Installation & Maintenance Manual
MGN 2100 – 2500 – 2800 Modulating
Gas Burner
Tel: +44 (0) 1905 794331 Fax: +44 (0) 1905 794017 Email: info@nu-way.co.uk Web: www.nu-way.co.uk
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 KLC1000 ....................................................................................................... 8
19 Control unit MPA 22.................................................................................................................... 9
20 MPA 22 control unit display ....................................................................................................... 9
21 Start-up ....................................................................................................................................... 9
22 Gas train .................................................................................................................................. 10
23 Adjustment mode - pneumatic gas-fired operation ................................................................... 11
24 Calculation principles for gas burner adjustment ..................................................................... 12
25 Adjustment tables ..................................................................................................................... 14
26 Troubleshooting / process description ...................................................................................... 16
27 Adjustments log ........................................................................................................................ 20
28 Explosion drawing ..................................................................................................................... 21
29 Spare parts list ......................................................................................................................... 22
30 Overall dimensions .................................................................................................................. 24
31 Working ranges ......................................................................................................................... 24
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2
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 MG1310-2800 M3D 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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3
7 Key for code designation
MGN(L)1310
Burner output max.
Natural gas LL + E ="N", LPG = "L"
Series
All dimensions are given in mm
M12
Ø260
Ø328
8 Technical specifications
Burner type
Technical data MG1310 MG2100 MG2500 MG2800
Min. burner output in kW 458 533 639 793
Max. burner output in kW 1340 2148 2539 2800
Gas type for natural gas LL + E = “-N” , LPG = „-L“
Method of operating modulating
Voltage 3 / PE ~50 Hz 400 V / T 20 A
max. current consumption start/operatiopn 12 A max./
7.1 Aeff.
Electric motor power (at 2800min-1) in kW
Flame failure controller KLC1000
Control box MPA 22
Air pressure monitor LGW50
Weight in kg 110 115 120 125
3.0 4.0 4.5 5.5
14.5 A max. /
10.2 A eff.
16.5 A max./
11.4 A eff.
22.5 A max./
15.5 A eff.
9 Boiler connection dimensions
4
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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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5
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.
Modulating operation
IMPORTANT !
The coding plug X85 with jack X86 must be connected
during two-stage operation (as-delivered condition, see
Fig.).
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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6
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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7
17 Adjustment of the ignition electrodes
ca. 3 - 4
ca. 5
The ignition electrodes are preset at the factory.
18 Flame control with KLC1000
Operating Indicator LED:
LED is OFF: KLC is not switched on – no power supply
or ‘no flame’ is detected.
LED is FLASHING: KLC has detected a flame; the qual-
ity of the flame signal is indicated by the intensity of the
flashing of the LED – fast flashing indicates a healthy
flame signal and vice versa - slow flashing indicates a
weak flame signal.
LED is ON: KLC has detected the strongest level of
flame signal.
Commissioning and maintenance
The installation and commissioning must be done by qualified personnel only. Before energising the KLC
flame detector please check the cable and wiring connections are in accordance to the diagram and instructions given above. For good maintenance which will ensure trouble free operation of the KLC flame
detector; please keep the sight glass clean by wiping with a soft dry clean cloth. Warning: Do not use any
kind of cleaning sprays or fluids. During commissioning and after any cleaning maintenance, the flame detector should be checked, as the UV tube is subject to a natural ageing process and towards the end of its
life span it is prone to malfunction.
To check that the flame detector is sound we recommend the following procedures be followed:
• Start the burner with the fuel supply closed-off or remove the flame detector from its mounting flange
and cover the UV tube using a soft cloth to avoid touching the glass lens. The control box will lock-out
at the end of the safety time due to absence of a flame signal.
• Remove the flame detector from its mounting flange. Start the burner while exposing the flame detector to an external UV radiation source such as a cigarette lighter flame, or a small gas flame (n.b. electric room lighting or a torch is inadequate). The burner Control Box must go to lock-out due to
detecting an extraneous light source either immediately or at the end of the air pre-purge cycle,
depending on the type/model of the Control Box.
• Close off the fuel supply or remove flame detector from its mounting flange and cover the UV tube
using a soft cloth when the burner is in the "run" position. The control box must go immediately to
lock-out resulting in the burner shutting down.
If any of these safety checks do not function as described i.e. they should always result in burner shutdown
and control box lock-out; then it is essential to replace the flame detector with a new KLC flame detector.
For safety and trouble free burner operation, we recommend that the flame detector should be replaced
after every 10,000 hours of burner operation or approximately every 30months for a burner operating on
an average of 10 hours per day.
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8
19 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
20 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.
21 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 22. Gas train KEV
• 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.
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9
1 ½" , KEV 2" and KEV DN65.
II
22 Gas train
Gas pressure switch
SKP 15
VGD
Pulse line p
G
SKP 75
"AIR" air pressure connection
(gas inlet pressure)
Gas pressure switch
for leak check
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
27. Adjustment tables. Follow the setting procedure described in 25. 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 27. 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 27. 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.
10
E. 13.11.06 • G. 21.09.11
23 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 hea-
ting 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.
E. 13.11.06 • G. 21.09.11
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.
11
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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12
24 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
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
ϑ
G
16°C
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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13
25 Adjustment tables
MGN1310 M3D Natural gas LL: H
Burner output
Boiler output
Position
air flap
[kW]
ηk = 92% [kW]
[ ° ]
Gas nozzle
pressure
[mbar]
= 9.3 [kWh/m3]
i.n
Gas thoughput
[m3/h]
Natural gas E: H
Gas nozzle
pressure
[mbar]
= 10.4 [kWh/m3]
i.n
Gas thoughput
[m3/h]
Stage 2 Stage 1 Stage 2 St 2P9St 1P1St 2 St 1 St 2 St1 St 2 St 1 St 2 St 1
913 458 840 22.0 3.5 12.8 3.0 104.4 52.3 10.4 2.4 93.4 46.8
1043 522 960 25.6 8.3 16.1 3.3 119.4 59.7 13.0 2.6 106.7 53.4
1174 652 1080 48.5 14.0 19.3 4.9 134.3 74.6 15.6 3.9 120.1 66.7
1340 652 1233 90.0 14.0 24.9 4.9 153.3 74.6 20.0 3.9 137.1 66.7
MGN1310 M3D LPG: Hu = 25.9 [kWh/m3]
Burner output
[kW]
Boiler output
ηk = 92% [kW]
Position
air flap
[ ° ]
Gas nozzle
pressure
[mbar]
Gas thoughput
[m3/h]
Stage 2 Stage 1 Stage 2 St 2P9St 1P1St 2 St 1 St 2 St1
916 458 843 41.0 3.0 14.0 2.2 36.5 18.2
1000 500 920 45.0 15.0 16.0 3.0 39.8 19.9
1100 550 1012 50.0 20.0 18.0 3.9 43.8 21.9
1200 600 1104 57.0 25.0 19.7 5.9 47.8 23.9
1340 670 1233 90.0 32.0 22.0 8.9 53.4 26.7
MGN2100 M3D Natural gas LL: H
Burner output
Boiler output
Position
air flap
[kW]
ηk = 92% [kW]
[ ° ]
Gas nozzle
pressure
[mbar]
= 9.3 [kWh/m3]
i.n
Gas thoughput
[m3/h]
Natural gas E: H
Gas nozzle
pressure
[mbar]
= 10.4 [kWh/m3]
i.n
Gas thoughput
[m3/h]
Stage 2 Stage 1 Stag 2 St 2P9St 1P1St 2 St 1 St 2 St1 St 2 St 1 St 2 St 1
913 533 840 28.0 6.2 13.0 6.6 104.4 60.9 10.6 5.1 93.4 54.5
1141 620 1050 31.2 10.4 20.4 9.6 130.5 70.9 16.4 7.5 116.7 63.4
1370 685 1260 34.6 14.0 36.6 11.1 156.7 78.3 29.1 8.7 140.1 70.0
1598 793 1470 41.5 21.0 46.1 13.6 182.8 90.8 36.6 10.6 163.4 81.2
1924 1022 1770 48.5 28.0 53.9 15.9 220.1 116.9 42.8 12.9 196.9 104.5
2054 1022 1890 59.0 28.0 68.0 15.9 235.0 116.9 53.8 12.9 210.1 104.5
2148 1022 1976 90.0 28.0 73.5 15.9 245.7 116.9 58.1 12.9 219.7 104.5
14
E. 13.11.06 • G. 21.09.11
MGN2100 M3D LPG: Hu = 25.9 [kWh/m3]
Burner output
[kW]
Boiler output
ηk = 92% [kW]
Position
air flap
[ ° ]
Gas nozzle
pressure
[mbar]
Gas thoughput
[m3/h]
Stage 2 Stage 1 Stage 2 St 2P9St 1P1St 2 St 1 St 2 St1
1060 533 975 28.0 6.0 6.8 1.7 42.2 21.2
1200 600 1104 31.0 9.0 8.3 2.1 47.8 23.9
1500 750 1380 37.0 18.0 11.2 3.5 59.7 29.9
1700 850 1564 43.0 23.0 18.0 4.5 67.7 33.8
1900 950 1748 47.0 26.0 22.0 5.8 75.7 37.8
2148 1080 1976 90.0 29.0 28.6 7.0 85.5 43.0
MGN2500 M3D Natural gas LL: H
Burner output
Boiler output
Position
air flap
[kW]
ηk = 92% [kW]
[ ° ]
Gas nozzle
pressure
[mbar]
= 9.3 [kWh/m3]
i.n
Gas thoughput
[m3/h]
Natural gas E: H
Gas nozzle
pressure
[mbar]
= 10.4 [kWh/m3]
i.n
Gas thoughput
[m3/h]
Stage 2 Stage 1 Stage 2 St 2P9St 1P1St 2 St 1 St 2 St 1 St 2 St 1 St 2 St 1
1359 639 1250 28.0 9.0 21.2 5.6 155.4 73.1 17.1 4.4 139.0 65.4
1630 761 1500 36.0 10.4 44.2 13.3 186.5 87.0 35.1 10.4 166.8 77.8
1848 880 1700 41.5 14.0 58.9 16.4 211.4 100.7 46.6 12.8 189.0 90.1
2174 1000 2000 52.0 17.3 63.9 19.9 248.7 114.4 50.6 15.5 222.4 102.3
2539 1000 2336 90.0 17.3 69.4 19.9 290.4 114.4 54.9 15.5 259.7 102.3
MGN2500 M3D LPG: Hu = 25.9 [kWh/m3]
Burner output
[kW]
Boiler output
ηk = 92% [kW]
Position
air flap
[ ° ]
Gas nozzle
pressure
[mbar]
Gas thoughput
[m3/h]
Stage 2 Stage 1 Stage 2 St 2P9St 1P1St 2 St 1 St 2 St1
1270 639 1168 29.0 6.0 10.0 2.5 50.6 25.4
1500 750 1380 34.0 16.0 14.8 4.3 59.7 29.9
1800 900 1656 40.0 21.0 20.0 5.5 71.7 35.8
2100 1050 1932 49.0 26.0 25.5 6.9 83.6 41.8
2539 1270 2336 90.0 29.0 36.0 10.7 101.1 50.6
MG2800 M3D Natural gas LL: H
Burner output
[kW]
Boiler output
ηk = 92% [kW]
Position
air flap
[ ° ]
Gas nozzle
pressure
[mbar]
= 9.3 [kWh/m3]
i.n
Gas nozzle
pressure
[mbar]
Natural gas E: H
Gas nozzle
pressure
[mbar]
= 10.4 [kWh/m3]
i.n
Gas nozzle
pressure
[mbar]
Stage 2 Stage 1 Stage 2 St 2P9St 1P1St 2 St 1 St 2 St 1 St 2 St 1 St 2 St 1
1533 793 1410 31.2 14.0 20.2 6.8 175.3 908.0 16.3 5.3 156.8 81.2
1913 950 1760 48.5 17.3 33.5 14.9 218.8 108.7 26.8 11.6 195.7 97.2
2359 1100 2170 62.5 21.0 46.7 18.2 269.8 125.8 37.1 14.2 241.3 112.5
2620 1100 2410 76.0 21.0 54.6 18.2 299.6 125.8 43.3 14.2 267.9 112.5
2800 1110 2580 90.0 21.0 59.7 18.2 320.8 125.8 47.3 14.2 286.8 112.5
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15
26 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
16
E. 13.11.06 • G. 21.09.11
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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17
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
18
E. 13.11.06 • G. 21.09.11
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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19
27 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
20
E. 13.11.06 • G. 21.09.11
28 Explosion drawing
ZBZ 2-170.1
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21
29 Spare parts list
Position Benennung VE Art. Nr.
1 Burner tube MG1310, MG2100 1 47-90-12833
1 Burner tube MG2500, MG2800 1 47-90-12834
1 Burner tube extended by 200 mm for MG1310, MG2100 1 47-90-21894
1 Burner tube extended by 200 mm for MG2500, MG2800 1 47-90-21933
2 Flow plate ∅190 for MG 1310 1 47-90-12830
2 Flow plate ∅178 for MG 2100 1 47-90-12831
2 Flow plate ∅204 for MG2500, MG2800 1 47-90-12832
3 Gas nozzle- N 1 47-90-12827
3 Gas nozzle - N for MG2800 1 47-90-22848
3 Gas nozzle- F 1 47-90-25308
4 Ignition electrode 1 36-90-10127
5 Ignition cable 2 47-50-25003
5 Ignition cable extended by 200 mm 2 47-50-25482
6 Gas nozzle elbar 1 47-90-12829
7 Gasket for gas nozzle 5 47-50-12791
8 Gas nozzle completet with electrode (Natural gas) for MG1310 1 46-90-12846
8 Gas nozzle completet with electrode (Natural gas) for MG2100 1 46-90-12847
8 Gas nozzle completet with electrode (Natural gas) for MG2500 1 46-90-12790
8 Gas nozzle completet with electrode (Natural gas) for MG2800 1 46-90-22851
8 Gas nozzle completet with electrode extended by 200 mm (Natural gas) for MG1310 1 46-90-21895
8 Gas nozzle completet with electrode extended by 200 mm (Natural gas) for MG2100 1 46-90-21938
8 Gas nozzle completet with electrode extended by 200 mm (Natural gas) for MG2500 1 46-90-12975
8 Gas nozzle completet with electrode extended by 200 mm (Natural gas) for MG2800 1 46-90-22921
8 Gas nozzle completet with electrode (LPG) for MG1310 1 47-90-22895
8 Gas nozzle completet with electrode (LPG) for MG2100 1 47-90-26152
8 Gas nozzle completet with electrode (LPG) for MG2500 1 47-90-26794
8 Gas nozzle completet with electrode (LPG) for MG2800 1 47-90-26794
8 Gas nozzle completet with electrode extended by 200 mm (LPG) for MG1310 1 47-90-26795
8 Gas nozzle completet with electrode extended by 200 mm (LPG) for MG2100 1 47-90-26796
8 Gas nozzle completet with electrode extended by 200 mm (LPG) for MG2500 1 47-90-26797
8 Gas nozzle completet with electrode extended by 200 mm (LPG) for MG2800 1 47-90-26797
9 Sealing ring for cover 1 47-90-12982
10 Actuator drive SAD 1.5 complete 1 47-90-26383
11 Air flap complete 1 47-90-24464
12 Cover for sight glas 5 47-50-12106
13 Cover 1 47-90-24999
14 Sight glas 1 36-90-11544
15 Holder for KLC 1 47-90-20434
16 Flame detector KLC1000 1 47-90-27184
17 Electronic Transformer 1 47-90-26790
18 Fan wheel ∅ 280 x 80 for MG1310 1 47-90-22579
18 Fan whee ∅ 280 x 100 for MG2100 1 47-90-22580
18 Fan whee ∅ 280 x 110 for MG2500 1 47-90-22881
18 Fan whee ∅ 290 x 114 for MG2800 1 47-90-22850
19 3 kW motor for MG1310 1 47-90-12802
19 4 kW moto for MG2100 1 47-90-12803
19 4,5 kW motor for MG2500 1 47-90-12804
19 5,5 kW motor for MG2800 1 47-90-22876
20 3 kW motor complete with fan wheel for MG1310 1 47-90-26791
20 4 kW motor complete with fan wheel for MG2100 1 47-90-26798
20 4,5 kW motor complete with fan wheel for MG2500 1 47-90-26800
20 5,5 kW motor complete with fan wheel for MG2800 1 47-90-26801
21 4-pole female connector, green 1 37-90-20744
22 7-pole female connector, black/brown 1 37-90-20731
23 Control box MPA 22 1 47-90-24166
24 Star-delta starter YKB7-30 1 47-90-25176
25 Thermal relay 2,4 - 4,0 A (Star-delta) for MG1310 1 47-90-24172
25 Thermal relay 4,0 - 6,0 A (Star-delta) for MG2100, MG2500 1 47-90-25173
25 Thermal relay 6,0 - 9,0 A (Star-delta) for MG2800 1 47-90-25174
26 7-pole female connector, green 1 37-90-10831
27 3-pole female connector, black 1 37-90-20739
28 Terminal box cover 1 47-90-25206
29 MPA display AM07 1 47-90-24167
30 Facing panel 1 47-90-24887
31/33/35 Gasket completet 1 47-90-26792
32 Gas jacket part 2, completet 1 47-90-12771
34 Gas jacket part 1, completet 1 47-90-12770
36 Securing rod 2 46-50-12809
37 Differerntial 1 47-90-26723
40 Thermal relay (overload) 6,0 - 9,0 A for MG1310 1 47-90-25174
40 Thermal relay (overrload)9,0 - 12,0 A for MG2100, MG2500, MG2800 1 47-90-25175
41 Motor contactor B7-30-10 1 47-90-25171
- Fan inlet device 1 47-90-12785
- Protective screen 1 46-90-12992
22
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E. 13.11.06 • G. 21.09.11
23
Enertech Limited,
P O Box 1,
Vines Lane
Droitwich,
Worcestershire,
WR9 8NA
Tel: +44 (0) 1905 794331 Fax: +44 (0) 1905 794017
Email: info@nu-way.co.uk Web: www.nu-way.co.uk
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