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 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

GIKH

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

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.

GIKH: The inlet pressure pumust be greater than 4x

the differential control pressure Δpsa plus the pressure

drop Δp.

psa

–

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

–

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

max. 150 mbar

GIK..F

a max. 300 mbar b

max. 150 mbar

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.

GIK

At low-ﬁre rate: control pressure at least 0.5mbar.

Factory setting: pd= psa

psa

3 mm

pd= psa

± 3 mbar

GIK..R

psa

6 mm

pd= psa ± 2 mbar

GIK..F

GIKH

At low-ﬁre rate: differential control pressure at least

0.2mbar.

Factory setting: pd= approx. 4 x Δpsa

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

0,3 0,4 0,6 0,8 1 2 3

0,2 0,3 0,4 0,6 0,8 1 2

0,2 0,3 0,4 0,6 0,8 1

4 5 6 8 10

4 75 6 8 10

3 4 75 6 8 10

2 3 4 75 6 8

100 1,5* 5* 6 7 8 942 3mm 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

/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

GIK..F

Installing the variable restrictor on the GIK..R

Installing the variable restrictor on the GIK..F

a b

d Seal the air control line at the thread with sealant.

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

10 20 30 40 50 60 80 100 200 300 400

20 30 40 50 60 80 100 200 300 400

78 10 20 30 40 50 60 80 100 200 300 400

6 7 8 10 20 30 40 50 60 80 100

2000 3000

1000200 300

600

Qn[m

/h]

600 1000

1000

600 1000 2000

400 600

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

−

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

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

max. 300 mbar

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.

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 +49 541 1214-0

[email protected]

www.kromschroeder.com

Global centralized service deployment coordination:

T +49 541 1214-365 or -555

[email protected]

Translation from the German

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