ASTEC Phoenix FURY, Operation And Service Manual

Page 1: ...ASTEC S ECONOMICAL AGGREGATE DRYING BURNER FURY Version 1 12 16 2014 OPERATION AND SERVICE MANUAL ASTEC Burner Group ...

Page 2: ...n 1b Component Identification and Location 8 Illustration 1c Component Identification and Location 9 Illustration 1d Component Identification and Location 9 Adjustments 9 Burner Dimensions 10 Burner Mounting 11 Burner Pilot System 11 Illustration 2 Pilot System 11 Illustration 3 Typical Pilot Gas Train 12 Adjustment and Operation of the Pilot System 12 Natural Gas Fuel Piping System 13 Illustratio...

Page 3: ... Cooling Air 22 Maintenance Trouble Shooting Guide 23 Maintenance Schedule 23 Trouble Shooting 24 Recommended Spare Parts 26 Table 10 Spare Parts List 26 Table 11 Nozzle Spare Parts List 26 Detailed Burner Performance Sheets 27 Altitude Correction Chart 28 High Altitude Blower Kit Addition Illustration 10a Burner High Altitude Blower Kit Addition 29 Illustration 10b Burner High Altitude Blower Kit...

Page 4: ... from power driven parts even if they are not moving unless they are locked out or chained down 4 Use extreme caution if you must approach running equipment 5 Check that all fuel sources are shut off and locked out prior to working on the burner 6 All the drive guards handrails and other safety devices must be in place before starting the equipment 7 Prior to start up check that all plant componen...

Page 5: ...ts department or any other parts specifically approved by the ASTEC Burner Systems Group 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 FURY burner is designed to provide maximum firing capability with minimum noise and pollut...

Page 6: ...ngs to protect them from rain snow or excessive moisture Burner Capacity Table 1 Burner Capacities Notes For Table 1 1 The maximum BTU hour rating is based on 25 excess air 2 The figures used in Table 1 are based on 60Hz AC and Standard Cubic Feet per Hour SCFH at 70F air temperature at sea level 3 Correction factors must be applied for altitude or temperature variations See Altitude Correction Ch...

Page 7: ...tor mounted to the combustion air damper which is mechanically linked to the fuel valves and air damper 2 The Programmable Logic Control PLC option to the burner control adds additional sophistication to the management of the fuel air ratio by adding another control motor that manipulates the fuel valve position 3 The PLC allows the fuel and air valve to be controlled independently 4 A combustion ...

Page 8: ...Phoenix FURY Operation and Service Manual 8 Illustration 1a Component Identification and Location Illustration 1b Component Identification and Location ...

Page 9: ...Phoenix FURY Operation and Service Manual 9 Illustration 1c Component Identification and Location Illustration 1d Component Identification and Location Adjustments ...

Page 10: ...Phoenix FURY Operation and Service Manual 10 Burner Dimensions PHOENIX FURY dimension drawings are located on the plant s flash drive If the drawings cannot be located please contact Astec Burner Group ...

Page 11: ...tion shield 4 Check burner blower rotation Rotation should be clockwise from the motor end Burner Pilot System The PHOENIX FURY 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 and included in the complete burner package The air for the pilot is provided from inside the fan housing where there is a c...

Page 12: ... pilot manifold can range from 2 to 25 psig 7 The entire pilot assembly can be removed from the burner by removing the strut bolts and pipe unions along the side of the burner then pulling the assembly backwards 8 Remove the spark plug wire boot then the spark plug can be removed with a standard spark plug socket 9 Make sure the spark igniter is connected to the ignition transformer 10 Remove the ...

Page 13: ...ner profile sheet found on the plant flash drive for more precise information See Detailed Burner Performance Sheets c Exact gas pressure must be set at the initial start up depending on piping configuration burner size and maximum rated capacity 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 regula...

Page 14: ...e the connection size on the burner shown in Table 3 below 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 safety valve a Shutoff valve facilitates servicing of the gas train b The strainer protects the valves from destructive dirt that could lodge in them c The Siemens double block gas valve has an integral strainer at...

Page 15: ...on WARNING The settings in Table 5 are for the regulator sizing only Final settings will have to be adjusted for the particular operating conditions 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 9 Metering natural gas is accomplished by taking a differential pressure across the orifice plate in the p...

Page 16: ...Phoenix FURY Operation and Service Manual 16 Oil Fuel Piping System Illustration 6 Heavy Oil Train ...

Page 17: ...il pressure is achieved See the Individual Burner Performance Data Sheets for the approximate settings 4 Depending on the system design the final pump pressure will have to be adjusted to attain the desired burner output 5 The low oil pressure switch is factory set at 30 PSIG 6 Leak test the piping before start up then check for leaks daily 7 The manual low fire bypass oil control valve is used to...

Page 18: ...l c For better combustion the viscosity can be lower than the 80 SSU maximum which means a higher oil temperature d Never heat the oil above 220º F or 10º F below the vapor point of the fuel whichever is lower e The oil temperature switch must be adjusted to the minimum temperature for good atomization for the particular oil being used f Make sure the fuel is not forming vapor steam pockets in the...

Page 19: ...justing fuel pressure or by restroking the oil valve Refer to individual burner performance sheets See Burner Performance Data Sheets 9 The manual low fire bypass oil control valve is used to set and maintain the low fire oil flow at the burner Refer to individual burner performance sheets See Burner Performance Data Sheets 10 The low oil pressure switch is factory set at 30 PSIG 11 The high oil p...

Page 20: ... off the manual oil ball valve on the burner oil train 3 Allow enough time for the oil in the piping to cool 4 Look at Illustration 8 to determine if the oil atomizing nozzle must be moved in or out to regain the proper adjustment 5 Make a note of the initial position of the oil nozzle 6 Loosen the set screws of the set collars on the mounting plate of the Oil Gun Pilot Assembly 7 Move the nozzle ...

Page 21: ...he burner blower with the four nuts Flame Shape Adjustments 1 The PHOENIX FURY Burner is preset at the factory for the shortest and narrowest flame possible This makes flame adjustment burners virtually obsolete 2 Do not change the spin vanes from the factory settings They are preset at 45 3 The length of the flame must be shorter than the combustion zone in your drum Material that showers through...

Page 22: ...nner Flame Scanner Cooling Air The flame scanner requires cooling air at a constant pressure from the burner blower 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 ...

Page 23: ...arly Maintenance 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 screen It is located at the inlet of the double blocking gas valve Check the oil nozzle for signs of wear Check fuel air piping for leaks and tightness Have combustion quality checked with a combustion analyzer Check the fun...

Page 24: ...nd that there is gas flow See No 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 Flame Relay f Then check the Flame Relay fix or replace as needed Fuel flow too low a Check the ...

Page 25: ... 30 excess air See Burner Performance Data Sheets for settings and confirm with flue gas analysis Limits not complete Pressure switch or limit switch not energized a See the component location drawings for Pressure and Limit Switch location b Check the Fuel Pressure Switch i Is it energized if not repair or replace it ii Is it plugged if it is clean replace it c Check the Limit Switch Too much fue...

Page 26: ...HOENIX FURY SPARE PARTS LIST Domestic Burners Only 120V 60Hz Recommended Spare Parts Table 10 Spare Parts List Table 11 Nozzle 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 Our complete line includes items for many brands and types of plants From liners and bearings to ...

Page 27: ...tation P I drawing which 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 I 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 ...

Page 28: ...l 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 Blowers at Constant Speed 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 ...

Page 29: ...Phoenix FURY Operation and Service Manual 29 Illustration 10a Burner High Altitude Blower Kit Addition Illustration 10b Burner High Altitude Blower Kit Addition ...

Page 30: ...Phoenix FURY Operation and Service Manual 30 Recommended Installation Guide for High Altitude Blower Kit Illustration 11 Burner High Altitude Blower Kit Assembly ...

Page 31: ...Phoenix FURY Operation and Service Manual 31 Illustration 12 Burner High Altitude Blower Kit Assembly Step 1 Remove the Burner inlet plate assembly located above the Oil train assembly ...

Page 32: ...lower Kit Assembly Step 2 Install bolt on cover plates to the back flange of the HA conversion weldment assembly as shown in illustration 13 above Apply RTV liberally around the oil guide pipe traveling through the center of the flange Step 3 Reinstall the burner inlet plate assembly ...

Page 33: ... isolating pads provided by the vendor Step 5 Thru holes Appropriately sized may need to be placed in the existing base frame in order to mount the new blower motor assembly Match drill holes with blower motor frame Step 6 Install the 3 hose onto the booster blower outlet first Finally install the 3 hose onto the blower air inlet Step 7 Make sure all hoses have been tighten in place and are ready ...

Page 34: ...Phoenix FURY Operation and Service Manual 34 Illustration 15 V Belt Tensioning Detail ...