THERMOSTAHL MTX-400 User manual

THERMOSTAHL POLAND Sp. z o.o.
Al. Wojska Polskiego 42B, 05- 00 Pruszków
tel. fax: [phone]
e-mail: [e-mail], Internet: www.thermostahl.pl
wer. 1/2018
MULTI-FUEL BURNER
SERVICE AND INSTALLATION MANUAL
MULTIMAX
MTX-400 AND MTX-400 KTS (250-450 KW)

SPIS TREŚCI:
1. Wstęp
2. Informacje ogólne
MTX-400 and MTX-400 KTS burner technical documentation
GENERAL INSTRUCTION MANUAL
THE PRESENT INSTRUCTION MANUAL IS SUPPLIED AS AN INTEGRAL COMPONENT OF THE APPLIANCE, AND
MUST BE TRANSFERRED TO THE USED ALONG WITH THE BURNER. WE ASK THE USER TO STORE THIS
MANUAL OVER THE TIME OF USE OF THE BURNER FOR REFERENCE.
1. GENERAL INFORMATION
This manual is delivered to the user as an integral part of the burner.
A thorough read of the manual shall let the user obtain important information concerning the assembly, use, safety and
maintenance of the burner. The burner may be installed only by qualified personnel, in line with the provisions in force,
and according to this manual.
Improper installation shall cause injury to persons and material damage, for which the supplier will not be liable. Before
commencement of any sort of maintenance or repair work, always shut off the electric power supply by pulling the power
supply line plug.
Make sure that the burner inlet and outlet meshes are not clogged.
In case of sale of the burner or of the entire appliance, where it is installed, this manual needs to be transferred
along, so that the subsequent user or installation specialist could get acquainted with it.
In case of any changes ot amendments to the burner equipment only use original parts provided by the
manufacturer.
The burner may be used exclusively for the purpose, for which it was constructed. Any other sort of use shall be
considered contrary to foreseen use, and, accordingly, hazardous. The burner supplied shall not be liable in any
way for damage arisen as a result of improper assembly or use and for lack of adherence to this manual.
The MTX-400/400 KTS burners are adapted for operation on pure fuel oil as well as waste fuel such as spent oil, engine
oil, crankcase oil, hydraulic oil and the synthetic material component - fraction (KTS-F)*.
*Only applies to model MTX-400 KTS.
NOTE!
The use of transformer oil, capacitor oil, petroleum and thinners is strictly forbidden!

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MTX-400 and MTX-400 KTS burner technical documentation
2. IMPORTANT REMARKS CONCERNING BURNERS
- The burner should be installed in an appropriate room with ventilation openings, according to requirements of provisions
in force, ensuring a sufficient supply of combustion air.
- Before connecting the burner, make sure that it is adapted to the power supply conditions at hand (electric power, fuel).
- For safety reasons, the burner must be effectively earthed, and the electric power supply line executed according to
current regulations.
- Before start-up of the burner and at least once per year, qualified personnel should execute the following activities:
a. Determine the amount of fuel supplied in accordance with the burner capacity.
b. Check the fuel feed system for tightness and lack of obstructions.
c. Determine the amount of air supplied for combustion in such a way so as to achieve a combustion efficiency
that would be in accordance with relevant separate provisions.
d. Check the operation of the burner concerning the combustion quality so that one avoids the risk of exceeding
permitted emission values of air pollutants.
e. Make sure that the control and security system operates properly.
f. Make sure that the combustion gas ventilation system operates properly.
g. Make sure that a copy of the burner instruction manual is available in the burner room.
WARNING! In case of repeating emergency burner shutdowns, do not attempt continued manual start-up
procedures. Contact the manufacturer's service department to remove the fault. Non-adherence to this
recommendation poses a risk of a grave failure of the entire heating appliance.
BURNER DIMENSIONS (MM)
Fig. 1.
TY: ABCDEFøG H
min maxLNX
MTX 400/400KTS 770 420 423 460 310 350 135 120 160 150 200 3/8’’

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MTX-400 and MTX-400 KTS burner technical documentation
SPECIFICATION: Type MTX400 / MTX400 KTS
Burner power - max. kW 450
Burner power - min. kW 250
Burner power - max. kcal/h 387000
Burner power - min. kcal/h 215000
Max. fuel consumption* l/h 42
Power supply V/Hz 230/50
Burner power consumption W 850
Heater power consumption W 900
Minimum compressor requirements l/min. 130
* The fuel consumption measurement is based on synthetic material fraction fuel. The calorific value is 38.5 MJ/litre.
BURNER ASSEMBLY PROCEDURE
1. The box contains, beside the burner, the following accessories:
- burner power supply and control plug (7-pin Euro connector)
- burner mounting flange
- flange sealant made of asbestos-free material
- sealing cord for the assembly flange
- flange mounting bolts and spacers
- pump set (pump with electric motor)
- multi-use oil filter, filter with a 100 W heater (KTS model)
- this instruction manual and warranty card
2. Assembly on the heating appliance
Fig. 2
The burner needs to be attached to the front face of a boiler or heater using the mounting flange (2) with adherence to the
order of work indicated in the figure above (fig. 2). To ensure safety, after installation of the burner, tighten the counterbolt
(1).
1. Counterbolt of the flame pipe
2. Mounting flange
3. Flange mounting bolt
4. Flange seal
5. Sealing cord
WARNING!
The burner may be mounted solely vertically with respect to the floor, on which the heating appliance is set.

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MTX-400 and MTX-400 KTS burner technical documentation
3. Connecting the compressed air line
In order to provide the burner with compressed air, it needs
to be connected to a hose terminating with an air connector
of type DN 7.2 at the location marked in fig. 3.
Compressed air is necessary for the burner to operate
properly. In order to prevent the burner from operating if the
air pressure falls or if there is no compressed air supply, a
sensor was used to cut the power to the fuel pump. Lack of
pressure in the circuit shall cause the fuel pump to be shut
off.
Warning!
The maximum permitted pressure of air connected to the
burner is 8 bar.
4. Fuel line connection
The fuel line, with a steel sheath, is delivered in bulk
together with the mounting flange and sealing rings. The
3/8'' hose connector needs to be screwed onto the fuel
pressure reducer see fig. 4.
Fig. 3
Fig. 4
5. Forming the fuel line
The fuel supply system should be designed and made according to Polish standards.Adhere to local provisions in force
as well.
To create the fuel line, the use of soft or hard copper piping is recommended, with an inner diameter of at least 14 mm.
Avoid the formation of siphons, in which air could collect. It is best to design the layout of the fuel line from the pump to
the burner in such a way that it exhibits a steady rise, protecting the system from air collecting in the line.
WARNING!
In case of supplying the burner with the synthetic material component fraction, the fuel system, filter and pump must be
thermally secured in a manner permitting the heating of the fuel system up to +40 °C (+/- 5 °C). Use a cable or heating
mat with a control thermostat as the heating unit.
Suggested diameters of the fuel lines on the pumping side:
- 16 mm for line lengths up to 15 m
- 18 mm for line lengths upwards of 15 m

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MTX-400 and MTX-400 KTS burner technical documentation
6. Electrical connection
230 V / 50 Hz power supply
Fig. 5
STB
Overheat thermostat, 110 °C
ON/OFF
Main switch
TS
Water/air temperature thermostat
LC
Fault indicator control
F
Fuse
P
Pump and operating time power supply
Warning!
The electric system powering the heater needs to be protected with a B16 circuit breaker.
7. Electric connection of the pump set
The pump unit is powered directly from the MTXburner Euro plug.
For the pump power supply, use a wire with a diameter of 3 x 2.5 mm2.
The pump motor needs to be connected according to the following diagram (fig. 6):
- N - zero
- B4 - phase
- PN - earth
Fig. 6

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MTX-400 and MTX-400 KTS burner technical documentation
Limitations concerning the length of the suction line and the raising height of the sucked oil.
- The height of the initial (suction) filter from the bottom to the fuel pump should not exceed (H) 3 m.
- The total length of the suction line may not exceed (L) 5 m (from pump to suction unit of floater).
In order to extend the intervals between fuel top-ups for the main fuel tank, the use of tanks not smaller than
having a volume of 1000 litres is required. Less frequent fuel provision shall enable the contaminants to fall to
the bottom of the tank. In order to improve on the purity of the fuel taken up, the suction mesh in the tank should
be equipped with an inlet floater, thanks to which the fuel will be taken from the top part of the tank.
Fig. 7
WARNING!
When using synthetic material fraction as fuel, one needs to remember that the solidification of this fuel occurs at
temperatures below 15 °C. In order to liquefy the fuel again, ensure fuel heating in the main tank to a value exceeding this
temperature. Asolution to ensure tank heating is the use of a heating coil within the central heating system of the boiler.

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MTX-400 and MTX-400 KTS burner technical documentation
Boiler hydraulic system diagram, single-line system:
Fig. 8
Description of markings:
1. Oil filter
2. Fuel pump with motor
3. Oil solenoid valve
4. Spray air pressure reducer
5. Air solenoid valve
6. Differential pressure switch (turbine operation sensor)
7. Air pressure switch (spray air minimum pressure sensor)
8. Air pressure gauge
9. Spray nozzle
10. Burner fan providing combustion air

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MTX-400 and MTX-400 KTS burner technical documentation
Chimney
The exhaust gas ventilation system is an important component of the entire heating system. For safety reasons, and to
ensure proper operation of the burner and boiler, the chimney structure should be designed and built by persons properly
authorised to do this. The construction and mode of execution of the chimney need to be in line with the relevant local
provisions of construction laws in force.
Chimney line draught
In order to ensure proper operation of the burner, it is recommended that a chimney draught regulator be installed within
the exhaust gas ventilation line. This regulator should be adjusted so that the underpressure in the combustion chamber
during operation would not exceed the value of 0.1 mbar.
Exhaust gas temperature measurement
Exhaust gas temperature measurement should be done using a manual or electronic thermometer, or with the use of an
exhaust gas analyser unit. The measurement is taken through an opening, diameter 8, executed on the exhaust gas
ventilation duct, at a distance of double the duct diameter from the heating appliance.
The temperature sensor should be placed in the centre of the gas stream, where the temperature is highest. the
measured temperature value should be between 160 °C and 240 °C. Above this range, chimney losses begin to increase
and the device efficiency falls.
Basic adjustment procedures of the burner
The burner adjustment work should be done necessarily using results of analyses of the exhaust gases. Only in this way
may it be guaranteed that the best values of combustion are ensured, at the same time adhering to a maximum purity of
the exhaust gases, in order to protect the environment.
In order to execute the exhaust gas analysis correctly, it is necessary to have the following devices at hand:
precise chimney draught sensor
soot analysis pump
carbon dioxide analyser
exhaust gas thermometer.
All the measurement values should be recorded in the burner inspection form. The measurements need to be taken at the
operating temperature of the heating appliance. In case of water-based boilers, the water temperature in the boiler must
be at least 60 °C. A condition of achievement of proper measurement results is tightness of the boiler and the exhaust gas
ventilation line. The measurement opening, diameter 8, should be made downstream from the heating appliance on the
exhaust gas ventilation duct, at a distance of double the diameter of the duct, in which it is made
Spray air pressure setting
The spray air pressure should be set on the reducer, fig. 9,
following the start-up phase. The correct air pressure value
is 1.2 bar. This value is appropriate for the full burner power
capacity range.
Fig. 9

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MTX-400 and MTX-400 KTS burner technical documentation
Combustion air throttle setting
In every burner, depending on the type of nozzle used in it,
the factory setting of the throttle controlling the air supply to
the combustion chamber allows start-up of the burner.
Precise adjustment should be made during the first start-up
of the burner, taking into account measurements of soot and
carbon dioxide.
A wrong setting of the air throttle may prevent the burner
from igniting or cause it to work erratically.
Fig. 10
Adjustment of the riser plate and the air flap
The plate and air flap settings permit the user to precisely
control the mix. Factory settings should allow the
achievement of a proper mix without the necessity to change
them, using only the combustion air throttle, fig. 10.
It is not recommended to change the factory setting.
In case of necessity of changing the factory settings, follow
the instructions below:
Changing the plate position
Fig. 11
The position is changed by screwing in or out of the bolt
found on the right side of the regulator, see fig. 11. In order
to determine the placement of the plate, the adjustment part
has a scale describing the position. Position 1 denotes
minimum extension of the plate, position 3 denotes
maximum extension.
Change of placement of the combustion air flap
The air flap is adjusted using the adjustment screw, see fig.
12. Before the position is changed, loosen the counternut.
Fig. 12
Warning!
The exhaust gases ventilated to the atmosphere should be checked and analysed concerning their content twice during
the heating period, or every one thousand hours of burner operation.
MTX-400 and MTX-400 KTS burner technical documentation

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MTX-400 and MTX-400 KTS burner technical documentation
Control thermostat units
The function of the capillary thermostats is the maintenance
of the imposed temperature of the individual heating blocks
in the burner and its actuation as required.
Thermostat functions:
1. Nozzle rod temperature
2. Main block temperature
3. Control thermostat (burner initiation)
Thermostat settings
Pure fuel oil, waste and spent oil:
1 - 60 °C, 2 - 60 °C, 3 - 55 °C
Synthetic material fraction
1 - 40 °C, 2 - 40 °C, 3 - 35 °C
Fig. 13
Warning!
Thermostats are adjusted using a flat head screwdriver. Excessive temperature of the heating blocks may
permanently damage heating components and prevent the boiler from operating altogether.
Burner periodic inspections
The MTX400 and MTX400 KTS burners are devices foreseen for continuous operation throughout the entire year, and
do not require daily maintenance. However, due to normal wear of burner components, it is recommended to have service
personnel maintain the appliances at least once per year before the start of the heating period. In case of burners
operating all year long without a seasonal brake, service the burner following up to 2500 hours of operation. The fuel
system requires maintenance in terms of cleaning of filters found in the fuel tank and the precision cleaning filter placed
just upstream from the pump. The filter cleaning frequency depends on the type of fuel used for combustion. For light fuel
oil (i. e. Ekoterm and similar), this time may be extended to several heating seasons. The manufacturer, despite this,
recommends cleaning of filters before each heating period. In case of use of waste fuel, mineral oils or plant oils, filter
cleaning is recommended every 700 hours of operation. Note the condition of used plant oils, whether they do not contain
excess solids, as these shall cause the filter cleaning periods to shorten drastically. It is recommended to place a vacuum
meter on the fuel filter clean side to control the filter cleanliness on a continuous basis, and will allow one to prevent
emergency burner shutdowns. The usual maintenance procedures for the burner also entail checking the combustion
chamber condition in the device, in which the burner operates. The combustion chamber condition lets one determine,
whether the mix combustion process runs correctly. Awet combustion chamber or dark colouring of the walls all point to
bad combustion of the mix, while a dry chamber with a beige hue covering it indicates a correct combustion process.
MTX-400 and MTX-400 KTS burner technical documentation

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MTX-400 and MTX-400 KTS burner technical documentation
Emergency conditions:
Symptoms
Causes
Remedies
The burner does not start up, no
indication of fault
Burner automatic unit failed
Replace burner automatic unit
No power supply on burner plug
Replace fuse or damaged pins
The fan does not turn during the start-
up cycle
Burner automatic unit failed
Replace
Motor capacitor or fan motor damaged
The fan turns, the burner locks in the
deaeration phase
Burner automatic unit or photoresistor
failed
Replace
Photoresistor wiring faulty
No fuel ignition following the start-up
cycle, no electric arc
No ignition transformer power supply,
transformer damaged, ignition wires
broken or shorted, damage to
insulation or contamination of
electrodes, wrong electrode
arrangement
Replace
Adjust electrodes
Low spray air pressure, below 0.7 bar
Adjust spray air pressure , fig. 9

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MTX-400 and MTX-400 KTS burner technical documentation
Emergency conditions, continued
No fuel ignition following the start-up
cycle with electric arc (no fuel in
nozzle, fuel pump does not operate)
No pressure in compressed air system
(compressor failure, closed ball cutoff
valve)
Check compressed air line
Air solenoid valve fault
Replace
No fuel ignition following the start-up
cycle with electric arc (no fuel on
nozzle, fuel pump operates)
No fuel in tank
Check fuel level
Clogged general cleaning filter
Clogged precision cleaning filter
Check and clean fuel filters
Suction line contains air
Deaerate the fuel pump, locate the
leak and remove
Oil solenoid valve fault
Replace solenoid valve
Nozzle clogged
Screw out and clean the nozzle
Oil line in heater block clogged
Service burner
Pump fault
Replace
No fuel ignition following the start-up
cycle with electric arc (fuel is sprayed
into combustion chamber)
Non-combustible substance in fuel
(i. e. water, coolant or brake fluid)
Check fuel
Bad configuration or contamination of
ignition electrodes
Adjust
Too low oil temperature on nozzle exit
Check and replace 'TC' thermostat
Air-fuel mix ratio wrong
Adjust burner
MTX-400 and MTX-400 KTS burner technical documentation

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MTX-400 and MTX-400 KTS burner technical documentation
Emergency conditions, continued
Mix ignites and detonates
Air-fuel mix ratio wrong, wrong
arrangement or contamination of
ignition electrodes
Adjust the burner, check whether the
fuel does not contain petrol, thinners
and other easily combustible or
explosive substances
Burner works in impulses (flame
disappears, unit restarts)
Clogged fuel system, fuel lines contain
air
Clean, deaerate, tighten or replace
components of the fuel system
Following start-up and ignition, burner
shutdown and repeated start-up
attempts
Too weak signal from photoresistor
Clean or replace photoresistor
Bad burner adjustment
Too little air (smoking flame)
Too much spray air (flame is
extinguished)
Adjust burner, check CO and CO2
levels
Too much combustion air (separation
of flame from plate)
Clean or replace nozzle, or clean the
plate
Irregular flame shape
WARNING!
Finding and repairing faults of the burner is very important for the health and life of the users.Always strictly adhere to
occupational health and safety rules. The burner, following repairs, must be completely functional, checked and absolutely
safe. In case of doubts, submit the burner to the manufacturer for appraisal and repair.

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MTX-400 and MTX-400 KTS burner technical documentation
The diagram curve describes approximate values of pressure in the combustion chamber, proportional to the burner
achieved capacity values. The values from the diagram were measured on a test bed system. Start-up resistance and
burner operating resistance are dependent on the combustion chamber design, exhaust gas ventilation type and start-up
load.
Precise values may in this regard be calculated for a particular installation only based on values from experience.
6
5
4
3
2
1
0
100 130 160 190 220 250 280 310 340 370 400 430 460 490 520 550
thermal power, kW

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MTX-400 and MTX-400 KTS burner technical documentation