SAACKE G100 User Manual EN
TEMINOX®
GL
Operating Instructions
Duoblock Burner
2021-06-22
BA-TEMINOX-GL-Duo2021-02
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Technical Documentation SAACKE
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Contents
TEMINOX®
GL
0 Contents
0 Contents ............................................................................................................................... 4
1 Safety .................................................................................................................................... 7
1.1 Documentation is a part of the product! ................................................................................................... 7
1.2 Symbols .................................................................................................................................................... 7
1.3 Safety in General ...................................................................................................................................... 8
1.4 Limit Values .............................................................................................................................................. 8
1.5 Authorized Use ......................................................................................................................................... 9
1.6 Limitation of Liability ................................................................................................................................. 9
1.7 Qualified Staff ......................................................................................................................................... 10
1.8 Transport and Interim Storage at Installation Site .................................................................................. 10
1.9 Danger from Hot Surfaces ...................................................................................................................... 10
1.10 Electrical Hazards................................................................................................................................... 11
1.11 Emergency Procedures .......................................................................................................................... 11
1.12 Explosion Protection in Potentially Explosive Atmospheres (ATEX) ..................................................... 11
1.13 Emergency Operation (Applies to Marine Plants Only).......................................................................... 11
1.14 Protective Clothing ................................................................................................................................. 11
2 Transport, Storage and Packing ....................................................................................... 12
2.1 Lifting Lugs ............................................................................................................................................. 12
2.2 Safety Instructions for Transport ............................................................................................................ 13
2.3 Checking the Delivery ............................................................................................................................ 13
2.4 Reporting Transport Damage ................................................................................................................. 13
2.5 Instructions for Storage .......................................................................................................................... 13
2.6 Disposal of the Packaging ...................................................................................................................... 14
2.7 Disposal of the Product .......................................................................................................................... 14
3 Design and Function ......................................................................................................... 15
4 Construction of the Refractory Brickwork ....................................................................... 20
4.1 Burner Head Variant C01 / C03 ............................................................................................................. 21
4.2 Burner Head Variant C02 ....................................................................................................................... 22
5 Mounting Instructions ....................................................................................................... 23
5.1 Mounting the Burner ............................................................................................................................... 23
5.2 Connecting Lines and Fittings ................................................................................................................ 25
6 Electrical Connections of the Burner ............................................................................... 27
7 Operation ............................................................................................................................ 28
7.1 Preparing the Heat Generator ................................................................................................................ 28
7.2 Preparing the Burner .............................................................................................................................. 28
7.3 Starting the Burner ................................................................................................................................. 28
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7.4 Controlled Operation .............................................................................................................................. 28
7.5 Switching Off the Burner ........................................................................................................................ 28
7.6 Service Interruption due to Fault ............................................................................................................ 29
8 Functional Schematic ........................................................................................................ 30
9 Maintenance / Cleaning ..................................................................................................... 34
9.1 General Information ................................................................................................................................ 34
9.2 Preparing Maintenance Work ................................................................................................................. 35
9.2.1 Periodical Maintenance (Fault not Acute) ............................................................................... 35
9.2.2 Maintenance after a Fault has Interrupted the Operation ....................................................... 36
9.3 Maintenance Intervals ............................................................................................................................ 36
9.4 Maintenance of General Components.................................................................................................... 37
9.4.1 Checking Supply Pressures .................................................................................................... 39
9.4.2 Cleaning the Flame Scanner / Performing a Function Test .................................................... 40
9.4.2.1 SAACKE FLUS 06 UV / FLS 09 UV ................................................................... 40
9.4.2.2 F 200 K2 ............................................................................................................. 41
9.4.3 Checking the Air Pressure Monitor ......................................................................................... 42
9.4.4 Checking the Protective Grating of the Fan ............................................................................ 43
9.4.5 Lubricating the Bearings of the Fan Motors (>75 kW Fan Output) ......................................... 43
9.4.6 Checking the Force Transmitter .............................................................................................. 43
9.4.7 Checking the Ignition Cables and Plug-and-Socket Connections .......................................... 43
9.4.8 Checking the Ignition Systems ZAP(ZDAP) and ZA0(ZDA0) ................................................. 44
9.5 Maintenance of Components Relevant to the Oil Operation Mode ........................................................ 45
9.5.1 Cleaning the Dirt Trap ............................................................................................................. 46
9.5.2 Checking the Fuel Lines Outside the Burner .......................................................................... 46
9.6 Maintenance of Components Relevant Especially to the Gas Operation .............................................. 47
9.7 After Completion of the Maintenance Work ........................................................................................... 47
10 Troubleshooting ................................................................................................................ 48
10.1 Troubleshooting (Gas Operation) ........................................................................................................... 48
10.2 Troubleshooting (Oil Operation) ............................................................................................................. 52
11 Dimensions / Types ........................................................................................................... 55
11.1 Arrangement of the Ignition Medium and Fuel Fittings .......................................................................... 55
11.2 Basic Dimensions ................................................................................................................................... 58
11.3 Weight .................................................................................................................................................... 59
11.3.1 Mixing System ......................................................................................................................... 59
11.3.2 Integrated Burner Control System (Optional) ......................................................................... 59
11.3.3 Motor Control (Optional) ......................................................................................................... 59
11.4 Center of Gravity .................................................................................................................................... 60
11.5 Position of the Fuel Inlets ....................................................................................................................... 61
11.6 Position of the Air Inlet Connection ........................................................................................................ 65
11.7 Burner Mounting Plate ............................................................................................................................ 66
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Conte
nts TEMINOX®
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11.8 Minimum Distances ................................................................................................................................ 68
11.8.1 All Duoblock Burners .............................................................................................................. 68
11.8.2 “Outer” Ignition and Fuel Fittings ............................................................................................ 69
11.8.3 “Inner” Ignition and Fuel Fittings ............................................................................................. 70
11.9 Connection Dimensions ......................................................................................................................... 71
11.10 Tightening Torque for Mounting Screws ................................................................................................ 72
12 Technical Data ................................................................................................................... 73
12.1 Capacity and Turndown Ratio ................................................................................................................ 73
12.2 Requirements for Fuels and Further Media ........................................................................................... 74
12.3 Distances of Fuel Supply System Components ..................................................................................... 75
12.4 Electrical Data ........................................................................................................................................ 75
12.5 Permitted Mounting Positions ................................................................................................................. 76
12.6 Acoustic Emissions................................................................................................................................. 77
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Safety
1 Safety
1.1 Documentation is a part of the product!
This document is an integral part of the product. It must be retained for the entire
service life of the product. Make this document available to the staff responsible for
the work described in it. Add any updates you receive later from SAACKE to the
document.
Help us improve this documentation!
We appreciate any feedback that improves the quality of our documentation. You
will find our address on the back of this document.
1.2 Symbols
Especially important information in this document is highlighted by the
corresponding symbols:
Warning!
The industrial safety symbol identifies safety instructions whose purpose is to
prevent physical injury or death. Follow these safety instructions carefully and be
especially cautious during the work/procedures they refer to.
Warning! Risk of death from electric shock!
The electricity symbol identifies safety instructions whose purpose is to prevent
physical injury or death from electric shock. Follow these safety instructions
carefully and be especially cautious during the work/procedures they refer to.
Caution!
The caution symbol identifies all safety warnings whose purpose is to prevent
damage or destruction of the product and/or other plant components.
2021-06-22
Note
This points to information or notes that are especially useful.
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Safety
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1.3 Safety in General
The "Safety" chapter gives you an overview of the safety aspects you must pay
attention to in order to work with the product safely. Any individual who assembles,
installs, mounts, commissions, operates and/or does maintenance on the product
described must read and follow the instructions in this chapter carefully to avoid
physical injury and material damage. Your safety is at stake.
In addition to these general safety instructions you will find specific safety
instructions in the product documentation related to individual actions or
procedures.
Only if you follow all of the safety instructions will you be able to provide the best
possible protection for yourself, your colleagues and the environment by ensuring
that the product functions safely and reliably.
In addition to this, it is imperative that you comply with the accident prevention and
safety regulations of the country you are working in.
1.4 Limit Values
The following products (apart from the burner) are considered as further
subsystems of a plant:
Heat generator / air supply system / flue gas system
Fuel supply system
Burner control system
Other plant components that are not part of the burner (e.g. sound absorbing
These subsystems are required to operate the plant but they are not an integral
part of the burner described in the present document and may vary depending on
the plant. For this reason, the present burner documentation does not include any
concrete contents on the other subsystems of the plant.
system, emissions-reducing systems)
We assume that the burner and the other subsystems are properly mounted and
electrically connected before they are commissioned and that the supply of the
burner with the fuel agreed on in the contract is ensured. We also assume that the
other subsystems comply with the relevant standards/regulations, that they are
compatible with the burner and have been tested for proper operation.
The burner must be integrated into a coherent plant environment. For instructions
on integrating the burner into a coherent plant environment, please refer to the
chapters "Furnace Dimensions" and "Burner Selection" in the planning
documentation. For any information required for mounting the burner, connecting
the burner to the electric system and for the construction of the refractory
brickwork, please refer to the planning documentation and to the operating
instructions.
The plant authorities must ensure compliance with the country-specific accident
prevention and safety regulations. They must also ensure that the work
environment (e.g. boiler house) complies with the regulations. We recommend that
the plant authorities compile operating instructions for the entire work environment.
The present document and all other manufacturer´s documentation for the plant
components should be used as a basis for these operating instructions.
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Safety
1.5 Authorized Use
The burner is exclusively designed to generate heat within the performance data
specified in the Technical Data by combusting the fuel specified on the rating plate.
The burner must be integrated into a coherent plant environment (fuel supply
system, heat generator etc.) (refer to chapter 1.4).
The energy generated by the burner, must be taken off, also during
commissioning.
To ensure proper operation of the burner, the pressure at the installation site must
not be negative relative to the atmosphere. The suction opening of the fan must be
free to ensure that it can draw in sufficient air.
Before the burner may be used for controlled operation, it must be commissioned
(with regard to its combustion performance). Only commissioning experts (refer to
"Qualified Staff") are permitted to commission the burner.
The commissioning expert is responsible for achieving proper combustion at all of
the firing rates and for ensuring that all the safety equipment (monitors etc.) are set
correctly. He/she must record all the values set in an approval and measurement
report and make it available to the plant authorities.
The settings made during commissioning must not be changed later on. Exception:
If the operating conditions change at a time following commissioning (e.g. due to
changed fuel properties or the plant environment), a commissioning expert must
check the settings and adjust them, if required. Again, the values set must be
recorded in an approval and measurement report.
The burner is fitted with safety equipment and has been tested for safety and
accepted. It may be operated only if the entire safety equipment has been adjusted
correctly and is in operation. The following is considered as safety equipment:
safety interlock circuits and all the associated components, all the other monitors
as well as construction-related protective measures such as safety fencing and
warning signs.
It is prohibited to modify or disable safety equipment unless the documentation
explicitly instructs you to disable and/or dismount such equipment temporarily. If
this should be required, e.g. for maintenance, the safety equipment must be
mounted and/or enabled again before the burner is taken into operation again. As
a rule, warning signs must never be covered or removed.
Unauthorized reconstruction and modification of the burner is prohibited. Only
original spare parts may be used! The use of third-party accessories must explicitly
be approved by SAACKE.
Comply with the instructions and regulations in the documentation in all the phases
of life of the burner. This applies especially to the burner maintenance (adhering to
the intervals for inspection and maintenance and for replacing safety-related
components).
To ensure operability, safety and economic efficiency, the plant must be inspected
by the manufacturer and/or authorized and trained personnel once a year. A
service agreement is recommended. SAACKE Service is at your disposal for more
detailed information.
1.6 Limitation of Liability
Any use deviating from the conditions specified above is considered as
unauthorized.
2021-06-22
SAACKE does not assume liability for damage resulting from unauthorized use.
Such use is at the risk of the operator/plant authorities.
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Safety
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1.7 Qualified Staff
Warning!
Risk of injury and property damage due to improper operation!
The plant authorities must ensure that only qualified and authorized personnel uses
the product.
In terms of the present documentation, the term qualified staff refers to persons
who have been trained in handling the described product and are authorized by the
plant authorities to mount, commission, operate and/or service the product.
The burner may only be commissioned by personnel especially trained and
certified to do so for the burner and the plant components concerned
("commissioning experts“). SAACKE will provide the training and certification for
the burner; either SAACKE or the respective manufacturer will provide the training
and certification for the other plant components.
1.8 Transport and Interim Storage at Installation Site
Risk of injuries if the burner falls over
If the burner falls over, it can cause serious injuries!
Always follow the transport and storage instructions.
1.9 Danger from Hot Surfaces
Warning! Risk of burns from hot surfaces!
If the burner is operated with preheated air, steam or preheated oil, the following
safety measures must be taken to avoid injury:
Burners operating with preheated air are designed to be insulated.
Protect all accessible surfaces with insulation (for instance, in the form of mineral
insulation), so that the surface temperature does not exceed 50 °C (in
accordance with DIN EN 563) and/or protect all accessible surfaces with a
protection plate.
Burners and associated components operated with steam or preheated oil that
were not insulated ex works upon delivery must also be insulated appropriately.
Nevertheless, ensure that all hazardous areas are equipped with clearly visible
warning signs to draw the personnel's attention to the risk of injury arising from
contact with hot surfaces.
Wear appropriate protective clothing when performing any work on the burner and
always comply with national accident prevention and safety regulations.
Warning! Risk of burns from hot surfaces!
The FGR line must be insulated at burners that are operated with recirculated flue
gas.
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Safety
1.10 Electrical Hazards
Warning! Risk of death from electric shock!
Damaged lagging or live components that are not covered correctly present a risk
of death from electric shock!
Warning! Risk of death from electric shock!
Carelessness can lead to an electric shock.
This is why when you work with electrical equipment, you must always first:
1. Disconnect each piece of equipment from the mains.
2. Secure it to prevent it from being switched back on.
3. Check that the equipment is de-energized.
4. Ground the equipment and short-circuit it.
5. Cover other components/equipment nearby that are energized.
6 Secure the danger zone, for example by blocking it off and/or putting up a
1.11 Emergency Procedures
conspicuous danger sign that no one can overlook.
In the case of danger:
Press the "Emergency stop button" of the plant and cut off the fuel supply!
1.12 Explosion Protection in Potentially Explosive Atmospheres (ATEX)
If the product is to be used in potentially explosive atmospheres, the plant
authorities must ensure that the product is integrated into an appropriate explosion
protection concept in compliance with directive 1999/92/EC.
1.13 Emergency Operation (Applies to Marine Plants Only)
SAACKE burners used in marine plants feature an emergency operation function
to meet the requirements of the corresponding classification societies. For more
information, please refer to the emergency operation documents that are part of
the plant documentation.
1.14 Protective Clothing
Warning!
When performing any work, always wear appropriate protective clothing that
complies with the accident prevention and safety regulations of the country you are
working in.
Transport
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Transport, Storage and Packing
TEMINOX®
GL
TMX029
2 Transport, Storage and Packing
The burner is delivered screwed onto a transport rack and secured with holding
straps.
Remove the transport rack before mounting the burner onto the heat generator.
2.1 Lifting Lugs
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Fig. 1: Lifting lugs
Note
Observe the information on weight and center of gravity in chapter "Dimensions /
Types".
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Transport, Storage and Packing
2.2 Safety Instructions for Transport
Warning! Risk of accidents during transport!
There is the risk of accidents during burner transport due to the heavy weight.
Do not stand under suspended loads.
Always use the appropriate aids when loading the burner (e.g. forklift or
crane).
Warning! Risk of injuries from hoists too weak for the load!
Hoists or lifting equipment that are too weak for the load can tear.
Always select hoists or lifting equipment with sufficient load bearing capacity.
Use only tested and reliable hoists and lifting equipment, such as:
– Shackles, e.g. according to DIN 82101.
– Sling chains, e.g. according to DIN 5687 Product Grade 8
Caution!
The improper use of means of transport and tools (e.g. forklift or crane) bears the
risk of damaging the burner or burner components.
2.3 Checking the Delivery
SAACKE products are packed and checked before they leave the factory.
When the product is delivered, first check whether the packaging is intact. This
would be the first indication that it has been transported correctly.
Check the product for transport damage.
2.4 Reporting Transport Damage
If damage has occurred during transport, follow these procedures:
Record the transport damage on the freight documents and take a
photograph and/or make a sketch of it.
Have the person responsible for the delivery (for example the truck driver)
confirm that the damage was noticed by signing the freight documents.
Report the transport damage right away to SAACKE or whichever company
supplied the product.
2.5 Instructions for Storage
Only store the burner on the pallet or in the crate that it was delivered on/in.
Store the burner on safe and firm ground.
Keep all components, especially electrical, pneumatic and hydraulic components,
dry, free of dust and at their correct temperature during storage. The relative
humidity must be below 80 %.
2021-06-22
Protect the burner with appropriate covering in the case of a long period of
inactivity. Preserve all metal surfaces.
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Transport, Storage and Packing
GL
2.6 Disposal of the Packaging
Dispose of all packaging correctly and ecologically.
When you do it, comply with the waste disposal regulations of the country in which
you are working.
2.7 Disposal of the Product
At the end of its service life the product must be disposed of correctly and
ecologically.
When you do it, comply with the waste disposal regulations of the country in which
you are working.
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Design and Function
TMX192
3 Design and Function
Note
A burner with standard equipment is shown. The equipment may vary depending
on the plant. As several burner head variants are possible, the presentation of the
burner head may differ.
Fig. 2: Burner components (1)
1 Right-hand maintenance cover
2 Servomotor for stabilizing disk retract mechanism
3 Driving linkage for stabilizing disk retract mechanism
4 Inspection glass
5 Component connection box / control box for optional integrated burner control system
6 Servomotor for oil flow controller / gas control damper
7 Return line pressure gauge (with manual shut-off fitting)
8 Power transmitter for oil flow controller / gas control damper
9 Gas control damper
10 Pressure monitor (L) for combustion air
11 Flame scanner (here: optional variant with 2 flame scanners)
12 Left-hand maintenance cover
13 Flange
14 Burner head
1
2
1
With TEMINOX G burners with burner head variant C02, a manual stabilizing disk retract mechanism is
installed as the standard. The servomotor is only available as an option for this variant.
2
Only TEMINOX GL (dual-fuel burner)
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Design and Functi
on TEMINOX®
GL
TMX193
Fig. 3: Burner components (2)
1 Ignition valves (here: manual shut-off fitting in open position)
2 Oil fittings block (see separate figure)
3 Driving linkage for air control dampers
4 Servomotor for air control dampers
5 Manual shut-off fitting supply line / return line (mechanically coupled) (here: open position)
6 Oil flow controller
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Design and Function
TMX254
Burner with Controlled Primary Gas (optional3)
Fig. 4: Burner with controlled primary gas4
1 Primary gas control damper
2 Servomotor for primary gas control damper
3
Standard with burner head variant C03
4
Oil fittings and component connection box are hidden for a better overview
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Desig
n and Function TEMINOX®
GL
TMX015
Oil Fittings Block
Fig. 5: Oil fittings block5
1 Rapid shut-off valve supply line
2 Rapid shut-off valve control line supply line
3 Dirt trap
4 Rapid shut-off valve control line return line
5 Rapid shut-off valve return line
6 Pressure monitor (H)
7 Pressure monitor (L)
8 Pressure gauge for supply flow pressure (with manual shut-off fitting)
Not illustrated: Manual shut-off fitting supply line / return line (see figures above)
Note
Depending on the arrangement of the ignition medium and fuel fittings, the oil
fittings block can have a laterally inversed design.
5
The example shows a monoblock burner, the duoblock burner has a similar design
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Design and Function
TMX194
Position of the Rating Plate and the Plate for Variant Designation
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Fig. 6: Position of the rating plate and the plate for variant designation
1 Rating plate and plate for variant designation
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Construction of the Refractory Brickwork
TEMINOX®
GL
4 Construction of the Refractory Brickwork
Before the burner can be mounted on the heat generator, refractory brickwork must
be constructed in keeping with the specifications in the present chapter.
The fireproof material for the refractory brickwork should have a AL
content of
2O3
at least 60 % and a spalling resistance of at least 15.
Warning!
The refractory brickwork must be parallel to the burner mounting plate and at right
angle to the center line of the burner, as shown in the figure.
With this burner head variant
please continue with chapter “Burner Head Variant C01 / C03”.
With this burner head variant
please continue with chapter “Burner Head Variant C02”.
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Construction of the Refractory Brickwork
TMX053
W
4.1 Burner Head Variant C01 / C03
Fig. 7: Refractory brickwork
Dimensions in mm
Burner size
W
Corrugated tube W Plain tube
50
70 475 470
100 480 475
140 480 475
200 480 475
280 495 490
≥130
≥130
and
≤160
X
Monoblock
burners
475 -
X
Duoblock
burners
R3
See chapter “Dimensions /
Types”, section “Burner
Mounting Plate”, dimension
MBP1 (monoblock burners) /
DBP1 (duoblock burners)
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Construction of the Refractory Brickwork
GL
4.2 Burner Head Variant C02
TMX043
X
burners
X
burners
W
1
1
TEMINOX®
Fig. 8: Refractory brickwork
1 Ceramic fibre mat (see chapter “Mounting Instructions”)
Dimensions in mm
Burner size
50 110 470 -
70 130 490 485
100 145 510 505
140 165 525 520
200 190 550 545
280 215 575 570
W
Monoblock
Duoblock
R3
See chapter “Dimensions / Types”,
section “Burner Mounting Plate”,
dimensions
MBP1 (monoblock burners) /
DBP1 (duoblock burners)
Transport
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GL Mounting Instructions
5 Mounting Instructions
Warning! Risk of injury and property damage due to the weight of the burner
and the fan!
For all the work described in the following, always follow the instructions and safety
instructions in the chapter "Transport, Storage and Packaging" before starting with
any of the tasks described here!
Caution! Faulty mounting of the burner possible!
The correct construction of the refractory brickwork (refer to the chapter entitled
"Construction of the Refractory Brickwork") is a requirement for mounting the
burner.
Note
Observe section “Burner Mounting Plate” (chapter “Dimensions / Types“).
Caution!
There may still be a small amount of oil from the pressure test in the oil-carrying
lines. Keep an oil drip tray ready during mounting and dispose of any oil correctly
and ecologically.
Warning! Health hazard due to ceramic fiber material!
Sealing cords and fiber plates for sealing contain ceramic high-temperature mineral
fibers, which may be a health hazard in the case of direct contact or if fiber dust is
inhaled. When handling sealing cords or fiber plates, wear appropriate protective
clothing (overall that fits loosely on your throat and wrists, gloves, safety goggles
with side shields, FFP2 respirators).
Caution!
The heat generator is subject to thermal expansion. Therefore flexible connectors
must be fitted between all fixed lines and ducts and the burner. When connecting
the flexible connectors, note the direction of the expansion.
5.1 Mounting the Burner
Note
With this burner head variant
please wind the supplied ceramic fiber mat around the thinner, cylindrical part of
the burner head before installing the burner (see chapter “Construction of the
Refractory Brickwork”)
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Mounting Instructions
TEMINOX®
GL
TMX049
Caution! Faulty mounting of the burner possible!
Take into consideration the entry position of the combustion air when mounting the
burner: In the figure, position 0° is shown as an example. This position differs
depending on the plant configuration!
In addition, please have in mind that that gas connection module must always be
in position 0°, independent of the plant configuration.
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Fig. 9: Mounting the burner
1 Burner mounting plate
2 Stud screw
3 Gasket (fiber plate)
4 Flange (burner)
5 Washer
6 Hexagonal nut
Caution!
Sealing cord and ceramic fiber plates shrink by up to 15 % during commissioning
due to the effects of the temperature. Therefore retighten all of the mounting
screws after the burner has been commissioned.
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