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Contents

  · Edition 09.22 · EN · 03250523

DE, EN, FR, NL, IT

, ES, DA, SV

, NO, PT

, EL, TR, CS, PL, RU, HU – www

.docuthek.com

Burners for gas ZIC, ZICW

1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 Checking the usage . . . . . . . . . . . . . . . . . . . . . 2
3 Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

4 Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

5 Preparing commissioning. . . . . . . . . . . . . . . . . 6
6 Commissioning  . . . . . . . . . . . . . . . . . . . . . . . . 8

7 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . 9

8 Assistance in the event of malfunction  . . . . . . 11
9 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . 12

10 Technical data  . . . . . . . . . . . . . . . . . . . . . . . 12
11 Logistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
12 Disposal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
13 Declaration of Incorporation  . . . . . . . . . . . . . 14
14 Certification  . . . . . . . . . . . . . . . . . . . . . . . . . 14

1 sAFetY

1.1 Please read and keep in a safe place

 Please read through these instructions care-

fully before installing or operating. Following the installa-
tion, 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. 

1.2 explanation of symbols

 = Action 

 

= Instruction

1.3 Liability

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

1.4 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.

1.5 Conversion, spare parts

All technical changes are prohibited. Only use OEM 

spare parts.

oPeRAtInG InstRUCtIons

Summary of Contents for ZIC 165

Page 1: ...be installed and commissioned in accordance with the regulations and standards in force These instructions can also be found at www docuthek com 1 2 Explanation of symbols 1 2 3 a b c Action Instruction 1 3 Liability We will not be held liable for damage resulting from non observance of the instructions and non com pliant use 1 4 Safety instructions Information that is relevant for safety is indic...

Page 2: ...butane butane M Propane propane butane butane with mixer L Low calorific value gas L Torch R Reduced capacity X X mm length of steel tube as of furnace flange L1 X X mm distance from furnace flange to front edge of burner head L2 X Burner head identifier XE Heat resistant version A Z Construction stage H High temperature version 2 3 Part designations 1 3 5 9 2 6 4 7 8 1 Burner insert 2 Gas housing...

Page 3: ...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 3 4 5 Place the burner insert in such a way that the in sulators are protected against damage No burner extension 1 2 Install the ceramic tube centrally and free of me chanical stress 3 4 Ce...

Page 4: ...brück Germany Attach the ceramic tube type label 4 5 3 4 Air connection gas connection ZIC GA LA ZICW GA LA Type Gas connec tion GA Air connec tion LA ZIC 165 Rp 1 1 2 DN 100 ZIC 200 Rp 2 DN 150 ZICW 165 Rp 1 1 2 DN 150 ZICW 200 Rp 2 DN 200 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 vi...

Page 5: ...e 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 Z Flame rod I Install the ionization cable well away from mains cables and interference from electromagnetic sources and avoid external electrical interference...

Page 6: ...ned personnel If the burner does not ignite even though 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 au tomatic burner control unit operating instructions μA Z I The burner must only be ignited at low f...

Page 7: ... air compensation The combustion air pressure pair must be increased in hot air operating mode lambda constant 0 50 100 150 200 250 300 350 400 450 500 550 600 100 150 200 300 250 Air temperature C Air pressure p air The gas pressure is increased by 5 10 mbar The total burner capacity Pgas rises as the air tem perature increases 0 50 100 150 200 250 300 350 400 450 500 550 600 100 110 120 Air teme...

Page 8: ...and air pressure of the main burner 6 COMMISSIONING 6 1 Igniting and adjusting the burner WARNING Ensure adequate ventilation of the furnace chamber before each burner start The burner body will become hot during operation with preheated combustion air Provide protection against accidental contact as required 1 All valves of the installation must be checked for tightness before ignition 6 2 Settin...

Page 9: ...must be cooled with a low air volume see page 9 6 6 Cooling air 6 6 Cooling air While the burner is switched off and depending on the furnace temperature there must be a certain air flow for cooling the burner components 600 500 700 800 900 1000 1100 1200 1300 1400 0 12 14 8 4 10 6 2 16 BIC ZIC BIC ZIC E Tfurnace C of cooling air also BIOW ZIOW Diagram the cooling air percentage specified in the d...

Page 10: ... 4 or insulator 3 is damaged replace the electrode Before changing the electrode measure the total length L 5 Connect the new electrode with the spark plug 1 using the dowel pin 2 6 Adjust spark plug and electrode to the measured total length L 7 8 Turning the spark plug makes it easier to feed the electrode into the burner insert 7 2 Checking the burner Removing and installing burner insert ZICW ...

Page 11: ...ust the gas and air supply so that the burner is always operated with excess air otherwise CO will form in the furnace chamber CO is odourless and poisonous Conduct a flue gas analysis 18 Produce a maintenance report 8 ASSISTANCE IN THE EVENT OF MALFUNCTION DANGER Electric shocks can be fatal Before working on possible live components ensure the unit is disconnected from the power supply DANGER Ri...

Page 12: ...SORIES 9 1 Ceramic paste For avoiding cold setting on screw connec tions after replacing burner components Order No 050120009 9 2 Adapter set 8 8 For connecting ZIC to NPT ANSI connections Burner Adapter set Order No ZIC 165 BR 165 NPT 74922636 ZIC 200 BR 200 NPT 74922637 Adapted set for ZICW on request 9 3 Nozzle set Available on request for connecting integrated pilots to NPT threads 10 TECHNICA...

Page 13: ...external forces blows shocks vibration Transport temperature see page 12 10 Technical data Transport is subject to the ambient conditions de scribed Report any transport damage on the unit or packaging without delay Check that the delivery is complete Storage Storage temperature see page 12 10 Technical data Storage is subject to the ambient conditions described Storage time 6 months in the origin...

Page 14: ...lled RoHS II 2011 65 EU The partly completed machine may only be com missioned once it has been established that the machine into which the product mentioned above is to be incorporated complies with the provisions of the Machinery Directive 2006 42 EC Elster GmbH 14 CERTIFICATION 14 1 Eurasian Customs Union The products ZIC meet the technical specifications of the Eurasian Customs Union 14 2 Chin...

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