Mark MEGAFLEX Technical Manual
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Mark MEGAFLEX Technical Manual

Mark MEGAFLEX Technical Manual

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Summary of Contents for Mark MEGAFLEX

  • Page 1 Technical manual...
  • Page 2 INSTRUCTIONS FOR USER If you have questions concerning the use of your boiler or heating system, please ask your installer. It is in your own interest and that of the installer that you are aware of how to operate your boiler and heating system safely and efficiently.
  • Page 3 Switching off the boiler During summer time the room thermostat can be set to a lower value to turn off the boiler. During winter or during a longer period of absence this temperature never should be set to a lower value than 15 °C.

  • Page 4: Table Of Contents

    Description boiler Technical data Component Matrix Dimensions Operation General Central Heating (CH) 4.2.1 On-off room thermostat 4.2.2 Optional 0-10V 4.2.3 Outside Temperature Control OTC (optional) 4.2.4 Optional digital communication 4.2.5 Slow start 4.2.6 Protection against insufficient flow through boiler 4.3 Domestic Hot Water (DHW) 4.3.1 External storage tank (choice by manufacturer between opt.
  • Page 5 Air-supply and flue-gas connection 6.5.1 B23 6.5.2 C33 6.5.3 C63 6.5.4 Pressure drop calculations 6.5.5 Installing flue-exhaust and air inlet Electrical connection 6.6.1 Wiring diagram 6.6.2 NTC resistance table Pneumatic connections PC-connection Commissioning Gas category Adjustment % CO %) and check input Errors General DHW errors...

  • Page 6: Description Boiler

    DESCRIPTION BOILER 1 Manometer 6 Sight glass 2 Display LCD 7 Flow NTC 3 Power switch 8 Ignition electrode 4 Fuse 9 Ionisation flame detector 5 Burnerhood 10 Inspection cover...
  • Page 7 11 Gas pipe 18 Exhaust 12 Gas valve 19 Return 13 Air supply 20 Maxsys 14 Fan 21 Terminal strip 15 Overheat limiter 22 Syphon pressure switch 16 Flow 23 Air pressure switch 17 Flue gas NTC...
  • Page 8 24 Sump inspection cover 28 Return NTC 25 Syphon 29 Automatic air vent 26 Fill and drain valve 30 Venturi 27 Water pressure switch...

  • Page 9: Technical Data

    TECHNICAL DATA Technical data Megaflex series Type 850-11 range rated 1020-13 range rated Central heating Nominal input max load (Hi) 1020 Power range percentage % Manual technician menu advanced setting CH Nominal input min load (Hi) Nominal ouput max load 80-60 °C...

  • Page 10: Component Matrix

    Maximum allowable power consumption 6900 6900 Fuse 400V~3N/10 400V~3N/10 * as coming from factory without extra devices connected COMPONENT MATRIX Overview of main components used in MegaFlex series Part 850-11 1020-13 Boiler control Honeywell Maxsys S4966V2052 S4966V2052 Display (user interface)

  • Page 11: Dimensions

    DIMENSIONS...
  • Page 12 The appliance is not to be used by children or persons with reduced physical, sensory or mental capabilities, or lack of experience and knowledge. Children, even if being supervised, must not play with the appliance. In the case of failure or malfunction of the appliance, do not attempt to repair it yourself.

  • Page 13: Operation

    OPERATION 4.1 General The Megaflex is a floor standing boiler, equipped with a cast aluminium heat-exchanger. During heat demand the controller activates the pump. The controller checks the air pressure switch (zero check) and increases the fan speed to perform an airflow-check. Once the air pressure switch closes, the fan speed increases to ignition speed and a 5 second pre-purge is performed.

  • Page 14: Outside Temperature Control Otc (Optional)

    In the user/technician menu, under diagnostics, boiler information the actual voltage input and boiler setpoint are displayed. Caution : Ensure that the 0-10V DC signal is free from electrical interference! 4.2.3 Outside Temperature Control OTC (optional) The boiler may use an outdoor sensor to provide weather compensation (OTC). To activate weather compensation connect an oudoor sensor to numbers 5 and 6 on the terminal strip C2.

  • Page 15: Slow Start

    4.2.5 Slow start The boiler uses the “slow start” procedure to prevent the boiler from supplying excessive power in low load situations. After “zero check” APS and closure APS with pre purge ignition starts. Following, a stabilization period, the boiler modulates down to low capacity and maintains this capacity for 1 minute. Subsequently the boiler power increases at a target rate of 4°C/min until maximum capacity or set temperature has been reached.

  • Page 16: Domestic Hot Water (Dhw)

    4.3 Domestic Hot Water (DHW) 4.3.1 External storage tank (choice to be made by manufacturer between option 1 and option 2) 4.3.1.1 Option 1. External storage tank with thermostat (hydraulic 3-way valve) As standard the DHW configuration is factory pre-set for an external storage tank + tank thermostat. For hydraulic connection of an external storage tank to the boiler one should either use : •...

  • Page 17: Dhw Priority/General Behaviour With External Storage Tank

    The set point temperature of the storage tank is adjustable (default set at 60°C,the flow temperature is DHW setpoint + 20K). Warning : if a CH heat demand exists immediately after finishing the heat request for DHW, it is possible for high temperatures to flow into the CH system regardless of CH set point (hot shot).

  • Page 18: Boiler Control

    BOILER CONTROL 5.1 Control Panel The control panel has 12 buttons and a display as shown in the figure below. 5.2 Push buttons on control panel Description of push button use R1-C1, R2-C1 and R3-C1 (back) buttons follow, if pressed, the associated icon in the display (left) R1-C2 and R3-C2 (up-down) buttons, scroll, if pressed, through the different menus R2-C2 button confirms, if pressed, the highlighted selection, or confirms what is requiered by LCD R1-C3 button (escape) returns, if pressed, to main screen...

  • Page 19: User Menu

    5.3 User menu By pressing the “menu-button” the display will show the text as given in the figure below. By pressing the button marked “3” in the figure above the user menu is accessed. Pressing the button marked “5” returns back to the main screen. By pressing the button marked “4” the installer menu is accessed.

  • Page 23: Installer (Technician) Menu

    5.4 Installer (technician) menu If the button marked “4” (page 21) is pressed the screen as given in the figure below will appear. The installer (technician) access code is 231 +- (R1-C1 and (R2-C1) buttons are used to increment/decrement value Up and down (R1-C2 and R3-C2) buttons are used to select character to be modified ok (R2-C2) button confirms value Once the menu is accessed by entering the code the following options will be shown...

  • Page 30: Manual Chimney Sweep Mode

    5.5 Manual Chimney sweep mode For routine maintenance and/or service purposes a CH request can be generated to force the burner to a specific load from minimum to nominal (0-100%). This is only possible if no error condition is present. The chimney sweep function can be started from the user menu and will be active for 15 minutes.While active it is possible to navigate through other menus to check the boiler status and functionality.
  • Page 31 USER MENU After factory Recommended reset 1. HEATING 1. CH tempera- 1. CH setpoint 90/Technician ture/OTC set 2. Outside temperature for CH off 2. ECO set- point reduction 3. Scheduler set 1. Enable/disable on Enabled Disabled Enabled Enabled board scheduler 2.
  • Page 32 Recom- After factory mended reset 2. ADVAN- 1. DHW power 1. Maximum power CED DHW 2. Minimum power SETTINGS 2. DHW 1. Storage temperature setpoint temperatures 2. Boiler temperature setpoint 3. DHW setpoint hysteresis 3. DHW pump 1. DHW post time settings 4.
  • Page 33 Recom- After factory mended reset 6. CASCADE 1. Cascade set 1. Cascade switch delay 2. Cascade min power 3. Burner power (default value x = 2550 17,21,25,29 boiler specific) 4. Boiler for DHW 5. Pi loop period 6. Burner water flow delay 7.

  • Page 34: Installation

    INSTALLATION 6.1 Installing the boiler The installation must be done in accordance with all local and national codes, regulations and standards, and in accordance with the directives of all relevant authorities. 1. The boiler must only be installed in an area where it is allowed to install it. Make sure that this area is protected against the danger of freezing.

  • Page 35: Water Connection

    6.3 Water connection 6.3.1 Pump The boiler does not have a built in CH-pump. Therefore a CH-pump must be mounted separately . Select a pump that matches the hydraulic resistance of the boiler and the installation. The graph below shows the resistance characteristics for the different boiler models.
  • Page 36 < 0,11 °dH < 0,11 °dH This means for the Megaflex boilers that the system should be filled with demineralised water (smallest capacity > 600 kW). Before filling, rinse the complete installation with water from the tap. Note that water softening by means of ion exchange principle is not allowed.

  • Page 37: Gas Connection

    • Always mount air vents at the highest points in the installation. • Install isolation/check valves near the boiler and on strategic locations (anticipating any future expansi- ons of the system) to avoid fills, refills and topping up as much as possible. •...

  • Page 38: C63

    T120 Pressure range Condensate resistance (W=wet / D=Dry) The minimal combustion products temperature, mass flow rate and CO are given in the table below. Vol. Flue Vol. Air T fluegas MegaFlex part load m³/h m³/h °C kg/m³ 850-11 1,12 1020-13...

  • Page 39: Pressure Drop Calculations

    Equivalent of pipe length in meters Bend Parallel Air/fluegas Ø200/ø250 mm Bend 90° Bend 45° Warning : Do not install the terminals for supply of combustion air and for the exhaust of combustion products on opposite walls of the building Terminals should be installed in the same pressure area (within a plane of 1m²) 6.5.4 Pressure drop calculations The first 90 °...
  • Page 40 Column 9: total pressure drop flue gas and air: column 6 + 7 + 8 Finally add all together column 9 Total pressure drop must be lower than 500 Pa (Megaflex 850-11) and (Megaflex 1020-13). If the combined inlet/outlet system exceeds the maximum allowed pressure, this will result in a decrease of more than 5 % of heat capacity.

  • Page 41: Installing Flue-Exhaust And Air Inlet

    Components OEM Art. no M&G Roof terminals ROOFTERM ALU 250 B23 40.045.26.65 ROOFTERM ALU 250/250-250/350 C33 41.007.65.59 EXPANDER AIR Ø200- Ø250 Pending LEAF CATCHER (AIR INLET GRILL) Pending Flue gas ALUMINUM Ø 250 mm ELBOW ALU 250 90° 40.045.16.86 ELBOW ALU 250 45° 40.045.16.88 EXTENSION ALU 250x1000 40.045.16.84...
  • Page 42 Air inlet If PP material is used for the air inlet a minimum distance of 35 mm between exhaust and air inlet should be respected. The minimum insert length of the sleeve, leaf catcher or pipe must be 40 mm. Flue exhaust A horizontal flue exhaust pipe must be installed with a fall of 3°...

  • Page 43: Electrical Connection

    Important notice If instructions as written above are not followed and or the materials for air inlet and flue gas exhaust as quoted above are not used Mark Climate Technology can not be held responsible for eventual conse- quences. 6.6 Electrical connection 1.
  • Page 44 pole 10 A (see figure beneath).The supply wire should be secured by a pull relief. 5. It is not permissible to alter the internal wiring as fitted by the manufacturer. 6. The enable connected to numbers 1 and 2 of the strip C2 must be Volt free (also see warning un- der 4.2.1).

  • Page 45: Wiring Diagram

    General remarks : Use the 5 tubes on the left side on the back to guide the high voltage The lowest of the 5 is for 400 VAC + 3N/50 Hz (supply) The upper 4 are for 230 VAC or eventually 400 VAC + 3N/50Hz Use the 2 tubes on left side on the back to guide the low voltage connections from C2 and C3 Also see wiring diagram on next pages...

  • Page 47: Ntc Resistance Table 47 En

    6.6.2 NTC resistance table Temperature Resistance [°C] [Ω] 98.200 75.900 58.800 45.900 36.100 28.600 22.800 18.300 14.700 12.000 9.800 8.050 6.650 5.520 4.610 3.860 3.250 2.750 2.340 1.940 1.710 1.470 1.260 1.100...

  • Page 48: Pneumatic Connections

    6.7 Pneumatic connections A pneumatic diagram for the Intermodul 850 kW (11 sections) and the Intermodul 1020 kW (13 secti- ons) is given in the figure below. The siphon pressure switch, connected to the sump, prevents overflow of the syphon in the case of ex- cess back pressure in the flue.

  • Page 49: Gas Category

    13. Bleed the installation again, topping up the water system pressure if required. 14. Explain the operation of the boiler to the user. 15. Explain to the user the significance of error codes and the need to report them when requesting service engineer support.

  • Page 50: (O 2 %) And Check Input

    As the responsible manufacturer of my products, I’m aware that the above mentioned countries have adopted the Gas Appliance Directive 2009/142/EC in their national law. I understand that the CE mark has meaning only in these countries, where the GAD is implemented in the national regulations. Although other countries might value and respect the CE mark, it has no formal value.

  • Page 51: Errors

    8 ERRORS 8.1 General If there is no data visible on the display, the circuit breaker must be checked on the panel that can be accessed after removal of the first side panel on the right. Main switch on the front panel should be checked (as well as the position of the on/off switch) and should if required be replaced (after the cause for break down has been determined and rectified).
  • Page 52 F1: T3.15A 250 V F2: T3.15A 250 V If you are not sure that there is any heat demand, you can force the boiler to start as described in 5.5. On heat demand, the boiler control will perform a zero-check of the air pressure switch before starting the fan.

  • Page 53: Dhw Errors

    8.2 DHW errors Boiler does not respond to DHW heat request - Check the storage tank-NTC or thermostat and its wiring (also see electrical wiring diagram). - Check if DHW is enabled using the control panel Insufficient DHW flow - Dirty filters in taps. - Insufficient water pressure.

  • Page 55: Annual Service

    9 ANNUAL SERVICE Maintenance should only be done by a qualified installer or technician. the following main- tenance routine should be done annually (see also 9.1). The appliance is not to be used by children or persons with reduced physical, sensory or mental capabilities, or lack of experience and knowledge.

  • Page 57: Service-Maintenance Table

    9.1 Service-maintenance table When commissioning the boiler, it is recommended to measure load, CO or O , CO, T flow, T return, ΔP air pressure switch and Psyphon pressure switch and write the values down in the table below. Measure these values when the boiler is in equilibrium at maximum load (also see chapter 5.5). During annual maintenance we advise to measure and write down these values also and compare them to the previous values and analyse any changes.
  • Page 58 FAX +31 (0)598 624584 TELEFAX +49 (0)2822 97728-10 info@mark.nl info@mark.de www.mark.nl www.mark.de MARK EIRE BV MARK POLSKA Sp. z o.o COOLEA, MACROOM UL. KAWIA 4/16 CO. CORK 42-200 CZE ˛STOCHOWA (POLSKA) P12 W660 (IRELAND) PHONE +48 34 3683443 PHONE +353 (0)26 45334...

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