13
BrightFire 200, V1, Operating Instructions, Edition 09.15
Maintenance and
Troubleshooting
Preventative maintenance is the key to a reliable, safe
and efficient system. The following are suggested
guidelines for periodic maintenance. Burners in severe
environments or operational conditions should be
checked more frequently.
NOTE:
The periodic, monthly, and yearly lists are an
average interval. If your environment is dirty, the intervals
may be shorter. Check with local authorities having
jurisdiction regarding their recommended maintenance
schedules.
Periodic Checklist
Remove and inspect the burners at least once per month,
paying close attention to any build-up/degradation of the
burner nozzles.
1. Frequently monitor flame patterns for flames that
appear to be deflected, abnormal, or impinging on
refractory surfaces. These are signs of dirty nozzles or
blocks.
2. Cooling air pressure should be monitored daily to
ensure proper tip cooling is maintained.
NOTE:
Excessive cooling air pressure may create
recirculation in the burner block and cause fouling. If
frequent burner block fouling is an issue, reduce the
cooling air pressure, making sure to not allow cooling air
pressure to go below 2 psi (138 mbar) or damage to the
burner nozzles may occur.
3. Burner gas flow and pressure should be monitored
daily. Irregularities in flow or pressure may indicate a
dirty burner or block.
4. Regular port flue gas readings should be taken to
ensure proper air/gas ratios are being maintained. Flue
gas irregularities may indicate plugging of the
regenerator ports, instrumentation issues, or furnace
wear allowing infiltration of ambient air. A side to side
bias in the ratios may be required.
5. Check the rear packing nuts to verify tightness to
prevent gas leaks. If the packing nuts bottom out,
contact the burner body, and cannot be tightened any
further, the packing needs to be replaced due to wear
from adjusting the area and flow valves or removing the
gas tube insert.
Monthly Checklist
1. Clean all burner nozzles on a routine bases once per
month and when required by flame appearance,
making sure the burner nozzles are not damaged or
distorted.
2. Test all the system alarms for proper response signals.
3. Check for the proper operation of ventilating
equipment.
4. Test the manual gas shut-off valves for proper
operation.
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 and comparing
these with the actual impulse pressure..
3. Clean and inspect all burners.
Instructions for Cleaning
NOTE:
A matching spare burner can be used to replace a
burner in need of cleaning to minimize furnace disruption
and eliminate the need to plug the burner block during
cleaning.
NOTE:
Only remove a burner during the off-firing cycle.
1. Shut off local gas and cooling air valve supplying the
burner to be cleaned.
2. Disconnect gas and cooling air hoses at the burner.
3. Loosen t-bolt or split ring clamp and remove burner
from the bracket.
4. Inspect the socket plate and carefully clean out any
debris using a steel rod.
■
Molten glass is electrically conductive. DO NOT
make contact with glass surface when cleaning
burner blocks.
CAUTION
5
