certified Qualitysystem

ISO 9001 / EN 29001

Reg. Nr. 10529 A Honeywell Company
MMI 810.1 (40-34)

Gas burner safty control

INTRODUCTION
The MMI 810.1 Mod 40-34 gas burner safety control is
suitable for fully automatic forced and inducqd draught gas
burners. It caters for burners with an intermittent pilot
system (expanding flame), and those with interrupted pilot
systems.
The control box provides a safe light-up and shut-down
sequence for the burner and incorporates pre-purge, ignition
and ignition safety time intervals, start or pilot flame and
main flame stages.
The control is suitable for use on flame rectification detection
only. It is certificated for use by most European Gas
Authorities, and for precise approval details, see under,
Technical Specification‘ the model numbers which apply in
various countries.
CONSTRUCTION
Control Box and Base

FEATURES The control box is housed in a tough transparent plastic

cover, so that the working parts are easily seen. The plastic
1. The control box has a working ambient temperature material used for the cover is of the self-extinguishing type.
rating of up to 60° C. Inside, a synchronous motor and cam switch assembly
2. The timing sequence is accurately controlled by a provide the timing sequence. The electronic flame detection
synchronous motor driving a cam switch assembly. This amplifier and electrical components are mounted onto two
produces a consistent performance despite variations in plug-in printed circuit boards, whilst power to the external
the supply voltage. circuits e.g. gas valves, ignition system etc, is carried
3. The control box automatically checks the air pressure through conventional ‚point-to-point‘ wiring.
proving switch in both the „no air“ and „air supply Manual reset from the lockout position is provided by a push
proved“ positions. button on top of the control and a lockout signal lamp is
4. A coloured programme indicator is incorporated, to incorporated underneath this button. A single screw through
show the position reached by the control at any state in the control box locks it onto the wiring base.
the sequence. This allows easier diagnosis when fault The wiring base is a robust plastic moulding, allowing
finding. adequate room when connecting up to the external wiring
5. The main relay operates on d.c. to assist noiseless terminals supplied for live, neutral, burner motor, ignition
operation with variations in the supply voltage. The etc.
electronic and electrical components are incor- porated A variety of cable entry points to the base is provided in the
onto two plug-in printed circuit boards. Power to the form of 4 easy knockout holes at the base ends and the
external circuits, eg. gas valves, ignition system etc, is underside. The base end holes are for PG11 screwed
carried by ‚point-to-point‘ internal wiring. electrical fittings.
6. 6. A start interlock circuit is provided, see under „Ope- In addition a detachable cable entry plate is supplied which
ration“, and fig. 3. allows for either further screwed cable entry or simple
7. The wiring base and control box have a positive plug-in entries for p.v.c. type wiring.
arrangement, making it impossible to achieve an incorrect
connection between the two parts.
8. Extra terminals for neutral and earth connections are Flame lonisation Probe
supplied in the wiring base, in all 3 for neutral, 3 for earth.
9. The control box is arranged such that it will largely ignore This is not supplied as part of the control system. A flame
the effects of ignition spark interference upon the flame electrode with good heat resisting properties and well
signal. insulated should be used for this. The flame electrode
should therefore be similar to a good ignition electrode.
0708.22-01-e/12/98

1
Failure to establish Flame

If flame is not established or detected during the light-up

sequence, the control box goes to lockout shutting down
the burner within 5 seconds from the initial switching on of
the start gas valve. Similarly, if the main flame is not
established or detected after the pilot valve has been
switched off, the control box goes to lockout.
The lockout signal lamp behind the reset button is illuminated,
and the burner cannot be restarted until the reset button is
pressed.
Reset can be effected immediately following a lockout and
a full light-up sequence begins.

Running Flame Failure

If during a run, the gas flame is extinguished, the flame

detection system reacts instantly to the loss of flame. The
gas valve circuits are switched off within 1 second and the
control box goes to lockout shutting down the burner
completely. See also under „Summary of Safety Features“.

INTERNAL & EXTERNAL WIRING DIAGRAM Fig.1

COLOURED PROGRAMME INDICATOR

A coloured programme indicator is incorporated on the cam
assembly, and the approximate colour positions indicate
the following steps in the sequence.
Blue line on White – Start position
Start of Blue sector – Start of pre-purge
Red line in Blue sector – Air supply proved.
See under fault finding
note 3
Blue sector – Pre-purge
End of Blue – End of pre-purge
End of Blue/Start of YelIow – Start of ignition safety time,
and initial fuel release
End of Yellow/Start of Red – Lockout position, due to
ignition or detection failure
Red sector – Start/Pilot flame proving
period
End of Red/Start of Yellow – Main flame establishment
period
End of Yellow/Start of Green – End of main flame
establishment time
End of Green/Start of White – „Run“ position

HS Main Isolator
GW Gas pressure proving switch, if fitted.
Th Control thermostat
v Gas valve proof of closure
switches, if fitted, see fig. 3.
SA External lockout signal
LW Air pressure proving switch
PV Pilot gas valve (interrupted system)
V1 Start gas valve
(expanding flame system)
V2 Main gas valve
Z Ignition Transformer
M Burner Fan Motor
lon Flame detection probe
RS Lockout relay, with contacts s1
RH Main relay with contacts h1
RF Flame relay with contacts f1
SY Synchronous timing motor
MMI 810.1

2
 INSTALLATION INSTRUCTIONS 7. Proof of closure switches on gas valves can be inter-
locked with the operation of the control box, across the
Control Box start interlock circuit over terminals 9 and 1. Where this
1. The control box wiring base is supplied with 2 fixing holes feature is required, the connections must be made in
for mounting onto the burner. accordance with those shown on fig. 3.
2. To assist trouble-free operation choose a position where 8. Where a timeswitch is to be fitted, the timeswitch contacts
if possible, it is not subject to harsh vibration. Similarly should be connected in series with the thermo- stats to
the control should not be mounted in a position where terminal 9.
the ambient temperature exceeds 60° C.
3. Ensure that the control box is correctly wired up in Flame lonisation Probe
accordance with the appropriate diagram. A general
diagram is provided on the underside of the control box, 1. For best results, the length of wiring run between flame
but it is advisable to refer to the burner manufac- turers probe and control box, should be kept as short as
scheme drawing, in case additional external interlocks possible. Maximum permissible length 20 metres.
are required for correct burner operation. 2. The flame probe should be well positioned in the flame,
4. The control box will only function providing a load is but remote as practical from the H.T. ignition electrode.
connected onto terminals 5 or C, eg. start gas or pilot gas The control box flame detection amplifier is suppressed
valve, see fig. 2. Similarly if this load employs half-wave for „spark splash“ onto the probe, nevertheless contact
rectification, the negative side of the load must be between H.T. ignition spark and flame probe must be
connected onto terminals 5 or C. avoided.
5. Observe correct wiring polarity of live and neutral, live 3. Ensure that the boiler/burner are effectively bonded to
onto terminal 9, neutral onto 8, see fig. 2. the incoming earth from the mains supply, otherwise little
6. Where the burner fan motor loading exceeds the control or no flame signal may result.
box current rating of 2A, a contactor or starter must be 4. The wiring to the flame probe and H.T. ignition electrode
used to switch the load. Similarly, if the motor is over should not be run adjacent to each other.
1/4 HP, and is of the split-phase start variety, a contactor
must be used to carry the electrical loading.

EXTERNAL WIRING DIAGRAM Fig.2

HS Main Isolator
GW Gas pressure proving switch, if fitted
ST Limit thermostat
RT Control thermostat
V2 approx. 10 secs.
IS Flame detection probe
Z Ignition Transformer
M Burner Fan Motor
PV Pilot gas valve (interrupted system)
V1 Start gas valve (expanding flame system)
V2 Main gas valve
SA External lockout signal 2. If this load
LW Air pressure proving switch side of the
B „Run“ position S „Lockout“

tw Waiting time at start position

start-up tv1 Pre-purge period
flame established ts1 Ignition safety time
tv2 Delay to high flame
ts2 Main flame establishment time

start-up, flame
not established

Use with proof of closure switches Fig.3 Refer generally, but the following
additional information applies.
v Gas valve proof of closure switches are
made when valves are shut.
BM Burner fan motor starter or contactor

The control must be wired in accordance with the

diagram shown above, so that when the burner fan
motor is energised, the „start interlock“ circuit cross
terminals 9 and 1 is maintained throughout the
remainder of the programme. This is not essential to
ensure that all safety features are retained during the
pre-purge period.

*Note: This control will only function correctly providing a load,

e.g. start gas valve or pilot gas valve, is connected onto
MMI 810.1

terminals 5 or C. If this load employs a half-wave

rectifier, the negative side of the load must be
connected to 5 or C.
3
COMMISSIONING & ROUTINE CHECKS Interference to flame signal
Generally the control box should not require any mainten- One principal source of problem with this system, is inter-
ance, and no attempt should be made to break the seal or ference to the flame signal from the ignition spark. The
remove the cover. On commissioning and during each ignition spark may produce its own ionisation current, the
routine service visit it is advisable to carry out the following polarity of which is often random, and may therefore oppose
checks. These should only be done by a competent Service and possibly swamp the flame signal current. The result will
Engineer. sometimes be a nuisance lockout.
The MMI 810.1 control box is designed to limit this problem
1. Close the main gas cock, link out the gas pressure switch to a minimum.
(if fitted) and allow the burner to start. The control box During the ignition sequence, the flame relay is purposely
should go to l ockout after the expiry of the ignition safety energised at the commencement of the ignition safety time.
time. Just prior to the lockout position being reached, the ignition
2. Re-open the main gas cock, reset the control box allow- circuit is switched off. This provides the flame detection
ing the burner to start. When the burner is at the „run“ system with a brief period to react to a tlame signal which will
position, close the main cock. When the flame goes out, then be free from ignition interference and allows the flame
the control box should go to lockout almost immediately. relay to be maintained if flame is detected at this point.
Remove link across gas pressure switch (if fitted) and The Satronic ZT 812 High Frequency Ignition System, see
open main gas cock. leaflet A12 issue 2, also eliminates the effects of spark
3. Allow the burner to start, and during the pre-purge interference. The output is so arranged that any ionisation
period, simulate a failure in the combustion air supply. current from the spark is polarised to be in the same direc-
The control box should go to lockout almost immediately. tion as the flame signal current.
4. Re-start the burner and during the pre-purge, simulate if
possible a false flame signal. The burner should shut
down immediately with the control box going to lock- out. Measurement of Flame Signal Current
Remove source of flame simulation. To ensure good positioning of the flame probe, a simple
5. Before attempting to start the burner, simulate current measurement can be taken. Figure 4 below shows
„combustion air supply established“. The control box the method using a d.c. micro-ammeter ranges 0 – 10µA,
synchronous motor will run, but start-up of the burner will 0 – 100µA.
be prevented. The measurement should not be taken whilst the ignition
Remove source of air supply simulation. spark is on, as this will influence the flame signal. Typical
readings which could be expected are 10µA – 15µA.

NOTES ON FLAME DETECTION Fig. 4 lonisation signal current

General
A flame detection or ionisation probe is simply a metal
electrode which is positioned in the flame. When an a.c. E 2
MMI 810.1
voltage is applied between the burner and probe, a d.c.
current flows through the probe via the flame to the burner
(earth). The flame therefore acts as a rectifier. The resulting
d.c. current is amplified such that it is sufficient to operate +
the flame relay within the burner control box.
If the insulation between the flame probe and earth is d.c meter
- 0 - 10 µA
insufficient, leakage currents will occur and these will be a.c.
0 - 100 µA
A filter incorporated in the control box amplifier will separate
leakage currents from the ionisation current. In cases of
flame probe
short circuit between the probe and burner, the rectifying
action will not take place and the burner control reacts as if
a „loss of flame“ occurs.

Use of MMI 810.1 Mod 40-34 as a replacement for earlier

series controls
The MMI 810.1 can be used as a direct replacement for
earlier series controls produced by Satronic.
Most TTG 760 or TTG 760-1 controls where used on the
flame rectification or ionisation mode can be directly replaced
by the MMI 810 series.
Simply unplug the TTG control box, and fit the MMI 810.1
directly into the existing wiring base.
Note: This does not apply in the case of TTG 760 Mod FN.
MMI 810.1

4
 SUMMARY OF SAFETY FEATURES 5. Burner starts, flame established but control box goes to
1. Flame failure during a run, results in burner shut-down lockout. Coloured programme indicator stopped at end
and lockout within 1 second. of yellow sector/start of red sector.
2. Failure to establish and detect flame during the light-up a) Check that flame detection probe is in contact with
sequence, results in burner shut-down and lockout within flame.
2 5 seconds from the initial release of fuel. The precise b) Check that flame probe insulator is not cracked. A
timing will depend on the model reference. cracked insulator will be sufficient to give rise to an
3. Failure to establish and detect the main flame will result a.c. leakage current. See notes on flame detection
in lockout after the pilot valve has been switched off. principIes.
4. Air supply failure at any time, results in burner shut-dowi c) Check that flame probe is not in contact with other
and immediate lockout. metallic parts of the burner.
5. The air pressure proving switch, is checked in both the 6. Burner starts, flame established but control box goes to
„no air“ and „air supply proved“ positions. From the initial lockout. Coloured programme indicator stopped at end
start up of the burner fan motor, a period of 5 seconds is of yellow/start of green sector. For burners using an
allowed by the control box for the pressure switch to interrupted pilot system, this is an indication that the
detect a combustion air supply. main flame has not been established or detected, and
6. Restoration of the power supply after an interruption, lockout has resulted immediately the pilot valve has been
results in a full light-up sequence to safely restart the switched off
burner. Power failure after a lockout, will not interfere with 7. Burner starts, flame established but control box goes to
this condition when the supply has been restored. Iockout. Coloured programme indicator stopped in green
7. False flame signats at the start point and during pre- sector. Check that when main gas valve has been switched
purge result in burner shut-down and lockout. on, the change in combustion or flame characteristics
8. The light-up sequence can only commence providing the has not caused the flame to „lift off“ the combustion head
cam switches and relay contacts within the control box and hence allow the flame probe to lose contact with the
are at their correct relative positions, and continuity of the flame.
lockout relay circuit is proved. 8. Burner starts, runs but subsequentty goes to lockout.
Coloured programme indicator stopped at end of green/
start of white sector.
a) Check for interruption in gas supply.
b) Check for failure of combustion air supply.
FAULT F INDING c) Check flame probe position for proper contact with
flame.
1. Burner will not start. Coloured programme indicator
d) Check flame probe insulator for soundness.
stopped on blue line in white sector.
e) If necessary, change control box.
a) Check electrical supply is switched on.
b) Check that thermostat circuit is „calling for heat“ and
Note: If the control box goes to lockout, it is generally
timeswitch circuit (if fitted) is made. A supply on
performing the function it is designed for.
terminal 9 will determine this.
c) Check that start interlock circuit across terminals 9 and
1 is made. Where proof of closure switches on gas
Causes of Lockout
valves are fitted and interlocked with the control box,
1. No Ignition.
failure to start could imply that the gas valves are not
2. ignition not in correct place, check electrode settings and
properly shut.
ceramic insulator for cracks or damage.
3. No gas supply.
2. Burner will not start. Synchronous motor runs, coloured
4. Gas valves not opening.
programme indicator rotates but burner does not start.
5. Failure of combustion air supply.
Check air pressure proving switch is in correct state i.e.
6. Incorrectly positioned flame probe, poor earth contact
„no air“ position.
with flame, interference to flame signal from ignition
spark.
3. Burner starts but goes to lockout. Programme indicator
7. Faulty control box.
stopped on red line in blue sector.
a) Check air pressure proving switch.
b) Check that a load, e.g. start gas valve is connected to
terminal 5.
c) Check continuity of start gas coil winding.
d) If start gas valve has coil with half-wave rectification,
check that negative side is connected to terminal 5.
e) Check for flame simulation or false flame signal.

4. Burner starts but goes to lockout. Coloured programme

indicator stopped in blue sector.
a) Check for combustion air supply failure.
b) Check for flame simulation, if necessary, change
control box.
c) Check for continuity of start gas valve coil circuit.
MMI 810.1

5
TECHNICAL SPECIFICATION
MMI 810.1 CONTROL BOX WITH WIRING BASE
1. Electrical
Sup¡ply: 240V (+10%, –15%) 5
50 Hz (50 – 60 Hz)
Supply variations: Timings will only vary in proportion
to the supply frequency.
Max. Fuse rating: 10A (rapid) 6A (slow)

67
Power consumption: 10 VA Max. PG 11

91
Max. output current
per terminal:
- Kl.3 2 A, cos ϕ 0.2
2 A, cos ϕ 0.4

24
- Kl. 4, B
- Kl. 5, 6. C 1 A, cos ϕ 0.4
Total output current: 5 A, cos ϕ 0.4 87 61
Air pressure proving 5 A rating at 220/240V, reaction Individual cable
switch contacts: time better than 5 seconds. Position of
entry plete
Flame detection reset button 24
system: lonisation
Min. Fiame signal

30
current: 1.0µA

44
35
Earth
Typical flame signal

16
current: 10µA – 15µA

30
25
Max. flame signal M4

16
current: 40µA – 50µA
Insulation standard: P44 30
ø 16 for underside cable
57-60 entry, if required
2. Timings
Waiting time at
start position: 9 secs approx.
Pre-purge time: 34 secs
Pre-ignition time: Nil Ignition safety
time ts1: 5 secs max.
Approx. delay time
to main flame: 10 secs. approx.
Main flame establish-
ment time ts2: 5 secs max.
Reaction to loss of
flame: Less than l.O sec.
Reset time from
lockout: None

3. General
Ambient temperature
rating: –20 ... +60 C all models.
Flame sensing probe: Heat resisting metal, well insulated.
(Material and insulation as for an
ignition electrode) Insulation
resistance better than 50MΩ
Max. wiring cable
length: 20m
Weight: 0.35 Kg, inclusive of wiring base.
Mounting attitude: Any

4. Model Nos.
The various model numbers below apply to the appropriate Stan-
dards and Approval in the tollowing countries, and are suitable for
intermittent pilot systems (expanding flame) only. See leaflet G27.

For intermittent or interrupted pilot systems MMI 810.1 Mod 40-34

is approved in the United K ingdom.

Special Note: If at any time this product requires to be repaired, such repair should only be carried out by Satronic or their
nominated Agent. It should not be repaired by unauthorised repairing agencies or companies.

MMI 810.1 (40-34) A Honeywell Company Satronic AG

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Postfach 324
6 CH-8157 Dielsdorf