Page 1
Installation & Maintenance Manual
MGN 860 – 1350 M3D DLU
Gas Burner
11/12
Page 2
Contents
1 General information ................................................................................................................... 3
2 Checking scope of delivery and electrical data .......................................................................... 3
3 Maintenance and customer service ........................................................................................... 3
4 Operating instructions ................................................................................................................ 3
5 Instruction of operating personnel.............................................................................................. 3
6 Filter/Strainer .............................................................................................................................. 3
7 Key for code designation ........................................................................................................... 4
8 Technical specifications .............................................................................................................. 4
9 Boiler connection dimensions .................................................................................................... 4
10 Mounting the gas jacket on the boiler ......................................................................................... 5
11 Mounting the burner housing on the gas jacket (service position) .............................................. 5
12 Electrical connection .................................................................................................................. 5
13 Air flap positioning motor .......................................................................................................... 7
14 Air pressure switch ..................................................................................................................... 7
15 Gas pressure switch for gas inlet pressure................................................................................. 7
16 Gas pressure switch for VPS ...................................................................................................... 7
17 Adjustment of the ignition electrodes ......................................................................................... 8
18 Flame control with Ionisation monitor.......................................................................................... 8
19 Adjustment of the burner head.................................................................................................... 9
20 Control unit MPA 22.................................................................................................................. 10
21 MPA 22 control unit display ..................................................................................................... 10
22 Start-up ..................................................................................................................................... 10
23 Gas train KEV II1 ½" , KEV 2" and KEV DN65......................................................................... 11
23a Gas train KEV25 1", KEV30 1½", KEV45 2" and KEV45 DN 65............................................... 12
24 Adjustment mode - pneumatic gas-fired operation ................................................................... 13
25 Calculation principles for gas burner adjustment ..................................................................... 15
26 Adjustment tables ..................................................................................................................... 16
27 Troubleshooting / process description ...................................................................................... 18
28 Adjustments log ........................................................................................................................ 22
29 Explosion drawing ..................................................................................................................... 23
30 Spare parts list ......................................................................................................................... 24
31 Overall dimensions .................................................................................................................. 26
32 Working ranges ......................................................................................................................... 26
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Page 3
1 General information
Installation of a gas-fired heating system must be performed in accordance with the applicable regulations
and guidelines. It is, therefore, the duty of the installation engineer to ensure that all regulations have been
read carefully and understood. 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.
Nu-Way MG860/1350-LN M3D DLU Series gas burners are suitable for combustion of natural gas or liquid
gas in accordance with EN 437 and are in compliance with the EN 676 European standard.
2 Checking scope of delivery and electrical data
Before installing the Nu-Way gas burner, please check that all items included in the scope of delivery are
present.
Scope of delivery:
burner housing, gas jacket with burner pipe, mounting kit, documentation and gas train.
Gas installation and commissioning are subject to the applicable national regulations. 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 gas train 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 sequence and throughflow direction of valves and fittings.
3 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 nongenuine parts or where the equipment has been used for purposes for which it was not intended.
4 Operating instructions
The operating instructions together with this technical information leaflet must be displayed in a clearly visible position in the boiler room. The address of the nearest customer service centre must be displayed on
the back of the operating instructions.
5 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.
6 Filter/Strainer
According EN676 a filter/strainer shall be fitted at the inlet of the safety shut-off valve to prevent the ingress
of foreign elements.
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7 Key for code designation
MGN(L)860-LN
LowNox
Burner output max.
Natural gas LL + E ="N", LPG = "L"
Series
All dimensions are given in mm
220
250-290
M10
45°
45°
8 Technical specifications
Burner type
Technical specifications MG860-LN M3D DLU MG1350-LN M3D DLU
Burner output in kW 225 - 860 225 - 1350
Gas type Natural gas LL + E = "N", LPG = "L"
Mode of operation Progressive two-stage or modulating
Voltage 3 / PE ~50 Hz 400 V / T16 A
Max. power consumption at start / during operation 6.5 A max./ 3.6 A eff. 8.0 A max./ 4.6 A eff.
Electric motor power (at 2800 rpm) in kW 1.1 2.2
Flame failure controller Ionisation
Control box MPA 22
Weight in kg 56 58
Noise emission in db(A)
≤
78
9 Boiler connection dimensions
≤
78
4
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Page 5
10 Mounting the gas jacket on the boiler
Air pressure connection
B
Use adhesive to affix the gas-jacket gasket to the
gas jacket.
The boiler connection plate has to be prepared in accordance with the sizes as stated in „9. Boiler connection dimensions“. You can use the gas-jacket gasket as
a template.
Using an 8 mm socket-head wrench, secure the gas
jacket to the boiler with the 4 M 10 fastening screws
and washers. The air pressure connection for the gas
train must be positioned at the top.
11 Mounting the burner housing on the gas jacket (service position)
Position the burner housing in the gas-jacket hinge
and secure it with a rod. The burner is now in the service position.
12 Electrical connection
Make sure that the gasket is correctly seated
between the gas jacket and the burner housing.
Swing the burner closed and insert the second securing rod into the hinge. Tighten the screw at the top to
secure the burner in position.
Always set the main switch to "Off" and remove
the fuse before connecting the cables or removing
electrical components.
The burner must be connected to the electricity supply
in accordance with the wiring diagram. This wok must
be performed by trained, qualified electricians. The
supply cable to the burner must be of the flexible type.
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See Circuit diagram
Cover
1
1
The cover has to be removed and set to the service position in order to permit access to the control unit. Remove the securing screws (1) and fold the cover down
to the left.
Once the connection to the electricity supply has been
established, check the wiring and briefly actuate the motor contactor with an electrician's insulated screwdriver
to check the direction of rotation of the burner motor.
The direction of rotation is correct if the fan turns toward
the boiler (see the arrow on the motor flange).
IMPORTANT !
The motor protective relay is set ex-works. The set value
should not be incorrectly adjusted.
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13 Air flap positioning motor
14 Air pressure switch
The air flap positioning motor is designed for air flap adjustment on progressive two-stage burners or modulating
burners. The motor is activated electronically via the
microprocessor-controlled control box.
Do not open the air flap positioning motor. The optics
can become damaged irreparably. No warranty will be
given if the seal is broken.
The air pressure switch is a differential pressure switch
and monitors pressure at the forced-air burner.
The air pressure switch is preset at the factory.
15 Gas pressure switch for gas inlet pressure
The gas pressure switch on the gas train serves to monitor the gas inlet pressure. The burner is shut down
if the gas inlet pressure drops below the set minimum value (preset at factory). The burner starts up automatically again when the minimum pressure is exceeded.
16 Gas pressure switch for VPS
The gas pressure switch for VPS is preset to 10 mbar at the factory.
The operating point of the gas pressure switch for VPS must be set to half the inlet flow
pressure.
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17 Adjustment of the ignition electrodes
2,5 - 3 mm
ignition electrode
ionisations
electrode
The ignition electrodes are preset at the factory.
18 Flame control with Ionisation monitor
In the presence of an alternating-current voltage between burner and ionisation rod, the rectifying effect of
the flame causes a direct current to flow. This ionisation current is the flame signal and is amplified before
being output to the control box. A flame cannot be simulated, because the rectifying effect collapses if there
is a short-circuit between sensor electrode and burner.
Measuring ionisation current
The ionisation current must be measured during burner start-up and maintenance or after a fault indication
in the control box. Disconnect the plug of the ionisation cable and connect the ionisation
measuring cable.
Perform measurement straight after the post-ignition time during the safety time period !
The ionisation current must be at least 1.5 µA. Currents lower than 1.5 µA cause unstable operation or shutdown. If the current is too low clean the ionisation rod and the inside of the burner tube. It may be necessary
to correct the shape of the ionisation rod. If the ionisation rod is defective, replace the electrode. Reverse
the polarity of the ignition transformer, if necessary. Check the cables for moisture formation and dry if necessary.
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19 Adjustment of the burner head
Set the position of the burner head according to
burner output in accordance with the table on page
16ff.
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20 Control unit MPA 22
Enter or Reset key
Key 1
Activation of gas valve
in combination
with +/- key
Key 2
Activation of air valve
in combination
with +/- key
Key + / Key -
Start-up comes on
during start-up, off when
burner is in operation
comes on when
is active
information mode
comes on when
adjustment mode
is active
comes on when
gas flap is active
symbol for
opening /
closing flaps
comes on when
air flap
is active
Visual
LC
h = service hours indicator
l, m3 = oil or gas consumption
comes on when service mode
is active
Fault
Operation, flame present
21 MPA 22 control unit display
The MPA 22 is a microprocessor-controlled intermittentduty control box for controlling and monitoring pneumatic
modulating forced-air burners with an actuator drive. For
operation as an automatic gas burner control with integral
valve proving system.
The MPA 22 has e-BUS connectivity.
22 Start-up
The burner can be put into operation once the gas and electrical installation and assembly work has been
completed.
• Check the connections on the gas train.
• Prepare the flue-gas analyser.
• Start the burner.
• Adjustment of air surplus and output. See 23. Gas train KEV
23.a Gas train KEV25 1" and KEV30 1 ½ ".
• Record the setting data.
• Check the gas pressure monitor after start-up. To do so, close ball valve slowly. The burner must shut
down, but must not go into fault mode. If the burner goes into fault mode, increase the setting on the
gas pressure monitor.
II
10
1 ½" , KEV 2" and KEV DN65 or
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23 Gas train KEV
Gas pressure switch
SKP 15
VGD
Pulse line p
G
SKP 75
Cover plate for
"AIR" air pressure connection
(gas inlet pressure)
Adjustment screws
Gas pressure switch
for leak check
Pressure gauge
Nozzle pressure p
G
detail
1 ½" , KEV 2" and KEV DN65
II
Installing the gas train
Installation position only in horizontal line, not tilted.
Minimum distance to walling 20 mm
Screw the combustion chamber pressure measuring nipple into the gas jacket at the top (see "10 Mounting the gas jacket on
the boiler").
Route the connecting hose between the measuring nipple for combustion chamber pressure and the gas train in a loose loop.
Screw each air pressure measuring nipple into the top of the gas jacket (see 10. Mounting the gas jacket
on the boiler).
Connect the blue hose to the "AIR" connection on the gas train and the air pressure connection on the gas
jacket. The blue hose serves as a control line for the gas train and must be routed in a loose loop without
kinking.
Remove the plate for covering the adjustment screws from the gas pressure regulator.
Start the burner.
1. Setting the air surplus in high and low-load operation
• Set the air flap positions P9 for high-load operation and P1 for low-load operation as specified in
26. Adjustment tables. Follow the setting procedure described in 24. Adjustment mode - pneumatic
gas-fired operation with MPA 22 display.
• In high-load operation, set the air surplus with the "large flame" adjustment screw on the gas pressure
regulator. The CO2 level in the flue gas should be 9-10% for natural gas.
• In low-load operation, set the air surplus with the "small flame" adjustment screw on the gas pressure
regulator. The CO2 level in the flue gas should be 9-10% for natural gas. The low-load setting influences the high-load setting.
• In high-load operation, check the air surplus and, if necessary, correct the setting with the "large
flame" adjustment screw on the gas pressure regulator.
2. Setting the output in high and low-load operation
• Check the high-load setting via the gas flow at the gas meter or compare the nozzle pressure with the
values stated in 26. Adjustment tables. The output can be increased by opening the air flap (to
increase P9) and reduced by closing the air flap (to reduce P9). The air surplus is not affected by this
adjustment.
• Check the low-load setting via the gas flow at the gas meter or compare the nozzle pressure with the
values stated in 26. Adjustment tables. The output can be increased by opening the air flap (increase
P1) and reduced by closing the air flap (reduce P1). The air surplus is not affected by this adjustment.
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23.a Gas train KEV25 1½" and KEV30 1"
Gas pressure switch
Pulse line p
G
V
N
Gas pressure switch
for leak check
(gas inlet pressure)
"AIR" air pressure
connection
Installing the gas train
Installation position only in horizontal line, not tilted.
Minimum distance to walling 20 mm
Screw the air pressure measuring nipple into the gas jacket at the top (see "10 Mounting the gas jacket on the boiler").
Route the connecting hose between the measuring nipple for combustion chamber pressure and the gas train in a loose loop.
Screw each air pressure measuring nipple into the top of the gas jacket (see 10. Mounting the gas jacket
on the boiler).
The blue hose serves as a control line for the gas train and must be routed in a loose loop without kinking.
Cut the blue hose into two sections. Connect the first sections of blue hose to the "pL" connection on the
gas train and the air pressure connection on the gas jacket, and connect the other section to the "pF" measuring point on the combustion chamber.
The hose must be routed in such a fashion that any condensate forming inside the combustion chamber flows back, and not into the gas train.
Start the burner.
1. Setting the air surplus in high and low-load operation
• Set the air flap positions P9 for high-load operation and P1 for low-load operation as specified in
26. Adjustment tables. Follow the setting procedure described in 24. Adjustment mode - pneumatic
gas-fired operation with MPA 22 display.
• In high-load operation, set the air surplus at the adjustment screw "V" on the gas pressure regulator.
The CO2 level in the flue gas should be 9-10% for natural gas.
• In low-load operation, set the air surplus with the adjustment screw "N" on the gas pressure regulator.
The CO2 level in the flue gas should be 9-10% for natural gas. The low-load setting influences the
high-load setting.
• In high-load operation, check the air surplus and, if necessary, correct the setting using the adjustment
screw "V" on the gas pressure regulator.
2. Setting the output in high and low-load operation
• Check the high-load setting via the gas flow at the gas meter or compare the nozzle pressure with the
values stated in 26. Adjustment tables. The output can be increased by opening the air flap (to
increase P9) and reduced by closing the air flap (to reduce P9). The air surplus is not affected by this
adjustment.
• Check the low-load setting via the gas flow at the gas meter or compare the nozzle pressure with the
values stated in 26. Adjustment tables. The output can be increased by opening the air flap (increase
P1) and reduced by closing the air flap (reduce P1). The air surplus is not affected by this adjustment.
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24 Adjustment mode - pneumatic gas-fired operation
1
2
OFF
OFFUPr
2
2
2
2
2
or
2
and
or
GAS Pn
P
9GAS
P
L/A
To enter this adjustment mode, the burner must be on standby.
Standby means that the burner is connected to the power supply, but no heat-
ing request has been issued. If OFF appears on the display on MPA 22,
the unit is running in standby mode and has already been configured.
If OFFUPr appears on the display, the MPA 22 is also running in standby mode,
but the unit is still unprogrammed and all setting parameters still have to be entered by the following procedure.
Important: If the setting operation is interrupted within 30 min. or not completed correctly, OFFUPr will also be displayed.
To change new setting parameters or old setting parameters, follow these
steps:
Step 1:
Enter the safety code. Press key 1 and key 2 simultaneously
Step 2:
7 horizontal bars are now displayed. Enter the password as follows.
Note:
The intervals between the individual inputs must not be longer than 20 sec., as
the MPA 22 will otherwise revert to standby mode. If this is the case, you will
have to start the code entry procedure from the beginning again.
- Press the minus key twice.
- Confirm your entry by pressing key 2 once.
- Press the minus key once.
- Confirm your entry by pressing key 2 twice.
- Press the plus key 4 x.
- Confirm your entry by pressing key 2 once.
- Press the plus key twice.
- Confirm your entry by pressing key 2 once.
- Press the plus key 3 x.
- Confirm your entry by pressing key 2 once.
- Press the minus key 4x.
- Press the enter key once.
Password entry is now finished.
Step 3:
after the correct password has been entered, EGAS Pn appears on the display.
Step 4:
the operating points P9 (max load), P1 (min load) and P0 (starting point)
can now be selected by pressing the plus or minus key.
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Step 5:
After the operating point P9 is selected, 9GAS appears on the display. The max
load operating point can be adjusted to values between 0° and 90 ° by holding
down key 2 and optionally pressing the plus or minus key.
For basic setting values, please refer to the adjustment table.
13
Page 14
or
2
and
or
2
and
1GAS
P
L/A
0GAS
P
L/A
GAS Pn
P
or
2
and
0GAS
P
L/A
or
1GAS
P
L/A
or
2
and
or
or
2
and
9GAS
P
L/A
1
2
and
Step 6:
After you have set P9, press the plus key to set P1. 1Gas appears on the dis-
play.
The min load operating point can be adjusted to values between 0° and 90 ° by
holding down key 2 and optionally pressing the plus or minus key.
For basic setting values, please refer to the adjustment table.
Step 7:
After you have set P1, press the plus key to set P0 (the starting point). 0 Gas
appears on the display.
The operating point (starting point) can now be set to a value between
0° and 90° by holding down key 2 and optionally pressing the plus or minus
key. The value of P1 should preferably be set. If P1, (min. load) is set to a very
low value, it is recommended to set P0 to a higher value than P1 in order to
ensure stable starting.
For basic setting values, please refer to the adjustment table.
Step 8:
After you have set P0, press the plus key.
GAS Pn. appears on the display.
Now close the safety chain and issue a heating request.
The burner should now start up and dwell in the ignition position. If this is not
the case, please repeat the procedure for adjustment of ignition point P0 under
step 7.
After the burner has started up, the gas train must be set to the nozzle pressure
specified in the adjustment table.
Step 9:
The setting values are now adjusted in relation to the boiler and the required
burner output. The burner is in operation throughout the adjustment procedure
so that all boilers and measured data relevant to the burner can be recorded.
Adjust the operating points in the order P0,P1 and P9 and make adjustments
by simultaneously pressing key 2 and the plus or minus key. To switch the
burner to normal operation, press key 1 and key 2 simultaneously for approximately 2 sec. The burner switches to min output P1 and then returns to normal
operation.
The setting procedure is now completed.
Note:
If you want to change values after finishing the setting procedure, you will have
to start from the beginning again.
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25 Calculation principles for gas burner adjustment
V
n
Q
n
η
k
H
×
i n,
--------------------
220kW
0 92 10×4
kWh
m
3
-----------
, ,
----------------------------------------= 23
m
3
h
------
= =
V
B
V
n
f
------
23
m
3
h
------
0 94,
-------------= 24
m
3
h
------
= =
f
B P
G
+
1013
--------------
273
273 ϑ
G
+
--------------------
×=
The values given in the tables are setting values for start-up.
The necessary system adjustment must be newly determined in each case.
General:
the calorific value (H
Natural gas type E H
Natural gas type LL H
LPG gas (propane) H
Gas counters measure the volume of gas in the operational state.
Gas flow determination:
To allow the heat generator load to be adjusted correctly, the gas flow rate must be determined in advance.
Example:
Altitude above seal level 230 m
Barometric air pressure B (acc. to table) 989 mbar
Gas pressure PG at counter 20 mbar
Gas temperature
Boiler output Q
Efficiency η
n
(assumed) 92%
K
Calorific value H
) of fuel gases is generally specified for the normal state (0°C, 1013 mbar).
i,n
= 10.4 kWh/m
i,n
= 9.3 kWh/m
i,n
= 25.89 kWh/m
i,n
ϑ
G
16°C
3
3
3
220 kW
i,n
10.4 kWh/m
3
Gas flow in standard state (Vn)
Gas flow in operating state (V B)
Conversion factor (f)
Annual average air pressure
Average geodetic altitude of the
supply region above sea level [m]
Annual average of air pressure (mbar) 1016 1013 1007 1001 995 989 983 977 971 965 959 953 947 942 936 930
from 1 51 101 151 201 251 301 351 401 451 501 551 601 651 701
to 0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750
Legend:
Qn = boiler output [kW]
η
= efficiency [%]
K
H
= lower standard calorific value [kWh/m3]
i,n
f = conversion factor
B = barometric air pressure [mbar]
= gas pressure at gas meter [mbar]
p
G
ϑ
= gas temperature at gas meter [°C]
G
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26 Adjustment tables
The values given in the tables are only setting values for start-up. The necessary system adjustment must be newly determined in the case
of deviating data such as boiler output, calorific value and altitude.
A correction is required in any case.
The maximal burner output can only be achieved in mixing head position 0. Due to the variable mixing head position, the operating behaviour of the
burner can be optimized for different heat generators.
MGN860-LN M3D DLU MGL860-LN M3D DLU
Natural gas LL
Hi,n = 9.3 [kWh/m
3
]
Natural gas E
H
i,n
= 10.4 [kWh/m
3
]
LPG
H
i,n
= 25.89 [kWh/m
3
]
Burner output
[kW]
Boiler
output
[kW]
Air flap
position
[ ° ]
Burner
head
position
[mm]
Gas nozzle
pressure
[mbar]
Gas flow rate
[m
3
/h]
Gas nozzle
pressure
[mbar]
Gas flow rate
[m
3
/h]
Gas nozzle
pressure
[mbar]
Gas flow rate
[m
3
/h]
St. 2 S. 1 St. 2
P 9
St. 1
P 1
St.2 St. 1 St. 2 St. 1 St. 2 St. 1 St. 2 St. 1 St. 2 St. 1 St. 2 St. 1
450 224 419 26.0 9 22 7.3 2.1 49.9 24.8 5.7 1.6 44.6 22.2 7.4 2.0 17.4 8.7
520 260 484 33.0 12 22 9.6 2.7 57.6 28.8 7.5 2.1 51.5 25.8 9.5 2.7 20.1 10.0
600 300 558 40.0 14 22 12.0 3.5 66.5 33.3 9.4 2.7 59.5 29.7 12.1 3.6 23.2 11.6
740 370 688 90.0 19 22 14.7 5.0 82.0 41.0 11.5 3.9 73.4 36.7 17.4 5.2 28.6 14.3
560 280 521 30.5 13 10 7.9 2.7 62.1 31.0 6.2 2.1 55.5 27.8 9.4 2.9 21.6 10.8
640 320 595 36.0 17 10 10.3 3.5 70.9 35.5 8.1 2.7 63.4 31.7 11.8 3.6 24.7 12.4
760 380 707 51.0 21 10 14.5 4.8 84.2 42.1 11.3 3.8 75.3 37.7 16.0 4.8 29.4 14.7
813 410 756 90.0 22.5 10 16.2 5.2 90.1 45.4 12.7 4.1 80.6 40.6 18.0 5.5 31.4 15.8
600 300 558 30.0 10 0 9.1 2.8 66.5 33.3 7.1 2.2 59.5 29.7 9.0 2.9 23.2 11.6
680 340 632 34.0 13 0 11.2 3.5 75.4 37.7 8.8 2.7 67.4 33.7 11.3 3.5 26.3 13.1
780 390 725 44.0 17 0 14.3 4.3 86.5 43.2 11.2 3.4 77.3 38.7 14.5 4.3 30.1 15.1
860 430 800 90.0 20 0 17.4 5.0 95.3 47.7 13.6 3.9 85.2 42.6 17.4 5.1 33.2 16.6
16
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Page 17
MGN1350-LN M3D DLU MGL1350-LN M3D DLU
Natural gas LL
Hi,n = 9.3 [kWh/m
3
]
Natural gas E
H
i,n
= 10.4 [kWh/m
3
]
LPG
H
i,n
= 25.89 [kWh/m
3
]
Burner output
[kW]
Boiler
output
[kW]
Air flap
position
[ ° ]
Burner
head
position
[mm]
Gas nozzle
pressure
[mbar]
Gas flow rate
[m
3
/h]
Gas nozzle
pressure
[mbar]
Gas flow rate
[m
3
/h]
Gas nozzle
pressure
[mbar]
Gas flow rate
[m
3
/h]
St. 2 St. 1 St. 2
P 9
St. 1
P 1
St. 2 St. 1 St. 2 St. 1 St. 2 St. 1 St. 2 St. 1 St. 2 St. 1 St. 2 St. 1
440 220 405 22 9 22 4.9 1.3 48.8 24.6 3.8 1.0 43.6 22.0 4.3 1.6 17.0 8.5
600 300 552 30 13 22 6.9 2.5 66.5 33.3 5.4 2.0 59.5 29.7 7.5 2.4 23.2 11.6
800 400 736 40 20 22 12.8 4.2 88.7 44.3 10.0 3.3 79.3 39.7 12.8 3.7 30.9 15.4
1000 500 920 90 25 22 19.6 5.2 110.9 55.4 15.3 4.1 99.1 49.6 19.5 5.4 38.6 19.3
500 250 460 25 9 10 5.0 1.2 55.4 27.5 3.9 0.9 49.6 24.6 4.5 1.5 19.3 9.7
660 330 607 32 17 10 7.0 3.0 73.2 36.6 5.5 2.3 65.4 32.7 7.4 2.2 25.5 12.7
860 430 791 41 22 10 13.0 4.2 95.3 47.7 10.2 3.3 85.2 42.6 12.3 3.4 33.2 16.6
1080 540 994 90 27 10 20.3 5.3 119.7 59.9 15.9 4.1 107.1 53.5 19.2 5.1 41.7 20.9
600 300 552 21 10 0 5.1 1.4 66.5 33.3 4.0 1.1 59.5 29.7 4.9 1.5 23.2 11.6
800 400 736 26 14 0 8.6 2.4 88.7 44.3 6.7 1.9 79.3 39.7 8.6 2.4 30.9 15.4
1100 550 1012 43 19 0 16.0 4.9 121.9 61.0 12.5 3.8 109.0 54.5 16.2 4.2 42.5 21.2
1350 680 1242 90 24 0 24.6 6.3 149.7 75.4 19.2 4.9 133.8 67.4 24.5 6.2 52.1 26.1
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27 Troubleshooting
Defect determined: Cause: Remedy: Fault code
Burner motor does not start upElectric supply lead faulty Rectify faults in electrical installation
Fuse faulty Replace
Safety thermostat locked Unlock 42 h
Burner starts up and
switches to fault mode
before or after expiry of
safety period
Temperature of controller setting is
exceeded
MPA 22 faulty Replace 04 h
Leak Rectify leak 44H / 43H
No gas Safeguard gas supply
Gas pressure monitor faulty Replace gas train 22 h
Filter in gas train dirty Clean or replace
Air pressure switch not in idle position Check air pressure switch (see page 7) 20 h
Burner motor faulty Replace
No load at terminal 5 Check plug connection and current path of
Mains voltage <
Air pressure monitor does not switch
through during pre-ventilation
Ignition influencing of ionization monitor See Page 8 26 h
Gas solenoid valve does not open Replace gas train
Starting gas quantity set too low Increase starting gas quantity
No ignition Check ignition electrode and setting, igni-
187 V
Renewed start attempt after temperature
drop
solenoid valve
Rectify faults in electrical
installation
See Page 7 21 h
tion transformer and cable
Flame extinguishes
during operation
Phase and zero mixed up Connect connector unit in correct phase
sequence
Flame control faulty Check according to Page 8 2BH
Air pressure switch opens during operation
Gas nozzle dirty or faulty Replace gas nozzle
No gas Safeguard gas supply
Filter in gas train
dirty
Flame blow-off Incorrect burner setting 27 h
Air pressure monitor contact opens Check/replace air pressure switch 21 h
Flame signal too weak Measure flame signal, check ionisation
See Page 7 21 h
Clean or replace
27 h
electrode
18
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Page 19
Service mode - pneumatic gas-fired operation
Adjustment point
Adjustment values
Service mode symbol
display value
Adjustment point information mode symbol
The service mode serves to display the set parameters and to read out the fault memory. It can be invoked
in any operating state of the burner.
Important:
setting values cannot be changed in service mode. If no key is pressed for longer than 20 sec., the
display returns to standby mode.
To access the service mode, press the enter key for approx. 2 sec.
The following now appear on the display: point P0 and the air flap posi-
tioning motor setting value at ignition in angular degrees, plus a wrench
symbol denoting the service mode.
The following points can be retrieved by repeatedly pressing the enter
key:
- The characteristic curves for points P0, P1 and P9
- The last 6 fault messages P10 to P15 (see fault code MPA)
- The testing times of the valve proving system P16 and P17
- The flame quality P18
- The eBus address of the MPA P19
- The switch setting of the valve proving system P21
- The eBus address of the external controller P24
- The modulation delay
- The set start points P26
To exit the service mode, please press the enter key or wait approx.
20 sec.
Information mode
The information mode is intended for display of consumption figures, operating hours and software data.
To access information mode, press the enter key for approx. 0.5 sec.
A zero and a value appear on the display.
The following values can be queried in information mode under setting
points 0 to 8. Retrieve by repeatedly pressing the enter key:
Important:
If no key is pressed for longer than 20 sec., the display returns to
normal operating mode.
0 = fuel consumption
1 = total operating hours
2 = for oil only
3 = for oil only
4 = number of successful startups
5 = display of software version
6 = software creation date
7 = hardware number
8 = date of production
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Troubleshooting the MPA
Code Description
04 h Internal hardware fault
05 h Internal hardware fault
06 h Internal hardware fault
07 h Internal hardware fault
09 h Internal hardware fault
10 h Internal hardware fault
11 h Internal hardware fault
12 h Internal hardware fault
13 h Internal hardware fault
14 h Internal hardware fault
15 h Internal hardware fault
20 h Air pressure switch is not in idle position
21 h Failure of air pressure switch
22 h Failure of gas pressure monitor
25 h No flame after safety period
26 h Outside light
27 h Flame failure during operation
29 h Internal hardware fault
2AH Internal hardware fault
2BH Short-circuit in photo resistor or internal fault
2CH Internal hardware fault
30 h Internal hardware fault
31 h Internal hardware fault
32 h Internal hardware fault
33 h Internal hardware fault
34 h Internal hardware fault
42 h Safety chain interrupted
43 h Y3 found to be leaking during leak check
44 h Y3 found to be leaking during leak check
45 h Internal hardware fault
46 h Internal hardware fault
47 h Internal hardware fault
48 h Internal hardware fault
4AH Internal hardware fault
5BH Internal hardware fault
4CH Internal hardware fault
4DH Internal hardware fault
4EH Internal hardware fault
50 h Internal hardware fault
51 h Internal hardware fault
52 h Internal hardware fault
53 h Internal hardware fault
54 h Internal hardware fault
55 h Internal hardware fault
56 h Internal hardware fault
57 h Internal hardware fault
58 h Internal hardware fault
59 h Internal hardware fault
20
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Code Description
5AH Internal hardware fault
5CH Internal hardware fault
5DH Internal hardware fault
5EH Internal hardware fault
63 h Internal hardware fault
64 h Internal hardware fault
65 h Internal hardware fault
67 h Internal hardware fault
68 h Incorrect feedback from air flap positioning drive
(check connector and cable, actuator drive mounting and air flap mechanism)
6AH Air-flap actuator position is out of tolerance
(check connector and cable, actuator drive mounting and air flap mechanism)
6CH Internal hardware fault
6DH Internal hardware fault
6EH Actuator drive interchanged or incorrectly connected
6FH Burner detection error
70 h Internal hardware fault
71 h Internal hardware fault
73 h Internal hardware fault
74 h Internal hardware fault
75 h Internal hardware fault
76 h Internal hardware fault
77 h Internal hardware fault
78 h Internal hardware fault
79 h Internal hardware fault
Process description
Startup tests Processor and program memory test / move actuator drives to reference position
State 01 Startup decision (heating request present)
State 02 Blower idle state check
State 03 Blower startup
State 04 Preventilation / operation of gas flap actuator over speed range
State 05 Preventilation / activate and test watchdog
State 06 Preventilation / move gas flap actuator to ignition position
State 07 Move air flap actuator to ignition position
State 08 Pre-ignition depending on parameters
State 09 Startup safety period
State 10 Stabilisation period
State 11 Move positioning drive from ignition point to operating characteristic
State 12 Operation
State 13 VPS - evacuate valve cavity / (post-ventilate)
State 14 Test duration Y2 / (remaining post-ventilation time)
State 15 VPS - fill valve cavity / (remaining post-ventilation time)
State 16 Test duration Y3 / (remaining post-ventilation time)
State 17 Remaining post-ventilation time
State 18 Restart disable time / waiting loop for low gas program
State 20 Standby position
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28 Adjustments log
Please enter the measured values into the Adjustments log.
Boiler type Gas fitting
Measured values min. max. Date
P0 (start point)
P1 (min load)
P9 (max load)
Flue gas temperature °C
Carbon dioxide (CO2 level) %
O2 content %
CO level %
Flue mbar
Nozzle pressure mbar
Boiler pressure mbar
Room temperature °C
Gas type
Setting value V at the fitting
Setting value N at the fitting
22
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29 Explosion drawing
ZBZ 2-297
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30 Spare parts list
Item Designation PU Art. No.
1 Burner tube MG860 1 47-90-24880
1 Burner tube MG860, extended by 100 mm 1 47-90-25260
1 Burner tube MG860, extended by 200 mm 1 47-90-25261
1 Burner tube MG1350 1 47-90-24878
1 Burner tube MG1350, extended by 100 mm 1 47-90-25258
1 Burner tube MG1350, extended by 200 mm 1 47-90-25559
2 Flow plate complete with ignition electrode 1 47-90-24877
3 Ignition electrode complete with fastening 2 47-90-22421
4 Ignition cable 2 47-50-25134
4 Ignition cable, extended by 100 mm 2 47-50-25004
4 Ignition cable, extended by 200 mm 2 47-50-25005
5 Ionisation electrode complete with fastening 1 47-90-26588
6 Ionisation cable 2 47-90-26718
6 Ionisation cable, extendet by 100 mm 1 47-90-26719
6 Ionisation cable, extendet by 200 mm 1 47-90-26720
7 Gasket for gas nozzle 5 47-50-25500
8 Gas nozzle complete with electrode (Natural gas) 1 47-90-26626
8 Gas nozzle complete with electrode, extended by 100 mm (Natural gas) 1 47-90-26698
8 Gas nozzle complete with electrode, extended by 200 mm (Natural gas) 1 47-90-26699
8 Gas nozzle complete with electrode (LPG) 1 47-90-26709
8 Gas nozzle complete with electrode, extended by 100 mm (LPG) 1 47-90-26710
8 Gas nozzle complete with electrode, extended by 200 mm (LPG) 1 47-90-26711
9 Sealing ring for cover 1 47-50-10698
10 Actuator drive SAD 1.5 complete till 08.08 1 47-90-24763
10 Actuator drive SAD 1.5 complete from 09.08 1 47-90-27032
11 Air flap complete till 08.08 1 47-90-24663
11 Air flap complete from 09.08 1 47-90-27030
12 Cover for sight glass 5 47-50-12106
13 Cover 1 47-90-24857
14 Sight glass 5 36-50-11544
15 Fan wheel ∅218 x 80 for MG860 1 36-90-11540-01
15 Fan wheel ∅224 x 82 for MG1350 1 47-90-24847
16 1.1 kW 400 V / 50 Hz motor for MG860 1 36-90-11538
16 2.2 kW 400 V / 50 Hz motor for MG1350 1 47-90-24846
17 1.1 kW motor complete with fan wheel for MG860 1 47-90-25205
17 2.2 kW motor complete with fan wheel for MG1350 1 47-90-25508
18 3-pole female connector, black 1 37-90-20739
19 7-pole female connector, black / brown 1 37-50-20731
20 5-pole female connector, black 1 37-50-20748
21 Thermal relay T7DU MG860 1 47-90-25172
21 Thermal relay T7DU MG1350 1 47-90-25173
22 Miniature motor contactor B7-30-10 1 47-90-25171
23 Control box MPA 22 V1.21 1 47-90-24166
24 Electronic ignition transformer TRK 2, complete 1 47-90-24469
25 7-pole female connector, green 5 37-50-10831
26 3-pole female connector, black 5 37-50-20739
27 Terminal box cover 1 47-90-24852
28 MPA display AM07 1 47-90-24167
29 Facing panel 1 47-90-24887
30/32/34 Gasket completet 1 47-90-26722
31 Gas jacket part 2, complete 1 44-90-30242
33 Gas jacket part 1, complete 1 44-90-30245
35 Securing rod 2 46-50-21085
36 Differential pressure switch 1 47-90-26723
37 Energy-converter DLU02 1 47-90-24198
- Fan inlet device 1 36-90-11541
- Protective screen 1 47-90-10696
24
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Page 26
Enertech Limited,
P O Box 1,
Vines Lane
Droitwich,
Worcestershire,
WR9 8NA
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