Enertech Nu-Way MGN 190 T1L Instruction Manual

Installation & Maintenance Manual
MGN 190 T1L (BG300-2)
Gas Burner
11/12
Tel:[phone] Fax: [phone] Email: [e-mail] Web: www.nu-way.co.uk

17220532 00-01
DESCRIPTION
COMPONENTS
1. Switch0-1
2. SwitchI-II
3. Cover,inspectionglass
4. Resetbutton
5. Air pressure switch
6. Dampermotor
7. Innerassemblyadjustment
(nottowngas)
8. Flamecone
9. Connectiongasfittings
10. Airdamper
11. Air intake
12. Ignitionelectrode
13. Electricpanel
14. Indicating lamp Stage 2
15. Indicating lamp Stage 1
16. Fanwheel
17. Motor
18. Ionizationelectrode
19. Transformer
20. Innerassembly
21. Nozzle
22. Brakeplate

TECHNICAL DATA
172 215 29 95-01
DIMENSIONS OF FLANGE
ø175-240
M10
ø120

SKELETON DIAGRAMS, 2-STAGE- OR MODULATING BURNERS
1. Ball valve
2. Filter
3. Governor
4. Pressuregaugewithshut-offcock
5a. Gas pressure switch, mini
5b. Gas pressure switch, maxi
6a. Main valve, 2 -stage. When mo-
dulatingoperationisrequiredthis
valve is equipped with controls
for variable opening.
7
6b 6a
5a
4
3
2
1
5b
10
9
8
Incorporated in the MultiBloc
6b. Safetyvalve
1) 7. Valveprovingsystem
8. Air damper motor
9. Air pressure switch
10. Gas burner control
Pos. 5b, 7: Components not required
according to EN 676.
1) Required over 1200 kW according
to EN 676.
172 415 05 00-01
WhenBiogasisused,BentoneABshallalwaysbecontacted.

MOUNTING ON THE BOILER
REMOVAL OF FAN HOUSE UNIT
FROM BURNER.
Loosen the screws. Swing out the fan
house. Remove the ionisation and ig-
nition cables from the electrodes. Re-
move the bolt on the flange.
Removethecombustionunitfromthe
burner. Fit the enclosed flange and
gaskettotheboiler.Ifnewfixingholes
must be drilled, use the fixing flange
as a pattern.
REMOVAL OF VALVE UNIT FROM
BURNER
Remove the plug-in contact from the
multi-bloc. Loosen the union nut.
172 205 42 94-01
INSTALLATION EXAMPLE
Connect the gas to the burner by
means of the ball valve. Ensure that
the union nut, ball valve and tubing
makeiteasytoremovetheburnerfor
inspection and service.

ELECTRIC EQUIPMENT
GAS BURNER CONTROL: LMG22.../LGB22...
WIRINGDIAGRAM
COMPONENTLIST
A1 Gasburnercontrol
B1 Ionizationelectrode
F1 Fuse
H1 Lamp, low capacity
H2 Lamp, high capacity
H3 Alarm signal 220 V
M1 Burnermotor
M2 Dampermotor,L&SSQN75.254.A21B
P1 Timemeter,totaloperatingtime
P2 Time meter, high capacity time
S1 Operatingswitch
S2 Operatingswitch, high/low capacity
S3 Controlthermostat
S4 Temperaturelimiter
S5 Microswitchforhingeddoor
S6 Controlthermostat,high/lowcapacity
S7 Main switch
S8 Air pressure switch
T1 Ignitiontransformer
X1 Connectionterminalboard
X2 Earthterminal
X3 Plug-incontact,burner
X4 Plug-incontact,boiler
X5 Plug-in contact, high/low capacity,
burner
X6 Plug-in contact, high/low capacity,
boiler
S9 Gaspressure switch
Y1 Gassolenoidvalve1 MultiBloc
Y2 Gassolenoidvalve2
Mains connection in accordance with local
regulations.
17242528 00-01
If there is no
Plug-in con-
tact (X4,X6)
on the boiler,
connecttothe
contactenclo-
sed.
If S6 is missing connect T6 and T8.
1N ~50-60 Hz 220V

ELECTRIC EQUIPMENT
GAS BURNER CONTROL : LMG222…/LGB22…
FUNCTION
1. Operating switch On – Thermostat On – gas pressure switch ON – Air damper closed
A control is made that the air pressure switch does not indicate fan pressure. Then the burner motor starts.
2. Air damper motor opens
The air damper motor opens the damper to full load. A Control is made that the air pressure switch
indicates sufficient fan pressure.
3. Air damper motor closes
The air damper motor closes to low load. Then the ignition spark is formed.
4. Main and safety valves open
The gas is ignited. The ionization electrode indicates a flame.
5. The safety time expires
The ignition spark goes out. The safety time expires. If there is no flame or if for some reason the flame
disappears after this time limit, the burner control locks out.
6. Operating position
The burner is in operating position and can now change over to full load if the opersting switch and the
thermostat for full load are in position On. the burner can alternate between full and low load depending
on set temperature.
7. Stop
The operation of the burner can now be interrupted by means of the operating switchor the thermostat.
●The control locks out
The red lamp in the control s lit. Restart the burner by pressing the reset button.
Please note: To facilitate the wiring connection to the control box, the this burner will require an
auxiliary panel to be fitted to the burner body.
Link terminals 4 to 7
Live wire from burner to terminal 11 on the burner terminal block
BOOSTER WIRING: This applies to a Nu-way single booster wired to drawing numbers
WA4-6278 or WA4-6770 only. For further details please refer to Nu-way.
1 2 3 4 5 6 7 8 9 10
Booster terminals
BOOSTER WIRING DETAILS

EXTERNAL WIRING CONNECTIONS FOR MGN SERIES BURNERS
MODULATING
Note:
Control Loop is via Alarm 1 in TLK
Control
For Modulating remove plug-in loose
connector on control
p
ack
BLACK BROWN/BLACK
GREEN
BROWN
3PH SUPPLY MPA HIGH/LOW
GAS TRAIN
MPA TLK MOD
BROWN/BLACK
PTC
WATER TEMP. SENSOR
KTY 81 - 121 B8
PRESSURE TRANSMITTER
0-20 mA OUTPUT
MIDAS JP 401001
VALVE PROVING
BLACK
BLACK

172 425 57 99-01
Operating concept
After lockout, the red fault LED is steady on. For reading the cause of fault, refer to the
blink code given in the following table:
Diagnosisofcauseoffault
AL
FS
LED on (waiting time 10 s)
Fault
Press lockout reset button
for > 3 s Blink code Off Blink code
Approx.
3 s
ELECTRICEQUIPMENT
CONTROL DIAGNOSIS UNDER FAULT CONDITIONS AND LOCKOUT INDICATION
GAS BURNER CONTROL: LMG ...
FS
AL
• Burner control has initiated lockout • Reset
> RedfaultLEDon Press lockout reset button for 0.5 ...3 s
• Diagnosisofcauseoffault
- Wait >10 s
- Press lockout reset buttonj for >3 s
- Read blink code of red fault LED
>«Errorcodetable»
• Burnercontrolinoperation • Restart
> GreenflamesignalLEDon Press lockout reset button for 0.5 ...3 s
• Readflameestablishmenttime
- Press lockout reset button for > 3 s
-Readblink code of greenflamesignal LED
>«Errorcodetable»
Error code table
Blink code Possiblecause
2x • Noestablishment of flame attheend of «TSA»
•• - Faulty or soiled detector electrode
- Faultyorsoiledfuelvalves
- Pooradjustmentofburner
3x • Air pressure monitor does not close
••• - «LP»faulty
- «LP» incorrectly adjusted
- Fan motor does not run
4 x • Air pressure monitor does not open or extraneous light on
burnerstartup
•••• -«LP» faulty
- «LP» incorrectly adjusted
5x • Extraneouslightduringpre-purging
••••• - Orinternal device fault
7 x • Loss of flame during operation
••••••• - Pooradjustmentofburner
- Faultyorsoiledfuelvalves
- Short-circuitbetweendetectorelectrode and ground
8...17 x • Free
••••••••
..................
••••••••••
•••••••
18x • Air pressure monitor opens during pre-purging or operation
•••••••••• - «LP» incorrectly adjusted
•••••••• - Four times loss of flame during operation (LMG25)
19x • Faultyoutputcontact
•••••••••• - Wiring error
••••••••• - Externalpowersupplyonoutputterminal
20x • Internaldevicefault
••••••••••
••••••••••
Duringthetimethecauseof
the fault is diagnosed, the
control outputs are deacti-
vated.
- Theburner remains shut
down
- Exception:faultstatussig-
nal «AL» at terminal 10
The burner is switched on
onlyafter a resetis made.
- Presslockoutresetbutton
for 0.5...3 seconds
RedLEDon

172 425 58 99-01
GAS BURNER CONTROL: LMG ...
Interrogationofflamees-
tablishmenttime Thisfunctionmeasurestheflameestablishmenttimewithionizationsupervision.Withthe AGQ2..., this function cannot be used.
In the running position, the green flame signal LED is steady on.
The flame establishment time is read in the running position according to the following
sequence:
GreenLEDon
FS AL
LEDon
Operation
Whenreadingtheflameestablishmenttime,theburnerisputoutofoperation.Readingis
in the form of a blink code as multiples of 0.4 s.
Press lockout
resetbutton
for > 3 s Blink code Off Blink code
Approx.
3 s
Diagnosticstable
Blink code Flameestablishmenttime Flameestablishmenttime
with «TSA» = 3 s with «TSA» = 5 s
1x 0.4 s 0.4 s
•
2x 0.8 s 0.8 s
••
7x 2.8 s 2.8 s
•••••••
12x --- 4.8 s
••••••••••
••
• Theflameestablishment time is the periodoftime from the moment «BV1»opensto
the moment the flame signal is detected for the first time
• Theflame establishment timeremains stored forone startup sequenceand is
reascertained the next time the burner is started up
• Duringtheperiodoftimetheflameestablishmenttimeisinterrogated,thefaultstatus
outputsaredeactivated:
- Burnerremains shut down
It is restarted only after a reset is made
- Press lockout reset button for 0.5...3 seconds
Note:
If ignition and ionization electrodes are not correctly located, ignition effects may
lead to incorrect measurements.

MEASURES AND CHECKS BEFORE START-UP, 2-STAGE- OR MODULATING
BURNERS
INNER ASSEMBLY
Ensure that the ignition and ionisa-
tion electrodes are correctly adjus-
ted. The sketch shows the correct
measurements.
GAS QUALITY
Ensurethattheburnerheadismeant
for the gas quality to be used (see
fig.).
VENTING
The gas line is vented by loosening
the screw on the test nipple for the
inletpressure.Connectaplastichose
and conduct the gas into the open.
After having vented the gas line tigh-
ten the screw again.
LEAKAGE CONTROL
Whenmakingaleakagecontrolofthe
gassupplysystemthesolenoidvalve
shouldbe closed. Connect apressu-
regaugetothetestnipplePa,seefig.
Thetestpressureinthesystemshould
be 1,5x max. inlet pressure or min.
150 mbar. If any leakage, locate the
source by means of soapy water or
aleaklocationspray.Aftertightening
repeat the test.
ELECTRIC FUNCTION TEST:
Ensurethatphaseandneutralarenot
reversed. The gas shut-off cock
should be closed.To prevent the gas
pressure switch from locking out it
should be linked temporarily.
After the main switch has been swit-
ched on and the thermostats have
beenadjustedthepre-purgingperiod
begins(30-35sec.).Attheendofthis
period the pre-ignition period starts
(0,5-2,5 sec. dependent on the de-
signofthegascontrol).Thegasvalve
is energized and opens and flame is
established. At the end of the safety
time (2-3 sec.) the gas control locks
out.Thesolenoidvalveandthemotor
will be "dead". Remove the link from
thegaspressureswitch after thetest
is finished.
Noteon2-stageand modulatingbur-
nersthatduringthepre-purgingperi-
odthedamperopenstothesetvalue
for air on stage 2 and just before the
end of the pre-purging period it goes
downtotheairsettingforstage1.On
some burners under 350kW the pre-
purging mainly takes place with the
air damper set for stage 1. 172 205 34 97-01
LEAKAGE CONTROL
NOTE! APPLIES ONLY TO GAS
BURNER CONTROL LFL1.
When using LPG (Propane) the bur-
ner should be connected for post-
purge.Moveconnectiontoterminal6
to terminal 7 in the base of LFL1.
MultiBloc
Gas train

MEASURES AND CHECKS BEFORE START-UP
INNER ASSEMBLY
Town gas
2,5
8
INNER ASSEMBLY
Natural gas, LPG
172 205 78 98-01
3,0
8,0
INNER ASSEMBLY
Biogas (UV-detector)
45°
Natural gas
LGP
45°
3,5-4
14

172 205 16 98-01
DETERMINATION OF GAS VOLUME FOR THE INSTALLATION
V = GasvolumeNm3/h
Q = Boiler output 120 kW
Hu= Calorific value of the gas A. 37 144 kJ/Nm3, B. 10.3 kWh/Nm3
= Expected efficiency 90%
Ex. A V = Q 3 600 = 120 3 600 12,9Nm3/h
Hu37 144 0,90
Ex. B V = 120 12,9 Nm3/h
10,3 0,90
Ifthebarometerheight,pressureandtemperatureofthegasdeviateverymuch
fromthe normal values this mustbe taken intoaccount as follows:
f = 273 + t . 1013,25
273 B + Pu
t = Temperature of the gas at the gas meter (15°C)
B = Barometer height (945 mbar)
Pu= Pressure of the gas at the gas meter (15,0 mbar)
f = 273 + 15 1013,25
273 945 + 15
f 1.11
The gas volume read on the gas meter actuallyreads 1,11 .12,9 = 14,4 m3/h.
Net calorific value
Gasquality kWh/Nm3kJ/Nm3kcal/Nm3
Naturalgas 10.3 37 144 8 865
Propane 26.0 93 647 22 350
Butane 34.3 123571 29 492
Towngas 4.9 17 653 4 213
Bio gas 7.0 25 219 6 019
Specifications on natural gas, town
gasandbiogasvary.Formoreexact
information please contact the gas
distributor.
EXAMPLE HOW TO CALCULATE THE GAS VOLUME (NATURAL GAS)
.
.
. .
.
.

17230554 98-02
FUNCTION, 2-STAGE DESIGN
AIRADJUSTMENT
Thedampermotorturnsthedamperbetweenthreepre-setpositions:fullyclosed,lowload,fullload.Thesepositonsare
controlled in the motor by cams of different colours. The black cam controls the gas valve for full load.
Iftheairvolumeneedschanging:Removethecoverofthedampermotorandchangethepositionofthecamsbyturning
themwith the tools accompanyingthe burner.
Low load:
Adjusttheoperatingswitchtofullload
(ll).
* Reducetheairvolume:
Turnorangecamtowards0°
* Increasetheairvolume:
Turnorangecamtowards90°
Adjust the operating switch back to
low load and check the air volume.
Full load
Adjusttheoperatingswitchtolowload
(l).
* Reducetheairvolume:
Turnredcamtowards0°
* Inreasetheairvolume:
Turnredcamtowards90°
If the red cam is moved, change the
black cam as much.
Adjusttheoperatingswitchtolowload
and check that the correct air volume
hasbeenobtained.
Note! The blue cam is the limit posi-
tionforfullycloseddamperand
it is normally not necessary to
change it.
Lowload(orange)
Fullload(red)
Closeddamper(blue)
Solenoidvalvefullload(black)

MULTI-BLOC, MB-ZRDLE 405-420
172 505 03 97-02
1. Ball valve
2. Fixing flange
3. Gas pressure switch
4. Governor with pressure adjust-
ment
5. Protective cover, start gas adjust-
ment
6. Hydraulic device, adjustment of
stage 2
7. Lock screw for flow adjustment
8. Main valve
9. Knob for adjustment of stage 1
10. Test nipple, inlet pressure
11. Test nipple, pressure after
governor
12. Test nipple, before governor
13. Filter
Max. inlet pressure: 360 mbar.
Adjustable governor pressure:
405 - 412 S50 = 4 - 50 mbar
415 - 420 S20 = 4 - 20 mbar
415 - 420 S50 =20 - 50 mbar
Solenoid valve: Slow opening valves
withadjustablestartload,stage1and
stage 2.

FLOW ADJUSTMENT
2-STAGE DESIGN
For stage 1, loosen the lock screw a.
Turn the hydraulic device e:
to the right = the gas flow is reduced
to the left = the gas flow is increased
Forstage 2,turn the hydraulic device
b:
to the right = the gas flow is
reduced to the left = the gas flow is
increased
Donotforgettotightenthelockscrew
again.
ADJUSTMENT OF MULTI-BLOC, MB-ZRDLE 405-420
ADJUSTMENT OF GOVERNOR
Adjust outlet pressure from governor
by means of a screw driver. Min. and
max. outlet pressures correspond to
appr. 60 turns of the spring. It is not
possible to change pressure springs
inordertochangetheoutletpressure.
Turn to the right = the outlet pressure
is increased
Turntotheleft=theoutletpressureis
reduced
ADJUSTMENT OF START GAS
FLOW
Remove the protective cover c.
Turn the adjustment knob d (use the
protective cover as a tool) to the
desired start gas flow.
Turntotheright=thestartgasflowis
reduced
Turn to the left = the start gas flow is
increased
ADJUSTMENT OF GOVERNOR
MULTI-BLOC
MB-ZRDLE 405-420
ADJUSTMENT OF START GAS
FLOW
FLOW ADJUSTMENT
172 505 05 97-01

GENERAL INSTRUCTIONS
ADJUSTMENT OF BURNER
Theburnerisfromthefactorypre-set
toanaveragevaluethatmustthenbe
adjusted to the boiler in question.
Allburneradjustmentsmustbemadein
accordancewithboilermanu-facturers
instructions.These must include the
checking of flue gas temperatures,
averagewatertemperatureandCO2or
O2concentration.
GENERALINSTRUCTIONS
Theinstallationofthegasburnermust
be carried out in accordance with
currentregulationsandstandards.The
installersofgasburnersshouldthere-
forebeacquaintedwithallregulations
and ensurethattheinstallationcomp-
lieswiththerequirements.Theinstal-
lation,mountingandadjustmentshould
be made with the greatest care and
only the correct gas should be used.
OPERATINGINSTRUCTIONS
Theoperatinginstructionsaccompanying
the burner should be left in a prominent
positionintheboilerroom.
INSTRUCTIONS
The user should be thoroughly in-
structed in the function of the gas
burnerandthewholeinstallation.The
supplier must instruct the user.
INSPECTIONANDMAINTENANCE
Daily inspection is advisable.
START UP
Aftertheburnerhasbeenfittedtothe
boilerandtheelectricconnection,the
leakage control, the venting and the
electric function test have been car-
ried out, the burner will be ready for
start-up.
Howerer, study the sections dealing
with adjustments of multi-bloc, com-
bustion air and combustion head.
Opentheballvalveandswitchonthe
main switch. If the burner starts the
actual adjustment can be made.
ADJUSTMENT OF BURNER HEAD
The burner is equipped with an ad-
justmentdevicechangingtheposition
of the brake plate in the burner head.
Thisisusedtoadjustthecorrectpres-
suredropoverthecombustiondevice
inordertoobtainagoodpulsationfree
combustion.
Which position to use depends on
input and overpressure in the boiler. 17230528 97-01
A general rule is that the lower capa-
citythe smaller theopening between
brakeplateandcombustiondevice.
COMMISSIONINGOFINSTALLA-
TION
Controlofthecombustion.Thecom-
bustion quality is checked by means
of a flue gas analysis device. Adjust
theburnertoappr.20%excessairin
accordancewiththetable.Checkthe
flue gas temperature. Calculate the
efficiency.Checkalsotheactualgas
volume on the gas meter so that the
correct input is achieved.
SERVICE
Serviceshouldonlybecarriedoutby
qualified personnel. Replacement
parts should be of the same make
and approved by the same authoriti-
es as the original. If the burner is
convertedtofireanothergasqualityit
must be re-commissioned. If town
gasistobefiredthecombustionhead
must be converted and the gas train
adjusted to suit (e.g.a larger gas ar-
mature or a different spring in the
governor may be required).
Gasquality CO2%0
2% max.CO2%
lambda1,2
Naturalgas 10,0 3,5 11,9
LPG 11,5 3,5 13,9

GENERAL INSTRUCTIONS
ADJUSTMENT OF BRAKE PLATE
- Loosen the screw on the adjust-
ment device.
- To reduce the opening: turn the
knob to the left.
- To increase the opening: turn the
knob to the right.
The adjustment of the position of the
brake plate affects the air flow. It is
therefore always necessary to make
a fine adjustment of the air by means
of the air adjustment device of the
burner.
CONTROL OF BURNER HEAD
Tochecktheburnerhead,brakepla-
teandelectrodesproceedasfollows:
Loosen the nuts a. Swing out the
burner. Remove the screw b and the
knob for adjustment of burner head.
Loosen the screw c so much so that
theinnerassemblycanbepulledout.
172 305 29 94-01
ADJUSTMENT OF INNER ASSEMBLY
CONTROL OF BURNER HEAD

172 305 25 00-01
FLAMEMONITORINGANDMEASU-
REMENTOFIONISATIONCURRENT
The burner is monitored according to
the ionisation principle. Check the io-
nisation current on start-up and on
each service call.
Thereasonforalowionisationcurrent
maybeleakingcurrents,badconnec-
tiontoearth,dirt orafaultypositionof
theflameelectrodeintheburnerhead.
Sometimesalsoafaultygas/airmixtu-
re may cause too weak a ionisation
current.
Theionisationcurrentismeasuredby
means of a microampere meter (µA)
connected in series with the flame
electrode and the gas burner control.
Connect the µA-meter, see figure.
Min. required ionisation current ac-
cording to table. In practice this cur-
rentmustbeconsiderablyhigher,pre-
ferably more than 10 µA. All the gas
burnersareequippedwithaionisation
cable that can be slit which facilitates
the connection of the µA-device.
GAS PRESSURE SWITCHES:
Adjustmentrange:
2,5-50 mbar GW 50
5-150 mbar GW 150
ADJUSTMENTOFMIN.GASPRES-
SURE SWITCH
Themin.pressureswitchshouldreact
if the gas pressure is too low and
prevent the burner from starting. Too
low a gas pressure during operation
should stop the burner. The burner
may start again when the rated gas
pressure has been reached.
Removetheprotectivecover.Connect
a pressure gauge for measuring the
ratedpressure.Decideonpressureat
whichthegasswitchshouldswitchoff.
Set this pressure by means of the
valve. Carefully turn the knob (see
figure) until the gas pressure switch
switches off. The value shown on the
scale should then approximately cor-
respond with the value shown on the
pressure gauge. Tolerance on scale
appr. ± 15 %. Open the ball valve.
GENERAL INSTRUCTION
ADJUSTEMNTOFMAX.GASPRES-
SURE SWITCH
Theburnerisequippedwithamax.gas
pressure switch only on request. It
shouldstoptheburnerifthegaspres-
sureexceedsthesetvalue.Theburner
can then only be re-started manually
(gas burner control or overpressure
switch).
Removetheprotectivecover.Connect
a pressure gauge for measuring the
rated gas pressure. Decide on pres-
sureatwhichthegaspressureswitch
shouldswitchoff.Turntheadjustment
knob to this value. Tolerance on the
scale ±15%.
ADJUSTMENT OF AIR PRESSURE
SWITCH
Theairpresureswitchshouldstopthe
burner if the air volume is reduced.
Theairprovingdeviceshall be adjus-
ted in such a way that if there is
insufficientairsupplyatthehighestor
lowest burner operating stage, the
deviceoperatesbeforethesupervised
pressureislessthan80%ofthepres-
sureatthecontrolledstageandtheCO
content of the combustion products
exceeds1%byvolume.
AIR PRESSURE SWITCH:
Adjustmentrangeca:
1-10 mbar LGW 10
2,5-50 mbar LGW 50
FLAMEMONITORING
GAS PRESSURE SWITCH, AIR
PRESSURESWITCH
Gascontrol Connectionto terminal Min. ionisation
in gas control current required
LMG 1 2 µ A
LGB 1 10 µ A
LFL 24 10 µ A
MMI810 2 5 µ A
TMG740-3 1 5 µ A