PHOENIX TALON 2 BURNERPhoeni Talon 2 Burner Burners for Aggregate Drying Applications ii V 10 2018-04-19 Natural Gas Fuel Piping System..... PT2-27 Oil Fuel Piping System

P H O E N I X T A L O N 2 B U R N E R

OPERATION, 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

P H O E N I X ® T A L O N 2 B U R N E R

V 1.0 2018-04-19Burners for Aggregate Drying Applications

Table of Contents

i

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

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

How to Use This Manual .......................................PT2-1

Introduction...................................................................PT2-1

Warnings, Cautions and Notices ............................PT2-1

Receiving Equipment ...........................................PT2-2

Documentation ............................................................PT2-2

Safety Management ..............................................PT2-3

Safety Sign Description .............................................PT2-4

Safety Sign Summary .................................................PT2-5

Danger Signs ...................................................................PT2-5

Warning Signs .................................................................PT2-6

Informational Signs .......................................................PT2-7

Basic Safety Instructions ...........................................PT2-8

Confined Spaces/Permit-Required ..........................PT2-8

Lockout/Tagout ..............................................................PT2-8

Personal Protection .......................................................PT2-9

Personal Safety Precautions .......................................PT2-9

Burns ................................................................................ PT2-10

Facility Safety ................................................................ PT2-10

General Safety .............................................................. PT2-11

Inspections .................................................................... PT2-12

Prepare for Emergencies .......................................... PT2-12

Be Aware of Surroundings ....................................... PT2-12

Avoid Alcohol and Drugs ......................................... PT2-12

Good Housekeeping .................................................. PT2-12

Operator Safety ............................................................ PT2-13

Electrical Installation ............................................... PT2-13

Electrical Systems ..................................................... PT2-14

Hydraulic and Pneumatic Systems ..................... PT2-14

Welding, Cutting or Grinding ............................... PT2-15

Clearing Jammed Material .................................... PT2-16

Hazardous Material .................................................. PT2-16

Flammable Liquids ................................................... PT2-17

Disposal ........................................................................ PT2-17

Hoisting & Handling Safety ................................... PT2-17

General Precautions ................................................... PT2-17

Chains, Wire Rope and Fiber or Synthetic Slings ............................................................................... PT2-17

Foreseeable Misuse .................................................. PT2-18

General Burner Information ............................. PT2-19

Combustion Flighting ............................................. PT2-20

Operation .................................................................... PT2-21

Adjustments ............................................................... PT2-23

Burner Mounting ...................................................... PT2-24

Burner Pilot System .................................................. PT2-25

Adjustment and Operation of the Pilot System .......................................................................... PT2-25

The Initial Pilot Adjustment .................................. PT2-26

Phoenix® Talon 2 Burner

V 1.0 2018-04-19Burners for Aggregate Drying Applications ii

Natural Gas Fuel Piping System ........................... PT2-27

Oil Fuel Piping System ............................................ PT2-30

Heavy Oil Fuel Piping System ............................... PT2-32

Fuel Oil Atomizer ...................................................... PT2-34

Resetting the Nozzle Position ................................. PT2-34

Removing the Oil Gun Assembly .......................... PT2-35

Liquid Propane Piping System ............................. PT2-36

Compressed Air Train .............................................. PT2-38

Setting the Low Pressure Switch ......................... PT2-39

Flame Shape Adjustments .................................... PT2-39

Flame Scanner ........................................................... PT2-40

Pilot and UV Cooling Air ......................................... PT2-40

Lubrication & Interval Maintenance ............... PT2-41

Safety Sign Placement....................................... PT2-43

Troubleshooting ................................................. PT2-46

Pilot Will Not Light .................................................... PT2-46

Main Burner Fuel Won't Ignite ............................. PT2-47

Flame Stability Problems on Heavy Oil ............. PT2-47

Limits Not Complete ................................................ PT2-48

High Stack Temperature ......................................... PT2-48

Oil Buildup on the Burner ...................................... PT2-48

Weak Flame Signal ................................................... PT2-48

Recommended Spare Parts .............................. PT2-49

Detailed Burner Performance Data Sheets .... PT2-50

Altitude Correction Chart ................................. PT2-51


V 1.0 2018-04-19Burners for Aggregate Drying Applications iii

Figure 1. Astec I.D. plate ........................................................... PT2-2

Figure 2. Phoenix Talon 2 burner ............................................ PT2-19

Figure 3. Component identification and location .................... PT2-22

Figure 4. Component identification and location .................... PT2-23

Figure 5. Pilot system ............................................................. PT2-25

Figure 6. Typical pilot gas train ............................................... PT2-26

Figure 7. Natural gas train components .................................. PT2-27

Figure 8. Mini-main gas train components ............................. PT2-28

Figure 9. Regulator requirements ........................................... PT2-29

Figure 10. Oil train .................................................................. PT2-30

Figure 11. Heavy oil piping schematic .................................... PT2-32

Figure 12. Fuel oil atomizer and nozzle................................... PT2-34

Figure 13. Liquid propane piping schematic ........................... PT2-36

Figure 14. Typical compressed air train ................................... PT2-38

Figure 15. Flame scanner ........................................................ PT2-40

Figure 16. Flame scanner cooling air train .............................. PT2-40

Figure 17. Lubrication points for Phoenix Talon 2 burner ........ PT2-41

Figure 18. Safety signs for Up Phoenix Talon 2 burner ............ PT2-44

Figure 19. Safety signs for Down Phoenix Talon 2 burner ....... PT2-45

Table A. Burner Capacity ......................................................... PT2-20

Table B. Natural Gas Regulator Requirements......................... PT2-27

Table C. Feed Pipe Size for Gas Runs Over 25 ft ....................... PT2-28

Table D. Feed Pipe Size for Gas Runs 25 ft or Under ................. PT2-28

Table E. Astec Part Numbers for Recommended Flexible Pipe Nipples ............................................................................. PT2-29

Table F. Oil Train Settings. ....................................................... PT2-30

Table G. Minimum Oil Line Sizes for Various Lengths (in) ........ PT2-31

Table H. LP Train Settings ....................................................... PT2-36

Table I. Line Sizes (in) ............................................................. PT2-36

Table J. Recommended Compressed Air Pipe Sizes (in) ........... PT2-38

Table K. Lubrication Points–Phoenix Talon 2 Burner ...............PT2-41

Table L. Maintenance Schedule–Phoenix Talon 2 Burner ....... PT2-42

Table M. Safety Signs–Phoenix Talon 2 Burner ....................... PT2-43

Table N. Phoenix Talon 2 Burner Spare Parts List .................... PT2-49

Table O. Phoenix Talon 2 Burner Nozzle Spare Parts List ......... PT2-49

Table P. Blower Factor vs Altitude (Constant Speed*) .............. PT2-51

List of Figures List of Tables

PT2-1 of 51



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 mineral drying applications.

Instructions are included to cover many circumstances. However, it is impossible to address every scenario that may be encountered. If you are unsure of what to do after reading this OSM, contact your 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 plant 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 you are unfamiliar with the dangers associated with the type of hazard identified by a signal word, reference Safety Signs for the description of the warning.

PT2-2 of 51



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 of 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 plant 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 -PT2 - XXXXXXXXXXXXXXXXXXJOB# - 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

PT2-3 of 51



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.

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.

PT2-4 of 51



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

0832744.75 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.

PT2-5 of 51



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.

PT2-6 of 51



Informational Signs


083312 4.0 in × 2.0 in

Burner body 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.

PT2-7 of 51



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.

PT2-8 of 51



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.

PT2-9 of 51



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.

PT2-10 of 51



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.

PT2-11 of 51



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.

PT2-12 of 51



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.

PT2-13 of 51



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.

PT2-14 of 51



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.

PT2-15 of 51



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.

PT2-16 of 51



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.

PT2-17 of 51



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.

PT2-18 of 51



PT2-19 of 51



The Phoenix® Talon 2 burner is designed to provide maximum firing capability with minimum noise and pollution.

With its compact flame shape, the Phoenix Talon 2 burner 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 Phoenix Talon 2 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. (See Table A.)

The fuel/air ratio is maintained throughout the burner’s operating range with either mechanically or electronically linked valves. Depending on burner configuration, the Phoenix Talon 2 burner will burn all commercial grades of fuel oil, natural gas or propane. The gaseous fuels are burned as “premix.” Fuel gasses and air are premixed in the burner body, well upstream of the ignition point at the burner nose. Being a premix burner enables the burner to operate more cleanly and quietly.

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.

General Burner Information

Figure 2. Phoenix Talon 2 burner

PT2-20 of 51



Table A. Burner Capacity

BURNER MODEL

AIR FLOW (SCFH)

AIR FLOW (SCFM)

BURNER BLOWER

HP

NATURAL GAS (SCFH)

OIL FLOW (GPM)

MAXIMUM CAPACITY

(BTU/HOUR)

PT2-35 422,520 7,042 30 35,000 4.1 35,000,000

PT2-50 603,000 10,050 40 50,000 5.9 50,000,000

PT2-75 905,400 15,090 60 75,000 8.8 75,000,000

PT2-100 1,207,200 20,120 75 100,000 11.7 100,000,000

PT2-125 1,509,000 25,150 100 125,000 14.7 125,000,000

PT2-150 1,810,800 30,180 125 150,000 17.6 150,000,000Notes:1. The maximum BTU/hour rating is based on 20% excess air.2. The figures used in Table A are based on: 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. 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.6. The air flow in the Phoenix Talon 2 burner can be monitored using the pressure tap on the side of the burner blower housing. The air pressure for a given flow is in the Burner Performance Data Sheets.7. The values of differential pressure versus gas flow using the gas line orifice plate is listed in the Burner Performance Data Sheets.8. The air required to atomize fuel is provided by compressed air during oil firing. (Refer to Note 4.)

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.

PT2-21 of 51



Operation

The Phoenix Talon 2 burner utilizes a variable frequency drive (VFD) to control the combustion air blower.

The fuel valve(s) have independent control motors, or actuators. There is no mechanical linkage between the fuel and air controls.

A programmable logic controller (PLC) or other ratio control system approved by the Astec Burner Group controls the air and fuel flows independently.

The combustion air blower pressure switch (normally open) must be made to prove the blower is operating. This pressure switch is usually set at 1/2 inWC. It will close as the air pressure exceeds the set point.

When the blower first comes on, it will be turning slowly (about 240 rpm). This is a normal operating condition. The combustion air blower will adjust to high speed automatically.

These conditions must be met to initiate the purge cycle prior to lighting the burner:

1. The safety limit parameters must be satisfied.

2. The purge pressure switch (normally open) must be energized for the purge cycle to begin. (This pressure switch is usually set at 7 inWC. It will close when the air pressure exceeds the set close point.)

3. The facility flue gas exhaust fan must be confirmed to be running.

4. The purge timer must be set so that a minimum calculated volume of air flows through the drum during the purge cycle. (The minimum purge time is the time required for this calculated volume of air to flow through the heating chamber. This is usually four times the chamber volume.)

Before light-off, the combustion air blower must be set at the low-fire speed.

The low-fire combustion air pressure switch (normally closed) must make to prove that the blower is at the low-fire speed. (This switch is usually set at about 1 1/2 inWC. It will make as the air pressure falls below the set point.)

For the light-off sequence to begin, the fuel valve(s) low-fire switch must be made to prove that the fuel valve(s) are at the low-fire position.

PT2-22 of 51



Figure 3. Component identification and location

Fuel Oil Modulating

ActuatorSafety

Shutoff Valves

Fuel Oil Train

Fuel Oil Connection

Electrical Junction Box

Combustion Air Blower Motor

Burner Body Air Pressure Tap

Mini Main Gas Train

Natural Gas Train

Gas Manifold Pressure Tap

Blower Silencer

Flame Scanner

Fuel Oil Atomization

Nozzle

Burner Nose Cone

Radiation Shield

Drum Noise Reduction Seal (Rubber Skirt)

Combustion Air Blower Motor

Mini Main Gas Train

Compressed Air Train

Natural Gas Train

Removable Cable Hanger

Fuel Oil Modulation Actuator

Flame Scanner Cooling Air Train

Blower Silencer

Pilot Gas Train

PT2-23 of 51



Adjustments

Because all combustion systems are inherently dangerous, only qualified and experienced personnel should attempt to start up and adjust 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 Phoenix Talon 2 burner or are under the supervision of the Astec Burner Service Department.

The fuel valves, fuel profile and air profile are preset at the factory to simplify burner and process setup. However, some adjustment will be required for operation. Refer to the Burner Performance Data Sheets for flows, operating pressures, and valve positions.

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.

1. Check the linkage settings (if applicable) to make sure they comply with the Burner Performance Data Sheets. Adjust them if necessary.

Figure 4. Component identification and location

Blower Silencer

Mini Main Gas Train

Natural Gas Train

Drum Suction Tube

Natural Gas Connection

Temperature Switch (Flashback Protection)

Gas Safety Shutoff Double Block Valve

Gas Orifice Plate

Burner Body Air Pressure Tap

PT2-24 of 51



2. 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 10.5% at high fire.

• The amount of CO should be less than 500 PPM referenced to 3% O2.

• Higher CO can be caused by having either too much or too little combustion air, or a problem with the combustion zone flighting.

Altering the fuel/air ratio of the burner requires care and expertise to prevent a dangerously rich firing condition.

The best way to alter the fuel/air ratio is to alter either the air or fuel profile within the burner control system.

A less-preferred alternative to alter the fuel/air ratio is to vary the fuel pressure slightly.

Prior to running, record any changes on the Burner Adjustment Sheet and retain it in your records.

The spin vanes affect both flame shape and fuel mixing.

• The spin vanes are preset at the factory and are optimized for most situations. They are not designed to be field adjustable.

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

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 nose.

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.

PT2-25 of 51



Burner Pilot System

The Phoenix Talon 2 burner incorporates a forced-air pilot system. (See Figure 5.) 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.

Adjustment and Operation of the Pilot

System

1. Only use natural gas (NG) or liquid propane (LP) vapor 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 an LP vapor line. (Refer to previous 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.)

Figure 5. Pilot system

Igniter Boot

IgniterIgniter Wire

Oil PipeSpin Vanes Pilot Flame

Cup

Compressed Air Pipe

Liquid Fuel Nozzle

Pilot Pipe

Liquid Fuel Nozzle

Insulation over RFO Oil Pipe

Immersion Heater

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

7. The entire pilot/oil gun assembly can be removed from the burner by removing the bolts on flange at the back of the burner, 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.

PT2-26 of 51



The Initial Pilot Adjustment

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

2. The initial recommended pressure setting is approximately 5 inWC for vaporized propane or 10 inWC for natural gas at the test port. (See Figure 6.)

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

Figure 6. Typical pilot gas train

Ball Valve

Test Port

SolenoidValves

Gas Limiting Orifice Valve

Regulator

Y-Strainer

PT2-27 of 51



Table B. Natural Gas Regulator Requirements

BURNER MODEL PT2-35 PT2-50 PT2-75 PT2-100 PT2-125 PT2-150

MAXIMUM CAPACITY (FT3/HR) 35,000 50,000 75,000 100,000 125,000 150,000

GAS INLET PRESSURE (PSI) 4.5* 5.0* 4.0* 4.5* 5.5* 7.0*

GAS INLET PIPE SIZE (IN) 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.

Natural Gas Fuel Piping System

Figure 7. Natural gas train components

Manual Shutoff

Test Valve

Control Butterfly Valve

High Gas Pressure Safety Switch Flow Orifice Plate

(between flanges)

Gas Inlet Pressure Tap

Automatic Safety Shutoff

Valve Actuators

Safety Shutoff Valve BodyPressure Snubber

Low Gas Pressure Safety Switch

Manual Shutoff ValveWith Lock

Gas Strainer (between flanges)

Install a controlling gas regulator in the main gas line within 25 ft of the burner. (See Figure 7.) The 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.

PT2-28 of 51



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 shown in Table C. If the gas run is 25 ft or less, use the connection sizes shown in Table D.

The mini-main adds gas behind the front bluff body at the center of the burner cone. (See Figure 8.) This allows the field technician to add flame stability at lower firing rates. The tubing should extend halfway between the front and rear bluff bodies.

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

• The gas 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.

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.

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


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

Figure 8. Mini-main gas train components

Ball Valve

Gas Limiting Valve

PT2-29 of 51



Install the flexible fitting 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 is closely coupled to its actuator, eliminating all linkages.

Refer to individual Burner Performance Data Sheets for air and gas flows.

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

Natural gas flow is to be determined by the differential across the gas orifice plate and can be correlated to a gas flow using the Burner Performance Data Sheets.

Figure 9. Regulator requirements

FROM GAS SUPPLY

Regulator Pilot Line

Gas Regulator (By Customer)

BY CUSTOMERBY Astec

4 Main Pipe Diameters

10 Main Pipe Diameters

Control Line

Burner Gas Inlet

Manual Shutoff Valve

Table E. Astec Part Numbers for Recommended Flexible Pipe Nipples


ASTEC PART NUMBER

070037 070037 048292 048292 048292 062133

PT2-30 of 51



Oil Fuel Piping System

Table F. Oil Train Settings.


MAXIMUM CAPACITY (GPM)

4.1 5.9 8.8 11.7 14.7 17.6

TYPICAL GAS INLET PRESSURE (PSI)

92* 98* 90 102 116 150*

OIL INLET PIPE SIZE (IN) 1/2 1/2 1 1 1 1

*Estimated

Figure 10. Oil train

Flexible Hose

Ball Valve

Fuel Control Valve

Inlet Shutoff Ball Valve

Automatic Safety Shutoff

Valves

Flow Meter

Y-Strainer

Pressure Gauge

NozzlePressure Gauge

Fuel Low Pressure Switch

Fuel High Pressure Switch

Low Fire Fuel Bypass Valve

Oil Flow Modulating

Valve

Modulation Valve Limit

SwitchFuel Bypass Y-Strainer

PT2-31 of 51



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

BURNER MODEL

DISCHARGE LINERETURN LINE

(LIGHT OIL)RETURN LINE

(HEAVY OIL–OVER 80 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

PT2-35–50 1/2 1/2 1 1/2 1/2 1 1/2 1 1

PT2-75 1 1 1 1 1 1/4 1 1/4 1 1/4 1 1/2 2

PT2-100 1 1 1 1/4 1 1/4 1 1/4 1 1/4 1 1/4 1 1/2 2

PT2-125 1 1 1/4 1 1/4 1 1/4 1 1/4 1 1/4 1 1/4 2 2

PT2-150 1 1 1/4 1 1/4 1 1/4 1 1/4 1 1/2 1 1/2 2 2

For recommended pipe sizes, see Table G.

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.

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 individual 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.

PT2-32 of 51



Heavy Oil Fuel Piping System

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.

Figure 11. 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 inches from bottom of tank

Burner Fuel Oil Train

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

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

Fuel PumpDuplex Strainer

A

B

C

Fuel Flow

Heavy OilFuel Tank

PT2-33 of 51



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 #004404) 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. For heavier oils, this setting will be hotter than the factory setting.

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’s 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 G.

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. Do not change the linkage settings. Instead use the burner profile in the control system to change the oil valve position. (Refer to the Burner Performance Data Sheets.)

4. The low oil pressure switch is factory set at 30 PSIG.


PT2-34 of 51



Fuel Oil Atomizer

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 12 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 Burner 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.

Figure 12. Fuel oil atomizer and nozzle

Nozzle Flush or Inset from Front Bluff Body Ring

Rear of Bluff Body Flush to the Burner

Nose Cone Spin Vanes

Mini-Main Gas Tubes Should Protrude 1/8–3/16 in Past the Rear Bluff BodySECTION A-A

A

A

PT2-35 of 51



Removing the Oil Gun Assembly

To remove 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 Burner 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.

PT2-36 of 51



Liquid Propane Piping System

Table H. LP Train Settings


MAXIMUM CAPACITY (GPM)

6.7 9.5 14.2 18.9 23.6 28.4

LP INLET PRESSURE (PSI)

190* 190* 220* 210* 200 –

*Estimated

Table I. Line Sizes (in)

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

PT2-35–50 1/2 1 1

PT2-75 1 1 1

PT2-100 1 1 1 1/4

PT2-125 1 1 1/4 1 1/4

PT2-150 1 1 1/4 1 1/4

Figure 13. 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 SwitchHydro Static

Relief Valve(HSRV)

Ball Valve

Inlet Pressure Gauge

Low Fire Limit Switch

Ball Valve

Automatic Safety Shutoff Valves

PT2-37 of 51




For recommended pipe sizes, see Table I.

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 individual 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 inlet pressure at high fire. (Refer to the Burner Performance Data Sheets.)

4. The high LP pressure switch shall be set at 125% of inlet pressure at low fire. (Refer to the Burner Performance Data Sheets.)

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.)

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.

PT2-38 of 51



Compressed Air Train

Figure 14. Typical compressed air train

Oil Gun Connection

Y-Strainer

Manual Shutoff Valve

Low Pressure Switch

Air Pressure Regulator

Solenoid Valve Atomizing Air

Slow-Opening Ball Valve with

Actuator

Flexible Hose

Heat Trace Switch Box(only with sub freezing option)

Low Low Atomizing Air Pressure Switch

Table J. 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

PT2-35–50 50 1/2 1/2 1/2 3/4 3/4 3/4

PT2-75 85 3/4 1 1 1 1 1

PT2-100 85 3/4 1 1 1 1 1

PT2-125 120 1 1 1 1 1 1/4 1 1/4

PT2-150 140 1 1 1 1/4 1 1/4 1 1/4 1 1/4

The Phoenix Talon 2 burner uses compressed air for atomizing fuel oil. 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 J.

These sizes will result in minimum pressure drop for proper oil atomization. See Figure 14 for location of the air inlet pipe.

PT2-39 of 51



Flame Shape Adjustments

The Phoenix Talon 2 burner is preset at the factory for the shortest and narrowest flame possible. This makes flame adjustment burners virtually obsolete.

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.

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 Burner Performance Data Sheets.)

The low low atomizing air 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.

PT2-40 of 51



Flame Scanner

The Phoenix Talon 2 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. (See Figure 15.)

Remove the flame scanner by unthreading the 1 ¼ inch conduit coupling 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.

Pilot and UV Cooling Air

The flame scanner cooling air train provides the pilot and flame scanner with cooled air at a constant pressure from the facility's compressed air supply. The cooled, pressurized air prevents dust from building up in front of the scanner lens. Dust buildup degrades accurate flame readings and may cause nuisance shutdowns.

Figure 15. Flame scanner

Flame Scanner

Scanner Guide Pipe

Cooling Air

Electrical Conduit Connection

Undo the Conduit Coupling to Service or Inspect Flame Scanner

Flexible Conduit

Figure 16. Flame scanner cooling air train

Air Pressure Regulator

(set to 25 psig)

Compressed Air Inlet

Ball Valve

PT2-41 of 51



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 K. Lubrication Points–Phoenix Talon 2 Burner

PTINTERVAL HOURS*

IDENTIFICATION# OF PTS

LUBRICANT TYPE (OR EQUIVALENT)

AMT

1 Motor: Refer to OEM for lubrication specifications.

Figure 17. Lubrication points for Phoenix Talon 2 burner

①

PT2-42 of 51



Table L. Maintenance Schedule–Phoenix Talon 2 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 oil Y-strainer on the fuel oil train. ◊

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. ◊

Inspect the gas mixing tubes, accessed using the hatch behind the gas piping. ◊

Thoroughly inspect the burner blower impeller for buildup and wash as necessary. ◊

Clean the pilot gas Y-strainer. ◊

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. ◊

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. Plant managers should develop a maintenance schedule based on the demands and operation of the facility.*Dirt can clog the atomizing air nozzle, cause burner firing problems, and waste fuel through poor atomizing. Also check to make sure the atomizing oil nozzle is at the proper position inside the burner. (See Figure 12.)

PT2-43 of 51



Safety Sign Placement

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 M. Safety Signs–Phoenix Talon 2 Burner

ITEM PART

NUMBERDESCRIPTION

DANGER SIGNS

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 SIGNS

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

INFORMATIONAL SIGNS

11 083312 Burner body pressure

12 083314 Gas manifold pressure

13 083315 Gas orifice differential pressure

14 098786 Gas inlet pressure

15 074579 Made in USAThese locations are shown for reference only. Actual locations may vary based on the design of the equipment.Illustrations on following pages.

PT2-44 of 51



Figure 18. Safety signs for Up Phoenix Talon 2 burner

④

⑫

⑪⑤

⑧

②①

⑮⑦⑩

⑭

⑥③⑨

⑬

PT2-45 of 51



Figure 19. Safety signs for Down Phoenix Talon 2 burner

⑤

③

⑥

⑨

⑪

④⑫

⑩

⑮

⑦⑧

①

②

⑭

⑬

PT2-46 of 51



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.

PT2-47 of 51




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 strainer and the Y-filters. There is a strainer at the flange inlet of the Siemens gas valve. (See Figure 7.)

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.

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 (Saybolt Seconds Universal). 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.

PT2-48 of 51




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 it 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

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.

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.

PT2-49 of 51



Recommended Spare Parts

Table N. Phoenix Talon 2 Burner Spare Parts List

ITEM QUANTITY ASTEC P/N DESCRIPTION

1 1 000346 Pressure Switch, High Fire

2 1 005786 Adjustable Level Arm

3 1 005788 Limit Switch, Single Pole

4 1 079542 Regulator with Liquid Gauge (Compressed Air)

5 1 014655 Pressure Switch, Low Fire

6 1 080222 Temperature Switch (Heavy Oil Only)

7 1 071180 3/4 inch Solenoid Valve

8 1 075697 3/4 inch Slow Opening Ball Valve

9 1 071195 Ignition Transformer, 110V 160 Hz

10 1 071711 Terminal HSG-32 (For Igniter)

11 18 ft 071710 Ignition Wire

12 2 071712 Terminal SSN (For Igniter)

13 2 071713 Boot #250 (For Igniter)

14 1 072318 1 inch Y-Strainer

15 1 077241 Temperature Switch, 400 °F, Flash Back

16 1 076926 Low Pressure Switch Oil 30 PSI

17 1 075050 Igniter

18 1 071179 1 inch Relief Valve 60–70 PSI

19 1 075069 Pressure Switch, Low Combustion Air

20 1 063336 Fireye UV Scanner

21 1 075703 1/4 inch Pressure Switch, 100 PSI, Scanner Cooling Air

Table O. Phoenix Talon 2 Burner Nozzle Spare Parts List

BURNER MODELNOZZLE CAP (ASTEC P/N)

NOZZLE MIXER LIGHT OIL

(ASTEC P/N)

NOZZLE MIXER HEAVY OIL

(ASTEC P/N)

PT2-35–50 075470 075469 077822

PT2-75 075306 075305 077823

PT2-100 075306 075305 077823

PT2-125 075309 075308 077824

PT2-150 076017 077240 077826

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]

PT2-50 of 51



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.

PT2-51 of 51



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.The Phoenix® 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 P. 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

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