Honeywell Ecomax 0C, Ecomax 1C, Ecomax 2C, Ecomax 4C, Ecomax 3C Technical Information

7 Edition 10 .17

Technical Information · GB

• For direct and indirect heating

• Economical, energy-saving operation by
virtue of internal air preheating up to 650°C

• Uniform distribution of temperature by
means of a high burner impulse

• 7 sizes from 25 to 500 kW

• Highly efficient with a ceramic burled tube recuperator or a cast
steel ribbed tube recuperator.

Self-recuperative burner ECOMAX for gas

ECOMAX · Edition 10.17 2

▼

= To be continued

Contents

Self-recuperative burner ECOMA X for gas ..........1

Contents ............................................2

1 Application ........................................4

1.1 Direct heating ......................................4

1.2 Indirect heating ....................................4

1.3 Application examples ..............................5

1.4 ECOMAX for direct heating systems...............6

1.4.1 Flow rate control.......................................6

1.4.2 Air/gas ratio control....................................7

1.4.3 No pneumatic air/gas ratio control system ...........8

1.5 ECOMAX® for indirect heating systems ...........9

1.5.1 No pneumatic air/gas ratio control system .........10

1.5.2 Air/gas ratio control .................................10

2 Certification ......................................11

3 Structure .........................................12

3.1 Burner body .......................................12

3.2 Recuperator.......................................13

3.3 Air guide tube .....................................14

3.4 Gas insert .........................................15

3.5 Version overview ..................................16

4 Function ..........................................17

5 Selection ........................................ 19

5.1 Burner type .......................................19

5.2 Burner size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

5.3 Burner length .................................... 20

5.4 Burner head .......................................21

5.4.1 Use....................................................21

5.4.2 Gas type ..............................................21

5.5 Type of heating ...................................22

5.6 Connection for additional furnace cooling .......23

5.7 Electrode made of Kanthal APM..................23

5.8 Selection table ...................................24

5.8.1 ECOMAX..C.......................................... 24

5.8.2 ECOMAX..M .........................................24

5.8.3 ECOMAX..P.......................................... 25

5.8.4 ECOMAX..F..........................................25

5.8.5 Type code............................................26

5.9 Selection table for flue gas eductor EJEK ........27

5.9.1 Type code............................................28

5.10 Selection table for flue gas connector FLUP....29

5.10.1 Type code ..........................................30

6 Project planning information for direct heating ..31

6.1 Heating system design ...........................31

6.2 Flue gas guide tube FGT set ......................32

6.3 Flue gas eductor EJEK............................33

6.4 Furnace flue gas system..........................34

6.5 Installation........................................35

6.5.1 Installation position ................................ 35

6.5.2 Tangential or angled burner installation ............35

6.5.3 Clearances .......................................36

6.5.4 Furnace temperature measurement.................37

6.5.5 Heat guard ...........................................37

6.6 Flame control .....................................38

6.7 Burner control units and ignition transformers ..39

6.7.1 Burner control unit configurations ..................40

6.8 Gas connection ..................................41

6.8.1 Selecting components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

6.8.2 Gas pressure .........................................41

6.8.3 Operation with LPG .................................42

6.9 Air connection ....................................43

6.9.1 Selecting components ..............................43

6.9.2 Air pressure ..........................................43

6.10 Air flow monitoring ............................. 44

6.11 Purge air and cooling air........................ 44

6.12 Condition on delivery............................45

6.13 Cooling with ECOMAX ..........................45

6.14 Emissions ...................................... 46

ECOMAX · Edition 10.17 3

▼

= To be continued

6.15 Build up of noise................................ 46

6.16 Process boundary conditions . . . . . . . . . . . . . . . . . . . 47

6.17 Resistance of SiSiC ..............................47

7 Project planning information for indirect heating 48

7.1 Heating system design........................... 48

7.2 Radiant tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

7.3 Flue gas channelling ............................. 50

7.4 Furnace flue gas system ..........................51

7.5 Installation ........................................52

7.5.1 Heat guard ...........................................52

7.6 Flame control......................................53

7.7 Burner control units and ignition transformers ...54

7.7.1 Burner control unit configurations...................55

7.8 Gas connection ...................................56

7.8.1 Selecting components...............................56

7.8.2 Gas pressure .........................................56

7.8.3 Operation with LPG ...................................57

7.9 Air connection .....................................58

7.9.1 Selecting components...............................58

7.9.2 Air pressure ..........................................58

7.10 Air flow monitoring ...............................59

7.11 Purge air and cooling air .........................59

7.12 Condition on delivery ........................... 60

7.13 Increased furnace cooling with ECOMA X..K.... 60

7.14 Build up of noise .................................61

7.15 Emissions ........................................61

8 Accessories.......................................62

8.1 Air connection set.................................62

8.2 Air flow detector set...............................62

8.3 VAH connection set ...............................63

8.4 UV adapter set ....................................63

8.5 Purge air/cooling air nozzles......................63

8.6 Flue gas guide tube FGT Set..D ...................64

8.7 Flue gas eductor EJEK............................65

8.8 Flue gas connector FLUP.........................65

8.9 Ceramic radiant tube SERC..................... 66

8.10 Segmented flame tube SICAFLEX ............. 66

8.11 Cruciform spacer ................................67

8.12 Flue gas guide tube FGT SET ECO..SERC......67

8.13 Piping........................................... 68

8.13.1 Direct heating......................................68

8.13.2 Indirect heating ....................................69

9 Technical data ................................... 70

9.1 Dimensions .......................................71

9.1.1 ECOMAX..C for direct heating........................71

9.1.2 ECOMAX..M for direct heating......................72

9.1.3 ECOMAX..F for direct heating.......................73

9.1.4 ECOMAX..C for indirect heating .................... 74

9.1.5 ECOMA X..M for indirect heating ....................75

9.1.6 ECOMAX..F for indirect heating.....................76

10 Maintenance ....................................77

Feedback ...........................................78

Contact.............................................78

ECOMAX · Edition 10.17 4

ECOMAX..M

ECOMAX..C

Application

1 Application

Self-recuperative burners ECOMAX are used for heating
on either direct or indirect furnace systems in ON/OFF
intermittent mode. The hot flue gases are fed through
the ceramic or metallic heat exchanger, which is integrat-
ed in the burner, heating the additional supply of cold
combustion air flowing in the opposite direction. The
maximum achievable air preheat temperature amounts
to approx. 650°C, depending on the application.

1.1 Direct heating

In conjunction with an eductor EJEK to extract the flue
gases, the burner ECOMAX is used to save energy in a
direct heating system without long hot air pipes requir-
ing insulation.

Applications include heat treatment furnaces in the

iron and steel industry and in the non-ferrous metal
industr y.

1.2 Indirect heating

Self-recuperative burners ECOMAX are used in con­junction with metallic or ceramic radiant tubes and
ceramic segmented flame tubes SICAFLEX for indirect
heating. Indirect heating equipment is used whenever
the combustion gases are to be separated from the
product, e.g. in heat treatment furnaces with inert gas
atmospheres in the steel industry or when heat-treating
aluminium.

ECOMAX · Edition 10.17 5

Application

Roller hearth furnace Bogie hearth furnace Batch furnace

1.3 Application examples

ECOMAX · Edition 10.17 6

ApplicationApplication > ECOMAX for direct heating systems

1.4 ECOMAX for direct heating systems

In direct heating systems, the burner ECOMAX is com-
bined with a flue gas guide tube FGT Set..D for routing
the flue gases through the furnace lining and a flue gas
eductor EJEK.

AGK

ECOMAX

FGT-SET..D

EJEK

Eductor EJEK generates a negative pressure by forc-

ing air through a centrally positioned nozzle and thus
draws the flue gases out of the furnace chamber
through the burner’s heat exchanger. The motive air

flow is adjusted on the basis of the negative pressure

measured on the pressure tap between the burner and
the motive air nozzle. A flue gas valve AGK on the educ-
tor, which closes due to its own weight, minimizes back-

flow of hot flue gas from the furnace into the burner or

infiltrated air being sucked into the furnace when the
burner is switched off.

1.4.1 Flow rate control

For direct heating, flow rate control should be inte­grated in the system. The pressure loss in the recu­perator depends on the furnace temperature. When
the furnace temperature is increased (at a constant air
supply pressure), the air flow rate drops. This change in
the air flow rate is measured by the orifice and the VAH
changes the gas volume accordingly to ensure that the
air index (lambda) on the burner is not dependent on
the furnace temperature.

BVHM + MB7..L

VMV EKO

LEH

ECOMAX

VAH

BCU

BZA

Prozess-Steuerung/

Process Control (PCC)

AKT

p

sa-

p

sa

p

d-

VAS..N

The ECOMAX is equipped with an integrated air orifice.
This can be used for recording the air flow rate as a

reference variable for the VAH. A separate upstream air
orifice is then no longer required. The impulse line pd­for gas is connected to the burner downstream of the
integrated orifice so that the minimum gas pressure is
sufficient.

ECOMAX · Edition 10.17 7

Application

1.4.2 Air/gas ratio control

If the system does not include flow rate control, tem-
perature-dependent pressure losses in the burner are
not compensated for. The air index lambda drops with
increasing furnace temperature (increasing air preheat-
ing). Therefore, in a cold furnace, an increased lambda
value is to be set to ensure sufficient excess air, even
when the furnace temperature is at its maximum. A fur-
nace at 1100°C with λ = 1.1 (approx. 2% O2) requires a
burner setting of approx. 4% O2, for example, when the

furnace is cold.

BVHM + MB7..L

VMV

ECOMAX

VAS..N

BCU

BZA

Prozess-Steuerung/

Process Control (PCC)

AKT

VAG

ECOMAX · Edition 10.17 8

ApplicationApplication

1.4.3 No pneumatic air/gas ratio control system

When there is no pneumatic air/gas ratio control sys-

tem, slow opening gas valves and quick opening air
control valves are to be used to ensure a safe burner
start.

If there is no pneumatic air/gas ratio control system,
the gas and air pressures must be controlled and moni-
tored in the supply lines. Fluctuations in the supply
pressure affect the burner capacity and the air index
(lambda).

Air flow monitoring is recommended as low air pressure

protection (pursuant to EN 7462 and ISO 135772) if
the system does not include a pneumatic air/gas ratio
control system. The ECOMAX is equipped with an inte-
grated air orifice which can be used for this. The air flow
monitoring system may also be used to monitor pre-
purge.

BVHM + MB7..N

VMV EKO

LEH

ECOMAX

VAS VAS..L

BCU

BZA

Prozess-Steuerung/

Process Control (PCC)

PDZ

DG

AKT

ECOMAX · Edition 10.17 9

Application

1.5 ECOMAX® for indirect heating systems

For indirect heating, various radiant tubes are used.

Single ended radiant tube

Indirect heating with the ECOMAX burner can be
carried out using a metallic radiant tube SERM or a
ceramic radiant tube SERC. A flame tube made of
SICAFLEX elements is fitted inside the radiant tube to
guide the flue gases. The flue gases are discharged via
a flue gas connector FLUP.

The high outlet velocity of the flame causes a recircula-

tion of the flue gases and thus:

– a reduction in NO

X

emissions,

– a uniform radiant tube temperature.

SER-M

FLUP

ECOMAX..M

SICAFLEX

SER-C

SICAFLEX

FLUP

ECOMAX..C

P and twin P radiant tube

P and twin P radiant tubes are used in some processes,
for example in heat treatment systems for steel strip as
an alternative to U or W radiant tubes. The new burner
version ECOMAX..P with a special recuperator head is
for use in P radiant tubes.

Gas Cold air

P radiant tube

Flue gas

Gas Cold air

Twin P

radiant tube

Flue gas

ECOMAX · Edition 10.17 10

Application

1.5.1 No pneumatic air/gas ratio control system

For indirect heating, slow opening gas valves and quick

opening air control valves are to be used to ensure a
safe burner start.

If there is no pneumatic air/gas ratio control system,
the gas and air pressures must be controlled and moni-
tored in the supply lines. Fluctuations in the supply
pressure affect the burner capacity and the air index
(lambda).

A system which includes air flow monitoring is recom-

mended to monitor pre-purge and as low air pressure
protection (pursuant to EN 7462 and ISO 135772).

The ECOMAX is equipped with an integrated air orifice

which can be used for this.

VR..N

VMV

ECOMAX

VG VG..L

BCU

BZA

Prozess-Steuerung/

Process Control (PCC)

PDZ

DG

AKT

1.5.2 Air/gas ratio control

The pneumatic air/gas ratio control system ensures

that changes in the air pressure in the air supply line are
compensated for by controlling the gas pressure at the
burner accordingly.

VR..N

VMV VG..L

ECOMAX

BCU

BZA

Prozess-Steuerung/

Process Control (PCC)

PDZ

DG

AKT

VAG

A system which includes air flow monitoring is also

recommended to monitor pre-purge (pursuant to
EN 7462 and ISO 135772) even if there is a pneumatic
air/gas ratio control system.

ECOMAX · Edition 10.17 11

Certification

2 Certification

Certificates – see w ww.docuthek.com.

Machinery Directive

The product ECOMAX is a partly completed machine

pursuant to Article 2g of Directive 2006/42/EC and
complies with the essential health and safety require-
ments in accordance with Annex I, as stated in the Dec-
laration of Incorporation.

Eurasian Customs Union

The product ECOMAX meets the technical specifica-

tions of the Eurasian Customs Union.

ECOMAX · Edition 10.17 12

Structure

3 Structure

The burner ECOMAX is composed of four modules:

burner body, recuperator, air guide tube and gas insert.

The modular design facilitates adapting the burners to

the respective application or integrating them into an
existing furnace system. Maintenance and repair times
are reduced, and existing furnace installations can eas-
ily be converted.

3.1 Burner body

The burner body is made of cast aluminium, which

means it has a low weight. The housing has a double-
wall design. The combustion air is fed into the burner
via the outer annular void. This cools the burner body
and reduces emissions. A shaped part made of vacu-
um-formed ceramic fibres (RCF) is fitted in the housing
as internal insulation on the flue gas side.

From construction stage B, the ECOMAX is equipped
with two pressure taps on the air connection, which al­low the differential pressure to be measured across the
orifice so that the burner can be adjusted.

ECOMAX · Edition 10.17 13

StructureStructure

3.2 Recuperator

The burner ECOMAX is available in three versions:
– ECOMAX..C with ceramic burled tube recuperator
– ECOMAX..M and ECOMAX..P with cast steel ribbed

tube recuperator

– ECOMAX..F with metallic flat tube recuperator

Ceramic burled tube recuperator

The surface of the ceramic recuperator, which is made

of SiSiC for high thermal stress, is burled in order to
achieve high efficiency.

Cast steel ribbed tube recuperator

The ribs on the cast steel ribbed recuperator offer a

large surface area, allowing it to achieve high efficiency
even at low temperatures.

The burner version ECOMAX..P with a special recu-

perator head is available for use in P radiant tubes. The
geometry is tailored to this application to improve gas
recirculation and therefore the temperature uniformity
of the radiant tube.

Flat tube recuperator

The flat tube recuperator has a smooth surface. It is a

cost-effective alternative at a lower efficiency level.

ECOMAX · Edition 10.17 14

Structure

3.3 Air guide tube

ECOMA X..C

Burners ECOMAX..C are equipped with a ceramic air

guide tube that for sizes 0 to 3 also serves as the com-
bustion chamber.

ECOMA X..M, ECOMAX..F and ECOMAX..P

Air guide tube for ECOMAX..M and ECOMAX..F

Burners ECOMAX..M and ECOMAX..F are equipped

with an air guide tube made of heat-resistant steel.

ECOMAX · Edition 10.17 15

Structure

3.4 Gas insert

The gas insert consists of the gas connection flange,

the torch with burner head and the spark electrode
(also serves as monitoring electrode). A measuring
orifice, which is integrated in the gas insert, allows for
simple measurement of the gas flow rate. The orifice is
designed depending on the gas types (see 5.4.2).

To ensure accurate measurements of the pressure

differential on the integrated orifice, flow to the ori-
fice must not be disturbed. For this reason, burners
ECOMAX are equipped as standard with a special pipe

nipple to serve as inlet section on the gas connection.

Gas insert without combustion chamber for ECOMAX..C
(sizes 0 to 3)

Gas insert with combustion chamber for ECOMAX..M
(sizes 1 to 3)

Gas insert with combustion chamber for ECOMAX
(sizes 4 to 5)

ECOMAX · Edition 10.17 16

ECOMAX..C 0 – 3

ECOMAX..C 4 – 5

ECOMAX..M 1 – 3

ECOMAX..M 4 – 5

Structure

3.5 Version overview

Burner Size Gas insert Air guide tube

ECOMAX..C

0– 3 With mixing funnel

Ceramic,

with integrated

combustion chamber

4– 5

With swirl plate and

ceramic combustion

chamber

Ceramic

ECOMAX..M
ECOMAX..P
ECOMAX..F

1– 3

With mixing funnel

and ceramic

combustion chamber

Metallic

4– 6

With swirl plate and

ceramic combustion

chamber

Metallic

ECOMAX · Edition 10.17 17

Function

4 Function

Recuperator

Combustion chamber

Air guide tube

Radiant tube or

flue gas guide tube

Flue gas

Combustion gas

Combustion air

Housing

Gas insert

The self-recuperative burner ECOMAX uses the heat

from the flue gases to preheat the combustion air. The

heat exchanger (recuperator) required for this is part of

the burner.

After entering the gap between the air guide tube and

the recuperator, the combustion air flows towards the

tip of the burner (blue arrows). Some of this air is fed

into the inside of the burner, where it is combusted in

the first combustion stage.

The rest of the combustion air flows out through the

gap between the combustion chamber and the recu­perator head at high speed before combustion takes
place in the second combustion stage here (violet ar­rows). This process means that fewer pollutant emis­sions are produced. The hot flue gases, flowing in
the opposite direction, leave the furnace chamber on
the outside of the recuperator (red arrows). Heat is
exchanged between the hot flue gases and the cold
combustion air through the recuperator wall.

ECOMAX · Edition 10.17 18

Function

Influence of the furnace temperature

The higher the furnace temperature, the greater the

pressure loss in combustion air and flue gas in the re-

cuperator.

When the furnace temperature is increased (at a

constant air supply pressure), the air mass flow rate

(= standard air flow rate) drops while the gas flow rate

remains virtually unchanged. In a system with air/gas

ratio control or without pneumatic air/gas ratio control,

temperature-dependent pressure losses in the burner

are not compensated for. The air index lambda drops

with increasing furnace temperature.

In direct heating systems with flue gas eductor EJEK,
the quantity of flue gas extracted from the furnace
chamber via the burner decreases as the furnace tem­perature increases. If flue gas extraction at maximum
furnace temperature is 80–90%, negative furnace
pressure is generally avoided even if the furnace tem­perature is reduced by 400–500°C.

Ignition and flame control

The burner is directly ignited.

Ignition and flame control are provided by a combined
spark electrode/flame rod (single-electrode operation).
Flame control with UV sensor is required if a furnace
temperature of 1150°C (2102°F) for direct heating or

1050°C (1922°F) for indirect heating is exceeded.

Recuperator

Combustion chamber

Air guide tube

Radiant tube or

flue gas guide tube

Flue gas

Combustion gas

Combustion air

Housing

Gas insert

ECOMAX · Edition 10.17 19

Selection

5 Selection

5.1 Burner type

Selection is dependent on the type of heating and

the furnace temperature. Details on selection, see

page 31 (Heating system design) for direct heat-

ing or page 48 (Heating system design) for indirect

heating.

Burner Max. flue gas temperature at recuperator inlet

[°C] [°F]

ECOMAX..C 1250 2282
ECOMAX..M

ECOMAX..P

1150 2102

ECOMAX..F 1050 1922

5.2 Burner size

Burner

Size

Capacity

1)

Recuperator

kW

2)

103 BTU/h

3)

C M P F

ECOMA X 0 25 95



– – –

ECOMA X 1 36 136

 

–



ECOMA X 2 60 227

   

ECOMA X 3 100 378

   

ECOMA X 4 180 681

   

ECOMA X 5 250 945

 

–



ECOMA X 6 500 1890 –



– –

 = available

1)

For operation with natural gas. For operation with coke oven gas,

the capacity is approx. 80%, for operation with LCV gas, approx.
65%.

2)

Capacities in kW refer to the lower calorific value Hu.

3)

Capacities in BTU/h refer to the upper calorific value Ho.

When using the burner in geodetic ranges over 500 m
above MSL, the possible capacity is reduced due to
a decrease in the density of gas and air. Guide value:
reduction of 5% per 1000 m above MSL, more details
on request.

ECOMAX · Edition 10.17 20

SelectionSelection

5.3 Burner length

The recuperator length G should be selected so that the

burner is flush with the inside edge of the furnace lining

(S1 = 0 ± 20 mm).

S1

G

S1

G

When using P radiant tubes, the recuperator head
should be positioned on the centre line of the radiant
tube (S1 = 0 ± 20 mm).

S1

G

S1

G

ECOMAX · Edition 10.17 21

SelectionSelection

5.4 Burner head

5.4.1 Use

The burner ECOMAX can be equipped with 2 different

burner heads. Stage combustion is standard. For some

burner variants, a menox version is also possible, which

allows for switchover to menox® low NOX mode with
flameless combustion when the furnace temperature

exceeds 850°C in a direct heating system.

Use Burner head code letter

Standard flame mode S

menox

®

low NOX mode

1)

M

1)

menox® low NOX mode on request.

5.4.2 Gas type

Gas type Code letter Calorific value range

Density ρ

kWh/m

3

(n)

2)

BTU/scf

3)

kg/m3(n) lb/scf

Natural gas L and H quality B 8– 12 810– 1215 0.7– 0.9 0.041– 0.053
Propane, propane/butane, butane G 25– 35 2560– 3474 2.0– 2.7 0.118– 0.159
Coke oven gas, town gas D 4– 5 421– 503 0.4– 0.6 0.024– 0.035
Low calorific value gas L 1.7

1)

–3 161– 290 0.9– 1.15 0.053– 0.068

1)

Calorific value range < 1.7 on request.

2)

Calorific value ranges in kWh/m3 refer to the

lower calorific value Hu.

3)

Calorific value ranges in BTU/SCF refer to the

upper calorific value Ho.

ECOMAX · Edition 10.17 22

Selection

5.5 Type of heating

The ECOMAX is supplied with an integrated orifice on

the gas and air connections.

The gas orifices depend on the gas type, the air orifices

on the type of control and the system configuration.

Type of heating Code letter Explanation

Direct heating with
eductor

/D

Air orifice adapted to an air

pressure of 65 mbar

(= EJEK motive air pressure)

Indirect heating without
an eductor

/R

Air orifice adapted to an air

pressure of 50 – 60 mbar

ECOMAX · Edition 10.17 23

Selection

5.6 Connection for additional furnace

cooling

The air volume supplied to the burner in cooling mode

can be increased using an optional intermediate flange

with an additional cooling air connection on the burner
ECOMAX.

The air supplied via the additional air connection flows

in the centre of the burner inside the air guide tube. The

air volume is twice the standard combustion air volume.

5.7 Electrode made of Kanthal APM

Burners ECOMAX..M and ECOMAX..P can be equipped
with a bend-resistant electrode made of Kanthal APM
as an option. This is recommend for direct heating
as of 1050°C and indirect heating as of 950°C, see
page 38 (Flame control).

On ECOMA X..C, the Kanthal electrode is standard.

ECOMAX · Edition 10.17 24

Selection

5.8 Selection table

5.8.1 ECOMAX..C

395 475 545 556 593 613 617 636 641 681 689 S B D G L1)/D /R (1–99) A–E – K T

ECOMA X 0C

● ● ● ● ● ● ● ● ● ● ● ●

  

ECOMA X 1C

● ● ● ● ● ● ● ● ● ● ● ●

  

ECOMAX 2C

● ● ● ● ● ● ●



● ● ● ●

  

ECOMA X 3C

● ● ● ● ● ● ●



● ● ● ●

  

ECOMA X 4C

● ● ● ● ●



● ● ● ●

  

ECOMAX 5C

● ● ● ● ●



● ● ● ●

  

1)

On request.

ECOMA X..C is supplied with Kanthal electrodes as standard.

●

= standard,  = available

Order example

ECOMA X 1C545SB/R(31)B

5.8.2 ECOMA X..M

545 595 645 695 S M B D G L1)/D /R (1–99) A–E – K A T

ECOMAX 1M

● ● ● ● ● ● ● ● ● ● ● ●

   

ECOMAX 2M

● ● ● ● ● ● ● ●



● ● ● ●

   

ECOMA X 3M

● ● ● ● ●



● ● ●



● ● ● ●

   

ECOMAX 4M

● ● ● ● ●



● ● ●



● ● ● ●

   

ECOMAX 5M

● ● ●



● ● ●



● ● ● ●

   

ECOMA X 6M

●



● ● ● ●



● ● ● ●

   

1)

On request.

●

= standard,  = available

Order example

ECOMA X 3M545SB/D(34)B

ECOMAX · Edition 10.17 25

Selection

5.8.3 ECOMAX..P

645 695 S B D G L

1)

/R (1–99) A–E – K T

ECOMAX 2P



● ● ●



●



● ● ●

  

ECOMA X 3P



● ● ●



●



● ● ●

  

ECOMAX 4P



● ● ●



●



● ● ●

  

1)

On request.

●

= standard,  = available

Order example

ECOMA X 3P695SB/R(34)B

5.8.4 ECOMAX..F

545 595 645 695 S B D G L

1)

/D /R (1–99) A–E – K T

ECOMAX 1F

●

  

● ●



● ● ● ● ●

  

ECOMAX 2F

●

  

● ●



●



● ● ● ●

  

ECOMA X 3F

●

  

● ●



●



● ● ● ●

  

ECOMAX 4F

●

  

● ●



●



● ● ● ●

  

ECOMAX 5F

●

  

● ●



●



● ● ● ●

  

1)

On request.

●

= standard,  = available

Order example

ECOMA X 3F545SB/D(34)B

ECOMAX · Edition 10.17 26

Selection

5.8.5 Type code

Code Description

ECOMAX Self-recuperative burner for gas
0– 6 Burner size
C

M
P
F

Ceramic burled tube recuperator made of SiSiC

Cast steel ribbed tube recuperator

Cast steel ribbed tube recuperator for P radiant tube

Flat tube recuperator, metallic
E Special recuperator version
395– 695 Recuperator length in mm
S

M

1)

Standard fl ame

menox® low NOX operation

B
D
G
L

1)

Gas type2):

natural gas

coke oven gas

LPG

LCV gas

/D
/R
/V
/E
/nnn­/N

For direct heating with eductor

For radiant tube heating without eductor

For radiant tube heating with VAH

Burner with customized orifi ces

Burner construction stage X for nnn kW

Burner without orifi ces
(1–99) Burner head identifi er
X, A, B, … Construction stage
– The following features differ from the standard version:

K

Additional cooling air connection for increased furnace

cooling
A Electrode made of Kanthal APM
T NPT connections
S SICAFLEX spacer
W Air connection without intermediate fl ange
Z Special version

1)

On request.

2)

Other t ypes of gas on request.

ECOMAX · Edition 10.17 27

Selection

5.9 Selection table for flue gas eductor EJEK

Axis spacing Kxxx* Height Tzzz* H V 3* * 9** F.. R.. AGK HT*** A B S

EJEK 0 - K269



- M625

    

● ● ● ●

EJEK 1 - K269



- M625



● ●

   

● ● ●

EJEK 2 - K285



- M540



● ●

   

● ● ● ●

EJEK 3 - K292



- M620

    

● ● ● ●

EJEK 4 - K345



- M920

    

● ● ● ●

EJEK 5 - K345



- M1165

    

● ● ● ●

EJEK 6 - K530



- M1618

    

● ● ● ●

* Special dimensions on request.
* Only relevant for special dimension Tzzz.
*** HT version for ECOMAX..C.

●

= standard,  = available

Order example

EJEK 4K345M920AGKHTAS

ECOMAX · Edition 10.17 28

Selection

5.9.1 Type code

Code Description

EJEK Flue gas eductor
0– 6 Size for ECOMAX 1 – 6
Kxxx Axis spacing K in mm
Myyy Height M in mm
Tzzz* Distance T in mm

H
V

Burner installation position:

horizontal

vertical

3
9

Installation on the burner**:

right-hand side

left-hand side

F5 to F15
R5 to R15

Eductor angle in °:

pointing towards furnace

pointing away from furnace
AGK With fl ue gas valve
HT*** High temperature version
A

B

Construction stage

S Standard dimension

* If “none”, this letter is omitted.
** Only required for special dimension Tzzz.
*** HT version for ECOMA X..C.

MKM

KT

M

ECOMAX · Edition 10.17 29

Selection

5.10 Selection table for flue gas connector FLUP

32 50 65 100 D F Kxxx Installation height Myyy* Tzzz* H** V** 0** 3** 9** C A HT B S

FLUP 0

● ●

 

-M230

    

●

 

● ●

FLUP 1–2

● ●

 

-M331

      

●

 

●

FLUP 3

● ●

 

-M353

    

●

 

●

FLUP 4–5

● ●

 

-M399

    

●

 

●

* Special dimensions on request.
** Only relevant for special dimensions K xxx and/or Tzzz.

●

= standard,  = available

Order example

FLUP 365DM3530S

ECOMAX · Edition 10.17 30

Selection

5.10.1 Type code

Code Description

FLUP Flue gas connector
0

1/2
3
4/5

For ECOMAX 0–5

32 to 100 Nominal size
D

F

Pipe connector

Flange to ISO 7005
Kxxx Axis spacing K in mm
Myyy Installation height M in mm
Tzzz* Distance T in mm

H
V

Burner installation position:

horizontal

vertical

0
3
9

Installation on the burner**:

top

right-hand side

left-hand side

C
A

Measuring port with sealing clip

Threaded pressure tap with cap
HT High temperature version
A

B

Construction stage

S Standard dimension

* If “none”, this letter is omitted.
** Only required for special dimension Tzzz.

DN

K

M

M

DN

T

DN

M

ECOMAX · Edition 10.17 31

Project planning information for direct heating

6 Project planning information for direct heating

6.1 Heating system design

Selection of the burner type is dependent on the fur-
nace temperature.

Burner

Recommended

range of use

Max. flue gas temperature at

recuperator inlet

[°C] [°F] [°C] [°F]

ECOMAX..C up to 1250 up to 2282 1250 2282
ECOMAX..M up to 1100 up to 2012 1150 2102
ECOMAX..F up to 1000 up to 1832 1050 1922

Burners ECOMAX..M (sizes 1 to 5) and ECOMAX..F can

be used for furnace temperatures up to the max. appli-
cation temperature if it is ensured that the burner head
cannot overheat, e.g. due to burners positioned oppo-
site the ECOMAX or non representative temperature
measurements, see also page 37 (Furnace tempera-
ture measurement).

Selection of the burner size is dependent on the net
heat output. From this, the required burner capacity is
calculated using the firing efficiency value.

Net heat output [kW]

= Burner capacity [kW]

Firing efficiency η

400 500 600 700 800 900 1000 1100

0

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8

0,9

1

1200

1300

1400

F

M

C

Firing efficiency η

Flue gas temperature on recuperator inlet [°C]

Cold air burner

Details on heating system design on request.

ECOMAX · Edition 10.17 32

Project planning information for direct heating

6.2 Flue gas guide tube FGT set

The furnace flue gases are routed by the flue gas guide

tube through the furnace lining via the recuperator. The

FGT set must be ordered separately and is not included

in the burner delivery, see page 64 (Flue gas guide
tube FGT Set..D).

The flange thickness P1 of the flue gas guide tube is
15 mm. Plan the length of the furnace extension M1 so

that the front edge of the recuperator is flush with the
inside edge of the furnace lining (S1 = 0 ± 20 mm).

∅A

G

P1

S1

FGT-Set

Burner FGT OD A in mm

ECOMA X 0C 142
ECOMA X 1C 180
ECOMAX 2C 200
ECOMA X 3C 236
ECOMA X 4C 300
ECOMAX 5C 336

Force must not be applied to the flue gas guide tube by
the furnace lining.

When installing the FGT, the tube must be wrapped in
a ceramic fibre blanket so as to ensure that no hot fur­nace atmosphere may reach the furnace wall or furnace
extension. The installation opening in the furnace wall
must thus be larger than the FGT outside diameter A,
leaving an annular gap corresponding to the size of the

fibre blanket, e.g. 25 mm.

S1

∅A

P1

G

M1

FGT-Set

Burner FGT OD A in mm

ECOMAX 1M/ECOMAX 1F 133
ECOMAX 2M/ECOMAX 2F 156
ECOMA X 3M/ECOMA X 3F 193
ECOMAX 4M/ECOMAX 4F 254
ECOMAX 5M/ECOMAX 5F 287
ECOMA X 6M/ECOMA X 6F 390

ECOMAX · Edition 10.17 33

Project planning information for direct heating

6.3 Flue gas eductor EJEK

Flue gas eductor EJEK is available in 2 versions. The

standard version EJEK is used in conjunction with

ECOMAX..M and ECOMAX..F. The high temperature

version EJEK..HT is intended for use in conjunction
with ECOMAX..C.

The eductors serve to extract the flue gas via the burner

ECOMAX and cannot be used for furnace pressure con-

trol. We recommend discharging 10 to 20% of the flue
gases via an additional flue gas opening on the furnace

fitted with a furnace pressure control system.

With 80 to 90% flue gas extraction at max. furnace
temperature, a positive furnace pressure can generally
be maintained even at low furnace temperatures. In the
case of heavily leaking furnaces, flue gas extraction
must be reduced, where necessary, to avoid pulling in
cold air due to negative pressure in the furnace cham-
ber.

p

FG

p

atm

p

FG

0

p

FG

The motive air is set at the eductor by measuring the negative
flue gas pressure pFG between the burner and eductor.

If the furnace temperature is too high, damage can oc­cur to burners which are switched off due to the flow of
hot flue gases over them.

For direct heating, eductors EJEK..AGK with mechani­cal flue gas valve (AGK) are recommended so as to
avoid gas creepage while the burner is switched off.

ECOMAX · Edition 10.17 34

Project planning information for direct heating

6.4 Furnace flue gas system

A flue gas system must be fitted on the furnace as a

means of guiding the flue gas to the chimney. In the

flue gas system there should be a low negative pressure

thanks to the draught of the chimney or an exhaust fan.

The flue gas system on the furnace should be fitted

flush with the eductor (± 10 mm). The diameter of the
flue gas pipe on the furnace should be twice the educ-

tor diameter P. If the diameter is too small, even with
the EJEK..AGK with flue gas valve there is the danger of
hot flue gases creeping through the burner when it is
switched off.

The branch lines from the furnace flue gas manifold to

the individual burners should be designed such that
condensate cannot seep upstream into the burner.

∅P

∅2P

0 mm (±10 mm)

∅1,5P

∅P

∅2P

0 mm

(±10 mm)

∅ P [mm]

ECOMA X 0 EJEK 0(B) 43
ECOMA X 1 EJEK 1 43
ECOMA X 2 EJEK 2(A) 83
ECOMA X 3 EJEK 3(A) 98
ECOMA X 4 EJEK 4(A) 128
ECOMA X 5 EJEK 5(A) 153
ECOMA X 6 EJEK 6(A) 215

ECOMAX · Edition 10.17 35

Project planning information for direct heating

6.5 Installation

6.5.1 Installation position

15°

0°

90°

The burner ECOMAX can be installed in any position

between 0° (horizontal) and 90° (vertical from top to
bottom). The ECOMAX may be oriented upwards at an
angle of max. 15° from the horizontal.

Eductor EJEK installation position:

vertical, max. angle 10°.

If the burner is installed at an angle of more than 10°

from the vertical or horizontal, a special version of flue

gas eductor EJEK is required. This is available on re-
quest.

6.5.2 Tangential or angled burner installation

If the burner is installed tangentially or at an angle, an
opening should be provided in the furnace lining to
ensure unobstructed flue gas extraction. The choice of
furnace lining in this area should take account of the
burner’s very high outlet velocity. In addition, reflection
from the furnace wall to the burner must be considered.

B

1,5 x B

ECOMAX · Edition 10.17 36

Project planning information for direct heating

6.5.3 Clearances

Y

X

X

X

2

X

X

RZ

Allow for adequate clearance from the charge and the

interior furnace wall so as to ensure complete combus-
tion and avoid local overheating. Due to the high air
preheat temperature of the ECOMAX, the flame tem-
perature is also higher than usual.

Z

2

Z

X

The minimum lateral clearance between two burners

or between a burner and the furnace side wall is de-
termined by the geometric dimensions of the burners
including the eductor.

In addition, it must be noted that burners facing each
other can cause overheating of the recuperator heads.

Flame mode

Burner

Reaction zone RZ (mm)

Clearance (mm)

X Z

ECOMA X 0 500 130 270
ECOMA X 1 700 155 270
ECOMA X 2 900 200 285
ECOMA X 3 1200 250 300
ECOMA X 4 1600 340 350
ECOMA X 5 1800 400 400
ECOMA X 6 2200 570 570

For menox® low NOX mode, a sufficiently large reaction

zone (RZ) and undisturbed recirculation of the flue gas

into the reaction zone are required. Operation in very
small combustion chambers leads to an increase in
NOX emissions.

menox

®

low NOX mode

Burner

Reaction zone RZ (mm)

Clearance (mm)

X Y Z

ECOMA X 3M 2100 300 320 300
ECOMAX 4M 2800 360 400 360
ECOMAX 5M 3300 400 480 400

ECOMAX · Edition 10.17 37

Project planning information for direct heating

6.5.4 Furnace temperature measurement

Measurement of the furnace temperature must be

representative for the flue gas temperature in the ex-
traction zone on the burner. If measurement is not rep-
resentative, this will involve a risk of overheating of the
recuperator head.

6.5.5 Heat guard

During operation, the burner body and eductor or flue

gas connector can reach surface temperatures of
over 80°C. Do not insulate the burner, eductor and flue
gas connector to prevent material overheating.

We recommend that warning signs and a contact guard
be fitted, for example made of perforated sheet metal.

ECOMAX · Edition 10.17 38

Project planning information for direct heating

6.6 Flame control

Burners ECOMAX are equipped with a combined spark

electrode/flame rod. For direct heating, ionization con-
trol is possible up to a temperature of 1150°C (single-
electrode operation). In this respect, it must be noted
that the burner control unit BCU must feature at least

firmware version FW 16xx, see page 39 (Burner con-

trol units and ignition transformers).

Flame control with UV sensor is only necessary if fur-

nace temperatures of 1050°C for direct heating or

1150 °C for indirect heating are exceeded.

We also recommend using bend-resistant Kanthal
electrodes for ignition on ECOMA X..M as of a furnace
temperature of more than 1050°C. These are fitted as
standard on ECOMAX..C.

We recommend the UV sensor UVS 10D1 with inte­grated purge air connection (Order No. 84315202) for
UV control.

For ECOMA X 0, the UV sensor UVS 10L1 (Order
No. 84315203) with lens is required for UV control. For
burners ECOMAX 1 –6 with a burner length of more
than 545 mm, the UV sensor UVD 10L1 with lens is
also required for UV control.

An adapter set is required for connection to the UVS 10,

see page 63 (UV adapter set).

ECOMAX · Edition 10.17 39

Project planning information for direct heating

6.7 Burner control units and ignition

transformers

ECOMAX burners with burner control unit BCU

ECOMAX burners are designed for On/Off control.

We recommend burner control unit BCU 460..L or

BCU 465..L. In order to be able to carry out ionization

control up to 1150°C, the burner control unit must be
equipped with firmware FW 16xx or higher.

For burners ECOMAX..K with additional cooling air
connection, we recommend using burner control unit
BCU..C with additional circuit board for signal distribu­tion.

For ignition, the ECOMAX burners require an ignition
transformer with 7.5 kV high voltage and an output cur­rent of 20 mA. An appropriate ignition transformer is
already integrated in burner control units BCU 460..8
and BCU 465..8.

For further information on burner control units and ig­nition transformers, see www.docuthek.com, Technical
Information BCU 460, 465.

ECOMAX · Edition 10.17 40

Project planning information for direct heating

6.7. 1 Burner control unit configurations

Description Configuration D1 Configuration D2 Configuration D3 Configuration D4

Flame control Ionization UVS 10 Ionization U VS 10
Pneumatic air/gas ratio control VAH/ VAG VAH/VAG None/VAH/VAG None/VAH/VAG
Air flow monitoring – –

Differential pressure switch PDZ Differential pressure switch PDZ

Hardware BCU 460..L BCU 460..L BCU 465 BCU 465

Ignition transformer 8 = TZI 7,520/33 8 = TZI 7,520/33 8 = TZI 7,520/33 8 = TZI 7,520/33
Rewiring for electrode operation 1 electrode 2 electrodes 1 electrode 2 electrodes

Description Parameter Configuration D1 Configuration D2 Configuration D3 Configuration D4

Switch-off threshold of the flame amplifier 04

4 μA 4 μA 4 μA 4 μA

Air flow monitoring during purging 06 N /A N/A 1 1
Air flow monitoring during operation 07 N/A N/A 1 1
Delayed air flow monitoring 08 N/A N /A 1 1
Safety time during operation t

SB

for V1 and V2 14 1 1 1 1

Minimum burner on time t

B

20 8 8 8 8

Minimum burner pause time t

BP

21 4 4 4 4

Safety time on start-up t

SA

22 3 3 3 3
Air valve control 30 1 1 1 1
Air valve can be activated externally on start-up 31 1 1 1 1
Low fire over-run time t

KN

after a controlled shut-down 36 N/A N/A 0 0

Pre-ventilation time t

VL

before start-up 37 N/A N/A 0 0

Post-ventilation time t

NL

after a controlled shut-down 38 N /A N/A 0 0
Pre-ventilation time after safety shut-down 39 N/A N/A 0 0
Pre-ventilation for restart/start-up attempts 40 N/A N/A 0 0
Pre-ventilation after reset 41 N/A N/A 0 0

BCU for direct heating Configuration D1 Configuration D2 Configuration D3 Configuration D4

230 V 88613276 88614259 88614263 88614267
230 V, Profibus 88611901 88613865 88614264 88614268
230 V, HT operation 88614257 88614260 88614265 88614269
230 V, HT operation, Profibus 88611887 88611883 8 861426 6 88614270

ECOMAX · Edition 10.17 41

Project planning information for direct heating

6.8 Gas connection

6.8.1 Selecting components

To ensure a safe burner start, use a pneumatic air/gas

ratio controller together with a slow opening air valve. If
there is no pneumatic air/gas ratio control system, use
a slow opening gas valve and a quick opening air valve.

The following gas valves are recommended for natural

gas:

Burner Flow rate control

Air/gas ratio

control

No pneumatic air/

gas ratio control

system

ECOMA X 0

VAS 115..N +
VAH 115..B +

VMV 115

VAS 115..N +
VAG 115..B +

VMV 115

VG 15..N +
VG 15..L +

VMV 115

ECOMA X 1

VAS 115..N +
VAH 115..B +

VMV 115

VAS 115..N +
VAG 115..B +

VMV 115

VG 15..N +
VG 15..L +

VMV 115

ECOMA X 2

VAS 115..N +

VAH 115..B +

VMV 115

VAS 115..N +
VAG 115..B +

VMV 115

VG 15..N +
VG 15..L +

VMV 115

ECOMA X 3

VAS 115..N +

VAH 115..B +

VMV 115

VAS 115..N +
VAG 115..B +

VMV 115

VG 15..N +
VG 15..L +

VMV 115

ECOMA X 4

VAS 120..N +

VAH 120..A +

VMV 120

VAS 120..N +
VAG 120..B +

VMV 120

VAS 120..N +
VAS 120..L +

VMV 120

ECOMA X 5

VAS 125..N +

VAH 125..A +

VMV 125

VAS 125..N +
VAG 125..B +

VMV 125

VAS 125..N +
VAS 125..L +

VMV 125

ECOMAX 6*

VAS 240..N +
VAH 240..A +

VMV 240

VAS 240..N +

VAG 240 +

VMV 240

VAS 240..N +

VAS 240..L +

VMV 240

* As of 360 kW, ignition with a start rate of < 33% is required

(pursuant to EN 746-2 and ISO 13577-2); a pneumatic ratio
control system and a BVH with IC 40 must be used for this.

A bellows unit EKO should be provided between the

burner and controls to prevent external force being ap­plied to the burner.

A connection set with 6 x 1 compression fittings

is available to connect the VAH control line, see
page 63 (VAH connection set). The set is installed on
the burner before delivery.

6.8.2 Gas pressure

The required gas pressure depends on the burner size,

the gas type and the system configuration.

Gas supply line pressure*

Gas pressure

upstream of

burner

Natural gas H

Natural gas L,

LPG

Flow rate control 50 –65 mbar 100 mbar 120 mbar

Air/gas ratio
control**

50 –65 mbar 100 mbar 120 mbar

No pneumatic air/
gas ratio control
system

50 –65 mbar 80 mbar 100 mbar

* If a stainless steel flexible tube ES is used instead of the

stainless steel bellows unit EKO, the higher pressure loss must
be taken into account.

** Gas pressure in the supply line min. 10 – 20 mbar greater than

the air pressure in the supply line.

ECOMAX · Edition 10.17 42

Project planning information for direct heating

6.8.3 Operation with LPG

GEH

For operation with LPG, it is essential to cool the gas

lance via a central air lance in order to prevent the LPG

from cracking in the gas lance and soot formation dur-

ing combustion.

GEH

The central air volume is approx. 3 to 5% of the com-

bustion air volume and must also flow while the burner
is switched off.

Open the adjuster in the central air lance fully. On the
ECOMAX 1, the adjuster must be restricted to 45° or 50%

.

If high temperature operation without flame control
using ionization or a UV sensor is intended for LPG, air

flow monitoring using an ECO air flow detector set must

be provided to prevent backflow of the central air into
the gas line or of gas into the air line in the event of the

flue gas route being blocked.

ECOMAX · Edition 10.17 43

Project planning information for direct heating

6.9 Air connection

6.9.1 Selecting components

In the case of a pneumatic air/gas ratio control system,
slow opening air valves or butterfly valves with solenoid ac-
tuator are required. If the system does not include a pneu-
matic air/gas ratio control system, quick opening air valves
or butterfly valves with solenoid actuator are to be used.

The following air control valves are recommended for air:

Burner

Flow rate control or
air/gas ratio control

No pneumatic air/gas

ratio control system

ECOMA X 0 VR 40..L VR 40..N
ECOMA X 1 VR 50..L VR 50..N
ECOMA X 2 VR 65..L VR 65..N
ECOMA X 3 BVHM 65 + MB 7..L BVHM 65 + MB 7..N
ECOMA X 4 BVHM 80 + MB 7..L BVHM 80 + MB 7..N
ECOMA X 5 BVHM 80 + MB 7..L BVHM 80 + MB 7..N
ECOMAX 6* BVHM 100 + MB 7..L BVHM 100 + MB 7..N

* As of 360 kW, ignition with a start rate of < 33% is required

(pursuant to EN 746-2 and ISO 13577-2); a pneumatic ratio
control system and a BVH with IC 40 must be used for this.

VR LEH

LEH

ECOMAX 0
ECOMAX

1

ECOMAX 2

MB

7

+

BVHM

LEH

LEH

ECOMAX 3

…

ECOMAX 6

6.9.2 Air pressure

The motive air setting for eductor EJEK is critical when

designing the air supply. The required pressure depends
on the burner capacity, the flue gas extraction via the
burner and the furnace temperature:

Motive air pressure

upstream of

eductor*

Air supply

line pressure*

ECOMA X 0 and 1 at a furnace
temperature of 1000°C

approx. 100 mbar approx. 115 mbar

ECOMA X 2C – 5C
with EJEK ..HTA (construction
stage A) at a furnace
temperature of 1250°C

approx. 65 mbar approx. 80 mbar

ECOMA X 2M – 6M
with EJEK ..A (construction
stage A) at a furnace
temperature of 1100°C

approx. 65 mbar approx. 80 mbar

* The air pressures apply for burner ratings at the specified

furnace temperatures and 80% flue gas extraction.

Flow rate curves are available in the Docuthek for EJEK
construction stage A to allow precise dimensioning.

To ensure accurate measurements of the pressure dif-

ferential on the integrated orifice, flow to the orifice
must not be disturbed. We recommend using the con­nection set for air, which guarantees correct measure­ment at the measuring orifice, see page 62 (Air con­nection set). The attachment of a coupling, a bellows
unit or a pipe bend directly upstream of the orifice can
cause turbulence in the gas flow resulting in the burner
being incorrectly adjusted.

ECOMAX · Edition 10.17 44

Project planning information for direct heating

6.10 Air flow monitoring

A system which includes air flow monitoring is recom-

mended to monitor pre-purge and as low air pressure
protection (pursuant to EN 7462 and ISO 135772) if
there is no pneumatic air/gas ratio control system. This
is implemented using a differential pressure switch at
the air connection together with a burner control unit

BCU 465. An air flow monitoring set is available for this

purpose as an accessory, see page 62 (Air flow de-
tector set).

6.11 Purge air and cooling air

Purge air must be connected to the burner ECOMA X in

order to ensure safe ignition and monitoring. Otherwise,
wet flue gas will enter the burner in the case of direct
heating, due to the furnace pressure.

The required purge air volume is approx. 0.5 to 1.0%

of the air volume for rated capacity, or a minimum of

1 m

3

(n)

/h.

The purge air is connected to the gas connection flange

next to the electrode, or in the case of UV control to
the purge air connection of the UV sensor. The purge
air is tapped upstream of the air control valve so that
the purge air continues to flow even if the burner is
switched off.

In order to limit the volume of purge air, special nozzles
can be used which are adjusted to the required air sup­ply pressure for the ECOMAX – see page 63 (Purge
air/cooling air nozzles).

Burner

Nozzle for electrode

purge

Purge air nozzle on

UV sensor

ECOMA X 0

Nozzle electrode ECO 0

Rp 1/4 D = 2.5 /E

Nozzle UV ECO 03

Rp 1/4 D = 2.5 /B

ECOMA X 1–3

Nozzle electrode ECO 13

Rp 1/4 D = 2.5 /E

Nozzle UV ECO 03

Rp 1/4 D = 2.5 /B

ECOMA X 4–6

Nozzle electrode ECO 46

Rp 1/4 D = 4.0 /E

Nozzle UV ECO 46

Rp 1/4 D = 4.0 /B

At very high furnace temperatures, we recommend

cooling the burner head by selecting a larger nozzle or a
supply line with a diameter of 8 mm without a nozzle.

ECOMAX · Edition 10.17 45

Project planning information for direct heating

6.12 Condition on delivery

The position of the gas, air and flue gas connections

can be customized depending on how the burner is to
be installed on the furnace. The connection positions
are coded using the numbers 0, 3, 6 and 9.

Code Connection position

0 Top
3 Right-hand side
6 Bottom
9 Left-hand side

The codes relating to the positions of the connections

are specified in the following order: flue gas – air – gas.

Provided that there are no specifications, the burners

are supplied as follows:

ECOMAX../D for direct heating with connector posi-

tion 366, i.e. flue gas connection for eductor installa-
tion on the right-hand side and gas and air connections
at the bottom.

0

3

6

9

The FGT Set..D for direct heating is installed on the

burner at the factory, provided that it is ordered at the

same time as the burner. This also applies to all add-on
components with the marking /E, such as the air flow
detector set, UV adapter set, purge air nozzle, inlet sec­tion for gas and air, see page 62 (Accessories).

6.13 Cooling with ECOMAX

Extraction of the flue gases via the burner and thus the
preheating of the combustion air can be switched off to
ensure controlled cooling of the furnace. Install sepa­rate valves for combustion air and motive air instead
of an air valve for this. In this case, a separate flue gas
route must be opened on the furnace, via which the
cooling air can be discharged from the furnace.

ECOMAX · Edition 10.17 46

Project planning information for direct heating

6.14 Emissions

CO and NOX values depend on the furnace tempera-

ture, air preheat temperature, burner type and burner
settings (NOX values on request).

If operated with LPG, NO

X

values are approx. 25%

higher.

600 700 800 900 1000 1100 1200 1300

0

100

200

300

400

500

600

ECOMAX..C

ECOMAX..M

Flue gas temperature at recuperator inlet [°C]

NO

x

[mg/m

3

ref. 5 % O

2

]

NOX values in the diagram apply to natural gas.

6.15 Build up of noise

The sound level of a naked flame may be significantly

more than 90 dB(A) due to the high flame velocity. In
the case of fitted burners, the sound level of the single
burner which can be measured outside the furnace is
usually between 75 and 82 dB(A).

In a furnace system, the value which can be measured
depends on the capacity, excess air volume, flue gas
extraction and flue gas temperature of the single burn­ers as well as the burner arrangement and ambient
influences.

ECOMAX · Edition 10.17 47

Project planning information for direct heating

6.16 Process boundary conditions

In direct heating systems, the flue gases are routed
out of the furnace chamber via the burner. Impurities

from the process can affect burner operation. Deposits

of dust or components from the material to be heated
which turn to gas (e.g. molybdenum) can accumulate
on the recuperator. This means that the volume of flue
gas routed via the recuperator falls and thus the burner
is less efficient. Furthermore, this can also lead to in-
creased furnace pressure and damage to the furnace
and burner. In this case, increased maintenance and
shorter cleaning intervals are required.

Other impurities, such as alkalis formed during the

heating of cast parts or from cooling and washing liq-
uids, can cause chemical attacks on the material. This
reduces the service life of the recuperator and the flue
gas guide tube. We therefore advise against use in forg-
ing and heating furnaces, in which raw materials are
heated. We also advise against use in aluminium smelt-
ing furnaces due to the dusty furnace atmosphere, the
danger of liquid metal spillings and possible chemical
attacks.

Avoid sub-stoichiometric burner operation. A reducing

atmosphere can lead to damage to the burner insula-
tion on the flue gas side, the metallic recuperator and

flue gas guide tube, and the vacuum-formed parts of

the flue gas guide tube for ECOMAX..C.

6.17 Resistance of SiSiC

The ceramic recuperator of the ECOMAX..C consists of

reaction-bound silicon carbide (SiSiC), infiltrated with
metallic silicon. During the manufacturing process, a
protective layer made of SiO2 is formed on the surface,
which ensures good chemical resistance.

When installing the burners, it must be ensured that
the protective layer on the ceramic surface is not dam­aged.

The burners should be adjusted so that an excess air

value of 1 – 5% O

2

in the flue gas is maintained in order
to preserve the protective layer. In the case of sub­stoichiometric burner operation (concentration of CO

> 1000 ppm), white deposits can build up on the SiSiC

over a long period of time. This reduces the service life
of the ceramic material.

Impurities such as fluorine, chlorine and alkali com­pounds (e.g. with sodium or potassium) in the furnace
atmosphere also lead to chemical attack and shorten
the service life of the ceramic recuperator. We therefore
advise against use in forging and heating furnaces, in
which raw materials are heated. We also advise against
use in aluminium smelting furnaces.

ECOMAX · Edition 10.17 48

Project planning information for indirect heating

7 Project planning information for indirect heating

7.1 Heating system design

When designing a radiant tube heating system, it must
be ensured that the energy can be transferred to the

furnace chamber via the surface of the radiant tube

to avoid exceeding the maximum permissible flue gas
temperature at the recuperator inlet of the burner.

It must also be ensured that the permitted material
temperature of the radiant tube and, in the case of sin-
gle ended radiant tubes, of the flame tube used is not
exceeded.

Burner Max. flue gas temperature at recuperator inlet

[°C] [°F]

ECOMAX..C 1250 2282
ECOMAX..M/ECOMAX..P 1150 2102
ECOMAX..F 1050 1922

The possible radiation output in the furnace depends

on the furnace temperature and the surface of the radi-
ant tube as well as the material that the radiant tube
and burner are made of.

The burner capacity also depends on how efficient the

burner is.

The heat exchange must be determined to ensure safe

design of a radiant tube heating system. To this end,
please consult a member of the sales team.

700 800 900 1000 1100 1200

0

60

40

20

50

30

10

90

70

80

100

0

60

40

20

50

30

10

90

70

80

100

1300

Furnace temperature [°C]

Max. radiation output in kW/m²

SER-C with ECOMAX..C
SER-M with ECOMAX..M

Spec. burner capacity in kW/m²

Depending on the system configuration, it may be nec­essary to reduce the power input on the basis of the
furnace temperature, e.g. by reducing the duty cycle.
In this case, the combustion time should not exceed

2 minutes to avoid thermal overload of the radiant tube

and burner.

100 %

Power input

Furnace temperature

ECOMAX · Edition 10.17 49

Project planning information for indirect heating

7. 2 Radiant tubes

For ECOMA X..C

Burners ECOMAX..C are intended for use with ceramic

radiant tubes SERC.

See Technical Information SERC.

Standard combinations:

Radiant tube Burner Segmented flame tube

SERC 100/088 ECOMA X 0C SICAFLEX 100/088/084
SE RC 142 /128 EC OMAX 1C SICAFLE X 142/127/123
SE RC 162/14 8 ECOMA X 2C SI CA FLEX 162 /147/143
SERC 202/188 ECOMAX 3C SICAFLE X 202/186/182

In special cases, a ceramic burner ECOMAX..C can be
installed in a metallic radiant tube. Here, external forces
on the ceramic burner due to the radiant tube being de-

formed must be excluded, however.

For ECOMAX..M

Metallic radiant tubes are available in a variety of di­mensions in either centrifugal casting or in welded
form. The efficiency of the burner ECOMAX..M is deter­mined by the inside diameter d

i

of the radiant tubes in
the vicinity of the burner. The following dimensions are
recommended:

Burner

Min.

radiant tube inside

diameter d

i

[mm]

Radiant tube inside

diameter d

i

as of which a

flue gas guide tube FGT

set is recommended

[mm]

ECOMAX 1M 128 140
ECOMAX 2M 147 164
ECOMA X 3M 185 202
ECOMAX 4M 248 266
ECOMAX 5M 280 298

If the inside diameter of the radiant tube is considerably
larger than that of the burner, a flue gas guide tube FGT
set should also be used.

Depending on the geometry, additional adapter flanges
may be required for radiant tubes.

ECOMAX · Edition 10.17 50

Project planning information for indirect heating

7.3 Flue gas channelling

A flue gas connector FLUP, which is to be ordered sepa-

rately, is available as standard to channel flue gas in
an indirect heating system. In special cases, an educ-
tor EJEK can also be installed to channel flue gas. This
also must be ordered separately.

Flue gas connector FLUP

SER-C

SICAFLEX

FLUP

ECOMAX..C

Flue gas connector FLUP serves to discharge the flue

gases into the furnace flue gas system and features an
opening which is closed by a clip to connect flue gas
analysis equipment.

Eductor EJEK

SER-M

EJEK

SICAFLEX

In indirect heating systems with metal radiant tubes,
eductor EJEK can generate a negative pressure in the
radiant tube. This prevents the inert gas atmosphere in
the furnace being contaminated by flue gases from the
burner in the event of leakage from the single ended
radiant tube.

ECOMAX · Edition 10.17 51

Project planning information for indirect heating

7.4 Furnace flue gas system

A flue gas system must be fitted on the furnace as a

means of guiding the flue gas to the chimney. In the

flue gas system there should be a low negative pressure

thanks to the draught of the chimney or an exhaust fan.

The branch lines from the furnace flue gas manifold to

the individual burners should be designed such that
condensate cannot seep upstream into the burner.

The branch lines to the burner should stop 10 mm away

from the flue gas connector FLUP, or be fitted flush

with the eductor EJEK.

For indirect heating with flue gas monitoring kit DW and
BCU 465, excessive negative pressure in the flue gas

system or an excessively narrow flue gas pipe diameter
on the furnace can cause problems with setting the
switching point of the pressure switch.

∅Q

∅

1,5Q

10 mm ±5

∅1,5Q

∅

2Q*

∅2Q*

∅Q

10 mm ±5

∅

P

∅1,5P

0 mm

(±10 mm)

* With flue gas monitoring kit DW; without flue gas monitoring

kit DW: 1.5Q to 2Q.

FLUP dia. Q EJEK dia. P

ECOMA X 0 DN 32 43
ECOMA X 1 DN 50 43
ECOMA X 2 DN 50 83
ECOMA X 3 DN 65 98
ECOMA X 4 DN 100 128
ECOMA X 5 DN 100 153

In a closed flue gas system, a pressure regulator is to
be fitted. The gas and air flow rates depend on the total
pressure differential between the supply lines and the

flue gas system. If the pressure in the flue gas system
fluctuates, the burner capacity changes. In a system

without air/gas ratio control, the lambda may also
change.

ECOMAX · Edition 10.17 52

Project planning information for indirect heating

7.5 Installation

Installation of burners with FLUP in the horizontal posi-
tion, in the vertical position with the firing end pointing
downwards or at an angle with the firing end pointing
downwards.

Allow for adequate clearance between the radiant tubes

and the furnace wall to avoid local overheating, see

Technical Information SERC.

Ensure that there is a recirculation gap D1 between burn-

er and flame tube, e.g. SICAFLEX, (30 mm for ECOMAX
0–3 or 50 mm for ECOMAX 4–5). The deflector gap V1
should equal 0.5 to 1.5 times the radiant tube diameter X.

X

SICAFLEX

SER

D1 (ECOMAX 0–3 = 30 mm)

(ECOMAX 4–5 = 50 mm)

V1 = 0.7 × max. 1.5 × X for SER-C

0.5 × max. 1.5 × X

for SER-M

7.5.1 Heat guard

During operation, the burner body and flue gas con-

nector or eductor can reach surface temperatures of
over 80°C. Do not insulate the burner, flue gas connec-
tor and eductor to prevent material overheating.

We recommend that warning signs and a contact guard

be fitted, for example made of perforated sheet metal.

ECOMAX · Edition 10.17 53

Project planning information for indirect heating

7.6 Flame control

Burners ECOMAX are equipped with a combined

spark electrode/flame rod. For indirect heating,
ionization control is possible up to a furnace tempera-
ture of approx. 1050°C (single-electrode operation).
In this respect, it must be noted that the burner con-
trol unit BCU must feature at least firmware version

FW 16xx, see page 54 (Burner control units and igni-

tion transformers).

Flame control with UV sensor is required if a furnace

temperature of 1050°C for indirect heating is ex-
ceeded. We recommend using bend-resistant Kanthal
electrodes for ignition on ECOMA X..M as of a furnace
temperature of more than 950°C. These are fitted as
standard on ECOMAX..C.

We recommend the UV sensor UVS 10D1 with inte­grated purge air connection (Order No. 84315202) for
UV control.

For ECOMA X 0, the UV sensor UVS 10L1 (Order
No. 84315203) with lens is required for UV control. For
burners ECOMAX 1 –6 with a burner length of more
than 545 mm, the UV sensor UVD 10L1 with lens is
also required for UV control.

An adapter set is required for connection to the UVS 10,

see page 63 (UV adapter set).

ECOMAX · Edition 10.17 54

Project planning information for indirect heating

7.7 Burner control units and ignition
transformers

ECOMAX burners are designed for On/Off control.

We recommend burner control units BCU 465. In order
to be able to carry out ionization control up to 1050°C,
the burner control units must be equipped with firm-
ware FW 16xx or higher.

Pre-ventilation should be performed after every safety

shut-down in order to purge the radiant tube (param-
eters 39 and 40 of the BCU 465).

For burners ECOMAX..K with additional cooling air

connection, we recommend using burner control unit

BCU..C with additional circuit board for signal distribu-

tion.

For ignition, the ECOMAX burners require an ignition

transformer with 7.5 kV high voltage and an output cur-
rent of 20 mA. An appropriate ignition transformer is
already integrated in burner control units BCU 460..8
and BCU 465..8.

For further information on burner control units and ig-

nition transformers, see www.docuthek.com, Technical
Information BCU 460, 465.

ECOMAX · Edition 10.17 55

Project planning information for indirect heating

7.7. 1 Burner control unit configurations

Description Configuration R1 Configuration R2

Recuperator Metallic Ceramic
Flame control Ionization UV S 10
Pneumatic air/gas ratio control None/VAG None/VAG
Air flow monitoring Differential pressure switch PDZ Differential pressure switch PDZ

Hardware BCU 465..L BCU 465..L

Ignition transformer 8 = TZI 7,520/33 8 = TZI 7,520/33
Rewiring for electrode operation 1 electrode 2 electrodes

Description Parameter Configuration R1 Configuration R2

Switch-off threshold of the flame amplifier 04

4 μA 4 μA

Air flow monitoring during purging 06 1 1
Air flow monitoring during operation 07 1 1
Delayed air flow monitoring 08 1 1
Safety time during operation t

SB

for V1 and V2 14 1 1

Minimum burner on time t

B

20 8 8

Minimum burner pause time t

BP

21 4 4

Safety time on start-up t

SA

22 3 3
Air valve control 30 1 1
Air valve can be activated externally on start-up 31 1 1
Low fire over-run time t

KN

after a controlled shut-down 36 0 0

Pre-ventilation time t

VL

before start-up 37 0 0

Post-ventilation time t

NL

after a controlled shut-down 38 0 0
Pre-ventilation time after safety shut-down 39 7 7
Pre-ventilation for restart/start-up attempts 40 1 1
Pre-ventilation after reset 41 1 1

BCU for indirect heating Configuration R1 Configuration R2

230 V 88 614271 88614275
230 V, Profibus 88614272 88614276
230 V, HT operation 88614273 88614277
230 V, HT operation, Profibus 88 614274 88614278

ECOMAX · Edition 10.17 56

Project planning information for indirect heating

7.8 Gas connection

7.8.1 Selecting components

For indirect heating, slow opening gas valves and quick

opening air control valves are to be used to ensure a
safe burner start.

The following gas valves are recommended for natural

gas:

Burner

No pneumatic air/gas

ratio control system

Air/gas ratio control

ECOMA X 0

VG 15..N +
VG 15..L +

VMV 115

VAG 115..B +

VG 15..L +

VMV 115

ECOMA X 1

VG 15..N +
VG 15..L +

VMV 115

VAG 115..B +

VG 15..L +

VMV 115

ECOMA X 2

VG 15..N +
VG 15..L +

VMV 115

VAG 115..B +

VG 15..L +

VMV 115

ECOMA X 3

VG 15..N +
VG 15..L +

VMV 115

VAG 115..B +

VG 15..L +

VMV 115

ECOMA X 4

VAS 120..N +
VAS 120..L +

VMV 120

VAG 120..B +
VAS 120..L +

VMV 120

ECOMA X 5

VAS 125..N +
VAS 125..L +

VMV 125

VAG 125..A +
VAS 125..L +

VMV 125

A bellows unit EKO should be provided between the

burner and controls to prevent external force being ap-
plied to the burner.

7.8.2 Gas pressure

The required gas pressure depends on the burner size,

the gas type and the system configuration.

Gas supply line pressure*

Gas pressure

upstream of

burner

Natural gas H

Natural gas L,

LPG

Air/gas ratio control 65–70 mbar 100 mbar 120 mbar
No pneumatic air/gas

ratio control system

65–70 mbar 80 mbar 100 mbar

* If a stainless steel flexible tube ES is used instead of the

stainless steel bellows unit EKO, the higher pressure loss must
be taken into account.

ECOMAX · Edition 10.17 57

Project planning information for indirect heating

7.8.3 Operation with LPG

GEH

For operation with LPG, it is essential to cool the gas

lance via a central air lance in order to prevent the LPG

from cracking in the gas lance and soot formation dur-

ing combustion.

GEH

The central air volume is approx. 3 to 5% of the com-

bustion air volume and must also flow while the burner
is switched off.

Open the adjuster in the central air lance fully. On the
ECOMAX 1, the adjuster must be restricted to 45° or
50%.

If high temperature operation without flame control is
intended for LPG, air flow monitoring using an air flow
detector set ECO must be provided. If the flue gas route
is blocked, the central air will be prevented from flowing
into the gas line or gas will be prevented from flowing
into the air line.

ECOMAX · Edition 10.17 58

Project planning information for indirect heating

7.9 Air connection

7.9.1 Selecting components

For indirect heating, a quick opening air valve should

always be used to ensure a safe burner start. The fol-
lowing air valves or butterfly valves/solenoid actuators
are recommended:

Burner

No pneumatic air/gas

ratio control system

Air/gas ratio control

ECOMA X 0 VR 20..N VR 20..N
ECOMA X 1 VR 25..N VR 25..N
ECOMA X 2 VR 40..N VR 40..N
ECOMA X 3 VR 50..N VR 50..N
ECOMA X 4 VR 65..N VR 65..N
ECOMA X 5 BVHM 65/MB 7..N BVHM 65/MB 7..N

VR

ECOMAX 0
…
ECOMAX 4

MB 7

+

BVHM

ECOMAX 5

7.9.2 Air pressure

The required air pressure depends on the burner size,

the gas type and the system configuration.

Air supply line pressure

Air pressure

upstream of burner

Natural gas H

Natural gas

L / LPG

Air/gas ratio
control

approx. 50–60 mbar 80 mbar 100 mbar

No pneumatic
air/gas ratio
control system

approx. 50–60 mbar 80 mbar 80 mbar

To ensure accurate measurements of the pressure dif-

ferential on the integrated orifice, flow to the orifice
must not be disturbed. We recommend using the con­nection set for air, which ensures correct measurement
at the measuring orifice, see page 53 (Connection set
for gas and air). The attachment of a coupling, a bellows
unit or a pipe bend directly upstream of the orifice can
cause turbulence in the gas flow resulting in the burner
being incorrectly adjusted.

ECOMAX · Edition 10.17 59

Project planning information for indirect heating

7.10 Air flow monitoring

A system which includes air flow monitoring is recom-

mended to monitor pre-purge (pursuant to EN 7462
and ISO 135772). This is implemented using a dif-

ferential pressure switch at the air connection together

with a burner control unit BCU 465. An air flow monitor-
ing set is available for this purpose as an accessory, see
page 62 (Air flow detector set).

7.11 Purge air and cooling air

Purge air must be connected to the burner ECOMA X in

order to ensure safe ignition and monitoring, and in or-
der to avoid problems caused by condensation and/or
overheating:

The required purge air volume is approx. 0.5 to 1.0%

of the air volume for rated capacity, or a minimum of

1 Nm

3

/h.

The purge air is connected to the gas connection flange

next to the electrode, or in the case of UV control to
the purge air connection of the UV sensor. The purge
air is tapped upstream of the air control valve so that
the purge air continues to flow even if the burner is
switched off.

In order to limit the volume of purge air, special nozzles
can be used which are adjusted to the required air sup­ply pressure for the ECOMAX – see page 63 (Purge
air/cooling air nozzles).

Burner

Nozzle for electrode

purge

Purge air nozzle on

UV sensor

ECOMA X 0

Nozzle electrode ECO 0

Rp 1/4 D = 2.5 /E

Nozzle UV ECO 03

Rp 1/4 D = 2.5 /B

ECOMA X 1–3

Nozzle electrode ECO 13

Rp 1/4 D = 2.5 /E

Nozzle UV ECO 03

Rp 1/4 D = 2.5 /B

ECOMA X 4–5

Nozzle electrode ECO 46

Rp 1/4 D = 4.0 /E

Nozzle UV ECO 46

Rp 1/4 D = 4.0 /B

ECOMAX · Edition 10.17 60

Project planning information for indirect heatingProject planning information for indirect heating

7.12 Condition on delivery

The position of the gas, air and flue gas connections

can be customized depending on how the burner is to
be installed on the furnace. The positions of the con-
nections are coded using the numbers 0, 3, 6 and 9.

Code Connection position

0 top
3 right-hand side
6 bottom
9 left-hand side

The codes relating to the positions of the connections

are specified in the following order: flue gas – air – gas –
and cooling air (increased furnace cooling) if required.

Provided that there are no specifications, the burners

are supplied as follows:

ECOMAX../R for indirect heating with connector posi-

tion 066, i.e. with flue gas connection at the top and
gas and air connection at the bottom.

0

3

6

9

Add-on components with the marking /E, such as the

air flow detector set, UV adapter, purge air nozzle, etc,
are installed on the burner at the factory, provided that
they are ordered at the same time as the burner.

7.13 Increased furnace cooling with
ECOMAX..K

VR..N

VG..L

BCU 465..C

12

23

DI

L1, N, PE

µC

P

22 4

19
18

17
16

A

P

5

3

DI

6

26

GEH

EKO

32

33

VG

PLC

Depending on the technical requirements for the pro­cess, cooling can be implemented in two stages.

▼

ECOMAX · Edition 10.17 61

Project planning information for indirect heating

Actuating the air valve for the burner (terminal 22) initi-

ates “normal” cooling; actuating a second air valve for
the additional cooling air connection initiates additional
cooling. The additional cooling air valve is actuated
separately by the process control system. For wiring on
site, we recommend using a BCU..C with a supplemen-
tary terminal strip (e.g. terminals 32/33 for additional
air valve).

In the case of “additional” cooling air, the combustion
air valve must be activated together with the cooling air
valve in order to prevent the recuperator from overheat-
ing.

7.14 Build up of noise

In the case of fitted burners, the sound level of the sin-
gle burner which can be measured outside the furnace
is usually between 75 and 82 dB(A).

In a furnace system, the value which can be measured
depends on the capacity, excess air volume, flue gas
extraction and flue gas temperature of the single burn-
ers as well as the burner arrangement and ambient
influences.

7.15 Emissions

CO and NOX values depend on the furnace tempera­ture, air preheat temperature, burner type and burner
settings (NOX values on request).

If operated with LPG, NO

X

values are approx. 25%

higher.

600 700 800 900 1000 1100 1200 1300

0

100

200

300

400

500

600

ECOMAX..C

ECOMAX..M

Flue gas temperature at recuperator inlet [°C]

NO

x

[mg/m

3

ref. 5 % O

2

]

NOX values in the diagram apply for natural gas

ECOMAX · Edition 10.17 62

Accessories

8 Accessories

8.1 Air connection set

Specially machined barrel nipples which ensure reliable,
correct measurement at the orifices installed in the
burner. Version /E is installed in the burner on delivery.

Designation Order No.

Air inlet pipe ECO 0–1 R 1 /E 22802897
Air inlet pipe ECO 2 R 1 1/2 /E 22802898
Air inlet pipe ECO 3–5 R 2 /E 22802899
Air inlet pipe ECO 6 R 3 /E 22802900

8.2 Air flow detector set

The differential pressure switch for air flow monitor-

ing is used for the automatic monitoring of the air flow
on the burner ECOMAX in conjunction with the burner
control unit BCU 465. The differential pressure switch
monitors the air flow during pre-purge and burner op­eration. If there is no air pressure, the burner is switched
off or is not enabled. The pressure switch switching
point should be set to approx. 80% of the differential
pressure in normal operation.

Designation Order No.

Air flow detector set ECO /E 21802994

ECOMAX · Edition 10.17 63

Accessories

8.3 VAH connection set

The VAH connection set also comprises the connection

for gas control line pd-, which is connected behind the

gas orifice integrated in the burner to ensure that a gas
supply pressure of 80 mbar in the supply line (recom-
mended value: 100 mbar) is sufficient.

Designation Order No.

Connection set VAH ECO /E 21800791

8.4 UV adapter set

For attaching the UVS 10, an adapter is required.

Designation Order No.

Adapter set Eco 15UVS 10 /E 21800791

8.5 Purge air/cooling air nozzles

Nozzle to limit the volume of purge air in order to
achieve safe ignition and monitoring of the ECOMAX
burner and to avoid condensation and overheating.

Nozzle for electrode purge

Burner Nozzle designation Order No.

ECOMA X 0

Nozzle electrode ECO 0

Rp 1/4 D = 2.5 /E

21802944

ECOMA X 1–3

Nozzle electrode ECO 13

Rp 1/4 D = 2.5 /E

21802945

ECOMA X 4–6

Nozzle electrode ECO 46

Rp 1/4 D = 4.0 /E

21802946

UV sensor purge air nozzle

Burner Nozzle designation Order No.

ECOMA X 0–3

Nozzle UV ECO 03

Rp 1/4 D = 2.5 /B

21802989

ECOMA X 4–6

Nozzle UV ECO 46

Rp 1/4 D = 4.0 /B

21802990

ECOMAX · Edition 10.17 64

Accessories

8.6 Flue gas guide tube FGT Set..D

for ECOMAX..C

for ECOMAX..M

When using the ECOMAX burners for direct heating, a

flue gas guide tube FGT Set..D is required.

The FGT Set..D is available in lengths in various incre-

ments, which are suited to different burner lengths.

For ECOMA X 1C, 2C and 3C, there is a standard ver-

sion for furnace temperatures up to 1200°C and a high
temperature version for furnace temperatures from

1200°C to 1250°C.

Scope of delivery: flue gas guide tube FGT with burner
gasket, mounting gasket, as well as 4 threaded bolts,
washers and nuts for attaching it to the burner.

ECOMA X..C

Flue gas guide tube Order No.

FGT SET ECO 1C545/DHT 21800926
FGT SET ECO 2C545/DHT 21800928
FGT SET ECO 3C545/DHT 21800930
FGT SET ECO 4C545/DHT 21800629
FGT SET ECO 5C545/DHT 21801325

ECOMA X..M

Flue gas guide tube Order No.

FGT SET ECO 1M545/D 21800195
FGT SET ECO 2M545/D 21800177
FGT SET ECO 3M545/D 21800694
FGT SET ECO 4M545/D 21800162
FGT SET ECO 5M545/D 21800499
FGT SET ECO 6M545/D 21800660

ECOMAX · Edition 10.17 65

Accessories

8.7 Flue gas eductor EJEK

For direct heating

The eductor EJEK generates a vacuum with a centrally

positioned nozzle and thus draws the flue gases out
of the furnace chamber through the burner’s heat ex-
changer.

Designation for ECOMAX..C Order No.

EJEK 1K269M625HAGKHTS 22800872
EJEK 2K285M540HAGKHTAS 22802953
EJEK 3K292M620AGKHTAS 22801413
EJEK 4K345M920AGKHTAS 22801701
EJEK 5K345M1165AGKHTAS 22801828

Special version on request.

Designation for ECOMAX..M Order No.

EJEK 1K269M625HAGKS 22800931
EJEK 2K285M540HAGKAS 22802952
EJEK 3K292M620AGKAS 22801159
EJEK 4K345M920AGKAS 22801700
EJEK 5K345M1165AGKAS 22801826
EJEK 6K530M1618AGKAS 22801903

8.8 Flue gas connector FLUP

In indirect heating systems, flue gas connector FLUP
discharges the flue gas into the furnace flue gas sys­tem to be provided by the customer.

Designation Order No.

FLUP 032DM230CBS 21801830
FLUP 1/250DM331CS 21100612
FLUP 365DM353CS 21102259
FLUP 4/5100DM399CS 21102718

Special version on request.

ECOMAX · Edition 10.17 66

Accessories

8.9 Ceramic radiant tube SERC

For heat treatment processes in which combustion

gases must be kept separate from the product. The pat-
ented flange connection is air-tight.

Material: SiSiC, max. application temperature: 1300°C.

Further information can be found in the Technical

Information bulletin “Ceramic radiant tube SERC”.

Order No. on request.

8.10 Segmented flame tube SICAFLEX

For guiding hot flue gases in single ended radiant tubes.

Further information can be found in the Technical
Information bulletin “Segmented flame tube
SICAFLEX”.

Order No. on request.

ECOMAX · Edition 10.17 67

Accessories

8.11 Cruciform spacer

For installation of the segmented flame tube SICAF
LEX® in vertical radiant tubes. The cruciform spacer en-

sures optimum sizing of the recirculation gap between
the segmented flame tube and the burner.

Material: refractory clay.

Available on request in different sizes depending on the

SICAFLEX

®

sizes and different heights.

8.12 Flue gas guide tube FGT SET ECO..
SERC

To guide the flue gases if smaller burners are used

than those normally intended; see page 49 (Radiant
tubes). The flue gas guide tube ensures sufficient heat
exchange via the burner recuperator.

Material: Shaped part made of vacuum-formed

ceramic fibres (RCF).

Available on request in different sizes and versions suit-

able for the SERC and ECOMAX burner sizes.

ECOMAX · Edition 10.17 68

Accessories

8.13 Piping

The burners can be optionally supplied with pre-mounted pipework for gas and air.

8.13.1 Direct heating

BVHM + MB7..L

VMV EKO

LEH

ECOMAX

VAH

BCU

BZA

Prozess-Steuerung/

Process Control (PCC)

AKT

p

sa-

p

sa

p

d-

VAS..N

ECOMAX Material No. Designation Combinations

Gas

0– 3 86594777 GVRS 15R0515R05WECO 03 VAS…N + VAH… + VMV…

4 86594778 GVRS 20R0520R05WECO 4 VAS…N + VAH… + VMV…
5 86 494779 GVRS 25R0525R05WECO VAS…N + VAH… + VMV…
6 86594776 GVRS 40R0540R05WECO 6 VAS…N + VAH… + VMV…

Air

0 86594782 L 40R25R32RWECO 0EJEK VR…L + LEH… + CIM…
1 86594783 L 50R25R32RWECO 1EJEK VR…L + LEH… + CIM…
2 86594784 L 65R40R40RWECO 2EJEK VR…L + LEH… + LEH…
3 86594785 L 65R50R50RWECO 3EJEK BVHM…MB7LW6 + LEH… + LEH…
4 86594786 L 80F50R65RWECO 4EJEK BVHM…MB7LW6 + LEH… + CIM…
5 86594787 L 80F50R65RWECO 5EJEK BVHM…MB7LW6 + LEH… + CIM…
6 – L 100F80R100FWECO 6EJEK BVHM…MB7LW6 + CIM… + CIM…

ECOMAX · Edition 10.17 69

Accessories

8.13.2 Indirect heating

VR..N

VMV

ECOMAX

VG VG..L

BCU

BZA

Prozess-Steuerung/

Process Control (PCC)

PDZ

DG

AKT

ECOMAX Material No. Designation Combinations

Gas

0– 3 86594195 GS 15R0215R02WECO 03 VG…N + VG…L + VMV…

4 86594654 GS 20R0520R05WECO 4 VCS 1 (VAS…N + VAS…L) + VMV…
5 86594687 GS 25R0525R05WECO 5 VCS 1 (VAS…N + VAS…L) + VMV…

Air

0– 1 86594689 L 25R25RWECO 01 VR…N + LEH…

2 86594693 L 40R40RWECO 2 VR…N + LEH…
3 86594694 L 50R50RWECO 3 VR…N + LEH…
4 86594696 L 65R50RWECO 4 VR…N + LEH…
5 86594697 L 65R50RWECO 5 BVHM… + CIM…

ECOMAX · Edition 10.17 70

Technical data

9 Technical data

Gas supply pressure and air supply pressure

each depend on the use and gas type (gas and air
pressures:see burner diagrams at www.docuthek.com –
registration required).

Type of heating: direct with eductor or indirect in radiant

tube.

Control type: On/Off.

Adjusting range: 60% to 100%.

Flame velocity: approx. 130 to 170 m/s.

Flame control: direct ionization control (UV control as

an option).

Ignition: direct spark ignition.

Burner Recuperator

Max. flue gas tempera-

ture at recuperator inlet

ECOMAX..C Ceramic (SiSiC) 1250°C*
ECOMAX..M Cast steel 1150°C
ECOMAX..F Metallic 1050°C

* We advise against use in forging and heating furnaces, in which

raw materials are heated.

Burner Capacity [kW] Flame length [mm]*

ECOMA X 0 25 300
ECOMA X 1 36 300
ECOMA X 2 60 400
ECOMA X 3 100 450
ECOMA X 4 180 800
ECOMA X 5 250 800
ECOMA X 6 500 1000

* Visible range for natural gas operation in the open air,

max. connection rating and air index 1.15.

The visible flame diameter is 0.3 to 0.5 times that of

the burner Ø B for natural gas operation in the open air,
max. connection rating and air index 1.15.

REACH Regulation

Information pursuant to REACH Regulation
No. 1907/2006, Article 33.
Insulation contains refractory ceramic fibres (RCF)/alu­minium silicate wool (ASW).
RCF/ASW are listed in the Candidate List of the Euro­pean REACH Regulation No. 1907/2006.

400 500 600 700 800 900 1000 1100

0

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8

0,9

1

1200

1300

1400

F

M

C

Firing efficiency η

Flue gas temperature on recuperator inlet [°C]

Cold air burner

ECOMAX · Edition 10.17 71

Technical data

9.1 Dimensions

9.1.1 ECOMAX..C for direct heating

K

M

ØP

V

LA

GA

H1

S1 = +/- 20 mm

G

∅B ∅A

C

D

G1

A1

ØF

I

Øn

m

Type ECOMAX FGT set EJEK

GA LA Ø B C

1)D1)

G1 G

H1

Ø A2)Ø F A1 Ø n I m V K M Ø P Weight

mm mm mm kg

3)

ECOMA X 0C R ½ Rp 1 86 60 179 ~78

395, 475,

556, 636

182 142 300 260 4 x 18 210 4 x M12 R 1¼ 269 625 43 ~11

ECOMA X 1C R ½ Rp 1 123 60 212 ~80

545, 593,

641, 689

236 180 330 280 4 x 19 290 4 x M16 R 1¼ 269 625 43 ~19

ECOMAX 2C R ½ Rp 1½ 142 60 212 ~80

545, 613,

681

236 200 330 280 4 x 19 290 4 x M16 R 1½ 285 540 83 ~21

ECOMA X 3C R ½ Rp 2 178 83 262 ~80

545, 617,

689

280 236 385 325 4 x 19 330 4 x M16 R 2 292 620 98 ~33

ECOMA X 4C R ¾ Rp 2 240 95 298 ~86 545 368 300 480 420 4 x 19 445 4 x M16 R 2½ 345 920 128 ~48
ECOMAX 5C R 1 Rp 2 273 95 298 ~86 545 368 336 480 420 4 x 19 445 4 x M16 G 2½ 345 1165 153 ~55

1)

Excluding gasket (t = 1.3 mm)

2)

Diameter excluding plate bracket (with plate bracket: Ø A + approx. 3 mm)

3)

Weight of burner of shortest length.

ECOMAX · Edition 10.17 72

Technical data

9.1.2 ECOMAX..M for direct heating

S1

G

∅B ∅A

C

D

G1

A1

ØF

I

Øn

m

K

M

ØP

V

LA

GA

H1

Type ECOMAX FGT set EJEK

GA LA Ø B C

1)D1)

G1 G

H1

Ø A Ø F A1 Ø n I m V K M Ø P Weight

mm mm mm kg

2)

ECOMAX 1M R ½ Rp 1 123 60 212 ~78

545, 595,

645, 695

236 133 330

280

4 x 19

290

4 x M16 R 1¼ 269 625 43 ~35

ECOMAX 2M R ½ Rp 1½ 142 60 212 ~80

545, 595,

645, 695

236 156 330

280

4 x 19

290

4 x M16 R 1½ 285 540 83 ~41

ECOMA X 3M R ½ Rp 2 178 83 262 ~80

545, 595,

645, 695

280 193 385

325

4 x 19

330

4 x M16 R 2 292 620 98 ~53

ECOMAX 4M R ¾ Rp 2 24 0 95 298 ~86

545, 595,

645, 695

368 254 480 420 4 x 19

445

4 x M16 R 2½ 345 920 128 ~90

ECOMAX 5M R 1 Rp 2 273 95 298 ~86 545, 695 368 287 480 420 4 x 19

445

4 x M16 G 2½ 345

1165

153 ~91

ECOMA X 6M R 1½ Rp 3 370 150 401

~137

545, 695 540 390 74 0

690

8 x 23

650

4 x M20 DN 100 530

1618

215 ~265

1)

Excluding gasket (t = 4 mm)

2)

Weight of burner of shortest length.

ECOMAX · Edition 10.17 73

Technical data

9.1.3 ECOMAX..F for direct heating

S1

G

∅B ∅A

C

D

G1

A1

ØF

I

Øn

m

K

M

ØP

V

LA

GA

H1

Type ECOMAX FGT set EJEK

GA LA Ø B C

1)D1)

G1 G

H1

Ø A Ø F A1 Ø n I m V K M Ø P Weight

mm mm mm kg

2)

ECOMAX 1F R ½ Rp 1 109 60 212 ~78

545, 595,

645, 695

236 133 330

280

4 x 19

290

4 x M16 R 1¼ 269 625 43 ~27

ECOMAX 2F R ½ Rp 1½ 128 60 212 ~80

545, 595,

645, 695

236 156 330

280

4 x 19

290

4 x M16 R 1½ 285 540 83 ~31

ECOMA X 3F R ½ Rp 2 164 83 262 ~80

545, 595,

645, 695

280 193 385

325

4 x 19

330

4 x M16 R 2

292

620 98 ~ 47

ECOMAX 4F R ¾ Rp 2 216 95 298 ~86

545, 595,

645, 695

368 254

480

420

4 x 19

445

4 x M16 R 2½

345

920 128 ~75

ECOMAX 5F R 1 Rp 2 224 95 298 ~86

545, 595,

645, 695

368 287

480

420

4 x 19

445

4 x M16 G 2½

345

1165 153 ~76

1)

Excluding gasket (t = 4 mm)

2)

Weight of burner of shortest length.

ECOMAX · Edition 10.17 74

Technical data

9.1.4 ECOMAX..C for indirect heating

≥ 8 mm

≥ 0.315"

∅X

W

B1

P1 + N1

W2

G

C

D

G1

V1 = 0.7 × max. 1,5 × ØX

S1 = +/-20 mm

30 mm

LA

GA

H1

DN

FLUP

M

A1

ØF

I

Øn

m

Type ECOMAX SERC FLUP

GA LA C

1)D1)

G1 G

H1

P1 + N1 W2 B1 Ø X W Ø F A1 Ø n l m DN M

Weight

kg

2)

ECOMA X 0C

R ½ Rp 1 60 179 ~78

395,

475,

556,

636

182 ~34 35 160

100

1000– 2600

290 240 4 x 14 210 4 x M12 32

230

~11

ECOMA X 1C

R ½ Rp 1 60 212 ~80

545,
593,
641,

689

236 ~37 50

200

142

1500– 2600

330 280 4 x 19 290 4 x M16 50

331

~19

ECO MAX 2C

R ½ Rp 1½ 60 212 ~80

545,
613,

681

236 ~37 50 220 162

1500– 3000

330 280 4 x 19 290 4 x M16 50

331

~21

ECOMA X 3C

R ½ Rp 2 83 262 ~80

545,

617,
689

280 ~37 50

260

202

1500– 3000

385 325 4 x 19 330 4 x M16 65

353

~33

1)

Excluding gasket (t = 1.3 mm)

2)

Weight of burner of shortest length.

ECOMAX · Edition 10.17 75

Technical data

9.1.5 ECOMAX..M for indirect heating

∅X

∅B

W

G

S1 = +/-20 mm

D1

V1 = 0,7 × bis 1,5 × ØX

C

D

G1

di

LA

GA

H1

DN

FLUP

M

A1

ØF

I

Øn

m

Type ECOMAX SERM FLUP

GA LA Ø B

C1)D1)G1 G

H1

D1 di Ø X2)Ø F3)A13)Ø n

3)

l m DN M Weight

mm mm mm kg

4)

ECOM AX 1M R ½ Rp 1 123 60 212 ~78

545, 595,

645, 695

236 30 > 128

di + 2

*

s

330 280 4 x 19 290 4 x M16 32

230

~35

ECOM AX 2M R ½ Rp 1½ 142 60 212 ~80

545, 595,

645, 695

236 30 > 147

di + 2

*

s

330 280 4 x 19 290 4 x M16 50

331

~41

ECOMA X 3M R ½ Rp 2 178 83 262 ~80

545, 595,

645, 695

280 30 > 185

di + 2

*

s

385 325 4 x 19 330 4 x M16 50

331

~53

ECOMA X 4M R ¾ Rp 2 240 95 298 ~86

545, 595,

645, 695

368 50 > 248

di + 2

*

s

480 420 4 x 19 445 4 x M16 65

353

~90

ECOM AX 5M R 1 Rp 2 273 95 298 ~86 545, 695 368 50 > 280

di + 2

*

s

480 420 4 x 19 445 4 x M16 100

399

~91

1)

Excluding gasket (t = 4mm)

2)

s = radiant tube wall thickness.

3)

provided by the customer. Data is just a recommendation.

4)

Weight of burner of shortest length.

ECOMAX · Edition 10.17 76

Technical data

9.1.6 ECOMA X..F for indirect heating

∅X

W

G

C1

S1 = +/-20 mm

V1 = 0,7 × bis 1,5 × ØX

D1

C

D

G1

di

LA

GA

H1

DN

FLUP

M

A1

ØF

I

Øn

m

Type ECOMAX SERM FLUP

GA LA Ø B

C1)D1)G1 G

H1

D1 di Ø X2)Ø F3)A13)Ø n

3)

l m DN M

Weight

mm mm mm kg

4)

ECOMAX 1F R ½ Rp 1 109 60 212 ~78

545, 595,

645, 695

236 30 > 128

di + 2

*

s

330 280 4 x 19 290 4 x M16 32

230

~35

ECOMAX 2F R ½ Rp 1½ 128 60 212 ~80

545, 595,

645, 695

236 30 > 147

di + 2

*

s

330 280 4 x 19 290 4 x M16 50 331 ~41

ECOMA X 3F R ½ Rp 2 164 83 262 ~80

545, 595,

645, 695

280 30 > 185

di + 2

*

s

385 325 4 x 19 330 4 x M16 50 331 ~53

ECOMAX 4F R ¾ Rp 2 216 95 298 ~86

545, 595,

645, 695

368 50 > 248

di + 2

*

s

480 420 4 x 19 445 4 x M16 65

353

~90

ECOMAX 5F R 1 Rp 2 224 95 298 ~86

545, 595,

645, 695

368 50 > 280

di + 2

*

s

480 420 4 x 19 445 4 x M16 100

399

~91

1)

Excluding gasket (t = 4mm)

2)

s = radiant tube wall thickness.

3)

provided by the customer. Data is just a recommendation.

4)

Weight of burner of shortest length.

ECOMAX · Edition 10.17 77

Maintenance

10 Maintenance

Twice per year, but if the media are highly contaminated,

this interval should be reduced.

ECOMAX · Edition 10.17

Finally, we are offering you the opportunity to assess this “Technical Information (TI)” and to give us your opinion,
so that we can improve our documents further and suit them to your needs.

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Remarks

Elster GmbH
Postfach 2809 · 49018 Osnabrück
Strotheweg 1 · 49504 Lotte (Büren)

Germany

Tel [phone]0

Fax [phone]370
[e-mail]

ww w.kromschroeder.com

The current addresses of our international agents

are available on the Internet:
ww w.kromschroeder.de/ Weltweit.20.0.html?&L=1

We reserve the right to make technical
modifications in the interests of progress.

Copyright © 2017 Elster GmbH
All rights reserved.

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03250971