Original Operating Instructions
Item number.:
1 119 525
D−HG 400
High Energy
Ignition Device
Before starting any work, please read the Operating Instructions!
GmbH · Kollaustraße 105 · 22453 Hamburg · www.durag.de
Original Operating Instructions
High Energy Ignition Device D−HG 400
Document:
man_dhg400_en.docx
Version:
26.04.2013
Last update:
26.04.2013
Print date:
26.04.2013
Previous
version:
21.11.2011
European
testing basis
Register number
Item number: 1 119 525
DURAG GmbH
Kollaustraße 105
22453 Hamburg
Telephone:
Fax:
Email:
Website:
+49 (40) 55 42 18 – 0
+49 (40) 58 41 54
[email protected]
www.durag.de
This documentation
 (approx. 124 pages) was compiled with the greatest care;
 is not intended for the US market. Documentation to ANSI Z535 is available on request. Order
addresses can be found on page 123;
 or parts thereof may not be reproduced or distributed without express permission from DURAG
GmbH, irrespective of how this is done, in what language or by what medium, electronic or
mechanical;
 always relates to the complete device, even if individual program modules or parts have not
been purchased;
 relates to the current design of the device at the time of update of this documentation (see
above);
 is subject to changes to its content without notification;
 contains figures which may differ due to further technical developments or to the manageable
scale of their actual appearance. No claims regarding the supply of identical products can
therefore be derived from the illustrations shown.
Contents
Contents
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
General
9
Information on Operating Instructions ..........................................................................................9
Explanation of symbols ..............................................................................................................10
Limitation of liability ....................................................................................................................11
Instructions on warranty .............................................................................................................12
Spare parts .................................................................................................................................12
Customer service .......................................................................................................................12
Copyright ....................................................................................................................................12
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
Safety
17
General safety instructions .........................................................................................................17
Designated use ..........................................................................................................................18
Responsibility of the operating company ...................................................................................19
Staff ............................................................................................................................................20
Personal protective equipment...................................................................................................21
Fundamental dangers ................................................................................................................22
Device-specific dangers and safety measures ..........................................................................25
Behaviour in the event of hazards and accidents ......................................................................26
Description and location of safety equipment and emergency stop mechanisms .....................27
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
Explosion protection
31
Basics .........................................................................................................................................31
Division of device groups into categories ...................................................................................32
Devices with pressure-resistant enclosures - "Ex d"..................................................................33
Increased safety - "Ex e" ............................................................................................................34
Protection by "Ex t" housing .......................................................................................................35
Safety for Ex devices .................................................................................................................35
Additional instructions for safe operation ...................................................................................36
Significance of the Ex data on the rating plate ...........................................................................37
4
4.1
4.2
4.3
4.4
4.5
Delivery
43
Instructions for delivery ..............................................................................................................43
Transportation, packaging and storage .....................................................................................43
Standard items supplied .............................................................................................................45
Optional equipment ....................................................................................................................46
Special accessories ...................................................................................................................48
5
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
Product description, principle, design and function
53
Basic features.............................................................................................................................53
Certifications...............................................................................................................................53
Device description ......................................................................................................................53
Areas of application, designated use .........................................................................................54
Conformity/approvals .................................................................................................................54
Designation of device components ............................................................................................55
Identification of the product ........................................................................................................56
Functional description ................................................................................................................57
Functional description battery module D−HG 400-81 ................................................................57
6
6.1
6.2
6.3
6.4
6.5
6.6
Installation, commissioning
61
Safety .........................................................................................................................................61
Transportation ............................................................................................................................62
Qualification of staff for installation and initial commissioning ...................................................62
Installation and initial commissioning .........................................................................................62
Operation....................................................................................................................................68
Commissioning ...........................................................................................................................68
D−HG 400
3
Contents
6.7
6.8
6.9
6.10
Emergency stop - shutting down in case of emergency ........................................................... 68
Turning on and off ..................................................................................................................... 68
Normal operation ....................................................................................................................... 69
Dismantling and disposal .......................................................................................................... 69
7
7.1
7.2
7.3
7.4
7.5
7.6
7.7
Maintenance
73
Safety ........................................................................................................................................ 73
Qualification of maintenance staff ............................................................................................. 74
Maintenance intervals ............................................................................................................... 74
Maintenance operations ............................................................................................................ 75
Customer service....................................................................................................................... 79
Spare parts ................................................................................................................................ 79
Identifying and rectifying faults .................................................................................................. 85
8
8.1
8.2
8.3
8.4
Technical data
89
Technical data for High Energy Ignition Device ........................................................................ 89
Technical data for ignition lances .............................................................................................. 90
Dimensional drawings - D−HG 400 ........................................................................................... 92
Authorised cable glands (only D−HG 400-53 /-54 /-72 Ex) ..................................................... 115
9
9.1
9.2
Documents
116
EC declaration of conformity ................................................................................................... 116
EC type test certificate ............................................................................................................ 118
10
Index
121
11
DURAG GROUP company addresses
123
Figures
Figure 3.1: Configuration of cable entries with sealing compound ...................................................... 36
Figure 3.2: Components of connection cable D-ZL 441 Ex................................................................. 37
Figure 3.3: Ex rating plate High Energy Ignition Device D−HG 400.................................................... 38
Figure 5.1: Parts definition ................................................................................................................... 55
Figure 5.2: Where can I find the rating plate? ..................................................................................... 56
Figure 5.3: Example rating plate High Energy Ignition Device D−HG 400 .......................................... 56
Figure 5.4: Example rating plate D−HG 400 ....................................................................................... 57
Figure 6.1: Retraction zone for igniting oil burners .............................................................................. 63
Figure 6.2: Optimum ignition position for igniting oil burners .............................................................. 64
Figure 6.3: Wiring diagrams - High Energy Ignition Device................................................................. 66
Figure 6.4: Wiring diagram - Ex High Energy Ignition Device ............................................................. 67
Figure 7.1: Replacement of ignition tip on the D−HG 400 ................................................................... 75
Figure 7.2: Replacing the ignition tip on the D-ZL 4xx ........................................................................ 77
Figure 7.3: Dismantling the ignition lance D-ZL 4xx ............................................................................ 78
Figure 7.4: Location of fuse on D−HG 400 .......................................................................................... 80
Figure 7.5: Opening the D−HG 400 ignition device housing ............................................................... 80
Figure 7.6: Opening the D−HG 400-54 Ex ignition device Ex housing ............................................... 81
Figure 7.7: Location of fuse on D−HG 400-54 Ex housing .................................................................. 82
Figure 7.8: Opening the D−HG 400-72 Ex ignition device Ex housing ............................................... 83
Figure 7.9: Location of fuse on D−HG 400-72 Ex housing .................................................................. 83
Figure 7.10: D−HG 400 o-ring in the front panel ................................................................................... 84
Figure 8.1: Dimensional drawing - High Energy Ignition Device D-HG 400-50/-51 ............................ 93
Figure 8.2: Dimensional drawing - Battery module D-HG 400-81 ....................................................... 94
Figure 8.3: Dimensional drawing - High Energy Ignition Device D-HG 400-80................................... 95
Figure 8.4: Dimensional drawing - D-ZL 411 CG ignition lance .......................................................... 97
Figure 8.5: Dimensional drawing - D-ZL 421 ignition lance for D−HG 400-65 .................................... 99
4
D−HG 400
Contents
Figure 8.6: Dimensional drawing - D-ZL 422 ignition lance for D−HG 400-65 ...................................101
Figure 8.7: Dimensional drawing - D-ZL 423 ignition lance ...............................................................103
Figure 8.8: Dimensional drawing - D-ZL 430 /431 Ex ignition lance ..................................................105
Figure 8.9: Dimensional drawing - D-ZL 441 Ex ignition lance for D-HG 400 -54 Ex and -72 Ex......107
Figure 8.10: Dimensional drawing - High Energy Ignition Device D−HG 400−65/D-ZL 425 ign.lance 109
Figure 8.11: Dimensional drawing - Ex housing D−HG 400-53 Ex ......................................................110
Figure 8.12: Dimensional drawing - Ex housing D−HG 400-54 Ex ......................................................111
Figure 8.13: Dimensional drawing - Ex housing D−HG 400-72 Ex ......................................................112
Figure 8.14: Dimensional drawing for ignition lance ..........................................................................113
Figure 8.15: Dimensional drawing - Weather protection hood D−HG 400 WSH .................................114
Tables
Table 3.1 Division into zones for DURAG devices ...............................................................................32
Table 5.1 D−HG 400 options ................................................................................................................54
Table 5.2 Key for part definition ...........................................................................................................55
Table 7.1 Maintenance schedule .........................................................................................................74
Table 8.1 Technical data for ignition devices .......................................................................................90
Table 8.2 Technical data for ignition lances .........................................................................................91
Table 8.3 Ordering texts for type D−HG 400 – 50 / 51 ........................................................................92
Table 8.4 Ordering texts for type D−HG 400 – 80 /81 .........................................................................94
Table 8.5 Ordering texts for type D-ZL 411 CG ignition lance .............................................................96
Table 8.6 Ordering texts for type D-ZL 421 ignition lance....................................................................98
Table 8.7 Ordering texts for ignition lance (hand lance), type D-ZL 422 ...........................................100
Table 8.8 Ordering texts for type D-ZL 423 ignition lance..................................................................102
Table 8.9 Ordering texts for type D-ZL 430 ignition lance..................................................................104
Table 8.10 Ordering texts for type D-ZL 441 Ex ignition lance ............................................................106
Table 8.11 Authorised cable glands .....................................................................................................115
D−HG 400
5
D−HG 400
High Energy Ignition Device
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
General
Information on Operating Instructions
Explanation of symbols
Limitation of liability
Instructions on warranty
Spare parts
Customer service
Copyright
1. General
1
General
We hope that our products and services will make a significant contribution to
your success. We will be delighted if the information in these Operating
Instructions achieves this.
Should you require information that is not sufficiently covered in this document,
then please request the information you need from your appropriate DURAG
GmbH agent. Our Support & Service department is also available to answer
any questions on DURAG GROUP products and services. You will find the
addresses and telephone numbers on page 123 (DURAG GROUP company
addresses).
If anything is unclear:
get in touch with the manufacturer!
Information on the company and its products can also be found on the Internet
at www.durag.de
1.1 Information on Operating Instructions
These Operating Instructions provide important information on how to use the
High Energy Ignition Device D−HG 400. Compliance with all specified safety
instructions and handling guidelines is a prerequisite for safe working.
In addition, the applicable local accident prevention regulations and general
health and safety rules must be adhered to for the High Energy Ignition Device
and their application.
Before starting any work, please read the Operating Instructions!
In particular read the section "Safety" and the appropriate safety instructions
thoroughly.
These operating instructions are a component part of the product and must be
kept in the close vicinity of the High Energy Ignition Device D−HG 400, so that
the staff have access to them at all times.
This documentation
 (approx. 124 pages) was compiled with the greatest care;
 is not intended for the US market. Documentation to ANSI Z535 is available
on request. Order addresses can be found on page 123;
 or parts thereof may not be reproduced or distributed without express
permission from DURAG GmbH, irrespective of how this is done, in what
language or by what medium, electronic or mechanical;
 always relates to the complete device, even if individual program modules
or parts have not been purchased;
 relates to the current design of the device at the time of update of this
documentation (see above);
 is subject to changes to its content without notification;
D−HG 400
9
1. General
 contains figures which may differ due to further technical developments or
to the manageable scale of their actual appearance. No claims regarding
the supply of identical products can therefore be derived from the
illustrations shown.
1.2 Explanation of symbols
In order to make the text of these Operating Instructions clear, text elements
such as safety instructions, warnings, tips, keyboard symbols, menu
addresses etc. are displayed differently.
Warning notices are represented by symbols in these Operating Instructions.
The instructions are introduced by signal words, which express the extent of
the hazard.
Comply strictly with these instructions and act responsibly to prevent
accidents, personal injury and damage to property.
Warnhinweise
DANGER!
... refers to an immediately hazardous situation, which if not prevented will
result in death or serious injury.
WARNING!
…refers to a possible hazardous situation, which if not prevented may result
in death or serious injury.
CAUTION!
... refers to a possible hazardous situation, which if not prevented may result
in slight or minor injury.
Tips and recommendations
An instruction or tip is shown as follows:
... highlights useful tips and recommendations, as well as information aimed
at ensuring efficient and fault-free operation.
Specific safety instructions
To draw attention to specific dangers, warning notices and signal words are
used in conjunction with the following symbols:
10
D−HG 400
1. General
General warning symbol
Hot surface
Electric power
Devices
with
an
electrostatic
hazard
(ESD)
Explosive atmosphere
Other symbols used
Apart from the warning notices and safety instructions, the following general
instructions and associated pictograms are also used to draw particularly
important information to your attention:
Before starting any work, please read the Operating Instructions!
Concerns instructions for environmental protection
Disposal instructions: product must not be handled as normal household
waste, undertake disposal as special waste in accordance with local
regulations.

An (→) indicates that the following term is explained in the glossary.
×
An × in a list indicates that something must not be done or that something
is not suitable.

Unless otherwise indicated: all measurements in mm

These Operating Instructions are also available as a pdf file, on CD/DVD,
or on the Internet!
1.3 Limitation of liability
All information and instructions in this manual have been compiled on the
basis of the applicable standards and regulations, current technology and
many years of knowledge and experience.
The manufacturer accepts no liability for damages arising from:
D−HG 400

failure to adhere to the Operating Instructions

incorrect use

use of unauthorised staff (see section 2.4 starting on page 20)

unauthorised modifications

technical changes
11
1. General

use of unapproved spare parts

use of defective and/or improperly repaired devices
Furthermore, the obligations agreed in the contract of sale, the general
conditions of business ("Conditions of supply for goods and services in the
electrical industry" (ZVEI)) and the manufacturer's Conditions of Supply,
together with the statutory regulations in force at the date of signing the contract,
are all applicable.
1.4 Instructions on warranty
The terms of the warranty can be found as a separate document in the
General Terms and Conditions of Business.
Modifications and changes to the High Energy Ignition Device are not
permitted. Any tampering with the device will cause the warranty to lapse.
Fault-free and safe operation of the device depends on appropriate
transportation, correct storage, installation and assembly, as well as careful
operation.
1.5 Spare parts
WARNING!
Danger of personal injury due to incorrect spare parts!
Incorrect or faulty spare parts may lead to damage, malfunctions or complete
failure, as well as affecting safety.
 Only use original spare parts from the manufacturer.
Source spare parts from an authorised agent or directly from the manufacturer.
For the manufacturer's address, see page 2.
1.6 Customer service
If anything is unclear, get in touch with the manufacturer. Our Service
Department is available if you require any technical information.
Details of relevant offices or partners are available on the Internet at any time,
see the manufacturer's address on page 2, or DURAG GROUP company
addresses, see page 123.
1.7 Copyright
These Operating Instructions must be treated confidentially. They are intended
exclusively for staff employed to use the High Energy Ignition Device. Passing
on the Operating Instructions to third parties without the written consent of the
manufacturer is not permitted.
The Operating Instructions, or sections of them, may not be reproduced,
distributed or translated into other languages without the written consent of the
manufacturer, regardless of the form in which this is done and the media electronic or mechanical - involved.
© DURAG GmbH 2013 All rights reserved.
12
D−HG 400
1. General
The specifications, texts, drawings, pictures and other information contained
in this document are protected by copyright and subject to industrial property
rights. Any improper use is punishable by law.
D−HG 400
13
D−HG 400
High Energy Ignition Device
2
2.1
2.2
2.3
2.4
2.4.1
2.4.2
2.5
2.6
2.6.1
2.6.2
2.6.3
2.6.4
2.6.5
2.6.6
2.7
2.8
2.9
Safety
General safety instructions
Designated use
Responsibility of the operating company
Staff
Staff, qualification
Unauthorised staff
Personal protective equipment
Fundamental dangers
Hazard due to electrical equipment
Securing against reconnection
Hazard due to easily inflammable materials
Hazard due to hot surfaces
Hazard due to sharp edges and pointed corners
Avoidance of consequential damage in the event of a system fault
Device-specific dangers and safety measures
Behaviour in the event of hazards and accidents
Description and location of safety equipment and emergency stop mechanisms
2. Safety
2
Safety
Before starting any work, please read the Operating Instructions!
Legislation requires us to provide you with important information to ensure
your safety and to draw your attention to how damage to this device and other
equipment can be avoided. If you do not adhere to these instructions, DURAG
GmbH cannot be held liable for any damage resulting from negligent or
intentional non-compliance with the information in these instructions!
Please comply with the following warnings and safety instructions in this
manual. They are there to help avoid hazards that could endanger the life
or health of staff, and for avoidance of damage to property. They are also
intended to ensure safe and fault-free operation.
Commission the High Energy Ignition Device D−HG 400 as described in
section 6 "Installation, ” starting on page 61. Follow the instructions in this
manual.
2.1 General safety instructions
The DURAG High Energy Ignition Device D−HG 400 is designed and built
using state of the art technology and complies with the recognised safety
regulations. Despite this, dangers can arise.
You must only use the product when it is in perfect condition, while adhering to
the operating instructions. Any change to normal operation should be taken as
a serious indication of impaired functionality. In this regard, pay attention to:

emission of smoke or unusual smells,

unusual noises through and during operation of the device,

excessive temperatures of system components,

changes in power consumption without obvious cause,

tripping of monitoring devices.
Improper use or handling can result in damage to health or property. Follow
the instructions for all actions on the D−HG 400 and the safety instructions and
warning notices in the individual sections of this manual.
The following warning and safety instructions apply in full to the High Energy
Ignition Device:

When preparing and carrying out work:
Comply with the legal requirements applicable for the system and the
corresponding technical regulations. Adhere to national safety and accident
prevention.

Handle in accordance with:
... the local, plant-specific conditions,
... hazards caused by operational processes,
... specifications.
These operating instructions are a component part of the product and must be
kept in the close vicinity of the High Energy Ignition Device D−HG 400, so that
the staff have access to them at all times.
D−HG 400
17
2. Safety

Ensure compliance with the instructions set out for avoidance of dangers
and damage.

Suitable protective mechanisms and personal protective equipment must
be available in sufficient quantities and used by staff, in accordance with
the relevant potential hazards.

The device may only be operated in perfect condition in accordance with
the performance data and in compliance with the safety instructions!
Damage may nullify the explosion protection.

The device as an entity and also its individual components may be used
only when in their original configuration.

Maintenance work or repairs, which are not described in the Operating
Instructions, may not be carried out without the manufacturer's prior
approval.

Only supply the ignition lance with high voltage within the combustion
chamber.
2.2 Designated use
The High Energy Ignition Device D−HG 400 is designed exclusively for the
designated purpose described here.
The DURAG High Energy Ignition Device D−HG 400 is used for automatic
ignition of oil and gas burners of any capacity in the combustion chamber of:

industrial plants

cement plants

waste incinerators

steam generators

heating plants

refineries

power plants

chemical works
Also for the ignition of:

flare stacks and/or

H2S burners in claus plants
at refineries, this ignition equipment is well suited due to its high level of
operational safety.
The operator must take appropriate measures to ensure that ignition does not
take place in an explosive medium.
The High Energy Ignition Device D−HG 400 may:
18

be used exclusively for the designated purpose described here and only in
the design intended for the relevant application (see page 45 onwards).

only be operated in line with the specifications on the rating plate and within
the parameters set out in the Technical data starting on page 89. Otherwise
there is a risk of personal injury and damage to property.

be used for special tasks, such as the ignition of flares or in Ex zones of
claus plants (H2S burners), only in the configuration suited to this purpose
(see also section 3 Explosion protection and 4.4 Optional equipment.
D−HG 400
2. Safety
WARNING!

be used in explosion risk areas in an appropriate Ex configuration (see
rating plate).
×
The High Energy Ignition Device or ignition lance is not suitable for anyone
to climb on or stand on!
Risk if used other than for the designated purpose!
Any use of the High Energy Ignition Device beyond the designated purpose
and/or of another kind may lead to hazardous situations.
There is a risk of personal injury and damage to property.
Only operate the High Energy Ignition Device in accordance with the data on the
rating plate and the parameters given in the Technical data starting on page
89. All data in these Operating Instructions must be strictly adhered to!
Claims of any kind resulting from incorrect use will not be accepted.
The operator bears sole liability for all damage caused by use other than for
the designated purpose.
Fault-free and safe operation of this High Energy Ignition Device requires
appropriate transportation, proper storage, installation and assembly, as well
as careful operation and maintenance by qualified staff.
2.3 Responsibility of the operating company
The High Energy Ignition Device is intended for use in commercial operations.
This means that the operator of the High Energy Ignition Device is subject to
the statutory health and safety obligations, along with the relevant directives,
legislation and standards.
In addition to the health and safety instructions contained in these Operating
Instructions, the applicable safety, accident prevention and environmental
protection regulations for the area of application of the High Energy Ignition
Device must be complied with. In particular, the following apply to this:
D−HG 400

The operator must obtain information about the applicable health and safety
regulations and carry out a risk assessment to determine any additional
hazards arising from the special working conditions at the place of use of
the High Energy Ignition Device. He must implement these in the form of
operating instructions for operation of the High Energy Ignition Device.

Throughout the period of use of the High Energy Ignition Device, the
operator must check whether the operating instructions that he has compiled
satisfy the latest issue of the regulations, and must update them as required.

The operator must clearly regulate and specify who has responsibility for
installation, operation, maintenance and cleaning.

The operator must ensure that all employees who deal with the High
Energy Ignition Device have read and understood the Operating
Instructions . In addition, he must train the staff and inform them about the
hazards at regular intervals.

Furthermore, the operator is responsible for ensuring that the High Energy
Ignition Device is at all times in technically perfect condition, i.e. that the
maintenance work has been carried out (see section 7).

The operator must provide the necessary protective equipment for the staff.

When using the Ex configuration, the operator must document all measures
taken to protect employees in the explosion protection document.
19
2. Safety
2.4 Staff
2.4.1 Staff, qualification
WARNING!
Risk of personal injury where qualification is insufficient!
Improper use can lead to severe personal injury and damage to property.
Activities should only be carried out by appropriately trained specialist staff.
Specific training programmes and levels of knowledge are assumed for
various jobs in these Operating Instructions. Only when staff have this
knowledge, are they qualified and authorised in terms of these Operating
Instructions.
In order to work on the D−HG 400, authorised staff members have the
following qualifications. On each occasion it is indicated which qualifications
are needed for the various activities in these Operating Instructions.

Specialist staff (operating staff)
have the specialist training, knowledge and experience, along with the
knowledge of the applicable regulations, to enable them to carry out the
work assigned to them and assess potential hazards independently.

Explosion risk knowledge
is a requirement for all staff who work on the High Energy Ignition Device in
any kind of Ex zone. Knowledge of how to identify and avoid explosion
hazards in line with the explosion protection document is required.
Employees must be familiar with how acute hazards can be prevented and
how and where work on the devices can be undertaken safely.
The specialist explosion risk knowledge must be appropriate for the region
in which the device is installed (ATEX, FM, CSA, etc.). The approval of
which training or test is required in order to be able to work in Ex zones is
governed by national regulations or legislation.

Electricians (maintenance staff)
have the specialist training, knowledge and experience, along with the
knowledge of the applicable standards and regulations, to enable them to
carry out work on electrical equipment and assess potential hazards
independently. Electricians are specially trained for the working
environment in which they operate, and they know the relevant standards
and regulations.
The following knowledge is specifically required for the above-mentioned
specialist staff through up-to-date training provided by the operator:

precise knowledge of operationally-related hazards and their avoidance.

knowledge of system conditions, applicable standards, regulations,
directives, operating instructions and accident prevention regulations in the
context of the work assigned.

possible hazards due to incorrect behaviour.

sufficient knowledge about the D−HG 400 (High Energy Ignition Device).

for acquisition of specialist knowledge of the device, DURAG offers
appropriate courses.
information on these is available on the Internet on the DURAG Homepage
or by telephone (see manufacturer's address on page 2).
Only those people are accredited as staff who can be expected to perform
their work reliably.
20
D−HG 400
2. Safety
People whose responsiveness is compromised by substances such as drugs,
alcohol or medications will not be authorised.
When selecting staff, the local regulations regarding age and professional
qualifications should be complied with.
2.4.2 Unauthorised staff
WARNING!
Danger for unauthorised staff!
Unauthorised staff who do not meet the requirements described here, are not
familiar with the hazards in the working area. Incorrect behaviour can lead to
severe personal injury and damage to property.
For this reason:
 Ensure that unauthorised staff do not enter the working area.
 If in any doubt, approach staff and instruct them to leave the working area.
 Stop all work if any unauthorised staff are in the working area.
2.5 Personal protective equipment
During work, it may be necessary to wear personal protective equipment to
minimise health hazards.
Detailed specifications must be set out by the operator, depending on the
potential plant-specific hazards.

The protective equipment necessary for the relevant work must be worn at
all times when working.
×
Do not wear any rings, necklaces or other jewellery when working on the
D−HG 400.

Comply with any signs relating to personal protective equipment in the
working area, e.g.:
Protective work clothing
is tight fitting work clothing with low tear strength, narrow sleeves and no
protruding parts. It is primarily intended to protect against burns.
Safety helmet
for protection against parts falling and flying around, as well as against
pointed or sharp edges.
Safety shoes
for protection against heavy, falling parts and prevention of slipping on a
slippery floor surface.
Face protection
to protect the eyes and the face against flames, sparks or embers, as well as
hot particles or exhaust gases.
D−HG 400
21
2. Safety
Protective gloves
to protect the hands against friction, abrasion, cuts or deeper wounds, as well
as contact with hot surfaces.
2.6 Fundamental dangers
This section sets out the remaining risks identified by the risk assessment.
The safety instructions set out here and the warning notices in the other
sections of these Operating Instructions must be adhered to, in order to
prevent health hazards and hazardous situations.
2.6.1 Hazard due to electrical equipment
Das mit Installation, Inbetriebnahme und Wartung betraute Personal muss
gründlich mit allen Gefahrenquellen und Instandsetzungsmaßnahmen gemäß
dieser Operating Instructions vertraut sein.
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 1,500 volts is generated to create the ignition sparks in the
ignition device.

If there is any damage to the insulation, switch off the power immediately
and have repairs carried out.

Before servicing, cleaning or repairing the device, disconnect the power
supply and secure it against reconnection.

Before removing any casings or guards, de-energise the devices and
check that they are dead.
The High Energy Ignition Device contains capacitors whose discharge
time is a minimum of 60 seconds. Only then can work be carried out
safely on the device and ignition tip (in the Ex zone wait at least 5
minutes due to possible spark generation).

Only allow electricians to work on electrical equipment.

Never bypass fuses or render them inoperative. When replacing fuses,
always comply with the correct amperage and the correct characteristics
(see rating plate).

Keep moisture away from live components. Moisture can lead to short
To avoid hazards:
22

Only connect the High Energy Ignition Device to the supply voltage stated
on the rating plate.

Only connect and switch on the operating voltage after complete
installation. Switching on the operating voltage means the device (standard
version) immediately starts ignition!

Cables must be routed so as exclude the risk of accidents by people
tripping over them or catching themselves up in them.

Only operate the High Energy Ignition Device's ignition lance within the
combustion chamber.

An electrical voltage may only be applied when all housing covers are
properly sealed! All housing sections must be undamaged! Nobody must
stay within the danger area of the ignition lance.
D−HG 400
2. Safety
ATTENTION!
Damage to electronic components due to
electrostatic discharge (ESD)
Electronic components are becoming increasingly small and complex. This
means their susceptibility to damage from electrostatic discharge is
increased. For all work on the open device, measures must be taken against
electrostatic discharges for the protection of these components (ESD
protection).
For prevention of static charging of the human body, service employees can for
instance be equipped with a personal grounding system.
2.6.2 Securing against reconnection
DANGER!
Risk of fatal injury due to unauthorised reconnection!
When working in the danger area, there is the danger of the power supply
being switched on without authorisation. This leads to the risk of fatal injury
for people in the danger area.


Comply with the instructions on ensuring against reconnection in the
sections of this manual.
Always adhere to the procedure for ensuring against reconnection
described below.
Securing against reconnection:
Switch secured with a lock
on: ………….. at …….. o'clock
DO NOT SWITCH ON!
The lock for this must only be
1. Switch off the power supply.
2. If possible, secure the switch with a lock and affix a
clearly visible sign to the switch.
3. Have the key kept by the member of staff named on the
sign.
removed
by: ……………….
after making sure that nobody is
in the danger area.
Switched off
on: ………….. at …….. o'clock
DO NOT SWITCH ON!
This may only be switched on
by: ……………….
after making sure that nobody is in
the danger area.
D−HG 400
4. If it is not possible to secure a switch with a lock, affix a
clearly visible sign to the switch.
5. After all the work has been carried out, make sure that
nobody is in the danger area any longer.
6. Make sure that all protective equipment is installed and
functioning properly.
7. Until this point, do not remove the sign, and if applicable
the lock, or switch on the power supply again.
23
2. Safety
2.6.3 Hazard due to easily inflammable materials
WARNING!
Fire risk due to easily inflammable materials!
Easily inflammable materials, liquids or gases can catch fire and cause
serious or fatal injuries.




Do not store or deposit any materials of this kind within the danger area
and in close proximity to the High Energy Ignition Device.
Keep fire extinguishers readily available.
Immediately report suspect materials, liquids or gases to those
responsible.
Immediately stop work in the event of fire and, if applicable, cut off the
electricity, water or gas supply. Leave the danger area until the all clear is
given!
2.6.4 Hazard due to hot surfaces
CAUTION!
Risk of burning due to hot surfaces!
Contact with hot components can cause burns.


When carrying out any work in the vicinity of hot components, in principle
always wear protective work clothing and protective gloves.
Before carrying out any work, make sure that all components have cooled
to the ambient temperature.
2.6.5 Hazard due to sharp edges and pointed corners
CAUTION!
Danger of injury on edges and corners!
Sharp edges and pointed corners can cause scratches and cuts on the skin.


When working close to sharp edges and pointed corners, proceed with
care.
If in doubt, wear protective gloves and/or a safety helmet..
2.6.6 Avoidance of consequential damage in the event of a system fault
In order to prevent and limit faults that can directly or indirectly result in
physical injuries or damage to property, the operator must ensure that:
24

at any time responsible maintenance staff can be informed and are
available at short notice.

maintenance staff have been trained to identify and rectify faults in the
D−HG 400 and the associated systems.

if necessary, defective system components can be switched off immediately.

switching off the device will not lead to unpredictable consequential faults
and damage.
D−HG 400
2. Safety
2.7 Device-specific dangers and safety measures
The ignition equipment is designed in such a way that no risks can arise for
the operating staff when it is used properly.
ATTENTION
D−HG 400

Where there are ignition lances which comprise several component parts
(as a rule with lengths over 4 m):
Only connect to the mains power after complete installation!

Before removing the plug-in electronics unit or before opening an Ex
housing:
Switch off the mains power supply to the ignition device!
The High Energy Ignition Device contains capacitors whose discharge
time is a minimum of 60 seconds. Only then can work be carried out
safely on the device and ignition tip (in the Ex zone wait at least 5 minutes
due to possible spark generation).

Tips of the ignition lances are subject to natural wear. This means they are
usually replaceable. Before replacing ignition lance tips:
Switch off the mains power supply to the ignition device. For this purpose,
see the section on "Replacing ignition tips" (device-specific) starting on
page 75.

All devices, as long as there are plug connections available, are supplied
with the required pre-assembled connection cables.
For all connections and installations carried out by the operator on the
ignition device or the ignition lance:
Comply with local regulations on the installation of electrical equipment!

Locate the ignition lance in the burner in such a way that the lance tip
protrudes into the fuel mist during the ignition process. After successful
ignition, withdraw the lance tip from the temperature zone of the flame.
With automatic feeding and retraction of the ignition device, for example
with the pneumatic retraction unit D-VE 500, carry out the burner design in
such a way that there is no risk for the operating staff from the moving
parts!

For D-HG 400-53 Ex, D-HG 400-54 Ex, D-HG 400-72 Ex, D-HG 400-65:
Before commissioning, firmly fix the ignition lance and the separate
green/yellow earth connection (PE) in accordance with the relevant
connection diagrams.

For ignition devices which are set up in an Ex zone, take the appropriate
regulations for installation and handling into consideration. Do not open Ex
housings when they are live and at the earliest 5 minutes after deenergising (see above)!
Explosion protection (ATEX, FM, CSA, etc.)
When using Ex devices or components (see rating plate), it is absolutely
essential to read the information and safety instructions in section 3 Explosion
protection as well.
25
2. Safety
2.8 Behaviour in the event of hazards and accidents
Preventive measures

Always be prepared for accidents or fire! Note emergency numbers.

Store first aid equipment (first aid kits, blankets, etc.) and fire extinguishers
within easy reach.

Familiarise staff with accident reporting, first aid and emergency equipment.

Keep access routes for emergency vehicles clear.
In case of emergency: take the correct action

Initiate first aid measures.

Rescue staff from the danger zone.

Notify the person responsible at the place of use.

Notify a doctor and/or the fire brigade.

Clear access routes for emergency vehicles.
Emergency reporting - doing it properly!
Dial the emergency number.
Speak slowly, loudly and clearly and give clear information:

Where did it happen? - Exact location information is required:

What happened? - Is it a fire, an explosion or an operational accident? Are
any people trapped or buried?

How many people are injured?

What injuries do they have? - Is the patient responsive? Are there any
breathing or circulation problems? Is anyone bleeding heavily?

Wait for any queries!
Measures in the event of accidents affected by high voltage
26

Notify the people responsible at the place of use.

Notify a doctor and/or the fire brigade.

If providing help, make absolutely sure you pay attention to your own
protection!
Make sure the equipment has been de-energised.
Disconnect equipment and devices from the power supply via the
emergency stop button or fuse. Simply switching off the device or the circuit
does not ensure that there is no voltage.

Do not under any circumstances touch people who are under the influence
of high voltage without protection. Use protective equipment or nonconducting insulation material.

Move exposed live cables (or ignition lance) away from the injured person
using non-conducting items (a dry wooden broom handle).

When patients are unconscious, the priority, after switching off the power
supply, is to ensure respiratory and cardiovascular functions. If necessary
initiate CPR immediately.
Trained first-aid staff carry out defibrillation where there is ventricular
fibrillation. If available, a public-access defibrillator is used.
D−HG 400
2. Safety

Where patients are able to respond, cool the burn injuries down and cover
with a low-germ, lint-free dressing.
The patient should not be left unattended, even if they feel completely well,
until any heart damage has been ruled out (by a doctor and an
electrocardiogram).
Further measures are generally carried out by the emergency services which
have been alerted.
Authoritative instructions on how to proceed after an accident are always
given by the trained first-aider on site. The measures listed above are not a
substitute for either training in first aid or specialist medical care .
2.9 Description and location of safety equipment and emergency
stop mechanisms
The operator must incorporate safety measures for the High Energy Ignition
Device into the safety concept for the overall system. This also involves the
provision and description of safety and emergency stop equipment, including
information on the location of the emergency stop button.
D−HG 400
27
D−HG 400
High Energy Ignition Device
3
3.1
3.2
3.2.1
3.2.2
3.2.3
3.2.4
3.3
3.4
3.5
3.6
3.7
3.7.1
3.7.2
3.8
3.8.1
Explosion protection
Basics
Division of device groups into categories
Division into zones
Types of ignition protection
Temperature classes
Equipment protection levels - EPL
Devices with pressure-resistant enclosures - "Ex d"
Increased safety - "Ex e"
Protection by "Ex t" housing
Safety for Ex devices
Additional instructions for safe operation
D−HG 400-72 Ex - professional use of cable entries - Ex d with sealing compound
D-ZL 441 Ex ignition lance
Significance of the Ex data on the rating plate
Identification of Ex zone(s) on the rating plate (ATEX compliance)
3. Explosion protection
3
Explosion protection
This section only concerns devices and components which may be used in
areas with a risk of explosion.
It gives you basic information about explosion protection and you will learn
something about the meaning of the Ex data on the rating plate and find the
required safety instructions for Ex devices.
We hope that our products and services will make a significant contribution to
your success. We will be delighted if the information in these Operating
Instructions achieves this.
Should you require information that is not sufficiently covered in this document,
then please request the information you need from your appropriate DURAG
GmbH agent. Our Support & Service department is also available to answer
any questions on DURAG GROUP products and services. You will find the
addresses and telephone numbers on page 123 (DURAG GROUP company
addresses).
If anything is unclear:
get in touch with the manufacturer!
Information on the company and its products can also be found on the Internet
at www.durag.de
3.1 Basics
Flammable gases, vapours, mist or dust arise during manufacture, processing,
transport and storage in many industrial sectors. These inflammable materials
can for example form explosive atmospheres with oxygen from the air. If
ignition were to occur, for example through electrical sparks, the result may be
serious personal injury and damage to property. It is the operator's responsibility to
avoid any risk of explosion with the devices and to ensure the necessary safety.
This means it is necessary to design the product according to state-of-the-art
knowledge in terms of explosion protection and ensure appropriate quality
during manufacture. In addition, it all depends on professional installation and
preventive maintenance of all the relevant components.
Devices for explosion risk areas are safety-relevant and are subject to a
special duty of care. Technical know-how in the explosion protection field
(appropriate to the local region) is a prerequisite for planning or work of any
kind. This includes both the choice of suitable types of ignition protection and
Ex zone divisions, and the proper assembly, commissioning, repair or
replacement of devices and accessories.
The basic principles of explosion protection are the same all over the world.
In European Union member states, explosion protection is governed by the
ATEX guidelines (from the French 'ATmosphère EXplosible'). The guidelines
are implemented through harmonised European standards, which are also
accepted worldwide as IECEx (International Electrotechnical Commission
Explosive).
D−HG 400
31
3. Explosion protection
There are differences for example with the North American explosion
protection as per FM (Factory Mutual) or CSA (Canadian Standards
Association).
Specific DURAG devices also meet these standards.
3.2 Division of device groups into categories
Device group I covers explosion-protected devices which are used in areas
with explosive atmospheres in the mining industry.
Device group II involves all other explosion-protected devices.
DURAG devices according to ATEX are only suitable for Ex zones of device
group II.
Device group II is divided into categories 1, 2 and 3 with a reducing level of
safety.
DURAG devices are available in category 2 (high safety level) and 3 (low
safety level) for explosive atmospheres containing gas (G) and dust (D).
3.2.1 Division into zones
Basically, the areas where explosive mixtures may occur, are divided into
zones with varying levels of safety. A distinction is made between
atmospheres containing gas and dust and also depending on the expected
frequency of occurrence of explosive mixtures.
The following are relevant for DURAG devices
Zone
Ex atmosphere
Suitability of the
device
Zone 1
frequent (2), containing gas (G)
II 2G
Zone 2
rare (3), containing gas (G)
II 3G
Zone 21
frequent (2), containing dust (D)
II 2D
Zone 22
rare (3), containing dust (D)
II 3D
Table 3.1 Division into zones for DURAG devices
3.2.2 Types of ignition protection
The highest level of safety when using flammable materials is achieved, when
the occurrence of an explosive atmosphere is prevented (primary explosion
protection).
In areas where an explosive atmosphere must be reckoned with, in spite of
any measures taken, only explosion-protected equipment may then be used.
The type of ignition protection identifies various design principles to prevent
the simultaneous presence of an explosive atmosphere and an ignition source.
Explosion protection is for instance achieved through gas/dust-tight enclosure
of devices. That is, any possible ignition is prevented, because the explosive
atmosphere does not reach the ignition source.
Another method of preventing an explosion is pressure-resistant enclosure
(see also section 3.3). This means that the device housing is designed in such
a way that it can resist any possible explosion that occurs inside it. Ignition
cannot extend outside the device. With these devices, particular attention must
be paid to seals being intact and sealing surfaces being free from damage.
There are therefore different types of ignition protection with various levels of
32
D−HG 400
3. Explosion protection
safety (device categories) which devices may be subject to.
All types of ignition protection of DURAG devices are standardised and are to
be considered as equivalent in terms of safety technology.
3.2.3 Temperature classes
Flammable gases or dusts are divided into temperature classes according to
their ignition point. The ignition point of an explosive gas or dust atmosphere
indicates the maximum surface temperature, which may be reached here by
the devices being used.
Electrical equipment which may be used in Ex zones is divided and marked
according to the same temperature classes. The temperature class indicated
on the device must correspond to the Ex atmosphere or be higher than it.
The surface temperature of the devices is naturally influenced by the ambient
temperature. This means that the ATEX ambient temperature range (Ta)
which is indicated on the device (rating plate) also has to be complied with.
3.2.4 Equipment protection levels - EPL
Consideration of EPLs (Equipment Protection Levels) for Ex equipment
represents another alternative for the concept of zones in terms of device
selection. It is mentioned at this point for information purposes. Internal ignition
risks can be evaluated in a better and more flexible way by using a risk
assessment. An equipment protection level can be allocated to each zone
without an additional risk assessment.
The following allocations are relevant for DURAG devices:

Zone 1 – Gb

Zone 2 – Gc

Zone 21 – Db

Zone 22 – Dc.
3.3 Devices with pressure-resistant enclosures - "Ex d"
This type of ignition protection is used for device group and category II 2G
(zone 1). Housings for devices with this type of ignition protection are so
robust that they survive internal explosions without suffering any damage.
Design measures prevent the explosion from extending into a possible
explosive atmosphere outside the device (tertiary explosion protection).
There may be unavoidable joints from inside into the exterior (e.g. between the
device housing and the cover plate). They are designed to be so small that the
flame front of an internal explosion is extinguished as it emerges.
The joint surfaces must not be cleaned using mechanical devices, such as
wire brushes, or abrasives. Even small scratches on the joint surfaces
constitute hazardous damage, which may mean it is no longer flameproof.
Components which seal these housings or hold them together (e.g O-rings,
screws or cable glands) are relevant for safety. To achieve a sufficient level of
safety with cable glands in the Ex d area, at least five perfect threads are
required in meshing. Safety-relevant components must only be replaced by
authorised spare parts. These are the only parts with evidence of withstanding
the stresses that occur.
D−HG 400
33
3. Explosion protection
WARNING!
Risk of explosion due to explosive atmosphere!
Explosions can endanger the health and safety of people who are present
and cause significant damage to property.
Gas atmosphere:
So as not to alter joint dimensions in an unauthorised way:

Do not do any subsequent work on housings.

When joint surfaces are damaged, replace the whole housing.

Only use original screws for seals.

Only use approved cable glands to ensure Ex protection (see section 0).
Adhere to the range of the cable diameter which is permissible for the
cable gland for the cable being used.

Only use cables which are suitable for Ex zones.
Dust atmosphere:


Do not do any subsequent work on housings. In particular, do not apply an
unauthorised surface protection (e.g. paint) (protection against
electrostatic charging is affected).
Keep absolutely to the existing protection type (IPxx).
3.4 Increased safety - "Ex e"
This ignition protection type is also used for device group and category II 2G
(zone 1). In Europe, its use is popular for terminal boxes in combination with
the "Ex d" ignition protection type (pressure-resistant enclosure). As with
"pressure-resistant enclosure", you are assuming an explosive atmosphere
inside the Ex e area, when the device is located in a zone with flammable
substances. With the "Increased safety" ignition protection type, design and
technical measures are taken to prevent the possibility of sparks or arcs
occurring during normal operation or in the event of a fault. Hot surfaces are
also prevented from developing. The housings are mechanically robust and
have a protection type (DIN EN 60529 and DIN 40 050 part 9) of at least IP54.
This means the ingress of moisture and dirt is only permitted within the limits
of the given protection type.
The objectives of air and creep paths not being reduced during operation and
no sparks being able to arise due to short circuits are achieved. Contact points
for cables are safeguarded against accidental disconnection.
DANGER!
Risk of explosion due to electrical sparks in an explosive
atmosphere!
Explosions can endanger the health and safety of people who are present and
cause significant damage to property.
Do not disconnect lines in Ex zones when the power is on.
The cable diameters are dimensioned in such a way that overheating due to
high current densities are avoided (adhere to permissible surface temperatures).
The rated values for the terminals are applicable, in particular the cable
diameter and the tightening torques as well.
Free the cable ends sufficiently from the insulation, so as to ensure a firm
seating. Wires must not however be loose outside the terminal.
34
D−HG 400
3. Explosion protection
The operator is responsible for the following regular tests:
Housing check
Check the integrity of the housing through a visual inspection. Holes and
cracks in the housing jeopardise protection against moisture and dust
(according to the specified protection type). Also check the sealing system.
The seal should not be brittle or damaged mechanically. There must not be
any dirt deposits or moisture to be found inside the housing.
Cable check
The contact points must not have any dark discolouration, which might be a
sign of impermissible overheating. The cables must be firmly connected to the
terminal. If necessary, retighten the screw contact.
Surface temperature
Check the surface temperature of the devices. The maximum ambient
temperature for the device must not be exceeded.
Cable entry
Check the cable entry (entries) are leaktight. In particular, the seal of the strain
relief must not be brittle and it must be firmly up against the cable sheath.
3.5 Protection by "Ex t" housing
This type of ignition protection is used for device group and category II 2D
(zone 21). Devices with this type of ignition protection have a dust-tight
housing (IP6X) and prevent hot surfaces which could ignite explosive dusts.
This means it is important to adhere to the permissible ambient temperatures.
Threads which pass through the housing are either self-sealing or protected
against the ingress of dust by seals.
3.6 Safety for Ex devices
Devices with authorisation for use in Ex zones must only be installed,
commissioned and maintained by qualified staff with explosion risk knowledge!
Specialist explosion risk knowledge must be appropriate for the region where
the device is being installed or maintained (ATEX, FM, CSA, etc.).
National assembly and installation regulations apply (e.g. IEC/EN 60079-14)
ATTENTION!
D−HG 400
The High Energy Ignition Device D−HG 400 which is authorised for use in Ex
zones (with all the associated components) is a type-approved device.
Any modifications to the design of type approved devices results in loss of
the approval. Repairs may only be carried out by the manufacturer or an
authorised agent. This is the only way to ensure responsible compliance with
the regulations for type approval from the certification body.
35
3. Explosion protection
WARNING!
Risk of explosion due to use of devices in an explosive atmosphere!
Explosions can endanger the health and safety of people who are present and
cause significant damage to property.
Use of the High Energy Ignition Device D−HG 400 in explosion risk areas is
only permissible for versions of the devices which are appropriately marked
and intended for this environment (see rating plate)!

Damage may nullify the explosion protection.

Only use authorised original spare parts.

If anything is unclear, get in touch with the manufacturer (see page 123)
3.7 Additional instructions for safe operation
3.7.1 D−HG 400-72 Ex - professional use of cable entries - Ex d with sealing
compound
DURAG supplies the associated cable entries for Ex d equipment with the
relevant devices. In order to ensure explosion protection, the cable entries for
external connection cables coming into the pressure-resistant area must be
sealed with Ex d devices (D−HG 400-72 Ex). This requirement involves
devices with a volume of more than 2,000 cm³ which have a potential ignition
source in the housing (see also EN 60079-14).
For Ex d devices (e.g. D−HG 400-54 Ex), there is no requirement for the
sealing of cable entries for external connection cables coming into the
increased safety area.
The operator is responsible for carrying out the work in accordance with the
regulations.
In doing so, the following must be adhered to amongst other things:
Use the associated cable entries for shielded and unshielded cables in each case.
Cables must suitable for use in Ex zones and for sealing.
Only use cable diameters and cable entries which fit together perfectly.
As a rule, the sealing compound comprises two components. Only use the
components that belong together. Do not under any circumstances mix up
individual components from different manufacturers. Where components are
mixed, there is no assurance of an explosion-proof seal with the required joint
size and strength.
Before sealing, mix the components until sure they are homogeneous.
33
Sealant tube
34
Sealant
35
Tube spacer
D
Length of the sealant
Figure 3.1: Configuration of cable entries with sealing compound
When sealing the cable entries, always proceed strictly in accordance with the
manufacturer's accompanying work instructions.
36
D−HG 400
3. Explosion protection
3.7.2 D-ZL 441 Ex ignition lance
The D-ZL 441 Ex ignition lance is authorised for use in Ex zones. Any repair to
the flameproof joints may only be carried out according to the manufacturer's
design specifications. Repairs according to the values of table 1 or 2 of EN
60079-1 are not permissible.
Connection conditions
36
Connection
cable
37
Cable gland
38
Terminal
enclosure
Figure 3.2: Components of connection cable D-ZL 441 Ex

DANGER!
The D-ZL 441 Ex ignition lance is connected to the ignition device
D−HG 400 via a connection unit comprising a connection cable, cable
gland and terminal enclosure (see Figure 3.2). To ensure the required Ex
protection, some of these components are bonded together and are
destroyed when disassembled. Replacement of individual components of
this connection unit is not permitted and leads to loss of the (type) approval.
Explosion risk due to damaged sealing surfaces!
Improper use leads to severe personal injury and damage to property.
Do not disassemble the cable gland from the terminal enclosure, as the HV
cable is destroyed in the process. Only replace the whole connection unit
(Figure 3.2).

Put the connection cable of the ignition lance D-ZL 441 Ex firmly in place. It
must be sufficiently protected against mechanical damage. Selection of the
quality of the connection cable must ensure that it is sufficient to meet the
thermal, chemical and mechanical requirements in the area of application.
Inform the manufacturer about special requirements when ordering. The
connection unit will then be manufactured according to your requirements.

When the connection is made in the explosion risk zone:
Connect the connection cables of the ignition lance D-ZL 441 Ex in an
enclosure which meets the requirements of a recognised type of ignition
protection according to EN 60079-0, Section 1.
3.8 Significance of the Ex data on the rating plate
The approval for operation in Ex zones is only valid in conjunction with the
corresponding marking on the rating plate of the High Energy Ignition Device.
D−HG 400
37
38
2G
Device category 2G = Atmosphere (gas) zone 1
21
T6
IP 66
ATEX test number
the device is administered under this number; all relevant information
can be found in the associated certificate. (see Appendix 0 on
page 114)
20
Ta = permissible ambient temperature
Ex de IIC
IP 66 = protection category (6 = protection against solid bodies; complete
protection against contact, protection against ingress of dust; 6 = protection
against water ingress where there is temporary flooding
IIC = explosion group for gases (as per IEC, CENELEC and NEC 505;
typical gas: hydrogen)
T6 = temperature class for gases; (maximum permissible housing
surface temperature 85°C; in compliance with IEC, CENELEC and
NEC 505)
d = pressure-resistant enclosure, e = increased safety
(ignition protection types for electrical equipment in
areas with a risk of gas explosions)
II
Device group II = other areas with a risk of explosion (not mining)
"Ex" mark
3. Explosion protection
Figure 3.3: Ex rating plate High Energy Ignition Device D−HG 400
Legend - see following section.
3.8.1 Identification of Ex zone(s) on the rating plate (ATEX compliance)
Devices for use in Ex zone 1 or Ex zone 21 must be identified by the following
additional information on the rating plate:
22
Ta.:
PTB 06 ATEX
20°C…+60°C
1077
Legend to Figure 3.3
D−HG 400
3. Explosion protection
Only devices with appropriate identification may be used in environments with
a risk of explosion!
Information for further data on the rating plate can be found in section 5.7.1
starting on page 56.
D−HG 400
39
D−HG 400
High Energy Ignition Device
4
4.1
4.2
4.2.1
4.3
4.4
4.5
Delivery
Instructions for delivery
Transportation, packaging and storage
Safety instructions for transportation
Standard items supplied
Optional equipment
Special accessories
4. Delivery
4
Delivery
This section contains information about the scope of delivery, special
accessories, approvals, warranty and areas of application of the D−HG 400
(all versions).
4.1 Instructions for delivery
The items delivered, according to the valid sales contract, are listed on the
shipping documents enclosed with the delivery. On receipt, check the delivery
without delay for completeness and damage in transport.
4.2 Transportation, packaging and storage
4.2.1 Safety instructions for transportation
The High Energy Ignition Device D−HG 400 is an electronic device. Handle it
with the necessary care.
If there are major temperature or humidity fluctuations, condensation can lead
to the formation of moisture inside the High Energy Ignition Device. This can
cause a short circuit.
After transporting the devices, do not start commissioning until the devices
have adjusted to the ambient temperature, including internally.
Incorrect transportation
WARNING!
Risk of injury due to incorrect transportation!
Incorrect transportation can lead to severe personal injury or damage to
property.

When unloading the packages, during delivery and internal transportation,
proceed with care and adhere to the symbols and information on the
packaging.

If necessary, unload the packages with appropriate lifting gear. The load
capacity of the lifting gear must be at least the total weight of the items
delivered.

As from an external tube length of 3 m, use several lifting points or
appropriate lifting gear with documentation.

Only use the lifting points provided.

Secure the High Energy Ignition Device, so that it cannot fall down or topple
over.

When lifting and moving, do not stand under the load and stay outside the
danger area.
Transport inspection
Upon receipt, immediately check the delivery for completeness and transport
damage. If any external damage in transport is evident:
1. Make a complaint immediately to the shipper and DURAG GROUP
(DURAG GROUP company addresses see page 123).
2. Only give the delivery qualified acceptance.
D−HG 400
43
4. Delivery
3. Endorse the transport documents or the carrier's delivery note with particulars of
the damage.
4. Submit the claim.
Transport damage not evident at first sight must be the subject of a claim
within 7 days.
Submit a claim for every defect as soon as it is detected. Claims for damages
can only be made within the contractual time limits for complaints.
Packaging
The individual packages are packed according to the expected transportation
conditions.
The packaging should protect the individual components against transport
damage, corrosion and other damage until they are installed. Therefore, do not
destroy the packaging and only remove it shortly before installation.
Where possible, also use the original packaging for future transportation. The
materials and any moulded parts used are designed to ensure safe
transportation.
Handling packaging materials
If no return agreement has been made for the packaging, separate the
materials by type and size and either store for further use or send for recycling.
ATTENTION!
Environmental damage due to incorrect disposal!
Packaging materials are valuable raw materials and can in many cases be
reused or sensibly processed and recycled.
Dispose of packaging materials in an environmentally friendly way.
Comply with the disposal regulations which apply locally.
Storage conditions
Store the High Energy Ignition Device and spare parts under the following
conditions:
44

Do not store outdoors.

Store in a dry, dust-free location.

No not expose to aggressive media.

Avoid storage below the dew point.

Protect the High Energy Ignition Device against mechanical damage.

Storage temperature: -20°C to +60°C

Relative humidity: max. 60%

If stored for longer than 3 months, regularly check the general condition of
all parts and the packaging. If required, top up or replace the anti-corrosion
agent. The transport packaging is not normally suitable for long-term
storage.
D−HG 400
4. Delivery
Under some circumstances, the packages may display additional storage
instructions to the requirements set out here. These must be appropriately
observed.
4.3 Standard items supplied
The actual delivery may differ from the explanations and illustrations described
here for special designs, where additional ordering options are used or due to
the latest technical modifications. The High Energy Ignition Device delivered is
described in detail on the delivery note in each case.
Basically, various types are available which differ in equipment, lance length
and the kind of plug connections. In addition, the High Energy Ignition Devices
are available in various explosion protection versions.
In the following tables, the deliverable High Energy Ignition Devices are listed
with their features.
Scope of supply of the standard overall system D−HG 400:
with battery
connection cable
Lance separate
Lance fitted
Ex d IIC T6
Ex de IIC T6
Designation
Description
Push button
Equipment
D−HG 400-50
Basic unit complete with directly fitted
ignition lance (standard length 2 m) and
connection plug.
(the actual devices may vary from those illustrated)
Operating Instructions (order separately for all systems):
Language
German
English
Item number
119 524
119 525
Specify
language *
* Check availability!
Standard delivery outside the EU is English, unless otherwise specified!
D−HG 400
45
4. Delivery
4.4 Optional equipment
Scope of supply optional equipment D−HG 400:
101 238
120 100
120 101
101 239
106 222
120 106
120 107
107 321
46
with battery
connection cable
Lance separate
Lance fitted
Ex d IIC T6
Designation
Description
Ex de IIC T6
Item
number
Push button
Equipment
D−HG 400-51
230 Vac
115 Vac
24 Vdc
Basic unit complete with directly fitted
ignition lance (standard length 2 m) and
connection plug., with additional push
button fitted for triggering ignition. The
push button is protected against being
switched on accidentally by a flap.
Ignition takes place for the duration of
activation of the push button.
D−HG 400-54 Ex
Basic unit and ignition lance separate
The ignition device is built into an
explosion-proof housing. Explosion
protection II 2G Ex de IIC T6, test
certificate PTB 06 ATEX 1076U.
The D-ZL 441 Ex ignition lance, which is
available separately, is connected to the
ignition device via a high-voltage cable.
D−HG 400-65
230 Vac
115 Vac
24 Vdc
Basic unit and ignition lance separate
D-ZL 421, 422, 423 and 425 ignition lances
can be connected using a high-voltage
plug on the connection cable. The ignition
device has several threaded bushings for
mechanical fitment.
D−HG 400-72 Ex
Basic unit and ignition lance separate
The ignition device is built into an
explosion-proof housing. Explosion
protection II 2GD Ex d IIC Ex tD A21
IP 66 T85°C, test certificate
CESI 01 ATEX 036.
The D-ZL 441 Ex ignition lance, which is
D−HG 400
4. Delivery
Scope of supply optional equipment D−HG 400:
D−HG 400-80
Basic unit complete with directly fitted
ignition lance
(Standard length 800 mm) and connection
cable for the battery module D−HG 40081 (order extra). With additional fitted
push button for triggering ignition. The
push button is protected against being
switched on accidentally by a flap.
Ignition takes place for the duration of
activation of the push button.
In addition, an isolating handle forms part
of the D−HG 400-80.
107 357
107 358
with battery
connection cable
107 356
Lance separate
D−HG 400 WSH
Weather protection hood for ignition
devices D−HG 400-50 and -51
(further information on request).
Lance fitted
106 060
Ex d IIC T6
Designation
Description
available separately, is connected to the
ignition device via a high-voltage cable.
Ex de IIC T6
Item
number
Push button
Equipment
D−HG 400-81
Portable battery module with built-in
charger for power supply independent of
the mains network for the D−HG 400-80
ignition device.
230 Vac
115 Vac
(Abbildungen können vom tatsächlichen Aussehen abweichen)
D−HG 400
47
4. Delivery
4.5 Special accessories
Scope of supply special accessories D−HG 400:
Item number
Designation
Description
Ignition lances
(standard length 3 m, standard cable length 3 m)
length can be manufactured according to customer
data, in accordance with the requirements of the burner.
Minimum length 700 mm (except for D-ZS 425)
For lengths > 4 m, provide separation points
106 127
D-ZL 421
Ignition lance with high-voltage cable for
D-HG 400-65
106 128
D-ZL 422
Ignition lance with high-voltage cable and handles for
D-HG 400-65 for manual operation
106 129
D-ZL 423
Ignition lance with high-voltage cable for D-HG 400-65,
with additional plug on the ignition lance
D-ZL 425
Short ignition lance with a length of 250 mm and 3 m
high-voltage cable. With this ignition lance, the ignition
tip cannot be replaced!
108 340
D-ZL 430
Ignition lance with high-voltage cable for
Class I, Div.1, Group A, B, C & D
108 338
D-ZL 431
Ignition lance with high-voltage cable for
Class I, Div.2, Group A, B, C & D
D-ZL 441 Ex
Ignition lance with certification for explosion risk zones,
for use with
D−HG 400-53 Ex, D−HG 400-54 Ex, D−HG 400-72 Ex
All ignition lances (except for D-ZS 425) are also available with the high-temperature tip D_HG ZS/HT;
Devices with a fitted ignition lance can also be equipped with this high-temperature tip.
The external diameter of the ignition lance is 22 mm. If required, a reinforced design (25 mm) can also
be manufactured. The reinforced version can be identified by /25 at the end of the product name. The
option is not available for D-ZL 422 and D-ZL 425 and is not to be combined with the retraction unit.
48
100 638
D_HG ZS
Replacement ignition tip standard with a length of 591 mm
(+ 2 mm copper sealing ring) for all D-HG 400 ignition
devices and D-ZL 4xx ignition lances (except for D-ZL 425).
In the event of replacement, the D-ZL 425 must be
ordered in full.
108 430
D_HG ZS/HT
High-temperature replacement ignition tip with a length
of 591 mm (+ 2 mm copper sealing ring) for a maximum
temperature of 1,000° C.
D−HG 400
4. Delivery
Scope of supply special accessories D−HG 400:
Item number
Designation
Description
Retraction unit
Pneumatic retraction unit for introduction and retraction
of ignition lances and ignition devices
see also page 62 (6.4.2)
(the actual devices may vary from those illustrated)
D−HG 400
49
D−HG 400
High Energy Ignition Device
5
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.7.1
5.8
5.9
Product description, principle, design and function
Basic features
Certifications
Device description
Areas of application, designated use
Conformity/approvals
Designation of device components
Identification of the product
Information about the rating plate
Functional description
Functional description battery module D−HG 400-81
5. Product description, principle, design and function
5 Product description, principle, design and function
This section sets out the basic characteristics of the High Energy Ignition
Device, defines the designation of the device components, describes the
device and explains the different designs.
5.1 Basic features

Compact and robust design (complete functionality in a single module),
ignition tips also available for high temperatures.

Thyristor controlled, which means no wear on the ignition device.

Device connections preassembled, ready to plug in.

Authorised for use in Ex zones (ATEX) in the appropriate design (-Ex).

Simple replacement of ignition tips.
5.2 Certifications

GOST-R

ATEX
5.3 Device description
DURAG-High Energy Ignition Devices enable automatic ignition of oil and gas
burners of any capacity in industrial and power plants. These ignition devices
have also proved themselves for ignition of flare stacks and H2S burners in
refineries, due to their high level of operational reliability.
The ignition lance and the ignition device are combined into one complete unit
in the standard design. For special tasks, such as ignition of flares or in Ex
zones of claus plants (H2S burners), these devices can also be delivered in a
separate configuration of ignition lance and ignition device or in an Ex
configuration.
Taking into account the wear of the ignition tip, these system components are
retracted out of the flame zone after successful ignition and the ignition device
is de-energised. To automate the procedure, the pneumatic retraction units of
the D-VE 500 or D-VE 900 series are available separately.
High Energy Ignition Devices are available in the following configurations:
D−HG 400
53
5. Product description, principle, design and function
Version
Example:
-54
Ex
Type, additional equipment
Compact configuration;
electronics unit and ignition lance form one unit
Compact configuration;
electronics unit and ignition lance form one unit
additional: push button for triggering ignition
-50
-51
Separate configuration;
-54
electronics unit and ignition lance are linked together via a high-voltage
cable;
additional Ex: configuration for explosion risk zones as per
II 2G Ex de IIC T6
Ex
Separate configuration;
-65
electronics unit and ignition lance are linked together via a high-voltage
cable
Separate configuration;
-72
electronics unit and ignition lance are linked together via a high-voltage
cable;
additional Ex: configuration for explosion risk zones as per
II 2GD Ex d IIC Ex T6 tD A21 IP 66 T85°C
Ex
Compact configuration;
-80
electronics unit and ignition lance form one unit
additional: portable configuration, in combination with optional D−HG 400-81
(order separately):
portable battery module with built-in charger for power
supply independent of the mains network
additional: connection cable for the battery module
additional: push button for triggering ignition
Compact configuration;
-90
electronics unit and ignition lance form one unit (separate instructions)
however: with flexible ignition lance for tilting burners;
only in conjunction with external guide tubing D−HG 400-91
Table 5.1 D−HG 400 options
5.4 Areas of application, designated use
For area of application and designated use of the High Energy Ignition Device
D−HG 400, see from page 18 on.
5.5 Conformity/approvals
The D−HG 400 has been developed, manufactured, tested and documented in
compliance with the applicable safety standards. If the handling and safety
instructions described for configuration, assembly, use for the designated
purpose and maintenance are complied with, no dangers normally arise from the
device in respect of damage to property or people's health.
54
D−HG 400
5. Product description, principle, design and function
5.6 Designation of device components
The High Energy Ignition Device consists essentially of:

Ignition device in housing or Ex housing

Ignition lance

Ignition tip

Connection cable

If applicable, high-voltage cable
The connection by the operator is achieved through a plug connection with 1.5
m (standard) of cable connected.
Figure 5.1: Parts definition
1 Union nut with locking pin
10 Ignition device
2 Wrench size
11
Push button for triggering the
ignition (only on D−HG 400-51)
4 Copper sealing ring
12
Protective cover for push button
(only on D−HG 400-51)
6 Electrode
13 Handle
7 Ignition tip
14 LED (Ignition mode display)
8 Lance tube
15 R 15 plug connection
9 Reinforced lance tube (optional)
16 Connection cable with R 15 plug
Table 5.2 Key for part definition
D−HG 400
55
5. Product description, principle, design and function
5.7 Identification of the product
The device identification can be found on the rating plate.
The rating plate is located on the front of the housing.
Figure 5.2: Where can I find the rating plate?
5.7.1 Information about the rating plate
The data on the rating plate have the following meaning:
Figure 5.3: Example rating plate High Energy Ignition Device D−HG 400
56
1 D-HG 400
Device type designation
2 DURAG
Manufacturer
3 -54 Ex
Device versions (as per order)
4 IP66
Protection type
5 www.durag.de
Manufacturer's address, homepage
6 Part-No.:
Order number
7 Dat.:
Date of manufacture (year of manufacture)
8 .
Reserved
9 -20…+60°C
Permissible ambient temperature
10
Before starting any work, please read the Operating
Instructions!
11 300 s (50%)
Max. duration of the power-on time *
)
D−HG 400
5. Product description, principle, design and function
12
Declaration of conformity
13 2A tr.
Permissible fuse
14 .
Reserved
15 U: 230Vac/220VA
Permissible operating voltage max. power input
16 Ser.-No.:
Serial number
)
* Power-on time is the max. permissible duration of the device's active phase;
The percentage gives the ratio from pause to active phase;
i.e. max. 300 s of activity follow 300 s pause (≙ 50%).
or 100 s activity followed by 100 s pause (≙ 50%).
Figure 5.4: Example rating plate D−HG 400
For Ex devices, see also section 3.8ff.
5.8 Functional description
4.5 Ws of energy is loaded into a high-voltage capacitor inside the ignition
device. This energy is switched to the ignition tip using a non-wearing
switching unit (thyristor), where it is converted to heat via an arc discharge
(ignition spark). This high-energy discharge ignites the fuel.
To ensure safe ignition in the start phase, for the first minute after the ignition
device is switched on, it generates 20 ignition sparks/s and then switches back
to around 5 ignition sparks/s.
If the operating voltage is switched on, the device immediately begins ignition.
When the ignition device is functioning perfectly (operating voltage and ignition
discharge monitoring) there is ignition function signalling via the contact output
of the ignition signal relay. The ignition is displayed on the device by means of
a built-in LED (see figure on the left).
5.9 Functional description battery module D−HG 400-81
The D−HG 400-81 battery module serves as a power supply for the
D−HG 400-80 High Energy Ignition Device.
The capacity of the fully-charged battery is sufficient for an ignition time of
around one hour (120 x 30s with 20 ignition sparks/s).
The battery module has an internal charger, which can be connected to the
mains power for an unlimited time. The charging time from a completely flat
battery is several hours.
The D−HG 400-81 battery module is equipped with two lead gel batteries,
which behave in a similar way to a "car battery".
The service life of the batteries is several years. At temperatures over 40°C,
the service life is however significantly reduced.
Lead batteries are designated as "hazardous waste" and must be disposed of
properly! (see section 6.10.2)
D−HG 400
57
D−HG 400
High Energy Ignition Device
6
6.1
6.2
6.3
6.4
6.4.1
6.4.2
6.4.3
6.4.4
6.4.5
6.5
6.5.1
6.6
6.7
6.8
6.9
6.10
6.10.1
6.10.1
6.10.2
Installation, commissioning
Safety
Transportation
Qualification of staff for installation and initial commissioning
Installation and initial commissioning
Installation sequence
Preparations on the combustion chamber
Assembly of the High Energy Ignition Device
Position the ignition lance in the ignition zone
Connection of power supply and ignition function signalling
Operation
Safety
Commissioning
Emergency stop - shutting down in case of emergency
Turning on and off
Normal operation
Dismantling and disposal
Dismantling
Disposal of the High Energy Ignition Device
D−HG 400-81 (optional portable battery module) disposal
6. Installation, commissioning
6
Installation, commissioning
In this section, we explain the key points for installing the High Energy Ignition
Device and how to connect the device.
6.1 Safety
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
1,500 volts is generated to create the ignition sparks in the ignition device.





Before starting work, switch off the power supply and secure it against
reconnection.
Before removing the housing or protection against contact, check that the
devices are de-energised.
The High Energy Ignition Device contains capacitors whose discharge
time is a minimum of 60 seconds. Only then can work be carried out
safely on the device and ignition tip (in the Ex zone wait at least
generation Original Textmarke Sicherheitszeit_Kondensator nicht
löschen
Only allow electricians to work on electrical equipment.
Never bypass fuses or render them inoperative. When replacing fuses,
always comply with the correct amperage and the correct characteristics
(see rating plate).
Keep moisture away from live components.
DANGER!
Risk of fatal injury due to explosion!
When ignition sparks are generated in explosive atmospheres, there is an
immediate risk of fatal injury.
The operator must therefore take appropriate measures to ensure that the
legal provisions for burner management are complied with and that ignition
does not take place in an explosive medium in the burner area (if necessary
pre-aeration).
CAUTION!
Damage to property by unauthorised staff
Incorrect handling can lead to serious damage to property.
Only have work done on this device by appropriately qualified and trained
staff.
ATTENTION!
Damage to electronic components due to
electrostatic discharge (ESD)
Electronic components are becoming increasingly small and complex. This
means their susceptibility to damage from electrostatic discharge is
increased. For all work on the open device, measures must be taken against
electrostatic discharges for the protection of these components (ESD
protection).
For prevention of static charging of the human body, service employees can for
instance be equipped with a personal grounding system.
D−HG 400
61
6. Installation, commissioning
Pay attention to the instructions in section 2.7 Device-specific dangers and
safety measures and those in section 4.2 Transportation, packaging and
storage
The technical documentation required for commissioning is to be found on the
following pages. The technical data in the appendix, starting on page 89.
Comply with the legal requirements applicable for the system and the
corresponding technical regulations. Adhere to national safety and accident
prevention.
6.2 Transportation
Avoid heavy impacts. Wherever possible, use the original packaging for
transportation: the packaging used for this is designed to ensure safe
transportation.
6.3 Qualification of staff for installation and initial commissioning
The electrical work during installation and initial commissioning may only be
carried out by electricians (requirements see section 2.4 starting on page 20).
As a matter of principle, qualified specialist staff are required for all work on
the High Energy Ignition Device.
In particular, in Ex zones of any kind, the appropriate Ex knowledge is
absolutely essential for all people working there on the High Energy Ignition
Device.
6.4 Installation and initial commissioning
6.4.1 Installation sequence
1. Preparations on the combustion chamber.
2. Fit the High Energy Ignition Device-components together, assemble them and
push them into the mounting flange or fit them on the pneumatic retraction unit
(e.g. D-VE 500 or D-VE 900).
3. Position the ignition lance in the ignition area.
(For adjustment of the pneumatic retraction unit, see Operating Instructions of
the retraction unit).
4. Electrically connect the D−HG 400 ignition device and the ignition lance.
6.4.2 Preparations on the combustion chamber
The ignition spark of a High Energy Ignition Device generally has a diameter of
just a few centimetres. For successful ignition, the spark must be positioned in
an area where a fuel / air mix is present (see Figure 6.1/page 63). After
ignition, temperatures of over 1,000°C can occur in this location, which would
destroy the ignition tip after a short time. To protect it, you are recommended
to use a retraction unit. The unit moves the ignition lance into the ignition zone
for ignition and retracts it again out of the hot zone after successful ignition
(retraction unit see page 48).
62
D−HG 400
6. Installation, commissioning
OL Oil lance
ZL Ignition lance
RZB Retraction zone
α
Spray angle
SK Spray cone
Figure 6.1: Retraction zone for igniting oil burners
In accordance with the local conditions, with the design of the burner and with
the devices used, make preparations which enable the ignition lance to be
inserted into the combustion chamber. If applicable, this also includes fitting
guide tubes and/or flanges with an appropriate diameter on the burner plate.
6.4.3 Assembly of the High Energy Ignition Device
Mechanical installation is carried out according to the appropriate dimension
sheets for the ignition device designs or the retraction unit.
Connection of the operating voltage for the device and the ignition function
signalling is achieved via a circular plug connector on standard devices and via
connection terminals on explosion-proof designs.
For designs with separate ignition lances, the high-voltage cable is attached to
the ignition device and the ignition lance's green/yellow PE earth cable is also
connected to the ignition device.
The connection of the high-voltage cable and the ignition lance is configured
to be a permanent one. Repeated assembly/disassembly can lead to
damage. (Exception: ignition lance D-ZL 423)
D−HG 400
63
6. Installation, commissioning
6.4.4 Position the ignition lance in the ignition zone
DANGER!
Risk of fatal injury due to explosion!
When ignition sparks are generated in explosive atmospheres, there is an
immediate risk of fatal injury.
The operator must therefore take appropriate measures to ensure that the
legal provisions for burner management are complied with and that ignition
does not take place in an explosive medium in the burner area (if necessary
pre-aeration).
Oil burner
For oil burners, the optimum position of the ignition lance tip is generally the
area around the edge of the spray cone behind the swirl vanes or the baffle
plate. The absolute position can be established by axial adjustment. Make
sure there is sufficient pre-heating of the oil when using heavy oil
(recommended value 90°C ... 130°C). The finer the atomising of the heavy oil
particles (steam atomising) is, the easier it is to ignite the mixture.
OL Oil lance
ZL Ignition lance
OZ Optimum ignition position
α Spray angle
SK Spray cone
Figure 6.2: Optimum ignition position for igniting oil burners
Gas burner
To a large extent, the position of the ignition tip is not critical for gas burners.
However, a good mixing of fuel and air must already have taken place in this
position.
Ein sicherer weicher Start wird bei geringer Strömungsgeschwindigkeit
(Anfahrstellung des Brenners) erreicht.
64
D−HG 400
6. Installation, commissioning
After successful ignition, withdraw the ignition lance from the area of the
flame and switch off the supply voltage, so that the ignition tip does not suffer
6
any unnecessary wear. The service life of the ignition tip is around 10
ignition sparks. This corresponds to a continuous operating time of about 14
hours with an ignition sequence of 20 sparks/s.
Higher temperature impact, for example due to the ignition tip being
withdrawn too late from the flame, leads to greater wear or to damage.
Accumulations of moisture or fuel residues on the ignition tip do not lead to
any disruption of ignition and ignition performance.
6.4.5 Connection of power supply and ignition function signalling
DANGER!
Risk of fatal injury due to electrical power!
Improper use leads to severe personal injury. Once the housing or accidental
contact guards have been opened and on the ignition lance, live parts are
accessible. When working on the device, the mains power leads must
therefore be disconnected and secured against unauthorised reconnection.
Any contact guards that may have been removed must be replaced before
switching on the mains power.
A high voltage of 1,500 V is generated in the ignition device: This means you
must never connect the power with the housing open or with a drawn or
unprotected ignition lance!
Make sure there is proper supply of the operating voltage and the earth
conductor. Before commissioning, it is essential to connect the green/yellow
earth conductor (PE) with the ignition device.
Comply with VDE (German Electrical Engineering Association) regulations and
those of the local electricity supplier.
If the operating voltage is switched on, the device immediately begins ignition.
Sparks are generated at the ignition tip. The operating voltage must therefore
not be connected and switched on until assembly is complete.
The mains power supply cable of the High Energy Ignition Device should be
executed in 3 x 1.5 mm². The conductor and sheath material must be suitable
for conditions at the respective application location. To protect the power
supply cable install a min. 4A automatic fuse, tripping characteristic for example
type K, as close as possible to the High Energy Ignition Device. Secure the
individual conductors of the mains power supply cable reciprocally in such a
way that they cannot touch neighbouring terminals whilst being disconnected
(e.g. through cable ties). The High Energy Ignition Device has a max. power
consumption of 220 VA.
The mains power is connected to the ignition device. The electrical connection
is made via a plug connection with a cable pre-wired at the factory. The cable
length is 1.50 m for the standard configuration, but can be supplied in other
lengths on request.
The electrical connection to the cable is made as per Figure 6.4. The High
Energy Ignition Device is connected to the mains power network by the
customer via contacts 1 and 2.
Cables 4 – 6 for ignition feedback signalling (ZR) are laid via the ignition
signalling relay (ZMR), which can serve as an NCC and/or NOC.
Depending on the configuration, the High Energy Ignition Device meets the
requirements for protection type IP 54, IP 55, IP 65 or IP 66 (NEMA 4.4).
D−HG 400
65
6. Installation, commissioning
Figure 6.3: Wiring diagrams - High Energy Ignition Device
Terminal
1
2
Colour
Black
Blue
3
PE
Green/
yellow
4
Yellow
5
Grey
6
White
7
HV
0
PE
66
Function
Designation
Function
L+
AC
Alternating current
conn.
L–
DC
Direct current conn.
n.c.
PE
Earth conductor conn.
PE
ZR
Ignition function
signalling
R15
Plug (Harting)
ZMR
Ignition signalling relay
Ignition feedback
signalling
n.c.
Red/brown Ignition lance conn.
Black
Ignition lance conn.
Green/yell
ow
Ignition lance conn.
D−HG 400
6. Installation, commissioning
Comply with the operating instructions of the relevant Ex housing
manufacturer during installation!
 for D-HG 400-53/-54 Ex → R. Stahl Schaltgeräte GmbH
 for D-HG 400-72 Ex → Cortem S.p.A.
(Legend see page 66)
Figure 6.4: Wiring diagram - Ex High Energy Ignition Device
D−HG 400
67
6. Installation, commissioning
6.5 Operation
6.5.1 Safety
The DURAG High Energy Ignition Device D−HG 400 is designed and built
using state of the art technology and complies with the recognised safety
regulations. Despite this, dangers can arise.
You must only use the product when it is in perfect condition, while adhering to
the operating instructions. Any change to normal operation should be taken as
a serious indication of impaired functionality. In this regard, pay attention to:

WARNING!
tripping of monitoring devices.
Risk if used other than for the designated purpose!
Any use of the High Energy Ignition Device beyond the designated purpose
and/or of another kind may lead to hazardous situations.
There is a risk of personal injury and damage to property.
Only operate the High Energy Ignition Device in accordance with the data on the
rating plate and the parameters given in the Technical data starting on page
89. All data in these Operating Instructions must be strictly adhered to!
6.6 Commissioning
There are no special measures required for commissioning the High Energy
Ignition Device.
Before commissioning the system, it is also vital to pay attention to the
requirements for commissioning the whole system.
6.7 Emergency stop - shutting down in case of emergency
The enclosed and operational High Energy Ignition Device does not normally
represent any danger. However, a special emergency shutdown function for
the High Energy Ignition Device is fitted as part of and in conjunction with the
overall system. The operator must incorporate the relevant safety
measurements into the safety concept for the overall system as early as the
planning phase. This also includes the description and location of safety
equipment and emergency stop mechanisms.
6.8 Turning on and off
The High Energy Ignition Device can normally be turned on using the controls
for the overall system (in accordance with the control diagram and the
operator's specifications).
It is also normally turned off using the overall system controls. There are no
special requirements to be met prior to and when turning off the High Energy
Ignition Device.
68
D−HG 400
6. Installation, commissioning
6.9 Normal operation
Special operation of the High Energy Ignition Device is not required in normal
circumstances.
6.10 Dismantling and disposal
6.10.1 Dismantling
DANGER!
Risk of fatal injury due to electrical power!
Improper use leads to severe personal injury. Once the housing or accidental
contact guards have been opened and on the ignition lance, live parts are
accessible. When working on the device, the mains power leads must
therefore be disconnected and secured against unauthorised reconnection.
Any contact guards that may have been removed must be replaced before
switching on the mains power.
1. Disconnect the High Energy Ignition Device from the mains and check that there
is no voltage.
2. Disconnect all plug connections from the device.
Comply with the operating instructions of the relevant Ex housing
manufacturer during installation!
 for D-HG 400-53/-54 Ex → R. Stahl Schaltgeräte GmbH
 for D-HG 400-72 Ex → Cortem S.p.A.
3. Disconnect the High Energy Ignition Device from the electricity by disconnecting
the wires at the terminal connection strip (only Ex versions).
4. Open the screw terminals with an appropriate tool. Pull out the cable and screen
(only Ex versions).
5. Dismantle used cables.
6. The operator must remove the High Energy Ignition Device and connected
ignition lances from the overall system on an organisational level.
6.10.1
Disposal of the High Energy Ignition Device
Disposal of used electrical and electronic devices (to be applied in
European Union countries and other European countries with a separate
collection system for these devices)
This product is not to be treated as normal household waste. It must be taken
to a reception centre for recycling of electrical and electronic devices. Your
contribution to the correct disposal of this product protects the environment
and the health of your fellow human beings. Incorrect disposal puts the
environment and health at risk. Materials recycling helps reduce the
D−HG 400
69
6. Installation, commissioning
consumption of raw materials. You can get further information on the recycling
of this product from your local authority and the municipal waste disposal
companies.
6.10.2 D−HG 400-81 (optional portable battery module) disposal
For disposal of the D−HG 400-81, the information in section 6.10.1 also
applies. In addition, the following must be adhered to for disposal of the built-in
accumulator:
Disposal of used batteries and accumulators
(to be applied in European Union countries and other European countries with
a separate collection system for these devices)
The symbol on the battery/accumulator or the packaging indicates that this
product is not to be treated as normal household waste. An additional
chemical symbol Pb (lead) or Hg (mercury) under the struck-through refuse bin
means that the battery/accumulator has a lead content of more than 0.004% or
a mercury content of more than 0.0005%. Your contribution to the correct
disposal of these batteries/accumulators protects the environment and the
health of your fellow human beings. Incorrect disposal puts the environment and
health at risk. Materials recycling helps reduce the consumption of raw
materials.
Only have the battery/accumulator replaced by qualified service staff. To
ensure that these batteries/accumulators are disposed of properly, the
products must be taken for disposal to a reception centre for recycling of
electrical and electronic devices.
You can get further information on the recycling of batteries/accumulators from
your local authority and the municipal waste disposal companies.
70
D−HG 400
D−HG 400
High Energy Ignition Device
7
7.1
7.2
7.3
7.4
7.4.1
7.4.2
7.4.3
7.5
7.6
7.6.1
7.6.2
7.6.3
7.6.4
7.7
Maintenance
Safety
Qualification of maintenance staff
Maintenance intervals
Maintenance operations
Visual inspection
Replacing the ignition tip on the High Energy Ignition Device-50/51/80
Replacing the ignition tip with a separate ignition lance D-ZL 4xx
Customer service
Spare parts
D−HG 400-50, -51, -65, -80 fuse
D−HG 400-54 Ex fuse
D−HG 400-72 Ex fuse
Replacing the o-ring - D−HG 400-50, -51, -65, -80
Identifying and rectifying faults
7. Maintenance
7
Maintenance
This section explains the necessary maintenance work for the High Energy
Ignition Device, such as visual inspections, cleaning and replacement of
ignition tips.
7.1 Safety
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
1,500 volts is generated to create the ignition sparks in the ignition device.





Before starting work, switch off the power supply and secure it against
reconnection.
Before removing the housing or protection against contact, check that the
devices are de-energised.
The High Energy Ignition Device contains capacitors whose discharge
time is a minimum of 60 seconds. Only then can work be carried out
safely on the device and ignition tip (in the Ex zone wait at least
generation Original Textmarke Sicherheitszeit_Kondensator nicht
löschen
Only allow electricians to work on electrical equipment.
Never bypass fuses or render them inoperative. When replacing fuses,
always comply with the correct amperage and the correct characteristics
(see rating plate).
Keep moisture away from live components.
DANGER!
Risk of fatal injury due to explosion!
When ignition sparks are generated in explosive atmospheres, there is an
immediate risk of fatal injury.
The operator must therefore take appropriate measures to ensure that the
legal provisions for burner management are complied with and that ignition
does not take place in an explosive medium in the burner area (if necessary
pre-aeration).
CAUTION!
Damage to property by unauthorised staff
Incorrect handling can lead to serious damage to property.
Only have work done on this device by appropriately qualified and trained
staff.
ATTENTION!
Damage to electronic components due to
electrostatic discharge (ESD)
Electronic components are becoming increasingly small and complex. This
means their susceptibility to damage from electrostatic discharge is
increased. For all work on the open device, measures must be taken against
electrostatic discharges for the protection of these components (ESD
protection).
For prevention of static charging of the human body, service employees can for
instance be equipped with a personal grounding system.
D−HG 400, xxx
73
7. Maintenance
7.2 Qualification of maintenance staff
Maintenance must be carried out by the specialist staff, who are designated in
each case in the maintenance schedule (Table 7.1), working in their specialist
area (for requirements, see section 2.4, starting on page 20).
The electrical work during installation and initial commissioning may only be
carried out by electricians (requirements see section 2.4 starting on page 20).
As a matter of principle, qualified specialist staff are required for all work on
the High Energy Ignition Device.
7.3
Maintenance intervals
The individual maintenance schedule for the High Energy Ignition Device is
established by the operator. In the process, local climatic and environmental
influences, pollution at the location and the operator's individual maintenance
specifications are taken into consideration.
The following table can be used as the basis for the individual maintenance
schedule under normal operating conditions:
Process (What)
Interval (When)
Execution (Who)
Maintenance operations
Quarterly
(see section 7.4)
Check cable bushings and plug connections for correct fit, to
prevent ingress of moisture and guard against internal
corrosion.
Check for deformation and damage to the housing, and
reliable fitting of the devices on the assembly panel or flange.
Ex configurations: Unused openings for cable entries must
be sealed. Pay attention to the Ex housing manufacturer's
(R. Stahl Schaltgeräte GmbH  Cortem S.p.A.) operating
instructions!
Operator
Operating staff,
Maintenance staff
Clean device
as required
Before starting work, switch off the power supply and secure
it against reconnection. If moisture or sticky dust result in
caking, clean the devices from outside with a (damp) cloth or
with compressed air. Repeat cleaning at regular intervals.
Operator
Operating staff,
Maintenance staff
Visual inspection of the large o-ring
every 2 years
on D-HG 400-50/51/65/80
(between the housing and housing cover), if applicable
replacement
(to preserve the protection type according to DIN EN 60529 and
DIN 40 050)
on Ex configuration: pay attention to the Ex housing
manufacturer's (R. Stahl Schaltgeräte GmbH  Cortem
S.p.A.) operating instructions!
Operator
Maintenance staff
Replace ignition tip (see section
or 7.4.3)
depending on wear Operator
Maintenance staff
Replacement of large o-ring (see section 7.6.4)
(between housing and housing cover)
depending on wear Operator
Maintenance staff
Fuse replacement (see section 7.6.1 or 7.6.2)
Ignition device
when required
Operator
Maintenance staff
Table 7.1 Maintenance schedule
74
D−HG 400
7. Maintenance
7.4 Maintenance operations
7.4.1 Visual inspection

Check the cable for correct fit, ageing and wear. The same applies to the
plug connections which are present.
Have porous cables, defective insulation and/or plug connectors replaced
immediately by original spare parts.

Check the device for dirt
Before starting cleaning work, which is carried out using a damp cloth,
switch off the power supply and secure it against reconnection.
If there is contamination due to high relative humidity or sticky dust, the
device is to be cleaned from outside with a (damp) cloth or with
compressed air. Cleaning is then to be repeated at regular intervals.
7.4.2 Replacing the ignition tip on the High Energy Ignition Device-50/51/80
Ignition tips are subject to natural wear, corresponding to the material stress
6
occurring in their surroundings. The service life is given as 10 ignition sparks
where the permissible ambient temperature and max. power-on time (see
Technical data) are adhered to. It is then necessary to replace the ignition tip.
Service life
at ignition sparks/s
≙ hours
20
14
5
56
Under practical operating conditions, this can result in a service life from
several months to several years.
6
10 ignition sparks
2
1
7
HG400_13a_000
6
5
3
4
1 M6 threaded pin in the union nut
5 Teflon sealing plug
2 Wrench size 19 mm
6 Electrode
3 Separation point (electrode)
7 Ignition tip
4 Copper sealing ring
Figure 7.1: Replacement of ignition tip on the D−HG 400
1. Switch off the power supply and secure it against reconnection.
The High Energy Ignition Device contains capacitors whose discharge time is a
D−HG 400
75
7. Maintenance
2.
3.
4.
5.
minimum of 60 seconds. Only then can work be carried out safely on the
device and ignition tip (in the Ex zone wait at least 5 minutes due to possible
spark generation).
Check the device has been de-energised.
Switch off the system in accordance with the operator's operating instructions.
Disconnect the device plug, pull it out and dismantle the High Energy Ignition
Device along with the ignition lance and put it safely to one side.
Release the M6 threaded pin (Figure 7.1-1) in the union nut and unscrew the
union nut with 3 - 4 turns.
Release the ignition lance with a 19 mm sized screw wrench (Figure 7.1-2 top)
and unscrew it from the ignition device housing. Pull the ignition lance out of the
housing.
With two 19 mm screw wrenches, unscrew the ignition tip from the ignition lance
(Figure 7.1-2 middle).
If, when unscrewing the ignition tip from the lance, the electrode (Figure 7.1-6)
has not been released, the electrode is released and unscrewed using two
pincers at the separation point (Figure 7.1-3).
If the ignition lance comprises several parts, the electrode can only be very
slightly pulled out. When assembling later, make sure that the separation points
of the electrode are also firmly screwed together.
Caution!
Where this is not done properly, ceramic insulators may be destroyed.
Only let the work be done by specially trained staff; do not pull excessively on
the electrodes!
6. First screw the new ignition tip onto the electrode (M4 thread) (Figure 7.1–3).
Before screwing on, make sure that the copper sealing ring (Figure 7.1-4) is
properly seated on the threaded bushing of the ignition tip. If the electrode does
not protrude from the lance, it is pushed through by around 10 cm from the other
end. Tighten the electrode with two pincers.
Attention!
Do not tighten the electrode on the external tube by turning the ignition tip!
Otherwise, the electrode might shear off with too great a torque.
7. Push the electrode carefully into the lance and make sure that no ceramic
insulators get damaged. Screw the ignition tip and the lance firmly together with
two 19 mm screw wrenches. The electrode must now protrude about 105 mm out
of the lance tube. Press the Teflon sealing plug (Figure 7.1-5) firmly into the lance
tube.
8. Insert the ignition lance carefully into the ignition device housing. A funnel in the
ignition device ensures the electrode is guided into the contact bushing. Next,
just hand-tighten the ignition lance.
9. Firmly tighten the union nut and then tighten the ignition lance firmly with a 19
mm screw wrench. Secure the ignition lance with the M6 threaded pin in the
union nut (Figure 7.1-1).
10. Refit the High Energy Ignition Device, including the ignition lance, on the
combustion chamber. Plug in the device plug and secure it with the union nut.
76
D−HG 400
7. Maintenance
DANGER!
Risk of fatal injury due to explosion!
When ignition sparks are generated in explosive atmospheres, there is an
immediate risk of fatal injury.
The operator must therefore take appropriate measures to ensure that the
legal provisions for burner management are complied with and that ignition
does not take place in an explosive medium in the burner area (if necessary
pre-aeration).
11. Switch on the system in accordance with the operator's operating instructions. If
the operating voltage is connected, the device immediately begins ignition.
Sparks are generated at the ignition tip.
7.4.3 Replacing the ignition tip with a separate ignition lance D-ZL 4xx
Ignition tips are subject to natural wear, corresponding to the material stress
6
occurring in their surroundings. The service life is given as 10 ignition sparks
where the permissible ambient temperature and max. power-on time (see
Technical data) are adhered to. It is then necessary to replace the ignition tip.
Service life
at ignition sparks/s
≙ hours
20
14
5
56
Under practical operating conditions, this can result in a service life from
several months to several years.
6
10 ignition sparks
2 Wrench size 19 mm
6 Electrode
3 Separation point (electrode)
7 Ignition tip
4 Copper sealing ring
10 Terminal enclosure
Figure 7.2: Replacing the ignition tip on the D-ZL 4xx
1. Switch off the power supply and secure it against reconnection.
The High Energy Ignition Device contains capacitors whose discharge time is a
minimum of 60 seconds. Only then can work be carried out safely on the
device and ignition tip (in the Ex zone wait at least 5 minutes due to possible
D−HG 400
77
7. Maintenance
spark generation).
pay attention to the Ex housing manufacturer's (R. Stahl Schaltgeräte GmbH 
Cortem S.p.A.) operating instructions!
Check the device has been de-energised.
2. Switch off the system in accordance with the operator's operating instructions.
Disconnect the device plug (on Ex devices terminals), pull it out, then dismantle
the ignition lance and put it safely to one side.
8 Lock screw
Separate the ignition lance from the terminal
9 enclosure
10 Terminal enclosure
Figure 7.3: Dismantling the ignition lance D-ZL 4xx
3. Release the hexagon socket lock screw (Figure 7.3-8) on the terminal enclosure
and then unscrew the ignition lance from the terminal enclosure (Figure 7.3-9).
4. With two 19 mm screw wrenches, unscrew the ignition tip from the ignition lance
(Figure 7.2-2 middle).
If, when unscrewing the ignition tip from the lance, the electrode (Figure 7.2-6)
has not been released, the electrode is released and unscrewed using two
pincers at the separation point (Figure 7.2-3).
If the ignition lance comprises several parts, the electrode can only be very
slightly pulled out. When assembling later, make sure that the separation points
of the electrode are also firmly screwed together.
Caution!
Where this is not done properly, ceramic insulators may be destroyed.
Only let the work be done by specially trained staff; do not pull excessively on
the electrodes!
5. If the electrode connection has been completely released when unscrewing the
ignition tip and does not protrude from the lance tube, it must be carefully pulled
out. If applicable, the electrode can be firmly seated in the lance tube through the
sealing ring.
Attention! Do not damage the thread (M4) when pulling out the electrode!
6. First screw the new ignition tip onto the electrode (M4 thread) (Figure 7.2-3).
Before screwing on, make sure that the copper sealing ring (Figure 7.2-4) is
properly seated on the threaded bushing of the ignition tip. If the electrode does
not protrude from the lance, it is pushed through by around 10 cm from the other
end. Tighten the electrode with two pincers.
Attention!
Do not tighten the electrode on the external tube by turning the ignition tip!
Otherwise, the electrode might shear off with too great a torque.
7. Push the electrode carefully into the lance and make sure that no ceramic
insulators get damaged. The electrode can only be pushed into the lance tube
78
D−HG 400
7. Maintenance
through the sealing ring with a certain amount of pressure. Screw the ignition tip
and the lance firmly together with two 19 mm screw wrenches.
8. Fit the ignition lance on the terminal enclosure and tighten the lock screw.
9. Refit the ignition lance on the combustion chamber. Plug in the device plug (with
Ex devices, reconnect the cable to the terminal).
DANGER!
Risk of fatal injury due to explosion!
When ignition sparks are generated in explosive atmospheres, there is an
immediate risk of fatal injury.
The operator must therefore take appropriate measures to ensure that the
legal provisions for burner management are complied with and that ignition
does not take place in an explosive medium in the burner area (if necessary
pre-aeration).
10. Switch on the system in accordance with the operator's operating instructions.
Before the power supply is turned on again, make sure that no explosive
atmosphere has formed in the combustion chamber and that the High Energy
Ignition Device is only actuated via a burner management system, or similar.
11. Switch on the system in accordance with the operator's operating instructions. If
the operating voltage is connected, the device immediately begins ignition.
Sparks are generated at the ignition tip.
7.5 Customer service
In case of questions, contact customer service. Addresses can be found on
page 2 and in section 11 on page 123. We will be happy to help you!
7.6 Spare parts
WARNING!
7.6.1
Danger of personal injury due to incorrect spare parts!
Incorrect or faulty spare parts may lead to damage, malfunctions or complete
failure, as well as affecting safety.
 Only use original spare parts from the manufacturer.
D−HG 400-50, -51, -65, -80 fuse
The ignition device is provided with a standard miniature fuse to protect it
against short circuits, overloading and surges. The data regarding the fuse to
be used are noted on the rating plate.
Replacing the device fuse:
1. Switch off the power supply and secure it against reconnection.
The High Energy Ignition Device contains capacitors whose discharge time is a
minimum of 60 seconds. Only then can work be carried out safely on the
device and ignition tip (in the Ex zone wait at least 5 minutes due to possible
spark generation).
Then check the device has been de-energised.
If necessary, release the device plug and pull it out.
D−HG 400
79
7. Maintenance
2. Release the four hexagon socket head screws (3 mm allen key).
3. Pull the plug-in electronics unit out of the housing by the grip and put it safely to
one side.
Figure 7.4: Location of fuse on D−HG 400
4. Replace fuse (see Figure 7.4).
5. Check the sealing area on the front panel and housing for dirt and clean, if
applicable.
6. Replace the o-ring in the front panel, if applicable (see section 7.6.4).
Figure 7.5: Opening the D−HG 400 ignition device housing
7. Push the plug-in electronics unit back into the housing. Pay attention to
alignment (top and bottom). In each case, insert the guide pin and electrode into
the sockets in the housing which are located opposite (see arrows - Figure 7.5).
8. Tighten the four hexagon socket head screws (3 mm allen key), all to the same
torque (hand-tight), so as to press the o-ring onto the housing with equal
pressure.
9. Plug the device plug back in if it has been pulled out. Switch on the system in
accordance with the operator's operating instructions. If the operating voltage is
connected, the device immediately begins ignition. Sparks are generated at the
ignition tip.
80
D−HG 400
7. Maintenance
7.6.2
D−HG 400-54 Ex fuse
The Ex ignition device is provided with a standard miniature fuse to protect it
against short circuits, overloading and surges. The data regarding the fuse to
be used are noted on the rating plate.
Replacing the device fuse:
1. Switch off the power supply and secure it against reconnection.
The High Energy Ignition Device contains capacitors whose discharge time is a
minimum of 60 seconds. Only then can work be carried out safely on the
device and ignition tip (in the Ex zone wait at least 5 minutes due to possible
spark generation).
Pay attention to the Ex housing manufacturer's (R. Stahl Schaltgeräte GmbH)
operating instructions! Then check the device has been de-energised.
Figure 7.6: Opening the D−HG 400-54 Ex ignition device Ex housing
2. Release the hexagon socket head screw (2.5 mm allen key) on the round
housing cover (Figure 7.6 - 1).
3. Insert the two grips to the corresponding circular recesses of the round housing
cover. Using the two grips, unscrew the cover from the housing (Figure 7.6 - 2)
and put it safely to one side. Take care when putting it aside, the thread is
provided with a lubricant paste.
DANGER!
D−HG 400
Explosion risk due to damaged sealing surfaces!
Improper use leads to severe personal injury and damage to property.
Do not scratch or damage the "flameproof joints" of the housing. If there is
scoring in this area (this can also involve threads), it is absolutely essential to
replace the housing element. The gas-proof seal is no longer guaranteed and
there is a risk of explosion!
81
7. Maintenance
Figure 7.7: Location of fuse on D−HG 400-54 Ex housing
4. Replace fuse (location, see Figure 7.7).
5. Check the sealing area on the cover and housing for dirt and damage and clean
or replace, if applicable.
6. Place the housing cover carefully on the thread of the housing and carefully
screw in place using both the grips (Figure 7.6 – 2). In the process, pay attention
to correct insertion of the thread. Do not screw on the cover using force. The
thread could be damaged in the process. Explosion protection is then no longer
ensured (see note above).
7. Screw the hexagon socket head screw (2.5 mm allen key) on the round housing
cover hand-tight (Figure 7.6 - 1).
8. Switch on the system in accordance with the operator's operating instructions. If
the operating voltage is connected, the device immediately begins ignition.
Sparks are generated at the ignition tip.
7.6.3
D−HG 400-72 Ex fuse
The Ex ignition device is provided with a standard miniature fuse to protect it
against short circuits, overloading and surges. The data regarding the fuse to
be used are noted on the rating plate.
Replacing the device fuse:
1. Switch off the power supply and secure it against reconnection.
The High Energy Ignition Device contains capacitors whose discharge time is a
minimum of 60 seconds. Only then can work be carried out safely on the
device and ignition tip (in the Ex zone wait at least 5 minutes due to possible
spark generation).
pay attention to the Ex housing manufacturer's (Cortem S.p.A.) operating
instructions! Then check the device has been de-energised.
82
D−HG 400
7. Maintenance
Figure 7.8: Opening the D−HG 400-72 Ex ignition device Ex housing
2. Release the hexagon socket head screw (2.5 mm allen key) on the round
housing cover (Figure 7.8 - 1).
3. Using the grips, unscrew the cover from the housing (Figure 7.8 - 2) and put it
safely to one side. Take care when putting it aside, the thread is provided with a
lubricant paste.
DANGER!
Explosion risk due to damaged sealing surfaces!
Improper use leads to severe personal injury and damage to property.
Do not scratch or damage the "flameproof joints" of the housing. If there is
scoring in this area (this can also involve threads), it is absolutely essential to
replace the housing element. The gas-proof seal is no longer guaranteed and
there is a risk of explosion!
Figure 7.9: Location of fuse on D−HG 400-72 Ex housing
D−HG 400
83
7. Maintenance
4. Replace fuse (location, see Figure 7.9).
5. Check the sealing area on the cover and housing for dirt and damage and clean
or replace, if applicable.
6. Place the housing cover carefully on the thread of the housing and carefully
screw in place using the grips (Figure 7.8 – 2). In the process, pay attention to
correct insertion of the thread. Do not screw on the cover using force. The thread
could be damaged in the process. Explosion protection is then no longer
ensured (see note above).
7. Screw the hexagon socket head screw (2.5 mm allen key) on the round housing
cover hand-tight (Figure 7.8 - 1).
8. Switch on the system in accordance with the operator's operating instructions. If
the operating voltage is connected, the device immediately begins ignition.
Sparks are generated at the ignition tip.
7.6.4 Replacing the o-ring - D−HG 400-50, -51, -65, -80
The ignition device is provided with an o-ring between the plug-in electronics
unit (front panel) and the housing. To preserve the protection type (IP65), this
o-ring must be replaced once every two years. Proceed as follows to do this.
Replacing the o-ring:
1. Switch off the power supply and secure it against reconnection.
The High Energy Ignition Device contains capacitors whose discharge time is a
minimum of 60 seconds. Only then can work be carried out safely on the
device and ignition tip (in the Ex zone wait at least 5 minutes due to possible
spark generation).
Then check the device has been de-energised.
If necessary, release the device plug and pull it out.
2. Release the four hexagon socket head screws (3 mm allen key).
3. Pull the plug-in electronics unit out of the housing by the grip and put it safely to
one side.
4. Check the sealing area on the front panel and housing for dirt and clean, if
applicable.
Figure 7.10: D−HG 400 o-ring in the front panel
1. Pull the o-ring (Figure 7.10 - 1; here represented in red for better recognition) out
of the slot in the front panel. Insert the new o-ring carefully into the o-ring slot.
2. Push the plug-in electronics unit back on the housing. Pay attention to alignment
(top and bottom). In each case, insert the guide pin and electrode into the
84
D−HG 400
7. Maintenance
sockets in the housing which are located opposite (see arrows - Figure 7.5 on
page 80).
3. Tighten the four hexagon socket head screws (3 mm allen key), paying attention
to equal torque (hand-tight), so as to press the o-ring onto the housing with equal
pressure.
4. Plug the device plug back in if it has been pulled out. Switch on the system in
accordance with the operator's operating instructions. If the operating voltage is
connected, the device immediately begins ignition. Sparks are generated at the
ignition tip.
7.7 Identifying and rectifying faults
Secondary-side short circuits on the power supply of the High Energy Ignition
Device are electronically fused. After rectification of the cause, the power is
automatically made available again by the High Energy Ignition Device after a
short time.
All further failures are rectified by replacing the whole High Energy Ignition
Device. When making corresponding queries, please have the device serial
number to hand.
D−HG 400
85
D−HG 400
High Energy Ignition Device
8
8.1
8.2
8.3
8.4
Technical data
Technical data for High Energy Ignition Device
Technical data for ignition lances
Dimensional drawings - D−HG 400
Authorised cable glands (only D−HG 400-53 /-54 /-72 Ex)
9
9.1
9.2
Documents
EC declaration of conformity
EC type test certificate
10
Index
11
DURAG GROUP company addresses
8. Technical data
8
Technical data
8.1 Technical data for High Energy Ignition Device
Ignition device
Mains voltage
115 / 230 Vac, 48 – 60 Hz
or 24 Vdc
Max. power consumption
220 VA
Ignition voltage
1,500 V
Ignition power
4.5 Ws = 4.5 joules per ignition spark
Switching power
250 Vac / 4 A
Max. power-on time
300 s (ED 50%)
Peak inrush current
approx. 100 A (230 V 50 Hz)
Inrush current
approx. 2.5 A s (230 V 50 Hz)
Cable protection (on the
mains)
Controller 4 A type K with 230 Vac
2
Ignition frequency
Turn-on phase (about 60 s) 20 ignition sparks/s ± 10%
Remaining time
5 ignition sparks/s ± 20%
6
Service life of the ignition tip
10 ignition sparks = 14 h at 20 ignition sparks/s
= 56 h at 5 ignition sparks/s
Switching capacity of the
ignition signalling relay
250 V AC,
250 V AC,
250 V AC,
24 V DC,
Ignition device housing
Aluminium
Colour
Traffic blue RAL 5017 (not on Ex devices)
4A
cos = 1.0 (ohmic load)
2A
cos = 0.4 (inductive load)
0.4 A cos = 0.2 (inductive load)
3A
with spark extinguishing
Protection type
D-HG 400-50 /51 /65 /80
IP 65
D-HG 400-54 Ex
IP 66 (NEMA 4.4x)
D-HG 400-72 Ex
IP 66
D-HG 400-81
IP 55
Torque for the M5x25 mm
housing screws
(not on Ex devices)
D−HG 400
approx. 1.8 Nm
(1 Nm corresponds to 0.7 lbf ft)
89
8. Technical data
Mounting holes (for Ex
devices)
see Figure 8.11, Figure 8.12, Figure 8.13 starting
on page 110
Explosion protection
D-HG 400-54 Ex
II 2G Ex de IIC T6
D-HG 400-72 Ex
II 2GD Ex d IIC T6 Ex tD A21 IP 66 T85°C
Permissible ambient
temperature
Ignition device
D-HG 400-50 /51 /65 /80 /81
- 20°C … +60°C
Ignition device
D-HG 400-54 Ex
- 20°C < Ta < +60°C
Ignition device
D-HG 400-72 Ex
- 20°C < Ta < +40°C
Ignition tip
Continuous operation:
max. 600°C
Short-time operation (2 min): max. 800°C
HT Ignition tip
Continuous operation:
max. 1,000°C
Weight
Ignition device
D-HG 400-50 /51 /65 /80
4.3 kg (including plug-in electronics unit)
Plug-in electronics unit
1.9 kg
D-HG 400-81
approx. 11 kg (including plug-in electronics unit)
D-HG 400-54 Ex
approx. 18 kg (including plug-in electronics unit)
D-HG 400-72 Ex
approx. 16 kg (including plug-in electronics unit)
Dimensions (approx.)
Ignition device
See dimensional drawings section 8.3, starting
on page 92
Year of manufacture
See rating plate
Table 8.1 Technical data for ignition devices
8.2 Technical data for ignition lances
Ignition lance for D−HG 400-50, -51
L1
90
2
Lance length L1
min. 0.7 m
Lance tube weight
1.6 kg/m with Ø 22 mm
Weight of reinforced lance tube
2.1 kg/m with Ø 25 mm
591
max. 15 m
D−HG 400
8. Technical data
Ignition lance for D−HG 400-65
L1
D-ZL 421
L2
86
2
Cable length L1
min. 1 m
max. 50 m
Lance length L2
min. 0.7 m
max. 15 m
Cable weight
0.5 kg + 0.5 kg/m
Lance tube weight
1.6 kg/m with Ø 22 mm
Weight of reinforced lance tube
2.1 kg/m with Ø 25 mm
Cable off-take angle
on the lance
0° or 90°
Cable off-take angle
on the device
0° or 90°
Ignition lance for D−HG 400-54 Ex /-72 Ex
591
D-ZL 441 Ex
Cable length L1
min. 1 m
max. 50 m
Lance length L2
min. 0.7 m
max. 15 m
Cable weight
0.5 kg + 0.5 kg/m
Lance tube weight
1.6 kg/m with Ø 22 mm
Weight of reinforced lance tube
2.1 kg/m with Ø 25 mm
Cable off-take angle
on the lance
0° or 90°
ATEX test certificate
PTB 11 ATEX 1004 X
Explosion protection
II 2G Ex d IIC T6, T5 or T4 Gb
II 2G Ex tb IIIC T80, 95 or 130°C Db IP65
Ex zone ambient temperature
-40 … +80°C
Table 8.2 Technical data for ignition lances
D−HG 400
91
8. Technical data
8.3 Dimensional drawings - D−HG 400
D−HG 400-50 /-51:
The ignition lance is also available as an option with a reinforced lance tube with
an external diameter of 25 mm. It is not possible to use the reinforced lance
tube (Figure 8.1 – 9 page 93) in combination with the D-VE 500 retraction unit.
For lengths > 4 m, provide for separation points!
Manufacturing tolerance L1: ± 1 mm/1,000 mm lance tube.
Basic type
Reinforced Mains
Model lance tube voltage
L1
lance
length
[m]
Connection
cable length
[m]
Any other
special
features
D-HG 4001. Order e.g.
D-HG 400 -
50
3,5
5,0
2. Order e.g.
D-HG 400 -
51
4,0
1,5
3. Order e.g.
D-HG 400 -
51
115 Vac
3,5
5,0
4. Order e.g.
D-HG 400 -
50
24 Vdc
3,5
1,5
/25
Table 8.3 Ordering texts for type D−HG 400 – 50 / 51
92
D−HG 400
8. Technical data
12
14
591
22
7
Ø 22
SW 19
SW 19
L1
2
SW 22
Ø 25
9
37
29
155
D-HG 400 -50 / -51
45
8
15
188
Protective cover for push button
7 Ignition tip
12
8 Lance tube
14 LED for ignition feedback signalling
9
Reinforced lance
tube (optional)
(only on D-HG 400-51)
108
L1 Lance length
15 R 15 plug connection (Harting)
Figure 8.1: Dimensional drawing - High Energy Ignition Device D-HG 400-50/-51
D−HG 400
93
8. Technical data
D−HG 400-80 /81:
Basic type
Model
D-HG 400 -
80
1. Order e.g.
D-HG 400 -
80
2. Order e.g.
D-HG 400 -
81
Mains
voltage
230 Vac
L1 lance
length
[m]
Connection
cable length
[m]
3,5
1,5
3,5
2,5
Any other
special
features
Table 8.4 Ordering texts for type D−HG 400 – 80 /81
X1 Mains power connection
X4 Ignition device connection N1 Charging device
X2 Internal connection
U1 Lead gel battery
X3 Internal connection
U2 Lead gel battery
Figure 8.2: Dimensional drawing - Battery module D-HG 400-81
94
D−HG 400
8. Technical data
12
21
14
591
22
7
2
Ø 22
L1
27
166
140
26
drw_HG400_09_001
7
29
37
155
D-HG 400 -80
45
27
15
188
Ignition tip
108
15 R15 plug (Harting)
12 Push button
26 Insulated handle
14 LED for ignition feedback signalling
27 Stop (for handles)
L1 Lance length
Figure 8.3: Dimensional drawing - High Energy Ignition Device D-HG 400-80
D−HG 400
95
8. Technical data
D-ZL 411 CG ignition lance:
The ignition lance is also available as an option with a reinforced lance tube with
an external diameter of 25 mm. It is not possible to use the reinforced lance
tube (Figure 8.1 – 9 page 93) in combination with the D-VE 500 retraction unit.
For lengths > 4 m, provide for separation points!
Manufacturing tolerance L2: ± 1 mm/1,000 mm lance tube.
The D-ZL 411 CG ignition lance can indeed be connected to the High Energy
Ignition Device D−HG 400-54 Ex /-72 Ex, but is not authorised for use in
explosion risk zones.
Basic type
L1 cable
length
[m]
Cable takeoff angle on
the lance
(see
)
L2 lance length
[m]
Any other
special features
3
90°
4,0
+ flange
D-ZL 411 CG
Order e.g.
D-ZL 411 CG
Table 8.5 Ordering texts for type D-ZL 411 CG ignition lance
96
D−HG 400
8. Technical data
7 Ignition tip
22 90° fitting (optional)
25 90° fitting (optional)
8 Lance tube
23 Earth conductor 4 mm²
L1 Cable length
9
Reinforced lance tube
(optional)
24
Plug connection for
D−HG 400-65
L2 Lance length
Figure 8.4: Dimensional drawing - D-ZL 411 CG ignition lance
D−HG 400
97
8. Technical data
D-ZL 421 ignition lance:
Ignition lance with high-voltage cable for D−HG 400-65
The ignition lance is also available as an option with a reinforced lance tube with
an external diameter of 25 mm. It is not possible to use the reinforced lance
tube (Figure 8.1 – 9 page 93) in combination with the D-VE 500 retraction unit.
For lengths > 4 m, provide for separation points!
Manufacturing tolerance L2: ± 1 mm/1,000 mm lance tube.
Cable takeoff angle on
Reinforced the device
(see
)
Basic type lance tube
L1
cable
length
[m]
Cable take-off
angle on the
lance
(see
)
L2
lance
length
[m]
Any
other
special
features
0°
3
90°
4.1
+ flange
0°
4
0°
5.0
+ flange
D-ZL 421
1. Order e.g.
D-ZL 421
2. Order e.g.
D-ZL 421
/25
Table 8.6 Ordering texts for type D-ZL 421 ignition lance
98
D−HG 400
8. Technical data
7 Ignition tip
22 90° fitting (optional)
25 90° fitting (optional)
8 Lance tube
23 Earth conductor 4 mm²
L1 Cable length
9
Reinforced lance tube
(optional)
24
Plug connection for
D−HG 400-65
L2 Lance length
Figure 8.5: Dimensional drawing - D-ZL 421 ignition lance for D−HG 400-65
D−HG 400
99
8. Technical data
D-ZL 422 ignition lance:
Ignition lance with high-voltage cable and handles for D−HG 400-65
The insulated handle Figure 8.6 (26) B can also be moved on the ignition lance
by releasing the stops (location also used). For ignition lance effective lengths (N)
of up to 2,000 mm, it is recommended to set the dimension X to around
300 mm.
For ignition lance lengths (N) of over 2,000 mm, it is recommended to set the
dimension X to around 500 mm.
A reinforced lance tube is not possible for this length.
For lengths > 4 m, provide for separation points!
Manufacturing tolerance L2: ± 1 mm/1,000 mm lance tube.
Calculation for lance length L2:
L2 = N [m] + X [m] + 0,32 m
Basic type
Cable takeoff angle on
the device
(see
)
L1 cable
length
[m]
L2 lance
length
[m]
Any other
special
features
0°
3
2.2
+ stop ring
D-ZL 422
Order e.g.
D-ZL 422
Table 8.7 Ordering texts for ignition lance (hand lance), type D-ZL 422
100
D−HG 400
8. Technical data
7
Ignition tip
25 90° fitting (optional)
L1 Cable length
8
Lance tube
26 Insulated handles
L2 Lance length
27 Stop (for handles)
X
23 Earth conductor 4 mm²
24
Plug connection for
D−HG 400-65
Handle clearance
N Effective length
Figure 8.6: Dimensional drawing - D-ZL 422 ignition lance for D−HG 400-65
D−HG 400
101
8. Technical data
D-ZL 423 ignition lance:
Ignition lance with high-voltage cable for D−HG 400-65, with additional plug on
the ignition lance
The ignition lance is also available as an option with a reinforced lance tube with
an external diameter of 25 mm. It is not possible to use the reinforced lance
tube (Figure 8.1 – 9 page 93) in combination with the D-VE 500 retraction unit.
For lengths > 4 m, provide for separation points!
Manufacturing tolerance L1: ± 1 mm/1,000 mm lance tube.
Fertigungstoleranz L1: ± 1 mm/1.000 mm Lanzenrohr.
Basic type
Cable take-off
angle on the
lance
(see
)
L2
lance
length
[m]
Any
other
special
features
3
90°
4.1
+ flange
4
0°
5.0
+ flange
L1 cable
Reinforced length
lance tube
[m]
D-ZL 423
1. Order e.g.
D-ZL 423
2. Order e.g.
D-ZL 423
/25
Table 8.8 Ordering texts for type D-ZL 423 ignition lance
102
D−HG 400
8. Technical data
7
Ignition tip
22 90° fitting (optional)
28 Plug connection for lance
8
Lance tube
23 Earth conductor 4 mm²
L1 Cable length
9
Reinforced lance
tube (optional)
24
Plug connection for
D−HG 400-65
L2 Lance length
Figure 8.7: Dimensional drawing - D-ZL 423 ignition lance
D−HG 400
103
8. Technical data
D-ZL 430 Ex ignition lance:
Class 1, Div. 1, Group B, C & D
D-ZL 431 Ex ignition lance:
Class 1, Div. 2, Group B, C & D
Ignition lances connectable to D−HG 400-54 Ex /-72 Ex
For lengths > 4 m, provide for separation points!
Basic type
L1 cable length
[m]
L2 lance length
[m]
Any other special
features
D-ZL
1. Order e.g.
D-ZL 430
3
1.5
2. Order e.g.
D-ZL 430
5
3.5
3. Order e.g.
D-ZL 431
3
1.5
4. Order e.g.
D-ZL 431
5
3.5
+ flange
+ flange
Table 8.9 Ordering texts for type D-ZL 430 ignition lance
104
D−HG 400
8. Technical data
7
8
Ignition tip
30 Conduit outlet body
L1 Cable length
Lance tube
Metal hose, Ex-certified,
31 Class I, Div.1, Group A, B, C & D
on D-ZL 430
L2 Lance length
Flange incl. seal optional
29 (optional)
see page 113
Metal protective hose,
with UL/CSA authorisation
32
Class I, Div.2, Group A, B, C & D
on D-ZL 431
Figure 8.8: Dimensional drawing - D-ZL 430 /431 Ex ignition lance
D−HG 400
105
8. Technical data
D-ZL 441 Ex ignition lance:
Ex-certified ignition lance for use together with D−HG 400-54 Ex and
D−HG 400-72 Ex in explosion risk zones.
The ignition lance is also available as an option with a reinforced lance tube with
an external diameter of 25 mm. It is not possible to use the reinforced lance
tube (Figure 8.1 – 9 page 93) in combination with the D-VE 500 retraction unit.
For lengths > 4 m, provide for separation points!
Manufacturing tolerance L2: ± 1 mm/1,000 mm lance tube.
Basic type
Reinforced
lance tube
L1
cable
length
[m]
Cable take-off
angle on the
lance
(see
)
L2
lance
length
[m]
Any other
special
features
3
0°
4.1
+ flange
4
0°
5.0
+ flange
D-ZL 441 Ex
1. Order e.g.
D-ZL 441 Ex
2. Order e.g.
D-ZL 441 Ex
/25
Table 8.10 Ordering texts for type D-ZL 441 Ex ignition lance
106
D−HG 400
8. Technical data
7
Ignition tip
22 90° fitting (optional)
L1 Cable length
8
Lance tube
23 Earth conductor 4 mm²
L2 Lance length
9
Reinforced lance tube
(optional)
Flange incl. seal
29 (optional)
see page 113
Figure 8.9: Dimensional drawing - D-ZL 441 Ex ignition lance for D-HG 400 -54 Ex
and -72 Ex
D−HG 400
107
8. Technical data
D−HG 400-65:
7
Ignition lance,
D-ZL 425 shown here
17
High-voltage plug
connection
20
High-voltage cable with
metal protective hose
15
R 15 plug connection
(Harting)
18
Cable length if applicable
Earth conductor 4 mm²
L1 including strain relief
(green/yellow)
sleeve according to order
16
8 x M6 threaded blind holes,
10 mm deep
19
*Strain relief sleeve
Ø 30 x 60
* Attention:
Where high voltage cable with a length of over 25 m is laid vertically, a strain relief sleeve must be used
(ordered at the same time). Without a strain relief sleeve, the cable will be pulled out of the ignition lance
by its own weight. The strain relief sleeve must be fitted with a pipe clamp. The hexagon socket head
screw may not be used for this purpose!
For lengths > 4 m, provide for separation points!
108
D−HG 400
8. Technical data
Figure 8.10: Dimensional drawing - High Energy Ignition Device
D−HG 400−65/D-ZL 425 ign.lance
D−HG 400
109
8. Technical data
Ex housing D−HG 400-53 Ex
385
16
229
280
drw_D-HG400-53_000
234
619
346
303
235
6
17,5
89
172
150
131
42
12,5
68
62
Figure 8.11: Dimensional drawing - Ex housing D−HG 400-53 Ex
110
D−HG 400
8. Technical data
Ex housing D−HG 400-54 Ex
A Standard: M20
½“ NPT on request
Figure 8.12: Dimensional drawing - Ex housing D−HG 400-54 Ex
D−HG 400
111
8. Technical data
Ex housing D−HG 400-72 Ex
A
3x
½“ NPT
B 3x
M20 x 1,5
Figure 8.13: Dimensional drawing - Ex housing D−HG 400-72 Ex
112
D−HG 400
8. Technical data
Flange for ignition lance (not for lances with reinforced tubes)
(Material: 1.4541)
Figure 8.14: Dimensional drawing for ignition lance
D−HG 400
113
8. Technical data
Weather protection hood D−HG 400 WSH
1
Rear panel
Material: 1.4301
2
Stop plate (complete)
Material: 1.4301
4
Threaded pin
5
Window (acrylic glass)
3
Side element (complete)
Material: 1.4301
Figure 8.15: Dimensional drawing - Weather protection hood D−HG 400 WSH
114
D−HG 400
8. Technical data
8.4 Authorised cable glands (only D−HG 400-53 /-54 /-72 Ex)
Use of cable glands
Device/use
Manufacturer*
Model
Ignition cable
Cortem
EYS1
Connection cable
Cortem
FB1
D-ZL 411 CG ignition cable
Cortem
FG1F
D-ZL 441 Ex ignition cable
Stahl
8161/5
Connection cable
Stahl
8161/5
D-ZL 411 CG ignition cable
Cortem
FG1F
D-ZL 441 Ex ignition cable
Stahl
8161/5
Connection cable
Stahl
8161/5
D-ZL 441 Ex NPT ignition cable
Stahl
8163/2-A2F
NPT connection cable
Stahl
8163/2-A2F
D-HG 400-72 Ex
D-HG 400-53 Ex
D-HG 400-54 Ex
Table 8.11 Authorised cable glands
(EC type test certificates are available with the manufacturer)
* Cortem Group  20129 Milan  Italy  .cortemgroup.com
R. Stahl AG  74638 Waldenburg  Germany  stahl.de
D−HG 400
115
9. Documents
9
Documents
9.1 EC declaration of conformity
EG-Konformitätserklärung
EC Declaration of Conformity
Hersteller
Manufacturer
Anschrift
Address
DURAG GmbH
Kollaustrasse 105, 22453 Hamburg
Produktbezeichnung
Hochenergie - Zündgerät
D-HG 400 ...
Product description
High Energy Ignition Device
D-HG 400 ...
Das bezeichnete Produkt erfüllt die Anforderungen
folgender europäischer Normen und Richtlinien,
vorausgesetzt, dass es ordnungsgemäß installiert,
gewartet und entsprechend seiner Bestimmung eingesetzt wird. Die einschlägigen Vorschriften und
Hinweise der Bedienungsanleitung sind zu
beachten.
.
The described product complies with the following
provisions of Council Directive, provided that it is
installed, maintained and used in applications for
which it was made, in accordance with relevant
installation standards and manufacturer's
instructions.
.
EU-Richtlinien
2004/108/EG (EMV-Richtlinie)
2006/95/EG (Niederspannungsrichtlinie)
Directives
2004/108/EC (EMC Directive)
2006/95/EC (Low Voltage Directive)
Normen
EN 60730-1
Standards
EN 60730-1
(2002)
Qualitätsmanagement
DIN EN ISO 9001 (2008)
TÜV NORD CERT GmbH
(2002)
Quality Management
DIN EN ISO 9001 (2008)
TÜV NORD CERT GmbH
Aussteller
Issuer
Ort, Datum
Place, date
DURAG GmbH
Hamburg, 14.12.2009
Rechtsverbindliche Unterschrift
Legally binding signature
ppa. Norbert Rink
The original declarations of conformity for the D-HG 400-54 Ex and D-HG 400-72 Ex ignition devices are
enclosed with the devices in each case.
116
D−HG 400
9. Documents
D−HG 400
117
9. Documents
9.2 EC type test certificate
118
D−HG 400
9. Documents
D−HG 400
119
9. Documents
120
D−HG 400
10. Index
10
Index
A
Accidents 26
Applications 54
Approvals 54
Assembly High Energy Ignition Device 63
ATEX 38, 53
Ex- zone 62
Explanation of symbols 10
Explosion protection 31
division of zones 32
equipment protection levels 33
temperature classes 33
types of ignition protection 32
Explosion risk knowledge, definition 20
B
Battery module 57
disposal 70
Behaviour in the event of hazards 26
C
Cable entries 36, 115
Cable glands 36, 115
clean, device 74
Company addresses 123
Connection power supply 65
Customer service 12, 79
D
Danger due to electrical equipment 22
Designation of system components 55
Device components, designation 55
Device description 53
D-HG 400-72 36
Dimensional drawings 92
Dismantling 69
the ignition lance D-ZL 4xx 78
Disposal 69
D-ZL 441 Ex 37
E
Electricians, definition 20
Emergency stop 68
Ex d 33
Ex e 34
Ex ignition lance 37
D-ZL 430 104
D-ZL 431 104
D-ZL 441 Ex 106
Ex knowledge 62
Ex t 35
D−HG 400
F
Faults
identifying 85
rectifying 85
Features 53
Functional description
battery module 57
ignition device 57
Fuse 79, 81, 82
G
Gas burner 64
GOST-R 53
H
Hazard 26
I
Ignition sparks 57
Instructions
D-HG 400-72 36
D-ZL 441 Ex 37
for delivery 43
Items supplied
standard 45
L
Lance ignition position, optimum 64
Lead gel battery 57
Limitation of liability 11
M
Mains power connection 65
Maintenance 73
121
10. Index
intervals 74
schedule 74
work 74, 75
N
Normal operation 69
Note Environmental protection 11
O
Oil burner 64
Operating voltage 57
O-ring 74, 80, 84, 85
P
Power consumption 65
Power supply cable 65
Power-on time 57
Protection type 56
Protective equipment, personal 21
Push button 95
R
Rating plate 37, 56
significance of the data 56
Replace fuse 84
Retraction unit 25, 48, 49, 62
S
Safety instructions 17
general 17
specific 10
Scope of supply
equipment, optional 46
special accessories 48
Sealing compound 36
Sealing surfaces 32, 37, 81, 83
Securing against reconnection 23
Serial number 57
Shutting down in case of emergency 68
Spare parts 12, 79
122
Specialist staff, definition 20
Staff, qualification 20
Storage conditions 44
Switching off the High Energy Ignition Device 68
Switching on the High Energy Ignition Device 68
Symbols, other 11
System components, designation 55
T
Technical data 89
High Energy Ignition Device 89
ignition lances 90
power supply 89
Tips, recommendations 10
Transport
damage 43
inspection 43, 62
Triggering characteristic automatic fuse 65
U
Use, designated 18, 54
W
Warning instructions, specific
ESD 11
Explosion 11
Operating Instructions read 11
Warning notices, general
High risk - danger 10
Lesser risk - caution 10
Medium risk - warning 10
Warnings
specific - electric power 11
specific - general warning symbol 11
specific - hot surfaces 11
Warranty 12
Wiring diagram 66, 67
Y
Year of manufacture 56
D−HG 400
11. DURAG GROUP company addresses
11
DURAG GROUP company addresses
Kollaustr. 105
22453 Hamburg Germany
Tel. +49 (0)40 55 42 18 – 0
Fax +49 (0)40 58 41 54
E-Mail: [email protected]
DVN – DURAG
Vertrieb/Service Nord
DVO – DURAG
Vertrieb/Service Ost
DVS – DURAG
Vertrieb/Service Süd
DVW – DURAG
Vertrieb/Service West
E-Mail: [email protected]
E-Mail: [email protected]
E-mail: [email protected]
E-Mail: [email protected]
Kollaustr. 105
22453 Hamburg
Tel. +49 (0)40 55 42 18 – 0
Fax +49 (0)40 58 41 54
Halsbrücker Str. 34
09599 Freiberg
Tel. +49 (0)37 31 30 04 – 0
Fax +49 (0)37 31 30 04 – 22
Weidenweg 16
73087 Bad Boll
Tel. +49 (0)71 64 9 12 25 – 0
Fax +49 (0)71 64 9 12 25 – 50
An der Pönt 53a
40885 Ratingen
Tel. +49 (0)21 02 74 00 – 0
Fax +49 (0)21 02 74 00 – 28
DURAG UK Office
DURAG France Sarl
DURAG Italia S.r.l
E-Mail: [email protected]
E-Mail: [email protected]
E-Mail: [email protected]
Suite 17
Brookside Business Park
Cold Meece,
Stone ST15 0RZ
Great Britain
Tel. +44 (0)17 85 76 00 07
Fax +44 (0)17 85 76 00 14
49 rue Léonard de Vinci
BP 70166
95691 Goussainville
France
Tel. +33 (0)1 30 18 11 80
Fax +33 (0)1 39 33 83 60
Via Carlo Panseri, 118
28100 Novara
Italy
Tel. +39 03 21 67 95 69
Fax +39 03 21 47 41 65
DURAG GmbH
DURAG, Inc.
Durag India
Instrumentation
Private Limited
E-Mail: [email protected]
E-Mail: [email protected]
1355 Mendota Heights Road,
Suite 200
Mendota Heights,
Minnesota MN 55120
USA
Tel. +1 (0)65 14 51 – 17 10
Fax +1 (0)65 14 57 – 76 84
#143/16, 4th Main Road,
Industrial Town,
Rajajinagar
Bangalore 560 044
India
Tel.: + 91 (0)80 23 14 56 26
Ext 20
Fax: + 91 (0)80 23 14 56 27
DURAG process &
systems technology gmbh
DURAG data systems
GmbH
Hegwein GmbH
Smitsvonk Holland B.V.
E-Mail: [email protected]
E-Mail: [email protected]
E-Mail: [email protected]
E-Mail: [email protected]
Kollaustr. 105
22453 Hamburg
Germany
Tel. +49 (0)40 55 42 18 – 0
Fax +49 (0)40 58 41 54
Kollaustr. 105
22453 Hamburg
Germany
Tel. +49 (0)40 55 42 18 – 30 00
Fax +49 (0)40 55 42 18 – 30 99
Am Boschwerk 7
70469 Stuttgart
Germany
Tel. +49 (0)7 11 13 57 88 – 0
Fax +49 (0) 7 11 13 57 88 – 5
P.O.Box 180 · 2700AD
Zoetermeer
Loodstraat 57 · 2718 RV
Zoetermeer
The Netherlands
Tel. +31 (0)79 361 35 33
Fax +31 (0)79 361 13 78
VEREWA Umwelt- und
Prozessmesstechnik GmbH
E-Mail: [email protected]
Kollaustr. 105
22453 Hamburg
Germany
Tel. +49 (0)40 55 42 18 – 0
Fax +49 (0)40 58 41 54
D−HG 400
123
GmbH · Kollaustraße 105 · 22453 Hamburg · www.durag.de