Hauck BBG BETA Series Instruction Manual Download | Manualshive

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03250560 Edition 12.11

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© 2011 Elster GmbH

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 opera-
tor. This unit must be installed and commissioned
in accordance with the regulations in force. These
instructions can also be found at www.docuthek.com.

Explanation of symbols
• , 1 , 2 , 3

... = Action

▷

= Instruction

Liability

We will not be held liable for damages 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.

Transport

On receipt of the product, check that the delivery is
complete (see Part designations). Report any trans-
port damage immediately.

Storage

Store the product in a dry place. Ambient tempera-
ture: see Technical data.

Contents

Operating instructions

Translation from the German

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Ionization pilot burners

ZAI, ZMI, ZKIH

Checking the usage . . . . . . . . . . . . . . . . . . . . . 2
Setting the gas type. . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Tightness test . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . 7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Replacing the electrodes . . . . . . . . . . . . . . . . . . 8

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Technical data. . . . . . . . . . . . . . . . . . . . . . . . . 11

Declaration of Incorporation. . . . . . . . . . . . . 12

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Summary of Contents for BBG BETA Series

Page 1: ...instructions are intended to serve as guidelines covering the installation operation and maintenance of Hauck equipment While every attempt has been made to ensure completeness unforeseen or unspecified applications details and variations may preclude covering every possible contingency WARNING TO PREVENT THE POSSIBILITY OF SERIOUS BODILY INJURY DO NOT USE OR OPERATE ANY EQUIPMENT OR COMPONENT WIT...

Page 2: ... AND INSPECTION Upon receipt check each item on the bill of lading and or invoice to determine that all equipment has been received A careful examination of all parts should be made to ascertain if there has been any damage in shipment WARNING This equipment is potentially dangerous with the possibility of serious personal injury and property damage Hauck Manufacturing Company recommends the use o...

Page 3: ...w c 27 7 27 7 27 7 27 7 mbar 68 9 68 9 68 9 68 9 Gas Inlet Pressure in w c 5 8 1 5 11 8 2 9 mbar 14 4 3 7 29 4 7 1 Flame Length ft 14 0 15 0 17 0 25 0 m 4 3 4 6 5 2 7 6 Flame Diameter ft 4 0 4 5 5 0 5 0 m 1 2 1 4 1 5 1 5 NOTES 1 Capacities based on Natural Gas with HHV of 1034 Btu ft3 Standard and LHV of 10 21 kWh nm 3 Metric 0 59 S G and a stoichiometric ratio of 9 74 1 with burner firing into ch...

Page 4: ...tile mounting flange 3 Place the tile mounting gasket on the furnace studs 4 Wrap tile with one layer of 1 25mm fiber rated for a higher temperature than the furnace Secure fiber wrap with tape or twine to compress the ceramic fiber wrap and retain the fiber during installation 5 Install the burner tile on the furnace shell and secure with appropriate lock washers and nuts 6 Place the tile cushion...

Page 5: ...e burner port 7 Form the burner port to dimensions per Figure 3 or Figure 4 using wood or metal mandrels centered on mounting plate studs Mandrel dimensions must include sufficient draft or taper for easy removal 8 For installations where the furnace wall is thicker than the burner port length a port flare must be provided at D If required a maximum straight extension of 6 152mm may be provided at...

Page 6: ...Page 6 BBG 9 Figure 1 Burner Installation With Refractory Tile Figure 2 Burner Installation With Alloy Tile W7324 NOT TO SCALE W7783 NOT TO SCALE ...

Page 7: ...Page 7 BBG 9 Figure 3 Customer Supplied Refractory Port Figure 4 Custom Installation For Thick Wall or Angle X4195 NOT TO SCALE X8427 NOT TO SCALE ...

Page 8: ...G_124 Forced Air Premix Pilot Install the air fuel premix outlet of the pilot manifold assembly to the pilot assembly Connect pilot air and gas to the appropriate connections on the pilot manifold NOTE All piping must be properly supported and aligned to avoid stresses on the burner and associated equipment Hauck recommends that flexible connections be used on all air and fuel lines to isolate the...

Page 9: ...V scanner must be relocated during installation due to interferences with piping etc the alternate ports can be utilized as follows see Figure 5 a Remove the pipe plugs or caps from the alternate port connections b Remove the ceramic fiber insulation from the ports c Insert a rod into each port and gently tamp on the plug of high temperature cement to dislodge the plug Use caution not to chip away...

Page 10: ... port 2 Connect the high voltage ignition wire from the transformer to the spark plug on the gas pilot igniter A snap on ignition type connector is recommended 3 See attached IPG literature for detailed operating instructions For ZMI Gas Pilot Ignited Burners BBG_304 E through _312 E 1 Ensure that the ZMI gas pilot is threaded tightly into the pilot port 2 See Dimensional Drawings for the proper i...

Page 11: ...t adjustment clockwise rotation decreases gas flow and counterclockwise rotation increases gas flow Replace the hex screw cap when adjustment is complete 8 Energize the ignition transformer and supply air and then gas to the pilot manifold Observe the pilot flame through one of the observation ports on the side of the burner Adjust the pilot gas limiting valve and pilot air butterfly valve if nece...

Page 12: ...ition transformer 6 If the spark is adequate re install spark igniter into burner If the spark is weak or absent adjust the spark gap as shown in Figure 7 and repeat until adequate spark is obtained 7 See dimensional drawing for the correct insertion depth of the spark igniter Figure 7 Air Cooled Spark Igniter Gap Adjustment G INITIAL SETUP BBG burners typically operate with automatic control syst...

Page 13: ...perature hot components and exhaust gas Verify proper installation and condition of gaskets seals In addition to heat and noise burning paint solvents or sealing material exhaust leaks carbon monoxide CO and other by products of the combustion process may be present at or near the combustion equipment Always wear appropriate clothing and personal protective gear gloves ear plugs safety glasses res...

Page 14: ...ted to air flows if an air orifice meter is not available Static gas pressure is very low and should not be used to extrapolate flows 9 Drive the burner to the low fire position and verify that the settings are consistent Repeat steps 6 through 9 as necessary until high and low fire settings remain constant 10 Lock all control motor linkage or direct couplings in place and return all control syste...

Page 15: ... baffle use the following procedure 1 Disconnect fuel line 2 Loosen the backplate bolts 3 Remove burner backplate and gas tube Be careful not to damage the internal body insulation BBG 3000 series For 1000 series stainless steel baffle a Remove the brass nuts on the baffle retaining clips inside the burner b Remove the old stainless steel baffle and replace with the new part making sure it seats a...

Page 16: ...areful not to damage the internal body liners BBG 3_00 models d For 1_00 series models stainless steel baffle 1 Remove 3 1 4 hex head cap screws and baffle from gas tube 2 Place new baffle on gas tube 3 Replace hex screws and tighten e For 2_00 and 3_00 series models refractory baffle 1 If baffle has remained attached to gas tube separate baffle from tube 2 If baffle has remained inside burner aft...

Page 17: ...nting plate studs 6 Remove the existing burner tile from the furnace wall and clean the tile port opening 7 Inspect the furnace wall insulation or refractory in the area surrounding the tile and repair any damage 8 Replace the burner tile mounting gasket 9 Replace the tile cushion gasket into the recess in the burner tile 10 Mount the new burner tile 11 Replace tile mounting nuts and tighten 12 Re...

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Page 28: ...s 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 Transport On receipt of the...

Page 29: ...ctrode 2 Adapter for ionization electrode 3 Ionization electrode 4 Ignition electrode 5 Air slide valve 6 Gas connection 7 0 7 mm gas nozzle for LPG 8 Cone olive only for ZAI K 9 Cap screw only for ZAI K 10 Enclosed documentation operating instructions Gas connection see type label D Osnabrück Germany ZAI K ZMI Type code ZMI Ionization pilot burner with forced air supply and one electrode 16 25 Bu...

Page 30: ...e of gas retrofit the burner for its use 0 7 2 2 5 6 2 3 4 1 Gas nozzle Ø 0 7 mm 0 028 for LPG Order gas nozzle for town gas Ø 1 8 mm 0 07 separately Order No 74472880 0 7 2 2 5 6 2 3 4 1 Gasdüse 0 7 mm 0 028 für Flüssiggas Gasdüse für Stadtgas 1 8 mm 0 07 separat bestellen Best Nr 74472880 Gas nozzle Ø 0 7 mm 0 028 for LPG Order gas nozzle for town gas Ø 1 8 mm 0 07 separately Order No 74472880 Z...

Page 31: ...In the case of higher inlet pressures insert a gas restrictor orifice Ensure air intake is not obstructed The ZAI has bare electrodes and no protective flame tube Protective tube see page 10 Acces sories WARNING Risk of injury Observe the projecting ionization electrode 2 mm 1 2 9 8 Attach the burner using the two holes on the fastening lug Connect the pilot gas line with 8 mm tube When tightening...

Page 32: ... Accessories 1 2 2 3 4 Connect the pilot gas line with Rp and the air line with Rp For connecting pilot gas and air lines with NPT thread order the adapter set see page 10 Ac cessories Wiring DANGER Electric shocks can be fatal Before working on possible live components ensure the unit is discon nected from the power supply For the ionization and ignition cables use unscreened high voltage cable F...

Page 33: ...n ionization and ignition cables securely WARNING Electric shocks can be fatal Live components in the housing connection chamber 7 Replace seal and cover and screw into place 8 Connect the PE wire for burner ground to the burner Tightness test DANGER Risk of explosion and poisoning To ensure that there is no danger resulting from a leak check the gas connections on the burner for leaks immediately...

Page 34: ...the manual valve 3 Ignite the burner via the automatic burner control unit 4 Adjust the burner Set the ionization current by adjusting the air volume DANGER Risk of explosion in case of CO being formed in the furnace chamber An incorrect change of the burner settings may change the gas air ratio and lead to unsafe operating conditions CO is odourless and poisonous ZAI 5 The air slide is open on de...

Page 35: ...ozzles for dirt Replacing the electrodes ZAI 7 8 6 9 Loosen the screw of the retaining plate by turning it approx 3 turns Groove for correct posi tioning of the electrode 9 When slid ing in the electrodes ensure they are aligned For correct positioning slide in the electrodes until the projection of the retaining plate engages into the groove 10 Once the electrodes have been positioned hand tighte...

Page 36: ...tion on a smooth working surface 1 1 2 10 11 2 Loosen the screws a turn Replace the electrodes one after the other 22 mm 2 mm 6 mm 14 12 13 16 15 17 1 2 1 2 Adjust the spacing of the electrode tips Slide the rear guide lug as far as it will go in the direction of the burner housing Hand tighten the screw Align the ignition electrode 1 and the ionization electrode 2 22 mm 2 mm 6 mm 14 12 13 16 15 1...

Page 37: ...5455149 75448031 D 1 78 0 070 75455148 B Natural gas G LPG D Town gas coke oven gas Adapter set For connecting the pilot burner ZKIH to pilot gas and air lines Comprising one adapter with 1 4 18 NPT internal thread and one adapter with 1 2 14 NPT internal thread 74923430 1 Gas restrictor orifice Rp 1 4 For operation of the ZKIH at the following inlet pressures Inlet pressure in mbar Hole mm Order ...

Page 38: ...ypes natural gas LPG gaseous and coke oven gas other gases on request For cold air only Flame control with ionization electrode Ignition direct spark ignition 5 kV ignition trans former Ignition electrode adapter interference suppressed Housing AlSi Flame tube heat resistant steel Max temperature at the tip of the flame tube 1000 C 1832 F 900 C 1652 F for lambda 1 ZKIH Capacity approx 2 to 5 kW Ga...

Page 39: ...ed Annex I Articles 1 1 3 1 1 5 1 3 2 1 5 1 1 5 2 1 5 7 The special technical documentation pursuant to Annex VII B has been produced and will be transmit ted to the competent national authorities in electronic form on request Furthermore the partly completed machine complies with all the provisions of the following Directives Electromagnetic Compatibility Directive 2004 108 EC The following harmo...

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