he a ignitor

8/20/2019 He a Ignitor

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HT- MANUAL, S12-1

HIGH ENERGY PULSED ARC IGNITION

OPERATION AND MAINTENANCE

MANUAL


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TABLE OF CONTENTS

1. SYSTEM DESCRIPTION......................................................................... 5

2. COMPONENT SPECIFICATION ............................................................ 6

3. COMPONENT DESCRIPTIONS ............................................................. 7

4. GENERAL THEORY OF OPERATION.................................................. 9

5. EXCITER MOUNTING AND WIRING .................................................. 11

6. INSTALLATION INSTRUCTIONS......................................................... 11

7. TROUBLESHOOTING............................................................................. 14

8. REPAIR/ REPLACEMENT...................................................................... 16

LIST OF TABLES AND ILLUSTRATIONS

TABLE 1-1 .................................................................................................... 7

FIGURE 1 ...................................................................................................... 10

TABLE 2-1 .................................................................................................... 14

APPENDIX.................................................................................................... 17


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HEA IGNITION SYSTEM:- COMPONENTS PARTS

DESCRIPTION PART NUMBER

EXCITER 115 V AC – 50/60-3.0 AMPS. 0775.0004.01

EXCITER 230 V AC – 50/60-1.5 AMPS. 0775.0004.02

FLEXIBLE CABLE 0757.0017.02.144

FLEXIBLE SPARK ROD 0645.0026.01.LLLRIGID SPARK ROD 0645.0027.01.LLL

SPARK ROD TIP 0147.0002.01

RETRACTOR 8 INCH (203mm)STROKE

115V AC 50/60 Hz 0645.0046.01

230V AC 50/60 Hz 0645.0046.02

COMPONENTS PARTS:-EXCITER P/N 0775.0004.01 (115 V AC) OR 0775.0004.02(230 V AC)


TRANSFORMER 0126.0002.01

RECTIFIER 28609

INDUCTOR (CHOKE) 88296RESISTOR 88304

BLEED RESISTOR (R1 OR R4) 0152.5760.00

(FORMERLY X 88307,ONE REQUIRED)

OPEN CIRCUIT RESISTOR (R2 OR R5) 88305

CAPACITOR (C1 & C2) 12003-006

SPARK GAP TUBE 85908

PC BOARD ASSEMBLY 5000077

COMPONENTS PARTS:-FLEXIBLE CABLE P/N 0757.0017.02.LLL(LLL=LENGTH IN INCHES)



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COMPONENTS PARTS:-FLEXIBLE SPARK ROD P/N 0645.0026.01.LLL(LLL=LENGTH IN INCHES)


FLEX. SPARK ROD SHELL 30’ SECTION 5000020

FLEX. SPARK ROD COMPLETE SHELL 5000050

CONTACT (1) 126165

INSULATOR MOLDED (3) 126166

WIRE HIGH TEMP. (4) 0392.0502.12

SOCKET CONNECTOR (7) 5000013

RETAINING RING (8) 12553

NUT RETAINER (9) 5000104INSULATOR (10) 5000103

RETAINER NUT TOOL 0570.0001.01

COMPONENTS PARTS:-REGID SPARK ROD P/N 0645.0027.01.LLL(LLL=LENGTH IN INCHES)


RIGID SPARK ROD SHELL 5000049

CONTACT (1) 126165

INSULATOR MOLDED (3) 126166

WIRE HIGH TEMP. (4) 0392.0502.12

SOCKET CONNECTOR (7) 5000013

RETAINING RING (8) 12553

NUT RETAINER (9) 5000104INSULATOR (10) 5000103

RETAINER NUT TOOL 0570.0001.01

COMPONENTS PARTS:-REGID SPARK ROD P/N 0645.0046.XX/RETRACTOR 12” STROKE P/N 0645.0050.XX


AIR CYLINDER 8” STROKE (2) 126214AIR CYLINDER 12” STROKE (2) 126304

AIR CYLINDER BARREL 8” STROKE 0539.0003.01

PISTON SEAL KIT 0670.0012.01

ROD BUSHING SEAL KIT 0670.0011.01

PACKING ROD GUIDE (31) 126315


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1. SYSTEM DESCRIPTION

This manual contains operation and maintenance instructions as applicable to the SParc S12-1

High Energy Pulsed Arc Ignitor manufactured by Hindusthan Thermometers. This system is designed

for use in ignition of fossil fuel on industrial and utility power boilers.

Several design configurations are available based upon fuel burning equipment and purchaser

preference. This is a general document covering a wide range of possible configurations. Contract bill

of materials and drawings should be referenced for specific configuration when ordering replacement

components and spare parts. The quantity of specific drawings attached to this manual will vary

depending on the contract bill of material.

WARNING

THIS SYSTEM CONTAINS HIGH VOLTAGES AND CURRENTS THATCOULD KILL OR SERIOUSLY INJURE PERSONS COMING INTO

CONTACT WITH THEM. THIS MANUAL MUST BE READ AND

UNDERSTOOD BEFORE ANY ATTEMPT IS MADE TO INSTALL OR

OPERATE THIS SYSTEM OR ANY OF ITS COMPONENTS.


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2. COMPONENT SPECIFICATION

The SParc S12-1 High Energy Pulsed Arc Ignition system consists of five (5) basic components. Refer

to the appendix for a list of complete drawing titles.

1) 12 Joule HT Exciter P/N 0775.0004.01

2) Flexible Cable Assembly, single socket P/N 0757.0017.01

3A) Flexible Spark Rod Assembly P/N 0645.0026.01

3B) Rigid Spark Rod Assy, Single socket P/N 0645.0027.01

4) Spark Rod Tip P/N 0147.0002.01

5A) Retractor (8” stroke) P/N 5000086

5B) Retractor (12” stroke) P/N 5000087


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3. COMPONENT DESCRIPTIONS

TABLE 1-1

EXCITER ASSEMBLIES P/N 0775.0004.01

Enclosure Heavy Duty 9.52” x 9.40” x 8.19” NEMA 4

Supply Voltage 110-130 VAC (Optional 240 VAC)

Frequency 50/60 Hz

Current in Amps 5 @ 120 VAC

Output Energy 12 Joules per spark nominal

Spark Rate 4 sparks per second nominal

Duty Cycle (Intermittent) 15 minutes on 30 minutes off

Temperature Range (1) -40°F to +165°F

FLEXIBLE CABLE P/N 0757.0017.01

Operating Voltage 3600 Volts pulsed arc

Cable Length (2) Length specified by purchaser

Bend Radius 4 inch minimum

Temperature Range (1) -65°F to +300°F

FLEXIBLE SPARK ROD P/N 0645.0026.01

Operating Voltage 3600 Volts pulsed arcRod & Tip combined length (2) 15 feet max specified by purchaser

Flexible Section length 30 inches standard

Temperature Range (1) Tip End -65°F to +1000°F

Cable End -65°F to +300°F

RIGID SPARK ROD P/N 0645.0027.01

Operating Voltage 3600 Volts pulsed arc

Rod & Tip combined length (2) 15 feet max specified by purchaser

Temperature Range (1) Tip End -65°F to +1000°F

Cable End -65°F to +300°F


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SPARK ROD RETRACTOR P/N 5000086

Air Cylinder 1-1/2” Diameter x 8” Stroke

Cylinder Seals Viton

Cylinder Operating Pressure 70 to 100 psi

Solenoid Valve Two position four ways.

Solenoid Valve Electrical Requirements:

A) Coil Voltage 120 VAC (Optional 240 VAC)

B) Coil frequency 50 to 60 Hz

C) Inrush @ 50 Hz 42 VA +5% -15% Volts tolerance

D) Inrush @ 60 Hz 35 VA +10% -15% Volts tolerance

E) Holding @ 50 Hz 22 VA +5% -15% volts toleranceF) Holding @ 60 Hz 18 VA +10% -15% volts tolerance

Solenoid Valve Mechanical ¼” NPT Ports

Limit Switches (2)

Voltage 120/240 VAC

Frequency 50 to 60 Hz

Characteristic SPDTCurrent 10 AMPS Continuous @ 120 VAC

Temperature Range -20°F to +230°F

SPARK ROD RETRACTOR P/N 5000087

This is a P/N 5000086 with a 12” stroke limiting adaptor attached.


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4. GENERAL THEORY OF OPERATION

IGNITION EXCITER

Application of 110-130 VAC (optional 220-260 VAC), 50/60 Hz to the primary induces a high voltage

in the secondary coil of the power transformer (See Figure 1). The high voltage generated in the

secondary of the power transformer is rectified in the voltage doubler circuit by the action of two solid

state rectifiers and two capacitors. With each change of polarity, a pulse of DC current charges the

storage capacitors. The resistor R3 and inductor L1 serve as current limiters. When this voltage reachesthe predetermined level that the Spark Gap Discharge Controller (SGDC) has been calibrated, the

SGDC will ionize. Current will flow from the storage capacitors C1 and C2 through the SGDC, to the

center conductor of the output lead to the Spark Rod Tip; returning to storage capacitor through the

ground lead. When the energy is dissipated at the Spark Rod Tip, the storage capacitors will be

recharged. There is a voltage drop across the SGDC so a spark does not completely discharge the

capacitors. Bleed resistors R1 and R4 are provided to dissipate any residual charge on storage

capacitors between duly cycles. Resistors R2 and R5 in the output circuit provide a discharge path for

storage capacitor energy in the event that the Spark Rod Tip fails to fire, or the unit is subjected tooperation without a flexible cable, Rod, and Tip. Resistors R2 and R5 are essential to protect the

capacitors from an over voltage in the situations describe above.

DANGER

DISCONNECTING INPUT POWER WILL RESULT IN REDUCING

THE OUTPUT POTENTIAL FOR SEVERE SHOCK AFTER 5

MINUTES. DO NOT DISCONNECT OUTPUT CABLE OR SPARK

ROD WHILE UNIT IS RUNNING OR BEFORE THE EXPIRATION OF

A 5 MINUTE INTERVAL FOLLOWING REMOVAL OF INPUT

POWER. DO NOT REMOVE TIP WHILE INPUT POWER IS

CONNECTED TO UNIT BEFORE A 5 MINUTE PERIOD

FOLLOWING REMOVAL OF INPUT POWER.


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5. EXCITER MOUNTING AND WIRING

Refer to drawing 0775.0004.XX, 5000066 or 5000067 in the appendix for exciter enclosuredimensions and wiring information.

6. INSTALLATION INSTRUCTIONS

6.1 EXCITER

Mount the Exciter at eye level or lower. Avoid locating near furnace hot spots, casing gas leaks and

direct contact with the windbox. Refer to the Exciter drawing for applicable dimensions and hole sizes.

6.2

FLEXIBLE CABLE

When routing the Flexible Cable between the Exciter and the Spark Rod, avoid coiling the cable since

this may reduce the energy transferred to the Spark Rod Tip due to additional reactance. During

Installation caution should be exercised not to subject the flexible cable to a bend radius of less than 4

inches at any point as damage to the flexible cable could result. Care should also be taken to orient the

elbow in a vertical position to prevent the elbow from impacting with retractor frame during operation.

6.3 RETRACTOR

Refer to drawing 5000087 in the appendix. If possible, install the retractor at eye level or lower on the

mounting guide pipe assembly which is welded to the surface of the boiler.

6.4 SPARK ROD AND TIP

Insert the Spark Rod and Tip (through the Retractor packing glands if in contract, see section

D-D and) into the guide tube When the Spark Rod has been inserted to the operating depth fully


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6.5 WIRING

Check local codes and the national electrical code for over current protection and external disconnect

wiring requirements. Insure all power is disconnected before installation is attempted.

Attach wiring for the Flexible Cable exciter end to the exciter, and spark rod end to the

Spark Rod. Electrical input specifications for the Exciter and Retractor assemblies are outlined in

Table 1-1. Specific requirements which should be noted are shown inside junction box covers or on

nameplates of the Exciter and Retractor assemblies.

6.5.1

Input voltage required to operate the Exciter is specified as 110 to 130VAC (or optional 220/260

VAC) 50/60 Hz. A hole is provided on the Exciter for a ½” conduit fitting. Wiring to the terminal

block in the Exciter should meet National Electrical Code requirements.

6.5.2

Input voltage required to operate a Retractor assembly is specified as 120 VAC (optional 220 VAC),

50/60 Hz. A hole is provided in the junction box on the Retractor assembly for a ½” conduit fitting.

Wiring to the terminal block in the junction box should meet National Electrical Code requirements.

6.6

COMPRESSED AIR LINES

Compressed air specifications for the Retractor assembly air cylinder are outlined in Table 1-1.

Specific requirements which should be noted are as follows:

6.6.1

Operating pressure for the air cylinder is 70-100PSI.

6.6.2

Conditioned air, free of oil, water and dirt, is connected to the pressure inlet on the solenoid valve.


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6.7 PRE-START CHECKS

CAUTION: Before applying power to the Exciter, the system, should be checked to make absolutelysure that:

1. The Exciter is properly mounted to its electrically grounded supporting structure.

2. The Flexible Cable is tightened to both the Exciter assembly and the Spark Rod assembly, with

proper alignment of elbows.

3.

The Spark Rod Tip is properly tightened to the Spark Rod Assembly.

FAILURE TO COMPLY WITH THE ABOVE COULD RESULT IN PERSONE BEING SERIOUSLY INJURED

BY COMING IN CONTACT WITH HIGH VOLTAGES AND CURRENTS.

6.8 ELECTRICAL

With the Spark Rod fully retracted in the reverse position, apply input voltage to the Exciter. Audible

sparking should be observed at the Spark Rod Tip.

6.9 MECHANICAL

Activate the Retractor mechanism. A positive full stroke should be observed as the Spark Rod travels

to the forward position, and in turn to the reverse position.


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7. TROUBLESHOOTING

7.1

Troubleshooting procedures are outlines in Table 2-1, TROUBLES AND REMEDIES.

TABLE 2-1

TROUBLES AND REMEDIES

CONDITION: Retractor Mechanism fails to actuate.

PROBABLE CAUSE REMEDY

1. A loss of electrical impulse control to the

Retractor.

2. A significant drop in air pressure supply

to the retractor.

3. Air leaking at cylinder.

1. Check electrical control system and

make repairs as necessary.

2. Check Plant air supply and filters.

Repair as necessary.

3. Rebuild air cylinder using piston seal

kit P/N 0670.0012.01 and rod Bushing

Seal kit p/N 0670.0011.01

Condition: Spark Rod Tip fails to fire.

PROBABLE CAUSE REMEDY

1. Open Circuit condition exists in input

power supply to the Exciter.

2. Defective Flexible Cable.

1. Check control system output voltage

and repair as necessary.

2. Separate the Flexible Cable from the

Exciter and the Spark Rod, then using a

Simpson 260 voltmeter or equivalent:


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3. Defective Spark Rod Tip.

4.

Defective Spark Rod.

5. Defective Exciter.

3. Replace Spark Rod Tip.

4.

Remove Spark Rod Tip, disconnectflexible cable and:

A) Check continuity between the socket

connector, Spark Rod Tip end, and the

contact at the Flexible Cable end. If

resistance is more than 1.0 Ohm,

rebuild or replace cable.

B)

Measure the resistance between the

center conductor and the outer surface

of the Spark Rod using a standard

multimeter. Replace center conductor if

resistance is less than 10 Megohms.

C) Check Rod Tip Insulator. If broken,

replace with P/N 5000103 using

Retainer Nut Removal Tool

P/N 0570.0001.01.

5. Remove electrical supply, then:

A) Discharge capacitors C1 and C2.

Disconnect one lead from capacitorsC1 and C2. Using a standard

multimeter on a high Ohms range, put

leads across capacitors terminals.

Meter should rapidly swing right then

slowly drift left (infinite resistance).

Replace if defective.

B)

Check transformer, resistors and diodes

using a standard multimeter. Replace if

defective.

C) Substitute Spark Gap Discharge

C ll l if d f i


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8. REPAIR/ REPLACEMENT

Filed Repair. Extreme caution is recommended with all field repairs, and should be limited to

trained personnel in a suitably equipped workshop. No field repairs should be attempted on the

boiler where proper access is not available.

Spark Rod Tips are not repairable either in he field or at the factory.

SPARE PARTS: Spare parts may be ordered by using the part numbers listed on the drawings.

FACTORY REPAIR: Based upon return material authorization, Exciters, Flexible cables, and

Spark Rods may be returned for factory rebuilding. Contact the factory for tagging and shippinginstructions. Repair costs will be estimated prior to initiating work.

For spare parts ordering on repair assistance please contact:

HINDUSTHAN THERMOMETERS,

5-B, INDUSTRIAL ESTATE,

AMBALA CANTT – 133 006,

HARYANA, INDIA

PH: +91-171-2699237

FAX: +91-171-2699037

E-mail: [email protected]


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APPENDIX

DRAWING DESCRIPTION NUMBER

EXCITER ASS’Y 12 JOULE 0775,0004.XX

FLEX. CABLE ASS’Y SINGLE SOCKET TER. 0757.0041.XXFLEX. CABLE ASS’Y 2 WIRE CONN. 0757.0042.XX

FLEX. CABLE ASS’Y SParc S12-1 0757.0017.XX

ASS’Y 5/8” FLEX. SPARK ROD 0645.0026.XX

ASS’Y 5/8” RIGID SPARK ROD PIN BASE CONN. 0645.0027.XX

RIGID SPARK ROD ASSY 2 WIRE CONN. 0645.0029.XXALUMIN INSULATOR FOR IGNITOR ROD HT-AIIR-01

SPARK ROD TIP 0147.0002.01

RETRACTOR ASSEMBLY (8” STROKE) 5000086

HIGH VOLTAGE CAPACITOR (ROUND SHAPE) HT-10/2300-1

HIGH VOLTAGE CAPACITOR (ROUND SHAPE) HT-12/3000-1

YN10-2500R4C-HC HT-10/2500-HC

BOARD ASSEMBLY 5000078

BOARD ASSEMBLY 5000079

WIRING DIAGRAM 12.0 JOULE EXICITER 5000080

HEA IGNITOR INSTALLATION IN T.T. BURNER PSG-79-10-9226

HEA IGNITOR INSTALLATION 2-41-500-00320


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