Krom Schroder GIK 40TN02-5, GIK 50TN02-5, GIK 15TN02-5B, GIK 25TN02-5B, GIK 40TN02-5B Technical Information

...
AIR/GAS RATIO CONTROLS
GIK, GIK..B
Technical Information
T-Product 2004 November
For maintaining constant gas/air ratios Cross-connected operation with modulating or
high-low control of nozzle mix burners Zero regulator operation for premix burners Precise pressure regulation over wide turndown
ranges Low maintenance Valve seat design for consistent low fire repeatability Balanced double diaphragm design allows regula-
tor to operate over a wide range of inlet pressures
while minimally affecting outlet pressure CE certied models available
2
T-Product · GIK, GIK..B · 2004 November
= To be continued
Table of Contents
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . 2
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Nozzle Mix Burner . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Premix Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
Dimensions and Weights. . . . . . . . . . . . . . . . . . .
6
Sizing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
Bypass Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
How to install the air control line. . . . . . . . . . . . . .
10
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
To adjust the low fire position at GIK. . . . . . . . . . . .
11
To adjust the low fire position at GIK..B (with internal
Bypass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
Special Features Conversion Kit for zero
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
Order Information . . . . . . . . . . . . . . . . . . . . . . .
15
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . .
16
Flow at low fire position too high? . . . . . . . . . . . .
16
Air control pressure too high? . . . . . . . . . . . . . . .
16
Gas/Air ratio is not 1:1 at high re . . . . . . . . . . . . .
17
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
Spare parts GIK ½" to 2" . . . . . . . . . . . . . . . . . . .
19
Spare parts GIK 2½" to 4" . . . . . . . . . . . . . . . . . .
20
Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
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T-Product · GIK, GIK..B · 2004 November
M
* Cross connection line should be no smaller than ¼ pipe or 3/8
OD tubing, as short and with as few bends as possible.

Application

GIK Regulators hold constant gas/air ratios as cross­connected ratio regulators with modulating or high-low control of nozzle mix burners or as zero governors on premix systems.
When used as cross-connected regulator for nozzle mix burners, GIK regulator provide outlet gas pressure at a
1:1 pressure ratio with air loading. For leaner or richer low
re ratios, the bias spring can be adjusted to provide an outlet pressure up to 1.2 WC (3 mbar) higher or lower than the loading pressure.
For repeatable control of extremely small low fire inputs (frequently, only the pilot), the GIK..B Regulator, with a xed internal Bypass (1/2 to 2), is recommended. When the system drives to low re, the regulator valve closes completely, and the low re gas flow is controlled accurately by precision-machined internal orifice.
Typical air and gas piping layouts for nozzle-mixing and
premix systems are shown in the pictures “Nozzle Mix Burners and Premix Burners. These schematics contain only those components related to the gas-air ration control system. A complete combustion sys­tem must also contain a suitably-sized combustion air source and safety-related components, such as safety shutoff valves, air and gas pressure switches and flame supervisor components. Consult the latest versions of the standards which apply to your installation, such as NFPA 86 or CAN/CGA-B149.1, for guidance. If in doubt about which components are required, contact Kromschroder for assistance.
Nozzle Mix Burners with High-Low Control, including Pulse Firing
Manual Shutoff Valve
Orifice
GIK..B
Flexible Gas Connection
Orice
Orice
Safety Shutoff Valve, Slow Opening
Automatic Air Control Valve
Cross-connection Line*
To Other Zones
GAS
AIR
Nozzle Mix Burners with Modulating Control
Manual Shutoff Valve
Orifice
GIK
Flexible Gas Connection
Orice
Manual Air Trim Valve or Orice
Safety Shutoff Valve, Slow Opening
Motorized Zone Air Control Valve
Cross-connection
Line*
To Other Zones
GAS
AIR
To Other Zones
4
T-Product · GIK, GIK..B · 2004 November
Application
M

Premix Burners

Manual Shutoff Valve
Mixer
GIK..B
Flexible Gas Connection
Orice
Safety Shutoff Valve, Slow Opening
Motorized Zone Air Control Valve
Burner
To Other Mixers
GAS
AIR
To Other Zones

Nozzle Mix Burner

The cross connection line should be no smaller than 1/4”
pipe or 3/8 OD tubing, as short and with a few bends as possible.
See installation instructions for other recommenda­tions.
Premix Burners
If burner is sealed in and combustion chamber pressure is other than zero, connect vent to combustion chamber. Otherwise leave it open to atmosphere.
Vent
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T-Product · GIK, GIK..B · 2004 November
Specifications
Operating Limits
Type of gas: Natural, LPG, clean coke oven gas and clean biogas
Ambient temperature range: GIK ½ to 2 = -4 °F to 158 °F (-20 °C to 70 °C)
GIK 2½ to 4 = 5 °F to 140 °F (-15 °C to 60 °C) Maximum inlet pressure: 3 psig (200 mbar) Maximum operational inlet-
to-outlet differential pressure: 1.5 psig (100 mbar) Combustion air loading pressure: 0.2 to 48 WC (0.5 to 120 mbar) Outlet pressure range: 0.1 to 47.6 WC (0.2 to 119 mbar)
Adjusting range at min. ow: GIK ½ to 2 = -1.2 to +1.2 WC (-3 to +3 mbar)
GIK 2½ to 4 = -0.8 to +0.8 WC (-2 to +2 mbar) Connection for Control line: GIK ½ to 2 = ¼ NPT
GIK 2½ to 4 = ½ NPT
Mechanical Data
Available pipe sizes NPT-threaded: ½, ¾", 1, 1½, 2
ANSI anged: 2½, 3, 4
Materials of Construction
GIK ½” to 2”: Pressure die-cast aluminium alloy valve bodies and diaphragm housings. Diaphragms and
valve discs are nitrile rubber. Valve stems are precision molded plastic.
GIK 2½” to 4”: Sand-cast aluminium alloy valve bodies and diaphragm housings. Diaphragms and valve discs
are nitrile rubber. Valve stems are made of aluminium.
6
T-Product · GIK, GIK..B · 2004 November

Dimensions and Weights

GIK 15 50TN GIK 65 100TA
H1
L
H2
øD
Rp
1
/4
¼ NPT
d2
k
D2
H2
øD
H1
L
Rp
1
/2
½ NPT
Type Connection max. inlet
pressure
Dimensions Flange Drilling Weight
L D H1 H2 D2 k d2 No. psig mbar inch mm inch mm inch mm inch mm inch mm inch mm inch mm lbs kg GIK 15TN NPT ½"
3 200 4.72 120 5.28 134 1.34 34 5.20 132 2.20 1.0
GIK 20TN NPT ¾"
3 200 4.92 125 5.28 134 1.34 34 5.20 132 2.20 1.1
GIK 25TN NPT 1"
3 200 4.92 125 5.28 134 1.34 34 5.20 132 2.20 1.1
GIK 40TN NPT 1½"
3 200 6.10 155 7.29 185 1.77 45 5.87 149 4.19 1.8
GIK 50TN NPT 2"
3 200 7.87 200 9.21 234 2.03 52 6.57 167 6.82 2.8
GIK 65TA
ANSI 2½"
3 200 11.42 290 10.24 260 3.50 89 16.22 412 7.01 178 5.51 140 0.75 19 4
26.46
12.0
GIK 80TA ANSI 3"
3 200 12.20 310 12.20 310 3.94 100 17.56 446 7.52 191 5.98 152 0.75 19 4
35.50
16.1
GIK 100TA ANSI 4"
3 200 13.78 350 15.35 390 4.53 115 19.72 501 9.02 229 7.52 191 0.75 19 8
57.33
26.0
7
T-Product · GIK, GIK..B · 2004 November

Sizing

Selection

For premix and modulating control of nozzle mix burn- ers, select the GIK. For high-low control of nozzle mix burners, including pulse ring, use the GIK..B regulator with the internal bypass.
When used as cross-connected regulators, GIK turn- down depends on the range of their outlet (loading) pres- sures between high and low re. The greater the range, the greater the turndown. Always gure the turndown before sizing the regulator, because this determines the inlet pressure required.
Flow Turndown Ratio
High Fire Outlet or Loading Pressure
Required to get Turndown if Low
Fire Loading Pressure is 0.2" WC
(0.5 mbar)
10 to 1 20" WC (50 mbar)
8 to 1 12.6" WC (32 mbar) 6 to 1 7.1" WC (18 mbar) 5 to 1 4.9" WC (12.5 mbar)
GIK..B Regulator turndown will depend on the sizing of the internal bypass orice.
1. Determine the gas pressure that will be supplied to the regulator inlet and convert it from psig to WC (psig x 27.7 = " WC). It should be at least equal to the
regulator’s high fire outlet pressure plus the pressure drop across the regulator itself. The high re outlet pressure will be 0 for zero governors. On cross-con
- nected nozzle-mixing applications, it will equal the high fire outlet pressure determined under Turndown above. For best results, the pressure drop across the
regulator should be about 10" WC. If the inlet pres­sure is considerably less than what’s needed, try to obtain higher supply pressure. If this isn’t possible, use a lower pressure drop across the regulator, but dont go below 2" WC.
2. Multiply the maximum gas ow through the regulator by the correction factors for specific gravity, tempera
-
ture and altitude/line pressure from the tables below.
This is the corrected ow
.
Flow Correction Factors
Specic Gravity Factor Air (1.0 s. g.) 1.27 Propane (1.56 s. g.) 1.61 Butane (2.00 s. g.) 1.83 Propane/Air (1.29 s. g.) 1.47 Coke Oven (0.45 s. g.) 0.87
Temperature Factor
60°F (16°C) 1.0 100°F (38°C) 0.96 120°F (46°C) 0.95
Line Pressure [psig]
Altitude
1 2 3
Sea Level 1.00 1.03 1.06 1000 (305 m) 0.98 1.01 1.05
2000 (610 m) 0.97 1.00 1.03
3000 (915 m) 0.95 0.98 1.01 4000 (1220 m) 0.93 0.97 1.00
5000 (1525 m) 0.92 0.95 0.98
6000 (1830 m) 0.90 0.94 0.97 7000 (2135 m) 0.88 0.92 0.95
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T-Product · GIK, GIK..B · 2004 November
3. On the sizing chart, nd where the corrected flow in­tersects the pressure drop from Step 1. Move down from this point. The rst regulator curve you come to is the size to use.

Bypass Sizing

1. Correct the low re bypass ow you want with the same factors used to size the regulator.
2. Find this ow at the bottom of the bypass orifice sizing chart and read up to the pressure drop that will be available across the regulator. (At low fire, this nearly equals the inlet pressure to the regulator, so you can simply use the inlet pressure.)
3. Move down from this point. The rst orifice curve you come to is the size to use.
Sizing
Flow rates natural gas [m3/h]
mbar
inch WC
Pressure drop p
207 9 30 40 50 60 80 100
8 10
0.2 0.3 0.4 0.6 0.8 1 2
200 700300 400 500
3 4 5 6 8 10 20
SCFH
20
30
40
4
5
6
8
10
10
20
30
40
50
60
80
100
ø
GIK: bypass plug standard no hole GIK..B: bypass plug standard * GIK 15–25..B: 0.06 inch (1,5 mm) ** GIK 40–50..B: 0.197 inch (5 mm)
Bypass screw GIK..B
inch (mm) Ø
0.06 (1.5)*
0.079 (2
)
0.118 (3
)
0.157 (4
)
0.197 (5)*
*
0.236 (6
)
0.267 (7
)
0.315 (8
)
0.354 (9)
GIK 1525..B
GIK 4050..B
inch WC
mbar
Pressure drop p
2
3
4
5
6
8
1000 2000 3000 6000 10000 20000
Flow rates natural gas [m3/h]
SCFH
Flow rate
300 500
10 20 30 40 60 80100 200 300 500 1000
10
0.8
1
20
30
40
50
2
3
4
5
6
8
10
20
30
40
50
60
80
100
GIK 15
GIK 20
GIK 25
GIK 40
GIK 50
80000
40000
2000
G
IK
65
G
IK
80
G
IK 10
0
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T-Product · GIK, GIK..B · 2004 November

Installation

WARNING: Improper installation, adjustment, modifi-
cation, operation or maintenance could lead to injury or damage. All adjustments must be made by a qualified technician.
Wiring must comply with local codes and National Electrical Codes. To prevent the posibility of property damage, turn off electrical power, depressurize instal­lation, vent uid to safe area before servicing.
Remove thread protectors
Observe direction of ow: arrow on housing
Spring dome must point vertically downwards
The housing must have clearance of ¾" from any vertical surface. Allow access to spring adjustment at top of housing
Use suitable sealant, apply sparingly, only to outer threads.
Check for gas leaks. Apply pressure to regulator (do not exceed name plate rating) measured at test point.
Soap pipe joints and check for leaks.
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T-Product · GIK, GIK..B · 2004 November
5x
nominal Diameter
Air
5x
nominal Diameter
Installation

How to install the air control line

GIK ½ to 4
The connection of the air control line must be at a
distance of 5 × nominal Diameter from other air control elements.
Connection of the air control line
GIK ½ to 2: NPT ¼ GIK 2 ½ to 4: NPT ½
11
T-Product · GIK, GIK..B · 2004 November
0
0
0
+
p
a
p
L
0
p
L
3 mm
+
p
a
6 mm
pa = pL± 2 mbar
p
a
=
pL± 3 mbar

Operation

To adjust the low fire position
at GIK
Set the high re rate using re­stricting orices or adjustment element on the burner
At low re position: Control pres­sure at least 0.2 “WC (0,5 mbar).
Factory setting without Bypass: outlet pressure = control line pressure
Factory setting with Bypass:
outlet pressure = control line pressure 0.8“ WC (2 mbar)
to keep the valve closed for con­stant low re
GIK ½" to 2" the outlet pressure is adjustable between ± 1.2" WC (3 mbar)
GIK 2½" to 4" the outlet pressure is adjustable between ± 0.8" WC (2 mbar)
12
T-Product · GIK, GIK..B · 2004 November
1 2 3
4 5
max. 300 mbar
GIK 15–25..B, GIKH 25..B
GIK 40–50..B
The bypass screws and the housing have had markings since November
2000. Only marked screws may be used with marked housings.
Flow rates natural gas [m3/h]
mbar
inch WC
Pressure drop p
207 9 30 40 50 60 80 100
8 10
0.2 0.3 0.4 0.6 0.8 1 2
200 700300 400 500
3 4 5 6 8 10 20
SCFH
20
30
40
4
5
6
8
10
10
20
30
40
50
60
80
100
ø
GIK: bypass plug standard no hole GIK..B: bypass plug standard * GIK 15–25..B: 0.06 inch (1,5 mm) ** GIK 40–50..B: 0.197 inch (5 mm)
Bypass screw GIK..B
inch (mm) Ø
0.06 (1.5)*
0.079 (2
)
0.118 (3
)
0.157 (4
)
0.197 (5)*
*
0.236 (6
)
0.267 (7
)
0.315 (8
)
0.354 (9)
GIK 1525..B
GIK 40–50..B
To adjust the low re position at GIK..B (with
internal Bypass)
The air control line (air control pressure) must be less than 0.8" WC (2 mbar) at low fire position
The bypass screw and the housings have been marked since Nov. 2000. Only marked screws may be used with marked housings
The bypass orices determines the low fire rate. Standard: GIK 15 to 25 (½ to 1) = 0.059 “ (1.5 mm) GIK 40 to 50 (1½ to 2) = 0.20 “ (5 mm) GIK 65 to 100 (2½ to 4) = use external Bypass
Enlarge the orice if necessary (max.) GIK 15 to 25 (½ to 1) = 0.16 “ (4 mm) GIK 40 to 50 (1½ to 2) = 0.35 “ (9 mm)
Operation
Order-No. Bypass Screws
For GIK 15 to 25 (½" to 1")
Bypass screw 0.059" (1.5 mm)
03089217
Bypass screw without orice
03089215
Bypass variable 74919806
For GIK 40 to 50 (1½" to 2")
Bypass screw 0.2" (5 mm)
03089218
Bypass screw without orice
03089216
Bypass variable
74919821
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T-Product · GIK, GIK..B · 2004 November
GIK..N
GIK..A
1
1
Order No.: 03351039
Order No.: 74910853

Special Features Conversion Kit for zero Pressure

14
T-Product · GIK, GIK..B · 2004 November

Function

The GIK has 4 basic elements that allow to operate. These are:
1 Valve seat
A valve seat or orice through which the gas supply will ow. This has a disc or plug that can close against the seat to limit the ow of gas. By moving the disc, the outlet ow and pressure can be altered from fully open to fully closed. The position of the disc will determine the flow and pressure the outlet of the regulator.
2 Internal or external impulse
Usually a tube located on the regulator outlet senses the outlet pressure. The diaphragm is linked to the valve stem. A change in the sensed pressure above the diaphragm causing the restricting element to alter it’s position.
3 Air control line
The air control pressure acts against the force of the
measuring element. When state of equilibrium is achieved between the measuring element and the loading ele­ment the resulting position of the restricting element will determine the outlet pressure. The spring is for fine adjusting at low re.
4 Compensating diaphragm
A secondary diaphragm is used in compensated regu
­lators. This diaphragm has the same area as the valve, so it compensates the effect of varying inlet pressures on the valve.
Compensating
Diaphragm
Valve seat
Internal or ex
-
ternal Impuls
Air Control Line
Spring
Working
Diaphragm
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T-Product · GIK, GIK..B · 2004 November
GIK 15 – 50TN
GIK 65– 100TA

Order Information

GIK air/gas ratio regulator 15 100 (½" to 4") nominal diameter T T-product
A ANSI-flanged
N NPT-internal thread
02 max. inlet pressure 3 psig (200 mbar)
-3 screw plug at the inlet and outlet
-5 pressure test point at the outlet B
with drilled bypass screw
Designation Order no. For continous control, with NPT internal thread GIK 15TN02-5 03155176 GIK 20TN02-5 03155128 GIK 25TN02-5 03155140 GIK 40TN02-5 03155152 GIK 50TN02-5 03155164 For High/Low/Off control, with NPT internal thread GIK 15TN02-5B 03155177 GIK 20TN02-5B 03155129 GIK 25TN02-5B 03155141 GIK 40TN02-5B 03155153 GIK 50TN02-5B 03155165 For continous control, with ANSI ange GIK 65TA02-3 85092320 GIK 80TA02-3 85093320 GIK 100TA02-3 85094320
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T-Product · GIK, GIK..B · 2004 November
1
2

Trouble Shooting

Trouble Shooting is a term used to indicate a systematic
approach to locate regulator malfunction. As with installa­tion and maintenance, successful regulator troubleshoot­ing depends on careful analysis and planning before taking action. Regulators are relatively simple devices with few faults. The most common faults are:
Flow at low re position too high?
It sometimes happens that the ow rate at low fire
position is to high. This is due to dirt at the valve seat or disc. These parts should be cleaned with suitable solvent.
Spring adjustment set too high.

Air control pressure too high?

The maximum possible gas outlet pressure is lower
than the max. air control pressure (air impulse line). Use a reducing tting (Order no. GIK 15 to 50 = 03351040) (Order no. GIK 65 to 100 = 74910779)
Regulator is not responding?
The working or compensating diaphragm could
be broken. Should these happen in short intervals check the diaphragms. Always use special air dia
-
phragms for air media.
17
T-Product · GIK, GIK..B · 2004 November
Real characteristic Curve
Ideal characteristic Curve
1:1
Gas outlet
Pressure
Air Control Pressure
Gas/Air ratio is not 1:1 at high fire
For example:
at low re the air control pressure is 2" WC (5 mbar), the gas outlet pressure is also 2" WC (5 mbar) at high re the air pressure is 40" WC (100 mbar), the gas outlet pressure is lower depending on the ow rate.
For the gas/air ratio for high re use gas limiting orifice
valve for ne adjustments
Trouble Shooting
18
T-Product · GIK, GIK..B · 2004 November

Maintenance

All regulators which control the systems pressure are
subject to periodic servicing by authorized personnel. By carrying out a regular maintenance schedule, you can
prevent problems from occuring. The regulator type and its service conditions will help you determine how often to conduct inspections. The more severe the working conditions, the more frequently you should examine the regulator.
Generally, small, modern regulators can operate for considerable periods without attention, minimizing the need for periodic maintenance.
When a regulator is serviced, the following general pro
-
cedure should be followed.
1 Check that a shut off valve is located in the area of
the regulator.
2 Try to ensure that there is a clear working area, and
that you have somewhere to put the regulator com
-
ponents, once removed, so they will not be lost or
damaged.
3 Always use the correct tools, in the proper sizes, to
dismantle the regulator. Rough treatment can dam
-
age an otherwise useable component.
4 If available, follow the maintenance instructions issued
by the manufacturer of the regulator.
5 Make careful note of the position of each component
before removal to aid reassembly.
6 Unless the maintenance instructions say otherwise,
take off the top cover and remove the loading
spring.
7 Dismantle the regulator, removing the diaphragm(s)
and valve.
8 Clean all parts of the body and casings. 9 Check the diaphragms and replace if necessary.
10 Clean the regulator valve. If it has a rubber seat, check
and replace if necessary.
11 Examine the orice or valve seating. Check for burrs
and replace if damaged or worn. Avoid the use of
abrasives on valve or seats. 12 Reassemble the parts in reverse order. 13 When reassembling a ring of screws or bolts, tighten
gradually and in opposing pairs. 14 Check the regulator for leakage. 15 Reset outlet pressure to the regulator. 16 Update maintenance records for the unit.
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T-Product · GIK, GIK..B · 2004 November
1
1
1
1
1
1
1

Spare parts

Spare parts GIK ½" to 2"

Spare part kit (1) contains the diaphragms and o­rings.
Type
For Gas For Air
GIK 15
03089204 03089201
GIK 20
03089204 03089201
GIK 25
03089204 03089201
GIK 40
03089205 03089202
GIK 50
03089206 03089203
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T-Product · GIK, GIK..B · 2004 November
1
3
2
4
5
6
7
8

Spare parts GIK 2½" to 4"

Pos. Description GIK 65
(2½")
GIK 80
(3")
GIK 100
(4")
1 O-ring 03109276 03109277 03109277
2 O-ring 03110203 03109170 03109232 3 Valve train 74960325 74960024 74960316 4 Compensating diaphragm 35454179 34328850 35442690 5 Working diaphragm 34328846 34328856 34212875 6 Safety diaphragm 74324141 74324291 74324201
7 O-ring 03109170 03109170 03109170
8 O-ring 03109159 03109159 03109159
Spare parts
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T-Product · GIK, GIK..B · 2004 November
Warning
Situations dangerous to personnel and property can result from the misapplication and incorrect operation of combustion equipment.
Kromschroder advises compliance with the National Fire Protection Association standards that apply for related
equipment and Insurance Underwriters recommendation, and care of operation.
We reserve the right to make technical changes designed to improve our products without prior notice. For current product information, visit our website at www.kromschroder.co
m.

Contact

G. Kromschröder AG Strotheweg 1 D-49504 Lotte (Büren)
Tel.:+49 (0)5 41 / 12 14 - 0
Fax:+49 (0)5 41 / 12 14 - 370
KROMSCHRODER INC.
1595-H Georgetown Rd.
Hudson, OH 44236 Ph. 330-342-0595
Fax 330-342-0596 info@kromschroeder.com info@kromschroder.com www.kromschroeder.co
m www.kromschroder.com
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