Technical Information • Installation Instructions Oil / gas

Technical Information • Installation Instructions
MK2
Issue March 2012
As our policy is one of continuous
improvement we reserve the right to
make technical modifications!
Oil / gas
GB
Contents
1. General information ............................................................................................................. 3
2. Scope of delivery .................................................................................................................. 3
3.
4.
5.
6.
Maintenance and customer service.....................................................................................
Operating instructions .........................................................................................................
Instruction of operating personnel .......................................................................................
Key for code designation .....................................................................................................
3
3
3
4
7.
8.
9.
10.
Technical specifications ........................................................................................................ 4
Boiler connection dimensions .............................................................................................. 4
Ignition electrode .................................................................................................................. 5
Flame monitor....................................................................................................................... 5
11.
12.
13.
14.
Oil connection....................................................................................................................... 6
Oil pump ............................................................................................................................... 7
External oil pump (option) .................................................................................................... 8
Front panel ........................................................................................................................... 8
15. Air flap positioning motor .................................................................................................... 8
16. Remote switching ................................................................................................................. 8
17. Air pressure switch .............................................................................................................. 9
18.
19.
20.
21.
Gas pressure monitor ........................................................................................................... 9
Functional control ................................................................................................................. 9
Start-up............................................................................................................................... 10
Troubleshooting / process description ................................................................................ 14
22.
23.
24.
25.
Control unit ........................................................................................................................ 19
MPA 22 control unit display ................................................................................................ 19
Calculation principle for gas burner adjustment ................................................................ 20
Gas burner with gas train KEV II1 ½" , KEV 2" and KEV DN65 ........................................ 21
26. Gas burner with gas train KEV25 1", KEV30 1½", KEV45 2"
and KEV45 DN 65 .............................................................................................................. 22
27. Nozzle selection diagram ................................................................................................... 23
28. Circuit diagram ................................................................................................................... 24
29. Terminal diagram connector pin assignments .................................................................... 34
30. Adjustment tables ............................................................................................................... 35
31. Adjustments log .................................................................................................................. 37
32. Exploded views / spare parts lists ...................................................................................... 38
33. Declaration of conformity for dual-fuel burner for heating oil
and natural gas or liquid gas ..................................................................................................... 45
34. Overall dimensions ............................................................................................................ 46
E. 28.01.09 • G. 28.03.12
35. Working ranges .................................................................................................................. 46
2
1. General information
Installation of a combined gas/oil burner must be performed in accordance with extensive regulations and
guidelines. It is therefore the duty of the installer to be familiar with all applicable regulations and requirements. Installation, start-up and maintenance must be performed with utmost care.
The burner must not be operated in rooms with high levels of air humidity (laundry rooms), dust or corrosive
vapours. The boiler room must be ventilated accordingly with ventilation air.
Heating oil EL in accordance with DIN 51603 must be used.
The burners are suitable for combustion of natural gas or liquid gas and are in compliance with European
standard DIN EN 676.
2. Scope of delivery
Before installing the GIERSCH Series MK2 combined gas/oil burner, please check that all the items included in the scope of delivery are present.
Scope of delivery:
burner, mounting kit, separate operating instructions, technical information, separate circuit diagram, flange
seal, one 7- pin connector and one 4- pin plug connector (Wieland connector).
Caution !
Oil nozzles are not included in the scope of delivery.
For gas:
Gas train
Gas installation and commissioning are subject to the applicable Technical Regulations of the DVGW
(DVGW-TRGI).
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 as well as 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 fittings
3. Maintenance and customer service
The complete system should be checked once a year for correct functioning and leaks in accordance with
DIN 4755 by a representative of the manufacturer or other suitably qualified person.
According to DIN EN 267 it is not permissible to perform repairs on components with a safety function. On
the other hand, the replacement of parts with genuine parts or approved equivalent parts is permitted.
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.
E. 28.01.09 • G. 28.03.12
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.
3
6. Key for code designation
MK 2-Z(-M)-L
air damper
Luftabschlussklappe
two-stage orgleitend
modulating
Zweistufig
Baugröße
burner type
Baureihe
burner series
7. Technical specifications
Burner type
Technical specifications
Burner output in kW
(in gas-fired operation)
Burner output (in oil-fired operation)
in kg/h
(in kW)
Fuel
MK2.1
MK2.2
280 - 760
415 - 1070
23.6 - 64.1
(280 - 760)
39.5 - 90.2
(469 - 1070)
Heating oil in accordance with DIN 51603,
natural gas LL + E, liquid gas
Mode of operation
Optionally oil/gas two-Stage or gas modulating, oil two-Stage
Voltage
3 / N / PE ~ 50 Hz / 400 V
Power consumption at start / during operation *
6.5 A max./ 3.6 A eff.
Electric motor power (at 2800rpm) in kW
1.1
Flame failure control unit
2.2
KLC 1000
Control box
MPA 22
* The power consumption of the version with external oil pump is 2.7 A higher.
8. Boiler connection dimensions (All dimensions are given in mm)
10
M
E. 28.01.09 • G. 28.03.12
Ø220
Ø250 - 290
4
9. Ignition electrode
The following clearances between the nozzle and ignition electrode should be observed:
The given dimensions are intended for checking purposes after making necessary corrective adjustments
or replacing an electrode.
Oil nozzle, Stage 1
4 mm
Ignition electrode
Oil
Gas ignition electrode
Oil nozzle, Stage 2
27 mm
Gas ignition
electrode
13 mm
10. Flame failure control unit
During commissioning and after any cleaning maintenance, the flame detector should be checked.
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.
E. 28.01.09 • G. 28.03.12
• 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.
5
Operating Indicator LED
The flame detector KLC 1000 indicates the following operating conditions and flame signal strengths via
the built-in LED..
No burner operation
LED is OFF
No heating request
Pre-ventilation
LED is OFF
No flame present
Burner operation
LED is flashing
Flame present
Clean the sight glass of the KLC 1000 with a clean, lint-free cloth. Under no circumstances may burner
clean-ing sprays be used. Further tests are not necessary because internal checks are carried out on
KLC 1000.
11. Oil connection
Oil lines must be routed to the burner as far as necessary to allow the oil hoses to be connected without
tension. Care must be taken to ensure that the burner can easily be moved into the service position.
Important: an oil filter must be installed before the oil pump.
The tables for single and double line installation show the maximum possible pipe length in dependence
on 3 factors with reference to heating oil type EL 4.8 cST.
• Height differential between pump and tank,
• nozzle delivery rate or pump type,
• pipe diameter.
4 brackets, 1 valve and 1 check valve for resistance were factored into the suction line length. Due to possible degassing of the oil, dimension "X" should not exceed a length of 4 m.
Double line system
Suntec AJ4
L (m)
H (m)
10
23
12
49
14
91
16
100
3.0
2.0
20
17
43
37
80
69
100
100
1.0
0.5
14
13
31
28
58
53
100
91
0
-0.5
11
10
25
22
47
42
81
72
-1.0
-2.0
9
6
19
13
36
25
62
43
-3.0
-4.0
3
-
7
-
14
-
24
5
E. 28.01.09 • G. 28.03.12
∅ mm
4.0
6
Single-pipe system
Nozzle
14 (gph)
20 (gph)
30 (gph)
45 (gph)
.∅ mm
8
10
12
8
10
12
14
10
12
14
16
10
12
14
16
H (m)
L (m)
L (m)
L (m)
L (m)
L (m)
L (m)
L (m)
L (m)
L (m)
L (m)
L (m)
L (m)
L (m)
L (m)
L (m)
4.0
21
52
100
14
36
75
100
23
49
92
-
15
32
61
100
3.0
18
45
95
12
31
66
100
20
43
81
-
13
28
53
92
2.0
16
39
82
11
27
57
100
17
37
70
-
11
24
46
79
1.0
13
33
69
9
23
48
89
15
31
59
-
9
20
38
66
0.5
12
30
62
8
20
43
81
13
28
53
-
8
18
35
60
0
11
27
56
7
18
39
72
12
25
48
82
7
16
31
54
-0.5
9
23
49
6
16
34
64
10
22
42
72
-
14
27
47
-1.0
8
20
43
5
14
30
55
9
19
36
63
-
12
23
41
-2.0
5
14
30
3
10
21
39
6
13
25
44
-
8
16
28
-3.0
3
8
17
-
5
11
22
3
7
14
25
-
4
8
15
-4.0
-
-
4
-
-
-
5
-
-
-
5
-
-
-
-
12. Oil pump
Oil lines must be routed to the burner as far as necessary to allow the oil hoses to be connected without
tension. Care must be taken to ensure that the burner can easily be moved into the service position.
Important: an oil filter must be installed before the oil pump.
4
Suntec oil pump
3
1 Supply
2 Return
3 Nozzle connection
4 Pressure gauging connection
5 Vacuum gauging connection
6 Pressure setting
6
5
2
E. 28.01.09 • G. 28.03.12
1
To change over the pump for single line operation, the following points should be noted: disconnect return
line and remove connecting nipple. Unscrew the bypass plug in the return line port and tightly seal the port
with a sealing plug. The pump suction flow will then be identical to the flow rate through the nozzle.
7
13. External oil pump (option)
7
2
5
6
3
1
4
1 Three-phase a.c. motor connecting cable
2 Oil pump power cord
3 Oil pressure switch connecting cable
4 Pressure line to burner
5 Oil pressure switch
6 Oil pressure setting screw
7 Oil pump
The external oil pump is supplied for burners which primarily
operate in gas burning mode.
In oil burning mode, the pump starts when a heating request
is issued. Oil pressure switch (5) is fitted for pressure monitoring. In the event of loss of oil pressure, the burner shuts
off automatically. The oil pressure switch is pre-set at the factory. Pressure can be adjusted using the setting screw (6).
14. Front panel
Control unit (option)
On/Off
Display and operating unit AM01
Selector switch
Oil operation/gas-fired operation
15. Air flap positioning motor
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.
Caution
The housing must not be opened while the power
is on, as the incident light will cause irreparable
damage to the drive.
Note
If the selector switch under the burner hood is in the "Remote" position, it is not possible to change over
between oil and gas operation with the selector switch on the front panel. It is only possible to change over
between oil and gas operation if the selector switch under the burner hood is in the "Manual" position.
8
E. 28.01.09 • G. 28.03.12
16. Remote switching
17. Air pressure switch
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 to 8 mbar.
Note
In the event of low air pressure, check to see if CO levels were above the stipulated value before the burner
reached its shut-off point.
Possible causes:
- Incorrect setting
- Motor is not running
- Motor is rotating in the wrong direction.
18. Gas pressure monitor
The gas pressure monitor 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. Initially set half the inlet pressure. Check for CO formation. For
this purpose, reduce the gas inlet pressure and check the CO concentration. The CO concentration must
be below the stipulated value.
19. Function test
The flame monitor must undergo a safety test both at initial start-up and after modifications or if the system
has been out of use for a lengthy period of time.
Start-up test with blacked-out flame sensor:
The burner must go into lockout mode on expiration of the safety interval.
Start-up with exposed flame sensor:
The burner must go into lockout mode after approx. 20 s of pre-ventilation.
E. 28.01.09 • G. 28.03.12
to ISO standards. Start-up; if the burner is in operation, cover the flame sensor:
New start-up attempt; on expiration of the safety period, the burner must go into fault mode.
9
20. Commissioning: Adjustment mode - oil-fired operation
To enter this adjustment mode, the burner must be on standby.
Standby means that the burner is connected to the power supply, but no heating request has been issued and the burner is switched to oil-fired operation.
If OFF appears on the display on MPA 22, the unit is running in standby mode
and has already been configured.
OFF
OFFUPr
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:
2
1
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.
2
- Confirm your entry by pressing key 2 once.
- Press the minus key once.
2
- Confirm your entry by pressing key 2 twice.
- Press the plus key 4 x.
2
- Confirm your entry by pressing key 2 once.
- Press the plus key twice.
2
- Confirm your entry by pressing key 2 once.
- Press the plus key 3 x.
2
- 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, EOIL appears on the display.
E OIL
or
9 OIL
P
2
and
L/A
or
Step 4:
the operating points 9OIL (Stage 3), 3OIL (Stage 2) and 1OIL (Stage 1) can
now be selected by pressing the plus or minus key.
Step 5:
After Stage 3 has been selected, 9OIL appears on the display. The Stage 3
operating point can be adjusted to values between 0° and 90° by holding down
key 2 and optionally pressing the plus or minus key.
Note: The setting value for Stage 3 should be set to a value 0.1° greater than
the value for Stage 2!
10
E. 28.01.09 • G. 28.03.12
P
3 OIL
P
2
and
or
1 OIL
P
2
and
0 OIL
and
2 OIL
and
4 OIL
0 OIL
P
and
E. 28.01.09 • G. 28.03.12
1
L/A
or
P
2
L/A
or
P
2
L/A
or
P
2
L/A
L/A
L/A
or
and
2
Step 6:
After you have set Stage 3, press the plus key to set Stage 2 . 3OIL appears
on the display.
The Stage 2 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 Stage 2, press the plus key to set Stage 1. 1OIL. appears
on the display.
The Stage 1 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 8:
After you have set Stage 1 , press the plus key to set the ignition point P0.
0OIL. appears on the display.
The ignition point P0 can be adjusted to values between 0° and 90° by holding
down key 2 and optionally pressing the plus or minus key.
Step 9:
After you have set the ignition point P0 , press the plus key
to set the Stage 1 / 2 switch-over point. 2OIL. appears on the display.
The Stage 1 / 2 switch-over point can be adjusted to values between 0° and
90° by holding down key 2 and optionally pressing the plus or minus key.
Step 10:
After the Stage 1 / 2 switch-over point has been set, press the plus key. 4OIL
of the Stage 3 / 3 switch-over point appears on the display. The setting value
should be at Stage 3. Press the plus key again. OIL.
appears on the display.
Close the safety loop. 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
the ignition point under Step 8.
Step 11:
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 Stage 1, Stage 2, Stage 3 (0.1° greater
than Stage 2), Stage 1 /2 switch-over point, Stage 3 / 4 switch-over point (0.1°
greater than Stage 2) 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 Stage 1 and then returns to normal operation. The setting procedure is now
completed and the values have been stored.
Note:
If you want to change values after finishing the setting procedure, you will have
to start from the beginning again, i.e. OFF.
Note: faults are cleared by pressing the enter key.
11
Adjustment mode - gas-fired operation
To enter this adjustment mode, the burner must be on standby.
Standby means that the burner is connected to the power supply, but no heating request has been issued and the burner is switched to gas-fired operation.
If OFF appears on the display on MPA 22,
the unit is running in standby mode and has already been configured.
OFF
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.
OFFUPr
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:
2
1
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.
2
- Confirm your entry by pressing key 2 once.
- Press the minus key once.
2
- Confirm your entry by pressing key 2 twice.
- Press the plus key 4 x.
2
- Confirm your entry by pressing key 2 once.
- Press the plus key twice.
2
- Confirm your entry by pressing key 2 once.
- Press the plus key 3 x.
2
- Confirm your entry by pressing key 2 once.
- Press the minus key 4x.
- Press the enter key once.
Password entry is now finished.
Pn
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.
or
9GAS
P
2
and
Step 3:
after the correct password has been entered, EGAS Pn appears on the display.
L/A
or
Step 5:
After the operating point P9 has been 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.
E. 28.01.09 • G. 28.03.12
P GAS
12
1GAS
P
2
and
or
0GAS
P
2
and
0GAS
P
and
Pn
L/A
or
or
1GAS
P
2
L/A
or
P GAS
2
L/A
and
L/A
Step 6:
After you have set P9, press the plus key to set P1. 1 Gas appears on the display.
The min load operating 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.
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 starting point can now be adjusted to values 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 loop 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.
or
or
9GAS
2
P
L/A
and
or
and
2
E. 28.01.09 • G. 28.03.12
1
13
21. Troubleshooting / process description
Defect determined:
Cause:
Remedy:
Burner motor does not start Electric supply lead faulty
up
Fuse faulty
Safety thermostat locked
Rectify faults in electrical installation
Replace
Unlock
42 h
Temperature of control unit setting is
exceeded
MPA 22 faulty
Renewed start attempt after temperature
drop
Replace
Leak
No gas
Rectify leak
Safeguard gas supply
Gas pressure monitor faulty
Replace compact unit or gas pressure
switch
Filter in gas train dirty
Air pressure switch not in idle position
Clean or replace
Check air pressure switch (see page 8)
20 h
Burner motor faulty
Replace
Rectify faults in electrical
installation
See Page 8
21 h
Mains voltage < 187 V
Burner starts up and switAir pressure switch does not switch
ches to fault mode before or through during pre-ventilation
on expiration of the safety
Fault: external light
period
Gas solenoid valve does not open
See Page 5
Replace gas train
Starting gas quantity set too low
No ignition
Increase starting gas quantity
Check ignition electrode and setting, ignition transformer and cable
Phase and zero mixed up
Connect connector unit in correct phase
sequence
Check according to Page 5
Flame control faulty
Air pressure switch opens during opera- See Page 8
tion
04 h
44H / 43H
22 h
26 h
2BH
21 h
Gas nozzle dirty or faulty
No gas / oil
Clean or replace gas nozzle
Safeguard gas supply
Filter in gas train
dirty
Flame blow-off
Clean or replace
Incorrect burner setting
27 h
Air pressure switch contact opens
Flame signal too weak
Check/replace air pressure switch
Measure flame signal (see page 5)
21 h
27 h
E. 28.01.09 • G. 28.03.12
Flame extinguishes
during operation
Fault code
14
Service mode - pneumatic gas-fired operation
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 positioning motor setting value at ignition in angular degrees, plus a wrench
symbol denoting the service mode.
Adjustment
point
Adjustment
values
Service mode
symbol
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 control unit 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.
display
value
Adjustment Information mode symbol
point
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.
E. 28.01.09 • G. 28.03.12
0 = fuel consumption
1 = total operating hours
2 = for oil only
3 = for oil
only 4 = number of successful start-ups
5 = display of software version
6 = software creation date
7 = hardware number
8 = date of production
15
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
16
E. 28.01.09 • G. 28.03.12
Troubleshooting the MPA
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
Fault message NoID:
If this fault message appears, this means that the internal parameter values of
the MPA have been altered by external influences.
NoID
To change the setting parameters, carry out the following steps:
1
2
Step 1:
Press keys 1 and 2 simultaneously for approx. 2 seconds.
Step 2:
7 horizontal bars are now displayed. Enter the password.
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.
Step 3:
Confirm the password. Press keys 1 and 2 simultaneously for approx. 2 seconds.
1
2
Step 4:
Select control box type MPA 22.
Step 5:
Confirm your input by simultaneously pressing keys 1 and 2.
E. 28.01.09 • G. 28.03.12
1
2
If you are unable to perform a reset, replace the unit. To determine the cause
of the fault within the immediate vicinity of the burner, please contact the manufacturer.
17
Description of procedure for gas-fired operation:
Start-up tests
State 01
State 02
State 03
State 04
State 05
State 06
State 07
State 08
State 09
State 10
State 11
State 12
State 13
State 14
State 15
State 16
State 17
State 18
State 20
Process and program memory test / ramp actuator drives to reference point
Start-up decision (heating request issued)
Blower idle state check
Blower start-up
Pre-ventilation
Pre-ventilation / activate and test watchdog
Pre-ventilation
Air drive unit to ignition position
Pre-ignition depending on parameter
Start-up safety period
Stabilisation period
Ramp actuator drive from ignition point to operating characteristic, controller enable time
Operation
VPS - Evacuate valve cavity / (post-vent)
Test period Y2 / ( residual post-ventilation time )
VPS - Fill valve cavity / (residual post-ventilation time)
Test period Y3 / (residual post-ventilation time)
Residual post-ventilation time
Restart inhibit period / wait loop for low gas program
Standby setting
Description of procedure for oil-fired operation:
State 12
State 17
State 18
State 20
Processor and program memory test / ramp actuator drives to reference point
Start-up decision (heating request issued)
Blower idle state check
not used
Load watchdog
Activate and test watchdog
Pre-ventilation
Ramp air drive unit to ignition point
Delay until ignition point
Start-up safety period
Stabilisation period
Ramp actuator drive from ignition point to operating characteristic,
controller enable time
Operation
Residual post-ventilation time
Restart inhibit period
Standby setting
E. 28.01.09 • G. 28.03.12
Start-up tests
State 01
State 02
State 03
State 04
State 05
State 06
State 07
State 08
State 09
State 10
State 11
18
22. Control unit MPA 22
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.
Gas certification
EU type test approval according to EU Gas Appliance
Directive.
MPA 22 CE-0085AU316
23. MPA 22 control unit display
Start-up
Lights up during
the run-up phase,
OFF during
operation
Lights up when the
gas-flow control Symbols for
flap is active
open/close flaps
Lights up when the
Liquid-crystal
air-flow control
display
flap is active
h = Operating hours indicator
l, m3 = Oil or gas consumption
h
l,m3
On when
setup mode
is selected
P
S
i
G
L/A
+
Lights up when
service mode
is active
Fault
Operation, flame burning
2
1
Key 1
Actuation of gasflow control flap
in conjunction
with +/- key
Key 2
Actuation of airflow control flap
in conjunction
with +/- key
E. 28.01.09 • G. 28.03.12
Acknowledgment or reset
key
19
–
On when
information
mode is active
Key + / Key In conjunction
with key 1 or 2
24. Calculation principles for gas burner adjustment
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 (Hi,n) of fuel gases is generally specified for the normal state (0°C, 1013 mbar).
Natural gas type E
Hi,n = 10.4 kWh/m3
Natural gas type LL
Hi,n = 9.3 kWh/m3
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 m.s.l.
230 m
barometric air pressure B (acc. to table)989 mbar
gas pressure PG at meter
20 mbar
gas temperature ϑG
16°C
430 kW
boiler output Qn
efficiency hK (assumed)
90%
calorific value Hi,n
10.4 kWh/m3
Gas flow in standard state (Vn)
3
Qn
430kW
m
Vn = -------------------- = ---------------------------------------- = 46 -----η k × H i, n
kWh
h
-----------
0, 90 × 10, 4
m3
Gas flow in operating state (V B)
3
m
-----46
3
V
h
m
V B = -----n- = ------------- = 49 -----0, 94
f
h
Conversion factor (f)
B+P
273
f = --------------G × -------------------1013 273 + ϑG
Annual average air pressure
Mean geodetic altitude of the
supply region above m.s.l. [m]
Annual average of air pressure
from
1
51
101
151
201
251
301
351
401
451
501
551
601
651
701
50
100
150
200
250
300
350
400
450
500
550
600
650
700
750
(mbar) 1016 1013 1007 1001 995
989
983
977
971
965
959
953
947
942
936
930
to
0
E. 28.01.09 • G. 28.03.12
Legend:
Qn = boiler output [kW]
hK = efficiency [%]
Hi,n = lower standard calorific value [kWh/m3]
f=
conversion factor
B = barometric air pressure [mbar]
pG = gas pressure at gas meter [mbar]
ϑG = gas temperature at gas meter [°C]
20
25. Gas burner with gas train KEV II1 ½" , KEV 2" and KEV DN65
Installing the gas train
Installation position
only in horizontal line, not tilted.
Minimum distance to walling:
20 mm
Screw the measuring nipple for combustion chamber pressure into the gas jacket at the top.
Route the connecting hose between the measuring nipple for combustion chamber pressure and the gas train in a loose loop.
The air pressure connection nipple must be screwed into the gas jacket at the top.
Cover plate for
Adjustment screws
SKP 75
"AIR" air pressure connection
Detail
SKP 15
Pulse line pG
Burner
VGD
Measuring socket
adjustment
Gas connection
Gas pressure monitor
(gas inlet pressure)
f
tion o
Direc
Gas pressure monitor
for leak check
flow
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.
E. 28.01.09 • G. 28.03.12
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 according to 24.
Adjustment tables. Follow the setting procedure described in 22. Adjustment mode for pneumatic gasfired 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 high-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 24. 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 24. 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.
21
26. Gas burner with gas train KEV25 1", KEV30 1½", KEV45 2" and
KEV45 DN 65
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.
Route the connecting hose between the air pressure measuring nipple and the gas train in a loose loop.
The air pressure connection nipple must be screwed into the gas jacket at the top.
V
N
pG
Pulse line pG
Gas pressure monitor
(gas inlet pressure)
Gas pressure monitor
for leak check
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.
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 24. 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 24. 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.
22
E. 28.01.09 • G. 28.03.12
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 according to 24.
Adjustment tables. Follow the setting procedure described in 22. Adjustment mode for pneumatic gasfired 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.
27. Nozzle selection diagram
If the desired output deviates from the values specified in the tables, the nozzle size and the pump pressure
can be determined on the basis of the following diagram.
Burner
Brenneroutput
leistung
[kW]
[kW]
2100
1800
1500
1300
1100
960
850
750
650
540
480
370
320
ÖlOil
durchsatz
throughput
[kg/h]
[kg/h]
200
Nozzle
Düsensize
größe
[gph]
[gph]
160
140
30
28
26
24
22
120
110
20
18
100
90
80
16
15
14
13
70
12
11
10
60
9
50
8
7,5
7
6,5
6
5,5
5
40
30
4,5
250
4
20
200
3,5
160
3
2,75
2,5
130
110
10
9
10
11
12
13
14
15
16
17
18
19
20
E. 28.01.09 • G. 28.03.12
Oil
pump pressure
[bar]
Pumpendruck
[bar]
23
28. Circuit diagram
PE
Fault (S3)
1
Valve 1
Operation (B4)
Control chain (T1,T2)
Valve 2
2
N
Valve 3
3
Power control unit
(T6, T7, T8)
6
7
GWmin.
8
GWVPS
9
Gas/oil coding plug
12
KLC 1000
10
Air pressure switch
Pulse counter
13
Safety chain
11
L1
PE
N
L1
5
Ignition transformer
Mains (PE)
4
Blower motor
14
15
Actuator drive
Air flap
16
17
e-Bus
E. 28.01.09 • G. 28.03.12
Display
24
Key:
X122
X123
X140
X141
X142
X150
E. 28.01.09 • G. 28.03.12
B7
F2, F5
F3
F4
F11
KLC 1000
Motor protection switch
Safety temperature limiter
Air pressure switch
ext. boiler controller fuse 6.3 AT /
max 10 AF
F12
ext. temp. controller
F51
Gas pressure monitor
F52
Leak monitor
F60
Oil pressure switch
H11
ext. status lamp
H13
ext. fault indicator lamp
K1
Motor contactor
K2
Remote release solenoid actuator
K3, K4
Isolating relay
K9
Run-on relay
KM1
Star contactor
KM5
Motor contactor ext. Oil pump
M1
Burner motor
M2
External oil pump motor
Q1
Heater power switch
S1
Control box MPA 22
S3
ON/OFF switch with indicator lamp
S9
Manual/remote switch
S10
Gas/oil switch
S16
Stored program controller
T2
Ignition transformer (gas)
T3
Ignition transformer (oil)
X11,X31 Boiler controller plug
X12,X32 Burner socket
X13
7-pin plug on MPA
X33
4-pin plug on MPA
X41
Plug for compact unit
X42
7-pin socket for burner
X61
Plug for oil solenoid valve
X62
socket for oil solenoid valve
X63
Plug for oil solenoid valve Stage 2
X64
Socket for oil solenoid valve Stage
2 X65
Plug for safety solenoid valve
X66
Socket for safety solenoid valve
X71
Plug for oil ignition transformer
X72
Socket for oil ignition transformer
X73
Plug for gas ignition transformer
X74
Socket for gas ignition transformer
X81, X91 Terminal strip
X84
Terminal strip for 3-phase
AC connection
X85
Two-pin coding plug MPA
Two-Stage/modulating
X86
Two-pin coding socket MPA
Two-Stage/modulating
X90
Terminal strip
X112
ext. socket SV/gas pressure monitorLeak monitor
X113
Gas pressure monitor plug Leak monitor
X121
Motor terminal plug
X151
X152
X153
Y2
Y3
Y6
Y7
Y8
25
Burner motor connection socket
Motor activation plug MPA
Coding plug MPA
Actuator drive plug
Operating unit plug
Motor plug ext. Oil pump
pump side
ext. motor socket Oil pump, pump side
Oil pressure switch socket
Oil pump, pump side
Oil pressure switch plug
Oil pump, pump side
Gas solenoid valve
Gas safety solenoid valve Stage 2
Oil solenoid valve
Oil solenoid valve Stage 2
Safety solenoid valve
Circuit diagram page 1
S1
K2.12
X13
P
E
2
1
MPA22
1 valve
4
3
1
B4
6
X81.6
S3
S3
5
X81.5
T2
T2
4
S16.Q4/2
T1
T1
3
X81.2
N
N
2
X81.N24
PE
PE
L1
L
1
19
2 valve
7
6
5
2
K2.11
B4
b
4
K3.9
S3
on/off
switch
1b
b
bk
1a
1
bn
K1.10
5
K1.9
6
1
L1
X113
F4
airpressure
monitor
X112
PE
2
N
2(NO)
2
P
3(COM)
1
4 blower
5 ignition
y/gn
SPS.PE
1
S16.Q1/2
X81.12
T8
T8
5
T7
T7
4
T6
T6
1
B5
B5
X81.11
X81.9
18
6 supply
1
7
8
safety chain
gaspressure min
oilpressure min
13
9
gas tightness
control
12
air-pressure
10 monitor
11
X81.12
x33
X81.8
2
K6
3
A1
A2
12
11
6
14
b
X85
X86
KM1.A2
3 valve
1 2 3 4 5 6 7 8 9
bn
F2.95
31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10
9
8
3
K2.10
2
X81.N24
b
B3
bk
bn
Option
321
B7
bn
14
15
16
17
X81.1
X143
X142
eBus
connection
display AM01
E. 28.01.09 • G. 28.03.12
X141
servo motor SAD
SP_1-527.1
X140
coding plug gas/oil
26
Circuit diagram page 2
Y6
T2
gas
T3
oil
N
X61 L1 PE N
X71 L1 PE N
L1 PE N X73
X64 L1 PE N
X66 L1 PE N
X62 L1 PE N
X72 L1 PE N
L1 PE N X74
X81.N25
b
X81.N25
bn
X81.PE
X81.PE
max. 10 A fast
H13
H11
b
X81.N25
B4 S3
T2
T1
N
PE
L1
X11
B4
S3
T2
T1
N
PE
L1
X12
6
5
4
3
2
gn/ye
1
b
X81.N24
bn
F3
υ
X65 L1 PE N
b
υ
F11
F21
X63 L1 PE N
b
230V
Y7
L1
50Hz
Q1
oil
Y8
X81.N24
X81.PE
X81.PE
X81.PE
K6.A1
X33/T8
X33/T7
X41
K3.10
X42
L1
K3.12
PE
N
T6 B5
T7
T8
2
5
1
3
X33/T6
K3.4
4
K3.11
B7.3
Y6.PE
b
X81 PE PE
T3.N
Y6.N
Y8.N
T3.PE
T2.N
K7.A2
bn bn bn
b
3
5
4
2
8
N N N
20 19 18 17 16 15 15 14 13 12 12 11 10 9
26 25 25
1
9
4
8
7
b
bn
6
6
5
4
3
2
1
1
b
PLC.PE
b
1 N N N N
P P P
E E E
24 24 24 24
1
b
5 bn bk 3
2
7
8
5
1
3
7
6
6
5
bk 3
bk bk b
2
2
Y7.PE
Y8.PE
T2.PE
X84.PE
2
1
X151.PE
3
X13.N
K2.1
K6.A2
Y7.N
S16.N
K2.5
S16.L
K1.1
S9.1
K1.2
X13/T1
K2.3
S16.Q4/1
K2.2
X13/S3
K2.7
X13/B4
K2.8
K6.14
X32 X31
K3.5
B5
B5
T6
T6
T7
T7
T8
T8
K3.1
K3.3
E. 28.01.09 • G. 28.03.12
K3.7
27
Externe
Steuerung
stufig oder
modulierend
Circuit diagram page 3
change-over with
230V AC 50 Hz from
switchgear cabinet
X81.1
1
bk
bk
change over
switch
S9
manual /
remote
1
change over
switch oil /
gas
1
2
K4
14
A2
S10
2
A1
11
X81.N24
bk
K2.9
X81.1
bk
2
bk
bk
b b
L1 N N I1
I2
I3
S16
I4
I5
I6
I7
I8
ABB PLC
Q1
Q2
1
2
1
bk
1
bk
Q3
2
1
bk
bk
Q4
2
1
2
bk
bk
bk
X13/L1
F5.95NC
KM1.A1
X81.15
S1.14
4
X81.3
X13/T2
X81.18
bk
X81.16
X140 6 5 4 3
X81.17
X84.4
X81.19
X84.5
X81.20
X81.8
X81.11
X81.12
X81.N 25
bk
X81.14
X81.13
X81.N 26
y
gr bn bn bk b bn
8
gn
8
4 7
3
6
2
5
1
5 1
A1
8
4
7
3
6
2
5
1
A1
K2
12
11
10
12
9
11
1
bk
5
b
S1.8/23
S1.8/25
10
4
7
3
6
2
1
5
1
2
A2
9
3
12
b
S1.1/2
S1.2/5
S1.3/8
11
8
b
6
8
bk 5
3
K3
A2
A2
S16.N
2
4 7
K1
b
3
10
6
9
2
4
S1.5/14
X81.10
X81.7
X81.9
E. 28.01.09 • G. 28.03.12
A1
7
28
Circuit diagram page 4a (gas train SKP)
F51
gas-pressure monitor
GAS
Y2
Y3
PE
PE
SKP70
SKP10
LN
LN
NC/2
NO/1
1 2 3 4 5 6
1 2 3 4 5 6
1 2
1 2
COM/3
P
PE
1
X41
T6
2
L1 B5
T8
N
PE
T7
X42
1
L1
PE
2
NO/1
NC/2
COM/3
tightness
control
F52
P
E. 28.01.09 • G. 28.03.12
PE
29
N
X113
X112
Circuit diagram page 4b (gas train CG)
gas
F51
gas-pressure monitor
2
1
X41
T6
Y3
CGV / MBC
P
PE 1
Y2
3
2
L1 B5
PE 1
2
3
3
1
y/gn
2
T8
N
PE
T7
X42
1
L1
PE
2
NO/1
NC/2
X113
X112
N
COM/3
tightness
control
F52
P
E. 28.01.09 • G. 28.03.12
PE
30
Circuit diagram page 5
blower motor
Sicherungen extern 16 A
L1 L2 L3
PE
X121
L1 L2 L3
N PE
X122
L1 L2 L3
N PE
1
X84
2
bk
KM5.L2
bk
bk
KM5.L1
L1 L2 L3
PE
X81.PE
L1
L2
L3
T1
T2
T3
A2
95
F2
T2
2
U1
V1
T3
3
W1
M1
3
E. 28.01.09 • G. 28.03.12
1,1 kW 2,7 A
2,2 kW 4,6 A
b
bk
bk
A1
T1
1
bn
S16.Q
2/1
KM1
1,1 kW Motor
2,4 - 4 A
2,2 kW Motor
4-6A
S1.4/13
y/gn
3
bk bk bk
KM5.L3
S1.4/11
31
96
Circuit diagram page 6
SAD 1.5
servermotor
X141
S1.15
Circuit diagram page 7
Display AM01
Enertech
S1.16
32
E. 28.01.09 • G. 28.03.12
X142
Circuit diagram page 8
connection external oilpump
bk
bk
bk
bk
A1
L1
L2
KM1.L1
KM1.L2
KM1.L3
L3
KM5
T1
T2
T3
A2
K1.6
K1.5
bn
b
4
5
1
2
b
X84
X81.N24
PE
S16.Q2/2
bk
95NC
1,1 kW Motor
2,4 - 4 A
F5
X81.PE
96NC
T1
T2
T3
1
2
3
X151
L1
L2
L3
PE
N
X150
L1
L2
L3
PE
N
1
2
3
y/gn
X153
L1
PE
N
X152
L1
PE
N
1 y/gn 2
y/gn
NO/4
PE
NC/2
P
F60
U1
V1
W1
M2
3
E. 28.01.09 • G. 28.03.12
1,1 kW Motor 2,7 A
33
C/1
29. Terminal diagram - connector pin assignments
connector unit
X31, X11
unitX32,X12
X32, X12
Buchsenteil
Steckerteil
X31,X11 socket
am burner
Brenner
boiler controlzum Kessel
on
socket
unitX22
X22 Steckerteil
connector
unit X21
Buchsenteil
X21
on
am burner
Brenner
unit
zurcompact
KE
H11
N
P11
N
H13
F21
B4
L1
S3
PE
T2
N
T1
B5
N
N
T6
PE
PE
T7
L1
T8
L1
Q1
F3
F1
X11
F51
Y1
Y3
X12
socket unit
X32,
X32,
X12 X12
connectorSteckerteil
unit X31,
X11 Buchsenteil
X31,X11
am
zum Kessel
onBrenner
burner
boiler control
T8
F22
T7
Anschluß für MK3-Z-L
Connectivity
for MK2-Z-L
T6
N
P12
B5
X31
X32
H12
socket unit
X32,
connector Steckerteil
unit X31, X31,X11
X11
Buchsenteil
X32,
X12X12
onBrenner
burner
boiler control
am
zum Kessel
Y9
auf
T8
zu
T7
Anschluß
für MK3-M-L
Connectivity
for MK2-M-L
T6
B5
X31
PE
N
PE
N
L3
L3
L2
L1
L2
L1
F12
Klemmleiste
Terminal
strip X9X9
auf SteuergerätTrägerplatte
X32
Q2
When using cable lengths of over 50 m for heating requests T1 and T2, install a relay for
isolating purposes. Install the relay in the vicinity of the burner.
N Neutral conductor
PE Grounded conductor
P11 Operating hours counter, Stage 1
P12 Operating hours counter, Stage 2
Y1 Solenoid valve, Stage 1
Y3 Safety solenoid valve
Y11 ext. controller (e. g. RWF 32)
34
E. 28.01.09 • G. 28.03.12
L1 Phase 1
L2 Phase 2
L3 Phase 3
F11 Fuse max. 10 A
F12 Fuse 10 AT
F21 Regulating thermostat
F22 Regulating thermostat, Stage 2
F3 Safety thermostat
F51 Gas pressure monitor
Q1,Q2Heater power switch
H11 Status indicator lamp
H12 Status indicator lamp, Stage 2
H13 External fault indicator lamp
35
17.5
18
21
24
St.
1
280
300
350
385
St.
2
560
600
700
770
521
558
651
716
St.
2
37.1
44.1
72.1
90.0
9 OIL
37
44
72
89.9
3 OIL
18.5
19
22
25
1 OIL
17.5
18
21
24
0 OIL
[°]
2.7
3.5
4
5
St.
1
η= 92% [kW]
8
10
12.9
13.2
St.
2
[kW]
MK2.1-ZM-L
37
44
72
90
St.
1P1
Air flap position
521
558
651
716
St.
2P9
Gas nozzle pressure
pG
[mbar]
Boiler output
280
300
350
385
560
600
700
770
St.
2
Air flap
position
[°]
21
22
25
28
2 OIL
62.1
66.5
77.6
85.4
St.
2
St.
1
37.1
44.1
72.1
90.0
4 OIL
31.0
33.3
38.8
42.7
[m3/h]
2.1
2.7
3.1
3.9
St.
1
22
18
22
20
[bar]
Pump pressure
6.3
7.8
10.1
10.3
St.
2
4/60°S
5/60°S
5/60°S
6/60°S
St. 2
SS/60°
55.5
59.5
69.4
76.3
St.
2
St.
1
8.3
10.1
13.5
15.2
St.
2
Oil nozzle
(Steinen)
4/60°S
5/60°S
5/60°S
6/60°S
St. 1
SS/60°
2.9
3.4
4.5
5.2
St.
1
47.2
50.6
59.0
64.9
St.
2
[kg/h]
11.1
11.9
13.9
15.3
St.
1
23.6
25.3
29.5
32.5
St.
1
Oil flow rate
22.3
23.9
27.9
30.7
St.
2
[m3/h]
Gas flow rate
Liquid gas
Hi,n = 25.89 [kWh/m3]
MK2.1-ZM-L-F
Gas nozzle pressure
pG
[mbar]
Heating oil EL
Hi = 11.86 [kWh/kg]
27.8
29.7
34.7
38.2
[m3/h]
Gas flow rate
Natural gas H
Hi,n = 10.4 [kWh/m3]
Gas nozzle pressure
pG
[mbar]
MK2.1-ZM-L-N
Gas flow rate
Natural gas L
Hi,n = 9.3 [kWh/m3]
Burner output
St.
1
η= 92% [kW]
[kW]
St.
2
Boiler output
MK2.1-ZM-L
Burner output
E. 28.01.09 • G. 28.03.12
30. Adjustment tables
36
14
14
17
26
450
450
480
540
830
900
960
1070
E. 28.01.09 • G. 28.03.12
St.
1
St.
2
772
837
893
995
St.
2
43.1
52.1
57.1
85.1
9 OIL
43
52
57
85
3 OIL
15
15
18
27
1 OIL
14
14
17
26
0 OIL
[°]
4
4.8
5
7.6
St.
1
η= 92% [kW]
13
14
14.5
16.5
St.
2
[kW]
MK2.2-ZM-L
43
52
57
85
St.
1P1
Air flap position
772
837
893
995
St.
2P9
Gas nozzle pressure
pG
[mbar]
Boiler output
450
450
480
540
830
900
960
1070
St.
2
Air flap
position
[°]
18
18
21
30
2 OIL
92.0
99.8
106.4
118.6
St.
2
St.
1
43.1
52.1
57.1
85.0
4 OIL
49.9
49.9
53.2
59.6
[m3/h]
3.1
3.8
3.9
5.9
St.
1
20
20
18
22
[bar]
Pump pressure
10.2
10.9
11.3
12.9
St.
2
6/60°S
7/60°S
8/60°S
8/60°S
St. 2
SS/60°
82.3
89.2
95.2
106.1
St.
2
St.
1
17.5
21.2
25.9
29.9
St.
2
Oil nozzle
(Steinen)
7/60°S
7/60°S
8/60°S
8/60°S
St. 1
SS/60°
5.6
5.6
6.5
7.8
St.
1
70.0
75.9
80.9
90.2
St.
2
[kg/h]
17.9
17.9
19.1
21.5
St.
1
37.9
37.9
40.5
45.5
St.
1
Oil flow rate
33.1
35.8
38.2
42.6
St.
2
[m3/h]
Gas flow rate
Liquid gas
Hi,n = 25.89 [kWh/m3]
MK2.2-ZM-L-F
Gas nozzle pressure
pG
[mbar]
Heating oil EL
Hi = 11.86 [kWh/kg]
44.6
44.6
47.6
53.5
[m3/h]
Gas flow rate
Natural gas H
Hi,n = 10.4 [kWh/m3]
Gas nozzle pressure
pG
[mbar]
MK2.2-ZM-L-N
Gas flow rate
Natural gas L
Hi,n = 9.3 [kWh/m3]
Burner output
St.
1
η= 92% [kW]
[kW]
St.
2
Boiler output
Burner output
MK2.2-ZM-L
31. Adjustments log
Please enter the measured values into the Adjustments log.
Boiler type
Gas fitting
Measured values
min.
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
E. 28.01.09 • G. 28.03.12
Setting value N at the fitting
37
max.
Date
32. Exploded views / spare parts lists
ZBZ_2-237
Oil pump unit MK2
Item
Designation
PU
Art. No.
1
Motor 1.1 kW 50 Hz
1
36-90-11538
2
Coupling compl. for pump unit MK
1
47-90-27103
3
Hydraulic hose DN 8, 1500 mm lg.
1
47-90-25302
4
Pressure switch compl. with cable
1
47-90-25363
5
T-piece compl. for pump unit
1
44-90-23080
6
Conical nipple AL 14 x 10 x 2
50
37-50-10788
7
Pressure pipe nipple
5
47-50-20127
8
Conical nipple AL 13 x 18 x 2
50
37-50-11293
Hose nipple R 1/4“
10
47-50-20862
Pressure pipe compl. for pump unit MK
1
47-90-27104
11
Oil pump AJ4, compl. for pump unit MK2
1
47-90-27109
12
Sealing washer AL 13 x 18 x 2
50
37-50-11293
13
Hose nipple NW6 R 1/4“
10
37-50-11348
14
Metal hose NW6 1200 mm lg.
1
47-90-11347
15
Screwed sealing plug R 1/4“ with hexagon socket
5
37-50-11798
E. 28.01.09 • G. 28.03.12
9
10
38
ZBZ_2-202.2
E. 28.01.09 • G. 28.03.12
Combined gas/oil burner MK2.1
39
Designation
PU
Art. No.
1
Burner pipe MK2.1
1
47-90-25517
1
Burner pipe MK2.1, extended 100 mm
1
47-90-25514
1
Burner pipe MK2.1, extended 200 mm
1
47-90-26419
2
Mixing head MK2 welded
1
47-90-27084
2
Mixing head MK2 welded, extended 100 mm
1
47-90-27085
2
Mixing head MK2 welded, extended 200 mm
1
47-90-27086
3
Baffle plate MK2
1
47-90-25515
4
Oil ignition electrodes compl.
1
47-90-26213
5
Oil ignition cable set
2
47-50-26104
5
Oil ignition cable set, extended 100 mm
2
47-50-25134
5
Oil ignition cable set, extended 200 mm
2
47-50-25005
6
Gas ignition electrode compl.
1
47-90-24921
7
Gas ignition cable set
2
47-50-25134
7
Gas ignition cable set, extended 100 mm
2
47-50-25004
7
Gas ignition cable set, extended 200 mm
2
47-50-25005
8
Seal for mixing head MK2
5
47-50-25521
9
Nozzle holder MK2 compl. pre-assembled
1
47-90-25548
9
Nozzle holder MK2 compl. pre-assembled, extended 100 mm
1
47-90-25561
9
Nozzle holder MK2 compl. pre-assembled, extended 200 mm
1
47-90-26240
10
Hydraulic set
1
47-90-27087
11
Mixing head MK2 compl. pre-assembled, excl. ignition cable
1
47-90-25473
11
Mixing head MK2 compl. pre-assembled, extended 100 mm,
excl. ignition cable
1
47-90-25562
11
Mixing head MK2 compl. pre-assembled, extended 200 mm,
excl. ignition cable
1
47-90-26108
12
Actuator drive SAD 1.5 for MG20-ZM
1
47-90-24763
13
Air damper MG20 to 12.08
1
47-90-24663
13
Air damper MG20 from 12.08
1
47-90-27030
14
Cover for MG20 with seals
1
47-90-10698
15
Pressure pipe MK2.1 compl.
1
47-90-25560
16a
Hydraulic sealing nipple T2320V, compl.
1
47-90-25465
16b
Hydraulic coupling compl.
1
47-90-25464
17
Double solenoid valve block compl.
1
47-90-27105
18
Sight glass with seal
1
36-90-11544
19
Cover MG20
1
47-90-24857
20
Cover for sight glass
5
47-50-12106
21
Oil pump AL95, compl. for MK2.1
1
47-90-27125
22
Conical nipple AL 13 x 18 x 2
50
37-50-11293
23
Hose nipple R 1/4“ x R 3/8“
10
46-50-10554
24
Sealing washer AL 14 x 10 x 2
50
37-50-10788
25
Pressure pipe nipple GES 6LLR
5
47-50-20127
26
Metal hose NW8 1500 mm lg.
1
57-90-10348
27
Coupling compl.
1
36-90-11539
28
Fan wheel Ø 218 x 80
1
36-90-11540-01
29
1.1 kW 400 V / 50 Hz motor
1
47-90-26721
30
1.1 kW motor with fan wheel
1
47-90-25205
31
4-pin socket green
1
37-90-20744
32
7-pin socket black/brown
1
37-90-20731
33
5-pin socket black
1
37-90-20748
40
E. 28.01.09 • G. 28.03.12
Item
Item
Designation
PU
Art. No.
34
Logic module CL-LSR
1
47-90-25177
35
Control box MPA 22
1
47-90-24166
36
Ignition transformer Fida Mod. 26/35 incl. ignition cable 460 mm lg.
1
47-90-24469
37
Ignition transformer Fida Mod. 26/48 incl. ignition cable 460 mm lg.
1
47-90-26930
38
7-pin socket green
1
37-90-10831
39
3-pin socket black
1
37-90-20739
40
Miniature motor contactor B7-30-10
1
47-90-25171
41
Thermal overload relay 2.4 - 4 A
1
47-90-25172
42
Remote-manual switch
1
47-90-25040
43
Relay CR-P230AC2
1
47-90-25199
44
Base CR-PLSx
1
47-90-26713
45
Relay CR-M230AC4
1
47-90-25181
46
Base CR-M4LS
1
47-90-26731
-
Mini motor contactor B7-30-10 for pump unit
1
47-90-25171
-
Thermal overload relay for pump unit 2.4 - 4 A
1
47-90-25172
47
Hood for switch box MK30
1
47-90-25206
48
MPA display AM07
1
47-90-24167
49
Facing panel MK3
1
47-90-25074
50
Seal set
1
47-90-26722
51
Gas jacket MG20 part 2
1
44-90-30242
52
Gas jacket MG20 part 1
1
44-90-33245
53
Securing rod MG20
2
46-50-21085
54
Differential pressure monitor 2.5 - 50 mbar
1
47-90-26723
55
KLC 1000
1
47-90-27184
Inlet nozzle
1
36-90-11541
E. 28.01.09 • G. 28.03.12
-
41
E. 28.01.09 • G. 28.03.12
ZBZ_2-240.2
Combined gas/oil burner MK2.2
42
E. 28.01.09 • G. 28.03.12
Item
Designation
PU
Art. No.
1
Burner pipe MK2.2
1
47-90-25472
1
Burner pipe MK2.2, extended 100 mm
1
47-90-26420
1
Burner pipe MK2.2, extended 200 mm
1
47-90-26421
2
Mixing head MK2 welded
1
47-90-27084
2
Mixing head MK2 welded, extended 100 mm
1
47-90-27085
2
Mixing head MK2 welded, extended 200 mm
1
47-90-27086
3
Baffle plate MK2
1
47-90-25515
4
Oil ignition electrodes compl.
1
47-90-26213
5
Oil ignition cable set
2
47-50-26104
5
Oil ignition cable set, extended 100 mm
2
47-50-25134
5
Oil ignition cable set, extended 200 mm
2
47-50-25005
6
Gas ignition electrode compl.
1
47-90-24921
7
Gas ignition cable set
2
47-50-25134
7
Gas ignition cable set, extended 100 mm
2
47-50-25004
7
Gas ignition cable set, extended 200 mm
2
47-50-25005
8
Seal for mixing head MK2
5
47-50-25521
9
Nozzle holder MK2 compl. pre-assembled
1
47-90-25548
9
Nozzle holder MK2 compl. pre-assembled, extended 100 mm
1
47-90-25561
9
Nozzle holder MK2 compl. pre-assembled, extended 200 mm
1
47-90-26240
10
Hydraulic set
1
47-90-27087
11
Mixing head MK2 compl. pre-assembled, excl. ignition cable
1
47-90-25473
11
Mixing head MK2 compl. pre-assembled, extended 100 mm,
excl. ignition cable
1
47-90-25562
11
Mixing head MK2 compl. pre-assembled, extended 200 mm,
excl. ignition cable
1
47-90-26108
12
Actuator drive SAD 1.5 for MG20-ZM
1
47-90-24763
13
Air damper MG20 to 12.08
1
47-90-24663
13
Air damper MG20 from 12.08
1
47-90-27030
14
Cover for MG20 with seals
1
47-90-10698
15
Cover for sight glass
5
47-50-12106
16
Cover MG20
1
47-90-24857
17
Sight glass with seal
1
36-90-11544
18
Pressure pipe MK2.2 compl.
1
47-90-25468
19
Double solenoid valve block compl.
1
47-90-27105
20
Hydraulic coupling compl.
1
47-90-25464
21
Hydraulic sealing nipple T2320V, compl.
1
47-90-25465
22
Hose nipple R 1/4“ x6LL
1
47-90-20862
23
Conical nipple AL 13 x 18 x 2
50
37-50-11293
24
Solenoid valve R 1/4“ compl. for MK burner
1
47-90-27106
25
Oil pump AJ4 compl. for MK burner
1
47-90-26063
26
Pressure pipe nipple GES 6LLR x 1/8“
5
47-50-20127
27
Conical nipple AL 14 x 10 x 2
50
37-50-10788
28
Hose nipple R 1/4“ x R 3/8“
10
46-50-10554
29
Metal hose NW8 1500 mm lg.
1
57-90-10348
30
Coupling MK2.2 compl.
1
47-90-27179
31
Fan wheel Ø 224 x 82
1
47-90-24847
32
2.2 kW 400 V / 50 Hz motor
1
47-90-24846
33
2.2 kW motor with fan wheel
1
47-90-25508
34
5-pin socket black
1
37-90-20748
43
Item
Designation
PU
Art. No.
35
4-pin socket green
1
37-90-20744
36
7-pin socket black/brown
1
37-90-20731
37
Logic module CL-LSR
1
47-90-25177
38
Control box MPA 22
1
47-90-24166
39
Ignition transformer Fida Mod. 26/35 incl. ignition cable 460 mm lg.
1
47-90-24469
40
Ignition transformer Fida Mod. 26/48 incl. ignition cable 460 mm lg.
1
47-90-26930
41
7-pin socket green
1
37-90-10831
42
3-pin socket black
1
37-90-20739
43
Hood for switch box MK30
1
47-90-25206
44
MPA display AM07
1
47-90-24167
45
Facing panel MK3
1
47-90-25074
46
Miniature motor contactor B7-30-10
1
47-90-25171
47
Thermal overload relay 4 - 6 A
1
47-90-25173
48
Remote-manual switch
1
47-90-25040
49
Relay CR-P230AC2
1
47-90-25199
50
Base CR-PLSx
1
47-90-26713
51
Relay CR-M230AC4
1
47-90-25181
52
Base CR-M4LS
1
47-90-26731
-
Mini motor contactor B7-30-10 for pump unit
1
47-90-25171
-
1
47-90-25172
Seal set
1
47-90-26722
54
Gas jacket MG20 part 2
1
44-90-30242
55
Gas jacket MG20 part 1
1
44-90-33245
56
Securing rod MG20
2
46-50-21085
57
Differential pressure monitor 2.5 - 50 mbar
1
47-90-26723
58
KLC 1000
1
47-90-27184
Inlet nozzle
1
36-90-11541
-
E. 28.01.09 • G. 28.03.12
Thermal overload relay for pump unit 2.4 - 4 A
53
44
33. Declaration of conformity for dual-fuel burner for heating oil EL and
natural gas or liquid gas
We, Enertech GmbH, D-58675 Hemer, hereby declare on its own responsibility that the products
MK2. ... and MK3. ...
are in conformity with the following standards and regulations:
EN 267
EN 676
EN 61000-6-2
EN 61000-6-3
EN 60335-1
EN 60335-2-102
These products are CE labelled in compliance with the provisions of the following directives:
2006 / 42 / EC Machinery Directive
2004 / 108 / EC EMC Directive
2006 / 95 / EC Low Voltage Directive
92 / 42 / EEC Energy Efficiency Directive
CE - approved
CE - 0085BR0306 according to Test Report 143192E1/15563 (GWI) and
CE - 0085BR0307 according to Test Report 139082E1/15564 (GWI).
Hemer, 1 September 2008
E. 28.01.09 • G. 28.03.12
Dipl.-Ing. R. Rebbe, Head of Development
45
34. Dimensions (All dimensions are given in mm)
230
630
310
200
265
45°
45°
315
M10
220
250 - 290
835
8
6
4
2
0
0
2 00 4 0 0 6 0 0 8 0 0
B r e n n e r l eBurner
i s t u noutput
g [ k[kW]
W]
10
MK 2 .2
8
6
4
Gas
2
0
4 0 0 6 0 0 8 0 0 1000 1200
B r e n n e r l Burner
e i s t u noutput
g [ k[kW]
W]
All information in this technical documentation as well as the drawings, photos
and technical descriptions placed at your disposal remain our property and may
not be duplicated without our written permission given in advance.
Right reserved to effect modifications.
Enertech GmbH • Brenner und Heizsysteme
Adjutantenkamp 18 • D-58675 Hemer •
Telephone +49 (0)2372/965-0 • Telefax +49 (0)2372/61240
email: kontakt@giersch.de • Website: http://www.giersch.de
Print No. 03-2012• Art. No. 70-10-57471-GB • Printed in Germany • Enertech GmbH
MK2.1
E. 28.03.12
10
Furnace
Fe u e r r a u m
w i d e r resistance
s t a n d [ m[mbar]
bar]
Feuerraumwiderstand
Furnace resistance[mbar]
[mbar]
35. Working ranges