Giersch MG3-ZM-LN Manual

Issued in September 2021
Subject to tech. modifications
to improve the product!
Gas
Technical Information • Installation Instructions
MG3-ZM-LN
GB

2/32 01.09.21, Subject to alterations
Contents
1 General information ................................................................................................................... 3
2 Checking the scope of delivery and electrical ratings ................................................................ 3
3 Maintenance and customer service ........................................................................................... 4
4 Operating instructions ................................................................................................................ 4
5 Instruction of operating personnel.............................................................................................. 4
6 Key for code designation ........................................................................................................... 4
7 Technical specifications .............................................................................................................. 5
8 Boiler connection dimensions .................................................................................................... 5
9 Mounting the gas jacket mantel at the boiler .............................................................................. 5
10 Mounting the burner housing on the gas jacket (service position) ............................................. 6
11 Terminal diagram connector pin assignments ............................................................................ 7
12 Electrical connection ................................................................................................................... 8
13 Air flap positioning motor .......................................................................................................... 9
14 Air pressure switch ..................................................................................................................... 9
15 Gas pressure monitor ............................................................................................................... 10
16 Adjusting the ignition electrode ................................................................................................. 11
17 Adjusting the mixing head ......................................................................................................... 11
18 Flame control with ionisation monitor........................................................................................ 12
19 Connection diagram LMV27 ..................................................................................................... 13
20 Operating instructions and equipment description LMV............................................................ 14
21 Start-up and calibration ............................................................................................................ 15
22 Gas burner with gas train KEV
II
1 ½", KEV 2", DN65, DN80, DN100........................................ 21
23 Calculation principles for gas burner adjustment .................................................................... 23
24 Adjustment tables .................................................................................................................... 24
25 Error code list LMV .................................................................................................................. 25
26 Adjustments log ........................................................................................................................ 27
27 Exploded view / spare parts list................................................................................................. 28
28 Declaration of conformity .......................................................................................................... 30
29 Overall dimensions .................................................................................................................. 32
30 Working range.......................................................................................................................... 32

Subject to alterations, 01.09.21 3/32
General information
1 General information
Installation of a gas-fired heating system must be
performed in accordance with the applicable regula-
tions and guidelines. It is therefore the duty of the in-
staller to be fully familiar with all regulations.
Installation, start-up and maintenance must be per-
formed with utmost care.
The burner must not be operated in rooms with high
levels of air humidity (laundry rooms), dust or corro-
sive vapours. The boiler room must be ventilated ac-
cordingly with ventilation air.
MG Series gas burners are suitable for combustion
of natural gas in accordance with DIN EN 437 and
are in compliance with the DIN EN 676 European
standard.
2 Checking scope of supply and
electrical ratings
Before installing the gas burner, please check the
scope of delivery.
Scope of delivery:
burner housing, gas jacket with burner pipe, mount-
ing kit, documentation and gas train.
Gas installation and commissioning are subject to
the applicable national regulations, e.g. in Germany
the Technical Regulations of the DVGW (DVGW-TR-
GI).
The following must be observed for Switzerland:
SVGW Gas Provisions G1, G3: Gas installation
EKAS Form.
1942: Liquefied gas regulation, Part 2 Regulations
of cantonal authorities (e. g. fire department regula-
tions).
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 short-
est 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 connec-
tion flow pressure.
Caution !
Observe sequence and through-flow direction
of valves and fittings.

4/32 01.09.21, Subject to alterations
Maintenance and customer service
3 Maintenance and customer service
The complete system should be checked once a
year for proper functioning and leak tightness by an
authorised representative of the manufacturer or by
another expert.
Only qualified personnel may open only for mainte-
nance, not during on-going operation. Prior to open-
ing/swinging out, de-energise the burner and let it
cool down. After completion of work, close the burn-
er again.
Wear protective clothing|/hearing protection when
working in the boiler house
We accept no liability for consequential damage in
cases of incorrect installation or repair, the fitting of
non-genuine parts or where the equipment has
been used for purposes for which it was not intend-
ed.
4 Operating instructions
The operating instructions together with this techni-
cal information leaflet must be displayed in a clearly
visible position in the boiler room. The address of
the nearest customer service centre must be dis-
played on the back of the operating instructions.
5 Instruction of operating personnel
Failures are often caused by operator error. The op-
erating personnel must be properly instructed in
how the burner works. In the event of recurring
faults, Customer Service should be notified.
6 Key for code designation
MG 3-ZM-L-N-LN
LowNox
Erdgas E, LL ="N"
Luftabschlussklappe
zweistufig gleitend / modulierend
Brennertyp
Brennerserie
Series
Size
Air shut-off flap
Natural gas LL + E
Two-stage / modulating
LowNox

Subject to alterations, 01.09.21 5/32
Technical specifications
7 Technical specifications
8 Boiler connection dimensions
Dimensions in mm
9 Mounting the gas jacket on the
boiler
The boiler connection plate must be prepared ac-
cording 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 Allen
key. The air pressure switch for the gas train must be
at the top.
Burner type
Technical data MG3-ZM-LN
Burner output in kW 450 - 2300
Gas type for natural gas LL + E = “-N” , LPG = „L“
Method of operating 2-stage sliding / modulating
Voltage 230 / 400 V - 50 Hz
max. current consumption start/operatiopn 16,5 A max./ 11,4 A eff.
Electric motor power (at 2800min
-1
) in kW 4,5
Flame failure controller Ionisation
Control box LMV27
Weight in kg 120
Gas burner class 3
NOx Limit value
≤ 80 mg/kWh
Air pressure connection
M12
Ø260
Ø328

6/32 01.09.21, Subject to alterations
Mounting the burner housing on the gas jacket (service position)
10 Mounting the burner housing on
the gas jacket (service position)
Position the burner housing in the gas-jacket hinge
and secure it with a rod. The burner is now in the
service position.
Attach the ignition and ionisation cable to the igni-
tion and ionisation electrodes.
Carefully swing the burner closed.
Do not pinch electrical cables.
Insert the second mounting rod into the hinge. Tight-
en the screw at the top to secure the burner in posi-
tion.

Subject to alterations, 01.09.21 7/32
Terminal diagram - connector pin assignments
11 Terminal diagram - connector pin
assignments
If the male connector has already been wired:
check the connections according to the
connection diagram!
The electrical connection of the burner must be
made in the male connector included according 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.
Information,
the following circuit diagram is enclosed separately:
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Connection in two stages
Boiler-Burner
Modulating connection
Boiler-Burner
Power light
lock out
Main switch
External fuse
Thermostat
heat requirement
Safety temperature
limiter
Boiler
Extract wiring diagram page 2
Extract wiring diagram page 7
External fuse

8/32 01.09.21, Subject to alterations
Electrical connection
12 Electrical connection
De-energise the burner when carrying out
connection work and removing electrical parts!
The burner must be connected to the electricity sup-
ply in accordance with the wiring diagram. This work
must be performed by trained, qualified electricians.
The supply cable to the burner must be of the flexi-
ble type.
To access the firing unit, the cover must be brought
to the service position. To do this, remove the secur-
ing screws (1) and fold the cover down to the left.
After wiring has been completed, check the direc-
tion of rotation of the burner motor.
The direction of rotation is correct when the fan
wheel turns towards the boiler (also see arrow on
the motor flange).
IMPORTANT !
The motor protection relay is set at the factory. The
set value should not be modified.
B
Cover
1
1

Subject to alterations, 01.09.21 9/32
Air flap positioning motor
13 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 electron-
ically via the microprocessor-controlled control box.
Do not open the air flap actuator while it is under
voltage. The internal optics would be destroyed.
No warranty if the seal is broken!
14 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.

10/32 01.09.21, Subject to alterations
Gas pressure monitor
15 Gas pressure monitor
15.1 Gas pressure switch min.
The gas pressure switch MIN at the gas fitting
serves to monitor the gas inlet pressure. If the mini-
mum gas inlet pressure is not reached (factory set-
ting), the burner is switched off. The burner
automatically starts again when the minimum pres-
sure is exceeded. The gas pressure monitor as den-
sity control DK generally serves to check the valves
and must be set to 50% of the static gas inlet pres-
sure.
The monitoring of the gas inlet pressure and the
tightness control are carried out either only with the
gas pressure switch DK (the plug bridge GDW MIN
must not be removed) or with the gas pressure
switch MIN and the gas pressure switch DK (in this
case the plug bridge GDW MIN must be replaced
with the connection of the gas pressure switch
MIN).
Additional parameterization of the LMV is not
required here.
15.2 Gas pressure switch max.
Optionally, a gas pressure switch max. to be built in.
The LMV and the wiring are prepared so far that only the bridge in the socket (brown) on the burner has to
be removed. In addition, the plug and the gas pressure switch must be max. Wired according to wiring di-
agram. If the gas pressure switch max. has triggered a fault in the display (AZL) displayed.
First, the gas pressure switch must be max. be unlocked, the lid of the gas pressure switch must max. un-
screwed and the red button pressed.
Then the fault in the display (press the i / reset button for 3 sec.) Can be deleted.

Subject to alterations, 01.09.21 11/32
Set the electrodes
16 Set the electrodes
The electrodes are preset at the factory
17 Adjusting the mixing head
The position of the mixing head is set depending on
the output according to the tables on page 24:
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12/32 01.09.21, Subject to alterations
Flame control with ionisation monitor
18 Flame control with ionisation
monitor
In the presence of an alternating-current voltage be-
tween burner and ionisation rod, the rectifying effect
of the flame causes a direct current to flow. This ion-
isation current is the flame signal and is amplified
before being output to the control box. A flame can-
not be simulated, because the rectifying effect col-
lapses if there is a short-circuit between sensor
electrode and burner.
Measuring ionisation current
The ionisation current must be measured during
burner start-up and maintenance or after a fault in-
dication in the control box. Disconnect the plug of
the ionisation cable and connect the ionisation
measuring cable.
Perform measurement straight after the post-igni-
tion time during the safety time period !
The ionisation current must be at least 1.5 µA. Cur-A. Cur-
rents lower than 1.5 µA cause unstable operation orA cause unstable operation or
shutdown. If the current is too low clean the ionisa-
tion rod and the inside of the burner tube. It may be
necessary to correct the shape of the ionisation rod.
If the ionisation rod is defective, replace the elec-
trode. Reverse the polarity of the ignition transform-
er, if necessary. Check the cables for moisture
formation and dry if necessary.

Subject to alterations, 01.09.21 13/32
Connection diagram LMV27
19 Connection diagram LMV27
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Power supply
Safety chain
Fuel valve (V2)
Fuel valve (V1)
Limit switch
Burner
Blower motor protection
Alarm
Fan continuous running
Safety valve (SV)
Ignition (Z)
Fuel valve (V3)
Pilotz valve (PV)
Pressure switch
Leak control gas (PLT)
Pressure switch
min gas / min oil (P min)
external
power controller
Air pressure switch
Pressure switch max gas/
max oil (P max) or POC
Fuel indicator oil / gas
Unlocking / locking
UV flame detector QRA
flame detector
QRB / QRC
Ionization flame sensor
Fuel counter
Connection
AZL
Frequency-
converters
Building-
automation
Actuator
fuel
Actuator
oil

14/32 01.09.21, Subject to alterations
Operating instructions and equipment description LMV
20 Operating instructions and
equipment description LMV
Button Function
F button
- To adjust the fuel drive
(Hold down the F button and set the value with the - or + button)
A button
- To adjust the air drive
(Hold down the A button and set the value with the - or + button)
F and A button
- To shift to parametrisation mode P
(F and A button press simultaneously with - or + button)
- To adjust the speed for frequency converter operation (FC)
(F and A button press simultaneously with - or + button)
Information and enter button
- To navigate in information and service mode
* Selection (flashing symbol) increment (press button < 1 s)
* To switch to a lower menu level (press button < 1 ... 3 s)
* To switch to a lower menu level (press button < 3 ... 8 s)
* To switch the operating mode (press button > 8 s)
- Enter in parametrisation mode
- Unlock in case of fault
- One menu level down
- Button
- Reduce value
- For navigating in curve setting, information and service mode
+ Button
- Increase value
- For navigating in curve setting, information and service mode
- and + button: Escape function
(Press - and + button simultaneously)
- Do not accept the value
- One menu level higher
118/217
Building Technologies Division Basic Documentation LMV27... CC1P7541en
20 Operating via AZL2 unit 23.01.2017
20.2 Meaning of symbols on the display
P
V h min s %
Parameter setting mode
Info mode
Service mode
Actuator closing
Actuator opening
Fan motor controlled
Oil preheater on
Heat request from controllers
Ignition controlled
Valve controlled
Flame present
Fault status message
Unit of current display
Bild 2e/0807
Figure 77: Meaning of display
20.3 Brightness of display
Only available with backlit LCD:
The function of the backlit display is dependent on the type of LMV27.
The brightness of the display can be adjusted from 0…100% using parameter 126.
No. Parameter
126 Brightness of display
/reset

Subject to alterations, 01.09.21 15/32
Start-up and calibration
21 Start-up and calibration
Determine the burner output according to the table on page 24. P0 = Start stage, P1 = 1st stage / min.
output, P9 = 2nd stage / max. output.
Normally, P0 = P1. For the condensing boiler, P0 must be set higher than P1. The setting is dependent on
the boiler. The mixer head must be set according to the table.
To enter this adjustment mode, the burner must be on standby.
Standby means that the burner is supplied with voltage, gas pressure is built up and there is no demand
for heat.
The firing managers are parametrized in the factory. OFF UPr appears in the display during first start-up.
Enter password
Action button Display Description
OFF UPr means burner off and
non-programmed.
OFF means burner off and programmed.
Action button Display Description
Press F and A button simultaneously.
The display CodE appears
After releasing the buttons, 7 bars appear and
the first one flashes.
Use the - or + button to select a number or let-
ter.
Confirm each value with i/reset.
Confirm the password 1234 with i/reset after the
last input.
After correct input, the following appears for a
max. of two seconds
/reset
/reset

16/32 01.09.21, Subject to alterations
Start-up and calibration
Switch on the burner
Continuous heat requirement is necessary for further start-up!
LMV programmed
Start load preset
Use the values from the setting tables to preset the values.
Action button Display Description
When the firing machine is programmed, run is
displayed.
i/reset skips the next steps an continues at the
section Start heat settings with curve point P1
Small load.
Action button Display Description
Set the start position air flap.
Hold down button A and set the value with the -
or + button.
Move to the next curve point.
/reset
/reset

Subject to alterations, 01.09.21 17/32
Start-up and calibration
High load preset
Start identifier for curve programming - Calibration with flame
Action button Display Description
Set the high load air flap.
Hold down button A and set the value with the -
or + button.
Move to the next curve point.
Action button Display Description
When heat demand is present.
Confirm with i/reset button.
Burner start with pre-ventilation.
Blower start-up and safety valve ON
Run in pre-ventilation position
Pre-ventilation
If the leakage check is activated, Ph80, Ph81, Ph82 and Ph83 are displayed first.
/reset

18/32 01.09.21, Subject to alterations
Start-up and calibration
Start heat setting
Driving in ignition position
Action button Display Description
The ignition position P0 cannot be set until the
symbols  disappear.
Hold down A button a set the value with the - or
+button.
Press + button to confirm.
Ignition ON
Valves ON
Ignition OFF
Flame in start position
When transferring P1 to P2 for the first time,
CALC appears briefly
The curve points P2 to P9 are calculated auto-
matically as a straight line.
Use + button to confirm all curve points up to
curve point P9.
In curve point P9, set the excess air for the high
load at the gas train using the adjusting screw
"V" or "large flame" . The CO
2
value should be
9-10% for natural gas.
Action button Display Description

Subject to alterations, 01.09.21 19/32
Start-up and calibration
Setting the output in high and low-load operation
Use the -button to select curve point P1.
In curve point P1, set the excess air for the high
load at the gas train using the adjusting screw
"N" or "small flame" . The CO2 value should be
9-10% for natural gas.
Use the + button to select curve point P9 again.
In curve point P9, check the excess air for the
high load at the gas train and correct using the
adjusting screw "V" or "large flame" .
Action button Display Description
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.
Hold down A button and use the - or + button to
set the output for curve point P9.
The air surplus is not affected by this adjustment.
Use the - button to select curve point P1.
Check the small-load setting via the gas flow at
the gas meter or compare the nozzle pressure
with the values stated in 24. Adjustment tables.
Back to curve point P9
After setting all curve points, the burner is ready
for operation.
Press the ESC button briefly 3x to save all curve
points and access automatic mode.
Action button Display Description

20/32 01.09.21, Subject to alterations
Start-up and calibration
LMV phase display
Display Description
Ph00 Fault phase
Ph01 Safety phase
Ph10 Go home
Ph12 Standby (stationary)
Ph22 Blower start-up time (blower motor = ON, safety valve = ON)
Ph24 Run in pre-air position
Ph30 Pre-air time
Ph36 Run in ignition position
Ph38 Pre-ignition phase
Ph39 Leakage check filling time (test pressure switch min for installation between fuel valve 1 and
fuel valve 2)
Ph40 First safety time (ignition transformer ON)
Ph42 First safety time (ignition transformer OFF)
Ph44 Interval 1
Ph50 Second safety time
Ph52 Interval 2
Ph60 Operation 1 (stationary)
Ph62 Maximum time small-load setting (operation 2, preparation decommissioning, run in small-load
setting)
Ph70 After-burn time
Ph72 Run in post-ventilation position
PH74 Post-ventilation time (no external leak test)
Ph78 Post-ventilation time (abort when power controller ON)
Ph80 Leakage check idle time
Ph81 Leakage check test time atmospheric pressure, atmosphere test
Ph82 Leakage check filling test, filling
Ph83 Leakage check test time gas pressure, pressure test
Ph90 Gas shortage waiting time