Honeywell Ecomax 3M User manual

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D GB F NL I E RUS
© 2021 Elster GmbH · Edition 02.21
Safety
Please read and keep in a safe place
Please read through these instructions
carefully before installing or operating. Following the
installation, pass the instructions on to the opera-
tor. 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.
Explanation of symbols
• ,  ,  ,  ... = Action
▷= Instruction
Liability
We will not be held liable for damage resulting from
non-observance of the instructions and non-com-
pliant use.
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.
Conversion, spare parts
All technical changes are prohibited. Only use OEM
spare parts.
Contents
Operating instructions
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GB-1
0585
Translation from the German
Self-recuperative burner
ECOMAX®
Self-recuperative burner ECOMAX®.......
Contents ..............................
Safety.................................
Checking the usage .....................
Installation ............................
ECOMAX®for direct heating systems ........3
ECOMAX®for indirect heating systems .......4
Connecting the gas and air pipes .........5
Wiring ................................6
Preparing commissioning ................7
Commissioning.........................9
Igniting and adjusting the burner ............9
Coarse adjustment with the furnace cold ......9
Fine adjustment with a hot furnace .........10
Maintenance ..........................0
Assistance in the event of malfunction ....5
Accessories ..........................6
Flue gas eductor EJEK...................16
Flue gas connector FLUP................. 17
Air connection set ...................... 17
Flue gas guide tube FGT for SER-C ......... 17
Segmented flame tube SICAFLEX®........ 17
Purge air/cooling air nozzles............... 17
Technical data ........................8
Logistics .............................8
Declaration of Incorporation.............9
Certification ..........................9
Contact ..............................0
Safety
Contents

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Checking the usage
Intended use
Self-recuperative burner ECOMAX®for gas with inte-
grated recuperator for the direct and indirect heating
of furnace systems in intermittent mode.
Direct heating
Flue gases are returned using an eductor.
Indirect heating
Combustion flue gases are separated from the prod-
uct using metallic or ceramic radiant tubes and ce-
ramic segmented flame tubes.
This function is only guaranteed when used within the
specified limits– see page18 (Technical data). Any
other use is considered as non-compliant.
Type code
Code Description
ECOMAX® Self-recuperative burner for gas
0 to 6 Burner size
C
M
P
F
Ceramic burled tube recuperator
(SiSiC)
Cast steel ribbed tube recuperator
Cast steel ribbed tube recuperator for
P radiant tube
Flat tube recuperator, metallic
395 to
695 Recuperator length in mm
-S
-M1)
Standard flame
menox low NOXoperation
B
D
G
L1)
Gas type2):
natural gas
coke oven gas
LPG
LCV gas
/D-
/R-
/V-
/E-
/nnn-
/N-
For direct heating with eductor
For radiant tube heating without eductor
For radiant tube heating with VAH
Burner with customized orifices
Burner construction stage X for nnn kW
Burner without orifices
(1 to 99) Burner head identifier
X, A, B ... Construction stage
–The following features differ from the
standard version:
KAdditional cooling air connection for
increased furnace cooling
AElectrode made of Kanthal APM
TNPT connections
SSICAFLEX spacer
W
Air connection without intermediate flange
ZSpecial version
1) On request.
2) Other gas types on request.
Part designations
ECOMAX®direct
1
2
57
89
3
2
6
4
12
10
11
Gas insert
Gaskets (set)
Intermediate flange
4LFR unit (air guide tube)
5Body with internal insulation
6Eductor EJEK (to be ordered separately)
7Recuperator
8Gas flange set
9Type label
0 Air flange set
 Intermediate flange
 Enclosed documentation (flow rate curves, op-
erating characteristic diagrams, spare parts list,
spare parts drawing)
ECOMAX®indirect
1
2
5
7
89
12
4
2
6
10
11
Gas insert
Gaskets (set)
4LFR unit (air guide tube)
5Body with internal insulation
6Flue gas connector FLUP (to be ordered sepa-
rately)
7Recuperator
8Gas flange set
9Type label
0 Air flange set
 Intermediate flange
 Enclosed documentation (flow rate curves, op-
erating characteristic diagrams, spare parts list,
spare parts drawing)

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Type label
Maximum burner capacity, gas type– see type label.
Elster GmbH
Osnabrück, Germany
kW
20
Installation
CAUTION
We recommend that lifting gear be used for instal-
lation due to the weight involved.
Please observe the following to ensure that the
ECOMAX®is not damaged during installation and
operation:
▷ Dropping the device can cause permanent dam-
age. In this event, replace the entire device and
associated modules before use.
▷
With the ECOMAX®0 to 3C, to prevent transport
damage, the ceramic air guide tube LFR is sup-
plied separately or is fitted with extra transport
protection. See enclosed documentation.
Installation on the furnace
▷
The burner has three air connections and one flue
gas connection. During installation, the burner
must be aligned appropriately (flue gas upwards
or to the side).
ECOMAX®for direct heating systems
▷For a direct heating system, the flue gas guide
tube FGT set..D and the eductor EJEK are re-
quired, see page16 (Accessories).
EJEK
FGT-Set..D
 Remove the transport safety device.
▷The installation opening in the furnace wall must
be greater than the outside diameter of the FGT.
▷ Do not stress the FGT with forces from the
furnace lining. Wrap the FGT in a fibre blanket
before installing the burner.
Complete the fibre wrapping to match the ap-
erture in the furnace wall. Depending on the fur-
nace lining and the type of expected movements
in the furnace wall, the annular void must be at
least 25 mm. Use a larger annular void if neces-
sary. Wrap the cut to size fibre blanket around
the FGT. Fasten the blanket over its entire length
using conventional adhesive tape (compress it
to around 50% of its thickness). After commis-
sioning, the adhesive tape burns off and the fibre
blanket expands evenly inside the annular void.
▷Slide the FGT over the recuperator if it has not
yet been installed.
3
4
2
5
▷ Tighten the nuts in two cycles in a crosswise
fashion, torque: 46Nm.
▷ When installing, always ensure that when the
burner is mounted, it is sealed tightly on the
furnace.
Installing the eductor
▷
The eductor is mounted to the side of the burner.
▷ Align the eductor’s pressure test point to the
control side.
13
2
▷Use the correct torque so that the body is not
damaged:
Type Torque
ECOMAX®1 26 Nm
ECOMAX®2 26 Nm
ECOMAX®3 30 Nm
ECOMAX®4 35 Nm
ECOMAX®5 35 Nm
▷
After installing the eductor, connect the
ECOMAX®to the air and gas circuits.

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ECOMAX®for indirect heating systems
▷ For an indirect heating system, the radi-
ant tube SER, the segmented flame tubes
SICAFLEX
®
and the flue gas connectorFLUP
are required, see page16 (Accessories).
With ceramic radiant tube (SER-C)
Sicaflex®
SER-C
FLUP
▷The ceramic radiant tube (SER-C) must be cor-
rectly installed on the furnace before the burner
is installed, see www.docuthek.com →Thermal
Solutions →Products →07 Industrial burners →
07bSelf-recuperative and radiant tube burners
→Radiant tube SER-C.
▷
Installation of the internal segmented flame tubes
SICAFLEX®, see www.docuthek.com →Ther-
mal Solutions →Products →07 Industrial burn-
ers →07bSelf-recuperative and radiant tube
burners →Segmented flame tube SICAFLEX.
▷ Depending on the installation situation and ra-
diant tube diameter, a flue gas guide tubeFGT
may be required, see page16 (Accessories).
Installation of SER-C
CAUTION
Please observe the following to ensure that the
ceramic radiant tube SER-C is not damaged during
installation and operation:
▷ Open packaging carefully and without using
force.
▷ Insert into the furnace chamber without any
impacts or scratches to avoid damage and
breakage. Depending on the furnace atmos-
phere during operation, damage to the protec-
tive oxide layer on the surface of the radiant
tube can cause corrosion and thus reduce
the service life.
▷
We recommend that someone be inside the
furnace chamber to receive the radiant tube.
Note: for detailed information, refer to SER-C
operating instructions.
1
2
3
▷ Depending on the installation situation, a flue gas
guide tube FGT-set...SER-C may be required.
With metallic radiant tube (SER-M)
FLUP
Sicaflex®
SER-M
With metallic radiant tube (SER-M) and
eductor
EJEK
Sicaflex®
SER-M
▷The metallic radiant tube (SER-M) must be cor-
rectly installed on the furnace before the burner
is installed. Ensure there is a good seal between
the burner and SER-M.
▷ Installation of the internal segmented flame tubes
SICAFLEX®, see www.docuthek.com →Ther-
mal Solutions →Products →07 Industrial burn-
ers →07bSelf-recuperative and radiant tube
burners →Segmented flame tube SICAFLEX.
▷ Depending on the installation situation, a flue gas
guide tube FGT set..D or an adapter flange may
be required (available on request as accessories).
CAUTION
Risk of breakage. Avoid impacts when inserting the
burner into the ceramic radiant tube and placing
on the stud bolts.
 Remove the transport safety device.
 Slide the FGT over the burner recuperator if it
has not yet been installed.
 Wrap a ceramic fibre blanket over the entire
length of the FGT. Compress the fibre blanket
to half its original thickness.

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6 7
4
8
5Fit the
gasket.
▷
Tighten the nuts in two cycles in a crosswise
fashion, torque: 46Nm.
▷
When installing, ensure that the components
are sealed tightly.
▷Ensure that no lateral forces act on the burner
recuperator.
Heat guard
▷During operation, the burner body and eductor
or flue gas connector can reach surface tem-
peratures of over80°C.
▷ We recommend that warning signs and a contact
guard be fitted, for example made of perforated
sheet metal.
▷ Do not insulate the burner body, eductor and flue
gas connector to prevent material overheating.
Connecting the gas and air pipes
Gas connection (GA) and air connection (LA)
LA
GA
Cooling air connection (KA)
▷Optional intermediate flange with an additional
cooling air connection on the burner.
▷To increase the air volume in cooling mode.
KA
Table of threaded and flanged connections
▷ Threaded connection to ISO7, flange dimensions
to ISO7005, PN16.
Type GA* LA KA
ECOMAX®0 R ½" Rp 1" Rp 1"
ECOMAX®1 R ½" Rp 1" Rp 1½"
ECOMAX®2 R ½" Rp 1½" Rp 1½"
ECOMAX®3 R ½" Rp 2" Rp 1½"
ECOMAX®4 R ¾" Rp 2" Rp 2"
ECOMAX®5 R 1" Rp 2" Rp 2"
ECOMAX®6 R 1½" Rp 3" N/A
* On the ECOMAX
®
..L for LCV gas, connections
may differ depending on the project specifications.
▷Install flexible tubes or bellows 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.
▷ The gas insert can be rotated in 90°steps if
necessary.
▷ We recommend that all the gaskets that are
removed to rotate the gas insert be replaced.
▷The electrode must remain in its position at the
top left when the gas insert is rotated. The mixing
device (gas lance) must be rotated for this pur-
pose, see page11 (Replacing the gas lance).
▷ If necessary, another air connection may be used.
The burner has three air connections, two of
which are sealed with blind flanges.
▷Ensure undisturbed flow to the orifices in the air
and gas connections. The ECOMAX®is delivered
with a connection set for gas. In the air circuit,
we also recommend the use of a connection set
for air, see page16 (Accessories).

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Restrictors
▷The appropriate restrictors are to be fitted in the
supply lines for fuel gas, combustion air and
motive air for the eductor to adjust the burner.
Central air connection for LPG operation
▷The LPG version of the burner has an additional
central air lance.
▷
The gas lance must be cooled to prevent the
gas cracking and soot forming inside the burner.
▷The connection is made with an Ermeto pipe.
▷ The purge air connection must be located in the
air supply line to the burner upstream of the air
control valve, for example at the inlet of the air
solenoid valve.
▷ Open the adjuster in the central air lance fully;
on ECOMAX®1, the adjuster must be restricted
to 45° or 50%.
Purge air connections for electrode and UV
sensor
▷ The electrode and the UV sensor should be
cooled and purged with air.
▷ The air must be branched off upstream of the
air control valve, for example at the inlet of the
air solenoid valve.
▷Connect the purge air to the gas flange next to
the electrode.
▷In the case of UV control, use the purge air con-
nection of the UV sensor.
▷The nozzles are adapted to the relevant burner,
see page16 (Accessories). The nozzles do
not need any adjustment.
Wiring
DANGER
Electric shocks can be fatal! Before working on
possible live components, ensure the unit is discon-
nected from the power supply.
▷
The flame is monitored by a combined flame
rod/spark electrode as standard on the burner
ECOMAX®.
▷Flame control with a UV sensor is necessary if a
furnace temperature of 1050°C is exceeded for
direct heating or 950°C for indirect heating. In
this case, we recommend a UV sensor UVS10
with a purge air connection be used.
▷ An adapter set (Order No. 21800791), which
must be ordered separately, is available for in-
stalling the UVS10. If the adapter set has been
ordered with the burner, it is fitted to the burner
on delivery and the UV sensor can be screwed
on to it.
▷ For high temperature operation without flame
control using ionization or a UV sensor, the air
flow must be monitored by a pressure switch.
▷ We recommend an ignition transformer ≥7.5kW,
≥20mA.
▷ For the ignition/ionization cable, use (unscreened)
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.
▷ Length of cable: max. 5m, recommended <1m.
▷ Lay cable individually and not in a metal conduit.
▷ Install cable well away from mains cables and
interference from electro-magnetic sources.
▷ In particular, avoid external electrical interference
when using ionization control.
▷ For UV control, route the ignition cable separately
from the UV cable.
13 2

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4 Connect the PE wire for grounding to the gas
insert. Route the PE wire from the gas insert di-
rectly to the connection on the automatic burner
control unit.
WARNING
High-voltage risk! It is essential that a high-voltage
warning label be attached to the ignition/ioniza-
tion cable.
▷
For more detailed information on how to wire
the ignition/ionization cable, refer to the oper-
ating instructions and connection diagrams of
the automatic burner control unit and ignition
transformer.
▷For further information about using a UV sensor,
refer to the relevant operating instructions.
Preparing commissioning
Safety instructions
▷ Agree settings and commissioning of the burner
with the system operator or manufacturer.
▷ Check the entire system, upstream devices and
electrical wiring/connections.
▷ Note the operating instructions for individual
controls.
DANGER
The burner must only be commissioned by author-
ized trained personnel.
Risk of explosion! Please observe the appropriate
precautions when igniting the burner.
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! A flue gas analysis
is to be conducted.
CAUTION
▷ Pre-purge the furnace chamber or radiant tube
with air (5x volume) before every ignition at-
tempt.
▷If the burner does not ignite although the auto-
matic burner control unit has been switched on
and off several times: check the entire system.
DANGER
Risk of explosion! Fill the gas line to the burner
carefully and correctly with gas and vent it safely
into the open air – do not discharge the test volume
into the furnace chamber.
Determining the gas and combustion air flow
rates
Q
gas
= P
B
/H
i
Qair = Qgas .λ.Lmin
▷Qgas: Gas flow rate in m3/h (ft3/h)
▷PB: Burner capacity in kW (BTU/h)
▷Hi: Gas heating value in kWh/m3(BTU/ft3)
▷Qair: Air flow rate in m3(n)/h (SCFH)
▷λ: Lambda, air index
▷ Lmin: Minimum air requirement in m3(n)/m3(n)
(SCF/SCF)
▷Information on the gas quality supplied can be
obtained from the competent gas supply com-
pany.
Common gas qualities
Gas type
Heating value Lmin
m3(n)/m3(n)
(SCF/SCF)
Hi
kWh/m3(n)
Hs
(BTU/SCF)
Natural
gas H 11 1114 10.6
Natural
gas L 8.9 901 8.6
Propane 25.9 2568 24.4
Town gas 4.09 425 3.67
Butane 34.4 3406 32.3
▷
Data in kWh/m
3
(n) refer to the lower heating
value H
i
and data in BTU/SCF refer to the higher
heating value Hs(gross calorific value).
▷ A minimum air excess of 20% (lambda=1.2)
should be set in a cold furnace for initial adjust-
ment since the air volume falls as the tempera-
ture rises.
▷ Fine adjustment should be carried out at max.
furnace temperature and at as high a capacity
demand as possible.
Notes on the flow rate curve
▷
If the gas density in the operating state differs
from that reflected in the flow rate curve, convert
the pressures according to the local operating
state.
pB = pM . δB
δM
▷δM: Gas density reflected in the flow rate curve
[kg/m3(lb/ft3)]
▷ δB : Gas density in operating state [kg/m
3
(lb/ft
3
)]
▷pM: Gas pressure reflected in the flow rate curve
▷pB: Gas pressure in operating state

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Determining the gas and combustion air
settings
▷Orifices are installed in the gas and combustion
air connections on the burner.
▷
Adjustment is made on the basis of the flow rate-
dependent pressure differential. The required
pressure differentials for gas and air are shown
in the burner diagram.
[mbar ("WC)]
[m3/h (ft3/h)]
Qgas
∆pair
∆pgas
Qair
∆pgas ∆pair
▷ Ensure an undisturbed flow to the orifice. The
ECOMAX®is delivered with a connection set for
gas. In the air circuit, we also recommend the
use of a connection set for air, see page16
(Accessories).
▷ If pipe elbows and angles, reducing fittings, cou-
plings, etc. are used in the immediate vicinity
of the burner connection, differences from the
flow rate curves will occur which may result in
incorrect burner settings.
WARNING
Incorrect burner settings may result in sub-
stoichiometric burner operation.
CO formation in furnace chamber! CO is odour -
less and poisonous! A flue gas analysis is to be
conducted.
Notes on motive air at the eductor
▷
The motive air is set at the eductor by measuring
the negative flue gas pressurepFG between the
burner and eductor.
pFG
▷The required negative pressure is shown in the
eductor diagram, see www.docuthek.com, on
the basis of the maximum furnace temperature
and burner capacity.
▷ If the gas flue extraction rate is 80–90% at
maximum furnace temperature, a negative fur-
nace pressure will generally be avoided even at
a furnace temperature reduced by 400–500°C.
In the case of heavily leaking furnaces, flue gas
extraction must be reduced, where necessary, to
avoid pulling in cold air due to negative pressure
in the furnace chamber.
▷ During the commissioning procedure, the motive
air setting must be optimized (maximization of
flue gas extraction). The furnace pressure must
remain slightly positive in all operating states
(0.1to 0.3mbar).
If the positive pressure exceeds approx. 0.3mbar,
increase the flue gas extraction rate to prevent
the burner being damaged.
If there is a negative pressure in the furnace
chamber, reduce the flue gas extraction rate to
avoid infiltrated air.
Coarse adjustment of the combustion air
volume
 Close the gas supply.
 Start pre-purge.
▷
To adjust the air volume, especially for direct heat-
ing, use the differential pressure measurement
facility in the air circuit.
▷ Air measuring nipple L, outside dia.= 9mm
(0.35").
Measuring the differential air pressure
L
p2
p1
p1p2
0
∆p
4
3
5
Loosen
the screws
2turns.
Measuring the differential air pressure with
versionW without an intermediate flange
L
L
p
2
p
1
p1p2
0
∆p
4
3
5
Loosen
the screws
2turns.
6 Set the required air pressure differential on the
air restrictor.

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Coarse adjustment of motive air at the
eductor
▷The settings of the air volume and the motive air
at the eductor affect each other. Coarse adjust-
ment should be carried out at the same time
during pre-purge.
pFG
patm pFG
0
p
FG
8
7
9
Loosen
the screw
2turns.
▷
Measure the negative flue gas pressurepFG
against atmospheric pressurepatm.
0 Set the required negative flue gas pressure on
the motive air restrictor. Use the values from the
eductor diagram, see www.docuthek.com.
Pressure switch
▷
If the burner is equipped with an air flow detector
set ECO/E, the switching point should be set to
approx. 80% of the pressure differential for the
combustion air.
▷Set the DW set for monitoring the flue gas flow
to the required pressure shown in the enclosed
documentation.
Preparing the gas pressure measurement
 Connect all measuring devices to the burner for
later adjustment.
▷Leave the gas supply closed.
 Read off the differential pressure for the required
gas flow rate from the enclosed flow rate curve.
 p1: gas pressure upstream of the measuring
orifice, p2: gas pressure downstream of the
measuring orifice. Measuring range: select ap-
prox. 15mbar.
▷Gas measuring nipple G, outside dia.= 9mm
(0.35").
G
p1
p2
4
5
Loosen
the screws
2turns.
Commissioning
Igniting and adjusting the burner
WARNING
Ensure adequate ventilation of the furnace chamber
before each burner start!
Risk of burning! Outflowing flue gases and burner
components are hot.
Wear ear defenders to protect yourself from harm-
ful noise.
▷When heating up for the first time, vapours may
be emitted from gaskets or paint coatings, for
example, which may cause unpleasant odours.
 All valves of the installation must be checked for
tightness before ignition.
Coarse adjustment with the furnace cold
▷
Coarse adjustment of the air volumes, see
page7 (Preparing commissioning).
 Limit the maximum gas volume.
▷Open the restrictor around halfway.
 Open the gas supply.
4 Ignite the burner.
▷The safety time of the automatic burner control
unit starts to elapse.
5 Check and adjust the gas and air pressures.
6 If no flame is formed, reset the automatic burner
control unit, purge the combustion chamber and
ignite the burner again.
CAUTION
Pre-purge the furnace chamber or radiant tube
with air (5x volume) before every ignition attempt.
▷The burner ignites and proceeds to normal op-
eration.
▷
If no flame is formed after repeating steps 5and
6multiple times– see page15 (Assistance in
the event of malfunction).
7 Check the differential pressures∆pgas and∆pair
and the negative flue gas pressurepFG, and set
them to their desired values.
▷The gas, air and motive air settings affect each
other. We recommend reading these pressures
at the same time.
▷ Check the settings by conducting a flue gas
analysis (in the flue gas connector in the case of
an indirect heating system or in the furnace in the
case of a direct heating system). Ensure that the
furnace pressure is positive for a direct heating
system to avoid falsification of the measurements
by infiltrated air.

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Leak test
DANGER
To ensure that there is no danger resulting from a
leak, check the gas connections on the burner for
leaks immediately after the burner has been put
into operation.
8
Fine adjustment with a hot furnace
▷ Final adjustment of the burner should be carried
out at maximum furnace temperature and high
capacity demand.
9 Heat the furnace.
0 Watch the furnace pressure and O2value in the
furnace atmosphere. Avoid negative pressure
and sub-stoichiometric operation of the burner. If
necessary, adjust the settings of the combustion
air and motive air.
 Check the differential pressures∆pgas and ∆pair
and the negative flue gas pressurepFG at max.
furnace temperature, and adjust them using the
appropriate restrictor.
∆p
0
p2 p1
▷ Check the settings by conducting a flue gas
analysis (in the flue gas connector or eductor in
the case of an indirect heating system or in the
furnace in the case of a direct heating system).
Ensure that the furnace pressure is positive for
a direct heating system to avoid falsification of
the measurements by infiltrated air.
DANGER
Risk of explosion and poisoning in case of
burner adjustment with an air deficiency! Ad-
just 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.
 Watch the furnace pressure at high capacity
demand and various furnace temperatures to
optimize the motive air setting.
▷ The furnace pressure should be slightly posi-
tive in all operating states (0.1to 0.3mbar).
If the positive pressure exceeds approx.
0.3 mbar, increase the flue gas extraction
rate to prevent the burner being damaged.
▷ If there is a negative pressure in the furnace
chamber, reduce the flue gas extraction rate to
avoid infiltrated air.
Blocking and recording the settings
 Produce a measurement report.
4 Remove the measuring devices and close off
the pressure taps– 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 several times while
monitoring the automatic burner control unit.
8 Produce an acceptance report.
DANGER
An incorrect change of the burner settings may
change the gas/air ratio and lead to unsafe operat-
ing conditions: risk of explosion in case of CO being
formed in the furnace chamber! CO is odourless
and poisonous!
Maintenance
We recommend a function check every six months.
If the media are highly contaminated, this interval
should be reduced.
DANGER
Maintenance work on the burner must be carried
out by authorized trained personnel only.
Risk of explosion! Please observe the appropriate
precautions when igniting the burner.
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! A flue gas analysis
is to be conducted.
Risk of burning! Outflowing flue gases and burner
components are hot.
▷
We recommend that all the gaskets removed
during maintenance work be replaced. The ap-
propriate gasket set is available separately as
a spare part.
 Check the cable to the electrode.
 Measure the ionization current.
▷The ionization current must be at least 5µA and
must not vary.
▷Read off the ionization signal on the burner con-
trol unit.
 Disconnect the system from the electrical power
supply.
4 Shut off the gas and air supply– do not change
the restrictor settings.
5 Disconnect the gas line from the gas insert.
6 Disconnect the grounding cable.

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Checking the spark electrode and mixing
device
▷
The complete gas insert must be removed to
check the spark electrode and mixing device.
CAUTION
On the ECOMAX®..C, do not allow the mixing fun-
nel to strike the ceramic air guide tube fitted in the
burner. Risk of breakage.
▷
On ECOMAX®..M, ECOMAX®..F and
ECOMAX®..P of sizes 1–3, ensure that the
retaining bolts for the combustion chamber do
not fall out.
78
10
9
11
Check the
retaining bolts
as they are
only inserted
loosely.
78
10
9
11
 Place the gas insert in a safe place.
 ECOMAX®..M, ECOMAX®..F, ECOMAX®..P:
remove the retaining bolts for the combustion
chamber and remove the combustion chamber.
4 Check the electrode, mixing device (gas lance)
and insulator for dirt, wear and thermal damage
and cracks; clean or replace if necessary.
Checking and replacing the spark electrode/
flame rod
15
20
L
1
34
▷ Ensure that the electrode length does not change.
6 Remove dirt from electrode or insulator.
7 Replace the electrode if the tip 4or insulator
is damaged.
▷
The electrode rod can also be replaced on its
own.
▷
Before changing the electrode, measure the
total lengthL.
15
20
L
1
34
8 Connect the new electrode rod to the spark
plug.
9 Adjust spark plug and electrode rod to the meas-
ured total lengthL.
15
20
L
1
34
Replacing the gas lance
1,5 – 2 mm
3,4–3,8 mm
X
X
15
18
16
17
19
20
21
Tighten the
union nut
only slightly.
Align the gas
lance so that
the electrode
is not subject
to mechanical
stress.
ECOMAX 4–5:
distance
between
insulator and
burner head
ECOMAX 0–3:
align and
centre the
electrode.

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1,5 – 2 mm
3,4–3,8 mm
X
X
15
18
16
17
19
20
21
Fully tighten
the union
nut.
Rotating the gas insert
1,5 – 2 mm
3,4–3,8 mm
X
X
15
16
17
18
20
19
21
22
23
Tighten the
union nut
only slightly.
Align the gas
lance so that
the electrode
is not subject
to mechanical
stress.
ECOMAX
0–3: align
and centre
the elec-
trode.
The electrode
must always
be positioned
at the top left.
1,5 – 2 mm
3,4–3,8 mm
X
X
15 16
17
18
20
19
21
22
23
Fully tighten
the union
nut.
Replacing the combustion chamber on
ECOMAX®4–5
15
17
18
16
21
20
19
Press the
retaining star
against the
spring.
Guide the
feet through
the openings
provided for
them.
Slowly allow
the star to
be pressed
against the
ceramic
component.
Release
the feet by
turning them.
Press the ce-
ramic compo-
nent against
the star,
position the
feet by turning.
ECOMAX
4–5: distance
between
insulator and
burner head

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Checking the body insulation
Burner with flue gas connector FLUP
12 3
Burner with eductor
12 3
4 Follow the reverse procedure when reassem-
bling.
▷ If possible, carefully check the body insulation
from the front for signs of damage.
26
5 If the insulation is worn or damaged, it must be
replaced.
Checking/replacing the air guide tube LFR
and recuperator
ECOMAX®..C
CAUTION
Risk of breakage. The air guide tube and recu-
perator in the ECOMAX®..C are made of ceramic
material.
1
4
2
3
5
1
4
2
3
5
Check the
recuperator.
▷If any ceramic components are damaged, they
must be replaced.
▷
To check the body insulation carefully and replace
the recuperator, remove the burner and suspend
it vertically, e.g. on two beams.
8
6 7
91110
Checking the insulation
▷ If the insulation is worn or damaged, it must
be replaced.
8b
8c
8a
8d
ba
Ensure that the
flue gas
insulation is
installed in the
correct position.
a < b
Remove the
body insula-
tion from the
front.

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8
6 7
911
10
▷Tighten the nuts in a crosswise fashion, torque:
3.5Nm.
14
12 13 Torque for
ECOMAX®
0–3: 18Nm,
ECOMAX®
4–5: 35 Nm.
Fibre gasket
only for
LFR 0–3C.
ECOMAX®..M, ECOMAX®..P, ECOMAX®..F
2
1
3
4Check the
recuperator.
WARNING
The body insulation is made of ceramic fibres (RCF).
Wear protective equipment. Safety data sheet avail-
able on request.
▷
To replace the recuperator, remove the burner,
place it vertically and secure it to prevent it falling
over. The gas insert must be removed to avoid
breaking the ceramic combustion chamber when
placing the burner.
▷We recommend that the body insulation be re-
placed when fitting a new recuperator.
ba
9
7
56
8
10 11
12
▷ Place the new recuperator vertical and secure
it to prevent it falling over.
ba
9
7
5 6
8
10 11
12
Hold the body
insulation
together, e.g.
using adhe-
sive tape.
▷
Tighten the nuts in two cycles in a crosswise
fashion, torque: 3.5Nm.
13 14
▷ Tighten the nuts in two cycles in a crosswise
fashion. Torque for ECOMAX
®
1–3: 18Nm,
ECOMAX®4–5: 35 Nm.
Ensure that the
flue gas insula-
tion is installed
in the correct
position.
a < b

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Installing the gas insert
CAUTION
ECOMAX®..C: do not strike the mixing funnel
against the ceramic air guide tube. Risk of breakage.
ECOMAX®..M: the gas insert must be slid into the
air guide tube with no resistance. External forces
may damage the ceramic combustion chamber.
▷
ECOMAX®..M, ECOMAX®..F and ECOMAX®..P,
sizes 1–3: install the combustion chamber us-
ing ceramic retaining bolts. During installation,
ensure that the retaining bolts do not fall out.
78
10
9
11
Check the
retaining bolts
as they are
only inserted
loosely.
42
5
3
2
4
1
▷ Tighten the nuts in two cycles in a crosswise
fashion. Torque for ECOMAX®0–3: 18Nm,
ECOMAX®4–5: 35 Nm.
6 Connect the grounding cable.
7 Connect the gas line to the gas insert.
8 Connect voltage to the system.
9 Open the gas and air supply.
0 Check for tightness, see page10 (Leak test).
 Start the burner, see page 9 (Commission-
ing).
DANGER
Risk of explosion and poisoning in case of
burner adjustment with an air deficiency! Ad-
just 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.
 Produce a maintenance report.
Assistance in the event of
malfunction
DANGER
Electric shocks can be fatal! Before working on
possible live components, ensure the unit is discon-
nected from the power supply.
Risk of injury! Burner heads have sharp edges.
Fault-clearance must only be undertaken by author-
ized trained personnel.
▷If no fault is detected when checking the burner,
proceed to the automatic burner control unit and
check for faults in accordance with the relevant
operating instructions.
? Faults
! Cause
• Remedy
? Burner does not function?
! Valves do not open.
• Check the voltage supply and wiring.
! Gas inlet pressure is too low.
• Check the filter for dirt.
• Check the gas supply.
! Air inlet pressure is too low.
• Check the fan and air supply.
! Gas and air pressures on the burner are too low.
• Check the restrictors.
• Check/adjust the start rate setting, see operating
instructions for solenoid valve.
! Automatic burner control unit does not function
correctly.
• Check the device fuse.
• Note the automatic burner control unit operating
instructions.
! Short-circuit of the UV sensor.
• Replace the UV sensor.
• Note the UV sensor operating instructions.
! Automatic burner control unit signals a fault.
• Check the ionization cable.
• Check the ionization current. The ionization cur-
rent must be at least 5µA– stable signal.
• Check whether the burner is adequately ground-
ed.
• Note the automatic burner control unit operating
instructions.
! No ignition spark is created.
• Check the ignition cable.
• Check the voltage supply and wiring.

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• Check whether the burner is adequately ground-
ed.
• Check the electrode – see page10 (Mainte-
nance).
! Defective insulator on the electrode, ignition spark
jumps over incorrectly.
• Check the electrode– depending on the burner
construction stage.
? Burner flame ignites with a loud bang?
! Incorrect electrode adjustment.
• Check the electrode– depending on the burner
construction stage – see page10 (Mainte-
nance).
! Incorrect burner adjustment– air volume too low
or too high.
• Correct the burner adjustment– see page 7
(Preparing commissioning).
! Incorrect burner adjustment– gas volume re-
leased too quickly, defective or incorrectly set
damping unit on the solenoid valve.
• Check the solenoid valve.
• Reduce the start gas rate.
• Adjust the damping speed, see Operating in-
structions VAS, VCS, VAS..L.
• ECOMAX
®
0C: if the burner still ignites with a
loud bang after the damping speed has been
adjusted, set pre-ventilation to 0.5s using the
BCU (parameter 37).
! Excessive central air volume for LPG operation.
• Carefully restrict the central air at the adjust-
ing cock. Excessive restriction may cause soot
formation.
? Burner performs a fault lock-out after burn-
ing faultlessly in normal operation?
! Incorrect gas and air flow rate settings.
• Check the gas and air pressures.
! Automatic burner control unit signals a fault.
• Check the ionization cable.
• Check the ionization current. The ionization cur-
rent must be at least 5µA– stable signal.
! Mixing device or swirl plate soiled.
• Clean gas and air bore holes and air slots.
• Remove deposits from mixing funnel or swirl
plate.
! Excessive pressure fluctuations in the furnace
chamber.
• Ask Honeywell Kromschröder for control con-
cepts.
Accessories
Flue gas guide tube FGT set..D
1
3
2
ECOMAX..M, ECOMAX..F
ECOMAX..C
1
3
2
Burner gasket
Flue gas guide tube FGT
Mounting gasket
For a direct heating system a flue gas guide tubeFGT
is required.
The FGT set..D is not supplied with the ECOMAX®
and must be ordered separately. If the FGT set..D
is ordered with the ECOMAX
®
, it will be supplied
ready-fitted on the burner.
Flue gas eductor EJEK
The eductor generates a negative pressure with a
centrally positioned nozzle and thus draws the flue
gases through the burner’s heat exchanger.
The EJEK is not included in the delivery and must be
ordered separately.

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Flue gas connector FLUP
The FLUP is not supplied with the ECOMAX®and
must be ordered separately.
If the FLUP is ordered with the ECOMAX®, it will be
supplied ready-fitted on the burner.
Air connection set
Specially machined barrel nipple which ensures a
reliable, correct measurement at the orifices installed
in the burner. The /E version is installed when the
burner is supplied.
Ceramic radiant tube SER-C
1
2 3
4
Burner gasket
Flange connection
Radiant tube (SiSiC)
4Mounting gasket
For heat treatment processes in which combustion
gases must be kept separate from the product. The
patented flange connection is air-tight.
Material: SiSiC, max. application temperature:
1300°C.
The SER-C is not supplied with the ECOMAX®and
must be ordered separately.
Flue gas guide tube FGT for SER-C
To guide the flue gases if smaller burners are used
than are standard for the radiant tube diameter.
Material: vacuum moulded pulp.
Available on request in different sizes suitable for the
SER-C radiant tube and ECOMAX®burner sizes.
Segmented flame tube SICAFLEX®
Segmented ceramic flame tubes to guide hot flue
gases in radiant tubes.
Material: SiSiC.
The SICAFLEX®is not supplied with the ECOMAX®
and must be ordered separately.
Purge air/cooling air nozzles
Nozzles to limit the volume of purge air in order to
achieve safe ignition and monitoring of the ECOMAX®
and to avoid condensation and overheating.
Nozzle for electrode purge
Burner Designation
of nozzle Order number
ECOMAX®0
nozzle electrode
ECO 0
G 1/4 D=2.5 /E
21802944
ECOMAX®
1 – 3
nozzle electrode
ECO 1-3
G 1/4 D=2.5 /E
21802945
ECOMAX®
4 – 6
nozzle electrode
ECO 4-6
G 1/4 D=4.0 /E
21802946
UV sensor purge air nozzle
Burner Designation of nozzle Order number
ECOMAX®
0 – 3
nozzle UV ECO 0-3
G 1/4 D=2.5 /B 21802989
ECOMAX®
4 – 6
nozzle UV ECO 4-6
G 1/4 D=4.0 /B 21802990
Purge air connection set
To connect the purge air for the spark electrode or
UV sensor.
Designation Order number
PURGE AIR-SET 1/4-8/6 ECO PTFE-1M 21803332
PURGE AIR-SET 1/4-8/6 ECO PTFE-2M 21803645

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Technical data
Heating: direct with eductor or indirect in radiant tube.
Control type: On/Off.
Adjusting range: 60% to 100%.
Flame velocity: approx. 130 to 170 m/s.
Flame control: direct ionization control (UV control
as an option).
Ignition: direct spark ignition.
Burner Recuperator
Max. flue gas
temperature at
recuperator inlet
ECOMAX®..C Ceramic
(SiSiC) 1250°C*
ECOMAX®..M/
ECOMAX®..P Cast steel 1150°C
ECOMAX®..F Metallic 1050°C
* We advise against using this in forging and heat-
ing furnaces in which raw material is heated.
Burner Capacity [kW] Flame length
[mm]*
ECOMAX®0 25 300
ECOMAX®1 36 300
ECOMAX®2 60 400
ECOMAX®3 100 450
ECOMAX®4 180 800
ECOMAX®5 250 800
ECOMAX®6 500 1000
* Visible range for natural gas operation in the
open air, max. connection rating and air in-
dex1.15.
If the burners are used at geodetic altitudes of over
500m above MSL, the possible capacity will be
lower as a result of the reduced density of gas and air.
Guide value: 5% per 1000 m above MSL.
WARNING
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.
▷
Information on the safe handling of products
containing ceramic fibres can be found in the
safety data sheets.
▷Safety data sheets are available on request.
Logistics
Transport
Protect the unit from external forces (blows, shocks,
vibration). On receipt of the product, check that the
delivery is complete, see page2 (Part designa-
tions). Transport the product in dry, clean conditions.
Report any transport damage immediately.
Storage
Store the product in a dry and clean place.
Storage temperature: see page18 (Technical data).
Storage time: 2years before using for the first time. If
stored for longer than this, the overall service life will
be reduced by the corresponding amount of extra
storage time.
Packaging
The packaging material is to be disposed of in ac-
cordance with local regulations.
Disposal
Components are to be disposed of separately in
accordance with local regulations.

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Declaration of Incorporation
according to 2006/42/EC, Annex II, No. 1B
The product “Self-recuperative burner for gas
ECOMAX
®
” is a partly completed machine pursuant
to Article2g and is designed exclusively for instal-
lation in or assembly with another machine or other
equipment.
The following essential health and safety requirements
in accordance with Annex I of this Directive are ap-
plicable and have been fulfilled:
Annex I, Articles 1.1.3, 1.1.5, 1.3.2, 1.3.4, 1.5.2, 1.7.4
The relevant technical documentation has been com-
piled in accordance with partB of AnnexVII and will
be sent to the relevant national authorities on request
as a digital file.
The following (harmonized) standards have been
applied:
– EN 746-2:2010 – Industrial thermoprocessing
equipment; Safety requirements for combustion
and fuel handling systems
– EN ISO 12100:2010 – Safety of machinery–
General principles for design – Risk assessment
and risk reduction (ISO12100:2010)
The partly completed machine may only be commis-
sioned 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
Einbauerklärung
/ Declaration of Incorporation
nach 2006/42/EG, Anhang II, Nr. 1B
/ according to 2006/42/EC, Annex II No. 1B
Folgendes Produkt / The following product:
Bezeichnung: Rekuperatorbrenner für Gas
Description Self-recuperative burner for gas
Typenbezeichnung / Type: ECOMAX…
Markenname / Branding:
Anhang I, Artikel / Annex I, Article
1.1.3, 1.1.5, 1.3.2, 1.3.4, 1.5.2, 1.5.10, 1.7.4
Folgende (harmonisierte) Normen wurden angewandt: / The following (harmonized) standards have been applied:
Folgende EU-Richtlinien werden erfüllt: / The following EU directives are fulfilled:
Wuppertal
Hubert Wunderlich
Datum / Date Konstrukteur / Designer
Hubert Wunderlich ist bevollmächtigt, die speziellen technischen Unterlagen gemäß Anhang VII B zusammenzustellen.
Hubert Wunderlich is authorized to compile the relevant technical documentation according to Annex VII B.
09.07.2019
Die speziellen technischen Unterlagen gemäß Anhang VII B wurden erstellt und werden der zuständigen nationalen Behörde auf Verlangen
in elektronischer Form übermittelt.
The relevant technical documentation has been compiled in accordance with part B of Annex VII and will be sent to the relevant national
authorities on request as a digital file.
Die unvollständige Maschine darf erst dann in Betrieb genommen werden, wenn festgestellt wurde, dass die Maschine, in der das
oben bezeichnete Produkt eingebaut werden soll, den Bestimmungen der Richtlinie für Maschinen (2006/42/EG) entspricht.
The partly completed machine may only be commissioned 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.
– Industrial thermoprocessing equipment; Safety requirements for combustion and fuel handling systems
EN ISO 12100:2010 – Sicherheit von Maschinen – Allgemeine Gestaltungsleitsätze – Risikobeurteilung
und Risikominderung (ISO 12100:2010)
– Safety of machinery – General principles for design – Risk assessment
and risk reduction (ISO 12100:2010)
RoHS II (2011/65/EU)
RoHS III (2015/863/EU)
ist eine unvollständige Maschine nach Artikel 2g und ausschließlich zum Einbau in oder zum Zusammenbau mit einer anderen Maschine
oder Ausrüstung vorgesehen.
is a partly completed machine pursuant to Article 2g and is designed exclusively for installation in or assembly with another machine or other
equipment.
Folgende grundlegende Sicherheits- und Gesundheitsschutzanforderungen gemäß Anhang I dieser Richtlinie kommen zur Anwendung und
wurden eingehalten:
The following essential health and safety requirements in accordance with Annex I of this Directive are applicable and have been fulfilled:
EN 746-2:2010 – Industrielle Thermoprozessanlagen; Sicherheitsanforderungen an Feuerungen und Brennstoffführungssysteme
Elster GmbH
Postfach 28 09
D-49018 Osnabrück
Strotheweg 1
D-49504 Lotte (Büren)
Tel. [phone]
Fax [phone]
[email protected]
www.kromschroeder.com
Certification
Eurasian Customs Union
The product ECOMAX®meets the technical specifi-
cations of the Eurasian Customs Union.
Conformity certified under Technical Regulations
TRCU010/2011

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Contact
If you have any technical questions, please contact
your local branch office/agent. The addresses are
available on the Internet or from ElsterGmbH.
We reserve the right to make technical modifications
in the interests of progress.
Elster GmbH
Strotheweg 1, D-49504 Lotte (Büren)
Tel. [phone]
Fax [phone]
[email protected], www.kromschroeder.com
Contact