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GB-12

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GB

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NL

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Assistance in the event of 
malfunction

 DANGER

Electric shocks can be fatal! Before working on 
possible live components, ensure the unit is discon-
nected from the power supply.
Risk of injury! Burner heads have sharp edges.
Fault-clearance must only be undertaken by author-
ized trained personnel.

 

If no fault is detected when checking the burner, 
proceed to the automatic burner control unit and 
check for faults in accordance with the relevant 
operating instructions.

 ? 

 

Faults

 ! 

 

Cause

  • 

 

Remedy

 ? 

  

Burner does not function?

 ! 

   Valves do not open.

  • 

 Check the voltage supply and wiring.

 !  

Tightness control signals a fault.

  • 

 Check the valves for tightness.

  • 

 Note the tightness control operating instructions.

 !  

Control valves do not move to low-fire position.

  • 

 Check the impulse lines.

 !  

Gas inlet pressure is too low.

  • 

 Check the filter for dirt.

 !  

Gas and air pressures on the burner are too low.

  • 

 Check the restrictors.

 !  

Automatic burner control unit signals a fault.

  • 

 Check the ionization cables and ionization cur-

rent.

  • 

 Check whether the burner is adequately 

 grounded.

  • 

 Note the automatic burner control unit operating 

instructions.

 ? 

 

Burner performs a fault lock-out after burn-
ing faultlessly in normal operation?

 !  

Incorrect gas and air flow rate settings.

  • 

 Check the gas and air pressures.

 !  

No ignition spark is created.

  • 

 Check the ignition cable.

  • 

 Check the voltage supply and wiring.

  • 

 Check whether the burner is adequately 

 grounded.

  • 

 Check the electrodes – see page 10 (Checking 

the ignition and ionization electrodes).

 !  

Automatic burner control unit signals a fault.

  • 

 Check the ionization cable.

  • 

 Measure the ionization current by connecting a 

micro-ammeter into the ionization cable: min. 
5 µA ionization current – stable signal.

+

 

μ

Z

I

 !  

Burner head dirty.

  • 

 Clean gas and air bore holes and air slots.

  • 

 Remove deposits on the burner head.

 WARNING

Risk of injury! Burner heads have sharp edges.

 !  

Excessive pressure fluctuations in the furnace 
chamber.

  • 

 Ask Elster Kromschröder for control concepts.

Accessories

Ceramic paste

Apply ceramic paste to the relevant screw connec-

tions after replacing any burner components in order 
to avoid cold-setting.
Order number: 05012009.

Adapter set

For connecting ZIC to NPT/ANSI connections.

Burner

Adapter set

Order No.

ZIC 165

BR 165 NPT

74922636

ZIC 200

BR 200 NPT

74922637

Nozzle set 

 

Available on request for connecting integrated 

ignition lances to NPT threads.

Summary of Contents for ZIC 165

Page 1: ... 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 11 11 The following chapters have been changed Checking the usage Installation Preparing commissioning Commissioning Technical data Logistics Declaration of Incorporation Operating instructio...

Page 2: ...pane butane Butane propane propane butane Low calorific value gas Coke oven gas town gas L R Ignition lance Reduced max connection rating 0 100 200 Length of burner extension mm none 100 200 35 135 235 Position of burner head mm 1 to 199 1E to 199E Burner head identifier High temperature version A F Construction stage Part designations 1 3 5 9 2 6 4 7 8 1 Burner insert 2 Gas housing gasket 3 Air h...

Page 3: ...e 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 3 2 1 4 5 Place the burner insert in such a way that the insulators are protected against damage No burner extension 7 6 9 8 10 Centre the ceramic tube Tighten in crosswise fashion Install the...

Page 4: ...500 Si 1500 y n a m r e G k c ü r b a n s O 8 1 0 9 4 D Attach the ceramic tube type label Air connection gas connection GA LA Type Gas connection GA Air connection LA ZIC 165 Rp 1 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...

Page 5: ...iscon nected 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 Z 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...

Page 6: ...furnace chamber volume before every ignition attempt If the burner does not ignite although the auto matic burner control unit has been switched on and off several times check the entire system After ignition monitor the flame and the gas and air pressure measured on the burner Measure the ionization current Switch off threshold see automatic burner control unit operating instruc tions µA Z I The ...

Page 7: ...all the effects caused by the equipment are known setting the burner using the pressure values is only approximate It is possible to set the burner precisely by measuring the flow rates or flue gas Restrictors The air volume required for the low fire rate at a given air pressure is determined by the ignition position of a butterfly valve a bypass hole in the air valve or an external bypass with re...

Page 8: ... 35 g l 1 2 g l Loosen the screws 2 turns Ignition lance pgas 30 50 mbar pair 30 50 mbar Check flame stability and ionization current The gas and air pressure of the ignition lance must be higher than the gas and air pressure of the main burner Commissioning Igniting and adjusting the burner WARNING Ensure adequate ventilation of the furnace chamber before each burner start The burner housing will...

Page 9: ...the burner is always oper ated with excess air otherwise CO will form in the furnace chamber CO is odourless and poisonous Conduct a flue gas analysis Measure the gas and air flow rates if possible Determine the lambda value and re adjust the settings if required Tightness test DANGER To ensure that there is no danger resulting from a leak check the gas connections on the burner for leaks immediat...

Page 10: ...ents are hot 1 Check the ionization and ignition cables 2 Measure the ionization current The ionization current must be at least 5 µA and must not vary μA Z I 3 Disconnect the system from the electrical power supply 4 Shut off the gas and air supply do not change the restrictor settings Checking the ignition and ionization electrodes 6 5 Ensure that the electrode length does not change 7 Remove di...

Page 11: ...t Tighten the burner insert with max 37 Nm 27 3 lb ft 25 Connect the system to the electrical power sup ply 26 Open the gas and air supply 27 28 Set the burner to low fire and compare the pres sure settings to those stated in the acceptance report 29 Set the burner to low and high fire several times while monitoring the pressure settings flue gas values and flame patterns DANGER Risk of explosion ...

Page 12: ...ntrol unit operating instructions Burner performs a fault lock out after burn ing faultlessly in normal operation Incorrect gas and air flow rate settings Check the gas and air pressures No ignition spark is created Check the ignition cable Check the voltage supply and wiring Check whether the burner is adequately grounded Check the electrodes see page 10 Checking the ignition and ionization elect...

Page 13: ...Weight kg ZIC 165 23 ZIC 200 34 6 Shortest overall length WARNING applies to ZICW only Information pursuant to REACH Regulation No 1907 2006 Article 33 Insulation contains refrac tory ceramic fibres RCF aluminium silicate wool ASW RCF ASW are listed in the Candidate List of the European REACH Regulation No 1907 2006 Logistics Transport Protect the unit from external forces blows shocks vibration O...

Page 14: ...chnischen Unterlagen gemäß Anhang VII B zusammenzustellen Sandra Runde is authorized to compile the relevant technical documentation according to Annex VII B Die speziellen technischen Unterlagen gemäß Anhang VII B wurden erstellt und werden der zuständigen nationalen Behörde auf Verlangen in elektronischer Form übermittelt The relevant technical documentation has been compiled in accordance with ...

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