whisper jet burner - astecinc.com · whisper jet® burner burners for aggregate drying applications...

WHISPER JET BURNEROPERATION, SERVICE & MAINTENANCE MANUAL

®

®

Requirements for Proper Use and Operation of Equipment

The burner described in this manual should only be operated by qualified personnel. Qualified personnel are those who, based on experience and training, are capable of identifying and avoiding potential risks and hazards when operating this burner.

These instructions are intended to serve as guidelines covering the installation, operation, and maintenance of this burner. 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 the Astec Burner Group for clarification before proceeding.

Proper transportation, storage, installation, assembly, commissioning, operation, and maintenance is required to ensure proper and safe operation of the equipment.

Disclaimer of Liability

The contents of this manual has been reviewed to ensure consistency with the hardware and software described. Since variance cannot be entirely eliminated, we cannot guarantee full consistency. If discrepancies are found within this document, corrections will be included in later editions.

Reporting Errors and Recommending Improvements

You can help improve this publication. If you find any errors, or if you would like to recommend any improvements to the procedures in this publication, please let us know. The preferred method is to email your comments to [email protected].

Astec, Inc.4101 Jerome Avenue

Chattanooga, TN 37407 USAwww.astecinc.com

W H I S P E R J E T ® B U R N E R

V 1.1 2018-04-19Burners for Aggregate Drying Applications

Table of Contents

i

List of Figures ........................................................................iii

List of Tables ..........................................................................iii

How to Use This Manual ................................................. WJ-1

Introduction.....................................................................WJ-1

Warnings, Cautions and Notices ..............................WJ-1

Receiving Equipment ..................................................... WJ-2

Documentation ..............................................................WJ-2

Safety Management ........................................................ WJ-3

Safety Sign Description ...............................................WJ-4

Safety Sign Summary ...................................................WJ-5

Danger Signs .................................................................... WJ-5

Warning Signs .................................................................. WJ-6

Informational Signs ........................................................ WJ-7

Basic Safety Instructions .............................................WJ-8

Confined Spaces/Permit-Required ........................... WJ-8

Lockout/Tagout ............................................................... WJ-8

Personal Protection ........................................................ WJ-9

Personal Safety Precautions ........................................ WJ-9

Burns ..................................................................................WJ-10

Facility Safety ..................................................................WJ-10

General Safety ................................................................WJ-11

Inspections ......................................................................WJ-12

Prepare for Emergencies ............................................WJ-12

Be Aware of Surroundings .........................................WJ-12

Avoid Alcohol and Drugs ...........................................WJ-12

Good Housekeeping ....................................................WJ-12

Operator Safety ..............................................................WJ-13

Electrical Installation .................................................WJ-13

Electrical Systems .......................................................WJ-14

Hydraulic and Pneumatic Systems .......................WJ-14

Welding, Cutting or Grinding .................................WJ-15

Clearing Jammed Material ......................................WJ-16

Hazardous Material ....................................................WJ-16

Flammable Liquids .....................................................WJ-17

Disposal ..........................................................................WJ-17

Hoisting & Handling Safety .....................................WJ-17

General Precautions .....................................................WJ-17

Chains, Wire Rope and Fiber or Synthetic Slings .................................................................................WJ-17

Foreseeable Misuse ....................................................WJ-18

General Burner Information ........................................ WJ-19

Combustion Flighting ...............................................WJ-20

Operation ......................................................................WJ-21

Burner Startup Guide ................................................WJ-24

Burner Front End/Nose ...............................................WJ-24

Fuel Control Valve Setup ............................................WJ-25

An Explanation of the Burner Safety Limits .........WJ-26

Initial Burner Setup .......................................................WJ-27

Adjustments .................................................................WJ-30

Whisper Jet® Burner

V 1.1 2018-04-19Burners for Aggregate Drying Applications ii

Burner Dimensions ....................................................WJ-30

Burner Mounting ........................................................WJ-31

Burner Pilot System ....................................................WJ-31

Adjustment and Operation of the Pilot System ............................................................................WJ-31

The Initial Pilot Adjustment ....................................WJ-32

Natural Gas Fuel Piping System .............................WJ-33

Oil Fuel Piping System ..............................................WJ-36

Heavy Oil Fuel Piping System .................................WJ-38

Liquid Propane Piping System ...............................WJ-40

Front End Configuration ..........................................WJ-42

Resetting the Nozzle Position ...................................WJ-45

Removing the Oil Gun Assembly ............................WJ-45

Compressed Air Train ................................................WJ-46

Setting the Low Pressure Switch ...........................WJ-47

Flame Shape Adjustments ......................................WJ-47

Flame Scanner .............................................................WJ-48

Flame Scanner Cooling Air ......................................WJ-48

Lubrication & Interval Maintenance .......................... WJ-49

Safety Signs .................................................................... WJ-51

Troubleshooting ............................................................ WJ-54

Pilot Will Not Light ......................................................WJ-54

Main Burner Fuel Won't Ignite ...............................WJ-55

Flame Stability Problems on Heavy Oil ...............WJ-55

High Stack Emissions .................................................WJ-55

Limits Not Complete ..................................................WJ-56

High Stack Temperature ...........................................WJ-56

Oil Buildup on the Burner ........................................WJ-56

Weak Flame Signal .....................................................WJ-56

Recommended Spare Parts ......................................... WJ-57

Detailed Burner Performance Data Sheets ............... WJ-58

Altitude Correction Chart ............................................ WJ-59


V 1.1 2018-04-19Burners for Aggregate Drying Applications iii

List of Tables

Table A. Burner Capacity ...........................................................WJ-20

Table B. Natural Gas Regulator Requirements...........................WJ-33

Table C. Feed Pipe Size for Gas Runs over 25 ft ..........................WJ-34

Table D. Feed Pipe Size for Gas Runs 25 ft or Under ...................WJ-34

Table E. Astec Part Numbers for Recommended Flexible Pipe Nipples ...............................................................................WJ-35

Table F. Natural Gas Orifice Meter Size ......................................WJ-35

Table G. Oil Train Settings .........................................................WJ-36

Table H. Minimum Oil Line Sizes for Various Lengths (in) .........WJ-37

Table I. LP Train Settings ...........................................................WJ-40

Table J. LP Pipe Sizes (in) ..........................................................WJ-40

Table K. Front End Settings .......................................................WJ-42

Table L. Recommended Compressed Air Pipe Sizes (in) ............WJ-46

Table M. Lubrication Points–Whisper Jet Burner ......................WJ-49

Table N. Maintenance Schedule–Whisper Jet Burner ...............WJ-50

Table O. Safety Signs–Burner ...................................................WJ-51

Table P. Whisper Jet Burner Spare Parts List ..............................WJ-57

Table Q. Whisper Jet Burner Nozzle Spare Parts List ..................WJ-57

Table R. Blower Factor vs Altitude (Constant Speed*) ...............WJ-59

List of Figures

Figure 1. Astec I.D. plate .............................................................WJ-2

Figure 2. Whisper Jet burner .....................................................WJ-19

Figure 3. Component identification and location ......................WJ-22

Figure 4. Component identification and location ......................WJ-23

Figure 5. Pilot system ...............................................................WJ-32

Figure 6. Typical pilot gas train .................................................WJ-32

Figure 7. Natural gas train components ....................................WJ-33

Figure 8. Regulator requirements .............................................WJ-34

Figure 9. Oil train (heavy oil shown) .........................................WJ-36

Figure 10. Heavy oil piping schematic ......................................WJ-38

Figure 11. Liquid propane piping schematic .............................WJ-40

Figure 12. Front end settings ....................................................WJ-42

Figure 13. Nozzle settings .........................................................WJ-44

Figure 14. Typical compressed air train .....................................WJ-46

Figure 15. Flame scanner and cooling air train .........................WJ-48

Figure 16. Lubrication points for Whisper Jet Burner ................WJ-49

Figure 17. Safety Signs for Up Whisper Jet Burner ....................WJ-52

Figure 18. Safety Signs for Down Whisper Jet Burner ...............WJ-53

WJ-1 of 59



How to Use This Manual

Introduction

This operation, service, and maintenance manual (OSM) is designed to help safely and efficiently operate and maintain burners purchased from ASTEC for aggregate drying applications.

Instructions are included to cover many circumstances. However, it is impossible to address every scenario that may be encountered. If unsure of what to do after reading this OSM, contact a direct supervisor.

These instructions provide the user with a general knowledge of the burner and operating procedures.

The user's best guide will be knowledge of the facility and its operation. In an emergency, a quick instinctive response based on that knowledge is essential.

Warnings, Cautions and Notices

Read all WARNINGS, CAUTIONS, and NOTICES, including the warning summary before performing any procedure. If unfamiliar with the dangers associated with the type of hazard identified by a signal word, reference Safety Signs for the description of the warning.

WJ-2 of 59



Upon receipt of the burner:

1. Check each item on the bill of lading and/or invoice to determine that all the equipment that was shipped has been received.

2. Carefully examine all the equipment, assemblies and subassemblies to check if there has been any damage in shipment.

If there are any damaged or missing parts, contact the Astec Burner Service Department for assistance. (CALL 423-867-4210 or FAX 423-867-9761)

If the installation is delayed and the equipment is to be stored outside, provide adequate protection as dictated by climate and the period of exposure. Special care should be given to all motors, hydraulics, electrical parts and bearings to protect them from rain, snow or excessive moisture.

Documentation

To ensure accuracy when ordering parts or requesting service information, always refer to the facility serial number and model number.

The serial number is on the I.D. tag. (See Figure 1.) Keep these numbers at hand for easy reference and identification.

Figure 1. Astec I.D. plate

BURNER MODEL - WJ- XXXXXXXXXXXXXXXXXXXJOB# - XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXPLANT VOLTAGE - XXXXXXXXXXXXXXXXXXXXX CONTROL VOLTAGE - XXXXXXXXXXXXXXXXXXX FUELS - XXXXXXXXXXXXXXXXXXXXXXXXXXXXXFUEL THROUGHPUT - XXXXXXXXXXXXXXXXXXX DESIGN FUEL HEATING VALUE - XXXXXXXXXXXXBTU RATING - XXXXXXXXXXXXXXXXXXXXXXXXXHP/KW RATING - XXXXXXXXXXXXXXXXXXXXXXXDESIGN ALTITUDE - XXXXXXXXXXXXXXXXXXXXXOIL TRAIN MAX INLET PRESSURE - XXXXXXXXXXOIL NOZZLE PRESSURE MIN - XXXXXXXXXXXXXXOIL NOZZLE PRESSURE MAX - XXXXXXXXXXXXXGAS INLET PRESSURE - XXXXXXXXXXXXXXXXXXGAS MANIFOLD PRESSURE MIN - XXXXXXXXXXXGAS MANIFOLD PRESSURE MAX -XXXXXXXXXXXBUILT TO THE PROVISIONS OF NFPA - 86

THIS EQUIPMENT IS PROTECTED BYONE OR MORE PATENTS.

SEE APPLICABLE PATENTS AThttp://www.astecinc.com/patents/

ASTEC INDUSTRIES INC.4101 JEROME AVE.

CHATTANOOGA, TN 37407USA

SN: XX-XXX-XXXXXX-X-X

Receiving Equipment

WJ-3 of 59



It is the responsibility of the management team to develop a comprehensive safety awareness program.

Ensure that all personnel:

• Receive appropriate safety training as required by regulations.

• Are thoroughly familiar with the equipment and any potential hazards.

• Are trained and demonstrate proficiency in the use of personal protective equipment (PPE) that the employer is required to provide.

• Recognize and understand the meaning of the safety signs on the equipment.

• Follow all maintenance procedures to prevent personal injury and equipment damage.

Replace any missing or damaged safety signs.

Safety Management

Operating this burner outside its design parameters and/or removing, disabling, or bypassing any burner safety device can cause an explosion, serious injury, or death.

WJ-4 of 59



Safety Sign Description

Safety signs used on equipment and in manuals are designed to meet the ANSI Z535 standard. These warnings have three levels of hazard classification by the signal words: DANGER, WARNING and CAUTION.

This is a safety alert symbol. It is used to alert you to potential physical injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

The signal word, DANGER, always appears in white on a safety red background for identification.

Personnel should be trained to recognize the severity and likelihood of serious injury or death indicated by the DANGER signal word. Establish measures for personnel to avoid the hazard indicated.

WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

The signal word, WARNING, always appears in black on a safety orange background for identification.

Personnel should be trained to recognize the severity and likelihood of serious injury or death indicated by the WARNING signal word. Establish measures for personnel to avoid the hazard indicated.

CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury or to caution against unsafe practices.

The signal word, CAUTION, always appears in black with a safety yellow background for identification.

Personnel should be trained to recognize the severity and likelihood of minor or moderate injury indicated by the CAUTION signal word. Establish measures for personnel to avoid the hazard indicated.

NOTICE indicates information that is considered important, but not hazard-related.

The signal word, NOTICE, always appears in white with a safety blue background for identification.

Personnel should be trained to recognize the importance of information indicated by the NOTICE signal word. Establish measures to avoid damage to equipment or property as indicated.

WJ-5 of 59



Safety Sign Summary

Danger Signs

When ordering a new safety sign, provide the part number and the preferred second language, if not Spanish.

Sign Part No./Size/Description

083274

4.75 in × 8.0 in

Lock out power for maintenance or adjustments. Warns to follow lockout/tagout/blocking procedures to relieve or control all potential energy and isolate from any source of electrical energy.

0832984.75 in × 9.0 in

Electrical shock hazard.


0833016.25 in × 7.125 in

0833024.7 in x 9.0 in

Misadjusting this equipment or removing, disabling or bypassing safety devices can cause explosion, serious injury, or death.

WJ-6 of 59



Warning Signs


083276 4.75 in × 8.0 in

083277 6.25 in × 7.125 in

Machine may start without warning. Keep clear of equipment which may automatically start up, causing injury.

083285 4.75 in × 9.0 in

Lock out power before removing access door. Hazard due to coming in contact with moving machinery. Warns to follow lockout/tagout procedures to relieve or control all potential energy and isolate from any source of electrical energy.

083297 4.75 in × 9.0 in

Read and understand operator's manual before operating or servicing this machine.


083311 4.0 in × 6.0 in

Moving machinery: Serious injury or death can result if the blower inlet is accessible. If a blower silencer is not installed, an inlet guard screen must be installed.

083316 4.0 in × 7.25 in

Burner should not be operated on oil in weather below 0 °C (32 °F) ambient. Operating the burner in these conditions can cause equipment damage, explosion, serious injury, or death.

WJ-7 of 59



Informational Signs


083312 4.0 in × 2.0 in

Burner body pressure.

083313 4.0 in × 2.0 in

Blower pressure.

083314 5.0 in × 2.0 in

Gas manifold pressure.

083315 5.0 in × 2.0 in

Gas orifice differential pressure.


098786 5.0 in × 2.0 in

Gas inlet pressure.

074579 4.75 in × 3.5 in

Made in USA.

WJ-8 of 59



Basic Safety Instructions

Failure to observe the precautions contained in this chapter can result in death or serious injury. If you have any questions regarding the safe operation and maintenance of equipment, contact the Astec Burner Group.

Confined Spaces/Permit-Required

DO NOT enter or break the threshold of a confined space without following OSHA confined space procedures. The operator is responsible to determine if the space requires a permit before entry.

A confined space is large enough for a person to enter fully and perform assigned work, but is not designed for continuous occupancy by the person. It also has a limited or restricted means of entry or exit.

A permit-required confined space means a confined space that also has one or more of the following characteristics:

• Contains or has the potential to contain a hazardous atmosphere

• Contains a material with the potential to engulf someone who enters the space

• Has an internal configuration that might cause an entrant to be trapped or asphyxiated by inwardly converging walls or by a floor that slopes downward and tapers to a smaller cross section

• Contains any other recognized serious safety or health hazards

A Permit-Required Confined Space Program protects personnel from the hazards of entry into permit-required confined spaces. It is the responsibility of the management team to establish a Permit Confined Space Entry Program in accordance with prevailing laws and regulations. Refer to 29 CFR 1910.146 at osha.gov for a detailed definition and requirements.

Lockout/Tagout

Lockout/tagout is a means to ensure that personnel are protected from harm due to unexpected energization or startup of equipment, or the release of stored energy.

It is the responsibility of the management team to write a lockout/tagout procedure in accordance with prevailing laws and regulations.

Always lockout power to any facility equipment before working on it.

Equipment that is de-energized can still retain residual energy, or may be susceptible to gravity or other potential energy sources.

WJ-9 of 59



Personal Protection

Personnel must use approved fall protection PPE, restraints and procedures when climbing and working at heights to inspect or maintain equipment.

Always use approved respirators when working in areas or conditions with high concentrations of dust.

Always wear personal protective equipment (PPE) suitable for the job and conditions and where mandatory. Training for the use of these protective items must be provided by the employer prior to using them. PPE may include protective clothing, helmets, goggles, masks, face shields, headsets, earplugs, gloves, respirators, fall protection gear, protective footwear, etc.

PPE must be inspected for damage and expiration before each use. Damaged PPE must be repaired or replaced before use. Expired PPE must be replaced before use.

Observe the following precautions to reduce the risk of serious injury or death when processing and handling material:

• Wear safety glasses or goggles outside of an approved operator’s enclosure. Failure to wear appropriate eye protection can result in permanent eye injuries or loss of sight.

• Wear appropriate ear protection when working within 50 ft of any operating machine and where noise levels are high. Prolonged exposure to high noise levels can cause permanent hearing loss.

• Wear safety boots, protective gloves and a hard hat in most areas of the facility.

• Use an appropriate fall protection device, such as a safety harness and lanyard, in areas that present a danger of falling.

• Other PPE, such as a full face shield or safety harness, may be necessary for a specific job assignment or when required by prevailing laws and regulations.

Personal Safety Precautions

Always keep loose items of clothing, including shirttails and sleeves, and long hair and beards properly confined. Do not wear wristwatches, rings, necklaces or neckties near moving equipment.

Take special care whenever reaching into a large access opening in a piece of equipment. Loss of balance can result in a fall.

Be aware of flammable liquids and other potential fire hazards. Do not smoke when using cleaning solvents.

To avoid back injuries, always use proper lifting techniques to safely lift heavy objects. Lift with legs and keep back straight. Keep the materials or object close to body. Seek assistance if the load cannot be lifted safely by one person.

Do not stand or walk under equipment or components that are being hoisted or suspended. Never allow other personnel to do so.

To avoid engulfment by loose material, never walk on stockpiles or material in the cold feed bins.

WJ-10 of 59



Burns

First Aid at the Accident Site

Do not delay treatment. Immediately cool the affected area of the body with any available clean water that is cooler than body temperature.

1. Options for cooling skin, listed in order of preference:

2. Completely submerge the affected area in cold water for at least 15 minutes.

3. Completely submerge the affected area in cool tap water.

4. Run cool tap water over the affected area. Do not apply ice directly to the affected area.

Severe Burns

IMMEDIATELY contact emergency response for treatment of severe burns including the following:

• Injury to head, face or extremities.

• Injury to a large percentage of skin area.

• Burns involving large quantities of molten asphalt in contact with parts of the body.

How to Recognize Shock

Shock is caused by a rapid loss of blood pressure. Symptoms include:

• A rapid and weak pulse• Rapid breathing• Dizziness, weakness or fainting• Confused thinking or anxiety• The skin becomes cold, sweaty and pale

First Aid for Shock

IMMEDIATELY contact emergency response for help.

While waiting for emergency personnel to respond for proper treatment:

1. Have the person lie down and remain quiet.

2. Elevate the person’s feet to promote blood supply to the head and chest.

3. Cover the person with a blanket to keep the body temperature near 98 °F.

Facility Safety

Failure to observe the precautions contained in this chapter can result in death or serious injury.

Employer’s policy rules and prevailing laws and regulations may take precedence over recommendations and prohibitive statements made herein.

Basic safety rules need to be followed. However, each situation may have a risk that cannot always be covered by simple rules or past experience.

Be familiar with the safety signs on the equipment and the hazards against which they warn.

Follow fire safety standards and procedures in accordance with insurance company requirements and prevailing laws and regulations.

WJ-11 of 59



General Safety

Verify that the equipment is in good operating condition.

Never remove, disable, defeat or bypass any safety feature on the equipment.

Make no modifications to Astec equipment unless approved by the Astec Service Department or the Engineering Department.

Keep away from moving parts (even if they are not in motion) unless they are locked out and rendered inoperative.

Personnel working in situations where equipment cannot be locked out must use extreme caution to avoid contact with energized components and moving machinery.

Always sound startup alarm to alert personnel before starting any equipment.

Be sure all personnel are safely clear before energizing the equipment.

Keep all spectators and unauthorized persons away from the equipment while it is in operation.

Do not allow personnel into areas where material might fall on them, such as under silos, bypass/reject chutes and conveyors.

Stay clear of rotating or moving parts during operation.

Use caution when working near heated equipment. Avoid contact with hot surfaces and materials to reduce risk of burn injury. Allow hot surfaces to adequately cool before servicing equipment.

Follow prevailing laws and regulations for all storing and handling of flammable materials.

Avoid exposure to the release of high-pressure fluids or air. Refer to Hydraulic and Pneumatic Systems for more information.

Ladders meet OSHA requirements; however to ensure safety, advise personnel that only one person should be on a ladder at a time.

Never leave the control center unattended while the facility is in operation.

Any new piece of equipment may contain hazards that are unfamiliar.

Allow only properly authorized and instructed personnel to operate this equipment. Carefully supervise inexperienced operators.

Before assembling, operating, cleaning, lubricating or adjusting machinery, read and understand all procedures contained in the OSM. Verify that all hazard statements contained within the OSM are completely understood.

When a task is unfamiliar, insist on a new maintenance procedure and additional training. The new task may seem similar to others, but there may be hidden hazards not yet encountered.

Follow approved lockout/tagout procedures before working on equipment. Maintain awareness of all known and discovered hazards.

Do not operate the equipment without all guards, access covers, and doors and other safety devices correctly installed and tightly secured.

WJ-12 of 59



Be aware of machinery that could start up without warning and stay clear.

Know where other personnel are located around the facility and be aware of their movement from one area to another.

Avoid Alcohol and Drugs

Avoid alcohol and other drugs that can result in reduced alertness and impaired judgment. Do not operate or work near machinery when under the influence of alcohol or other drugs.

Some prescription and non-prescription medicines can cause drowsiness or other adverse side effects. Do not operate or work near machinery when under the influence of such medications.

Good Housekeeping

Keep designated work areas clean.

Do not store tools or equipment on walkways.

Keep all walkways, platforms, stairs, and ramps free of spilled material and debris. A buildup of material in these areas can cause slips and falls.

If ladders, stairs or walkways are exposed to oil or grease, clean immediately with a solvent. Make repairs as required in these areas to prevent spillage.

Do not allow machinery to become buried under piles of spilled material. This will make the machinery more difficult to inspect and may hide broken welds, loose fasteners and other serious problems that could cause a safety hazard.

Inspections

Conduct routine safety inspections, including a cursory visual inspection.

Prepare for Emergencies

Know proper emergency shutdown procedures for the equipment.

Know where fire extinguishers are kept and how to use them. Verify that the fire extinguishers are properly rated, and that they remain fully charged and ready for use at all times.

Know the procedure for contacting emergency medical personnel. Keep a list of emergency phone numbers handy at all times.

Know where a first aid kit, stretcher, and other emergency supplies are kept. Verify that first aid supplies are properly maintained and ready for use.

Make sure that a clear path to emergency equipment and exits is always maintained. Do not allow equipment, spilled materials or other obstructions to get in the way.

Know how to report accidents. Always report all accidents immediately to the appropriate supervisor.

Be Aware of Surroundings

Use extreme caution to avoid being struck by trucks, loaders, and other vehicles operating at the facility.

Keep a safe distance from equipment when not wearing PPE or when there is a potentially hazardous situation near the equipment.

WJ-13 of 59



Keep areas around control panels and machinery free of spilled material. Free access must be maintained at all times. In the event of an emergency, quick access to controls could prevent injury or death.

Clean up spilled oil immediately to eliminate slipping hazards. If necessary, use an oil-absorbing product.

Always use lockout/tagout to isolate electrical and mechanical hazards before cleaning up a spill.

Operator Safety

Allow only trained and authorized personnel to operate and maintain machinery.

Become familiar with the controls, functions and settings of the burner.

Become familiar with the burner safety signs and the hazards against which they warn.

Check the legibility of all safety signs during routine safety inspections. Order new signs from ASTEC if they become illegible or worn.

Always perform a safety inspection at the beginning of each shift.

Test all warning devices before starting machinery. Never disable or bypass any alarm system or interlock.

Always report any unsafe conditions or defective equipment to the appropriate supervisor.

During initial facility startup, sound pressure levels should be measured near the equipment to determine what level of hearing protection is required.

Wear appropriate ear protection when working within 50 ft of any operating machinery and in other areas where noise levels are high. Prolonged exposure to high noise levels can cause permanent hearing loss.

Before making repairs to the machinery, always clear all material from the feed and discharge devices (feeders, conveyors, chutes, etc.).

Have any defective components or systems properly repaired by a qualified technician before the equipment is started.

Electrical Installation

Allow only trained and licensed electricians to install, troubleshoot and repair electrical equipment. All procedures must be in compliance with prevailing laws and regulations.

When installing any electrical equipment, follow the manufacturer's instruction. Failure to observe this precaution could result in a dangerous electrical shock hazard or death.

1. Verify that all electrical equipment is properly grounded.

2. Verify that all auxiliary control panels and power supply panels can be securely locked out.

3. Verify that all electrical components are located in an area that will be safe from accidental contact during operation

4. Verify that all connections are in accordance with prevailing laws and regulations.

NEVER run computer cables in the same conduit as electrical power cables. This will cause interference with the computer communication cable.

WJ-14 of 59



Incoming power and utility company transformers should be located away from the equipment and vehicle travel ways. Any modifications to these components or to the power supply must be approved in writing by the Astec Engineering Department.

All cabling entering the cabinet shall maintain NEMA Type 3R or IP54 when connected to panel. No cabling shall enter the roof or top of the panel.

Before operation of electrical panel ensure that service ground (PE) has been installed to the panel. Minimum size service ground protective earth (PE) conductor to be determined from Table 250.66 of the US National Electrical Code (NEC), or prevailing laws and regulations.

Ensure that all grounds are connected to service ground PE.

Electrical Systems

Always read, understand and follow appropriate electrical system troubleshooting, maintenance and repair instructions in OSM.

Always assume that an electrical system is live until it has been confirmed de-energized and locked out. Some electrical components may retain stored electrical energy for up to 30 minutes after power is removed. Maintenance and service should be performed by certified electricians.

Always use lockout/tagout and verify the system has been de-energized before servicing an electrical system. Never use safety switches as a method of lockout/tagout.

Repair any obviously worn or damaged wires and connectors.

Inspect power cables and connections routinely for signs of wear, cracked insulation and worn or damaged connectors. Repair or replace as required.

Do not store tools inside electrical cabinets.

Verify that all power tools are grounded with a three-wire plug or double insulated.

Verify that all extension cords are grounded with a three-wire plug.

Do not tamper with machinery alarm components. Never attempt to defeat electrical interlocks or to disable machine protective devices.

Hydraulic and Pneumatic Systems

When servicing equipment actuated by compressed air or hydraulic fluid, all relevant components shall be locked out, including electricity and air/fluid pressure, before any maintenance begins. Always refer to the OEM Manual for proper operating, service and maintenance of the power unit.

Always follow approved lockout/tagout procedures before working on a pressurized system. Never attempt to work on a pressurized system or loosen a fitting while the system is pressurized or operating. Serious injury or death could result.

Hydraulic and pneumatic systems operate at high pressures. Small leaks can cause serious injection injuries to the skin. Always wear eye protection and gloves to prevent injury. Relieve all internal pressure before disconnecting hydraulic and pneumatic lines. Thoroughly tighten all connections before applying pressure. If accidental skin injection occurs, IMMEDIATELY get the person to a Hospital Emergency Room for surgical treatment.

WJ-15 of 59



NEVER place hands on hydraulic or pneumatic cylinder rods while equipment is in operation.

Before loosening any fittings or removing components, always recheck that ALL pressure is relieved from the system, and that gauges indicate zero pressure.

NEVER have your face near, or stand directly in front of a hydraulic line when loosening a fitting, even after system pressure has been relieved. Always assume the line has pressure.

Use a piece of cardboard, not a hand, to check for suspected leaks by passing the cardboard near hoses and fittings. A leak will be detected as it wets, cuts or impacts the cardboard.

Repair any leaks promptly.

Promptly clean up any spills, especially hydraulic oil, to avoid risk of slips and falls.

Relief valves are provided to protect system integrity. Never tamper with relief valves. Replace only with equivalent replacement parts.

Do not operate any hydraulic or pneumatic system with obviously worn, damaged or leaking components. Always replace them immediately.

Before performing repairs on equipment:

5. Wear safety glasses or face shield when working on pressurized systems.

6. Allow time for hot hydraulic oil to cool before performing any maintenance or repairs.

7. Lock out equipment from the source of pressure.

8. De-energize all hydraulic and/or pneumatic pressure supplied to the equipment, including stored energy within the equipment.

• Cycle the controls through all operating positions to relieve any trapped pressure.

• Verify that ALL pressure is relieved from the system. Pressure gauges must read zero pressure.

9. Lock out the power supply to the equipment.

10. Chain or block any item that is subject to shifting during maintenance due to gravity or other forces even if all potential sources of energy have been locked out.

Welding, Cutting or Grinding

No hot work (flame cutting,

welding or grinding) is permitted outside or inside components without appropriate safeguards.

Provide adequate ventilation when welding, cutting or grinding inside enclosed areas to prevent the buildup of hazardous fumes.

Wear the proper welding shield, welding gloves and clothing. Do not wear synthetic fabric or clothing which could be easily ignited by sparks.

Always follow all standard safety procedures when welding. Always lockout/tagout affected equipment and isolate sensitive electrical components before welding. Provide welding screens to protect others working in the area.

DO NOT weld near flammable liquids, hydraulic oils, lubrication oils or grease.

WJ-16 of 59



DO NOT weld lifting eyes or hooks to any components. Always use approved lifting devices and methods. Welds on components made of manganese, cast iron, ductile iron or other alloyed materials may fail when the components are lifted or moved.

Choose a grounding point that prevents damaging electrical power from flowing through bearings and movable or rotating parts, electronic and other sensitive equipment or hydraulic components.

Verify that all compressed gas cylinders are stored upright, chained and capped. Close all cylinder valves when not in use.

Choose a grounding point that prevents damaging electrical power from flowing through bearings and movable or rotating parts, electronic and other sensitive equipment or hydraulic components.

Verify that all compressed gas cylinders are stored upright, chained and capped. Close all cylinder valves when not in use.

Clearing Jammed Material

To avoid death or serious

injury, never attempt to remove jammed material while the machinery is in operation, or while the equipment is energized.

If material becomes jammed in the machinery:

1. Immediately stop the machinery.

2. Lockout/tagout power. Warn others that the machinery is being serviced.

3. Follow instructions in the OSM of affected equipment.

4. Remove all jammed material before restarting the machinery. To prevent damage, never attempt to restart a stalled machine without first removing the jammed material.

Hazardous Material

Be aware of potentially hazardous chemicals or materials. Such items can be harmful if improperly used, stored, mixed or transported, or if inhaled, swallowed or allowed to contact the skin.

Consult your employer’s hazard communications plan for instructions regarding the proper handling and use of hazardous materials. Read and understand the labels attached to the product containers. Always follow the instructions carefully.

Consult the manufacturer's safety data sheet (SDS) for potential hazards and appropriate medical procedures should an accident occur.

Store hazardous materials only in approved containers. Verify that containers are clearly labeled.

To avoid potential health hazards, persons in regular contact with hydraulic oils must be aware of the importance of thorough hygiene, and the proper methods for handling mineral oils.

Always wear suitable protective clothing when handling oil. Verify that protective clothing and proper wash up facilities are available to all personnel that may come in contact with oils.

WJ-17 of 59



Flammable Liquids

Store flammable liquids in a safe place away from machinery and personnel. Use approved safety containers that are clearly marked. Containers must be closed when not in use.

Keep flammable liquids away from sparks, open flame, and other ignition sources. Do not smoke around flammable liquids. Obey posted “no smoking” signs.

Be familiar with the locations of fire extinguishers throughout the facility. They must remain accessible at all times. Verify that they are not blocked by obstructions.

Do not use gasoline or other flammable liquids to clean tools or parts. Use only approved non-flammable solvents.

Disposal

Always dispose of used rags or paper towels in the correct and safe manner.

DO NOT dispose of unused fuels, used lubricating oils, used hydraulic oils and other toxic materials in an unapproved manner. All hydraulics/lubricants must be recycled in accordance with prevailing laws and environmental regulations. Do not dispose by pouring down drain.

All electrical/electronics must be recycled in accordance with prevailing laws and environmental regulations. Do not dispose with the trash.

Metal and other parts of equipment must be recycled in accordance with prevailing laws and environmental regulations.

Hoisting & Handling Safety

General Precautions

Use appropriate marked lift points.

Do not allow personnel to work or walk under suspended loads.

Use appropriate lifting devices to secure the load and use the correct lifting hooks to support the load.

Always include the weight of the hook block, slings, chains, spreader bars and any additional equipment when determining the maximum load that can be safely lifted.

Chains, Wire Rope and Fiber or Synthetic Slings

Chains and wire rope require careful use, handling and maintenance to ensure long life and safe operation.

Always observe the following precautions:

• Use the correct size for the application.• Inspect regularly for wear.• Refer to manufacturer guidelines and

recommendations for replacement.• Maintain an inspection-replacement log.• Avoid sudden or shock loading. Do not

jerk load upright or allow load to fall over because of too much slack.

• Do not use near sharp corners or edges without using suitable padding to protect from damage.

• Avoid dragging chains, ropes or slings under or over obstacles.

WJ-18 of 59



Chains

Always follow proper rigging procedures as provided by the chain manufacturer. The angle of rigging may decrease the rated lifting capacity of the chain.

Wire Ropes

Never use wire rope that is damaged or unsafe, e.g. cut, kinked, frayed, crushed, rusted.

Verify end fittings are properly sized. Use appropriate sized thimbles in the eye fittings at all times. Never attempt to use an undersized thimble in forming a wire rope eye.

Safe Operating Temperatures

Fiber core wire rope slings of all grades shall be permanently removed from service if they are exposed to temperatures in excess of 200 °F.

Non-fiber core wire rope slings of any grade may be used in a temperature range from −60 °F to 400 °F. For operations outside this temperature range, follow OEM recommendations.

Follow OEM instructions for lubrication if using wire rope for lifting purposes.

Fiber or Synthetic Slings

Avoid sudden or shock loading. Do not jerk load upright.

Keep slings clean and free of solvents, oils and grease.

Safe Operating Temperatures

Natural and synthetic fiber rope slings, except for wet, frozen slings, may be used in a temperature range from –30 °F to 180 °F without decreasing the working load limit. For operations outside this temperature range, and for wet, frozen slings, follow the sling OEM recommendations. Wet or frozen slings should never be used until thoroughly dried.

Foreseeable Misuse

Foreseeable misuse of equipment is addressed specifically throughout this manual by means of prohibitive statements wherever appropriate. Employer’s policy rules, prevailing laws and regulations may take precedence over recommendations and prohibitive statements made herein.

WJ-19 of 59



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 burner flame provides the ideal means for drying aggregate. The flame shape is preset 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 20% 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 burner will burn all commercial grades of fuel oil, waste oil, natural gas and liquid propane, 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. In most cases, the available turndown is much higher.

Figure 2. Whisper Jet burner

WJ-20 of 59



Table A. Burner Capacity

BURNER MODEL

AIR FLOW (SCFH)

AIR FLOW (SCFM)

BURNER BLOWER

HP

NATURAL GAS

(SCFH)

OIL FLOW (GPM)

LP FLOW GPM

MAXIMUM CAPACITY

(BTU/HOUR)

WJ-35 467,000 7,783 40 38,500 4.5 7.0 38,400,000

WJ-40 540,000 9,000 50 44,000 5.2 8.0 44,000,000

WJ-50 660,000 11,000 60 55,000 6.5 10.0 55,000,000

WJ-75 990,000 16,500 75 83,000 9.7 15.0 82,500,000

WJ-100 1,320,000 22,000 100 110,000 12.9 20.0 110,000,000

WJ-125 1,650,000 27,500 125 137,000 16.1 25.0 137,500,000

WJ-150 1,900,000 33,000 150 165,000 19.4 30.0 165,000,000Notes:1. The maximum BTU/hour rating is based on 20% excess air.2. The figures used in Table A are based on: 60Hz AC and Standard Cubic Feet per Hour (SCFH) at 70 °F air temperature, at sea level.3. Correction factors must be applied for altitude or temperature variations. (Refer to 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 (0.20–0.30 inWC) at the burner 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 Burner Performance Data Sheets.8. Gas burners are supplied with a metering orifice plate. This creates a differential pressure at a given flow rate measured in inWC with a differential pressure gauge or manometer. The values of differential pressure versus flow are listed in the Burner Performance Data Sheets.

Combustion Flighting

The flight design in the combustion zone of the drum is especially important for minimizing flue gas pollutant emissions. The flights also provide heat shielding for the metal drum skin by preventing the flame from radiating directly onto the drum.

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.

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 to fit inside.

Refer to the Burner Performance Data Sheets for the flame dimensions. Burner Performance Data Sheets are located on the facility flash drive. If the Burner Performance Data Sheets are missing, contact the Astec Burner Group for a copy.

The combustion 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.

The Astec Parts Department can supply combustion flights designed for your application.

WJ-21 of 59



Operation

The basic model Whisper Jet burner uses a firing rate control motor mounted to the combustion air damper, which is mechanically linked to the fuel valves and air damper.

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.

The PLC allows the fuel and air valve to be controlled independently.

A combustion blower pressure switch (normally open) must be made to prove the blower is operating. This pressure switch is usually set at 1.5 inWC.

The combustion air control damper must open to initiate the purge cycle prior to lighting the burner.

1. The safety limit parameters must be satisfied.

2. The combustion air high fire pressure switch (located downstream from the combustion air damper) must be tripped for the purge cycle to begin. This pressure switch is usually set at 15 inWC. (See Figure 3.)

3. The facility flue gas exhaust fan must be confirmed to be running and the fan damper must be open enough for the calculated volume of air to flow during the programmed purge time.

4. The minimum purge time is the time required for four volumes of air to flow through the heating chamber.

Before light-off, the combustion air damper must be at the low-fire position.

5. The low-fire proof combustion air damper limit switch is set to close its contacts at the minimum fire light off position.

6. 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.

WJ-22 of 59



Figure 3. Component identification and location

Combustion Air Blower MotorElectrical

Junction Box

Main Gas Train Inlet

Natural Gas Train

Burner Body Pressure Tap

Low Fire Combustion Air Damper Limit Switch

Gas Butterfly Valve Limit

SwitchRemovable Cable Hanger

Low Combustion Air Pressure

Switch

Air & FuelModulating Actuator

Oil Valve Limit Switch

Compressed Air Train

Pilot Gas Train

Drum Noise Reduction Seal (Rubber Seal)

Blower Silencer

Electrical Junction Box

Combustion Air Damper

Gas StrainerBetween Flanges

Heat Seal Ring

Fuel Oil Atomization

Nozzle

Combustion Air High Fire or Air Purge Pressure Switch

Oil Safety Shutoff Valves

Air & Fuel Modulating

Actuator

Gas Manifold Pressure Tap

Drum Suction

Pipe

Fuel Oil Train Inlet

Burner Pilot

Blower Silencer

Natural Gas Train

WJ-23 of 59



Figure 4. Component identification and location

Drum Suction Tube

Natural Gas TrainGas Orifice Plate

Natural Gas Connection

Flame Scanner

Burner Body Pressure Tap

Flame Scanner Cooling Air Train

Blower Body Pressure (Duplicated on the Other Side of

the Fan Housing)

Blower Silencer

WJ-24 of 59



Burner Startup Guide

Burner Front End/Nose

Check the position of the liquid fuel atomizing nozzle and the castellated ring.

The position of the nozzle and bluff body ring affects the ability of the burner to properly atomize the liquid fuel. The nozzle and bluff body ring position is preset at the factory and should be positioned as shown in the Liquid Fuel Atomizers section of this manual. Note that the nozzle and bluff body positions for the LP arrangement will be different than those for the oil arrangement. This is due to the nature of LP to atomize much differently than oil.

If the oil nozzle has come loose in shipping, correct the nozzle position by the following steps:

1. Make a note of the current orientation of the nozzle in the burner.

2. Determine if the nozzle must be moved in or out to maintain the proper distance.

3. Loosen the setscrews at the back plate of the fuel gun.

4. Push the nozzle pipes in or out to effect the required retraction or extension of the atomizer nozzle

5. Retighten the set screws.

6. Check the piping for leaks.

If the oil guide tube / castellated ring has come loose in shipping; correct the position by the following steps:

1. Make a note of the current orientation of the oil guide tube and bluff body ring in the burner.

2. Remove the hatch on the side of the burner.

3. Determine if the guide tube must be moved in or out to maintain the proper distance.

4. Loosen the setscrews holding the guide tube in place at the air damper.

5. Loosen the U-bolt behind the front-end assembly.

6. Reposition the guide tube using Table K.

7. Tighten the setscrews to hold the position of the guide tube at the damper and the U-bolt.

8. Put the hatch back on.

Check the nozzle to ensure it is free from debris.

Dirt can clog the fuel atomizing nozzle, as well as causing combustion problems, and possibly equipment damage because of poor fuel atomization.

All compressed air and fuel lines should be blown down to remove debris prior to connecting them to the burner.

Note: LP does not require compressed air for atomization.

WJ-25 of 59



To check the nozzle for debris:

1. Make a note of the current positions and orientation of the nozzle, oil guide tube and bluff body ring in the burner.

2. To remove the nozzle from inside the drum, use the provided nozzle tool to disassemble the nozzle. Skip down to step 7.

3. To remove the nozzle from outside, first remove the bolts that secure the atomizing air back plate.

4. Detach the compressed air line and fuel line.

5. Remove the back plate and its attached fuel and air pipes and the atomizing nozzle.

6. Disassemble the nozzle.

7. Clean all the components of any oil or other foreign material that may be plugging the nozzle holes.

8. If used on heavy oil, remove the nozzle and soak it in a good solvent to loosen the oil deposits.

9. If necessary, scrape the nozzle body and holes using wooden tools only, being careful not to damage machined parts.

10. Reassemble the nozzle. Tighten using a torque wrench to 60 ft-lbs.

11. If the fuel gun has been removed, carefully re-insert the nozzle in the primary air tube and attach the burner back plate to the burner body.

12. Reattach the compressed air line, fuel oil line, and pilot fuel line and ignition wire.

Fuel Control Valve Setup

OIL VALVE

1. Ensure that the valve is stroking through the full range of positions listed on the appropriate burner profile sheet (a slight short stroke is common and not necessarily a problem). The valve stroke is factory preset, but it is possible for it to move or come loose during shipping.

2. Check slide-wire calibration to ensure 0%–100% feedback to control system. If the valve is moving through its full stroke but the position feedback is different than 0%–100%, please contact the Astec Service Department for instructions on correcting this problem on your particular burner control.

GAS VALVE

1. Check the position feedback calibration to ensure 0%–100% feedback to control system. If the valve is moving through its full stroke but the position feedback is different than 0%–100%, please contact the Astec Service Department for instructions on correcting this problem on your particular burner control.

2. The gas control valve is not a tight shutoff valve. Typically the valve will have to be opened approximately 10% to achieve minimum fire. The burner has to be set up using the flows and pressures listed in the Burner Performance Data Sheets. The valve positions listed are approximations only.

3. Check the coupling between the actuator and the valve to ensure that no slippage has occurred. Tighten and adjust as necessary.

4. Valve setup is factory preset, but should you need this information, please contact the Astec Service Department for an instructional memo.

WJ-26 of 59



An Explanation of the Burner Safety Limits

COMBUSTION AIR LIMITS

There are two pressure switches connected to the combustion air blower, one on the blower body and one on the transition downstream of the damper. These are the low combustion air pressure switch and the combustion air high-fire pressure switch, respectively. There is also a mechanical position switch on the damper called the damper low fire position switch.

• The low combustion air pressure switch proves that the blower is running. This is a normally open switch, usually set to about 1.5 inWC of pressure. (See Figure 3). This switch must be made before you can purge your system.

• The combustion air high-fire pressure switch proves that the blower has reached its high fire setting. During a purge, the flame safeguard will not proceed until this switch is made. This is a normally open switch and is set to make at about 15 inWC of pressure.

• The damper low-fire position switch is a normally open mechanical position switch. It makes as the burner is driving back to low fire during the purge sequence. Once this switch is made, you are free to light a pilot.

FUEL LIMITS

1. Fuel Oil Limits

• The high oil pressure switch is normally closed and breaks on rising pressure. It prevents burner firing if there is excess fuel oil pressure. This switch is normally set to break at about 150 psig.

• The low oil pressure switch is normally open and makes on rising pressure. It proves that there is adequate oil pressure for ignition. It is normally set at about 30 psig.

• The low oil temperature switch is normally open and makes on rising temperature. It proves adequate fuel preheating for ignition. It should be set at about 10 °F below the temperature of the oil at a viscosity of 80 SSU. This switch is only present on burner set up for heavy/recycled fuel oil.

• The oil safety shutoff valve proof of closure switch is a mechanical position switch. There are two of them and they are internal to the safety shutoff valves. They make when the valves are in the closed position, which is required to begin the pre-ignition purge sequence.

• The oil control valve proof of low fire switch is a mechanical position switch wired normally open. It makes when the fuel oil flow control valve is in the low fire position, which is required to ignite the burner.

2. Liquid Propane (LP) Limits

• The high LP pressure switch is normally closed and breaks on rising pressure. It prevents burner firing if there is excess LP pressure. This switch is normally set to break at about 10% higher than the burner running pressure.

• The low LP pressure switch is normally open and makes on rising pressure. It proves that there is adequate LP pressure for ignition. It is normally set at about 25% lower than the burner running pressure.

• The LP control valve proof of low fire switch is a mechanical position switch wired normally open. It makes when the LP flow control valve is in the low fire position, which is required to ignite the burner.

WJ-27 of 59



3. Natural Gas Limits

• The high gas pressure switch is normally closed and breaks on rising pressure. It prevents burner firing if there is excess fuel gas pressure. This switch is normally set to about 25% higher than the burner running pressure.

• The low gas pressure switch is normally open and makes on rising pressure. It proves that there is adequate gas pressure for ignition. It is normally set at about 1 psig.

• The gas safety shutoff valve proof of closure switch is a mechanical position switch. There are two of them and they are internal to the safety shutoff valves. They make when the valves are in the closed position, which is required to begin the pre-ignition purge sequence.

• The gas control valve proof of low fire switch is a mechanical position switch wired normally open. It is external to the gas flow control valve and is actuated by the linkage arm. It makes when the fuel gas flow control valve is in the low fire position, which is required to ignite the burner.

ATOMIZING AIR LIMITS

1. The low atomizing air pressure switch is upstream of the atomizing air regulator. It is a normally open switch and makes on rising pressure. It proves that adequate atomizing air pressure is available to attempt the ignition of liquid fuels which require atomization. (LP does not.) This switch should be set about 5–10 psig higher than the required atomizing air pressure downstream of the regulator. Refer to the Burner Performance Data Sheets to determine the proper atomizing air pressure for a particular burner.

2. The low low atomizing air pressure switch is downstream of the atomizing air solenoid valve. It is a normally open switch and makes on rising pressure. It proves that adequate atomizing air pressure is available to continue firing. The control system bypasses this switch during the ignition sequence. It comes into play a few seconds after the flame safeguard releases control of the main flame to the burner control. This switch is non-adjustable and is set at 60 psig.

Initial Burner Setup

You must have at least one manometer in order to properly set up any burner. If you do not have a manometer, please contact the Astec Parts Department and purchase part #037358.

COMBUSTION AIR

1. Make sure the damper is stroking through the entire correct range.

• This should be preset at the factory. It is noted on the Burner Performance Data Sheets as “Damper Position.” The range of movement may vary with burner size and is not necessarily the entire stroke that is possible.

• If the range of movement needs to be altered, change only the linkage at the damper actuator. Do not change the linkage between the blades.

2. Make sure all the damper blades are closed when the damper is in the closed position. If they are open even a little, it can interfere with the ability to light the burner.

• When the damper is in the closed position, all of the blades should be resting against their internal stops. It is possible for one or more of them to become misadjusted.

WJ-28 of 59



• There are visual indicators in the form of lines on the end of each damper shaft that show the relative position of the blades. In the closed position these should be close to vertical.

• Check the pressure. There is a pressure tap on the burner body, downstream of the damper. With the blower running, check the pressure with your manometer. It should closely match the Burner Body Pressure at 0% burner output when the damper is shut properly.

• If any damper blade(s) are more open than intended, it will result in a higher pressure and possible difficulty lighting off. If they are found open, adjust them and recheck the pressure.

ATOMIZING AIR

Compressed air for fuel atomization is required for fuel oils, but not LP.

1. With the burner off, set the pressure downstream of the regulator to that listed under “Compressed Air Pressure.” This is close to the correct setting, but will need to be increased later.

2. The air pressure will drop once the burner is lit. Increase it back to the proper setting while running at low fire (0% burner output).

ALL FUEL OILS

1. Make sure the oil control valve is stroking through the entire correct range.

• This should be preset at the factory. This is noted on the Burner Performance Data Sheets as Oil Control Valve Position. The proper range of movement may vary with burner size, and is not necessarily the entire stroke that is possible.

2. Set the fuel oil pressure.

• The fuel pressure is regulated using the ful-flo oil pressure regulating valve, and the pressure gauge located near the inlet of the fuel train.

• The proper initial pressure is listed under Oil Pressure at Train Inlet at 0% burner output. This pressure setting may be changed in a later step as the burner is tuned.

• The final pressure should be set as near high fire as possible. With the control valve in the high fire position, set the fuel flow to the correct amount using the fuel pressure gauge. This should be only a minor adjustment at this point.

HEAVY/RECYCLED OIL

In addition to the above steps, it is also necessary to make sure that the oil is preheated properly to achieve the correct viscosity for proper atomization.

Astec burners are designed to use oil at 80 SSU or lower.

Use a handheld viscometer to test the viscosity of the oil and determine the proper temperature setting for the preheater. For a viscometer, obtain Astec part #004404.

1. To measure viscosity, fill viscometer by dipping it in heated oil, removing it, and measuring time required for cup to empty.

2. Start time as soon as cup is removed and stop time when the oil stream breaks from solid to a drip. If this time is more than 80 seconds, the temperature of the oil must be increased.

Note: The temperature required to achieve the proper viscosity can change from one load to the next.

WJ-29 of 59



NATURAL GAS

1. Make sure the gas control valve is stroking through the entire correct range.

• This should be preset at the factory. This is noted on the Burner Performance Data Sheets as Gas Mod Valve Position. The proper range of movement may vary with burner size and is not necessarily the entire stroke that is possible.

2. Set the initial gas pressure.

• The fuel pressure is regulated using the main fuel regulator. This is normally a customer-supplied regulator and therefore its model and size may vary.

• The proper initial pressure is listed under Gas Pressure In Train at 0% burner output. This pressure should be set with the burner running at low fire.

• The final pressure should be set as near high fire as possible. With the control valve in the high fire position, set the fuel flow to the correct amount using a fuel pressure gauge. This gage should be only a minor adjustment at this point.

LIQUID PROPANE (LP)

1. Make sure the LP control valve is stroking through the entire correct range.

• This should be preset at the factory. This is noted on the Burner Performance Data Sheets as LP Control Valve Position. The proper range of movement may vary with burner size and is not necessarily the entire stroke that is possible.

2. Set the initial LP pressure.

• The fuel pressure is regulated using the main fuel regulator. This is normally located near the LP pump. It’s model and size may vary.

• The proper initial pressure is listed under LP Pressure at inlet to LP Train at 0% burner output.

• This can be set initially with the burner off, but should be reset later with the burner running at low fire.

• The final pressure should be set as near high fire as possible. With the control valve in the high fire position, set the fuel flow to the correct amount using the fuel pressure. This should be only a minor adjustment at this point.

The Burner Performance Data Sheets should be considered a starting point. Correct burner setup depends on many conditions that are specific to a particular facility and location. Final tuning and setup must be performed by a trained professional using a flue gas analyzer.

Once final setup has been completed, print the burner profile from the burner control. Store one copy on site and another copy off site. Please fax a copy to Astec Service Department at 423-867-9761 and we will be happy to put it in the burner service file as well. Please include your facility number, a contact name and contact phone number.

WJ-30 of 59



Adjustments

Because all combustion systems are inherently dangerous, only qualified and experienced personnel should attempt to start-up and adjust Astec burner systems.

Qualified personnel are defined as those trained by the Astec Burner Service Department.

Experienced personnel are defined as those who have previously fired an Astec Whisper Jet burner, or are under the supervision of the Astec Burner Service Department. The fuel valves, air valves and burner spin vanes are preset at the factory to simplify burner and process setup. However, some adjustment or at least verification for operation is required.

Refer to the Burner Performance Data Sheets for flows, operating pressures, and valve positions.

1. 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.

2. Check the linkage settings to make sure they comply with the Burner Performance Data Sheets. Adjust them if necessary.

3. 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%–12%, depending on the firing rate.

Altering the fuel/air ratio of the burner requires a qualified burner technician to prevent a dangerously rich firing condition.

4. The best way to alter the fuel/air ratio is to change the fuel pressure slightly. If a PLC burner control with two control motors is used, either the fuel or air motors can be adjusted. If these methods are not satisfactory, then slightly adjust the valve settings using the linkage.

5. 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.(Refer to Flame Shape Adjustments.)

6. For most drums, the spin vanes should not need to be adjusted. If adjustment is required, it must be done by a qualified burner technician.

Take flue gas measurements during the adjustment process to verify complete combustion.

Burner Dimensions

Whisper Jet burner dimension drawings are located on the facility flash drive. If the drawings cannot be located, please contact the Astec Burner Group.

WJ-31 of 59



Burner Mounting

1. The centerline of the burner should be mounted on the centerline of the drum at the same pitch as the drum. Refer to the drawings located on the facility flash drive for burner weight and dimensions.

2. 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.

3. The mounting flange allows the positioning of the burner at the correct insertion depth past the breeching plate. The insertion depth should be determined by the Astec Engineering Department at the time the order is placed.

4. Cut out a hole in the breeching plate 2 inches larger than the burner nose flange.

5. Check burner blower rotation. Rotation should be clockwise from the motor end.

Burner Pilot System

The Whisper Jet burner incorporates a forced-air pilot system. The pilot and the main flame are monitored by a single ultraviolet (UV) flame detector. This is included in the complete burner package and comes attached to the burner.

The air for the pilot is provided from inside the fan housing where there is a constant air pressure. The following section details the adjustment and operation of the pilot system.

Adjustment and Operation of the Pilot

System

1. Only use natural gas (NG) or vaporized propane (VP) to fuel the pilot.

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.

3. If you will be firing using liquid fuels, and/or natural gas service is not currently available, connect the gas feed piping to a vaporized propane line. (Refer to above warning.)

4. Purge the fuel piping of any contaminants 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 ft long, use a minimum of 3/8 inch pipe.)

6. Gas pressures at the inlet of the gas pilot manifold can range from 16–125 psig.

7. The entire pilot assembly can be removed from the burner by removing the bolts on flange at the back 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.

WJ-32 of 59



Figure 6. Typical pilot gas train

Test Port

SolenoidValve

Gas Limiting Valve

Regulator

Y-Strainer

Figure 5. Pilot system

1⁄8 to 3⁄16 in Gap

Key Stock

Terminal (Inside)

Igniter Wire

Fuel Pipe

Pilot Nozzle Assembly

Pilot Air Tube

Igniter Boot

The Initial Pilot Adjustment

1. Make sure the spark igniter is connected to the ignition transformer.

2. Remove the protective cover on the gas limiting valve. Connect a manometer to the test port.

• Turn the adjustment screw clockwise to decrease the gas pressure.

• Turn the adjustment screw counterclockwise to increase the gas pressure.

3. The initial recommended pressure setting is approximately 1 inWC for vaporized propane and 2 inWC for natural gas measured at the test port.

4. At this rate, the pilot should light the main burner easily and deliver a sufficient UV flame signal.

5. Solenoid valves must be open to adjust flow.

The pilot ignition transformer can cause a painful shock. Use care around the ignition cable. Only leave the pilot gas on for a very short period of time while lighting the burner. If pilot does not light at once, shut it off, and then purge it before attempting to relight.

WJ-33 of 59



Natural Gas Fuel Piping System

Table B. Natural Gas Regulator Requirements

BURNER MODEL WJ-35 WJ-40 WJ-50 WJ-75 WJ-100 WJ-125 WJ-150

MAXIMUM CAPACITY (FT3/HR) 38,500 44,000 55,000 82,500 110,000 125,000 150,000

GAS INLET PRESSURE (PSI) 6.0* 6.0* 6.0* 6.0* 6.5* 7.0* 7.0*

GAS INLET PIPE SIZE (IN) 4 4 4 6 6 6 8

*Estimated

The settings in Table B are for initial setup 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.

Manual Shutoff Valve

Control Butterfly Valve

High Gas Pressure Safety Switch Flow Orifice Plate

Gas Inlet Pressure Tap

Automatic Safety Shutoff Valve Actuators

Safety Shutoff Valves BodyPressure Snubber

Low Gas Pressure Safety Switch

Manual Shutoff ValveWith Lock

Gas Strainer Between Flanges

Figure 7. Natural gas train components

Install a controlling gas regulator in the main gas line within 25 ft of the burner. (See Figure 7.) This regulator should be sized to provide the required gas flow at the inlet of the burner manifold.

The nominal expected gas pressure required at the burner is listed in Table B. Refer to the Burner Performance Data Sheets for more information.

WJ-34 of 59



Exact gas pressure must be set at the initial startup depending on piping configuration, burner size and maximum capacity desired.

The piping from the gas regulator outlet to the burner gas manifold should be sized to minimize pressure losses. It is normal for the regulator size to be smaller than the line size.

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. However, it is normal for the regulator size to be smaller than the line size. If the gas run is more than 25 ft, use the connection sizes in Table C. If the gas run is 25 ft or less, use the connection sizes Table D.

The supplied manual shutoff valve must be installed upstream of the gas control regulator.

• The strainer protects the valves from destructive dirt that could lodge in them.

• The shutoff valve facilitates servicing of the gas train.

• The Siemens gas valves have an integral strainer at the inlet of the first valve.

The gas company should purge the main gas line for scale and dirt before it is attached to the burner gas manifold.

Table C. Feed Pipe Size for Gas Runs over 25 ft


PIPE SIZE (MIN DIA. IN INCHES) 4 4 4 6 6 6 8

Table D. Feed Pipe Size for Gas Runs 25 ft or Under


PIPE SIZE (MIN DIA. IN INCHES) 3 3 3 4 4 6 6

Figure 8. Regulator requirements

Manual Shutoff Valve

Metal Flex Line

10 Main Pipe Diameters

Regulator Pilot Line

Control Line

4 Main Pipe Diameters

Gas Regulator

FROM GAS SUPPLY

BY CUSTOMERBY ASTEC

Burner Gas Inlet

WJ-35 of 59



It is highly recommended to install a strainer before the burner gas regulator. Astec sells a basket strainer that installs in the main piping without any piping modifications required. (Inline, between two flanges.)

• 4 inch strainer is PN 082366.• 6 inch strainer is PN 082367.

If the gas pressure to the burner regulator is higher than 30 psi, overpressure protection must be installed. Consult a local gas provider for more information.

Install the flexible pipe nipple supplied with the burner gas manifold to reduce flexing of the manifold produced by facility vibrations. (Refer to Table E.)

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 50% of the running pressure for the low gas pressure switch and 125% of the operating pressure for the high gas pressure switch.

The gas valve linkage must be adjusted for proper flow control. Refer to the Burner Performance Data Sheets for specific air and gas flows.

Use the utmost care in making any adjustment to prevent an unsafe condition.

The settings in Table F are for initial setup 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.

Metering natural gas is accomplished by taking a differential pressure across the orifice plate in the pre-piped gas train.

To find the actual gas flow, take the square root of the measured differential pressure, then multiply it by the flow shown in Table B.

For example, with 3 inWC differential pressure on the WJ-100, the gas flow would be:

√3 × 30,000 = 52,000 SCFH (Standard Cubic Feet per Hour)

Table E. Astec Part Numbers for Recommended Flexible Pipe Nipples


ASTEC PART NUMBER 070037 070037 070037 048292 048292 048292 062133

Table F. Natural Gas Orifice Meter Size


NATURAL GAS FLOW (SCFH AT 1 INWC/5 PSI)

7000 7000 15,000 30,000 30,000 30,000 51,000

GAS ORIFICE INSIDE DIAMETER (IN)

2.5 2.5 3 4.6 4.6 4.6 6

GAS INLET PIPE SIZE (IN) 4 4 4 6 6 6 8

WJ-36 of 59



Oil Fuel Piping System

Figure 9. Oil train (heavy oil shown)

Thermocouple

Flexible Hose

Ball ValveHeat Trace

Switch (Heavy Oil Only)

Automatic Safety Shutoff

Valves

Temperature Gauge

(Heavy Oil Only)

Temperature Switch

(Heavy Oil Only)

Flow Meter

Y-Strainer

Inlet Pressure Gauge

NozzlePressure Gauge

Fuel Low Pressure Switch

Fuel High Pressure Switch

Low Fire Fuel Bypass Valve

Oil Flow Modulating

Valve

Modulation Valve Limit

Switch

Table G. Oil Train Settings


MAXIMUM CAPACITY (GPM)

4.5 5.2 6.5 9.7 12.9 16.1 19.4

LF OIL INLET PRESSURE (PSI)

85 95* 116 132 138 130 145

*Estimated

WJ-37 of 59



For recommended pipe sizes, see Table H.

1. Before attaching the fuel lines, purge the piping to remove scale, dirt, and other contaminants that could clog and damage the fuel system.

2. Adjust the pressure control valve until the required oil pressure is achieved. Refer to the individual Burner Performance Data Sheets for the approximate settings.

3. Depending on the system design, the final pump pressure will have to be adjusted to attain the desired burner output.

4. The low oil pressure switch is factory set at 30 PSIG. The low oil pressure switch should be set about 10 PSIG lower than the actual pressure required.

Fuel leaked from the oil piping presents an extreme fire danger.

5. Test the piping for leaks before startup, then check for leaks daily.

6. The manual low fire bypass oil control valve is used to set and maintain the low fire oil flow at the burner. Refer to the Burner Performance Data Sheets for the low fire oil setting.

7. The burner oil flow (metering) control valve range is usually set from positions 0–12.

8. The high fire oil flow can be set by varying the fuel pressure, or by changing the valve profile in the control system. Refer to the Individual Burner Performance Data Sheets for proper fuel flows.

9. Oil flow rates can be checked with the inline oil flow meter in the fuel control valve train.

10. Oil flow rates can be confirmed using the nozzle pressure and the Burner Performance Data Sheets.

These settings are for initial setup 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.

Table H. Minimum Oil Line Sizes for Various Lengths (in)

BURNER MODEL

DISCHARGE LINERETURN LINE

(LIGHT OIL–UP TO 100 SSU)RETURN LINE

(HEAVY OIL–OVER 100 SSU)0–25 FT 25–49 FT 50–100 FT 0–25 FT 25–49 FT 50–100 FT 0–25 FT 25–49 FT 50–100 FT

WJ-35–50 1/2 1/2 1 1/2 1/2 1 1/2 1 1

WJ-75 1 1 1 1 1 1/4 1 1/4 1 1/4 1 1/2 2

WJ-100 1 1 1 1/4 1 1/4 1 1/4 1 1/4 1 1/4 1 1/2 2

WJ-125 1 1 1/4 1 1/4 1 1/4 1 1/4 1 1/4 1 1/4 2 2

WJ-150 1 1 1/4 1 1/4 1 1/4 1 1/4 1 1/2 1 1/2 2 2

WJ-38 of 59



Be very careful with heavy oil:

• Heavy oil has to be heated to lower its viscosity for proper atomization.• To avoid fire, do not heat the heavy oil higher than its vapor point.• Contact with the hot oil or piping can cause severe burns.

Heavy Oil Fuel Piping System

Figure 10. Heavy oil piping schematic

• Burner fuel train insulated and heat traced when using heavy oil.

• Insulation from A to B.

• Spiral wrapped heat trace and insulation from B to C.• When using sub-freezing option, heavy oil gun includes

insertion heater.

Unloading Pump

Sock Filter

FulFlo Relief Valve

Fuel Oil Pre-Heater

Fuel Pump Skid Assembly

(A)

(B)

(C)

Water Drain (installed as low

as practical)

Heavy Oil Piping (from tank to pump suction)

to be installed 12 in from bottom of tank

Burner Fuel Oil Train

(Δ) Heavy Oil Return Line (Refer to Table H for sizes.)

(=) Fuel Supply Line to Burner(Refer to Table H for sizes.)

Fuel PumpDuplex Strainer

A

B

C

Fuel Flow

Heavy OilFuel Tank

WJ-39 of 59



The burner should fire on all commercially available heavy oils.

Proper fuel viscosity is required for satisfactory atomization and combustion of heavy oil.

The viscosity of the oil must be 80 SSU (Saybolt Seconds Universal) or lower.

Use a viscometer (Astec Part #00404), or other suitable device to determine the oil temperature to achieve the proper viscosity.

Every shipment of oil must be individually tested.

Check the fuel specifications to check the vapor point of the fuel.

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 cavitation, which can damage the pump. Vapor pockets can also interrupt fuel flow, causing the burner to falter. They can even cause pipes to burst, causing damage and possible injury.

Set the oil heater temperature regulator and the indicating low oil temperature switch (located on the burner oil manifold) to the temperature determined by viscometer. This will prevent the burner from operating when the oil is too thick to be atomized and burn well, and will prevent damage to the facility.

For the pipe sizes recommended for heavy oil, see Table H.

1. Purge the lines before attaching them to the fuel manifold.

2. Adjust the pressure relief valve until the required oil pressure and flow is achieved. (Refer to the Burner Performance Data Sheets.)

3. The manual low fire bypass oil control valve is used to set and maintain the low fire oil flow at the burner. (Refer to the Burner Performance Data Sheets.)

4. The manual low fire bypass oil control valve is used to set and maintain the low fire oil flow at the burner. (Refer to the Burner Performance Data Sheets.)

5. The low oil pressure switch is factory set at 30 PSIG. Set according to local code requirements.


WJ-40 of 59



Liquid Propane Piping System

Table I. LP Train Settings


MAXIMUM CAPACITY (GPM) 7 8 10 15 20.0 25 30

LP INLET PRESSURE (PSI) 200 200 200 210 250 245 –

Table J. LP Pipe Sizes (in)

BURNER MODEL 0–25 FT 25–49 FT 50–100 FT

WJ-35–50 1/2 1 1

WJ-75 1 1 1

WJ-100 1 1 1 1/4

WJ-125 1 1 1/4 1 1/4

WJ-150 1 1 1/4 1 1/4

Figure 11. Liquid propane piping schematic

Flow Meter

HSRV

HSRV

Modulating Valve

Linkage Arm For Actuator

Y-Strainer

Nozzle Pressure Gauge

High Fuel Pressure Switch

Low Fuel Pressure Switch

Hydro Static Relief Valve

(HSRV)

Ball Valve

Inlet Pressure Gauge

Low Fire Limit Switch

Ball Valve

Automatic Safety Shutoff

Valve

WJ-41 of 59




For recommended pipe sizes, see Table J.

1. Before attaching the fuel lines, purge the piping to remove scale, dirt, and other contaminants that could clog and damage the fuel system.

2. Adjust the pressure control valve until the required LP pressure is achieved. Refer to the Burner Performance Data Sheets for the approximate settings.

• Depending on the system design, the final pump pressure will have to be adjusted to attain the desired burner output.

3. The low LP pressure switch shall be set at 50% of profile inlet pressure at high fire.

4. The high LP pressure switch shall be set at 125% profile inlet pressure at low fire.

5. Leak test the piping before startup, then check for leaks daily.

• The burner LP flow (metering) control valve range is usually set from position 1 to Position 12. The LP train does not use a low fire bypass.

6. The high fire LP flow can be set by varying the fuel pressure, or by changing the valve profile in the control system. Refer to the Burner Performance Data Sheets for proper fuel flows.

7. LP flow rates can be checked with the inline flow meter in the fuel control valve train.

8. LP flow rates can be confirmed using the nozzle pressure and the Burner Performance Data Sheets.

WJ-42 of 59



Figure 12. Front end settings

ØHØJ

ØG

ØQ

ØR

ØE

ØD

ØFØT

ØS

ALIGN CASTELLATIONSAS SHOWN IN THE PICTURE

Front End Configuration

Table K. Front End Settings

SETTING DESCRIPTIONBURNER

WJ-35 WJ-40 WJ-50 WJ-75 WJ-100 WJ-125 WJ-150

A Oil Nozzle (in) 3/4 3/4 7/8 3/4 3/4 3/4 1/2

OIL Atomizing Air Tube (in) 5/8 5/8 1 7/8 1 7/8 1 7/8 1 1/2 2 3/8

ØBLP/OIL Bluff Body

Dia. (in)8 8 8 9 9 – –

LP/OIL Atomizing Air Tube (in) – – 4 4 4 – –

C Sec. Air Choke (in) 2 7/8 2 7/8 2 7/8 3 3 3 3 1/2

ØDAtomizing Air Castell.

Ring Outer Dia. (in)Ø5 Ø5 Ø5 1/4 Ø6 1/2 Ø6 1/2 Ø6 1/2 Ø9

ØEAtomizing Air Castell.

Ring Inner Dia. (in)Ø4 Ø4 Ø4 1/4 Ø5 15/32 Ø5 15/32 Ø5 15/32 –

WJ-43 of 59



Table K. Front End Settings

SETTING DESCRIPTIONBURNER

WJ-35 WJ-40 WJ-50 WJ-75 WJ-100 WJ-125 WJ-150

ØFAtomizing Air Castell.

Ring I.D. (in)Ø2 5/8 Ø2 5/8 Ø2 5/8 Ø3 1/2 Ø3 1/2 Ø4 1/4 Ø5 1/2

ØGSec. Air Choke Ring

Outer Dia. (in)Ø7 3/4 Ø8 3/8 Ø10 15/16 Ø11 1/8 Ø13 Ø14 1/4 –

ØHSec. Air Choke Ring

Inner Dia. (in)Ø6 11/16 Ø7 1/4 Ø9 1/2 Ø10 1/8 Ø11 1/2 Ø12 3/4 Ø14 1⁄2

ØJ Sec. Air Ring I.D. (in) Ø9 3/4 Ø9 3/4 Ø14 Ø15 Ø15 Ø15 Ø16 1/2

L*Number of Sec.

Gas Pipes2 2 2 2 2 4 4

M Outer Vane Angle 55° 55° 55° 55° 55° 55° 55°

N Sec. Vane Angle 45° 45° 45° 45° 45° 45° 45°

P Outer Air Gap (in) 9/16 11/16 1/2 1/2 1 1 1/4 1 1/2

ØQ Outer Cone I.D. (in) Ø21 5/16 Ø21 5/16 Ø25 Ø32 3/4 Ø33 Ø33 Ø37

ØR Outer Caste. I.D. (in) Ø19 7/8 Ø19 7/8 Ø22 Ø29 3/4 Ø29 3/4 Ø29 3/4 Ø33 13/16

ØS Outer Gas Elbow (in) – – – 1/2, 8 1, 8 1, 8 1, 8

ØTInner Gas Elbow

Size & Qty (in)– – – 1/2 3/4 1 1

U Nozzle Spin Vane 3/8 3/8 3/8 5/8 5/8 5/8 1

*Refer to gas manifold drawings for location of the open pipes

WJ-44 of 59



Figure 13. Nozzle settings

U

U

ØB

A

ØF

LP/Oil

C

3⁄4 inch to 7⁄8 inch (ref.)

6 inch (ref.)

L

N°

Compressed Air

Gas Diversion Angle Plate

Fuel Oil

Natural Gas

M° P

Oil

ØF

A

OIL ONLY SETUP

OIL/LP SETUP

WJ-45 of 59



Resetting the Nozzle Position

The position of the fuel oil atomizer in the nozzle affects its ability to atomize the oil. The nozzle is preset at the factory.

To reset the nozzle position:

1. Shut down the burner and de-energize the burner compressed air system.

Lockout facility power before working on the burner.

2. Shut off the manual oil ball valve on the burner oil train.

3. If heated heavy oil is being used, allow enough time for the oil in the piping to cool.

4. Refer to Figure 13 and Setting A on Table K 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 pipes in or out to effect the required retraction or extension of the oil gun/pilot assembly.

Contact the Astec Service Department for any questions about proper positioning.

Once the proper positioning of the oil gun/pilot assembly is completed:

1. Re-tighten the set screws of the set collars on the mounting plate of the oil gun/pilot assembly.

2. Install the oil atomizer assembly in the burner/blower with the four nuts.

Removing the Oil Gun Assembly

1. Shut down the burner and de-energize the burner compressed air system.

Lockout facility power before working on the burner.

2. Shut off the manual oil ball valve on the burner oil train.

3. If heated heavy oil is being used, allow enough time for the oil in the piping to cool.

4. Remove the four nuts holding the oil gun/pilot assembly onto the burner/blower.

5. Pull out the oil gun/pilot assembly from the burner/blower body.

6. Make a note of the initial position of the oil nozzle.

Contact the Astec Service Department for any questions about proper positioning.

Once the proper positioning of the oil gun/pilot assembly is completed:

1. Re-tighten the set screws of the set collars on the mounting plate of the oil gun/pilot assembly.

2. Install the oil atomizer assembly in the burner/blower with the four nuts.

WJ-46 of 59



Table L. Recommended Compressed Air Pipe Sizes (in)

BURNER MODEL

MAXIMUM AIR FLOW

(SCFM)

LENGTH OF COMPRESSED AIR LINE (FT) (100 PSIG SUPPLY AIR PRESSURE)

50 100 150 200 250 300

WJ-35–50 50 1/2 1/2 1/2 3/4 3/4 3/4

WJ-75 85 3/4 1 1 1 1 1

WJ-100 85 3/4 1 1 1 1 1

WJ-125 120 1 1 1 1 1 1/4 1 1/4

WJ-150 140 1 1 1 1/4 1 1/4 1 1/4 1 1/4

Figure 14. Typical compressed air train

Low Low Pressure Switch

Metal Flex Hose

Atomizing Air Solenoid Valve

Low Pressure Switch

Y-Strainer

Air Inlet

Air Pressure Regulator

Fuel Nozzle Cooling Air Solenoid (only on combo gas/oil burners)

Ball Valve

Sub Freezing Switch (only with sub freezing option)

Compressed Air Train

The Whisper Jet burner uses compressed air for atomizing fuel oil and for nozzle cooling when firing on natural gas. Compressed air is supplied to the inlet of the compressed air train.

Size the compressed air feed line according to recommended compressed air pipe sizes in Table L. These sizes will result in minimum pressure drop for proper oil atomization. See Figure 14 for location of the air inlet pipe.

WJ-47 of 59



The compressed air train includes: a manual shutoff valve, “Y” strainer, low pressure switch, pressure regulator, pressure gauge, compressed air solenoid and a flexible hose. (See Figure 14.)

Figure 14 is a general arrangement. Each burner has its own drawings on the facility flash drive.

Setting the Low Pressure Switch

1. Use the "tee" handle on top of the pressure regulator to adjust the low pressure switch to just slightly under the recommended air pressure.

2. Set the compressed air pressure to the recommended pressure. (Refer to the Burner Performance Data Sheets.)

The low low pressure switch is factory set at 60 PSIG and is not adjustable. (See Figure 14.)

Lockout power prior to working on high pressure piping. Relieve pressure in the piping, valves and solenoids prior to working on the piping. Remember that dangerous air pressure can also be trapped between valves or controllers.

Flame Shape Adjustments

The Whisper Jet burner is preset at the factory for the shortest and narrowest flame possible. This makes flame adjustment burners virtually obsolete.

The nose spin vanes affect the flame shape and combustion intensity. Do not change the spin vanes from the factory settings of 45–60°.

The length of the flame must be shorter than the combustion zone in the drum because material showering through the flame causes increased pollutants in the flue gas.

The width of the flame must be less than the interior diameter of the combustion flights.

Refer to the Burner Performance Data Sheets for the proper flame size and diameter.

WJ-48 of 59



Flame Scanner

The Whisper Jet burner is supplied with a flame scanner that detects ultraviolet (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 ¼ inch aluminum cap on the back of the burner and pulling the flexible conduit attached to it out.

Be careful not to physically shock or overheat the flame detector as this can cause it to fail.

Flame Scanner Cooling Air

The flame scanner requires cooling air at a constant pressure from the facility 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.

Air Pressure Regulator

Set to 25 psig

Ball Valve

FLAME SCANNER

COOLING AIR TRAIN

Compressed Air Inlet

Figure 15. Flame scanner and cooling air train

Flame Detector

FLAME SCANNER

WJ-49 of 59



Lubrication & Interval Maintenance

Attempting to lubricate, clean, adjust, service or maintain equipment while it is

energized can result in death or serious injury. Read and follow instructions before servicing the equipment. Always follow lockout/tagout procedures.

The following lubrication chart illustrates the locations of lubrication points for typical burners.

Table M. Lubrication Points–Whisper Jet Burner

PTINTERVAL HOURS*

IDENTIFICATION# OF PTS

LUBRICANT TYPE (OR EQUIVALENT)

AMT

1 2000 Bearing, Air Damper 8Lithium Complex Grease - NLGI GR 2, 350 °F Drop Point

2 Strokes

2 Motor: Refer to OEM for lubrication specifications.

Figure 16. Lubrication points for Whisper Jet Burner

①Near & far side

②

WJ-50 of 59



Table N. Maintenance Schedule–Whisper Jet Burner

Maintenance Item

Dai

ly

Whi

le

Runn

ing

Wee

kly

Mon

thly

12 M

onth

s

Clean all oil filters and strainers as needed. ◊

Verify proper oil temperature and viscosity of waste oil. ◊

Check fuel pressure. ◊

Verify proper atomizing oil nozzle position inside the burner. ◊

Check atomizing air pressure. ◊

Inspect all points of the valve linkage. Mark the linkage so that any slippage will be noticed.

◊

Clean the oil nozzle and atomizer. ◊

Clean the flame scanner using a soft cloth and lens cleaner. ◊

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 buildup on the front of the burner. ◊

Thoroughly wash and inspect the burner blower impeller. ◊

Clean the pilot gas Y-strainer. ◊

Clean the gas screen. ◊

Clean the compressed air Y-strainer. ◊

Inspect oil nozzle for signs of wear. ◊

Verify fuel and air piping connections are secure. ◊

Check for leaks where appropriate. ◊

Have combustion quality checked with a combustion analyzer. ◊

Inspect the air damper bearings. ◊

Check the function of all safety equipment (pressure switches, limit switches, etc), to make sure they are all fully operational.

◊

The Maintenance Schedule on this page should be used for reference only. Facility managers should develop a maintenance schedule based on the demands and operation of the facility.Dirt can clog the atomizing air nozzle, as well as causing burner firing problems. It can also waste fuel through poor atomizing.To remove and clean the burner oil tube and nozzle assembly, use the procedure from the Burner Front End/Nose section.

WJ-51 of 59



Safety Signs

It is extremely important to maintain signs on the equipment. The safety sign location drawings are provided to assist the facility manager with identifying signs needing replacement.

Table O. Safety Signs–Burner

ITEM PART

NUMBERDESCRIPTION

DANGER

1 083274 Lock out power for maintenance or adjustments

2 083298 Electrical shock hazard

3 083301 Misadjusting this equipment

4 083302 Misadjusting this equipment

WARNING

5 083276 Machine may start without warning

6 083277 Machine may start without warning

7 083285 Lock out power before removing access door

8 083297 Read and understand operator's manual

9 083311 Serious injury or death can result

10 083316 Burner should not operate on oil in weather below 32 °F

INFORMATION

11 083312 Burner body pressure

12 083313 Blower pressure

13 083314 Gas manifold pressure

14 083315 Gas orifice differential pressure

15 098786 Gas inlet pressure

16 074579 Made in USAThese locations are shown for reference only. Actual locations may vary based on the design of the equipment.Illustrations on the following pages.

WJ-52 of 59



⑬

⑪④③⑫

⑤

②⑧①⑦

⑩

⑯

Figure 17. Safety Signs for Up Whisper Jet Burner

⑮

⑮

⑭

⑨⑥

WJ-53 of 59



⑬

⑪④

⑫③

⑥

⑨

⑤

⑮

②⑧①⑯⑩

⑭Figure 18. Safety Signs for Down Whisper Jet Burner

WJ-54 of 59



Troubleshooting

PROBLEM CAUSE SOLUTION

Pilot Will Not Light

Malfunction 1: No spark

1. Check to see if the plug has a spark.

2. If there is no spark, check the plug, cable, and ignition transformer.

3. Check to see if voltage is going to the ignition transformer.

4. Check the terminal connection to the ignition transformer.

5. Check the connection at the back of the burner.

6. Check the connection at the junction box.

7. Remove the oil gun/pilot assembly and check the connection to the plug.

8. Inspect the spark plug cable for tears and cuts.

9. Check the spark plug for carbon buildup.

10. Check the spark plug gap.

Malfunction 2: No pilot gas

1. Check the LP tank for fuel level.

2. Check the cut-off valve position.

3. Check for LP gas leakage.

4. Check the LP fuel pressure.

5. Verify the pilot solenoids are opening and that there is gas flow.

6. Check the pilot strainer for dirt.

Malfunction 3: No flame signal

1. Verify the pilot solenoids are opening, and that there is gas flow. (Refer to "No pilot gas" above.)

2. Pull the flame sensor from the burner and clean the lens.

3. Check the signal from the flame sensor. If there is no signal, replace the flame scanner.

4. If the pilot is lighting and there is no flame signal, replace the flame scanner.

5. Check the wires to the flame relay.

6. Check the flame relay. Fix or replace as needed.

Follow approved lockout/tagout procedures before working on equipment. Maintain awareness of all known and discovered hazards.

WJ-55 of 59




Main Burner Fuel Won't Ignite

Malfunction 1: Fuel flow too low

1. Oil fired burners: Check the linkage, fuel pressure, and compressed air pressure settings. They may have changed.

2. Check the burner setup sheets for standard settings.

3. Check/clean the Y-strainer on the fuel train.Be careful when increasing the fuel flow not to make the mixture too rich or the low fire setting too high. Fuel flow adjustment should be done by qualified personnel. Qualified personnel are those trained by the Astec Service Department.

Malfunction 2: Air damper set too high for low fire

Check air pressure at burner downstream of air damper. It should be less than 1 inWC and air damper should be between 0 and 1.

Flame Stability Problems on Heavy Oil

Malfunction 1: Oil too hot, causing vapor pockets OR Oil too cold, causing poor atomization

1. The viscosity of the oil must be no higher than 80 SSU. Use a viscometer to determine the proper oil temperature to achieve this viscosity.

• Every shipment of oil must be individually tested.

2. Check the fuel specifications to verify the vapor point of the fuel.

3. For better combustion, the viscosity can be lower than 80 SSU, which means a higher oil temperature is required.

4. Never heat the oil above 10 °F below the vapor point of the fuel.

5. Make sure the fuel Is not forming vapor (steam) pockets in the oil lines.

• The fuel pressure will become erratic if the lines are vapor-locked or pressure is building.

6. Check the nozzle/atomizer to see if it is dirty.

7. Check the filters and strainers to see if they are partially blocked.

8. Check the atomizing air pressure to see if it is erratic.

Malfunction 2: Dirty atomizer

Pull out the burner nozzle and clean it.

Malfunction 3: Poor quality oil

1. Some recycled oil contains non-flammable fluids. Hydraulic fluid, for example, will not burn well or at all.

2. Replace the oil and purge the fuel lines.

High Stack Emissions

Malfunction: Too much or too little fuel

To get the best emissions and fuel economy, the burner should be set up with 10%–30% excess air. Refer to Burner Performance Data Sheets for settings, and confirm with flue gas analysis.

WJ-56 of 59




Limits Not Complete

Malfunction: Pressure switch or limit switch not energized

1. Refer to the component location drawings for pressure and limit switch location.

2. Check the fuel pressure switch.

• If it is not energized, repair or replace it.• If it is clogged, clean or replace it.

3. Check the limit switch.

High Stack Temperature

Malfunction 1: Too much fuel at low fire

1. Check the fuel flow at low fire. Set to recommended flow.

2. Check the fuel pressure. Set to recommended pressure.

3. Check the low atomizing air pressure. Set to recommended pressure.

Malfunction 2: Incorrect flighting in the drum

Contact the Astec Service or Engineering Department and have Astec personnel check the flights.

Oil Buildup on the BurnerOil buildup on the burner does not occur in normal operation unless the set collars holding the oil gun in place loosen, which sometimes occurs due to vibration.

Malfunction 1: Oil not atomizing correctly

1. Check nozzle for dirt. Clean if required.

2. Check oil viscosity and temperature.

3. Check atomizing oil pressure and flow.

4. Check the pintle. Replace if worn.

5. Check to see if the atomizer/pintle holding cup is loose.

Malfunction 2: Oil atomizer in incorrect position

1. Check the location of the oil nozzle in the burner.

• If the nozzle is too far into the burner, it could cause oil buildup at low fire.

2. Reset oil atomizer position to dimensions in Figure 16.

The oil nozzle is factory set and does not need to be removed during routine

maintenance.

Weak Flame Signal

Malfunction: Dust on the flame scanner lens

Clean lens with soft cloth and lens cleaner.

WJ-57 of 59



Recommended Spare Parts

Table P. Whisper Jet Burner Spare Parts ListDomestic Burners Only (120V/60Hz)

ITEM QUANTITY ASTEC P/N DESCRIPTION

1 1 075050 Igniter

2 1 001001 Motor, Barber Coleman #EA57 on two-control motor burners and WJ-50

3 1 063336 Fireye® UV scanner

4 1 075699 Low or high gas air pressure switch 30 inWC

5 1 079558 Motor, Barber Coleman #EA71 on on-control motor burners

6 1 080021 Flame safeguard module Fireye® YB110UV

7 1 081185 Pilot solenoid valve

8 2 005788 Switch limit single pole 3SE03-AR1

9 1 078550 High pressure switch oil 150 psi

10 1 076926 Low pressure switch oil 30 psi

11 1 080222 Temperature switch 100°–350 °F (heavy oil only)

12 1 076217 Thermocouple 1/2 inch NPT 350°–1400 °F (heavy oil only)

13 1 071195 Ignition transformer 110V/60Hz

14 18 ft 071710 Ignition wire

15 1 071711 Terminal HS 6-32

16 1 071712 Terminal SSN

17 1 071713 Boot #250

18 1 075700 Low or high gas pressure switch 0-30 psi

19 1 077247 Actuator SKP15.011 U1 (gas burner)

20 1 079542 Regulator with liquid gauge (compressed air regulator)

Table Q. Whisper Jet Burner Nozzle Spare Parts List

BURNER MODEL

NOZZLE BODY (ASTEC P/N)

NOZZLE CAP (ASTEC P/N)

NOZZLE MIXER LIGHT OIL

(ASTEC P/N)

NOZZLE MIXER HEAVY OIL

(ASTEC P/N)

NOZZLE MIXER LP

(ASTEC P/N)

WJ-35–50 076715 076205 081496 081497 079533

WJ-75 076003 076005 076004 077818 078876

WJ-100 076003 076005 076004 077818 078876

WJ-125 076010 076012 076011 077819 –

WJ-150 076010 076017 076016 077821 –

Parts Hotline 1-800-251-6042Hours: Monday thru Friday 7:00 a.m. to 12:00 a.m. midnight, EST

Saturday 8:00 a.m. to Noon ESTTelephone: 423-867-4210 | Fax: 423-867-7609

Email: [email protected]

WJ-58 of 59



Detailed Burner Performance Data Sheets

The Burner Performance Data Sheets are located on the facility flash drive.

Other items that should be found on the facility flash drive are:

1. The burner general arrangement, which will have the dimensions and overall weight of the burner.

2. The burner specification plaque information will have the maximum firing rate, fuel pressures, and flow rates listed.

3. The process and instrumentation (P&ID) 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 black plastic tags on the components match the P&ID drawing and have the Astec part numbers on them. 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.

Should further information be required, or answers to questions not covered generally, or should particular problems occur which are not covered in this manual, contact the Astec Service Department or the Astec Burner Group.

Whenever any replacement parts are needed, call the Astec Parts Department any time day or night at 1-800-251-6042.

WJ-59 of 59



Altitude Correction Chart

* 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.Astec burners use 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 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 × 0.86 = 860,000 SCFH at 5000 ft.Additionally, if the fan had a static pressure reading of 10 inWC at sea level, it would be reduced to 10 × 0.86 = 8.6 inWC 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 inWC) 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 Astec Burner Group for assistance at 423-867-4210.

100%

95%

90%

85%

80%

75%

70%

65%

60%

55%

1000

50% 2000

3000

4000

5000

6000

7000

8000

9000

10000

11000

12000

13000

14000

15000Bl

ower

Fac

tor

Altitude (ft)

Table R. Blower Factor vs Altitude (Constant Speed*)

ALTITUDE

ABOVE

SEA

LEVEL

(FT)

AIR

DENSITY

(LB/FT³)

BLOWER

CORRECTION

FACTOR

(%)

ALTITUDE

ABOVE

SEA

LEVEL

(FT)

AIR

DENSITY

(LB/FT³)

BLOWER

CORRECTION

FACTOR

(%)

ALTITUDE

ABOVE

SEA

LEVEL

(FT)

AIR

DENSITY

(LB/FT³)

BLOWER

CORRECTION

FACTOR

(%)

0 0.077 100 4500 0.067 87 9000 0.058 76

500 0.075 99 5000 0.066 86 9500 0.057 75

1000 0.074 97 5500 0.065 85 10000 0.057 74

1500 0.073 96 6000 0.064 84 11000 0.055 72

2000 0.072 94 6500 0.063 82 12000 0.053 69

2500 0.071 93 7000 0.062 81 13000 0.051 67

3000 0.070 92 7500 0.061 80 14000 0.050 65

3500 0.069 90 8000 0.060 79 15000 0.048 63

4000 0.068 89 8500 0.059 77

whisper jet burner - astecinc.com · whisper jet® burner burners for aggregate drying applications...

Documents