Elster ECOMAX 0C Manual

www.lbe-online.de
Edition 02.11
Technical Information · GB
• For direct and indirect heating equipment
• Economical, energy-saving operation by virtue of internal
air preheating up to 700°C
• Great flexibility due to its maintenance-friendly modular design
• Uniform distribution of temperature by means of a high burner impulse
• Low polluting level thanks to staged combustion
• Direct ignition and monitoring
• 7 sizes for a broad output range from 15–500kW
• Highly efficient with a ceramic burled tube recuperator, a cast steel ribbed
tube recuperator or a flat tube recuperator
Self recuperative burner ECOMAX® for gas

ECOMAX · Edition 02.11
2
t = To be continued
Contents
Self recuperative burner ECOMAX® for gas . . . . . . . . . . . . 1
Contents........................................2
1 Application.....................................4
1.1 Indirect heating.................................4
1.2 Direct heating..................................4
1.3 Examples of application . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3.1 ECOMAX® in radiant tubes...........................6
1.3.2 ECOMAX® in direct heating systems . . . . . . . . . . . . . . . . . .7
2 Certification....................................8
2.1 Approval for Russia.............................8
3 Mechanical construction. . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 Burner housing ................................9
3.2 Recuperator...................................9
3.3 Air guide tube ................................10
3.4 Gas insert ...................................10
3.4.1 Versions.........................................11
4 Function...................................... 12
5 Selection .....................................13
5.1 Burner type...................................13
5.2 Burner design ................................14
5.3 Gas types....................................15
5.4 Burner length................................. 15
5.5 Connection for additional furnace cooling . . . . . . . . . 16
5.6 Differential air pressure measuring kit DA 1 . . . . . . . . 17
5.7 Differential air pressure measuring kit DA2 with
pressure switch.................................. 17
5.8 Flue gas monitoring kit DW . . . . . . . . . . . . . . . . . . . . . 18
5.9 Selection table................................20
5.9.1 Type code .......................................21
6 Project planning information . . . . . . . . . . . . . . . . . . . . . 22
6.1 Flame control.................................22
6.2 Purging air and cooling air . . . . . . . . . . . . . . . . . . . . . 23
6.3 Recommended burner control units . . . . . . . . . . . . . . 24
6.4 Gas connection...............................25
6.4.1 Valves ......................................... 25
6.4.2 Operation with LPG .............................. 26
6.4.3 Air/gas ratio control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.5 Air connection................................27
6.5.1 Indirect heating...................................27
6.5.2 Direct heating................................... 28
6.6 Flue gas guide tube FGT for direct heating . . . . . . . . . 29
6.6.1 For ECOMAX..C.................................. 29
6.6.2 For ECOMAX..M................................. 30
6.7 Radiant tubes ................................31
6.7.1 Ceramic radiant tube SER-C for indirect heating . . . . . . . . 31
6.7.2 Metallic radiant tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.7.3 Radiant tube distances . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.7.4 Eductor on burners with metallic single-ended
radiant tubes........................................ 33
6.8 Flue gas channelling. . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.8.1 Indirect heating.................................. 34
6.8.2 Direct heating................................... 35
6.9 Burner adjustment ............................36
6.9.1 Differential air pressure measuring kit DA2 with
pressure switch...................................... 36
7 Technical data.................................37
7.1 Efficiency .....................................37
7.1.1 ECOMAX..C ..................................... 38
7.1.2 ECOMAX..M..................................... 39
7.1.3 ECOMAX..FTR.................................... 40
7.2 Dimensions ..................................41
7.2.1 ECOMAX..C ......................................41
7.2.2 ECOMAX..M .................................... 43
7.2.3 ECOMAX..FTR ................................... 45
7.2.4 ECOMAX standard piping . . . . . . . . . . . . . . . . . . . . . . . . . .47
8 Maintenance..................................48

ECOMAX · Edition 02.11
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t = To be continued
9 Accessories...................................49
9.1 Flue gas guide tube FGT kit . . . . . . . . . . . . . . . . . . . . . . 49
9.2 Flue gas eductor ..............................49
9.3 Ceramic radiant tube SER-C . . . . . . . . . . . . . . . . . . . . .50
9.4 SICAFLEX® segmented flame tube. . . . . . . . . . . . . . . .50
9.5 P2/P3 set Eco.................................51
Feedback ......................................52
Contact........................................52

ECOMAX · Edition 02.11
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ECOMAX..C ECOMAX..M ECOMAX..FTR
1 Application
The burners with integrated recuperator ECOMAX® are used
for heating on either direct or indirect furnace systems in in-
termittent mode.
1.1 Indirect heating
ECOMAX® self recuperative burners are used in conjunction
with metallic or ceramic radiant tubes and the segmented
ceramic flame tube SICAFLEX® as indirect heating equipment
whenever the combustion gases are to be separated from
the product.
1.2 Direct heating
In conjunction with an eductor to extract the flue gases, the
burner is used to save energy in a direct heating system. Ap-
plications include industrial furnaces and firing systems in the
iron and steel industry and in the non-ferrous metal industry.

ECOMAX · Edition 02.11
5 Application
Roller hearth furnace Bogie hearth furnace Batch furnace

ECOMAX · Edition 02.11
6 Application
1.3 Examples of application
1.3.1 ECOMAX® in radiant tubes
The high outlet velocity of the combustion gases generates a
pressure at the outlet of the ceramic burner tube, resulting in
the recirculation of the flue gases. This leads to the following:
– a reduction in NOx emissions,
– a uniform radiant tube temperature.
The hot flue gases are fed through the ceramic or metallic heat
exchanger, heating the additional supply of cold combustion
air flowing in the opposite direction. The maximum achievable
air preheat temperature amounts to approx. 700°C, depend-
ing on the application.
Gas Cold air
Metallic radiant tube
Flue gas
Sicaflex®
Ceramic radiant tube
SER-C
Flame tube
Gas Cold air
Flue gas
SICAFLEX® segmented flame tubes must be fitted in the single-
ended (metallic or ceramic) radiant tube to guide the hot flue
gases.
Gas Cold air
P radiant tube
Flue gas
Gas Cold air Twin P
radiant tube
Flue gas

ECOMAX · Edition 02.11
7 Application > Examples of application
1.3.2 ECOMAX® in direct heating systems
Gas Cold air
Flue gas
ECOMAX® self recuperative burner in a direct heating sys-
tem with an eductor for extracting the flue gases from the
furnace. The eductor generates a vacuum with a centrally
positioned nozzle and thus draws the flue gases out of the
furnace chamber through the burner’s heat exchanger. The
maximum achievable air preheat temperature amounts to
approx. 700°C, depending on the application.
ECOMAX® with eductor and burner control unit BCU

ECOMAX · Edition 02.11
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2 Certification
2.1 Approval for Russia
Certified by Gosstandart pursuant to GOST-R.
Approved by Rostekhnadzor (RTN).

ECOMAX · Edition 02.11
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3 Mechanical construction
The ECOMAX® burner unit is composed of four modules:
burner housing, recuperator, air guide tube and gas insert.
The modular design facilitates adapting the burners to the
respective application or integrating them into an existing
furnace system. Maintenance and repair times are reduced,
and existing furnace installations can easily be converted.
3.1 Burner housing
The burner housing accomodates the connections for the
combustion air, gas, cooling air and flue gas channelling. It
also secures the burner insert. It is made of cast aluminium,
which means it has a low weight. The housing has a double-
wall design. The combustion air is fed into the burner via the
outer annular gap. This cools the burner housing und reduces
emissions.
3.2 Recuperator
All-ceramic
The surface of the all-ceramic recuperator, which is made
of SiSiC for high thermal stress, is burled in order to achieve
high efficiency.
Cast steel
The ribs on the cast steel recuperator offer a large surface area,
allowing it to achieve high efficiency even at low temperatures.
Flat tube
The flat tube recuperator has a smooth surface. It is a cost-
effective alternative at a lower efficiency level and is suitable
for lower application temperatures.

ECOMAX · Edition 02.11
10 Mechanical construction
3.3 Air guide tube
Burners Ecomax..C have a ceramic air guide tube that for sizes
0 to 3 also serves as the combustion chamber.
Burners Ecomax..M and Ecomax..FTR have an air guide tube
made of heat-resistant steel.
3.4 Gas insert
The gas insert consists of the gas connection flange, the gas
lance with mixer unit and the ignition electrode (also serves
as monitoring electrode). For operation with LCV gas, the gas
insert is equipped with a special mixing system.
Gas insert with combustion chamber for Ecomax M and Ecomax FTR
Gas insert without combustion chamber for Ecomax C (sizes 1 to 3)

ECOMAX · Edition 02.11
11 Mechanical construction > Gas insert
3.4.1 Versions
Burner Size Gas insert Air guide tube
ECOMAX..C
0 – 3 With mixing
funnel
Ceramic,
with integrated
combustion
chamber
4 – 5
With swirl plate
and ceramic
combustion
chamber
Ceramic
ECOMAX..M
1 – 3
With mixing fun-
nel and ceramic
combustion
chamber
Metallic
4 – 6
With swirl plate
and ceramic
combustion
chamber
Metallic
ECOMAX..FTR
1 – 3
With mixing fun-
nel and ceramic
combustion
chamber
Metallic
4 – 5
With swirl plate
and ceramic
combustion
chamber
Metallic

ECOMAX · Edition 02.11
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4 Function
Recuperator
Combustion chamber
Air guide tube
Flue gas
Combustion gas
Combustion air
Housing
Gas insert
The self recuperative burner ECOMAX® uses the heat from the
flue gases to preheat the combustion air. The heat exchanger
(recuperator) required for this is part of the burner.
After entering the burner, the combustion air flows in the gap
between the air guide tube and the inside of the recuperator
towards the tip of the burner. Some of this air is fed into the
inside of the burner, where it combusts in the first combustion
stage. The rest of the combustion air flows out through the gap
between the combustion chamber and the recuperator head
at high speed before combustion takes place in the second
combustion stage here. This process means that fewer pol-
lutant emissions are produced.
The hot flue gases, flowing in the opposite direction, leave the
furnace chamber on the outside of the recuperator. Heat is ex-
changed between the hot flue gases and the cold combustion
air through the recuperator wall. The burner is directly ignited.

ECOMAX · Edition 02.11
13
ECOMAX..C
ECOMAX..M
ECOMAX..FTR
5 Selection
5.1 Burner type
The burner ECOMAX is available with a ceramic burled
tube recuperator (Ecomax..C), a cast steel ribbed tube re-
cuperator (Ecomax..M) or a metallic flat tube recuperator
(Ecomax..FTR). Selection is dependent on the type of heating
and the furnace temperature.
Burner
Furnace temperature [°C]
Heating
direct indirect*
Ecomax..C 1300 approx. 1200
Ecomax..M 1150 approx. 1000
Ecomax..FTR 950 approx. 850
* The max. allowable temperature of the radiant tube must
be observed.

ECOMAX · Edition 02.11
14
5.2 Burner design
Selection of the burner size is dependent on the net heat output.
From this, the required burner output is calculated using the
firing efficiency value.
Net heat output [kW]
= Burner output [kW]
Firing
efficiency η
Determine the firing efficiency for the desired furnace tem-
perature using the diagram.
400 500 600 700 800 900 1000 1100
0
0,1
0,2
0,3
0,4
0,5
0,6
0,7
0,8
0,9
1
1200 1300 1400
FTR
M
C
Firing efficiency η
Flue gas temperature on recuperator inlet [°C]
Cold air burner
Burner
Size
Recuperator Output*
ceramic
C
metallic
M
metallic,
flat tube
FTR
[kW]
Ecomax 0 – – 25
Ecomax 1 36
Ecomax 2 60
Ecomax 3 100
Ecomax 4 180
Ecomax 5 250
Ecomax 6 – – 500
 = available.
* For operation with natural gas. For operation with coke oven gas,
the output is approx. 80%, for operation with LCV gas, approx.
65%.
Precise dimensioning is available on request using the
ECOMAX calculation tool. For this, the following information
is required:
– Type of heating
– Furnace temperature
– Required net heat output
– Gas type
– Geometric furnace data (wall thickness, furnace extension,
clear width)
Selection

ECOMAX · Edition 02.11
15
5.3 Gas types
Gas type Code letter
Calorific value
range
[kWh/m3(n)]
Density ρ
[kg/m3]
Natural gas L
and H quality B 8 – 12 0.7– 0.9
Propane, pro-
pane/butane,
butane
G 25 – 35 2.0 – 2.7
Town gas,
coke oven
gas
D 4 – 6 0.4 – 0.6
LCV gas L 1.7 – 3.9 0.9 –1.15
The output of the burners – see page 14 (Burner design) – refers
to natural gas and LPG.
In the case of coke oven gas, the output of the burners is
reduced to about 80%; higher outputs are only possible with
higher supply pressure.
In the case of LCV gas, the output of the burners is reduced
to about 65% of the rated output.
5.4 Burner length
The burner length G should be selected so that the burner is
flush with the inside edge of the furnace lining (S1 = 0 ± 20 mm).
S1
P1
N1
G
M1
L1
K1
Selection

ECOMAX · Edition 02.11
16
5.5 Connection for additional furnace cooling
The air volume supplied to the burner in cooling mode can
be increased using an optional intermediate flange with an
additional cooling air connection on the burner ECOMAX.
VR..N
VG..L
BCU 465..C
12
23
DI
L1, N, PE
µC
P
22 4
19
18
17
16
A
P
5
3
DI
6
26
GEH EKO
32
33
PLC
Depending on the technical requirements for the process, cool-
ing can be implemented in two stages. Actuating the air valve
for the burner (terminal 22) initiates “normal” cooling; actuating
a second air valve for the additional cooling air connection
initiates additional cooling. The additional cooling air valve is
actuated separately by the process control system. For wiring
on site, we recommend using a BCU..C with a supplementary
terminal strip (e.g. terminals 32/33 for additional air valve).
Additional purging air connection on the ECOMAX® burner
Selection

ECOMAX · Edition 02.11
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5.6 Differential air pressure measuring kit DA 1
For adjusting the air volume, especially for direct heating, we
recommend using the optional intermediate flange for dif-
ferential pressure measurement.
The differential air pressure measuring kit DA1 is fitted at the
factory.
Order No. For burners
22800614 ECOMAX 1, 2
22800615 ECOMAX 3, 4, 5
22800666 ECOMAX 6
Differential air pressure measuring kit DA 1 on the ECOMAX® burner
5.7 Differential air pressure measuring kit DA2 with
pressure switch
The differential air pressure measuring kit DA2 is used for the
automatic monitoring of the air flow on the burner ECOMAX
®
in
conjunction with the burner control unit BCU465– see page24
(Recommended burner control units) The pressure switch
monitors the air flow during pre-purge and burner operation.
If there is no air pressure, the burner is switched off via the
pressure switch, or the burner is not enabled.
Selection

ECOMAX · Edition 02.11
18
The pressure switch switching point should be set to approx.
80% of the differential pressure in normal operation.
VR..N
ECOMAX
BCU 465..L 12
23
DI
L1, N, PE
µC
P
22 4
19
18
17
16
A
P
5
3
DI
6
26 21
VG..L
GEH
EKO
Gas Kaltluft
Metallisches Strahlrohr
Abgas
Sicaflex®
PLC
The differential air pressure measuring kit DA2 is fitted at
the factory.
Order No. For burners
22800971 ECOMAX 1, 2
22800972 ECOMAX 3, 4, 5
22800973 ECOMAX 6
5.8 Flue gas monitoring kit DW
The flue gas monitoring kit DW with pressure switch is used in
conjunction with the burner control unit BCU465– see page24
(Recommended burner control units)– on ceramic radiant
tubes for automatically checking for ruptures. The pressure
switch monitors the flow rate of air and/or flue gas during
pre-purge and burner operation.
VR..N
VG..L
BCU 465..L 12
23
DI
L1, N, PE
µC
P
22 4
19
18
17
16
A
P
5
3
DI
6
26 21
GEH EKO
PLC
Selection

ECOMAX · Edition 02.11
19
When using the flue gas monitoring kit DW, the fan pressure
must be 10mbar higher, as the measuring orifice causes a
pressure loss in the flue gas pipe.
Selection

ECOMAX · Edition 02.11
20 Selection
5.9 Selection table
B D G L1) 395 475 545 556 593 595 613 617 636 641 645 681 689 695 -22 to -5002) P03) K
3)
A
3)
DA13) DA23) DW3) T
3)
S
3)
Z
3)
ECOMAX 0C ● ● ● ● ● ● ● ● ● ●     
ECOMAX 1C ● ● ● ● ● ● ● ● ● ●     
ECOMAX 2C ●●●● ● ● ● ● ●     
ECOMAX 3C ●●●● ● ● ● ● ●     
ECOMAX 4C ●●●● ● ● ●     
ECOMAX 5C ●●●● ● ● ●     
ECOMAX 1M ● ● ● ● ● ● ● ● ●        
ECOMAX 2M ●●●● ● ● ● ● ●        
ECOMAX 3M ●●●● ● ● ● ● ●        
ECOMAX 4M ●●●● ● ● ● ● ●        
ECOMAX 5M ●●●● ● ● ●        
ECOMAX 6M ●●●●● ●       
ECOMAX 1FTR ●● ●    ●        
ECOMAX 2FTR ●●●   ●        
ECOMAX 3FTR ●●●   ●        
ECOMAX 4FTR ●●●   ●        
ECOMAX 5FTR ●●●   ●        
1)
On request.
2)
Orifi ce size on request.
3)
If “none”, this specifi cation is omitted.
● = standard,  = available
Order example
ECOMAX 3MB545-100P0DA1
t