actuator STA 13 B0 .......................................................................................................... 10
15. Adjusting the mixing head............................................................................................................ 11
16. Adjusting the ignition electrode .................................................................................................... 11
17. Adjusting the inlet nozzle .............................................................................................................. 11
18. Gas burner with gas train............................................................................................................. 12
19. Adjustment tables ........................................................................................................................ 14
20. Modulating or 2-stage sliding gas burner with gas train................................................................ 17
21. Calculation principle for gas burner adjustment........................................................................... 19
Service instructions/dimensions ........................................................................21
22. Flame control using ionization electrode...................................................................................... 21
23. Measuring the ionization flow....................................................................................................... 21
24. Servicing the air pressure monitor ............................................................................................... 21
25. Circuit diagram GG20-LN ........................................................................................................... 22
26. Possible errors ............................................................................................................................ 25
27. Exploded drawings....................................................................................................................... 26
28. Spare parts list .............................................................................................................................. 27
29. Declaration of conformity for the forced-air gas burner................................................................. 28
30. Burner dimensions / boiler connecting dimensions...................................................................... 30
31. Working ranges............................................................................................................................ 30

3
E.04.99 • G. 09.05.12
1. General information
Installation of a gas-fired heating system must be performed in accordance with the applicable regulations
and guidelines. It is therefore the duty of the installer to be familiar with all applicable regulations and re-
quirements. 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 GG20-LN gas in
accordance with DIN EN 437 and comply with the European Standard DIN EN 676:2008-11.
2. 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. Gas train and gasket.
Gas installation and commissioning are subject to the applicable national regulations, e.g. in Germany the
Technical Regulations of the DVGW (DVGW-TRGI).
The following must be observed for Switzerland: SVGW Gas Provisions G1, G3: Gas installation EKAS
Form.
1942: Liquefied gas regulation, Part 2 Regulations of cantonal authorities (e. g. fire department regula-
tions).
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 gas ramp 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 the through-flow direction of the gas train.
3. Operating instructions
The operating instructions together with this technical information leaflet must be displayed in a clearly vis-
ible position in the boiler room. It is essential to enter the address of the nearest customer service centre
in the operating instructions.
4. 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.
5. 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.
Overview

4
E.04.99 • G. 09.05.12
6. Key for code designation
7. Technical specifications
Burner type
Technical data GG20/1-Z-(M)-L-LN GG20/2-Z-(M)-L-LN
Product ID No. CE-0085
Burner output in kW 55 - 170 65 - 235
Gas type Natural gas LL + E = "-N", liquefied gas 3B/P = "-F"
Gas input pressure with MB VEF 407 ¾“ 20
Gas input pressure with MBC 300 VEF 1 “
20
Gas input pressure with MB VEF 412 1“ 20
Mode of operation 2-stage/modulating
Voltage 1 / N PE ~ 50 Hz 220 - 240 V
Current consumption
start max. / operation 1.9 / 1.3 A 3.9 / 2.6 A
Electric motor power (at 2800rpm) in kW 0.18 0.37
Flame control Ionisation
Control box DMG 972
Weight in kg 15.0
18.7
Noise emission in db(A) 72
72
GG20/1-Z-(-M)-L-N(-F)-LN
LowNox
Erdgas LL+E ="-N" oder Flüssiggas ="-F"
Luftabschlussklappe
Zweistufig oder Modulierend
Baugröße
Baureihe
LowNox
Natural gas LL + E = "-N", liquefied gas 3B/P = "-F"
Air damper
2-stage/modulating
Burner type
Burner series
Overview

5
E.04.99 • G. 09.05.12
8. Install flange and burner
Important: Secure the sliding flange so that the
clamping screw 3 is positioned at the top!
When installing the sliding flange, only tighten screws
1 and 2 otherwise it will not be possible to secure the
burner tube 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.
9. Checking electrode setting
• Move the burner into the service position as
described on Page 6.
• Check the setting of the ignition and ionisation elec-
trodes (see Page 11).
10. Installing the gas train
• Remove plastic protective plug.
• Mount the connections and apply the seals
included.
• Observe the installation position.
• Check connecting point of gas ramp with non-corro-
sive foaming agent for leaks and vent the gas pipe.
• When venting, use a hose to discharge the gas
safely to the atmosphere.
For proportional pressure control
GG 20/25(-Z)-M-L-LN with KEV:
Fit the furnace pressure meter tube to the boiler door
with the gradient towards the boiler (if required).
Lay the pressure impulse to the KEV to the corre-
sponding connections p
L
and p
F
.
Use the blue PU hoses supplied.
• Lay the pressure impulse so that no condensate
can flow into the gas ramp.
• Connect hose to furnace pressure meter tube with
connection p
F
(if required).
• Connect hose to connection p
L
with measuring nip-
ple for
air pressure on burner base plate.
If this connection is not made, the magnetic valves
will not open.
Installing the gas train
Installation position for vertical line as desired
Installation position for horizontal line tilted up to max. 90° to left or right, not overhead
Minimum distance to masonry 20 mm
Installation position MBC...
Installation position CG...
Installation position MB...
Installation

6
E.04.99 • G. 09.05.12
11. Service position
Risk of injury by fan impeller on activation in service
position.
• Release quick-release locks (5 x) and detach base
plate,
• Place the keyhole openings in the base plate onto
the socket head cap screws of the housing and lock
them into place.
Installation

7
E.04.99 • G. 09.05.12
12. Connect to power supply
• De-energise the system. Move the master switch into the "OFF" position.
• Check the polarity of all connecting plugs.
• Wire the plug as shown in the terminal diagram. Lay the flexible control line so that the boiler door
remains swivellable.
• Attach cube connector connected to the gas pressure monitor connector A (grey) and to solenoid
valves B1 (black), and secure with screw.
• Connect the 4-pin plug of the power controller (X31) to the black-green socket on the burner (X32).
• If plugs X11 and X31 are wired as shown the terminal diagram, check that the pins are correctly
assigned.
• Connect the 7-pin plug of the boiler controller (X11) to the black-brown socket on the burner (X12).
• The power cord of the 7-pin connecting plug X11 must be fused with a slow-acting fuse rated for min.
6.3 A or a quick-acting fuse rated for max. 10 A.
Connection diagram:
T8
T7
T6
B5
Buchsenteil X32, X12
am Brenner
Steckerteil X31,X11
zum Kessel
X31 X32
zu
auf
Anschluss für GG20-M-L-LN
Y9
T8
T7
T6
B5
Buchsenteil X32, X12
am Brenner
Steckerteil X31,X11
zum Kessel
X32
N
F22
P12
X31
Anschluss für GG 20-Z-L-LN
H12
B4
S3
T2
T1
N
PE
L1
N
PE
L1
N
N
F1 F3
F21
H11
P11
H13
Q1 X11 X12
Buchsenteil X32,X12
am Brenner
Steckerteil X31,X11
zum Kessel
male adapter X31, X11
to boiler
female adapter X32, X12
on burner
male adapter X31, X11
to boiler
female adapter X32, X12
on burner
male adapter X31, X11
to boiler
female adapter X32, X12
on burner
Connection for GG20-Z-L-LN
Connection for GG20-M-L-LN
Legend:
F1 External fuse
F21, F22 Ext. temp. controller, 1st/2nd stages
F3 Ext. safety thermal cutout
F51 Gas pressure monitor
Q1 Main heating switch
H11, H12 Ext. pilot lamp
H13 Ext. fault signal lamp
L1 Phase
PE Protective earth
P11, P12 Time meter
Y1, Y2 Solenoid valve
Y3 Safety solenoid valve
Y9 Ext. controller
N Neutral conductor
Installation

8
E.04.99 • G. 09.05.12
13.Control unit DMG 972
Function testing the control unit
Danger of fatal injury from electric shocks!
Disconnect electrical cable from power supply before car-
rying out any work on live parts!
Troubleshooting may only be carried out by authorised
and trained personnel!
Unlocking may only be carried out by an authorised spe-
cialist.
Check air pressure monitor contact: device goes into fault mode when silicone connecting hose is de-
tached. Reconnect the hose to coupling "+".
Bypass air pressure monitor before start-up: burner motor starts for approx. 2-3 seconds, followed by fault
shut-down. After 10 seconds, an intermittent fault is output and then automatically
reset. A second start-up attempt is made. If the air pressure switch contact is still closed, a true fault shut-
down will occur. If the air pressure switch opens the contact within 10 sec., the burner will go into operation.
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 within 1 sec. Since the faults are not reset after a power failure, the burner motor
switches on for approx. 2-3 sec. when the supply voltage is connected before the device goes into fault
mode again and displays the last fault that occurred.
If a flame signal is given during the pre-ventilation phase, a failure shut-down will occur immediately.
The position of the air pressure controller is continuously checked. There can be no start-up if it is not in its
neutral position. If the NO contact does not close or reopens during the pre-ventilation phase, a failure shut-
down will occur. If there is an insufficient supply of air during operation, the air pressure controller contact
opens and the valves close immediately. The device switches to fault mode within 1 sec.
Fault cause diagnosis
In the event of a fault, the LED remains continuously lit. Every 10 seconds this is interrupted and a flash
code is signalled to provide information about the fault. This results in the following sequence, which re-
peats itself continually until the fault is acknowledged, i.e. the appliance is reset.
Following sequence:
Reader for failure code display:
SatroPen Art. No. 47-10-22542
SatroCom Art. No. 47-10-22563
Luminous phase Dark phase
lasting 10 secs. lasting 0.6 sec.
Dark phase
lasting 1.2 secs.
Flash code
Function

9
E.04.99 • G. 09.05.12
Fault message Flash code Cause of fault
Fault shut-down safety time No flame detection within the safety interval
Extraneous light fault External light during monitored phase, possible sensor
fault
Air controller in working posi-
tion
Air controller contact fused
Air controller time-out Air controller does not close within a defined time span
Air controller opens Air controller contact opens during start-up or operation
Flame failure Flame failure signal in operation
Honeywell: DMG 972 mod. 04
t
v1
= monitored pre-purge time for air pressure monitor 42 sec.
t
vz
= pre-ignition cycle 3 sec.
t
lk
= open air flap command during pre-purging 24 sec.
t
r
= air flap return 18 sec.
t
n
= post-ignition time 1.5 sec.
t
f
= flame simulation supervision 5 sec.
t
s
= safety period 2 sec.
t
v2
= delay at terminal 6 / C 10 sec.
Function

10
E.04.99 • G. 09.05.12
14. Air flap positioning motor
The positioning drive STA 13 B0 is used to adjust the
air flap on burners with a 2-stage or modulating operat-
ing modes. Make the adjustment using the limit switch
cams on the positioning drive roller.
After each normal shut-down, the positioning drive
moves to fully closed (ST0).
For this purpose, remove the hood from the air flap po-
sitioning motor. Alter the cam positions via the adjust-
ing screws with a standard screwdriver.
The switching cams can be readjusted when calibrat-
ing the burner.
The cam positions for adjusting the burner to the re-
quired min/max output are given in the adjustment ta-
ble.
see adjustment tables on pages 14 - 15.
For this:
Remove the hood from the positioning drive. Alter the cam positions via the adjusting screws with a stand-
ard screwdriver.
The switching cams can be readjusted when calibrating the burner.
Higher number = increase air
Lower number = reduce air
Adjustments to ST1 and ST2 do not become effective until a brief switchover between 1st/2nd stage (or
triggering of Up/Down on output controller) has taken place.
Do not adjust cam ST1/min. to a value that is greater than ST2/max.
After readjusting the burner, refasten the positioning
motor hood and set the switch on the lower part of the
control unit to the position 2nd stage.
ST1
ST0
ST2
Start-up