Table of Contents
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Table of Contents
Troubleshooting
Summary of Contents for Hegwein ZT0
- Page 1 Inhaltsverzeichnis Operating Manual Gas fired igniter Hegwein GmbH © Before first use, read the operating manual! Am Boschwerk 7 70469 Stuttgart, Germany 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...
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Page 2: Table Of Contents
Gas fired igniter ZT0 Contents General ............3 Gas and air adjusting components Information on the operating manual ... 3 (accessories) ..........24 Electrical wiring versions ......25 Explanation of symbols ........ 3 Liability disclaimer ........4 Installation and initial commissioning .. 26 Copyright protection ........ -
Page 3: General
Gas fired igniter ZT0 General General Information on the operating manual This operating manual provides important information on working with the gas fired igniter. Safe working can only be ensured by adhering to all the safety remarks and instructions provided. -
Page 4: Liability Disclaimer
Gas fired igniter ZT0 General Recommendations REMARK! … highlights useful recommendations and information designed to permit efficient, trouble- free operation. Special safety remarks In order to draw attention to special hazards, the following symbol is used in conjunction with safety remarks:... -
Page 5: Copyright Protection
Gas fired igniter ZT0 General Copyright protection These operating instructions must be treated in confidence. They are exclusively intended for the persons operating the gas fired igniter and may not be made available to third parties without the prior written consent of the manufacturer. -
Page 6: Safety
Gas fired igniter ZT0 Safety Safety This section provides an overview of all important safety aspects for optimum protection of personnel as well as safe, trouble free operation. Failure to observe the operating instructions and safety remarks contained in this manual can cause serious injury. -
Page 7: Operating Personnel
Gas fired igniter ZT0 Safety Operating personnel 2.2.1 Requirements WARNING! Danger of injury due to insufficient qualification Incorrect handling of the equipment can result in severe personal injury and material damage. – Only allow activities to be performed by suitably qualified specialist personnel. -
Page 8: Unauthorized Persons
Gas fired igniter ZT0 Safety 2.2.2 Unauthorized persons WARNING! Danger for unauthorized persons! Persons who do not comply with the requirements described here are not aware of the dangers inherent in the work area. – Keep unauthorized persons away from the work area. -
Page 9: Personal Protective Gear
Gas fired igniter ZT0 Safety Personal protective gear Personal protective gear must be worn while working with the equipment in order to minimize potential health hazards. Wear the protective gear necessary for performance of the relevant task at all times while working. -
Page 10: Special Dangers
Gas fired igniter ZT0 Safety Special dangers Remaining dangers are listed in the section below. The remarks provided here and the safety instructions in the subsequent chapters of this operating manual must be observed in order to reduce the possible risk to health and prevent the occurrence of dangerous situations. - Page 11 Gas fired igniter ZT0 Safety Electrical current DANGER! Danger to life due to electrical current! When touching with current conducting parts, there is a danger to life. Damage to the insulation or individual components can have potentially life- threatening consequences.
- Page 12 Gas fired igniter ZT0 Safety Highly inflammable materials WARNING! Danger of burns due to flammable materials! Highly flammable materials, liquids or gases can catch fire and cause serious to fatal injuries. – Do not smoke in the danger area and in the close vicinity.
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Page 13: Securing Against Unauthorized Switching Use
Gas fired igniter ZT0 Safety Securing against unauthorized switching use DANGER! Risk of fatal injury due to unauthorized use! When working in the danger area, there is a risk that the energy supply could be switched on by an unauthorized person. This creates a potentially fatal hazard for persons working in the danger area. -
Page 14: Response In Case Of Danger Or Accident
Gas fired igniter ZT0 Safety Response in case of danger or accident Preventive actions Always be prepared for accidents and for fires! Keep first aid equipment (first aid kit, blankets etc.) and a fire extinguisher on hand. ... -
Page 15: Transport, Packaging And Storage
Gas fired igniter ZT0 Transport, packaging and storage Transport, packaging and storage Safety instructions for transport Incorrect transport WARNING! Danger of injury as a result of incorrect transport! In the case of incorrect transport, considerable material damage can occur. – When unloading packaged items on delivery,... -
Page 16: Packaging
Gas fired igniter ZT0 Transport, packaging and storage Packaging Packaging The individual products are packaged in accordance with the transport conditions expected for the consignment. Exclusively environmentally friendly materials are used for the packaging. The packaging should protect the individual components from transport damage, corrosion and other damage up until such time as they are assembled. -
Page 17: Specifications
Gas fired igniter ZT0 Specifications Specifications Type designation with type key Example of type designations with the most important igniter data: Fig. 1: Type key Status: 11-2018 - 17 -... -
Page 18: Gas Fired Igniter
Gas fired igniter ZT0 Specifications Gas fired igniter Characteristic 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 dia. -
Page 19: Power Head
Gas fired igniter ZT0 Specifications Power head Characteristic Value Supply voltage of spark transformer Primary: 220 – 230 V AC, 50/60 Hz (standard) or in accordance with rating plate Secondary: 5 kV against ground Protection rating IP 54 (standard) or... -
Page 20: Dimensional Drawing
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... -
Page 21: Service Life
Gas fired igniter ZT0 Specifications Service life NOTE! This product does not have an unlimited service life! It has been designed for a maximum service life at nominal load. In applications involving 50 switching processes per day, this service life is set at around 10 years. -
Page 22: Functional Characteristics And Structure
Gas fired igniter ZT0 Functional characteristics and structure Functional characteristics and structure Functional characteristics The gas fired igniter is a device whose flame is designed to ignite and support a main burner. A high voltage is generated from an input voltage (mains voltage), which generates an ignition spark at the gas nozzle. -
Page 23: Flame Monitoring
Gas fired igniter ZT0 Functional characteristics and structure The outer tube (6) is screwed to the power head (1) and can be removed or depending on the position of the air supply pipe can be turned by 90°. The gas port can be on the left or right. The unused opening is sealed off by a sealing screw, into which a gas pressure testing nipple (3) is screwed. -
Page 24: Gas And Air Adjusting Components (Accessories)
Gas fired igniter ZT0 Functional characteristics and structure Gas and air adjusting components (accessories) REMARK! Accessories and special tools have to be ordered separately. Air regulating sleeve Z 945 Z 2/0FV Housing: Malleable cast iron, galvanized Taper: Brass Ms 58 ... -
Page 25: Electrical Wiring Versions
Gas fired igniter ZT0 Functional characteristics and structure Electrical wiring versions The gas fired igniter can be interconnected with the following units: Flame monitor AAL 76 P0… for continuous operation or intermittent operation, top hat rail mounting, 230 V AC, 50/60 Hz, (special voltages possible), see relevant HEGWEIN operating manual ... -
Page 26: Installation And Initial Commissioning
Gas fired igniter ZT0 Installation and initial commissioning Installation and initial commissioning Safety Personnel Installation may only be performed by suitably qualified specialist staff of the plant installer. Initial commissioning may only be performed by employees of the manufacturer or by trained personnel. - Page 27 Gas fired igniter ZT0 Installation and initial commissioning DANGER! Explosion risk due to leaking fuel or release of additional units! Downstream units (e.g. burner/igniter) can be connected via incorrect operation of the gas fired igniter. – The gas fired igniter, and the external flame monitor signal of the gas fired igniter should be incorporated into an overriding safety controller.
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Page 28: Installation And Electrical Connection
Gas fired igniter ZT0 Installation and initial commissioning Installation and electrical connection Ensure that the following tasks are only performed by suitably trained personnel. DANGER! Danger to life due to electrical current! When touching with current conducting parts, there is a danger to life. - Page 29 Gas fired igniter ZT0 Installation and initial commissioning Push the gas fired igniter into the installation opening. Tighten the mounting flange (1) using two or four suitable screws. (Observe the max. torque specified in the table, use a suitable tool). Select the screw lengths in line with the wall thickness.
- Page 30 Gas fired igniter ZT0 Installation and initial commissioning REMARK! The gas fired igniter must be connected by the owner to the plant control system in accordance with the terminal diagrams. REMARK! The high-voltage ignition spark can suppress the ionization signal to such a degree that the flame monitor may not work trouble-free.
- Page 31 Gas fired igniter ZT0 Installation and initial commissioning Special version, IP 65, permanently sealed mains cable and flame signal cable (with shielding) Colour/ Designation Meaning Core green/ Protective earth conductor yellow blue Spark transformer (primary) brown Shielding* Ion. Flame signal cable* * If wired to flame monitors or automatic burner control systems consider the relevant wiring schedule.
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Page 32: Electrical Function Test
Gas fired igniter ZT0 Installation and initial commissioning Electrical function test This test must only be carried out by a specialist trained in the handling of the plant and its components. Additionally required protective gear: Face protection ... - Page 33 Gas fired igniter ZT0 Installation and initial commissioning With the aid of test diode A10Z2, it is possible to simulate the flame signal. Switch off the power (after recommissioning). Open the red terminal (1) of the test diode by pressing button (2).
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Page 34: Setting The Required Air Volume
Gas fired igniter ZT0 Installation and initial commissioning Setting the required air volume This may only be performed by trained personnel. Required special tools: Customarily available pressure gauge with a measurement range of 0 – 200 mbar... -
Page 35: Setting The Required Gas Volume
Gas fired igniter ZT0 Installation and initial commissioning 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 measurement range of 0 –... - Page 36 Gas fired igniter ZT0 Installation and initial commissioning Fig. 13: Gas volume diagram Characteristic Gas type Nozzle article number Flame length (mm) Z330F2510 max. 600 Natural gas Z330F4013 max. 600 * Bottled gas can come with different propane/butane mixtures. Deviations from the chart given above may occur.
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Page 37: Checking The Setting Result
Gas fired igniter ZT0 Installation and initial commissioning Turn the Allen screw (size 2.5) in the centre of the gas pressure test nipple (1) 1 ½ turns counter clockwise in order to open the gas pressure test nipple. Connect the pressure gauge to the gas pressure test nipple (1) immediately. -
Page 38: Operation
Gas fired igniter ZT0 Operation Operation Safety Personal To be executed by suitably trained personnel only. Basics WARNING! Danger of injury due to incorrect operation! Incorrect operation can result in serious personal injury or material damage. – Before starting work, ensure that all covers and safety devices are installed and in correct working order. -
Page 39: Maintenance
Gas fired igniter ZT0 Maintenance Maintenance Safety Personnel To be executed by suitably trained personnel only. Basics WARNING! Danger of injury due to incorrectly executed maintenance work! Incorrectly done maintenance work can result in serious personal injury or material damage. -
Page 40: Conditions For Maintenance Work
Gas fired igniter ZT0 Maintenance Conditions for maintenance work Take care of the following warnings before carrying out any maintenance work (sections 8.3.1 to 8.3.4): DANGER! Fatal danger due to electrical voltage or high voltage! High voltage is present in the ignition electrode for ignition purposes. -
Page 41: Exchanging The Outer Tube
Gas fired igniter ZT0 Maintenance 8.3.1 Exchanging the outer tube This may only be performed by suitably qualified personnel. Remove the four Allen screws (1). Pull off the outer tube (2). Position the new outer tube (2). Tighten the four Allen screws (1) again. -
Page 42: Exchanging The Power Head
Gas fired igniter ZT0 Maintenance 8.3.2 Exchanging the power head This may only be performed by suitably qualified personnel. Remove the four Allen screws (1). Pull off the outer tube (2). Remove the final electrode support ring (3) and any existing intermediate support rings (7) as well as the connecting rods (4). -
Page 43: Exchanging The Final Electrode Support Ring
The complete electrode support rings with ready pre-bent and adjusted electrodes can be ordered from HEGWEIN (for address see the cover sheet of the table of contents). Remove the four Allen screws (1). Pull off the outer tube (2). -
Page 44: Exchanging The Intermediate Support Rings
Gas fired igniter ZT0 Maintenance 8.3.4 Exchanging the intermediate support rings This may only be performed by suitably qualified personnel. REMARK! Intermediate support rings are used from a tube length of 600 mm. New intermediate support rings must be inserted in the previous position. -
Page 45: Troubleshooting
If faults occur on a more frequent basis, reduce the maintenance intervals in line with the actual degree of stress on the system. In case of faults which cannot be remedied following these instructions, contact HEGWEIN. For the servicing address, see the cover sheet of the table of contents. Safety ... -
Page 46: Troubleshooting Table
Gas fired igniter ZT0 Troubleshooting Troubleshooting table Fault Possible cause Solution To be done by Spark does not form Gas fired igniter is not receiving Check wiring Qualified any voltage Check control system electrician (Not: Carry out optical check of... - Page 47 Gas fired igniter ZT0 Troubleshooting Fault Possible cause Solution To be done by Combustion air contaminated If necessary use a filter or Qualified clean/replace existing filter personnel No gas available, as gas supply Check function and position of Gas specialist/...
- Page 48 Gas fired igniter ZT0 Troubleshooting Fault Possible cause Solution To be done by Lock-out because a Flame was not extinguished Replace the gas valve Gas specialist flame is signalled at when switching off due to a personnel/ the start before the...
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Page 49: Dismantling / Disposal
Gas fired igniter ZT0 Dismantling / Disposal Dismantling / Disposal Once it has reached the end of its service life, the gas fired igniter has to be dismantled and sent for ecologically responsible disposal. 10.1 Safety Personnel This may only be performed by trained personnel. -
Page 50: Disposal
Gas fired igniter ZT0 Dismantling / Disposal DANGER! Risk of explosion due to leaking gas! Accidental gas leaks can cause an explosion or serious burns! When dismantling, shut off the gas valve! – Ensure that no residual gas remains, if necessary inert the gas lines. -
Page 51: Spare Parts List
Gas fired igniter ZT0 Spare parts list Spare parts list 11.1 Spare and wearing parts Fig. 19: Spare parts drawing Item Qty. Designation Part number Voltages Material/ Remarks configuration Power head / Z112K5 220-230 V With housing, Standard IP 54... - Page 52 Gas fired igniter ZT0 Spare parts list Item Qty. Designation Part number Voltages Material/ Remarks configuration Intermediate support ring Z960K4 Steel * length dependent with 2 ceramic insulators Z960K104 Stainless steel Final electrode support Z960K13 Steel Standard ring with 2 ceramic insulators and...
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Page 53: Annex
Gas fired igniter ZT0 Annex Annex 12.1 EU Declaration of conformity 12-011_de_en-Rev7 Fig. 20: EU Declaration of conformity Status: 11-2018 - 53 -...
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