Eclipse Combustion Vortometric v2.00 User manual

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Vortometric
Burners
Installation Guide 248
4/10/07
E
clipse

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.
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.
COPYRIGHT
DISCLAIMER NOTICE
LIABILITY AND
WARRANTY
ii Eclipse Vortometric Burner v2.00, Installation Guide 248, 4/10/07

About this manual
iii
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 theVortometric
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 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 control system
operation.
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.
AUDIENCE
SCOPE
VORTOMETRIC
PUBLICATIONS
Eclipse Vortometric Burner v2.00, Installation Guide 248, 4/10/07

iv
• EFE-825 (Combustion Engineering Guide)
• Eclipse Bulletins & Instruction Manuals:818,820,826,832,852,854,856
• 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.
DOCUMENT
CONVENTIONS
IMPORTANT NOTICES
RELATED PUBLICATIONS
Eclipse Vortometric Burner v2.00, Installation Guide 248, 4/10/07

About this manual................................................................ ii
Table of Contents.................................................................. v
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
Table of Contents
1
2
3
vEclipse Vortometric Burner v2.00, Installation Guide 248, 4/10/07

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
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
5
vi
4
Eclipse Vortometric Burner v2.00, Installation Guide 248, 4/10/07

PRODUCT
DESCRIPTION
The EclipseVortometric 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.
TheVortometric’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 theVortometric
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
Introduction
1-1
1
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Eclipse Vortometric Burner v2.00, Installation Guide 248, 4/10/07

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

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.
INTRODUCTION
SAFETY
2-1
afety 2
Eclipse Vortometric Burner v2.00, Installation Guide 248, 4/10/07

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.
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.
OPERATOR TRAINING
REPLACEMENT PARTS
2-2
CAPABILITIES
Eclipse Vortometric Burner v2.00, Installation Guide 248, 4/10/07

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.
INTRODUCTION
Installation
3-1
HANDLING AND
STORAGE
3
Eclipse Vortometric Burner v2.00, Installation Guide 248, 4/10/07

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.
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
NewYork, NY 10018
The UL Standards are available from:
United Laboratories
333 Pfingsten Road
Northbrook, IL 60062
APPROVAL OF COMPONENTS
Limit controls and safety
equipment
Electrical wiring
Gas piping
Where to get the standards
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: [phone]
Fax: [phone]
Comité Européen de Normalisation Electronique
Stassartstraat 36
B-1050 Brussels
Phone: [phone]
Fax: [phone]
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.
3-3
CHECKLIST BEFORE
INSTALLATION
Eclipse Vortometric Burner v2.00, Installation Guide 248, 4/10/07

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.
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. 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".
BURNER MOUNTING
PREPARE THE BURNER
Gas, Gas/Oil or Oil Gun
Positioning
3-4 Eclipse Vortometric Burner v2.00, Installation Guide 248, 4/10/07

Figure 3.1 Vortometric Gas Gun Position
3-5
Figure 3.2 Vortometric Gas/Oil Gun Position
End of
oil atomizer
is flush with
throat cone ring
Gland “B”
Used to adjust the position
of entire gun assembly
within burner throat
Gland “A”
Used to adjust the position
of oil gun within gas gun.
6
31
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 3-7/8
Eclipse Vortometric Burner v2.00, Installation Guide 248, 4/10/07

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

An ultraviolet flame sensing device, or U.V. scanner, must be used
with a 3/4" N.P.T. swivel connector. The scanner and connector can
be used in three possible locations: two mounting ports are located
near the gun assembly adjacent to the pilot which sight both pilot
and main flames, while a third mounting port on the side of the
combustor sights only the main flame. Flame detection methods
are affected by fuels and applications:
•For gas, light oil, or heavy oil with air atomization, locate a U.V.
scanner in one of the two mounting ports near the pilot to prove
pilot and main flames.
•For heavy oil with steam atomization, two scanners must be used.
Because atomizing steam absorbs ultraviolet light, a scanner
mounted near the pilot will only prove the pilot flame.Therefore,
a 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 of the burner.
Danger:
If you connect the flame sensor of a burner to the
electrical circuit of the wrong burner, then you can
cause fires and explosion.
For detailed information on how to install and connect a U.V.scanner,
refer to:
•straight U.V. scanner; Bulletin/Instruction Manual 854
•90°U.V. scanner; Bulletin/Instruction Manual 852
•self-check U.V. scanner; Bulletin/Instruction Manual 856.
Install the flame sensor
3-7
U.V. Scanner
(Model 5600-91)
90°U.V.
Scanner
(Model 5600-90A)
Self-Check
U.V. Scanner
(Model 5602-91)
Eclipse Vortometric Burner v2.00, Installation Guide 248, 4/10/07

3-8
Piping
Pilot Pilot ignition
The standardVortometric spark-ignition pilot requires an ignition
transformer with a minimum of 6000 volt secondary. Mount the
transformer in a location where it will not overheat while allowing
as short an ignition lead as possible.
Pilot assembly positioning
The relation of the pilot assembly to the main burner gun affects air
flow through the throat cone.Therefore, it is important that the pilot
be as far away as possible from the throat cone while maintaining
reliable ignition. For initial start-up, the pilot assembly 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 recommended. Adjustments of the main gas, pilot gas and
oil guns may be required during burner setup.
Avoid large pressure drops
Note:
The pressure drop of the gas in the piping is a critical
parameter. Make sure that the size of all the piping is large
enough to prevent excessive pressure losses.
Eclipse Vortometric Burner v2.00, Installation Guide 248, 4/10/07

Oil fuel considerations
1. In heavy oil (#5 or #6) applications, the oil temperature at the
burner inlet should be 220°to 270°F for good viscosity
(maximum 150 SSU). Depending on burner location, steam or
electric tracing AND pipe insulation are usually needed to
ensure this oil temperature range. Other oils (wastes, residues,
etc.), may also require similar provisions to ensure good
viscosity.
2. Foreign material can easily clog the small injection holes in the oil
nozzle tip. Therefore, ensure that all inside surfaces of assembled
piping to the burner are free of dirt, grit, shavings or any other
foreign material.To avoid contamination, use thread sealants such
as Teflon paste only on pipe threads that will not come in contact
with the oil flow.
3. A purge of the oil nozzle should be conducted after burner
shutdown.To do so, connect a line between the atomizing
medium and the oil piping just upstream of the oil nozzle, and
install check valves in this line and the oil piping.
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 oil vapor from the air compressor to contaminate the
atomizer.Therefore, include preventative measures against this
possibility when designing the air distribution system.
2. ALL compressors should be equipped with a suitable aftercooler,
oil separator, and automatic traps or drain valves.
3. When compressed air is used for atomization of heavy oils (#5
or #6), preheat the air to a temperature between 220°and
270°F and insulate the air lines.
Pilot gas considerations
1. ALL supplied gas pilot piping (natural, propane, etc.) MUST be
fitted with a pilot gas pressure regulator.
2. ALL supplied gas pilot piping (natural, propane, etc.) SHOULD BE
fitted with an adjustable orifice valve for pilot gas flow adjustment.
3-9Eclipse Vortometric Burner v2.00, Installation Guide 248, 4/10/07

3-10
No matter what fuel is used, it is essential that the valve train
components, the atomizer and the fuel oil tip be protected from
foreign material damage.Therefore, it is suggested that strainers be
used as follows:
Oil valve trains
1. It is recommended that an edgeplate type filter with 0.0035"
separations (170 mesh) be used UPSTREAM of all valve train
components.
2. It is recommended that a strainer with 100 mesh screen be used
ADJACENT to the oil gun inlet.
Atomizing valve trains
It is recommended that a strainer with 1/32" diameter perforated or
20 mesh screen be used UPSTREAM of all valve train components
for steam or compressed air applications.
Fuel gas valve trains
It is recommended that a strainer with 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 differential pressure regulator which is “top
loaded”with the oil pressure at the nozzle, which allows the
atomizing pressure to increase proportionally with the oil
pressure.To do so, set the atomizing pressure approximately 20
psig above the oil pressure, but not exceeding 50/55 psig.To
ensure this maximum pressure is not exceeded, adjust the
pressure regulator for the incoming atomizing supply to not
exceed 50/55 psig.
Strainers
Atomizing control methods
Eclipse Vortometric Burner v2.00, Installation Guide 248, 4/10/07