operation and service manual operation and service
Contents
1. 28 Recommended Spare Parts asso 30 MAIC Val es spare Parte E se Sus D DISC OPE DUNS 30 Table 12 Nozzle Spare Parts 30 Detailed Burner Performance Shieets eee eee ee eee eee eee eee 31 Altitude Correction CUP ver 32 WHISPER JET Operation and Service Manual Introduction 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 Whisper Jet safety device can cause an explosion serious injury o2. SSS ts 4 MAN X 2222 MN METAL FLEX LINE ee AR E lt lt Tr BURNER GAS INLET 7 T 10 MAIN PIPE CONTROL DIAMETERS REGULATOR PILOT LINE i FROM GAS SUPPLY Illustration 5 Regulator Requirements 6 The gas valve linkage must be adjusted for proper flow control 7 See individual burner performance sheets for air and gas flows See Detailed Burner Performance Sheets 8 Use the utmost care in making any adjustment to prevent an unsafe condition WARNING e The settings in Table 5 are for the initial set up only e Final settings will have to be adjusted for the particular operating conditions 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 pre piped gas train e The gas flows are shown in the Detailed Burner Performance Sheets e To find the actual gas flow take the square root of the measured differential pressure then multiply it by the flow shown in Table 6 For example with 3 WC differential pressure on the WJ 100 Gas Flow 3 times 30 000 52 000 SCFH Standard Cubic Feet per Hour 17 WHISPER JET Operation and Service Manual
3. Y STRAINER SWITCH SOLENOID VALVE e 9 ale AIR INLET T L BEM ni B gt BALL VALVE CJ Li O AIR PRESSURE SUB FREEZING SWITCH FUEL ATOMIZER ONLY WITH SUB FREEZING OPTION COOLING AIR SOLENOID FOR GAS AND OIL BURNERS METAL FLEX HOSE LOW LOW PRESSURE dd 35 BUSH PRESSURE Jio Y STRAINER SWITCH SOLENOID EN VALVE 0 181 AIR INLET il i JE 28 8 BALL VALVE O CHR AIR PRESSURE SUB FREEZING SWITCH REGULATOR ONLY WITH SUB FREEZING OPTION FOR OIL ONLY BURNERS Illustration 9 Typical Compressed Air Train WARNING e Lock out power prior to working on high pressure piping e Relieve pressure in the piping in the valves and solenoids prior to working on the piping e Remember that dangerous air pressure can also be trapped between valves or controllers Flame Shape Adjustments 1 The WHISPER JET 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 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
4. 2 Carefully examine all of the equipment assemblies and subassemblies to check if there has been any damage in shipment 3 If there are any damaged or missing parts contact ASTEC Burner Systems Group for assistance 423 867 4210 or FAX 423 827 1560 NOTE 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 SEN AIR AIR BURNER NATURAL MAXIMUM MODEL FLOW FLOW BLOWER GAS CAPACITY SCFH SCFM HP SCFH BTU HOUR 660 000 1190 55000 65 55 000 000 W J 150 1 900 000 33 000 165 000 165 000 000 Table 1 Burner Capacities Notes For Table 1 1 The maximum BTU hour rating is based on 20 excess air 2 he figures used in Table 1 are based on 60Hz AC and Standard Cubic Feet per Hour SCFH at 70 air temperature at sea level 3 Correction factors must be applied for altitude or temperature variations See Altitude Correction Chart 4 Viscosity of the oil delivered to the burner at 220 F must be 80 SSU maximum or lower 5 During oil firing the air to atomize the fuel is provided by compressed air 6 The system exhaust fan must have enough capacity to provide a slight negative pressure 0 20 to 0 30 water column at the bu
5. ASTEC Parts Department has one of the largest spare parts inventories for hot mix asphalt plants in the world A new warehouse and shipping facility has expanded the capabilities of this facility even further Ten in house parts technicians take your calls and make sure you get the part you need when you need it If you need next day delivery we will put that part on a plane and get it to you If you need a Field service Technician to come install it we will send one The ASTEC Parts Department runs two shifts daily from 7 00 am to 12 00 midnight Eastern Standard Time After 12 midnight and on weekends our phones are forwarded to an answering service that will have the Astec Parts Technician on call contact you right away 30 WHISPER JET 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 2 3 The burner general arrangement which will have the dimensions and overall weight of the burner The burner specification plaque It will have the maximum firing rate fuel pressures and flow rates listed The piping and instrumentation 8 1 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 stainless
6. Check the fuel specifications to check the vapor point of the fuel d For better combustion the viscosity can be lower than the 80 SSU maximum which means a higher oil temperature Never heat the oil above 220 F or 10 F below the vapor point of the fuel whichever is lower The oil temperature switch must be adjusted to the minimum temperature for good atomization for the particular oil being used Make sure the fuel is not forming vapor steam pockets in the oil lines These vapor pockets can cause the pump to cavitate causing damage to tt Vapor pockets can also interrupt fuel flow causing the burner to falter They can even cause pipes to burst causing damage and possible injury t m o vg 20 WHISPER JET Operation and Service Manual k Set the oil heater temperature regulator and the indicating low oil temperature switch located the burner s oil manifold to the temperature determined in item 2b above 1 This will prevent the burner from operating when the oil is too thick to be atomized and burn well and will prevent damage to your plant Purge the lines before attaching them to the fuel manifold Adjust the pressure relief valve until the required oil pressure is attained See the individual burner performance sheets for approximate valve settings See Burner Performance Data Sheets for proper fuel flows 6 Final pump pressure will have to be adjusted to attain desired burner output depending
7. Illustration 6 Oil Train Heavy 18 Table s Ol Tan S 19 Table 9 Minimum Oil Line Size for various lengths 19 Heavy Oil TTA DANI c 20 Illustration 7 Heavy Oil Piping 20 TES VOICE T E 22 Illustration 6 Nozzle Setttigs sciistici Ee s cue Do cab ee laesit entes uetus 22 23 To Reset the Nozzle Position use the following steps eere 23 To Remove the Oil Gun Assembly use the following steps 24 COImDFOSSeU AU TTO HEC EDU UE MI NM M II IM ND DE 24 Table 10 Recommended field pipe size for compressed air at various lengths tasers 24 Illustration 9 Typical Compressed Air 22 Llame Shape AUS NCIS pU Lee cm IMP 25 FAME S se 26 Illustration 10 Flame Scanner and Cooling Air 26 nsu UV COO 26 Maintenance amp Trouble Shooting Guide cccccccccccscssssssssssssssccccccccccccccccccccccccsssssssessesseeeeeeeeees 27 Maintenance Schedule 27 WE OUDIC SHOO UN
8. causing poor Poor quality oil Pressure switch or limit switch not energized Too much fuel at low fire Incorrect flighting in the drum Oil not atomizing correctly Oil atomizer in incorrect position oolution a The viscosity of the oil must be no higher than 80 SSU Saybolt Seconds Universal b Use a Viscometer to determine the proper oil temperature to achieve this viscosity NOTE Every shipment of oil must be individually tested c Check the fuel specifications to verify the vapor point of the fuel d For better combustion the viscosity can be lower than 80 SSU which means a higher oil temperature is required atomization e Never heat the oil above 10 deg F below the vapor point of the fuel f Make sure the fuel Is not forming vapor steam pockets in the oil lines NOTE The fuel pressure will become erratic if the lines are vapor locked or pressure is building g Check the Nozzle Atomizer to see if it is dirty h Check the Filters and Strainers to see if they are partially blocked i Check the atomizing air pressure to see if it is erratic Pull out the Burner Nozzle arid clean it dirty a Some recycled oil contains non flammable fluids Hydraulic fluid for example will not burn well or at all b Replace the oil and purge the fuel lines Too much fuel To get the best emissions and fuel economy the burner should be set up with or too little 10 to 3096 excess air See Burner Perform
9. on system design 7 High fire oil flow can be set by adjusting fuel pressure or by restroking the oil valve Refer to individual burner performance sheets See Burner Performance Data Sheets 8 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 9 The low oil pressure switch is factory set at 30 PSIG Set according to local code requirements AA WARNING These settings are for the initial set up only e Final settings will have to be adjusted for the particular operating conditions sure not to have more fuel flow than there is combustion air available or puffing and a dangerously rich firing condition could occur 21 WHISPER JET Operation and Service Manual Fuel Oil Atomizer ALIGN CASTELLATIONS AS SHOWN IN THE PICTURE BURNER B o t wj flo f y s or v SEC ATOMIZINGAIR ATOMIZINGAIR ATIMIZING SECONDARY AIR SECONDARYAIR SEC NUMBER OUTER SEC OUTER OUTER OUTER OUTER STABILIZING furore eine aun soo soc oc Jae we ee ot NOZZLE AIRTUBE CHOKE OUTER DIA INNER DIA RING I D OUTER DIA INNSERDIA RINGI D RINGI D GASPIPES ANGLE ANGLE GAP ELBOW ELBOW NOZZL wao ye rye y geyr gsar guys gpaw ost oe e r yw pm r ye y
10. 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 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 Department or the Astec Burner Systems Group Whenever any replacement parts are needed call Astec Parts Department any time day or night at 1 800 251 6042 31 WHISPER JET 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 8696 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
11. wis ye nup s geyr guie onam gist qos ru gs dne r r a yor om ay sy a sy 1 ee dr fr Illustration Nozzle Settings 22 WHISPER JET Operation and Service Manual H EL FUEL OIL I CC NERCD 5 ie E ry NATURAL GAS gan Illustration 6b Nozzle Settings The position of the fuel oil atomizer in the nozzle affects its ability to atomize the oil The nozzle is preset at the factory as shown in Illustration 8b In case of variation changing the oil atomizer nozzle position is accomplished by the following To Reset the Nozzle Position 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 2 Shut off the manual oil ball valve on the burner oil train If heated heavy oil is being used allow enough time for the oil in the piping to cool 4 Look at Illustration 8b to determine if the oil atomizing nozzle must be moved in or out to regain the proper adjustment Make a note of the initial position of the oil nozzle Loosen the set screws of the set collars on the mounting plate of the Oil Gun Pilot Assembly Move the nozzle pipes in or out to effect the required retraction or extension of the Oil Gun Pilot Assembly 8 Contact ASTEC Burner Syste
12. 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 2 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 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 CUTTY LLL ELE EL IHE ANE LUE E LE ELLE LL TT IHE OLEI LUE E LE EL EHE EL DAL ELE ELLE LL EL LUE E LEE ERU L LS EEUU EL LLL EL A A TTT Altitude ft 32
13. AL COMBUSTION AIR JUNCTION BOX BLOWER MOTOR Illustration 1b Component Identification and Location 9 WHISPER JET Operation and Service Manual lt I AT p NI 4 BLOWER SILENCER NATURAL GAS CONNECTION DRUM SUCTION TUBE NATURAL GAS GAS ORIFICE TRAIN PLATE Illustration Ic Component Identification and Location DRUM SUCTION TUBE SUE BLOWER BODY PRESSURE DUPLICATED ON THE OTHER SIDE OF THE FAN HOUSING 12 ES z NNI 4 b b e t o FLAME SCANNER COOLING AIR TRAIN WO lt r cm 7 NATURAL GAS GAS ORIFICE TRAIN PLATE Illustration Id Component Identification and Location 10 WHISPER JET 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 WHISPER JET Burner under the supervision of the ASTEC Burner Systems Group or ASTEC Service Department NOTE The fuel valves air valves and burner spin vanes are pre set at the factory to simplify burner and process set up However some adjustment or at least verification for operation
14. ASTEC P N Description 1 075050 niter 001001 otor Barber Colman EA57 on two control motor burners and WJ50 lt 063336 Fireye UV Scanner 075699 Low gas air pressure switch 30 i w c 079558 otor Barber Colman 71 on one control motor burners Flame Safeguard Module Fireye YB110UV Pilot Solenoid Valve Switch limit single pole 3SE03 AR1 High Pressure Switch Oil 150 PSI Low Pressure Switch Oil 30 PSI Temperature Switch 100 350 F Heavy Oil Only hermocouple 1 2 NPT 350 1400 F Heavy Oil Only Table 11 Spare Parts List WHISPER JET NOZZLE SPARE PARTS LIST Nozzle Mixer Nozzle Mixer N le B N 07219 Light Oil ASTEC P N ASTEC P N 772 50 WJ 75 WJ 100 WJ 125 WJ 150 Table 12 Nozzle Spare Parts List Burner Model 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 Email parts astecinc com Our complete line includes items for many brands and types of plants From liners and bearings to fabricated assemblies we ve got it all ASTEC Parts Department is the for Barber Greene asphalt plants and is the only OEM for Barber Greene asphalt plant replacement parts We also supply computerized asphalt plant controls customized to your requirements And our engineers are available to assist you with facility upgrade design
15. NATURAL GAS ORIFICE METER SIZE Burner Model WJ 50 WJ 75 WJ 100 W J 125 W J 150 Fiow SCFH natural gas at 1 WC Differential Pressure 15 000 30 000 30 000 30 000 51 000 with 5 PSI static Gas Inlet Gas Inlet Pipe Size Table 6 Natural Gas Orifice Meter Sizes Oil Fuel Piping System FLEXIBLE HOSE THERMOCOUPLE BALL VALVE AW 0 NOZZLE PRESSURE GAUGE HEAT TRACE SWITCH lt FUEL OIL PRESSURE HEAVY OIL ONLY x REGULATOR FLOW METER OIL FLOW TEMPERATURE GAUGE MODULATING VALVE HEAVY OIL ONLY J a gt MODULATING VALVE LIMIT SWITCH TEMPERATURE SWITCH HEAVY OIL ONLY FUEL HIGH Y STRAINER PRESSURE SWITCH BALL VALVE LOW FIRE FUEL FUEL LOW AUTOMATIC SAFETY BYPASS VALVE PRESSURE GAUGE PRESSURE SWITCH SHUTOFF VALVES Illustration 6 Oil Train Heavy Oil Shown 18 p WHISPER JET Operation and Service Manual OIL TRAIN SETTINGS Burner Model W J 50 WJ 75 W J 100 WJ 125 WJ 150 6 5 9 7 12 9 16 1 Capacity 92 PSI 132 PSI 116 PSI 130 PSI Pressure Table 8 Oil Train Settings OIL LINE SIZES DischargeLinein Feet _ Return Line In Feet Return Line In Feet Light Oil Up to 100 SSU Heaw Oil Over 100 SSU Table 9 Minimum Oil Line Size for various lengths For recommended pipe sizes see Table 9 2 Before attaching the fuel lines purge the piping to remove scale dirt and other contaminates that could clog and damage the f
16. WHISPER WHISPER JET Operation and Service Manual WHISPER JET Operation and Service Manual Table of Contents 3 D oduc O 5 Operation and Service 5 5 SCOPE 0f MiS 5 Danger Safety and Warnings ninina 5 DANGER Combustion lt 5 Basic Safety MSUVUCHONS virisi niia aai aii 5 TO RECOGNIZE ED 6 WARNING ore 6 General Burner Information e 6 ReCern iP and 7 POC 7 Tables d Burner Capacities 7 FOr TaD co MID T 7 COmbPUSHOH PRU a seeks cena 2055 038992375 4 7277 MEC 8 Illustration Component Identification and Location 9 Illustration 1b Component Identi
17. act 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 89 Qo w WHISPER JET Operation and Service Manual How to Recognize Shock Shock is caused by a rapid loss of blood pressure the symptoms include 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 Cover the victim with a blanket to maintain body temperature 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 Always lock out power before working on any plant equipment 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 approv
18. ance Data Sheets for settings and confirm with flue gas analysis a See the component location drawings for Pressure and Limit Switch location b Check the Fuel Pressure Switch i ls it energized if not repair or replace it ii Is it plugged if it is clean replace it c Check the Limit Switch a Check the fuel flow at low fire set to recommended flow b Check the fuel pressure set to recommended pressure c Check the Low Atomizing Air Pressure set to recommended pressure Contact the ASTEC Service or Engineering Departments to have ASTEC personnel check the flights Check nozzle for dirt clean if required Check oil viscosity and temperature Check atomizing oil pressure and flow Check the Pintle replace if worn Check to see if the Atomizer Pintle Holding Cup is loose Check the location of the oil nozzle in the burner If the nozzle is location is too far into the burner it could cause oil build up at low fire c Check for oil build up on the burner NOTE This does not occur in normal operation unless the set collars holding it in place loosen which sometimes occurs due to vibration d Reset oil atomizer position to dimensions in Illustration 8 NOTE The oil nozzle is factory set and does not need to be removed during routine maintenance 20 SN WHISPER JET Operation and Service Manual Recommended Spare Parts WHISPER JET SPARE PARTS LIST Domestic Burners Only 120V 60Hz Quantity
19. be less than the 1 0 of the combustion flights 6 Seethe detailed Burner Performance Data Sheets for the flame size and diameter See Burner Performance Data Sheets 25 WHISPER JET Operation and Service Manual Flame Scanner The WHISPER JET is supplied with a Flame Scanner that detects Ultra Violet UV radiation 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 44 aluminum 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 AIR PRESSURE REGULATOR SET TO 25PSIG BALL VALVE COMPRESSED AIR INLET Illustration 10 Flame Scanner and Cooling Air Train Pilot and UV Cooling Air The Pilot and flame scanner require 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 26 SN WHISPER JET Operation and Service Manual Maintenance amp Trouble Shooting Guide The WHISPER JET Talon 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 Cl
20. ding to Recommended Compressed Air Pipe Table 10 These sizes will result in minimum pressure drop for proper oil atomization 4 See drawing for location of inlet pipe 5 The compressed air train includes a manual shutoff valve Y strainer Low compressed air switch pressure regulator pressure gauge compressed air solenoid and a flexible hose See Illustration 9 this is a general arrangement Each burner has its own drawings in the burner junction panel See Burner Performance Data Sheets 6 Adjust the low compressed air pressure switch to just slightly under the recommended air pressure Compressed air pressure is adjusted by the tee handle on top of the pressure regulator 8 Set the compressed air pressure to the pressure recommended See Burner Performance Data Sheets 9 The low low compressed air switch is factory set at 60 PSIG and is not adjustable See Illustration 9 p COMPRESSED AIR PIPE SIZES 100 PSIG Supply Length of Compressed Air Line Air Pressure Burner MEER Pipe Pipe Pipe Pipe Pipe Pipe Air Flow Model SCFM Size Size Size Size Size Size g wo 1 1 P 120 rye ry CUT wes 85 94 v v r 120 Table 10 Recommended field pipe size for compressed air at various lengths 24 WHISPER JET Operation and Service Manual METAL FLEX HOSE n LOW LOW PRESSURE LOW BI SWITCH PRESSURE
21. ean all oil filters and strainers as needed Check oil temperature and viscosity of waste oil It must be less than 80 SSU Check fuel pressure Check atomizing air pressure which should be 65 70PSIG when running Weekly Maintenance e Clean the oil nozzle and atomizer Clean the flame scanner using a soft cloth and Windex Monthly Maintenance e Remove the oil gun assembly from the back of the burner Clean the swirl plate attached to the back of the nozzle body Clean and inspect the igniter plug and igniter wire Inspect the heat tracing Inspect the burner cone for signs of distortion or other heat damage Remove any build up on the burner front 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 screen It is located at the inlet of the double blocking gas valve Clean the compressed air Y strainer Check the oil nozzle for signs of wear Check fuel amp air piping for leaks and tightness Have combustion quality checked with a combustion analyzer Check and lubricate the air damper bearings Check the function of all safety equipment pressure switches limit switches etc to make sure they are all fully operational Maintenance Notes 1 Check and lubricate all points of the valve linkage 2 Mark the linkage so that any slippage will be noticed 3 Dirt can clog the atomizing air noz
22. ed 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 WHISPER JET burner is designed to provide maximum firing capability with minimum noise and pollution With its compact flame shape the Whisper Jet flame provides the ideal means for drying aggregate The flame shape is pre set at the factory for the most efficient profile for your drum and burner configuration The WHISPER JET Burner is a sealed in Combustion System that provides all the necessary combustion air This ensures that the combustion air plus 2096 excess air is available for efficient operation at maximum capacities The Fuel Air ratio is maintained throughout the burner s operating range with either mechanically or electronically linked valves The WHISPER JET will burn all commercial grades of fuel oil and natural gas depending on your configuration The burner provides a nominal 7 1 turndown from its maximum firing rate This provides efficient operation at various production rates most cases the available turndown is much higher WHISPER JET Operation and Service Manual Receiving and Inspection Upon receipt of the Burner 1 Check each item the bill of lading and or invoice to determine that all the equipment that was shipped has been received
23. erously rich firing condition could occur 19 WHISPER JET Operation and Service Manual Heavy Oil Fuel Piping System WARNING Be very careful with Heavy oil Heavy oil has to be heated to lower its viscosity for proper atomization Do not heat the Heavy oil higher that it s vapor point to avoid fire e Contact with the hot oil or piping can cause a severe burns OIL PIPING RETURN OIL PIPING BY PASS TO PUMP HEAVY OIL FUEL TANK FLEX METAL HOSE p OIL PIPING SUPPLY qe BURNER FUEL TRAIN INSULATED SEMANA AND HEAT TRACED BY FLAMETE RELIEF VALVE ONLY IF HEAVY FUEL IS ORDERED gt t C amu TNCS BY PASS USED ONLY ON HEAVY OIL n NEN LIGHT OIL SYSTEMS FUEL OIL PRE HEATER FUEL PUMP TRAINE 2 FUEL OIL PIPING SCHEMATIC PUMP SUCTION TO TANK WATER TRAP TUTTI Illustration 7 Heavy Oil Piping Schematic For recommended pipe size see Table 9 Your burner should fire on all commercially available heavy oils 3 Proper fuel viscosity is required for satisfactory atomization and combustion of heavy oil a The viscosity of the oil must be 80 SSU Saybolt Seconds Universal or lower b Use the included Viscometer ships in 5 gallon bucket with burner or other suitable device to determine the proper oil temperature to achieve this viscosity NOTE Every shipment of oil must be individually tested
24. fication and 9 Illustration Component Identification and Location 10 Illustration Id Component Identification and Location 10 T HE 11 E E E E EA 11 Von 12 BUROL LOSIS OI 12 FITS Graco 2 Pilot SVS E 12 Illustration 3 Typical Pilot Gas 13 Adjustment and Operation of the Pilot ee reeeee nennen nnn 13 pe MiNal iei 14 Natural Gas QI ERI C I5 Illustration 4 Gas Train 15 Table 2 Feed Pipe Size for Gas Runs Over 25 15 Table 3 Feed Pipe Size for Gas Runs 25 Feet or Under 15 Table 4 Recommended Pipe 16 Table Natural Gas Regulators ccionrc us 16 Illustration 5 Regulator 17 Table 6 Natural Gas Orifice Meter 5178 18 3 WHISPER JET Operation and Service Manual WOU MM SNB NUMEN I MM IBN 18
25. hen pulling the assembly backwards 8 Remove the spark plug wire boot then the spark plug can be removed with a standard spark plug socket 13 WHISPER JET Operation and Service Manual The Initial Pilot Adjustment 1 Make sure the spark igniter is connected to the ignition transformer 2 Remove the protective cover on the adjustable pilot gas orifice rotate the adjustment screw clockwise for less gas pressure Turn counter clockwise to increase the gas pressure 3 The initial recommended pressure setting is approximately 1 Water Column for Vaporized Propane 2 Water Column for Natural Gas measured at the test port 4 Atthis rate the pilot should light the main burner easily and deliver a sufficient UV flame signal WARNING The pilot ignition transformer can cause a painful shock use care around the ignition cable e Only leave the pilot gas on for a very short period of time while lighting the burner e f pilot does not light at once shut it off and then purge it before attempting to relight 14 WHISPER JET Operation and Service Manual Natural Gas Fuel Piping System MANUAL MANUAL SHUTOFF VALVE SHUTOFF VALVE WITH LOCK FLOW ORIFICE PLATE LOW GAS PRESSURE SAFETY SWITCH CONTROL y GAS STRAINER BUTTERFLY VALVE BETWEEN FLANGES HIGH GAS PRESSURE M NN AUTOMATIC SAFETY SAFETY SWITCH SHUTOFF VALVES Illustration 4 Gas Train Components 1 Install a controlling gas regulator in
26. is required 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 and the atomizing compressed air pressure at the pressure listed on the Burner Performance Data Sheets 3 Check the linkage settings to make sure they comply with the Burner Performance Data Sheets Adjust them if necessary 4 Check the flue gas readings for O2 and CO On a 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 TO 12 depending on the firing rate 5 Altering the fuel air ratio of the burner requires a qualified burner technician to prevent a dangerous rich condition 6 The best way to alter the fuel air ratio is to change the fuel pressure slightly or if a PLC burner control with two control motors is used either the fuel and air motors can be adjusted If these methods are not satisfactory then slightly adjust the valve settings using the linkage 7 The spin vanes affect the flame shape and mixing They are preset at the factory at an initial adjustment that is optimal for most situations See Flame Shape Adjustments 6 For most drums the spin vanes should not need be adjusted If adjustment is required it must be done by a qualified b
27. k 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 Flame Relay f Then check the Flame Relay fix or replace as needed Main Fuel flow ja Check the linkage fuel pressure and compressed air pressure settings for Burner too low oil fired burner only they may have changed Fuel won t b Check the burner set up sheets for standard settings ignite c Check clean the Strainer and the Y Filters NOTE Be careful when increasing the fuel flow not to make the mixture too rich or the low fire setting could be too high i This adjustment should be done by qualified personnel ii Qualified personnel are those trained by ASTEC Service Department Air Damper Check air pressure at burner downstream of air damper it should be less than set too high 1 w c and air damper should be between 0 and 1 for low fire 28 BN WHISPER JET Operation and Service Manual Trouble Shooting Continued Oil too hot Flame stability problems on heaw oil High Stack emissions Limits not complete High stack temperature Oil Build up on burner causing vapor pockets Or to cold
28. ms Group for any questions about proper positioning 9 Once the proper positioning of the Oil Gun Pilot Assembly is completed a Re tighten the set screws of the set collars on the mounting plate of the Oil Gun Pilot Assembly b Install the Oil Atomizer Assembly in the burner blower with the four nuts oo 23 WHISPER JET Operation and Service Manual To Remove the Oil 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 Shut off the manual oil ball valve on the burner oil train If heated heavy oil is being used allow enough time for the oil in the piping to cool Remove the four nuts holding the Oil Gun Pilot Assembly onto the burner blower Pull out the Oil Gun Pilot Assembly from the burner blower body Make a note of the initial position of the oil nozzle Contact ASTEC Burner Systems Group for any questions about proper positioning Once the proper positioning of the Oil Gun Pilot Assembly is completed a He tighten the set screws of the set collars on the mounting plate of the Oil Gun Pilot Assembly b Install the Oil Atomizer Assembly in the burner blower with the four nuts ep TOO VR W I Compressed Air Train 1 The WHISPER JET uses compressed air for atomizing fuel oil 2 Compressed air is supplied to the inlet of the compressed air train 3 Size compressed air feed line accor
29. ner protects the valves from destructive dirt that could lodge in them b Shutoff valve facilitates servicing of the gas train The Siemens gas valves have an integral strainer at the inlet of the first 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 WJ 50 WJ 75 W J 100 WJ 125 WJ 150 Ae TES 076046 048292 048292 048292 048292 Part Number Table 4 Recommended Pipe Nipple 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 5096 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 W J 50 WJ 75 W J 100 W J 125 WJ 150 Maximum 55 000 82 500 110 000 137 500 165 000 Capacity Cu Ft Hr Cu Ft Hr Cu Ft Hr Cu Ft Hr Cu Ft Hr ioc et 5 1 PSI 6 8 PSI 5 8 PSI 8 5 PSI 6 1 PSI Pressure Gas Inlet 4 Pipe Size Table 5 Natural Gas Regulators 16 WHISPER JET Operation and Service Manual EM v 2 57 ey MANUAL SHUTOFF VALVE SX
30. purge time e The minimum purge time is the time required for four volumes of air to flow through the heating chamber 5 Before light off the combustion air damper must be at the low fire position 6 The low fire combustion air damper limit switch is set to close its contacts at the minimum fire light off position 7 The low fire proof fuel valve limit switch the switch that contacts the fuel valve linkage arm must be closed with the low fire combustion air switch for the light off sequence to begin WHISPER JET Operation and Service Manual BLOWER COMBUSTION AIR SILENCER MODULATING ACTUATOR AIR PURGE PRESSURE SWITCH OIL SAFETY TRAIN SALVES DRUM NOISE TRAIN VALVES REDUCTION SEAL RUBBER SKIRT DU fecun are Ji BURNER PILOT DRUM SUCTION Psy PIPE FUEL OIL TRAIN INLET FUEL OIL ATOMIZATION ELECTRICAL NOZZLE JUNCTION BOX HEAT SEAL RING BURNER BODY E PRESSURE TAP COMBUSTION AIR GAS MANIFOLD BLOWER MOTOR PRESSURE TAP COMBUSTION AIR NATURAL GAS GAS STRAINER DAMPER TRAIN BETWEEN FLANGES Illustration la Component Identification and Location FUEL OIL MODULATING ACTUATOR BLOWER SILENCER PILOT GAS TRAIN ex n od Se a BURNER BODY COMPRESSED AIR J Sg 7 PRESSURE TRAIN _ i REMOVABLE pot CABLE HANGER ATN fod es MAIN GAS TRAIN INLET ELECTRIC
31. r 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 and 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 Whisper Jet 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 Cont
32. rner breech plate This will exhaust the products of combustion and prevent puffing at the breeching plate 7 The air flow in the WHISPER JET can be monitored using the pressure tap in front of the damper The body pressure for a given flow is in the individual burner capacity tables 8 Gas burners are supplied with a metering orifice plate This creates a differential pressure at a given flow rate measured in inches of water column with a differential pressure gauge or manometer 9 The values of differential pressure versus flow are listed in the individual burner capacity sheets See Detailed Burner Performance Sheets WHISPER JET 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 comb
33. s a constant air pressure The adjustment and operation of the pilot system is detailed below TERMINAL INSIDE IGNITER BOOT KEY STOCK PILOT AIR TUBE IGNITER WIRE FUEL PIPE PILOT NOZZLE ASSEMBLY Illustration 2 Pilot System 12 WHISPER JET Operation and Service Manual SOLENOID VALV Illustration 3 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 causing either an explosion or fire in the burner 2 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 4 Purge the fuel piping of any contaminates before connecting it to the pilot assembly 5 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 6 Gas pressures at the inlet of the gas pilot manifold can range from 2 to 40 psig 7 The entire pilot oil gun assembly can be removed from the burner by removing the bolts on flange at the back of the burner t
34. 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 4 8 5is the nominal expected gas pressure required at the burner Consult the burner profile sheet found in the burner junction panel 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 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 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 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 Burner Model Pipe Size Table 5 Feed Pipe Size for Gas Runs 25 Feet or Under 15 WHISPER JET Operation and Service Manual 4 The supplied manual shutoff valve must be installed upstream of the gas control regulator a strai
35. uel system 3 Adjust the pressure control valve until the required oil 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 Thelow oil pressure switch should be set about 10 PSIG lower than the actual pressure required 7 Leak test the piping before start up then check for leaks daily 8 The manual low fire bypass oil control valve is used to set and maintain the low fire oil flow at the burner See the Individual Burner Performance Data Sheets for the low fire oil setting 9 The burner oil flow metering control valve range is usually set from position O to Position 12 10 The high fire oil flow can be set by varying the fuel pressure or by changing the valve profile in the control system See the Individual Burner Performance Data Sheets for proper fuel flows 11 Oil flow rates can be checked with the inline oil flow meter in the fuel control valve train 12 Oil flow rates can be confirmed using the nozzle pressure and the burner performance data sheet WARNING The settings are for the initial set up only e Final settings will have to be adjusted for the particular operating conditions e sure not to have more fuel flow than there is combustion air available to burn or puffing and a dang
36. urner technician NOTE Take the flue gas measurements during the adjustment process to verify complete combustion Burner Dimensions WHISPER JET dimension drawings are located in the burner junction panel If the drawings cannot be located please contact Astec Burner Group 11 WHISPER JET 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 Department at the time the order is placed 6 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 Burner Pilot System The WHISPER JET 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 i
37. ustion 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 designed for your application Operation 1 The basic model WHISPER JET uses a firing rate control motor mounted to the combustion air damper which is mechanically linked to the fuel valves and air damper 2 he 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 combustion blower pressure switch normally open must be made to prove the blower is operating This pressure switch is usually set at 1 5 w c 5 he combustion air control damper must open to initiate the purge cycle prior to lighting the burner a The safety limit parameters must be satisfied b The purge pressure switch must be tripped for the purge cycle to begin This pressure switch is usually set at 15 w c c The plant flue gas exhaust fan must be confirmed to be running d fan damper must be open enough for the calculated volume of air to flow during the required
38. zle as well as causing burner firing problems it can also waste fuel through poor atomizing 4 To remove and clean the burner oil tube and nozzle assembly use the procedure from Section M 5 Check to make sure the atomizing oil nozzle is at the proper position inside the burner See Illustration 8b 6 Periodically check the functioning of all safety equipment pressure switches limit switches and solenoids to make sure they are not clogged with dirt or in any way inoperative 7 Frequently a weak flame signal is caused by dust on the lens of the flame scanner 27 WHISPER JET Operation and Service Manual Trouble Shooting Trouble Shooting Pilot will No Spark 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 Oil Gun Pilot 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 Gas a Check the LP Tank for fuel level b Check the Cut Off Valve position c Check for LP gas leakage d Check the LP fuel pressure e Verify the Pilot Solenoids are opening and that there is gas flow f Chec
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