Kromschroeder BIO 50 User manual

CONTENTS
· Edition 09.22 · EN · 03250472
DE, EN, FR, NL, IT, ES, DA, SV, NO, PT, EL, TR, CS, PL, RU, HU – www.docuthek.com
Burners for gas BIO, BIOA, BIOW
1 Safety ................................1
2 Checking the usage .....................2
3 Installation ............................2
4 Wiring................................5
5 Preparing commissioning.................6
6 Commissioning ........................9
7 Maintenance..........................11
8 Assistance in the event of malfunction ......13
9 Accessories ..........................14
10 Technical data .......................15
11 Logistics ............................15
12 Disposal ............................15
13 Declaration of Incorporation .............16
14 Certification .........................16
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

BIO · Edition 09.22
EN-2
2 CHECKING THE USAGE
Burner for heating industrial thermoprocessing equip-
ment. For installation in a burner block or for use with
an extended, heat-resistant burner tube. For natural
gas, town gas and LPG. Other types of gas on request.
This function is only guaranteed when used within the
specified limits– see also page 15 (10 Technical
data). Any other use is considered as non-compliant.
2.1 Type label
Construction stage, rated capacity Qmax, gas type and
diameter of gas measuring orifice (as of construction
stageE)– see type label.
Elster GmbH
Osnabrück, Made in Germany
BIO 80HB-100/35-(16)F
84021014
P 150 kW
Ø 13 mm
.3322
2.2 Type code
BIO, ZIO Burner for gas
BIOA Burner for gas, with aluminium housing
BIOW Burner for gas, with ceramic fibre
insulation (RCF)
50-140 Burner size
RCold air
KFlat flame
HHot air/high furnace temperature
BNatural gas
DCoke oven gas, town gas
GPropane, propane/butane, butane
MPropane, propane/butane, butane (with
mixer)
LLow calorific value gas
Fbiogas
LTorch
RReduced capacity
-X X mm length of steel tube as of furnace
flange (L1)
/X X mm distance from furnace flange to
front edge of burner head (L2)
-(X) Burner head identifier
A-Z Construction stage
BWith purge air bore holes
HHigh temperature version
ZSpecial version
2.3 Part designations
1
3
4
5
6
7
2
1 Burner insert
2 Type label
3 Gas housing gasket
4 Air housing
5 Burner tube set
6 Mounting gasket (not included in the delivery)
7 Operating instructions – for more documents
and calculation tools, see www.adlatus.org
2.4 Burner head
➔Check letter marking and identification marks on
the burner head using the information provided
on the type label.
3 INSTALLATION
3.1 Conical burner block
➔For industrial furnaces and kilns and for burning in
an open combustion chamber.
➔Control: High/Low, continuous.
➔Type of burner head: R.
➔Max. capacity: 100%.
➔We recommend the cold air operating mode; oth-
erwise the nitric oxide values will be too high.

BIO · Edition 09.22
EN-3
3.2 Cylindrical burner block
➔For industrial furnaces and kilns and for burning in
an open combustion chamber.
➔Control: High/Low, High/Low/Off, continuous.
➔Type of burner head: R, H.
➔Max. capacity: 100%.
➔Normal to medium flow velocity.
3.3 Tapered burner block
➔For industrial furnaces and kilns and for burning in
an open combustion chamber.
➔Control: High/Low, High/Low/Off, continuous.
➔Type of burner head: R, H.
➔ Max. capacity: approx. 80%, depending on the
outlet diameter of the burner block.
➔Medium to high flow velocity.
3.4 Flat flame burner block
➔For industrial furnaces and kilns and for burning in
an open combustion chamber.
➔Control: High/Low, High/Low/Off, continuous (lim-
ited turndown).
➔Type of burner head: K.
➔Capacity range: 40–100%.
3.5 Burners with attachment tube
➔
Position of the burner head near the interior furnace
wall ( L2 = LO ± 50mm).
L2= LO± 50 mm
LO
1
➔ Do not fit the attachment tube 1directly in the
furnace wall.
➔Furnace temperature ≤600°C.
3.6 Radiant tube heating
2
➔ Reduce the outlet diameter of the radiant tube
using an orifice 2to the point where a pressure
loss of approx. 10mbar occurs at the burner’s
rated capacity.
3.7 Hot air generation
➔At flow velocities of > 15m/s, the flame tube FPT
is used to protect the flame from being cooled.

BIO · Edition 09.22
EN-4
3.8 Installation on the furnace
➔
When installing, always ensure that when the burner
is mounted, it is sealed tightly on the furnace wall.
1 2
3 4
3.9 Air connection, gas connection
BIO
GA
LA
BIOW
GA
LA
(14,16,17)
Type Gas connec-
tion GA
Air connec-
tion LA*
BIO 50 Rp 1/2 Rp 1/2
BIOA 65 Rp 1/2 Ø 48mm
BIO 65 Rp 3/4 Rp 1 1/2
BIO 80 Rp 3/4 Rp 2
BIO 100 Rp 1 Rp 2
BIO 125 Rp 1 1/2 DN 65
BIO 140 Rp 1 1/2 DN 80
BIOW 65 Rp 3/4 DN 65
BIOW 80 Rp 3/4 DN 80
BIOW 100 Rp 1 DN 80
BIOW 125 Rp 1 1/2 DN 100
BIOW 140 Rp 1 1/2 DN 125
* Up to burner size 100, threaded connection;
as from burner size 125, flanged connection,
BIOA 65: tube connection.
➔
Threaded connection to DIN2999, flange dimen-
sions to DIN2633, PN 16.
➔ 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.
➔ On delivery, the threaded gas connection is situated
opposite the air connection; it can be rotated in
increments of 90°.
3.10 Connection to ANSI/NPT
➔An adapter set is required for connection to ANSI/
NPT, see page 14 (9 Accessories)
Type Gas connec-
tion GA
Air connec-
tion LA
BIO 50 ½–14 NPT 1½–11.5 NPT
BIO 65 ½–14 NPT Ø 1.89"
BIO 65 ¾–14 NPT 1½–11.5 NPT
BIO 80 ¾–14 NPT 2–11.5 NPT
BIO 100 1–11.5 NPT 2–11.5 NPT
BIO 125 1½–11.5 NPT Ø 2.94"
BIO 140 1½–11.5 NPT Ø 3.57"
BIOW 65 ¾ NPT Ø 2.94"
BIOW 80 ¾ NPT Ø 3.57"
BIOW 100 1 NPT Ø 3.57"
BIOW 125 1½ NPT Ø 4.6"
BIOW 140 1½ NPT Ø 5.6"
➔
BIO 50 to BIO 100: use NPT adapter Jfor air
connection LA and NPT thread adapter Hfor gas
connection GA.
H
J
GA
LA
➔ BIO 125, BIO 140, BIOW: weld flange Kto air
pipe Pfor air connection LA and use NPT thread
adapter Hfor gas connection GA.

BIO · Edition 09.22
EN-5
BIO 125 and BIO 140
H
K
GA
LA
P
BIOW
GA
LA K
P
H
(14,16,17)
3.11 Pilot connections on the BIO..L
➔Air connection la: Rp3/8".
➔ Gas connection ga (as from burner size 65):
Rp1/4".
la
ga
➔Pilot capacity: 1.5kW.
3.12 Installing the burner insert
WARNING
– BIOW: do not damage the surface of the
insulation. Avoid the formation of dust.
➔ The burner insert can be rotated to the required
position in increments of 90°.
1 Insert the gas housing gasket between the burner
insert and the air housing.
2 Tighten burner insert in a crosswise fashion:
BIO(A) 50–100 with max. 15 Nm (11 lb ft),
BIO 125–140 with max. 30Nm (22lbft).
4 WIRING
DANGER
Electric shocks can be fatal!
– Before working on possible live components,
ensure the unit is disconnected from the power
supply.
➔For the ignition and ionization cables, use (un-
screened) 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.
Z
I
Flame rod I
➔ Install the ionization cable well away from mains
cables and interference from electromagnetic
sources and avoid external electrical interference.
Max. length of ionization cable – see automatic
burner control unit operating instructions.
➔ Connect the flame rod to the automatic burner
control unit via the ionization cable.
Spark electrode Z
➔Length of ignition cable: max. 5 m (15ft), recom-
mended <1m (40").
➔For permanent ignition, max. ignition cable length
1 m(40").
➔
Lay the ignition cable individually and not in a metal
conduit.

BIO · Edition 09.22
EN-6
➔Install the ignition cable separately from ionization
and UV cables.
➔A ≥7.5kV, ≥12mA ignition transformer is recom-
mended; 5kV for integrated pilot.
Flame rod and spark electrode
1
2 3 4
5
6 Connect the PE wire for burner ground to the burn-
er insert. In the case of single-electrode operation,
route the PE wire from the burner insert directly to
the terminal on the automatic burner control unit.
WARNING
High-voltage risk!
– It is essential that a high-voltage warning label
be attached to the ignition cable.
7 For more detailed information on how to wire the
ionization and ignition cables, refer to the operating
instructions and connection diagrams of the auto-
matic burner control unit and ignition transformer.
5 PREPARING COMMISSIONING
5.1 Safety instructions
➔ Agree on settings and commissioning of the burner
with the system operator or manufacturer.
➔ Check the entire system, upstream devices and
electrical connections.
➔Note the operating instructions for individual con-
trols.
DANGER
Risk of explosion!
– Please observe the appropriate precautions
when igniting the burner.
– Pre-purge the furnace chamber or radiant tube
with air (5x volume) before every ignition
attempt.
– 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.
DANGER
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! Conduct a flue gas
analysis.
– The burner must only be commissioned by
authorized trained personnel.
➔If the burner does not ignite even though the auto-
matic burner control unit has been switched on and
off several times: check the entire system.
➔After ignition, monitor the flame and the gas and
air pressure measured on the burner. Measure the
ionization current. Switch-off threshold– see au-
tomatic burner control unit operating instructions.
+μA –
Z
I
➔ The burner must only be ignited at low-fire rate
(between 10 and 40% of the rated capacityQmax)–
see type label.
5.2 Determining the gas and combustion air
flow rates
➔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 gas supply company.
Common gas qualities
Gas type Heating value
HuHoLmin
kWh/
m3(n)
BTU/
SCF
m3(n)/
m3(n)
(SCF/
SCF)
Natural gas H 11.0 1114 10.6
Natural gas L 8.9 901 8.6
Propane 25.9 2568 24.4
Low calorific
value gas 1.7–3 161– 290 1.3–2.5
Butane 34.4 3406 32.3
➔
Data in kWh/m
3
(n) refer to the lower heating val -
ueH
u
and data in BTU/SCF refer to the higher
heating valueHo(gross calorific value).

BIO · Edition 09.22
EN-7
➔ A minimum air excess of 20% (lambda=1.2) should
be set in a cold furnace for initial adjustment since
the air volume falls as the temperature rises.
➔ Fine adjustment should be carried out at max.
furnace temperature and at as high a capacity
demand as possible.
5.3 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 .
δ
B
δ
M
➔ δM: Gas density reflected in the flow rate curve
in kg/m3(lb/ft3)
➔ δB: Gas density in operating state in kg/m3(lb/ft3)
➔pM: Gas pressure reflected in the flow rate curve
➔pB: Gas pressure in operating state
5.4 Burners without gas measuring orifice
1 Read the gas pressure pgas and air pressure pair
from the enclosed flow rate curve for cold air on
the basis of the calculated flow ratesQ.
[mbar (inch WC)]
[m3/h (ft3/h)]
pgas pair
pair
pgas
Qair Qgas
➔ Note possible capacity changes due to positive
or negative pressures in the furnace/combustion
chamber. Add positive pressures or subtract neg-
ative pressures.
➔As not all the effects caused by the equipment are
known, setting the burner using the pressure values
is only approximate. It is possible to set the burner
precisely by measuring the flow rates or flue gas.
5.5 Burners with gas measuring orifice
1 Read the differential pressureΔpgas and air pres-
surep
air
from the flow rate curve for cold air on the
basis of the calculated flow rates.
[mbar (inch WC)]
[m3/h (ft3/h)]
Δpgas pair
pair
pgas
Qair Qgas
pgas
∆pair
➔Note possible capacity changes (air) due to pres-
sure loss in the furnace/combustion chamber. Add
positive pressures or subtract negative pressures.
➔
The differential gas pressure Δp
gas
measured on
the integrated gas measuring orifice is independent
of the furnace chamber pressure.
WARNING
– If reducing fittings or manual valves with internal
thread are installed, Δpgas on the integrated gas
measuring orifice is reduced.
➔Reducing fitting with internal and external thread:
deviation from the flow rate curves may occur when
the cross-section of the reducing fitting differs from
that of the threaded gas connectionGA or when
a manual valve is screwed directly into the burner.
➔ Reducing nipple with external thread at both ends:
no deviation from the flow rate curves occurs.
➔ Ensure an undisturbed flow to the measuring orifice!
➔As not all the effects caused by the equipment are
known, setting the burner using the pressure values
is only approximate. It is possible to set the burner
precisely by measuring the flow rates or flue gas.
5.6 Restrictors
➔
The air volume required for the low-fire rate at a
given air pressure is determined by the ignition
position of a butterfly valve, a bypass hole in the air
valve or an external bypass with restrictor.
➔ Burners as from construction stage E (see type
label) are equipped with gas flow adjustment to
replace the restrictor in the gas pipe.
5.7 Hot air compensation
➔
The combustion air pressure p
air
must be increased
in hot air operating mode (lambda=constant).
0 50 100 150 200 250 300 350 400 450 500 550
600
100
150
200
300
250
Air temperature [°C]
Air pressure p
air
[%]
➔The gas pressure is increased by 5–10mbar.
➔The total burner capacity Pgas rises as the air tem-
perature increases.
0 50 100 150 200 250 300 350 400 450 500 550 600
100
110
120
Air temerature [°C]
Total capacity Ptot [%]

BIO · Edition 09.22
EN-8
5.8 Burners with electrodes with air connection
➔Burner head marking (..D) or (..E)
purge air tube
purge air nozzle
d=4.5mm
Rp 1/4
10
20
30
40
123
p [mbar]
0
10
20
30
40
0
123
Pressures for purges electrodes
Q purging air [m
3
/h]
➔ A purge air volume of approx. 1.5 to 2m³/h per
electrode is recommended.
➔
The purge air may not be switched off until the
furnace is cold and formation of condensation is
no longer possible.
5.9 Setting the air pressure for low fire and
high fire
1 Shut off the gas and air supply.
BIO
➔
Air measuring nipple L, outside dia. = 9mm (0.35").
2
L
➔Loosen the screw 2turns.
3
L
4 Fully open the air supply.
5
p
atm.
pair
0
➔patm. = atmospheric pressure.
BIOA
➔
Air measuring nipple L, outside dia. = 9mm (0.35").
1
L
➔Loosen the screw 2turns.
2
L
3 Fully open the air supply.
4
p
atm.
pair
0
➔patm. = atmospheric pressure.
Low-fire rate
➔
The burner must only be ignited at low-fire rate
(between 10 and 40% of the rated capacity Q
max
–
see page 2 (2.1 Type label)).
5 Reduce the air supply on the air control valve and
set the desired low-fire rate, e.g. using a limit switch
or mechanical stop.
➔ On air control valves with bypass, the bypass orifice
should be determined on the basis of the required
flow rate and the existing supply pressure if required.
High-fire rate
6 Set the air control valve to high-fire rate.
7 Set the required air pressure pair on the air restric-
tor upstream of the burner.
8 When using air restricting orifices: check the air
pressurepair.
5.10 Preparing the gas pressure measurement
for low fire and high fire
1 Connect all measuring devices for subsequent fine
adjustment of the burner.
➔Leave the gas supply closed.
➔ Gas measuring nipple G, outside dia.= 9mm
(0.35").
5.11 Burners without gas measuring orifice
1 Read the gas pressure p
gas
for the required flow
rateQ from the enclosed flow rate curve for cold
air.
[mbar (inch WC)]
[m3/h (ft3/h)]
pgas pair
pair
pgas
Qair Qgas

BIO · Edition 09.22
EN-9
BIO..50
1
G
➔Loosen the screw 2turns.
2
G
BIOA
1
G
➔Loosen the screw 2turns.
2
G
5.12 Burners with gas measuring orifice
1 Read the differential pressure for the required gas
flow rateQ from the enclosed flow rate curve for
cold air.
[mbar (inch WC)]
[m3/h (ft3/h)]
Δpgas pair
pair
pgas
Qair Qgas
pgas
∆pair
2 p1: gas pressure upstream of the measuring orifice,
p2: gas pressure downstream of the measuring
orifice. Measuring range: select approx. 15mbar.
3
G
G
➔Loosen the screws 2turns.
4
p2
p1
5.13 Integrated pilot on the BIO..L
➔
Air pressure test nipple l, outside dia. = 9mm
(0.35").
➔
Gas pressure test nipple g, outside dia. = 9mm
(0.35").
1
g
l
➔Loosen the screws 2turns.
2
g
l
➔Pilot:
pgas = 30–50mbar,
pair = 30–50mbar.
➔Check flame stability and ionization current.
➔
The gas and air pressure of the integrated pilot
must be higher than the gas and air pressure of
the main burner.
6 COMMISSIONING
6.1 Igniting and adjusting the burner
WARNING
– Ensure adequate ventilation of the furnace
chamber before each burner start!
➔The burner body will become hot during operation
with preheated combustion air. Provide protection
against accidental contact as required.
1 All valves of the installation must be checked for
tightness before ignition.
6.2 Setting the low-fire rate
1 Set the valves to ignition position.
2 Limit the maximum gas volume.
➔
Should an adjustable gas restrictor be installed
upstream of the burner, open the restrictor by ap-
prox. a quarter.
➔ On burners with integrated gas flow adjust-
ment (BIO 65–140): on delivery, the flow rate
restrictor is 100% open. Close the flow rate rate
restrictor with approx. 10turns:
3
4

BIO · Edition 09.22
EN-10
➔Loosen the lock nut only.
5
Q-
➔Set flow rate Q.
6
7
8 Gaszufuhr öffnen.
9 Ignite the burner.
➔
The safety time of the automatic burner control unit
starts to elapse.
10 If no flame forms, check and adjust the gas and air
pressures of the start gas adjustment.
11 In the case of operation with bypass (e.g. when
using an air/gas ratio control): check the bypass
nozzle and adjust if required.
12 In the case of operation without bypass (e.g. when
using an air/gas ratio control without bypass): in -
crease the low-fire rate setting.
13 Check the basic setting or bypass of the air control
valve.
14 Check the position of the restrictor in the air line.
15 Check the fan.
16 Reset the automatic burner control unit and re-ig-
nite the burner.
➔ The burner ignites and proceeds to normal op-
eration.
17 Check flame stability and ionization current at low-
fire rate. Switch-off threshold– see automatic
burner control unit operating instructions.
+μA –
Z
I
18 Monitor flame formation.
19 Adjust the low-fire rate settings if required.
20 If no flame is detected– see page 13 (8 Assis-
tance in the event of malfunction).
6.3 Setting the high-fire rate
1 Set the air and gas circuit of the burner to high fire
while continuously monitoring the flame.
➔
Avoid CO formation– always operate the burner
with excess air when starting up!
➔Burners without gas measuring orifice: when
the desired maximum valve positions are reached,
set the gas pressure pgas using the restrictor up-
stream of the burner.
p
gas
0
patm.
➔ Burners with gas measuring orifice: set the
differential pressure Δpgas using the gas restrictor
or via the integrated flow adjustment.
p
1
p
2
0
∆p
2
3
➔Turn the lock nut 1/4 turn to the left only.
4
Q-
Q+
➔Set flow rate Q.
5
➔ Tighten the lock nut. Do not alter the flow rate
setting!
6
6.4 Readjusting the air flow rate
1 Check the air pressure pair on the burner and adjust
using the air restrictor if required.
2 When using air restricting orifices: check the air
pressure pair and rework the orifice if required.
DANGER
Risk of explosion and poisoning in case of burner
adjustment with insufficient air!