Kromschroeder ZIC 165 Manuale utente

CONTENTS

· Edition 09.22 · EN · 03250523

DE, EN, FR, NL, IT, ES, DA, SV, NO, PT, EL, TR, CS, PL, RU, HU – www.docuthek.com

Burners for gas ZIC, ZICW

1 Safety ................................1

2 Checking the usage .....................2

3 Installation ............................3

4 Wiring................................5

5 Preparing commissioning.................6

6 Commissioning ........................8

7 Maintenance...........................9

8 Assistance in the event of malfunction ...... 11

9 Accessories ..........................12

10 Technical data .......................12

11 Logistics ............................13

12 Disposal ............................13

13 Declaration of Incorporation .............14

14 Certification .........................14

1 SAFETY

1.1 Please read and keep in a safe place

Please read through these instructions care-

fully before installing or operating. Following the installa-

tion, pass the instructions on to the operator. This unit

must be installed and commissioned in accordance

with the regulations and standards in force. These

instructions can also be found at www.docuthek.com.

1.2 Explanation of symbols

1, 2, 3, a, b, c = Action

➔= Instruction

1.3 Liability

We will not be held liable for damage resulting from

non-observance of the instructions and non-com-

pliant use.

1.4 Safety instructions

Information that is relevant for safety is indicated in the

instructions as follows:

DANGER

Indicates potentially fatal situations.

WARNING

Indicates possible danger to life and limb.

CAUTION

Indicates possible material damage.

All interventions may only be carried out by qualiﬁed

gas technicians. Electrical interventions may only be

carried out by qualiﬁed electricians.

1.5 Conversion, spare parts

All technical changes are prohibited. Only use OEM

spare parts.

OPERATING INSTRUCTIONS

ZIC · Edition 09.22

EN-2

2 CHECKING THE USAGE

Burner for heating industrial thermoprocessing equip-

ment. Burners BIC or BICA can be used in conjunction

with the ceramic tube set TSC in industrial furnaces or

ﬁring systems with brick lining or ceramic ﬁbre lining. No

burner block is necessary. For natural gas, town gas

and LPG. Other types of gas on request. This function

is only guaranteed when used within the speciﬁed

limits– see also page 12 (10 Technical data). Any

other use is considered as non-compliant.

2.1 Type label

Construction stage, rated capacity Q

max

, gas type –

see type label.

Elster GmbH

Osnabrück, Made in Germany

ZIC 165HB-0/35-(18)F

84246518

P 630; 550 kW

Ø mm

.3322

2.2 Type code

ZIC Burner for gas, with connection for

ceramic tube

ZICW Burner for gas, with ceramic ﬁbre insula-

tion (RCF)

165-200 Burner size

RCold air

HHot air/high furnace temperature

BNatural gas

DCoke oven gas, town gas

GPropane, propane/butane, butane

MPropane, propane/butane, butane (with

mixer)

LLow caloriﬁc value gas

LTorch

RReduced capacity

-X X mm length of steel tube as of furnace

ﬂange (L1)

/X X mm distance from furnace ﬂange to

front edge of burner head (L2)

-(X) Burner head identiﬁer

-(XE) Heat-resistant version

A-Z Construction stage

HHigh temperature version

2.3 Part designations

1 Burner insert

2 Gas housing gasket

3 Air housing

4 Mounting ﬂange

5 Mounting gasket

6 Type label

7 Burner extension (for ZIC..-100, ZIC..-200)

8 Clamping ring

9 Operating instructions – for more documents

and calculation tools, see www.adlatus.org

2.4 Burner head

➔Check letter marking and identiﬁcation marks on

the burner head using the information provided

on the type label.

2.5 Ceramic tube

Type label

Length and diameter – see type label.

D-49018 Osnabrück Germany

TSC 200A180-300/35-

74924401 SI-1500

2.6 Type code

TSC Ceramic tube set

165-200 Burner size

ACylindrical shape

BTapered shape

154, 180 Outlet diameter [mm]

200–300 Length [mm]

/35–, Distance from furnace ﬂange to front

edge of burner bafﬂe plate [mm]

Si Silicon-inﬁltrated SiC

1500 Up to 1500°C

ZIC · Edition 09.22

EN-3

D4D5

2.7 Part designations

1 Burner tube gasket

2 Ceramic tube

3 Type label

3 INSTALLATION

3.1 Installing the ceramic tube

WARNING

– Install the ceramic tube centrally and free of

mechanical stress to avoid damage.

Remove and dispose of the transport safety

device; to do this, remove the mounting ﬂange

or clamping ring.

➔

Remove the burner insert in order to install the

ceramic tube. For this purpose, the air housing

can be placed in a vertical position on a smooth

working surface.

➔

On ZICW, avoid the formation of dust when dis-

mantling the burner insert and do not damage the

surface of the internal insulation.

1 2

3 4

5 Place the burner insert in such a way that the in

sulators are protected against damage.

No burner extension

1 2

➔

Install the ceramic tube centrally and free of me

chanical stress.

➔Centre the ceramic tube.

➔Tighten the screws in a crosswise fashion.

➔Mounting ﬂange and furnace ﬂange must be ﬂush.

With burner extension

1 2

➔Centre the ceramic tube.

➔Insert lock washer pairs.

➔Tighten the screws in a crosswise fashion.

ZIC · Edition 09.22

EN-4

3.2 Insulating the ceramic tube

➔Protect the burner extension from thermal stress.

➔We recommend solid shaped partsA or high tem-

perature resistant ceramic ﬁbrous materialB for

insulation.

➔

Observe an annular void of at least 10 mm

(0.4inches).

➔

Insulate the ceramic tube at least as far as the

burner head, to a maximum of 20mm (0.8 inches)

behind the burner head.

➔Burners without extension:

A/B

≥ 10 mm

≥ 0.4 inch

20 mm

0.8 inch

➔Burners with extension:

A/B

20 mm

0.8 inch

≥10 mm

≥0.4 inch

3.3 Installation on the furnace

➔

When installing, always ensure that when the burner

is mounted, it is sealed tightly on the furnace wall.

1 2

➔Attach the ceramic tube type label.

4 5

3.4 Air connection, gas connection

ZIC

ZICW

Type Gas connec-

tion GA

Air connec-

tion LA

ZIC 165 Rp 1 1/2 DN 100

ZIC 200 Rp 2 DN 150

ZICW 165 Rp 1 1/2 DN 150

ZICW 200 Rp 2 DN 200

➔

Threaded connection to DIN2999, ﬂange dimen-

sions to DIN2633, PN16.

➔

Install ﬂexible tubes or bellows units to prevent

mechanical stress or transmission of vibration.

➔Ensure that the gaskets are undamaged.

DANGER

Risk of explosion!

– Ensure the connection is air-tight.

3.5 Connection to ANSI/NPT

➔An adapter set is required for connection to ANSI/

NPT, see page 12 (9.2 Adapter set).

Type Gas connec-

tion GA

Air connec-

tion LA*

ZIC 165 2–11.5 NPT 4.57"

ZIC 200 2–11.5 NPT 6.72"

ZICW 165 1½ NPT–11,5

NPT 6.72"

ZICW 200 2 NPT–11,5

NPT 8.71"

Flange hole diameter.

➔

Weld ﬂange Jto air pipe Pfor air connection LA and

use NPT thread adapter Hfor gas connection GA.

ZIC · Edition 09.22

EN-5

➔

The nozzle set with NPT thread is required for in-

tegrated pilots, see page 12 (9.3 Nozzle set).

3.6 Pilot connections on the ZIC..L

➔Air connection la.

➔Gas connection ga.

➔Pilot capacity: 1.5kW.

Type Pilot gas

connection ga

Pilot air

connection la

ZIC..L Rp ¼ Rp ½

ZIC..L

with

adapter

set

¼" NPT ½" NPT

3.7 Installing the burner insert

WARNING

– ZICW: do not damage the surface of the

insulation. Avoid the formation of dust.

➔

The burner insert can be rotated to the required

position in increments of 90°.

1 Insert the gas housing gasket between the burner

insert and the air housing.

2 Tighten the burner insert in a crosswise fashion

with max. 37Nm (27.3lbfft):

4 WIRING

DANGER

Electric shocks can be fatal!

– Before working on possible live components,

ensure the unit is disconnected from the power

supply.

➔For the ignition and ionization cables, use (un-

screened) high-voltage cable:

FZLSi 1/6 up to 180°C (356°F),

Order No. 04250410, or

FZLK 1/7 up to 80°C (176°F),

Order No. 04250409.

Flame rod I

➔

Install the ionization cable well away from mains

cables and interference from electromagnetic

sources and avoid external electrical interference.

Max. length of ionization cable – see automatic

burner control unit operating instructions.

➔

Connect the ﬂame rod to the automatic burner

control unit via the ionization cable.

Spark electrode Z

➔Length of ignition cable: max. 5 m (15ft), recom-

mended <1m (40").

➔For permanent ignition, max. ignition cable length

1 m(40").

➔

Lay the ignition cable individually and not in a metal

conduit.

➔Install the ignition cable separately from ionization

and UV cables.

➔A ≥7.5kV, ≥12mA ignition transformer is recom-

mended; 5kV for integrated pilot.

Flame rod and spark electrode

ZIC · Edition 09.22

EN-6

2 3 4

6 Connect the PE wire for burner ground to the burn-

er insert. In the case of single-electrode operation,

route the PE wire from the burner insert directly to

the terminal on the automatic burner control unit.

WARNING

High-voltage risk!

– It is essential that a high-voltage warning label

be attached to the ignition cable.

7 For more detailed information on how to wire the

ionization and ignition cables, refer to the operating

instructions and connection diagrams of the auto-

matic burner control unit and ignition transformer.

5 PREPARING COMMISSIONING

5.1 Safety instructions

➔

Agree on settings and commissioning of the burner

with the system operator or manufacturer.

➔

Check the entire system, upstream devices and

electrical connections.

➔Note the operating instructions for individual con-

trols.

DANGER

Risk of explosion!

– Please observe the appropriate precautions

when igniting the burner.

– Pre-purge the furnace chamber or radiant tube

with air (5x volume) before every ignition

attempt.

– Fill the gas line to the burner carefully and

correctly with gas and vent it safely into the

open air – do not discharge the test volume into

the furnace chamber.

DANGER

Risk of poisoning!

– Open the gas and air supply so that the burner

is always operated with excess air– otherwise

CO will form in the furnace chamber. CO is

odourless and poisonous! Conduct a ﬂue gas

analysis.

– The burner must only be commissioned by

authorized trained personnel.

➔If the burner does not ignite even though the auto-

matic burner control unit has been switched on and

off several times: check the entire system.

➔After ignition, monitor the ﬂame and the gas and

air pressure measured on the burner. Measure the

ionization current. Switch-off threshold– see au-

tomatic burner control unit operating instructions.

+μA –

➔

The burner must only be ignited at low-ﬁre rate

(between 10 and 30% of the rated capacityQmax)–

see type label.

5.2 Determining the gas and combustion air

ﬂow rates

➔Qgas: Gas ﬂow rate in m3/h (ft3/h)

➔PB: Burner capacity in kW (BTU/h)

➔Hi: Gas heating value in kWh/m3(BTU/ft3)

➔Qair: Air ﬂow rate in m3(n)/h (SCFH)

➔ λ: Lambda, air index

➔

Lmin: Minimum air requirement in m3(n)/m3(n) (SCF/

SCF)

➔

Information on the gas quality supplied can be

obtained from the gas supply company.

Common gas qualities

Gas type Heating value

HuHoLmin

kWh/

m3(n)

BTU/

SCF

m3(n)/

m3(n)

(SCF/

SCF)

Natural gas H 11.0 1114 10.6

Natural gas L 8.9 901 8.6

Propane 25.9 2568 24.4

Low caloriﬁc

value gas 1.7–3 161–

290 1.3–2.5

Butane 34.4 3406 32.3

➔

Data in kWh/m

(n) refer to the lower heating val

ueH

and data in BTU/SCF refer to the higher

heating valueHo(gross caloriﬁc value).

➔

A minimum air excess of 20% (lambda=1.2) should

be set in a cold furnace for initial adjustment since

the air volume falls as the temperature rises.

➔

Fine adjustment should be carried out at max.

furnace temperature and at as high a capacity

demand as possible.

5.3 Notes on the ﬂow rate curve

➔

If the gas density in the operating state differs from

that reﬂected in the ﬂow rate curve, convert the

pressures according to the local operating state.

pB = pM .

ZIC · Edition 09.22

EN-7

➔

δM: Gas density reﬂected in the ﬂow rate curve

in kg/m3(lb/ft3)

➔ δB: Gas density in operating state in kg/m3(lb/ft3)

➔pM: Gas pressure reﬂected in the ﬂow rate curve

➔pB: Gas pressure in operating state

1 Read the gas pressure pgas and air pressure pair

from the enclosed ﬂow rate curve for cold air on

the basis of the calculated ﬂow ratesQ.

[mbar (inch WC)]

[m3/h (ft3/h)]

pgas pair

pair

pgas

Qair

Qgas

➔

Note possible capacity changes due to positive

or negative pressures in the furnace/combustion

chamber. Add positive pressures or subtract neg-

ative pressures.

➔As not all the effects caused by the equipment are

known, setting the burner using the pressure values

is only approximate. It is possible to set the burner

precisely by measuring the ﬂow rates or ﬂue gas.

5.4 Restrictors

➔

The air volume required for the low-ﬁre rate at a

given air pressure is determined by the ignition

position of a butterﬂy valve, a bypass hole in the air

valve or an external bypass with restrictor.

5.5 Hot air compensation

➔

The combustion air pressure p

air

must be increased

in hot air operating mode (lambda=constant).

0 50 100 150 200 250 300 350 400 450 500 550 600

100

150

200

300

250

Air temperature [°C]

Air pressure p

air

[%]

➔The gas pressure is increased by 5–10mbar.

➔The total burner capacity Pgas rises as the air tem-

perature increases.

0 50 100 150 200 250 300 350 400 450 500 550 600

100

110

120

Air temerature [°C]

Total capacity Ptot [%]

5.6 Burners with electrodes with air connection

➔Burner head marking (..D) or (..E)

purge air tube

purge air nozzle

d=4.5mm

Rp 1/4

123

p [mbar]

123

Pressures for purges electrodes

Q purging air [m

/h]

➔

A purge air volume of approx. 1.5 to 2m³/h per

electrode is recommended.

➔

The purge air may not be switched off until the

furnace is cold and formation of condensation is

no longer possible.

5.7 Setting the air pressure for low ﬁre and

high ﬁre

1 Shut off the gas and air supply.

➔

Air measuring nipple L, outside dia. = 9mm (0.35").

➔Loosen the screw 2turns.

4 Fully open the air supply.

atm.

pair

➔patm. = atmospheric pressure.

Low-ﬁre rate

➔

The burner must only be ignited at low-ﬁre rate

(between 10 and 40% of the rated capacity Q

max

–

see page 2 (2.1 Type label)).

ZIC · Edition 09.22

EN-8

6 Reduce the air supply on the air control valve and

set the desired low-ﬁre rate, e.g. using a limit switch

or mechanical stop.

➔

On air control valves with bypass, the bypass oriﬁce

should be determined on the basis of the required

ﬂow rate and the existing supply pressure if required.

High-ﬁre rate

7 Set the air control valve to high-ﬁre rate.

8 Set the required air pressure pair on the air restric-

tor upstream of the burner.

9 When using air restricting oriﬁces: check the air

pressurepair.

5.8 Preparing the gas pressure measurement

for low ﬁre and high ﬁre

1 Connect all measuring devices for subsequent ﬁne

adjustment of the burner.

➔Leave the gas supply closed.

➔

Gas measuring nipple G, outside dia.= 9mm

(0.35").

1 Read the gas pressure p

gas

for the required ﬂow

rateQ from the enclosed ﬂow rate curve for cold

air

[mbar (inch WC)]

[m3/h (ft3/h)]

pgas pair

pair

pgas

Qair

Qgas

➔Loosen the screw 2turns.

5.9 Integrated pilot on the ZIC..L

➔

Air pressure test nipple l, outside dia. = 9mm

(0.35").

Gas pressure test nipple g, outside dia. = 9mm (0.35").

➔Loosen the screws 2turns.

➔Pilot:

pgas = 30–50mbar,

pair = 30–50mbar.

➔Check ﬂame stability and ionization current.

➔

The gas and air pressure of the integrated pilot

must be higher than the gas and air pressure of

the main burner.

6 COMMISSIONING

6.1 Igniting and adjusting the burner

WARNING

– Ensure adequate ventilation of the furnace

chamber before each burner start!

➔The burner body will become hot during operation

with preheated combustion air. Provide protection

against accidental contact as required.

1 All valves of the installation must be checked for

tightness before ignition.

6.2 Setting the low-ﬁre rate

1 Set the valves to ignition position.

2 Limit the maximum gas volume.

➔

Should an adjustable gas restrictor be installed

upstream of the burner, open the restrictor by ap-

prox. a quarter.

3 Open the gas supply.

4 Ignite the burner.

➔

The safety time of the automatic burner control unit

starts to elapse.

5 If no ﬂame forms, check and adjust the gas and air

pressures of the start gas adjustment.

6 In the case of operation with bypass (e.g. when

using an air/gas ratio control): check the bypass

nozzle and adjust if required.

7 In the case of operation without bypass (e.g. when

using an air/gas ratio control without bypass): in

crease the low-ﬁre rate setting.

8 Check the basic setting or bypass of the air control

valve.

9 Check the position of the restrictor in the air line.

10 Check the fan.

11 Reset the automatic burner control unit and re-ig-

nite the burner.

➔

The burner ignites and proceeds to normal op-

eration.

12 Check ﬂame stability and ionization current at low-

ﬁre rate. Switch-off threshold– see automatic

burner control unit operating instructions.

ZIC · Edition 09.22

EN-9

+μA –

13 Monitor ﬂame formation.

14 Adjust the low-ﬁre rate settings if required.

15 If no ﬂame is detected– see page 11 (8 Assis-

tance in the event of malfunction).

6.3 Setting the high-ﬁre rate

1 Set the air and gas circuit of the burner to high ﬁre

while continuously monitoring the ﬂame.

➔

Avoid CO formation– always operate the burner

with excess air when starting up!

➔

When the desired maximum valve positions are

reached, set the gas pressure p

gas

using the re-

strictor upstream of the burner.

gas

patm.

6.4 Readjusting the air ﬂow rate

1 Check the air pressure pair on the burner and adjust

using the air restrictor if required.

2 When using air restricting oriﬁces: check the air

pressure pair and rework the oriﬁce if required.

DANGER

Risk of explosion and poisoning in case of burner

adjustment with insufﬁcient air!

– Adjust the gas and air supply so that the burner

is always operated with excess air– otherwise

CO will form in the furnace chamber. CO is

odourless and poisonous! Conduct a ﬂue gas

analysis.

3 Measure the gas and air ﬂow rates if possible. De-

termine the lambda value and readjust the settings

if required.

6.5 Tightness test

DANGER

Escaping gas!

Danger from a leakage at the gas connections.

– Check the gas connections on the burner for

leaks immediately after commissioning the

burner.

1 2

➔

Avoid condensation due to the furnace atmos-

phere entering the burner body. While the burner

is switched off, at furnace temperatures above

500°C (932°F), it must be cooled with a low air

volume – see page 9 (6.6 Cooling air).

6.6 Cooling air

➔

While the burner is switched off and depending on

the furnace temperature, there must be a certain air

ﬂow for cooling the burner components.

600500 700 800 900 1000 1100 1200 1300 1400

BIC/ZIC*

BIC/ZIC..(..E)*

furnace

°C

% of cooling air

* also BIOW/ZIOW

➔

Diagram: the cooling air percentage speciﬁed in

the diagram refers to the operating ﬂow rate for air.

➔Leave the air fan switched on until the furnace has

cooled down completely.

6.7 Blocking and recording the settings

1 Produce a measurement report.

2 Set the burner to low ﬁre and check the settings.

3 Set the burner to low and high ﬁre several times

while monitoring the pressure settings, ﬂue gas

values and ﬂame patterns.

4 Remove the measuring devices and close off the

test nipples– tighten the grub screws.

5 Block and seal the adjusting elements.

6 Induce a ﬂame failure, e.g. by pulling the terminal

boot off the ﬂame rod. The ﬂame detector must

close the gas safety valve and signal a fault.

7 Switch the system on and off several times while

monitoring the automatic burner control unit.

8 Produce an acceptance report.

DANGER

Risk of explosion in case of CO being formed

in the furnace chamber! CO is odourless and

poisonous!

An incorrect change of the burner settings may

change the gas/air ratio and lead to unsafe operat-

ing conditions:

– All interventions may only be carried out by

qualiﬁed gas technicians.

7 MAINTENANCE

➔

Maintenance and function check every six months.

If the media are highly contaminated, this interval

should be reduced.

DANGER

Risk of explosion!

– Please observe the appropriate precautions

when igniting the burner.

ZIC · Edition 09.22

EN-10

– Maintenance work on the burner must be

carried out by authorized trained personnel only.

DANGER

Risk of burning!

– Outﬂowing ﬂue gases and burner components

are hot.

➔

We recommend that all the gaskets removed during

maintenance work be replaced. The appropriate

gasket set is available separately as a spare part.

1 Check the ionization and ignition cables.

2 Measure the ionization current.

➔

The ionization current must be at least 5µA and

must not vary.

+μA –

3 Disconnect the system from the electrical power

supply.

4 Shut off the gas and air supply– do not change

the restrictor settings.

7.1 Checking the spark electrode and ﬂame

rod

➔Ensure that the electrode length does not change.

3 Remove dirt from electrodes or insulators.

4 If the star 4or insulator 3is damaged, replace the

electrode.

➔Before changing the electrode, measure the total

lengthL.

5 Connect the new electrode with the spark plug1

using the dowel pin2.

6 Adjust spark plug and electrode to the measured

total lengthL.

➔Turning the spark plug makes it easier to feed the

electrode into the burner insert.

7.2 Checking the burner

Removing and installing burner insert ZICW

➔Do not damage the surface of the insulation.

➔Avoid the formation of dust.

ZIC and ZICW

1 2

➔If the burner insert is dismantled, the gas housing

gasket will have to be renewed.

5 Place the burner insert in a safe place.

➔Depending on the amount of dirt or wear: replace

the spark electrode/ﬂame rod and dowel pin during

servicing– see page 10 (7.1 Checking the spark

electrode and ﬂame rod).

6 Check burner head for dirt and thermal cracks.

WARNING

Risk of injury!

– Burner heads have sharp edges.

➔

When replacing any burner components: apply

ceramic paste to the screw connections in order

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