GOK GS Pro-Fi 3 User instructions

Assembly and operating manual
Combined heating oil filter breather type GS Pro-Fi® 3
Breather device with filter and shut-off fitting according to EN 12514-2
CONTENTS
ABOUT THE MANUAL ............................................................................................................................. 1
SAFETY ADVICE ..................................................................................................................................... 2
GENERAL PRODUCT INFORMATION .................................................................................................... 2
INTENDED USE ...................................................................................................................................... 3
INAPPROPRIATE USE ............................................................................................................................ 3
USER QUALIFICATION ........................................................................................................................... 3
ADVANTAGES AND EQUIPMENT .......................................................................................................... 3
DESIGN ................................................................................................................................................... 4
CONNECTIONS ....................................................................................................................................... 5
DETERMINATION OF THE FLOW RATE, THE PIPE DIAMETER, AND THE PRESSURE LOSS ........... 5
ASSEMBLY .............................................................................................................................................. 6
LEAK CHECK .......................................................................................................................................... 8
START-UP ............................................................................................................................................... 9
OPERATION ............................................................................................................................................ 9
TROUBLESHOOTING ............................................................................................................................. 9
MAINTENANCE ..................................................................................................................................... 10
REPLACEMENT .................................................................................................................................... 10
RESTORATION ..................................................................................................................................... 10
SHUT-DOWN ......................................................................................................................................... 11
DISPOSAL ............................................................................................................................................. 11
TECHNICAL DATA ................................................................................................................................ 11
LIST OF ACCESSORIES ....................................................................................................................... 12
WARRANTY .......................................................................................................................................... 12
TECHNICAL CHANGES ........................................................................................................................ 12
NOTES .................................................................................................................................................. 13
APPROVAL ............................................................................................................................................ 14
ABOUT THE MANUAL
•This manual is part of the product.
•This manual must be observed and handed over to the operator to ensure that
the component operates as intended and to comply with the warranty terms.
•Keep it in a safe place while you are using the product.
•In addition to this manual, please also observe national regulations, laws and
installation guidelines.
Translation of original / Item No. 13 512 53 Version 01.2016
2Y115

Combined heating oil filter breather type GS Pro-Fi® 3
SAFETY ADVICE
Your safety and the safety of others are very important to us. We have provided many
important safety messages in this assembly and operating manual.
Always read and obey all safety messages.
This is the safety alert symbol.
This symbol alerts you to potential hazards that can kill or hurt you and others.
All safety messages will follow the safety alert symbol and either the word
“DANGER”, “WARNING”, or “CAUTION”. These words mean:
describes a personal hazard with a high degree of risk.
 May result in death or serious injury.
describes a personal hazard with a medium degree of risk.

May result in death or serious injury.
describes a personal hazard with a low degree of risk.
 May result in minor or moderate injury.
describes material damage.
 Has an effect on ongoing operation.
Escaping, liquid fuels:
•are hazardous for water
•are inflammable category 1, 2 or 3 liquids
•can ignite and cause burning
•can cause injury through people falling or slipping
Capture fuels during maintenance work.
GENERAL PRODUCT INFORMATION
The combined heating oil filter breather type GS Pro-Fi® 3 is a professional filter breather
system of the 3rd generation as “closed system” (GS). The GS Pro-Fi® 3 meets the
requirements of EN 12514-2, E DIN EN 12514-3, the technical regulation for oil firing
installations DIN 4755:2004-11, the technical regulation for oil systems TRÖl and TRÖL (AT),
respectively, as well as worksheet DWA-A 791 part 1 “Erection, operational requirements, and
shut-down of fuel oil consumer systems”.
The GS Pro-Fi® 3 is a combination of a breather device, a filter, and an upstream shut-off
fitting. It ensures that the liquid fuel oil is filtered and the gases released during the suction
process are discharged at the same time. The gas is not discharged into the environment, but
within the closed system via the burner nozzle in the combustion chamber, which is why the
system works without producing any smell.
The GS Pro-Fi® 3 is only installed into the suction lines of supply/oil systems designed
according to the single string system with return supply.
2 / 16 Item No. 13 512 53

Combined heating oil filter breather type GS Pro-Fi® 3
INTENDED USE
Operating media
•Diesel fuel
•Kerosene
•FAME
•Fuel oil
•Bio fuel oil, 30% (V/V) FAME
You will find a list of operating media with descriptions, the
relevant standards and the country in which they are used in the Internet at
www.gok-online.de/de/downloads/technische-dokumentation.
Installation location
•for being installed in oil systems designed as single string system with return supply
•above and below the tank crown, respectively
INAPPROPRIATE USE
All uses that are not appropriate:
• e.g. operating with different media,
•different inlet or outlet pressures
•installation against the flow direction
USER QUALIFICATION
This product may be installed only by qualified experts. These are personnel who are familiar
with setting up, installing, starting up, operating and maintaining this product.
"Equipment and systems requiring supervision may be operated only by persons aged at
least 18, who are physically capable and who have the necessary specialist knowledge or
who have been instructed by a competent person. Instruction at regular intervals, but at least
once per year, is recommended."
ADVANTAGES AND EQUIPMENT
Combined heating oil filter breather type GS Pro-Fi® 3:
•guaranteed smell-tight, without any further accessories
•no escaping oil and oil foam, respectively
•safety function in the event of hose rupture
•integrated ball cock as required shut-off fitting upstream of the consumption equipment
•connection hose for oil suction pump
•version with vacuum pressure gauge -1.0 to +0.6bar, for controlling the vacuum in the
suction line and therefore the operating states
Item No. 13 512 53 3 / 16

Combined heating oil filter breather type GS Pro-Fi® 3
DESIGN
vent screw
vent tray
holding plate for wall assembly
connection burner return line
connection burner supply line
clamping ring
filter insert
filter tray
vacuum pressure gauge
connection for tank line
shut-off fitting
screws for accepting the holding plate
Fuel oil consumer installation in single conduit system
Anti-siphon device
Pressure compensation valve Typ DAV
Withdrawal valve Typ VTK-3
Aspiration line
Combined heating oil filter breather
type GS Pro-Fi
®
3
4 / 16 Item No. 13 512 53

Combined heating oil filter breather type GS Pro-Fi® 3
CONNECTIONS
Inlet,
optional
Trading name and dimensions
acc. to standard
Installation notes
screw-in fitting
•IG G 3/8
For accepting a screw-in fitting with O-ring
•compression fitting RVS
•compr. fit. 6
Outlet,
optional
Trading name and dimensions
acc. to standard
Installation notes
ball-cone connector
•thread AG G 3/8-KN
torque 15Nm
DETERMINATION OF THE FLOW RATE, THE PIPE DIAMETER, AND THE PRESSURE
LOSS
Flow rate
The outlet pipe must be dimensioned pursuant to DIN 4755 in such a way that the mean flow
rate of the fuel oil is between (0.2 and 0.5) m/s. In the event of too large a pipe diameter with
low flow rates, undesired formation of gas bubbles may occur.
Determination of the flow rate w in m/s
Installation in
⇒
Single string
system
Double string
system
Conveyor
system
Calculation
.
V
=
Volume flow rate
Operating medium
(L/h)
≈
Heat input
in kW / 10
=
Gear output of the
Oil burner pump
=
Delivery rate
of the booster
pump
w = 0.3537 •
.
V
/ ID2
ID=inner pipe
diameter (mm)
For supply / oil systems, the following mean flow rate is applicable pursuant to DIN
4755:
Suction: (0.2 ÷ 0.5) m/s
Discharge: (1.0 ÷1.5) m/s
Taking into account the length of the suction
line, the geodesic height, the suction height,
and the fuel oil volume flow rate, the following
can be recommended for selecting the piping:
⇒
.
V
Fuel oil
∅ x t
Copper pipe
1 ÷ 10L/h
6 x 1mm
8 ÷ 45L/h
8 x 1mm
25 ÷ 130L/h
10 x 1mm
90 ÷ 170L/h
12 x 1mm
•Lower flow rates in suction mode will result in an undesired formation of bubbles.
•Piping with inner diameters of less than 4mm is not recommended!
Maximum total pressure loss of all fittings in the suction line = 0.4bar
Item No. 13 512 53 5 / 16

Combined heating oil filter breather type GS Pro-Fi® 3
The pressure loss of the GS Pro-Fi® 3 depending on the fuel oil volume flow rate and the
filter insert used can be found in the diagram:
NOTICE ON THE FILTER INSERT :
There is no such thing as a universal filter insert. The filter insert should be selected
based on the specifications of the burner manufacturer according to filter mesh and
the present operating conditions. According to the recommendation of the IWO Institut
für Wärme- und Öltechnik e.V, filter inserts made of sintered plastic materials with a
mesh width of 30-75μm should be used. Regarding oil systems with so-called
“Low-NOx burners” and burners with lower heat outputs, the GOK filter inserts
FEINFILTERUNG (fine filtration) with a mesh width of < 35μm are recommended.
ASSEMBLY
Before assembly, check that the product is complete and has not suffered any damage during
transport.
Installation, maintenance and start-up may only be carried out by companies that are
specialist companies for this work in terms of Section 3 of the German Ordinance on
Facilities Handling Substances Hazardous to Water (VAwS) from 31 March 2010 (Federal
Law Gazette, P. 377).
Connection assembly
Female thread G 3/8 acc. to EN ISO 228-1, as
screw-in opening G 3/8-UA-O acc. to
prEN 12514-4:2009 Figure D.1
O-ring dimensions 14x2 mm, included with
delivery
Screw-in connectors, type B acc. to EN ISO 1179-
4 or prEN 12514-4 Annex C (adequate with type A
acc. to DIN 3852-2)
The recommended maximum torque with steel
screw-in connector is 15 Nm
6 / 16 Item No. 13 512 53

Combined heating oil filter breather type GS Pro-Fi® 3
Universal connection set (UA):
The female thread can also take the GOK universal
connection set type UA, which corresponds to a
compression joint type G acc. to prEN 12514-4:2009
Annex D.
Piping used:
Copper pipe with outer diameter 6, 8 or 10 mm, e.g.
acc. to EN 1057
The housing is made from a zinc die-cast alloy:
Do not use a conical pipe thread acc. to EN 10226-1.
Flexible pipe assembly
The following connections may be used in addition for
flexible oil lines and their pendant:
•cap nut G 3/8 with inside taper 60° pursuant to
prEN 12514-4 Appendix B
More information about Universal connection fitting type UA can be found at
www.gok-online.de/de/downloads/technische-dokumentation.
A reinforcement ring must be used with all thin-walled
pipes and with soft pipe materials.
Brass reinforcement rings may not come into contact with aluminium
pipe. Risk of corrosion!
More information about compression fittings can be found at
www.gok-online.de/en/downloads/technical-documentation/Assembly
instructions - Compression fittings.
Installation position and mounting
Installation position vertical as a matter of principle,
•filter tray with filter insert at the bottom
•vent tray at the top.
The GS Pro-Fi 3® is delivered with pre-mounted holding plate for wall assembly. It can be
mounted on both sides of the housing.
•Pull down the holding plate, remove the holding plate, suspend it with the screws on the
opposite side of the housing, and push it upwards.
The specialised company and the operator must observe, comply with and understand all of
the following instructions in this assembly and operating manual. For the system to function
as intended, it must be installed professionally in compliance with the technical rules
applicable to the planning, construction and operation of the entire system.
Item No. 13 512 53 7 / 16

Combined heating oil filter breather type GS Pro-Fi® 3
Malfunctions caused by residues.
Proper functioning is not guaranteed.
Visually check that there are no metal chips or other residues in the connections.
It is important that metal chips or other residues are blown out.
Install with suitable tools, if required.
Regarding screw connections, use a second spanner to brace against the connection nozzle.
Do not use unsuitable tools, such as pliers.
Option assembly metal filter tray PS 16bar instead of plastic filter tray
•Loosen the clamping ring by anti-clockwise rotation, hold and remove the filter tray
•Do not damage the O-ring, refurbish if required (oil new O-ring!)
•Fit the metal filter tray and the O-ring and manually tighten by rotating the clamping ring
in a clockwise direction
•Perform leak testing activities!
LEAK CHECK
Check the condition of the system:
•before initial start-up,
•after major changes,
•after repairs,
•after the system has been out of operation for more than one year.
Check the system with 1.1 x the operating pressure using air or an inert gas. The system is
leakproof if the test pressure does not drop after 10 minutes.
Prior to start-up, the oil system with GS Pro-Fi® 3, including the connections, must be
subjected to leak testing. This may be performed within the framework of leak testing
pursuant to TRÖI and worksheet DWA-A 791, as well as function check of the oil system.
In the event of possible leaks, these must be eliminated, e.g. repeated assembly of the
connections using new gaskets, tightening of the screwed connections.
Observe the notice in MAINTENANCE!
NOTICE FOR LEAK TESTING
We recommend using the vacuum test device for oil systems pursuant to TRÖl
type UPE-300 item no. 13 602 00 for leak testing.
NOTICE
Please find comprehensive information on leak testing pursuant to TRÖI and
worksheet DWA-A 791 on the Internet.
Pursuant to TRÖl chapter 4.10.4.2. “Vacuum
leak testing”, the test time is:
•10 minutes plus the time required for
temperature equalisation.
The oil line is deemed tight if the pressure
increase during the specified test time is not
higher than 30mbar. If this requirement is not
met, the leak must be found applying a slight
over-pressure and foam-forming substances
and the error must be eliminated. Thereafter,
the oil system must be re-checked.
8 / 16 Item No. 13 512 53

Combined heating oil filter breather type GS Pro-Fi® 3
START-UP
Once leak testing is completed and the system is leak-tight, only the toggle valve of
the tank discharge fitting or, for systems without toggle valve, the shut-off safety
device must be opened. The vacuum still present in the line will suck fuel oil
immediately. If required, re-pump.
Unless specified differently in the burner/boiler manufacturer’s manual, the procedure is as
follows:
•bleed the installed oil lines (burner supply and return
lines) and the fittings using a suction pump and fill
in fuel oil
•open the shut-off fitting and the vent screw
•connect the suction pump directly at the vent screw
using the supplied adapter item no. 13610-60
•only stop the suction process once the vent tray is
filled with oil as well
•close the vent screw in a leak-tight manner
OPERATION
During ongoing operation of the oil system, the GS Pro-Fi® 3 does not require any operation.
The integrated shut-off fitting must be opened. For this, the rotary handle must be rotated in
the flow direction.
Due to the design of the GS Pro-Fi® 3, the full fuel oil column without any noticeable shares of
air is available when starting the burner.
TROUBLESHOOTING
Fault cause
Action
Hose rupture in the supply or
return line
•Burner switches to failure due to the sucked in ambient air
Restore the leak-tightness of the system
Released air in the vent tray
•Burner switches to failure due to the sucked in ambient air
Restore the leak-tightness of the system
Strong noise generation of the
burner pump
•Filter insert is clogged
For replacing the filter insert, see MAINTENANCE
Level in the filter tray
decreases
•System has a leak
Restore the leak-tightness of the system
Filter tray runs empty,
•System has a leak
Restore the leak-tightness of the system
Item No. 13 512 53 9 / 16

Combined heating oil filter breather type GS Pro-Fi® 3
MAINTENANCE
The following is recommended within the framework of annual maintenance or after extended
periods of non-use:
•leak testing of the fitting, including the connections
•visual inspection of the plastic filter tray and the vent tray for possible damage: cracks
or deformation
•replacement of the filter insert
•after flooding, clean the external contamination on the filter using a commercially available
domestic cleaning agent
When using solvent-containing cleaning agents, the plastic filter trays or other plastic parts
may be destroyed
REPLACEMENT
If there is any sign of wear or if the product or parts thereof are damaged, it must be replaced.
When the product has been replaced, observe the steps ASSEMBLY, LEAK TESTING and
START-UP.
Replacing the filter insert:
•Switch off the burner and prevent the return of the oil column into the tank
•Close the shut-off fitting
•Use a collector
•Clean the line sections downstream of the filter particularly carefully prior to re-installation
without replacement filter
with replacement filter
•Loosen the clamping ring by anti-
clockwise rotation, hold and remove the
filter tray
•Do not damage the O-ring, refurbish if
required (oil new O-ring!)
Use red GOK O-ring only!
•Unscrew the old filter insert
•Clean the sealing surface and the O-ring
•Insert the new filter insert firmly
•Fit the filter tray and the O-ring and
tighten by rotating the clamping ring in a
clockwise direction
Loosen the replacement filter by anti-
clockwise rotation, hold adapter using a jaw
spanner SW 70
•Oil the gasket of the new replacement filter
•Fit new replacement filter and tighten
through clockwise rotation
If the filter tray is damaged or destroyed, it must be replaced by a new one, the approach
is identical to the procedure of replacing the filter insert.
The vent tray can only be replaced completely with the vent screw .
RESTORATION
If the actions described in TROUBLESHOOTING do not lead to a proper restart and if there is
no dimensioning problem, the product must be sent to the manufacturer to be checked. Our
warranty does not apply in cases of unauthorised interference.
10 / 16 Item No. 13 512 53

Combined heating oil filter breather type GS Pro-Fi® 3
SHUT-DOWN
During extended periods of non-use or MAINTENANCE work, the rotary handle of the shut-off
fitting must be rotated to the position perpendicular to the flow direction - the shut-off fitting is
closed.
When using the product the next time, observe the steps LEAK TESTING and START-UP!
DISPOSAL
In order to protect the environment, products contaminated with water-
hazardous substances or that have come in contact with such substances must
not be disposed of in the domestic waste, to public waters or channels.
The product must be disposed of via local collection stations or a recycling station.
TECHNICAL DATA
Maximum admissible
pressure PS
PS 6bar with plastic tray
PS 10bar with replacement filter insert
PS 16bar with metal tray
Housing material
Pressure resistance housing
Zinc die cast ZP0410
PS 16bar
Nominal flow rate Vn
110L/h
Pressure loss Siku 70μm
Pressure loss Siku 70μm
Pressure loss Siku 70μm
MC 7, 5 - 20μm
110mbar
210mbar
105mbar
120mbar
Ventilation output
10L/h
Flow rate V
n,R
return line – supply line
at maximum pressure
difference
Δpo,d,max = 1.3bar
Ambient temperature
-10°C to +60°C
Item No. 13 512 53 11 / 16

Combined heating oil filter breather type GS Pro-Fi® 3
LIST OF ACCESSORIES
Product name
Item no.
Vacuum test device Typ UPE-300
13 602 00
Oil suction pump with suction and discharge hoses
13 610 00
Spare parts for filters
Filter tray 500 plastic blue-transparent 79mm (PS 6bar)
13 850 22
Filter tray 500 plastic blue-transparent 170mm (PS 6bar)
13 850 23
Filter tray 500 metal zinc die cast (PS 16bar)
13 850 25
Clamping ring 500 metal zinc die cast
13 850 60
O-ring 500 NBR
13 850 24
O-ring 500 FKM
25 521 64
Adapter for replacement filter metal zinc die cast
13 851 65
Sealing ring for adapter NBR
13 851 68
Retrofit kit replacement filter consisting of: Adapter, sealing ring for adapter
and O-ring 500 NBR, without replacement filter (PS 10bar) for GS Pro-Fi® 3
type
13 851 67
Filter tray 500 plastic blue-transparent 79mm with ventilation valve
(PS 6bar)
13 514 25
Filter tray 500 metal zinc die cast with ventilation valve
13 514 26
Accessories for filter assembling
Installation wrench clamping ring 500 plastic
13 850 88
Changeover kits for filter type GS Pro-Fi® 3
to filter insert long Siku 70μm
13 852 53
to filter insert long Siku 35μm
13 852 54
to replacement filter 25µm
13 851 62
WARRANTY
We guarantee that the product will function as intended and will not leak during
the legally specified period. The warranty term begins when the product is
handed over to the customer. The scope of our warranty is based on Section 8
of our terms and conditions of delivery and payment.
TECHNICAL CHANGES
All the information contained in this assembly and operating manual is the result of product
testing and corresponds to the level of knowledge at the time of testing and the relevant
legislation and standards at the time of issue. We reserve the right to make technical changes
without prior notice. Errors and omissions excepted. All figures are for illustration purposes
only and may differ from actual designs.
12 / 16 Item No. 13 512 53

Combined heating oil filter breather type GS Pro-Fi® 3
NOTES
Item No. 13 512 53 13 / 16

Combined heating oil filter breather type GS Pro-Fi® 3
APPROVAL
•DoCMR pursuant to Building Rules List according to EN 12514-2
14 / 16 Item No. 13 512 53

Combined heating oil filter breather type GS Pro-Fi® 3
Item No. 13 512 53 15 / 16

Combined heating oil filter breather type GS Pro-Fi® 3
Regler- und Armaturen-Gesellschaft mbH & Co. KG
Obernbreiter Straße 2-16 • 97340 Marktbreit / Germany
Tel.: [phone] • Fax: [phone]
E-Mail: [e-mail] • Internet: www.gok-online.de
16 / 16 Item No. 13 512 53