The Algas-SDI Phoenix VH Direct Fired Burner, available in models VH100 and VH200, is a direct-fired nozzle-mix burner designed for industrial applications requiring high-temperature flame. It utilizes ambient combustion air to supply a focused high-temperature flame, offering flexibility with various fuel options. The VH100 model provides 1,000,000 BTU/hr, while the VH150 offers 1,500,000 BTU/hr, and the VH200 delivers 2,000,000 BTU/hr. These burners are suitable for use with LPG and Natural Gas, both of which are flammable fuels, necessitating strict adherence to safety protocols during operation and maintenance.
Key Components:
The burner assembly comprises several essential parts:
- Burner Body: The main structural component.
- Burner Nozzle: Directs the fuel and air mixture for combustion.
- Burner Rear Cover: Protects internal components and can be rotated for desired positioning.
- Combustor: Where the fuel and air mixture ignites and burns.
- Fuel Inlet Block: Manages fuel entry into the burner.
- Air Inlet Block: Controls combustion air entry.
- Igniter: Initiates the flame.
- Flame Supervision: Monitors the presence and stability of the flame.
- O-rings: Provide seals between components.
- Orifice Plates: Regulate flow rates.
The design utilizes a nozzle mix, where fuel enters through the center of the body, and air enters through holes in the nozzle, with combustion occurring within the nozzle and combustor.
Installation and Handling:
Proper handling and installation are crucial for the burner's performance and longevity.
- Handling: The burner should be protected from weather, dirt, moisture, and excessive temperatures. Care must be taken to avoid dropping or damaging the unit.
- Storage: Store the burner in a cool, clean, dry room, ensuring it is free of damage. If possible, keep it in its original packaging.
- Intake: To ensure adequate fresh combustion air, provide an opening in the room of at least one square inch per 4,000 BTU/hr. In environments with corrosive fumes, supply clear air from an uncontaminated area or use a filtering system that does not impede burner operation.
- Exhaust: Implement means for exhausting combustion products from the furnace and building to prevent accumulation in the work area.
- Access: Install the burner in a location that allows easy access for inspection and maintenance.
- Environment: Verify that the local environment matches the burner's operating specifications, considering fuel type and supply pressure, fresh and clean combustion air availability, humidity, altitude, temperature, and absence of damaging corrosive fumes or materials.
- Rear Cover Rotation (Optional): The rear cover can be rotated to a desired position. This involves disconnecting fuel piping, removing bolts from the fuel inlet and rear cover, rotating the cover, and then reassembling, ensuring O-rings are undamaged.
- Flame Supervision Installation: Install the flame supervision into the ½" NPT opening in the rear cover, verifying the connection to the burner's flame supervision circuit. Both UV scanner and flame rod supervision options are available, depending on the Phoenix VH specification sheet. A 7000-volt ignition transformer is required for the igniter.
- Igniter Installation: Verify the gap between the center electrode and grounding rod is between 1.5mm and 2.0mm. Install the igniter into the opening opposite the flame supervision in the rear cover. Avoid applying grease to the spark plug threads, as this can lead to a weak spark.
- Burner Installation: The wall of the chamber must be strong enough to support the burner's weight. Refractory furnace walls must allow for thermal expansion, and the combustor or burner block should move as a unit in the event of unequal expansion. The combustor should not extend beyond 1" inside the furnace wall. If the combustor is shorter than the furnace wall thickness, it should be recessed into the wall, and a 45° chamfer applied to prevent refractory overheating.
- Alloy Combustor: Verify the gasket is installed between the burner and chamber wall and is not leaking. Check the clearance between the furnace wall and combustor; if the gap around the firing tube and furnace chamber is larger than ½", pack the gap with ceramic fiber.
Checklist After Installation:
Before startup, verify:
- No leaks in gas and air lines.
- All components of the flame monitoring control system are properly installed.
- All switches are installed in correct locations, and all wiring, pressure, and impulse lines are properly connected.
- Spark ignition system components are installed and functioning.
- The blower rotates in the correct direction; if not, a qualified electrician must rewire it.
- All valves are installed in the proper location and oriented correctly relative to gas or air flow direction.
Operation:
- Initial Setup: Fully open the main air valve and start the combustion air supply. Adjust the control valve in the air supply line to achieve the specified air differential pressure between taps A and B for high fire. Ignite the burner according to instructions for fixed air or on-ratio gas systems, using taps C and D to set gas flow at high fire. Confirm flame safety systems are functional.
- Fixed Air Systems (Air Flow): Open pressure taps A and B, attach a manometer, and adjust the air valve until the differential pressure matches the Phoenix VH specification sheet.
- Fixed Air Systems (Gas Flow): Turn gas valves to low fire, start ignition, and visually confirm flame. Open pressure taps C and D, attach a manometer, turn gas valve to high fire, and adjust until differential pressure matches the specification sheet.
- On-ratio Gas Systems (Air Flow): Adjust air valve to low fire. Open pressure taps A and B, attach a manometer, and adjust the air valve until differential pressure is approximately 0.2" WC.
- On-ratio Gas Systems (Gas Flow): Turn the gas flow limiting valve to 50% open, open the gas shut-off valve, and start ignition. Visually confirm flame. Turn air valve to high fire, confirm air differential pressure is at the set point, and adjust. Open pressure taps C and D, attach a manometer, and adjust the gas valve until differential pressure matches the specification sheet. Do not exceed the pressure rating of the ratio regulator. Adjust the ratio regulator for lowest fire while maintaining flame signal. Run the burner through a low fire to high fire to low fire cycle and confirm settings.
- Manual Startup Guide: Start combustion air supply, open gas shut-off valve, and start ignition. Visually check for flame. If no flame, close the gas valve, allow flame safety to purge, and then restart.
- Manual Shutdown Guide: Close the gas shut-off valve. Allow air supply to run until chamber temperature is below 1000 °F, then shut off combustion air supply.
Maintenance:
Preventative maintenance is key to a reliable, safe, and efficient system. Regular monthly and annual checks are recommended.
- Monthly Checklist (Optional):
- Leak test safety shut-off valves for tightness.
- Test air pressure switch settings by checking switch movements against pressure settings and actual impulse pressure.
- Visually check ignition cable and connectors.
- Inspect impulse piping for leaks.
- Clean and inspect burners.
- Verify that the following components are not damaged or distorted: burner nozzle, igniter, flame supervision, combustor, and orifice plates (clean if applicable).
- Annual Checklist:
- Inspect flame supervision devices for good condition and cleanliness.
- Check for proper inlet air/gas ratios.
- Test all alarm systems for proper signals.
- Check igniters for proper 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 by manually failing each interlock and noting equipment response.
- Test the flame monitoring control system by manually shutting off gas to the burner.
- Test main fuel hand-valves for operation.
- Clean or replace the combustion air blower filter.
Troubleshooting:
The manual provides a comprehensive troubleshooting guide for common issues:
- Start-up sequence runs but burner does not light: Possible causes include malfunction of flame monitoring control system, electrical noise, incomplete flame safety purge, power off, no power to control unit, not enough gas/air, gas solenoid valve not open, low gas pressure, or improper gas train valve sequence. Solutions involve checking electrical connections, power supply, gas/air flow, solenoid valve, and adjusting gas pressure.
- No ignition (igniter related): The igniter may not be correctly grounded, fouled, or there might be an open circuit between the ignition transformer and igniter. Solutions include cleaning/repairing the igniter and checking connections.
- Weak or unstable low fire flame: Could be due to low fire adjusted too low, not enough gas, or not enough air. Solutions involve increasing low fire gas setting and checking air/gas plumbing and controls.
- Burner turns off when cycling to high fire: Often caused by a fuel-rich mixture. Solutions include checking air plumbing, controls, and valves.
- Burner unstable or produces soot/smoke: Indicates an incorrect air/gas ratio. Solutions involve measuring and comparing gas/air pressures to initial start-up settings.
- Burner not performing as specified or not responding to adjustment: May be due to a weak flame signal, internal damage, or loose/dirty parts. Solutions include checking the flame monitoring device or contacting Algas-SDI.
- Cannot achieve full burner capacity: Possible causes include a blocked air filter, increased furnace chamber pressures, or low gas pressure into the main gas pressure regulator. Solutions involve cleaning/replacing the air filter, re-checking setup pressures, and adjusting gas pressure.
Spare Parts:
The manual includes a detailed spare parts list for models VH100, VH150, and VH200, covering components such as combustors (alloy, high/medium velocity), nozzle (cast iron), igniter, flame rod, O-ring, nozzle set screw, and mounting gasket. Each item is listed with its quantity and corresponding part number for each model.
To Next Page
Need help?
General