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GB-4

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GB

F

NL

I

E

Insulating the ceramic tube

 

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

≥ 10 mm ≥ 

0.4

 in

A/B

20 mm

0.8 in

20 mm

0.8 in

 10 mm

 0.4

 in

 

Burner with extension:

A/B

≥ 10 mm ≥ 

0.4

 in

A/B

20 mm

0.8 in

20 mm

0.8 in

 10 mm

 0.4

 in

Installation on the furnace

 

When installing, always ensure that when the 

burner is mounted, it is sealed tightly on the 
furnace wall.

2

4

1

 5

3

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48-300/35

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Si-1500

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Attach the 

ceramic tube 
type label.

Air connection, gas connection

GA

LA

Type

Gas connection 

GA

Air connection  

LA

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 gas-
tight.

Connection to ANSI/NPT

 

An adapter set is required for connection to ANSI/

NPT, see page 12 (Adapter set).

Type

Gas connection 

GA

Air connection 

LA*

ZIC 165

1½ – 11.5 NPT

4.57"

ZIC 200

1½ – 11.5 NPT

6.72"

* 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

.

GA

LA

H

J

P

 

The nozzle set with NPT coupling is required for 

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

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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