Algas SDI Phoenix SH, Operation & Maintenance Manual

Page 1: ...ations Maintenance Manual 151 South Michigan Street Seattle Washington USA 98108 Tel 206 789 5410 Fax 206 789 5414 Web www algas sdi com This manual covers units built after S N FILE MANUAL PN 57002 SH100 SH200 rev 05 18 2022 ...

Page 2: ...t and a thorough understanding of the equipment is required to allow safe operation and maintenance Allow only a TRAINED and FULLY QUALIFIED PERSON to service this equipment Any time a component must be replaced use the same type model etc DO NOT SUBSTITUTE The consequences from such actions are unpredictable and may lead to dire consequences ...

Page 3: ...es a potential hazard which can result in severe personal injury or death Use extreme care and follow the instructions given ELECTRICAL DISCONNECT REQUIRED Indicates a potentially dangerous situation which can result in severe personal injury or death or damage to equipment Use great care and follow the instruction given PARTS AND PRICES For parts and prices contact your Algas SDI distributor ASDI...

Page 4: ...NG 7 BURNER PIPING 8 SUPPLY PIPING 8 SUPPLY PIPING 9 CHECKLIST AFTER INSTALLATION 9 PREPARE FOR START UP ADJUSTMENT 10 3 OPERATION 1 INITIAL SETUP 1 STEP 1 RESET THE SYSTEM 2 STEP 2 IGNITE THE BURNER 2 STEP 3 SET THE HIGH FIRE FUEL FLOW 3 STEP 4 SET THE LOW FIRE FUEL FLOW 3 STEP 5 STOP PROCEDURE 4 4 MAINTENANCE 5 MAINTENANCE 5 MONTHLY CHECKLIST OPTIONAL 5 ANNUAL CHECKLIST 6 5 TROUBLESHOOTING 1 TRO...

Page 5: ...t utilizes an integral air blower designed to operate with fixed combustion air over a wide turndown range The Phoenix SH burners are available in three models all with straight combustors SH100 1 000 000 Btu hr SH150 1 500 000 Btu hr SH200 2 000 000 Btu hr For performance and operational specifications refer to the Phoenix SH Specification Sheet Figure 1 1 Phoenix SH Burner ...

Page 6: ...canner Adapter O rings Orifice Plates Integral Blower Control Valve and Actuator Ratio Regulator Air proving pressure switch Utilizing a nozzle mix design fuel enters through the center of the body while air is supplied by the integral blower and enters around and through the inlet holes in the nozzle Fuel flow is controlled by the control valve and air flow remains fixed throughout its operating ...

Page 7: ...rature and humidity Transport in original shipping container Use appropriate support equipment i e harnesses straps chains etc when lifting burner components Take care not to drop or damage the burner Storage Verify that the burner is clean and free of damage Store burner in a cool clean dry room After ensuring that everything is present and in good condition keep the burner in the original packag...

Page 8: ...ust to accumulate in the work area Provide means for exhausting them from the furnace and the building Access Install the burner in such a way that you can get easy access for inspection and maintenance Environment Verify the local environment matches the operating specifications of the burner Check the following items Type and supply pressure of the fuel Availability of enough fresh clean combust...

Page 9: ... to supply power to igniter If equipment other than those that are recommended are used performance may vary from Algas SDI published values Install the flame supervision into the NPT opening in the rear cover Verify that you connect the flame supervision of a burner to the electrical circuit of that burner WARNING If you connect the flame supervision of a burner to the flame safety system of the ...

Page 10: ...utside diameter of the combustor Provide an accessible pressure tap on the chamber wall to measure the pressure inside the firing chamber The pressure tap should be located near the burner Verify that the wall of the chamber is strong enough to support the weight of the burner If necessary reinforce the area where you plan to install the burner to support the weight of the burner Refractory furnac...

Page 11: ...with the burner is installed between the burner and the chamber wall Verify the gasket does not leak To ensure that radiated heat doesn t reach the exterior of the chamber insulate the combustion tube over the length contained within the chamber wall filling and clearance completely If the firing tube extends beyond the chamber wall thickness DO NOT insulate the exposed end of the tube Figure 2 3 ...

Page 12: ... flow Integral fuel orifice and both O rings 2 are re installed Same straight run of pipe 3 remains between the ratio regulator and the burner Figure 2 4 Burner Piping Supply Piping Inlet pressure to the ratio regulator if supplied should be as specified on the Phoenix SH Specification Sheet It should not exceed the maximum pressure rating of the ratio regulator Locate the valve train close to the...

Page 13: ...Installation To verify proper system installation do the following Verify that there are no leaks in the gas and air lines Verify all components of the flame monitoring control system are properly installed This includes verifying that all switches are installed in correct locations and all wiring pressure and impulse lines are properly connected Verify components of spark ignition system are inst...

Page 14: ... to the main gas valve train Set the high gas pressure switch at 20 above the gas pressure measured at the inlet to the main gas valve train Close all the burner shut off valves Try to light a burner before the purge and other timing relays have finished their cycles Verify that the flame monitoring system indicates a flame failure Trip pressure switches and other limit interlocks Verify that the ...

Page 15: ...pass any safety feature fire or explosion could result Never try to light a burner if it shows signs of damage or malfunction Initial Setup Upon adjustment of a Phoenix SH Burner for the first time you must follow the steps listed below to ensure proper setup and operation Each step listed are explained in full detail in the next sections 1 Reset the system 2 Ignite the burner 3 Set high fire fuel...

Page 16: ... consider increasing low fire Make sure pressure taps C and D are open Connect manometer to pressure taps C and D Verify combustion air blower is running Drive the gas control valve to low fire Open all manual gas valves feeding the burner Initiate the ignition sequence through the flame monitoring control system Verify that the burner has ignited through flame monitoring and visual observation op...

Page 17: ... pressure rating of the ratio regulator Remove manometer from pressure taps Close pressure taps DANGER Insufficient gas inlet pressure may cause the ratio regulator to remain full open if there is a loss of air flow to the burner This can cause excess fuel operation and the possible accumulations of unburned fuel in the chamber In extreme cases this may cause explosions or fires STEP 4 Set the low...

Page 18: ...til the chamber temperature is below 250 F 121 C This will prevent hot gases from back flowing into the burner and blower causing damage to the burner Stop the burner through the burner control system Run the combustion air blower until the chamber temperature drop below 250 F 121 C Shut off the combustion air blower Close all manual gas valves to the burner ...

Page 19: ...reating an ignition Do not operate any equipment that may create a spark during maintenance WARNING High voltage ignition transformer can cause severe injury or death when handled incorrectly Do not perform maintenance until power has been disconnected from ignition transformer Monthly Checklist Optional Leak test safety shut off valves for tightness of closure Test air pressure switch settings by...

Page 20: ...per gap Check valve motors and control valves for free smooth action and adjustment Check for proper operation of ventilating equipment Test the interlock sequence of all safety equipment manually make each interlock fail noting that related equipment closes or stops as specified by the manufacturer Test the flame monitoring control system by manually shutting off gas to burner Test main fuel hand...

Page 21: ...etting and operation Low gas pressure switch has activated Check incoming gas pressure Adjust gas pressure if necessary Check pressure switch setting and operation Start up sequence runs but burner does not light Not enough gas Air in the gas line Check output from flame safety Open gas ball valve Purge gas line Not enough gas Gas valve not open Check wiring to the automatic gas shut off valve Not...

Page 22: ...ough gas Check start up settings and adjust to increase low gas flow Not enough air Check start up settings Check air plumbing controls and valves for leaks The burner turns off when cycling to high fire Fuel rich mixture Check start up settings Check air plumbing controls and valves Loading line to the ratio regulator is leaking Repair the lead in the loading line The burner is unstable or produc...

Page 23: ...Troubleshooting Algas SDI Operation and Maintenance Manual SH100 SH200 5 3 Spare Parts List Models SH100 SH200 ...

Page 24: ...00 10 Combustor Alloy Straight 1 7001 4008 7001 4008 7001 4008 30 Nozzle Cast Iron 1 7001 5005 7001 5005 7001 5005 90 Igniter 1 7001 9001 7001 9001 7001 9001 100 Flame Rod 1 7001 9015 7001 9015 7001 9015 130 O ring 2 7001 9006 7001 9006 7001 9006 200 Nozzle Set Screw 2 7001 9014 7001 9014 7001 9014 210 Mounting Gasket 2 7001 5029 7001 5029 7001 5029 ...

Page 25: ...Algas SDI International LLC 151 South Michigan Street Seattle Washington 98108 Ph 1 206 789 5410 Fax 1 206 789 5414 www algas sdi com ...