Phoenix® Phantom Burner Manual
Contents
1. OPERATION AND SERVICE MANUAL ASTEC Burner Group Version 1 1 27 15 PHOENIX Phantom Operation and Service Manual AN PHOENIX Phantom Operation and Service Manual Table of Contents On O A 3 TO 5 Operation and Service Statement meu x VDO Dax 5 SocobpeolinisNanual 5 Danger Safety and eas 5 DANGER Combustion EQUIDINGDIU uusiioa ioo chis cusa oun v spouse cuum any Essa Kur usn 5 Basic Safety IDnSIFUCTTOLISaiseiiietorsuciuessa bei sU MEC 5 FOW TO RECOGNIZE ED 6 WARNING 6 General Burner Information ee 6 ReCern iP and VIV MIS IU os DIN 7 7 Tables d Burner Capacities 7 AIME 7 ODN 8 MEC n 8 Wan 9 USE 9 WO 10 4 11 12 72 JE DIE NG 12 Illustration 5 Typical Pilot Gas Train pt 13 Adjustment and Operation of the Pilot ee reeeee enne nnn nnn 13 The In2. 10 in H2O and HP 75 Do not exceed the maximum motor speed or the maximum blower speed whichever is lower If you have any questions please contact the burner group for assistance at 423 867 4210 A O LL um gt em Im IHE ANE LUE E LE ELLE LL TT DDN TTT PTT A A TTT Altitude ft 25
3. length of the flame must be shorter than the combustion zone in your drum Material that showers through the flame causes increased pollutants in the flue gas 5 The width of the flame must be less than the 1 0 of the combustion flights 6 See the detailed Burner Performance Data Sheets for the flame size and diameter See Burner Performance Data Sheets 18 PHOENIX Phantom Operation and Service Manual Flame Scanner The PHOENIX PHANTOM is supplied with a Flame Scanner that detects Ultra Violet UV in the flame The flame scanner is located in an air cooled guide tube near the front of the burner It can be removed by unthreading the 1 4 aluminum cap on the back of the burner and pulling the flexible conduit attached to it out NOTE Be careful not to physically shock or overheat the Flame Detector as this can cause it to fail COOLING AIR FLEXIBLE CONDUIT SCANNER GUIDE PIPE SIR a a ee J REMOVE CAP TO SERVICE OR INSPECT FLAME SCANNER ELECTRICAL CONDUIT COANE FLAME SCANNER LIE S Sr b Illustration 12 Flame Scanner Scanner Cooling Air The flame scanner requires cooling air at a constant pressure from the plant compressed air supply to prevent dust buildup in front of the scanner lens Dust buildup on the scanner lens will degrade accurate flame readings and may cause nuisance shutdowns 19 AN PHOENIX Phantom Operation and Service Manual Maintenance amp Troubl
4. through the heating chamber This is usually 4 times the chamber volume 7 Before light off the combustion air blower must be set at the low fire speed 8 Thelow fire combustion air pressure switch normally closed must make to prove that the blower is at the low fire speed This switch is usually set at about 1 1 2 W C It will make as the air pressure falls below the set point 9 Forthe light off sequence to begin the fuel valve s low fire switch must be made to prove that the fuel valve s are at the low fire position AN PHOENIX Phantom Operation and Service Manual RAIN COVER AIR FLOW METER BLOWER SILENCER MINI MAIN GAS TRAIN DRUM NOISE REDUCTION SEAL RUBBER SKIRT ELECTRICAL CONE JUNCTION BOX AIR LANCE COMBUSTION AIR BLOWER MOTOR BLUFF BODY ASSEMBLY NATURAL GAS GAS MANIFOLD lt TRAIN PRESSURE TAP Illustration 1 TEMPERATURE SWITCH FLASHBACK PROTECTION BLOWER SILENCER GAS MANIFOLD PRESSURE TAP PILOT GAS TRAIN MINI MAIN GAS TRAIN REMOVABLE CABLE HANGER ELECTRICAL JUNCTION BOX GAS ORIFICE COMBUSTION AIR PLATE BLOWER MOTOR NATURAL GAS TRAIN Illustration 2 9 AN PHOENIX Phantom Operation and Service Manual COMPRESSED AIR TRAIN FOR AIR LANCE AND SCANNER NOTE INLET TO BE CONNECTED TO DRUM AIR TEMPERATURE SWITCH FLASHBACK PROTECTION AIR LANCE TIMER NOTE SET TO 2 SEC EVERY 5 MINUTES BLOWER SILENCER FLAME SCANNER TUBE NATUR
5. AL GAS CONNECTION DRUM SUCTION TUBE MINI MAIN GAS TRAIN NATURAL GAS TRAIN Illustration 3 10 AN PHOENIX Phantom Operation and Service Manual Adjustments WARNING Because all combustion systems are inherently dangerous only qualified and experienced personnel should attempt to start up and adjust PHOENIX burner systems Qualified personnel are defined as those trained by the ASTEC Burner Systems Group or ASTEC Service Department Experienced personnel are defined as those who have previously fired an ASTEC Phoenix Burner under the supervision of the ASTEC Burner Systems Group or ASTEC Service Department NOTE The fuel valves fuel profile and air profile are pre set at the factory to simplify burner and process set up However some adjustment will be required for operation 1 See the complete Burner Performance Data Sheets for flows operating pressures and valve positions Data sheets are located inside the burner junction box If data sheets are missing contact ASTC Burner Group for a copy 2 Set the fuel pressure at the entrance of the burner fuel train at the pressure listed on the Burner Performance Data Sheet 3 Check the flue gas readings for O2 and CO a Ona DOUBLE BARREL drum where there are minimal amounts of air leaking into the exhaust system a typical O2 level in the exhaust stack is 10 5 at high fire b The amount of CO should be less than 500 PPM referenced to 396 O2 C Higher CO c
6. ASTEC Burner Systems Group for assistance 423 867 4210 or FAX 423 827 1560 NOTE If the installation is delayed and the equipment is to be stored outside 1 Provide adequate protection as dictated by your climate and the period of exposure 2 Special care should be given to all motors hydraulics electrical parts and bearings to protect them from rain snow or excessive moisture Burner Capacity BURNER AIR BURNER NATURAL MAXIMUM MODEL FLOW BLOWER GAS CAPACITY SCFH HP SCFH BTU HOUR PP 50 804 800 50 000 50 000 000 PP 75 1 207 200 75 000 75 000 000 PP 125 2 012 000 125 000 125 000 000 PP 150 2 414 400 150 000 150 000 000 Table 1 Burner Capacities PP 100 1 609 600 100 000 100 000 000 Notes For Table 1 The maximum BTU hour rating is based on 60 excess air 2 The figures used in Table 1 are based on 60Hz AC and Standard Cubic Feet per Hour SCFH at air temperature at sea level 3 Correction factors must be applied for altitude or temperature variations See Altitude Correction Chart 4 The system exhaust fan must have enough capacity to provide a slight negative pressure 0 20 to 0 30 water column at the burner breech plate This will exhaust the products of combustion and prevent puffing at the breeching plate 5 The air flow in the PHOENIX Phantom can be monitored using the pressure tap on the side of the burner blower housing The air pressure for a given flow is i
7. FEET OR UNDER Burner Model PP 50 PP 75 PP 100 PP 125 PP 150 Pipe Size Table 3 Feed Pipe Size for Gas Runs 25 Feet or Under 4 The supplied manual shutoff valve must be installed upstream of the gas control regulator a The strainer protects the valves from destructive dirt that could lodge in them b This shutoff valve facilitates servicing of the gas control train c The Siemens gas valves have an integral strainer at the inlet of the valve 5 The gas company should purge the main gas line for scale and dirt before it is attached to the burner gas manifold NOTE Install the flexible fitting supplied with the burner gas manifold to reduce flexing of the manifold produced by plant vibrations ASTEC PART NUMBERS FLEXIBLE PIPE NIPPLES Burner Model PP 50 PP 75 PP 100 PP 125 PP 150 ASTEC 076046 048292 048292 048292 048292 Part Number Table 4 Recommended Pipe Nipple 15 PHOENIX Phantom Operation and Service Manual NOTE The low and high gas pressure switches should be set just above and below the safe operating range of gas inlet pressures respectively This should be individually determined on each installation Typically this would be 50 of the running pressure for the low gas pressure switch and 125 of the operating pressure for the high gas pressure switch NATURAL GAS REGULATOR REQUIREMENTS Burner Model PP 50 PP 75 PP 100 PP 125 PP 150 Maximum 50 000 75 000 100 000 125 000 150 000 Capaci
8. PRESSURE SAFETY SWITCH CONTROL GAS STRAINER BUTTERFLY VALVE BETWEEN FLANGES HIGH GAS PRESSURE AUTOMATIC SAFETY SAFETY SWITCH SHUTOFF VALVES Illustration 6 Gas Train Components 1 Install a controlling gas regulator in the main gas line within 25 feet of the burner a This regulator should be sized to provide the required gas flow at the inlet of the burner manifold b Seethe burner performance data sheet for the nominal expected gas pressure required at the burner c Exact gas pressure must be set at the initial start up depending on piping configuration burner size and maximum capacity desired 2 The piping from the gas regulator outlet to the burner gas manifold should be sized to minimize pressure losses 3 The pipe size from the control regulator to the gas train can be identical to the gas pipe size at the entrance to the burner gas train see tables below NOTE It is normal for the regulator size to be smaller than the line size 14 AN PHOENIX Phantom Operation and Service Manual NOTE If the Gas run is more than 25 use the connection size on the burner shown in Table 2 below FEED PIPE SIZE FOR GAS RUNS OVER 25 FEET Burner Model PP 50 PP 75 PP 100 PP 125 PP 150 Pipe Size Minimum Dia Table 2 Feed Pipe Size for Gas Runs Over 25 Feet NOTE If the Gas run is 25 feet or less use the connection size on the burner shown in Table 3 below FEED PIPE SIZE FOR GAS RUNS 25
9. Scanner 075703 1 4 Pressure Switch 100 PSI 081185 Pilot Solenoid Valve 1 2 1 1 Table 9 Spare Parts List Parts Hotline 1 800 251 6042 Hours Monday thru Friday 7 00 a m to 12 00 a m midnight EST Saturday 8 00 a m to Noon EST Telephone 423 867 4210 Fax 423 867 7609 23 AN PHOENIX Phantom Operation and Service Manual Detailed Burner Performance Sheets The burner performance data sheet s are located on the door of the burner junction panel in a clear tube Other items that should be found inside the junction panel are 1 The burner general arrangement which will have the dimensions and overall weight of the burner 2 he burner specification plaque It will have the maximum firing rate fuel pressures and flow rates listed The piping and instrumentation P amp 1 drawing is a representation of all the piping and electrical components on the burner The components which are tagged for example PI 1 1 will have the Astec part number listed with it The tags on the components match the P amp drawing This will allow you to call the Astec Parts Department and obtain an identical part If you cannot locate or are missing any of these documents please contact the Astec burner group to obtain a replacement Note e Should further information be required or answers to questions not covered generally or should particular problems arise which are not covered in this manual contact the Astec Service D
10. The flame shape is pre set at the factory for the most efficient profile for your drum and burner configuration The PHOENIX Phantom is a sealed in combustion system that provides all the necessary combustion air This ensures that the combustion air plus approximately 6096 excess air is available for efficient operation at maximum capacities The Fuel Air ratio is maintained throughout the burner s operating range with electronically linked valves Depending on burner configuration the PHOENIX Phantom will burn all commercial grades of natural gas or propane The gaseous fuels are burned as Premix Fuel gasses and air are premixed in the burner body well upstream of the ignition point at the burner nose Being a Premix Burner enables the PHOENIX Phantom to operate more cleanly and quietly The burner provides a nominal 7 1 turndown from its maximum firing rate providing efficient operation at various production rates In most cases the actual turndown available is somewhat higher See the Individual Burner Performance sheets AN PHOENIX Phantom Operation and Service Manual Receiving and Inspection Upon receipt of the Burner 1 Check each item on the bill of lading and or invoice to determine that all the equipment that was shipped has been received 2 Carefully examine all of the equipment assemblies and subassemblies to check if there has been any damage in shipment If there are any damaged or missing parts contact
11. an be caused by having either too much or too little combustion air or a problem with the combustion zone flighting 4 Altering the fuel air ratio of the burner requires care and expertise to prevent a dangerously rich condition 5 The best way to alter the fuel air ratio is to alter either the air or fuel profile within the burner control system 6 Aless preferred alternative is to vary the fuel pressure slightly Record any changes prior to running and retain for your records 8 The spin vanes affect both flame shape and fuel mixing a The spin vanes are preset at the factory and are optimized for most situations b The spin vanes are not designed to be field adjustable NOTE Take the flue gas measurements during the adjustment process to verify complete combustion 11 PHOENIX Phantom Operation and Service Manual Burner Mounting 1 The centerline of the Burner should be mounted on the centerline of the drum at the same pitch as the drum 2 Refer to the drawings located in burner junction panel for burner weight and dimensions 3 For stationary breeching plates i e not Double Barrel Drums the burner comes with a split mounting flange that can be bolted onto the drum breeching plate and welded to the burner nose 4 The mounting flange allows the positioning of the burner at the correct insertion depth past the breeching plate 5 The insertion depth should be determined by the ASTEC Engineering D
12. ches and solenoids to make sure they are not clogged with dirt or in any way inoperative 4 Frequently a weak flame signal is caused by dust on the lens of the flame scanner 20 AN PHOENIX Phantom Operation and Service Manual Trouble Shooting Trouble Shooting Pilot will No Spark a Check to see if the plug has a spark not light b If there is no spark check the Plug Cable and Ignition Transformer c Check to see if voltage is going to the Ignition Transformer d Check the terminal connection to the Ignition Transformer e Check the connection at the back of the Burner f Check the connection at the J Box g Remove the Pilot Gun Assembly and check the connection to the Plug h Inspect the Spark Plug Cable for tears and cuts i Check the Spark Plug for carbon build up j Check the Spark Plug Gap No Pilot Check the LP Tank for fuel level Gas Check the Cut Off Valve position Check for LP gas leakage Check the LP fuel pressure Verify the Pilot Solenoids are opening and that there is gas flow f Check the Pilot Strainer for dirt No Flame a Verify the Pilot Solenoids are opening and that there is gas flow See No Signal Pilot Gas above b Pull the Flame Sensor from the Burner and clean the lens c Check the signal from the Flame Sensor if there is no signal replace the Flame Scanner d If the Pilot is lighting and there is no Flame Signal replace the Flame Scanner e Check the wires to the Flam
13. d locked out prior to working on the burner All the drive guards handrails and other safety devices must be in place before starting the equipment Prior to start up check that all plant components are in good working condition Never remove disable defeat or bypass any safety device on this equipment Make no modifications to your PHOENIX Phantom Burner without the recommendation or approval of a representative of ASTEC Burner Group Engineering or Service Departments 10 Account for all your personnel on the jobsite before plant startup 11 Avoid wearing loose clothing long hair necklaces neckties or anything that could become entangled in rotating machinery 12 Never leave the control house unattended while the plant is in operation 13 To avoid engulfment by loose aggregate never walk on the material stockpiles or on the material in the cold feed bins 14 Never enter a potentially hazardous enclosed space without an OSHA enclosed space permit program in effect Contact ASTEC Parts Department for an outline of these requirements 15 Relieve internal pressure before working on any equipment containing high pressure 16 Carefully vent any flammable gas using safety measures that will prevent ignition 17 Thoroughly tighten all fittings before reapplying pressure pu es e oo AN PHOENIX Phantom Operation and Service Manual How to Recognize Shock Shock is caused by a rapid loss of blood pressure t
14. e Relay f Then check the Flame Relay fix or replace as needed Main Fuel flow Check the fuel pressure as may have changed Burner too low b Check the burner set up sheets for standard settings Fuel won t c Check clean the gas strainer at the inlet of the Siemens gas valve ignite NOTE Be careful when increasing the fuel flow not to make the mixture too rich or the low fire setting could be too high This adjustment could be done by qualified personnel ii Qualified personnel are those trained by ASTEC Service Department 21 AN PHOENIX Phantom Operation and Service Manual Trouble Shooting Continued Limits not Pressure See the component location drawings for Pressure and Limit Switch complete switch or location limit b Check the Fuel Pressure Switch switch not i Is it energized if not repair or replace it energized ii Is it plugged if it is clean replace it c Check the Limit Switch High stack Too much Check the fuel flow at low fire set to recommended flow temperature fuel at low b Check the fuel pressure set to recommended pressure fire Incorrect Contact the ASTEC Service or Engineering Departments to have ASTEC flighting personnel check the flights in the drum 22 AN PHOENIX Phantom Operation and Service Manual Recommended Spare Parts PHOENIX PHANTOM SPARE PARTS LIST 1 10 11 12 13 4 5 075069 Pressure Switch Low Combustion Air 063336 Fireye UV
15. e Shooting Guide The PHOENIX Phantom burner has minimal internal moving parts and is relatively maintenance free however there are a few items that for safety reasons and for fuel efficiency should be periodically checked Maintenance Schedule Daily Maintenance e Clean all strainers as needed e Check fuel pressure Weekly Maintenance e Clean the flame scanner using a soft cloth and Windex Monthly Maintenance e Remove the gun assembly from the back of the burner e Clean the swirl plate attached to the back of the nozzle body e Clean and inspect the igniter plug and igniter wire e Inspect the burner cone for signs of distortion or other heat damage Yearly Maintenance e Thoroughly wash and inspect the burner blower impeller It is accessed through the hatch on the back of the blower Clean the pilot gas Y strainer Clean the gas Y strainer It is located at the inlet of the double blocking gas valve Check fuel piping for leaks and tightness Have combustion quality checked with a combustion analyzer Check the function of all safety equipment pressure switches limit switches etc to make sure they are all fully operational Maintenance Notes 1 To remove and clean the pilot gun assembly use the procedure from page 17 2 Check to make sure the pilot gun assembly is at the proper position inside the burner See Illustration 10 3 Periodically check the functioning of all safety equipment pressure switches limit swit
16. egain the proper adjustment Loosen the set screws of the set collars on the mounting plate of the pilot gun assembly Move the nozzle pipes in or out to effect the required retraction or extension of the pilot gun assembly Once the proper positioning of the pilot gun assembly is completed re tighten the set screws of the set collars on the mounting plate of the pilot gun assembly 17 AN PHOENIX Phantom Operation and Service Manual To Remove the Gun Assembly use the following steps 1 Shut down the burner and de energize the burner compressed air system WARNING Lock out the plant power before working on the burner Remove the four nuts holding the pilot gun assembly onto the burner blower Pull out the pilot gun assembly from the burner blower body Make a note of the initial position of the gun by paint marking the pipe Once the proper positioning of the pilot gun assembly is completed a Re tighten the set screws of the set collars on the mounting plate of the pilot gun assembly b Install the pilot gun assembly in the burner blower with the four bolts ols e Flame Shape Adjustments 1 The PHOENIX PHANTOM Burner is preset at the factory for the shortest and narrowest flame possible This makes flame adjustment burners virtually obsolete 2 he nose spin vanes affect the flame shape and combustion intensity 3 Do not change the spin vanes from the factory settings They are preset at 45 to 60 4 The
17. epartment or the Astec Burner Systems Group e Whenever any replacement parts are needed call Astec Parts Department any time day or night at 1 800 251 6042 24 AN PHOENIX Phantom Operation and Service Manual Altitude Correction Chart Blowers at Constant Speed Altitude Air Density Blower Above Sea Correction Level ft Factor Blower Factor vs Altitude Constant Speed 0 069 90 4000 0 068 89 0 066 86 950 0057 75 _ 11000 005 72 _ 12000 0053 69 _ 13000 0051 67 15000 0048 63 For constant speed blowers blower capacity power usage and blower pressure are all related linearly to the density of air To find a burner s performance at altitude multiply the desired property as determined at sea level by the blower correction factor The Phoenix burners uses a variable speed drive This allows it to have its speed raised to compensate for the lower air density For example A blower using 75 HP at sea level would use 75 0 86 64 5 HP at 5000 ft Likewise if the blower capacity had been 1 000 000 SCFH at sea level it would be would be reduced to 1 000 000 x 0 86 860 000 SCFH at 5000 ft Additionally if the fan had a static pressure reading of 10 in H2O at sea level would be reduced to 10 x 0 86 8 6 in H2O at 5000 ft To compensate for this lower density the fan speed must be raised above what is listed on the burner profile to obtain the desired static pressure
18. epartment at the time the order is placed Cut out a hole in the breeching plate 2 larger in diameter than the burner nose flange 7 Check burner blower rotation Rotation should be clockwise from the motor end p Burner Pilot System The PHOENIX Phantom incorporates a forced air pilot system The Pilot and the main flame are monitored by a single Ultra Violet UV flame detector attached to the burner The air for the pilot is provided from the burner blower where there is positive air pressure The adjustment and operation of the pilot system is detailed below IGNITER PLUG IGNITER BOOT IGNITER WIRE PRIMARY AIR TUBE Mill VILLE ve wy A A LESSSSSSSSSSSSSSSSSSY 5 CU MAAR i 7 0 LESSSSSSO SMO SPIN VANES PILOT FLAME CUP IGNITER BOOT PASS THROUGH IGNITER PLUG TERMINAL IGNITER m ON a on SILICONE WIRE IGNITER BOOT TERMINAL _IGNITER PLUG Illustration 4 Pilot System AN PHOENIX Phantom Operation and Service Manual SOLENOID VALV Y STRAINER Illustration 5 Typical Pilot Gas Train Adjustment and Operation of the Pilot System 1 Use Natural Gas NG or Liquid Propane LP vapor only to fuel the pilot WARNING Never connect the LP fuel line to the pilot from the bottom of the LP tank LP would likely be sent to the pilot where it could quickly boil off cau
19. gned for your application Operation 1 The PHOENIX Phantom utilizes a variable frequency drive VFD to control the combustion air blower 2 The fuel valve s have independent control motors or actuators There is no mechanical linkage between the fuel and air controls 3 A programmable logic controller PLC or other ratio control system approved by ASTEC Burner Systems Group controls the air and fuel flows independently 4 The combustion air blower pressure switch normally open must be made to prove the blower is operating This pressure switch is usually set at 0 2 W C It will close as the air pressure exceeds the set point Note When the blower first comes on it will be turning slowly about 240 RPM This is a normal operating condition 5 The combustion air blower will adjust to high speed automatically 6 These conditions must be met to initiate the purge cycle prior to lighting the burner a The safety limit parameters must be satisfied b The purge pressure switch normally open must be energized for the purge cycle to begin This pressure switch is usually set at 10 W C It will close when the air pressure exceeds the set close point C The plant flue gas exhaust fan must be confirmed to be running d The purge timer must be set so that a minimum calculated volume of air flows through the drum during the purge cycle The minimum purge time is the time required for this calculated volume of air to flow
20. he symptoms include e A rapid and weak pulse Rapid breathing A feeling of tiredness or sleepiness Confused thinking Pale cold and sweaty skin First aid for shock e Have the victim lie down and remain quiet e Elevate the victim s feet to improve circulation to the head and chest e Cover the victim with a blanket to maintain body temperature e Transport the victim to a hospital medical clinic or doctor s office as soon as possible WARNING Carefully read the safety instructions in this operating and service manual Follow all the safety warning messages located throughout this manual e Always lock out power before working on any plant equipment e To prevent serious bodily injury do not operate any plant equipment with the guards or other safety components removed e Never repair this burner with replacement parts not approved by the manufacturer Approved parts are only those available through ASTEC parts department or any other parts specifically approved by the ASTEC Burner Systems Group e These instructions are intended for use only by experienced and qualified personnel Qualified personnel are those trained by ASTEC Burner Systems Group or ASTEC s Service Department General Burner Information The PHOENIX Phantom is designed to provide maximum firing capability with a minimum of noise and pollution With its compact flame shape the PHOENIX Phantom provides the ideal means for drying aggregate
21. itial Pilot Adjustment me 13 Natural Gas Fuel Pipine 14 Illustration 6 Gas Train Components pt 14 Table 2 Feed Pipe Size for Gas Runs Over 25 Feet 4 15 Table 3 Feed Pipe Size for Gas Runs 25 Feet or Under 15 Table 4 Recommended Pipe 1 15 Table Nat ral Gas FR CUAL OS 16 Illustration 7 Regulator Regqulrements pp 16 OU 17 Illustration 10 Atomizer and Nozzle ee 17 To Reset the Nozzle Position use the following steps eee 17 3 AN PHOENIX Phantom Operation and Service Manual To Remove the Gun Assembly use the following steps Leere 18 Flame Shape Adjustments 18 INI 19 Illustration 12 blame Scanner pe 19 GO 19 Maintenance amp Trouble Shooting Guide c eee eee ee ecce ee eee eee eee eere eene eee eene eene 20 Au lniie Eei cl c 20 ATOUDIC SNOOUN er 21 Recommended Spare ON 23 Eee 23 Detailed Burner Performance 72ee1S eee eee ee esee eee eee eee eene eee tette eese ees ette ette esee 24 ETT Correchon NT 25 AN PHOENIX Phantom Operation and Service Manual Introduc
22. n the individual burner capacity tables 6 The values of differential pressure versus flow are listed in the individual burner capacity sheets 7 The gas flow in the PHOENIX Phantom can be measured using an orifice plate if the flow meter readings are suspect AN PHOENIX Phantom Operation and Service Manual Combustion Flighting 1 The flight design in the combustion zone of the drum is especially important for minimizing flue gas pollutant emissions 2 The flights provide heat shielding to keep the drum skin temperature low Protecting the metal drum skin from the flame radiating directly onto the drum 3 For the lowest possible emissions of CO and Total Hydrocarbons the combustion zone must be clear of veiling material Showering material through the flame is a common cause of incomplete combustion 4 The combustion zone must be large enough to accommodate complete combustion The length and diameter of the combustion zone must be large enough for the burner flame fit inside See the Burner Performance Data Sheets for the flame dimensions 5 he combustion flights are designed to be self cooling to prevent their failure through overheating A good combustion flight design plows most of the material over the fights while allowing some to flow under them next to the shell insulating the drum from radiant heat and using the aggregate to cool the flights 6 The ASTEC Parts Department can supply combustion flights desi
23. sing either an explosion or fire in the burner If natural gas is the primary fuel the pilot fuel supply should be connected to the natural gas feed piping upstream of the main regulator If you will be firing using liquid fuels and or natural gas service is not currently available connect the gas feed piping to a LP vapor line See above warning Purge the fuel piping of any contaminates before connecting it to the pilot assembly Size the pilot gas supply line to avoid an excessive pressure drop For a pilot gas supply line up to 50 feet long use a minimum of 3 8 pipe Gas pressures at the inlet of the gas pilot manifold can range from 2 to 25 psig The entire pilot oil gun assembly can be removed from the burner by removing the bolts on flange at the back of the burner then pulling the assembly backwards Remove the spark plug wire boot then the spark plug can be removed with a standard spark plug Socket The Initial Pilot Adjustment Make sure the spark igniter is connected to the ignition transformer The initial recommended pressure setting is approximately 5 water column for vaporized propane 10 water column for natural gas at the test port At this rate the pilot should light the main burner easily and deliver a sufficient UV flame signal 13 PHOENIX Phantom Operation and Service Manual Natural Gas Fuel Piping System MANUAL MANUAL SHUTOFF VALVE SHUTOFF VALVE WITH LOCK FLOW ORIFICE PLATE LOW GAS
24. tion Operation and Service Statement These instructions are intended to serve as guidelines covering the installation operation and maintenance of ASTEC Burner Systems Group equipment While every attempt has been made to ensure completeness unforeseen or unspecified applications details or variations may preclude covering every possibility If there is any information that is unclear contradictory or absent from this manual please contact ASTEC Burner Group for clarification before proceeding Scope of this Manual The objectives of this manual are to document the installation operation and maintenance of ASTEC Burner Systems Group equipment It provides policies procedures and references for assuring and controlling quality and compliance to requirements Danger Safety and Warnings DANGER Combustion Equipment Operating this Burner outside its design parameters and or removing disabling or bypassing any PHOENIX Phantom safety device can cause an explosion serious injury or death Basic Safety instructions 1 Always lockout power to any plant equipment before working on it 2 Equipment that is de energized can still retain residual energy or may be susceptible to gravity or other potential energy sources 3 Keep away from power driven parts even if they are not moving unless they are locked out or chained down Use extreme caution if you must approach running equipment Check that all fuel sources are shut off an
25. ty Cu Ft Hr Cu Ft Hr Cu Ft Hr Cu Ft Hr Cu Ft Hr Gas Inlet Pipe Size Table 5 Natural Gas Regulators BY CUSTOMER GAS REGULATOR BY CUSTOMER REGULATOR PILOT LINE CONTROL LINE FROM GAS SUPPLY Illustration 7 Regulator Requirements 6 The gas valve is close coupled to its actuator eliminating all linkages 7 See individual burner performance sheets for air and gas flows See Detailed Burner Performance Sheets 8 Use the utmost in making any adjustment to prevent an unsafe condition WARNING e Final settings will have to be adjusted for the particular operating conditions e Be sure not to have more fuel flow than there is combustion air available to burn or puffing and a dangerously rich firing condition could occur 16 PHOENIX Phantom Operation and Service Manual Pilot Gun Assembly 5 16 FROM BACK OF FRONT BLUFF BODY TO FRONT OF PILOT FLAME CUP REAR BLUF BODY FLUSH WITH FINS SECTION DETAIL B SCALE 1 4 Illustration 10 Pilot Nozzle The position of the pilot gun affects scanner flame strength and light off of the main flame The gun assembly is preset at the factory as shown in Illustration 10 To Reset the Nozzle Position use the following steps 1 Shut down the burner WARNING Lock out the plant power before working on the burner 2 3 4 Look at lllustration 10 to determine if the pilot gun assembly must be moved in or out to r
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