Giersch GG35 Manual

Technical Information • Installation Instructions
Oil
Issue February 2002
Right reserved to effect techn.
modifications in the interest of
product improvement !
GB
Brenner und Heizsysteme
GG35/55/80

2
G. 04.02.02
Contents
1. Safety notices
Observethe rules ofengineering,the building inspection regulations andthe statutory stipulationsconcerning
the erection and operation of the plant.
Installation of the oil and exhaust gas connections, the commissioning, power connection, servicing and
maintenance may be performed by a specialized company only.
For the making of the electrical connections the VDE or ÖVE regulations and the regulations of the respon-
sible electricity supply company must be taken into consideration.
Any work on the electrical system may be performed only by a skilled electrician in accordance with the rele-
vantly valid VDE and ÖVE stipulations.
2. Service
Pursuant to section9 of the heating systems ordinance it isrequired that you have the plant regularly serviced
in order to ensure reliable and safe operation of the equipment.
Servicing is required annually. We recommend that you conclude a service contract with an approved spe-
cialized company.
3. Conformity declaration
We declare that the Giersch GG35/55/80 oil blow burner meets the basic requirements of the following direc-
tives:
•"Low-Voltage Directives" in compliance with 73/23/ EEC in conjunction with DIN VDE 0700 part 1/
issue 04.88 and DIN VDE 0722/issue 04.83
•"Electromagnetic Compatibility" in compliance with directive 89/336/EEC in conjunction with
EN 55014/ issue 04.93 and EN 50082-1/issue 01.92
•"Machine Directives" in compliance with directive 98/37/ EEC
•"Efficiency Directive" in compliance with directive 92/42/EEC in conjunction with DIN EN 267/issue 10.91
1. Safety notices ...............................................................................................................................2
2. Service..........................................................................................................................................2
3. Conformity declaration..................................................................................................................2
4. Technical specifications................................................................................................................3
5. Installing the flange and burner ....................................................................................................3
6. Electrical connection.....................................................................................................................3
7. Oil pump .......................................................................................................................................4
8. Oil connection...............................................................................................................................4
9. Service position ............................................................................................................................5
10. Changing the nozzle.....................................................................................................................5
11. Adjustment of the ignition electrodes............................................................................................5
12. Adjustment of the air volume (dimension "B" and dimension "A")................................................6
13. Operability check..........................................................................................................................7
14. Oil preheating ...............................................................................................................................8
15. Oil control......................................................................................................................................8
16. Boiler/burner conditioning...........................................................................................................10
17. Smokestack connection..............................................................................................................10
18. Exhaust gas thermometer...........................................................................................................10
19. Circuit diagram............................................................................................................................11
20. Troubleshooting..........................................................................................................................13
21. Table of settings .........................................................................................................................14
22. Burner cross-section and spare parts list ...................................................................................15
23. Burner overall dimensions / boiler connection dimensions.........................................................16
24. Working ranges...........................................................................................................................16

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G. 04.02.02
4. Technical specifications
5. Installing the flange and burner
- Fit the sliding flange and gasket loosely to the boiler door.
- Insert the burner.
- Comply with the tightening sequence of the screws.
- When tightening the screws lift up the burner.
The insertion depth of the burner tube is
optimally adjusted by way of the sliding flange to the relevant combustion chamber.
6. Electrical connection of the boiler control unit
Effect the electrical connection in the plug unit in accordance with the wiring diagram and taking into consi-
deration local regulations. Protect the supply line with a 10 A fuse. It is expedient to use a flexible cable. When
the plug unit is ready wired, check the that the terminals comply with the wiring diagram below.
GG 35-V GG 35 GG 55-V GG 55 GG 80
Burner output
in kg/h
in kW
1.00-3.35
12-40
1.20-3.35
14-40
1.00-5.05
12-60
1.20-5.05
14-60
3.35-6.75
40-80
Recommended
boiler output in kW 13,5-38 16,5-38 11-57 13-57 37-73.5
Voltage 230 V/ 50 Hz
Power consumption in
W (max.)
start / in operation 520/255 400/180 520/245 400/180 400/180
Weight in kg (approx.) 11
Noise emission in dB(A) 58 58 59 59 60
B4
S3
T2
T1
N
L1
0000
N
PE
L1
230 V
50 Hz
F11
Empfehlung
max. 10A
Q1F3
F21
H13H11
P11
N
N

4
G. 04.02.02
7. Oil pump
The pump pressure must be adjusted to suit the relevant output (see Table of settings on p. 14).
The specified pump pressures are only guide values and may deviate depending on plant conditions.
To do so:
•Unscrew and remove the pressure measuring connection ➄
•Screw in the pressure gauge and set the pump pressure by
means of the pressure adjuster ➁as per the table of settings.
➀=nozzle outlet
➁=pressure adjuster
➂=feed line
➃=return line
➄=pressure measuring connection
➅=vacuum measuring connection
➆=filter
➇=by-pass plug for 2-line operation
8. Oil connection
The tablesrelate to heating oil EL 4.8 cStand the inner diameter of the oil pipes. In the case ofthe suction line
length 4 elbows, 1 valve and 1check valve have been taken into consideration for the resistance. On acccount
of possible gassing-off of the oil, dimension X should not exceed a length of 4 mtrs.
• Using the metal hoses provided connect the oil pump to the oil line.
• The pump should be connected to the feed and return lines (two-line system).
• If the tanks are positioned higher the pump can be converted to a single-line system.
For pure single-line operation unscrew and remove the seal with the by-pass plug ➇which lies beneath it and
screw the cap only back in. Seal the return line opening ➃ by means of the gasket and metal plug.
For conversion to a single-line system we recommend the use of
a heating oil filterwith return linefeed. In this way the pump isleft
in two-line mode. Fit the feed and return line burner hoses tothe
filter. Open the oil cock on the filter. Put the plant into operation.
8
7
3
4
1
2
5
6
Two-line system Single-line system
5 kg/h
∅6mm
L [m]
100
97
65
32
16
100
100
100
69
37
6
∅8mm
L [m]
100
100
100
100
59
10
Düse
Leitungs-
innen-∅
H [m]
4,0
3,0
2,0
1,0
0,5
0,0
-0,5
-1,0
-2,0
-3,0
-4,0
∅4mm
L [m]
51
38
26
13
6
52
46
40
27
15
2
∅6mm
L [m]
100
100
100
65
32
100
100
100
100
75
12
∅4mm
L [m]
26
19
13
6
3
26
23
20
14
7
1
∅6mm
L [m]
100
100
100
51
26
66
58
50
34
19
3
2,5 kg/h
∅4mm
L [m]
31
23
16
8
4
10 kg/h
H [m]
4,0
3,5
3,0
2,5
2,0
1,5
1,0
0,5
0
-0,5
-1,0
-1,5
-2,0
-2,5
-3,0
-3,5
-4,0
L [m]
∅8mm
100
98
91
85
79
72
66
60
53
47
41
34
28
22
15
9
3
L [m]
∅10mm
100
100
100
100
100
100
100
100
100
100
99
84
68
53
37
22
6
L [m]
∅6mm
33
31
29
27
25
23
21
19
17
15
13
11
9
7
5
3
1
nozz
l
e
pipe inner
dia

5
G. 04.02.02
9. Service position -Release the quick-action fasteners
-Pull the mounting plate out of the housing
-Hook the mounting plate by its retaining straps onto the two top
screws (service position).
To reassemble insert the mounting plate into the housing and
secure with the quick-action fasteners.
Caution ! Ensure that the mounting plate
is correctly seated in the housing.
10.Changing the nozzle -Hook the mounting plate in service position.
-Release the ignition cable from the ignition electrode.
-Release the retarding disc and pull it up and off.
-Release the oil nozzle(open-end wrenchsize16), whileholding
the nozzle stock against turning with an open-end wrench size
19 (see illustration on left).
-Replace the oil nozzle.
Reassemble in the reverse order. When doing so on the GG55
take heed of the position of the measuring nipple (small bore in
the retarding disc, Ident „M“).
The stop for the retarding disc must always be positioned in the
rear groove (60° position).
11.Adjustment of the ignition electrodes
The electrodes have been set ex-works. The dimensions are
specified for checking purposes.
Measuring nipple
Stop ring
for retarding disc

6
G. 04.02.02
12. Adjustment of the air volume dimension "B" and dimension "A"
Dimension "B"
The scale serves as an orientation aid for easier adjustment
of the air volume. The air volume is altered by means of a
hexagon spanner (size 17) depending on the output in com-
pliance with the table of settings. The values of the table of
settingscan beread directly onthe scale.If thereis overpres-
sure in the furnace, set the value higher, and if there is sub-
pressure the value must be set lower. Readjustment is
necessary in any case on account of the type of plant.
To achieve constant combustion values we recommend
installation of a draught regulator or of a secondary air
device.
While changing the air adjustment pinion be aware of posi-
tioning the zero mark of the pinion fits the adjusting mark
while the scale shows a value of 5 degrees.
Dimension "A"
Dimension "A" (see Table of settings) serves as an orienta-
tion aid for adjusting the burner.
Dimension "A" describes the position of the nozzle stock
with the retarding disc in the cone of the burner tube.
Example: Adjusting nut is turned clockwise
The air throughput increases,the CO2content in the exhaust
gas falls and the air pressure before the retarding disc drops.
By measuring the CO2at the measuring point in the exhaust
gas pipe the correct adjustment for dimension "B" and
dimension "A" is checked.
Air pressure before the retarding disc
(see Table of settings)
CO
2
= 12-13% Pressure too high Pressure too low
CO2too high Adjusting nut clockwise
Retarding disc back
Increase dimension "A".
Increase dimension "B"
CO2too low Reduce dimension "B" Adjusting nut counter-clockwise
Retarding disc forwards
Reduce dimension "A".
In special cases the limits for the guide values can be exceeded, e.g.
if extreme installation situations exist.
Dimension "B"
Pressure measuring nipple
Lock nut
Adjusting nut
Zero mark Scale
Adjusting mark
Dimension "A"

7
G. 04.02.02
13.Operability check of the flame monitoring control device
Carry out the following checks after commissioning and each time after the burner has been serviced:
1 Restart with covered up flame failure controller:
The control device must switch to fault upon expiry of the safety period.
2. Burner startup with flame failure controller exposed to external light, e.g. a fluorescent lamp,lighter, incandescent
lamp (daylight is not sufficient !! ):
The control device must switch over to fault during the pre-ventilation period as a consequence of the external
light.
3. Normal startup - if burner is in operation during the post-ignition period black out the flame failure controller:
(e.g. pull out the flame failure controller and cover it up !).
TF 830/832, The ignition must switch on and upon expiry of the safety period the device must switch
LOA 24: over to fault.
DKW 972/976: The fuel supply must be immediately interrupted and a post-ventilation of 60 secs.
must be initiated. A restart is then effected whereby the automatic firing device
must go to fault position at the end of the safety period.
Safety devices and switching functions
In the event of a flame failure duringoperation the fuel supply is immediately switched off and the device makes a new
startup attempt with pre-ventilation and post-ignition. If no flame has formed, upon expiry of the safety period the de-
vice switches over to fault. Following a mains power failure a restart takes place in any case. In the presence of ex-
ternal light during the pre-ventilation period the control device switches over to fault upon expiry of the safety period.
The control device may only be plugged in or unplugged, if the main switch is in the "OFF" position or if the
7-pin plug connector is disconnected, because the bottom part of the control device carries 230 V. The inci-
dence of external light onto the photoresistor or onto the flame failure controller (e.g. through a sight glass or
after-glowing refractory bricks) must be prevented. Only then is fault-free operation of the plant ensured.
TF 830/832 and DKW 972/976 and LOA 24
Satronic: TF 830 TF 832 DKW
972/976 LOA 24
tv1 = pre-ignition time + pre-ventilation 12 secs. 12 secs. 20 secs. 13 secs.
ts= safety period 10 secs. 10 secs. 5 secs. 10 secs.
tn= post-ignition time 20 secs. 2-5 secs. 7 secs. 15 secs.
Post-ventilation after flame cut-off none none 60 secs. none
Wait time after fault switch-off 90 secs. 90 secs. none 50 secs.
Photoresistor (flame failure controller) MZ 770 QRB 1B
Minimum photocurrent [ µA ] 30 30 70 70
Start with flame formation
Releasing thermostat oil-preheater ON
Ventilator
Ignition
Magnetic valve
Photo-electric cell
Fault indicating lamp
tsFault
Ventilator
Ignition
Magnetic valve
Photo-electric cell
Fault indicating lamp
tv1
ts
tn
Operation
Start without flame formation
TF 830 / MMO 872

8
G. 04.02.02
Measurement of the photocurrent (MZ 770)
If there is a negative deflection of the measuring instrument, turn the plug on the measuring instrument lead around !
Set the measuring instrument to ampere metering for DC, measuring range up to approx. 200 µA !
Useful measuring accessory
Digital measuring instrument art. no. 59-20-50263
14.Oil preheating (GG35/55-V only)
The oil preheating is upline from the burner program sequence and remains in operation until the oil burner is
switched off by the control thermostat.
The cold-start disable is effected via a thermostat, which is integrated into the preheater, and which does not
enable the supply of current to the control device until the heating-up has taken place.
The electrical preheater is integrated into the nozzle holder and has a controlled heating output. This is adap-
ted via a posistor to the relevant heat requirement.
15.Oil control (optional)
Measuring range: 1 to 40 l/h
Working temperature: 0-60 °C
Permissible pressure: < 25 bar
Measuring precision: ± 2.5 %
This multifunction device provides information about the oil consumption, the number of burner startups, the
burner operating hours etc. and in addition givesa warning when the oil throughputdrops below the set target
value (e. g. nozzle blocked). Through early detection and elimination of the deficiency, uneconomical and
environmentally harmful operation of the burner can be prevented. In operation ensure that the flow, pressure
and temperature are within the permissible limits.
As a rule no special servicing of the oil control is necessary. Clean the upline dirt trap (in the pump and oil fil-
ter) when the annual burner check is performed !
Caution: The display will disappear off screen 1 day after a mains power failure, (e. g.
phase connected). However, all values are retained and can be called again when mains
power is switched back on. The set and reset functions are not possible during a mains
power failure.
Method of operation of the mode key
By brieflypressing the modekey theindividualdisplays can be called in consecutive order. The relevant mode
is displayed by a function symbol and/or the corresponding unit when the key is released.
Flame failure controller
Bottom part
device
for control-
500
µ
A
or
200
µ
A

9
G. 04.02.02
The following functions can be displayed:
Resetting the oil volume counter
Resetting of the oil volume counter can be effected in the mode ◊.:
=> Hold down the key for at least 10 secs.
Press the key, after 5 secs.the displayed value will flash for 5 secs. Subsequently the (old) value remains
on the display again, now release the key and 0L appears on the display.
Definition of the momentary consumption target value
Definition of the momentary consumption target value is effected in the mode/function momentary consump-
tion:
=> Hold down the key for at least 30 secs., but 32 secs. at the longest
Press the key, after 25 secs. the displayed momentary consumption will flash for 5 secs. As soon as the
flashing stops, release the key. As confirmation the service symbol and the momentary consumption as the
newly defined target value will flash for 5 secs.
Following a change in burner output (nozzle change, change in pump pressure etc.) the target value must be
redefined as specified above. The old target value is thereby overwritten.
Service function
If the oil flow is reduced by more than 10 % (e.g. in the event of a slowly blocking nozzle, preheater etc.), the
service symbol will appear on the display unit.
The prerequisite for this service function is previous input of the target value (see Definition ofthe momentary
consumption target value) with correct burner operation.
Deactivation of the service function
Procedure as for definitionof the momentary consumption target value,however, hold down the keyfor longer
than 32 secs. This clears the target value and the service symbol:
=> Hold down the key for at least 32 secs.
Upon being released the service symbol flashes and the zero value on the display flashes for 5 secs. as
confirmation.
Function Display
Momentary consump-
tion
Oil volume
(resettable) ◊
Oil volume
(total)
S
Total operating hours
Number of
burner startups
Reduced throughput
(see Service function)
Service
000000
l
0000.00
l/h
000000
l
0000.00
l/h
000000
h

10
G. 04.02.02
16.Boiler/burner conditioning
Precise boiler/burner conditioning is ncessary for low-emission and energy-saving combustion. For this pur-
pose a burner is assigned to the boiler in accordance with the working ranges and in consideration of the fur-
nace resistance. Via the sliding flange set the insertion depth of the burner tube to suit the relevant burner
chamber.
17.Smokestack connection
The prerequisite for perfect operation of the furnace is a correctly dimensioned smokestack. Dimensioning is
effected in accordance with DIN 4705 in consideration of DIN 18160 and based on the boiler and burner out-
puts. Ifoperating on a sliding basis, provide smokestacks as per DIN 18160 part 1, group 1. The exhaust gas
mass flow of the total rated heat output must be put in for the calculation. The effective smokestack height is
counted from the point of exhaust gas introduction into the smokestack. Furthermore, we refer you to the sta-
tutory building regulations of the individual German federal states. Select a smokestack design so that the
danger of condensation or of a cold smokestack inner wall is reduced to a minimum.
For exact adjustment and stabilization ofthe smokestack draught we recommend the installation of a
draught limiter.
By this means:
1. any draught fluctuations are equalized
2. moisture in the smokestack is largely excluded
3. stoppage losses are reduced
IMPORTANT !
When refurbishing existing plants over-dimensioned smokestack cross-sections or unsuitable smokestacks
are very often specified for NT operation etc.We recommend that you make an appraisal of the smokestack
system together with the responsible local chimney sweep prior to installing the boiler plant so that suitable
refurbishing measures can be defined at an early stage for the smokestack as well.
18.Exhaust gas thermometer
For exhaust gas temperature monitoring the heating system should be equipped with an exhaust gas ther-
mometer. The higher the exhaust gas temperature, the greater the exhaust gas loss. Rising exhaust gas tem-
peratures indicate increasing deposits that will reduce the degree of combustion efficiency. In the event of an
increasing exhaust gas temperature have the heating plant cleaned and readjusted by a suitably skilled per-
son.
Legend:
B1Flame failure controller
E1Preheater
F1,F11Ext. fuse (10 A max. recommended)
F21 Ext. temp. controller
F3Ext. safety temp. limiter
H11 Ext. operating lamp
H13 Ext. fault signal lamp
H14 Oil preheater control lamp
M1Burner motor
P11 Ext. operating hours counter
P21 Burner operating hours counter (optional)
Q1Main heating switch
S1Automatic firing unit Satronic TF830/832 or LOA 24
for hot air generators with DKW 972 f. GG35/55/80
for hot air generators with DKW 976 f. GG35/55-V
S2,S9Oil control (optional)
T1,T3Ignition transformer
X11 Boiler control plug unit
X12 Burner socket unit
Y6Oil solenoid valve
PE=earth lead
bl = blue
br = brown
ge = yellow
gr = grey
grü = green
sw = black
ro = red
ws = white