AESYS TurboFire II User manual

York- Shipley Global
Division of AESYS T ec hnologie s, LLC
TurboFire® II Burner
INSTALLATION, OPERATION AND
MAINTENANCE MANUAL
AESYS Techno l og i es , LL C
693 N orth Hill s R oad
York, PA 1 7402
Tel: [phone] Fax : [phone]
webs i te :w ww . aesystec h .co m

TurboFire ® II Burner
INSTALLATIO N, OPERATI ON AND
MAINTENANCE MANUAL
TABLE OF CONTENTS
FOREWORD ................................. ... ..................................................
SECTION 1: WARNIN GS ... ............... ... .... .... .. ........................................................ 1
SECTION 2: DESCRIPTJON................................................................................. 2
SECTION 3: INSPECTION & HANDLING ...................................................... 3
INSPEC TI O N· ······ ··· ·······--··············.............................................. 3
U
NL OAD IN G.................................................................................. 3
SECTION 4: lNSTALLATION................................................................................ 4
SEC TIONS : START·UP .............. .... ................................................... ... ................. 11
PRE S
TART -UP CH ECK LIST.................................................... 12
START-UP PROCEDURE........................................................... 15
LINKAGE TEST............................................................................. 16
PILOT TEST................................................................................... 17
MAIN FLA METEST (GAS).......................................................... 18
MAIN FLAME TEST (OIL)............................................................ 20
MAIN FLAME TEST (LO W NO x PACKAGE)............................ 23
SECT ION 6: MAINTENANCE ......................................................................... .. .... 24
DAILY PROCEDURE.................................................................... 24
WEEKLY PROCEDURE............................................................... 24
MO NT HLY PROCEDURE............................................................ 25
SEMI-ANNUAL PROCEDURE ..................................... .. ............ 25
ANNUAL PROCEDUR E. .. ... ................................................. .. ...... 25
SECTION 7: SERV1CE. ........................................................................................... 26
REFRACTORY REPLACE MENT ................................................ 26
BURNER SHELL.......................................................................... 26
OIL NOZZLE REPAIR................................................................... 27
SECTION 8: TROUBLE SHOOTING ................................................................. 28
SECTION 9: PARTS LIST............. .. ........... .. ......................................................... 32
APPENDIX
FIRE TEST REPORT..................................................................... A-1
BURNER SPEC IF IC ATIONS ...................................................... A-2
START-UP INSPECT IO N FORM................................................ A-3
WARRANTY CERTIFIC ATE .........................................-.............. A-4

Figure 1a.
Figure 1b.
Figure
2.
Figure 3.
Figure
4.
Figure 5.
Figure 6.
Figure 7.
Figure 8.
Figure 9.
Figure 10.
Figure 11.
Figure 12.
Figure 13.
Figure 1
4.
Figure 15.
Figure 16.
Figure 17.
Figure
18 .
Figure 19.
Figu
re 20.
Figure 21 .
Figure 22.
TurboFire® II Burner
LIST OF FIGURES
Page No .
General Burner Arrangement.....................................................
..
General Burner Arrangement..................................................... ..
Refractory Insert..............................................................................
Preparing Mounting Flange Area.............................................. ..
Refractory Orifice................ ..... ........................................................
Preferred Burner Lifting Arrangement.........................................
Alternative Burner Lifting Arrangement....................................
..
Burner Orientation and Insertion..................................................
Retrofrt Gas Train (Main)................................................................
Pressure Tap on Gas Train...........................................................
Typical Linkage Arrangement......................................................
Pilot Gas Train.................................................................................
Oil Nozzle Assembly ................................................................... .. .
Atomizing
Air Compressor ( No.2 Fuel Oil).............................. ..
No. 2 Fuel Oil Piping Schemat ic .............. .. ..................................
Fuel Oil Pump Set (No. 2 Fuel Oil}............................................
..
Scanner Assembly ....................................................................... ..
Forced Draft Blower Assembly .. ................................................. ..
Pilot Gas Train Assembly............................................................ ..
Main Gas Train Schematic (Standard Pressures)....................
Modulation Assembly (Standard}................................................
Control Panel Assembly
(YSHIL- N/2}..................................... ..
Pilot Assembly Drawing............................................................... ..
4
5
6
7
7
8
8
9
10
15
16
17
27
32
33
34
34
35
35
36
37
38
39

FOREWORD
The vork·Sntpt ev packaged boiler has been carefullydesigned and built in accordance with theBoiler
and Pressure Vessel Code of the American Socie ty of Mechanical Engineers and the complete
packaged boiler is li sted by the Underwriter s' Laboratory, Tnc.
Manufacturing operations are constantly monitored byYor k·Shlpteviospectors and an Authorized
National Board commissioned inspector.
The packaged boiler complies with the wr:itten vorJ<·Shiptey
Quality Control Procedure which has been reviewed and accepted by the authorized agencies which
control boiler and pressure vessel manu f acruring.
The packaged boileroperation is essentially autOmatic. It does require proper installation, trained
operators, and maintenance to provide safeand efficient lo ng-life service. This manual, which is
shipped with the packaged boiler, pre.sents inJormarion which will help the owner and operators to
achieve thatle vel of service.
It is very imponant that this manual be carefully studied and retained in a location where it is
read il y available to the pack aged boiler operat o rs fo r re ference at all times.
ff tbere are questions, consult York -Sh ipley before undertaking any unloading, movement,
installation. operation. maintenance, orservice, including
partS re placem e nt
York- Sh ipl ey} S NOT RE SP ONS IDL E FO R THE OVERALL SY STE M DES I GN ( INC L UDING
UREEC Bl NG AND ST ACK ) ~NO THE SYS TE M'S PE RF OR MANCE OR ARIL ITY TO MEET
T HE RE QU IR EM ENTS Of THE OW NER. DON L EE R ECOMMENDS THAT T HE OWN ER
AN D /O R T HE I NSTA LLER P LA CE T HA T RE SP ONSffi lLI TY W ITH A CO MP ET ENT
ENG I NEER.
Treutmem of the boiler water is nece ssa ry to prevent excessi ve corrosion of th e waterside surfa ces
of the bailee DONLEE. recognizing the need for specific chemical analysis of local water to
provide proper treatmen t, ne ither prescribes nor recommen ds the type or amount of wa ter
treatment. The owner sh
al l engage a com pe tent water treating company or consultant to
recommend the proper water rreaanent and procedure of the boilerwater in question.
The Limited Warranty applying
to the packaged boiler is included with this manual. Read il
c ar e full y.
Additional copies of this manual are available from tbevork-Sh l p t e ~iterarure Departmentfor a fee of
$15.00 perco py. The contact address is:
Yor k-S hipl ey G l obal
693 No rth Hills Road
Yo rk PA 17402
• Co nt en ts of thisinanual a re subj ec t to c han ge withoul no tice.
• Specific perfo rman ce sp ecifica ti ons will be prov ided with the job quot at i on.

SECTION 1: WARNINGS
Inspect the burner when it arrives at fts shipping destinati on to identify and record any
shipping damage. Reporting this damage
to the carrier is the responsibility of the consignee
and SUCH DAMAGE IS NOT C
OV ERED BY THE WA RRANT Y. Refer to Section 3 for
more details.
If the burner is stored prior
to installation. it is the responsibility of others (not York-Shipley)
to provide. the necessary protection from damage due to conditions such as:
• Freezing temperatures
• Flooding
Dust and dirt
Falling articl es. etc.
SUCH DAMAGE IS NOT COVERED BY THE WARRANTY (see Section 3).
It Is the owner's responsibility; in cooperation with the installer, to obtain t he required
inspections of the installation f
or compliance with state and local jurisdictional codes and
requirements and to obtain boiler insurance, operati ng certification and periodic third-party
inspections during t
he li fe of the burner.
The owner has the responsibility
to provide qualified and trained operators and to assure t hat
the burner is operated and maintained to provfde efficient and safe operati on . This manua l
provides information
to assist the owner and operators but is not intended to supplant
thoughtful and diligent dedication on the part of the owner and operators to this task. The
owner and operators must comply
with the regulations and requirements of the insurance
carrier, and state and local jurisdictions. Their legal requirements take precedence over
anything included in this manual.
The burner ~: 1i iizes combustible fuels and water or steam at pressures higher than
atmospheric. Industry accepted safety standards are met or exceeded in the desi
gn and
manufacture of the burner. INSTALLERS AND OPERATORS OF THE BURNER A RE
WARNED THAT THEIR IMPROPER OR CAREL ES S ACTIONS CAN RE SULT IN A
HAZARDOUS CONDITION.
The equipment is not intended for use in furnishing temporary heat to the structure in which it
is installed prior to the completion and acceptance of such structure and installation
by the
owner or other person for whom the entire project
is being constructed. Therefore, the
warranty
and warranty service normally issued with respect to this equipment will not apply
during and a ft er such use.
WHEN SERVICING THE BURNER, DISCONNECT
ALL POWER SUPPLIES.
Equipment furnished by York-Shipley Global includes various safety, performance,
temperature and operation systems and limits. ANY ACTIONS BY THE PURCHASER,
PURCHASER'S PERSONNEL OR PERSONS ACTING ON PURCHASER 'S
BEHALF WHICH TEND TO NULLIFY OR CHANGE SUCH SYSTEMS OR LIMITS
WILL BE TAKEN AT PURCHASER 'S SOLE RISK AND RESPONSIBILITY AND
WILL V OID York-Shipley Global's WARRANTY AND
PERFORMANCE RESPONSIBILITIES AND WILL RELIEVE York-Shipley
OF
ALL LIABILITIES RESULTING THEREFROM.
Secti on 1 - W arnings

SECTION 2:
DESCRIPTION
The York-Shipley TurboFire® II unit is a packaged burner system consisting
of a burner body, controls, forced draft blower, piping, gas and/or oil train, electric panel and
otheritems. A lifting lug is attached to the burner for handling.
At the request of the purchaser or for foreign shipments, certain parts and/or assemblies may
be rem oved from the packaged boiler and shipped separately. Reassembly of these pans
and/or assemblies is completely the responsibility of the pu rchaser.
Gas, oil, steam and electrical supply power connections need to be made by the installer.
THE CONTROL SYSTEM VOLTAGE FOR THE BURNER IS ALWAYS 120 VOLTS
REGARDLESS OFTHE BOILER VOLTAGE.
The Cyclonic burner differs from existing forced draft burners and its operation is extremely
simple. There are no internal baffles, dampers or other appurtenances in the burner.
The high tangential velocity created within the burner causes an in ti mate mixing of fuel and
air resulting
in extremely good combustion and low excess air.
This high tangential velocity is maintained throughout the length of the furnace which
increases the convective heat transfer and the residence time of the combustion gases in the
furnace resulting in the gases exiting from the furnace at a relatively lo wer temperature than
with conventional burners.
The packaged burner is fire tested at the factory priorto shipment. A sample copy ofthe test
report is inclu
ded in the APPENDIX.
2 TurboFire®
II Burner

SECTION 3: INSPECTION & HANDLING
INSPECTION
York-Ship l ey Global is not responsible for damage to the burner and/or fo r items
missing during shipment from the factory
to the shipping destination. RESOLUTION OF
SUCH CLAIMS AGAINST THE CARRIER IS THE RESPONSIBILITY OFTHE CONSIGNEE.
Immediately upon the arrival of the shipment and before. it Is unloaded from the carrier's
vehicle, the consignee
or his agent shall make a thorough inspection ofthe shipment.
Look
fo r the following:
• Is the blocking and/or strapping in place and tight?
• Has the unit shifted on the carrier's vehicle?
• Are the temperature and pressure gauges and controls in place and undamaged?
• Is the piping to accessories intact and undamaged?
• Do the skids and supports show evidence ofstress or damage?
• Are the lifting lu gs bent or distorted?
• Is the burner dented or marred?
• Is there evidence of pilfering?
If there is evidence of damage or items missing, notations of the speciiic damage and/or
missi
ng items shall be made on the freight bill and a record of such notations retained by the
consignee. The consignee shall immediately advise the carrier's agent ofthe condition of
the
shipment In writing, demand an inspecti on of the damage and file the damage claim with the
carrier.
UNLOADING
The packaged burner is a heavy and bulky piece of equipment which may be damaged if it is
not handled properly by skilled persons using special equipment.
Unloading the burner from the carrier's vehicle and/or moving it into position
re qu ires skill
and proper equipment and should.not be attempted by those who lack the qualifications.
York-Shipley Glo'?al recommends that a competent rigger be engaged to perform
that task. The consignee should advise the rigger
as to the time w hen his services will be
needed in order to eliminate charges for delays.
If delays do occur, it is important tha t the burner be protected from the weather, dust, dirt,
pilferage and damage. Panicular attention shall
be given to protection of electrical items:
controls, motors and wiring.
REFER TO FIGURES 5 & 6 FOR LIFTING INFORMATION.
Se c tion 3 - lnstallatio n & Handling
3

SECTION 4: INSTALLATION
BURNER INSTALLATION INSTRUCTIONS
1. Familiarize yourself with the burnerby studying F ig ures 1a and 1b "General Burner
Arrangement."
4
BUR N ER
ASSEMBLY
GAS TRAIN
(PILOT)
BLOWER A IR
SWITCH
Figure 1a. General Burner Arrangment
TurboFire® ll Burner

NOZZLE ASSCMSL Y
\OIL)
METER I I\'G VALVe
(OIL)
F ig ure 1b. General Burn er Arrangement
2. Turn off all electrical power to the boiler.
3. Close all natural gas valves.
4. Disconnect and
tag any electrical, gas or oil connections whi ch may interfere with the
removal of the existing burner
or the gas train.
5. Read and follow the instructions for removal
of the old burner which we re supplied from
the original manufacturer.
Section4 - Ins tallation 5

6. Remove the refractory cylinder in to which your old burner was in serted. Figure 2
"Refractory
In sert.·
WARNING: Your Turbofire ® II burner may require the installation oi refractory tile.
Consult a
qu laified TurboFire® II technician.
Figure 2. Refractory Insert
7. Remove any gasketing rope from the mounting flange area of the boiler.
6 TurboFire® II Burner

8. Remove any rust, scale, rope or refractory left in the firing tube or the front mounting
fl ange area with a wire brush. Figure 3 "Preparing Mounting Flange Area.·
9. Inspect the refractory orifice located inside the firing tube. The orifice should be
replaced if there are any loose
or cracked bricks. Figure 4 "Refractory Target."
Fig ur e 3. Prep ari ng Mo unting
Fl ange Ar ea
Fig ur e 4. Refract or y Target
NOTE: THE TURBOFIRE® II BURNER NORMALLY REQUIRES A REFRACTORY
ORIFICE
IN THE BOILER MORISON TUBE. CONSULT THE FACTORY
REPRESENTATIVE FOR THE PROPER SIZE AND INSTALLATION
INSTRUCTIONS.
WAR NIN G: Do not operate your Turbofire® II without a properly sized boiler orifice.
Unsafe burner operati
on will result
Section4 - Installation 7

1o. Place a chain, cable, or belt sling rated for a minimum of 2000 lb. around the burner
between the mounting flange on the burner, and the blower. With a properly sized
lifting device, pi ck up the burner. Figures 5 and 6 illustrate the preferred and
alternative burner lifiting arrangements.
LIFTING SUNG
(20 00 LBS. MINIMUM
CAPACITY)
LIFTI NG DEV I CE
( 2000 LBS. MINIMUM
CAPACITY)
Figure 5. Preferred Burner Lifting
Arrangement
LIFTING DEVICE
(2000 LBS . MINIMUM
CAP ACITY)
Figure 6. Alternative Burner Lift i ng
Arrangement
8 Tu:cboFire®
II Burner

11. Rotate the burner in the lifting sling so that the air inlet of the blower is square to the
floor. Rgure 7 "BurnerOrientation and Insertion."
NOTE: THE BOILER DESIGN MAY REQUIRE THE TURBOFIRE® II BURNER TO BE
INSTALLED WITH THE BLOWER ABOVE THE BURNER. CONSULT FACTORY
REPRESENTATIVE.
12. liberally spray adhesive onto the front mounting flange area oft he boiler. Wa it a few
moments until t he adhesive becomes "tacky". Wr ap 3/8" gasketing rope around the
circumference of the firi
ng tube two ( 2) times on the inside of the mountinq stud
diameter on the front cover ofthe boiler.
NOTE: DO NOT USE FIBERGLASS GASKET
13. Slide the burner end head into the firing tube of th e boiler. Rotate the burner so that
the mounting flange holes of the burner are aligned with the mounting studs of the
boiler and s
li de the burner onto the studs. Rgure 7.
518 ' OIAMETEf\
STAAWASHER
5.9. NUT
(BRASS)
Figure 7. Burner Orientation and Insertion
Sect ion 4. -Installation 9

14. Screw washers and brass nuts onto the boiler studs.
15. Lower the lifting device so that the studs support the burner and remove the sling f rom
around the burner.
16. Tighten
the brass nuts on the studs evenly to seal the burner to t he boiler.
CAUTION: Failure to tighten the brass nuts may result
in a combustion
gas leak and burner overheating.
17. Connect main gas line to gas train connection on TurboFire® II.
See Figure 8 "Retrofit Gas Train (Main)".
18. Have an electrical contractor connect all electrical connections to the gas train and
boiler safety and control switches f
rom the control panel provided with the burner
exactly as shown
in the provided wiring diagram.
19. Connect oil (and steam) supp
ly to the burner.
10
GAS LINE
CONNECTIO N COON
(FIELD)
CHARACTERIZED
GAS VALVE
LOW PRESSURE
CUT OUT SWITCH
Figure 8. Retrofit Gas Train (Main)
Turbo Fire® II Burner
HIGH PRESSURE
CUTOUT SWITCH
GAS
VALVE

SECTION 5: START-UP
Your Tu rb oFire® II burner has been tested and adjusted at the fa ctory to provide
optimum performance and reliability. However, each burner installation is slightly
different and your burner will require some fine tun in g and safety checks once it is
installed.
ATTENTION: A
York -S h ip ley Global REPRESENTATIVE
MUST CONDUCT THE PRE-START-UP INSPECTION AND THE
ACTUAL START-UP PROCEDURE.
Section 5- Start -u p 11

PRE ST ART-UP CHECK LIST
12
GENERAL
If refractory has been added to the combustion chamber as
part of the installation, is it completely dry, cured, and ready
for firing at full bo iler input? 0
Has the proper electrical voltage been connected to the
burner control cabinet
as shown on t he burner wiring diagram? 0
Has the burner wiring been checked for completeness and
accuracy? Have 3-phase motors been properly wired and
checked for correct rotation? 0
Are the boiler mounted limit controls such as low water cutoffs, high limit
controls, operating controls, modulating controls, etc., properly Installed
and wired? 0
Are the boiler controls the right type and adjusted to the proper setting
and range for
the installation? 0
Is the boiler water supply, including feed pumps, properly
connected and is
the boiler filled with water? 0
Is sufficient load connected to the boiler so that it can be fired
continoously
at full rating? 0
If the boiler load is not connected, can steam be wasted so that the
bo
il er can be fired continuously at full rating without endangering
personnel or equipment? 0
If the installation is a hot water boiler, have the circulating pumps been
completely installed, wired and properly tested to assure proper operation
so that the burner can be fired contifluously at full rating? 0
For new boiler installations, has the boiler been boiled out in accordance
with the boiler manufacturer's instructions? 0
Have the boiler breaching connections to the stack been completed
and are they open and unobstructed? 0
Is draft control equipment required and, if so, installed? 0
Have adequate provisions for combustion air been installed? 0
TmboFire® ll Burner

Have the persons listed below been notified of the burner start-up date?
0 Owner's Representative?
0 Mechanical Contractor's Representative?
0 Electrical Contractor's Representative?
0 Service Organization's Representative?
0 York-Shipley Representative?
Is all specified auxiliary equipment mounted and wired? This may include
outdoor temperature controls, oil flow switches, space thermostats,
water flow switches, motorized combustion air louvers, etc. 0
GAS FIRING
Are all gas train components installed and have they been
properly selected, sized and assembled? 0
Have properly sized vent lines been installed on all gas train components
whi
ch require venting? This includes such items as pressure regulators,
normally open vent valves, diaphragm valves, lo w and hi gh gas pressure
switches, etc. 0
Have gas train piping and components been tested and proven gas ti ght?_ 0
Have the gas lines been purged? 0
Is the proper gas pressure available
at the in letto the controls which
meets the requirement shown on the burner material list? 0
OIL FIRING
Is the oil tank installed and filled with the proper type and
grade of fuel oil
as required by the burnermaterial list? ------- 0
Is the proper oil pressure, temperature and viscosity available
at the inlet to the controls which meets the requirements shown
on the burner fire test report and/or oil system sheet?
_______ _ 0
Have oil supply and return li nes been properly sized to meet
the maximum pumping capacity of the pump and has the system
been purged and proven leak proof?
------------- - 0
Section 5 • Start -u p 13

SIGNATURE OF INSPECTOR($)
(Name) (Date)
(Name) (Date)
(Name) (Date)
(Name) (Date)
(Name) (Date)
14
Turbo F ir e® II Burner

S TAR~UP PROCEDURE
STEP 1: Tighten all electrical, conduit, air, steam and fuel lines.
STEP 2: Set the natural gas li ne pressure taken at the beginning of the gas train to the
value li sted in t he burner fire test report, by adjusting the natural gas regulator.
Figure 9 "Pressure
Tap on Gas T ra in"
• Connect manometer
to gas pressure tap .
• Place oxygen analyzer in boiler stack.
FI.StiOLE TV&ING
Figu re 9. Pr e9'Su re Tap on Gas Tr ain
STEP 3: Read the Fireye E100, (o r YS-7000 if so equipped) Flame Control Manual
NOTE: THE FIREYE E100 OR Y-S 7000 SYSTEM, WHICH IS USED ON YOUR
TURBOFIRE®
II BURNER, PROVIDES FLAME SUPERVISION AND
SEQUENCING FUNCTIONS. YOU SHOULD BE THOROUGHLY FAMI LIAR
WITH ALL OF THEIR FUNC T IO NS AND FEATURES BEFORE ATTEMPTING
THE START-UP PROCEDURE.
STEP 4: Tum on electrical power to the boilerat the main boiler room electric pa
nel.
Section 5 - Start-up 15

S TE P 5: LIN KAGE TEST
Procedure:
1. Tighten all linkage nuts located on all li nkage rods.
2. With the flame controller in the check mode and all fuel manual valves open except
the manual valve located closest
to the burner (Figure 10), place the boiler ON/OFF
switch in the ON position. (The ON/OFF sWitch is located on the side of the burner
control panel).
NOTE: THE BLOWER WILL NOT START UN LE SS THE LOW GAS PRESSURE
SWITCH
(I F EQUIPPED) ' IS RESET.
The blower should start and the li nkage should begin to move.
Re peat Step 2 several times to assure proper linkage movement.
3. Watch the linkage arrangement
as it mo ves up and do w n.
1 6
The fuel valves, air damper,
lin kage ro ds and modulation motor should all move
with a smooth act
io n with no binding. The fuel valves and air damper should
not bind at the FULL OPEN orCLOSED
pos ition.
CAMPER CC"'TRRL
AAV.
\
MOOUlATlON
t.OTOR
MET'El11NG VALVE
(OIL)
JACI<SHAFT
BRACKET
BliT"TEAFL Y VALVE
{AIR)
Fig ur e 10. Typical Li nk age Ar rangement
Turbo Fire® II Bum er