GOK GS Pro-Fi 3 Assembly And Operating Manual

Assembly and operating manual

Combined heating oil filter breather type GS Pro-Fi® 3

installation guidelines.

Breather device with filter and shut-off fitting according to EN 12514-2

2Y115

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

Translation of original / Item No. 13 512 53 Version 01.2016

Combined heating oil filter breather type GS Pro-Fi® 3

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.

“DANGER”, “WARNING”, or “CAUTION”. These words mean:

 May result in death or serious injury.

May result in death or serious injury.

 May result in minor or moderate injury.

 Has an effect on ongoing operation.

Capture fuels during maintenance work.

SAFETY ADVICE

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

describes a personal hazard with a high degree of risk.

describes a personal hazard with a medium degree of risk.



describes a personal hazard with a low degree of risk.

describes material damage.

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

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
according to the single string system with return supply.

®

3 is only installed into the suction lines of supply/oil systems designed

2 / 16 Item No. 13 512 53

Combined heating oil filter breather type GS Pro-Fi® 3

www.gok-online.de/de/downloads/technische-dokumentation.

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

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

vent screw

Anti-siphon device

Withdrawal valve Typ VTK-3

Aspiration line

type GS Pro-Fi® 3

DESIGN

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

Pressure compensation valve Typ DAV

4 / 16 Item No. 13 512 53

Combined heating oil filter breather

CONNECTIONS

Inlet,

Trading name and dimensions

Installation notes

screw-in fitting

• compression fitting RVS

Outlet,

Trading name and dimensions

Installation notes

ball-cone connector

torque 15Nm

Single string
system

Double string
system

Conveyor
system

Calculation

.

V

Operating medium
(L/h)

≈

=
Gear output of the

=

.

V

Suction: (0.2 ÷ 0.5) m/s

Discharge: (1.0 ÷1.5) m/s

Taking into account the length of the suction

.

V

∅ 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

Combined heating oil filter breather type GS Pro-Fi® 3

optional

acc. to standard

• IG G 3/8
For accepting a screw-in fitting with O-ring

• compr. fit. 6

optional

acc. to standard

• thread AG G 3/8-KN

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 ⇒

=

Volume flow rate

Heat input
in kW / 10

Oil burner pump

Delivery rate
of the booster
pump

w = 0.3537 •

ID=inner pipe

diameter (mm)

For supply / oil systems, the following mean flow rate is applicable pursuant to DIN
4755:

line, the geodesic height, the suction height,

Fuel oil

and the fuel oil volume flow rate, the following
can be recommended for selecting the piping:

⇒

Item No. 13 512 53 5 / 16

/ ID2

Combined heating oil filter breather type GS Pro-Fi® 3

NOTICE ON THE FILTER INSERT :

Female thread G 3/8 acc. to EN ISO 228-1, as

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-

screw-in connector is 15 Nm

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:

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

screw-in opening G 3/8-UA-O acc. to

4 or prEN 12514-4 Annex C (adequate with type A
acc. to DIN 3852-2)
The recommended maximum torque with steel

6 / 16 Item No. 13 512 53

Combined heating oil filter breather type GS Pro-Fi® 3

The female thread can also take the GOK universal

The housing is made from a zinc die-cast alloy:

Flexible pipe assembly

www.gok-online.de/de/downloads/technische-dokumentation.

pipes and with soft pipe materials.

pipe. Risk of corrosion!

instructions - Compression fittings.

Universal connection set (UA):

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

Do not use a conical pipe thread acc. to EN 10226-1.

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

A reinforcement ring must be used with all thin-walled

Brass reinforcement rings may not come into contact with aluminium

More information about compression fittings can be found at

www.gok-online.de/en/downloads/technical

-documentation/Assembly

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

It is important that metal chips or other residues are blown out.

Do not use unsuitable tools, such as pliers.

NOTICE FOR LEAK TESTING

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

Malfunctions caused by residues.

Proper functioning is not guaranteed.

Visually check that there are no metal chips or other residues in the connections.

Install with suitable tools, if required.

Regarding screw connections, use a second spanner to brace against the connection nozzle.

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!

We recommend using the vacuum test device for oil systems pursuant to TRÖl

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

Once leak testing is completed and the system is leak-tight, only the toggle valve of

immediately. If required, re-pump.

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

START-UP

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

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
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

direction.

Item No. 13 512 53 9 / 16

Combined heating oil filter breather type GS Pro-Fi® 3

Replacing the filter insert:

• Switch off the burner and prevent the return of the oil column into the tank

without replacement filter

with replacement filter

• Loosen the clamping ring by anti-

clockwise direction

Loosen the replacement filter by anti-

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.

• Close the shut-off fitting

• Use a collector

• Clean the line sections downstream of the filter particularly carefully prior to re-installation

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!

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

• 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

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

In order to protect the environment, products contaminated with water-

The product must be disposed of via local collection stations or a recycling station.

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

MC 7, 5 - 20μm

110mbar

120mbar

Ventilation output

10L/h

Flow rate V

difference

Ambient temperature

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

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.

TECHNICAL DATA

Pressure loss Siku 70μm
Pressure loss Siku 70μm

n,R

210mbar
105mbar

return line – supply line
at maximum pressure

Δp

o,d,max

= 1.3bar

-10°C to +60°C

Item No. 13 512 53 11 / 16

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

type

Filter tray 500 plastic blue-transparent 79mm with ventilation valve
(PS 6bar)

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

We guarantee that the product will function as intended and will not leak during

of our terms and conditions of delivery and payment.

Combined heating oil filter breather type GS Pro-Fi® 3

and O-ring 500 NBR, without replacement filter (PS 10bar) for GS Pro-Fi® 3

13 851 67

13 514 25

WARRANTY

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

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

NOTES

Combined heating oil filter breather type GS Pro-Fi® 3

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

r- und Armaturen-Gesellschaft mbH & Co. KG

Regle

Obernbreiter Straße 2-16 • 97340 Marktbreit / Germany

Tel.: [phone] • Fax: [phone]

16 / 16 Item No. 13 512 53

E-Mail: [e-mail] • Internet: www.gok-online.de