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operation manual for the authorized specialist dual-fuel burner ek 6 7 8 9 gl-e gl-eu 01/2006 102.880.2028

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overview inhalt contents overview overview contents 2 important information warranty product description 3 technical data 4 dimensioned drawings 14 start-up mode oil operating mode general safety functions 19 gas start-up mode gas operating mode 20 fuel-air compound control gas valves and instruments group 21 hydraulic diagram l-e gl-e burner ek 6 ek 9 22 hydraulic valves and instruments group 23 burner head settings 24 mounting to boiler electrical connection presetting 29 boiler lining for burner gl-r/e 30 boiler lining for burner gl-ru/eu 31 gas connection 32 oil connection oil pressure control feed 33 return nozzle rod type rdn burner type ek 6 34 nozzle selection type w2-50° 35 return nozzle rod rdg 1250 burner ek 7 ek 9 36 nozzle selection for sonic 37 checking procedure 38 gas pressure gas/air flow rate adjusting procedure 39 elektronic burner control with electronic compound controller 40 flame detecting system type flw 05 41 servomotor type sad 15.0 42 electrical actuator stm 40 43 starting the bcs etamatic vms/fms electronic compound controller 44 oil pressure switch option air pressure switch 45 gas pressure switch 46 automatic furnace controller lfl 1 lgk 16 regulator ks 92 47 flame monitor sensor current measurement 48 description 49 basic construction 50 gas pressure regulator 51 double solenoid valve type dmv-d 53 gas filter safety vent valve 54 combined ignition gas controller 55 fan impeller 56 burner maintenance 57 exhaust gas test 58 trouble shooting instructions 59 operating trouble 61 system diagram 62 operation operation start-up installation installation start-up start-up start-up adjusting instructions adjusting instructions adjusting instructions adjusting instructions operation adjusting instructions gas valves and instruments group adjustment adjustment servicing instructions 2

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overview important information warranty product description important information the burners of type ek 6 7 8 9 gl-e/eu have been designed for the combustion of natural gas or light fuel oil el the burners should be installed and taken into operation by qualified personnel only who will be responsible for the proper performance of this work in accordance with the applicable regulations and guidelines only duly authorized specialists should be entrusted with the installation of the gas system any repair work on monitors limiters and automatic furnace controllers and on the other safety facilities are allowed to be done only by the manufacturers themselves or specialists authorized by them original parts should only be exchanged by a duly qualified specialist standards and regulations the following standards should be observed in the interest of a safe easyon-the-environment and energy-saving operation of the burner en 676 din 4788 en267 din4787 vde 0116 gas burners with blower oil atomizer burners electrical equipment of furnace screwed unions of metal used in gas lines should be fitted with approved sealing elements prior to taking the burner into operation make sure to vent the gas line but this should in no case be done through the furnace place of installation the burner must not be operated in rooms containing aggressive vapours e.g spray perchloroethylene hydrocarbon tetrachloride solvent etc or tending to heavy dust formation or high air humidity adequate ventilation must be provided at the place of installation of the furnace system to ensure a reliable supply with combustion air maintenance the furnace system should be serviced at least once a year by an authorized specialist it is recommended to conclude a maintenance agreement to this effect warranty manufacturer will not accept any warranty if the operating instructions have not been duly observed in the start-up and maintenance of the burner and damages have been caused by improper installation incorrect adjustment unauthorized interference or operating errors product description the burners of types ek 6 ek 7 ek 8 ek 9 gl-e/eu are dual-fuel burners for the combustion of technical fuel gases dvgw-g 260/1 gasfamily 2 and 3 or light fuel oil to the din 51603-1 in the gl-eu version the burners are fitted alternatively with a delta burner head designed for low nox combustion the burners are equipped with combustion air fan and air pressure switch with test key windbox with servomotor for the dampers oil pressure atomizer with oil high-pressure pump nozzle rod return nozzle and oil hydraulics block with pressure switches valves and control shaft pressure hoses and gas burner system with gas lance head and gas damper with servomotor gas ignition burner electrical igniter in oil firing mode the burners are designed for operation with an electronic compound controller note it is recommended to take precautions prior to changing over the burner from oil to gas mode to prevent the oil in the nozzle and nozzle rod from getting cracked in the case of longer periods of gas operation it will be necessary to empty the nozzle rod before starting the burner according to din 4755 and din 4756 the user must be instructed in the operation of the burner for the installation of a gas furnace system care should be taken to observe din 4756 trgi technical regulation on gas installations the worksheets of dvgw german association of the gas and water sector and the local furnace construction regulations applicable in the country for the installation of an oil furnace system care should be taken to observe din 4755 trbf technical regulation on combustible liquids and the local furnace construction regulations applicable in the country 3

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technical data sheet technical data monoblock dual-fuel burner ek 6.170 200 gl-e ek 6.170 200 gl-e technical data burner output fuel flow rate operating mode type of fuel burner control box flame sensor fan motor pump unit gear output pressure nozzle rod nozzle oil hoses external connection gas connection gas inlet butterfly valve actuator ignition transformer ignition burner weight operating range ek 6.170 200 gl-e 6.170 g 6.170 l 6.200 g 6.200 l 6.170 gl-e 224 1675 kw 43 150 kg/h fully modulating natural gas and heavy fuel oil bcs lfl1 lgk16 qra 2 qra 53/55 400 690 v 50hz 3,0 kw 6,4 a 2800 min-¹ smg 1945 0,75 kw 520 l/h 30 bar rdn thread 7/8 dn 16 x 1500 r 1/2 dn 80 pn 16 dn 80 d 40-80 mm sad 15 stm 40 mm1004 za20 140 zm20-14 and ebi zb12 160 kg 6.200 gl-e 265 2077 kw 56 193 kg/h fully modulating natural gas and light oil el bcs lfl1 lgk16 qra 2 qra 53/55 400 690 v 50hz 3,0 kw 6,4 a 2800 min-¹ smg 1945 0,75 kw 520 l/h 30 bar rdn thread 7/8 dn 16 x 1500 r 1/2 dn 80 pn 16 dn 80 d 40-80 mm sad 15 stm 40 mm1004 za20 140 zm20-14 and ebi zb12 160 kg air temperature 20°c test values according to en 676 and en 267 din 4787 at 171 m above sea level pressure in combustion chamber [mbar 25 20 15 10 5 0 0 500 1000 1500 2000 2500 qf burner output [kw 03/05 no 102.880.5196 4

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technical data sheet technical data monoblock dual-fuel burner ek 6.170 200 gl-eu ek 6.170 200 gl-eu low-nox with delta-mixing unit low-nox with delta-mixing unit technical data burner output fuel flow rate operating mode type of fuel burner control box flame sensor fan motor pump unit gear output pressure nozzle rod nozzle oil hoses external connection gas connection gas inlet butterfly valve actuator ignition transformer ignition burner weight operating range ek 6.170 200 gl-eu 6.170 g 6.170 l 6.200 g 6.200 l 6.170 gl-eu 249 1454 kw 42 141 kg/h fully modulating natural gas and light oil el bcs lfl1 lgk16 qra 2 qra 53/55 400 690 v 50hz 3,0 kw 6,4 a 2800 min-¹ smg 1945 0,75 kw 520 l/h 30 bar rdn thread 7/8 dn 16 x 1500 r 1/2 dn 80 pn 16 dn 80 d 40-80 mm sad 15 stm 40 mm1004 za20 140 zm20-14 and ebi zb12 160 kg 6.200 gl-eu 279 1710 kw 50 163 kg/h fully modulating natural gas and light oil el bcs lfl1 lgk16 qra 2 qra 53/55 400 690 v 50hz 3,0 kw 6,4 a 2800 min-¹ smg 1945 0,75 kw 520 l/h 30 bar rdn thread 7/8 dn 16 x 1500 r 1/2 dn 80 pn 16 dn 80 d 40-80 mm sad 15 stm 40 mm1004 za20 140 zm20-14 and ebi zb12 160 kg air temperature 20°c test values according to en 676 and en 267 din 4787 at 171 m above sea level pressure in combustion chamber [mbar 20 18 16 14 12 10 8 6 4 2 0 0 500 1000 1500 2000 2500 qf burner output [kw 03/05 no 102.880.5185 5

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technical data sheet technical data monoblock dual-fuel burner ek 6.240 300 gl-e ek 6.240 300 gl-e technical data burner output fuel flow rate operating mode type of fuel burner control box flame sensor fan motor pump unit gear output pressure nozzle rod nozzle oil hoses external connection gas connection gas inlet butterfly valve actuator ignition transformer ignition burner weight operating range ek 6.240 300 gl-e 6.240 g 6.240 l 6.300 g 6.300 l 6.240 gl-e 287 2589 kw 76 231 kg/h fully modulating natural gas and light oil el bcs lfl1 lgk16 qra 2 qra 53/55 400 690 v 50hz 4,0 kw 8,5 a 2800 min-¹ smg 16026 1,1 kw 735 l/h 30 bar rdn thread 7/8 dn 20 x 1500 r 1/2 dn 80 pn 16 dn 80 d 40-80 mm sad 15 stm 40 mm1004 za20 140 zm20-14 and ebi zb12 170 kg 6.300 gl-e 373 2886 kw 82 259 kg/h fully modulating natural gas and light oil el bcs lfl1 lgk16 qra 2 qra 53/55 400 690 v 50hz 4,0 kw 8,5 a 2800 min-¹ smg 16026 1,1 kw 735 l/h 30 bar rdn thread 7/8 dn 20 x 1500 r 1/2 dn 80 pn 16 dn 80 d 40-80 mm sad 15 stm 40 mm1004 za20 140 zm20-14 and ebi zb12 170 kg air temperature 20°c test values according to en 676 and en 267 din 4787 at 171 m above sea level pressure in combustion chamber [mbar 25 20 15 10 5 0 0 500 1000 1500 2000 2500 3000 3500 qf burner output [kw 03/05 no 102.880.5210 6

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technical data sheet technical data monoblock dual-fuel burner ek 6.240 300 gl-eu ek 6.240 300 gl-eu low-nox with delta-mixing unit low-nox with delta-mixing unit technical data burner output fuel flow rate operating mode type of fuel burner control box flame sensor fan motor pump unit gear output pressure nozzle rod nozzle oil hoses external connection gas connection gas inlet butterfly valve actuator ignition transformer ignition burner weight operating range ek 6.240 300 gl-eu 6.240 g 6.240 l 6.300 g 6.300 l 6.240 gl-eu 300 2012 kw 70 195 kg/h fully modulating natural gas and light oil el bcs lfl1 lgk16 qra 2 qra 53/55 400 690 v 50hz 4,0 kw 8,5 a 2800 min-¹ smg 16026 1,1 kw 735 l/h 30 bar rdn thread 7/8 dn 20 x 1500 r 1/2 dn 80 pn 16 dn 80 d 40-80 mm sad 15 stm 40 mm1004 za20 140 zm20-14 and ebi zb12 170 kg 6.300 gl-eu 347 2452 kw 65 225 kg/h fully modulating natural gas and light oil el bcs lfl1 lgk16 qra 2 qra 53/55 400 690 v 50hz 4,0 kw 8,5 a 2800 min-¹ smg 16026 1,1 kw 735 l/h 30 bar rdn thread 7/8 dn 20 x 1500 r 1/2 dn 80 pn 16 dn 80 d 40-80 mm sad 15 stm 40 mm1004 za20 140 zm20-14 and ebi zb12 170 kg air temperature 20°c test values according to en 676 and en 267 din 4787 at 171 m above sea level pressure in combustion chamber [mbar 25 20 15 10 5 0 0 500 1000 1500 2000 2500 3000 qf burner output [kw 03/05 no 102.880.5209 7

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technical data sheet technical data monoblock dual-fuel burner ek 7 gl-e ek 7 gl-e technical data burner output fuel flow rate operating mode type of fuel burner control box flame sensor fan motor pump unit gear output pressure nozzle rod nozzle oil hoses external connection gas connection gas inlet butterfly valve actuator ignition transformer ignition burner weight operating range ek 7 gl-e 7.350 g 7.350 l 7.450 g 7.450 l 7.350 gl-e 830 4000 kw 93 338 kg/h fully modulating natural gas and light oil el bcs lfl 1.3 lfl 1.6 lgk 16 qra2 qra 2 qra 53 400 690 v 50 hz 5,5 kw 11,7 a 2800 min-¹ kl-ta 4 c -2,2 kw smg 19065 1,5 kw 900 l/h 30 bar rdg 1250 thread m14 dn 20 x 1500 r 3/4 dn 80 pn 16 dn 80 d 40-80 mm sad 15 stm 40 mm1004 ea2 za20 140 zm20-14 zb 2 310 kg 7.450 gl-e 768 4839 kw 111 408 kg/h fully modulating natural gas and light oil el bcs lfl 1.3 lfl 1.6 lgk 16 qra2 qra 2 qra 53 400 690 v 50 hz 7,5 kw 15,5 a 2800 min-¹ kl-ta 5 c -2,2 kw smg 1629 2,2 kw 1200 l/h 1200 l/h 30 bar rdg 1250 thread m14 dn 20 x 1500 r 3/4 dn 80 pn 16 dn 80 d 40-80 mm sad 15 stm 40 mm1004 ea2 za20 140 zm20-14 zb 2 320 kg air temperature 20°c test values according to en 676 and en 267 din 4787 at 171 m above sea level pressure in combustion chamber [mbar 30 25 20 15 10 5 0 0 1000 2000 3000 4000 5000 6000 qf burner output [kw 03/05 no 102.881.1381 8

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technical data sheet technical data monoblock dual-fuel burner ek 7 gl-eu ek 7.450 gl-eu low-nox with delta-mixing unit low-nox with delta-mixing unit technical data burner output fuel flow rate operating mode type of fuel burner control box flame sensor fan motor pump unit gear output pressure nozzle rod nozzle oil hoses external connection gas connection gas inlet butterfly valve actuator ignition transformer ignition burner weight operating range ek 7 gl-eu 7.450 g 7.450 l 7.450 gl-eu 768 3854 kw 76 325 kg/h fully modulating natural gas and light oil el bcs lfl 1.3 lfl 1.6 lgk 16 qra2 qra 2 qra 53 400 690 v 50 hz 7,5 kw 15,5 a 2800 min-¹ kl-ta 4 c -2,2 kw smg 19065 1,5 kw 900 l/h 30 bar rdg 1250 thread m14 dn 20 x 1500 r 3/4 dn 80 pn 16 dn 80 d 40-80 mm sad 15 stm 40 mm 1004 ea2 za20 140 zm20-14 zb 2 320 kg f kg air temperature 20°c test values according to en 676 and en 267 din 4787 at 171 m above sea level pressure in combustion chamber [mbar 25 20 15 10 5 0 0 500 1000 1500 2000 2500 3000 3500 4000 4500 qf burner output [kw 03/05 no 102.881.1405 9

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technical data sheet technical data monoblock dual-fuel burner ek 8 gl-e ek 8 gl-e technical data burner output fuel flow rate operating mode type of fuel burner control box flame sensor fan motor pump unit gear output pressure nozzle rod nozzle oil hoses external connection gas connection gas inlet butterfly valve actuator ignition transformer ignition burner weight operating range ek 8 gl-e 8.550 g 8.550 l 8.700 g 8.700 l 8.550 gl-e 684 5815 kw 165 541 kg/h fully modulating natural gas and light oil el bcs lfl 1.3 lfl 1.6 lgk 16 qra2 qra2 qra 53 400 690 v 50hz 11 kw 22,5 a 2800 min-¹ kl-ta 5 c 2,2 kw smg 1629 2,2 kw 1200 l/h 1200 l/h 30 bar rdg 1250 thread m14 dn 20 x 1500 r 3/4 dn 150 pn 16 dn 150 d 80 150 mm sad 15 stm 40 mm1004 ea2 za20 140 zm20-14 zb 2 400 kg 8.700 gl-e 798 7111 kw 185 643 kg/h fully modulating natural gas and light oil el bcs lfl 1.3 lfl 1.6 lgk 16 qra2 qra2 qra 53 400 690 v 50hz 15 kw 30 a 2800 min-¹ kl-t 3 c 3,0 kw smg 1630 3,0 kw 1700 l/h 1700 l/h 30 bar rdg 1250 thread m14 dn 25 x 1500 r 1 dn 150 pn 16 dn 150 d 80 150 mm sad 15 stm 40 mm1004 ea2 za20 140 zm20-14 zb 2 430 kg air temperature 20°c test values according to en 676 and en 267 din 4787 at 171 m above sea level pressure in combustion chamber [mbar 30 25 20 15 10 5 0 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 qf burner output [kw 03/05 no 102.880.5254 10

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technical data sheet technical data monoblock dual-fuel burner ek 8 gl-eu ek 8 gl-eu low-nox with delta-mixing unit low-nox with delta-mixing unit technical data burner output fuel flow rate operating mode type of fuel burner control box flame sensor fan motor pump unit gear output pressure nozzle rod nozzle oil hoses external connection gas connection gas inlet butterfly valve actuator ignition transformer ignition burner weight operating range ek 8 gl-eu 8.550 g 8.550 l 8.700 g 8.700 l 8.550 gl-eu 658 4358 kw/h 114 385 kg/h fully modulating natural gas and light oil el bcs lfl 1.3 lfl 1.6 lgk 16 qra2 qra2 qra 53 400 690 v 50hz 11 kw 22,5 a 2800 min-¹ kl-ta 5 c 2,2 kw smg 19065 1,5 kw 1200 l/h 900 l/h 30 bar rdg 1250 thread m14 dn 20 x 1500 r 3/4 dn 150 pn 16 dn 150 d 80 150 mm sad 15 stm 40 mm 1004 ea2 za20 140 zm20-14 zb 2 400 kg 8.700 gl-eu 495 5240 kw 112 508 kg/h fully modulating natural gas and light oil el bcs lfl 1.3 lfl 1.6 lgk 16 qra2 qra2 qra 53 400 690 v 50hz 15 kw 30 a 2800 min-¹ kl-t 3 c 3,0 kw smg 1629 2,2 kw 1700 l/h 1200 l/h 30 bar rdg 1250 thread m14 dn 25 x 1500 r 1 dn 150 pn 16 dn 150 d 80 150 mm sad 15 stm 40 mm 1004 ea2 za20 140 zm20-14 zb 2 430 kg air temperature 20°c test values according to en 676 and en 267 din 4787 at 171 m above sea level pressure in combustion chamber [mbar 30 25 20 15 10 5 0 0 1000 2000 3000 4000 5000 6000 7000 qf burner output [kw 03/05 no 102.880.5243 11

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technical data sheet technical data monoblock dual-fuel burner ek 9 gl-e ek 9 gl-e technical data burner output fuel flow rate operating mode type of fuel burner control box flame sensor fan motor pump unit gear output pressure nozzle rod nozzle oil hoses external connection gas connection gas inlet butterfly valve actuator ignition transformer ignition burner weight operating range ek 9 gl-e 9.850 g 9.850 l 9.1000 g 9.1000 l 9 850 gl-e 1148 8182 kw 218 850 kg/h fully modulating natural gas and light oil el bcs lfl 1.3 lfl 1.6 lgk 16 qra2 qra2 qra 53 400 690 v 50hz 18,5 kw 35 a 2800 min-¹ kl-t 4 c 4,0 kw smg 1631 4,0 kw 2250 l/h 2200 l/h 30 bar rdg 1250 thread m14 dn 25 x 1500 r 1 dn 150 pn 16 dn 150 d 80 150 mm sad 15 stm 40 mm1004 ea2 za20 140 zm20-14 zb 2 530 kg 9.1000 gl-e 796 11200 kw 224 970 kg/h fully modulating natural gas and light oil el bcs lfl 1.3 lfl 1.6 lgk 16 qra2 qra2 qra 53 400 690 v 50hz 22 kw 42,5 a 2800 min-¹ kl-t 4 c 4,0 kw smg 1631 4,0 kw 2250 l/h 2200 l/h 30 bar rdg 1250 thread m14 dn 25 x 1500 r 1 dn 150 pn 16 dn 150 d 80 150 mm sad 15 stm 40 mm1004 ea2 za20 140 zm20-14 zb 2 570 kg air temperature 20°c test values according to en 676 and en 267 din 4787 at 171 m above sea level pressure in combustion chamber [mbar 35 30 25 20 15 10 5 0 0 2000 4000 6000 8000 10000 12000 14000 q f burner output [kw 03/05 12 no 102.880.5276

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technical data sheet technical data monoblock dual-fuel burner ek 9 gl-eu ek 9 gl-eu low-nox with delta-mixing unit low-nox with delta-mixing unit technical data burner output fuel flow rate operating mode type of fuel burner control box flame sensor fan motor pump unit gear output pressure nozzle rod nozzle oil hoses external connection gas connection gas inlet butterfly valve actuator ignition transformer ignition burner weight operating range ek 9 gl-eu 9.850 g 9.850 l 9.1000 g 9.1000 l 9 850 gl-eu 900 7000 kw 175 660 kg/h fully modulating natural gas and light oil el bcs lfl 1.3 lfl 1.6 lgk 16 qra2 qra2 qra 53 400 690 v 50hz 18,5 kw 35 a 2800 min-¹ kl-t 4 c 4,0 kw smg 1630 3,0 kw 2250 l/h 1700 l/h 30 bar rdg 1250 thread m14 dn 25 x 1500 r 1 dn 150 pn 16 dn 150 d 80 150 mm sad 15 stm 40 mm 1004 ea2 za20 140 zm20-14 zb 2 530 kg 9.1000 gl-eu 1111 9201 kw 239 875 kg fully modulating natural gas and light oil el bcs lfl 1.3 lfl 1.6 lgk 16 qra2 qra2 qra 53 400 690 v 50hz 18,5 kw 35 a 2800 min-¹ kl-t 4 c 4,0 kw smg 1630 4,0 kw 2250 l/h 1700 l/h 30 bar rdg 1250 thread m 14 dn 150 pn16 dn 150 d 80-150 mm sad 15 stm 40 mm 1004 ea2 za20 140 zm20-14 zb2 0 kg air temperature 20° test values according to en 676 and en 267 din 4787 c at 171 m above sea level pressure in combustion chamber [mbar 30 25 20 15 10 5 0 0 2000 4000 6000 8000 10000 12000 q f burner output [kw 03/05 no 102.880.5265 13

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overview dimensioned drawings ek 6 gl-e eu ek 6.170/200 gl-e ignition gas connection tube 12x1 dimensions in boiler connection plate ek 6.170/200 gl-eu ignition gas connection tube 12x1 dimensions in boiler connection plate 14

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overview dimensioned drawings ek 6 gl-e eu ek 6.240/300 gl-e ignition gas connection tube 12x1 dimensions in boiler connection plate ek 6.240/300 gl-eu dimensions in boiler connection plate 15

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