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Hegwein ZA0 Series, Operating Manual

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Hegwein ZA0 Series Operating Manual Download Page 1

  

 

 

 

 

 

Operating Manual 

 

 

 

Gas fired igniter 
ZA0 / ZDA0 

 
 

 

© 

Hegwein GmbH  
Am Boschwerk 7 
70469 Stuttgart, Germany 

Before first use, read the operating manual! 

 

Tel.: +49 (0)711 13 57 88-0 
Fax: +49 (0)711 13 57 88-5 

 

 

E-Mail: [email protected] 
www.hegwein.de 

 

 

Status: 11-2018 

 

   

 

Summary of Contents for ZA0 Series

Page 1: ...fired igniter ZA0 ZDA0 Hegwein GmbH Am Boschwerk 7 70469 Stuttgart Germany Before first use read the operating manual Tel 49 0 711 13 57 88 0 Fax 49 0 711 13 57 88 5 E Mail info hegwein de www hegwei...

Page 2: ...haracteristics 25 5 2 Structure 25 5 3 Ionisation flame monitor 26 5 3 1 Flame monitoring 26 5 3 2 Safety time flame failure detection time FFDT 26 5 3 3 Test sockets 27 5 4 Connections on the transfo...

Page 3: ...s in this operating manual are intended to aid understanding of the content They are not necessarily true to scale and may differ slightly in some details from the actual configuration of the gas fire...

Page 4: ...into account applicable standards and regulations the state of the art and our many years of experience and expertise The manufacturer is consequently unable to accept any liability for damage caused...

Page 5: ...structions may not be duplicated in any form nor may they be used and or communicated to any third party without the written consent of the manufacturer Any breach of this obligation shall render the...

Page 6: ...er sales service Information can be obtained at any time by phone fax e mail or Internet For the manufacturer s address see the cover sheet on the table of contents Our employees are always open to fe...

Page 7: ...ons applicable at the location in which the igniter is used by performing a risk assessment This must be implemented in the form of operating instructions governing operation of the gas fired igniter...

Page 8: ...ations of working on electrical installations and of independently recognizing possible hazards Electrical specialists have received training specifically for the work environment in which they are em...

Page 9: ...se off lighting and supporting any gas oil or solid fuel fired burner of medium heat release in industrial furnaces thermo processing plants and boilers WARNING Danger due to use not in accordance wit...

Page 10: ...arts This is required primarily to protect against burns Safety shoes To protect the feet against heavy falling articles and to prevent slipping on floors Protection helmet Protection helmets protect...

Page 11: ...rrect transport WARNING Danger of injury as a result of incorrect transport In the case of incorrect transport considerable material damage can occur Note the intrinsic weight of the gas fired igniter...

Page 12: ...ive parts Never bypass or decommission fuses When changing fuses adhere to the correct amperage and the correct characteristics Only connect the gas fired igniter and the integrated ionisation flame m...

Page 13: ...fety gloves Before performing any work ensure that all components have cooled to ambient temperature Sharp edges and pointed corners CAUTION Danger of injury on edges and corners Sharp edges and point...

Page 14: ...OT SWITCH ON The lock may only be removed by once steps have been taken to ensure that no persons are located in the danger area Securing against unauthorized use 1 Switch off the power supply 2 If po...

Page 15: ...a fire extinguisher on hand Familiarize personnel with accident alarm first aid and rescue facilities Ensure that access paths for emergency vehicles are kept unobstructed In case of accident React co...

Page 16: ...ght of the delivery Please mind the centre of gravity Only use the provided lashing points Do not stand under the load while lifting or lowering it and stay out of the danger zone REMARK Extreme vibra...

Page 17: ...due to incorrect disposal Packaging materials are valuable raw materials and in many cases can be reused or usefully processed and recycled Ensure environmentally responsible disposal of packaging mat...

Page 18: ...Gas fired igniter ZA0 ZDA0 Specifications 18 Status 11 2018 4 Specifications 4 1 Type designation with type key Example of type designations with the most important igniter data Fig 1 Type key...

Page 19: ...ic Value Heat release max 120 kW Flame length depending on the gas max 600 mm Outer tube length in 10 mm increments from to 240 15000 mm Outer tube diameter Outer tube length up to 4000 mm Outer tube...

Page 20: ...voltage of spark transformer Primary 230 V AC 50 60 Hz standard or in accordance with rating plate Secondary 5 kV against ground Protection rating IP 54 standard or IP 65 special version Connection ty...

Page 21: ...nal characteristics and structure Contact load with ZDA configuration at terminals 4 5 and 6 SPDT contact flame relay max 250 V AC 1A cos 1 ohmic fusing 1A quick blowing on front plate 1 2 Safety time...

Page 22: ...plate of gas fired igniter The rating plate is located on the housing of the ionisation flame monitor and contains the following information 1 Manufacturer 2 Date of manufacture Hegwein code 3 Type 4...

Page 23: ...following information 1 Manufacturer 2 Manufacturer s address 3 Type 4 Operating voltage frequency power consumption 5 Ambient temperature 6 Protection rating not built in IP 00 built in IP 7 Serial n...

Page 24: ...in the event of increased stress temperature vibrations dirt etc System operators and owners must take the steps to ensure that regular safety checks are performed depending on the actually occurring...

Page 25: ...park transformer 1 3 Electrical plug 1 4 Allen screw 1 5 Contact spring 3 Gas pressure test nipple opposite gas port 4 Allen screw 5 Air pressure test nipple 6 Outer tube 7 Intermediate support ring w...

Page 26: ...itored by the flame rod which must immerse in the direction of the flame Alternating voltage is applied to this flame rod The burning flame creates an electrically conductive connection to the igniter...

Page 27: ...0 25 A measuring range max 50 A switching threshold 1 A 2 Fuse holder for SPDT contact only with ZDA with fuse A665Z5 1A quick blowing 3 LED flame present 4 10 pin plug connector REMARK Only use test...

Page 28: ...using Malleable cast iron galvanized Taper Brass Ms 58 Lid Brass Ms 58 Max temperature range 20 C to 60 C Max pressure 300 mbarg Special version e g free of non ferrous metal on request Fig 10 Double...

Page 29: ...iter can be interconnected with the following units Burner control ASD 75 P0 for continuous operation or intermittent operation top hat rail mounting 230 V AC 50 60 Hz special voltage possible see rel...

Page 30: ...al material damage Prior to any commissioning maintenance work that part of the plant where the gas fired igniter is installed must be switched off and secured against accidental restart All feedlines...

Page 31: ...e measurement sockets for distance or continuous display Do not bridge measurement sockets or bring them into contact with mass under any circumstances On commissioning it must be ensured that in the...

Page 32: ...gas fired igniter is suitable for the mains voltage provided The installer operator is responsible for the installation of the gas fired igniter into a system which fulfils the stated system specific...

Page 33: ...nts can cause damage to the gas fired igniter The temperature at the dividing moving point must not exceed 180 C REMARK Permanent cooling must be provided At an ambient temperature of the outer tube b...

Page 34: ...short ignition free period approx 0 5 s 8 Connect the gas fired igniter in accordance with the relevant terminal diagram Remove the plastic blind in the second cable gland if a cable is to be introduc...

Page 35: ...item 11 LED flame present Fig 15 Terminal diagram IP 65 12 core Special version IP 65 with 12 core control cable sealed ionisation flame monitor connection type ZDA0 Core Designation Meaning PE Protec...

Page 36: ...igh voltage is present in the ignition electrode for ignition purposes Due to the supply voltage of the ionisation flame monitor electrical voltage is also applied to the flame rod Contact with the el...

Page 37: ...rod 3 4 Release key 2 in order to clamp the red terminal 5 Release the voltage to the ionisation flame monitor 6 Bring the yellow plug 4 of the test diode briefly into contact with the outer tube 5 7...

Page 38: ...0 mbar for every m of tube length is required A gas fired igniter with a tube length of 5 m should therefore be supplied with 10 mbar 5 x 10 mbar i e 60 mbar in total any backpressures need to be take...

Page 39: ...chamber back pressure REMARK If a higher gas inlet pressure was specified in the order then pressure reducing orifices have already been screwed into the two gas inlet threads in the factory The ignit...

Page 40: ...Status 11 2018 Fig 19 Gas volume diagram Characteristic Gas type Nozzle article number Flame length mm P LPG Z330F2510 max 600 M Natural gas Z330F4013 max 600 Bottled gas can come with different prop...

Page 41: ...is in a mounted status Ensure that the combustion products generated by the flame are extracted via the opened flue gas path of the entire plant DANGER Fuel leaks or the release of other devices may...

Page 42: ...t the following setting results should be in place following initial commissioning Immediate ignition Optically good flame pattern flame signal 90 110 V DC or optimized ionisation flow 10 A test socke...

Page 43: ...rs and safety devices are installed and in correct working order Never disable safety devices during operation Only operate the gas fired igniter in installed condition Ensure order and cleanliness in...

Page 44: ...re removed ensure correct reassembly Remount all fastening components and adhere to specified screw tightening torque levels 8 2 Maintenance general The gas fired igniter should be function tested at...

Page 45: ...n electrode or the flame rod Performing work at the spark transformer entails a risk of fatal injury due to electric shocks Before starting work switch off the power supply and make sure it cannot be...

Page 46: ...r tube This may only be performed by suitably qualified personnel 1 Release the four Allen screws 1 2 Pull off the outer tube 2 3 Position the new outer tube 2 4 Tighten the four Allen screws 1 again...

Page 47: ...he two gas inlet threads unscrew these and change them over to the new power head 8 6 Assembly takes place in reverse sequence 7 Mount the rating plate on the new power head 8 8 3 3 Exchanging the ion...

Page 48: ...ube 2 3 Release the clamping screw 6 of the final electrode support ring 3 and pull the ring off the gas tube 4 4 Position the new final electrode support ring 3 5 All plug in sleeves 7 should be sque...

Page 49: ...leeves at the igniter head and into the plug in sleeves on the final electrode support ring 3 Ensure that the connecting rods 5 are not twisted or bent 11 Mount the final electrode support ring 3 and...

Page 50: ...ensure that there is sufficient freedom of movement for the installation work Ensure that the installation site is clean and tidy Loose components and tools lying around or piled on top of each other...

Page 51: ...sing emery paper Qualified personnel Ceramic insulator broken Exchange ceramic insulator intermediate support ring or final electrode support Qualified personnel Flame fails to form No combustion air...

Page 52: ...voltage As the operating voltage must lag behind the bias voltage by at least 5 s always leave the bias voltage switched on Qualified electrician When using control unit from a different manufacturer...

Page 53: ...s suffocated Change the position of the gas fired igniter Qualified personnel Use more powerful gas fired igniter Lock out because a flame is signalled at the start before the gas valve has opened Fla...

Page 54: ...r on the required tools can cause injury Before starting work ensure that there is sufficient space available Take particular care when dealing with sharp edged components Ensure that the installation...

Page 55: ...erials as well as residual processing materials and ensure their ecologically responsible disposal The gas fired igniter can now be cleaned for separation and dismantled in compliance with applicable...

Page 56: ...K3 Z860K3 00M Z860K3 00C Z860K3 00B 230 V 115 V 125 V 250 V Standard Special version Special version Special version 1 1 1 Ionisation flame monitor A0516Z with housing for ZA0 Z341K2 Z341K2 00M Z341K2...

Page 57: ...ith type key see chapter Specifications 1 Ionisation flame monitor A0516Z with housing for ZDA0 Z341K8_ _ _ 3 1 Complete outer tube incl mixing chamber heat resistant tube 1 4841 and mounting flange w...

Page 58: ...Gas fired igniter ZA0 ZDA0 Annex 58 Status 11 2018 12 Annex 12 1 EU type examination certificate...

Page 59: ...Gas fired igniter ZA0 ZDA0 Annex Status 11 2018 59 12 001_en Rev7 Fig 27 EU type examination certificate...

Page 60: ...Gas fired igniter ZA0 ZDA0 Annex 60 Status 11 2018 12 2 EU Declaration of conformity 12 025_de_en Rev4 Fig 28 EU Declaration of conformity...

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