p. 1

operation manual for the authorized specialist gas duoblock burner ek-duo 2 3 4 g-e 01/2008 102.879.7806 rev b

[close]

p. 2

inhalt important information warranty 3 technical data 4 mounting the burner to the boiler 10 burner installation muffle type burner ek-duo 2 3 4 g-e 11 combustion air fan drive modes 12 burner electrical connection 13 gas connection 14 burner diagram gas valves and instrument group 15 ignition gas solenoid valve 16 gas pressure regulator 17 mounting position leak test ignition gas connection ignition burner type zt0 19 burner adjustment 23 burner construction ek-duo 2 3 4 g-e 24 ek-duo g-e dimensions of mixing unit 25 preoperational checks burner operation 26 gas start-up burner shutdown what to do in case of trouble 27 air adjustment gas adjustment 28 mixing ignition unit maintenance 29 adjusting instructions elektronic burner control with electronic compound controller 30 start-up of burner control system type bcs 300 flame detecting system type flw 05 31 start-up of burner control system type bcs 300 servomotor type sad 15.0 32 electrical actuator stm 40 33 actuator type aris wan 2a n2a wan 3/n3 34 starting the bcs etamatic vms/fms electronic compound controller 35 operation automatic furnace controller lfl 1 lgk 16 regulator ks 92 36 adjusting instructions flame monitor sensor current measurement 37 adjusting instructions gas pressure switch air pressure switch 38 exhaust gas test 39 trouble shooting instructions 40 2

[close]

p. 3

overview important information warranty important information the burners of type ek-duo 3 g-e have been designed for the combustion of natural gas 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 vde 0116 gas burners with fans electrical equipment of furnaces start-up the furnace system should be started initially by the installer manufacturer or other specialized personnel prior to taking the furnace system into operation make a test of all automatic control safety and control facilities for proper functional order and check them for correct setting if of adjustable type furthermore check the control circuits fans etc for proper fuse rating and whether suitable precautions have been taken to prevent accidental contact inspection and maintenance the furnace system should be inspected and serviced at least once a year by an authorized specialist of the installer to ensure its proper functional order operational safety and energy-saving operation check the system for absence of leaks and functional order for the combustion analysis proceed as described in the section entitled exhaust gas test 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 according to en 676 the user must be instructed in the operation of the burner and according to din 4756 the user must be introducted in to gas firing system 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 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 chamber 3

[close]

p. 4

technical data technical data gas duoblock burner ek-duo 2 g-e feld52 ek-duo 2 g-e technical data burner output fuel flow rate operating mode fuel type automatic burner controller flame sensor ignition burner ignition transformer actuator gas connection gas flow regulator weight burner pressure loss air side 320 kg 28 mbar ek-duo 2.550 600 6000 kw 60 600 m³/h fully modulating natural gas bcs/etamatic/fms/vms qra 2 qra 53 hegwein za 20 140 e21 sad15 stm40 schimpf flange c 80 x 88,9 din 2633 gas butterfly valve 320 kg 30 mbar ek-duo 2.700 700 7500 kw 70 750 m³/h output range kw 8000 7500 7000 6000 6000 5000 4000 3000 2000 1 000 600 0 ek-duo 2.550 ek-duo 2.700 700 01/08 art no 102.882.4282 4

[close]

p. 5

ek-duo 2.550 700 g-e description dimensioned drawing operating mode the burner is designed as an automatic controllable gas-fired blast burner with an electronic compound control system safety equipment according to en 676 and is provided for a high control range finishing the burner is supplied with connection leads fixed to terminal block ready for connection to boiler system the automatic furnace controller is housed in a separate control cabinet combustion air a separately arranged combustion air fan with steep characteristic is provided to ensure a high pressure build-up the fan makes possible a pulsation-free and steady combustion behaviour also on boilers with a high exhaust gas resistance the flame geometry can be adjusted by means of variable air swirlers flow rate control for gas flow rate control an actuator is provided to the gas control valve for air flow rate control an actuator is provided to the air control valve monitors a uv monitor and approved automatic furnace controller are provided for flame monitoring an air pressure switch is provided for combustion air monitoring a speed monitor is fitted if an automatic speed control system is used ignition an electric high-voltage ignition system rated at 5000 v is fitted with integrated pilot burner dimensioned drawing ek-duo 2 g-e removal lenght ignition burner gas connection with 45° division rotatable flange c80x88.9 din 2633 ignition gas connection g1/2 boiler plate holes air connection with 45° division rotatable air connection flange set screw m12x40 5

[close]

p. 6

technical data technical data gas duoblock burner gas duoblock burner ek-duo 3 g-e feld52 ek-duo 3 g-e technical data burner output fuel flow rate operating mode fuel type automatic burner controller flame sensor ignition burner ignition transformer actuator gas connection gas flow regulator weight burner pressure loss air side 450 kg 32 mbar ek-duo 3 850 900 9000 kw 90 900 m³/h fully modulating natural gas bcs/etamatic/fms/vms qra 2 qra 53 hegwein za 20 140 e21 sad15 stm40 schimpf flange c 80 x 88,9 din 2633 gas butterfly valve 450 kg 32 mbar ek-duo 3.1000 1000 12000 kw 100 1200 m³/h output range kw 1 4000 1 2000 1 2000 1 0000 9000 8000 6000 4000 2000 900 0 ek-duo 3 850 1 000 ek-duo 3.1 000 01/08 art no 102.882.4293 6

[close]

p. 7

ek-duo 3.850 1000 g-e description dimensioned drawing operating mode the burner is designed as an automatic controllable gas-fired blast burner with an electronic compound control system safety equipment according to en 676 and is provided for a high control range finishing the burner is supplied with connection leads fixed to terminal block ready for connection to boiler system the automatic furnace controller is housed in a separate control cabinet combustion air a separately arranged combustion air fan with steep characteristic is provided to ensure a high pressure build-up the fan makes possible a pulsation-free and steady combustion behaviour also on boilers with a high exhaust gas resistance the flame geometry can be adjusted by means of variable air swirlers flow rate control for gas flow rate control an actuator is provided to the gas control valve for air flow rate control an actuator is provided to the air control valve monitors a uv monitor and approved automatic furnace controller are provided for flame monitoring an air pressure switch is provided for combustion air monitoring a speed monitor is fitted if an automatic speed control system is used ignition an electric high-voltage ignition system rated at 5000 v is fitted with integrated pilot burner maßbild ek-duo 3 g-e removal lenght ignition burner flange din 2633 dn pn 16 gas connection with 90° division rotatable ignition gas connection g1/2 air connection flange set screw m12x40 boiler plate holes air connection with 45° division rotatable 7

[close]

p. 8

technical data gas duoblock burner gas duoblock burner ek-duo 4 g-e feld52 ek-duo 4 g-e technical data burner output fuel flow rate operating mode fuel type automatic burner controller flame sensor ignition burner ignition transformer actuator gas connection gas flow regulator weight burner pressure loss air side 320 kg 34 mbar sad15/stm40/schimpf flange c100 x 114,3 din 2633 gas butterfly valve 320 kg 34 mbar ek-duo 4.1300 kw m³/h fully modulating natural gas bcs/etamatic/fms/vms ffs05/f200k/d-lx100 hegwein ek-duo 4.1600 2000 16000 kw 200 1600 m³/h output range kw 1 8000 1 6000 1 6000 1 4000 1 2000 1 0000 8000 6000 4000 2000 2000 0 ek-duo 4.1 300 ek-duo 4.1 600 01/08 art no 140.228.92 8

[close]

p. 9

ek-duo 4.1600 g-e description dimensioned drawing operating mode the burner is designed as an automatic controllable gas-fired blast burner with an electronic compound control system safety equipment according to en 676 and is provided for a high control range finishing the burner is supplied with connection leads fixed to terminal block ready for connection to boiler system the automatic furnace controller is housed in a separate control cabinet combustion air a separately arranged combustion air fan with steep characteristic is provided to ensure a high pressure build-up the fan makes possible a pulsation-free and steady combustion behaviour also on boilers with a high exhaust gas resistance the flame geometry can be adjusted by means of variable air swirlers flow rate control for gas flow rate control an actuator is provided to the gas control valve for air flow rate control an actuator is provided to the air control valve monitors a uv monitor and approved automatic furnace controller are provided for flame monitoring an air pressure switch is provided for combustion air monitoring a speed monitor is fitted if an automatic speed control system is used ignition an electric high-voltage ignition system rated at 5000 v is fitted with integrated pilot burner maßbild ek-duo 4 g-e removal lenght ignition burner flange din 2633 dn pn 16 gas connection with 90° division rotatable ignition gas connection g1/2 boiler plate holes air connection with 45° division rotatable set screw m20x40 din 937 air connection flange 9

[close]

p. 10

mounting mounting the burner to the boiler the burner plate of the boiler must be fabricated to the specified dimensions mount the burner to the boiler with its insulation backing apply a layer to graphite or similar lubricant to the bolts and tighten by equal amounts mixing ignition units extended in length are available for boilers requiring a specific installation depth of the burner flame tube refer to the drawing for the mounting dimensions of the burner and air duct and exhaust gas connection if any boiler lining the boiler lining must consist of heatresistant materials temperature resistance >1400°c the space between the burner flame tube and lining is pakked with mineral wool burner mounting inspection 1 check the mixing ignition unit according to the boiler output 2 adjust the pilot burner 3 refer to the dimensioned drawing for adjusting the mixing ignition unit 4 standard swirl plate position radial swirl angle 0° boiler lining burner flange sealing mineral wool isolierung kesselplatte textile compensator air duct mounting bracket combustion air fan baseframe to anti-vibration mounting 10

[close]

p. 11

mounting burner installation muffle type burner ek-duo 2 3 4 g-e boiler lining the boiler lining must be placed at right angles to the burner outlet tube d t burner type d standard t ek-duo 2 ek-duo 3 ek-duo 4 400 480 525 320 350 350 11

[close]

p. 12

combustion air fan drive modes 1 direct drive in this concept the motor is coupled directly to the fan impeller the fan impeller is mounted directly on the motor shaft end the speeds used are those of the drive motors only the bearing of the motor shaft must be specifically designed for the fan impeller used recommendation up to 10 mw output air duct and fan baseframe pre-mount exactly do not prestress for mounting direction of rotation check for proper direction of rotation fans with v-belt drive should be chekked for v-belt tension after about 12 hours of operation and the v-belts retensioned if necessary if the v-belts are not properly tensioned this will cause slip with resultant lower speed and a considerably reduced service life mount the air ducts in a way to ensure an accurate and reliable fixing of the fan connect the air duct by means of a compensator to avoid transmission of stress the air ducts are made from 3-4 mm metal sheet 2 drive via flexible coupling the fan impeller is mounted on its own shaft by means of a bearing specifically designed for the purpose the power is transmitted from the drive motor via a torsionally flexible coupling the speeds used are those of the drive motor 3 v-belt drive the fan impeller is mounted on its own shaft by means of a bearing specifically designed for the purpose the power is transmitted from the drive motor via vbelts which can provide practically any desired speed 12

[close]

p. 13

burner electrical connection electrical connection the installation material and all electrical connections and earthing points must be in accordance with the vde 0116 specifications and the local regulations the electrical connection of the burner must be made as shown in the circuit diagram attached hereto the electrical control lines are installed through the screwed cable joints and connected to the numbered terminal strip in accordance with the circuit diagram control boxes related to the burner must also be connected in accordance with the enclosed circuit diagram and vde 0116 and taking into account the local regulations after the electrical connections have been completed a check must be made for the correct wiring of all items of the equipment also the direction of rotation of the fan should be checked 1 2 3 4 electrical terminal box plug connector terminal strip cable bushings 13

[close]

p. 14

gas connection for the installation and taking into operation of the gas lines care should be taken to observe the regulations of dvgw german association of the gas and water sector especially dvgwtrgi technical regulation for gas installations and trf technical regulation for furnaces din 4756 and trd 412 contain specifications for the construction design and safety requirements of gas furnaces in heating installations furnace systems of higher operating pressures are subject to the dvgw worksheets g 460 and g 461 the gas lines must meet specifications set out in dvgw-trgi in the case of furnace systems with operating pressures up to 100 mbar or above 100 mbar gas control group with two gas valves and leak tester the gas section is designed in accordance with en 676 and trd 412 two gas valves and leakage tester are prescribed for burners with a capacity above 1200 kw the operation mounting and adjustment of the valve leak testers is described in detail on a separate sheet gas connection pressure the gas line must be dimensioned in accordance with the throughput rate and the available gas pressure and installed to the burner on the shortest possible way with minimum pressure loss to provide the most effective conditions for start-up take care that the burner and gas stop valve are installed with the minimum possible distance between one another this means that the 2nd gas valve looking in the direction of the gas flow should be mounted in the immediate vicinity of the burner note the gas pressure loss of the gas control group and burner the gas control group can be connected directly to the gas feed line note the order in which the valves and instruments are mounted and the direction of flow prior to installation and taking into operation check the valves and instruments and the connection fittings for the possible accumulation of dirt and foreign matter 1 2 3 4 5 6 7 8 10 11 12 13 14 15 16 17 ignition gas connection min 50 mbar max 150 mbar gas connection 100 mbar gas stop valve ignition gas pressure regulator ignition gas solenoid valves gas filter pressure gauge with pushbutton valve test burner gas meter gas pressure switch gas pressure regulator with safety blow-off valve safety blow-off valve gas motor valve 1/solenoid valve gas motor valve 2/solenoid valve compensator gas butterfly control valve gas pilot burner burner 14

[close]

p. 15

burner diagram gas valves and instrument group ek-duo 2 3 /4 g-e for trd 604 72 h the pressure switches 310 313 313a are approved in double design or according to special design for trd 604 24 h the pressure switches 310 313 313a are of single design for en the pressure switches 310 313 are of single design the maximum pressure switch 313a is not required burner diagram trd 604 72 h gas 155 ignition gas zündgas ignition electrodes zündelektroden ignition air zündluft secondary air sekundärluft air luft gas valves and instrument group trd 604 72 h air 100 120 141 142 143 144 145 147 148 150 151 152 153 154 155 burner air damper ball valve gas filter pressure gauge with stop valve gas pressure controller safety stop valve test burner with stop valve safety blow-off valve gas butterfly control valve pilot burner regulating valve main gas solenoid valve safety solenoid valve ignition gas solenoid valve or individual components 157 regulating valve not with ignition gas solenoid valve 310 air pressure switch 313 minimum gas pressure switch 313a maximum gas pressure switch 314 leak tester 350 actuator 15

[close]