Eclipse Combustion Vortometric v2.00 Installation Manual
E
clipse
Installation Guide 248
4/10/07
Vortometric
Burners
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.
DISCLAIMER NOTICE
LIABILITY AND
WARRANTY
In accordance with the manufacturer’s policy of continual product
improvement, the product presented in this brochure is subject to
change without notice or obligation.
The material in this manual is believed adequate for the intended use of
the product. If the product is used for purposes other than those
specified herein, confirmation of validity and suitability must be
obtained. Eclipse Combustion warrants that the product itself does not
infringe upon any United States patents. No further warranty 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 understood that Eclipse Combustion’s liability for its
products, whether due to breach of warranty, negligence, strict liability,
or otherwise, is limited to the furnishing of replacement parts and
Eclipse Combustion will not be liable for any other injury, loss, damage
or expenses, whether direct or consequential, including but not limited
to loss of use, income of, or damage to material arising in connection
with the sale, installation, use of, inability to use or the repair or
replacement of Eclipse Combustion’s products.
ii
Eclipse Vortometric Burner v2.00, Installation Guide 248, 4/10/07
About this manual
AUDIENCE
SCOPE
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.
This manual provides information for installing the Vortometric
burner ONLY and does not include the burner control system
(such as fuel/air ratio controls, flame supervision systems, etc.).
When Eclipse Combustion sells the burner as part of a complete
package, then schematic piping and wiring diagrams will be furnished
which explain the control system operation. When Eclipse
Combustion sells only the Vortometric 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 control system
operation.
VORTOMETRIC
PUBLICATIONS
Installation Guide No. 248
• This publication.
Data Sheets No. 248-1, 248-2
• Lists burner models information including dimensions.
Bulletin No. 248
• Used with Data Sheets to define burner specifications and
available options.
Price Sheet No. 248
• Used to order burners.
Eclipse Vortometric Burner v2.00, Installation Guide 248, 4/10/07
iii
RELATED PUBLICATIONS
• EFE-825 (Combustion Engineering Guide)
• Eclipse Bulletins & Instruction Manuals: 818, 820, 826, 832, 852, 854, 856
IMPORTANT NOTICES
DOCUMENT
CONVENTIONS
• 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. Contact your Eclipse sales office or Eclipse Combustion.
There are several special symbols in this document. You must know
their meaning and importance.
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 personal injury or damage.
Act with great care and follow the instructions.
Caution:
Indicates hazards or unsafe practices which could result in
damage to the machine or minor personal injury.
Act carefully.
Note:
Indicates an important part of the text.
Read the text thoroughly.
iv
Eclipse Vortometric Burner v2.00, Installation Guide 248, 4/10/07
Table of Contents
About this manual................................................................ ii
Table of Contents.................................................................. v
1
2
3
Introduction............................................................................... 1-1
Product Description ........................................................................ 1-1
Safety............................................................................................... 2-1
Introduction....................................................................................... 2-1
Safety ................................................................................................... 2-1
Capabilities ......................................................................................... 2-2
Operator Training ............................................................................. 2-2
Replacement Parts ........................................................................... 2-2
Installation .................................................................................. 3-1
Introduction....................................................................................... 3-1
Handling and Storage....................................................................... 3-1
Position of Components................................................................. 3-1
Approval of Components............................................................... 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 ............................................................. 3-14
vEclipse Vortometric Burner v2.00, Installation Guide 248, 4/10/07
4
Adjustment, Start & Stop .............................................. 4-1
Introduction....................................................................................... 4-1
Adjustment Procedure.................................................................... 4-1
Step 1: Reset the system .......................................................... 4-1
Step 2: Set low fire combustion air pressure drop ........... 4-2
Step 3: Verify air settings .......................................................... 4-2
Step 4: Ignite the pilot............................................................... 4-2
Step 5: Ignite the burner .......................................................... 4-3
Step 6: Adjust low fire ............................................................... 4-4
Step 7: Adjust high fire .............................................................. 4-5
Step 8: Verify settings ................................................................. 4-5
Start Procedure ................................................................................ 4-6
Stop Procedure ................................................................................. 4-7
5
Maintenance & Troubleshooting............................... 5-1
Introduction....................................................................................... 5-1
Maintenance Schedules ................................................................... 5-1
Monthly Checklist........................................................................ 5-1
Yearly Checklist ............................................................................ 5-2
Maintenance Procedures ................................................................ 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–Oil Nozzle Press. Drop vs. Burner Heat Input.... A-4
Table A.5– Atomizing Air Press. Drop vs. Air Flow ............... A-4
Table A.6–Atomizing Steam Press. Drop vs. Steam Flow ..... A-5
Recommended Spare Parts ............................................................ A-5
Conversion Factors ......................................................................... A-6
System Summary .............................................................................. A-7
vi
Eclipse Vortometric Burner v2.00, Installation Guide 248, 4/10/07
Introduction
1
PRODUCT
DESCRIPTION
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.
The high combustion air swirl rate produced by the Vortometric
burner results in a stable flame with high turndown 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 clean, smoke-free combustion.
Vortometric v2.00 burners are available with capacities of 6mmBtu/
hr. to 210mmBtu/hr. Low combustion air pressure is used (7.5"w.c.)
with all sizes and atomization of the fuel oil can be by steam, air, or
any gaseous fuel.
Figure 1.1 Vortometric v2.00 Burner
Eclipse Vortometric Burner v2.00, Installation Guide 248, 4/10/07
1-1
Eclipse Vortometric Burner v2.00, Installation Guide 248, 4/10/07
Safety
2
INTRODUCTION
SAFETY
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.
Never try to light the burner if the burner shows
signs of damage or 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 attempt to start the
system. If you do not understand any part of the information
in this manual, then contact your Eclipse representative or
Eclipse Combustion before you continue.
Eclipse Vortometric Burner v2.00, Installation Guide 248, 4/10/07
2-1
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
REPLACEMENT PA RT S
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.
Order replacement parts from Eclipse only. Any customer-supplied
valves or switches should carry UL, FM, CSA, CGA and/or CE approval
where applicable.
2-2
Eclipse Vortometric Burner v2.00, Installation Guide 248, 4/10/07
Installation
3
INTRODUCTION
HANDLING AND
STORAGE
In this section you will find the information and instructions that you
need to install the burner.
Handling
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. 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;
improper handling and storage will cause premature failure.
Eclipse Vortometric Burner v2.00, Installation Guide 248, 4/10/07
3-1
APPROVAL OF COMPONENTS
Limit controls and safety
equipment
Electrical wiring
All limit controls and safety equipment must comply with the following
current standards:
• NFPA Standard 86
• NFPA Standard 86C
•UL
•FM
• CGA
• CSA
• EN 746-2
• all applicable local codes and/or standards.
All of electrical wiring must comply with the one of the following
standards:
• NFPA Standard 70
• ANSI-C11981
• CSA
• EN 746-2
• the electrical wiring must be acceptable to the local authority having
jurisdiction.
Gas piping
Where to get the standards
All of the gas piping must comply with 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
New York, NY 10018
The UL Standards are available from:
United Laboratories
333 Pfingsten Road
Northbrook, IL 60062
3-2
Eclipse Vortometric Burner v2.00, Installation Guide 248, 4/10/07
The FM Standards are available from:
Factory Mutual
1151 Boston-Providence Turnpike
P.O. Box 9102
Norwood, MA 02062
The CGA Standards are available from:
Canadian Gas Association
55 Scarsdale Road
Toronto, Ontario
Canada M3B 2R3
The CSA Standards are available from:
Canadian Standards Association
178 Rexdale Boulevard
Etobicoke, Ontario
Canada M9W 1R3
Information on the EN standards, and where to get the standards is
available from:
Comité Européen de Normalisation
Stassartstraat 36
B-1050 Brussels
Phone: +32-25196811
Fax: +32-25196819
CHECKLIST BEFORE
INSTALLATION
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, frequency and stability of the electrical power
• type and supply pressure of the fuel
• availability of enough fresh, clean combustion air
• humidity, altitude and temperature of air
• presence of damaging corrosive gases in the air.
Eclipse Vortometric Burner v2.00, Installation Guide 248, 4/10/07
3-3
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.
• Use gasketing between the burner mounting flange and the
furnace casing and ensure that you have a gas-tight joint between
these two surfaces. This tightness is especially critical for systems
operating under positive pressures.
PREPARE THE BURNER
Gas, Gas/Oil or Oil Gun
Positioning
There are several components that must be installed to a burner
systems before it can operate. Instructions to do that follow below.
Prior to starting the burner, the 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 depending on
your application.
For Gas Only Burners (see Figure 3.1):
1. To adjust the gas gun, loosen the gland.
2. Using the chart in Figure 3.1, determine the “X” dimension
based on your burner size.
3-4 Eclipse Vortometric Burner v2.00, Installation Guide 248, 4/10/07
3. Once the “X” dimension is verified and the gas gun is centered
in relation to the throat cone, tighten the gland.
Note:
Failure to center the gun in the burner throat will cause uneven
air flow and flame instability. The gun should be centered with
+/- 1/8".
Figure 3.1 Vortometric Gas Gun Position
4
Gland
To Adjust
Gun Position
3
2
1
Gas Inlet
2
Gas Gun
3
Throat Cone
4
Air Inlet
5
Refractory Block Walls
1
Figure 3.2 Vortometric Gas/Oil Gun Position
Gland “B”
Used to adjust the position
of entire gun assembly
within burner throat
2
31
Gland “A”
Used to adjust the position
of oil gun within gas gun.
5
4
6
throat cone ring
“X”
Dim.
7
End of
oil atomizer
is flush with
5
5
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 3-7/8
8
1
Oil Inlet
2
Oil Gun
3
Steam/Air Inlet
4
Gas Inlet
5
Gas Gun
6
Throat Cone
7
Air Inlet
8
Refractory Block Walls
8
Eclipse Vortometric Burner v2.00, Installation Guide 248, 4/10/07
3-5
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. Adjust the entire gas/oil gun assembly by loosening gland “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 oil gun is centered in relation to the throat cone;
once verified, tighten the large gland nuts.
Note:
Failure to center the gun in the burner throat will cause uneven
air flow and flame instability. The gun should be centered with
+/- 1/8".
3-6
Eclipse Vortometric Burner v2.00, Installation Guide 248, 4/10/07
Loading...