Hegwein ZA0 Series User manual

Operating Manual
Gas fired igniter
ZA0 / ZDA0
©
Hegwein GmbH
Am Boschwerk 7
70469 Stuttgart, Germany
Before first use, read the operating manual!
Tel.: [phone]
Fax: [phone]
E-Mail: [email protected]
www.hegwein.de
Status: 11-2018

Gas fired igniter ZA0 / ZDA0
Contents
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1General .......................................................3
1.1 Information on the operating manual...........3
1.2 Explanation of symbols................................3
1.3 Liability disclaimer .......................................4
1.4 Copyright protection ....................................5
1.5 Spare parts..................................................5
1.6 Warranty regulations ...................................5
1.7 After-sales service.......................................6
2Safety..........................................................7
2.1 Owner’s responsibility..................................7
2.2 Operating personnel....................................8
2.2.1 Requirements ..............................................8
2.2.2 Unauthorized persons .................................9
2.3 Intended purpose of the equipment.............9
2.4 Personal protective gear............................10
2.5 Special dangers.........................................11
2.6 Securing against unauthorized switching
use.............................................................14
2.7 Response in case of danger or accident...15
3Transport, packaging and storage ........16
3.1 Safety instructions for transport.................16
3.2 Transport inspection..................................16
3.3 Packaging..................................................17
3.4 Storage conditions.....................................17
4Specifications ..........................................18
4.1 Type designation with type key .................18
4.1.1 Type key of ionisation flame monitor.........19
4.2 Gas fired igniter .........................................19
4.3 Power head ...............................................20
4.4 Dimensional drawing.................................22
4.5 Rating plate of gas fired igniter..................22
4.5.1 Rating plate of ionisation flame monitor....23
4.6 Service life.................................................24
5Functional characteristics and
structure...................................................25
5.1 Functional characteristics..........................25
5.2 Structure....................................................25
5.3 Ionisation flame monitor ............................26
5.3.1 Flame monitoring.......................................26
5.3.2 Safety time (flame failure detection time
FFDT) ........................................................26
5.3.3 Test sockets ..............................................27
5.4 Connections on the transformer part front
panel.......................................................... 27
5.5 Gas and air adjusting components
(accessories)............................................. 28
5.6 Electrical wiring versions........................... 29
6Installation and initial commissioning.. 30
6.1 Safety........................................................ 30
6.2 Installation and electrical connection ........ 32
6.3 Electrical function test............................... 36
6.4 Setting the required air volume................. 38
6.5 Setting the required gas volume ............... 39
6.6 Checking the setting result........................ 42
7Operation ................................................. 43
7.1 Safety........................................................ 43
7.2 Operation................................................... 43
8Maintenance ............................................ 44
8.1 Safety........................................................ 44
8.2 Maintenance, general................................ 44
8.3 Conditions for maintenance work.............. 45
8.3.1 Exchanging the outer tube........................ 46
8.3.2 Exchanging the power head...................... 47
8.3.3 Exchanging the ionisation flame monitor.. 47
8.3.4 Exchanging the final electrode support
ring ............................................................ 48
8.3.5 Exchanging the intermediate support
rings........................................................... 49
8.4 Actions following completed maintenance
work........................................................... 49
9Troubleshooting...................................... 50
9.1 Safety........................................................ 50
9.2 Troubleshooting table................................ 51
10 Dismantling / Disposal............................ 54
10.1 Safety........................................................ 54
10.2 Dismantling................................................ 54
10.3 Disposal..................................................... 55
11 Spare parts list ........................................ 56
11.1 Spare and wearing parts........................... 56
12 Annex ....................................................... 58
12.1 EU type examination certificate ................ 58
12.2 EU Declaration of conformity .................... 60

Gas fired igniter ZA0 / ZDA0
General
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1 General
1.1 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.
In addition, the locally applicable accident prevention laws and
general safety regulations must be followed.
Read the operating manual carefully before using the gas fired
igniter the first time. These instructions form an integral part of the
product and must be kept near the equipment at all times within
easy reach for personnel.
When the gas fired igniter is transferred on to third parties, it must
always be accompanied by the operating instructions.
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 signal words
which indicate the degree of severity of the hazard.
The instructions must be adhered to without fail and acted upon
prudently in order to prevent accidents, personal injury or material
damage.
DANGER!
… denotes a hazardous situation which results in
death or serious injury unless prevented.
WARNING!
… denotes a hazardous situation which could result
in death or serious injury unless prevented.
CAUTION!
… denotes a hazardous situation which could result
in minor or slight injury unless prevented.
NOTE!
… denotes a hazardous situation which could result
in material damage unless prevented.

Gas fired igniter ZA0 / ZDA0
General
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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:
DANGER!
Fatal danger due to electrical current!
… denotes a potentially fatal situation due to
electrical current. Failure to adhere to the safety
instructions can give rise to the danger of serious
injury or death.
The work to be performed may only be carried out
by a suitably qualified electrician.
1.3 Liability disclaimer
All instructions and remarks contained in this operating manual are
collated taking into account applicable standards and regulations,
the state of the art and our many years of experience and
expertise.
The manufacturer is consequently unable to accept any liability for
damage caused 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 parts
The actual scope of the delivery may differ in some details from the
explanations and illustrations provided here in the case of special
versions, where additional optional features are made use of or
due to the latest technical modifications.
Otherwise, the obligations agreed in the Supply Agreement, the
General Terms and Conditions and the Manufacturer’s Conditions
of Supply and the statutory regulations in force at the time of
conclusion of contract shall be applicable.

Gas fired igniter ZA0 / ZDA0
General
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1.4 Copyright protection
These operating instructions may not be shared with third parties.
They are exclusively intended for those operating the gas fired
igniter and may not be made available to third parties without the
prior written consent of the manufacturer.
REMARK!
The information, texts, drawings, illustrations and
other representations are protected by copyright
and are subject to industrial property rights.
Utilization for any other than their intended purpose
renders the perpetrator liable to prosecution.
The contents of all or part of these operating instructions may not
be duplicated in any form, nor may they be used and/or
communicated to any third party without the written consent of the
manufacturer. Any breach of this obligation shall render the
perpetrator liable 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 use original spare parts from the
manufacturer.
Order spare parts through your authorized dealer or directly from
the manufacturer. Address: see table of contents on the cover
sheet.
1.6 Warranty regulations
The warranty regulations are provided as a separate document in
the General Terms and Conditions.

Gas fired igniter ZA0 / ZDA0
General
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1.7 After-sales service
For any technical information, consult our after-sales service.
Information can be obtained at any time by phone, fax, e-mail or
Internet. For the manufacturer’s address, see the cover sheet on
the table of contents.
Our employees are always open to feedback and comments
related to all of our products which could be of use in the continual
and improvement of our products.

Gas fired igniter ZA0 / ZDA0
Safety
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2 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.
2.1 Owner’s responsibility
As the gas fired igniter is used commercially, the owner of the gas
fired igniter is obliged to adhere to occupational safety regulations
as well as any other applicable directives, legislation and
standards.
Alongside the occupational safety remarks contained in these
operating instructions, the safety, environmental and accident
prevention regulations governing the field of application of the gas
fired igniter must be adhered to, whereby the following regulations
in particular apply:
The owner must be aware of the valid occupational safety
regulations and also determine any additional potential hazards
arising as a result of the specific working conditions 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
regulations, and must update these where applicable.
The owner must clearly regulate and define fields of
responsibility for installation, operation, maintenance and
cleaning.
The owner must ensure that all employees involved in working
with the gas fired igniter have read and understood the
operating instructions.
Furthermore, the owner must provide personnel training at
regular intervals and inform staff of potential hazards.
As the owner is also responsible for ensuring that the gas fired
igniter is always in good technical working order the following
requirements additionally apply:
The owner must ensure that maintenance work is performed
regularly.
The owner must regularly check that all safety devices are fully
functional and complete.
The owner must provide the necessary protective gear for
personnel.

Gas fired igniter ZA0 / ZDA0
Safety
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2.2 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.
The following qualifications are required for the various fields of
activity:
Qualified personnel
are capable on the basis of their specialist training, knowledge
and experience as well as their knowledge of the applicable
regulations of executing the work assigned to them and of
independently recognizing possible hazards.
Electrical specialists
are capable on the basis of their specialist training, knowledge
and experience as well as their knowledge of the applicable
regulations 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 applicable
regulations of working on gas installations and of independently
recognizing possible hazards.
Gas specialists have received training specifically for the work
environment in which they are employed and are familiar with
the relevant standards and regulations.
Only persons who may be expected to perform their task reliably
may be authorized to use the equipment. Persons whose reaction
capacity is impaired, for example due to drugs, alcohol or medicine
use, may not be authorized.
When selecting suitable personnel, observe the age and
profession-specific regulations applicable at the place of use.

Gas fired igniter ZA0 / ZDA0
Safety
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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.
–In case of doubt, approach the person in
question and direct them out of the work area.
–Interrupt work for as long as any unauthorized
person remains in the work area.
2.3 Intended purpose of the equipment
The gas fired igniter is exclusively designed to perform the
intended purpose described here.
The gas fired igniter is a piece of equipment that has to be
integrated into a gas-consuming installation. It must not be
operated without an overriding safety control system.
It is designed for the sole purpose 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 igniter when in a
mounted condition. Ensure that the combustion
points created by the flame are fitted with a
suitable extraction facility over the exposed flue
gas channel throughout the plant.
–Only operate the gas fired igniter according to
the specifications indicated on the rating plate.
Otherwise, potential danger of personal or
material damage can arise.
–Adhere to all the instructions provided in this
operating manual without fail.
The manufacturer can not be held liable for physical or material
harm caused by misuse of equipment or use for anything other
than its intended purpose.

Gas fired igniter ZA0 / ZDA0
Safety
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2.4 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.
Observe all signs relating to personal protective gear in the
work area.
To be worn at all times
Wear the following for the performance of all work:
Protective work clothing
This comprises tight-fitting work clothes which are resistant to
tearing, have tight-fitting sleeves and no projecting parts. 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 is covered in depth in the individual chapters of
this instruction manual. These types of special protective gear are
described in the following:
Face protection
To protect one’s eyes and face from flames, sparks or embers as
well as hot particles or flue gases.
Protective gloves
To protect one’s hands from rubbing, chafing, puncturing or deeper
injuries and from contact with hot surfaces.

Gas fired igniter ZA0 / ZDA0
Safety
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2.5 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.
Incorrect 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 the gas fired igniter from dropping down
or falling over.
–Do not stand under the load while lifting or
lowering it and stay out of the danger zone.

Gas fired igniter ZA0 / ZDA0
Safety
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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.
–In the event of damage to the insulation of the
power supply, switch off immediately and
arrange for repairs to be carried out.
–Work on the electrical system may only be
carried out by suitably qualified electricians.
–Before starting work, switch off the power
supply and make sure it cannot be inadvertently
switched back on. Observe the 5 safety rules:
–De-energise.
–Secure against reconnection.
–Ascertain de-energised 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 and the
integrated ionisation flame monitor to the
permitted operating voltage / load according to
the technical data.
–The ionisation flame monitor is only provided as
a built-in appliance in the gas fired igniter.
–The operator/installer is responsible for
adherence to the permitted environmental
conditions and/or ambient atmosphere in
accordance with the technical data.
–Keep moisture away from live components. This
can create a short circuit.
Electrostatic charge (ESD)
CAUTION!
Damage of electronic components due to
electrostatic discharge (ESD)!
Electronic components become steadily smaller
and more complex. This also increases the
susceptibility to electrostatic discharging.
–Take measures to protect the components
against electrostatic discharge.
–Take measures to prevent static charging of the
human body.

Gas fired igniter ZA0 / ZDA0
Safety
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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. Do not use any naked flames or
ignition sources.
–Keep a fire extinguisher on hand.
–Report suspicious substances, liquids or gases
immediately to the responsible officer.
–In case of fire, stop work immediately. Leave
the danger area until the all-clear is given.
Hot surfaces
CAUTION!
Danger of burns due to hot surfaces!
Contact with hot components can cause burns.
–When carrying out any work near hot
components, always wear protective work
clothing and safety 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!
Danger of damage due to special
environmental influences!
Vibrations affecting the gas fired igniter or welding
work performed in the area of the gas fired igniter
can result in damage.
–In order to prevent damage to the gas fired
igniter, it must not be exposed to any vibrations.
–When carrying out any welding work in the area
of the gas fired igniter, it must be electrically
disconnected and removed.
–Before welding work on the outer tube of the
gas fired igniter can be carried out, this must
first be disconnected from the power head.

Gas fired igniter ZA0 / ZDA0
Safety
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2.6 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.
–Observe the instructions provided on securing
against unauthorized switching back on in the
chapters of this operating manual.
–Always observe the procedure described below
to secure against unauthorized switching back
on.
Switch safeguarded by lock
on: …….. at ……hours
DO NOT 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
The lock may only be removed
by: …………………
once steps have been taken to ensure
that no persons are located in the
danger area..
4. Should it not be possible to secure a switch using a lock, set
up a sign.
5. Once all the work has been carried out, ensure that there are
no longer any persons located in the danger area.
6. Ensure that all safety devices are installed and are fully
functional.
7. Only then may the sign be removed.

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Safety
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2.7 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.
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 emergency vehicles.

Gas fired igniter ZA0 / ZDA0
Transport, packaging and storage
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3 Transport, packaging and storage
3.1 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,
and when transporting within the premises, take
extreme care and observe the symbols and
instructions on the packaging.
–Depending on the length of the product and the
scope of delivery suitable lifting equipment
should be used for unloading. The load capacity
of the lifting equipment should exceed the total
weight 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 transport damage, report the
damage immediately, adopting the following procedure:
Only conditionally accept the delivery.
Note the extent of the damage on the transport documents or
on 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. Claims
for damages can only be asserted within the
applicable deadlines for the filing of complaints.

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Transport, packaging and storage
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3.3 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. For this reason, do not destroy the
packaging and only remove it shortly before assembly.
Handling packaging materials
If no outline agreement has been reached for packaging, separate
the materials according to type and size, and send for re-use or
recycling.
NOTE!
Environmental damage due to incorrect
disposal!
Packaging materials are valuable raw materials
and in many cases can be reused or usefully
processed and recycled.
–Ensure environmentally responsible disposal of
packaging 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-free conditions.
Do not expose to any corrosiv substances.
Avoid any drop in temperature below the dew point.
Protect the gas fired igniter from mechanical damage.
Storage temperature: 0 °C to 60 °C
Relative humidity: max. 60 %
When storing for longer than 3 months, regularly check the
condition of all parts and the packaging. If necessary refresh or
replace the conservation.
REMARK!
The packaging units may come with storage
instructions applicable in addition to the
requirements outlined here. These must be
adhered to.

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Specifications
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4 Specifications
4.1 Type designation with type key
Example of type designations with the most important igniter data:
Fig. 1: Type key

Gas fired igniter ZA0 / ZDA0
Specifications
Status: 11-2018 - 19 -
4.1.1 Type key of ionisation flame monitor
Fig. 2: Type key of ionisation flame monitor
1) The designation A0516Z… refers to the internal ionisation flame monitor. The spare parts (incl. according
part numbers) enclosed in the ionisation flame monitor can be found in chapter 11 “Spare parts list”.
4.2 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
Outer tube length from 4000 mm
dia. 48 mm
dia. 50 mm
For the stainless steel version always dia. 50 mm
Design pressure gas flange
max. 10 bar
Gas port
Rp ½, left or right
Maximum counter pressure in gas fired igniter
housing
200 mbarg overpressure
Air port
Rp 1, rotatable 4 x 90°
Air volume
max. 50 m³/h
Air temperature
max. 80 °C
Relative humidity
max. 70 %
Air quality
free of dust, oil, grease and aerosols

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Specifications
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Characteristic
Value
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 delivery)
approx. 3.5 kg power head with mounting flange +
approx. 3.5 kg/m (length of outer tube in cm, as
indicated in the rating plate)
Total dimensions (depending on scope of delivery)
Length of power head with mounting flange (see
dimensional drawing in section 4.4) + outer tube
length (in cm, as indicated in the rating plate)
4.3 Power head
Characteristic
Value
Supply voltage of ionisation flame monitor
230 V AC +10%/-15%, 50/60 Hz (standard)
or in accordance with rating plate
Supply voltage of spark transformer
Primary:
230 V AC, 50/60 Hz (standard)
or in accordance with rating plate
Secondary:
5 kV against ground
Protection rating
IP 54 (standard) or
IP 65 (special version)
Connection type
Standard version, IP 54, with plug connection,
type ZA..., ZDA...
Electrical connecting plug (10-pin) with 2 cable
glands (M20x1.5) for cable diameter 7 –13 mm;
Line-/screw connection 0.5 –2.5 mm2
(2.5 mm2only without core cable ends)
Connection type
Special version, IP 65, with 7-core control cable,
sealed ionisation flame monitor connection,
type ZA…
Permanently sealed control cable,
wire gauge 1 mm2,
cable diameter approx. 9.5 mm
Connection type
Special version, IP 65, with 12-core control cable,
sealed ionisation flame monitor connection,
type ZDA...
Permanently sealed control cable,
wire gauge 1 mm2,
cable diameter approx. 12.1 mm
Power consumption
Spark transformer:
100 VA (fusing 2 A slow blowing, to be fused
externally)
Ionisation flame monitor:
10 VA (fusing 2 A slow blowing, to be fused
externally)