HT- MANUAL, S12-1

HIGH ENERGY PULSED ARC IGNITION

OPERATION AND MAINTENANCE

MANUAL

HINDUSTHAN THERMOMETERS
5 Industrial Estate, Ambala Cantt 133 006 India
Ph: +91-171-2699237, Fax: +91-171-2699037
E-mail: ignitor@rediffmail.com

TABLE OF CONTENTS
1. SYSTEM DESCRIPTION......................................................................... 5
2. COMPONENT SPECIFICATION ............................................................ 6
3. COMPONENT DESCRIPTIONS ............................................................. 7
4. GENERAL THEORY OF OPERATION.................................................. 9
5. EXCITER MOUNTING AND WIRING .................................................. 11
6. INSTALLATION INSTRUCTIONS......................................................... 11
7. TROUBLESHOOTING............................................................................. 14
8. REPAIR/ REPLACEMENT ...................................................................... 16

LIST OF TABLES AND ILLUSTRATIONS

TABLE 1-1 .................................................................................................... 7
FIGURE 1 ...................................................................................................... 10
TABLE 2-1 .................................................................................................... 14
APPENDIX.................................................................................................... 17

HINDUSTHAN THERMOMETERS

HEA IGNITION SYSTEM:- COMPONENTS PARTS

DESCRIPTION

PART NUMBER

EXCITER 115 V AC 50/60-3.0 AMPS.

EXCITER 230 V AC 50/60-1.5 AMPS.

0775.0004.01
0775.0004.02

FLEXIBLE CABLE
FLEXIBLE SPARK ROD
RIGID SPARK ROD
SPARK ROD TIP

0757.0017.02.144
0645.0026.01.LLL
0645.0027.01.LLL
0147.0002.01

RETRACTOR 8 INCH (203mm)STROKE

115V AC 50/60 Hz
230V AC 50/60 Hz

0645.0046.01
0645.0046.02

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

DESCRIPTION

PART NUMBER

TRANSFORMER
RECTIFIER
INDUCTOR (CHOKE)
RESISTOR
BLEED RESISTOR (R1 OR R4)
(FORMERLY X 88307,ONE REQUIRED)
OPEN CIRCUIT RESISTOR (R2 OR R5)
CAPACITOR (C1 & C2)
SPARK GAP TUBE
PC BOARD ASSEMBLY

0126.0002.01
28609
88296
88304
0152.5760.00
88305
12003-006
85908
5000077

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

DESCRIPTION

PART NUMBER

WIRE 12 AWG (15)

RETAINING RING (11)
CONTACT (8)
CONTACT SPRING (10)
CONTACT SOCKET (11)
INSULATOR (1)
INSULATOR (2)
CONDUIT 3/8 INCH I.D.

0392.0602.12
12553
120615
126388
133291
5000048
5000049
0389.0002.01

HINDUSTHAN THERMOMETERS

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

DESCRIPTION

PART NUMBER

FLEX. SPARK ROD SHELL 30 SECTION

FLEX. SPARK ROD COMPLETE SHELL
CONTACT
(1)
INSULATOR MOLDED
(3)
WIRE HIGH TEMP.
(4)
SOCKET CONNECTOR
(7)
RETAINING RING
(8)
NUT RETAINER
(9)
INSULATOR
(10)
RETAINER NUT TOOL

5000020
5000050
126165
126166
0392.0502.12
5000013
12553
5000104
5000103
0570.0001.01

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

DESCRIPTION

PART NUMBER

RIGID SPARK ROD SHELL

CONTACT
(1)
INSULATOR MOLDED
(3)
WIRE HIGH TEMP.
(4)
SOCKET CONNECTOR
(7)
RETAINING RING
(8)
NUT RETAINER
(9)
INSULATOR
(10)
RETAINER NUT TOOL

5000049
126165
126166
0392.0502.12
5000013
12553
5000104
5000103
0570.0001.01

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

DESCRIPTION

PART NUMBER

AIR CYLINDER 8 STROKE (2)

AIR CYLINDER 12 STROKE (2)
AIR CYLINDER BARREL 8 STROKE
PISTON SEAL KIT
ROD BUSHING SEAL KIT
PACKING ROD GUIDE
(31)
LIMIT SWITCH
(3)
SOLENOID VALVE 115 VAC (5)
SOLENOID VALVE 230 VAC
(5)
SOLENOID VALVE COIL 115 V AC
SOLENOID VALVE COIL 115 V AC

126214
126304
0539.0003.01
0670.0012.01
0670.0011.01
126315
022085-001
028062-001
028062-002
30042-001
30042-002

HINDUSTHAN THERMOMETERS

1. SYSTEM DESCRIPTION

This manual contains operation and maintenance instructions as applicable to the SParc S12-1
High Energy Pulsed Arc Ignitor manufactured by Hindusthan Thermometers. This system is designed
for use in ignition of fossil fuel on industrial and utility power boilers.

Several design configurations are available based upon fuel burning equipment and purchaser
preference. This is a general document covering a wide range of possible configurations. Contract bill
of materials and drawings should be referenced for specific configuration when ordering replacement
components and spare parts. The quantity of specific drawings attached to this manual will vary
depending on the contract bill of material.

WARNING
THIS SYSTEM CONTAINS HIGH VOLTAGES AND CURRENTS THAT
COULD KILL OR SERIOUSLY INJURE PERSONS COMING INTO
CONTACT WITH THEM. THIS MANUAL MUST BE READ AND
UNDERSTOOD BEFORE ANY ATTEMPT IS MADE TO INSTALL OR
OPERATE THIS SYSTEM OR ANY OF ITS COMPONENTS.

HINDUSTHAN THERMOMETERS

2. COMPONENT SPECIFICATION
The SParc S12-1 High Energy Pulsed Arc Ignition system consists of five (5) basic components. Refer
to the appendix for a list of complete drawing titles.
1)

12 Joule HT Exciter

P/N 0775.0004.01

2)

Flexible Cable Assembly, single socket

P/N 0757.0017.01

3A)

Flexible Spark Rod Assembly

P/N 0645.0026.01

3B)

Rigid Spark Rod Assy, Single socket

P/N 0645.0027.01

4)

Spark Rod Tip

P/N 0147.0002.01

5A)

Retractor (8 stroke)

P/N 5000086

5B)

Retractor (12 stroke)

P/N 5000087

HINDUSTHAN THERMOMETERS

3. COMPONENT DESCRIPTIONS
TABLE 1-1
EXCITER ASSEMBLIES P/N 0775.0004.01
Enclosure
Supply Voltage
Frequency
Current in Amps
Output Energy
Spark Rate
Duty Cycle (Intermittent)
Temperature Range (1)

Heavy Duty 9.52 x 9.40 x 8.19 NEMA 4

110-130 VAC (Optional 240 VAC)
50/60 Hz
5 @ 120 VAC
12 Joules per spark nominal
4 sparks per second nominal
15 minutes on 30 minutes off
-40F to +165F
FLEXIBLE CABLE P/N 0757.0017.01

Operating Voltage
Cable Length (2)
Bend Radius
Temperature Range (1)

3600 Volts pulsed arc

Length specified by purchaser
4 inch minimum
-65F to +300F
FLEXIBLE SPARK ROD P/N 0645.0026.01

Operating Voltage
Rod & Tip combined length (2)
Flexible Section length
Temperature Range (1)

3600 Volts pulsed arc

15 feet max specified by purchaser
30 inches standard
Tip End -65F to +1000F
Cable End -65F to +300F

RIGID SPARK ROD P/N 0645.0027.01

Operating Voltage
Rod & Tip combined length (2)
Temperature Range (1)

3600 Volts pulsed arc

15 feet max specified by purchaser
Tip End -65F to +1000F
Cable End -65F to +300F
SPARK ROD TIP P/N 0147.0002.01

Temperature Range (1)

Length

Notes:
1.)
2.)

-65F to +1000F
7 inches collar to tip

Do not operate outside of the operating temperature range. Temperature below +32F are
based upon the absence of freezing moisture or water.
Flex Cable, Spark Rod and Spark Rod Tip combined length should not exceed 30 feet.

HINDUSTHAN THERMOMETERS

SPARK ROD RETRACTOR P/N 5000086

Air Cylinder

1-1/2 Diameter x 8 Stroke

Cylinder Seals

Viton

Cylinder Operating Pressure

70 to 100 psi

Solenoid Valve

Two position four ways.

Solenoid Valve Electrical Requirements:

A) Coil Voltage
120 VAC (Optional 240 VAC)
B) Coil frequency
50 to 60 Hz
C) Inrush @ 50 Hz
42 VA +5% -15% Volts tolerance
D) Inrush @ 60 Hz
35 VA +10% -15% Volts tolerance
E) Holding @ 50 Hz
22 VA +5% -15% volts tolerance
F) Holding @ 60 Hz
18 VA +10% -15% volts tolerance
Solenoid Valve Mechanical

NPT Ports

Limit Switches (2)

Voltage
Frequency
Characteristic
Current

120/240 VAC
50 to 60 Hz
SPDT
10 AMPS Continuous @ 120 VAC

Temperature Range

-20F to +230F

SPARK ROD RETRACTOR P/N 5000087

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

HINDUSTHAN THERMOMETERS

4. GENERAL THEORY OF OPERATION

IGNITION EXCITER
Application of 110-130 VAC (optional 220-260 VAC), 50/60 Hz to the primary induces a high voltage
in the secondary coil of the power transformer (See Figure 1). The high voltage generated in the
secondary of the power transformer is rectified in the voltage doubler circuit by the action of two solid
state rectifiers and two capacitors. With each change of polarity, a pulse of DC current charges the
storage capacitors. The resistor R3 and inductor L1 serve as current limiters. When this voltage reaches
the predetermined level that the Spark Gap Discharge Controller (SGDC) has been calibrated, the
SGDC will ionize. Current will flow from the storage capacitors C1 and C2 through the SGDC, to the
center conductor of the output lead to the Spark Rod Tip; returning to storage capacitor through the
ground lead. When the energy is dissipated at the Spark Rod Tip, the storage capacitors will be
recharged. There is a voltage drop across the SGDC so a spark does not completely discharge the
capacitors. Bleed resistors R1 and R4 are provided to dissipate any residual charge on storage
capacitors between duly cycles. Resistors R2 and R5 in the output circuit provide a discharge path for
storage capacitor energy in the event that the Spark Rod Tip fails to fire, or the unit is subjected to
operation without a flexible cable, Rod, and Tip. Resistors R2 and R5 are essential to protect the
capacitors from an over voltage in the situations describe above.

DANGER
DISCONNECTING INPUT POWER WILL RESULT IN REDUCING
THE OUTPUT POTENTIAL FOR SEVERE SHOCK AFTER 5
MINUTES. DO NOT DISCONNECT OUTPUT CABLE OR SPARK
ROD WHILE UNIT IS RUNNING OR BEFORE THE EXPIRATION OF
A 5 MINUTE INTERVAL FOLLOWING REMOVAL OF INPUT
POWER. DO NOT REMOVE TIP WHILE INPUT POWER IS
CONNECTED TO UNIT BEFORE A 5 MINUTE PERIOD
FOLLOWING REMOVAL OF INPUT POWER.

HINDUSTHAN THERMOMETERS

5. EXCITER MOUNTING AND WIRING

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

6. INSTALLATION INSTRUCTIONS

6.1

EXCITER

Mount the Exciter at eye level or lower. Avoid locating near furnace hot spots, casing gas leaks and
direct contact with the windbox. Refer to the Exciter drawing for applicable dimensions and hole sizes.

6.2

FLEXIBLE CABLE

When routing the Flexible Cable between the Exciter and the Spark Rod, avoid coiling the cable since
this may reduce the energy transferred to the Spark Rod Tip due to additional reactance. During
Installation caution should be exercised not to subject the flexible cable to a bend radius of less than 4
inches at any point as damage to the flexible cable could result. Care should also be taken to orient the
elbow in a vertical position to prevent the elbow from impacting with retractor frame during operation.

6.3

RETRACTOR

Refer to drawing 5000087 in the appendix. If possible, install the retractor at eye level or lower on the
mounting guide pipe assembly which is welded to the surface of the boiler.

6.4

SPARK ROD AND TIP

Insert the Spark Rod and Tip (through the Retractor packing glands if in contract, see section
D-D and) into the guide tube. When the Spark Rod has been inserted to the operating depth, fully
extend the air cylinder of the Retractor and clamp it onto the Spark Rod.

HINDUSTHAN THERMOMETERS

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6.5

WIRING

Check local codes and the national electrical code for over current protection and external disconnect
wiring requirements. Insure all power is disconnected before installation is attempted.
Attach wiring for the Flexible Cable exciter end to the exciter, and spark rod end to the
Spark Rod. Electrical input specifications for the Exciter and Retractor assemblies are outlined in
Table 1-1. Specific requirements which should be noted are shown inside junction box covers or on
nameplates of the Exciter and Retractor assemblies.
6.5.1
Input voltage required to operate the Exciter is specified as 110 to 130VAC (or optional 220/260
VAC) 50/60 Hz. A hole is provided on the Exciter for a conduit fitting. Wiring to the terminal
block in the Exciter should meet National Electrical Code requirements.
6.5.2
Input voltage required to operate a Retractor assembly is specified as 120 VAC (optional 220 VAC),
50/60 Hz. A hole is provided in the junction box on the Retractor assembly for a conduit fitting.
Wiring to the terminal block in the junction box should meet National Electrical Code requirements.

6.6

COMPRESSED AIR LINES

Compressed air specifications for the Retractor assembly air cylinder are outlined in Table 1-1.
Specific requirements which should be noted are as follows:
6.6.1
Operating pressure for the air cylinder is 70-100PSI.
6.6.2
Conditioned air, free of oil, water and dirt, is connected to the pressure inlet on the solenoid valve.

HINDUSTHAN THERMOMETERS

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6.7

PRE-START CHECKS

CAUTION: Before applying power to the Exciter, the system, should be checked to make absolutely
sure that:
1.

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

2.

The Flexible Cable is tightened to both the Exciter assembly and the Spark Rod assembly, with
proper alignment of elbows.

3.

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

FAILURE TO COMPLY WITH THE ABOVE COULD RESULT IN PERSONE BEING SERIOUSLY INJURED
BY COMING IN CONTACT WITH HIGH VOLTAGES AND CURRENTS.

6.8

ELECTRICAL

With the Spark Rod fully retracted in the reverse position, apply input voltage to the Exciter. Audible
sparking should be observed at the Spark Rod Tip.

6.9

MECHANICAL

Activate the Retractor mechanism. A positive full stroke should be observed as the Spark Rod travels
to the forward position, and in turn to the reverse position.

HINDUSTHAN THERMOMETERS

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7. TROUBLESHOOTING
7.1
Troubleshooting procedures are outlines in Table 2-1, TROUBLES AND REMEDIES.

TABLE 2-1
TROUBLES AND REMEDIES
CONDITION: Retractor Mechanism fails to actuate.
PROBABLE CAUSE

REMEDY

1.

A loss of electrical impulse control to the

Retractor.

1. Check electrical control system and

make repairs as necessary.

2.

A significant drop in air pressure supply

to the retractor.

2. Check Plant air supply and filters.

Repair as necessary.

3.

Air leaking at cylinder.

3. Rebuild air cylinder using piston seal

kit P/N 0670.0012.01 and rod Bushing
Seal kit p/N 0670.0011.01

Condition: Spark Rod Tip fails to fire.

PROBABLE CAUSE

REMEDY

1. Open Circuit condition exists in input

power supply to the Exciter.

1. Check control system output voltage

and repair as necessary.

2. Defective Flexible Cable.

2. Separate the Flexible Cable from the

Exciter and the Spark Rod, then using a
Simpson 260 voltmeter or equivalent:
A) Check continuity between the socket
connector Rod end and the contact at
the Exciter end. If resistance is more
than 1.0 Ohm, rebuild or replace cable.
B) Measure resistance between the center
conductor and the shield of the Flexible
Cable using an Ohmmeter. Replace
Flexible Cable if resistance is less than
10 Megohms.

HINDUSTHAN THERMOMETERS

14

3. Defective Spark Rod Tip.

3. Replace Spark Rod Tip.

4. Defective Spark Rod.

4. Remove Spark Rod Tip, disconnect

flexible cable and:
A) Check continuity between the socket
connector, Spark Rod Tip end, and the
contact at the Flexible Cable end. If
resistance is more than 1.0 Ohm,
rebuild or replace cable.
B) Measure the resistance between the
center conductor and the outer surface
of the Spark Rod using a standard
multimeter. Replace center conductor if
resistance is less than 10 Megohms.
C) Check Rod Tip Insulator. If broken,
replace with P/N 5000103 using
Retainer Nut Removal Tool
P/N 0570.0001.01.

5. Defective Exciter.

5. Remove electrical supply, then:

A) Discharge capacitors C1 and C2.
Disconnect one lead from capacitors
C1 and C2. Using a standard
multimeter on a high Ohms range, put
leads across capacitors terminals.
Meter should rapidly swing right then
slowly drift left (infinite resistance).
Replace if defective.
B) Check transformer, resistors and diodes
using a standard multimeter. Replace if
defective.
C) Substitute Spark Gap Discharge
Controller. Replace if defective.

HINDUSTHAN THERMOMETERS

15

8. REPAIR/ REPLACEMENT

Filed Repair. Extreme caution is recommended with all field repairs, and should be limited to
trained personnel in a suitably equipped workshop. No field repairs should be attempted on the
boiler where proper access is not available.

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

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

FACTORY REPAIR: Based upon return material authorization, Exciters, Flexible cables, and
Spark Rods may be returned for factory rebuilding. Contact the factory for tagging and shipping
instructions. Repair costs will be estimated prior to initiating work.

For spare parts ordering on repair assistance please contact:

HINDUSTHAN THERMOMETERS,
5-B, INDUSTRIAL ESTATE,
AMBALA CANTT 133 006,
HARYANA, INDIA
PH: +91-171-2699237
FAX: +91-171-2699037
E-mail: ignitor@rediffmail.com

HINDUSTHAN THERMOMETERS

16

APPENDIX

DRAWING DESCRIPTION

NUMBER

EXCITER ASSY 12 JOULE

0775,0004.XX

FLEX. CABLE ASSY SINGLE SOCKET TER.

0757.0041.XX

FLEX. CABLE ASSY 2 WIRE CONN.

0757.0042.XX

FLEX. CABLE ASSY SParc S12-1

0757.0017.XX

ASSY 5/8 FLEX. SPARK ROD

0645.0026.XX

ASSY 5/8 RIGID SPARK ROD PIN BASE CONN.

0645.0027.XX

RIGID SPARK ROD ASSY 2 WIRE CONN.

0645.0029.XX

ALUMIN INSULATOR FOR IGNITOR ROD

HT-AIIR-01

SPARK ROD TIP

0147.0002.01

RETRACTOR ASSEMBLY (8 STROKE)

5000086

HIGH VOLTAGE CAPACITOR (ROUND SHAPE)

HT-10/2300-1

HIGH VOLTAGE CAPACITOR (ROUND SHAPE)

HT-12/3000-1

YN10-2500R4C-HC

HT-10/2500-HC

BOARD ASSEMBLY

5000078

BOARD ASSEMBLY

5000079

WIRING DIAGRAM 12.0 JOULE EXICITER

5000080

HEA IGNITOR INSTALLATION IN T.T. BURNER

PSG-79-10-9226

HEA IGNITOR INSTALLATION

2-41-500-00320

NOTE: The XX in the drawing number is a place holder for the variation of the part.

HINDUSTHAN THERMOMETERS

17