Installation Guide 248 4/10/07 E clipse Vortometric Burners yyyy ;;;; ;;;; yyyy ;;;; yyyy ;;;; yyyy
COPYRIGHT Copyright 1997 by Eclipse Combustion. All rights reserved worldwide. This publication is protected by federal regulation and shall not be copied, distributed, transmitted, transcribed or translated into any human or computer language, in any form or by any means, to any third parties, without the express written consent of Eclipse Combustion.
About this manual AUDIENCE This manual has been written for those persons who are already familiar with all the aspects of a burner and its add-on components, also referred to as “the burner system”. These aspects are: • design/selection • installation • use • maintenance The audience is expected to have previous experience with this kind of equipment.
RELATED PUBLICATIONS • EFE-825 (Combustion Engineering Guide) • Eclipse Bulletins & Instruction Manuals: 818, 820, 826, 832, 852, 854, 856 IMPORTANT NOTICES • Read this manual carefully. Make sure that you understand the structure and contents of this manual. • Obey all the safety instructions. • Do not deviate from any instructions or application limits in this manual without written consent from Eclipse Combustion. • If you do not understand any part of the information in this manual, do not continue.
Table of Contents 1 About this manual ................................................................ ii Table of Contents .................................................................. v Introduction ............................................................................... 1-1 1-1 Product Description ........................................................................ 2 Safety ...............................................................................................
4 Adjustment, Start & Stop .............................................. Introduction ....................................................................................... Adjustment Procedure .................................................................... Step 1: Reset the system .......................................................... Step 2: Set low fire combustion air pressure drop ........... Step 3: Verify air settings ..........................................................
Introduction PRODUCT DESCRIPTION 1 The Eclipse Vortometric v2.00 is a dual-fuel, high intensity burner which operates at maximum efficiency whether firing fuel oils or natural, propane, butane, manufactured or other mixed gases. The Vortometric’s versatility and rugged design make it the right choice for any heating process, including driers, kilns, thermal fluid heaters, thermal oxidizers, oil heaters, vaporizers, boilers, liquid and waste incineration, and many air heating applications.
Eclipse Vortometric Burner v2.
Safety INTRODUCTION SAFETY 2 In this section, you will find important notices about safe operation of a burner system. Danger: The burners covered in this manual are designed to mix fuel with air and burn the resulting mixture. All fuel burning devices are capable of producing fires and explosions when improperly applied, installed adjusted, controlled, or maintained. Do not bypass any safety feature. You can cause fires and explosions.
CAPABILITIES Adjustment, maintenance and troubleshooting of the mechanical and the electrical parts of this system should be done by qualified personnel with good mechanical aptitude and experience with combustion equipment. OPERATOR TRAINING The best safety precaution is an alert and competent operator.Thoroughly instruct new operators so they demonstrate an adequate understanding of the equipment and its operation. Regular retraining must be scheduled to maintain a high degree of proficiency.
Installation 3 INTRODUCTION In this section you will find the information and instructions that you need to install the burner. HANDLING AND Handling STORAGE 1. Make sure that the area is clean. 2. Protect the components from the weather, damage, dirt and moisture. 3. Protect the components from excessive temperatures and humidity. 4. Take care not to drop or hit components. Storage 1. Make sure that the components are clean and free of damage. 2. Store the components in a cool, clean, dry room. 3.
APPROVAL OF COMPONENTS Limit controls and safety equipment All limit controls and safety equipment must comply with the following current standards: • • • • • • • • Electrical wiring All of electrical wiring must comply with the one of the following standards: • • • • • Gas piping NFPA Standard 70 ANSI-C11981 CSA EN 746-2 the electrical wiring must be acceptable to the local authority having jurisdiction.
The FM Standards are available from: Factory Mutual 1151 Boston-Providence Turnpike P.O.
BURNER MOUNTING Depending on your application, please keep the following in mind when mounting a burner: • Ensure that the burner is level and that the furnace or burner casing has sufficient rigidity to support the burner. If necessary, provide stiffeners on the casing or supports under the burner. • Remember to compensate for the burner’s combustor liner extension for the refractory combustion block.
Figure 3.1 Vortometric Gas Gun Position 4 5 Burner Size “X” (Inches) 6V 8V 10V 12V 11/16 1-3/8 1-5/16 1-1/2 14V 16V 18V 22V 1-11/16 2-1/16 2 2-5/16 24V 28V 32V 36V 2-1/4 3-3/16 3-1/16 3-7/8 Gland To Adjust Gun Position 3 2 1 Gas Inlet 2 Gas Gun 3 Throat Cone “X” Dim. 1 4 Air Inlet 5 Refractory Block Walls 5 Figure 3.
For Combination Gas/Oil Burners–Initial Adjustment (see Figure 3.2): 1. Adjust the oil gun position by loosening gland “A”. 2. Align the conical faces of the oil and gas guns. 3. Once both guns are aligned, tighten gland “A” on the oil gun. Note: After this initial adjustment, all subsequent adjustments for combination gas/oil burners require that both guns be moved as a single unit. For Combination Gas/Oil Burners–Subsequent Adjustments (see Figure 3.2): 1.
Install the flame sensor U.V. Scanner (Model 5600-91) An ultraviolet flame sensing device, or U.V. scanner, must be used with a 3/4" N.P.T. swivel connector. The scanner and connector can be used in three possible locations: two mounting ports are located near the gun assembly adjacent to the pilot which sight both pilot and main flames, while a third mounting port on the side of the combustor sights only the main flame.
Pilot Pilot ignition The standard Vortometric spark-ignition pilot requires an ignition transformer with a minimum of 6000 volt secondary. Mount the transformer in a location where it will not overheat while allowing as short an ignition lead as possible. Pilot assembly positioning The relation of the pilot assembly to the main burner gun affects air flow through the throat cone. Therefore, it is important that the pilot be as far away as possible from the throat cone while maintaining reliable ignition.
Oil fuel considerations 1. In heavy oil (#5 or #6) applications, the oil temperature at the burner inlet should be 220° to 270°F for good viscosity (maximum 150 SSU). Depending on burner location, steam or electric tracing AND pipe insulation are usually needed to ensure this oil temperature range. Other oils (wastes, residues, etc.), may also require similar provisions to ensure good viscosity. 2. Foreign material can easily clog the small injection holes in the oil nozzle tip.
Strainers No matter what fuel is used, it is essential that the valve train components, the atomizer and the fuel oil tip be protected from foreign material damage. Therefore, it is suggested that strainers be used as follows: Oil valve trains 1. It is recommended that an edgeplate type filter with 0.0035" separations (170 mesh) be used UPSTREAM of all valve train components. 2. It is recommended that a strainer with 100 mesh screen be used ADJACENT to the oil gun inlet.
INSTALLING AND CURING REFRACTORY BLOCK It is the customer’s choice whether the combustion refractory block is factory or field installed. The following provisions deal with installing either choice. The standard, general purpose refractory for Vortometric combustor blocks is Plibrico 80 Air Bond with an 80% alumina plastic ramming mix. Factory installed refractory The Eclipse factory installed refractory has been oven cured at relatively low temperatures to remove most of the water content.
Field installed refractory The customer is responsible for supplying all refractory materials for field installation as follows: 1. Cover the inside surfaces of the combustor shell with an 1/8" layer of Plibrico “Plisulate” fibrefax paper or equivalent. 2. Install alloy anchors in the combustor shell according to the refractory supplier’s recommendations. The alloy anchors should be coated with bitumastic wherever they protrude through the layer of Plibric Plisulate. 3.
Figure 3.3 Vortometric Burner Mounting Arrangements Suggested Mounting Arrangement For Standard Burner 229mm (9")* Flange position on standard burner allows correct shell dimension above *178mm (7") for 6V and 8V medium intensity burner sizes. Provide adequate shell stiffeners Furnace backstay Furnace shell plate Weld heads of mounting bolts inside furnace shell plate. Allow for 3mm (1/8") thick, high temperature gasket between the burner flange and shell plate.
CHECKLIST AFTER INSTALLATION To make sure that the system is installed correctly, do the steps that follow: 1. Make sure that there are no leaks in the gas lines. 2. Make sure that the blower rotates in the correct direction. If incorrect, then have a qualified electrician rewire the blower to reverse its rotation. 3. Set the air proving switch. 4. Set the low gas pressure switch. 5. Set the high gas pressure switch. 6. Close all the burner gas cocks. 7.
Adjustment, Start & Stop 4 INTRODUCTION In this chapter you will find instructions on how to adjust a system and how to start and stop a system. Danger: Do not bypass any safety features.You can cause fires and explosions. Obey the safety precautions in the Safety chapter. Read all of this chapter before starting your system. ADJUSTMENT PROCEDURE If you are adjusting the burner system for the first time, then you must follow these steps: 1. Reset the system 2. Set combustion air pressure drop 3.
Step 2: Set low fire combustion air pressure drop 1. Start the combustion air fan. Step 3: Verify air settings Make sure that all the settings are still the same after you cycle the system several times between high fire and low fire. Check air proving switch and adjust if necessary. 2. Set the air control damper to produce the desired pressure drop across the burner. Air pressure drop should be read as a differential pressure between the windbox pressure test port and the chamber.
Step 5: Ignite the burner Note: This procedure assumes that automatic flame safety is installed and is serviceable. For Gas Burners 1. Make sure the supply air fan is running. 2. Adjust the main gas regulator to supply the minimum pressure required; see the Appendix for gas pressure drop information. 3. Verify that the main gas control valve is at its minimum open position. 4. Light the pilot. 5. Open all manual fuel shut-off valves. 6. Initiate the ignition sequence through the flame safety. 7.
For Oil Burners 1. Make sure the supply air fan is running. 2. Adjust the main oil regulator to supply the minimum pressure required; see the Appendix for oil nozzle pressure drop information. 3. Turn on the atomizing medium and adjust atomizing pressure to approximately 20 to 30 psig. Note: If using heavy oil as the fuel with either steam or preheated air for atomization, then warm up the oil feed pipe and fuel oil nozzle by running the atomizing medium through the burner bypass valve.
achieved or is too high while the main gas control valve is fully open, two adjustments can be made: a. the main gas control valve can be adjusted open or closed, or b. the main gas pressure regulator can be adjusted higher or lower. 3. The main gas flame should have a slightly blue periphery and a somewhat yellowish center at high fire; refer to Table 4.2 below for flame length estimates. For Oil Burners 1. Drive the main oil control valve to high fire. 2.
START PROCEDURE 1. Start the air supply fan. 2. Open all the gas or oil cocks. 3. Start the automatic ignition sequence. Danger: If a burner does not light, and the system does not shut down automatically, then you must close the main gas cock on gas burner systems. An uncontrolled flow of gas can cause fires and explosions. Do not touch the ignition plug or the ignition wire when the ignition is on. You will get a shock. 4. Make sure that you can see the flame in the burner system.
STOP PROCEDURE For Gas Burners 1. Drive combustion air and gas valves to low fire position. 2. Shut off main gas supply valves and pilot. 3. Leave combustion air at low fire until combustion chamber and block are cooled; once cooled, shut off combustion air fan. 4. Shut off all manual valves as required. For Oil Burners 1. Drive combustion air and fuel valves to low fire position; shut down the oil supply. 2. Turn on the pilot. 3.
Eclipse Vortometric Burner v2.
Maintenance & Trouble-shooting 5 INTRODUCTION This section is divided into two parts: • The first part describes the maintenance procedures. • The second part helps you to identify problems that may occur, and gives advice on how to solve these problems. MAINTENANCE Preventative maintenance is the key to a reliable, safe and efficient system. The following are sugested guidelines for periodic maintenance. Burners in severe environments or operational conditions should be checked more frequently.
Yearly Checklist 1. Test (leak test) safety shut-off valves for tightness of closure. 2. Test pressure switch settings by checking switch movements against pressure settings. 3. Visually check ignition cable and connectors. 4. Check the refractory combustion block to ensure that it is not badly cracked or spalled. Minor hairline cracks are of no consequence and should be considered normal. Examine the refractory around the throat cone, since this area is where breakage can easily occur.
When inspecting and cleaning the fuel oil tips, please observe the following: • Vortometric oil nozzles are manufactured of stainless steel, with all surfaces manufactured to close tolerances and highly polished. Therefore, avoid marring the nozzle’s machined surfaces in any way when the atomizer is dismantled. • Never use abrasive cleanser or emery cloth on the internal surfaces of the nose cone. However, a wire brush may be used on the outside surfaces of the nose cone where carbon has accumulated.
Dismantling of Atomizer Note: Refer to Figure 5.1 for oil nozzle component identification and location. 1. Remove the complete oil gun from the burner by removing the bolts on the rear flange of the gun assembly. 2. Place the oil gun in a pipe vise. 3. Loosen the bolts on the packing gland at the rear (outer) end of the oil gun. 4. Using a spanner wrench, loosen the nose cone assembly, which has a standard right hand thread. 5.
12. Referring to Table 5.2, select the correct drill size. Use this drill bit to check the hole diameters of the venturi inlets in the tangential inlet ring. If the holes are worn beyond the corresponding maximum throat diameter number shown in Table 5.2, then replacing the venturi insert should be considered. 13. Examine the flat faces of the base and nose cone, which form the front and rear of the vortex chamber, respectively.
Assembly of Atomizer 1. With all of the parts clean of foreign material, put a smear of anti-seize compound or similar lubricant on all mating surfaces and on all threads. 2. Slide the retainer ring onto the fuel pipe. 3. Screw the fuel pipe into the oil tip and tighten securely. 4. Assemble the base and inlet ring onto the nose cone using the provided cap screws. Tighten all cap screws securely and evenly. The tangential inlet ring can provide either clockwise or counterclockwise rotation to the steam.
10. Tighten the packing gland at the outer end of the atomizing steam pipe. A final check on the location of the oil holes in relation to the nose cone lip can be done as follows: a. Connect the oil feed line to a water supply line and spray water out of the nozzle at 5 PSIG. b. If properly located, then the water streams emerging out of the oil holes should be separate, distinct and uniform; the water streams should also clear the inside lip of the nose cone or just barely touch the lip’s edge. 11.
TROUBLE-SHOOTING Table 5.1 Trouble-shooting PROBLEM Cannot initiate start-up sequence. POSSIBLE CAUSE SOLUTION Air pressure switch has not made contact: • Air flow too low. Check air flow and investigate any changes. • Air pressure switch incorrectly set. Check air pressure switch adjustment. • Air pressure drop measured incorrectly. Move pressure taps on chamber to a better location. High gas pressure switch has tripped: • Gas pressure too high.
TROUBLE-SHOOTING Table 5.1 Trouble-shooting PROBLEM Start-up sequence runs but pilot does not light. POSSIBLE CAUSE SOLUTION No spark: • No power to ignition transformer. Have electrician investigate. • Open circuit between the ignition transformer and the spark plug. Repair or replace wiring to spark plug. • Spark plug has carbon build-up. Clean or replace spark plug. • Spark plug not correctly grounded. Clean spark plug threads. Do not apply grease or pipe compound to pipe threads.
TROUBLE-SHOOTING Table 5.1 Trouble-shooting PROBLEM Start-up sequence runs, pilot lights but main burner does not light. POSSIBLE CAUSE No UV signal. SOLUTION Check wiring and control logic. Not enough main fuel: • Main fuel regulator set too low. Check outgoing fuel pressure of main regulator; increase as necessary. • Fuel pressure into main regulator too low. Check incoming fuel pressure against initial settings; increase as necessary. • Main fuel cock closed. Open all fuel cocks.
TROUBLE-SHOOTING Table 5.1 Trouble-shooting PROBLEM POSSIBLE CAUSE SOLUTION • Fuel pressure too high at burner inlet. Check fuel pressure against design. Adjust main fuel pressure regulator, or adjust control valve. • Combustion air pressure drop/flow is too low. Open air damper on main air blower. • Combustion air pressure drop/flow is too high. Check pressure drop or flow. Check air damper on main air blower. • Burner is firing below rated input. Check fuel pressure differential/flow.
Appendix FLOW AND INPUT Table A.1 Combustion Air Pressure Drop vs. Burner Heat Input for Medium Intensity Burners (MI) CHARTS • Operation with 15% excess air on natural gas under standard conditions (14.7 psia @ 70°F). • Pressure drop should be taken between the chamber and windbox pressure tap. 8V 7.5 6V 6 5 Combustion Air Pressure Drop ("w.c.)* 10V 12V 14V 16V 18V 22V24V 28V 32V 36V 4 3 2 1 0.8 0.6 0.4 0.2 0.1 0.6 0.8 1 2 4 6 8 10 20 40 60 80 100 Burner Gross Heat Input (MMBtu/hr.
Table A.2 Combustion Air Pressure Drop vs. Burner Heat Input for High Intensity Burners (HI) • Operation with 15% excess air on natural gas or #2 oil under standard conditions (14.7 psia @ 70°F). • Pressure drop should be taken between the chamber and windbox pressure tap. 6V 7.5 8V 10V 12V 14V 16V 18V 22V 24V 28V 32V 36V Combustion Air Pressure Drop ("w.c.) 6 5 4 3 2 1 0.8 0.6 0.4 0.2 0.1 0.6 0.8 1 2 4 6 8 10 20 40 60 80 100 200 300 Burner Gross Heat Input (MMBtu/hr.
Table A.3 Gas Gun Press. Drop vs. Burner Heat Input • Pressure drops for natural gas, 1,000 Btu/SCF gross, 0.6 specific gravity. • Pressure drop should be taken as differential between the chamber and gas gun pressure tap. Gas Gun Pressure Drop ("w.c.)* Note: Fuel pressure drop curves should be used as a guide for setting up burner. It is recommended to use a direct fuel flow measurement (orifice plate or flow meter) for calculating actual fuel flows.
Table A.4 Oil Nozzle Press. Drop vs. Burner Heat Input • Pressure drops for #2 Oil with 137,000 Btu/lb. gross heating value. Note: Fuel pressure drop curves should be used as a guide for setting up burner. It is recommended to use a direct fuel flow measurement (orifice plate or flow meter) for calculating actual fuel flows. 10V 40 12V 14V 16V 18V 22V 24V 28V 32V 36V 8V 6V 20 10 8 6 4 2 1 2 4 6 8 10 20 40 60 80 100 200 300 Burner Gross Heat Input (MMBtu/hr.) Table A.
Table A.6 Atomizing Steam Press. Drop vs. Steam Flow Atomizing Steam Pressure Drop (psig) • Atomizing steam must be dry and superheated a minimum of 20°F above saturated at the atomizer inlet. 8V 60 50 10V 12V 14V 16V 18V 22V 24V 28V 32V 36V 6V 40 30 20 15 10 10 20 40 60 80 100 200 400 600 1,000 2,000 4,000 Atomizing Steam Flow (lb/hr) RECOMMENDED SPARE PARTS To make sure that the downtime of the system is as short as possible in case of a failure, you should keep a stock of spare parts.
CONVERSION FACTORS Metric to English. FROM TO MULTIPLY BY cubic meter (m3) cubic foot (ft3) 35.31 cubic meter/hour (m /h) degrees Celsius (°C) cubic foot/hour (cfh) degrees Fahrenheit (°F) 35.31 (°C x 1.8) + 32 kilogram (kg) kilowatt (kW) pound (lb) Btu/hr 2.205 3414 meter (m) millibar (mbar) foot (ft) inches water column ("wc) 3.28 0.401 millibar (mbar) millimeter (mm) pounds/sq in (psi) inch (in) 14.5 x 10-3 3.
SYSTEM SUMMARY GENERAL SYSTEM PARAMETERS Customer: Customer P.O.
Offered By: Power Equipment Company 2011 Williamsburg Road Richmond, VA 23231 Phone: 804-236-3800 Fax: 804-236-3882 www.peconet.
