Table of Contents
Summary of Contents for CTC Giersch MG40 Series
- Page 1 Technical Information • Installation Instructions MG40-ZM-L-LN January 2019 edition In the i nte re sts of co ntin uous product im- pro vemen t, tech nical spec ifica tion s are su bje ct to ch ange without prio r n otic e!
- Page 2 Declaration of Conformity for gas burner We, Enertech GmbH, declare under Adjutantenkamp 18 in D-58675 Hemer responsibility that our sole Gas burner type MG40/.. complies with the stipulations of directives MD2006/42/EG EMV2014/30/EG LVD2014/35/EG GAR 2016/426/EG MCP2015/2193/EU 1. BImSchV 2010 RoHS 2011/65/EU DIN EN 676 and is designated as follows: CE-0085...
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Page 3: Table Of Contents
Contents Page Safety-relevant information 4 Symbols ..........4 General information on safety . -
Page 4: Safety-Relevant Information
Safety-relevant information Safety-relevant information This document is part of the product. It must be trained over the entire lifetime of the product. Make this document available to the operator or personnel responsible for ac- tivities describe in it. Incorporate supplements that you receive later from GIERSCH to the documents. -
Page 5: Limits
Safety-relevant information Limits The following products (in addition to the burner) apply as further subsystems in the plant: • Heat generator / air supply / exhaust system • Fuel supply system (gas train / oil suply system) • Burner control •... -
Page 6: Restriction Of Liability
Safety-relevant information The adjustments made during commissioning must not be modified afterwards. Excep- tion: If the operating conditions change at a point in time after commissioning (due to changes in the fuel characteristics or plant environment for example), a firing technician must check the adjustments and adapt them where necessary. -
Page 7: Transport And Intermediate Storage At Installation Location
Safety-relevant information Transport and intermediate storage at the installation location Warning! Risk of injury from burner falling down! If a burner falls down, this can cause most serious injuries! Be sure to obeserve the in- structions for transport and storage. Behaviour if there is a smell of gas •... -
Page 8: Technical Specifications
Technical specifications Technical specifications Technical specifications Burner type Technical specifications MG40/1-LN MG40/2-LN Burner output in kW 490 - 4500 611 - 6300 Gas type Natural gas LL + E = „-N“ Perm. operating pressure 200 - 700 mbar Mode of operation 2-stage/modulating Voltage 3 / N / PE ~ 50 Hz 400 V / 230 V... -
Page 9: Gas Train Dimensions
Technical specifications Gas train dimensions Op tio nal compo nents Standard componen ts Designation KEE 2“ KEE DN65 KEE DN80 KEE DN100 a Gas fitting approx. 705 approx. 705 approx. 705 approx. 705 b Gas throttle c Double gas valve d Gas filter e Manometer/test burner approx. -
Page 10: Dimensions
Technical specifications Dimensions All dimensions are given in mm 10/44 22.01.19, Subject to alterations... -
Page 11: Burner Assembly
Burner installation Burner installation Mounting the gas jacket on the boiler The boiler connection plate must be prepared according 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 SW8 Allen key. -
Page 12: Gas Mixer Head Adjustments
Burner installation Settings for gas mixer head The position of the mixing head (dimension "B") is preset at the factory. . Di men sio n "B" Burner pipe Diaphragm plate Electrodes The electrodes are preset at the factory. Ionisation electr ode, Distan ce to Diaph ragm p late... -
Page 13: Gas Fitting Installation
Burner installation Gas fitting installation Installation position of the gas fitting Mount the burner housing at the gas jacket Subject to alterations, 22.01.19 13/44... -
Page 14: Swivel Position / Service Position
Burner installation 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 ignition and ionisation electrodes. Carefully swing the burner closed. Do not pinch electrical cables. Secure the burner housing with the fixing screws (3 x M16). -
Page 15: Electrical Installation
Electrical installation Electrical installation Air / gas actuator The air actuator is designed for air flap adjustment on progressive two-stage burners or modulating burners. The gas actuator is designed for gas flap adjustment on progressive two-stage burners or modulating burners. They are controlled electronically via the burner management system. -
Page 16: Gas Input Pressure Min. With Leakage Check
Electrical installation Gas pressure switch min. with leakage check The gas pressure switch at the gas train serves to monitor the gas input pressure and test the valves for leaks. The gas pressure switch must be set to 50% of the static gas input pressure. -
Page 17: Flame Monitor With Ionisation
Electrical installation Flame monitoring with ionisation When a flame is present, an ionisation current flows between the electrode and the LMV burner management system. The ionisation current produces the flame signal. The ionisation current must be measured during commissioning or maintenance. To do this, disconnect the connector in the ionisation cable and connect the current meter series. -
Page 18: Connection Diagram For Connector Assignment
Electrical installation Terminal diagram - connector pin assignments If the connectors have already been pre-wired: check the connections in accord- ing to the connection diagram! The electrical connection of the burner must be made in the connectors included accord- ing to the connection diagram, taking account of the local regulations. The supply cable must be fused with max. -
Page 19: Burner Management System Lmv
Electrical installation LMV burner management system Subject to alterations, 22.01.19 19/44... -
Page 20: Adjustments
Settings Settings Gas supply Connecting bend Gas throttle The gas throttle regulates the quantity of gas according to the power required. It is con- trolled by the burner management system using an actuator. Double gas valve The double gas valve opens and blocks the gas supply automatically. The leakage check for the gas pressure switch is located between the valves. -
Page 21: Setting Tables
Settings Adjustment tables The values specified in the tables are only reference inputs for start-up. The system set- tings required in each case must be redefined if values such as boiler output, calorific value and altitude deviate. A correction is required in any case. The maximal burner output can only be achieved in mixer head position 0. - Page 22 Settings 22/44 22.01.19, Subject to alterations...
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Page 23: Principles Of Calculation For Gas Burner Adjustment
Settings Calculation principles for gas burner adjustment The values given in the tables are setting values for start-up. The necessary system ad- justment 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). -
Page 24: Commissioning
Start-up Start-up Prior to commissioning General information Installation of a gas-fired heating system must be performed in accordance with the ap- plicable 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. -
Page 25: Operation And Device Desription
Start-up Operation and device description The black bar in the display indicates the status of the inputs and outputs, the unit for the values and the active level. 1 Heat reques t from boiler control (s tart) 2 Burner motor 3 Ignition 4 Fuel v alves 5 Flame s ignal on... -
Page 26: Lmv Programming
Start-up LMV programming Burner cold adjustment Determining burner output according to adjustment table. P0 = Starting level, P1 = 1st level / min. output, P9 = 30% of P0. The maximum burner power is not programmed until setting the heat. Normally, P0 = P1. - Page 27 Start-up Switch on the burner Continuous heat requirement is necessary for further start-up! LMV programmed Action button Display Description /reset When the LMV is programmed, run is dis- played. i/reset skips the next steps an continues at the section Start heat settings with curve /reset point P1 Small load.
- Page 28 Start-up Activate frequency converter Action button Display Description If a frequency converter is present, it must be activated. 0 = Without frequency converter - deacti- vate s min % 1 = With frequency converter - activate Continue to the next parameter with the + button Speed standardisation of the frequency converter Action button...
- Page 29 Start-up Action button Display Description Adjust start speed of blower motor in con- junction with frequency converter. Move to the next curve point. High load preset Action button Display Description Set the large load. Hold down F button and set the value with the - or + button Hold down button A and set the value with the - or + button.
- Page 30 Start-up Start identifier for curve programming - Calibration with flame Action button Display Description When heat demand is present. Confirm with i/reset button. /reset Burner starts 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. Run in ignition position 30/44 22.01.19, Subject to alterations...
- Page 31 Start-up Start heat setting In the heat setting, the burner is adjusted to max. output point by point. 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.
- Page 32 Start-up Action button Display Description Use + button to confirm all curve points up to curve point P9. Check the curve points and emission val- ues. Adapt the curve points if necessary. Hold down F button and set the value for fuel with the - or + button.
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Page 33: Adjustment Protocol - First Commissioning
Start-up Adjustment protocol - First commissioning Please enter the measured values into the Adjustments log. Boiler type Gas fitting Measured values min. max. P0 (start point) P1 (min load) P9 (max load) Flue gas temperature °C Carbon dioxide (CO level) content CO level Flue... -
Page 34: Lmv Phase Display / Operating Display
Decommissioning LMV phase display / operating 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... -
Page 35: Maintenenace Positions
Maintenance Maintenance positions Maintenance position ventilation wheel / ventilation grille Maintenance position mixer head / electrodes / ignition and ionisation line Subject to alterations, 22.01.19 35/44... -
Page 36: Maintenance Schedule
Name, Date: Name, Date: Name, Date: Name, Date: Measures Measures Measures Measures Gas nozzle (clean) Diaphragm plate (clean) Mixer head (clean) Ignition electrodes (clean) Ionisation electrode (clean) Ignition cable (check for damage) Ionisaation line (check for damage) Gas filter (clean) Gas pressure (check) Air supply / grille / burner inside... -
Page 37: Information
Information Information Error code list LMV Description Measure loc.C: loc.d: No communication between Check wiring for interruptions/ basic unit LMV27... and loose contacts AZL2… 1 - 4 No flame at the end of the safety time 0 - 84 Compressed air fault No compressed air 0 - 86 External light... - Page 38 Information Description Measure loc.C: loc.d: 0 - 3 Special position undefined Parametrise actuators 75-84 Internal fault group Error group fuel drive Referencing of fuel drive not suc- cessful. Unable to reach reference point. 1. Check whether the drives have been exchanged 2.
- Page 39 Information Description Measure loc.C: loc.d: Safety relay welded or exter- Measure the contacts: nal voltage at safety contact 1. Device at voltage: Blower out- put must be de-energised 2. Deactivated voltage: Discon- nect blower. There must be no ohmic connection between blower output and N.
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Page 40: Exploded View / Spare Parts List
Information Exploded view drawing / spare parts list 40/44 22.01.19, Subject to alterations... - Page 41 Information Position Designation Art. no. Burner pipe MG40 47-90-29072 Primary gas nozzle MG40/1, 8 x Ø3.9 47-90-29860 Primary gas nozzle MG40/2, Ø90, 4 x Ø25, 8 x Ø3.9 47-90-29171 Diaphragm plate MG40/1, 8 slots 6 mm 47-90-29859 Diaphragm plate MG40/2, Ø305 x Ø92, 4 x Ø36 47-90-29170 Spacer MG40/1 47-90-29858...
- Page 42 Information MG40/1 with DN65 Position Designation Art. no. Connection elbow DN100-DN65 with flange 47-90-29543 Throttle flap DN65 47-90-29820 Attachment kit for VKF41 47-90-29526 SKP set 2.65 consisting of VGD40, SKP15, AGA62, 47-90-26226 AGA64 SKP25, drive for gas valve 47-90-29942 Gas pressure switch QPL15 5 - 150 mbar cpl. 47-90-26764 Gas filter DN65 1 bar 44-90-23126...
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Page 43: Subject To Alterations, 22.01.19
Information Subject to alterations, 22.01.19 43/44... - Page 44 All information in this technical documentation as well as the drawings, photos and technical descriptions placed at your disposal remain our property and may not be duplicated without our written permission given in advance. Subject to alterations. Enertech GmbH • Brenner und Heizsysteme Postfach 3063 •...
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