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Contents

  · Edition 09.22 · EN · 03250472

DE, EN, FR, NL, IT

, ES, DA, SV

, NO, PT

, EL, TR, CS, PL, RU, HU – www

.docuthek.com

Burners for gas BIo, BIoA, BIoW

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

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

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

5 Preparing commissioning. . . . . . . . . . . . . . . . . 6
6 Commissioning  . . . . . . . . . . . . . . . . . . . . . . . . 9

7 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . 11

8 Assistance in the event of malfunction  . . . . . . 13
9 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . 14

10 Technical data  . . . . . . . . . . . . . . . . . . . . . . . 15
11 Logistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
12 Disposal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
13 Declaration of Incorporation  . . . . . . . . . . . . . 16
14 Certification  . . . . . . . . . . . . . . . . . . . . . . . . . 16

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 BIO 100

Page 1: ...st 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 in...

Page 2: ...s D Coke oven gas town gas G Propane propane butane butane M Propane propane butane butane with mixer L Low calorific value gas F biogas 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 A Z Construction stage B With purge air bore holes H High temperature version Z Special ver...

Page 3: ...3 4 Flat flame burner block For industrial furnaces and kilns and for burning in an open combustion chamber Control High Low High Low Off continuous lim ited turndown Type of burner head K Capacity range 40 100 3 5 Burners with attachment tube Position of the burner head near the interior furnace wall L2 LO 50 mm L2 LO 50 mm LO 1 Do not fit the attachment tube 1 directly in the furnace wall Furnac...

Page 4: ... units to prevent mechanical stress or transmission of vibration Ensure that the gaskets are undamaged DANGER Risk of explosion Ensure the connection is air tight On delivery the threaded gas connection is situated opposite the air connection it can be rotated in increments of 90 3 10 Connection to ANSI NPT An adapter set is required for connection to ANSI NPT see page 14 9 Accessories Type Gas co...

Page 5: ...GER Electric shocks can be fatal Before working on possible 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 Z I Flame rod I Install the ionization cable well away from mains cables and interference from electrom...

Page 6: ...ischarge the test volume into the furnace chamber DANGER Risk of poisoning Open 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 The burner must only be commissioned by authorized trained personnel If the burner does not ignite even though the auto matic burner contro...

Page 7: ... pres sure loss in the furnace combustion chamber Add positive pressures or subtract negative pressures The differential gas pressure Δpgas measured on the integrated gas measuring orifice is independent of the furnace chamber pressure WARNING If reducing fittings or manual valves with internal thread are installed Δpgas on the integrated gas measuring orifice is reduced Reducing fitting with inte...

Page 8: ...The burner must only be ignited at low fire rate between 10 and 40 of the rated capacity Qmax see page 2 2 1 Type label 5 Reduce the air supply on the air control valve and set the desired low fire rate e g using a limit switch or mechanical stop On air control valves with bypass the bypass orifice should be determined on the basis of the required flow rate and the existing supply pressure if requ...

Page 9: ...0 50 mbar Check flame stability and ionization current The gas and air pressure of the integrated pilot must be higher than the gas 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 protect...

Page 10: ... μA Z I 18 Monitor flame formation 19 Adjust the low fire rate settings if required 20If no flame is detected see page 13 8 Assis tance in the event of malfunction 6 3 Setting the high fire rate 1 Set the air and gas circuit of the burner to high fire while continuously monitoring the flame Avoid CO formation always operate the burner with excess air when starting up Burners without gas measuring ...

Page 11: ...igh fire several times while monitoring the pressure settings flue gas values and flame patterns 4 Remove the measuring devices and close off the test nipples tighten the grub screws 5 Block and seal the adjusting elements 6 Induce a flame failure e g by pulling the terminal boot off the flame rod The flame detector must close the gas safety valve and signal a fault 7 Switch the system on and off ...

Page 12: ...age the surface of the insulation Avoid the formation of dust 1 2 3 If the burner insert is dismantled the gas housing gasket will have to be renewed 4 Place the burner insert in a safe place Depending on the amount of dirt or wear replace the spark electrode flame rod and dowel pin during servicing see page 12 7 1 Checking the spark electrode and flame rod Check burner head for dirt and thermal c...

Page 13: ...nts ensure the unit is disconnected from the power supply DANGER Risk of injury Burner heads have sharp edges Burner inspection must only be performed by authorized trained personnel If no issues are found when checking the burner proceed to the automatic burner control unit and check for faults in accordance with the relevant operating instructions Fault Cause Remedy Burner does not function Valv...

Page 14: ...50120009 9 2 Adapter set 8 8 BIO 125 140 BIO 50 100 BIOA 65 For connecting burners BIO BIOA to NPT ANSI connections Burner Adapt er set Gas con nection Air con nection Order No BIO 50 BR 50 NPT 14 NPT 1 11 5 NPT 74922630 BIO 65 BR 65 NPT 14 NPT 1 11 5 NPT 74922631 BIOA 65 14 NPT Ø 1 89 75456281 BIO 80 BR 80 NPT 14 NPT 2 11 5 NPT 74922632 BIO 100 BR 100 NPT 1 11 5 NPT 2 11 5 NPT 74922633 BIO 125 BR...

Page 15: ...2 F BIOA up to 200 C 392 F BIOW up to 600 C 1112 F REACH Regulation applies to BIOW only Information pursuant to REACH Regulation No 1907 2006 Article 33 Insulation contains refractory ceramic fibres RCF aluminium silicate wool ASW RCF ASW are listed in the Candidate List of the European REACH Regulation No 1907 2006 10 1 REACH Regulation applies to BIOW only Information pursuant to REACH Regulati...

Page 16: ...lfilled 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 BIO meet the technical specifications of the Eurasian Customs Union 14 2 C...

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