Ba DDZG TF 02

Duoblock Burner TF-DDZG
Operating Instructions
2011-08-04
BA-DDZG-TF-02 Combustion and Energy Systems

2011
Technical Documentation SAACKE
Original Manual
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Combustion and Energy Systems

Contents TF-DDZG
0 Contents
0 Contents ............................................................................................................................... 4
1 Safety .................................................................................................................................... 6
1.1 Documentation is a part of the product! ............................................................................................. 6
1.2 Symbols .............................................................................................................................................. 6
1.3 Safety in General................................................................................................................................ 7
1.4 Limit Values ........................................................................................................................................ 7
1.5 Authorized Use ................................................................................................................................... 8
1.6 Limitation of Liability ........................................................................................................................... 9
1.7 Qualified Staff ..................................................................................................................................... 9
1.8 Transport and Interim Storage at Installation Site .............................................................................. 9
1.9 Danger from Hot Surfaces ................................................................................................................. 9
1.10 Electrical Hazards ............................................................................................................................ 10
1.11 Emergency Procedures .................................................................................................................... 10
1.12 Explosion Protection in Potentially Explosive Atmospheres (ATEX) ............................................... 10
1.13 Emergency Operation (Applies to Marine Plants Only) ................................................................... 10
1.14 Protective Clothing ........................................................................................................................... 10
1.15 Burner with Gun Retract Mechanism ............................................................................................... 11
2 Transport, Storage and Packing ....................................................................................... 12
2.1 Safety Instructions for Transport ...................................................................................................... 13
2.2 Checking the Delivery ...................................................................................................................... 13
2.3 Reporting Transport Damage ........................................................................................................... 13
2.4 Instructions for Storage .................................................................................................................... 13
2.5 Disposal of the Packaging ................................................................................................................ 14
2.6 Disposal of the Product .................................................................................................................... 14
3 Design And Function ......................................................................................................... 15
3.1 Function ............................................................................................................................................ 15
3.2 Air and Fuel Flow ............................................................................................................................. 16
3.3 Burner Components ......................................................................................................................... 19
4 Construction of the Refractory Brickwork ....................................................................... 21
5 Mounting Instructions ....................................................................................................... 23
5.1 Installation Preparations ................................................................................................................... 24
5.2 Mounting the Burner ......................................................................................................................... 24
5.3 Connecting Lines and Fittings .......................................................................................................... 25
5.4 Lines connected ex works ................................................................................................................ 26
6 Electrical Connections of the Burner ............................................................................... 27
7 Operation............................................................................................................................ 28
8 P&I Diagrams ..................................................................................................................... 29
9 Maintenance / Cleaning ..................................................................................................... 30
9.1 General Information.......................................................................................................................... 30
9.2 Preparing Maintenance Work ........................................................................................................... 31
9.2.1 Periodical Maintenance (Fault not Acute) ........................................................................................ 31
Technical Documentation
4 / 60 BA-DDZG-TF-02 2011-08-04
TF-DDZG Contents
9.2.2 Maintenance after a Fault has Interrupted the Operation ................................................................ 32

9.3 Maintenance Intervals ...................................................................................................................... 32
9.4 Maintenance of General Components ............................................................................................. 33
9.4.1 Checking the Plant for Proper Operation ......................................................................................... 35
9.4.2 Checking Inlet Pressures ................................................................................................................. 36
9.4.3 Checking the Driving Linkage of the Actuators ................................................................................ 36
9.4.4 Checking the Detachable Connections ............................................................................................ 37
9.4.5 Checking the Air Pressure Monitor .................................................................................................. 37
9.4.6 Checking the Flexible Tubes ............................................................................................................ 38
9.4.7 Cleaning the Flame Scanner / Performing a Function Test ............................................................. 39
9.4.8 Cleaning the igniter .......................................................................................................................... 40
9.5 Maintenance of Components Relevant to the Oil Firing Operation Mode ....................................... 41
9.6 Maintenance of Components Relevant Especially for Gas Firing Operation Mode ......................... 41
9.7 After Completion of the Maintenance Work ..................................................................................... 42
10 Troubleshooting ................................................................................................................ 43
10.1 Troubleshooting (Oil Firing Operation Mode) ................................................................................... 43
10.2 Troubleshooting (Gas Firing Operation Mode) ................................................................................ 47
11 Dimensions / Types ........................................................................................................... 51
11.1 Burner Weight .................................................................................................................................. 53
11.2 Dimensions for the Burner Mounting Plate ...................................................................................... 53
11.3 Position of Air Inlet / Position of Gas Inlet ........................................................................................ 54
11.4 Connection Dimensions ................................................................................................................... 55
11.4.1 Combustion Air (Air Duct) ................................................................................................................ 57
11.4.2 Main Fuel Oil / Atomizing Medium ................................................................................................... 58
11.4.3 Main Fuel Gas .................................................................................................................................. 58
11.4.4 Pneumatic System for the Gun Retract Mechanism ........................................................................ 59
11.4.5 Ignition Medium ................................................................................................................................ 59
11.4.6 Cooling Air for the Flame Scanner ................................................................................................... 59
12 Technical Data ................................................................................................................... 59
12.1 Acoustic Emissions .......................................................................................................................... 59
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Safety TF-DDZG
1 Safety
1.1 Documentation is a part of the product!
This document is an integral part of the product. It must be retained for the entire
service life of the product. Make this document available to the staff responsible for
the work described in it. Add any updates you receive later from SAACKE to the
document.
Help us improve this documentation!

We appreciate any feedback that improves the quality of our documentation. You
will find our address on the back of this document.
1.2 Symbols
Especially important information in this document is highlighted by the
corresponding symbols:
Warning!
The industrial safety symbol identifies safety instructions whose purpose is to
prevent physical injury or death. Follow these safety instructions carefully and be
especially cautious during the work/procedures they refer to.
Warning! Risk of death from electric shock!

The electricity symbol identifies safety instructions whose purpose is to prevent
physical injury or death from electric shock. Follow these safety instructions
carefully and be especially cautious during the work/procedures they refer to.
Caution!
The caution symbol identifies all safety warnings whose purpose is to prevent
damage or destruction of the product and/or other plant components.
Note
This points to information or notes that are especially useful.
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TF-DDZG Safety
1.3 Safety in General

The "Safety" chapter gives you an overview of the safety aspects you must pay
attention to in order to work with the product safely. Any individual who assembles,
installs, mounts, commissions, operates and/or does maintenance on the product
described must read and follow the instructions in this chapter carefully to avoid
physical injury and material damage. Your safety is at stake.
In addition to these general safety instructions you will find specific safety
instructions in the product documentation related to individual actions or
procedures.
Only if you follow all of the safety instructions will you be able to provide the best
possible protection for yourself, your colleagues and the environment by ensuring
that the product functions safely and reliably.
In addition to this, it is imperative that you comply with the accident prevention and
safety regulations of the country you are working in.
1.4 Limit Values

The following products (apart from the burner) are considered as further
subsystems of a plant:
Heat generator / air supply system / flue gas system
Fuel supply system (gas valve train / oil supply system)
Burner control system
Other plant components that are not part of the burner (e.g. sound absorbing
system, emissions-reducing systems)
These subsystems are required to operate the plant but they are not an integral
part of the burner described in the present document and may vary depending on
the plant. For this reason, the present burner documentation does not include any
concrete contents on the other subsystems of the plant.
We assume that the burner and the other subsystems are properly mounted and
electrically connected before they are commissioned and that the supply of the
burner with the fuel agreed on in the contract is ensured. We also assume that the
other subsystems comply with the relevant standards/regulations, that they are
compatible with the burner and have been tested for proper operation.
The burner must be integrated into a coherent plant environment. For instructions
on integrating the burner into a coherent plant environment, please refer to the
chapters "Furnace Dimensions" and "Burner Selection" in the planning
documentation. For any information required for mounting the burner, connecting
the burner to the electric system and for the construction of the refractory
brickwork, please refer to the planning documentation and to the operating
instructions.
The plant authorities must ensure compliance with the country-specific accident
prevention and safety regulations. They must also ensure that the work
environment (e.g. boiler house) complies with the regulations. We recommend that
the plant authorities compile operating instructions for the entire work environment.
The present document and all other manufacturers documentation for the plant
components should be used as a basis for these operating instructions.
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Safety TF-DDZG
1.5 Authorized Use

The burner is exclusively designed to generate heat within the performance data
specified in the Technical Data by combusting the fuel specified on the rating plate.
The burner must be integrated into a coherent plant environment (fuel supply
system, heat generator etc.) (refer to chapter 1.4).
The energy generated by the burner, must be taken off, also during
commissioning.
To ensure proper operation of the burner, the pressure at the installation site must
not be negative relative to the atmosphere. The suction opening of the fan must be
free to ensure that it can draw in sufficient air.
Before the burner may be used for controlled operation, it must be commissioned
(with regard to its combustion performance). Only commissioning experts (refer to
"Qualified Staff") are permitted to commission the burner.
The commissioning expert is responsible for achieving proper combustion at all of
the firing rates and for ensuring that all the safety equipment (monitors etc.) are set
correctly. He/she must record all the values set in an approval and measurement
report and make it available to the plant authorities.
The settings made during commissioning must not be changed later on. Exception:
If the operating conditions change at a time following commissioning (e.g. due to
changed fuel properties or the plant environment), a commissioning expert must
check the settings and adjust them, if required. Again, the values set must be
recorded in an approval and measurement report.
The burner is fitted with safety equipment and has been tested for safety and
accepted. It may be operated only if the entire safety equipment has been adjusted
correctly and is in operation. The following is considered as safety equipment:
safety interlock circuits and all the associated components, all the other monitors
as well as construction-related protective measures such as safety fencing and
warning signs.
It is prohibited to modify or disable safety equipment unless the documentation
explicitly instructs you to disable and/or dismount such equipment temporarily. If
this should be required, e.g. for maintenance, the safety equipment must be
mounted and/or enabled again before the burner is taken into operation again. As
a rule, warning signs must never be covered or removed.
Unauthorized reconstruction and modification of the burner is prohibited. Only
original spare parts may be used! The use of third-party accessories must explicitly
be approved by SAACKE.
Comply with the instructions and regulations in the documentation in all the phases
of life of the burner. This applies especially to the burner maintenance (adhering to
the intervals for inspection and maintenance and for replacing safety-related
components).
To ensure operability, safety and economic efficiency, the plant must be inspected
by the manufacturer and/or authorized and trained personnel once a year. A
service agreement is recommended. SAACKE Service GmbH is at your disposal
for more detailed information.
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TF-DDZG Safety
1.6 Limitation of Liability

Any use deviating from the conditions specified above is considered as
unauthorized.
SAACKE does not assume liability for damage resulting from unauthorized use.
Such use is at the risk of the operator/plant authorities.
1.7 Qualified Staff
Warning!
Risk of injury and property damage due to improper operation!
The plant authorities must ensure that only qualified and authorized personnel uses
the product.
In terms of the present documentation, the term qualified staff refers to persons
who have been trained in handling the described product and are authorized by the
plant authorities to mount, commission, operate and/or service the product.
The burner may only be commissioned by personnel especially trained and
certified to do so for the burner and the plant components concerned
("commissioning experts). SAACKE will provide the training and certification for
the burner; either SAACKE or the respective manufacturer will provide the training
and certification for the other plant components.
1.8 Transport and Interim Storage at Installation Site
Risk of injuries if the burner falls over

If the burner falls over, it can cause serious injuries!
Always follow the transport and storage instructions.
1.9 Danger from Hot Surfaces
Warning! Risk of burns from hot surfaces!

If the burner is operated with preheated air, steam or preheated oil, the following
safety measures must be taken to avoid injury:
Burners operating with preheated air are designed to be insulated.
Protect all accessible surfaces with insulation (for instance, in the form of mineral
insulation), so that the surface temperature does not exceed 50C (in
accordance with DIN EN 563) and/or protect all accessible surfaces with a
protection plate.
Burners and associated components operated with steam or preheated oil that
were not insulated ex works upon delivery must also be insulated appropriately.
Nevertheless, ensure that all hazardous areas are equipped with clearly visible
warning signs to draw the personnel's attention to the risk of injury arising from
contact with hot surfaces.
Wear appropriate protective clothing when performing any work on the burner and
always comply with national accident prevention and safety regulations.
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Safety TF-DDZG
1.10 Electrical Hazards

Damaged lagging or live components that are not covered correctly present a risk
of death from electric shock!

Carelessness can lead to an electric shock.
This is why when you work with electrical equipment, you must always first:
1. Disconnect each piece of equipment from the mains.
2. Secure it to prevent it from being switched back on.
3. Check that the equipment is de-energized.
4. Ground the equipment and short-circuit it.
5. Cover other components/equipment nearby that are energized.
6 Secure the danger zone, for example by blocking it off and/or putting up a
conspicuous danger sign that no one can overlook.
1.11 Emergency Procedures
In the case of danger:

Press the "Emergency stop button" of the plant and cut off the fuel supply!
1.12 Explosion Protection in Potentially Explosive Atmospheres (ATEX)

If the product is to be used in potentially explosive atmospheres, the plant
authorities must ensure that the product is integrated into an appropriate explosion
protection concept in compliance with directive 1999/92/EC.
1.13 Emergency Operation (Applies to Marine Plants Only)

SAACKE burners used in marine plants feature an emergency operation function
to meet the requirements of the corresponding classification societies. For more
information, please refer to the emergency operation documents that are part of
the plant documentation.
1.14 Protective Clothing
Warning!
When performing any work, always wear appropriate protective clothing that
complies with the accident prevention and safety regulations of the country you are
working in.
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TF-DDZG Safety
1.15 Burner with Gun Retract Mechanism
Warning!
Risk of injury from extending or protruding oil gun!
If the burner features a gun retract mechanism, the oil gun moves out of the heat
generator when the burner is switched off or when the fuel is being changed to
gas.
The gun remains in the protruding position while the burner is not in oil firing mode.
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Transport, Storage and Packing TF-DDZG
Trans port
2 Transport, Storage and Packing
DDZ061
1
Fig. 1: Condition upon delivery (example)
Depending on the size, the burner is delivered in one of the following ways:
In horizontal position or upright on a pallet with a wooden frame (for sizes up
to 1.60 m x 1.20 m)
On a transport rack (for sizes exceeding 1.60 m x 1.20 m)
Remove the transport rack before mounting the burner.
1
The figure is a schematic diagram with the example of a DDZG burner model. It applies apply analogously
for the DDZ and DDG burner models.
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TF-DDZG Transport, Storage and Packing
2.1 Safety Instructions for Transport
Warning! Risk of accidents during transport!

There is the risk of accidents during burner transport due to the heavy weight.
Do not stand under suspended loads.
Always use the appropriate aids when loading the burner (e.g. forklift or
crane).
Warning! Risk of injuries from hoists too weak for the load!
Hoists or lifting equipment that are too weak for the load can tear.
Always select hoists or lifting equipment with sufficient load bearing capacity.
Use only tested and reliable hoists and lifting equipment, such as:
Shackles, e.g. according to DIN 82101.
Sling chains, e.g. according to DIN 5687 Product Grade 8
Caution!
The improper use of means of transport and tools (e.g. forklift or crane) bears the
risk of damaging the burner or burner components.
2.2 Checking the Delivery

SAACKE products are packed and checked before they leave the factory.
When the product is delivered, first check whether the packaging is intact. This
would be the first indication that it has been transported correctly.
Check the product for transport damage.
2.3 Reporting Transport Damage

If damage has occurred during transport, follow these procedures:
Record the transport damage on the freight documents and take a
photograph and/or make a sketch of it.
Have the person responsible for the delivery (for example the truck driver)
confirm that the damage was noticed by signing the freight documents.
Report the transport damage right away to SAACKE or whichever company
supplied the product.
2.4 Instructions for Storage

Only store the burner on the pallet or in the crate that it was delivered on/in.
Store the burner on safe and firm ground.
Keep all components, especially electrical, pneumatic and hydraulic components,
dry, free of dust and at their correct temperature during storage. The relative
humidity must be below 80%.
Protect the burner with appropriate covering in the case of a long period of
inactivity. Preserve all metal surfaces.
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Transport, Storage and Packing TF-DDZG
2.5 Disposal of the Packaging

Dispose of all packaging correctly and ecologically.
When you do it, comply with the waste disposal regulations of the country in which
you are working.
2.6 Disposal of the Product

At the end of its service life the product must be disposed of correctly and
ecologically.
When you do it, comply with the waste disposal regulations of the country in which
you are working.
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TF-DDZG Design And Function
3 Design And Function

3.1 Function
When entering the damper frame, the combustion air is divided into
primary air 1 (variable or fixed adjustment)
variable primary air 2,
variable secondary air 1
variable secondary air 2.
A very small portion of the combustion air can also be used as combustion air for
the igniter, as sealing air for the flame scanner and as sealing air for the gun. For
plants operating with preheated combustion air, these partial flows are provided by
a separate cold air fan.
2
The main fuel oil (light or heavy oil) and the atomizing medium (steam or
compressed air) are controlled in a separately documented oil fitting station. After
entering the burner, they are conveyed through the oil gun to the oil nozzle. The
atomized mixture is discharged from the nozzle in several jets.
3
The main fuel gas is divided into a variable primary gas and a secondary gas
(variable or fixed adjustment). The primary gas is distributed among gas guns via
the primary gas ring and exits via drill holes at the end of the gas guns. The
secondary gas flows through a secondary gas ring and exits via jets each with a
drill hole in the area of the secondary air.
The drill holes for primary and secondary gas are optimally adapted to the gas and
the furnace with respect to the outlet surface and arrangement. Upon
commissioning, the orientation of the drill holes for the primary gas can be changed
by turning the gas guns about their center line.
The main flame is ignited by an igniter with integrated flame detection system
(ionization). It burns in the area of the refractory brickwork.
Safety Equipment
Flame detection system
The ignition flame is monitored via an ionization electrode in the igniter.
The main flame is monitored by at least one flame scanner.
Ignition valves including solenoid ignition valves
Combustion air pressure monitor (not installed for plants with differential
pressure control)
Safety equipment for main fuel and atomizing medium is provided via an oil
fitting station (documented separately)
2
DDZ and DDZG only, according to the conditions specified in the chapter entitled "Technical Data"
3
DDG and DDZG only, according to the conditions specified in the chapter entitled "Technical Data"
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Design And Function TF-DDZG
3.2 Air and Fuel Flow
DDZ506
Fig. 2: Air and fuel flow (1)
A Main fuel oil inlet

B Inlet for atomizing medium
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DDZ505
A Main fuel gas

B Primary gas
C Secondary gas
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DDZ504
A Primary air 1 C Secondary air 1

Av Primary air 2 (twisted) D Gun sealing air
B Secondary air 2
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3.3 Burner Components
DDZ500
Fig. 5: Burner components (1)
1 Damper frame 7 Servomotor for secondary gas control

2 Windbox damper (optional; alternative: throttle)
3 Servomotor for primary air control 8 Main fuel inlet for gas
damper 1 9 Gas ring
(optional; alternative: throttle) 10 Hood
4 Inspection glass 11 Oil gun with (optional) gun retract
5 Refractory quarl ring 4 (delivery mechanism
condition: with transport protection)
6 Igniter
4
The refractory quarl ring is a partial refractory brickwork that is integrated in the burner. It does not replace
the actual refractory brickwork in the boiler. See chapter entitled "Construction of the Refractory
Brickwork".
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DDZ501
Fig. 6: Burner components (2)
1a Flame scanner
1b Flame scanner 2 (optional)
5
3 Ignition valves
4 Rating plate
5 Adjusting screw for swirl plate (2 x)
6 Servomotor for primary air control damper 2
7 Servomotor for secondary air control damper 1
8 Servomotor for secondary air control damper 2
9 Air pressure monitor (L) 6 / Pressure gauge for pressure upstream of main air control dampers
10 Atomizing medium inlet
11 Main fuel inlet (oil)
5
Configuration varies depending on the plant configuration, either installed on the burner or externally
6
Not installed in variant with differential pressure control
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TF-DDZG Construction of the Refractory Brickwork
4 Construction of the Refractory Brickwork

Before the burner can be mounted on the heat generator, refractory brickwork must
be constructed in keeping with the specifications in the present chapter. The
fireproof material for the refractory brickwork should have a AL2O3 content of at
least 60% and a spalling resistance of at least 15.
DDZ541
Fig. 7: Construction of the refractory brickwork (1)
1 Burner mounting plate

2 Sealing cord 7, see following diagram (dimension S)
3 Refractory quarl ring 8
4 Refractory brickwork7
7
Not included in the scope of delivery oft he burner
8
The refractory quarl ring is a partial refractory brickworl that is integrated in the burner. It does not replace
the actual refractory brickwork in the boiler.
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Construction of the Refractory Brickwork TF-DDZG
DDZ540
Fig. 8: Construction of the refractory brickwork (2)
1 Refractory brickwork
2 Refractory quarl ring
Dimension Burner size

S Bis 320 10 mm
S Ab 400 15 mm
Observe the specifications in the plant drawing which you have received from
SAACKE.
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TF-DDZG Mounting Instructions
Trans port
5 Mounting Instructions
Warning! Risk of injury and property damage due to the weight of the burner
and the fan!
For all the work described in the following, always follow the instructions and safety
instructions in the chapter "Transport, Storage and Packaging" before starting with
any of the tasks described here!
Caution! Faulty mounting of the burner possible!

The correct construction of the refractory brickwork (refer to the chapter entitled
"Construction of the Refractory Brickwork") is a requirement for mounting the
burner.
Warning! Health hazard due to ceramic fiber material!

Sealing cords and fiber plates for sealing contain ceramic high-temperature mineral
fibers, which may be a health hazard in the case of direct contact or if fiber dust is
inhaled.
When handling sealing cords or fiber plates, wear appropriate protective clothing
(to protect your throat and wrists, loosely fitting overalls, gloves, safety goggles
with side shields, FFP2 respirators).
Caution!
The heat generator is subject to thermal expansion. Therefore flexible connectors
must be fitted between all fixed lines and ducts and the burner. When connecting
the flexible connectors, note the direction of the expansion.
Caution!
An expansion joint must be installed between the (external) fan and the
combustion air inlet into the burner. The expansion joint is not included in the
burner product package.
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Mounting Instructions TF-DDZG
DDZ547
Fig. 9: Transport protection and lifting lugs (view from above, example)
1 Lifting lugs (arrangement can vary according to the plant)

2 Transport protection
5.1 Installation Preparations
Note
Observe the section entitled "Dimensions for the Burner Mounting Plate" in the
chapter entitled "Dimensions / Types".
Prepare the burner mounting plate on the heat generator for the weld seam before
the installation.
Remove the transport protection.
5.2 Mounting the Burner

The burner is fitted with lifting lugs to enable you to lift it into the mounting position
using a hoist.
Push the burner head through the burner mounting plate into the heat generator.
Observe the specifications in the chapter entitled Construction of Refractory
Brickwork and in the plant drawing which you have received from SAACKE.
Weld the burner onto the burner mounting plate.
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TF-DDZG Mounting Instructions
5.3 Connecting Lines and Fittings

After mounting the burner, connect the lines and fittings intended for your plant to
the burner. The corresponding connection dimensions can be found in the chapter
entitled "Dimensions / Types". A diagram of the lines already connected ex works
can be found at the end of this chapter.
More detailed information on the plant-specific arrangement of the burner, the
fittings, the lines and the burner control system, as well as on the materials, which
you must use, can be found in the plant drawing and in the circuit diagram in your
operator's manual.
In principle, you should comply with the following installation instructions:
Install all fuel lines, the air duct, the electrical cabling and the linkage in such a way
that
they are not in the way during operation and maintenance of the burner.
they can withstand the mechanical, chemical and thermal stresses which
occur during operation.
Install flexible pipelines, which are used as a connection between pipelines and the
burner, according to the installation instructions which you can find in your
operator's manual.
Install suitable supports for the fittings and pipelines.

Install an expansion joint on the air inlet of the burner.
Caution!
Install the fuel lines in the pressure range preferably only horizontally or vertically to
prevent the formation of gas bubbles.
Burners which are intended for operation with heavy oil, steam and/or
preheated air:
Follow the instructions in the Safety chapter, section "Dangers due to hot
surfaces", for all heavy oil, steam and air lines.
Equip heavy oil and steam lines with a suitable heating tracer.
Then insulate the lines.
Note
Ensure that the insulation surrounds both the line and the heating tracer.
Install the temperature sensor for the control of the heating tracer in a suitable
position.
Warning!
Ensure that the lines for burners that are insulated (e.g. for operation with
preheated air) are laid at a sufficient distance from the burner.
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Mounting Instructions TF-DDZG
5.4 Lines connected ex works
DDZ502
9
Fig. 10: Condition upon delivery (example )
9
The example shows a burner for the combustion of oil and gas.
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TF-DDZG Electrical Connections of the Burner
Wartung / R ei nigungTrans pot
6 Electrical Connections of the Burner

Depending on the plant configuration...
...the burner is equipped with a component connection box.
In this case, the components are wired to the component connection box.
You have to establish the wiring between the component connection box
and the control cabinet.
...direct wiring of the components to the control cabinet is intended.
Wire the components according to the plant-specific circuit diagram.
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Operation TF-DDZG
7 Operation
The burner does not feature any components that require special instructions for
operation.
The instructions for operating your plant are included in the operator's manual for
your plant.
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TF-DDZG P&I Diagrams
8 P&I Diagrams
The plant-related P&I diagram can be found in the Operator's Manual for your
plant.
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Maintenance / Cleaning TF-DDZG
Wartung / R ei nigungTrans pot
9 Maintenance / Cleaning
9.1 General Information
The chapter entitled "Maintenance / Cleaning" contains mandatory instructions for
the inspection and maintenance of the burner as well as for the replacement of
components.
Before and during maintenance activities, always follow the instructions in the
chapter on "Safety" and comply with the national regulations in respect of personal
and environmental protection as well as the accident prevention regulations.
The tasks described in this context may only be performed by personnel explicitly
authorized to do so by the plant authorities. The plant authorities must ensure that
the personnel is qualified to perform the described tasks correctly. It is crucial that
these persons are capable of detecting potential hazards in due time and of
preventing them. SAACKE Service GmbH is at your disposal for more detailed
information on training courses. You will find our contact data on the rear of this
document.
Persons performing tasks on the electric system must have specialized knowledge.
For this reason, tasks involving the electric system may be performed by
electricians only.
Tasks identified by the term "Service Personnel" may influence the proper
operation of the burner and the quality of the combustion considerably. For this
reason, only personnel with product-specific and task-related specialized
knowledge with access to the equipment required to perform the tasks (e.g.
measuring instruments) may perform the related tasks. SAACKE ensures the
smooth course of service tasks of this kind by taking internal qualification
measures and a persistent quality management. In addition, SAACKE also offers
plant authority training courses. SAACKE Service GmbH is at your disposal for
more detailed information on this topic as well. You will find our contact data on the
rear of this document.
Caution!
If a burner component is defective, it must be replaced. Please observe that only
service personnel is permitted to replace some of the security-related parts.
Only original spare parts may be used for replacing components within the scope
of maintenance work. For more detailed information, please refer to the chapter
entitled "Safety".
Repairs may only be performed by specialized staff explicitly authorized to do so

by the manufacturer. SAACKE Service GmbH is at your disposal for more detailed
information.
30 / 60 BA-DDZG-TF-02 2011-08-04
TF-DDZG Maintenance / Cleaning
Note
The other subsystems of the plant (e.g. heat generator, fuel supply system, refer to
the chapter entitled "Safety") are required to operate the plant but they are not an
integral part of the burner described in the present document and may vary
depending on the plant. For this reason, the present burner documentation does not
include any concrete contents on the other subsystems of the plant.
Observe the instructions in the manufacturer's documentation on the other

subsystems to ensure safe operation of the plant.
9.2 Preparing Maintenance Work
9.2.1 Periodical Maintenance (Fault not Acute)

Agree the terms with the plant manager before starting any maintenance work.
Ensure that the shut-down of the plant for maintenance purposes does not cause
faults or damage to other plants or plant components.
Note
The following instructions apply to all the maintenance tasks.
Exception: Tasks, for which it is explicitly pointed out that they can only be
performed on the running system.
Run the burner to the low-load position.
Switch the burner and the burner control system off.

Disconnect the power supply to the plant and safeguard it against restarting.
Warning!
Risk of electrocution and danger through inadvertent restarting of the burner!
Disconnecting from the mains includes the following:
Switching off the main switch of the plant
Or switching off the automatic cut-outs of the plant
Or removing the fuse links (all phases).
Ensuring that the system cannot be turned on again means:

Placing the turned off main switch in the 0-position
Or placing a clearly visible warning sign on the automatic cut-outs or on the fuse
bottom part.
Cut off the fuel supply. Heed the instructions for the fuel supply system in the
manufacturer's documentation.
Close the manual rapid shut-off for the ignition medium.

Let the burner cool off.
2011-08-04 BA-DDZG-TF-02 31 / 60
Take the following measures before working on fuel-carryingcomponents:
Warning! Danger through open fire!

Ensure that there isn't any open fire on the plant while maintenance work is being
performed. Do not use any open fire (not even a lighter or a welding apparatus)
during maintenance!
Professionally remove the residual fuel in the lines.

Dispose of the fuel ecologically.
9.2.2 Maintenance after a Fault has Interrupted the Operation

Proceed as described in the chapter entitled "Operation", section "Operation
Interruption due to Fault".
9.3 Maintenance Intervals

The following recommended, average maintenance intervals are based on normal
operating conditions and periodical use with interrupted operation (Installation
Category B according to DIN 31052).
Particular operating conditions may necessitate correspondingly shorter
maintenance intervals. Particular operating conditions are, for example:
A higher concentration of impurities of the fuel oil
Special environmental factors, e.g. salty or particularly dusty air, high air
humidity, extreme temperatures
Continuous operation
Caution!
Immediately repair damaged surface coating to avoid corrosion.
Remedy immediately defects detected in the burner.
32 / 60 BA-DDZG-TF-02 2011-08-04
9.4 Maintenance of General Components

Daily... Refer to chapter
Check the plant for proper operation (visual inspection, listen for noise) monitor 9.4.1
operating notifications and fault messages. Remove any leaked fuels, coolants
and lubricants.
Check the inlet pressures of combustion air, atomising medium (DDZ / DDZG), 9.4.2
ignition medium and fuel and compare them to the approval and measurement
report.
Weekly... Chapter
Check the driving linkage of the actuators and all the other detachable connections 9.4.3
of the moving components and connectors. 9.4.4
Check the air pressure monitor. 9.4.5
Quarterly... Chapter
Check the flexible tubes 9.4.6
Clean the flame scanner; check the function while doing so 9.4.7
Clean the igniter. 9.4.8
Biannually... Chapter
Check emission values (O2, CO, NOx and smoke spot number). Service personnel
Check igniter and ignition valves Service personnel
Annually (or after 6,000 operating hours) Chapter

Check the flow paths of the combustion air, atomising medium (DDZ / DDZG), fuel Service personnel
and ignition medium.
Check components that come into contact with fire. Service personnel
Check whether security-related components have reached their rated service life Service personnel
and, if so, inform the plant authorities.
Every two years (or after 12,000 operating hours) Chapter

Check the main and core air control dampers. Service personnel
2011-08-04 BA-DDZG-TF-02 33 / 60
Replacement of security-related components (service life)
Interval in Replacement
Component DDZ DDG DDZG
years by
10
Gas pressure monitor X X 10 Service personnel
Pressure monitor for combustion air X X X 10 Service personnel
10
Pressure monitor for atomising medium X X 10 Service personnel
10
Oil pressure monitor X X 10 Service personnel
10
Automatic firing sequence controller / fuel-air
10 10 X X X 10 Service personnel
compound regulation / flame monitor
Flame scanner X X X 10 Service personnel
10
Solenoid gas valves
X X 15 Service personnel
(incl. solenoid ignition valves for gas igniters)
Flexible Tubes X X X 5 Service personnel
10
Solenoid oil valves
X X 10 Service personnel
(incl. solenoid ignition valves for oil igniters)
10
Valves for atomising medium X X 15 Service personnel
10
This component is not part of the burner but it is important for the proper operation of the burner.
34 / 60 BA-DDZG-TF-02 2011-08-04
9.4.1 Checking the Plant for Proper Operation

Monitor the operating notifications and fault messages of the plant.
Check the plant for proper operation (visual inspection, listening for noise).
If you detect a burner problem:

Observe the instructions in the chapter entitled "Troubleshooting".
If you notice large amounts of fuel escaping in oil firing operation mode:
Immediately switch off the burner.
Find the leak and repair it, if possible.

If in doubt, revert to the service personnel.
DDZG only:
Switch to gas firing operation mode (refer to the chapter entitled "Operation").
Dispose of any leakage oil correctly and in an ecologically compatible manner.
If you notice small amounts of fuel escaping in gas firing operation mode:
Find the leak and repair it, if possible.
If you notice large amounts of fuel escaping in gas firing operation mode:
Immediately press the emergency stop button of the plant and close the manual
rapid shut-off in the gas valve train.
Find the leak.

If the leak is in the gas valve train (between the safety shut-off valve and the
solenoid gas valves):
Discharge the gas into the atmosphere via the blow line ("via the roof").
Contact the service personnel.
DDZG only:
Switch to oil firing operation mode (refer to the chapter entitled "Operation").
2011-08-04 BA-DDZG-TF-02 35 / 60
9.4.2 Checking Inlet Pressures

Read the inlet pressures of the combustion air, fuel, ignition medium and atomising
medium at the corresponding pressure gauges.
Compare these values to the values documented in the approval and

measurement report.
If you detect deviations: Check whether the supply lines are open.
Revert to the service personnel, if you are unable to detect the fault.
9.4.3 Checking the Driving Linkage of the Actuators
Note
The tasks described in the present chapter must be performed for all the driving
linkages.
DDZ063
Fig. 11: Driving linkage (schematic diagram)
First, check whether the nuts (a) are tight or not.
36 / 60 BA-DDZG-TF-02 2011-08-04
DDZ064
Fig. 12: Driving linkage: rod end, screw and lock nut
Make sure the rod end (2) can be moved easily.

Ensure the screwed glands 1) and 3) have been tightened firmly.
9.4.4 Checking the Detachable Connections

Check all the moving and detachable elements (e.g. screws, plug-and-socket
connections) on the burner.
9.4.5 Checking the Air Pressure Monitor
Note
The variant with differential pressure control is not equipped with an air pressure
monitor. In this case, the present chapter is not relevant to maintenance.
Note
This check can be performed only while the burner is in operation.
Caution!
The check will trigger a safety shut-off. Agree the terms with the plant manager
before starting the check.
The air pressure monitors integrated into the burner differ in their designs and
measuring ranges, depending on the order. The procedures for checking them,
however, are identical. Below is a typical example of an air pressure monitor.
2011-08-04 BA-DDZG-TF-02 37 / 60
DDZ066
Fig. 13: Air pressure monitor
1 Air pressure monitor

2 Test unit (here, shown in the "closed" operating position)
3 Shut-off cock for pressure gauge
4 Pressure gauge
Run the burner to low-load position.

Throw the lever to open the test unit.
This must trigger a safety shut-off.
If a safety shut-off was triggered, the check was successful. Close the test
equipment again and reset the burner at the burner control system.
If a safety shut-off is not triggered, the air pressure monitor is probably defective.
Contact the service personnel.
9.4.6 Checking the Flexible Tubes

Check the flexible tubes.
Caution!
Even small structural damage on tubes is critical. It may cause destruction of the
tubes
If you notice damage to the structure of a tube:
Immediately switch off the burner.

Replace the damaged tube. Make sure that you mount the new tube without
torsion.
Dispose of any leaked fuels, coolants and lubricants (e.g. leakage oil) correctly and
in an ecologically compatible manner.
38 / 60 BA-DDZG-TF-02 2011-08-04
9.4.7 Cleaning the Flame Scanner / Performing a Function Test

The flame detection system consists of the flame scanner (detector, on the burner)
and the flame monitor (analyzing unit). Refer to the separate documentation.
Note
Observe the manufacturer's documentation on the flame detection system.
Warning! Risk of injuries due to air containing particles!

When removing the flame scanner, air containing particles may escape. We
recommend wearing safety goggles.
Note
This check can be performed only while the burner is in operation.
Caution!
The check will trigger a safety shut-off. Agree the terms with the plant manager
before starting the check.
Run the burner to low-load position.
DDZ062
Fig. 14: Flame scanner (example)
Dismount the flame scanner as follows:
Loosen the knurled-head screw (1).
Pull the flame scanner (3) out of its mount.

Cover the lens. When doing so, be sure not to soil or scratch the lens.
This must trigger a safety shut-off.
2011-08-04 BA-DDZG-TF-02 39 / 60
Warning!
If a safety shut-off is not triggered when a function check is made, actuate the
emergency stop switch of the plant and contact the service personnel. Start the
plant only after the service personnel has checked the flame detection system.
Clean the lens of the flame scanner using a soft cloth.

Push the flame scanner back into its mount.
Tighten the knurled-head screw (1).
Reset the burner at the burner control system.
9.4.8 Cleaning the igniter

Depending on the plant configuration, different types of igniters may have been
integrated. However, the igniter is always dismounted identically.
DDZ057
Fig. 15: Igniter (example)
Note for oil igniters

In the next step, a small amount of residual oil may escape. For this reason, keep
an oil drip tray ready and dispose of any escaped oil correctly and in an
ecologically compatible manner.
Dismount the tubes for the igniter air and the ignition medium.
Dismount the electric cable to the ignition electrodes. Observe the manufacturer's
documentation on the igniter.
Screw out the Allen screws (1, four screws in total) on the igniter mount (2).
Pull the igniter (3) out of its mount.
40 / 60 BA-DDZG-TF-02 2011-08-04
Clean the igniter.
Caution!
Clean the igniter on the outside only. The igniter may be disassembled only by
personnel specially trained for this purpose.
Re-mount the igniter.
Note
To re-mount the igniter, proceed in reverse order.
9.5 Maintenance of Components Relevant to the Oil Firing Operation Mode

Daily... Refer to chapter
Check the oil drip tray(s) for the relief lines, dispose of any leakage oil in an ---
ecologically compatible manner.
Biannually... Refer to chapter

Manufacturer's
Check the components of the oil fittings station. documentation on the oil
fittings station
Check the core-air swirler. Service personnel
Check the oil nozzle. Service personnel
Every two years (or after 12,000 operating hours) Refer to chapter
Replace oil nozzle. Service personnel
9.6 Maintenance of Components Relevant Especially for Gas Firing Operation Mode
Biannually... Refer to chapter
Check the gas ring, tube bends, gas guns and gas nozzles Service personnel
Check the gas control damper Service personnel
Manufacturer's
Check the components of the gas valve train. documentation on gas valve
train
Annually... Refer to chapter

Check the restrictors for gas guns (if available). Service personnel
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9.7 After Completion of the Maintenance Work

Prepare the burner (refer to chapter "Operation", section "Preparing the Burner)
once you have completed the maintenance work.
Restart the burner.
42 / 60 BA-DDZG-TF-02 2011-08-04
TF-DDZG Troubleshooting
Trans pot
10 Troubleshooting
Note
If problems arise that cannot be solved with the help of the following descriptions,
please contact the SAACKE Service Company.
10.1 Troubleshooting (Oil Firing Operation Mode)

Burner does not start
Possible cause Measures
Control voltage not available Provide for a supply with control voltage.
Fuel has not been preselected Preselect fuel.
Burner still locked by the burner control system after Unlock the burner at the burner control system.
the safety shut-off
General safety interlock circuit of the plant
interrupted; typical causes e.g.
Low water Follow the instructions in the manufacturer's
documentation on the heat generator.
Flue gas damper of the heat generator not open Manually driven flue gas damper:
Open flue gas damper.
Flue gas damper driven by the plant control system:
Remove any foreign particles that block the flue gas
damper.
If this does not solve the problem: follow the
instructions in the manufacturer's documentation on
the heat generator and/or the plant control system
or revert to the service personnel.
Emergency stop button of the plant was actuated Find out whether the button was actuated
accidentally and/or whether the reason for the
emergency stop has been eliminated.
If the reason has been eliminated: Reset the
emergency stop button of the plant.
The safety manostat / thermostat of the heat Reset the safety manostat / thermostat. Follow the
generator has interrupted the safety interlock instructions in the manufacturer's documentation on
circuit and is locked the heat generator.
Boiler control circuit interrupted Check the boiler control circuit, if in doubt, revert to
the service personnel.
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Troubleshooting TF-DDZG
Purge phase does not start

Pressure monitor (L) for protection against dry
running in the fuel supply system has interrupted the
safety interlock circuit
Fuel not available on the upstream side of the Check whether the available oil pressure /
booster pump or insufficient fuel pressure / temperature corresponds to the plant configuration.
temperature
Follow the instructions in the manufacturer's
documentation on the fuel supply system.
One or more actuators do not reach the purge Restore the free movement of the actuators. If in
position doubt, revert to the service personnel.
The motor circuit breaker (fan) has interrupted the Reset the motor circuit breaker.
If the fault persists: Revert to the service personnel.
Safety shut-off during the purge phase

Pressure monitor for combustion air has interrupted
the safety interlock circuit
Combustion air not available or insufficient Check whether the available pressure corresponds
pressure to the plant configuration.
Incorrect pressure monitor setting or pressure Revert to the service personnel.
monitor defective
General safety interlock circuit of the plant interrupted Refer to "Burner does not start".
Flame scanner detects extraneous light Check furnace.
Oil safety interlock circuit interrupted, causes e.g.
Fuel not available or insufficient/excessive fuel Check whether the available fuel pressure /
pressure / temperature temperature corresponds to the plant configuration.
Oil pressure monitor in the fuel supply system Revert to the service personnel.
incorrectly set or defective
Ignition does not start

One or more actuators do not reach the ignition Restore the free movement of the actuators. If in
44 / 60 BA-DDZG-TF-02 2011-08-04
No ignition flame
No ignition spark
Ignition transformer does not deliver secondary Check whether the ignition transformer is supplied
voltage with voltage
Check connections and cables.
Ignition electrodes soiled or defective Revert to the service personnel.
Ignition medium not available or Check whether the available pressure corresponds
insufficient/excessive pressure to the plant configuration.
Check whether all the manual shut-off devices in the
ignition gas supply system are in the correct
position.
Check the pressure reducing valve (if available).
Igniter defective Follow the instructions in the manufacturer's
documentation for the igniter.
If in doubt: Revert to the service personnel.
Solenoid ignition valves do not open Revert to the service personnel.
Problems with the ignition

Flame scanner does not detect ignition flame Follow the instructions in the manufacturer's
documentation on the igniter (with integrated flame
detection system).
If this does not solve the problem: Revert to the
service personnel.
Ignition flame instable Revert to the service personnel.
No main flame
Main fuel not available or insufficient/excessive Check whether the available pressure / temperature
pressure / temperature corresponds to the plant configuration.
Check oil pressure in the closed circular pipeline
(fuel supply system).
Check booster pump in the fuel supply system.
documentation for the fuel supply system.
fuel supply system are in the correct positions.
Solenoid oil valves in the fuel supply system do not
open Follow the instructions in the manufacturer's
Oil pressure monitor in the fuel supply system documentation on the fuel supply system.
Air in the fuel line
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Unsatisfactory combustion or fault in controlled operation

Another subsystem of the plant (e.g. fuel supply Follow the instructions in the manufacturer's
system, control cabinet, heat generator) has triggered documentation on the defective subsystem or revert
a fault / caused a safety shut-off to the service personnel.
One or more actuators do not reach their intended Restore the free movement of the actuators. If in
The flame detection system has interrupted the Clean flame scanner lens.
Ensure sufficient cooling.
service personnel.
Nozzle system dirty Revert to the service personnel.
General safety interlock circuit interrupted Refer to "Burner does not start".
Oil safety interlock circuit interrupted Refer to "Safety shut-off during the purge phase".
Burner emits soot, unsatisfactory burnout or any Revert to the service personnel.
other undesired operating mode of the burner not
described in any other context
In the case of marine plants only: Temperature Check whether there is low pressure in the machine
monitor for combustion air has interrupted safety room.
interlock circuit and/or fan is running, even though the
burner is not firing. Check windbox: Fire?
Revert to the service personnel.
46 / 60 BA-DDZG-TF-02 2011-08-04
10.2 Troubleshooting (Gas Firing Operation Mode)

Burner does not start
Control voltage not available Provide for a supply with control voltage.
Fuel has not been preselected Preselect fuel.
Burner still locked by the burner control system after Unlock the burner at the burner control system.
the safety shut-off
General safety interlock circuit of the plant
interrupted; typical causes e.g.
Low water Follow the instructions in the manufacturer's
documentation on the heat generator.
Flue gas damper of the heat generator not open Manually driven flue gas damper:
Open flue gas damper.
Flue gas damper driven by the plant control system:
Remove any foreign particles that block the flue gas
damper.
If this does not solve the problem: follow the
instructions in the manufacturer's documentation on
the heat generator and/or the plant control system
or revert to the service personnel.
Emergency stop button of the plant was actuated Find out whether the button was actuated
accidentally and/or whether the reason for the
emergency stop has been eliminated.
If the reason has been eliminated: Reset the
emergency stop button of the plant.
The safety manostat / thermostat of the heat Reset the safety manostat / thermostat. Follow the
generator has interrupted the safety interlock instructions in the manufacturer's documentation on
circuit and is locked the heat generator.
Boiler control circuit interrupted Check the boiler control circuit, if in doubt, revert to
Gas safety interlock circuit interrupted, causes e.g.
Fuel not available or insufficient/excessive fuel Check whether the available gas pressure
pressure corresponds to the plant configuration.
documentation on the fuel supply system or revert to
Gas pressure monitor in the fuel supply system Follow the instructions in the manufacturer's
incorrectly set or defective documentation on the fuel supply system or revert to
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Purge phase does not start

Leak test of the fuel supply system has interrupted
Following a safety shut-off, pressure was still Relieve the fuel supply system. Follow the
"trapped" between the solenoid gas valves in the instructions in the manufacturer's documentation on
fuel supply system the fuel supply system.
Manual shut-off device(s) in the fuel supply Check whether all the manual shut-off devices in the
system are not in the correct position fuel supply system are in the correct positions.
Solenoid gas valve in the fuel supply system Follow the instructions in the manufacturer's
leaky or defective documentation on the fuel supply system.
One or more actuators do not reach the purge Restore the free movement of the actuators. If in
The motor circuit breaker (fan) has interrupted the Reset the motor circuit breaker.
If the fault persists: Revert to the service personnel.
Safety shut-off during the purge phase

Pressure monitor for combustion air has interrupted
Combustion air not available or insufficient Check whether the available pressure corresponds
Incorrect pressure monitor setting or pressure Revert to the service personnel.
monitor defective
General safety interlock circuit of the plant or gas Refer to "Burner does not start".
safety interlock circuit interrupted
Flame scanner detects extraneous light Check furnace.
Ignition does not start

One or more actuators do not reach the ignition Restore the free movement of the actuators. If in
48 / 60 BA-DDZG-TF-02 2011-08-04
No ignition flame
No ignition spark
Ignition transformer does not deliver secondary Check whether the ignition transformer is supplied
voltage with voltage
Check connections and cables.
Ignition electrodes soiled or defective Revert to the service personnel.
Ignition medium not available or Check whether the available pressure corresponds
insufficient/excessive pressure to the plant configuration.
ignition gas supply system are in the correct
position.
Check the pressure reducing valve (if available).
Solenoid ignition valves do not open Revert to the service personnel.
Igniter defective Follow the instructions in the manufacturer's
documentation on the igniter. If in doubt: Revert to
Problems with the ignition

Flame scanner does not detect ignition flame Follow the instructions in the manufacturer's
documentation on the igniter (with integrated flame
detection system).
service personnel.
Ignition flame instable Revert to the service personnel.
No main flame
Main fuel not available or insufficient/excessive Check whether the available pressure corresponds
fuel supply system are in the correct positions.
Solenoid gas valves in the fuel supply system do not
open Follow the instructions in the manufacturer's
Gas pressure monitor in the fuel supply system documentation on the fuel supply system.
Air in the fuel line
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Unsatisfactory combustion or fault in controlled operation

Another subsystem of the plant (e.g. fuel supply Follow the instructions in the manufacturer's
system, control cabinet, heat generator) has triggered documentation on the defective subsystem or revert
a fault / caused a safety shut-off to the service personnel.
One or more actuators do not reach their intended Restore the free movement of the actuators. If in
The flame detection system has interrupted the Clean the lens of the flame scanner (refer to the
safety interlock circuit chapter entitled "Maintenance/Cleaning").
Ensure sufficient cooling.
service personnel.
General safety interlock circuit interrupted Refer to "Burner does not start".
Gas safety interlock circuit interrupted Refer to "Burner does not start".
Burner emits soot, unsatisfactory burnout or any Revert to the service personnel.
other undesired operating mode of the burner not
described in any other context
50 / 60 BA-DDZG-TF-02 2011-08-04
TF-DDZG Dimensions / Types
11 Dimensions / Types
DDZ543
Fig. 16: Burner dimensions TF-DDZG
DDZ544
Fig. 17: Burner dimensions TF-DDG
Legend see below
2011-08-04 BA-DDZG-TF-02 51 / 60
Dimensions / Types TF-DDZG
DDZ545
Fig. 18: Burner dimensions TF-DDZ
1 Atomizing medium inlet

2 Main fuel oil inlet
3 Main fuel gas inlet
(See following sections fort he fuel connection dimensions)
Note
Plant-specific dimensional differences are possible. For this reason, the
dimensions specified here are intended for planning purposes only. The
dimensions applicable for your plant are specified in the operators manual for your
plant.
Burner size F F
A B C E Eb G
(TF-DDZG) (TF-DDZ)
100 1000 700 900 655 800 510 310 390
150 1300 800 1050 750 1000 510 310 390
200 1300 800 1050 750 1100 510 310 390
260 1550 1000 1300 1000 1200 565 365 390
320 1550 1000 1300 1000 1300 565 365 390
400 1900 1400 1850 1200 1400 680 450 495
500 1900 1400 1850 1200 1500 680 450 495
Table 1: Burner dimensions (1)
52 / 60 BA-DDZG-TF-02 2011-08-04
Burner size K K L Mb MF MF N
H
(TF-DDZG) (TF-DDZ) (TF-DDZ/DDZG) (TF-DDG)
100 910 1810 1400 300 820 2500 1900 70
150 960 2010 1700 500 1020 2800 1900 70
200 960 2010 1700 500 1120 2800 1900 70
260 1100 2400 2075 650 1220 3200 2300 70
320 1100 2400 2075 650 1320 3200 2300 70
400 1360 3210 2800 800 1430 3800 2900 80
500 1360 3210 2800 800 1530 3800 2900 80
Table 2: Burner dimensions (2)
11.1 Burner Weight

Weight in kg
Burner size
TF-DDZ TF-DDG TF-DDZG
100 1150 1240 1250
150 1650 1740 1750
200 1750 1840 1850
260 2600 2680 2700
320 2700 2780 2800
400 4150 4200 4250
500 4250 4300 4350
Table 3: Burner weight
11.2 Dimensions for the Burner Mounting Plate

Observe dimension A in the figure "Burner dimensions".
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11.3 Position of Air Inlet / Position of Gas Inlet

180
157,5 202,5
135 225
112,5 247,5
90 270
67,5 292,5
45 315
22,5 337,5
DDZ080c
Fig. 19: Position of air and gas inlet
In the planning phase three rules must be observed for the arrangement of air and
gas inlets:
Position of air inlet = 0, 22.5 or a multiple of 22.5
Position of gas inlet =

Sizes 260 to 500: 0, 45 or a multiple of 45
Sizes 100 to 200: 0, 60 or a multiple of 60
The air inlet and the gas inlet should not be "directly above one another"
(e.g. not both at 180)
54 / 60 BA-DDZG-TF-02 2011-08-04
11.4 Connection Dimensions
DDZ503
Fig. 20: Connections
1 Combustion air
2 Main fuel oil
3 Atomizing medium
4 Pneumatic connection for gun retract mechanism (see following figure)
5 Main fuel gas
6 Ignition medium
Not visible: Combustion air for igniter 11
11
For information on the connection dimension, refer to the manufacturers documentation
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DDZ089
Fig. 21: Pneumatic connection for gun retract mechanism (optional)
56 / 60 BA-DDZG-TF-02 2011-08-04
11.4.1 Combustion Air (Air Duct)
DDZ542
Fig. 22: Connection dimensions for air duct
Dimensions in mm
Size
A (Depth) S T U V W X Y Z
100 8 600 450 700 660 6 x 95 550 510 4 x 105
150 8 800 550 900 860 7 x 110 650 610 6 x 90
200 8 800 550 900 860 7 x 110 650 610 6 x 90
260 8 1000 700 1100 1060 10 x 95 800 760 7 x 95
320 8 1000 700 1100 1060 10 x 95 800 760 7 x 95
400 8 1200 850 1300 1260 11 x 105 950 890 9 x 90
500 8 1200 850 1300 1260 11 x 105 950 890 9 x 90
Table 4: Connection dimensions for air duct
2011-08-04 BA-DDZG-TF-02 57 / 60
11.4.2 Main Fuel Oil / Atomizing Medium

Gun connection Flexible tubes
(Fixed connection) (Union nut)
Atomizing
Atomizing medium Oil Oil
medium
Burner size DN SW 12 DN SW12 SW12 SW12
100 12 22 15 27 27 32
150 12 22 15 27 27 32
200 12 22 15 27 27 32
260 15 27 20 32 32 36
320 15 27 20 32 32 36
400 20 32 25 41 36 41
500 20 32 25 41 36 41
Table. 5: Connection dimensions for main fuel oil / atomizing medium
11.4.3 Main Fuel Gas
DDZ070
Fig. 23: Connection flange for main fuel gas, PN16
Dimensions in mm Number of drill-

Size
DN d1 D b k s d2 holes
100 100 114,3 220 20 180 3,6 18 8

150 125 139,7 250 22 210 4 18 8
200 125 139,7 250 22 210 4 18 8
260 150 168,3 285 22 240 4,5 22 8
320 150 168,3 285 22 240 4,5 22 8
400 200 219,1 340 24 295 6,3 22 12
500 200 219,1 340 24 295 6,3 22 12
Table. 6: Connection flange for main fuel gas
12
Wrench size
58 / 60 BA-DDZG-TF-02 2011-08-04
TF-DDZG Technical Data
11.4.4 Pneumatic System for the Gun Retract Mechanism
Note
The gun retract mechanism is an optional component.
The connection dimensions for the pneumatic system depend on the gun retract
mechanism used. You can find the dimensions in the operator's manual for your
plant.
11.4.5 Ignition Medium

The dimensions for connection of the ignition medium to the ignition valves depend
on the ignition valves used. You can find the dimensions in the operator's manual
for your plant.
11.4.6 Cooling Air for the Flame Scanner

The connection dimensions for the cooling air depend on the flame scanner used.
You can find the dimensions in the operator's manual for your plant.
12 Technical Data
The minimum and maximum power of your burner can be found on the rating plate.
All other information, for example the requirements of the fuels, can be found on
the plant drawing and/or in the corresponding documents in the Operator's Manual
for your plant.
12.1 Acoustic Emissions

The acoustic emissions depend on the plant configuration. Please contact
SAACKE GmbH, Bremen. You will find our contact address on the back of this
document.
2011-08-04 BA-DDZG-TF-02 59 / 60
a
SAACKE GmbH
Suedweststrasse 13 28237 Bremen
GERMANY
Phone: +49 - 421- 64 95 0
Fax: +49 - 421- 64 95 5224
E-Mail: info@saacke.de
www.saacke.com
b
SAACKE Service GmbH
Suedweststrasse 13 28237 Bremen
GERMANY
Phone: +49 - 421- 64 95 0
Fax: +49 - 421- 64 95 5244
E-Mail: service@saacke.de
www.saacke.com
SAACKE-Hotline: +49-421-64 95 5201

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Duoblock Burner TF-DDZG

BA-DDZG-TF-02 Combustion and Energy Systems

Combustion and Energy Systems

9.2.2 Maintenance after a Fault has Interrupted the Operation ................................................................ 32

Help us improve this documentation!

Warning! Risk of death from electric shock!

1.3 Safety in General

1.4 Limit Values

1.5 Authorized Use

1.6 Limitation of Liability

1.7 Qualified Staff

1.8 Transport and Interim Storage at Installation Site

Risk of injuries if the burner falls over

1.9 Danger from Hot Surfaces

Warning! Risk of burns from hot surfaces!

1.10 Electrical Hazards

Warning! Risk of death from electric shock!

Warning! Risk of death from electric shock!

1.11 Emergency Procedures

In the case of danger:

1.12 Explosion Protection in Potentially Explosive Atmospheres (ATEX)

1.13 Emergency Operation (Applies to Marine Plants Only)

1.14 Protective Clothing

1.15 Burner with Gun Retract Mechanism

2 Transport, Storage and Packing

Remove the transport rack before mounting the burner.

2.1 Safety Instructions for Transport

Warning! Risk of accidents during transport!

2.2 Checking the Delivery

Check the product for transport damage.

2.3 Reporting Transport Damage

2.4 Instructions for Storage

2.5 Disposal of the Packaging

2.6 Disposal of the Product

3 Design And Function

3.2 Air and Fuel Flow

A Main fuel oil inlet

A Main fuel gas

A Primary air 1 C Secondary air 1

3.3 Burner Components

1 Damper frame 7 Servomotor for secondary gas control

4 Construction of the Refractory Brickwork

1 Burner mounting plate

Dimension Burner size

Caution! Faulty mounting of the burner possible!

Warning! Health hazard due to ceramic fiber material!

1 Lifting lugs (arrangement can vary according to the plant)

5.1 Installation Preparations

Remove the transport protection.

5.2 Mounting the Burner

Weld the burner onto the burner mounting plate.

5.3 Connecting Lines and Fittings

Install suitable supports for the fittings and pipelines.

Then insulate the lines.

5.4 Lines connected ex works

Wartung / R ei nigungTrans pot

6 Electrical Connections of the Burner

Wire the components according to the plant-specific circuit diagram.

Wartung / R ei nigungTrans pot

Repairs may only be performed by specialized staff explicitly authorized to do so

Observe the instructions in the manufacturer's documentation on the other

9.2 Preparing Maintenance Work

9.2.1 Periodical Maintenance (Fault not Acute)