Honeywell Kromschroder GIK Series User manual

CONTENTS
· Edition 09.21 · EN · 03250312
DE, EN, FR, NL, IT, ES, DA, SV, NO, PT, EL, TR, CS, PL, RU, HU – www.docuthek.com
Air/gas ratio controls GIK,
variable air/gas ratio controls GIKH
1 Safety ................................1
2 Checking the usage .....................2
3 Installation ............................2
4 Installing the air control line................3
5 Installing the breather line.................4
6 Tightness test..........................4
7 Setting the low-fire rate...................4
8 Bypass for staged control ................5
9 Installing the variable restrictor .............6
10 Maintenance cycles .................... 7
11 Accessories ..........................7
12 Technical data ........................8
13 Designed lifetime ......................9
14 Certification ..........................9
15 Logistics ............................10
1 SAFETY
1.1 Please read and keep in a safe place
Please read through these instructions care-
fully before installing or operating. Following the installa-
tion, pass the instructions on to the operator. This unit
must be installed and commissioned in accordance
with the regulations and standards in force. These
instructions can also be found at www.docuthek.com.
1.2 Explanation of symbols
1, 2, 3, a, b, c = Action
➔= Instruction
1.3 Liability
We will not be held liable for damage resulting from
non-observance of the instructions and non-com-
pliant use.
1.4 Safety instructions
Information that is relevant for safety is indicated in the
instructions as follows:
DANGER
Indicates potentially fatal situations.
WARNING
Indicates possible danger to life and limb.
CAUTION
Indicates possible material damage.
All interventions may only be carried out by qualified
gas technicians. Electrical interventions may only be
carried out by qualified electricians.
1.5 Conversion, spare parts
All technical changes are prohibited. Only use OEM
spare parts.
OPERATING INSTRUCTIONS

GIK, GIKH · Edition 09.21
EN-2
2 CHECKING THE USAGE
Air/gas ratio controls GIK for maintaining a constant
gas/air ratio of 1:1 and for gas pressure control in
systems without preheated combustion air.
Variable air/gas ratio controls GIKH for maintaining
a constant gas/air ratio of 4:1 and for gas pressure
control in systems using a recuperative air preheating
system.
GIK, GIKH for continuous control. GIK..B, GIKH..B
for staged control.
GIK..L, GIKH..L for air only.
This function is only guaranteed when used within the
specified limits– see page 8 (12 Technical data).
Any other use is considered as non-compliant.
2.1 Type code
GIK Air/gas ratio control
15-150 Nominal size
RRp internal thread
FFlange to ISO 7005
02 pumax. 200mbar
-5 Pressure test point at the outlet
-6 Pressure test point at the inlet and outlet
LOnly for air (without approval)
BWith bypass screw (GIK15-25: 1.5mm;
GIK40-50: 5mm)
ANSI flange version GIK..A available up to DN100.
GIKH Variable air/gas ratio control
25 Nominal size
RRp internal thread
02 pumax. 200mbar
-5 Pressure test point at the outlet
LOnly for air (without approval)
BWith bypass screw
2.2 Part designations
Rp 1/4 Rp 1/2
GIK..R GIK..F
1
22
3
4
5
3
5
1
1 Adjusting screw
2 Connection for air control pressure
3 Test point for air control pressure
4 Bypass screw
5 Test point for outlet pressure
Rp 1/2
Rp 3/8
Rp 3/8
GIKH
1
2
3
6
4
5
1 Adjusting screw
2 Connection for breather line
3 Bypass screw
4 Connection and test point for air control pres-
sure (+)
5 Connection and test point for air control pres-
sure (–)
6 Test point for outlet pressure
2.3 Type label
Technical limits, e.g. max. inlet pressure and control
pressure: see type label or page 8 (12 Technical
data).
Elster GmbH
Osnabrück, Germany
GIK/GIKH
3 INSTALLATION
CAUTION
Incorrect installation
Please observe the following to ensure that the
unit is not damaged during installation:
– Always install a manual valve, filter and safety
valve upstream of the air/gas ratio control or
variable air/gas ratio control.
– The installation location must be dry, see page
8 (12 Technical data).
– Dropping the device can cause permanent
damage. In this event, replace the entire device
and associated modules before use.
– Install the unit in the pipe free of mechanical
stress.
– Do not clamp the unit in a vice or use it as a
lever. Risk of external leakage.
➔ Only install the unit in horizontal pipelines, the spring
dome must point vertically downwards.
➔ We recommend that a slowing down section of
3xDN be provided downstream of the regulator.

GIK, GIKH · Edition 09.21
EN-3
➔ The regulator must not be in contact with masonry.
Ensure that there is sufficient space for adjusting
the low-fire rate.
> 20 mm
> 20 cm
1 Remove the screw caps.
➔Obey the direction of flow as marked on the hous-
ing.
GIK..R, GIKH..R
➔Use approved sealing material only.
➔ Use a suitable spanner. Do not use the spring dome
as a lever.
a b
GIK..F
a b
Inlet pressure pu
GIK: the inlet pressure p
u
must always be greater than
the air control pressurepsaplus the pressure dropΔp
to ensure that the air/gas ratio control is not overloaded.
p
sa
p
u
GIKH: The inlet pressure pumust be greater than 4x
the differential control pressure Δpsa plus the pressure
drop Δp.
p
sa
+
psa
–
p
u
4 INSTALLING THE AIR CONTROL
LINE
➔ Every signal line whose failure may lead to the
uncontrolled escape of gas and therefore to an
unsafe status and gas fire must be made of metal.
➔The connection of the air control line must be at a
distance of 5 x DN from other air control elements.
Rp 1/4
12 x 1,5
GIK..R
Rp 1/2
12 x 1,5
GIK..F
➔Install the measuring orifice in the air line.
Rp 3/8
+
Rp 3/8
–
GIKH

GIK, GIKH · Edition 09.21
EN-4
5 INSTALLING THE BREATHER LINE
GIKH
➔ When fitting the unit into a gas line, an Rp1/2
breather line must be connected, which must be
routed to a safe area. A breather line is not neces-
sary if the unit is installed in the air line.
Rp 1/2
6 TIGHTNESS TEST
➔ Check the tightness again, even after a function
check.
1 Block the pipeline at the outlet.
2 Close the valve or close off the outlet with a blank-
ing plate.
3 Slowly pressurize the regulator.
GIK..R
a max. 300 mbar b
c
max. 150 mbar
d
GIK..F
a max. 300 mbar b
c
max. 150 mbar
d
7 SETTING THE LOW-FIRE RATE
Set the high-fire rate using restricting orifices or ad-
justment elements on the burner.
1 Switch on the burner.
➔The cover cap must be removed from the GIK..R
and GIKH for setting the low-fire rate.
2
GIK
At low-fire rate: control pressure at least 0.5mbar.
Factory setting: pd= psa
pd
psa
3 mm
pd= psa
± 3 mbar
GIK..R
pd
psa
6 mm
pd= psa ± 2 mbar
0
0
GIK..F
GIKH
At low-fire rate: differential control pressure at least
0.2mbar.
Factory setting: pd= approx. 4 x Δpsa
0
pd
+
-
0
3 mm
3 Fit the cover cap again once the settings have been
made successfully on the GIK..R and GIKH.

GIK, GIKH · Edition 09.21
EN-5
8 BYPASS FOR STAGED CONTROL
For staged control, the spring is decompressed at the
factory in such a way that the low-fire rate only flows
through the bypass.
The bypass orifice in the bypass screw determines
the low-fire rate.
Use
➔
The bypass screws and the housings have been
marked since 11.2000. Only marked screws may
be used with marked housings.
GIK 15–25..B,
GIKH 25..B
GIK 40–50..B
Control pressure
➔GIK..B: the air control pressure must be less than
2mbar at low-fire rate.
➔GIKH..B: the differential control pressure must be
less than 0.5mbar at low-fire rate.
Bypass flow rate
∆
p [mbar]
0,2 0,3 0,4 0,6 0,8 1 2 3 7
1
0,3 0,4 0,6 0,8 1 2 3
2
0,2 0,3 0,4 0,6 0,8 1 2
4
0,2 0,3 0,4 0,6 0,8 1
20
20
10
4 5 6 8 10
4 75 6 8 10
3 4 75 6 8 10
2 3 4 75 6 8
3
10
20
30
40
50
60
80
100 1,5* 5* 6 7 8 942 3mm ø
ø
GIK 15–25..B, GIKH 25..B GIK 40–50..B
2,4
2,2
2,6
2,8
3,2
3,4
3,6
3,8
Q [m
3
/h (n)]
* Standard bypass orifice
1 = natural gas (ρ = 0.80kg/m3)
2 = town gas (ρ = 0.58kg/m3)
3 = propane (ρ = 2.01kg/m3)
4 = air (ρ = 1.29kg/m3)
➔Bypass screw, for variable adjustment for GIK15–
25, see page 7 (11 Accessories).
➔ Bypass screws, diameter to order for GIK15–25
and GIK40–50, see page 7 (11 Accessories).

GIK, GIKH · Edition 09.21
EN-6
9 INSTALLING THE VARIABLE RE-
STRICTOR
If air control pressure psa > inlet pressure pu: install a
variable restrictor on the GIK.
CAUTION
Incorrect installation
Please observe the following to ensure that the
unit is not damaged:
– The variable restrictor must only be installed on
the GIK.
➔The outlet opening on the fitted restrictor must be
protected from dirt.
1 Install a filter upstream of the variable restrictor.
2 Ensure that the variable restrictor is the correct
design for GIK..R or GIK..F.
GIK..R
12
2
1
GIK..F
Installing the variable restrictor on the GIK..R
a
1
b
2
c
Installing the variable restrictor on the GIK..F
a b
1
c
2
d Seal the air control line at the thread with sealant.
e
3 Enter the maximum gas flow rate in the diagram
and read off the pressure dropΔp for the appro-
priate nominal size.
➔Min. pressure drop Δp = 2.5mbar
➔psa max. = pu– Δp
Flow rate
2
3
4
5
6
8
10 20 30 40 50 60 80 100 200 300 400
1
20 30 40 50 60 80 100 200 300 400
2
78 10 20 30 40 50 60 80 100 200 300 400
4
6 7 8 10 20 30 40 50 60 80 100
2000 3000
2000 3000
1000200 300
3
600
Qn[m
3
/h]
600 1000
1000
600 1000 2000
400 600
10
20
30
40
50
60
80
100
GIK 80
GIK 65
GIK 20
GIK 25
GIK 50
GIK 15
GIK 40
GIK 100
GIK 150
∆p [mbar]

GIK, GIKH · Edition 09.21
EN-7
4 Open the air valve fully.
5 Adjust it until the air control pressure p
sa max.
reach-
es the calculated value. Observe the gas and air
pressures on the downstream consumers.
psa
−
+
GIK..R
psa
0
+
−
GIK..F
6 Open the gas valve upstream of the air/gas ratio
control.
➔It must be possible to identify a change in the gas
outlet pressure pdover the entire turndown range,
corresponding to the air control pressure psa. If only
the air control pressure p
sa
rises in the upper capac-
ity range and the gas outlet pressure pddoes not:
7 Turn the adjusting screw towards “–” and increase
the flow rate to maximum volume again, making
any adjustments that may be required.
10 MAINTENANCE CYCLES
GIK, GIKH requires little servicing.
We recommend that a function check is carried out
once per year, or at least twice a year if biogas is used.
11 ACCESSORIES
11.1 Bypass screw GIK15–25, variable
The bore hole diameter for the flow rate can be adjusted
as desired and corresponds to holes of 1.5–4mm, see
page 5 (8 Bypass for staged control).
OrderNo.: GIK15–25: 74919806.
11.2 Bypass screw, diameter to order
The bore hole diameter of the bypass screw is made
to order.
➔The bypass orifice can be enlarged if required.
Type Bypass orifice [mm]
Standard Enlarged
GIK15–25, GIKH25
Order No.: 74919820 Ø 1.5 Max. Ø 4
GIK40–50
Order No.: 74919821 Ø 5 Max. Ø 9
Enlarging the bypass orifice
1 2 3
4
max. 300 mbar
5

GIK, GIKH · Edition 09.21
EN-8
11.3 Conversion kit for zero pressure control
The zero shut-off prevents an increase in the outlet
pressure when the consumer is switched off.
The conversion kit for zero pressure control is screwed
in instead of the air control line.
➔
The device has been converted to a zero governor.
We recommend labelling the device clearly.
➔ Install the air/gas ratio control, see page 2 (3
Installation).
➔
Set the air/gas ratio control, see page 4 (7 Set-
ting the low-fire rate).
GIK15–50
Rp 1/4
OrderNo.: 03351039
GIK65–150
Rp 1/2
OrderNo.: 74910853
12 TECHNICAL DATA
12.1 Ambient conditions
Icing, condensation and dew in and on the unit are
not permitted.
Avoid direct sunlight or radiation from red-hot surfaces
on the unit. Note the maximum medium and ambient
temperatures!
Avoid corrosive influences, e.g. salty ambient air or SO2.
The unit may only be stored/installed in enclosed
rooms/buildings.
Long-term use in the upper ambient temperature
range accelerates the ageing of the elastomer ma-
terials and reduces the service life (please contact
manufacturer).
This unit is not suitable for cleaning with a high-pressure
cleaner and/or cleaning products.
Ambient temperature:
GIK15–50: -20 to +60°C,
GIK65–150: -15 to +60°C,
GIKH25: -20 to +60°C.
Storage temperature: GIK15–50: -20 to +40°C,
GIK65–150: -15 to +40°C,
GIKH25: -20 to +40°C.
Transport temperature = storage temperature.
12.1.1 Mechanical data
Gas types: town gas, natural gas, LPG (gaseous)
and biogas (max. 0.02 %-by-vol. H2S). GIK..L/
GIKH..L for air only. The gas must be clean and dry
in all temperature conditions and must not contain
condensate.
Medium temperature = ambient temperature.
12.1.2 GIK
The inlet pressure pumust be greater than the con-
trol pressure psa plus the pressure drop Δp.
Max. pressure drop Δp = 100mbar.
Air control pressure: 0.5 to 120mbar.
Outlet pressure: 0.2 to 119mbar.
Gas/air pressure ratio: 1:1.
Turndown: 1:10.
Rp internal thread pursuant to ISO7-1 and NPT
internal thread.
ISO flange pursuant to ISO7005 (PN16) and ANSI
flange.
Type Weight [kg]
GIK15R, GIK15N 1
GIK20R, GIK20N 1.1
GIK25R, GIK25N 1.1
GIK40R, GIK40N 1.8
GIK50R, GIK50N 2.8
GIK65F, GIK65A 12
GIK80F, GIK80A 16.1
GIK100F, GIK100A 26
GIK150F 45.5

GIK, GIKH · Edition 09.21
EN-9
Housing: AlSi.
Diaphragms: NBR.
Bypass screw: brass.
GIK15–25 bypass orifice:
standard Ø 1.5mm, up to Ø 4mm possible.
GIK40–50 bypass orifice:
standard Ø 5mm, up to Ø 9mm possible.
GIK15–50
Adjusting range at low fire: -3 to +3mbar.
Connection for control line: Rp 1/4.
Valve plate: plastic.
Valve plate seal: NBR.
GIK65–150
Adjusting range at low fire: -2 to +2mbar.
Connection for control line: Rp 1/2.
Valve plate: aluminium.
Valve plate seal: vulcanized NBR seal.
12.1.3 GIKH
Gas/air pressure ratio: 4:1.
Inlet pressure pu: max. 200mbar.
The inlet pressure pumust be greater than 4x the
differential control pressureΔpsa plus the pressure
dropΔp.
Max. pressure drop Δp = 100mbar.
Rp internal thread pursuant to ISO7-1 and NPT
internal thread.
Housing: aluminium.
Valve seat and stem: aluminium.
Diaphragms: NBR.
Valve plate: plastic.
Valve plate seal: NBR.
Bypass screw: brass.
When used for air: special version.
Weight: 3.4kg.
13 DESIGNED LIFETIME
This information on the designed lifetime is based on
using the product in accordance with these operat-
ing instructions. Once the designed lifetime has been
reached, safety-relevant products must be replaced.
Designed lifetime (based on date of manufacture) in
accordance with EN88 for GIK, GIKH: 15years.
You can find further explanations in the applicable
rules and regulations and on the afecor website (www.
afecor.org).
This procedure applies to heating systems. For ther-
moprocessing equipment, observe local regulations.
14 CERTIFICATION
Declaration of conformity
We, the manufacturer, hereby declare that the prod-
ucts GIK15–50 and GIKH25 with product ID No.
2797CE688640 as well as GIK65–150 with product
ID No. CE-0085AQ0973 comply with the requirements
of the listed Directives and Standards.
Directives:
– 2011/65/EU – RoHS II
– 2015/863/EU – RoHS III
Regulation:
– (EU) 2016/426 – GAR
Standards:
– EN88-1:2011+A1:2016
The relevant product corresponds to the tested type
sample.
The production is subject to the surveillance procedure
pursuant to Regulation (EU) 2016/426 AnnexIIIB.
Elster GmbH
Scan of the Declaration of conformity for GIK (D,GB)–
see www.docuthek.com, Declaration of conformity for
GIKH (D,GB)– see www.docuthek.com.
Eurasian Customs Union
The products GIK, GIKH meet the technical specifica-
tions of the Eurasian Customs Union.

GIK, GIKH · Edition 09.21
EN-10
15 LOGISTICS
Transport
Protect the unit from external forces (blows, shocks,
vibration).
Transport temperature: see page 8 (12 Technical
data).
Transport is subject to the ambient conditions de-
scribed.
Report any transport damage on the unit or packaging
without delay.
Check that the delivery is complete.
Storage
Storage temperature: see page 8 (12 Technical
data).
Storage is subject to the ambient conditions described.
Storage time: 6months in the original packaging 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 accord-
ance with local regulations.
Disposal
Components are to be disposed of separately in ac-
cordance with local regulations.
© 2021 Elster GmbH We reserve the right to make technical modifications in the interests of progress.
The Honeywell Thermal Solutions family of products includes
Honeywell Combustion Safety, Eclipse, Exothermics, Hauck,
Kromschröder and Maxon. To learn more about our products, visit
ThermalSolutions.honeywell.com or contact your Honeywell Sales
Engineer.
Elster GmbH
Strotheweg 1, D-49504 Lotte
T [phone]
[email protected]
www.kromschroeder.com
Global centralized service deployment coordination:
T [phone] or -555
[email protected]
Translation from the German
FOR MORE INFORMATION