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Eclipse Combustion Vortometric v2.00 Installation Manual Download Page 33

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.

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.

Note:
The monthly and yearly lists are an average interval. If your
environment is dirty, then the intervals may be shorter. Check
with local authorities having jurisdiction on their recommended
maintenance schedules.

Caution:
Turn off power to burner and controls before proceeding with
burner inspection.

Monthly Checklist

1. Inspect flame-sensing devices for good condition and cleanliness.

2. Test all alarms for proper signals.

3. Check ignition spark electrode operatin and check proper gap.

4. Check all valve motors and control valves for free, smooth

action and adjustment.

5. Test interlock sequence of all safety equipment and manually

make each interlock fail, noting that related equipment closes
or stops as specified by the manufacturer.  Test flame safeguard
by manually shutting off gas to burner.

6. Test all manual fuel valves for operation.

7. Check filters on main air fan for cleanliness.

8. Check gas filter or strainers.

I

NTRODUCTION

M

AINTENANCE

SCHEDULES

5-1

 Maintenance &
Trouble-shooting

5

Eclipse Vortometric Burner v2.00, Installation Guide 248, 4/10/07

Summary of Contents for Vortometric v2.00

Page 1: ... yyyy yyyy yyyy yyyy Vortometric Burners Installation Guide 248 4 10 07 E clipse ...

Page 2: ...arranty is expressed or implied We have made every effort to make this manual as accurate and complete as possible Should you find errors or omissions please bring them to our attention so that we may correct them In this way we hope to improve our product documentation for the benefit of our customers Please send your corrections and comments to our Marketing Communications Manager It must be und...

Page 3: ...te package then schematic piping and wiring diagrams will be furnished which explain the control system operation When Eclipse Combustion sells only theVortometric burner then it is the purchaser s responsibility to ensure that the control system is adequate for the application the control system meets all applicable codes and regulations and the operating personnel are fully familiar with safe co...

Page 4: ...ce The explanation of these symbols follows Please read it thoroughly Danger Indicates hazards or unsafe practices which WILL result in severe personal injury or even death Only qualified and well trained personnel are allowed to carry out these instructions or procedures Act with great care and follow the instructions Warning Indicates hazards or unsafe practices which could result in severe pers...

Page 5: ...3 2 Limits controls and safety equipment 3 2 Electrical wiring 3 2 Gas piping 3 2 Where to get the standards 3 2 Checklist before Installation 3 3 Burner Mounting 3 4 Prepare the Burner 3 2 Gas Gas Oil or Oil Gun Positioning 3 2 Install the flame sensor 3 7 Pilot 3 8 Piping 3 8 Strainers 3 10 Atomizing Control Methods 3 10 Installing and Curing Refractory Block 3 11 Checklist after Installation 3 ...

Page 6: ...ocedures 5 2 Fuel Oil Tip Cleaning 5 2 Dismantling of Atomizer 5 4 Assembly of Atomizer 5 6 Troubleshooting 5 8 Appendix A 1 Flow and Input Charts A 1 Table A 1 Combustion Air Pressure Drop vs Burner Heat Input for Medium Intensity Burners A 1 Table A 2 Combustion Air Pressure Drop vs Burner Heat Input for High Intensity Burners A 2 Table A 3 Gas Gun Press Drop vs Burner Heat Input A 3 Table A 4 O...

Page 7: ...capabilities on a wide range of fuels The burner can be operated with low excess air where maximum efficiency is required or high excess air for high volume process air heating The intense and thorough mixing of the air and gas results in low NOx and CO emissions The novel design of the oil atomizer uses shear forces and acoustical energy created by a vortex generator to vaporize the fuel for clea...

Page 8: ...Eclipse Vortometric Burner v2 00 Installation Guide 248 4 10 07 ...

Page 9: ... malfunctioning Warning The burner and duct sections are likely to have HOT surfaces Always wear protective clothing when approaching the burner Note This manual gives information for the use of these burners for their specific limited design purpose Do not deviate from any instructions limits in this manual without written advice from Eclipse Combustion Note Read this entire manual before you att...

Page 10: ...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 Order replacement parts from Eclipse only Any customer supplied valves or switches should carry UL FM CSA CGA and or CE approval where applicable OPERATOR TRAINING REPLACEMENT PARTS 2 2 CAPABILITIES...

Page 11: ...d free of damage 2 Store the components in a cool clean dry room 3 After you have made sure that everything is present and in good condition keep the components in the original package as long as possible Caution When the refractory combustion block is supplied with the burner it is critical that the instructions for handling and storage are followed The refractory should be considered fragile imp...

Page 12: ...the one of the following standards NFPA Standard 54 ANSI Z223 EN 746 2 the gas piping must be acceptable to the local authority having jurisdiction The NFPA Standards are available from National Fire Protection Agency Batterymarch Park Quincy MA 02269 The ANSI Standards are available from American National Standard Institute 1430 Broadway NewYork NY 10018 The UL Standards are available from United...

Page 13: ... Fax 32 25196819 Comité Européen de Normalisation Electronique Stassartstraat 36 B 1050 Brussels Phone 32 25196871 Fax 32 25196919 Access Make sure that you install the system in such a way that you can get easy access to the burner for inspection and maintenance Environment Make sure that the local environment matches the original operating specifications Check the following items voltage frequen...

Page 14: ...he gun position in relation to the burner throat cone must be checked Note Burners are not necessarily shipped with guns in the correct position it is also possible that the gun could shift during shipment Note All of the following adjustments provide a relative position for safe operation for all applications occasionally adjustments in or out from the relative positions may be necessary dependin...

Page 15: ...thin gas gun 6 3 1 7 4 5 2 8 8 1 2 3 4 5 6 7 8 Oil Inlet Oil Gun Steam Air Inlet Gas Inlet Gas Gun Throat Cone Air Inlet Refractory Block Walls X Dim Gland To Adjust Gun Position 3 4 1 2 5 5 1 2 3 4 5 Gas Inlet Gas Gun Throat Cone Air Inlet Refractory Block Walls Burner X Size Inches 6V 11 16 8V 1 3 8 10V 1 5 16 12V 1 1 2 14V 1 11 16 16V 2 1 16 18V 2 22V 2 5 16 24V 2 1 4 28V 3 3 16 32V 3 1 16 36V ...

Page 16: ... B 2 Move the entire gun assembly until the oil nose cone aligns with the small diameter of the throat cone 3 Once both cones are aligned and the gas gun is centered in relation to the throat cone tighten gland B For Oil Only Burners see Figure 3 2 1 Adjust the oil gun position so that the end of the oil nose cone aligns with the small diameter of the throat cone as shown at left 2 Verify that the...

Page 17: ...second scanner mounted on the combustor side is needed to prove the main flame Note Due to the low U V content of oil flames some U V scanner flame safety systems may have difficulty sighting oil flames at high inputs In these cases a more sensitive U V detector may be required or an infrared I R detector may be used Make sure that you connect the flame sensor of a burner to the electrical circuit...

Page 18: ... should be between 6 and 8 away from throat cone if necessary adjust the pilot assembly gland to achieve this distance Support the piping and ductwork Use brackets or hangers to support the piping and ductwork to avoid placing undue loads on the burner If you have questions consult your local gas company Pipe connections The use of flexible pipe in gas oil and atomizing air lines to the burner is ...

Page 19: ...ping Atomizing steam considerations 1 Atomizing steam must be dry and superheated to at least 20 F above saturated at the burner inlet Therefore this piping line must be insulated up to the burner inlet Provisions must also be made for continuous condensate disposal via a steam trap and drain Compressed air considerations 1 When compressed air is used for atomization it is possible for water and o...

Page 20: ...h 1 32 diameter perforated or 20 mesh screen be used UPSTREAM of all valve train components There are two possible control methods for atomizing air and steam 1 Fixed If the burner s turndown ratio requirement does not exceed 5 1 then the atomizing pressure at the burner may be set to run constantly at 50 55 psig eliminating the need for a differential pressure regulator 2 Modulating Use a differe...

Page 21: ...ances of cracking or spalling 1 Set the combustion air at its minimum input 2 Light only the pilot and leave on for approximately three hours 3 After three hours light the main burner at the minimum input 4 Increase the heat input by 150 F per hour 5 Water evaporation steam is usually heaviest and most prominent around 1 000 F If steam is still prevalent after the hour at 1 000 F hold at that temp...

Page 22: ...forementioned Eclipse drawing are maintained Provide vent holes so moisture can escape during dry out Note The corner angle between the cone and the sidewall must be 90 or slightly less but NOT MORE After the burner and refractory have been installed the following steps will ensure proper curing and maximum strength to reduce chances of cracking or spalling 1 Set the combustion air at its minimum ...

Page 23: ...ng box by customer 229mm to 457mm 9 to 18 229mm 9 minimum Cup angle or special anchor fitting welded to shell plate 1 2 3 4 5 6 7 Furnace Backstay Furnace Shell Plate Block Insulation Insulated Fire Brick Fire Brick Castable Refractory Ring Alternate Plastic Refractory or Alloy Anchor 305mm to 457mm or 12 to 18 apart 5 6 7 4 3 1 2 Alternate Mounting Arrangement ForThin Walls Alternate Mounting Arr...

Page 24: ... 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 Trip out pressure switches and other limit interlocks Make sure that the main gas valves close Danger If simulated limits or simulated flame failures do not shut down the fuel system within the required failure response time then immediately correct the problem CHECKLIST ...

Page 25: ...m 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 Verify the air settings 4 Ignite the pilot 5 Ignite the burner 6 Set low fire fuel flow 7 Set high fire fuel flow 8 Verify the settings Close the automatic gas valves and the gas cocks ADJUSTMENT PROCEDURE Adjustment Start Stop 4 1 INTRODUCTION Step 1...

Page 26: ... air out of the gas pipework 5 Trim pilot with adjustable gas cock to obtain pressure drops of 1 5 to 2 0 w c for natural gas 0 6 to 0 9 w c for propane butane Refer to Table 4 1 at left for pilot input capacities Pressure drop is differential between pilot gun inlet and chamber Note The pilot flame should be a bushy blue flame which curls around the main gas oil gun nozzle This flame should provi...

Page 27: ...mes have ignited 8 The gas flame should be a pale blue color set inside the refractory combustion block Note Combination gas oil burners may be operated on gas with the oil gun in place provided that the atomizing medium is left on at a minimum pressure of 5 to 10 psig When shutting down leave the atomizing medium on until the block and combustion chamber are cool Combination gas oil burners may a...

Page 28: ...lve is at its minimum open position 6 Light the pilot 7 Open all manual fuel shut off valves 8 Initiate the ignition sequence through the flame safety 9 Check that the pilot and main burner flames have ignited 10 The oil flame should be a bright yellow color set inside the refractory combustion block Note The first time that the burner is started allow the refractory combustion block to warm up sl...

Page 29: ...page 3 10 for further details 4 The high fire oil flame should be bright yellow refer to Table 4 2 below for flame length estimates 1 Once the high and low fire conditions have been set cycle the burner from high to low fire several times to check repeatability of settings 2 Shut down the burner and relight to ensure automated pilot and main flame ignition operates correctly 3 Check all safety int...

Page 30: ... wire when the ignition is on You will get a shock 4 Make sure that you can see the flame in the burner system If the burner system does not light and the system does not shut down automatically then close the main gas or oil cock manually DO NOT operate the system Go to Checklist after Installation on page 3 8 and verify the steps After that repeat the start procedure the system shut downs automa...

Page 31: ... and fuel valves to low fire position shut down the oil supply 2 Turn on the pilot 3 Purge the oil nozzle with the atomizing medium through the bypass connection valves 4 When the oil nozzle is clear of oil then turn off the pilot 5 Leave combustion air and atomizing medium on until the combustion chamber and block are cooled once cooled shut off the combustion air and atomizing medium supplies 6 ...

Page 32: ...Eclipse Vortometric Burner v2 00 Installation Guide 248 4 10 07 ...

Page 33: ...les Caution Turn off power to burner and controls before proceeding with burner inspection Monthly Checklist 1 Inspect flame sensing devices for good condition and cleanliness 2 Test all alarms for proper signals 3 Check ignition spark electrode operatin and check proper gap 4 Check all valve motors and control valves for free smooth action and adjustment 5 Test interlock sequence of all safety eq...

Page 34: ...ssembly and clean the gas orifices Use compressed air to blow all scale or dust out of the ports 7 Remove the oil gun assembly and clean the oil injection orifices and atomizing air nozzles according to the instructions that follow in this chapter Fuel OilTip Cleaning Vortometric burner sizes 6V through 12V use an oil nozzle held by a retaining ring With these sizes the nose cone assembly must be ...

Page 35: ... procedure is as follows 1 Soak the tip in a solvent such asVarsol especially if the atomizer has been used with heavy oil 2 Blow out the tip with compressed air in the reverse direction to the oil flow 3 Wash the tip again in solvent 4 Select the correct drill size needed fromTable 5 1 Use a new bit to avoid potential marring Insert the drill bit by hand into each hole in the oil tip to clear any...

Page 36: ...p the nose cone assembly and rotate it while pulling it foward This action separates the nose cone inlet ring and base assembly from the tip Be careful not to lose or damage the spacer washers 8 Remove the oil tip by using a pipe wrench on the fuel oil feed pipe and an adjustable wrench on the oil tip flats 9 Refer to the previous section Fuel Oil Tip for the proper oil tip cleaning procedure 10 I...

Page 37: ... sooty 14 Clean any accumulated carbon from the internal bore of the nose cone but do not scratch or mar these surfaces Figure 5 1 Atomizer Assembly Components 5 5 Orig Max Max Insert Orig Worn Worn Burner No of Throat Drill Throat Drill Size Inserts Dia in Size Dia in Size 6V 6 0760 48 0820 45 8V 6 0995 39 1093 7 64 10V 6 1250 1 8 1360 29 12V 6 1440 27 1570 22 14V 6 1695 18 1875 3 16 16V 6 1935 1...

Page 38: ...ecified drill from Table 5 1 into the oil holes as shown at left The drill s sides should JUST TOUCH the nose cone s lip If you have trouble inserting the drill into the oil holes there are two probable causes a if the drill cannot be inserted easily then the oil tip is too far back in the nose cone a thinner spacer is needed so the oil tip can come further forward or b if there is an obvious spac...

Page 39: ...r 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 Reinstall the oil gun into the burner and connect all hoses securely 5 7 Eclipse Vortometric Burner v2 00 Installation G...

Page 40: ... and investigate any changes Check air pressure switch adjustment Move pressure taps on chamber to a better location Check incoming gas pressure against initial settings adjust as required Adjust setting to be approximately 4 w c above gas pressure Check incoming gas pressure against initial settings adjust as required Adjust setting to be approximately 4 w c below gas pressure Checkflamesafeguard...

Page 41: ...rk plug Clean or replace spark plug Clean spark plug threads Do not apply grease or pipe compound to pipe threads Set gap to 1 8 Remove spark plug and clean inside of pipe and star insulators Check incoming gas pressure against initial settings increase as necessary Check outgoing gas pressure of main regulator increase as necessary Open pilot gas cock Have qualified electrician check power supply...

Page 42: ...t of gas lines Repeat start up several times to fill oil lines and nozzle Reduce piping length if necessary Trim control valve to give pressure indicated in Appendix Check wiring and control logic Check and reset low pressure switch setting Check start up settings and adjust to increase fuel flow Check combustion air pressure drops flow across the burner and adjust Adjust pressure regulator so pre...

Page 43: ... diameter of the combustor surface OR Carbon deposits on the inside of the refractory block Carbon accumulation on the oil nozzle cone Check fuel pressure against design Adjust main fuel pressure regulator or adjust control valve Open air damper on main air blower Check pressure drop or flow Check air damper on main air blower Check fuel pressure differential flow Adjust main fuel pressure regulat...

Page 44: ...0 6 0 8 1 2 3 4 5 6 7 5 Burner Gross Heat Input MMBtu hr Combustion Air Pressure Drop w c 7 5 w c is the nominal design pressure drop for all models except for model 6V of the medium intensity burners 14 7 psia 70 F Pressure drop should be taken between the chamber and windbox pressure tap A 1 Operation with 15 excess air on natural gas under standard conditions Eclipse Vortometric Burner v2 00 In...

Page 45: ...onditions 14 7 psia 70 F Pressure drop should be taken between the chamber and windbox pressure tap 0 1 6V 8V 10V 12V 14V 16V 22V 28V 18V 24V 32V 36V 0 6 0 8 1 2 4 6 8 10 20 40 60 80 100 200 300 0 2 0 4 0 6 0 8 1 2 3 4 5 6 7 5 Burner Gross Heat Input MMBtu hr Combustion Air Pressure Drop w c A 2 Eclipse Vortometric Burner v2 00 Installation Guide 248 4 10 07 ...

Page 46: ...10V 12V 14V 16V 1 6 4 2 1 8 10 20 40 60 100 200 300 2 4 6 8 10 20 30 45 Burner Gross Heat Input MMBtu hr or Natural Gas Flow 1000 s SCFH Gas Gun Pressure Drop w c 36V 32V 28V 24V 22V 18V Nominal pressure drop at maximum capacity is 24 w c for 6V through 16V models and 45 w c for all other models Note Fuel pressure drop curves should be used as a guide for setting up burner It is recommended to use...

Page 47: ...en air is used for atomization of heavy oil it should be preheated to approximately the same temperature as the oil 10 60 40 20 10 80 100 1 000 200 400 600 20 30 15 40 50 60 Atomizing Air Flow SCFM Atomizing Air Pressure Drop psig 8V 6V 10V 12V 14V 18V 22V 28V 36V 16V 24V 32V A 4 Note Fuel pressure drop curves should be used as a guide for setting up burner It is recommended to use a direct fuel f...

Page 48: ...ressure Drop psig 8V 6V 10V 14V 18V 24V 32V 12V 16V 22V 28V 36V 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 Recommended spare parts PART NAME QTY PART NO Pilot assembly 1 1 Spark rod assembly 1 1 Oil gun assembly 1 1 U V scanner if used 2 2 1 1 4 N P T peepsight glass 2 13046 1 1 4 N P T pe...

Page 49: ...ds sq in psi 14 5 x 10 3 millimeter mm inch in 3 94 x 10 2 Metric to Metric FROM TO MULTIPLY BY kiloPascals kPa millibar mbar 10 meter m millimeter mm 1000 millibar mbar kiloPascals kPa 0 1 millimeter mm meter m 0 001 English to Metric FROM TO MULTIPLY BY Btu hr kilowatt kW 0 293 x 10 3 cubic foot ft3 cubic meter m3 2 832 x 10 2 cubic foot hour cfh cubic meter hour m3 h 2 832 x 10 2 degrees Fahren...

Page 50: ...s pressure Customer P O Air pressure from the blower Customer signature Air pressure drop across the burner Date Gas pressure drop across the burner Furnace type Main oil pressure Furnace temperature Oil pressure across the burner Number of burners Atomizing pressure High fire input per burner Atomizing pressure drop across the burner Orifice sizes Flame signal strength Operating voltage frequency...

Page 51: ...Offered By Power Equipment Company 2011 Williamsburg Road Richmond VA 23231 Phone 804 236 3800 Fax 804 236 3882 www peconet com ...

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