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Mark MEGAFLEX, Technical Manual

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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. Please contact your installer. Repairs must only be carried out by qualified technicians. 

Failure to comply with these requirements can compromise the safety of the appliance.

Summary of Contents for MEGAFLEX

Page 1: ...EN 1 Technical manual MARK MEGAFLEX 0660440 ...

Page 2: ...your installation should be checked by an installer Disconnect from the main Connect the filling hose to the cold water tap and to the fill and drain valve of the boiler Before tightning the coupling in the installation slowly fill the hose with water allowing any air present to escape Open the fill and drain valve and slowly fill the installation until a pressure between 1 5 and 2 0 bar is reache...

Page 3: ...ator valves open Is the water pressure in the installation higher than 1 bar Is the installation bled thoroughly An error is indicated by a code on the display It is very important for the sake of a correct diagnosis to mention this code when calling your installer Reset the burner controller by pressing the ok button on the control panel If the error occurs frequently contact your installer Maint...

Page 4: ...ith external storage tank 17 4 4 Cascade 17 5 Boiler control 18 5 1 Control Panel 18 5 2 Push buttons on control panel 18 5 3 User menu 19 5 3 1 Parameter value setting 19 5 3 2 Parameters accessible by user 19 5 4 Installer technician menu 23 5 4 1 Parameters accessible by installer technician 23 5 5 Manual Chimney sweep mode 30 5 6 Disabling CH request 30 5 7 Service code 30 5 8 Tacho fan speed ...

Page 5: ...41 6 6 Electrical connection 43 6 6 1 Wiring diagram 45 6 6 2 NTC resistance table 47 6 7 Pneumatic connections 48 6 8 PC connection 48 7 Commissioning 48 7 1 Gas category 48 7 2 Adjustment CO2 O2 and check input 50 8 Errors 51 8 1 General 53 8 2 DHW errors 53 8 3 CH errors 53 8 4 Errors hard and soft lockouts 53 9 Annual service 55 9 1 Service maintenance table 57 ...

Page 6: ...6 1 DESCRIPTION BOILER 1 Manometer 2 Display LCD 3 Power switch 4 Fuse 5 Burnerhood 6 Sight glass 7 Flow NTC 8 Ignition electrode 9 Ionisation flame detector 10 Inspection cover ...

Page 7: ...EN 7 11 Gas pipe 12 Gas valve 13 Air supply 14 Fan 15 Overheat limiter 16 Flow 17 Flue gas NTC 18 Exhaust 19 Return 20 Maxsys 21 Terminal strip 22 Syphon pressure switch 23 Air pressure switch ...

Page 8: ...8 24 Sump inspection cover 25 Syphon 26 Fill and drain valve 27 Water pressure switch 28 Return NTC 29 Automatic air vent 30 Venturi ...

Page 9: ...480 Pa Emission CO 96 96 ppm Emission NOx class 6 6 6 6 Types B23 C33 C63 yes yes yes yes Gas Gas flow max load G25 104 5 83 6 125 4 104 5 m3 h Gas flow min load G25 21 21 25 1 25 1 m3 h Gas flow max load G25 3 99 9 79 9 119 8 99 9 m3 h Gas flow min load G25 3 20 20 24 24 m3 h Gas flow max load G20 90 72 108 90 m3 h Gas flow min load G20 18 18 21 6 21 6 m3 h CO2 content max load G25 G20 G25 3 9 3 ...

Page 10: ...NT MATRIX Overview of main components used in MegaFlex series Part 850 11 1020 13 Boiler control Honeywell Maxsys S4966V2052 S4966V2052 Display user interface DSP 49G2193 DSP 49G2193 2 Line EMC Filter 250V EPCOS B84112G Fan MVL 230VAC G3G250MW5001 G3G250250MW5001 Gas valve Dungs 230VAC MBC 700 SE S02 MBC 1200 SE S02 Venturi type DT DT850 DT1020 Texi Burner round 140 mm Worgas 1011 1200 Silencer fl...

Page 11: ...EN 11 3 DIMENSIONS ...

Page 12: ...nowledge 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 Please contact your installer Repairs must only be carried out by qualified technicians Failure to comply with these requirements can compromise the safety of the appliance ...

Page 13: ...mostat The room thermostat has to be connected to the pin nrs 1 2 on the terminal strip Open Therm will be recognized if connected on 1 2 The desired flow temperature is adjustable but as standard is set to 85 C At CH heat request from the room thermostat and no DHW heat request present the CH pump is activated after 10 seconds The controller will adjust the burner input in such a way that a flow ...

Page 14: ...menu advanced CH settings A OTC offset minimum CH setpoint value B OTC setpoint maximum maximum CH setpoint value C OTC weather cold external temperature value at which the maximum CH value will be used D OTC weather warm external temperature value at which the minimum CH value will be used E OTC warm weather shutdown external temperature value at which the CH demand will end In the user menu an e...

Page 15: ...e has been reached Once heat demand has finished the burner will turn off following a set post purge period The graph below illustrates this 4 2 6 Protection against insufficient flow through boiler When the requirements of 6 3 2 are fulfilled the boiler will protect itself against insufficient flow This is done by checking the difference in temperature between flow and return so called ΔT In a lo...

Page 16: ...2 pumps 230VAC DHW pump terminal strip C1 6 7 8 and CH pump terminal strip C1 9 10 11 an electric 3 way valve with a maximum travel time of 255 sec terminal strip C1 6 7 8 9 At the end of the travel time in either direction DHW or CH the 230VAC on the 3 way valve will be switched off The 2 wires of the tank thermostat must be connected to numbers 7 and 8 on terminal strip C2 In the case of using a...

Page 17: ...r operation press Summer Winter button R2 C4 active in main screen See later in manual for further explanation In the default boiler configuration 2 pumps DHW and CH pump a DHW request has priority over CH request In the technician menu advanced DHW settings DHW priority the DHW priority over CH can either be disabled or a maximum DHW priority time may be set In the case where the DHW priority is ...

Page 18: ...ifferent 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 R1 C4 on off button puts boiler in off mode main logo and date time stay displayed R2 C3 menu button enables if pressed access to both user and installer menu R2 C4 summer winter button enables disables if pressed CH and DHW in main sc...

Page 19: ...ption will be selected Once an option has been slected it is possible to change the parameters corresponding with the chosen option 5 3 1 Parameter value setting Pressing the up and down R1 C2 and R3 C2 buttons will highlight the desired parameter Pressing the OK button R2 C2 will allow the chosen parameter to be modified This is shown below The actual value can be changed by pressing the R1 C1 an...

Page 20: ...able on board scheduler Enable Enable on board scheduler Disable Disable on board scheduler 2 Scheduler set Select to set scheduler 1 Monday 2 Tuesday 3 Wednesday 4 Thursday 5 Friday 6 Saturday 7 Sunday 8 Monday Friday 9 Monday Sunday 10 Saturday Sunday Used to program on board scheduler On Off Eco 2 DOMESTIC HOT WATER Domestic hot water user settings 1 DHW set point Set the DHW temperature in cas...

Page 21: ...e date Show next service due date When date expire a MSG is shown on lower part of main screen asking for service 5 SERVICE Boiler option settings 1 Select Language Allow selection of different language English Select for English Italian Select for Italian German Select for German Russian Select for Russian Spanish Select for Spanish 2 Select units Allow selection of different unit Fahrenheit Sele...

Page 22: ...CH request 2 DHW demand 3 Firing rate 4 Flame ionization current 5 Boiler set point 6 Boiler supply temperature 7 Return temperature 8 Flue temperature 9 Outdoor temperature 10 DHW storage temperature 11 Boiler fan speed 12 CH ignitions 13 CH runtime 14 DHW ignitions 15 DHW runtime 16 System pressure 17 Heat Exchanger Temp 18 0 10V input 19 Target power Will display the information shown in SUBMEN...

Page 23: ...TEM SETTINGS 4 DIAGNOSTICS 5 USER SETTINGS 6 CASCADE 7 RESTORE FACTORY SETTINGS Pressing the up and down R1 C2 and R3 C2 buttons will highlight the desired parameter group Pressing the up and down R1 C2 and R3 C2 buttons will highlight the desired parameter subgroup Pressing the OK button R2 C2 selects the chosen parameter subgroup Once a parameter subgroup option has been chosen it is possible to...

Page 24: ...al temperature at which OTC will set maximum CH setpoint 2 Outside temp for CH Define external temperature at which OTC will set the minimum CH setpoint 3 Outside temp for CV off Set the external temperature at which Heat demand is removed If set OFF heat de mand will never be removed by controller only by removing RT or bridge between terminal strip C2 1 2 4 OTC set point table Show in a table th...

Page 25: ...t tings Define pump usage in DHW mode DHW post pump time Set the DHW pump overrun time added to the prefixed time of 3 minutes 4 DHW priority Define DHW priority over CH 1 DHW priority status Enable disable DHW priority over CH Enabled Enable Disabled Disable 2 DHW priority timeout Define after how much time DHW priority is ended CH can be served if present for the same amount of time Off Select f...

Page 26: ...udrate default 38400 bps Frame Set frame 8N 8 3 way valve travel time Select for setting travel time 3Wv in seconds 1 255 sec Set travel time 3Wv DHW CH 2 User interface settings 1 Select language Allow selection of a different language English Select for English Italian Select for Italian German Select for German Russian Select for Russian Spanish Select for Spanish 2 Select unites Allow selectio...

Page 27: ...of the line means that hitting OK when the line is highlighted will open a graph that shows the latest 120 variable values stored every 12 minutes 24 hour history 2 Lockout history Shows the list of recent errors Hitting OK on the highlighted error will open new screen that contains details of the boiler status when the error occured 3 Manuel test See chimney sweeper 5 USER SETTINGS Access the use...

Page 28: ...stic hot water Domestic hot water user settings 1 DHW set point Set the DHW temperature in case of a DHW with sensor this is the actual DHW temperature in case of DHW with thermostat this is the base boiler flow tempera ture 2 ECO set point reduction Invoke scheduler menu 3 Scheduler set Invoke scheduler menu 1 Enable disable on board scheduler Based on selection is possible to enable disable on b...

Page 29: ...HW CH CH only Disabled Disable Heterogeneous mode Enabled Enable Heterogeneous mode 8 Cascade pump speed Cascade pump full speed 9 Cascade pump min speed Cascade pump min speed 2 Cascade info 1 Cascade role Role of boiler in cascade mode MASTER SLAVE TERMINAL SLAVE If not in cascade mode STANDALONE 2 System tempera ture Cascade temperature value Hitting OK when highlighted will open graph that sho...

Page 30: ...the ECO button R3 C4 is pressed a programmable value see user menu 1 HEATING under 2 ECO set point reduction is automatically subtracted from the flow temperature setpoint weather com pensated OTC set point or 0 10V setpoint The same principal is applicable for DHW see user menu 2 DOMESTIC HOT WATER under 2 ECO set point reduction 5 11 Holiday mode When the Holiday button R3 C3 is pressed a start ...

Page 31: ...1 Select language English English Italian German Russian Spanish 2 Select units Celsius Fahrenheit Celsius 3 Set date set date 4 Set time 24 hours 24 hours 12 hours 5 Restore factory settings Reset to factory check settings 6 CHIMNEY SWEEPER OFF 0 100 1 Boiler information Real time boiler status 2 Lockout history Overview lockout history Status boiler at time of lock block TECHNICIAN MENU Recom me...

Page 32: ...ect language English English Italian German Russian Spanish 2 Select units Celsius Fahrenheit Celsius 3 Set date Set date 4 Set time 24 Hours 24 Hours 12 Hours 3 Service settings 1 Service information Set telephone number 2 Service due date Set service date 4 DIAGNOS TICS 1 Boiler information Real time boiler status 2 Lockout history Overview lockout history Status boiler at time of lock block 3 M...

Page 33: ...led Disabled 8 Cascade pump speed mx 100 15 100 100 9 Cascade pump speed min 40 15 100 30 2 Cascade info 1 Cascade role see Cascade auto detection Standalone Standalone Master Slave 2 System temperature Actual temperature cascade system sensor 3 Number of boilers on Actual number of burners boilers on in cascade 4 Modulation level Actual cascade modulation level 3 Cascade auto detect press OK to s...

Page 34: ...drain into the syphon and fill it 6 2 Frost protection The boiler is protected against frost If the boiler detects an NTC flow temperature below 8 ºC the CH pump will be activated If tempe ratures continues to fall the boiler will start at a flow temperature of 6 ºC and it will run on minimum load until the flow NTC senses a temperature of 15 C The CH pump will stay running for another 10 minutes ...

Page 35: ...nnections see chapter 6 7 6 3 2 Minimum flow The minimum flows shown below must be guaranteed Input in kW Flow m3 h delta T 25 full load Flow m3 h delta T 30 Start 25 Flow m3 h delta T 30 part load 850 11 29 2 9 7 4 9 680 11 23 4 9 7 4 9 1020 13 35 1 11 9 5 8 850 13 29 2 11 9 5 8 6 3 3Water treatment Before filling up the installation old and new the installation should be rinsed thoroughly with c...

Page 36: ...g products Especially in low tempereature hea ting systems normal degassing systems are insufficient The use of an advanced system is required Water pressure must be higher than 0 8 bar The water quality must be checked on a regular base at least once every year There are many products available on the market which pretend to clean and protect heating systems Unfortunately there are only a few tha...

Page 37: ... At the highest point of the installation a de airing device should be mounted 6 4 Gas connection 1 The gas connection must be done in accordance with all local and national codes regulations and standards and in accordance with the directives of all relevant authorities 2 The gaspipe of the boiler has a R 2 connection 3 In order to avoid blockage of the gas valve ensure that there is no dirt in t...

Page 38: ...lue system can corrode the aluminium parts of the boiler A condensate trap collector must be mounted just before entering the silencer s of the boiler also see 6 5 5 1 general T P W Class Temperature range T120 Pressure range P1 Condensate resistance W wet D Dry W The minimal combustion products temperature mass flow rate and CO2 are given in the table below Vol Flue Vol Air CO2 T fluegas rho Mega...

Page 39: ...and air supply is given in the table below Air connection All types have air connection ø 200 mm Flue gas connectio ø 250 mm for all types Type Boiler Total available Pressure drop In Pa for B23 C33 C63 850 11 500 1020 13 500 For pressure drop calculation of appliance types B23 C33 use the next two tables on the following pages Pressure drop table per component 1 2 3 4 Component 680 850 11 850 102...

Page 40: ...op table component for air components Select the correct column for the selected boiler type 850 11 1 2 1020 13 3 4 Column 6 total pressure drop flue gas multiply column 2 4 Column 7 total pressure drop air multiply column 3 5 Column 8 total pressure drop terminal 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...

Page 41: ...00x500 41 007 04 01 GENERAL WALL BRACKET 250 40 045 22 35 WALL BRACKET 200 41 008 71 98 SEAL SIL 250 mm for DN250 ALU 40 045 18 15 SEAL SIL 200 ALU 200 41 002 73 70 SEAL EPDM 200 PP DN 200 41 007 52 95 WEATHER SLATE FLAT ALU 368 0 for 41 007 65 59 41 007 65 71 WEATHER SLATE FLAT ALU 275 for 40 045 26 65 40 045 31 98 6 5 5 Installing flue exhaust and air inlet 6 5 5 1 General Do not use materials f...

Page 42: ... mm If PP is used pay attention to the expansion elongation of the PP due to rise in flue gas temperature Insert the PP pipe into the sleeve and redraw over a length of 10 mm 10 mm for maximum pipe length of 2 mtr After mounting the minimum insert length into the sleeve and the pipe end must be 40 mm Condensate trap collector The condensate trap collector must be either connected by a tube to a sy...

Page 43: ...ore the bend All brackets must be obtained from M G 6 5 5 3 Seals and joining Prevent incorrect or damaged seals by shortening pipes squarely and by deburring after shortening Joins or connections in the exhaust flue may not be screwed In the air inlet only aluminium or stainless steel joins or connections may be screwed It is not allo wed to screw PP joins or connections Do not use glue or foam l...

Page 44: ...to the numbers 7 PE 8 L 9 N on strip C1 if in use in combination with a 3 way valve also see chapter 4 3 A PWM pump should be connected to 21 PE and 22 N on strip C1 If 230VAC is applicable than 23 24 or 25 can be used for L The PWM signal should be connected to 14 PWM signal and 13 PWM ground om strip C2 From the technician menu system settings boiler parameters the max and min pump speed can be ...

Page 45: ...al heating pump DHW P Domestic hot water pump PWM P Modulating pump A P Appliance pump max 0 8A HE Heat exchanger NTC1 Flow temperature sensor NTC2 Return temperature sensor NTC3 Domestic hot water sensor or switch NTC4 Outside temperature sensor NTC5 Flue gas temperature sensor NTC6 Cascade sensor MT Maximal thermostat 1 4 WPS Waterpressure sensor APS Air pressure switch SPS Siphon pressure switc...

Page 46: ...46 ...

Page 47: ...e Ω 12K 30 20 98 200 15 75 900 10 58 800 5 45 900 0 36 100 5 28 600 10 22 800 15 18 300 20 14 700 25 12 000 30 9 800 35 8 050 40 6 650 45 5 520 50 4 610 55 3 860 60 3 250 65 2 750 70 2 340 75 1 940 80 1 710 85 1 470 90 1 260 95 1 100 100 950 105 110 115 120 ...

Page 48: ...e installation is automatically bled by a built in automatic air vent 2 Check all gas and water connections thoroughly for leaks 3 Bleed the gas pipe 4 As standard the boiler is set for G20 or G25 Check that the installation provides the correct type of gas to the boiler 5 Check the inlet pressure 20 mbar or 25 mbar 6 Turn on the boiler by setting the main switch on the control panel of the boiler...

Page 49: ...es vary by country In the table below the gas category and supply pressure are listed by country Countries Category Pressure mbar AT Austria 12H 20 BE Belgium 12E R 20 25 BG Bulgaria 12H 20 HR Croatia 12H 20 CY Cyprus 12H 20 CZ Czech Republic 12H 18 DE Germany 12E 20 DK Denmark 12H 20 EE Estonia 12H 20 ES Spain 12H 20 FI Finland 12H 20 FR France I2Esi I2Er 20 25 GB United Kingdom 12H 20 GR Greece ...

Page 50: ...below Type of boiler Gas type inlet pressure CO2 on max load CO2 on min load 850 11 G20 G25 G25 3 20 25 mbar 9 3 0 2 0 05 9 1 0 15 0 2 1020 13 G20 G25 G25 3 20 25 mbar 9 3 0 2 0 05 9 1 0 15 0 2 For O2 percentage see Chapter 2 Technical data The boiler has a gas valve that is connected to a venturi See figure below Adjustment for max load wait until the boiler is stable and measure CO2 if required ...

Page 51: ...MAXSYS Also see electrical wiring diagram If there is 230VAC present terminal connector C1 25 22 then the 230V fuses F1 and F2 inside the Maxsys should be renewed Disconnect the boiler from the main supply and remove the connectors from the Maxsys Notice for this it is not necessary to unscrew the Maxsys from the mounting plate Release the six security clips with a long thin screw driver Then remo...

Page 52: ...owing this the fan will start and wait for air pressure switch to close As soon as APS has closed starting procedure will continue APS closes at ΔP 40 Pa If there is a problem with APS the display will show blower speed error The boiler control checks the status of the built in pressure switches for water gas and syphon just befo re ignition Water pressure should be 1 4 bar E47 Gas pressure should...

Page 53: ... panel is switched off boiler off Room thermostat defect incorrect wiring temperature set too low Outdoor sensor and or its wiring defect CH operation off 3 way valve defect remains in direction towards storage tank 8 4 Errors hard and soft lockouts Errors are indicated by a text and an E code on the bottom line on the display The error message can be displayed by pressing the information button F...

Page 54: ...54 ...

Page 55: ...spection cover of the sump on the front side beneath the controls The inner part of the sump and the bottom part of the heat exchanger should be inspected and if neces sary be cleaned If the bottom part of the heat exchanger is clogged the inspection covers on the left hand side of the heat exchanger should be removed Using a special tool see figure below makes it possible to clean the heat exchan...

Page 56: ...56 ...

Page 57: ...ue to malfunctioning of the fan or other causes At maximum load the installation should be designed for nominal ΔT of 15 K to 20 K When the ΔT is higher than 25 K the boiler cannot continue at maximum load anymore and will start to modulate because water flow through the boiler is insufficient T flow and T return can be read in info mode on the display see 5 4 diagnostics Valves malfunctioning pum...

Page 58: ...m be www markbelgium be MARK DEUTSCHLAND GmbH MAX PLANCK STRASSE 16 46446 EMMERICH AM RHEIN DEUTSCHLAND TELEFON 49 0 2822 97728 0 TELEFAX 49 0 2822 97728 10 info mark de www mark de MARK POLSKA Sp z o o UL KAWIA 4 16 42 200 CZE STOCHOWA POLSKA PHONE 48 34 3683443 FAX 48 34 3683553 info markpolska pl www markpolska pl S C MARK ROMANIA S R L STR KOS KAROLY NR 1 A 540297 TARGU MURES ROMANIA TEL FAX 4...

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