OPERATION AND MAINTENANCE E-LIGHT - DURAG · INSTALLATION OPERATION AND MAINTENANCE MANUAL SMITSVONK HIGH ENERGY IGNITION UNIT TYPE: E-LIGHT-161609 Read before commencement of all

INSTALLATION OPERATION AND MAINTENANCE MANUAL

SMITSVONK HIGH ENERGY IGNITION UNIT TYPE: E-LIGHT-161609

Read before commencement of all work!

This ignition unit must be mounted in accordance with the applicable regulations.

Smitsvonk Holland B.V. P.O. Box 180 E-mail : [email protected] 2700 AD Zoetermeer Phone: +31(0)79 3613533 The Netherlands Fax: +31(0)79 3611378

mailto:[email protected]

Smitsvonk_IOM _manual_E-LIGHT-161609_2016-AprilApril 2

Table of contents Page Introduction............................................................................................................................................ .3

Safety .................................................................................................................................................... .3 Storage and transportation.................................................................................................................... .4 General technical data .......................................................................................................................... .5 Model number ...................................................................................................................................... .6

Product description .............................................................................................................................. .7 Installation ............................................................................................................................................ .8

Operation instruction ............................................................................................................................. 12

Maintenance instruction ........................................................................................................................ 12 Trouble shooting ................................................................................................................................... 13 Dismantling and disposal ...................................................................................................................... 13

EC declaration of conformity ................................................................................................................. 14 Durag Group company addresses ........................................................................................................ 15 WARNING:

Please read this manual and adhere to it when making use of the device! Installation and maintenance procedures may only be carried out by authorized personnel! All local regulations and the prevailing codes of practice must be observed during installation! Improper installation, alignment and maintenance, as well as modifications by the customer, can all lead to personal injury or properly damage, as well as loss of warranty!

DANGER !

High voltage. Risk of fatal injury due to electrical power! There is a risk of immediate fatal injury if live components are touched. Damage to the insulation or to individual components can lead to fatal injury. A voltage of 2.000 Volts is generated to create the ignition sparks in the ignition device.

Post address: Visit and delivery address: Smitsvonk Holland B.V. Smitsvonk Holland B.V. P.O. Box 180 Goudstraat 6 2700 AD Zoetermeer 2718 RC Zoetermeer The Netherlands The Netherlands E-mail: [email protected] Website: www.smitsvonk.nl Phone: +31(0)79 3613533 : www.durag.de Fax: +31(0)79-3611378

mailto:[email protected]


INTRODUCTION. Smitsvonk Holland B.V. designs, manufactures and installs ignition systems which have their application all over the world. Years of experiences are the foundations of Smitsvonk Holland B.V knowledge about burner technology and ignition mechanism. And yet this knowledge is still increasing. In order to increase the quality of our services, the knowledge is used to improve the existing ignition systems as well as in developing new ignition systems. The long operational life and the reliability of the ignition devices are characteristic of Smitsvonk products. Designing the products to the customer’s required specifications attained this and this is where Smitsvonk Holland has strongly her believes in. Smitsvonk guarantees a safe use of the ignition systems only when this is used in the customers required application that is mentioned in her specifications. To use these ignition systems in applications of which it was not designed for is not recommendable. It can lead to dangerous situations. Users should be informed correctly before they start to use the ignition system. Smitsvonk user manual gives detailed information about the use, mounting, maintenance and other information about ignitions system. But users should be aware that these instructions cannot be given in the finest details. Whenever there is a situation the manual is not giving an answer, Smitsvonk advices you to contact our service department.

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.

Owner’s responsibility As the ignition unit is used commercially, the owner of the ignition unit 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 portable ignition unit must be adhered to, whereby the following regulations in particular apply:

The owner must be aware of the valid occupational safety regulations and also determine any additional potential hazards arising as a result of the specific working conditions applicable at the location in which the portable ignition unit is used, by performing a risk assessment. This must be implemented in the form of operating instructions governing operation of the portable ignition unit.

The owner must test; throughout the service life of the ignition unit, 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 ignition unit 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 ignition unit 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.


STORAGE AND TRANSPORTATION. Important:

Till the day of delivery Smitsvonk is responsible for the supplied materials. Damages caused after the delivery are not under the guarantees of Smitsvonk anymore. If the customer is taking care of the transport itself the responsibility of Smitsvonk stops at the moment of transfer of the products.

To minimise the chance of damages to the supplied materials Smitsvonk advises to observe the following points:

Storage:

If no assembling takes place in a short term, keep the goods in the packaging as long as possible.

Be sure that in the storage accommodation the chances for damages are minimised.

Device is to be stored in a dry and dust-free place. Ambient temperature during storage shall be 0 - 60 °C. No operation and storage below dew point. Moisture must not exceed 60 %. Device shall be protected from mechanical damages.

Transportation:

The packaging protects the materials against shocks or others forms of extreme strains. During transportation of the goods and after removing the packaging please obtain the next:

Prevent the goods against shocks or other extreme forms of strains that can damage the goods.


GENERAL TECHNICAL DATA Ignition unit Enclosure dimensions : See model number Material enclosure (Safe area) : Aluminium, painted blue Material enclosure (explosion proof) : Cast aluminium Power supply (Min. – Max.) : 10 – 30 VDC Power consumption ignition unit : 13 VA Protection : IP66 Ignition energy : 2 Joule per spark Ignition tension : 2000 V Ignition frequency : 3 sparks per second Maximum continuous use

till 60 ⁰C : 3 minutes, 3 minutes pause

from 60 ⁰C to 70 ⁰C : 3 minutes, 6 minutes pause

Maximum ignition cable length 1,5 mm2 : 35 meter Maximum ignition cable length 4 mm2 : 100 meter Connection Ignition signal : M3 (Screw terminal) Connection Power supply : Max. 2,5 mm2 Cable gland connection : 2 x M20*1,5

Ambient and storage temperature range : -40 to 70 ⁰C.

Operating Humidity max. : 95% non-condensing humidity Mechanical shock : 9G, EN60068-2-27: 2008 (Direction X+/-, Y+/-, Z+/-) Vibration : 2G, EN60068-2-6: 2008 (Direction X, Y, Z) Weight : 2,5 kg


MODEL NUMBER IGNITION UNIT E-LIGHT-161609

TYPE: E-LIGHT-161609-195 1 2 3 4

1 E-LIGHT ignition unit in aluminium enclosure

2 Enclosure dimension: 160 x 160 x 90 mm

3 Cable glands 2 x M20x1,5: 195 – 2 x Hummel EMC cable gland, range 7-12 mm 205 – 1 x Hummel EMC cable gland, range 7-12 mm 1 x DNC/RCN for flexible protection conduit for ignition cable.

4 Z = Option, special

160

16

0

90

16

0

110

14

0

Ø7

160

90

160

5555 50

50 M20 M20


PRODUCT DESCRIPTION An ignition unit supplies the tension that is needed to make a reliable spark for an ignition (pilot) burner, a spark plug or an ignition lance. The unit is built into an aluminium die-cast box, protection grade IP66. The ignition unit is suitable for a supply voltage as mentioned on the type plate. The diagram fig. A shows that the DC power supply is converted to 2000 V,

-E

IGNITION UNIT

+B

C+ C-

1 µF CAPACITOR

10 – 30

VDC2 KV

Power cable not

by Smitsvonk

Enclosure

Mounting plate

Sparkplug

Fig. A

E

The capacitor will be discharged via the thyristor across the low-tension spark plug in a short time and with a high current. Due to this short time of discharge and high current a flame-shaped spark on the spark plug is obtained, which is unaffected by filthiness, humidity and other disturbances. The ignition unit generates about 180 sparks a minute, also indicated by a red LED on the P.C.B. An bleeder resistor is installed to ensure that the capacitor will be discharged when the unit is switched off.

Remark: the time for the ignition unit to spark, should not exceed the maximum of 3 minutes.

Before opening the housing, switch off the power supply and wait for about one minute. Lethal voltages are generated inside the box. Do not touch any metal part inside the ignition unit.


INSTALLATION Please pay attention to the following.

Ignition unit

The ignition has to be mounted on a stable background with a minimum bolt size of 4 x M6.

Take care for sufficient earthing of the ignition unit.

When mounting the ignition unit outside, be sure that there is sufficient protection against the weather conditions.

Don’t place the unit to close to heat resources. The low voltage ignition unit shall be mounted in a vertical position with the cable glands down. When the cover of the unit is mounted properly, no special measures need to be taken to prevent the ingress of dust or humidity into the box. Ignition cable Smitsvonk strongly recommend to use a Smitsvonk high energy ignition cable, type SEKB000270 (1,5 mm2), SEKB000247 (4 mm2) or type SEKB000272 (1,5 mm2 – Halogen free) The central conductor of the ignition cable is to be connected to the terminal marked 'B'.

OUTER SHEATH

CONDUCTOR

BRAIDING

EARTHING LEAD

The earthing lead (drain wire) under the braiding should be connected to the earth terminal. This earthing lead (drain wire) is un-isolated wire and should be isolated with shrink foil. The B-terminal is for the signal to the Sparkplug (Bougie). This signal can be 2 kV. Use suitable cable thimbles to connect the different wires.


The power supply cable shall be connected to the terminals marked '+'(Line) and '-'(Neutral). The earth conductor shall be connected to the earth terminal. The electrical connection for the power supply is by screw terminals for stranded conductor wi th a cross-section between 0,75 and 2,5 mm2.

CONNECTOR POWER

SUPPLY CABLE

Cable glands Unit is provided with 2 brass nickel plated cable glands for braided cable. Install the cable braiding according instruction of the cable gland supplier.

COVER

PLEXIGLAS PROTECTION PLATE IGNITION CABLE

POWER

SUPPLY

CABLE


WARNING !!! Cables must be connected carefully:

The insulation must extend up to the terminal. Notice the maximum cable temperature. Do not operate the equipment above the

maximum cable and equipment temperature. Take care not to damage the conductor. Do not clamp in any conductor insulation. Do not confuse conductors. All screws on the connection terminals must be tightened securely. Max. torque to the

power supply terminal is from 0,5 to 0,6 Nm. All cores must be connected to the terminals. Do not forget to place the Plexiglas protection plate at the inside of the enclosure Do not forget to close the cover with the integrated gasket.


Cable gland information.


OPERATION When power supply is switch on to the ignition unit it will produce the energy for the sparks. Energy is conducted via the ignition cable to the sparkplug of the ignition (pilot) burner, sparkplug or ignition lance.

MAINTENANCE Ignition unit The ignition unit hardly needs any maintenance during normal operation. Periodical maintenance, e.g. once a year, is confined to inspection of the interior of the unit. Inspect both the wiring as well as the components. Check whether all connections are still firmly fixed. When the sparkplugs are worn out the load of the capacitor will flow to earth by the bleeder resistor. When this will take too long (> 10 minutes) internal parts can be damaged! This device does not have an unlimited service life. It is designed for 2.000.000 start-up cycles at nominal load. If 500 start-up cycles per day are assumed, its lifetime would therefore be approx. 10 years. This lifetime can be decrease considerably if the unit operates under harsh conditions (temperature, vibrations, dirt etc.) The end user shall therefore take care that regular safety-related checks are carried out at site. When the unit has reached the end of its lifetime it must be disposed of according to local regulations. Fuse, see fig. B Unit is provided with a replaceable 1,6 A (slow) type TR5 fuse.

RED LED Fuse 1,6 A slow

Fig. B

Recommended spare part: Fuse 1,6 A (slow) type TR5, Smitsvonk part number SEKM090116


TROUBLE SHOOTING

When the system is malfunctioning the following checkpoints can be used in order to find the failure. The ignition unit is provided with a LED indicator (see fig. B) with the following blinking code: Possible causes can be:

Failure Cause Result Action No power supply No LED blinking No power supply to the

ignition unit Check and or connect power supply.

Broken fuse No LED blinking No power supply to the ignition unit

Replace fuse.

Under voltage (< 10 Vdc at ignition unit)

LED Continuous on

Unit not in operation. Correct power supply.

Over voltage > 30 Vdc at ignition unit.

LED Slow blinking (1 Hz)

Unit not in operation. Correct power supply and do a reset by power off for 10 seconds.

Open loop, worn out sparkplug or broken cable

LED blinking 3 Hz (normal)

No spark Check cable connection or replace sparkplug.

When the above mentioned points didn’t solve the problems than Smitsvonk Holland B.V. advice you to contact us.

DISMANTLING AND DISPOSAL

Dismantling Switch off the system and secure against inadvertently being switched back on. Disconnect all electrical cables from the ignition unit E-LIGHT…. Remove the ignition unit E-LIGHT… and send for recycling. Disposal After the end of its service life, the flame monitor must be dismantled and sent for environmentally responsible recycling. By making your contribution to the correct disposal of this product, you are helping to protect the environment and preserve the health of your fellow human beings. Irresponsible disposal places the environment and our health at risk. Material recycling helps to reduce the consumption of raw materials. Current information on the recycling of this product can be obtained from your local authority and municipal waste management agency.



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OPERATION AND MAINTENANCE E-LIGHT - DURAG · INSTALLATION OPERATION AND MAINTENANCE MANUAL SMITSVONK HIGH ENERGY IGNITION UNIT TYPE: E-LIGHT-161609 Read before commencement of all