Self-recuperative burner ECOMAX for gas Technical Information · GB 7 Edition 10.17 • For direct and indirect heating • Economical, energy-saving operation by virtue of internal air preheating up to 650°C • Uniform distribution of temperature by means of a high burner impulse •...
Application 1 Application ECOMAX..M ECOMAX..C Self-recuperative burners ECOMAX are used for heating Applications include heat treatment furnaces in the on either direct or indirect furnace systems in ON/OFF iron and steel industry and in the non-ferrous metal intermittent mode. The hot flue gases are fed through industry.
Application Application > ECOMAX for direct heating systems 1 .4 ECOMAX for direct heating systems 1 .4 .1 Flow rate control For direct heating, flow rate control should be inte- In direct heating systems, the burner ECOMAX is com- grated in the system. The pressure loss in the recu- bined with a flue gas guide tube FGT Set..D for routing perator depends on the furnace temperature.
Application 1 .4 .2 Air/gas ratio control If the system does not include flow rate control, tem- perature-dependent pressure losses in the burner are not compensated for. The air index lambda drops with increasing furnace temperature (increasing air preheat- ing). Therefore, in a cold furnace, an increased lambda value is to be set to ensure sufficient excess air, even when the furnace temperature is at its maximum.
Application Application 1 .4 .3 No pneumatic air/gas ratio control system Prozess-Steuerung/ When there is no pneumatic air/gas ratio control sys- Process Control (PCC) tem, slow opening gas valves and quick opening air control valves are to be used to ensure a safe burner VAS VAS..L start.
Application 1 .5 ECOMAX® for indirect heating systems P and twin P radiant tube P and twin P radiant tubes are used in some processes, For indirect heating, various radiant tubes are used. for example in heat treatment systems for steel strip as Single ended radiant tube an alternative to U or W radiant tubes.
Application 1 .5 .1 No pneumatic air/gas ratio control system 1 .5 .2 Air/gas ratio control For indirect heating, slow opening gas valves and quick The pneumatic air/gas ratio control system ensures opening air control valves are to be used to ensure a that changes in the air pressure in the air supply line are safe burner start.
Certification 2 Certification Certificates – see www.docuthek.com. Machinery Directive The product ECOMAX is a partly completed machine pursuant to Article 2g of Directive 2006/42/EC and complies with the essential health and safety require- ments in accordance with Annex I, as stated in the Dec- laration of Incorporation.
Structure 3 Structure The burner ECOMAX is composed of four modules: burner body, 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. Maintenance and repair times are reduced, and existing furnace installations can eas- ily be converted.
Structure Structure 3 .2 Recuperator Cast steel ribbed tube recuperator The burner ECOMAX is available in three versions: – ECOMAX..C with ceramic burled tube recuperator – ECOMAX..M and ECOMAX..P with cast steel ribbed tube recuperator – ECOMAX..F with metallic flat tube recuperator Ceramic burled tube recuperator The ribs on the cast steel ribbed recuperator offer a large surface area, allowing it to achieve high efficiency...
Structure 3 .3 Air guide tube ECOMAX . .C Burners ECOMAX..C are equipped with a ceramic air guide tube that for sizes 0 to 3 also serves as the com- bustion chamber. ECOMAX . .M, ECOMAX . .F and ECOMAX . .P Air guide tube for ECOMAX..M and ECOMAX..F Burners ECOMAX..M and ECOMAX..F are equipped with an air guide tube made of heat-resistant steel.
Structure 3 .4 Gas insert The gas insert consists of the gas connection flange, the torch with burner head and the spark electrode (also serves as monitoring electrode). A measuring orifice, which is integrated in the gas insert, allows for simple measurement of the gas flow rate.
Function 4 Function Flue gas Housing Radiant tube or Air guide tube flue gas guide tube Gas insert Recuperator Combustion chamber Combustion gas Combustion air The self-recuperative burner ECOMAX uses the heat The rest of the combustion air flows out through the from the flue gases to preheat the combustion air.
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Function Flue gas Housing Radiant tube or Air guide tube flue gas guide tube Gas insert Recuperator Combustion chamber Combustion gas Combustion air Influence of the furnace temperature In direct heating systems with flue gas eductor EJEK, The higher the furnace temperature, the greater the the quantity of flue gas extracted from the furnace pressure loss in combustion air and flue gas in the re- chamber via the burner decreases as the furnace tem-...
Selection 5 Selection 5 .2 Burner size Burner 5 .1 Burner type Capacity Recuperator Size Selection is dependent on the type of heating and BTU/h the furnace temperature. Details on selection, see ECOMAX 0 – – – page 31 (Heating system design) for direct heat- ECOMAX 1 –...
Selection Selection 5 .3 Burner length When using P radiant tubes, the recuperator head should be positioned on the centre line of the radiant The recuperator length G should be selected so that the tube (S1 = 0 ± 20 mm). burner is flush with the inside edge of the furnace lining (S1 = 0 ±...
Selection Selection 5 .4 Burner head 5 .4 .1 Use The burner ECOMAX can be equipped with 2 different burner heads. Stage combustion is standard. For some burner variants, a menox version is also possible, which allows for switchover to menox ®...
Selection 5 .5 Type of heating The ECOMAX is supplied with an integrated orifice on the gas and air connections. The gas orifices depend on the gas type, the air orifices on the type of control and the system configuration. Type of heating Code letter Explanation...
Selection 5 .6 Connection for additional furnace 5 . 7 Electrode made of Kanthal APM cooling Burners ECOMAX..M and ECOMAX..P can be equipped with a bend-resistant electrode made of Kanthal APM as an option. This is recommend for direct heating as of 1050°C and indirect heating as of 950°C, see page 38 (Flame control).
Selection 5 .9 .1 Type code Code Description EJEK Flue gas eductor 0 – 6 Size for ECOMAX 1 – 6 -Kxxx Axis spacing K in mm -Myyy Height M in mm -Tzzz* Distance T in mm Burner installation position: horizontal vertical Installation on the burner**: right-hand side...
Selection 5 .10 .1 Type code Code Description FLUP Flue gas connector For ECOMAX 0 – 5 -32 to -100 Nominal size Pipe connector Flange to ISO 7005 -Kxxx Axis spacing K in mm -Myyy Installation height M in mm -Tzzz* Distance T in mm Burner installation position: horizontal vertical...
Project planning information for direct heating 6 Project planning information for direct heating 6 .1 Heating system design Selection of the burner type is dependent on the fur- nace temperature. Recommended Max. flue gas temperature at Burner range of use recuperator inlet [°C] [°F]...
Project planning information for direct heating 6 .2 Flue gas guide tube FGT set Force must not be applied to the flue gas guide tube by the furnace lining. The furnace flue gases are routed by the flue gas guide When installing the FGT, the tube must be wrapped in tube through the furnace lining via the recuperator.
Project planning information for direct heating 6 .3 Flue gas eductor EJEK Flue gas eductor EJEK is available in 2 versions. The standard version EJEK is used in conjunction with ECOMAX..M and ECOMAX..F. The high temperature version EJEK..-HT is intended for use in conjunction with ECOMAX..C.
Project planning information for direct heating 6 .4 Furnace flue gas system A flue gas system must be fitted on the furnace as a means of guiding the flue gas to the chimney. In the flue gas system there should be a low negative pressure ∅2P thanks to the draught of the chimney or an exhaust fan.
Project planning information for direct heating 6 .5 Installation 6 .5 .2 Tangential or angled burner installation If the burner is installed tangentially or at an angle, an 6 .5 .1 Installation position opening should be provided in the furnace lining to 15°...
Project planning information for direct heating 6 .5 .3 Clearances Flame mode Burner Clearance (mm) Reaction zone RZ (mm) ECOMAX 0 ECOMAX 1 ECOMAX 2 ECOMAX 3 1200 ECOMAX 4 1600 ECOMAX 5 1800 ECOMAX 6 2200 Allow for adequate clearance from the charge and the For menox ®...
Project planning information for direct heating 6 .5 .4 Furnace temperature measurement Measurement of the furnace temperature must be representative for the flue gas temperature in the ex- traction zone on the burner. If measurement is not rep- resentative, this will involve a risk of overheating of the recuperator head.
Project planning information for direct heating 6 .6 Flame control We recommend the UV sensor UVS 10D1 with inte- grated purge air connection (Order No. 84315202) for UV control. For ECOMAX 0, the UV sensor UVS 10L1 (Order No. 84315203) with lens is required for UV control. For burners ECOMAX 1 – 6 with a burner length of more than 545 mm, the UV sensor UVD 10L1 with lens is also required for UV control.
Project planning information for direct heating 6 . 7 Burner control units and ignition For burners ECOMAX..K with additional cooling air connection, we recommend using burner control unit transformers BCU..C with additional circuit board for signal distribu- tion. For ignition, the ECOMAX burners require an ignition transformer with 7.5 kV high voltage and an output cur- rent of 20 mA.
Project planning information for direct heating 6 . 7 .1 Burner control unit configurations Description Configuration D1 Configuration D2 Configuration D3 Configuration D4 Flame control Ionization UVS 10 Ionization UVS 10 Pneumatic air/gas ratio control VAH/VAG VAH/VAG None/VAH/VAG None/VAH/VAG Air flow monitoring –...
Project planning information for direct heating 6 .8 Gas connection A bellows unit EKO should be provided between the burner and controls to prevent external force being ap- 6 .8 .1 Selecting components plied to the burner. To ensure a safe burner start, use a pneumatic air/gas A connection set with 6 x 1 compression fittings ratio controller together with a slow opening air valve.
Project planning information for direct heating 6 .8 .3 Operation with LPG Open the adjuster in the central air lance fully. On the ECOMAX 1, the adjuster must be restricted to 45° or 50%. If high temperature operation without flame control using ionization or a UV sensor is intended for LPG, air flow monitoring using an ECO air flow detector set must be provided to prevent backflow of the central air into...
Project planning information for direct heating 6 .9 Air connection 6 .9 .2 Air pressure The motive air setting for eductor EJEK is critical when 6 .9 .1 Selecting components designing the air supply. The required pressure depends In the case of a pneumatic air/gas ratio control system, on the burner capacity, the flue gas extraction via the slow opening air valves or butterfly valves with solenoid ac- burner and the furnace temperature:...
Project planning information for direct heating 6 .10 Air flow monitoring The required purge air volume is approx. 0.5 to 1.0% of the air volume for rated capacity, or a minimum of A system which includes air flow monitoring is recom- mended to monitor pre-purge and as low air pressure The purge air is connected to the gas connection flange protection (pursuant to EN 746-2 and ISO 13577-2) if...
Project planning information for direct heating 6 .12 Condition on delivery same time as the burner. This also applies to all add-on components with the marking /E, such as the air flow The position of the gas, air and flue gas connections detector set, UV adapter set, purge air nozzle, inlet sec- can be customized depending on how the burner is to tion for gas and air, see page 62 (Accessories).
Project planning information for direct heating 6 .14 Emissions 6 .15 Build up of noise CO and NO values depend on the furnace tempera- The sound level of a naked flame may be significantly ture, air preheat temperature, burner type and burner more than 90 dB(A) due to the high flame velocity.
Project planning information for direct heating 6 .16 Process boundary conditions 6 .17 Resistance of SiSiC In direct heating systems, the flue gases are routed The ceramic recuperator of the ECOMAX..C consists of out of the furnace chamber via the burner. Impurities reaction-bound silicon carbide (SiSiC), infiltrated with from the process can affect burner operation.
Project planning information for indirect heating 7 Project planning information for indirect heating 7 .1 Heating system design When designing a radiant tube heating system, it must be ensured that the energy can be transferred to the furnace chamber via the surface of the radiant tube to avoid exceeding the maximum permissible flue gas temperature at the recuperator inlet of the burner.
Project planning information for indirect heating 7 .2 Radiant tubes For ECOMAX . .M Metallic radiant tubes are available in a variety of di- For ECOMAX . .C mensions in either centrifugal casting or in welded Burners ECOMAX..C are intended for use with ceramic form.
Project planning information for indirect heating 7 .3 Flue gas channelling Eductor EJEK A flue gas connector FLUP, which is to be ordered sepa- rately, is available as standard to channel flue gas in EJEK an indirect heating system. In special cases, an educ- tor EJEK can also be installed to channel flue gas.
Project planning information for indirect heating 7 .4 Furnace flue gas system A flue gas system must be fitted on the furnace as a ∅1,5Q means of guiding the flue gas to the chimney. In the ∅2Q* ∅2Q* flue gas system there should be a low negative pressure ∅1,5P ∅Q ∅Q...
Project planning information for indirect heating 7 .5 Installation Installation of burners with FLUP in the horizontal posi- tion, in the vertical position with the firing end pointing downwards or at an angle with the firing end pointing downwards. Allow for adequate clearance between the radiant tubes and the furnace wall to avoid local overheating, see Technical Information SER-C.
Project planning information for indirect heating 7 .6 Flame control We recommend the UV sensor UVS 10D1 with inte- grated purge air connection (Order No. 84315202) for UV control. For ECOMAX 0, the UV sensor UVS 10L1 (Order No. 84315203) with lens is required for UV control. For burners ECOMAX 1 – 6 with a burner length of more than 545 mm, the UV sensor UVD 10L1 with lens is also required for UV control.
Project planning information for indirect heating 7 . 7 Burner control units and ignition transformers ECOMAX burners are designed for On/Off control. We recommend burner control units BCU 465. In order to be able to carry out ionization control up to 1050°C, the burner control units must be equipped with firm- ware FW 16xx or higher.
Project planning information for indirect heating 7 .8 Gas connection 7 .8 .2 Gas pressure The required gas pressure depends on the burner size, 7 .8 .1 Selecting components the gas type and the system configuration. For indirect heating, slow opening gas valves and quick Gas supply line pressure* opening air control valves are to be used to ensure a Gas pressure...
Project planning information for indirect heating 7 .8 .3 Operation with LPG Open the adjuster in the central air lance fully. On the ECOMAX 1, the adjuster must be restricted to 45° or 50%. If high temperature operation without flame control is intended for LPG, air flow monitoring using an air flow detector set ECO must be provided.
Project planning information for indirect heating 7 .9 Air connection 7 .9 .2 Air pressure The required air pressure depends on the burner size, 7 .9 .1 Selecting components the gas type and the system configuration. For indirect heating, a quick opening air valve should Air supply line pressure always be used to ensure a safe burner start.
Project planning information for indirect heating 7 .10 Air flow monitoring The purge air is connected to the gas connection flange next to the electrode, or in the case of UV control to A system which includes air flow monitoring is recom- the purge air connection of the UV sensor.
Project planning information for indirect heating Project planning information for indirect heating 7 .12 Condition on delivery Add-on components with the marking /E, such as the air flow detector set, UV adapter, purge air nozzle, etc, The position of the gas, air and flue gas connections are installed on the burner at the factory, provided that can be customized depending on how the burner is to they are ordered at the same time as the burner.
Project planning information for indirect heating 7 .15 Emissions Actuating the air valve for the burner (terminal 22) initi- ates “normal” cooling; actuating a second air valve for CO and NO values depend on the furnace tempera- the additional cooling air connection initiates additional ture, air preheat temperature, burner type and burner cooling.
Accessories 8 Accessories 8 .2 Air flow detector set 8 .1 Air connection set Specially machined barrel nipples which ensure reliable, correct measurement at the orifices installed in the burner. Version /E is installed in the burner on delivery. Designation Order No.
Accessories 8 .3 VAH connection set 8 .5 Purge air/cooling air nozzles Nozzle to limit the volume of purge air in order to achieve safe ignition and monitoring of the ECOMAX burner and to avoid condensation and overheating. Nozzle for electrode purge Burner Nozzle designation Order No.
Accessories 8 . 7 Flue gas eductor EJEK Designation for ECOMAX..M Order No. EJEK 1-K269-M625-H-AGK-S 22800931 EJEK 2-K285-M540-H-AGK-A-S 22802952 EJEK 3-K292-M620-AGK-A-S 22801159 EJEK 4-K345-M920-AGK-A-S 22801700 EJEK 5-K345-M1165-AGK-A-S 22801826 EJEK 6-K530-M1618-AGK-A-S 22801903 8 .8 Flue gas connector FLUP For direct heating The eductor EJEK generates a vacuum with a centrally In indirect heating systems, flue gas connector FLUP positioned nozzle and thus draws the flue gases out...
Accessories 8 .9 Ceramic radiant tube SER-C 8 .10 Segmented flame tube SICAFLEX For heat treatment processes in which combustion gases must be kept separate from the product. The pat- For guiding hot flue gases in single ended radiant tubes. ented flange connection is air-tight.
Accessories 8 .11 Cruciform spacer 8 .12 Flue gas guide tube FGT SET ECO . . SER-C For installation of the segmented flame tube SICAF- ® in vertical radiant tubes. The cruciform spacer en- To guide the flue gases if smaller burners are used sures optimum sizing of the recirculation gap between than those normally intended;...
Accessories 8 .13 Piping The burners can be optionally supplied with pre-mounted pipework for gas and air. 8 .13 .1 Direct heating Prozess-Steuerung/ Process Control (PCC) VAS..N ECOMAX BVHM + MB7..L ECOMAX Material No. Designation Combinations 0 – 3 86594777 GVRS 15R05-15R05-W-ECO 0-3 VAS…N + VAH…...
Technical data 9 Technical data The visible flame diameter is 0.3 to 0.5 times that of the burner Ø B for natural gas operation in the open air, Gas supply pressure and air supply pressure max. connection rating and air index 1.15. each depend on the use and gas type (gas and air pressures:see burner diagrams at www.docuthek.com –...
Technical data 9 .1 Dimensions 9 .1 .1 ECOMAX . .C for direct heating ØP S1 = +/- 20 mm Øn ∅B ∅A ØF Type ECOMAX FGT set EJEK Ø B C H1 Ø A Ø F Ø n Ø P Weight 395, 475, ECOMAX 0C R ½...
Technical data 9 .1 .2 ECOMAX . .M for direct heating ØP Øn ∅B ∅A ØF Type ECOMAX FGT set EJEK Ø B C H1 Ø A Ø F Ø n Ø P Weight 545, 595, ECOMAX 1M R ½ Rp 1 123 60 212 ~78 236 133 330 280 4 x 19 290 4 x M16 R 1¼...
Technical data 9 .1 .3 ECOMAX . .F for direct heating ØP Øn ∅B ∅A ØF Type ECOMAX FGT set EJEK Ø B C H1 Ø A Ø F A1 Ø n Ø P Weight 545, 595, ECOMAX 1F R ½ Rp 1 109 60 212 ~78 236 133 330 280 4 x 19 290 4 x M16 R 1¼...
Technical data 9 .1 .5 ECOMAX . .M for indirect heating S1 = +/-20 mm FLUP ∅X ∅B Øn V1 = 0,7 × bis 1,5 × ØX ØF Type ECOMAX SER-M FLUP Ø B C Ø X Ø F Ø n Weight H1 ECOMAX 1M R ½...
Technical data 9 .1 .6 ECOMAX . .F for indirect heating S1 = +/-20 mm FLUP ∅X Øn ØF V1 = 0,7 × bis 1,5 × ØX Type ECOMAX SER-M FLUP Ø B C Ø X Ø F Ø n Weight H1 109 60 212 ~78 545, 595,...