Kromschroder ZIC Series, ZIC 200, ZIC 165 Operating Instructions Manual

03250523

F

NL

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D GB F NL I E

TR CZ PL RUS H

DK S N P GR

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Operating instructions

Burners for gas ZIC

© 2014 Elster GmbH · Edition 05.14

Contents

Translation from the German

Burners for gas ZIC . . . . . . . . . . . . . . . . . . . . . 

Contents ..............................

Safety.................................

Checking the usage .....................

Installation ............................

Installing the ceramic tube . . . . . . . . . . . . . . . . . 3

Installation on the furnace .................4

Air connection, gas connection .............4

Installing the burner insert .................5

Wiring ................................5

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

Determining the flow rates . . . . . . . . . . . . . . . . . 6

Notes on the flow rate curve ............... 7

Restrictors .............................7

Hot-air compensation .................... 7

Commissioning.........................8

Igniting and adjusting the burner ............8

Tightness test...........................9

Cooling air .............................9

Blocking and recording the settings .........10

Maintenance ..........................0

Assistance in the event of malfunction ....

Accessories ..........................

Technical data ........................

Logistics .............................

Declaration of Incorporation.............4

Certification ..........................4

Contact ..............................4

Safety

Please read and keep in a safe place

Please read through these instructions
carefully before installing or operating. Following the
installation, pass the instructions on to the opera­tor. This unit must be installed and commissioned
in accordance with the regulations and standards
in force. These instructions can also be found at
www.docuthek.com.

Explanation of symbols

• ,  ,  ,  ... = Action

▷ = Instruction

Liability

We will not be held liable for damage resulting from
non-observance of the instructions and non-com­pliant use.

Safety instructions

Information that is relevant for safety is indicated in
the instructions as follows:

DANGER

Indicates potentially fatal situations.

WARNING

Indicates possible danger to life and limb.

CAUTION

Indicates possible material damage.

All interventions may only be carried out by qualified
gas technicians. Electrical interventions may only be
carried out by qualified electricians.

Conversion, spare parts

All technical changes are prohibited. Only use OEM
spare parts.

Changes to edition .

The following chapters have been changed:
– Checking the usage
– Installation
– Preparing commissioning
– Commissioning
– Technical data
– Logistics
– Declaration of Incorporation

GB

GB-1

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Checking the usage

Burner for heating industrial thermoprocessing equip­ment. The burner ZIC can be used in conjunction
with the ceramic tube set TSC in industrial furnaces
or firing systems with brick lining or ceramic fibre
lining. No burner quarl is necessary. For natural gas,
town gas and LPG. Other types of gas on request.

This function is only guaranteed when used within the

specified limits – see also page13 (Technical data). Any
other use is considered as non-compliant.

Burner

Construction stage, rated capacity Q
see type label.

GB

D-49018 Osnabrück Germany

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

BR 84246518

Qmax

BE 74970471 BK 18

Gas N SN

630 kW

Type code

Code Description

ZIC

Burner for gas with cast steel

ZICW

Burner for gas with cast steel

housing and internal insulation

65 – 00 Burner size
R
H
B
G
M
L
D

Butane, propane, propane/butane
Butane, propane, propane/butane

Low calorific value gas

Coke oven gas, town gas

L
R

Reduced max. connection rating

Length of burner extension [mm]:

-0

-00

-00…
/5­/5-

Position of burner head [mm]

/5-…

-() to

Burner head identifier

-(99)

-(E) to

High temperature version

-(99E)
A – F Construction stage

, gas type–

max

D

17.11.

housing

Normal flame

Long, soft flame

Natural gas

Ignition lance

none

100
200

Part designations

4

2

3

5

1

9

6

7

8

 Burner insert
 Gas housing gasket
 Air housing
4 Mounting flange
5 Mounting gasket
6 Type label
7 Burner extension (for ZIC..-100, ZIC..-200)
8 Clamping ring
9 Enclosed documentation (flow rate curves,

operating characteristic diagrams, dimension
sheet, spare parts list, spare parts drawing
and Declaration of Incorporation)

 • Check letter marking and identification marks on

the burner head using the information provided
on the type label.

Ceramic tube

Length and diameter – see type label.

D-49018 Osnabrück Germany

TSC 165A154-300/35-Si-1500

RS MA Si-1500 SN

Type code

Code

TSC
65 – 00
A
54, 80

-00
/5­Si-500

Position of burner head L9 [mm]

Tube length L8 [mm]

Ceramic tube material

Description

Ceramic tube set

Burner size

Cylindrical

Outlet dia. D4 [mm]

GB-2

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L9

76

L8

5 Place the burner insert in such a way that the

insulators are protected against damage.

No burner extension

D4

Part designations

2

1

3

 Burner tube gasket
 Ceramic tube
 Type label

Installation

Installing the ceramic tube

CAUTION

Install the ceramic tube centrally and free of me­chanical stress to avoid damage.
Remove and dispose of the transport safety de­vice; to do this, remove the mounting flange or
clamping ring.

▷ Remove the burner insert in order to install the

ceramic tube. For this purpose, the air housing
can be placed in a vertical position on a smooth
working surface.

▷ On ZICW, avoid the formation of dust when dis-

mantling the burner insert and do not damage
the surface of the internal insulation.

1

2

8

9

10

With burner extension

76

8

9

Install the ce­ramic tube
centrally and
free of me­cha nical stress.

Centre the
ceramic tube.

Tighten in

crosswise
fashion.

Install the ce ­ramic tube
cen trally and
free of me­chanical stress.

Insert lock

washer pairs.

GB

3

4

10

Tighten in

crosswise
fashion.

GB-3

F

NL

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Insulating the ceramic tube

A/B

≥ 10 mm

≥ 0.4 in

20 mm

0.8 in

▷

Protect the burner extension from thermal stress.

▷

We recommend solid shaped parts A or high
temperature resistant ceramic fibrous material
B for insulation.

▷

Observe an annular gap of at least 10mm (0.4").

 Insulate the ceramic tube at least as far as the

burner head, to a maximum of 20mm (0.8")
behind the burner head.

▷ Burner without extension:

A/B

GB

20 mm

0.8 in

≥ 10 mm

≥ 0.4 in

▷ Burner with extension:

A/B

≥ 10 mm

≥ 0.4 in

20 mm

0.8 in

Installation on the furnace

▷

When installing, always ensure that when the
burner is mounted, it is sealed tightly on the
furnace wall.

1

2

Air connection, gas connection

GA

LA

Type

ZIC 165 Rp 1½ DN 100
ZIC 200 Rp 2 DN 150

▷

Threaded connection to DIN 2999, flange dimen-

sions to DIN 2633, PN 16.

▷ Install flexible tubes or bellows units to prevent

mechanical stress or transmission of vibration.

▷ Ensure that the seals are undamaged.

DANGER

Risk of explosion! Ensure the connection is gas­tight.

Connection to ANSI/NPT

An adapter set is required for connection to ANSI/

▷

NPT, see page12 (Adapter set).

Type

ZIC 165 1½ – 11.5 NPT
ZIC 200 1½ – 11.5 NPT

* Flange hole diameter.

▷

Weld flange J to air pipe P for air connection
LA and use NPT thread adapter H for gas con-

nection GA.

Gas connection GAAir connection

LA

Gas connection GAAir connection

LA*

4.57"

6.72"

3

D

-

4

9

0

1

8

O

s

n

a

b

r

ü

c

k

G

e

r

m

a

n

y

T

S

C

6

5

A

O

4

8

-

3

0

0

/

3

5

-

S

S

i

1

i

-

1

5

5

0

0

4

5

0

0

Attach the
ceramic tube
type label.

▷ The nozzle set with NPT coupling is required for

GA

H

LA

J

P

integrated ignition lances, see page12 (Nozzle set).

GB-4

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Ignition lance connections on the ZIO..L:

▷ Air connection la.
▷ Gas connection ga.
▷ Ignition lance capacity: 1.5kW.

la

ga

Type

gas connection

ga

ZIC..L Rp ¼ Rp ½

Ignition lance

ZIC..L with
adapter set

¼" NPT ½" NPT

Installing the burner insert

▷ The burner insert can be rotated to the required

position in increments of 90°.

▷

Insert the gas housing gasket between the
burner insert and the air housing.
On ZICW, avoid the formation of dust and do

▷

not damage the surface of the internal insulation.

1 2

▷ Tighten the burner insert in a crosswise fashion

with max. 37Nm (27.3lbfft).

Ignition lance

air connection

la

Wiring

DANGER

Electric shocks can be fatal! Before working on
possible live components, ensure the unit is discon­nected from the power supply.

▷

For the ignition and ionization cables, use (un-

screened) high-voltage cable:
FZLSi 1/6 up to 180°C (356°F),
Order No. 04250410, or
FZLK 1/7 up to 80°C (176°F),
Order No. 04250409.

I

Ionization electrode I

▷

Install the ionization cable well away from mains

cables and interference from electro-magnetic

sources and avoid external electrical interference.

Max. length of ionization cable – see automatic

burner control unit operating instructions.

▷

Connect the ionization electrode to the automatic

burner control unit via the ionization cable.

Ignition electrode Z

▷

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

mended < 1 m (40").

▷

For permanent ignition, max. ignition cable length

1 m (40").

Lay the ignition cable individually and not in a

▷

metal conduit.

▷

Install the ignition cable separately from ionization

and UV cables.

▷ A ≥ 7.5kV, ≥ 12mA ignition transformer is rec-

ommended; 5kV for ignition lance.

Z

GB

GB-5