CTC Union GIERSCH RG1-L-Na Handbuch

Technical Information • Installation Instructions

Gas

Edition August 2019

Right reserved to effect techn. modifica-

tions in the interest of product improvement.

RG1

E.04.99 • G. 08.08.19

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

E. 04.99• G.08.08.19

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.

E.04.99 • G. 08.08.19

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

Voltage

1/N/PE ~50 Hz - 230 V

Current consumption

start max. / operation

1.9 A / 0.8 A

Electric motor power in W

ignition transformer

1x8 kV / 20 mA

Control box

LME 11

Weight in kg

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

E. 04.99• G.08.08.19

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

E.04.99 • G. 08.08.19

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

Ext. fault message lamp

L1 Phase

PE Protective earth

P11 Service hour meter

N Neutral

F21

H11

P11

H13

X11 X12

F11

Female adapter X12

on burner

Male adapter X11

to boiler

E. 04.99• G.08.08.19

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.

E.04.99 • G. 08.08.19

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

.........



E. 04.99• G.08.08.19

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

E.04.99 • G. 08.08.19

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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