Giersch GL20-Z-L-LN Manual

Technical Information • Installation Instructions
Oil
Issued May 2011
Right reserved to effect techn. modifications
in the interest of product improvement!
GB
GL20-Z-L-LN

E.25.05.11
2
Contents
1. General information ............................................................................................................................3
2. Safety guidelines ................................................................................................................................3
3. Maintenance ....................................................................................................................................... 3
4. Declaration of conformity ....................................................................................................................3
5. Boiler connection dimensions .............................................................................................................4
6. Key for code designation ....................................................................................................................4
7. Technical specifications......................................................................................................................4
8. Installing flange and burner ................................................................................................................5
9. Connecting to power supply ...............................................................................................................6
10. Installing the oil line ............................................................................................................................7
11. Oil pump .............................................................................................................................................8
12. Checking the operation of the flame monitor control unit ...................................................................9
13. Setting the air flow rate.....................................................................................................................11
14. Actuator drive.................................................................................................................................... 12
15. Setting the ignition electrodes........................................................................................................... 12
16. Service position ................................................................................................................................13
17. Adjusting the inlet nozzle..................................................................................................................13
18. Notes about the mixing unit .............................................................................................................. 14
19. Nozzle replacement..........................................................................................................................14
20. Nozzle replacement..........................................................................................................................14
21. Start-up .............................................................................................................................................15
22. Calibration of the boiler-burner ......................................................................................................... 15
23. Flue connection ................................................................................................................................15
24. Exhaust gas thermometer................................................................................................................. 15
25. Circuit diagram ................................................................................................................................. 16
26. Troubleshooting ................................................................................................................................ 17
27. Adjustment table ...............................................................................................................................18
28. Explosion drawings / spare parts lists............................................................................................... 20
29. Dimensions.......................................................................................................................................26
30. Working ranges................................................................................................................................. 26

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General information
3
1. General information
The GL20-LN oil burners are tested and approved to DIN EN 267 for heating oil EL according to
DIN 51603, ÖNORM C 1109, SN 181 160/2.
We recommend that the operator use low-sulphur heating oil EL or "eco heating oil" (where regionally available).
2. Safety guidelines
The rules of good engineering practice as well as construction supervision and statutory requirements must be
observed during installation and operation of the system.
Assembly, oil and flue gas connections, commissioning and connection to the power supply, as well as mainte-
nance and servicing may only be performed by a certified specialist.
Electrical connections must be in conformity with the applicable VDE, SEV and ÖVE specifications as well as
the regulations of the local utility.
Work on electrical equipment may only be carried out by qualified personnel in accordance with the relevant
VDE, SEV and ÖVE regulations.
Risk of injury by fan wheel on activation in service position.
3. Maintenance
The equipment must be checked regularly by trained personnel to ensure reliable and safe functioning of the
system. Annual maintenance is required. We recommend that users take out a maintenance contract with a
certified specialist.
4. Declaration of conformity
We declare that GL20-LN Series oil blower burners with the assigned product identification number
meet the basic requirements of the following directives:
• "Electromagnetic Compatibility" according to Directive 2004/108/EEC
• "Machinery Directive" as per directive 2006/42/EG in conjunction with DIN EN 60204-1
• "Efficiency Directive" according to Directive 2006/42/EWG in conjunction with EN 267/Ed.10.91
These products conform with the design sample tested at the designated centre 0032.

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Boiler connection dimensions (All dimensions are given in mm)
5. Boiler connection dimensions (All dimensions are given in mm)
6. Key for code designation
7. Technical specifications
Burner type
Technical specifications GL20/1-LN GL20/2-LN GL20/3-LN
Burner capacity
in kW
in kg/h
44 - 116
37 - 9.8
78 - 216
66 - 18.2
126 - 262
106 - 22.1
Mode of operation 2-stage
Voltage 1 / N / PE ~ 50 Hz / 220 - 240 V
Max. power consumption at start / during
operation
4 A max. / 2 A eff. 6.5 A max. / 3.5 A eff.
Electric motor power (at 2800rpm) in kW 0.250 0.370 0.370
Oil pump (type) Suntec AT2 45 D
Flame failure controller Flame failure controller IRD 1010
Control box DKO 972 Mod. 22
Weight in kg 16.5 20 23.5
M8
k
d
f
90°
GL20/1 GL20/2/3
Hole diameter d1 102 130
Hole circle diameter k 140-180 170-200
Outer diameter f 194 220
d1
GL20/1-Z-L-LN
LowNox"
Luftabschlussklappe
Zweistufig
Baugröße
Baureihe
burner series
burner type
2 stage
air damper
LowNox

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Installing flange and burner
5
8. Installing flange and burner
GL20/1/2-LN
• Attach the sliding flange and gasket loosely to the
door of the boiler.
• Slide in the burner.
• Observe the tightening sequence for the screws.
• Raise the burner when tightening the screws.
GL20/3-LN
• Attach the sliding flange and gasket loosely to the
door of the boiler.
• Remove the front part of the burner pipe from the
burner, slide in the burner.
• Observe the tightening sequence for the screws.
• Raise the burner when tightening the screws.
• Replace the front of the burner pipe and
fasten it (see figure).

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Connecting to power supply
9. Connecting to power supply
• Disconnect the system from the power supply. Main switch "OFF".
• Check the polarity of all connectors.
• Connect the plug unit as indicated in the connection diagram. Route the flexible control lines so that the
hinged door of the boiler is not obstructed.
• Connect the 4-pin connector for capacity regulation (X31) to the black-green socket unit on the burner
(X32).
• Where the X11 and X31 connections are used, check for correct assignment according to the connection
diagram.
• Connect the 7-pin connector of the boiler control (X11) to the black-green socket unit at the burner
(X12)..
• The connection cable to the 7-pin X11 connection on the plug unit must be fused with max. 6.3 A slow-
acting or max. 10 A fast-acting.
Connection diagram:
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
T8
T7
T6
B5
Buchsenteil X32, X12
am Brenner
Steckerteil X31,X11
zum Kessel
X32
N
F22
P12
X31
Anschluss für GL20-Z-L
H12
Connection for GL20-Z-L
connector unit X31, X11
boiler control
socket unit X31, X12
on burner
connector unit X31, X11
boiler control socket unit X31, X12
on burner
Key:
F1 External fuse
F21, F22 External temperature controller 1st/2nd stage
F3 External safety temperature limiter
Q1 Heater power switch
H11, H12 Ext. status lamp
H13 Ext. fault indication lamp
L1 Phase
PE Grounded conductor
P11, P12 Operating hours counter
Y9 Ext. control
N Neutral conductor

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Installing the oil line
7
10. Installing the oil line
Twin-pipe system
Single-line system
The tables refer to heating oil EL 4.8 cSt and the inner diameter (Di) of the oil pipes. 4 brackets, 1 valve and
1 non-return valve were included for resistance with the suction line length. To prevent possible oil vapours, the
dimension X should not exceed a length of 4 m.
• Connect oil pump to the oil line with the enclosed metal hoses.
• The pump should be connected with a feed and return line (twin-pipe system).
• With elevated tanks, the pump can be converted to a single-pipe system.
For pure single-pipe operation the bypass stopper must be unscrewed out of the return line opening 
(see page 8) and the return line opening must be sealed with a gasket and metal stopper.
Pump Di
[mm] H [m]
4 3 2 1 0 -1 -2 -3 -4
Suntec 621 18 16 13 11 8 5 - -
867 58 50 42 34 25 17 9 -
10 100 100 100 100 82 62 42 21 -
Oil
throughput
[kg/h]
Di
[mm]
H [m]
4 3 2 1 0 -1 -2 -3 -4
up to 2.5
477 68 58 49 40 31 22 13 -
6100 100 100 100 100 100 87 64 18
8100 100 100 100 100 100 100 100 56
2.5 - 5.0
439 34 29 25 20 16 11 6 -
6100 100 100 100 100 79 56 32 9
8100 100 100 100 100 100 100 65 28
5.0 - 10.0
419 17 15 12 10 8 - - -
698 86 74 63 51 39 28 16 4
8100 100 100 100 100 100 88 51 14
10.0 - 23.0 642 37 32 27 22 17 12 7 -
8100 100 100 85 69 54 38 22 6

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Oil pump
We recommend that you use a heating oil filter with return inlet when changing over to a single-pipe system.
This leaves the pump operating in twin-pipe mode. Install the feed
and return burner hoses to the filter. Open the oil tap on the filter.
Start up the system.
11. Oil pump
The pump pressure must be set to match the relevant capacity.
The specified pump pressures are standard values and may vary according to system conditions.
For this:
Remove the 4 sealing plug.
Screw in the pressure gauge and adjust the pump pressure with the regulating screw.
1 = Feed line
2 = Return line
3 = Pressure pipe connection
4 = Pressure measuring connection
5 = Vacuum measuring connection
6 = Pressure adjustment 1st stage
7 = Pressure adjustment 2nd stage
8 = Solenoid valve 1st stage
9 = Solenoid valve 2nd stage
9
6
5
7
1
2
3
4
8
4

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Checking the operation of the flame monitor control unit
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12. Checking the operation of the flame monitor control unit
The DKO control unit uses a microprocessor-based programming sequence to produce extremely stable tim-
ings independent of fluctuations in the line voltage and ambient temperature. The built-in visual information sys-
tem allows continuous progress monitoring and provides information on the causes of a fault shutdown.
The last cause of fault is stored in the appliance and can even be reconstructed when restarting the appliance
after a power failure. The control unit is protected against under voltage. A restart takes place in all cases fol-
lowing a mains power failure.
Information system
The information system displays information on the processes in connection with burner control and monitoring.
In addition to monitoring the program, it allows faults to be localised immediately during the program sequence
or operation without the need for auxiliary devices.
The troubleshooting button has an LED. The LED is used to indicate status information and faults. The status
messages are intended for output to Satro Com and Satro Pen, and cannot be interpreted by operators due to
the rapid flashing sequence. Status messages are translated to plain text by the Satro Com and Satro Pen
devices. Faults are transferred at a slower flashing speed and can therefore be interpreted by users.
Program sequence DKO 972 Mod.22
The built-in microprocessor controls both program sequence and the information system. The individual phases
of the program sequence are indicated as flash codes.
Fault cause diagnosis
In the event of a fault, the LED remains continuously lit. Every 10 seconds, this is interrupted by the flashing code
indicating the fault that has occurred. This results in the following sequence repeats itself continually until the
fault is acknowledged, i.e. the appliance is reset.
Sequence:
Message Flashing Code
Wait until the release thermostats are closed
Pre-ignition phase
Safety and post-ignition times
Operation
Mains undervoltage
Waiting for RT or pcb fuse defective
Failure message Flashing Code Cause of fault
Fault shutdown No flame detection within the safety interval
Extraneous light
fault
External light during monitored phase, sensor possibly defective
Thermostat time-out FT contact does not close within 400 sec.
LED continuously ON Dark phase
lasting 10 secs. lasts 0.6 secs.
Dark phase
lasting 1.2 secs.
Flashing Code
.
.
.
.
.
= short pulse
= long pulse
= short interval
= long interval
Description:

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Checking the operation of the flame monitor control unit
Function test
A safety inspection must be carried out on the flame monitor on commissioning as well as after a service or
lengthy shutdown.
Start-up with covered flame detector:
The burner must go into fault mode after the safety period.
Start-up with flame detector exposed to light:
The control device must switch over to fault mode, see IRD function description.
Normal start-up if the burner is in operation, cover the flame detector:
Attempted restart; upon expiry of the safety period, the control device must switch
over to fault mode.
Safety and switching functions
If a flame failure occurs during operation, the fuel feed shuts off immediately and the system tries a restart, with
pre-aeration and retarded ignition. If no flame results, the control box indicates a fault after the safety period
expires. The control unit also goes into lockout mode if external light is present during the pre-aeration interval.
The device remains locked out and the cause of the fault is indicated until the automatic burner control system
is unlocked (enabled) by internal or external fault clearing.
The control unit may only be connected or disconnected when the master switch is at "OFF", or the 7-pin
connector is disconnected. Incidence of external light on the flicker detector (e.g. due to a sight glass)
must be prevented. Only then is a fault-free functioning of the system guaranteed. The flicker detector
must be set so that the incidence of light (e.g. through a sight glass or after-glowing refractory bricks)
does not affect the flicker detector.
Satronic: DKO 972 Mod. 22
t
v1
= pre-purge and pre-ignition time 17 sec.
t
v2
= delay time, 2nd stage 60 sec.
t
f
= flame simulation supervision 5 sec.
t
s
= safety period 5 sec.
t
n
= post-ignition time 20 sec.
Post-ventilation after
flame cut-off -
Delay after switching-off fault -
Flicker detector IRD 1010