Operating Manual - SES Combustion AB

InhaltsverzeichnisOperating ManualGas fired igniterfor harzardous areas,zone 1 and zone 2ZAVEX© Hegwein GmbHAm Boschwerk 770469 Stuttgart, GermanyTel.: +49 (0)711 13 57 88-0Fax: +49 (0)711 13 57 88-5E-Mail: info@hegwein.dewww.hegwein.deBefore first use, read the operating manual!2.71/1e / Status: 11/07

Gas fired igniter ZAVEXContents1 General ....................................................... 31.1 Information on the operating manual........... 31.2 Explanation of symbols................................ 31.3 Liability disclaimer ....................................... 41.4 Copyright protection .................................... 41.5 Spare parts .................................................. 51.6 Warranty regulations ................................... 51.7 After-sales service ....................................... 52 Safety.......................................................... 62.1 Owner’s responsibility.................................. 62.2 Operating personnel .................................... 72.2.1 Requirements .............................................. 72.2.2 Unauthorized persons ................................. 82.3 Intended purpose of the equipment............. 82.4 Personal protective gear.............................. 92.5 Special dangers......................................... 102.6 Securing against unauthorized switchinguse............................................................. 132.7 Response in case of danger or accident... 143 Transport, packaging and storage ........ 153.1 Safety instructions for transport................. 153.2 Transport inspection .................................. 153.3 Packaging.................................................. 163.4 Storage conditions..................................... 164 Specifications .......................................... 174.1 Type designation with type key ................. 174.2 Gas fired igniter ......................................... 184.3 Power head ............................................... 194.4 Dimensional drawing ................................. 204.5 Rating plate ............................................... 204.6 Service life ................................................. 215 Functional characteristics andstructure ................................................... 225.1 Functional characteristics.......................... 225.2 Structure .................................................... 225.3 Flame monitoring....................................... 235.3.1 Safety time................................................. 235.4 Gas and air adjusting components(accessories) ............................................. 245.5 Burner controls...........................................256 Installation and initial commissioning...266.1 Safety .........................................................266.2 Installation and electrical connection .........276.3 Electrical function test ................................326.4 Setting the required air volume ..................346.5 Setting the required gas volume ................356.6 Checking the setting result.........................387 Operation ..................................................397.1 Safety .........................................................397.2 Operation....................................................398 Maintenance .............................................408.1 Safety .........................................................408.2 Maintenance, general.................................408.3 Conditions for maintenance work...............418.3.1 Exchanging the outer tube .........................428.3.2 Exchanging the power head.......................438.3.3 Exchanging the final electrode supportring .............................................................448.3.4 Exchanging the intermediate supportrings............................................................458.4 Actions following completed maintenancework............................................................459 Troubleshooting.......................................469.1 Safety .........................................................469.2 Troubleshooting table.................................4710 Dismantling / Disposal.............................5010.1 Safety .........................................................5010.2 Dismantling.................................................5010.3 Disposal......................................................5111 Spare parts list .........................................5211.1 Spare and wearing parts............................5212 Annex ........................................................5312.1 EC type examination certificates................5312.2 EC Declaration of conformity .....................57- 2 - 2.71/1e Status: 11/07

Gas fired igniter ZAVEXGeneral1 General1.1 Information on the operating manualThis operating manual provides important information on workingwith the gas fired igniter. Safe working can only be ensured byadhering to all the safety remarks and instructions provided.In addition, the locally applicable accident prevention legislationand general safety regulations with validity for the place ofoperation must be adhered to.Read through the operating manual carefully before starting anywork. These instructions form a constituent part of the product andmust be kept in the immediate vicinity of the equipment at all timeswithin easy reach for personnel.When the gas fired igniter is passed on to third parties, it mustalways be accompanied by the operating instructions.The illustrations in this operating manual are intended to aidunderstanding of the content. They are not necessarily true toscale and may differ slightly in some details from the actualconfiguration of the gas fired igniter.1.2 Explanation of symbolsWarning instructionsWarning instructions are indicated in this operating manual bysymbols. The remarks are introduced by the use of signal wordswhich indicate the degree of severity of the hazard.The instructions must be adhered to without fail and acted uponprudently in order to prevent accidents, personal injury or materialdamage.DANGER!… denotes a hazardous situation which results indeath or serious injury unless prevented.WARNING!… denotes a hazardous situation which could resultin death or serious injury unless prevented.CAUTION!… denotes a hazardous situation which could resultin minor or slight injury unless prevented.NOTE!… denotes a hazardous situation which could resultin material damage unless prevented.Status: 11/07 2.71/1e - 3 -

Gas fired igniter ZAVEXGeneralRecommendationsREMARK!… highlights useful recommendations andinformation designed to permit efficient, troublefreeoperation.Special safety remarksIn order to draw attention to special hazards, the following symbolis used in conjunction with safety remarks:DANGER!Fatal danger due to electrical current!… denotes a potentially fatal situation due toelectrical current. Failure to adhere to the safetyinstructions can give rise to the danger of seriousinjury or death.The work to be performed may only be carried outby a suitably qualified electrician.1.3 Liability disclaimerAll instructions and remarks contained in this operating manual arecollated taking into account applicable standards and regulations,the state of the art and our many years of experience andexpertise.The manufacturer is consequently unable to accept any liability fordamage 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 modifications Use of unapproved spare partsThe actual scope of the delivery may differ in some details from theexplanations and illustrations provided here in the case of specialversions, where additional optional features are made use of ordue to the latest technical modifications.Otherwise, the obligations agreed in the Supply Agreement, theGeneral Terms and Conditions and the Manufacturer’s Conditionsof Supply and the statutory regulations in force at the time ofconclusion of contract shall be applicable.1.4 Copyright protectionThese operating instructions must be treated in confidence. Theyare exclusively intended for the persons operating the gas firedigniter and may not be made available to third parties without theprior written consent of the manufacturer.- 4 - 2.71/1e Status: 11/07

Gas fired igniter ZAVEXGeneralREMARK!The information, texts, drawings, illustrations andother representations are protected by copyrightand are subject to industrial property rights.Utilization for any other than their intended purposerenders the perpetrator liable to prosecution.The contents of all or part of these operating instructions may notbe duplicated in any form, nor may they be used and/orcommunicated to any third party without the written consent of theManufacturer. Any breach of this obligation shall render theperpetrator liable to compensation of damages, without prejudiceto any further-reaching claims.1.5 Spare partsWARNING!Danger of injury due to the use of incorrectspare parts!Incorrect or faulty spare parts can result indamage, malfunctions or total failure of theequipment as well as posing a safety hazard.– Only ever use original spare parts from themanufacturer.Order spare parts through your authorized dealer or directly fromthe manufacturer. Address: see table of contents cover sheet.1.6 Warranty regulationsThe warranty regulations are provided as a separate document inthe General Terms and Conditions.1.7 After-sales serviceFor any technical information, consult our after-sales service.Information can be obtained through the responsible contact at anytime by phone, fax, e-mail or Internet. For the manufacturer’saddress, see the cover sheet on the table of contents.Our employees are always interested to receive any newinformation or experience arising from application which could beof use in the further development of our products.Status: 11/07 2.71/1e - 5 -

Gas fired igniter ZAVEXSafety2 SafetyThis section provides an overview of all important safety aspectsfor optimum protection of personnel as well as safe, trouble freeoperation.Failure to observe the operating instructions and safety remarkscontained in this manual can cause serious injury.2.1 Owner’s responsibilityAs the gas fired igniter is used commercially, the owner of the gasfired igniter is obliged to adhere to occupational safety regulationsas well as any other applicable directives, legislation andstandards.Alongside the occupational safety remarks contained in theseoperating instructions, the safety, environmental and accidentprevention regulations governing the field of application of the gasfired igniter must be adhered to, whereby the following regulationsin particular apply: The operator shall record in the document on the protectionfrom explosions all measures taken to protect the employees. The owner must be aware of the valid occupational safetyregulations and also determine any additional potential hazardsarising as a result of the specific working conditions applicableat the location in which the igniter is used, by performing a riskassessment. This must be implemented in the form of operatinginstructions governing operation of the gas fired igniter. The owner must test, throughout the service life of the gas firedigniter, whether the operating instructions drawn up by him stillcorrespond with the latest revision of the relevant rules andregulations, and must update these where applicable. The owner must clearly regulate and define fields ofresponsibility for installation, operation, maintenance andcleaning. The owner must ensure that all employees involved in workingwith the gas fired igniter have read and understood theoperating instructions.Furthermore, the owner must provide personnel training atregular intervals and inform staff of potential hazards.As the owner is also responsible for ensuring that the gas firedigniter is always in good technical working order the followingrequirements additionally apply: The owner must ensure that maintenance work is performedregularly. The owner must regularly check that all safety devices are fullyfunctional and complete. The owner must provide the necessary protective gear forpersonnel.- 6 - 2.71/1e Status: 11/07

Gas fired igniter ZAVEXSafety2.2 Operating personnel2.2.1 RequirementsWARNING!Danger of injury due to insufficient qualificationIncorrect handling of the equipment can result insevere personal injury and material damage.– Only allow activities to be performed by suitablyqualified specialist personnel.The following qualifications are required for the various fields ofactivity: Qualified personnelare capable on the basis of their specialist training, knowledgeand experience as well as their knowledge of the applicableregulations of executing the work assigned to them and ofindependently recognizing possible hazards. Electrical specialistsare capable on the basis of their specialist training, knowledgeand experience as well as their knowledge of the applicableregulations of working on electrical installations and ofindependently recognizing possible hazards.Electrical specialists have received training specifically for thework environment in which they are employed and are familiarwith the relevant standards and regulations. Gas specialistsare capable on the basis of their specialist training, knowledgeand experience as well as their knowledge of the applicableregulations of working on gas installations and of independentlyrecognizing possible hazards.Gas specialists have received training specifically for the workenvironment in which they are employed and are familiar withthe relevant standards and regulations.Only persons who may be expected to perform their task reliablymay be authorized to use the equipment. Persons whose reactioncapacity is impaired, for example due to drugs, alcohol or medicineuse, may not be authorized.When selecting suitable personnel, observe the age andprofession-specific regulations applicable at the place of use.Status: 11/07 2.71/1e - 7 -

Gas fired igniter ZAVEXSafety2.2.2 Unauthorized personsWARNING! Danger for unauthorized persons!Persons who do not comply with the requirementsdescribed here are not aware of the dangersinherent in the work area.– Keep unauthorized persons away from the workarea.– In case of doubt, approach the person inquestion and direct them out of the work area.– Interrupt work for as long as any unauthorizedperson remains in the work area.2.3 Intended purpose of the equipmentThe gas fired igniter is exclusively designed to perform theintended purpose described here.The gas fired igniter is a piece of equipment that has to beintegrated into a gas-consuming installation. It must not beoperated without an overriding burner control system.According to the current directive the igniter must only beused in zone 1 and 2 of those areas that run a risk ofexplosions.It is designed for the sole purpose off lighting andsupporting any gas-, oil- or solid fuel fired burner of mediumheat release in industrial furnaces, thermo-processingplants and boilers.WARNING!Danger due to use not in accordance with theintended purpose!Any application beyond and/or not in accordancewith the intended purpose of the gas fired ignitercan result in the occurrence of hazardoussituations.– Only operate the gas fired igniter when in amounted condition. Ensure that the combustionpoints created by the flame are fitted with asuitable extraction facility over the exposed fluegas channel throughout the plant.– Only operate the gas fired igniter according tothe specifications indicated on the rating plate.Otherwise, potential danger of personal ormaterial damage can arise.– Adhere to all the instructions provided in thisoperating manual without fail.- 8 - 2.71/1e Status: 11/07

Gas fired igniter ZAVEXSafety2.4 Personal protective gearThe manufacturer can not be held liable for physical or materialharm caused by misuse of equipment or use for anything otherthan its intended purpose.Personal protective gear must be worn while working with theequipment in order to minimize potential health hazards. Wear the protective gear necessary for performance of therelevant task at all times while working. Observe all signs relating to personal protective gear in thework area.To be worn at all timesWear the following for the performance of all work:Protective work clothingThis comprises tight-fitting work clothes which are resistant totearing, have tight-fitting sleeves and no projecting parts. This isrequired primarily to protect against burns.Safety shoesTo protect the feet against heavy falling articles and to preventslipping on floors.To be worn for special types ofworkWhen performing special types of work, special safety equipmentis required. This is covered in depth in the individual chapters ofthis instruction manual. These types of special protective gear aredescribed in the following:Face protectionTo protect one’s eyes and face from flames, sparks or embers aswell as hot particles or flue gases.Protective glovesTo protect one’s hands from rubbing, chafing, puncturing or deeperinjuries and from contact with hot surfaces.Status: 11/07 2.71/1e - 9 -

Gas fired igniter ZAVEXSafety2.5 Special dangersRemaining dangers are listed in the section below.The remarks provided here and the safety instructions in thesubsequent chapters of this operating manual must be observed inorder to reduce the possible risk to health and prevent theoccurrence of dangerous situations.Incorrect transportWARNING!Danger of injury as a result of incorrecttransport!In the case of incorrect transport, considerablematerial damage can occur.– Note the intrinsic weight of the gas fired igniteror the components. If necessary, use suitablehoisting gear.– From an outer tube length of 3 m use severallashing points or a suitable hoisting gear withsupports.– Please mind the centre of gravity.– Secure the gas fired igniter from dropping downor falling over.– Do not stand under the load while lifting orlowering it and stay out of the danger zone.Flammable atmosphereDANGER!Danger of explosion due to flammableatmosphere!Atmospheres susceptible to explosions canendanger the staff´s protection of health andsafety.– The operator shall define zones in such areaswhere a flammable atmosphere might beprevalent at times. Further to that he shall makesure that the organizational and technicalminimum requirements outlined in the directiveare adhered to.- 10 - 2.71/1e Status: 11/07

Gas fired igniter ZAVEXSafetySparkDANGER!Danger of an explosion caused by an escapingspark!If the enclosure is opened by removing the junctionroom or the gas flange, a spark might escape. Thiscould lead to an explosion.– In order to retain the explosion protection rating"flameproof enclosure" according to the currentdirective, the enclosure holding the transformerand the flame monitor must only be opened bythe manufacturer´s employees or throughtrained personnel. Any infringement on thisinstruction will entail the entire loss of allwarranty and guarantee claims.– Only the junction room of the transformer andflame monitor unit may be opened to connectthe control cables.Electrical currentDANGER!Potentially fatal injury due to electrical current!Contact with live components can cause fatalinjury. Damage to the insulation or individualcomponents can have potentially life-threateningconsequences.– In the event of damage to the insulation of thepower supply, switch off immediately andarrange for repairs to be carried out.– Work on the electrical system may only becarried out by suitably qualified electricians.– Before performing any work at the electricalsystem, disconnect it from the power supplyand check that it is no longer live.– Before starting work, switch off the powersupply and make sure it cannot be inadvertentlyswitched back on.– Never bypass or decommission fuses. Whenchanging fuses, adhere to the correct amperageand the correct characteristics.– Keep moisture away from live components. Thiscan create a short circuit.Status: 11/07 2.71/1e - 11 -

Gas fired igniter ZAVEXSafetyHighly inflammable materialsWARNING!Danger of burns due to flammable materials!Highly flammable materials, liquids or gases cancatch fire and cause serious to fatal injuries.– Do not smoke in the danger area and in theclose vicinity. Do not use any naked flames orignition sources.– Keep a fire extinguisher on hand.– Report suspicious substances, liquids or gasesimmediately to the responsible officer.– In case of fire, stop work immediately. Leavethe danger area until the all-clear is given.Hot surfacesCAUTION!Danger of burns due to hot surfaces!Contact with hot components can cause burns.– When carrying out any work near hotcomponents, always wear protective workclothing and safety gloves.– Before performing any work, ensure that allcomponents have cooled to ambienttemperature.Sharp edges and pointed cornersCAUTION!Danger of injury on edges and corners!Sharp edges and pointed corners can causechafing of the skin and cuts.– Take particular care when performing work nearto sharp edges and pointed corners.– In unsure, wear safety gloves.- 12 - 2.71/1e Status: 11/07

Gas fired igniter ZAVEXSafety2.6 Securing against unauthorized switching useDANGER!Risk of fatal injury due to unauthorized use!When working in the danger area, there is a riskthat the energy supply could be switched on by anunauthorized person. This creates a potentiallyfatal hazard for persons working in the dangerarea.– Observe the instructions provided on securingagainst unauthorized switching back on in thechapters of this operating manual.– Always observe the procedure described belowto secure against unauthorized switching backon.Switch safeguarded by lockon: ……..at ……hoursDO NOT SWITCH ONThe lock may only be removedby: …………………once steps have been taken to ensurethat no persons are located in thedanger area.Securing against unauthorized use1. Switch off the power supply.2. If possible, secure the switch with a lock and attach a sign inan easily visible location at the switch.3. Have the key looked after by the employee named on thesign.on: ……..Switched offat ……hoursDO NOT SWITCH ONThe lock may only be removedby: …………………once steps have been taken to ensurethat no persons are located in thedanger area..4. Should it not be possible to secure a switch using a lock, setup a sign.5. Once all the work has been carried out, ensure that there areno longer any persons located in the danger area.6. Ensure that all safety devices are installed and are fullyfunctional.7. Only then may the sign be removed.Status: 11/07 2.71/1e - 13 -

Gas fired igniter ZAVEXSafety2.7 Response in case of danger or accidentPreventive actions Always be prepared for accidents and for fires! Keep first aid equipment (first aid kit, blankets etc.) and a fireextinguisher on hand. Familiarize personnel with accident alarm, first aid and rescuefacilities. Ensure that access paths for emergency vehicles are keptunobstructed.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 emergency vehicles.- 14 - 2.71/1e Status: 11/07

Gas fired igniter ZAVEXTransport, packaging and storage3 Transport, packaging and storage3.1 Safety instructions for transportIncorrect transportWARNING!Danger of injury as a result of incorrecttransport!In the case of incorrect transport, considerablematerial damage can occur.– When unloading packaged items on delivery,and when transporting within the premises, takeextreme care and observe the symbols andinstructions on the packaging.– Depending on the length of the product and thescope of delivery suitable lifting equipmentshould be used for unloading. The load capacityof the lifting equipment should exceed the totalweight of the delivery.– The centre of gravity is assumed to be in themiddle of the longitudinal axis.– Only use the provided lashing points.– Do not stand under the load while lifting orlowering it and stay out of the danger zone.3.2 Transport inspectionCheck the delivery on receipt without delay for completeness andtransport damage.In the case of externally recognizable transport damage, report thedamage immediately, adopting the following procedure: Only conditionally accept the delivery. Note the extent of the damage on the transport documents oron the shipping agent’s delivery note. Initiate a complaint.Concealed transport damage must be reported within seven days.REMARK!Report any defect immediately it is noticed. Claimsfor damages can only be asserted within theapplicable deadlines for the filing of complaints.Status: 11/07 2.71/1e - 15 -

Gas fired igniter ZAVEXSpecifications4.2 Gas fired igniterCharacteristicHeat releaseFlame length (depending on the gas)Outside tube lengthin 10 mm increments from – toOutside tube diameterTube length up to 4000 mmTube length from 4000 mmDesign pressure gas flangeGas connectionMaximum counter pressure in gas fired igniterhousingValuemax. 250 kWmax. 1200 mm240 – 15000 mmdia. 65 mmdia. 70 mmFor the stainless steel version always dia. 70 mmmax. 10 bar¾“, top or bottom200 mbarg overpressureAir connection 1½“, rotatable 4 x 90°Air volumeAir coefficientThe remaining air volume must be made availablein the combustion chamber.Maximum ambient temperature of the outside tubeIf the temperature is higher, see chapter,“Mounting and electrical connection”.max. 120 m³/h0.3 – 0.5500 °CTotal weight (depending on scope of delivery) approx. 9.5 kg power head with mounting flange +approx. 5 kg/m (length of outer tube in cm, asindicated in the rating plate)Total dimensions (depending on scope of delivery)Length of power head with mounting flange (seedimensional drawing in section 4.4) + outer tubelength (in cm, as indicated in the rating plate)- 18 - 2.71/1e Status: 11/07

Gas fired igniter ZAVEXSpecifications4.3 Power headCharacteristicOperational prerequisitesKind of ex-protectionEx-ratingValueMonitoring of the gas and air pressureProtection rating "flameproof enclosure" and"increased safety" (for the junction room)II 2G EEx de IIB T4 or II 2G EEx de IIC T4Zone approval for gaseous atmosphere Zone 1 and zone 2Connected voltage of ionisation flame monitorConnected voltage of spark transformer230 VAC, 50/60 Hz (standard)or in accordance with rating platePrimary:230 VAC, 50/60 Hz (standard)or in accordance with rating plateSecondary:5 kV against groundProtection rating IP 65Connection typeStandard design, IP 65,with five wiring terminals and a PE terminalConnection typeSpecial design with volt-free SPDT contact, IP 65,with eight wiring terminals and a PE terminalCurrent consumptionON durationAmbient temperatureAmbient temperature (special version)InterconnectionContact load on the wiring terminals4, 5 und 6 (special version)Ionisation flame monitorJunction room with twoEx-rated cable glands (M20x1.5) forcable diameter 9 - 13 mmWiring terminal:Line-/screw connection 0.25 – 2.5 mm 2PE terminal:Line-/screw connection max. 4 mm 2Spark transformer:100 VA (fusing 2 A slow blowing, to be fusedexternally)Ionisation flame monitor:10 VA (fusing 2 A slow blowing, to be fusedexternally)Spark transformer:actuation via control unit, 100 % duty cycleIonisation flame monitor: 100 % duty cycle0 °C to + 60 °C (condensation must be avoided)- 40 °C to + 60 °C (condensation must be avoided)With Hegwein control units (see chapter “Functionalcharacteristics and structure”)Volt-free SPDT contact (flame relay),max. 250 VAC, 1A, cos φ 1 (ohmic), fusing 1A slowblowing (to be fused externally)Safety period/Lock-out time ≤ 1sSwitching threshold ≥ 1 µAStatus: 11/07 2.71/1e - 19 -

Gas fired igniter ZAVEXSpecifications4.4 Dimensional drawingFig. 2: Dimensional drawing, gas fired igniter4.5 Rating plateFig. 3: Example of rating plateThe rating plate is located on the housing of the ionisation flamemonitor and contains the following information:1 Manufacturer2 Date of manufacture3 Type4 Ex-rating5 EC type examination certificate number6 Connected voltage7 Protection rating8 Maximum current consumption9 Order confirmation number (with consecutive unit no.)10 Tester- 20 - 2.71/1e Status: 11/07

Gas fired igniter ZAVEXSpecifications4.6 Service lifeNOTE!This product does not have an unlimitedservice life!It was designed and type tested for a maximumservice life. In applications involving 50 switchingprocesses per day, this service life is set at around10 years. This period can be substantially reducedin the event of increased stress (temperature,vibrations, dirt etc.).– System operators and owners must take thesteps to ensure that regular safety checks areperformed depending on the actually occurringdegree of stress.– Exchange the gas fired igniter after it hasexceeded the specified service life. After expiryof the maximum operating period, functionaldefects can occur more frequently.– Check wearing parts independently of actualstress levels and exchange if required.Life of the ionisation flamemonitors (based on EN 298)Specification Value UnitMaximum operating life 250,000 SwitchcyclesStatus: 11/07 2.71/1e - 21 -

Gas fired igniter ZAVEXFunctional characteristics and structure5 Functional characteristics and structure5.1 Functional characteristicsThe gas fired igniter is a device whose flame is designed to ignite amain burner. A high voltage is generated from an input voltage(mains voltage), which generates an ignition spark at the gasnozzle. The resulting flame generates a flame signal via the flamerod. This flame signal is amplified in the ionisation flame monitorand enables the main burner.5.2 StructureFig. 4: Gas fired igniter (sectional drawing)1 Power head1.1 Junction room1.2 Junctin room cover1.3 Wiring terminal1.4 PE terminal1.5 Ex-rated cable gland1.6 Enclosure1.7 Gas flange3 Gas pressure test nipple (opposite gas inlet)4 Allen screw5 Air pressure test nipple6 Outer tube7 Intermediate support ring with two ceramicinsulators8 Connecting rods9 Gas tube10 Final electrode support ring11 Gas nozzle12 Ignition electrode13 Flame rod14 Air inlet15 Mixing chamber16 Mounting flange17 Earth rod18 Ceramic insulator- 22 - 2.71/1e Status: 11/07

Anschl üsseGas fired igniter ZAVEXFunctional characteristics and structureThe gas fired igniter comprises the following main components: the power head (1), in which the spark transformer and theionisation flame monitor are mounted, the junction room (1.1) which holds the wiring terminals (1.3)and the PE terminal (1.4) where the control cable has to behooked up, the complete outer tube (6), incl. mixing chamber(15) and mounting flange (16) with air inlet (14), the gas tube (9) and the gas nozzle (11), the final electrode support ring (10) with two ceramic insulators(18), ignition electrode (12), flame rod (13) and earth rod (17).The outer tube (6) is screwed to the power head (1) and can beremoved or depending on the position of the air supply pipe can beturned by 90°.The gas inlet can be from top or bottom. The unused opening issealed off by a sealing screw, into which a gas pressure testingnipple (3) is screwed.The final electrode support ring (10) is fastened on the end of thegas tube (9).The flame rod (13) and the ignition electrode (12) are extended byconnecting rods (8). These connecting rods are guided through thefloor of the transformer housing and are supported around every300 mm by intermediate support rings (7).5.3 Flame monitoringThe flame is monitored by the flame rod, which must immerse inthe direction of the flame. Alternating voltage is applied to thisflame rod. The burning flame creates an electrically conductiveconnection to the igniter earth and at the same time acts as arectifier for the ionisation current. This direct current signal ismeasured and amplified in the ionisation flame monitor. Theenforced flame signal activates the flame relay with one SPDTcontact (special version).5.3.1 Safety timeThe safety time is the response time of the ionisation flame monitoras the reaction to a failure of the flame signal (flame sensorcurrent) and as a result of that the clearing switch of the terminalsfor the „flame-on“ signal. The standard safety time is ≤ 1 s, amodification is not possible.Status: 11/07 2.71/1e - 23 -

Gas fired igniter ZAVEXFunctional characteristics and structure5.4 Gas and air adjusting components (accessories)REMARK!Accessories and special tools have to be orderedseparately.Air regulating sleeve Z 945 Z 3/0FV Housing: Malleable cast iron, galvanized Taper: Brass Ms 58 Lid: Brass Ms 58 Max. temperature range - 20 °C to + 60°C Max. pressure 300 mbargSpecial version (e.g. free of non-ferrous metal) on request.Fig. 5: Air regulating sleeveReducing nipple Z 946 F 4/00V Malleable cast iron, galvanized Max. temperature range - 20 °C bis + 60 °C Max. pressure 300 mbargFig. 6: Reducing nippleBallofix ball valve Z 845 Z4 Housing: Brass Ms 58Gaskets: Teflon Max. temperature range - 20 °C to + 60 °C Max. pressure 4 bargFig. 7: Ballofix ball valve- 24 - 2.71/1e Status: 11/07

Gas fired igniter ZAVEXFunctional characteristics and structure5.5 Burner controlsThe gas fired igniter can be interconnected with the followingcontrol units: Burner control AAUS 620 L 20for intermittent operation, add-on unit230 VAC, 50/60 Hz, IP 40 (special voltages possible, seealso separate HEGWEIN description) Burner control AASD 820 L 20for continuous operation, add-on unit230 VAC, 50/60 Hz, IP 40 (special voltages possible, seealso separate HEGWEIN description) Burner control A240 K3/ 306for intermittent or continuous operationwith 3 seconds safety time(versions with 5 or 8 seconds are also available)19“ plug-in Euro board,24 VDC (special versions possible, see also separateHEGWEIN description) Flame relay A285 K2.3with 2 volt-free SPDT contacts.Fixture for rail mounting to IEC/EN 60715for burner control systems complying with valid standardsand regulations, for safety integration of the gas fired igniter(see also separate HEGWEIN description).Status: 11/07 2.71/1e - 25 -

Gas fired igniter ZAVEXInstallation and initial commissioning6 Installation and initial commissioning6.1 SafetyPersonnel Installation may only be performed by suitably qualifiedspecialist staff of the plant installer. Initial commissioning may only be performed by employees ofthe manufacturer or by trained personnel.BasicsWARNING!Danger of injury due to faulty installation andinitial commissioning!Errors during installation and initial commissioningcan result in potentially fatal situations or entailsubstantial material damage.– Prior to any commissioning/maintenance workthat part of the plant where the gas fired igniteris installed must be switched off and securedagainst accidental restart. All feedlines to thegas fired igniter must be blocked, emptied andcleaned, if necessary.– Before starting work, ensure that there issufficient freedom of movement for theinstallation work.– Take care when handling open, sharp-edgedcomponents.– Ensure that the installation site is clean andtidy. Loose components and tools lying aroundor piled on top of each other are a possiblecause of accidents.– Assemble components professionally andcorrectly, observing prescribed screw tighteningtorque levels.– Secure components so that they cannot dropdown or fall over.- 26 - 2.71/1e Status: 11/07

Gas fired igniter ZAVEXInstallation and initial commissioningMonitoring of the gas and airpressure when using the device inhazardous areasDANGER!Danger of explosion due to faulty monitoring ofthe gas and air pressure!Faults in the monitoring of the gas and airpressure can lead to extremely dangeroussituations or entail considerable damage toproperty.– The gas and air pressure at site must bemonitored according to the current regulations.– Make sure that forced draught combustion air issupplied to the gas fired igniter and that it issufficiently purged prior to every re-start.– Any failure of the forced draught air must leadto an immediate shut down.– Even after a shut down of the gas fired igniter aminimum flow of combustion air shall passthrough the igniter. This prevents theaccumulation of a flammable mixture in the airflange or in the igniter tube.6.2 Installation and electrical connection Ensure that the following tasks are only performed by suitablytrained personnel.1. Prepare the installation location and installation opening.From an outer tube length of 3 m observe the following:– Use a guide tube to prevent sagging of the outer tube.– The end of the outer tube must project at least 150 mmover the inserted tube.– The annular gap between the outer tube and the push-intube must be at least 5 mm.Status: 11/07 2.71/1e - 27 -

Gas fired igniter ZAVEXInstallation and initial commissioning2. Push the gas fired igniter into the installation opening.3. Tighten the mounting flange (1) using four suitable screws.(Observe the max. torque specified in the table, use a suitabletool). Select the screw lengths in line with the wall thickness.4. Connect the combustion air at the air inlet (2).Fig. 8: Installation of the gas fired igniterThread sizeM 4M 5M 6M 8Tighteningtorque2.5 Nm5 Nm7 Nm15 Nm1/8“ 5 Nm1/4“ 7 Nm1/2“ 10 Nm3/4“ 15 Nm1“ 15 Nm1 ½“ 20 Nm2“ 25 NmREMARK!- If the temperature around the outer tube is higherthan 500 °C, connect the combustion air partially(20%) as cooling air and use a stainless steelouter tube.- At temperatures > 700 °C apply additionalcooling air in the annular gap between the pushinand the outer tube.NOTE!Excessive temperature can cause damage!In igniters which are designed to permit division orswivel action, the temperature at the dividing orswivel joints can cause damage to the gas firedigniter.– The temperature at the dividing / moving pointmust not exceed 180 °C.WARNING!Danger of burns due to wrong type of gas!Using an incorrect gas type can cause too large anignition flame to emerge from the gas fired igniter.This entails a risk of fatal injury due to seriousburns and danger of fire.– Only connect the gas fired igniter to the gastype indicated on the rating plate.5. At the gas inlet, connect a Ballofix ball valve for gas volumesetting.6. Connect the gas line at the Ballofix ball valve connector.7. Loosen the two Allen screws in the junction room cover. Twoscrew drivers may now be inserted into the two recesses andthe junction room may now be levered off evenly andcarefully.REMARK!The gas fired igniter must be connected by theowner to the plant control system in accordancewith the terminal diagrams.- 28 - 2.71/1e Status: 11/07

Gas fired igniter ZAVEXInstallation and initial commissioningREMARK!The high-voltage ignition spark can suppress theionization signal to such a degree that the flamerelay is not able to pick up. For this reason, theplant control system must ensure that the ignitionvoltage (“spark transformer” terminal) is switchedoff before the end of the ignition safety period (seeEN standard 298). This ensures a short ignitionfreeperiod (approx. 0.5 s).8. Wire the control cable to the terminals and the PE terminal asindicated in the wiring diagram. If only one of the two cablesglands installed is to be used, the unused cable gland shouldbe removed and the free issue Ex-plug screwed in instead.9. Tighten the cable glands for stress relief once the controlcables have been introduced into the junction room.REMARK!If several identical gas fired igniters are being used,the unction room cover must not be mixed up withthat of another igniter. The unit no. (punched figure)on the junction room cover must correspond withthat on the enclosure.10. In order to retain the protection from explosions the junctionroom cover must be re-inserted carefully. Make sure that theo-ring is not damaged. Tighten the two Allen screws.Status: 11/07 2.71/1e - 29 -

Gas fired igniter ZAVEXInstallation and initial commissioningStandard design, IP 65,with five wiring terminals and a PE terminalTerminal DesignationPE1 N2 LMeaningProtective earth conductorMains connection, ionisation flamemonitor8 L Spark transformer (primary)9 +10 -Flame signal output 90-110 VDCFig. 9: Terminal diagram standard version- 30 - 2.71/1e Status: 11/07

Gas fired igniter ZAVEXInstallation and initial commissioningSpecial design with volt-free SPDT contact, IP 65,with eight wiring terminals and a PE terminalTerminal Designation MeaningPE1 N2 LProtective earth conductorMains connection, ionisation flamemonitor4/5/6 Volt-free SPDT contact (flame relay),max. 250 VAC, 1A, cos φ 1 (ohmic),fusing 1A slow blowing (to be fusedexternally)8 L Spark transformer (primary)9 +10 -Flame signal output 90-110 VDCFig. 10: Terminal diagram special designStatus: 11/07 2.71/1e - 31 -

Gas fired igniter ZAVEXInstallation and initial commissioning6.3 Electrical function test This test must only be executed by a qualified electrician. Additionally required protective gear: Face protection Safety gloves Required special tools: Test diode A10Z2 (accessory part)DANGER!Fatal danger due to high voltage!High voltage is present in the ignition electrode forignition purposes. Contact with the electrode couldbe fatal.– Never come into contact with the ignitionelectrode.DANGER!Escaping fuel or the release of other devicesmay cause an explosion!A release of the gas fired igniter can cause thestart of subsequent devices (burners).– Any other devices such as burners and valvesshall therefore be blocked.DANGER!Risk of explosion due to leaking gas!Accidental gas leaks can cause an explosion orserious burns!– Before testing, shut off the gas valve!– Ensure that no residual gas remains, ifnecessary inert the gas lines.- 32 - 2.71/1e Status: 11/07

Gas fired igniter ZAVEXInstallation and initial commissioningWith the aid of test diode A10Z2, it is possible to simulate the flamesignal.Fig. 11: Test diode1. Switch off the power (after recommissioning).2. Open the red terminal (1) of the test diode by pressingbutton (2).3. Apply the red terminal (1) of the test diode to the flame 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 contactwith the outer tube (5).7. After contact with the test diode, a direct voltage of90-110 VDC must be measurable at the terminals of the flamesignal output.8. If no flame signal is produced, check the following:– Is mains voltage present at terminal 1 - 2?– Is the polarity of the test diode correct?– Are ceramic insulators damp, soiled or broken?If so, clean or exchange these or if necessary replace theionisation flame monitor.– Connect the flame rod to the power head.REMARK!In case of function problems, turn to the chapter“Troubleshooting”.Status: 11/07 2.71/1e - 33 -

Gas fired igniter ZAVEXInstallation and initial commissioning6.4 Setting the required air volume This may only be performed by trained personnel. Required special tools: Customarily available pressure gauge with a measurementrange of 0 - 200 mbar1. Define the air pressure:A supply pressure of 20 mbar plus another 13 mbar for everym of tube length is required. A gas fired igniter with a tubelength of 5 m should therefore be supplied with20 mbar + (5 x 13 mbar), i.e. 85 mbar in total (anybackpressures need to be taken into account).2. Turn the Allen screw (size 2.5) in the centre of the air pressuretest nipple (1) 1 1 / 2 turns counter clockwise in order to openthe air pressure test nipple.3. Connect the pressure gauge to the air pressure test nipple (1).4. Open the air supply (only on initial commissioning).5. Reduce the air pressure / the air volume using the airregulating sleeve to the length-dependent flow pressure, so atthe same time also compensating for any combustionchamber back pressure.Fig. 12: Air pressure test nippleREMARK!In case of a varying combustion chamber backpressure with fluctuations greater than 20 %,integrate an air-side differential pressure regulator.6. After measurement, remove the pressure gauge.7. Close the Allen screw.- 34 - 2.71/1e Status: 11/07

Gas fired igniter ZAVEXInstallation and initial commissioning6.5 Setting the required gas volume This may only be performed by trained personnel. Additionally required safety equipment: Face protection Protective gloves Required special tools: Customarily available pressure gauge with a measurementrange of 0 - 200 mbarDANGER!Risk of explosion due to gas leaks!An accidental gas leak can cause an explosion orserious burns!– Only unscrew the Allen screw of the gaspressure test nipple for the duration of the test.– Never allow any naked flame or ignition sourceto enter the danger area.1. Define the required gas volume on the basis of the relevantcharacteristic curve in the gas volume diagram.As a rule, the operating pressure is 100 mbar abovecombustion chamber back pressure.REMARK!If a higher gas pressure was specified in the order,then pressure reducing orifices have already beenscrewed into the two gas inlet threads in the factoryThe igniter is consequently adapted for gaspressures above 150 mbar.Precision setting is performed using the Ballofixball valve.In case of service pressure levels above 500 mbar,this setting is extremely difficult. In these cases, thepressure reducing orifices must be retrofitted.When ordering pressure reducing orifices, specifythe service pressure.REMARK!The illustrated diagram is based on average valuesin respect of gas density, gas composition, calorificvalue, igniter version, igniter tube length andoptimum ambient conditions, such as free burn-outand pressureless combustion chamber. Theservice pressure values determined from thediagram must consequently be viewed as guidelinevalues. Depending on the plant conditions, theactually required values may deviate from this.Status: 11/07 2.71/1e - 35 -

Gas fired igniter ZAVEXInstallation and initial commissioningP M NFig. 13: Gas volume diagramCharacteristic Gas type Nozzle article number Flame length (mm)P Propane/butane gas Z36F4515 max. 1000M Natural gas Z36F6020 max. 1200N * Town gas Z986F1 max. 600* Gas analysis required- 36 - 2.71/1e Status: 11/07

Gas fired igniter ZAVEXInstallation and initial commissioning2. Turn the Allen screw (size 2.5) in the centre of the gaspressure test nipple (1) 1 1 / 2 turns counter clockwise in orderto open the gas pressure test nipple.3. Connect the pressure gauge to the gas pressure testnipple (1) immediately.Fig. 14: Gas pressure test nippleDANGER!Fatal danger when executing ignition tests!When executing ignition tests, a large ignitionflame emerges from the gas fired igniter, whichcould fatal burns and also fire.Ignition tests should preferably be performed whenthe equipment is in a mounted status:– Ensure that the combustion products generatedby the flame are extracted via the opened fluegas path of the entire plant.If the gas fired igniter has to be tested when notmounted:– Execute ignition tests in such a way that thereare no persons located in the flame exit area ofthe outer tube.– Cordon off the danger area.– Only carry out ignition tests if there are nocombustible objects or inflammable materials inthe vicinity of the flame.DANGER!Fuel leaks or the release of other devices maycause an explosion!A release of the gas fired igniter can cause thestart of subsequent devices (burners).– Any other devices such as burners and valvesshall therefore be blocked.4. Open the gas supply (only on initial commissioning) andenable the tested plant by means of the control system.5. Set the previously selected gas pressure / gas volume at theBallofix ball valve.REMARK!In order to achieve a stable flame the air flowneeds to be adapted according to the gaspressure.6. After measurement, remove the pressure gauge.7. Close the Allen screw immediately.Status: 11/07 2.71/1e - 37 -

Gas fired igniter ZAVEXInstallation and initial commissioning6.6 Checking the setting resultIf correctly set, the following setting results should be in placefollowing initial commissioning: Immediate ignition Optically good flame pattern / flame signal 90-110 VDC Flame length max. 1200 mm at max. output of 250 kW and freeburn-out- 38 - 2.71/1e Status: 11/07

Gas fired igniter ZAVEXOperation7 Operation7.1 SafetyPersonal To be executed by suitably trained personnel only.BasicsWARNING!Danger of injury due to incorrect operation!Incorrect operation can result in serious personalinjury or material damage.– Before starting work, ensure that all covers andsafety devices are installed and in correctworking order.– Never disable safety devices during operation.– Only operate the gas fired igniter after ensuringthat nobody is near the area of the flame.– Ensure order and cleanliness in the work area.Loose components and tools lying around orpiled on top of each other are a possible causeof accidents.7.2 OperationREMARK!Operation of the gas fired igniters takes place atthe plant control system in which the device isintegrated. Manual operation at the gas fired igniteritself is not required.Status: 11/07 2.71/1e - 39 -

Gas fired igniter ZAVEXMaintenance8 Maintenance8.1 SafetyPersonnel To be executed by suitably trained personnel only.BasicsWARNING!Danger of injury due to incorrectly executedmaintenance work!Incorrectly done maintenance work can result inserious personal injury or material damage.– Before starting work, ensure that there issufficient freedom of movement for theinstallation work.– Ensure that the installation site is clean andtidy. Loose components and tools lying aroundor piled on top of each other are a possiblecause of accidents.– When components are removed, ensure correctreassembly. Remount all fastening componentsand adhere to specified screw tightening torquelevels.8.2 Maintenance, generalThe 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, checksmust be performed at shorter intervals, as electrically conductivedirt deposits or moisture on the ceramic insulators of the igniter canresult in malfunctions.The inner resistance of the ionization path is MΩ. These highresistance levels call for the ceramic insulators to be in perfectworking order.Only a few parts are subject to wear in normal operation (seechapter “Spare parts list”. These parts must be exchanged ifdefects and malfunctions occur with increased frequency.- 40 - 2.71/1e Status: 11/07

Gas fired igniter ZAVEXMaintenance8.3 Conditions for maintenance workTake care of the following warnings before carrying out anymaintenance work (sections 8.3.1 to 8.3.4):DANGER!Fatal danger due to high voltage!High voltage is present in the ignition electrode forignition purposes. Contact with the electrode couldbe fatal.– Never come into contact with the ignitionelectrodePerforming work at the spark transformer entails arisk of fatal injury due to electric shocks!– Switch off the gas fired igniter and secure itagainst being switched back on.– Before touching parts carrying voltage, ensurethat no residual voltage remains.DANGER!Risk of explosion due to leaking gas!Accidental gas leaks can cause an explosion orserious burns!When carrying out maintenance work, shut off thegas valve!– Ensure that no residual gas remains, ifnecessary inert the gas lines.– Completely separate the gas fired igniter fromthe power supply and disconnect the gas / airsupply.The maintenance work listed below can now be performed.Status: 11/07 2.71/1e - 41 -

Gas fired igniter ZAVEXMaintenance8.3.1 Exchanging the outer 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.REMARK!Depending on the position of the air connection,the outer tube can be turned into 4 x 90°increments and tightened.Fig. 15: Exchanging the outer tube- 42 - 2.71/1e Status: 11/07

Gas fired igniter ZAVEXMaintenance8.3.2 Exchanging the power head This may only be performed by suitably qualified personnel.1. Release the four Allen screws (1).2. Pull off the outer tube (2).3. Remove the final electrode support ring (3) and any existingintermediate support rings (7) as well as the connectingrods (4).4. Unscrew the gas tube (5) from the gas flange (6).5. If there are pressure reducing orifices screwed into the twogas inlet threads, unscrew these and change them over to thenew power head (8).6. Assembly takes place in reverse sequence.7. Mount the rating plate on the new power head (8).Fig. 16: Exchanging the power headStatus: 11/07 2.71/1e - 43 -

Gas fired igniter ZAVEXMaintenance8.3.3 Exchanging the final electrode support ringThis may only be performed by suitably qualified personnel.REMARK!The final electrode support ring counts as awearing component and is not included in thewarranty cover.The complete electrode support rings with readypre-bent and adjusted electrodes can be orderedfrom HEGWEIN (for address see the cover sheetof the table of contents).1. Release the four Allen screws (1).2. Pull off the outer tube (2).3. Release the clamping screw (6) of the final electrode supportring (3) and pull the ring off the gas tube (4).4. Position the new final electrode support ring (3).5. All plug-in sleeves (item 7) should be squeezed carefully witha pair of pliers to ensure a tight fit of the connecting rods(item 5) in the plug-in sleeves.6. Insert the connecting rods (5) into the plug-in sleeves at theigniter head and into the plug-in sleeves (7) on the finalelectrode support ring (3).Ensure that the connecting rods (5) are not twisted or bent.7. Check the distances at the final electrode support ring (3) andalign if necessary.8. Tighten the clamping screw (6).9. Mount the outer tube (2).Fig. 17: Exchanging the final electrode support ring- 44 - 2.71/1e Status: 11/07

Gas fired igniter ZAVEXMaintenance8.3.4 Exchanging the intermediate support ringsThis may only be performed by suitably qualified personnel.REMARK!Intermediate support rings are used from a tubelength of 600 mm. New intermediate support ringsmust be inserted in the previous position.Fig. 18: Exchanging the intermediatesupport rings1. Release the four Allen screws (1).2. Pull off the outer tube (2).3. Release the clamping screw of the final electrode support ringand pull off the final electrode support ring (3) from the gastube (4).4. Pull out the connecting rods (5).5. Release the clamping screws of the intermediate supportrings (6).6. Pull the intermediate support rings (6) off the gas tube (4).7. Push the new intermediate support rings onto the gas tube (4).8. Push on the final electrode support ring (3).9. All plug-in sleeves (7) should be squeezed carefully with a pairof pliers to ensure a tight fit of the connecting rods (5) in theplug-in sleeves.10. Insert the connecting rods (5) into the plug-in sleeves at theigniter head and into the plug-in sleeves on the final electrodesupport 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 supportrings (6).13. Mount the outer tube (2).8.4 Actions following completed maintenance workAfter completing the maintenance work and before switching on,carry out the following steps:1. Check all previously released screw connections for a firm fit.2. Check whether all previously removed protective devices andcovers have been correctly replaced.3. Ensure that all used tools, materials and other equipmenthave been removed from the work area.4. Clean the work area and remove any spilt substances such asfluids, processing materials or similar.5. Ensure that all safety devices are in perfect working order andthat the correct function of the equipment is guaranteed.Status: 11/07 2.71/1e - 45 -

Gas fired igniter ZAVEXTroubleshooting9 TroubleshootingThe following chapter provides information on possible causes forfaults and describes the work required to remedy them.If faults occur on a more frequent basis, reduce the maintenanceintervals in line with the actual degree of stress on the system.In case of faults which cannot be remedied following theseinstructions, contact HEGWEIN. For the servicing address, see thecover sheet of the table of contents.9.1 SafetyPersonal This may only be performed by trained personnel.BasicsWARNING!Danger of injury due to incorrectly performedmaintenance work!Incorrectly executed maintenance work can resultin serious personal injury or material damage.– Before starting work, ensure that there issufficient freedom of movement for theinstallation work.– Ensure that the installation site is clean andtidy. Loose components and tools lying aroundor piled on top of each other are a possiblecause of accidents.– When components are removed, ensure correctreassembly. Remount all fastening componentsand adhere to specified screw tightening torquelevels.Response in case of faultsBasic rules of procedure:1. Determine the cause of the fault.2. If remedying the fault entails work in the danger area, switchoff the gas fired igniter and secure it against being switchedback on.3. Completely disconnect the gas fired igniter from the energysupply and disconnect the fuel/air supply.4. Inform the person in charge at the site immediately about thefault.5. Depending on the type of fault, have it remedied by authorizedspecialist personnel.REMARK!The troubleshooting table listed below providesinformation on how to remedy faults.- 46 - 2.71/1e Status: 11/07

Gas fired igniter ZAVEXTroubleshooting9.2 Troubleshooting tableFault Possible cause Solution To be done bySpark does not form(Not: Carry outoptical check ofignition spark withgas valve closed indarkened room)Gas fired igniter is not receivingany voltageIgnition electrode is burned outCheck wiringCheck control systemClean the inside of the gas firedigniter and replace ignitionelectrode, bend to originalpositionQualifiedelectricianQualifiedpersonnelElectrode distance is too largeor electrode has short circuitedClean inside of gas fired igniterif necessary and bend ignitionelectrode to distance of2 - 3 mmQualifiedpersonnelSpark transformer defective Exchange power head Manufacturer/QualifiedelectricianLayer of scale on sparkelectrode or earth rod/ boltClean inside of gas fired igniterand remove deposits usingemery paperQualifiedpersonnelCeramic insulator brokenExchange ceramic insulator,intermediate support ring orfinal electrode supportQualifiedpersonnelFlame fails to formNo combustion air available dueto defective air flap or valveExchange air flap or valveQualifiedpersonnelNo combustion air available dueto closed throttle organsOpen throttle organsOperatorNo combustion air available dueto blocked supply lineUnblock lineQualifiedpersonnelNo gas available becausesupply line is too longDimension supply lineaccordingly, if necessarychange the position of theburnerQualifiedpersonnelNo gas available, as gas supplyline still inert with N 2Carry out several ignitionattempts until line has filled withgasOperatorNo gas available, as gas valvedefectiveExchange gas valve Gas specialist /ownerGas to air ratio is incorrectWrong gasCheck settings of the gas andair pressure. Check values andcorrect on the basis of thediagramsOnly use gas specified on therating plateQualifiedpersonnelQualifiedpersonnelStatus: 11/07 2.71/1e - 47 -

Gas fired igniter ZAVEXTroubleshootingFault Possible cause Solution To be done byCombustion air contaminatedIf necessary use a filter orclean/replace existing filterQualifiedpersonnelThe flame comes onfor a short time, buttrips once the ignitionsafety time haselapsedFlame rod is burned out,deformed or has short circuitedCeramic insulator of flame rodbrokenExchange the flame rod andbend back to original positionClean any scale / internalburner partsExchange ceramic insulator orelectrode support ringQualifiedpersonnelQualifiedpersonnelWhen switched together withthe Hegwein control unit,operating voltage is enabled atthe same time as the biasvoltageAs the operating voltage mustlag behind the bias voltage byat least 5 s, always leave thebias voltage switched onQualifiedelectricianWhen using control unit from adifferent manufacturer, theignition spark always disturbsthe ionization feedbackSwitch off ignition voltageapprox. 0.5 s before expiry ofthe ignition safety timeQualifiedelectricianGas fired igniter was exposedto excessively high temperaturein the combustion chamberwhen switched off. Ceramicinsulators too hot, the insulationresistance has dropped too farLeave fan air running when thegas fired igniter is switched offfor cooling purposesQualifiedpersonnelThe setting of the gas and airpressure levels at the gas firedigniter is not correct, flame rootnot in the area of the flame rodCheck settings and correctQualifiedpersonnelWrong connectionCheck complete wiring, carryout electrical function testQualifiedelectricianIonisation flame monitordefectiveCarry out electrical functiontest, exchange power headManufacturer/QualifiedelectricianFault shutdown takesplace duringoperationFluctuating combustionchamber of supply pressurelevels, resulting in flame blowoffCheck the pressure settings atthe test nipples. If necessaryprovide a differential pressureregulation system for gas andairQualifiedpersonnelIf possible, carry out ignitionand burning tests outside thecombustion chamber(observe local regulations)- 48 - 2.71/1e Status: 11/07

Gas fired igniter ZAVEXTroubleshootingFault Possible cause Solution To be done byPilot flame highly subject toinfluence by the main flame oris suffocatedChange the position of the gasfired igniterUse more powerful gas firedigniterQualifiedpersonnelLock-out because aflame is signalled atthe start before thegas valve hasopenedFlame was not extinguishedwhen switching off due to aleaking valve, and is alreadypresent when restartingIonisation flame monitordefectiveReplace the gas valveExchange power headGas specialistpersonnel/OwnerManufacturer/QualifiedelectricianThe gas fired igniterand control unit areoperational, but nosignals aretransmitted via theintegrated flamerelayExternal fuse defective Replace external fuse QualifiedelectricianStatus: 11/07 2.71/1e - 49 -

Gas fired igniter ZAVEXDismantling / Disposal10 Dismantling / DisposalOnce it has reached the end of its service life, the gas fired igniterhas to be dismantled and sent for ecologically responsibledisposal.10.1 SafetyPersonnel This may only be performed by trained personnel.BasicsWARNING!Danger of injury due to incorrect dismantling!Residual stored energy, sharp components,pointed corners and edges on or in the gas firedigniter or on the required tools can cause injury.– Before starting work, ensure that there issufficient space available.– Take particular care when dealing with sharpedgedcomponents.– Ensure that the installation site is clean andtidy. Loose components and tools lying aroundor piled on top of each other are a possiblecause of accidents.– If any points are unclear, consult themanufacturer.10.2 DismantlingBefore starting to dismantle it, carry out the following steps:DANGER!Potentially fatal injury due to electrical current!Contact with live components can cause fatalinjury.– Before starting dismantling work, switch off theelectrical supply and finally disconnect.- 50 - 2.71/1e Status: 11/07

Gas fired igniter ZAVEXDismantling / DisposalDANGER!Risk of explosion due to leaking gas!Accidental gas leaks can cause an explosion orserious burns!When dismantling, shut off the gas valve!– Ensure that no residual gas remains, ifnecessary inert the gas lines.– If gas is unintentionally released into theatmosphere, immediately shut off the gas flow.Prevent gas entering drainage systems,basements, work pits or other locations in whichcollected gas could cause a hazard.1. Switch off the gas fired igniter and secure it against beingswitched back on.2. Completely disconnect the gas fired igniter from the energysupply and gas / air supply.3. Remove operating and auxiliary materials as well as residualprocessing materials and ensure their ecologically responsibledisposal.The gas fired igniter can now be cleaned for separation anddismantled in compliance with applicable occupational safety andenvironmental protection legislation.10.3 DisposalProvided no return acceptance or disposal agreement has beenconcluded, the components once dismantled can be sent forrecycling: Scrap the metal. Send plastic elements for recycling. Dispose of the remaining components separated according tomaterial properties.NOTE!Environmental damage due to incorrectdisposal!Electric scrap, electronic components, lubricantsand other auxiliary materials are subject to specialwaste treatment and may only be disposed of byauthorized specialist companies!The local authorities or specialist disposal companies can provideinformation on environmentally responsible disposal.Status: 11/07 2.71/1e - 51 -

Gas fired igniter ZAVEXSpare parts list11 Spare parts list11.1 Spare and wearing partsFig. 19: Spare parts drawingItem Qty. Designation Part number Voltages Material/configurationRemarks11 Flame proofpower headII 2G EEx de IIB T41 Flame proofpower headII 2G EEx de IIC T4Z199K2/0001Z199K2/00M1Z199K2/00C1Z199K2/00B1Z199K3/0001Z199K3/00M1Z199K3/00C1Z199K3/00B1230 V115 V125 V250 V230 V115 V125 V250 VProtection rating"flameproofenclosure" and"increased safety"(for the junctionroom)1.1 1 Gasket W677F1 NBR / Ø 98 x 22 1 Complete outer tube, incl. Z1200Z_ _ _mixing chamber (heat orresistant tube 1.4841) and Z1206Z_ _ _mounting flange with airinlet3 * Intermediate support ringwith 2 ceramic insulators4 1 Final electrode supportring with2 ceramic insulators and2 electrodes5 1 GasnozzleZ944K3orZ944K103Z944K9orZ944K109Tube lengthgiven shouldbe the samein line withtype key (seechapter“Specifications”)SteelStainless steelSteelStainless steelSteelStainless steelNatural gas Z36F6020 Stainless steel1.4104Propane/butane gasTown/coke ovengasZ36F4515Z986F1Stainless steel1.4104Stainless steel1.4104StandardSpecial versionSpecial versionSpecial versionStandardSpecial versionSpecial versionSpecial versionStandardSpecial version* length dependentStandardSpecial versionWearing partStandardStandardStandard- 52 - 2.71/1e Status: 11/07

Gas fired igniter ZAVEXAnnex12 Annex12.1 EC type examination certificates12-001-1_de-Rev2Status: 11/07 2.71/1e - 53 -

Gas fired igniter ZAVEXAnnexFig. 20: EC type examination certificate12-001-2_de-Rev2- 54 - 2.71/1e Status: 11/07

Gas fired igniter ZAVEXAnnex12-006-1_uk-Rev0Status: 11/07 2.71/1e - 55 -

Gas fired igniter ZAVEXAnnexFig. 21: EC type examination certificate12-006-2_uk-Rev0- 56 - 2.71/1e Status: 11/07

Gas fired igniter ZAVEXAnnex12.2 EC Declaration of conformityFig. 22: EC Declaration of conformity12-010_de-Rev1Status: 11/07 2.71/1e - 57 -