Safety
Edition 02.12
D
GB
NL
RUS
Please read and keep in a safe place
PL
Please read through these instructions
carefully before installing or operating. Following the
installation, pass the instructions on to the operator. This unit must be installed and commissioned
in accordance with the regulations in force. These
­instructions can also be found at www.docuthek.com.
Explanation of symbols
• ,  ,  ,  ...= Action
▷
= Instruction
Liability
We will not be held liable for damages resulting
from non-observance of the instructions and noncompliant use.
Safety instructions
Information that is relevant for safety is indicated in
the instructions as follows:
D
Operating instructions
Heater GP 40
Translation from the German
© 2012 Elster-Instromet B.V.
DANGER
Indicates potentially fatal situations.
Contents
WARNING
Heater GP 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Checking the usage . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation position . . . . . . . . . . . . . . . . . . . . . . . 2
Connecting the gas supply . . . . . . . . . . . . . . . . . 3
Tightness test . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removing the protective cap (optional) . . . . 3
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Connecting the room thermostat for “Heating”
and “Controlled air flow” mode. . . . . . . . . . . . . . . 4
Connecting multiple heaters to a single room
thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Reset, alarm, external fan . . . . . . . . . . . . . . . . . . 5
Adjusting the switch-on delay tE . . . . . . . . . . . . . 5
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . 6
Adjusting the heater . . . . . . . . . . . . . . . . . . . . 6
Installing the protective cap . . . . . . . . . . . . . . 7
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assistance in the event of malfunction . . . . . 9
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 12
Checking the safety functions and burner
operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . 17
Declaration of conformity . . . . . . . . . . . . . . . 17
Goods return form . . . . . . . . . . . . . . . . . . . . . 18
Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Indicates possible danger to life and limb.
CAUTION
Indicates possible material damage.
Maintenance and repairs may only be carried out by
qualified gas technicians and electrical interventions
may only be carried out by qualified electricians.
Conversion, spare parts
All technical changes are prohibited. Only use OEM
spare parts.
Transport
On receipt of the product, check that the delivery is
complete (see Part designations). Report any transport damage immediately.
Storage
Store the product in a dry place. Ambient temperature: see Technical data.
GB-1
GB
➔ www.docuthek.com
Installation
DANGER
E
I
NL
GP 40
Heater with direct, open combustion for agricultural
stables and horticultural greenhouses. Depending
on the type and setting, the heater can be operated
with natural gas or LPG (propane/butane).
This function is only guaranteed when used within the
specified limits – see page 17 (Technical data).
Any other use is considered as non-compliant.
Type code
Code
Description
GP
Heater
40
Capacity 40 kW, jet length 40 m
F
GB
Checking the usage
Part designations
3, 5
2
1, 5
4
1 Burner control unit BCU
2 Gas combination control CG 10
3 Vane
4 Assembly accessories
5 Protective cap for use in agriculture (option)
Type label
Air circulation, electrical connection rating, voltage,
rated heat input, gas type, category, supply pressure,
burner pressure, enclosure: see type label.
Danger of death! Gases are generated during the
storage of slurry which remain partly dissolved in
the liquid. If the slurry is strongly agitated during
mixing and purging, poisonous, explosive gases
such as hydrogen sulphide and methane are released. If an ignition source is present, the released
gas can explode.
To avoid damage during operation, please observe
the following:
–Switch off the heater before mixing and purging
the slurry.
–Close the slide valves when storing slurry outside.
–The fan for the air supply must not be part of a
closed pipe system.
–The space to be heated must be adequately ventilated.
For mechanical extraction equipment: at least
10 m3/h of air per installed capacity.
In the case of natural ventilation, the structure
must have two apertures with a free opening area
of 60 x B in cm2. “B” is the installed capacity in
kW. Replacement of the full air volume per hour
is thus ensured.
–In the case of natural ventilation, the maximum
allowable total capacity of the heater is 1 kW per
20 m3 of volume.
–Respect the safety distance of the heater to inflammable materials, see Installation position.
–Consult your fire insurance provider and/or local
fire protection engineer to assess the foreseeable,
general risk of fire.
–For cleaning, care and maintenance, note the
applicable national regulations and directives.
Installation position
▷▷ To ensure that the vane functions faultlessly, install the unit in the horizontal position.
▷▷ Note the safety distance to walls and inflammable materials.
Elster Instromet B.V.
Industrieweg Zuid 32
NL-3958 VX Amerongen
> 1m
> 1m
> 1m
> 3m
> 1m
▷▷ Ensure sufficient free space around the device.
There must be no obstructions in front of the inlet
and outlet side of the heater.
▷▷ To avoid overheating, do not cover the electric
motor.
GB-2
Tightness test
▷▷ The system is disconnected from the electrical
power supply. The valves are thus closed.
1
OFF
AUTO
+AUTO
ON/OFF
MODE )
(RESET
Wiring
N2
= max. 70 mbar
Removing the protective cap
(optional)
3
▷▷ For agricultural use, the burner control unit and
vane switch are mostly protected against ingress
of dirt and moisture by a cap.
▷▷ To wire the burner control unit and to start and
adjust the heater, the protective cap is to be
removed as described below.
▷▷ Do not remove the protective cap on the vane
switch.
Burner control unit
1 Slowly pull apart the ends of the protective cap
on the back of the burner control unit until the
rivets come undone.
2 Pull the opened edges of the protective cap out
fully so that the edges are pulled out from between the burner control unit and the mounting
plate.
OFF
AUTO
+AUTO
MODE )
(RESET
GB-3
4
GB
CAUTION
Danger of electric shocks!
–Before working on possible live components,
ensure the unit is disconnected from the power
supply.
1 Disconnect the system from the electrical power
supply. The mains plug may only be pulled out
once the device has been switched off.
2 Shut off the gas supply.
▷▷ If there is a protective cap on the burner control
unit, this must first be removed.
▷▷ When opening the burner control unit, do not incline the upper housing section during its removal
to prevent the plug connectors from being bent.
2
ON/OFF
3 Remove the opened protective cap from the
burner control unit by pulling it upwards.
D
Connecting the gas supply
▷▷ If the heater is suspended on chains, use an
approved flexible gas hose.
1 Disconnect the system from the electrical power
supply.
2 Shut off the gas supply.
3 Remove the screw plug at the inlet of the gas
combination control CG.
4 Connect the gas pipe with threaded connection R ½" or gas hose, see page 14 (Accessories),
to the inlet of the gas combination control.
▷▷ Use approved sealing material only.
▷▷ Note the maximum inlet pressure, see page 17
(Technical data).
Burner control unit BCU connection diagram
BCU 300:THP-G
Z
E
I
WF
max. 5 A,
253 V
V1 V2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
I
NL
F1
max. 2 A,
253 V
ϑ
F2
ϑ
0V
AC/DC 24 V
N
N
F
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
GB
PE
ϑ
F1 T 8A H
L1 (L1)
N (L2)
PE
F2 T 3,15A H
IEC 60127-2/5
ϑ
5 Connect the terminals for Controlled air flow and Heating ϑ .
GB-4
+24 V =/~ 0
+24 V =/~
23 24 25 26 27 28
+24 V =/~
23 24 25 26 27 28
+24 V =/~ 0
230 V ~
28 29 30 31 32
230 V ~
28 29 30 31 32
▷▷ In order to ensure post-cooling, the heater constantly requires 230 V AC.
Connecting the room thermostat for “Heating”
and “Controlled air flow” mode
▷▷ Use a room thermostat with a hysteresis of ± 1°C.
It switches on if the room temperature is 1°C
less than the set temperature and switches off
again once the room temperature is 1°C more
than the set temperature.
▷▷ Do not directly connect the room thermostat to
terminals 1 and 3.
N L1
253 V AC
max. 5A
230 V~
2. GP
25 26 27
3. GP
25 26 27
24 V=/~
▷▷ Do not directly connect the thermostat to multiple heaters.
▷▷ Do not connect terminals 28, 29 and 30 directly
to the next heater. A short-circuit can occur due
to different phases and polarities.
2. GP
29 30
3. GP
29 30
3. GP
29 30
1. GP
28 29 30
1. GP
28 29 30
1. GP
28 29 30
tM
1. GP
28 29 30
tN
30 4
50 60
0
0
0
10 2
1. GP
29 30
▷▷ In case of a power failure, an emergency power
supply unit should automatically take over the
power supply. Emergency power supply units
with a cardan shaft drive for tractor attachment
are also suitable.
Adjusting the switch-on delay tE
▷▷ If multiple heaters switch on at the same time,
there can be a gas and/or power shortage on individual devices. To avoid this happening, adjust
the switch-on delay tE using the potentiometer
in the upper housing section of burner control
unit BCU.
▷▷ The potentiometer is set to 0 s at the factory.
7
tE
▷▷ We recommend using a switch-on delay tE of
5 to 10 s between each device.
▷▷ The post-cooling time tN is set to 50 s at the
factory and the minimum burner on time tM to
0 s. These values must not be changed.
▷▷ Once the wiring is complete, close the BCU
again. Ensure that the upper housing section is
not inclined when being replaced on the lower
housing section.
8
9
▷▷ To guarantee that the burner control unit complies with enclosure IP 54, make sure that the
screws are tightly secured after wiring and that
the cable glands are closed.
10Switch on the power supply.
11Release the gas supply.
GB-5
GB
6 For improved air circulation in the room, an adϑ
ditional fan can be connected.
▷▷ At 24 V DC/AC, multiple heaters can be con­
trolled in parallel.
▷▷ Note the polarity!
1. GP
25 26 27
230 V ~
D
K3/3
230 V~
230 V~
K3/2
3. GP
29 30
230 V ~
max. 2 A
21 22 23 24 25 26
K3
230 V~
24 V=/230 V~
K3/1
2. GP
29 30
N L1
28 29 30 31 32
1. GP
29 30
Reset, alarm, external fan
▷▷ For external fault signalling, an external
alarm and an external reset button ϑ
ϑ
can be connected.
19 20 21 22 23
Connecting multiple heaters to a single room
thermostat
▷▷ Phase reversal will result in a short-circuit.
▷▷ Do not install different phases of a three-phase
current system at the inputs if the voltage between the phases exceeds 230 V (+ 10%).
▷▷ Multiple heaters must be wired to the thermostat
via a relay.
3
4
+ AUTO
Commissioning
ON/OFF
▷▷ The heater may only be commissioned once it
has been ensured that the heater, gas pipes,
mains voltage supply and room thermostat have
been installed by authorized, trained personnel
according to the regulations.
1 Switch on the power supply.
2 Release the gas supply.
Part designations
OFF
1
AUTO
2
4
I
E
OFF
NL
F
GB
5
ON/OFF
3
AUTO
O
+AUT
1
E
MOD T)
F ESE
N/OF (R
2
O
1
2
3
4
5
▷▷
MODE/RESET selection button
BCU On/Off switch
Red lamp lights up if a fault is pending
Operating mode LED: Off
LEDs for selectable operating modes
The BCU is operated using two buttons:
using the ON/OFF button , the heater is
switched on and off. By pressing the MODE
selection button for > 1 s, it is possible to switch
between the different operating modes.
Operating
Explanation
1
modeOFF
OFF
1
BCU waits for the signals for controlled
2
AUTO
air flow
or heating.
2
AUTO
3
Heating
(continuous operation)
3
Controlled air flow (continuous opera4
tion)4
Controlled
air flow (continuous opera5
+ AUTO
tion)5and heating when thermostat sig+ AUTO
nal is applied
OFF
1
AUTO
2
Burner gas pressure pG
pe = Inlet pressure
pG= Gas pressure on the burner
▷▷ The gas pressure on the burner is adjusted using
pG on the combination control.
4
ON/OFF
OFF
1
AUTO
2
ON/OFF
MODE
ON/OFF
MODE
(RESET)
Switching
on
(RESET)
+ AUTO
5
MODE
(RESET)
–
+
pe
3
4
5
3 Switch on the burner control unit. Press
ON/OFF until an LED lights up.
▷▷ The BCU switches on in the last operating mode
selected.
▷▷ The heater starts once the set switch-on delay
time tE has elapsed, see page 5 (Adjusting the
switch-on delay tE).
▷▷ The burner starts after the safety time of 5 s has
elapsed and operates in the selected operating
mode.
▷▷ The operating mode can be changed using the
MODE selection button. The selected operating
mode is only activated once the device has been
in this position for at least 3 s. It is thus possible
to “scroll” through the different operating modes.
ON/OFF
5
MODE
(RESET)
Adjusting the heater
3
+ AUTO
MODE
(RESET)
3
+ AUTO
4
5
Switching off
4 Switch off the heater. Press ON/OFF . The LED
next to “ OFF ” lights1 up and the burner switches
off after 3 s. Mains 2voltage is still supplied howAUTO
ever.
3
▷▷ The fan cools the heater
down until it reaches
switch-off temperature.
4
Faults
5
+ AUT
O
▷▷ Flashing
LEDs
signal
the cause of a fault, see
page 9 (Assistance in the event of malfunction).
ON/OFF
MODEswitching on the power supply
▷▷ In the
first 4 s after
(RESET)
or pressing the ON/OFF button , an operating
mode is not yet active. Within these 4 s, a new
operating mode can be selected. As soon as
the MODE selection button has been pressed
and a new operating mode has been selected,
the 4 s are extended accordingly.
▷▷ If a fault has occurred, it is displayed immediately,
but 4 s are also available here during which a
new operating mode can be selected.
MODE
(RESET)
GB-6
pG
▷▷ Use a 2.5 mm Allen key for adjustment. Do not
use force!
▷▷ The outlet pressure pG must be measured on the
combination control for adjustment.
–
1 Disconnect the system from
the electrical power
+
A only be pulled out
supply. The mains plug may
once the device has been switched off and postcooling is complete.
2 Shut off the gas supply.
3 Open test nipple pG.
4 Connect a pressure gauge with display range
10 to 50 mbar to pG.
pe flow adjustment A.
pG
▷▷ Do not change the
It is set
to fully open at the factory.
–
+
–
+
A
5 Switch on the power supply.
6 Release the gas supply.
▷▷ The inlet pressure pe must comply with the technical data, see page 17 (Technical data).
3
+ AUTO
4
1
5
7 Switch on the burner control unit. Press the
2
AUTO
ON/OFF button until an LED lights up.
3
8 Select the Heating operating
mode.
9 Let all heaters burn for at 4least 20 s.
▷▷ The required gas pressure on the burner depends
5
+ AUTO
on the lower calorific
value/Wobbe
index.
10Selected the required gas pressure on the burner
ON/OFF
MODE
from the table.
(RESET)
Lower
Wobbe
calorific
GP 40
index
value
[MJ/m3]
[mbar]
Natural gas L
32.49
41.53
11.9
G 25
Natural gas H
37.78
50.71
7.8
G 20
LPG G 30
125.81
87.34
22
14Monitor combustion.
▷▷ The flame must be blue and must remain inside
the device.
▷▷ If the burner pressure pG and flame signal have
been checked and adjusted on all devices, the
system operates correctly.
15Remove the pressure gauge.
16Close the test nipple.
MODE
(RESET)
Installing the protective cap
Burner control unit
1 Pull the opened protective cap from the top over
the burner control unit. In doing so, pull the edges
of the protective cap apart.
D
ON/OFF
▷▷ Converting the lower calorific value/Wobbe index
to kWh/m3:
Lower calorific value/Wobbe index [MJ/m3]
kWh/m3 =
3.6
▷▷ Always use a pressure gauge to adjust the burner
gas pressure. The white scale on the adjusting
screw may differ.
11If all heaters are heating at the same time, compare the required gas pressure on the burner
with the gas pressure pG read off the pressure
gauge.
12Monitor the pressure gauge and set gas pressure pG at B. 1 turn = approx. 1.3 mbar.
OFF
AUTO
+AUTO
ON/OFF
OFF
AUTO
+AUTO
ON/OFF
OFF
AUTO
+AUTO
ON/OFF
+–
–
+
▷▷ All heaters must be operating for this adjustment.
Flame signal
▷▷ The flame signal is displayed for 20 s.
13Check the flame signal.
▷▷ For adjustment and maintenance work, the flame
signal can be displayed.
▷▷ Display of the flame signal starts when the selection button is pressed and within 1 s (almost
simultaneously), ON/OFF is pressed, too.
● = LED is constantly lit
○ = LED flashes
µA
2 3 4 6 8 10 12 14 16 18 20
OFF
1
○ ●
2
AUTO
○ ● ● ●
3
○ ● ● ● ● ●
4
○ ● ● ● ● ● ● ●
5
+ AUTO
○ ● ● ● ● ● ● ● ● ●
OFF
1
2
3
4
+ AUTO
ON/OFF
MODE )
(RESET
2 Slide the opened edges of the protective cap into
the gap between the burner control unit and the
mounting plate.
B
AUTO
MODE )
(RESET
5
MODE
(RESET)
MODE
▷▷ON/OFF
The flame
signal is sufficient when 2 LEDs are
(RESET)
constantly lit and the third LED flashes.
▷▷ If the flame signal is not sufficient, see page 9
(Assistance in the event of malfunction).
GB-7
MODE )
(RESET
▷▷ When it becomes difficult to move the edges
of the protective cap, this means the material
has turned cold and hard. The protective cap
will become soft again when it is heated briefly.
3 Hold the ends of the protective cap on the back
of the burner control unit together and close the
push-in rivets.
GB
OFF
▷▷ Do not spray the edges of the protective cap
which are closed using push-in rivets only or
the connection between the burner control
unit and the mounting plate directly with water,
high-pressure cleaning equipment or chemical
cleaning agents.
Cleaning
▷▷ Do not spray water or chemical cleaning agents
directly into the space between the fan shaft/
impeller wheel and motor and do not clean with
high-pressure cleaners.
E
I
NL
F
GB
CAUTION
To ensure that no damage occurs during operation
and cleaning, please observe the following instructions. Otherwise, injuries or damage to the device
may occur and/or the function of the device may
be impaired, and the manufacturer’s warranty will
be cancelled.
–Sharp-edged metal sheets. Always wear protective gloves.
–After cleaning, check that the components on and
in the heater are in good condition. The device
may only be restarted if all safety devices have
been installed and the safety functions have been
checked.
–Clean the heater once a year when used in horticulture and at regular intervals as well as after
each fattening period when used in agriculture, as
described below. Inadequate or irregular cleaning
can cause damage to the device or lead to fire
damage. For example, dirt particles can catch
fire and can be blown out of the device.
1 Switch off the burner control unit BCU.
2 Disconnect the system from the electrical power
supply. The mains plug may only be pulled out
once the device has been switched off and postcooling is complete.
3 Shut off the gas supply.
▷▷ If the burner control unit is not equipped with
a protective cap, we recommend cleaning the
heater with compressed air or a damp cloth only.
▷▷ Equipping the burner control unit BCU with a
protective cap allows the BCU to be cleaned
carefully with a water jet/high-pressure cleaner
during cleaning/disinfection of the animal shed.
▷▷ To guarantee that the burner control unit complies with enclosure IP 54, make sure that the
screws are tightly secured after wiring and that
the cable glands are closed.
▷▷ The distance between the nozzle and the surface
to be cleaned must always be at least 50 cm.
▷▷ Chemical cleaning agents, disinfectants and/or
pesticides contain corrosive substances which
can even corrode stainless steel. Always rinse
the devices with water after cleaning using such
agents to remove any residue of these agents
from the surface.
▷▷ Loosen the screw connection on the grille just
enough to be able to move the screw connection to the side.
4
5
6
7 Clean the grille.
8 Clean the fan and vane using a cloth.
9 Clean the interior of the device carefully using air
or a cloth.
> 50 cm
▷▷ Do not direct the water jet straight at the combination control and electrical components such
as the vane.
▷▷ The water jet from the high-pressure cleaner can
cause serious damage to the components in
the heater. For example, the vane can be bent
or other parts such as the spark plug or rubber
seals can be displaced. Avoid direct contact.
GB-8
▷▷ The vane must not be bent.
Assembly
▷▷ Ensure that the rubber seals between the electrodes and the electrode adapters are fitted
correctly.
12
13
▷▷ Check the burner is functioning faultlessly in normal operation, see page 14 (Checking the safety
functions and burner operation).
14When operating with propane, check that the
breather orifice of the pressure reducer on the
connection kit is clean.
? Fault
! Cause
• Remedy
Possible faults and suggested solutions
? LED 1 flashes.
OFF
AUTO
1
2
3
4
+AUTO
5
! Fuse F2 defective.
• Replace fuse (3.15 A, slow-acting, H). Ensure
that only one heater is directly wired to the thermostat, see page 3 (Wiring).
! Bridge between terminals 9 and 10 is interrupted.
• Check the wiring.
Assistance in the event of
malfunction
WARNING
? LED 2 flashes.
To avoid harm to persons and animals or damage
to the heater, please observe the following:
–Electric shocks can be fatal! Before working on
possible live components, ensure the unit is disconnected from the power supply.
–Fault-clearance must only be undertaken by authorized, trained personnel!
–Repairs to components, e.g. the burner control
unit BCU or the combination control CG, may only
be carried out by the manufacturer. Otherwise,
the guarantee will be cancelled. Unauthorized
repairs or incorrect electrical connections, e.g.
the connection of power to outputs, can cause
gas valves to open and the burner control unit to
become defective. In this case, fail-safe operation
can no longer be guaranteed.
–(Remote) resets may only be conducted by authorized personnel with continuous monitoring
of the devices concerned.
OFF
AUTO
1
2
3
4
+AUTO
5
! Vane switch does not switch off during the “no
flow” state check on burner start-up.
• Check that the vane switch is functional, see
page 12 (Maintenance).
GB-9
GB
klick
▷▷ In the event of an installation fault, the burner
control unit closes the gas valves and the red
LED on the burner control unit lights up. Then,
the fault is indicated by a combination of flashing
yellow LEDs which are numbered from 1 to 5.
▷▷ Faults may be cleared only using the remedies
described below.
1 Press the reset button on the BCU to reset it.
The unit then reverts to the last operating mode
selected.
▷▷ Faults marked with an * are warnings. Provided
that a restart has been programmed, they are
no longer displayed if the cause of the fault has
been remedied. It is not necessary to press the
reset button when these messages are displayed.
2 If the burner control unit does not respond even
though all faults have been remedied, remove
the unit and return it to the supplier.
D
10Check that the vane switch is functional.
▷▷ If the vane is moved a little in the direction of the
arrow, a quiet click can be heard. This means
that the switching path is correct.
? LED 3 flashes.
OFF
AUTO
1
2
3
4
5
E
I
NL
! The vane switch has not switched on 25 s after
the fan has been switched on.
• Vane, fan or grille are dirty. Clean, see page 12
(Maintenance).
• Fuse F1 defective (8 A, slow-acting, H). Check
the function of the fan and replace fuse F1 if
necessary.
! Motor defective.
• Remove the device and return it to the supplier.
F
GB
+AUTO
Attention! Only commission the new BCU once
the short-circuit or fault on the valve output of
the CG has been remedied. Otherwise, the new
BCU will be damaged.
• If the fault continues to be signalled, there may
be a short-circuit on the valve output. Return
the burner control unit to the manufacturer for
inspection.
• Short-circuit on ignition output. Replace fine-wire
fuse F2: 3.15 A (slow-acting, H) and check the
safety function, see page 14 (Checking the safety
functions and burner operation).
? LED 5 flashes.
OFF
AUTO
1
2
3
? LED 4 flashes*.
4
OFF
AUTO
1
+AUTO
2
3
4
+AUTO
5
! On burner start-up, the BCU has not detected
a flame during the safety time. If a restart has
been programmed, up to three automatic startup attempts will be performed. After successful
restart, fault signalling stops automatically once
the post-purge time has elapsed.
• Ignition is not working properly.
Clean the ignition electrode and check for correct
distance, see page 12 (Maintenance).
Check the connection of the ignition cables for
damage or moisture. The spark plug must be
fitted correctly.
Check the ignition spark optically and acoustically
from the fan side during the 4-second ignition
time.
• Poor flame signal due to incorrect burner adjustment. Readjust gas pressure pG, see page 6
(Adjusting the heater).
• Poor flame signal due to dirty/badly connected
ionization electrode.
Clean the ionization electrode and check for
correct distance, see page 12 (Maintenance).
Check the cable connection, cable and plug for
damage or moisture. The plug must be fitted
correctly.
Check the yellow and green burner ground cable
for corrosion and to ensure it is firmly connected.
• Air in the gas pipe. Vent the gas pipe.
• Valves do not open. Remove the valve plug on
the combination control CG and measure the
voltage between L1 and N during the safety time.
If the voltage is not adequate, first replace the
CG and return it to the supplier.
5
! Signal from safety temperature limiter (STL).
Temperature has been exceeded.
• No fan run-on due to soiling. Clean, see page 12
(Maintenance).
! Fan defective.
• Check function of fan.
? LEDs 4 and 5 flash*.
OFF
AUTO
1
2
3
4
+AUTO
5
! Signal from safety temperature monitor (STM).
Temperature has been exceeded.
• Leave heater to cool down for longer.
• No fan run-on due to soiling. Clean, see page 12
(Maintenance).
? LEDs 3 and 5 flash*.
OFF
AUTO
1
2
3
4
+AUTO
5
! During three consecutive restarts, the gas pressure switch has tripped during the safety time
or flame proving period (gas pressure switch
oscillates).
• Inlet pressure fluctuates. Establish stable gas
supply.
• Gas pressure pG too low. Readjust gas pressure pG, see page 6 (Adjusting the heater).
GB-10
? LEDs 2 and 5 flash.
2
? LEDs 1 and 4 flash*.
3
OFF
4
+AUTO
AUTO
5
! Incorrect flame signal through conductive ceramic insulation, e.g. surge via PE wire, possible.
• Remedy incorrect flame signal. Replace ionization
electrode and, if necessary, the BCU as well.
? LEDs 1 and 5 flash*.
1
2
3
1
2
3
4
+AUTO
5
AUTO
5
! The flame has not gone out within 5 s of the
burner being switched off. The gas valve does
not close correctly.
• Shut off the gas supply to the device. Check
the burner and gas valves for correct function,
see page 14 (Checking the safety functions and
burner operation).
? LEDs 1 and 2 flash*.
? LEDs 2 and 4 flash*.
OFF
AUTO
1
2
3
4
5
! The power supply has suffered a fault.
• Ensure there is sufficient mains voltage, see
page 17 (Technical data).
1
2
3
? LEDs 3, 4 and 5 flash.
4
+AUTO
2
4
+AUTO
+AUTO
AUTO
1
3
! The time (cycle lock) between two starts is too
short.
• The BCU ensures there is a pause of 15 s between the starts. This warning is displayed during
this time.
OFF
5
! A signal is applied for longer than 10 s to the
remote reset input (terminals 31 and 32) (permanent remote reset).
• Remote reset must only be used to reset the
device.
OFF
? LEDs 3 and 4 flash*.
OFF
4
+AUTO
5
! Temperature sensor is not functioning correctly.
• Check the temperature sensor connection.
• Temperature sensor is below -20°C.
! Temperature sensor defective.
• Replace the temperature sensor.
AUTO
3
? LEDs 1 and 3 flash.
4
+AUTO
2
D
OFF
AUTO
1
OFF
5
! The flame has gone out during operation. If a
restart has been programmed, an automatic restart is carried out provided that the burner has
been in operation for at least 2 s beforehand.
• Poor flame signal due to incorrect burner adjustment. Readjust gas pressure pG, see page 6
(Adjusting the heater).
• Poor flame signal due to dirty or badly connected
ionization electrode. Clean the ionization electrode and check for correct distance, see page 12
(Maintenance).
• Check the cable connection for damage or moisture. The plug must be fitted correctly.
AUTO
1
2
3
4
+AUTO
5
! While a fault was pending, more than 5 attempts
were made within 15 minutes to reset the device using the remote reset input (terminals 31
and 32).
• Reset is only possible using the reset button on
the BCU.
GB-11
GB
OFF
AUTO
• Check the yellow and green burner ground cable
for corrosion and to ensure it is firmly connected.
1
Maintenance
E
I
NL
F
GB
CAUTION
To ensure that no damage occurs during operation
and maintenance, please observe the following
instructions. Otherwise, injuries or damage to the
device may occur and/or the function of the device
may be impaired. The supplier/manufacturer cannot
accept liability for damage resulting thereof.
–Have the heater cleaned at least once a year by
qualified maintenance personnel.
–Have the safety functions checked at least once
a year by qualified maintenance personnel, see
page 14 (Checking the safety functions and burner
operation).
–Sharp-edged metal sheets. Always wear protective gloves.
–After cleaning or repair work, check that the
components on and in the heater are in good
condition. The device may only be restarted if all
safety devices have been installed and the safety
functions have been checked, see page 14 (Checking the safety functions and burner operation).
1 Switch off the burner control unit BCU.
2 Disconnect the system from the electrical power
supply. The mains plug may only be pulled out
once the device has been switched off and postcooling is complete.
3 Shut off the gas supply.
4
5
6
13Check that the vane switch is functional.
▷▷ If the vane is moved a little in the direction of the
arrow, a quiet click can be heard. This means
that the switching path is correct.
klick
▷▷ Check the nozzle and burner baffle plate for dirt
and if necessary, clean using a cloth. Remove
first the burner baffle plate, then the nozzle. To
do this, a special tool is required. Nozzle spanner size = A/F 35. The nozzle is secured via the
burner baffle plate by a cross-head screw.
14
13
15
16
17
▷▷ The ionization and ignition electrodes can be
removed without having to dismantle the burner
chamber.
18
19
20
SW 21
7
8
SW 22
9
21
10Clean the grille with a cloth.
11Clean the interior of the device carefully using air.
▷▷ The vane must not be bent.
12Clean the fan and vane using a cloth.
22
SW 21
23
24Check the electrodes for dirt and if necessary,
clean using a cloth. Remove stubborn dirt on
the electrode rod using fine abrasive paper.
25Check electrode and porcelain insulator for
cracks and replace the electrode in case of
damage.
▷▷ Replace the electrodes if necessary.
▷▷ Fit the electrode seal.
GB-12
26Clean the plates for the air intake using a cloth.
▷▷ Ensure that the rubber seals between the electrodes and the electrode adapters are fitted
correctly.
27
28
29
SW 22
30
31
SW 21
32
▷▷ Ensure the electrodes are at the correct distance
from one another and correctly positioned as
regards the nozzle.
2 mm
▷▷ The device may only be restarted if all safety
devices have been installed.
33
34
35
36
37
38
39Check the safety functions before commissioning, see page 14 (Checking the safety functions
and burner operation).
GB-13
GB
D
SW 21
Checking the safety functions and
burner operation
Accessories
Room thermostat
Use a room thermostat with a hysteresis of ± 1°C,
230 V, Type TH 215.
WARNING
If these checks are not carried out, the gas valves
might remain open allowing non-combusted gas
to escape. Risk of explosion!
OFF
1
AUTO
2
TH215
Safety functions
1 Switch off the heater during operation. Press
ON/OFF .
▷▷ The flame goes out < 1 s.
▷▷ The fan cools the heater down until it reaches
switch-off temperature.
4
30
5
35
I
E
MODE
(RESET)
NL
F
GB
25
10
5
+ AUTO
ON/OFF
20
15
3
2 Remove the valve plug on the combination control during operation.
▷▷ The gas valves close < 1 s.
▷▷ The flame goes out.
▷▷ The burner control unit BCU displays the fault
message “The flame has gone out during operation”. LEDs 2 and 4 flash.
▷▷ If a restart has been programmed, the burner
control unit will initially attempt to restart and will
then perform a fault lock-out. LED 4 flashes and
displays the fault message “No flame has been
detected during the safety time”.
3 Shut off the inlet pressure during operation.
▷▷ The burner control unit performs a safety shutdown: the gas valves are disconnected from the
electrical power supply.
▷▷ The flame goes out.
▷▷ The burner control unit BCU displays the fault
message “The flame has gone out during operation”. LEDs 2 and 4 flash.
▷▷ If the burner control unit responds in a different
way to that described, a fault has occurred, see
page 9 (Assistance in the event of malfunction).
0
Order No.: N50260145
Pressure reducer
Pressure reducer for LPG.
RECA 1.5 bar to 50 mbar, 2 x ½" internal thread
connection, 10 kg/h,
Order No.: N50260023.
Manual valve
Manual valve for gas.
2 x ½" internal thread connection,
Order No.: N50260019.
½" internal and external thread connection,
Order No.: N50260027.
CAUTION
The fault must be remedied before the system may
be operated.
OFF
1
Checking burner operation
2
AUTO
1 Switch on the BCU.
mode.
2 Select the Heating operating
3
3 Allow the burner to burn for 15 minutes.
4
4 During this time, monitor the
flame pattern.
▷▷ The flame must
be
blue.
5
+ AUTO
▷▷ No dirt particles must come out of the heater.
ON/OFF
°C
MODE
(RESET)
GB-14
Connection kit for natural gas
Manual valve and gas hose to connect the gas combination control CG to the gas supply.
R ½"
1,40
m
D
R ½"
GP 40 connection kit: R ½" threaded connection, total length = 1.50 m, Order No.: N52600073
Connection kit for propane
GP 14/GP 40
Rp ½"
R ½"
ø 6 mm
Rp ¾"
R ½"
R ½"
R ½"
Rp ½"
GP 70/GP 95/GP 120
Rp ½"
Pressure reducer, manual valve, hose (length = 2 m), 2 hose clamps, R ½" double nipple for GP 14/GP 40,
R ½ – Rp ¾" reducing fitting for GP 70 – GP 120, to connect the gas combination control CG to the gas supply, Order No.: N52600025
R 3/8"
ø 15 mm
R ½"
Manual valve and hose (DVGW certified, length = 2 m) to connect the gas combination control CG to the gas
supply, Order No.: N52990209
GB-15
GB
Rp ½"
Spare parts
▷▷ When ordering spare parts, please quote the order number along with the designation and item no. of
the spare part as well as the heater serial number.
▷▷ When ordering spare parts which are not listed here below, please quote the edition of these operating
instructions and the heater serial number.
▷▷ Use original spare parts only to ensure the replacement complies with the requirements stipulated by the
manufacturer.
2
5
3
9, 21
10
12, 8
13
11
E
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F
GB
1
23
20 19
14
15
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Order No.
N50260390
N50260013
N50260042
N50390028
N50260080
N50260030
N50260213
N50260004
N50260180
N50260168
N50260115
N50260031
N50260111
N50260099
N50260101
N50260102
N50260109
N50260147
N52800015
N50500063
N50260027
16, 17, 18
4
6, 7, 8
Designation
Fan Multifan 2E30 for GP 40, complete, motor and impeller wheel
90° bend, galvanized, Rp ¾"
Pipe 230 mm, galvanized, R ¾"
Vane switch, complete, for GP 14-120
Reducing socket, galvanized, Rp ¾ – 1", No. 240
Beru spark plug for GP 40/GP 70, RGA 100
Ignition cable kit for GP 40 – GP 120, complete with plug and cap
M14 x 1.25 nut for ignition and ionization electrodes
Natural gas nozzle for GP 40, 12 x Ø 1.8 mm
Burner baffle plate for GP 40/GP 70, Ø 62 mm
Burner chamber for GP 40/GP 70
Beru ZE14 ionization electrode for GP 40/GP 70
GP 40/GP 70 housing, stainless steel
Temperature sensor for STM/STL, 6 x 45 TSK1056 (Type: 36342411) NTC (5 kΩ/25°C)
BCU 300 upper housing section, incl. electronics, Kromschröder THP-GW 84636001
BCU 300 lower housing section, incl. ignition transformer
GP series ignition transformer, Eichhof E4718/55, gas, 1-pin
Protective cap for BCU, PVC, black, with viewing window
90° male/female bend, galvanized, Rp ½"/R ¾"
Gas combination control CG 10 for GP 14/GP 40, Kromschröder CG 10R70-D15WB
LPG nozzle for GP 40, 6 x Ø 1.6 mm
GB-16
We, the manufacturer, hereby declare that the product GP complies with the requirements of the listed
Directives and Standards:
Directives:
–2009/142/EC
–2004/108/EC
–2006/42/EC
–2006/95/EC
Standards:
–DIN 3362, EN 298
–EN 60730
–EN 1643, EN 525:2009
The relevant product corresponds to the type tested
by the notified body 0085.
The production is subject to the surveillance procedure pursuant to Directive 2009/142/EC according
to annex II, paragraph 3.
Elster-Instromet B.V.
Scan of the Declaration of conformity (D, GB) – see
www.docuthek.com
GB-17
GB
Inlet pressure pe:
natural gas: 20 – 25 mbar,
propane: 35 – 50 mbar.
Gas connection: Rp ½" internal thread.
Material:
casing: stainless steel 430,
burner chamber: stainless steel 430;
BCU: PPE.
Ambient temperature:
-10 to +60°C.
Cycle lock: 15 s.
Capacity: 40 kW.
Gas consumption:
natural gas L: ± 3.9 m3/h,
natural gas H: ± 3.3 m3/h,
propane: ± 2.9 m3/h.
Connection rating:
230 V AC, -15/+10%, 50/60 Hz, 410 W.
Power consumption: IA/IN: ± 4.5 A/1.8 A.
Air circulation:
Controlled air flow: ± 3875 m3/h,
Heating: ± 4500 m3/h.
Jet length: ± 40 m.
Housing:
length: 1200 mm,
width (total): 530 mm,
height/diameter: 440 mm,
weight: 24.2 kg.
Declaration of conformity
D
Technical data
Goods return form
Name of the operator
P.O. Box/Street
Postcode and town/city
Tel.
E-mail
Returned by (Mr./Ms.)
E
Number of returns
I
NL
F
GB
Date
Heater serial number
Power supply [V/Hz]
Inlet pressure pe [bar]
Reasons for return
Description of fault
Credit note
Replacement
Repair
Desired action
Remarks
Date and signature
Please send returns back to your supplier.
Contact
If you have any technical questions, please
contact your local branch office/agent. The addresses are available on the Internet or from
­Elster-Instromet B.V.
Elster-Instromet B.V.
P.O. Box 53, 3958 ZV Amerongen
Sales Office
Industrieweg Zuid 32, 3958 VX Amerongen
Postfach 2809, 49018 Osnabrück
The Netherlands
Strohteweg 1, 49504 Lotte (Büren)
T +31 343473720
Germany
F +31 343473730
T +49 541 1214 702
info-amerongen.nl@elster.com, www.ermaf.nl
F +49 541 1214 506
We reserve the right to make technical modifications
in the interests of progress.
info@kromschroeder.com, www.kromschroeder.com
GB-18