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Raab KW ZUMIKRON Series Original Operating Instructions

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ZUMIKRON
SERIES
®
The ne dust particle separators
ORIGINAL OPERATING INSTRUCTIONS

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Summary of Contents for Raab KW ZUMIKRON Series

  • Page 1 ZUMIKRON SERIES ® The ne dust particle separators ORIGINAL OPERATING INSTRUCTIONS...

  • Page 3: Table Of Contents

    CONTENTS 1 Overview ..............4 5 Zumikron Outdoor ............19 5.1 Technical data Zumikron Outdoor ..............19 2 Information on the operating instructions ......5 5.1.1 Dimensioned drawing ................19 2.1 General information ..................5 5.1.2 General information ................21 2.2 Operating instructions .................5 5.1.3 Connected loads ..................21 2.3 Symbols, abbreviations, terms ..............5 5.1.4 Technical values ..................21 2.4 Symbolerklärung ..................5...

  • Page 4: Overview

    1 OVERVIEW 1 Overview Fig. 1: Zumikron Outdoor DW and Outdoor Top Item No 2123902 | Status 10/2023...

  • Page 5: Information On The Operating Instructions

    2 INFORMATION ON THE OPERATING INSTRUCTIONS 2 Information on the operating instructions 2.3 Symbols, abbreviations, terms 2.1 General information Symbols, abbreviations and technical terms used in this document have the following meaning: Product Designation Information see at Machine designation Particle separator ▶...

  • Page 6: Explanation Of Symbols

    2 INFORMATION ON THE OPERATING INSTRUCTIONS 2.4 Explanation of symbols The following pictograms are used in connection with safety instructions to highlight specific hazards: Warnings and safety instructions Warnings and safety instructions in this manual are marked with a pictogram and addition- …...

  • Page 7: Limitation Of Liability

    2 INFORMATION ON THE OI 3 SAFETY 3 Safety 2.5 Limitation of liability All information and instructions given in this manual have been compiled under considera- tion of applicable standards and regulations, the best available technology as well as our This chapter provides an overview of important safety aspects to protect operating person- many years of insight and experience.

  • Page 8: Responsibilities

    3 SAFETY 3.3 Responsibilities 3.3.2 Responsibilities of the staff 3.3.1 Responsibilities of the operator The Zumikron particle separator is in private and commercial use. Therefore, the staff must follow legal obligations for occupational safety. Operator In addition to the warnings and safety instructions in this manual, it is necessary to follow The operator is any natural or legal person that uses the Zumikron particle separator or the applicable regulations for safety, accident prevention and environmental protection in allows third parties to use it and who is responsible for the safety of the user, the staff or...

  • Page 9: User Requirements

    3 SAFETY 3.4.2 User requirements Experienced specialist staff Any person performing activities on the Zumikron particle separator is considered a user. Experienced specialists are individuals who have acquired and demonstrated special Depending on their task, every user must meet the following qualification requirements: experience, knowledge and skills for safely performing tasks in specialized fields (e.g., specialist electricians, assembly and installation personnel) and who meet the requirements Qualification of users based on operation phase and task category...

  • Page 10: Unauthorized Individuals

    3 SAFETY 3.4.4 Unauthorized individuals 3.6.1 Risks due tomechanical hazards Crushing points on moving components WARNING! Risk of injury for unauthorized people! WARNING! Unauthorized individuals are not aware of the hazards in the working Crushing hazard area of the device and can seriously injure themselves and others Body parts may be crushed by moving parts during assembly/installation! –...

  • Page 11: Risks Due Tothermal Hazards

    3 SAFETY Electric current 3.6.3 Risks due to thermal hazards Hot flue gasses and dusts HAZARD! Mortal danger due to electric current! WARNING! Touching live parts and wires can lead to death. Damage to the insula- Risk of burns due to hot flue gasses and dusts! tion or individual parts can be life-threatening.

  • Page 12: Risks Due To Neglecting Ergonomic Principles

    3 SAFETY 3.6.5 Risks due to neglecting ergonomic principles 3.7 Spare parts, supply and use WARNING! Unhealthy posture, particular exertion Risk of injury due to wrong spare parts! CAUTION! Faulty spare parts can considerably reduce safety and cause damage, Health risks due to unhealthy posture! malfunctions and complete breakdown Lifting heavy components the wrong way and an unnatural posture while –...

  • Page 13: Safety Devices

    3 SAFETY 3.9 Safety devices 3.10 Securing against restarting WARNING! WARNING! Danger to life due to defective or bypassed safety devices! Risk of injury due to unauthorised restarting! Non-functioning, bridged or disabled safety devices do not protect When working on components, assemblies or individual parts, people against hazards and can lead to serious injury or death.

  • Page 14: Measurement Technology

    TÄM 1-2021: Gewährleistungsaufkleber Pos. 9 auf Glocke neu hinzu 28.10.2020 Lindenmüller TÄM 14-2020; Wetterschutzkasten geändert Index Datum Name Änderung Datum Name Bezeichnung Kutzner + Weber Joseph Raab Airjekt 1 outdoor mit WSK GmbH GmbH & Cie.KG Bearb. 05.05.2020 lindenmüller Gepr. 05.05.2020 Zick D-82216 Maisach D-56566 Neuwied www.kutzner-weber.de www.raab-gruppe.de...
  • Page 15 3 SAFETY Pos. Label Quantity Meaning ATTENTION! Staubabscheider Observe the installation direction, installation instructions and earthing! Zumikron KW – RA Luckenau Einbaurichtung, Montageanleitung und Z-7.4-3545 Erdung beachten! Observe installation direction, installation instructions and earthing! Respecter le sens de montage, les instruc- tions de montage et la mise à...

  • Page 16: Behaviour In The Event Of Danger And Accidents

    3 SAFETY Illegible signage 3.13 Environmental protection CAUTION! CAUTION! Risk of injury due to illegible symbols! Environmental damage due to incorrect handling of hazardous Labels and signs that have become unclear no longer make danger areas substances! sufficiently recognisable and cannot indicate possible risks of injury. Incorrect or negligent use of hazardous substances can lead to serious –...

  • Page 17: Transport

    4 TRANSPORT 4 Transport Personal protective equipment ▶ Always wear the following for any transport: - Industrial protective clothing NOTE! - Protective gloves Transport, installation and initial commissioning are to be carried out - Antislip safety boots exclusively by authorized employees of the manufacturer or individuals ▶...

  • Page 18: Transport And Storage

    4 TRANSPORT 4.4 Transport and storage Handling the packaging The transport goods are packed safely and in an environmentally friendly manner for the expected transport conditions. The packaging protects the components from damage and corrosions until assembly. ▶ Do not remove packaging and transport locks before assembly. ▶...

  • Page 19: Zumikron Outdoor

    Sulzer TÄM 52-2022: Gewährleistungsaufkleber entfällt, Deckelabdichtung mit Alu-Klebeband 10 mm (Pos. 9) hinzu Index Datum Name Änderung Datum Name Bezeichnung Kutzner + Weber Joseph Raab Verbindungsdose Zumikron outdoor Bearb. 05.05.2020 Lindenmüller GmbH GmbH & Cie.KG ohne Deckel gez. Gepr. 02.05.2022...
  • Page 20 TÄM 52-2022: Gewährleistungsaufkleber entfällt, Deckelabdichtung mit Alu-Klebeband 10 mm (Pos. 8) hinzu Index Datum Name Änderung Fig. 7: Dimensions view 3 Zumikron Outdoor particle separator (top view) Datum Name Bezeichnung Kutzner + Weber Joseph Raab Zumikron outdoor Bearb. 05.05.2020 Lindenmüller GmbH GmbH & Cie.KG Gepr. 02.05.2022 Zick D-82216 Maisach D-56566 Neuwied Freig.

  • Page 21: General Information

    5 ZUMIKRON OUTDOOR 5.1.2 General information 5.1.4 Technical values Specifi cation Value Unit Overall dimensions of Zumikron Outdoor particle separator Material of fl ue gas conducting parts 1.4571/1.4404 Specifi cation particle separator Value Unit Separation effi ciency up to 90 % Width 140 mm Flue gas system diameter...

  • Page 22: Structure And Function Of The Zumikron Outdoor

    5 ZUMIKRON OUTDOOR 5.2 Structure and function of the Zumikron Outdoor 1 Ionisation area 5 High-voltage cable 2 Flue gas 6 Insulator 5.2.1 Module overview 3 Sawtooth electrode 7 Length-adjustable electrode holder 4 Temperature sensor 8 Displacement lock NOTE! The separator insert is identical for all cross-sections. The position of the electrode can be adapted to the different pipe diameters ( chapter Assembly and installation).

  • Page 23: Functional Description

    5 ZUMIKRON OUTDOOR Control and display element Label Meaning Mains switch (bottom right) for switching the appliance on and off Fig. 12: Electrostatic particle separation function LED 1 green __ Standby LED 2 green - - - High voltage build-up Standby 1 Pipe wall 3 Electrode...

  • Page 24: Installation Approval

    5 ZUMIKRON OUTDOOR 5.3.2 Installation approval Flue gas system The Zumikron Outdoor particle separator may only be used in negative pressure flue gas Dimensioning, verification of chimney function systems of tightness class N1. After the installation location of the separator insert, there must be at least a 0.5 m long Before installation in flue gas systems, especially outside the installation separator section, measured from the tip of the electrode, for attaching a measuring CAUTION!

  • Page 25: Installation

    5 ZUMIKRON OUTDOOR 5.3.4 Installation Installation must be carried out in the order described below. Instructions can be found on the homepage at www.kutzner-weber.de. A 230 V/50 Hz power connection must be provided. WARNING! Danger due to incorrect installation! T-piece with screw-on adapter Installation work requires trained specialist personnel with extensive If the Zumikron Outdoor is installed on an existing brick chimney, a connection is made experience.

  • Page 26: Installation Of Double-Walled T-Piece (Dw)

    T-piece can be fi tted to the upper end of the fl ue gas system. WARNING! For the integration of the T-piece into stainless steel chimneys that are not made by Raab, Risk of injury from sharp components! a T-piece customised to the manufacturer can be produced.
  • Page 27 5 ZUMIKRON OUTDOOR Mounting the control module Drill four holes on a side facing away from the sun using the enclosed template. Insert the appropriate plugs and screws and hang the control module so that the ON/OFF rocker switch is on the lower side. ATTENTION! Use suitable cable ducts for cable routing to avoid tripping hazards.

  • Page 28: Commissioning Zumikron Outdoor

    5 ZUMIKRON OUTDOOR 5.4 Commissioning Zumikron Outdoor – If fl ashovers occur during the heating-up phase (slight cracking in the area of the electro- de), this may be due to moisture. As soon as the fl ue gas temperature is high enough, 5.4.1 Before initial commissioning there should be no more permanent fl ashovers.

  • Page 29: Operation Of Particle Separator

    5 ZUMIKRON OUTDOOR 5.5.2 Operation of particle separator Personnel ▶ User Personal protective equipment ▶ Protective work clothing ▶ Safety gloves ▶ Safety goggles 5.5.2.2 Switching off 5.5.2.1 Switching on To switch off the Zumikron Outdoor particle separator ( Fig. 37): 1.

  • Page 30: Shutting Down In An Emergency

    5 ZUMIKRON OUTDOOR 6 MAINTENANCE 6 Maintenance 5.5.3 Shutting down in an emergency In dangerous situations, stop the system as quickly as possible and switch off the power supply. 6.1 Safety Instructions Maintenance Shutting down in an emergency In the event of danger: WARNING! 1.

  • Page 31: Maintenance Work

    6 MAINTENANCE WARNING! CAUTION! Risk of burns due to hot flue gasses and dusts! Risk of injury at edges and corners! Before working on the flue gas system, turn off the furnace and wait for Sharp edges and pointy corners may cause abrasions, scratches and it to burn out and cool down completely.
  • Page 32 6 WARTUNG ATTENTION! Functional damage due to non-compliance with the maintenance and cleaning intervals! If maintenance and cleaning are neglected, flashovers may occur in the area of the separator cartridge. As a result, the separation performance can be significantly impaired. NOTE! Before the flue gas system is cleaned for the first time, the responsible The following table lists regularly required maintenance and cleaning work.

  • Page 33: Maintenance Protocol

    6 WARTUNG 6.3 Maintenance protocol 6.4 Actions to be taken after maintenance The required maintenance intervals depend on how intensely the system is used on site and After completing the maintenance work, but before restarting the system, perform the the resulting actual sings of wear. following steps: 1.

  • Page 34: Decommissioning

    7 DECOMMISSIONING 8 MALFUNCTIONS 7 Decommissioning 8 Malfunctions 7.1 Temporary shutdown 8.1 Safety instructions for troubleshooting If the Zumikron is shutdown only temporarily, it is sufficient to take the following measures: 8.1.1 Safety requirements ▶ Switch off the Zumikron. WARNING! ▶...

  • Page 35: Handling Malfunctions

    8 MALFUNCTIONS 8.1.2 Handling malfunctions WARNING! If the Zumikron is malfunctioning, please see table 24 for information on how to handle Falling hazard! the malfunction. When working in elevated positions, unsecured people may fall or be In case of a malfunction, the firing system can still be used. Fine dusts are separated only injured by falling objects.

  • Page 36: Malfunction Table

    8 MALFUNCTIONS 8.2 Malfunction table Malfunction Possible cause Troubleshooting Staff Audible discharges or Discharges due to humid flue gasses These can occur during the heat-up phase and disappear again once higher flue gas Operator loud crackling around the temperatures have been reached. No action necessary. separator cartridge Separator cartridge extremely dirty, cleaning Clean separator cartridge...

  • Page 37: Appendix

    9 APPENDIX 9 Appendix 9.1 Commissioning protocol – Declaration of compliance Name and address of the object Individual steps for commissioning Flue gas system operational according to calculations / negative-pressure operation/max. exhaust mass flow and temperature Adequate safety distance to flammable components Zumikron checked for stability / tightness Accessibility of Zumikron: Separator cartridge and control unit Chimney sweep informed about changes to/construction of firing system...

  • Page 38: List Of Figures

    10 LIST OF FIGURES 11 LIST OF TABLES 10 List of figures 11 List of tables Fig. 1: Zumikron Outdoor DW and Outdoor Top ............4 Tab. 1: Product information ..................5 Fig. 2: Emergency stop = ON/OFF rocker switch ............13 Tab. 2: Manufacturer information ................5 Fig.

  • Page 39: List Of Modifications

    12 LIST OF MODIFICATIONS 12 List of modifications Date modified by Section Reason for the modification Original operating instructions particle separator Zumikron...

  • Page 40: Index

    13 INDEX 13 Index Abbreviations ....................5 Industrial protective clothing Accidents.......................16 during maintenance ..................31 Appendix .......................37 during troubleshooting ................35 Authorised documentation representative .............5 Industrial safety helmet ................10 Safety boots ....................10 Safety goggles ...................10 Commissioning Zumikron Outdoor ..............28 Connected loads .....................21 Initial commissioning ..................28 Inspection and maintenance schedule ..............31 Control and display element ................23 Control module ....................22...
  • Page 41 13 INDEX Recommissioning ...................35 Repairs ......................36 Residual risks ....................10 Responsibilities ....................8 Responsibilities of the staff ................8 Risks due to materials and substances ..............11 due to neglecting ergonomic principles ............12 due to operational environment ..............12 electric ......................10 mechanical ....................10 thermal.....................11 Safety ......................7 during transportation...................17 during troubleshooting ................34 Safety devices ....................13...
  • Page 42 Kutzner + Weber GmbH +49 (0) 81 41/957-0 Stand 10/2023 · Version 1.6 Frauenstraße 32 info@kutzner-weber.de Art.-Nr. 2123902 82216 Maisach · GERMANY www.kutzner-weber.de Irrtümer und technische Änderungen vorbehalten.

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