BIO, BIOA, ZIO - Combustion 911

Burners for gas BIO, BIOA, ZIO 

Technical Information · GB 

7.2.14 Edition 05.10 

• Large capacity range up to 1000 kW 

• Maintenance-friendly thanks to modular design 

• Robust burner design 

• Safe flame control thanks to ionization electrode and reliable electrical ignition 

• Length increments enable individual adjustment either to new systems or 

when modernizing existing systems 

• Suitable for new systems and modernisation of existing systems thanks to 

individual length adjustment 

• Air preheating to 450°C available as an option 

• Low polluting level thanks to optimized combustion 

• For installation as ceiling or side-wall burner 

• Can be combined with different combustion chamber shapes 

www.kromschroeder.com

2 

Table of contents 

Burners for gas BIO, BIOA, ZIO . . . . . . . . . . . . . . . . . . . . . . 1 

Table of contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 

1 Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 

1.1 Examples of application. . . . . . . . . . . . . . . . . . . . . . . . . . 5 

1.1.1 Continuous control with pneumatic ratio control system . . .5 

1.1.2 Continuous control with pneumatic ratio control system 

and lance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 

1.1.3 Cascade control for extended control range . . . . . . . . . . . .6 

1.1.4 Staged control with pneumatic ratio control system . . . . . .6 

2 Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 

2.1 Approval for Russia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 

3 Mechanical construction. . . . . . . . . . . . . . . . . . . . . . . . . 8 

3.1 Burner housing (furnace flange) . . . . . . . . . . . . . . . . . . . 8 

3.2 Burner insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 

3.3 Burner tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 

3.3.1 Burner tube in burner quarl. . . . . . . . . . . . . . . . . . . . . . . . . .9 

3.3.2 Burner tube with attachment tube . . . . . . . . . . . . . . . . . . . .9 

4 Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 

5 Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 

5.1 Burner type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 

5.2 Burner size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 

5.3 Burner head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 

5.4 Field of application . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 

5.5 Calculating the burner length . . . . . . . . . . . . . . . . . . . 14 

5.5.1 Burners in burner quarls . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 

5.5.2 Burners with burner attachment tube . . . . . . . . . . . . . . . . 17 

5.6 Selection table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 

5.6.1 Type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 

6 Project planning information . . . . . . . . . . . . . . . . . . . . . 21 

6.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 

6.2 Recommended ignition transformer . . . . . . . . . . . . . . 21 

6.3 Non-return gas valve . . . . . . . . . . . . . . . . . . . . . . . . . . 21 

6.4 Flame control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 

BIO, BIOA, ZIO · Edition 05.10 

6.5 Hot air compensation . . . . . . . . . . . . . . . . . . . . . . . . . . 21 

6.6 Purging air/cooling air . . . . . . . . . . . . . . . . . . . . . . . . . 22 

6.7 Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 

6.8 Gas line connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 

6.9 Air line connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 

6.10 Condition on delivery. . . . . . . . . . . . . . . . . . . . . . . . . . 23 

7 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 

7.1 Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 

7.2 Ignition lance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 

8 Maintenance cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 

Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 

Contact. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 

t = To be continued

3 

BIO 

1 Application 

For industrial furnaces and firing systems in the iron and steel 

industries in the precious, non-ferrous and light metal sector, 

as well as in the plastics, fibre and paper industries. Other 

fields of application are thermal incineration installations, as 

well as driers and hot-air generators. 

For low temperature applications (e.g. for crucible heating, 

radiant tube heating or hot-air generation), the burners are 

equipped with a heat-resistant steel attachment tube. 

For high temperature applications (e.g. forging furnace), the 

burners are used in combination with a burner quarl made 

from refractory concrete. Different flame shapes can be 

achieved by using burner quarls with a different geometry. 

The burner may be adapted to the system requirements using 

different burner lengths. 

BIOA 

ZIO 

BIO, BIOA, ZIO · Edition 05.10

Application 

4 

Shaft melting and holding furnace Bogie hearth forging furnace Incineration installation for thermal regenerative 

flue air purification 

Strip galvanising plant Rotary table furnace Aluminium tank furnace 


Application 

5 

1.1 Examples of application 

Threepoint 

step 

AKT 

VAS 

M 

VAG 

GEH 

EKO 

EKO 

ZIO, BIO, BIOA 

1.1.1 Continuous control with pneumatic ratio control system 

The burner output is controlled in modulating mode by adjusting 

the butterfly valve BVA. The air/gas ratio control VAG 

ensures a constant gas/air flow ratio via the impulse line. This 

type of control is used in melting furnaces in the aluminium 

industry or in regenerative incineration installations in the 

environment industry, for example. 

IC 20 + BVA 

BVA 

AKT 

VAG 

GEH 

EKO 

BIO..L, ZIO..L 

1.1.2 Continuous control with pneumatic ratio control 

system and lance 

The burner’s flexibility is increased thanks to an ignition lance. 

This type of control is used in heat treatment furnaces in the 

iron and non-ferrous metal industries and in heating furnaces 

in the steel industry, for example. 

60DJZ VG 8 

GEH 

60DJLZ 

M 

GEH 

EKO 

IC 20..E + BVA 

BVA 


Application > Examples of application 

6 

VAS 

M 

IC 20 

+ LFC 

1.1.3 Cascade control for extended control range 

The burner is adjusted near-stoichiometrically to a low-fire 

rate of 10% using a pneumatic ratio control system. Smaller 

capacities can be adjusted with the IC 20 at a constant lowfire 

air flow rate by throttling down the gas flow. With cascade 

control, control ranges of 1:45 can be achieved with excess air. 

AKT 

VAS 

VAG 

GEH 

EKO 

ZIO, BIO, BIOA 

M 

IC 20 + BVA 

LEH 

EKO 

VAG+VBY 

1.1.4 Staged control with pneumatic ratio control system 

The burner capacity is switched cyclically between high fire 

and low fire by opening and closing the solenoid-operated 

butterfly valve for air. 

AKT 

MB 7 + BVHM 

GEH 

EKO 

LEH 

EKO 

BIO, BIOA, ZIO 

The pneumatic air/gas ratio control system offers maximum 

safety by an air deficiency cut-out, with a constant lambda 

value being maintained while the air pressure varies. The 

low-fire rate is guaranteed by the bypass valve VBY. The high 

output impulse at the burner produces a uniform temperature 

distribution and good circulation of the furnace or kiln 

atmosphere, e.g. in heat treatment furnaces in the iron and 

non-ferrous metal industries or kilns for heavy clay and fine 

ceramics. 


7 

2 Certification 

2.1 Approval for Russia 

Certified by Gosstandart pursuant to GOST-R. 

Approved by Rostekhnadzor (RTN). 


8 

3 Mechanical construction 

The burners are composed of three modules: burner housing, 

burner insert and burner tube. This structure allows the 

burners to be easily adapted to the respective process or to 

be integrated into existing systems. Maintenance and repair 

times are reduced, and existing furnace installations can 

easily be converted. 

3.1 Burner housing (furnace flange) 

BIO BIOA ZIO 

The burner is secured to the furnace by the burner housing. 

The burner housing accommodates the burner insert and the 

burner tube, and routes the combustion air. The combustion air 

pressure can be measured using an air pressure test nipple. 

3.2 Burner insert 

BIO BIOA ZIO 

The combustion gas is supplied to the burner head via the 

gas connection and the gas pipe. The gas connection flange 

comprises of the gauge glass, ground screw and electrode 

plugs with plug caps. 

As of construction stage E, a measuring orifice and flow adjustment 

are integrated in the connection flange to easily measure 

and adjust the gas flow rate. 

The ignition and ionization electrodes are screwed into the 

connection flange and can be replaced without removing the 

burner insert as of burner size 65. 

Burners BIO, BIOA and ZIO are nozzle-mixing burners. Gas 

and air are mixed only once they are in the burner head. This 

prevents explosive gases from being generated in the pipeline. 

There are various burner head versions for different flame 

shapes and gas types. 


Mechanical construction 

9 

3.3 Burner tube 

Different overall lengths enable adjustment to the furnace wall 

thickness of the system. 

3.3.1 Burner tube in burner quarl 

The burner head is positioned inside the burner tube. The 

burner quarl accommodates the burner tube and simultaneously 

acts as the combustion chamber for the complete 

combustion of the flame. The burner quarls are components 

of the refractory lining of the furnace and are usually supplied 

by the furnace manufacturer. 

3.3.2 Burner tube with attachment tube 

The burner head is positioned inside the burner tube. An attachment 

tube made of heat-resistant steel acts as the combustion 

chamber for the complete combustion of the flame 

for low- and medium-temperature applications. 


10 

4 Function 

The burner control unit opens the gas and air control valves. 

Gas flows through the gas connection flange and air flows 

through the burner housing as far as the nozzle-mixing burner 

head. 

The combustible gas/air mixture is produced downstream of 

the burner head. Slots and holes in the air disc vary the degree 

and manner of twisting of the combustion air and determine 

the flame geometry. Depending on the gas type, the geometry 

of the gas nozzle varies. 

The gas/air mixture is electrically ignited directly by an ignition 

electrode or an ignition lance. A flame forms which is 

monitored using an ionization electrode or optionally using 

the UV sensor. 

The choice of the respective combustion chamber material 

and geometry is primarily determined by the process. 

Using burner quarls, almost any flame shape and outlet velocity 

can be achieved. 

For low-temperature applications, a combustion chamber 

made of heat-resistant steel can be used. The flame burns 

inside the metal burner attachment tube. 

BIO, BIOA 


Burner insert 

Gas 

Burner housing 

Burner insert 

Gas 

Air 

Burner housing 

Air 

Burner head 

Burner tube 

Burner head 

Burner tube 

Burner head 

Ignition electrode 

Ionization electrode 

Gas nozzle 


11 

5 Selection 

5.1 Burner type 

Type 

Housing 

Air temperature Furnace temperature 

°C °C 

BIO GG 20 to 450 50 to 1600 

BIOA AlSi 20 to 200 50 to 1400 

ZIO ST 20 to 450 50 to 1600 

* For furnace temperatures of > 1450°C, special burner versions are available on request. 

5.2 Burner size 

Burner size 

Burner capacity 

[kW] 

BIO 50 40 

BIO, BIOA 65 90 





ZIO 165 630 

ZIO 200 1000 


Selection 

12 

5.3 Burner head 

The choice of burner head depends on the flame shape, gas type and variant. 

Burner head 

code letter 

Furnace temperature 

[°C] 

Air temperature2) 

[°C] 

Flame shape 

Control range Low fi re l λ1) 

Continuous Staged 

Normal R 1:10 1:10 > 1.05 0.8 to 1.3 50 to 350 20 to 150 4) 

Long H 1:10 1:10 > 1.3 0.8 to 1.5 500 to 1600 5) 20 to 450 

Flat K 3) – 1:10 > 1.05 0.9 to 1.2 50 to 100 4) 20 to 50 4) 

1) Indicates the rough range for the max. connection rating. For precise values for the individual versions, see burner diagrams. 

The ranges were determined for an ionization current of ≥ 5 µA. Extension of the working range using a UV sensor. 

2) The gas fl ow rate should be reduced in accordance with the enthalpy gain of the preheated combustion air. 

3) In conjunction with a burner quarl, for use as a radiant burner. 

4) Higher temperatures available on request. 

5) From a furnace temperature of > 1450°C, the control range is limited. 

Gas type 

Code letter 

Calorifi c value range 

[kWh/m 3 (n)] 

Density ρ 

[kg/m 3 ] 

Natural gas L and H quality B 8 to 12 0.7 to 0.9 

Propane, propane/butane, butane M 25 to 35 2.0 to 2.7 

Propane, propane/butane, butane G 1) 25 to 35 2.0 to 2.7 

Coke oven gas, town gas D 4 to 5 0.4 to 0.6 

Low calorifi c value gas L 2) 1.7 3 to 3 0.9 to 1.15 

1) For λ < 0.9 or when using the BIO 50. 

2) Not for all burner sizes. Burner capacity is limited to 50 % of the rated capacity. 

3) Calorifi c value range < 1.7 on request. 

Variant Code letter Output 

[kW] 

Ignition lance L approx. 1.5 

Reduced max. connection rating R – 


Selection 

13 

5.4 Field of application 

For optimal operation, the combustion chamber and flame shapes are combined according to the field of application. 

Field of application 

Illustration 

Combustion 

chamber 

Control 

Flame 

shape 

Max. 

capacity 

Remarks 

Industrial furnaces, open 

combustion chambers 

A 

Open cone 

High/Low 

Continuous 

R 100 % 

Recommended for cold-air operating 

mode only, otherwise the nitric oxide values 

are too high 



B 

Cylindrical 

High/Low 

High/Low/Off 

Continuous 

R, H 100 % Normal to medium fl ow velocity 



C 

Tapered 

High/Low 

High/Low/Off 

Continuous 

R, H 

approx. 

80% 

Medium to high velocity, capacity depending 

on the diameter 



D 

Flat fl ame 

quarl 

High/Low 

High/Low/Off 

(Continuous) 

K 100 % 

With continuous control, limited control 

range (≥ 40%) 

Radiant tube heating 

E 

Burner with 

attachment 

tube and 

purging air 

bore holes 

On/Off H 100 % 

For cold-air only. Note the capacity of the 

radiant tube in accordance with the manufacturer’s 

specifi cations. 

A draught blocker must be fi tted on the 

fl ue gas side. 

Hot-air generation 

F 

Burner attachment 

tube 

with purging 

air bore holes, 

protective 

fl ame tube 

FPT 

High/Low 

High/Low/Off 

continuous 

R 100 % 

Protection of the fl ame from cooling is ensured 

by using a protective fl ame tube 

FPT at fl ow velocities of > 15 m/s). 

Only where the furnace temperature is 

< 600°C. 


Selection 

14 

5.5 Calculating the burner length 

L1 

L2 

L O 

BKL 

Legend 

L1 = Burner tube length 

L2 = Position of burner head 

L O = Furnace wall thickness 

BKL = Burner chamber length (L 10 ) 

5.5.1 Burners in burner quarls 

The position of the burner head (L2) should be appropriately selected, so that the 

burner head extends into the burner quarl. 

The position of the burner head is available in the following lengths: 

35, 135, 235, 335 mm, etc. 

The burner chamber length BKL for ensuring optimum flame formation and stable 

burner operation can be found in the [Data table – p. 15]. 

Determine the position of the burner head: L2 = L O - BKL 

The burner tube length (L1) is predefined, depending on the flame shape R, K or 

H: R, K burner head: 

L1 = L2 + 15 mm, H burner head: L1 = L2 + 65 mm 

Example 

Desired burner quarl type = B, desired flame shape = R (normal). 

Selected burner with 90 kW capacity = BIO 65, 

suitable for burner chamber length (BKL) = 115 – 265 mm. 

Furnace wall thickness L O = 340 mm. 

Calculate shortest length L2: 

Select maximum burner chamber length: BKL = 265 mm. 

L2 = LO - BKL = 340 mm - 265 mm = 75 mm. 

Compare L2 (here 75 mm) with standard lengths (35, 135, 235, 335 mm, etc.). 

Select next longest standard length L2: L2 = 135 mm. 

Test whether the burner chamber length BKL fits: 

L O - L2 = BKL ➔ 340 mm - 135 mm = 205 mm. 

205 mm falls into the burner chamber length range for burners BIO 65: 

115 – 265 mm – see [Data table – p. 15]. 


Selection > Calculating the burner length > Burners in burner quarls 

15 

Data table 


Burner quarl type 

Flame shape 

Burner head* 

Burner chamber length 

BKL (L 10 ) 

[mm] 

50 A R 215 to 265 

50 B, C R 115 to 265 

50 B, C H 115 to 265 

50 D KB, KG 130 to 135 

65 A R 215 to 265 

65 B, C R 115 to 265 

65 B, C H 115 to 265 

65 D KB, KM, KD 155 to 175 

80 A R 215 to 265 

80 B, C R 165 to 265 

80 B, C H 165 to 265 

80 D KB, KM 205 to 225 

100 A R 215 to 315 

100 B, C R 165 to 265 

100 B, C H 165 to 315 

100 D KB, KM 230 to 250 

100 D KD 170 to 190 

125 A R 265 to 365 

125 B, C R 215 to 315 

125 B, C H 215 to 365 

125 D KB 190 to 210 

* Flame shape: R = normal, H = long, K = fl at. 

Gas type: B = natural gas, M, G = propane, butane/propane, butane, D = coke oven gas, 

town gas. 


BKL 

BKL 

BKL 

BKL 

∅ 

6° 

A 

B 

C 

D 


Selection > Calculating the burner length > Burners in burner quarls 

16 



Flame shape 

Burner head* 

Burner chamber length 

BKL (L 10 ) 

[mm] 

140 A R 315 to 415 

140 B, C R 265 to 365 

140 B, C H 265 to 415 

140 D KB, KM 215 to 235 

165 A R 315 to 465 

165 B R 265 to 415 

165 B, C H 265 to 465 

165 D KB, KM 240 to 260 

200 A R 415 to 565 

200 B R 315 to 465 

200 B, C H 315 to 565 

200 D KB 255 to 275 

* Flame shape: R = normal, H = long, K = fl at. 

Gas type: B = natural gas, M, G = propane, butane/propane, butane, D = coke oven gas, 

town gas. 

BKL 

BKL 

∅ 

6° 

A 

B 

C 

For further information on burner quarls – see www.docuthek.com 

BKL 

D 

BKL 


Selection > Calculating the burner length 

5.5.2 Burners with burner attachment tube 

Examples for fields of application 

E 

Radiant tube heating 

When using the burner in radiant tubes or protective flame 

tubes, the extended burner tube (attachment tube) acts as the 

combustion chamber. Burners for this field of application are 

supplied with purging air bore holes for optimal flame stability. 

The outlet diameter of the radiant tube must be reduced to 

the point where a pressure loss of approx. 10 mbar occurs at 

the burner’s rated capacity. 

17 

F 

Hot-air generation 

To generate hot air at a furnace temperature of < 600°C, burners 

with an attachment tube and purging air bore holes are 

used. 

At flow velocities of > 15 m/s, the protective flame tube FPT is 

used to protect the flame from being cooled. At flow velocities 

of < 15 m/s, the protective flame tube FPT is not needed. 


Selection > Calculating the burner length > Burners with burner attachment tube 

18 

L1 

L O 

L2 L 1-2 

Legend 

L1 = Burner tube length 

L2 = Position of burner head 

LO = Furnace wall thickness 

L 1-2 = Attachment tube length (distance 

from burner head to burner tube 

end) 

Calculation example 

Attachment tube lengths (L 1-2 ): 


H burner head 

R burner head 

[mm] 

[mm] 

50 115 115 

65 115 115 

80 165 165 

100 165 165 

125 215 215 

140 265 265 

165 265 165 

200 315 215 

Position of the burner head (near the interior furnace wall): 

L2 = L O ± 50 mm 

The burner tube length (L1) is calculated by adding the position of the burner 

head (L2) to the attachment tube length (L 1-2 ): 

L1 = L2 + L 1-2 

Example 

Desired flame shape = H (long) – see [Field of application – p. 13]. 

Selected burner with 90 kW capacity = BIO 65. 

Attachment tube length (L 1-2 ) = 115 mm. 

Furnace wall thickness L O = 300 mm. 

Calculate shortest length L2: 

L2 = L O - 50 mm = 300 - 50 mm = 250 mm. 

Compare L2 (here 250 mm) with standard lengths (35, 135, 235, 335 mm, etc.). 

Select next longest standard length L2: L2 = 335 mm. 

Calculate the related burner tube length (L1): 

L1 = L2 + L1-2 = 335 mm + 115 mm = 450 mm. 


Selection 

19 

5.6 Selection table 

50 65 80 100 125 140 165 200 H R K B G M L D L R - 50 –… /35 – … -(1) – -(99) A – Z B 

BIO 

BIOA 

ZIO 

= standard, = available 

Order example 

ZIO 165RB-50/35-(17)D 


Selection > Selection table 

20 

5.6.1 Type code 

Code 

Description 


Burner for gas 


Burner for gas with aluminium housing 


Burner for gas 

50 to 200 Burner size 

Flame shape: 

H 

long 

R 

normal 

K 

fl at 

B 

G, M 

L 

D 

Gas type: 

natural gas 

propane, propane/butane, butane 

low calorifi c value gas 

coke oven gas, town gas 

Variant: 

with ignition lance 

with reduced max. connection rating 

L 

R 

–50* 

–100** 

–150* 

–200** 

Burner tube length (L1) [mm] 

–250* 

–300** 

… 

/35– 

/135– 

Position of burner head (L2) 

/235– 

… 

-(1) to -(99) Burner head identifi er 

D to F 

Construction stage 

B 

With purging air bore holes 

* R, K burner head 

** H burner head 


21 

6 Project planning information 

6.1 Installation 

Installation position: any. 

Gas and air connection: can be rotated in 90° steps. 

Install and insulate the burner in order to avoid any overheating 

of the components during operation. Where applicable, 

purging air must be used to prevent ingress of aggressive 

gases and thermal overload of components. 

6.2 Recommended ignition transformer 

6.4 Flame control 

Flame control is performed using an ionization electrode or 

optionally using a UV sensor. 

6.5 Hot air compensation 

In order to maintain the λ constant in hot-air operating mode, 

the combustion air pressure is increased. The gas pressure 

increases in hot-air operating mode (450°C) by approx. 5 mbar 

for BIO..K and by approx. 10 mbar for BIO..H. The total capacity 

(gas capacity + hot air capacity) must not exceed the maximum 

possible burner capacity (see also burner operating characteristic 

diagrams at www.docuthek.com): 

Hot air capacity [%] 

20 

10 

≥ 7.5 kV, ≥ 12 mA, e.g. TZI 7,5-12/100 or TGI 7,5-12/100. 

6.3 Non-return gas valve 

Non-return gas valves are not required, since the burners are 

of the nozzle-mixing type. 

0 

0 50 100 150 200 250 300 350 400 450 

Hot air [°C] 

The air pressure is increased for a constant l. 

Air pressure [%] 

250 

200 

150 

100 

50 

0 

0 50 100 150 200 250 300 350 400 450 

Hot air [°C] 


Project planning information 

22 

6.6 Purging air/cooling air 

Cooling air at 20°C 

Air volume at rated capacity [%] 

Purging/cooling air volume for burners 

6 

5 

4 

3 

2 

1 

BIO/ZIO..K 

BIO, ZIO 

BIO/ZIO..KB..E 

0 

0 

700 800 900 1000 1100 1200 1300 1400 

Kiln temperature °C 

While the burner is switched off and depending on the furnace 

temperature, there must be a certain air flow in order to ensure 

safe ignition and monitoring of the burners, and for cooling 

the burner components. 

The relative air volume in percentage values, based on the 

air volume for the rated capacity of the relevant size, is given 

in the Purging/cooling air volume for burners diagram. For 

hot air, the values on the right-hand axis are based on the 

standard air volume for the relevant rated capacity. 

The air fan must remain switched on until the furnace has 

cooled down completely. 

12 

10 

8 

6 

4 

2 

Cooling air at 450°C 

Air volume* at rated capacity [%] 

* The cooling air volumes measured in standard 

cubic metres are converted into percentage values. 

6.7 Emissions 

NOX 

[mg/m3] 

5% O2 

600 

500 

400 

300 

200 

100 

70 

50 

H (450 °C) 

R, K (20 °C) 

H (20 °C) 

K (450 °C) 

10 50 100 

Capacity [%] 

Flame shape: 

R = Normal 

H = Long 

K = Flat 

T Furnace 

= 1000°C 

Emissions for cold-air operating mode do not exceed the limits 

stipulated by the German Clean Air Directive. 

NO X values depend on the temperature, burner head, combustion 

chamber, furnace chamber, λ value and output (NO X 

values on request). 

If operated with LPG, NO X values are approx. 25% higher. 


Project planning information 

23 

6.8 Gas line connection 

To ensure accurate measurements of the pressure differential 

on the integrated gas measuring orifice, the following applies 

for the design of the gas connection: 

– Ensure undisturbed flow to the gas connection on the burner 

for a distance of ≥ 5 DN. 

– Use a bellows unit with the same nominal dimensions as 

the gas connection on the burner. 

– Use a pipe bend up to an angle of 90° with the same nominal 

dimensions as the gas connection on the burner. 

– Only use reducing nipples with an external thread at both 

ends in order to reduce the nominal diameter on the burner 

(e.g. from 1” to ¾”). 

To ensure optimum flow, to avoid incorrect measurements and 

to enable burner operation with excess gas, we recommend 

the following: 

– Do not screw the manual valve directly into the burner. 

6.9 Air line connection 

Ensure there is a bellows unit and an air adjusting cock upstream 

of the burner. It is recommended to install a measuring 

orifice FLS to determine the air flow rate. 

6.10 Condition on delivery 

Gas and air connections are fitted opposite one another at 

the factory. 


24 

7 Technical data 

Gas supply pressure: approx. 20 to 50 mbar, 

Air supply pressure: approx. 25 to 40 mbar, 

each depending on flame shape and gas type (gas and air 

pressures – see burner diagrams at www.docuthek.com). 

Burner length increments: 100 mm. 

Gas types: natural gas, LPG (gaseous) and coke oven gas; 

other gases on request. 

Heating: direct using a burner quarl or an attachment tube, 

indirect using a burner attachment tube inside the radiant 

tube. 

Control type: 

staged: On/Off, High/Low/Off, 

continuous: constant λ value. 

Most of the burner components are made of corrosion-resistant 

stainless steel. 

Housing: 

BIO: cast steel, 

BIOA: AlSi, 

ZIO: ST. 

Flame control: with ionization electrode (UV sensor as an 

option). 

Ignition: direct, electrical, lance as an option. 

Maximum furnace temperature: 

BIO/ZIO in burner quarl: up to 1600°C, 

with K burner head: up to 1100°C (higher temperatures on 

request), 

BIO/ZIO with burner attachment tube: up to 600°C (higher 

temperatures on request). 

Maximum air temperature: 

BIO, ZIO: 450°C, 

BIOA: 200°C. 


Technical data 

25 

Burners Rated capacity 1) Burner quarl type Flame shape code letter Flame length 2) Flame outlet velocity 3) 

kW cm m/s 

BIO 50 40 A R 25 15 

BIO 50 40 B R 30 55 

BIO 50 40 B H 35 50 

BIO 50 40 D K – – 

BIO(A) 65 90 A R 40 20 

BIO(A) 65 90 B R 50 70 

BIO(A) 65 90 B H 60 65 

BIO(A) 65 90 D K – – 








BIO 100 230 D K – 









ZIO 165 630 A R 90 20 

ZIO 165 630 B R 110 75 

ZIO 165 630 B H 160 70 

ZIO 165 630 D K – – 

1) Higher capacities are possible – either on request or see burner diagrams at www.docuthek.com. 

2) Measured in the burner quarl from the front edge of the burner quarl. The fl ame diameter is approx. one to two times that of the burner tube or burner 

quarl outlet. 

3) Refers to rated capacity, with a fl ame temperature of 1600°C for R burner head and 1500°C for H burner head. The fl ow velocity is increased when the 

outlet diameter of the burner quarl is reduced. The rated capacity must then be adjusted to the outlet diameter. 



26 

Burners Rated capacity 1) Burner quarl type Flame shape code letter Flame length 2) Flame outlet velocity 3) 

kW cm m/s 

ZIO 200 1000 A R 100 25 

ZIO 200 1000 B R 130 85 

ZIO 200 1000 B H 200 80 

ZIO 200 1000 D K – – 

1) Higher capacities are possible – either on request or see burner diagrams at www.docuthek.com. 

2) Measured in the burner quarl from the front edge of the burner quarl. The fl ame diameter is approx. one to two times that of the burner tube or burner 

quarl outlet. 

3) Refers to rated capacity, with a fl ame temperature of 1600°C for R burner head and 1500°C for H burner head. The fl ow velocity is increased when the 

outlet diameter of the burner quarl is reduced. The rated capacity must then be adjusted to the outlet diameter. 



27 

7.1 Dimensions 

d3 

n3 

h H 

LA 

L5 

k3 

D3 

L3 

S 

D 

d2 

F 

n2 

h H 30 

GA 

LA 

L5 

L3 

S 

D 

d2 

F 

n2 

GA 

L4 

L6 

L2 

L1 

k2 

D2 

L6 

L4 

L2 

L1 

k2 

D2 

L1 (burner tube length) and L2 (position of burner head) are variable (see Calculating the burner tube length) 



Burner 

Max. 

Dimensions [mm] 

capacity* 

Gas connection 

Air connection 

Weight 

[kW] D** GA LA H h S L3 L4 L5 L6 D2 k2 d2 n2 F D3 k3 d3 n3 [kg] 

BIO 50 40 50 Rp 1 / 2 Rp 1 1 / 2 50 38 12 73 149 240 127 181 151 12 4 75 – – – – 5.4 

BIO 65 90 65 Rp 3 / 4 Rp 1 1 / 2 62 48 12 73 156 246 127 195 165 12 4 95 – – – – 7.2 

BIOA 65 90 65 Rp 1 / 2 ∅ 48 80 44 16 95 170 261 149 195 165 13 4 88 – – – – 3.6 

BIO 80 150 82 Rp 3 / 4 Rp 2 112 55 14 90 172 272 140 240 210 14 4 110 – – – – 11.2 

BIO 100 230 100 Rp 1 Rp 2 100 60 16 103 185 285 153 240 200 14 4 120 – – – – 12.6 

BIO 125 320 127 Rp 1 1 / 2 DN 65 135 73 16 120 254 350 212 270 240 14 4 145 185 145 18 4 21.7 

BIO 140 450 140 Rp 1 1 / 2 DN 80 150 80 18 130 271 381 232 300 265 14 4 160 200 160 18 8 29 

* Cold-air connection, open fl ame, λ = 1,1 

** Approx. 10 cm larger in the case of a deviation from the standard length, as a weld seam is applied. 


Technical data > Dimensions 

28 

L6 

S 

d2 

F 

n2 

D 

Z 

I 

d3 

H 

GA 

L4 

LA 

D3 

k3 

L3 

L2 

L1 

k2 

D2 


Burner 

Max. 

Dimensions [mm] 

capacity* 

Gas connection 

Air connection 

Weight 

[kW] D** GA LA H h S L3 L4 L5 L6 D2 k2 d2 n2 F D3 k3 d3 n3 [kg] 

ZIO 165 630 165 R 1 1 / 2 DN 100 213 – 20 150 359 – 230 285 240 14 4 ∅ 220 220 180 18 8 26 

ZIO 200 1000 194 R 2 DN 150 220 – 20 220 469 – 340 330 295 22 8 ∅ 255 285 240 22 8 37 

* Cold-air connection, open fl ame, λ = 1,1 

** Approx. 10 cm larger in the case of a deviation from the standard length, as a weld seam is applied. 



29 

7.2 Ignition lance 


Gas connection: Rp ¼. 

Air connection: Rp 3/8. 

Gas pressure: 30 to 50 mbar. 

Air pressure: 30 to 50 mbar. 

L7 


Gas connection: Rp ¼. 

Air connection: Rp ½. 

Gas pressure: 30 to 50 mbar. 

Air pressure: 30 to 50 mbar. 

L7 

B 

E2 

B 

gas 

E1 

Air 

W1 

I 

Z 

I 

Z 

C 

E1 

air 

C 

W2 

E2 

Gas 

I 

Burner 

Gas Air 

connection connection 

Dimensions 

B C E1 E2 L7 W1 W2 

mm mm mm mm mm ∠ ° ∠ ° 

BIO 80..L 57 54 7 10 177 36 45 




Burner 

Gas Air 

connection connection 

Dimensions 

B C E1 E2 L7 

mm mm mm mm mm 

ZIO 165..L 118 77 27 71 382 

ZIO 200..L 137 77 27 89 482 


30 

8 Maintenance cycles 

Twice per year, but if the media are highly contaminated, this 

interval should be reduced. 


Feedback 

Finally, we are offering you the opportunity to assess this “Technical Information (TI)” and to give us your opinion, so that we 

can improve our documents further and suit them to your needs. 

Clarity 

Found information quickly 

Searched for a long time 

Didn’t find information 

What is missing? 

No answer 

Comprehension 

Coherent 

Too complicated 

No answer 

Scope 

Too little 

Sufficient 

Too wide 

No answer 

31 

Use 

To get to know the product 

To choose a product 

Planning 

To look for information 

Navigation 

I can find my way around 

I got “lost” 

No answer 

My scope of functions 

Technical department 

Sales 

No answer 

Remarks 

(Adobe Reader 7 or higher required) 

1 Contact 

Elster GmbH 

Postfach 2809 · 49018 Osnabrück 

Strotheweg 1 · 49504 Lotte (Büren) 

Germany 

T +49 541 1214-0 

F +49 541 1214-370 

info@kromschroeder.com 

www.kromschroeder.com 

www.elster.com 

The current addresses of our international 

agents are available on the Internet: 

www.kromschroeder.com Sales 

Kromschröder, a product 

brand of the Elster Group 

We reserve the right to make technical 

modifications in the interests of progress. 

Copyright © 2007 Elster Group 

All rights reserved. 

03250786

BIO, BIOA, ZIO - Combustion 911

Create successful ePaper yourself

Delete template?

Save as template?