List of contents

Norms and regulations....................................................................................................................................................................... 4 Exhaust system and effective heat demand ........................................................................................................................................ 4 Modern conception ........................................................................................................................................................................... 4 Useful design..................................................................................................................................................................................... 4 Universal use ..................................................................................................................................................................................... 5 Two-stage Operation ......................................................................................................................................................................... 5 Easy Installation ................................................................................................................................................................................. 6 Instructions for using the burner ........................................................................................................................................................ 6 Leak test............................................................................................................................................................................................ 6 Rating of the gas ramps ..................................................................................................................................................................... 7 Gas compact ramp Rp 1 and Rp 1 ............................................................................................................................................... 7 Gas compact ramp Rp 1 and Rp 2 ............................................................................................................................................... 8 Gas compact ramp DN 65 to DN 100 ................................................................................................................................................. 8 Gas ramps GZ 3 liquid gas ................................................................................................................................................................. 8 Setting of the switches in the motor valve connection box.................................................................................................................. 8 Gasburner and Gas ramps assembly GZ 2 - GZ 4 ................................................................................................................................ 9 Table of basic settings and dimensions GZ 2 - GZ 4 ............................................................................................................................ 9 Adjusting the burner........................................................................................................................................................................ 10 Position air guidance device GZ 3 and GZ 4...................................................................................................................................... 11 Air inlet nozzle................................................................................................................................................................................. 11 Settings ........................................................................................................................................................................................... 12 Spark electrode setting .................................................................................................................................................................... 12 Installation position Multiblock......................................................................................................................................................... 12 Fault diagnosis................................................................................................................................................................................. 13 Fault diagnosis MMI 810.................................................................................................................................................................. 13 Fault diagnosis TMG 740-3 and TMG 740-2..................................................................................................................................... 14 Troubleshooting .............................................................................................................................................................................. 15 Burner dimensions ........................................................................................................................................................................... 17 Connections .................................................................................................................................................................................... 18 Boiler connections ........................................................................................................................................................................... 18 Electric supply diagram .................................................................................................................................................................... 18 Assembly with silencer hood for GZ 3 and GZ 4 .............................................................................................................................. 18 Circuit diagramm GZ 2..................................................................................................................................................................... 19 Circuit diagramm GZ 3.0.................................................................................................................................................................. 20 Circuit diagramm GZ 3.1 - GZ 3.3 .................................................................................................................................................... 21 Circuit diagramm GZ 4..................................................................................................................................................................... 22 Maintenance and service.................................................................................................................................................................. 23 Guarantee ....................................................................................................................................................................................... 24 Spare parts ...................................................................................................................................................................................... 24 Manufacturer's certificate ................................................................................................................................................................ 25 EC Declaration of Conformity .......................................................................................................................................................... 26

Safety instructions Please observe!

Please comply with the assembly, operation and maintenance instructions for installing and adjusting the gas burner! In Switzerland, the guidelines issued by PROCAL and those of the Vereinigung Kantonaler Feuerversicherungen, VKF (Association of Canton Fire Insurances) must be observed, in particular the fire guidelines "Thermal Heating Systems". Please read this installation manually carefully before starting installation. We cannot assume any liability or guarantee for damage caused by failure to comply with this installation manual! Work which is not carried out properly can cause injury to persons or damage to property! Work on the heating system y Installation, commissioning, maintenance and servicing work may only be carried out by an authorised firm of heating contractors.

When working on burner and boiler y switch off the heating system emergency switch and secure it to prevent it being switched on again. y shut off the oil feed pipe and secure it to prevent it being opened unintentionally. This symbol refers to instructions which must be heeded for your own safety and that of other people, and to avoid damage to property. This symbol refers to instructions which must be heeded for the gas burner to operate safety and function correctly. It also draws attention to statutory regulations which need to be observed.

Installation-Operation-Maintenance
Norms and regulations
The following standards and regulations are to be observed during installation and operation of the burner. HeizAnlV Heating system ordinance FeuVo Firing ordinance of the German federal states 1. BImSchV First ordinance for implementation of the German Emission Protection Law VDI 2035 Guidelines for preventing damage from corrosion and scale formation in hot water heating installations VDE Regulations and special requirements issued by the energy utility companies EN 303, part 1 and part 2 Heating boilers with forced draft burners EN 60335, part 1 Safety of household and similar electrical appliances DIN 4705 Calculating the dimensions of chimneys DIN 4751 Hot water heating installations safety requirements DIN 4755 Oil firing installations construction, execution, safety requirements DIN EN 267 Automatic forced draught burners for liquid fuels definitions, requirements, construction and testing DIN 51603, part 1 Fuel oils extra light DIN 57116 Electrical equipment of firing installations Please comply with the valid regional building code.

GZ 2 - GZ 4 / 100 - 1450 kW

Exhaust system and effective heat demand

Boiler, burner and exhaust system (chimney) constitute an operating unit; account must be taken of low exhaust temperatures when reducing the output For exhaust temperatures below 160C, the system must be designed so as to avoid damage from condensation. The uncondensed (humid) flue gas volume is an important indication of the size of the flue gas installations an chimneys required. It is advisable to install draft limiters (supplementary air systems) to achieve stable combustion values under varying conditions and to reduce possible humidity in the chimney. These should be installed in the chimney where possible, to avoid possible noises in the flue pipe.

Modern conception
The gas burners in the GZ 2 - GZ 4 series are fully automatic two-stage burners in monobloc design. They are suitable for natural gas and liquefied gas according to DVGW paper G 260, designed according to DIN 4788, and tested according to DVGW and CE. The burners are equipped with automatic gas firing units for intermittent operation as per DIN EN 298 or DIN 4788; automatic gas firing units for continuous operation on request. The GZ 2 - GZ 4 gas burners are pressurised burners with very high impeller pressing and a steep impeller characteristic line. Because of these features and the variable adjustment of the air admission nozzle, these burners are appropriate for modern high-performance boilers with reversible flames as well as for older natural draught boilers. The modern conception of the two-stage GZ 2 - GZ 4 burners with a maximum output range of 50:100% (GZ 2 - GZ 3) or 60:100% (GZ 4) guarantees ideal graduation of the two load-stages depending on operating conditions.

Useful design
Diecasting light metal case, power-dependent burner pipe and high-performance mixing system, adjustable air admission nozzle and air damper servomotor for two-stage operation, A.C. motor (GZ 2 - GZ 3.0) or threephase motor (GZ 3.1 - GZ 4), ignition transformer, fan impeller, gas compact ramp (GZ 2 - GZ 3.0) or gas ramps assembly (GZ 3.1 - GZ 4), air pressure switch, automatic firing sequence control with infrared flame detector (GZ 2 - GZ 3) or ionisation flame control (GZ 4), internal plug connections and plugs according to DIN 4791, mounting flange with gasket and fastening screws. Every burner is pre-tested.

GZ 2 - GZ 4 / 100 - 1450 kW
Universal use

Installation-Operation-Maintenance

The adjacent diagram depicts the approximate performance range of the different burner sizes as a function of the resistance measured at the boiler's gas exit during operation. The curves show maximum values and correspond with the model certification according to DIN 4788. The starting resistance of the boiler is of decisive importance to the attainable burner performance.

Fig. 3:

Performance diagram GZ 4

Two-stage Operation
The use of a modern, symmetrically designed high-performance mixing system in conjunction with precisely functioning adjustment at the compact gas ramps (GZ 2 - GZ 3.0) or at the gas ramps assembly (GZ 3.1 -GZ 4) makes it possible to adjust output precisely to heating requirements, resulting in optimum energy utilisation in both load stages with low-emission combustion. Two-stage operation is controlled by the air damper servomotor which adjusts the air flow for the two load stages and switches the gas solenoids in the compact gas ramps (GZ 2 -GZ 3.0) or gas ramps assembly (GZ 3.1 - GZ 4) by adjustable cam controllers.

Fig. 1:

Performance diagram GZ 2

Fig. 2: Performance diagram GZ 3

Installation-Operation-Maintenance
Easy Installation
The burner comes complete, including power dependent equipment, and every component is clearly designed so that a qualified heating engineer will have no problems with Installation, starting, and servicing. Screws and gaskets for the burner installation are included. The burner is electrically connected by a 7-pole plug according to DIN 4791. The burners are pre-tested and pre-set. The burner performance is changed by adjusting the gas-flow throttle and the settings (dimension B and air damper position). In Germany, the heating engineer has to consider the existing regulations of the DVGW (e.g. TRGI or TRF) and the local utility companies. General note as per DIN EN 676: This burner must be installed in compliance with the valid specifications and must only be operated in well aired rooms. The instructions before installing and operating the burner must be observed. The engineer must ensure that the heating room is suitably ventilated with an air exchange rate of at least 100 m/h. The gas pipes must be installed and connected by an authorised heating engineer. The weight of the gas compact ramps or assembly must be supported by a suitable bracket. The length of pipe between the gas ramps and the gas burner must not exceed max. 800 mm (for GZ 2 and max. 500 mm for GZ 3.0). The VDE and EVU specifications must be observed when installing the electrical connections. The burner must be connected with a flexible cable. Do not interchange the phase (live!) and neutral wires As a result of the new master firing ordinance, some German states stipulate the installation of thermally influenced gas stop valves.

GZ 2 - GZ 4 / 100 - 1450 kW

Instructions for using the burner

The burners GZ 2 GZ 4 are basically suitable for use in commercially available heating boilers (intermittent operation) for heating residential buildings and for service water. Product development and the test procedures have been geared to the operating conditions of these systems. The areas of application listed below make particular requirements with special operating conditions for the burner, so that MHG Heiztechnik reserves the right to issue explicit approval in these cases: y y y y y dark radiators baking ovens annealing furnaces drying chambers industrial applications

MHG Heiztechnik should also be consulted for installations with above average firing chamber or temperature loads. In the case of rooms where the air must be expected to be contaminated by halogenated hydrocarbons, e.g. hairdressers, printers, chemical dry cleaners, laboratories etc., the burners must only be operated if suitable measures are taken to ensure that there is an adequate supply of uncontaminated combustion air. Always consult MHG Heiztechnik if in any doubt. The burners must not be operated in rooms with high dust levels or high humidity (e.g. laundries). The heating room must be protected from frost and well aired. Failure to comply with these instructions renders the warranty null and void for any damage resulting from one of these causes.

Leak test
A programme-controlled leak detector which checks the solenoids for leaks can be installed simply and retroactively. An additional electrical connection at gas compact ramps is not necessary. The leak lest provides additional security for the users of gas firing systems. This feature is generally recommended, and is a stipulated-requirement for burner outputs of 1200 kW and more.

Fig. 4:

Gas-Geblsebrenner GZ 3

GZ 2 - GZ 4 / 100 - 1450 kW
Rating of the gas ramps

Installation-Operation-Maintenance

Depending on the available gas flow pressure, a correspondingly rated gas compact ramps or gas ramp system will be installed in the factory. If the minimum connection pressure is not achieved under rated heat load, a gas ramp system will have to be used with a larger rated width; the gas pressure must be increased at the utility company's gas transfer point, or the cross section of the supply line between the gas transfer point and the gas ramp system must be enlarged. Before the gas fan burner starts up for the first time, vent the gas pipe and then check the gas ramps for leaks.

Gas compact ramp Rp 1 and Rp 1

Burner and gas ramps taken from the table on page 9 form a complete unit , which has been subject to model certification. The conventional arrangement of the gas ramps is designed as an operational compact unit. Dirt pan with sieve and filter mat Pressure controller with admission pressure compensation and zero closing Pressure detector, setting range 2.5 - 50 mbar, blocked when liquefied gas is used Safety solenoid, opens and shuts quickly Two-stage solenoid, opens slowly, shuts quickly, adjustable starting volume, stage 1 and 2 Mounting flanges with measurement nipple Electrical connection with plug Supply-pressure up to max. 360 mbar {Comply with the Technical Rules for Gas Installations (DVGWTRGI) }
Fig. 5:

Installation-Operation-Maintenance
Gas compact ramp Rp 1 and Rp 2
Burner and gas ramps taken from the table on page 9 form a complete unit which has been subject to model certification. Key parts are: Dirt pan with sieve and filter mat Safety solenoid, opens and shuts quickly, with setting for gas volume stage 2 Solenoid with setting for starting volume and gas volume stage 1 , opens slowly and shuts quickly Pressure controller with admission pressure compensation and zero closing Pressure detector, setting range 2.5 - 50 mbar Electrical connection with plug Supply-pressure up to max. 360 mbar

GZ 2 - GZ 4 / 100 - 1450 kW

Key parts are: Dirt pan with sieve and filter mat Safety solenoid, opens and shuts quickly, with setting for gas volume stage 2 Motor valve with setting for gas volume stage 2, opens slowly and shuts quickly Pressure controller with admission pressure compensation and zero closing Pressure detector, setting range 2.5 - 50 mbar Electrical connection with plug Supply-pressure up to max. 200 mbar

Gas ramps GZ 3 liquid gas Pre-adjustment

Type Gas solenoid level 1 (partial quantity) opened approx. turn opened approx. 2 turn opened approx. 1 turn opened approx. 1 turn Gas solenoid level 2 (main quantity) opened approx. turn opened approx. 1 turn opened approx. 1 turn opened approx. 1 turn

Gas compact ramp DN 65 to DN 100

Burner and gas ramps taken from the table on page 9 form a complete unit which has been subject to model certification.

GZ 3.0 GZ 3.1 GZ 3.2 GZ 3.3

Set pressure switch to approx. 20 mbar Open start gas quantity 1 turn It is vital for the stated basic settings (see page 9) to be met for liquid gas operation!

Setting of the switches in the motor valve connection box

Fig. 6:

Fig. 7:

GZ 2 - GZ 4 / 100 - 1450 kW
Gas-burner and gas ramps assembly GZ 2 - GZ 4

Installation-Operation-Maintenance

Burnertype GZ 2.1 GZ 2.2 GZ 3.0 GZ 3.1 GZ 3.2 GZ 3.3 GZ 4.1 GZ 4.2

1) 2)

Gas type Natural gas H (L,LL) Liquefied gas Natural gas H (L,LL) 3) Liquefied gas Natural gas H (L,LL) 3) Liquefied gas Natural gas H (L,LL) 3) Liquefied gas Natural gas H (L,LL) 3) Liquefied gas Natural gas H (L,LL) 3) Liquefied gas Natural gas H (L,LL) 3) Liquefied gas Natural gas H (L,LL) 3) Liquefied gas
3)

Burner order number -1001 -1008 -1002 -1018 -3085

2)

Suitable for boiler performance kW 100 - 200 180 - 300 260 - 315 315 - 500 450 - 650 550 - 810 700 - 1020 900 -1450

Gas flow pressure mbar

Rated with 2) DN

Order number

Total weight

kg
28 26 28 26

-3175
2)

-3275
2)

-3305
2)

-4105 -4108 -4205 -4208

20 50 25-50 50 25-50 50 25-50 50 35-50 50 25-50 50

Rp 1 Rp 1 Rp 2 Rp 2 DN 65 DN 80

1)

50 67 73 74 173 201

-3044 -3054 -3054 -4065 -4080

included in burner order number

It is vital for the stated basic settings (see page 8) to be met for liquid gas operation!

Table of basic settings and dimensions GZ 2 - GZ 4

Burnertype GZ 2.1 GZ 2.2 GZ 3.0 GZ 3.1 GZ 3.2 GZ 3.3 GZ 4.1 GZ 4.2

3)

Gas type Natural gas H (L,LL) 3) Liquefied gas Natural gas H (L,LL) 3) Liquefied gas Natural gas H (L,LL) 3) Liquefied gas 3) Natural gas H (L,LL) Liquefied gas Natural gas H (L,LL) 3) Liquefied gas Natural gas H (L,LL) 3) Liquefied gas Natural gas H (L,LL) 3) Liquefied gas Natural gas H (L,LL) 3) Liquefied gas

Suitable for boiler Gas flow rate Dim. Dim. Dim. Air pressure Nozzle pressure Air performance B D Stage 1 Stage 2 Stage 1 Stage 2 supply Stage 1 Stage 2 A kW m3 /h m3 /h mm mm mm mbar mbar mbar mbar nozzle 10 14 50 2 7 6 10 9,5 100 - 200 18 95 4 5,5 57 3 8 13 16 7,5 16 23 5 5 9 180 - 300 18 70 110 2,5 9,5 6 9 7 11 20 19 32 65 3,4 7,2 5,5 11,7 260 - 315 23 110 0 7,6 13,8 75 1,2 7 2,2 10 26 43,5 20 88 130 3,5 11,5 4,8 12 7,5 315 - 500 9,5 15 25 135 126 2 6 3,5 9 1,5 39 65 20 118 5,5 11,5 4,2 11 7,5 450 - 650 145 14 25 27 120 1,5 9 2,5 9,5 2,5 53 75 117 3,5 9 6 13 8 550 - 810 27 145 16 28 120 2 10 3 11,5 3,5 58 91 125 9 17 6,5 14 2 700 - 1020 33 175 24,8 33,1 130 13,5 18,5 12 16,5 1,5 85 125 130 10,5 17,5 9 2 900 -1450 33 175 5 27,9 46,5 141 7,5 17 11 1,5

For operation with natural gas (L, LL), only the gas quantity is increased. The output-related basic setting does not have to be changed. Power reduction for natural gas (L) approx. 15%, for natural gas (LL) approx. 30%

Installation-Operation-Maintenance
Adjusting the burner
Every burner is pre-tested and pre-set. The basic adjustment is shown in the table above (reference values valid for the gas type indicated). The burner must be adjusted and started by a qualified heating engineer. Adjusting the gas flow range: gas pressure (nozzle pressure): at the adjusting screw of the gas pressure controller 2 increased gas pressure decreased gas pressure gas volume stage 2 - at the adjustment for valve 3 less gas more gas gas volume stage 1 - at the adjusting wheel of solenoid stage 14 less gas more gas for gas ramp systems DN 65/80/ 100 at the motor valve 4 (Johnson Controls see illustration on the left) starting gas volume - at the adjusting screw of valve 1 1 opening quickly opening slowly The gas pressure detector is to be set to the flow pressure at which perfect function of the gas burner is still possible. There are three possible ways of adjusting the combustion air: a. by adjusting the air supply nozzle according to burner output and local conditions:
Fig. 8:

GZ 2 - GZ 4 / 100 - 1450 kW

When the air volume is too large in stage 1 or too small in stage 2, the corresponding cam controller must be adjusted. To reduce an excessive air volume, the (orange) cam controller must be adjusted accordingly and the servomotor is closed by switching the controller for the second stage or by disconnecting the green 4-pole plug, then start up again in the operation setting. The switching point for the second solenoid (stage 2) or motor valve can be changed using the long black cam controller. When switching the burner off for regular servicing or to eliminate faults, the air damper can be closed using the (short black) cam controller of the servomotor. It is advisable to measure the air pressure before the baffle plate to check the setting (see table values for air pressure). The measuring point is located next to the gas supply pipe on the flange cover.

position 0 - 5 (0 -1) for natural draught boilers position 6 - 9.5 (2 - 4) for counter-pressure boilers b. by adjusting the baffle plate in the burner tube (see fable with basic settings); this adjusts the air velocity in the combustion head together with the flame shape to the combustion chamber conditions by adjusting the air damper for the 1st and 2nd stage using the (blue) cam controller for stage 1 and (orange) for stage 2; the air volume is reduced to the left and increased to the right. An inadequate air volume in stage 1 is adjusted as follows:

c.

adjust the (blue) cam controller up-wards (more air) briefly switch over to stage 2 at boiler thermostat 2. After switching back, the servomotor turns back into the required position.

10

GZ 2 - GZ 4 / 100 - 1450 kW
Position air guidance device GZ 3 and GZ 4

Installation-Operation-Maintenance
Air inlet nozzle

Fig. 10:

Adjusting the air inlet nozzle for GZ 2 / GZ 3

The air inlet nozzle can be adjusted once the burner has been opened. Both screws on the air inlet nozzle should be loosened slightly, and must be screwed tight again after the adjustment has been made.

Fig. 9:

Fig. 11:

Adjusting the air inlet nozzle for GZ 4

The air inlet nozzle can be adjusted once the burner has been switched off and the suction silencer has been hinged away. Both screws of the air inlet nozzle should be loosened slightly, and must be screwed tight again after the adjustment has been made.

11

Installation-Operation-Maintenance
Settings

GZ 2 - GZ 4 / 100 - 1450 kW

Spark electrode setting

GZ 2

GZ 3

GZ 4 natural gas

GZ 4 liquefied gas

Fig. 13:

Installation position Multiblock

All gas Multiblocks must only be installed as shown below Installation in the grey area is not permitted.

Fig. 12:

Fig. 14:

12

GZ 2 - GZ 4 / 100 - 1450 kW
Fault diagnosis

Installation-Operation-Maintenance
Fault diagnosis MMI 810
Fault Burner does not start, program display remains the same Remedy Faulty electric lead Thermostat or gas switch "OFF"" Air pressure switch not in idle position (working contact must be open) Connection terminal 1 terminal 9 interrupted Operating voltage < 180V Automatic unit shows a Air pressure switch contact does fault just after starting not close pre-venting (line in blue box) No load at terminal 5 Flame signal

Flame monitoring makes use of the conductivity and rectifier effect of the flame, by means of an ionisation electrode. The flame signal amplifier only reacts to the DC component of the flame signal. A short circuit between ionisation electrode and earth causes a fault cutout. MMI 810.1 necessary sensor current for reliable operation mains voltage UN = AC 230 V > 5 A

Burner does not start, program display turns constantly

Fig. 15:

Legend measuring circuit FE Ionisation electrode M Multimeter

Automatic unit shows a Air pressure switch contact fault during preopens venting (blue area) Flame signal Automatic unit shows a No flame formed (faulty ignition, fault during the safety valve does not open, etc.) period (yellow area) No or weak flame signal (flame does not hold, poor insulation of flame sensor, burner not correctly connected to earth conductor) Automatic unit shows a Flame breaks off fault during operation setting (red or green Air pressure switch contact opens area) Flame signal too weak

Fig. 16:

Position ionisation electrode GZ 2

Ionisation current in operation:

GZ 2:

15 - 22 A

13

Installation-Operation-Maintenance
Fault diagnosis TMG 740-3 and TMG 740-2
Fault Burner does not start, program display remains the same Remedy Faulty electric lead Thermostat or gas switch "OFF"" Air pressure switch defect or not in idle position (working contact must be open)

GZ 2 - GZ 4 / 100 - 1450 kW

Burner does not start, program display turns constantly

Automatic unit shows a Air pressure switch contact does fault just after starting not close pre-venting (line in Flame signal blue box) Automatic unit shows a Air pressure switch contact fault during preopens venting (blue area) Flame signal Automatic unit shows a No flame formed (faulty ignition, fault during the safety valve does not open, etc.) period (yellow area) No or weak flame signal (flame does not hold, poor insulation of flame sensor, burner not correctly connected to earth conductor) Automatic unit shows a Flame breaks off fault during operation setting (red or green Air pressure switch contact opens area) Flame signal too weak

14

GZ 2 - GZ 4 / 100 - 1450 kW
Troubleshooting

Installation-Operation-Maintenance

Check general operating status. Are the stated values met?

Strung Burner does not work Ursache Behebung Check main switch, fuse, boiler thermostat Check voltage (neutral and live wires) Check leak detector Check gas pre-pressure Check gas pressure detector (setting, function) Replace firing sequence controller Burner Starts Gas pressure and gas shown No ignition spark Check ignition transformer, ignition cable and spark electrode setting Replace firing sequence controller Air in the gas pipe Flame detector could be exposed to another source of light Check connection of neutral and live wires Check gas flow pressure (fluctuating pressure gauge display = gas pipe too small or pressure controller defect Set infrared flicker detector (IRD) (GZ 2 + GZ 4) to 7, check IRD's Position, replace IRD (GZ 3) Replace firing sequence controller Faulty electric lead Thermostat or gas pressure switch off Air pressure switch defect or not in idle position (contact must be open) Check electric leads Replace thermostat or gas pressure switch

Burner works Gas pressure shown Spark visible No flame Burner works Gas pressure shown Spark visible Flame OK No ionisation current (GZ 2 + GZ 4) No infrared display (GZ 3) Fault cutout

Burner does not start up, program display stays the same Burner does not start up, program display turns constantly Burner starts up, automatic unit shows fault just after starting pre-venting

Replace air pressure switch

Air pressure switch contact does not close

Check wiring for air pressure switch Replace air pressure switch

15

Installation-Operation-Maintenance
Fault Burner starts up, automatic device shows fault during pre-venting Cause Air pressure switch contact opens Flame signal

GZ 2 - GZ 4 / 100 - 1450 kW
Remedy Check pulse lead Check ionisation current [fault current?] (GZ 2 + GZ 4) check infrared flicker detector IRD (GZ 3) Check pulse lead Check ionisation current [fault current?] (GZ 2 + GZ 4) check infrared flicker detector IRD (GZ 3)

Burner starts up, automatic device shows fault during safety period

No flame formed (lacking ignition, valve does not open, etc.) No or weak ionisation current (GZ 2 + GZ 4) No or weak flame signal (GZ 3) [Flame does not hold, poor insulation of flame sensor, burner not correctly connected to earth conductor] Flame breaks off Air pressure switch contact opens Ionisation current too low (GZ 2 + GZ 4) Flame signal too low (GZ 3)

Burner starts up, automatic device shows fault during operation setting

Check pulse lead Check ionisation current [fault current?] (GZ 2 + GZ 4) check infrared flicker detector IRD (GZ 3) Safety warning! The mains voltage must be switched off and the main stop valve in the gas pipe closed whenever any kind of work is being performed to the burner and switchboard

16

GZ 2 - GZ 4 / 100 - 1450 kW
Burner dimensions

Installation-Operation-Maintenance

GZ 2.1 - GZ 3.3

GZ 4.1 - GZ 4.2

Fig. 17:

Burner type

Type of gas

Gas ramp system Rp 1 Rp 1 Rp 1 Rp 1 Rp 1 Rp 1 Rp 2 Rp 2 Rp 2 DN 65 Rp 2 DN 65 DN 80 DN 65 DN 80

GZ 2.1 Natural gas GZ 2.1 Liquefied gas GZ 2.2 Natural gas GZ 2.2 Liquefied gas GZ 3.0 Natural gas GZ 3.1 Natural gas GZ 3.1 Natural gas GZ 3.2 Natural gas GZ 3.3 Natural gas GZ 3.3 Natural gas GZ 4.1 Natural gas GZ 4.1 Natural gas GZ 4.1 Natural gas GZ 4.2 Natural gas GZ 4.2 Natural gas

Dim. Dim. Dim. L1 L2 L3 approx. approx. approx. 150 230 240 150 180 180 200 265 265 270 270 270 430 430 430 430 430 230 230 230 350 350 350 350 470 470 590 590 590 590 590 240 240 240 260 525 570 570 570 1580 1230 1650 2150 1650 2150

Dim. L4

Dim. L5 approx. 80 570 80 570 600 600 830 850 850 850 970 970 1380 1380 1380 1380 1380

Dim. D1 115 115 115 115 140 140 140 152 152 152 186 186 186 186 186

Dim. D2 115 115 130 130 140 175 175 200 200 200 230 230 230 280 280

Dim. H1 240 240 240 240 350 320 320 320 320 370 285 285 285 285 285

Dim. H2 355 355 355 355 490 490 490 490 490 490 650 650 650 650 650

Dim. H3 295 295 295 295 380 380 380 380 380 380 515 515 515 515 515

Dim. B 305 305 305 305 375 386 386 386 386 386 470 470 470 470 470

80 80 130 130 130 130 130 180 210 210 210 210 210

17

Installation-Operation-Maintenance
Connections
Burner type GZ 2 GZ 3.0 GZ 3.1 GZ 3.2 GZ 3.3 GZ 4 Motor output

GZ 2 - GZ 4 / 100 - 1450 kW

Electric supply diagram

Motor voltage 230 V WS 50 Hz 230 V WS 50 Hz 400 V DS 50 Hz 400 V DS 50 Hz 400 V DS 50 Hz 400 V DS 50 Hz

Connected wattage

0,25 kW 0,37 kW, ca. 2 A 0,45 kW 0,7 kW, 1,1 kW 1,4 kW, 1,1 kW 1,4 kW, 1,1 kW 1,4 kW, 3,0 kW 3,3 kW, ca. 3,2 A ca. 3 A ca. 3 A ca. 3 A ca. 6 A

Boiler connections Assembly with silencer hood for GZ 3 and GZ 4

Type GZ 2.1 GZ 2.2 GZ 3.0/1 GZ 3.2/3 GZ 4 D1 130 140 150 162 195 D2 M When a silencer hood is fitted, the pipe double nipple may have to be lengthened to a size of 200 mm. The pipe length between gas ramps and burner should be as short possible. For gas burners GZ 3 and GZ 4, the max. pipe length is 800 mm. A bracket is required to take the weight of the gas ramps. The dimension H must be checked before erecting boilers without boiler foundations.

160 180 8/10 160 180 8/10 180 205 220 240 246 276 10 10 12

Fig. 18:

Assembly with silencer hood for GZ 3 and GZ 4

18

Fig. 19:

Circuit diagramm GZ 2

Indication On-off-Switch Safety thermostat On-off-thermostat On-off-thermostat Gas pressure switch Air pressure switch Ionization Condenser Motor with condenser Ignition transformer Servomotor b5 b6 b8 IS k1 m1 m2 m3 s1 s2 u1 Gas burner automatic safety l tester Leakage u2 b4 b3 b2

GZ 2 - GZ 4 / 100 - 1450 kW

Item

Multibloc

Solenoid valve , two-stage (stage 1 and 2) Safety solenoid valve

Observe local and VDE-regulations. Connections to earth potential being executed carefully. Failure

Working hours 1

Also when using the leak check

Installation-Operation-Maintenance

Working hours 2

Caution: do not confuse phase and Mp.

19

20 Circuit diagramm GZ 3.0

Indication On-off-Switch Safety thermostat On-off-thermostat On-off-thermostat Gas pressure switch Air pressure switch Infra-red flicker detector Condenser Motor with condenser Ignition transformer Servomotor Solenoid valve , two-stage (stage 1 and 2) Safety solenoid valve b6 b8 IS k1 m1 m2 m3 s1 s2 u1 u2 Gas burner automatic safety control Leakage tester b5 b4 b3 b2 Item Observe local and VDE-regulations. Connections to earth potential being executed carefully.

Fig. 20:

Multibloc

Installation-Operation-Maintenance

GZ 2 - GZ 4 / 100 - 1450 kW

Working hours 2

Also when using the leak check

Working hours 1

Failure

Caution: do not confuse phase and Mp.

Fig. 21:

GZ 2 - GZ 4 / 100 - 1450 kW
Circuit diagramm GZ 3.1 - GZ 3.3

Indication

Item b2 b3 b4 b5 b6 b8 c1 e2 IS m1 m2 m3 s1 s2 u1

Failure

Installation-Operation-Maintenance

Working hours 2

Working hours 1

Gas ramp block or line with separate parts (without connector)

On-off-Switch Safety thermostat On-off-thermostat On-off-thermostat Gas pressure switch Air pressure switch Motor contactor Bimetallic relais Infra-red flicker detector Motor with condenser Ignition transformer Servomotor Solenoid valve , two-stage (stage 1 and 2) Safety solenoid valve Gas burner automatic safety control Leakage tester

u2

Observe local and VDE-regulations. Connections to earth potential being executed carefully.

1) Connector as per DIN 4791 LK = luster terminal in the base of the automatic gas firing device

21

22 Circuit diagramm GZ 4
Sensor selection switch to "ION" When using the leak check Engine valve Observe local and VDEregulations. * Parts to be supplied on site Principle circuit Connector as per DIN

Fig. 22:

Installation-Operation-Maintenance

Failure

Working hours 1

Working hours 2

GZ 2 - GZ 4 / 100 - 1450 kW

Indication On-off-Switch Safety thermostat On-off-thermostat 1 On-off-thermostat 2 Gas pressure switch Air pressure switch Motor contactor Motorsicherung Bimetallic relais Ionisation electrode Motor Ignition transformer Servomotor Solenoid valve Engine valve Gas burner automatic safety Leakage tester

Item b2* b3* b4* b5* b6 b8 c1 e1* e2 IS m1 m2 m3 s1 s2 u1 u2

GZ 2 - GZ 4 / 100 - 1450 kW
Maintenance and service

Installation-Operation-Maintenance

Many European laws require that combustion heating systems have to be checked once a year by a qualified heating engineer. The burner should be thoroughly checked and cleaned (tan impeller, mixing system, ignition system). The gas filter should be re-placed as required and the assembly of the air damper axle oiled in GZ 4 (see Fig. 25). For maintenance, the burner is removed from its housing by turning the four quick release screws and disconnecting the gas compact ramps or the gas ramps system, then hanging it in one of the service positions (GZ 2 - GZ 3). In GZ 4, the nozzle system can be removed separately after disconnecting the ignition cable plug and the ionisation cable and after unscrewing the flange cover screws. Before removing the nozzle system, care must be taken to ensure that the servomotor has returned to the closed position.

Fig. 24:

Heating room dimensions for GZ 4

Fig. 25:

Air damper assembly GZ 4

Fig. 23: Burner in service Position

23

Installation-Operation-Maintenance
Guarantee
MHG gas burners should work perfectly after beings installed and started by a qualified heating engineer, and when used for combustion of the gas types stipulated in DVGW paper G 250 certified for the particular gas burners. The guarantee period lasts for 24 months after first start-up and not more than 27 months after the date of dispatch. Please consult the burner documents for details. For details please consult the burner card.

GZ 2 - GZ 4 / 100 - 1450 kW

Spare parts
When replacing parts, only use original spare parts from MHG. Some components are specially designed and manufactured for MHG burners. When ordering spare parts, please always state the burner number.

All dimensions in mm. Technical details and components subject to change without prior notice.

24

GZ 2 - GZ 4 / 100 - 1450 kW

Your notes

as per 7 (2) 1. BImSchV (First ordinance for implementation of the German Emission Protection Law) MHG Heiztechnik GmbH herewith certifies for the gas burners stated below Product Trade name Type / design no Test standards Testing agency Quality management system Certified by Gas burner Forced draught burner GZ 2.1 - 2.2 / CE-0085AQ0916 GZ 3.0 - 3.3 / CE-0085AQ0916 GZ 4.1 - 4.2 / CE-0085AQ0916 DIN EN 676 Gaswrme Institut (GWI) Essen DIN EN ISO 9001 Germanischer Lloyd (GLC)

Manufacturer's certificate

Hamburg, 14.10.2005

that these products fulfil the requirements of the stated directives and standards, and correspond to the design tested by the above stated testing agency. However, this declaration does not constitute a warranty of any qualities In addition, this burner remains below the tolerable value of max. 120 mg/kWh for nitrogen oxide. stipulated in the ordinance text of 7 (2) 1. BImSchV (First ordinance for implementation of the German Emission Protection Law). The oil burners designed above are intended only for the installation in boilers which have also been certified to the corresponding directives and standards. The contractor assembling the system shall guarantee that all regulations relating to the interaction of oil burner and boiler have been observed. MHG Heiztechnik GmbH

Niedermayer

i. V. Gieseler

25

Installation-Operation-Maintenance

GZ 2 - GZ 4 / 100 - 1450 kW

EC Declaration of Conformity
MHG Heiztechnik GmbH herewith certifies that the forced draught gas burners stated below: Product Trade name Type Gas burner Forced draught burner GZ 2, GZ 3, GZ 4

Hamburg, 14.10.2005

correspond to the type/design described in the EU type/design test certificate They comply with the valid requirements of gas appliance directive 90/396 EEC dated 29.06.1990. MHG Heiztechnik GmbH

Zertifiziert nach ISO 9001

Niedermayer i. V. Gieseler
Germanischer Lloyd Certification

26

GZ 2 - GZ 4 / 100 - 1450 kW

Your notes

27