2.

35/0Ae

Heavy Duty Gas Ignitor

Maximum heat release: 120 kW (410,000 BTU),
Compact design with ignition transformer and
ionisation flame monitor in
EC-tested and approved design

Model ZA0...
for intermittent operation

Model ZDA0...
for continuous operation

03/00
345331588.doc

Georg Hegwein GmbH & Co. KG Am Boschwerk 7 70469 Stuttgart

Telefon +49 711 135788-0 Fax +49 711 135788-5 E-mail: Hegwein@durag.de
ZA0... / ZDA0...

Table of Contents

1. Part Numbering System......................................................................................................................... 3

2. Technical Data....................................................................................................................................... 4
3. Installation Instructions.......................................................................................................................... 4
4. Flame Monitoring................................................................................................................................... 5
5. Construction According to Sectional Drawing........................................................................................ 5
6. Parts List................................................................................................................................................ 7
7. Accessories........................................................................................................................................... 9
8. Electrical Connection........................................................................................................................... 10
9. Setting the Required Gas Flow............................................................................................................ 11
10. Setting the Required Air Flow............................................................................................................... 11
11. Maintenance and Alignment................................................................................................................ 12
12. Electrical Function Test (without Flame) Using A10Z1 Test Diode.......................................................14
13. Gas- and Air-Regulating Components (to be ordered separately).......................................................15

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ZA0... / ZDA0...

1 Part Numbering System

The example below shows how the most important ignitor information is incorporated into the part
number:
M a r k in g s
fo r s p e c ia l
Z A 0 ... o r Z D A 0 - 1 2 0 M 2 0 / m o d e ls

T y p e Z A ... F la m e m o n ito r f o r in t e r m it t e n t o p e r a t io n B a s ic
T y p e Z D A ... F la m e m o n ito r f o r c o n tin u o u s o p e r a t io n m odel

G iv e n in c m ( e .g . 1 2 0 0 m m ) T u b e le n g t h
T y p e o f g a s w ith
Type of gas In le t p r e s s u re / m b a r
p re s s u re ra n g e s
M (n a tu ra l g a s ) 5 0 - 150
M 20, M 30 2 0 0 -3 0 0 /3 0 0 -4 0 0
M 40, M 50, M 60 4 0 0 -5 0 0 /5 0 0 -6 0 0 /6 0 0 -7 0 0
M 70, M 80, M 90 7 0 0 -8 0 0 /8 0 0 -9 0 0 /9 0 0 -1 0 0 0
M 100, M 200 1 0 0 0 -2 0 0 0 /2 0 0 0 -3 0 0 0
N (m a n u fa c tu r e d g a s /
c le a n e d c o k e o v e n g a s ) 5 0 -1 5 0
N 20 2 0 0 -3 0 0
N 30 3 0 0 -4 0 0

P (P r o p a n e /B u ta n e ) 5 0 - 150
P 2 0, P30 2 0 0 -3 0 0 /3 0 0 -4 0 0
P 4 0, P50, P60 4 0 0 -5 0 0 /5 0 0 -6 0 0 /6 0 0 -7 0 0
P 7 0, P80, P90 7 0 0 -8 0 0 /8 0 0 -9 0 0 /9 0 0 -1 0 0 0
P 1 00, P 200 1 0 0 0 -2 0 0 0 /2 0 0 0 -3 0 0 0

Tu be
C h a ra c te r s A to Z
c o m p o n e n ts
e .g .
D = in n e r tu b e c o m p o n e n ts i n s ta in le s s s t e e l
E = o u te r tu b e s ta in le s s s te e l
N = o u te r tu b e a n d in n e r tu b e c o m p o n e n ts
in s ta in l e s s s t e e l

C h a ra c te r s A to L N o z z le s

C h a ra c te r s A to Z T ra n s fo rm e r
c o m p o n e n ts
e .g .
K = T ra n s fo rm e r m o d u le s e a le d , IP 6 5 (N E M A 4 x ),
c o n n e c ti n g c a b le > 5 m p e r m a n e n t ly c o n n e c t e d

C h a ra c te r s 5 -9 a n d A to R
L e n g th s o f th e
c o n n e c tin g c a b le s
5 -9 = 5 , 6, 7, 8, 9 m
A = 1 0 m
F = 1 5 m
L = 2 0 m
M = 2 5 m
N = 3 0 m
R = 4 0 m

C h a ra c te r s 1 -8 a n d A to W S p e c ia l v o lta g e s
e .g .
B = 240 - 250 V 50 / 60 Hz
C = 120 - 125 V 50 / 60 Hz
M = 11 0 - 11 5 V 50 / 60 Hz

3
ZA0... / ZDA0...

2 Technical Data
Burner Portion
Heat release...................................max. 120 kW (410,00 BTU)
Flame length...................................max. 600 mm (approx. 23.5)
Tube length....................................lengths available from 240 15000 mm, in 10 mm increments
Gas connection..............................1/2", from left or right
Air connection.................................1, 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: 500C (932F); if temperature is higher, combustion air
must be left on to serve as cooling air, and a stainless steel outer tube
must be used. At temperatures > 700C (1292F), additional cooling
air must be supplied in the gap between the guide tube and ignitor.
tube.

Transformer and Flame Monitor

Operating voltage (Flame monitor). 220/ 230 V 50/ 60 Hz (standard), or as specified in the part number
Ignition transformer........(primary) 220/ 230 V 50/ 60 Hz (standard),
or as specified in the part number
(secondary) 5 kV to ground
Enclosure rating.............................IP 54 (NEMA 4) (standard) or IP 65 (NEMA 4x) (special)
Connection type.............................plug connection (IP 54 version),
permanently sealed control cable (IP 65 version)
Power consumption........................ignition transformer: 100 VA
flame monitor: 10 VA
Duty cycle.......................................ignition transformer: usually limited to 2 3 s by the burner control
15% duty cycle (cycle time 3 min. = 100 %)
primary thermal winding protection
Flame monitor: any flame monitor: any
Ambient temperature......................0C to +60C (+32F to +140F), where EC approval is required,
otherwise, -20C to +60C (-4F to +140F)

May be connected to controllers on page 9.

3. Installation Instructions
If the tube is longer than 3 m (approx. 118), the ignitor must be provided with a guide tube. This prevents
the tube from bending too much. The end of the ignitor tube should project at least 150 mm (approx. 6 in)
from the end of the guide tube, if the ambient heat does not require otherwise.
The gap between carrier tube and ignitor tube ought to be 5 mm (app. 0,2) or more.
In case of higher furnace pressures additional cooling air may be supplied into the gap through a
separate port.

4
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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 burning of the ignitor flame is indicated by the yellow LED below the
plug connection on the transformer and flame monitor module (this does not apply, however, to special
models with an IP65 enclosure rating).
The ionisation electrode and the ignition electrode are aligned according to the drawing on page 13. If
new electrodes are employed, they must be bent accordingly, shortened and aligned. It is recommended
that a complete electrode support ring instead be ordered. The electrodes on the support ring are already
bent and aligned.
The internal resistance of the ionisation path is several M. This high resistance requires 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 500C
(932F), 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.

5. Construction According to Sectional Drawing

(see also page 6)
The ignitor consist essentially of the transformer module (item 1 or 2), into which the ignition transformer
and flame monitor are built, the ignitor tube with air/mounting flange (6), gas tube (9) and nozzle (11), as
well as the electrode support ring (10). The ignitor tube, which includes the air connection, is threaded
onto the transformer module, and, after loosening four screws (4), can be detached or rotated in 90
increments according to the location of the air supply. When rotating the tubes, one must be careful not to
twist the inner support rings and rods. This could disrupt operation of the ignitor.
The gas connection can be made from either the above or below. The unused opening is plugged with a
stopper into which the gas pressure test nipple (3) has also been screwed. The electrode support ring
(10) is attached to the end of the gas tube. The ionisation and ignition electrodes are lengthened with
connecting rods (8). These rods are guided via two ceramic insulators through the floor of the transformer
housing and are supported every 300 mm by intermediate support rings (7).

5
 S ta n d a r d m o d e l: tr a n s fo r m e r m o d u le e n c lo s u r e r a t in g IP 5 4 (N E M A 4 ) , w ith p lu g c o n n e c tio n
P ilo t b u r n e r in n a t u r a l g a s o r
330
p ro p a n e m o d e l
83
A t t u b e le n g th s > 4 0 0 0 m m , a n d f o r
1 .5 1 .2 1 .6 1 .1 1 .3 1 .4 1 .6 3 1 .7 32 6 7 8 9 10 a ll s t a in le s s s te e l t u b e s , t h e o u te r
ZA0... / ZDA0...

Rp 1 tu b e d ia m e te r is 5 0 m m !

11 12
G as L u ft

Ignitor Sectional Drawing

R p 1 /2

S ig n a l la m p 9 100
F la m e b u r n in g 2 4 0 - 1 5 ,. 0 0 0 m m
4
A
5
1 A i r te s t n ip p le

V ie w A 82
300

G a s t e s t n ip p le
3
80

0
10
11
44

S p e c ia l m o d e l: T r a n s f o r m e r m o d u le s e a le d t o m e e t IP 6 5 /N E M A 4 x ) ,
w it h c o n n e c tin g c a b le 63
M o u n t in g u s in g
A ll e n S c r e w s
H o u s in g m a t e r ia l G A l
C o n n e c t in g c a b le

6
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 ZA0... / ZDA0...

6. Parts List

Item. Qty. Description Part Number Voltages Material Remarks

1 Complete transformer Z860K2 220/230V Standard model
and flame monitor Z860K2/00M 110/115V Special model
module for ZA1... Z860K2/00C 120/125V Special model
Z860K2/00B 240/250V with housing, Special model
1 plug connection
1 for ZDA1... Z860K3 220/230V and gas flange Standard model
Z860K3/00M 110/115V Special model
Z860K3/00C 120/125V Special model
Z860K3/00B 240/250V Special model

1.1 42 Mounting screws M4 Allen screws

1 Single flame monitor Z341K2 220/230V Standard model
for ZA1... Z341K2/00M 110/115V Special model
Z341K2/00C 120/125V Special model
Z341K2/00B 240/250V with front plate Special model
1.2 and
1 for ZDA1... Z341K3 220/230V Standard model
plug connection
Z341K3/00M 110/115V Special model
Z341K3/00C 120/125V Special model
Z341K3/00B 240/250V Special model

1.3 1 Single ignition Z550K230 220/230V Standard model

transformer Z550K00F 110-125V without housing Special model
Z550K00B 240/250V Special model

1.4 1 Contact spring W509F1

1.5 1 90plug with 2 Pg 13.5 A5Z1 10-pole,
cable glands max. 2.5mm2
(AWG 14)
1.6 2 Gasket Z460F1 Rubber
(buna N)
1.7 1 Gasket Z863F1 Frenzelite or Asbestos-free
similar
1 Complete transformer Z860K7_ _ _ Special model instead of Item 1:
and flame monitor With supplementary information indicating cable
module/ length and voltage requirements
2 IP65 (NEMA 4X)
(see Part Numbering System, p.3)
for ZA0...
1 for ZDA0... Z860K8_ _ _
3 1 Gas pressure test Z138Z2 or MS58 Standard
nipple Z138Z102 Stainless steel Special model

4 4 Allen screw W826F108 Stainless steel

5 1 Air pressure test nipple Z138Z1 Brass Ms58 Standard
or
Z138Z101 Stainless steel Special model
6 1 Ignitor tube, complete Z1050Z_ _ _ Tube length Steel Standard model
with mixing chamber, or given should
mounting flange and air Z1056Z_ _ _ be the same Stainless steel Special model
flange as that in the
part number Can be rotated in
for the ignitor increments of 90

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7 * Intermediate support Z960K4 St VII 23 *Qty. required

ring with 2 ceramic or depends on tube
insulators (Z545F11) Z960K104 Stainless steel length:
3 rings per meter
8 2 Connecting rods Z675F_ _ _ Stainless steel 3.0 mm
Please state type
of ignitor in your
order
9 1 Gas tube Z521F_ _ 15 x 3 St 35, Standard
or galvanized or
Z521F _ _E stainless steel Special model
Please state type
of ignitor in your
order
10 1 Electrode support ring Z960K13 or St VII 23 Standard
with 2 ceramic Z960K113 Stainless steel Special model
insulators (Z545F111)
and 2 electrodes
(Z707F3)
Gas Natural gas Z330F4013 Stainless steel Standard
nozzle 1.4104
Propane gas Z330F2510 Stainless steel Standard
11 1
1.4104
Coke oven Z985F1 Stainless steel Standard
gas 1.4104
12 - Mixing chamber with Component 48 mm Stainless steel, Ignition proof
mixing ring part of item 6 100 mm long heat-resistant, to 1180C (2156F)
Mat.1.4841

8
ZA0... / ZDA0...

7. Accessories
The ignitors can be connected to the following devices:

AAUS 620 L20 Controller

for intermittent operation,
modular unit
230V 50/60 Hz IP 40
please also refer to the separate description 1.86Se of this product

AASD 820 L20 Controller

for continuous operation,
modular unit
230V 50/60 Hz IP 40
please also refer to the separate description 1.86De of this product

A600 K1 Burner Control

for intermittent, continuous and 72-hour operation,
available as a modular unit or 19 rack module
115V/ 230V; 50/ 60Hz
please also refer to the separate description 1.95e of this product

A240 K3/306 Controllers safety time 3 seconds

for intermittent or continuous operation, (5 or 8 seconds also available)
European standard size PC board, 19 rack module
24V DC
please also refer to the separate description 1.93e of this product

A285 K2.1 Flame Relay

with 2 volt-free relay contacts,
35 mm top hat mounting rail according to EN50022
For burner management systems that meet the applicable standards and requirements for safety-
related integration of the ignitor.

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.

Please also refer to the separate description 1.75e of this product.

9
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8. Electrical Connection
P lu g t e r m in a ls
S ta n d a r d m o d e l, IP 5 4 (N E M A 4 )
w it h p lu g c o n n e c t io n
PE
T y p e Z A 0 ..., Z D A 0 ...
1 N S u p p ly v o lt a g e
Io n is a tio n 2 L ( F la m e m o n it o r )
2AT 3 B r id g e * )
G a s n o z z le
K1 4 T e r m in a ls . 4 - 6
F la m e r e la is o n ly f o r
5 T y p e Z D A 0 ...
G ro u n d
6 m in . 6 0 V , m a x . 2 5 0 V , D C /A C
7 m ax. 2A ohm .
I g n it io n
8 L I g n it io n tr a n s fo r m e r
9 F la m m e n s ig n a l
10 90 VD C

S ig n a l la m p
F la m e b u r n in g

C o n n e c t in g c a b le
S p e c ia l m o d e l, IP 6 5 (N E M A 4 x ) w ith n u m e r ic c o d e
w it h 7 -c o n d u c to r c o n n e c tin g c a b le , tr a n s f o r m e r m o d u le s e a le d
T y p e Z A 0 ... 1
N
2
L
Io n is a tio n 3
N I g n it io n tr a n s fo r m e r
B r id g e * )
G a s n o z z le

G ro u n d

I g n it io n
4 L I g n it io n tr a n s fo r m e r
5 F la m e s ig n a l
6 90 VD C

P E ( G r e e n / y e llo w )

C o n n e c t in g c a b le
S p e c ia l m o d e l, IP 6 5 (N E M A 4 x ) w ith n u m e r ic c o d e
w it h 1 2 - c o n d u c t o r c o n n e c t in g c a b le , t r a n s fo r m e r m o d u le s e a le d
T y p e Z D A 0 ... 1 N S u p p ly v o lt a g e
Io n is a tio n 2 L ( F la m e m o n it o r )
3 N I g n it io n tr a n s fo r m e r
G a s n o z z le 4 B r id g e * )
K1
5 T e r m in a ls . 4 - 6
F la m e r e la is
G ro u n d 6 F u s e p r o te c t io n
2 A s lo w
I g n it io n b y c u s to m e r
8
L I g n it io n tr a n s fo r m e r
9
F la m e s ig n a l
10 90 VD C
P E ( G r e e n / y e llo w )

Power supply according to the name plate on the ignitor

*) Bridge 1-3 if the transformer and flame monitor voltages have the same phases

10
ZA0... / ZDA0...

9. Setting the Required Gas Flow

The ignitor operate in a pressure range of 50-150 mbarg, which may be measured using the gas
pressure test nipple (item 3/ sectional drawing). The gas flow can be selected according to the
diagram below. Pressure is set using a ball valve to a value of 100 mbar.
If, when placing an order, a higher gas pressure is given, then pressure-reducing restrictors are screwed
into the threads of both gas inlets at the factory. This allows the pressure of the ignitor to be set to a level
above 150 mbar. If high admission pressure is available at the plant, then pressure can be restricted to
levels below 150 mbar using the ball valve.
At admission pressure levels above 500 mbar, this setting becomes extremely difficult. In these cases one
should request from Hegwein the appropriate pressure-reducing restrictors and indicate the admission
pressure.
200
m b a rg

150

P M N
100

80
70

60

50

2 3 4 5 6 7 8 9 10 15 20 30 40
m 3/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

10. Setting the Required Air Flow

The required air flow or air pressure basically depends on the length of the ignitor tube. 15 mbar of flow
pressure are required for tube lengths up to 1 m, with an additional 10 mbar for each additional meter.
For example, the air pressure on a ignitor with a tube length of 5 m must be set to 15 mbar + 4 x 10, for a
total of 55 mbar.
The blower pressure has to be reduced by an air regulating sleeve to the actually required flow pressure
stipulated by the ignitors tubelength. Any furnace backpressure have to be compensated. The flow
pressure can be picked up at the air pressure test nipple (item 5/ sectional drawing).
Varying back pressures with fluctuations exceeding 20% require a differential pressure regulator on the
air supply side.
If the air pressure has been set correctly, the following will occur:
1. Immediate ignition
2. Good optical flame image / flame signal > 90VDC
3. Flame length approx. 500 mm at a maximum capacity of 120 kW (approx. 410,000 BTU)

11
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11. Maintenance and Alignment

These ignitor do not require any special maintenance. They should, however, be checked periodically
(e.g., every 3 months) for proper operation.
If the ignitor are operated using air that contains dust, this check should be performed at shorter intervals,
since electrically conductive dirt deposits or moisture on the ceramic insulators can lead to a fault in the
ignitor.
The intrinsic impedance of the ionisation path amounts to several M. Such high resistance requires that
the ceramic insulators be in perfect condition.

Performing Maintenance and Replacing Worn Parts

(please compare to the sectional drawing)
Ignitor Tube (may be rotated in 90 increments)
After loosening the four screws (item 4), the tube may be removed. Depending on the position of the air
connection, the tube may be turned and tightened.

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.
If only the ionisation flame monitor item 1.2 is to be replaced, loosen the 2 screws (item 1.1),
carefully remove the flame monitor with the housing and disconnect the four-pole plug
connection.
The ignition transformer may likewise be replaced by itself. After removing the flame monitor as
described above, the mounting screws of the ignition transformer are accessible. Loosen 4
screws item and remove the housing.
Caution: When reassembling the ignitor, be certain that the contact spring (item 1.3) is again in
the correct position.

Electrode Support Ring

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. 50 mm behind the gas nozzle. The alignment
of the electrodes is described on page 13. 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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F r o n t v ie w

2 - 3 m m
S id e v ie w
G r o u n d in g r o d

11 0
45

35

10

78

T o p V ie w
Z 5 4 5 F 1 1 1 C e ra m ic s
Z 7 8 9 F 1 0 1 S o c k e ts
I o n is a t io n E le c t r o d e

10 G r o u n d in g R o d

I g n it io n E le c t r o d e

W 7 1 5 F 1 0 1 W a s h e rs
Z 7 0 7 F 3 S p a r e E le c tr o d e s

Part Numbers for Individual Orders.

Alignment of the Z960K13 and Z960K113 Electrode Support Rings

Complete with ceramics and pre-bent electrodes

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12. Electrical Function Test (without Flame) Using A10Z1 Test Diode
This test diode is employed to perform a purely electrical function test.

Caution: The gas valve must first be closed!

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

Once contact is made, the burner control should go into operation.

If there is no flame signal, the following should be checked:

a) Is the supply voltage present on terminals 1-2?
b) Is the polarity of the test diode correct?
c) Are the ceramic insulators damp, dirty or broken?
Remedy: If so, clean or replace. If necessary replace the flame monitor module (item 1.2).

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13. Gas- and Air-Regulating Components (to be ordered separately)

L o c k in g S c r e w

S iz e 4 1
60

1
1"
53
70

Z 945 Z 2/0FV Air Regulator Z 946 F 3/00V Double Nipple

Housing: galvanized GTW 40 cast iron Galvanized GTW 40 cast iron
Cone: Ms 58 brass
Cover: Ms 58 brass

S iz e 2 5
1 /2

1 /2

44

Z 845 Z3 Ball Valve (for setting the gas flow pressure)

Housing: Ms 58 brass
Gaskets: Teflon

15