06hegw 1
06hegw 1
06hegw 1
70/0e
Gas Ignitor
Maximum heat release: 120 kW (410,000 BTU),
Compact design with ignition transformer and
ionisation flame monitor for
intermittent or continuous operation in
flame proof housing
EEx de IIB T4 or EEx de IIC T4, PTB-approved
Model ZAVEX/0...
09/02
man_zavex0_2700e_0902_uk
Table of Contents
1. Part Numbering System ................................................................................................................ 3
2. Technical Data ............................................................................................................................. 4
3. Storage and Installation Instructions ............................................................................................... 4
4. Flame Monitoring .......................................................................................................................... 5
5. Construction According to Sectional Drawing.................................................................................. 5
6. Part List ....................................................................................................................................... 7
7. Accessories.................................................................................................................................. 8
8. Electrical Connection .................................................................................................................... 9
9. Setting the Required Gas Flow .................................................................................................... 10
10. Setting the Required Air Flow ...................................................................................................... 10
11. Maintenance and Alignment ........................................................................................................ 11
10. Electrical Function Test (without Flame) Using A10Z1 Test Diode .................................................. 13
11. Gas- and Air-Regulating Components (to be ordered separately)................................................... 14
14. Approval .................................................................................................................................... 15
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ZAVEX/0...
Basic
model
P (Propane/Butane) 50 - 150
P20, P30 200-300/300-400
P40, P50, P60 400-500/500-600/600-700
P70, P80, P90 700-800/800-900/900-1000
P100, P200 1000-2000/2000-3000
Characters A to Z Tube
components
Characters A to L Nozzles
Characters A to Z Transformer
components
e.g.
B = Special paint
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2. Technical Data
Burner Portion
Heat release ................................ max. 120 kW (400,000 BTU)
Flame length ................................ max. 600 mm (approx. 23.5“)
Tube length.................................. lengths available from 240 –15,000 mm, in 10 mm increments
Gas connection ............................ ¾", from top or bottom
Air connection .............................. 1 ½“, may be rotated in increments of 90°
Air flow ........................................ max. 50 m3/h
Air ratio ........................................ 0.3 – 0.5; remainder must be available from combustion chamber
itself
Maximum ambient temperature ..... ignitor tube: 500°C (932°F); if temperature is higher, combustion air
must be left on to serve as cooling air. At temperatures > 700°C
(1292°F), additional cooling air must be supplied in the gap between
the guide tube and ignitor tube.
Maximum back pressure ............... 200 mbarg inside the ignitor housing
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ZAVEX/0...
4. Flame Monitoring
The flame is monitored using an ionisation electrode. The direct current serves as the flame signal. This
direct current flows via the flame from the ignitor tube ground to the ionisation electrode, and to the flame
monitor via the connecting rod.
The ionisation electrode and the ignition electrode are aligned according to the drawing on page 12. The
electrode support ring is only available as one unit. The electrodes on the support ring are already bent
and aligned.
The internal resistance of the ionisation path is several MΩ. This high resistance creates good insulation
for the electrodes and the connecting rods. Therefore, it is important to clean the insulators more often if
the combustion air contains dust; avoid moisture.
The ceramic insulator for the ionisation electrode may not be heated to temperatures exceeding 500°C
(932°F), since this may cause the ignitor to fault. It is therefore necessary to allow at least a minimum
quantity of air (10-20% of full load) to flow if, with the ignitor flame shut off, this temperature could still be
reached in a hot combustion chamber through either radiation or convection.
Caution: Do not leave the ignition voltage on during any of the safety time. An ignition-free period
of approx. 0.5 seconds must be guaranteed, since the high voltage can suppress the ionisation
signal.
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6. Part List
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7. Accessories
The ignitors can be connected to the following devices:
It must be ensured the ignition voltage (terminal 8 on the ignitor) is shut off before the end
of the ignition safety time, so that there is a brief segment of time without ignition. The
high-voltage spark gap can suppress the ionisation signal to such an extent that the flame
relay cannot close.
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ZAVEX/0...
8. Electrical Connection
Terminals in (Ex)e
junction room
PE
1 N
Ionisation Mains
2 L
Gas nozzle
Ground
Ignition
8 L Ignition voltage
9 Flame signal output
10 > 90 VDC
Terminals in (Ex)e
junction room
2 8
1 9
10
Electrical wiring
Make sure that external cables are connected properly. Tighten the strain relief nuts of the glands once
the cables have been introduced into the ignitor’s junction room. Local regulations should be adhered to.
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ZAVEX/0...
150
P M N
100
80
70
60
50
2 3 4 5 6 7 8 9 10 15 20 30 40
m3/h
Character Type of Gas Nozzle Orifices (mm) Flame Length (mm)
P Propane gas 1 x 2.5 + 6 x 1.0 approx. 600
M Natural gas 1 x 4.0 + 6 x 1.3 approx. 500
N Coke oven gas 1 x 5.0 + 8 x 2.3 approx. 500
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ZAVEX/0...
Transformer Part
The transformer module with the ionisation flame monitor is completely interchangeable. To do so, the
outer tube must be detached, and the electrode support ring (item 10) and the two 3 mm rods (item 8)
must be removed. The gas tube must then be unscrewed.
Caution: If necessary, remove the pressure-reducing restrictors, which are screwed in to the two
threaded gas inlets, and put them into the new transformer module.
Electrode Support Ring (subject to wear and tear, exempted from manufacturer´s warranty)
Remove the ignitor tube and loosen the locking screw on the support ring. The ring may then be removed
from the gas tube. Slide in the new ring, insert the connecting rods into the sockets and tighten the
locking screw. The electrode support ring is placed approx. 55 mm behind the gas nozzle. The alignment
of the electrodes is described on page 12. The electrode support rings are normally delivered with the
electrodes already bent. Only if individual electrodes are ordered is it necessary to bend, shorten and
align them once they are in place.
Intermediate Support Ring (for tube lengths greater than 600 mm)
Remove the ignitor tube and electrode support ring. Loosen the locking screw of each support ring and
remove them from the tube. Slide on the new intermediate support rings and insert the connecting rods.
The intermediate support rings should be spaced at intervals of 300 mm from one another. Finally, the
electrode support ring is slid onto the gas tube and the connecting rods are inserted into the sockets on
the ring. Tighten all locking screws on the support rings, while observing that the rods do not become
twisted.
Note
• Installation and maintenance procedures may only be carried out by authorized personnel.
• All local regulations must be observed during installation.
• Improper installation, alignment and maintenance, as well as modifications by the customer,
can all lead to personal injury or damage of equipment!
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Front view
2 - 3 mm
Side view
Grounding rod
110
45
35
10
78
Top View
Z545F111 Ceramics
Z789F101 Sockets
Ionisation Electrode
10 Grounding Rod
Ignition Electrode
W715F101 Washers
Z707F3 Spare Electrodes
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10. Electrical Function Test (without Flame) Using A10Z1 Test Diode
This test diode is employed to perform a purely electrical function test.
Ignition
Create an electrical connection to the separate burner control and apply power. The spark gap between
the ignition electrode and grounding rod must be visible.
If a spark cannot be seen, or if the device is arcing poorly, the following may be responsible:
a) Internal ignition components are damp or dirty: loss of high voltage occurs via the ceramic
insulators to ground.
b) One or several of the ceramic insulators are broken.
Spark discharge also is occurring to ground: remove the ignitor tube (see above), check the
insulators and replace if necessary.
c) If there is no spark what ever, check the wiring to the high voltage plug. If the wiring is in order, it
may be necessary to replace the transformer module or simply the individual transformer.
Ionisation
With the aid of the A10Z1 test diode, one may simulate a flame signal to the flame monitor, once power is
applied. The diode must be held between the ground and ionisation electrode (be sure to note the
polarity!)
Contact to ground,
i.e. ignitor tube Caution!
High Voltage: Do not
touch the ignition
electrode!
Contact to ionisation
electrode
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ZAVEX/0...
Locking Screw
Size 50
60
1½"
1"
1"
70
59
Size 25 Size 30
1/2”
1/2”
½"
¾"
44
25
Z 845 Z3 Ball Valve (for setting the gas flow Z 950 F2/00V Reducing Nipple
pressure) Galvanized GTW 40 cast iron
Housing: Ms 58 brass
Gaskets: Teflon
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14. Approval
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