Hegwein ZT0, Operating Manual

Page 1: ...ng Manual Gas fired igniter ZT0 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 hegwein de Status 11 2018 ...

Page 2: ...ctional characteristics and structure 22 5 1 Functional characteristics 22 5 2 Structure 22 5 3 Flame monitoring 23 5 3 1 Safety time 23 5 4 Gas and air adjusting components accessories 24 5 5 Electrical wiring versions 25 6 Installation and initial commissioning 26 6 1 Safety 26 6 2 Installation and electrical connection 28 6 3 Electrical function test 32 6 4 Setting the required air volume 34 6 ...

Page 3: ...ructions The illustrations 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 fired igniter 1 2 Explanation of symbols Warning instructions Warning instructions are indicated in this operating manual by symbols The remarks are introduced by the use of signa...

Page 4: ...nto 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 as a result of Failure to adhere to the instructions Use for any other than the designated purpose Deployment of untrained personnel Internally executed modifications or conversion work Technical modif...

Page 5: ...to compensation of damages without prejudice to any further reaching claims 1 5 Spare parts WARNING Danger of injury due to the use of incorrect spare parts Incorrect or faulty spare parts can result in damage malfunctions or total failure of the equipment as well as posing a safety hazard Only ever use original spare parts from the manufacturer Order spare parts through your authorized dealer or ...

Page 6: ...s 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 The owner must test throughout the service life of the gas fired igniter whether the operating instructions drawn up by him still correspond with the latest revision of the relevant rules and regulation...

Page 7: ...ions 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 employed and are familiar with the relevant standards and regulations Gas specialists are capable on the basis of their specialist training knowledge and experience as well as their knowledge of the appli...

Page 8: ... 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 with the intended purpose Any application beyond and or not in accordance with the intended purpose of the gas fired igniter can result in the occurrence of hazardous situations Only operate the gas fired ...

Page 9: ...ts 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 the head from falling parts swinging loads or bumping it against stationary equipment To be worn for special types of work When performing special types of work special safety equipment is required This...

Page 10: ...ect 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 or the components If necessary use suitable hoisting gear From an outer tube length of 3 m use several lashing points or a suitable hoisting gear with supports Please mind the centre of gravity Secure ...

Page 11: ...ised condition Earth and short circuit Cover or block off adjacent live parts Never bypass or decommission fuses When changing fuses adhere to the correct amperage and the correct characteristics Only connect the gas fired igniter to the permitted operating voltage load according to the technical data The operator installer is responsible for adherence to the permitted environmental conditions and...

Page 12: ...ety 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 pointed corners can cause chafing of the skin and cuts Take particular care when performing work near to sharp edges and pointed corners In unsure wear safety gloves Special environmental influences NOTE Da...

Page 13: ... 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 possible secure the switch with a lock and attach a sign in an easily visible location at the switch 3 Have the key looked after by the employee named on the sign Switched off on at hours DO NOT SWITCH ON...

Page 14: ...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 correctly Initiate first aid measures Evacuate any persons located in the danger area Inform those responsible at the incident location Alert the emergency medical fire services Clear access paths for eme...

Page 15: ...ht 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 vibration or shock may cause damage to electrical components 3 2 Transport inspection Check the delivery on receipt without delay for completeness and transport damage In the case of externally recognizable...

Page 16: ...e 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 materials Observe locally applicable disposal regulations 3 4 Storage conditions Storage Store the gas fired igniter and the spare parts under the following conditions Never keep outdoors Store in dry dust...

Page 17: ...Gas fired igniter ZT0 Specifications Status 11 2018 17 4 Specifications 4 1 Type designation with type key Example of type designations with the most important igniter data Fig 1 Type key ...

Page 18: ...erpressure Air port Rp 1 rotatable 4 x 90 Air volume max 50 m h Air temperature max 80 C Relative humidity max 70 Air quality free of dust oil grease and aerosols Air coefficient The remaining air volume must be made available in the combustion chamber 0 3 0 5 Maximum ambient temperature of the outer tube see chapter Installation and electrical connection Total weight depending on scope of deliver...

Page 19: ...ble ends Connection type Special version IP 65 with 3 core mains cable and 1 core flame signal cable with shielding Permanently sealed mains cable wire gauge 1 mm 2 and flame signal cable wire gauge 1 5 mm 2 cable diameter in each case approx 7 mm Power consumption Spark transformer 100 VA fusing 2 A slow blowing to be fused externally Duty cycle Spark transformer actuation via control unit 15 dut...

Page 20: ... Example of rating plate The rating plate is located on the housing of the power head and contains the following information 1 Manufacturer 2 Date of manufacture Hegwein code 3 Type 4 Gas type and maximum gas inlet pressure 5 Supply voltage 6 Protection rating 7 Maximum power consumption 8 Frequency 9 Serial number with consecutive device number ...

Page 21: ...riod can be substantially reduced 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 degree of stress Exchange the gas fired igniter after it has exceeded the specified service life After expiry of the maximum operating period functional defects can o...

Page 22: ...al drawing 1 Power head 1 1 Spark transformer 1 2 Electrical plug 1 3 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 with two ceramic insulators 8 Connecting rods 9 Gas tube 10 Final electrode support ring 11 Gas nozzle 12 Ignition electrode 13 Flame rod 14 Air port 15 Mixing chamber 16 Mounting flange 1...

Page 23: ...mm by intermediate support rings 7 5 3 Flame monitoring The flame is monitored by the flame rod which must immerse in the direction of the flame This flame rod will be supplied with changing voltages through the external flame monitor or the automatic burner control system The burning flame creates an electrically conductive connection to the igniter earth and at the same time acts as a rectifier ...

Page 24: ...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 6 Double nipple Double nipple Z 946 F 3 00V Malleable cast iron galvanized Max temperature range 20 C to 60 C Max pressure 300 mbarg Fig 7 Ballofix ball valve Ballofix ball valve Z 845 Z3 Housing Brass Ms 58 Ga...

Page 25: ...0 V AC 50 60 Hz special voltages possible see relevant HEGWEIN operating manual Flame monitor AAC 76 P0 with flame signal converter for continuous operation or intermittent operation top hat rail mounting 230 V AC 50 60 Hz special voltages possible see relevant HEGWEIN operating manual Burner control D GF 75 for continuous operation or intermittent operation top hat rail mounting 230 V AC 50 60 Hz...

Page 26: ...l 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 to the gas fired igniter must be blocked emptied and cleaned if necessary Before starting work ensure that there is sufficient freedom of movement for the installation work Take care when handling ope...

Page 27: ... into an overriding safety controller On commissioning it must be ensured that in the case of a flame signal breakdown the flame signal contact opens within 1 s and leads to the safety and fault shutdown via the overriding safety controller Definitions REMARK Air inlet pressure gas inlet pressure Air pressure respectively gas pressure at the gas fired igniter s air or gas port Air operating pressu...

Page 28: ...s 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 standards and guidelines The operator installer is responsible for adherence to the permitted environmental conditions and or ambient atmosphere in accordance with the technical data 1 Prepare the insta...

Page 29: ...s 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 between 300 500 C the combustion air shall be partly 20 switched as cooling air At an ambient temperature between 500 700 C proceed as follows Switch combustion air completely as cooling air Use stainles...

Page 30: ... transformer terminal is switched off before the end of the ignition safety period see EN standard 298 This ensures a 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 introduced there Fig 9 Terminal diagram IP 54 Standard version IP 54 with plug connection ...

Page 31: ...ielding Colour Core Designation Meaning green yellow PE Protective earth conductor blue N Spark transformer primary brown L 9 Shielding 10 Ion Flame signal cable If wired to flame monitors or automatic burner control systems consider the relevant wiring schedule REMARK Close the terminal box connecting plugs and check whether all seals cable strain relief devices etc are correctly connected ...

Page 32: ...ses Due to the supply voltage of the ionisation flame monitor electrical voltage is also applied to the flame rod Contact with the electrodes could be fatal Never come into contact with the ignition electrode or the flame rod DANGER Escaping fuel or the release of other devices may cause an explosion A release of the gas fired igniter can cause the start of subsequent devices burners Any other dev...

Page 33: ...tic burner control system 6 Bring the yellow plug 4 of the test diode briefly into contact with the outer tube 5 7 After contact with the test diode a flame signal at the external flame monitor or the automatic burner control system must be measurable 8 If no flame signal is produced check the following Is mains voltage present at the external flame monitor or the automatic burner control system I...

Page 34: ...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 taken into account Fig 12 Air pressure test nipple 2 Turn the Allen screw size 2 5 in the centre of the air pressure test nipple 1 1 turns counter clockwise in order to open the air pressure test nipple 3...

Page 35: ...amber 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 igniter is consequently adapted for gas inlet pressures above 150 mbar Precision setting is performed using the Ballofix ball valve In case of gas inlet pressures above 500 mbar this setting is extremely dif...

Page 36: ...Status 11 2018 Fig 13 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 propane butane mixtures Deviations from the chart given above may occur ...

Page 37: ... entire plant DANGER Fuel leaks or the release of other devices may cause an explosion A release of the gas fired igniter can cause the start of subsequent devices burners Any other devices such as burners and valves shall therefore be blocked 4 Open the gas supply only on initial commissioning and enable the tested plant by means of the control system 5 Set the previously selected gas operating p...

Page 38: ... 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 the work area Loose components and tools lying around or piled on top of each other are a possible cause of accidents 7 2 Operation REMARK Operation of the gas fired igniters takes place at the plant c...

Page 39: ...e 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 regular intervals e g every 3 months If the gas fired igniter is operated with air containing dust checks must be performed at shorter intervals as electrically conductive dirt deposits or moisture on ...

Page 40: ...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 inadvertently switched back on Observe the 5 safety rules Before touching parts carrying voltage ensure that no residual voltage remains DANGER Risk of explosion due to leaking gas Accidental gas leaks ...

Page 41: ... tube This may only be performed by suitably qualified personnel 1 Remove 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 REMARK Depending on the position of the air port the outer tube can be turned into 4 x 90 increments and tightened ...

Page 42: ...f the outer tube 2 3 Remove the final electrode support ring 3 and any existing intermediate support rings 7 as well as the connecting rods 4 4 Unscrew the gas tube 5 from the gas flange 6 5 If there are pressure reducing orifices screwed into the 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 ...

Page 43: ...be 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 squeezed carefully with a pair of pliers to ensure a tight fit of the connecting rods 5 in the plug in sleeves 6 Insert the connecting rods 5 into the plug in sleeves at the power head and into the plug in...

Page 44: ...eeves at the power 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 align 12 Tighten all clamping screws of the intermediate support rings 6 13 Mount the outer tube 2 REMARK Intermediate support rings are used from a tube length of 600 mm New intermediate support rings m...

Page 45: ...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 are a possible cause of accidents When components are removed ensure correct reassembly Remount all fastening components and adhere to specified screw tightening torque levels Response in case of faul...

Page 46: ...ng 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 available due to defective air flap or valve Exchange air flap or valve Qualified personnel No combustion air available due to closed throttle organs Open throttle organs Operator No combustion air avai...

Page 47: ...control unit from a different manufacturer the ignition spark always disturbs the ionization feedback Switch off ignition voltage approx 0 5 s before expiry of the ignition safety time Qualified electrician Gas fired igniter was exposed to excessively high temperature in the combustion chamber when switched off Ceramic insulators too hot the insulation resistance has dropped too far Leave fan air ...

Page 48: ...cause Solution To be done by Lock out because a flame is signalled at the start before the gas valve has opened Flame was not extinguished when switching off due to a leaking valve and is already present when restarting Replace the gas valve Gas specialist personnel Owner ...

Page 49: ... 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 site is clean and tidy Loose components and tools lying around or piled on top of each other are a possible cause of accidents If any points are unclear consult the manufacturer 10 2 Dismantling Befor...

Page 50: ...ials 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 occupational safety and environmental protection legislation 10 3 Disposal Provided no return acceptance or disposal agreement has been concluded the components once dismantled can be sent for recycling...

Page 51: ...110 125 V 240 250 V Without housing Standard Special version Special version 1 2 1 Electrical connecting plug with 2 cable glands A5Z1 2 1 Power head IP 65 permanently sealed mains cable and flame signal cable Z112K6_ _ _ Special version alternative to 1 With the addition of control cable length and voltage specification in line with type key see chapter Specifications 3 1 Complete outer tube incl...

Page 52: ...Z960K4 or Z960K104 Steel Stainless steel length dependent 5 1 Final electrode support ring with 2 ceramic insulators and 2 electrodes Z960K13 or Z960K113 Steel Stainless steel Standard Special version Wearing part 6 1 Gas nozzle Natural gas Z330F4013 Stainless steel Standard LPG Z330F2510 Stainless steel Standard Cleaned coke oven gas Z985F1 Stainless steel Standard 7 1 Gasket Z863F1 ...

Page 53: ...Gas fired igniter ZT0 Annex Status 11 2018 53 12 Annex 12 1 EU Declaration of conformity 12 011_de_en Rev7 Fig 20 EU Declaration of conformity ...