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Self recuperative burner ECOMAX
Technical Information · GB
Edition 02.11
• 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
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Table of Contents
Related Manuals for Elster ECOMAX 0C
Summary of Contents for Elster ECOMAX 0C
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Page 1: Self Recuperative Burner Ecomax ® For Gas
Self recuperative burner ECOMAX ® for gas Technical Information · GB Edition 02.11 • 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 •... -
Page 2: Table Of Contents
Contents ® Self recuperative burner ECOMAX for gas . . . . . . . . . . . . 1 6.3 Recommended burner control units ....24 6.4 Gas connection . - Page 3 9 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 9.1 Flue gas guide tube FGT kit .
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Page 4: Application
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 ®... - Page 5 Application Roller hearth furnace Bogie hearth furnace Batch furnace ECOMAX · Edition 02.11...
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Page 6: Examples Of Application
Application 1 .3 Examples of application SICAFLEX ® segmented flame tubes must be fitted in the single- ended (metallic or ceramic) radiant tube to guide the hot flue 1 .3 .1 ECOMAX ® in radiant tubes gases. The high outlet velocity of the combustion gases generates a pressure at the outlet of the ceramic burner tube, resulting in Flue gas the recirculation of the flue gases. -
Page 7: Ecomax ® In Direct Heating Systems
Application > Examples of application 1 .3 .2 ECOMAX ® in direct heating systems Flue gas Gas Cold air ECOMAX ® self recuperative burner in a direct heating sys- tem with an eductor for extracting the flue gases from the furnace. -
Page 8: Certification
2 Certification 2 .1 Approval for Russia Certified by Gosstandart pursuant to GOST-R. Approved by Rostekhnadzor (RTN). ECOMAX · Edition 02.11... -
Page 9: Mechanical Construction
3 Mechanical construction 3 .2 Recuperator 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. -
Page 10: Air Guide Tube
Mechanical construction 3 .3 Air guide tube 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. -
Page 11: Versions
Mechanical construction > Gas insert 3 .4 .1 Versions Burner Size Gas insert Air guide tube Ceramic, With mixing with integrated 0 – 3 funnel combustion chamber ECOMAX..C With swirl plate and ceramic 4 – 5 Ceramic combustion chamber With mixing fun- nel and ceramic 1 –... -
Page 12: Function
4 Function Flue gas Combustion gas Air guide tube Recuperator Gas insert Combustion chamber Housing Combustion air The self recuperative burner ECOMAX ® uses the heat from the The hot flue gases, flowing in the opposite direction, leave the flue gases to preheat the combustion air. The heat exchanger furnace chamber on the outside of the recuperator. -
Page 13: Selection
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. -
Page 14: Burner Design
Selection 5 .2 Burner design Burner Recuperator Output* Selection of the burner size is dependent on the net heat output. From this, the required burner output is calculated using the ceramic metallic metallic, Size firing efficiency value. flat tube [kW] Net heat output [kW] Ecomax 0 –... -
Page 15: Gas Types
Selection 5 .3 Gas types 5 .4 Burner length Calorific value The burner length G should be selected so that the burner is Density ρ Gas type Code letter range flush with the inside edge of the furnace lining (S1 = 0 ± 20 mm). [kg/m [kWh/m (n)]... -
Page 16: Connection For Additional Furnace Cooling
Selection 5 .5 Connection for additional furnace cooling 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. -
Page 17: Differential Air Pressure Measuring Kit Da 1
Selection 5 .6 Differential air pressure measuring kit DA 1 5 .7 Differential air pressure measuring kit DA 2 with pressure switch For adjusting the air volume, especially for direct heating, we recommend using the optional intermediate flange for dif- The differential air pressure measuring kit DA 2 is used for the ferential pressure measurement. -
Page 18: Flue Gas Monitoring Kit Dw
Selection The pressure switch switching point should be set to approx. 5 .8 Flue gas monitoring kit DW 80% of the differential pressure in normal operation. L1, N, PE µC The flue gas monitoring kit DW with pressure switch is used in conjunction with the burner control unit BCU 465 –... - Page 19 Selection 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. ECOMAX · Edition 02.11...
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Page 20: Selection Table
Selection 5 .9 Selection table 395 475 545 556 593 595 613 617 636 641 645 681 689 695 -22 to -500 ECOMAX 0C ● ● ● ● ● ● ● ● ● ● ECOMAX 1C ● ● ● ●... -
Page 21: Type Code
Selection > Selection table 5 .9 .1 Type code Code Description ECOMAX Burner type Burner size (max. burner output with natural gas): 0 (25 kW) 1 (36 kW) 2 (60 kW) 3 (100 kW) 4 (180 kW) 5 (250 kW) 6 (500 kW) Recuperator: metallic ceramic... -
Page 22: Project Planning Information
6 Project planning information 6 .1 Flame control ECOMAX ® burner with ionization control The flame is monitored by a combined ignition/ionization electrode as standard. Flame control with UV sensor is only necessary if furnace temperatures of 1050°C for direct heating or 950°C for indirect heating are exceeded. -
Page 23: Purging Air And Cooling Air
Project planning information 6 .2 Purging air and cooling air – In the case of indirect heating and vertical burner installa- tion, irrespective of temperature, in order to prevent con- densation forming in the burner. Otherwise the flue gas will enter the burner due to thermal lift. –... -
Page 24: Recommended Burner Control Units
Project planning information 6 .3 Recommended burner control units Recommended burner control unit Heating BCU 460..L..8 BCU 465..L..8 SER-C (ceramic radi- – 1), 2), 5) ant tube) Metallic radiant tube – 1), 5) Direct 3), 5) Pre-purge is required following a false start in order to avoid damage to the radiant tubes and flame tubes. -
Page 25: Gas Connection
Project planning information 6 .4 Gas connection 6 .4 .1 Valves A slow opening and quick closing gas valve is to be used as ECOMAX an automatic shut-off valve. A quick opening and quick clos- ® ing gas valve is to be installed as a second automatic shut-off valve, unless the relevant application standard allows using a single valve. -
Page 26: Operation With Lpg
Project planning information > Gas connection 6 .4 .2 Operation with LPG 6 .4 .3 Air/gas ratio control In order to ensure the required air/gas ratio when equipping the burners with only gas and air valves without a pneumatic ratio control system, precise control of the gas and air pres- sures, as well as monitoring of these pressures is necessary in accordance with the relevant standards (e.g. -
Page 27: Air Connection
Project planning information 6 .5 Air connection 6 .5 .1 Indirect heating Approx. 60 to 80 mbar air pressure should be present at the air connection of the ECOMAX burner. Furthermore, the ECOMAX 0 pressure losses due to pipework and valves are to be taken ECOMAX 5 …... -
Page 28: Direct Heating
Project planning information > Air connection 6 .5 .2 Direct heating A quick opening, quick closing air valve or solenoid actuator Approx. 90 to 100 mbar air pressure should be present at the should be used. eductor. Furthermore, the pressure losses due to pipework Butterfly valve/sole- and valves are to be taken into consideration. -
Page 29: Flue Gas Guide Tube Fgt For Direct Heating
The FGT is to be insulated with Cerablanket or similar mate- rial, so that no hot furnace atmosphere reaches the furnace Furnace extension extension. FGT external ∅ A Burner in mm ECOMAX 0C ECOMAX 1C ECOMAX 2C ECOMAX 3C ECOMAX 4C ECOMAX 5C ECOMAX · Edition 02.11... -
Page 30: For Ecomax
Project planning information > Flue gas guide tube FGT for direct heating 6 .6 .2 For ECOMAX . .M Flue gas guide tube FGT Furnace extension FGT external ∅ A Burner in mm ECOMAX 1M ECOMAX 2M ECOMAX 3M ECOMAX 4M ECOMAX 5M ECOMAX 6M ECOMAX ·... -
Page 31: Radiant Tubes
Project planning information 6 .7 Radiant tubes Installation dimensions For indirect heating, different combinations of radiant tubes and ECOMAX burners can be used. Annular gap The metallic burners Ecomax M or FTR are used in metallic radiant tubes (single-ended radiant tube, P radiant tube or twin P radiant tube). -
Page 32: Metallic Radiant Tube
Project planning information > Radiant tubes 6 .7 .2 Metallic radiant tube 6 .7 .3 Radiant tube distances Install the radiant tube free of mechanical stress. For furnace temperatures > 600°C: Ensure that there is an annular gap of ≥ 20 mm between the radiant tube and the furnace lining. -
Page 33: Eductor On Burners With Metallic Single-Ended Radiant Tubes
Project planning information > Radiant tubes 6 .7 .4 Eductor on burners with metallic single-ended radiant tubes The eductor ensures negative pressure in the radiant tube. This prevents the inert gas atmosphere in the furnace being contaminated by flue gases from the burner in the event of leakage from the single-ended radiant tube. -
Page 34: Flue Gas Channelling
Project planning information 6 .8 Flue gas channelling A flue gas system must be fitted on the furnace as a means ∅1.5Q of guiding the flue gas to the chimney. ∅2Q ∅2Q* In the flue gas system there should be a low negative pres- ∅1.5P ∅Q ∅Q... -
Page 35: Direct Heating
Project planning information > Flue gas channelling 6 .8 .2 Direct heating For furnace temperatures ≥ 1000°C, it is recommended that The eductors for flue gas extraction via the burner ECOMAX eductors with a mechanical flue gas valve (AGK) are used to cannot be used for furnace pressure control. -
Page 36: Burner Adjustment
Project planning information 6 .9 Burner adjustment Differential pressure curves are delivered with the burner docu- mentation to enable adjustment of the air and gas volumes thus changing the burner output accordingly. 6 .9 .1 Differential air pressure measuring kit DA 2 with pressure switch The pressure switch should be set to approx. -
Page 37: Technical Data
7 Technical data 7 .1 Efficiency Heating: direct with eductor or indirect in radiant tube. Heating: direct. Control type: On/Off. Flue gas extraction: 100%. Control range: approx. 1:3. Lambda: 1.1. Flame velocity: approx. 120 to 150 m/s. Duty cycle: 80%. Flame control: direct ionization control (UV control as an Diagrams for efficiency, flue gas temperature and air preheat- option). -
Page 38: Ecomax
Technical data > Efficiency 7 .1 .1 ECOMAX . .C Cold air burner ECOMAX..C Temperature on recuperator inlet [°C] 1300 1400 1000 1100 1200 ECOMAX · Edition 02.11... -
Page 39: Ecomax
Technical data > Efficiency 7 .1 .2 ECOMAX . .M Cold air burner ECOMAX..M Temperature on recuperator inlet [°C] 1300 1400 1000 1100 1200 ECOMAX · Edition 02.11... -
Page 40: Ecomax
Technical data > Efficiency 7 .1 .3 ECOMAX . .FTR Cold air burner ECOMAX..FTR Temperature upstream of recuperator [°C] 1000 1100 ECOMAX · Edition 02.11... -
Page 41: Dimensions
Technical data 7 .2 Dimensions 7 .2 .1 ECOMAX . .C (ECOMAX 0 = M12) ∅Y ∅X 0.7 – 1.5 × ∅X (ECOMAX 0–3 = 30 mm) ∅P ∅Q ∅A ∅B ∅U ∅J ECOMAX · Edition 02.11... - Page 42 Technical data > Dimensions > ECOMAX . .C Type [mm] ∅ A ∅ B ∅ J ∅ P ∅ Q ECOMAX 0C 545–695 R ½" DN 32 ECOMAX 1C 545–695 R ½" DN 50 ECOMAX 2C 545–695 R ½" DN 50 ECOMAX 3C 545–695...
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Page 43: Ecomax
Technical data > Dimensions 7 .2 .2 ECOMAX . .M (ECOMAX 0 = M12) (ECOMAX 6 = M20) ∅Y ∅X 0,5 – 1,5 × ∅X ∅P ∅Q ∅A ∅B ∅U ∅J ECOMAX · Edition 02.11... - Page 44 Technical data > Dimensions > ECOMAX . .M Type [mm] ∅ A ∅ B ∅ J ∅ P ∅ Q ECOMAX 1M 545–695 R 1/2" DN 50 ECOMAX 2M 545–695 R 1/2" DN 50 ECOMAX 3M 545–695 R 1/2" DN 65 ECOMAX 4M 545–695 R 3/4"...
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Page 45: Ecomax
Technical data > Dimensions 7 .2 .3 ECOMAX . .FTR (ECOMAX 0 = M12) ∅Y ∅X 0.5 – 1.5 × ∅X ∅P ∅Q ∅A ∅B ∅U ∅J ECOMAX · Edition 02.11... - Page 46 Technical data > Dimensions > ECOMAX . .FTR Type [mm] ∅ A ∅ B ∅ J ∅ P ∅ Q ECOMAX 1FTR 545–695 R 1/2" DN 50 ECOMAX 2FTR 545–695 R 1/2" DN 50 ECOMAX 3FTR 545–695 R 1/2" DN 65 ECOMAX 4FTR 545–695 R 3/4"...
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Page 47: Ecomax Standard Piping
Technical data > Dimensions 7 .2 .4 ECOMAX standard piping ∅P ∅P ECOMAX 3 ECOMAX 0 ECOMAX 4 ECOMAX 1 ECOMAX 5 ECOMAX 2 ECOMAX 6 ∅Q ∅Q ECOMAX 0 ECOMAX 5 … ECOMAX 4 ∅U ∅U ∅Z ∅Z ∅J Type [mm] ∅... -
Page 48: Maintenance
8 Maintenance Twice per year, but if the media are highly contaminated, this interval should be reduced. ECOMAX · Edition 02.11... -
Page 49: Accessories
9 Accessories 9 .2 Flue gas eductor 9 .1 Flue gas guide tube FGT kit When using the ECOMAX ® burners for direct heating, a flue gas guide tube FGT is required. For direct heating The eductor generates a vacuum with a centrally positioned The FGT kit is available in lengths in various increments, which nozzle and thus draws the flue gases out of the furnace are suited to different burner lengths. -
Page 50: Ceramic Radiant Tube Ser-C
Accessories 9 .3 Ceramic radiant tube SER-C Further information can be found in the Technical Information bulletin Ceramic radiant tube SER-C. Order No. on request. 9 .4 SICAFLEX ® segmented flame tube For heat treatment processes in which combustion gases must be kept separate from the product. -
Page 51: P2/P3 Set Eco
Accessories 9 .5 P2/P3 set Eco Nozzle to limit the volume of purging air in order to achieve safe ignition and monitoring of the ECOMAX ® burner and to avoid condensation and overheating. Nozzle* Order number P2 set Eco 2.5 /E 22801111 P2 set Eco 4.0 /E 22801108... -
Page 52: Feedback
Internet: modifications in the interests of progress. Elster GmbH Geschäftssegment LBE www.lbe-online.de/3184.0.html?&L=1 Copyright © 2007 – 2011 Elster Group Postfach 22 03 27 · 42373 Wuppertal All rights reserved. In der Fleute 153 · 42389 Wuppertal Germany...