CTC Giersch MG40 Series Manual

January 2019 edition
In the interests of contin uous product im-
pro vemen t, tech nical specifica tions are
su bject to change without prio r n otice!
Gas
Technical Information • Installation Instructions
MG40-ZM-L-LN
GB

2/44 22.01.19, Subject to alterations
Declaration of Conformity for gas burner
We, Enertech GmbH, Adjutantenkamp 18 in D-58675 Hemer declare under
our sole responsibility that
Gas burner type MG40/..
complies with the stipulations of directives
MD2006/42/EG
EMV2014/30/EG
LVD2014/35/EG
GAR 2016/426/EG
MCP2015/2193/EU
1. BImSchV 2010
RoHS 2011/65/EU
DIN EN 676
and is designated as follows:
CE-0085
Hemer, 15.07.2018

Subject to alterations, 22.01.19 3/44
Contents Page
1 Safety-relevant information 4
1.1 Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 General information on safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.5 Restriction of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.6 Qualifified personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.7 Transport and intermediate storage at installation location . . . . . . . . . . 7
1.8 Behaviour if there is a smell of gas 7
1.9 Hazards when handling electrical current . . . . . . . . . . . . . . . . . . . . . . . 7
1.10 Behaviour in the case of an emergency . . . . . . . . . . . . . . . . . . . . . . . . 7
1.11 Atmospheric explosion protection (ATEX) . . . . . . . . . . . . . . . . . . . . . . . 7
1.12 Recycling and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Working ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4 Gas train dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.5 Selection diagram for gas fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.6 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3 Burner assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 Installing the gas jacket at the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Gas mixer head adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3 Electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.4 Gas fitting installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.5 Installing the burner housing at the gas jacket . . . . . . . . . . . . . . . . . . . 13
3.6 Swivel position / service position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4 Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.1 Air / gas actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2 Air pressure monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.3 Gas input pressure min. with leakage check . . . . . . . . . . . . . . . . . . . . . 16
4.4 Gas pressure switch max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.5 Flame monitor with ionisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.6 Connection diagram for connector assignment . . . . . . . . . . . . . . . . . . . 18
4.7 Burner management system LMV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.1 Gas supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.2 Setting tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.3 Principles of calculation for gas burner adjustment . . . . . . . . . . . . . . . . 23
6 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.1 Prior to commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.2 Operation and device desription . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.3 LMV programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.4 Adjustment protocol - first commissioning 33
6.5 LMV phase display / operating display . . . . . . . . . . . . . . . . . . . . . . . . . 34
7 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8.1 Prior to maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
82. Maintenenace positions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8.3 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9.1 LMV fault code list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9.2 Exploded view / spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

4/44 22.01.19, Subject to alterations
Safety-relevant information
1 Safety-relevant information
This document is part of the product. It must be trained over the entire lifetime of the
product. Make this document available to the operator or personnel responsible for ac-
tivities describe in it. Incorporate supplements that you receive later from GIERSCH to
the documents.
1.1 Symbols
Particularly important information is hightlighted using corresponding symbols in this
document:
Warning
The work safety symbol marks safety information that is intended to prevent danger to
life and limb. Observe this safety information carefully and take special care when car-
rying out relevant work or procedures.
Warning! Danger of fatal injury from electric shocks!
The electrical symbol marks safety information that is intended to prevent danger to life
and limb caused by an electric shock. Observe this information carefully and take spe-
cial care when carrying out the work or procedures described.
Caution
The caution symbol marks al safety information that is intended to prevent damage or
destruction of the product and/or other plant components.
Note
Particularly usesful information or notes can be found here.
1.2 General information on safety
The chapter on "Safety" provides an overview of the safety aspects that must be ob-
served to ensure safe working with the product described. All persons who assemble, fit
or install the product described, commission it or operate and/or service it must read this
chapter carefully and observe the instructions in order to prevent injury or property dam-
age. It is all about your safety.
In addition to this general information, the product documentation provides specific safe-
ty information for individual actions.
Only if you observe all safety instructions, can you achieve optimum protection for your-
self, you colleagues and the environment through safe and reliable operation of the
product.
Also be sure to heed the national accident prevention and safety regulations.

Subject to alterations, 22.01.19 5/44
Safety-relevant information
1.3 Limits
The following products (in addition to the burner) apply as further subsystems in the
plant:
• Heat generator / air supply / exhaust system
• Fuel supply system (gas train / oil suply system)
• Burner control
• Further plants components that do not belong to the burner (e.g. acoustic insulation
system, emission-reduction systems)
These subsystems are required to operate the plant; however, they are not part of the
burner described in this document and may differ depending on the plant. This burner
documentation, therefore, does not contain concrete contents relating to further subsys-
tems of the plant.
It is assumed that the burner and the other subsystems are installed properly and have
been electrically connected, and that the burner is supplied with the correct fuel before
they are put into operation. It is also assumed that the further systems are in compliance
with the relevant standards / regulations and that they match the burner, and that func-
tional tests have been sucessfully performed.
All necessary information on installation and electrical connection of the burner is pro-
vided in the operating instructions.
The operator must ensure that the country-specific accident prevention and safety infor-
mation is observed. The operator must also ensure that the working environment (e.g.
boiler house) is compliant with the regulations. We recommend that the operator should
produce operating instructions that cover the entire working environment. This docu-
ment and all other manufacturer documentation for the plant components should serve
as a basis for these instructions.
1.4 Intended use
The burner is intended exclusively for the generation of heat by combustion of the fuel
specified on the type plate in conformance with the perfomance data specified in the
technical specifications.
The burner must be used in a matching plant environment (fuel management system,
heat generator, etc.) (see section 1.3).
The energy produced by the burner must be removed, also during commissioning.
To guarantee proper functioning of the burner, a negative pressure compared to the at-
mosphere must not prevail at the installation location. The intake opening of the blower
must be free to allow sufficient intake of air.
Before the burner can be used for standard operation, its firing must be commissioned.
This commissioing procedure must only be performed by a firing technician (see "Qual-
ified personnel").
The firing technician is responsible for ensuring that proper combustion is achieved in
all output stages and that all safety equipment (safegaurds, etc.) and controllers are set
correctly. All values set mut be documented in an acceptance and test report and made
available to the operator.

6/44 22.01.19, Subject to alterations
Safety-relevant information
The adjustments made during commissioning must not be modified afterwards. Excep-
tion: If the operating conditions change at a point in time after commissioning (due to
changes in the fuel characteristics or plant environment for example), a firing technician
must check the adjustments and adapt them where necessary. The set values must be
redocumented in an acceptance and test report.
The burner is equipped with safety devices and has been tested and inspected for safe-
ty. It may only be operated if all safety devices have been set properly and are in oper-
ation. The safety equipment includes the safety chains and all components, all other
safeguards as well as protective design measures, such as barriers and warning signs.
It is forbidden to modify the safety equipment or put it out of operation, unless it is ex-
pressely instructed in the documentation to deactivate and/or remove such equipment
for a short period. If this is necessary during maintenance, for example, it must be fitted
and/or activated again before the burner is restarted. As a rule, warning signs must not
be covered or removed.
Conversion measures are permissible only with written approval from GIERSCH. Install
only additional components that have been tested togehter with the device; do not use
combustion room inserts that would hinder burn-out of the flame, use only GIERSCH
original components.
The instructions and regulations in the documentation must be observed in a lifecylce
phases of the burner. This applies in particular for maintenance of the burner (obser-
vance of deadlines for inspection and maintenance work, and for the exchange of safe-
ty-relevant components).
The plant must be checked in its entirety by the manufacturer and/or authorised and
trained personnel once a year for reasons of operational safety and economy.
We recommend that a maintenance contract be concluded. GIERSCH Service will be
pleased to provide further information.
1.5 Limitation of liability
Any use that deviates from the conditions stated above shall be deemed improper use.
GIERSCH shall not be held liable for any damage that results from improper use. The
risk in this case shall be borne solely by the operator / owner.
1.6 Qualified personnel
Warning!
Risk of injury and property damage due to incorrect operation!
The operator must ensure that only qualified personnel work with the product.
Qualified personnel in the context of this documentation are persons who have complet-
ed qualifying training on the handling of the product described, ideally trained by
GIERSCH and authorised by the operator of the plant to assemble, commission operate
and/or service the product.
The burner may only be commissioned by a
firing technician. Training for the burner shall be provided by GIERSCH, training for the
other plant components by the relevant manufacturers.

Subject to alterations, 22.01.19 7/44
Safety-relevant information
1.7 Transport and intermediate storage at the installation location
Warning! Risk of injury from burner falling down!
If a burner falls down, this can cause most serious injuries! Be sure to obeserve the in-
structions for transport and storage.
1.8 Behaviour if there is a smell of gas
• Prevent open fire and sparks, e.g.:
• Do not switch lights on or off.
• Do not operate electrical devices.
• Do not use mobile telephones.
• Open widnows and doors.
• Close the gas ball valve.
• Warn house occupants; do not operate doorbells.
• Exit the building.
• Outside the building, notify the heating specialist or gas supply company.
1.9 Hazard when handling electric current
Warning! Danger of fatal injury from electric shocks!
If the insulation is damaged or live components are not covered properly, life is at risk
due to electric shock!
Warning! Danger of fatal injury from electric shocks!
Carelessness can result in an electric shock.
Therefore, always carry out the following steps when performing work on electrical de-
vices:
• De-energise the devices.
• Secure to prevent them from being switched on again.
• Check that they are de-energised.
• Ground and short-circuit the devices.
• Cover neighbouring, live components/devices.
• Cordon off the danger zone and/or position a noticable, readily visible warning sign.
1.10 Behaviour in the case of an emergency
In the event of danger:
Actuate the plant's "emergency stop switch" and interrupt the fuel supply!
1.11 Atmospheric explosion protection (ATEX)
If the product is to be used in a potentially explosive area, the operator must ensure that
it is incorporated in a coherent explosion protection concept that complies with Directive
1999/92/EC.
1.12 Recycling and disposal
Leave disposal of the packaging up to the specialist who installed the product.
Notes on disposal:
If the product is marked with this sign:
• Do not dispose of the product as household waste in this case.
• Hand it over to a collection point for old appliances instead.
• Disposal and recycling must take place in compliance local and national regulations
at commissioned and authorised collection points or disposal sites.

8/44 22.01.19, Subject to alterations
Technical specifications
2 Technical specifications
2.1 Technical specifications
2.2 Type code
2.3 Working ranges
Working ranges according to DIN EN 676 2008-11. The working ranges are referred to
15°C and 1013 mbar.
Burner type
Technical specifications MG40/1-LN MG40/2-LN
Burner output in kW 490 - 4500 611 - 6300
Gas type Natural gas LL + E = „-N“
Perm. operating pressure 200 - 700 mbar
Mode of operation 2-stage/modulating
Voltage 3 / N / PE ~ 50 Hz 400 V / 230 V
Fuse 400 V = 32 A
Current consumption during operation
in A
20 27
Electric motor (at 3000rpm) in kW 11 15
Flame control Ionisation
Burner management system LMV27
Weight in kg 346
Noise emission in db(A) 86 87
Degree of protection IP40
MG 40/1-ZM-L-N-LN
LowNox
Erdgas E+LL="-N" oder Flüssiggas="-F"
Luftabschlussklappe
zweistufig gleitend / modulierend
Brennertyp / Leistungsgröße
Brennerserie
Series
Size
Two stage / modulating
Air damper
Natural gas LL + E = "N"
LowNox
30
25
20
15
10
0
MG40/1-LN
1000 2000 3000 4000
Feuerraumwiderstand [mbar]
Brennerleistung [kW]
30
25
20
15
10
0
MG40/2-LN
2000 4000 6000
1000 8000
Feuerraumwiderstand [mbar]
Brennerleistung [kW]
Burner output [kW]
Burner output [kW]
Furnace resistance [mbar]
Furnace resistance [mbar]

Subject to alterations, 22.01.19 9/44
Technical specifications
2.4 Gas train dimensions
2.5 Selection diagram for gas fitting
Designation KEE 2“ KEE DN65 KEE DN80 KEE DN100
a Gas fitting approx. 705 approx. 705 approx. 705 approx. 705
b Gas throttle 30 30 30 30
c Double gas valve 240 290 310 350
d Gas filter 230 290 310 350
e Manometer/test burner
optional
approx. 120 215 200 205
f Compensator approx. 250 110 125 150
g Ball valve approx. 130 170 180 190
i Connecting bend 205 205 205 205
Optio nal compo nents
Standard componen ts
gas jacket
2000 2500 3000 3500 4000 4500
0
50
100
150
200
250
Anschlussdruck [mbar]
Erdgas LL, Hi,n = 9 kWh/m³n
5000
KEE DN100
KEE DN80
KEE DN65
KEE 2"
2000 2500 3000 3500 4000 4500 5000
0
50
100
150
200
250
Anschlussdruck [mbar]
Erdgas E, Hi,n = 10,4 kWh/m³n
KEE DN100
KEE DN80
KEE DN65
KEE 2"
Brennerleistung [kW]Brennerleistung [kW]
3500 4000 4500 5000 5500 6000
0
50
100
150
200
250
Anschlussdruck [mbar]
Erdgas LL, Hi,n = 9 kWh/m³n
6500
KEE DN100
KEE DN80
KEE DN65
3500 4000 4500 5000 5500 6000
0
50
100
150
200
250
Anschlussdruck [mbar]
Erdgas E, Hi,n = 10,4 kWh/m³n
KEE DN100
KEE DN80
KEE DN65
KEE2"
6500
Brennerleistung [kW]Brennerleistung [kW]
MG40/1-LN
MG40/2-LN
Burner output [kW]Burner output [kW]
Burner outp ut [kW]
Burner outpu t [kW]
Supply pressu re [mbar]
Supply pressure [mbar]
Supply pressure [mba r]
Supply pressu re [mbar]
Na tural gas LL, H
i,n
= 9 kWh/m
3n
Natural gas LL, H
i,n
= 9 kWh/m
3n
Natural gas E, H
i,n
= 10,4 kWh/m
3n
Natural gas E, H
i,n
= 10,4 kWh/m
3n

10/44 22.01.19, Subject to alterations
Technical specifications
2.6 Dimensions
All dimensions are given in mm

Subject to alterations, 22.01.19 11/44
Burner installation
3 Burner installation
3.1 Mounting the gas jacket on the boiler
The boiler connection plate must be prepared according to the dimensions specified for
the boiler connection dimensions. You can use the gas-jacket gasket as a template.
Screw the gas jacket to the boiler using the four M10 fastening screws with washers and
a size SW8 Allen key.
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Gas nozzle
1 flange
2 lining
3 annular gap
4 boiler door

12/44 22.01.19, Subject to alterations
Burner installation
3.2 Settings for gas mixer head
The position of the mixing head (dimension "B") is preset at the factory. .
3.3 Electrodes
The electrodes are preset at the factory.
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Burner pipe
Diaphragm plate
Di mension "B"
Ionisation electrode,
Distance to
Diaph ragm p late
Ceramic of the
electrodes,
Distance to
Diaphr agm pla te
Ignition electrode,
Distance to
Diap hragm plate

Subject to alterations, 22.01.19 13/44
Burner installation
3.4 Gas fitting installation
Installation position of the gas fitting
3.5 Mount the burner housing at the gas jacket

14/44 22.01.19, Subject to alterations
Burner installation
Position the burner housing in the gas-jacket hinge and secure it with a rod. The burner
is now in the service position.
Attach the ignition and ionisation cable to the ignition and ionisation electrodes.
Carefully swing the burner closed. Do not pinch electrical cables.
Secure the burner housing with the fixing screws (3 x M16).
3.6 Swivel position / service position

Subject to alterations, 22.01.19 15/44
Electrical installation
4 Electrical installation
4.1 Air / gas actuator
The air actuator is designed for air flap adjustment on progressive two-stage burners or
modulating burners.
The gas actuator is designed for gas flap adjustment on progressive two-stage burners
or modulating burners.
They are controlled electronically via the burner management system.
Do not open the burner under voltage. The internal optics would be destroyed.
No warranty if the seal is broken!
4.2 Air pressure monitor
The air pressure switch is a differential pressure switch and monitors the air pressure at
the forced-air burner. The air pressure switch is pre-set at the factory.
+-

16/44 22.01.19, Subject to alterations
Electrical installation
4.3 Gas pressure switch min. with leakage check
The gas pressure switch at the gas train serves to monitor the gas input pressure and
test the valves for leaks. The gas pressure switch must be set to 50% of the static gas
input pressure.
4.4 Gas pressure monitor max.
Optionally a gas pressure switch max. can be incorporated.
The LMV and the wiring have been prepared such that only the jumper in the socket part
(brown) at the burner needs to be removed. In addition, the male connector and the gas
pressure switch max. must be wired in accordance with the circuit diagram. If the gas
pressure switch max. has tripped, a fault is shown in the display (AZL).
First, the gas pressure switch max. must be unlocked; to do this the lid of the gas pres-
sure switch max. must be unscrewed and the red button pressed. Then, the fault in the
display can be deleted (press the i/reset button for 3 sec.).
The switching point must be adjusted such that it corresponds to half of the input
flow pressure.

Subject to alterations, 22.01.19 17/44
Electrical installation
4.5 Flame monitoring with ionisation
When a flame is present, an ionisation current flows between the electrode and the LMV
burner management system. The ionisation current produces the flame signal.
The ionisation current must be measured during commissioning or maintenance. To do
this, disconnect the connector in the ionisation cable and connect the current meter
series.
The required minimum probe current is 2.3 µA DC, the maximum possible probe current
is DC µ12... 30 A.
If the ionisation current is too small, this results in a fault shut-down. In this case, ionisa-
tion rod and the diaphragm plate must be cleaned. If necessary, re-bend the ionisation
rod. If the ionisation rod is defective, replace it. Check the cable for moisture and dry if
necessary.
Check the polarity of the supply cable (L1 and N)

18/44 22.01.19, Subject to alterations
Electrical installation
4.6 Terminal diagram - connector pin assignments
If the connectors have already been pre-wired: check the connections in accord-
ing to the
connection diagram!
The electrical connection of the burner must be made in the connectors included accord-
ing to the connection diagram, taking account of the local regulations.
The supply cable must be fused with max. 10 A fast blow or 6.3 A slow blow and must
be routed using flexible cable.
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Electrical installation
4.7 LMV burner management system
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20/44 22.01.19, Subject to alterations
Settings
5 Settings
5.1 Gas supply
Connecting bend
Gas throttle
The gas throttle regulates the quantity of gas according to the power required. It is con-
trolled by the burner management system using an actuator.
Double gas valve
The double gas valve opens and blocks the gas supply automatically. The leakage
check
for the gas pressure switch is located between the valves.
Gas pressure switch min. - leakage check
The gas pressure switch min. leakage check check the gas connection pressure. If the
specified gas pressure is undershot, the gas deficiency program starts.
It checks whether the valves are tight and signals to the burner management system if
the pressure rises or falls to an impermissible value during a leakage check.
The leakage check is performed automatically by the burner management system:
• After normal shutdown,
• Prior to burner start,
• After a fault shut-down,
• After a power failure.
Gas pressure switch max. (option)
If the gas pressure exceeds the set level, the gas pressure switch -max at the burner
management system triggers a safety shutdown.
The gas pressure switch -max is polled with a delay during commissioning of the burner.
Pressure that may have accumulated can be removed during this time.
Gas filter
The gas filter protects the downstream train against dirt particles.
,,Optional components
Manometer/test burner
 Compensator
 Ball valve
Gas jacket