Man Zxpa1 en

Operating Manual
Gas fired igniter

for hazardous area,
zone 2 or zone 22
ZX/PA1 // ZX/PDA1
© 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: 02-2019
Gas fired igniter ZX/PA1 // ZX/PDA1
Contents
1 General ....................................................... 3 5.4 Air adjusting components (accessories) ... 26

1.1 Information on the operating manual ........... 3 5.5 Electrical wiring versions ........................... 26
1.2 Explanation of symbols ................................ 3
1.3 Liability disclaimer ....................................... 4 6 Installation and initial commissioning .. 27
1.4 Copyright protection .................................... 4 6.1 Safety ........................................................ 27
1.5 Spare parts .................................................. 5 6.2 Installation and electrical connection ........ 29
1.6 Warranty regulations ................................... 5 6.3 Electrical function test ............................... 33
1.7 After-sales service ....................................... 5 6.4 Setting the required air volume ................. 35
6.5 Setting the required gas volume ............... 36
2 Safety .......................................................... 6 6.6 Checking the setting result ........................ 37
2.1 Owner’s responsibility.................................. 6
2.2 Operating personnel .................................... 7 7 Operation ................................................. 38
2.2.1 Requirements .............................................. 7 7.1 Safety ........................................................ 38
2.2.2 Unauthorized persons ................................. 8 7.2 Operation................................................... 38
2.3 Intended purpose of the equipment ............. 8 8 Maintenance ............................................ 39
2.4 Personal protective gear.............................. 9 8.1 Safety ........................................................ 39
2.5 Special dangers ......................................... 10 8.2 Maintenance, general................................ 39
2.6 Securing against unauthorized switching 8.3 Conditions for maintenance work .............. 40
use ............................................................. 13
8.3.1 Exchanging the outer tube ........................ 41
2.7 Response in case of danger or accident ... 14
8.3.2 Exchanging the power head...................... 42
3 Transport, packaging and storage ........ 15 8.3.3 Exchanging the final electrode support
3.1 Safety instructions for transport ................. 15 ring ............................................................ 43
3.2 Transport inspection .................................. 15 8.3.4 Exchanging the intermediate support
rings ........................................................... 44
3.3 Packaging .................................................. 16
8.4 Actions following completed maintenance
3.4 Storage conditions ..................................... 16 work ........................................................... 44
4 Specifications .......................................... 17 9 Troubleshooting ...................................... 45
4.1 Type designation with type key ................. 17 9.1 Safety ........................................................ 45
4.1.1 Type key of ionisation flame monitor ......... 18 9.2 Troubleshooting table ................................ 46
4.2 Gas fired igniter ......................................... 18
4.3 Power head ............................................... 19 10 Dismantling / Disposal ............................ 49
4.4 Dimensional drawing ................................. 21 10.1 Safety ........................................................ 49
4.5 Rating plate of gas fired igniter .................. 21 10.2 Dismantling................................................ 49
4.5.1 Rating plate of ionisation flame monitor .... 22 10.3 Disposal..................................................... 50
4.6 Service life ................................................. 23 11 Spare parts list ........................................ 51
5 Functional characteristics and 11.1 Spare and wearing parts ........................... 51
structure ................................................... 24
12 Annex ....................................................... 52
5.1 Functional characteristics .......................... 24
12.1 EU type examination certificate (DVGW) .. 52
5.2 Structure .................................................... 24
12.2 Type examination certificate (IBExU) ........ 54
5.3 Flame monitoring ....................................... 25
12.3 Declaration of conformity .......................... 59
5.3.1 Safety time (flame failure detection time
FFDT) ........................................................ 25
-2- Status: 02-2019

General
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!
in minor or slight injury unless prevented.
NOTE!
in material damage unless prevented.
Status: 02-2019 -3-

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:
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.
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.
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General
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.
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.
Status: 02-2019 -5-

Safety
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 operator shall record in the document on the protection
from explosions all measures taken to protect the employees.
 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.
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Safety
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
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
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.
Status: 02-2019 -7-

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.
– 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.
According to the current directive the gas fired igniter must
only be operated in hazardous area zone 2 or zone 22.
It is designed for ignition and warm-up of boilers according
to American standard.
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.
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Safety
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 When performing special types of work, special safety equipment
work 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.
Status: 02-2019 -9-

Safety
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.
Flammable atmosphere DANGER!

Danger of explosion due to flammable
atmosphere!
Atmospheres susceptible to explosions can
endanger the staff´s protection of health and
safety.
– The operator shall define zones in such areas
where a flammable atmosphere might be
prevalent at times. Further to that he shall make
sure that the organizational and technical
minimum requirements outlined in the directive
are adhered to.
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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.
– 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.
Status: 02-2019 - 11 -
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. 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.
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Safety
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 Securing against unauthorized use

on: …….. at ……hours 1. Switch off the power supply.
DO NOT SWITCH ON 2. If possible, secure the switch with a lock and attach a sign in
The lock may only be removed an easily visible location at the switch.
by: ………………… 3. Have the key looked after by the employee named on the
once steps have been taken to ensure sign.
that no persons are located in the
danger area.
Switched off 4. Should it not be possible to secure a switch using a lock, set
on: …….. at ……hours up a sign.
DO NOT SWITCH ON 5. Once all the work has been carried out, ensure that there are
The lock may only be removed no longer any persons located in the danger area.
by: ………………… 6. Ensure that all safety devices are installed and are fully
functional.
once steps have been taken to ensure
that no persons are located in the 7. Only then may the sign be removed.
danger area..
Status: 02-2019 - 13 -
Safety
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.
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Transport, packaging and storage
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.
Status: 02-2019 - 15 -
Transport, packaging and storage
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:
 The unit shall be stored neither outdoors nor in the hazardous
area.
 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
4 Specifications
4.1 Type designation with type key
Example of type designations with the most important igniter data:
Fig. 1: Type key
Status: 02-2019 - 17 -
Specifications
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. 600 kW (standard)

max. 1 MW (special version)
Flame length (depending on the gas) max. 2000 mm
Outer tube length

in 10 mm increments from – to 240 - 5000 mm
Outer tube diameter

Outer tube length up to 4000 mm dia. 65 mm
Outer tube length from 4000 mm dia. 70 mm
For the stainless steel version always dia. 70 mm
Design pressure gas flange max. 10 bar
Gas port Rp ¾, top or bottom
Maximum counter pressure in gas fired igniter 200 mbarg overpressure

housing
Air port Rp 1½, rotatable 4 x 90°
Air volume max. 120 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
Air coefficient 0.1 - 0.2

The remaining air volume must be made available
in the combustion chamber.
Maximum ambient temperature of the outer tube see chapter “Installation and electrical connection”
Total weight (depending on scope of delivery) approx. 9.5 kg power head with mounting flange +
approx. 4.5 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

Operational prerequisites Monitoring of the gas and air pressure
Kind of ex-protection Encapsulated device
Ex-rating for gaseous atmosphere

II 3G Ex nC IIC T5 Gc
II 3G Ex nC IIC T4 Gc (special version,

ambient temperature max. + 80 °C)
Ex-rating for dusty atmosphere

II 3D Ex tc IIIC T 100 °C
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 65
Connection type Permanently sealed control cable,

2
Version IP 65 with 7-core control cable, wire gauge 1 mm ,
sealed power head, type ZX/PA... cable diameter approx. 9.5 mm
Inside the hazardous area the free cable end must
be wired to enclosures that offer a standardized ex-
protection.
Connection type Permanently sealed control cable,

2
Version IP 65 with 12-core control cable, wire gauge 1 mm ,
sealed power head, type ZX/PDA... cable diameter approx. 12.1 mm
Inside the hazardous area the free cable end must
be wired to enclosures that offer a standardized ex-
protection.
Status: 02-2019 - 19 -
Specifications
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)
Duty cycle Spark transformer:

actuation via control unit, 100 % duty cycle
Ionisation flame monitor: 100 % duty cycle
Ambient temperature - 20 °C to + 60 °C (condensation must be avoided)
Ambient temperature (special version) - 40 °C to + 80 °C (condensation must be avoided)
Interconnection With Hegwein control units (see chapter “Functional

characteristics and structure”)
Contact load with ZX/PDA configuration at terminals SPDT contact (flame relay),
4, 5 and 6 max. 250 V AC, 1A, cos φ 1 (ohmic), fusing 1A
1) 2)
quick blowing (to be fused externally)
Safety time (flame failure detection time FFDT) ≤ 1 s (optional 3 or 5 s)

Switching threshold ≥ 1 µA
6
Mech. service life of ionisation flame monitor ≥ 1 x 10 switching cycles
Electr. service life of ionisation flame monitor 250.000 switching cycles

1)
Terminal 5: Flame OFF signal, terminal 6: Flame ON signal
2)
The special version with gold contacts is exclusively intended for connecting low power outputs (< 1 VA).
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Specifications
4.4 Dimensional drawing
Fig. 3: Dimensional drawing, gas fired igniter
4.5 Rating plate of gas fired igniter

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 Ex-rating
5 Type examination certificate number
6 Supply voltage
7 Protection rating
Fig. 4: Example for rating plate of gas fired 8 Maximum power consumption
igniter
9 Frequency
10 Serial number (with consecutive device number)
Status: 02-2019 - 21 -
Specifications
4.5.1 Rating plate of ionisation flame monitor
Fig. 5: Example for rating plate of ionisation flame monitor
The rating plate on the built-in ionisation flame monitor is located

on the transformer part front plate and includes the following
information:
1 Manufacturer
2 Manufacturer’s address
3 Type
4 Operating voltage/frequency/power consumption
5 Ambient temperature
6 Protection rating (not built-in IP 00/built-in IP..)
7 Serial number
8 Place holder for international registration mark
9 Date of manufacture (month/year)
10 Before first use, read the operating manual!
11 Article number
12 CE mark, test centre number with year identification
13 Code for internal purposes
14 Safety time (flame failure detection time FFDT)
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Specifications
4.6 Service life
NOTE!
This product does not have an unlimited
service life!
It has been designed for a maximum service life at
nominal load, the mounted ionisation flame monitor
is type approved. In applications involving 50
switching processes per day, this service life is set
at around 10 years. This period can be
substantially reduced in the event of increased
stress (temperature, vibrations, dirt etc.).
– System operators and owners must take the
steps to ensure that regular safety checks are
performed depending on the actually occurring
degree of stress.
– Exchange the gas fired igniter after it has
exceeded the specified service life. After expiry
of the maximum operating period, functional
defects can occur more frequently.
– Check wearing parts independently of actual
stress levels and exchange if required.
Life of the ionisation flame Specification Value Unit

monitors (based on EN 298)
Maximum operating life 250,000 Switch
cycles
Status: 02-2019 - 23 -
Functional characteristics and structure
5 Functional characteristics and structure

5.1 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. The resulting flame generates a flame signal via
the flame rod. This flame signal is amplified in the ionisation flame
monitor and enables the main burner.
5.2 Structure
Fig. 6: Gas fired igniter (sectional drawing)
1 Power head 9 Gas tube

1.1 Control cable 10 Final electrode support ring
1.2 Gas flange 11 Gas nozzle
2 Gas inlet 12 Ignition electrode
3 Gas pressure test nipple 13 Flame rod
4 Allen screw 14 Air port
5 Air pressure test nipple 15 Mixing chamber
6 Outer tube 16 Mounting flange
7 Intermediate support ring with two ceramic 17 Earth rod
insulators 18 Ceramic insulator
8 Connecting rods
The gas fired igniter comprises the following main components:

 the totally sealed power head (1), in which the spark
transformer and the ionisation flame monitor are mounted,
 the complete outer tube (6), incl. mixing chamber (15) and
mounting flange (16) with air port (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).
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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 (2) can be on the top or bottom. The unused opening
is sealed off by a sealing screw, into which a gas pressure testing
nipple (3) is screwed.
The final electrode support ring (10) is fastened on the end of the
gas tube (9).
The flame rod (13) and the ignition electrode (12) are extended by
connecting rods (8). These connecting rods are guided through the
floor of the transformer housing and are supported around every
300 mm by intermediate support rings (7).
5.3 Flame monitoring

The flame is monitored by the flame rod, which must immerse in
the direction of the flame. Alternating voltage is applied to this
flame rod. The burning flame creates an electrically conductive
connection to the igniter earth and at the same time acts as a
rectifier for the ionisation current. This direct current signal is
measured and amplified in the ionisation flame monitor. The
enforced flame signal activates the flame relay with one SPDT
contact (only series ZX/PDA…).
5.3.1 Safety time (flame failure detection time FFDT)

The safety time is the response time of the ionisation flame monitor
as the reaction to a failure of the flame signal (flame sensor
current) and as a result of that the clearing switch of the terminals
for the „flame-on“ signal. The standard safety time is ≤ 1 s (optional
3 or 5 s).
REMARK!
- In the case of a flame monitor exchange, steps
must be taken to ensure that the set safety times
of he devices are identical. The default safety
times is indicated on a type plate of the
transformer part front panel.
- To assess the permitted maximum safety time,
please observe the established safety norm for
which the operator is responsible.
- The default safety times may not be altered, as
this will lead to loss of type approval!
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5.4 Air adjusting components (accessories)

REMARK!
Accessories and special tools have to be ordered
separately.
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 mbarg
Special version (e.g. free of non-ferrous metal) on request.
Fig. 7: Air regulating sleeve
Double nipple Z 946 F 4/00V

 Malleable cast iron, galvanized
 Max. temperature range - 20 °C to + 60 °C
 Max. pressure 300 mbarg
Fig. 8: Double nipple
5.5 Electrical wiring versions

The gas fired igniter can be interconnected with the following units:
 Burner control ASD-75 P0…

for continuous operation or intermittent operation, top hat rail
mounting, 230 V AC, 50/60 Hz (special voltage possible),
see relevant HEGWEIN operating manual
 Flame relay A 285 K2.3

with 2 SPDT contacts, top hat rail mounting, see relevant
HEGWEIN operating manual
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Installation and initial commissioning
6 Installation and initial commissioning

6.1 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.
Basics WARNING!
Danger of injury due to faulty installation and
initial commissioning!
Errors during installation and initial commissioning
can result in potentially fatal situations or entail
substantial material damage.
– Prior to any commissioning/maintenance work
that part of the plant where the gas fired igniter
is installed must be switched off and secured
against accidental restart. All feedlines to the
gas fired igniter must be blocked, emptied and
cleaned, if necessary.
– Before starting work, ensure that there is
sufficient freedom of movement for the
installation work.
– Take care when handling open, sharp-edged
components.
– Ensure that the installation site is clean and
tidy. Loose components and tools lying around
or piled on top of each other are a possible
cause of accidents.
– Assemble components professionally and
correctly, observing prescribed screw tightening
torque levels.
– Secure components so that they cannot drop
down or fall over.
Status: 02-2019 - 27 -
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 flame monitor
signal of the gas fired igniter should be
incorporated into an overriding safety controller.
– On commissioning, it must be ensured that in
the case of a flame signal breakdown, the flame
signal contact opens within 1 s, and leads to
the safety and fault shutdown via the overriding
safety controller.
Monitoring of the gas and air DANGER!

volume flow when using the device Danger of explosion due to faulty monitoring of
in hazardous areas the gas and air volume flow!
Faults in the monitoring of the gas and air volume
flow can lead to extremely dangerous situations or
entail considerable damage to property.
– The gas and air volume flow at site must be
monitored according to the current regulations.
– Make sure that forced draught combustion air is
supplied to the gas fired igniter and that it is
sufficiently purged prior to every re-start.
– Any failure of the forced draught air must lead
to an immediate shut down.
– Even after a shut down of the gas fired igniter a
minimum flow of combustion air shall pass
through the igniter. This prevents the
accumulation of a flammable mixture in the air
flange or in the igniter tube.
Definitions REMARK!
Air inlet pressure/gas inlet pressure:
Air pressure, respectively gas pressure at the gas
fired igniter’s air or gas port.
Air operating pressure/gas operating pressure:
Permissible air pressure or gas pressure to
operate the gas fired igniter. Pressure to be picked
up at the air or gas pressure test nipple.
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6.2 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.
– Only pull out or unplug the connecting plug or
connector, when the operating current of the
gas fired igniter is switched off.
NOTICE!
- Before connection, check whether the gas fired
igniter is suitable for the mains voltage provided.
- The installer/operator is responsible for the
installation of the gas fired igniter into a system,
which fulfils the stated system specific standards
and guidelines.
- The operator/installer is responsible for
adherence to the permitted environmental
conditions and/or ambient atmosphere, in
accordance with the technical data.
1. Prepare the installation location and installation opening.

From an outer tube length of 3 m observe the following:
– Use a push-in tube to prevent sagging of the outer tube.
– The end of the outer tube must project 30 – 80 mm over
the guide tube.
– The annular gap between the outer tube and the guide
tube must be 5 – 15 mm.
Status: 02-2019 - 29 -
2. 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
suitable tool). Select the screw lengths in line with the wall
thickness.
4. At the air port (2), connect a air regulating sleeve for air
volume setting.
5. Connect the combustion air at the air regulating sleeve.
REMARK!
Fig. 9: Installation of the gas fired igniter
Permanent cooling must be provided. At an
ambient temperature of the outer tube between
300 – 500 °C, the combustion air shall be partly
Thread size Tightening
(> 20 %) switched as cooling air.
torque
At an ambient temperature between 500 – 700 °C,
M4 2.5 Nm proceed as follows:
- Switch combustion air completely as cooling air
M5 5 Nm - Use stainless steel outer tube
M6 7 Nm - Provide additional cooling air in the annular gap
between the guide and the outer tube
M8 15 Nm
In the case of an ambient temperature > 700 °C,
1/8“ 5 Nm contact Hegwein.
1/4“ 7 Nm
1/2“ 10 Nm
NOTE!
3/4“ 15 Nm Excessive temperature can cause damage!
1“ 15 Nm In igniters which are designed to permit division or
1 ½“ 20 Nm swivel action, the temperature at the dividing or
swivel joints can cause damage to the gas fired
2“ 25 Nm igniter.
– The temperature at the dividing / moving point
must not exceed 180 °C.
WARNING!
Danger of burns due to wrong type of gas!
Using an incorrect gas type can cause too large an
ignition flame to emerge from the gas fired igniter.
This entails a risk of fatal injury due to serious
burns and danger of fire.
– Only connect the gas fired igniter to the gas
type indicated on the rating plate.
6. At the gas port, connect a pressure setting device (by

customers) for gas volume setting.
7. Connect the gas line at the pressure setting device (by
customers).
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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
relay is not able to pick up. For this reason, the
plant control system must ensure that the ignition
voltage (“spark transformer” terminal) is switched
off before the end of the ignition safety period (see
EN standard 298). This ensures a short ignition-
free period (approx. 0.5 s).
8. Connect the gas fired igniter in accordance with the relevant
terminal diagram.
Version IP 65
with 7-core control cable, sealed power head, type ZX/PA1...
Core Designation Meaning
PE Protective earth conductor
1 N Mains connection, ionisation flame

2 L monitor
3 N
Spark transformer (primary)
4 L
5 +
Flame signal output 90 – 110 V DC
6 -
Fig. 10: Terminal diagram IP 65, 7-core
Status: 02-2019 - 31 -
Version IP 65
with 12-core control cable, sealed power head, type ZX/PDA1...
Core Designation Meaning
PE Protective earth conductor
1 N Mains connection, ionisation flame

2 L monitor
3 N Spark transformer (primary)
4/5/6 * SPDT contact (flame relay),

max. 250 V AC, 1A, cos φ 1 (ohmic),
fusing 1A quick blowing (to be fused
1)
externally)
8 L Spark transformer (primary)
9 +
Flame signal output 90 – 110 V DC
10 -
1)
The special version with gold contacts is exclusively intended for
connecting low power outputs (< 1 VA).
Fig. 11: Terminal diagram IP 65, 12-core
REMARK!
Close the terminal box/connecting plugs and check
whether all seals, cable strain relief devices etc.
are correctly connected.
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6.3 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
 Safety gloves
 Required special tools:
 Test diode A10Z2 (accessory part)
DANGER!
Danger of explosion by formation of sparks
caused by the visual check of the ignition spark
or when applying the test diode!
The formation of sparks in a flammable
atmosphere can result in an explosion or in severe
burns!
– Any checks should be carried out outside of the
hazardous area!
– Avoid flammable atmospheres!
DANGER!
Fatal danger due to electrical voltage or high
voltage!
High voltage is present in the ignition electrode for
ignition purposes. Due to the supply voltage of the
ionisation flame monitor, electrical voltage is also
applied to the flame rod. Contact with the
electrodes could be fatal.
– Never come into contact with the ignition
electrode or the flame rod.
DANGER!
Escaping fuel or the release of other devices
may cause an explosion!
A release of the gas fired igniter can cause the
start of subsequent devices (burners).
– Any other devices such as burners and valves
shall therefore be blocked.
Status: 02-2019 - 33 -
DANGER!
Risk of explosion due to leaking gas!
Accidental gas leaks can cause an explosion or
serious burns!
– Before testing, shut off the gas valve!
– Ensure that no residual gas remains, if
necessary inert the gas lines.
With the aid of test diode A10Z2, it is possible to simulate the flame
signal.
1. Switch off the power (after recommissioning).

2. Open the red terminal (1) of the test diode by pressing
button (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 contact
with the outer tube (5).
7. After contact with the test diode, a direct voltage of
90 – 110 V DC must be measurable at the cores of the flame
signal output.
8. If no flame signal is produced, check the following:
– Is mains voltage present at core 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 the
power head.
Fig. 12: Test diode – Connect the flame rod to the power head.
REMARK!
In case of function problems, turn to the chapter
“Troubleshooting”.
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6.4 Setting the required air volume

 This may only be performed by trained personnel.
 Customarily available pressure gauge with a measurement
range of 0 – 200 mbar
REMARK!
The required air operating pressure depends -
among other things- on the desired gas operating
pressure.
The calculation formula outlined in step 1 refers to
a normal case, i.e. the gas operating pressure is
1000 mbar above the combustion chamber back
pressure.
Any gas operating pressure deviating from this
standard case will require an adaptation of the air
operating pressure.
1. Define the air operating pressure:

A air inlet pressure of 20 mbar plus another 13 mbar for every
m of tube length is required. A gas fired igniter with a tube
length of 5 m should therefore be supplied with
20 mbar + (5 x 13 mbar), i.e. 85 mbar in total (any
backpressures need to be taken into account).
2. Turn the Allen screw (size 2.5) in the centre of the air pressure
1
test nipple (1) 1 /2 turns counter clockwise in order to open
the 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 operating pressure / the air volume using the
air regulating sleeve to the length-dependent value, so at the
same time also compensating for any combustion chamber
back pressure.
Fig. 13: Air pressure test nipple REMARK!

In case of a varying combustion chamber back
pressure with fluctuations greater than 20 %,
integrate an air-side differential pressure regulator.
6. After measurement, remove the pressure gauge.

7. Close the Allen screw.
Status: 02-2019 - 35 -
6.5 Setting the required gas volume

 This may only be performed by trained personnel.
 Additionally required safety equipment:
 Face protection
 Protective gloves
 Customarily available pressure gauge with a measurement
range of 0 – 2000 mbar
DANGER!
Risk of explosion due to gas leaks!
An accidental gas leak can cause an explosion or
serious burns!
– Only unscrew the Allen screw of the gas
pressure test nipple for the duration of the test.
– Never allow any naked flame or ignition source
to enter the danger area.
WARNING!
Risk of injuries – the Allen screw may be
ejected from the gas pressure test nipple!
The high gas supply pressure may cause the
ejection of the Allen screw. This could lead to
injuries.
– Do not unscrew the Allen screw completely.
– Open the Allen screw by 1 ½ turns only.
1. Turn the Allen screw (size 2.5) in the centre of the gas
1
pressure test nipple (1) 1 /2 turns counter clockwise in order
to open the gas pressure test nipple.
2. Connect the pressure gauge to the gas pressure test
nipple (1) immediately.
DANGER!
Fatal danger when executing ignition tests!
When executing ignition tests, a large ignition
flame emerges from the gas fired igniter, which
could fatal burns and also fire.
Fig. 14: Gas pressure test nipple
Ignition tests must be performed when the
equipment is in a mounted status:
– Ensure that the combustion products generated
by the flame are extracted via the opened flue
gas path of the entire plant.
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DANGER!
Fuel leaks or the release of other devices may
cause an explosion!
A release of the gas fired igniter can cause the
start of subsequent devices (burners).
– Any other devices such as burners and valves
shall therefore be blocked.
3. Open the gas supply (only on initial commissioning) and

enable the tested plant by means of the control system.
4. Set the previously selected gas operating pressure of
1000 mbar at the pressure setting device (by customers).
REMARK!
In order to achieve a stable flame the air flow
needs to be adapted according to the gas
operating pressure.
5. After measurement, remove the pressure gauge.

6. Close the Allen screw immediately.
6.6 Checking the setting result

If correctly set, the following setting results should be in place
following initial commissioning:
 Immediate ignition
 Optically good flame pattern / flame signal 90 – 110 V DC
 Flame length max. 2000 mm at max. output of 600 kW
(standard)/1 MW (special version) and free burn-out
Status: 02-2019 - 37 -
Operation
7 Operation
7.1 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.
– Never disable safety devices during operation.
– Only operate the gas fired igniter in installed
condition.
– Ensure order and cleanliness in the work area.
Loose components and tools lying around or
piled on top of each other are a possible cause
of accidents.
7.2 Operation
REMARK!
Operation of the gas fired igniters takes place at
the plant control system in which the device is
integrated. Manual operation at the gas fired igniter
itself is not required.
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Maintenance
8 Maintenance
8.1 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.
installation work.
cause of accidents.
– When components are removed, ensure correct
reassembly. Remount all fastening components
and adhere to specified screw tightening torque
levels.
8.2 Maintenance, general

The 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, checks
must be performed at shorter intervals, as electrically conductive
dirt deposits or moisture on the ceramic insulators of the igniter can
result in malfunctions.
The inner resistance of the ionization path is M. These high
resistance levels call for the ceramic insulators to be in perfect
working order.
Only a few parts are subject to wear in normal operation (see

chapter “Spare parts list”. These parts must be exchanged if
defects and malfunctions occur with increased frequency.
Status: 02-2019 - 39 -
Maintenance
8.3 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. Due to the supply voltage of the
ionisation flame monitor, electrical voltage is also
applied to the flame rod. Contact with the
electrodes could be fatal.
– Never come into contact with the ignition
electrode or the flame rod.
Performing work at the spark transformer entails a
risk of fatal injury due to electric shocks!
– Before starting work, switch off the power
supply and make sure it cannot be inadvertently
switched back on. Observe the 5 safety rules.
– Before touching parts carrying voltage, ensure
that no residual voltage remains.
DANGER!
serious burns!
When carrying out maintenance work, shut off the
gas valve!
– Completely separate the gas fired igniter from
the power supply and disconnect the gas / air
supply.
The maintenance work listed below can now be performed.
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Maintenance
8.3.1 Exchanging the outer tube

 This may only be performed by suitably qualified personnel.
1. Remove 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 port, the outer
tube can be turned into 4 x 90° increments and
tightened.
Fig. 15: Exchanging the outer tube
Status: 02-2019 - 41 -
Maintenance
8.3.2 Exchanging the power head

3. Remove the final electrode support ring (3) and any existing
intermediate support rings (7) as well as the connecting
rods (4).
4. Unscrew the gas tube (5) from the gas flange (6).
5. Assembly takes place in reverse sequence.
6. Mount the rating plate on the new power head (8).
Fig. 16: Exchanging the power head
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Maintenance
8.3.3 Exchanging the final electrode support ring

REMARK!
The final electrode support ring counts as a
wearing component and is not included in the
warranty cover.
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).

3. Release the clamping screw (6) of the final electrode support
ring (3) and pull the ring off the gas tube (4).
4. Position the new final electrode support ring (3).
5. All plug-in sleeves (7) should be squeezed carefully with a
pair of pliers to ensure a tight fit of the connecting rods (5) in
the plug-in sleeves.
6. Insert the connecting rods (5) into the plug-in sleeves at the
igniter head and into the plug-in sleeves (7) on the final
electrode 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) and
align if necessary.
8. Tighten the clamping screw (6).
9. Mount the outer tube (2).
Fig. 17: Exchanging the final electrode support ring
Status: 02-2019 - 43 -
Maintenance
8.3.4 Exchanging the intermediate support rings

REMARK!
Intermediate support rings are used from a tube
length of 600 mm. New intermediate support rings
must be inserted in the previous position.

3. Release the clamping screw of the final electrode support ring
and pull off the final electrode support ring (3) from the gas
tube (4).
4. Pull out the connecting rods (5).
5. Release the clamping screws of the intermediate support
rings (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 pair
of pliers to ensure a tight fit of the connecting rods (5) in the
plug-in sleeves.
10. Insert the connecting rods (5) into the plug-in sleeves at the
igniter head and into the plug-in sleeves on the final electrode
support 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 support
rings (6).
13. Mount the outer tube (2).
Fig. 18: Exchanging the intermediate

support rings
8.4 Actions following completed maintenance work

After 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 and
covers have been correctly replaced.
3. Ensure that all used tools, materials and other equipment
have been removed from the work area.
4. Clean the work area and remove any spilt substances such as
fluids, processing materials or similar.
5. Ensure that all safety devices are in perfect working order and
that the correct function of the equipment is guaranteed.
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Troubleshooting
9 Troubleshooting
The following chapter provides information on possible causes for
faults and describes the work required to remedy them.
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.
9.1 Safety
Personal  This may only be performed by trained personnel.
Basics WARNING!
Danger of injury due to incorrectly performed
maintenance work!
Incorrectly executed maintenance work can result
in serious personal injury or material damage.
installation work.
cause of accidents.
– When components are removed, ensure correct
reassembly. Remount all fastening components
and adhere to specified screw tightening torque
levels.
Response in case of faults Basic rules of procedure:

1. Determine the cause of the fault.
2. Before starting work, switch off the power supply and make
sure it cannot be inadvertently switched back on. Observe the
5 safety rules
3. Completely disconnect the gas fired igniter from the energy
supply and disconnect the gas/air supply.
4. Inform the person in charge at the site immediately about the
fault.
5. Depending on the type of fault, have it remedied by authorized
specialist personnel.
REMARK!
The troubleshooting table listed below provides
information on how to remedy faults.
Status: 02-2019 - 45 -
Troubleshooting
9.2 Troubleshooting table

Fault Possible cause Solution To be done by
Spark does not form Gas fired igniter is not receiving Check wiring Qualified
(Not: Carry out any voltage Check control system electrician
optical check of Ignition electrode is burned out Clean the inside of the gas fired Qualified
ignition spark with igniter and replace ignition personnel
gas valve closed in electrode, bend to original
darkened room) position
Electrode distance is too large Clean inside of gas fired igniter Qualified
or electrode has short circuited if necessary and bend ignition personnel
electrode to distance of
2 – 3 mm
Spark transformer defective Exchange power head Manufacturer/

Qualified
electrician
Layer of scale on spark Clean inside of gas fired igniter Qualified

electrode and remove deposits using personnel
emery paper
Ceramic insulator broken Exchange ceramic insulator, Qualified

intermediate support ring or personnel
final electrode support
Flame fails to form No combustion air available due Exchange air flap or valve Qualified
to defective air flap or valve personnel
No combustion air available due Open throttle organs Operator

to closed throttle organs
No combustion air available due Unblock line Qualified

to blocked supply line personnel
No gas available because Dimension supply line Qualified

supply line is too long accordingly, if necessary personnel
change the position of the gas
fired igniter
No gas available, as gas supply Carry out several ignition Operator

line still inert with N2 attempts until line has filled with
gas
No gas available, as gas valve Exchange gas valve Gas specialist /

defective owner
Gas to air ratio is incorrect Check settings of the gas and Qualified
air operating pressure, if personnel
necessary correct the
adjustment values
Wrong gas Only use gas specified on the Qualified

rating plate personnel
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Troubleshooting
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 /
line closed all gas valves in the gas supply owner
line. Reset safety shut-off valve
if necessary
The flame comes on Flame rod is burned out, Exchange the flame rod and Qualified
for a short time, but deformed or has short circuited bend back to original position personnel
trips once the ignition Clean any scale/internal burner
safety time has parts
elapsed
Ceramic insulator of flame rod Exchange ceramic insulator or Qualified
broken electrode support ring personnel
When switched together with As the operating voltage must Qualified

the Hegwein control unit, lag behind the bias voltage by electrician
operating voltage is enabled at at least 5 s, always leave the
the same time as the bias bias voltage switched on
voltage
When using control unit from a Switch off ignition voltage Qualified
different manufacturer, the approx. 0.5 s before expiry of electrician
ignition spark always disturbs the ignition safety time
the ionization feedback
Gas fired igniter was exposed Leave fan air running when the Qualified
to excessively high temperature gas fired igniter is switched off personnel
in the combustion chamber for cooling purposes
when switched off. Ceramic
insulators too hot, the insulation
resistance has dropped too far
The setting of the gas and air Check settings and correct Qualified
operating pressures at the gas personnel
fired igniter is not correct, flame
root not in the area of the flame
rod
Wrong connection Check complete wiring, carry Qualified

out electrical function test electrician
Ionisation flame monitor Carry out electrical function Manufacturer/

defective test, exchange power head Qualified
electrician
Status: 02-2019 - 47 -
Troubleshooting
Fault shutdown takes Fluctuating combustion Check the pressure settings at Qualified
place during chamber of supply pressure the test nipples. If necessary personnel
operation levels, resulting in flame blow- provide a differential pressure
off regulation system for gas and
air
Pilot flame highly subject to Change the position of the gas Qualified
influence by the main flame or fired igniter personnel
is suffocated
Use more powerful gas fired
igniter
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 leaking valve, and is already Owner
gas valve has present when restarting
opened
Ionisation flame monitor Exchange power head Manufacturer/
defective Qualified
electrician
The gas fired igniter External fuse defective Replace external fuse Qualified
and control unit are electrician
operational, but no
signals are
transmitted via the
integrated flame
relay
- 48 - Status: 02-2019
Dismantling / Disposal
10 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.
Basics WARNING!
Danger of injury due to incorrect dismantling!
Residual stored energy, sharp components,
pointed corners and edges on or in the gas fired
igniter or on the required tools can cause injury.
sufficient space available.
– Take particular care when dealing with sharp-
edged components.
cause of accidents.
– If any points are unclear, consult the
manufacturer.
10.2 Dismantling
Before starting to dismantle it, carry out the following steps:
DANGER!
Potentially fatal injury due to electrical current!
Contact with live components can cause fatal
injury.
– Before starting dismantling work, switch off the
electrical supply and finally disconnect.
Status: 02-2019 - 49 -
Dismantling / Disposal
DANGER!
serious burns!
When dismantling, shut off the gas valve!
– If gas is unintentionally released into the
atmosphere, immediately shut off the gas flow.
Prevent gas entering drainage systems,
basements, work pits or other locations in which
collected gas could cause a hazard.
1. Switch off the gas fired igniter and secure it against being
switched back on.
2. Completely disconnect the gas fired igniter from the energy
supply and gas / air supply.
3. Remove operating and auxiliary materials as well as residual
processing materials and ensure their ecologically responsible
disposal.
The gas fired igniter can now be cleaned for separation and
dismantled in compliance with applicable occupational safety and
environmental protection legislation.
10.3 Disposal
Provided no return acceptance or disposal agreement has been
concluded, the components once dismantled can be sent for
recycling:
 Send metals for recycling.
 Send plastic elements for recycling.
 Dispose of the remaining components separated according to
material properties.
NOTE!
Environmental damage due to incorrect
disposal!
Electric scrap, electronic components, lubricants
and other auxiliary materials are subject to special
waste treatment and may only be disposed of by
authorized specialist companies!
The local authorities or specialist disposal companies can provide

information on environmentally responsible disposal.
- 50 - Status: 02-2019
Spare parts list
11 Spare parts list

11.1 Spare and wearing parts
Fig. 19: Spare parts drawing
Item Qty. Designation Part number Voltages Material/ Remarks

configuration
1 Power head ZX420K7/ 230 V With housing, Standard

for ZX/PA1... ZX420K7/__M 115 V permanently Special version
ZX420K7/__C 125 V sealed control Special version
ZX420K7/__B 250 V cable Special version
1
1 Power head ZX420K8/ 230 V Standard
for ZX/PDA1... ZX420K8/__M 115 V Special version
ZX420K8/__C 125 V Special version
ZX420K8/__B 250 V Special version
2 1 Complete outer tube, incl. Z1010Z_ _ _ Tube length Steel Standard
mixing chamber (heat or given should
resistant tube 1.4841) and Z1016Z_ _ _ be the same Stainless steel Special version
mounting flange with air in line with
port type key (see
chapter
“Specifica-
tions”)
3 * Intermediate support ring Z944K3 Steel * length dependent
with 2 ceramic insulators or
Z944K103 Stainless steel
4 1 Final electrode support Z944K9 Steel Standard
ring with or
2 ceramic insulators and Z944K109 Stainless steel Special version
2 electrodes Wearing part
5 1 Gas Natural gas Z36Z6010 Stainless steel Standard (600 kW)
nozzle or
Z36Z7510 Stainless steel Special version
(1 MW)
LPG Z36Z5209 Stainless steel Standard (600 kW)
or
Z36Z6009 Stainless steel Special version
(1 MW)
Status: 02-2019 - 51 -
Annex
12 Annex
12.1 EU type examination certificate (DVGW)
- 52 - Status: 02-2019
Annex
12-001_en-Rev7
Fig. 20: EU type examination certificate
Status: 02-2019 - 53 -
Annex
12.2 Type examination certificate (IBExU)
- 54 - Status: 02-2019
Annex
Status: 02-2019 - 55 -
Annex
- 56 - Status: 02-2019
Annex
Status: 02-2019 - 57 -
Annex
12-005_en-Rev2
Fig. 21: Type examination certificate (IBExU)
- 58 - Status: 02-2019
Annex
12.3 Declaration of conformity
12-033_de_en-Rev6
Fig. 22: Declaration of conformity
Status: 02-2019 - 59 -

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Operating Manual

Gas fired igniter

© Hegwein GmbH Before first use, read the operating manual!

1 General ....................................................... 3 5.4 Air adjusting components (accessories) ... 26

-2- Status: 02-2019

1.2 Explanation of symbols

Status: 02-2019 -3-

1.3 Liability disclaimer

1.4 Copyright protection

-4- Status: 02-2019

The contents of all or part of these operating instructions may not

1.5 Spare parts

Order spare parts through your authorized dealer or directly from

1.6 Warranty regulations

1.7 After-sales service

Status: 02-2019 -5-

2.1 Owner’s responsibility

-6- Status: 02-2019

2.2 Operating personnel

The following qualifications are required for the various fields of

Only persons who may be expected to perform their task reliably

Status: 02-2019 -7-

2.2.2 Unauthorized persons

WARNING! Danger for unauthorized persons!

2.3 Intended purpose of the equipment

The gas fired igniter is a piece of equipment that has to be

The manufacturer can not be held liable for physical or material

-8- Status: 02-2019

2.4 Personal protective gear

Protective work clothing

Status: 02-2019 -9-

2.5 Special dangers

Incorrect transport WARNING!

Flammable atmosphere DANGER!

Electrical current DANGER!

Electrostatic charge (ESD) CAUTION!

Highly inflammable materials WARNING!

Hot surfaces CAUTION!

Sharp edges and pointed corners CAUTION!

Special environmental influences NOTE!

2.6 Securing against unauthorized switching use

Switch safeguarded by lock Securing against unauthorized use

2.7 Response in case of danger or accident

In case of accident: React correctly  Initiate first aid measures.

Transport, packaging and storage

3 Transport, packaging and storage

3.2 Transport inspection

Transport, packaging and storage

3.4 Storage conditions

Fig. 1: Type key

4.1.1 Type key of ionisation flame monitor

Fig. 2: Type key of ionisation flame monitor

4.2 Gas fired igniter

Heat release max. 600 kW (standard)

Flame length (depending on the gas) max. 2000 mm

Outer tube length

Outer tube diameter

Design pressure gas flange max. 10 bar

Gas port Rp ¾, top or bottom