Nu-Way MDFL 1880 Instruction Manual

Installation & Maintenance Manual
MDFL 1510
MDFL 1880
MDFL 2505
MDFL 2705
Dual Fuel Burner
11/12
Tel:[phone] Fax: [phone] Email: [email protected] Web: www.nu-way.co.uk

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Contents
1. General information............................................................................................................. 3
2. Scope of delivery..................................................................................................................3
3. Maintenance and customer service..................................................................................... 3
4. Operating instructions ..........................................................................................................3
5. Instruction of operating personnel ....................................................................................... 3
6. Filter/Strainer........................................................................................................................3
7. Key for code designation ..................................................................................................... 4
8. Technical specifications........................................................................................................4
9. Boiler connection dimensions .............................................................................................. 4
10. Ignition electrode .................................................................................................................. 5
11. Flame failure controller ......................................................................................................... 5
12. Oil connection....................................................................................................................... 6
13. Oil pump ............................................................................................................................... 8
14. External oil pump (option) ....................................................................................................8
15. Front panel ...........................................................................................................................9
16. Air flap positioning motor .................................................................................................... 9
17. Remote switching .................................................................................................................9
18. Air pressure switch ............................................................................................................ 10
19. Gas pressure monitor......................................................................................................... 10
20. Functional test .................................................................................................................... 10
21. Start-up............................................................................................................................... 11
22. Troubleshooting / process description ................................................................................ 15
23. Control unit ........................................................................................................................ 19
24. MPA 22 control unit display ................................................................................................ 19
25. Calculation principle for gas burner adjustment ................................................................ 20
26. Gas train KEVII 1 ½" , KEV 2" and KEV DN65 .................................................................. 21
27. Gas train KEV25 1" and KEV30 1½"..................................................................................22
28. Nozzle selection diagram ................................................................................................... 23
29. Adjustment tables ............................................................................................................... 24
30. Exploded views / spare parts lists .....................................................................................26
31. Adjustments log.................................................................................................................. 33
32. Declaration of conformity for dual-fuel burner for heating oil
and natural gas or liquid gas .............................................................................................. 34
33. Overall dimensions ............................................................................................................ 36
34. Working ranges .................................................................................................................. 36

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1. General information
Installation of a dual fuel 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.
Light oil in accordance must be used. The burners are suitable for combustion of natural gas or liquid gas
and are in compliance with European standard EN 676 and EN 267.
2. Scope of delivery
Before installing the Nu-Way Series MDFL1510/2705 dual fuel, 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
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 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 non-
genuine 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 vis-
ible position in the boiler room. The address of the nearest customer service centre must be displayed on
the back of the operating instructions.
5. Instruction of operating personnel
Faults are often caused by operator error. The operating personnel must be properly instructed in how the
burner works. In the event of recurring faults, Customer Service should be notified.
6. Filter/Strainer
According EN 676 a filter/strainer shall be fitted at the inlet of the safety shut-off valve to prevent the ingress
of foreign elements.

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7. Key for code designation
8. Technical specifications
* The power consumption of the version with external oil pump is 2.7 A higher.
9. Boiler connection dimensions (All dimensions are given in mm)
Burner type
Technical specifications MDFL1510 MDFL1880 MDFL2505 MDFL2705
Burner output in kW
(in gas-fired operation)
441 - 1510 738 - 1880 620 - 2505 887 - 2705
Burner output (in oil-fired operation)
in kg/h
(in kW)
46.2 - 127.3
(548 - 1510)
62.2 - 158.5
(738 - 1880)
64.0 - 211.2
(759 - 2505)
74.8 - 228.0
(887 - 2705)
Fuel Light oil, 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 *
10.5 / 6.5 15.0 / 9.0 15.5 / 9.3 16.3 / 11.3
Electric motor power (at 2800rpm) in kW 3.0 4.0 4.4 5.5
Flame failure controller KLC1000
Control box MPA 22
MDFL1510
Burner output max.
Series
M12
Ø260
Ø310 - 345

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10. 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.
11. Flame failure controller
Operating Indicator LED:
LED is OFF: KLC is not switched on – no power supply
or ‘no flame’ is detected.
LED is FLASHING: KLC has detected a flame; the qual-
ity of the flame signal is indicated by the intensity of the
flashing of the LED – fast flashing indicates a healthy
flame signal and vice versa - slow flashing indicates a
weak flame signal.
LED is ON: KLC has detected the strongest level of
flame signal.
Commissioning and maintenance
The installation and commissioning must be done by qualified personnel only. Before energising the KLC
flame detector please check the cable and wiring connections are in accordance to the diagram and in-
structions given above. For good maintenance which will ensure trouble free operation of the KLC flame
detector; please keep the sight glass clean by wiping with a soft dry clean cloth. Warning: Do not use any
kind of cleaning sprays or fluids. During commissioning and after any cleaning maintenance, the flame de-
tector should be checked, as the UV tube is subject to a natural ageing process and towards the end of its
life span it is prone to malfunction.
To check that the flame detector is sound we recommend the following procedures be followed:
• Start the burner with the fuel supply closed-off or remove the flame detector from its mounting flange
and cover the UV tube using a soft cloth to avoid touching the glass lens. The control box will lock-out
at the end of the safety time due to absence of a flame signal.
• Remove the flame detector from its mounting flange. Start the burner while exposing the flame detec-
tor to an external UV radiation source such as a cigarette lighter flame, or a small gas flame (n.b. elec-
tric room lighting or a torch is inadequate). The burner Control Box must go to lock-out due to
detecting an extraneous light source either immediately or at the end of the air pre-purge cycle,
depending on the type/model of the Control Box.
• Close off the fuel supply or remove flame detector from its mounting flange and cover the UV tube
using a soft cloth when the burner is in the "run" position. The control box must go immediately to
lock-out resulting in the burner shutting down.
ignition electrode gas
ignition electrode oil

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If any of these safety checks do not function as described i.e. they should always result in burner shutdown
and control box lock-out; then it is essential to replace the flame detector with a new KLC flame detector.
For safety and trouble free burner operation, we recommend that the flame detector should be replaced
after every 10,000 hours of burner operation or approximately every 30months for a burner operating on
an average of 10 hours per day.
12. 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 three factors relating 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 pos-
sible degassing of the oil, dimension "X" should not exceed a length of 4 m.
Double line system
Suntec AJ6 Suntec J7
H (m) L (m) L (m)
∅ mm 10 12 14 16 10 12 14 16 20
4.0 13 28 54 93 7 17 34 60 -
3.0 11 25 47 82 6 15 29 52 -
2.0 9 21 40 70 5 12 25 45 -
1.0 8 17 34 59 3 10 21 37 -
0.5 7 16 30 53 3 9 19 34 -
0 6 14 27 48 2 8 16 30 77
-0.5 5 12 24 42 - 6 14 26 67
-1.0 4 10 20 36 - 5 12 22 58
-2.0 2 7 14 25 - 3 8 15 40
-3.0 0 3 7 13 - - 3 7 22
-4.0 - - - - - - - - 4

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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 - - - -

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13. 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.
Suntec oil pump for MDFL1510 / MDFL1880
1 Supply
2 Return
3 Nozzle connection
4 Pressure gauging connection
5 Vacuum gauging connection
6 Pressure setting
Suntec oil pump for MDFL2505 / MDFL2705
1 Supply
2 Return
3 Nozzle connection
4 Pressure gauging connection
5 Vacuum gauging connection
6 Pressure setting
To convert the pump for operation on a single line system, the following points must be observed:
remove the return line and the connection 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.
14. External oil pump (option)
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 moni-
toring. In the event of loss of oil pressure, the burner shuts
off automatically. The oil pressure switch is pre-set at the fac-
tory. Pressure can be adjusted using the setting screw (6).
6
5
2
1
3
4
5
3
42
6
1
1
234
567

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15. Front panel
16. Air flap positioning motor
The air flap positioning motor is designed for air flap
adjustment on progressive two-stage burners or mod-
ulating burners. The motor is activated electronically
via the microprocessor-controlled control box.
17. Remote switching
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.
Controller (option)
Display and operating unit AM01
On/Off
Selector switch
Oil operation/gas-fired operation

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18. 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.
19. 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.
20. 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 after expiry of the safety interval.
Start-up with exposed flame sensor:
The burner must go into lockout mode after approx. 20 s of pre-ventilation.
Normal start-up; if the burner is in operation, black out the flame sensor:
repeat start-up test, the burner must go into lockout mode after expiry of the safety interval.

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21. 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 heat-
ing 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.
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 en-
tered by the following procedure.
Important: If the setting operation is interrupted within 30 min. or not complet-
ed correctly, OFFUPr will also be displayed.
To change new setting parameters or old setting parameters, follow these
steps:
Step 1:
Enter the safety code. Press key 1 and key 2 simultaneously
Step 2:
7 horizontal bars are now displayed. Enter the password as follows.
Note: The intervals between the individual inputs must not be longer than 20
sec., as the MPA 22 will otherwise revert to standby mode. If this is the case,
you will have to start the code entry procedure from the beginning again.
- Press the minus key twice.
- Confirm your entry by pressing key 2 once.
- Press the minus key once.
- Confirm your entry by pressing key 2 twice.
- Press the plus key 4 x.
- Confirm your entry by pressing key 2 once.
- Press the plus key twice.
- Confirm your entry by pressing key 2 once.
- Press the plus key 3 x.
- Confirm your entry by pressing key 2 once.
- Press the minus key 4x.
- Press the enter key once.
Password entry is now finished.
Step 3:
after the correct password has been entered, EOIL appears on the display.
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 op-
erating 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 of Stage 3 should be set to a value 0.1° greater than
the value of Stage 2!
1
2
OFF
OFFUPr
2
2
2
2
2
or
or
2
and
E OIL
P
9 OIL
PL/A

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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 Stage3 / 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 pro-
cedure 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
2and 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.
or
2
and
or
2
and
3 OIL
PL/A
1 OIL L/A
P
or
2
and
or
2
and
0 OIL
PL/A
2 OIL
PL/A
0 OIL
PL/A
4 OIL
PL/A
1
2
or
2
and
and

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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 heat-
ing 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.
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 en-
tered by the following procedure.
Important: If the setting operation is interrupted within 30 min. or not complet-
ed correctly, OFFUPr will also be displayed.
To change new setting parameters or old setting parameters, follow these
steps:
Step 1:
Enter the safety code. Press key 1 and key 2 simultaneously
Step 2:
7 horizontal bars are now displayed. Enter the password as follows.
Note: The intervals between the individual inputs must not be longer than 20
sec., as the MPA 22 will otherwise revert to standby mode. If this is the case,
you will have to start the code entry procedure from the beginning again.
- Press the minus key twice.
- Confirm your entry by pressing key 2 once.
- Press the minus key once.
- Confirm your entry by pressing key 2 twice.
- Press the plus key 4 x.
- Confirm your entry by pressing key 2 once.
- Press the plus key twice.
- Confirm your entry by pressing key 2 once.
- Press the plus key 3 x.
- Confirm your entry by pressing key 2 once.
- Press the minus key 4x.
- Press the enter key once.
Password entry is now finished.
Step 3:
after the correct password has been entered, EGAS Pn appears on the display.
Step 4:
the operating points P9 (max load), P1 (min load) and P0 (starting point)
can now be selected by pressing the plus or minus key.
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.
1
2
OFF
OFFUPr
2
2
2
2
2
or
2
and
or
GAS Pn
P
9GAS
PL/A

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Step 6:
After you have set P9, press the plus key to set P1. 1 Gas appears on the dis-
play.
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 operating point (starting point) can now be set to a value between
0° and 90° by holding down key 2 and optionally pressing the plus or minus
key. The value of P1 should preferably be set. If P1, (min. load) is set to a very
low value, it is recommended to set P0 to a higher value than P1 in order to
ensure stable starting.
For basic setting values, please refer to the adjustment table.
Step 8:
After you have set P0, press the plus key.
GAS Pn. appears on the display.
Now close the safety 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 approx-
imately 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
2
and
or
2
and
1GAS
PL/A
0GAS
PL/A
GAS Pn
P
or
2
and
0GAS
PL/A
or
1GAS
PL/A
or
2
and
or
or
2
and
9GAS
PL/A
1
2
and

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22. Troubleshooting / process description
Defect determined: Cause: Remedy: Fault code
Burner motor does
not start up
Electric supply lead faulty Rectify faults in electrical installation
Fuse faulty Replace
Safety thermostat locked Unlock 42 h
Temperature of controller setting is
exceeded
Renewed start attempt after temperature
drop
MPA 22 faulty Replace 04 h
Leak Rectify leak 44H / 43H
No gas Safeguard gas supply
Gas pressure monitor faulty Replace gas train 22 h
Filter in gas train dirty Clean or replace
Air pressure switch not in idle position Check air pressure switch (see page 10) 20 h
Burner motor faulty Replace
No load at terminal 5 Check plug connection and current path of
solenoid valve
Mains voltage <187 V Rectify faults in electrical
installation
Burner starts up and
switches to fault mode
before or after expiry of
safety period
Air pressure switch does not switch
through during pre-ventilation
See Page 10 21 h
Ignition influencing of ionization monitor See Page 11 26 h
Gas solenoid valve does not open Replace gas train
Starting gas quantity set too low Increase starting gas quantity
No ignition Check ignition electrode and setting, igni-
tion transformer and cable
Phase and zero mixed up Connect connector unit in correct phase
sequence
Flame control faulty Check according to Page 11 2BH
Air pressure switch opens during opera-
tion
See Page 10 21 h
Gas nozzle dirty or faulty Replace gas nozzle
Flame extinguishes
during operation
No gas Safeguard gas supply
Filter in gas train
dirty
Clean or replace
Flame blow-off Incorrect burner setting 27 h
Air pressure switch contact opens Check/replace air pressure switch 21 h
Flame signal too weak Measure flame signal, check ionisation
electrode
27 h

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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 posi-
tioning motor setting value at ignition in angular degrees, plus a wrench
symbol denoting the service mode.
The following points can be retrieved by repeatedly pressing the enter
key:
- The characteristic curves for points P0, P1 and P9
- The last 6 fault messages P10 to P15 (see fault code MPA)
- The testing times of the valve proving system P16 and P17
- The flame quality P18
- The eBus address of the MPA P19
- The switch setting of the valve proving system P21
- The eBus address of the external controller P24
- The modulation delay
- The set start points P26
To exit the service mode, please press the enter key or wait approx.
20 sec.
Information mode
The information mode is intended for display of consumption figures, operating hours and software data.
To access information mode, press the Enter key for approx. 0.5 sec.
Azero and a value appear on the display.
The following values can be queried in information mode under setting
points 0 to 8. Retrieve by repeatedly pressing the enter key:
Important:
If no key is pressed for longer than 20 sec., the display returns to
normal operating mode.
0 = fuel consumption
1 = total operating hours
2 = for oil only
3 = for oil
only 4 = number of successful start-ups
5 = display of software version
6 = software creation date
7 = hardware number
8 = date of production
Adjustment
point Adjustment
values
Service mode
symbol
Adjustment
point
Information mode symbol
display
value

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Troubleshooting the MPA
Code Description
04 h Internal hardware fault
05 h Internal hardware fault
06 h Internal hardware fault
07 h Internal hardware fault
09 h Internal hardware fault
10 h Internal hardware fault
11 h Internal hardware fault
12 h Internal hardware fault
13 h Internal hardware fault
14 h Internal hardware fault
15 h Internal hardware fault
20 h Air pressure switch is not in idle position
21 h Failure of air pressure switch
22 h Failure of gas pressure monitor
25 h No flame after safety period
26 h Outside light
27 h Flame failure during operation
29 h Internal hardware fault
2AH Internal hardware fault
2BH Short-circuit in photo resistor or internal fault
2CH Internal hardware fault
30 h Internal hardware fault
31 h Internal hardware fault
32 h Internal hardware fault
33 h Internal hardware fault
34 h Internal hardware fault
42 h Safety chain interrupted
43 h Y3 found to be leaking during leak check
44 h Y3 found to be leaking during leak check
45 h Internal hardware fault
46 h Internal hardware fault
47 h Internal hardware fault
48 h Internal hardware fault
4AH Internal hardware fault
5BH Internal hardware fault
4CH Internal hardware fault
4DH Internal hardware fault
4EH Internal hardware fault
50 h Internal hardware fault
51 h Internal hardware fault
52 h Internal hardware fault
53 h Internal hardware fault
54 h Internal hardware fault
55 h Internal hardware fault
56 h Internal hardware fault
57 h Internal hardware fault
58 h Internal hardware fault
59 h Internal hardware fault

18
E. 30.07.07 • G. 07.06.11
Process description
Start-up tests Processor and program memory test / move actuator drives to reference position
State 01 Start-up decision (heating request present)
State 02 Blower idle state check
State 03 Blower start-up
State 04 Preventilation / operation of gas flap actuator over speed range
State 05 Preventilation / activate and test watchdog
State 06 Preventilation / move gas flap actuator to ignition position
State 07 Move air flap actuator to ignition position
State 08 Pre-ignition depending on parameters
State 09 Start-up safety period
State 10 Stabilisation period
State 11 Move positioning drive from ignition point to operating characteristic
State 12 Operation
State 13 VPS - evacuate valve cavity / (post-ventilate)
State 14 Test duration Y2 / (remaining post-ventilation time)
State 15 VPS - fill valve cavity / (remaining post-ventilation time)
State 16 Test duration Y3 / (remaining post-ventilation time)
State 17 Remaining post-ventilation time
State 18 Restart disable time / waiting loop for low gas program
State 20 Standby position
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
Code Description

19
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23. Control unit MPA 22
The MPA 22 is a microprocessor-controlled intermittent-
duty 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
24. MPA 22 control unit display
+
–
12
PSiGL/A
h
l,m3
Acknowledg-
ment or reset
key
Key 1
Actuation of gas-
flow control flap
in conjunction
with +/- key
Key 2
Actuation of air-
flow control flap
in conjunction
with +/- key
Key + / Key -
In conjunction
with key 1 or 2
On when
setup mode
is selected
Start-up
Lights up during
the run-up phase,
OFF during
operation
Lights up when the
gas-flow control
flap is active
On when
information
mode is active
Lights up when the
air-flow control
flap is active h = Operating hours indicator
l, m3= Oil or gas consumption
Operation, flame burning
Fault
Lights up when
service mode
is active
Liquid-crystal
display
Symbols for
open/close flaps

20
E. 30.07.07 • G. 07.06.11
25. 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
LPG gas (propane) Hi,n= 25.89 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 sea level 230 m
Barometric air pressure B (acc. to table) 989 mbar
Gas pressure PGat meter 20 mbar
Gas temperature JG16°C
Boiler output Qn430 kW
Efficiency hK (assumed) 90%
Calorific value Hi,n 10.4 kWh/m3
Gas flow in standard state (Vn)
Gas flow in operating state (V B)
Conversion factor (f)
Annual average air pressure
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]
JG= gas temperature at gas meter [°C]
Average geodetic altitude of the
supply region above sea level [m]
from 1 51 101 151 201 251 301 351 401 451 501 551 601 651 701
to 0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750
Annual average of air pressure (mbar) 1016 1013 1007 1001 995 989 983 977 971 965 959 953 947 942 936 930
VnQn
η
kH×i n,
-------------------- 430kW
0 90 10×4kWh
m3
-----------
, ,
----------------------------------------= 46m3
h
------
= =
VBVn
f
------ 46m3
h
------
0 94,
-------------= 49m3
h
------
= =
fB PG
+
1013
-------------- 273
273 ϑG +
--------------------
×=