4200 Kinemax

Bulletin 4200

• Stir up the heat in your furnace with exit velocities up to 275 ft/sec (185 MPH) to promoteworkload heat penetration and better temperature uniformity

• Operate on-ratio, with excess fuel, or with excess air to meet the specific demands of yourcombustion process needs

• Burn most clean, low pressure gaseous fuels or #2 light oil with only 8-16 ouncecombustion air pressures

• 48:1 turndown capability promotes faster bring-up times without temperature override

• Maximum application flexibility provided with seven different sizes and capabilities up to8,400,000 Btu/hr per burner

• Lower fuel consumption by using preheated combustion air up to 800°F (427°C)

• Lightweight refractory-less burner with stainless steel combustion sleeve for air heatingapplications

• Alternate refractory block materials for chamber temperatures up to 3000°F (1649°C)

1-1/2" Series G KINEMAX® Burners with spark ignitor, optional pilot gas adjustable orifice, and arranged for UV scanner mounting.Standard refractory block is shown in background and burner equipped with seal and support assembly in foreground.

KINEMAX® Gas or Oil Burners

CORPORATION 201 East 18th Street, P.O. Box 2068, Muncie, Indiana, 47307-0068. Phone: (765) 284-3304. FAX (765) 286-8394

Page 4202

1/95

KINEMAX® BurnersPrinciple of Operation

With Series G KINEMAX® Burners,combustion air enters the burner body andis swirled out into the burner block (orsleeve) through the internal air orifice plate.

Low pressure gas enters the burnerbody and exits to the block throughmachined ports in the gas nozzle.

The gas and air are intimately mixed inthe cast burner block tunnel. The sparkignitor is positioned to intersect the fuel/airmixture directly in front of the nozzle face.

Pilot gas is introduced directly behind thegas ports in the gas nozzle and essentiallyflows through to the burner block throughthe same ports as does the main gas. Thepilot capacity is the minimum firing rate ofthe KINEMAX® Burner.

With Series C KINEMAX® Burners,combustion air enters the burner body andis swirled out into the burner block (orsleeve) through the air orifice plate. Lowpressure gas enters the body and exits tothe block/sleeve through the gas tube andnozzle.

For light oil firing, the #2 oil entersthrough the strainer and oil tube going to theoil spinner nozzle where the stream of liquidoil is atomized by the atomizing air directly infront of the spark ignitor.

Gas for the pilot comes in through aseparate inlet in the gas body and flowsdown the gas tube where it spins out theface of the gas nozzle in front of the sparkignitor.

Series G KINEMAX® Burnersfor gas only firing

Series C KINEMAX® Burnersfor gas/oil firing

set to give a choice between on-ratio and excess air,or excess fuel firing. As high as 4700% excess air ispossible at minimum capacity.

Maxon catalog bulletin7000 describes MICRO-RATIO® Control Valves whichthrottle air and fuel volumesto the KINEMAX® Burner.

KINEMAX® Burners provide a higher velocitystream of hot combustion gases that promote circula-tion within your furnace or lehr, improving bothtemperature uniformity and workload penetration.

When used in conjunction with Maxon’s MICRO-RATIO® Control Valves, a KINEMAX® Burner may beadjusted to fire on-ratio throughout the firing range or

CORPORATION 201 East 18th Street, P.O. Box 2068, Muncie, Indiana, 47307-0068. Phone: (765) 284-3304. FAX (765) 286-8394

KINEMAX® Burners Page 4203

1/95

Design and Application Details

Material temperature limitsStandard burner block material is suitable for

operating temperatures up to 2600°F (1427°C). Themaximum operating temperature limit may bedownrated to 2400°F (1316°C) if the KINEMAX®

Burner is operating under the following conditions:– burner is installed in a furnace with fiber wall

construction– frequent cycling is present, inducing thermal shock

and stressesOptional refractory block materials are available

to extend maximum operating temperature limits asfollows:– up to 2800°F (1538°C); or– up to 3000°F (1649°C)

These higher temperature material options areavailable at net extra cost and may extend normaldelivery schedules.

Preheated combustion air up to 800°F (427°C)can be accommodated by standard burner.

Seal and support assemblies reinforceburner blocks in thin wall construction, such as fiberwall furnaces and air heating installations. Their largerarea mounting plate and metallic cylinder surround aheavier round cast block, providing additional strengthand support.

Carbon steel seal and support assembly issuitable for return air temperatures across the burnerof up to 600°F (316°C) and/or downstreamtemperatures up to 900°F (482°C).

Stainless steel seal and support assemblyprovides for return air temperatures of up to 1000°F(538°C) and/or downstream temperatures up to1500°F (816°C).

KINEMAX® Burners are available inthree configurations:– Standard version with refractory block for

installation in refractory walls– Complete with block sleeve to provide additional

block support in chamber walls of softwallconstruction

– Complete with stainless steel combustionsleeve offering lightweight refractory-less burner foruse in air heating applications. Maximum upstreamtemperature is 1000°F (538°C) and maximumdownstream temperature for this configuration is1500°F (816°C).

A complete KINEMAX® Burner system includesgas train, air/fuel proportioning equipment, pressureblower, and a control panel. Your Maxonrepresentative can help you choose from the broadrange available.

Typical applications include kilns, forge furnaces,annealing furnaces, lehrs, and other applications thatrequire heating uniformity and broad ratio control.

Typical KINEMAX® Burner Installation

Page 4204 KINEMAX® Burners

Capacity/Selection Data

All KINEMAX® Burners can be fired on-ratio,excess fuel, or with excess air. They include built-intest port connections for simplified start-up andadjustments, spark ignitor and a raw gas nozzle-mixing pilot.

Performance data is provided in the tables belowand on the following page.

Raw gas nozzle-mixing pilot requires natural gasbe regulated separately and supplied to the pilot gasinlet connection at 3-4" wc differential gas pressure.Pilot capacity is that which gives reliable light-off with3" wc natural gas pressure and a combustion airdifferential pressure of 0.1" wc. To light off with fullexcess air requires considerably higher gaspressures.

Minimums are based on an air differential of 0.1"wc and include excess air. Minimums increase if on-

ratio adjustment is required, or if the burner is to beignited with full excess air.

Performance limits show the maximum excess airratio possible at minimum firing rate.

Maximum capacity is a function of differential airpressure supplied to the burner air inlet as readbetween air test connection and combustionchamber. Combustion air blower rating must be sizedto allow for manifolding pressure losses.

Fuel supply differential pressures (read betweengas

test connection and combustion chamber) are

shown for both natural gas and propane.Flame geometry is also shown in tables. Flame

remains within the KINEMAX® Burner’s refractoryblock at lower firing rates. The flame geometry shownis measured from the end of burner block atmaximum rated capacity.

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11/95

Capacity/Selection Data

KINEMAX® Burner DesignationAll KINEMAX® Burners are drilled and tapped to

accept flame rod or UV scanner. Use flame rodoption only with Series G (gas only) burners.

KINEMAX® Burners are designated by size (airinlet pipe size) and either Series G (for gas only) orSeries C (for gas/oil firing).

Example:6" Series C KINEMAX® assemblywith block

When ordering a KINEMAX® Burner, the followinginformation must be specified:

– Burner size (air inlet pipe size)

– Burner series (Series G or Series C)

– Block or sleeve arrangement

– For flame rod or UV scanner

If burner is to be used with a flame rod, anoptional flame rod kit must also be ordered.

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Accessory Options

1-1/2" Series G KINEMAX® Burner with standardrefractory block, spark ignitor assembly, optionalpilot gas adjustable orifice, and two optional testconnection kits. Optional pilot gas adjustable orificesimplifies pilot adjustments. Optional test connectionkits simplify manometer hook-up for air and/or gaspressure readings during burner start-up and adjust-ment. They include 1/8" brass hose barb and 1/8" testcock. Kit must be removed and the test connectionsplugged during normal burner operation. Notealternate UV scanner port located on all KINEMAX®

Burners.

4" Series G KINEMAX® Burner with stainless steelcombustion sleeve, optional mounting plategasket, and customer’s UV scanner. Optionalmounting plate gasket provides burner/wall sealingwhen special mounting flange is used.

6" Series C KINEMAX® Burner shown with stain-less steel combustion sleeve for lightweight,refractory-less burner used in various air heatingapplications.

Replacement spark ignitor sub-assembly includesignitor and rubber cover.

Gas Check Valves should beinstalled in multi-burner jobs asclose as possible to each burnerinlet for dependable light-off(gas manifold may otherwise actas a reservoir, preventing light-off during trial-for-ignitionperiod). Valve should be in-stalled horizontally or verticallywith flow in upward direction. Do notinstall laying on side.

Air and Gas Balancing Valvesmay be used on multi-burnerinstallations for improved heatinguniformity.

Refractory Block

Test Connection

Kit

UV Scanner(supplied bycustomer)

Spark IgnitorAlternate

UV Scanner PortTest Connection

Kit

Adjustable Orifice

Mounting PlateGasket

Stainless SteelCombustion Sleeve

UV Scanner(supplied bycustomer)

Optional Pilot GasAdjustable Orifice

OilTube

UV Scanner(supplied by customer)

Spark Ignitor

Combustion Sleeve


3/96

Dimensions (in inches)

1.5" – 2" Series “G” KINEMAX® Burners

Pipe threads on this page conform to NPT (ANSI Standard B2.1)

Flame Rod Spark Ignitor

Adjustable Orificefor all burner sizes

Test Connection Kitfor all burner sizes

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5/03


2" Series C KINEMAX® Burners

Pipe threads on this page conform to NPT(ANSI Standard B2.1)

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6" KINEMAX® Burners

Pipe threads on this page conform to NPT(ANSI Standard B2.1)

Spark Ignitor Burner arrangement (as shipped) is shown ondimensional drawing. Gas body (see sketch above)can be rotated in 60° increments to reposition gasand pilot inlets plus sight glass. Atomizing air body(gas/oil burners only) can be rotated in 90° incre-ments to reposition atomizing air inlet except that inletcannot be aligned with gas inlet because of clearanceneeds. NOTE: Be sure to remove spark ignitor fromassembly before attempting any repositioning of air orgas body to avoid cracking ignitor porcelain.

*Dimension is 16" if refractory block is chosen.


1/95

Component Identification

Series G KINEMAX® Burners (gas only)

To order replacement parts:1. Specify parts by the names shown in the sketches2. Indicate quantity desired3. Indicate burner size from numbers cast on side of

nozzle body and/or pipe size of air inlet connection4. If ordering refractory block sub-assemblies,

identify refractory material code stamped on blockframe near cast Maxon name

Series C KINEMAX® Burners (gas/oil) Nameplate


Notes

�CORPORATIONMUNCIE, INDIANA, USAINDUSTRIAL COMBUSTION EQUIPMENT AND VALVES

Maxon practices a policy of continuous product improvement. It reserves the right to alter specifications without prior notice.

KINEMAX® Burners Page 4200-S-1

7/94

Installation and Maintenance Instructions

Air Inlet ArrangementKINEMAX® Burners are furnished in standard

position illustrated at right. Since burner block isround, the entire burner assembly may be installedand rotated when mounting into combustion chamberwall. This will permit matching up to field site piping.Positions which would allow dirt or debris to fall downand block flame supervision port should be avoided.

Air inlet down is standard

Burner Block ReplacementIf the refractory block of your KINEMAX® Burner

ever requires replacement, Maxon can supplyreplacement block and frame sub-assemblies.

When ordering refractory block/frame sub-assemblies, identify refractory block material codestamped on the bolt heads of your existing KINEMAX®

Burner.

To install a new block sub-assembly:1. Secure heat processing equipment from operation

following manufacturer’s instructions.2. Disconnect piping, etc. and remove KINEMAX®

Burner from installation.3. Loosen and remove the nuts holding the burner

body to the burner block.4. Remove old block assembly and remount new

block assembly. Be sure gasket between block andbody is in place between the components.

Replacement Block & FrameSub-Assembly

�CORPORATIONMUNCIE, INDIANA, USA INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES


Page 4200-S-2 KINEMAX® Burners

Installation Instructions

General InstructionsThe burner itself is normally only a part of your

complete combustion system. Additional pipe trainaccessories and control components will be requiredfor a complete system installation. The sketch belowshows a typical pipe train system as might be usedwith gas-fired KINEMAX® Burners.

Important: Do not discard packing material untilall loose items are accounted for.

To prevent damage in transit, the control valves,pipe trains, spark ignitor, mounting gaskets, flame rodand connecting linkage components may be packedseparately and shipped loose with your new MaxonKINEMAX® Burner.

KINEMAX® Burners can fire in any direction, butthe scanner manufacturer may impose limitations.Avoid orientations which might permit flame supervi-sion port to collect debris and/or moisture.

Include observation ports in your combustionchamber design to provide a view of both main andpilot flame area. This will simplify start-up and adjust-ment procedures.

Maxon assumes no responsibility for the use or misuse of the pipinglayout shown. Specific piping and wiring diagrams should always besubmitted to the appropriate agencies for approval on each application.

Burner block and casting failure is frequently theresult of external stresses and strains transmitted tothe burner through the piping. Flexible connectionsare recommended in all piping to reduce pipingstresses and alignment/shifting problems. Installationof such connectors at certain key spots in the air orgas manifolding can prevent damage to the burnersfrom uneven thermal expansion.

Typical installation diagram of Series “G” KINEMAX® Burner system




Installation Instructions (continued)

KINEMAX® Burner requires a separate combus-tion air blower. The nozzle mixing burners serve astheir own fuel/air mixing device.

The blower should not be exposed to direct radiantheat or positioned where it might draw in inert gases.If problems exist, consider relocation.

Electrical service must match the voltage, phaseand cycle of all electrical system components and becompatible with nameplate ratings. Insure that allnormal control safeguards are satisfied. Combustionair blower should continue to run after shutdown toallow burner to cool.

Gas supply piping must be large enough tomaintain the required fuel pressures cataloged for theparticular burner size used with burner operating atfull-rated capacity.

Anything more than minimal distance or pipingturns may necessitate “oversizing” piping runs to keeppressure drops within acceptable ranges.

If multiple burners are fed from a single gas train,care should be taken to minimize pressure drop andgive maximum uniformity.

Clean fuel lines are essential to prevent blockageof pipe train components or burner gas ports.

Main shut-off cock should be upstream of boththe main gas regulator and pilot line take-off. Use it toshut off fuel to both pilot and main burner during shut-down periods of more than a few hours.

The fuel throttling MICRO-RATIO® Valve with aMaxon KINEMAX® Burner is not intended for tightshut-off.

Main gas regulator is essential to maintain auniform system supply pressure. If one pipe trainsupplies multiple burners, consider a separateregulator in the branch leading to each burner system.

Size the regulator for full system capacity at therequired pressure, carefully considering pipe trainlosses. Follow the instructions attached to the regula-tor during installation.

Pilot take-off should be upstream of the main gasregulator, but downstream of the main gas cock. Itshould normally include its own pilot gas regulator, asolenoid valve, and shut-off cock. A pilot adjustableorifice at the pilot inlet simplifies adjustment.

Pilot piping must be large enough to provide forthe full flow and pressures shown in the catalog foryour particular burner size.

Fuel shut-off valves (when properly connected toa control system) are designed to shut the fuel supplyoff with a loss of electrical power. Manual reset

valves require operator attendance each time thesystem is started up (or restarted after a trip-out).Motorized shut-off valves permit automatic start-restart when used with an appropriate control system.

Blower must deliver a reasonably clean and coolair supply. Care must be taken to keep air manifoldpressure drops to a minimum and to independentlysupport the weight of air piping.

Gas and air piping should be located reasonablyclose to the burner and sized for the pressure andvolume requirements of the burner, with supplypressures high enough to permit subsequent regula-tion at each burner. Gas piping drops should notexceed 10% of initial supply pressure.

Control systems should provide all normallyrecommended interlocks (including operation of fuelshut-off valves).

Control system’s circuitry must not allow mainfuel shut-off valve to be opened unless combustion airis on, and must de-energize valve upon loss ofcombustion air pressure, along with the other usualsystem interlocks. Motor starter is to be interlockedwith valve, whether or not a combustion air pressureswitch is used.

Flame sensing may be accomplished by UV scan-ner or flame rod. UV scanner should be kept as closeto burner as feasible. Heat block, if used may affectsignal strength with some brands of UV scanners. Flamerod sensing must not be used with oil firing.

Low fire start is essential to obtain catalogedminimums.

Burner and pipe manifold support will berequired to support weight of the burner and anyconnected pipe train components. Air control motors,in particular, require additional support. Maxonconnecting base and linkage assemblies aredesigned to position the control motors to work withthe control valve, not to support their weight.

Multi-burner installations require special consid-erations if supplied by a common pipe train and/or airsupply. Air and Gas Balancing Valves may be usedfor improved heating uniformity; Gas Swing CheckValves should be installed in horizontal pipe and asclose as possible to each burner inlet for dependablelight-off (gas manifold may otherwise act as a reser-voir, preventing light-off during trial-for-ignition pe-riod).

If burners are opposite and firing toward eachother, use alternate UV scanner connection onKINEMAX® Burner to lessen chance of direct orreflected UV radiation.

4/91



Check visually that no obstructions exist in front ofthe burner, then prepare a shell opening up to 1"larger than burner diameter (2" larger through refrac-tory part of wall). Attach studs to furnace shell or weldangle iron from buckstay to buckstay if additionalsupport is required, checking location carefully forappropriate burner arrangement.

NOTE: Discharge face of burner should be flushwith inner furnace wall for maximum recirculationeffectiveness. Entire burner may be rotated aboutits centerline to mount in any position.

Mount burner in position and draw up mountingbolts to provide support. Overtightening will preventlateral expansion of the furnace plate and can causedestructive stresses.


Installation Instructions (continued)

Burner MountingIn a refractory wall (sketch 1), basic burner may be

used with castable refractory rammed into the spacearound burner, supported with angle iron and retainedby mastic-coated anchors. The remaining gap shouldbe packed with ceramic fiber insulation.

Note: Slotted holes in the burner mountingframe are intended to allow for lateral expan-sion of furnace. Tighten mounting bolts onlyenough to hold the burner in position.

In a “soft” wall (sketch 2), burner should bespecified with optional burner block sleeve andwrapped tightly in fiber blanket. Remaining spaceshould be packed with ceramic fiber insulation.

For maximum burner life, burner frame and furnaceshell must be protected from hot gas flows. Use hightemperature gasketing between burner mountingflange and furnace shell.

21




Gas Firing Start-Up Instructions

4/91

Read complete instructions before proceeding,and familiarize yourself with all the system’s equip-ment components. Verify that your equipment hasbeen installed in accordance with the originalmanufacturer’s current instructions.

CAUTION: Initial adjustment and light-offshould be undertaken only by trained andexperienced personnel familiar with combus-tion systems, with control/safety circuitry, andwith knowledge of the overall installation.Instructions provided by the company and/orindividuals responsible for the manufactureand/or overall installation of complete systemincorporating Maxon burner take precedenceover these provided by Maxon. If Maxon in-structions conflict with any codes or regula-tions, contact Maxon Corporation beforeattempting start-up.

NOTE: The following instructions assume use ofpiloted burners and Standard Cam MICRO-RATIO®

Valves:The photograph below shows a MICRO-RATIO®

Valve assembly consisting of an air butterfly valve tocontrol combustion air flow and an adjustable-gradiantSYNCHRO gas flow control valve. The latter ismechanically linked to the air valve and a series ofadjusting screws permits setting of a desired air/fuelratio throughout the burner firing range. A pneumaticor electric control motor will normally be mounted tothis MICRO-RATIO®

Valve assembly andestablish firing ratesin accordance withsystem demands.

Additional dataon Maxon MICRO-RATIO® Valves isprovided in catalogbulletin 7000.

For initial system start-up:1. Close all burner fuel valves and/or cocks.

Make preliminary adjustments to regulators.2. Check all electric circuitry. Verify that all safety

devices and interlocks are operable and function-ing within their respective settings/ranges. Besure all manifolds are tight and that test ports areplugged if not being used.

3. Check that all duct and chamber dampers areproperly positioned and locked into operatingpositions.

Vent dampers and pressure controllersshould be used to maintain balanced orslightly positive furnace pressures (0.0" to0.05" wc) for maximum efficiency. Excessiveback pressure can damage furnace and/or reduceburner capacity. Negative pressures allow infiltra-tion of secondary air and can seriously affectefficiency and temperature uniformity.

4. Start all system-related fans and blowers.Check for proper motor rotation and impellerdirection. Verify that all safety interlocks areworking. Allow air handling equipment to run foradequate purge of manifold and combustionchamber plenums.

CAUTION: Do not by-pass control panel timerstypically controlling sequential operations.

5. Initial start-up adjustment should only beaccomplished during a “manual” controlmode.Using a 3/16" allen wrench, disconnect theautomatic control motor’s linkage from MaxonMICRO-RATIO® ControlValve by loosening yourcontrol motor’s con-necting rod from thevalve’s toggle linkage.

Test connections are essential for burner adjust-ment. Each KINEMAX® Burner includes air and fueltest connections but additional connections should beprovided (at minimum) downstream of the regulatorand MICRO-RATIO® Valve.

Do not attempt to use test connections in pipeelbows or tees, as internal turbulence can giveerroneous readings. Test connections must beplugged except when readings are being taken.

Disconnect thislinkage from

MICRO-RATIO® Valve



6. See appropriate catalog dimensional page fortest connection locations, then cross-connect amanometer between burner air test connectionand a piece of tubing inserted into the combustionchamber at a point that will reflect chamberpressure. This will provide a direct-reading ofdifferential air pressures.

In similar fashion, cross-connect a manometerbetween burner’s gas test port and combustionchamber to read differential gas pressures.


Gas Firing Start-Up Instructions (continued)

Rotate the air valve while watching themanometer for the minimum air differentialpressure of 0.1" wc. (Note: This is a very smallincrement on a normal manometer. Readings/settings above 0.1" wc will lessen turndown ratioof burner system.) Then mark red air valve dial(see sketch below) opposite crank pointer.

Maxon offers a “test connection kit” accessorywhich provides a convenient means of connectingplastic tubing to the burner test port connections.Kit should be removed after initial start-up and thetest ports plugged for normal burner operations.

General: To achieve rated capacities, a KINEMAX®

Burner must be adjusted to give the specific air andgas differential pressures as indicated in the chartsshown on pages 4200-S-8 and 9.

7. Set minimum air differential pressure at 0.1" w.c.With MICRO-RATIO® Valve combinations of air

and fuel valves, the minimum differential setting isinitially established with the air valve only.

Disconnect the linkage between the air valveand fuel valve(s) on the MICRO-RATIO® Valveassembly.

8. Establish the maximum combustion airdifferential pressure by moving MICRO-RATIO®

Valve assembly toward the higher numberedpositions until the desired air differential (inaccordance with burner specifications) is reached.Again, mark red air valve dial opposite crankpointer (refer to Chart 2 on page 4200-S-9).

For example: A combustion system may need theair valve to only be 15° open for the “minimum”setting and the “maximum” requirements aresatisfied with the air valve open to 60°. By markingthese points on the air valve’s indicating strip, youare ready to reconnect the SYNCHRO Fuel Valve’slinkage to the air valve.

9. Reconnect the SYNCHRO Fuel Valve linkageto the MICRO-RATIO® assembly’s air valve.

Having marked the MICRO-RATIO® air controlvalve’s settings for both minimum and maximumfiring positions, you may adjust the linkage andtravel of the SYNCHRO gas valve’s stroke (seesketch below).

Loosen to separate air valvemovement from fuel valve(s) travel



Loosen Allen set screw ① and binding screw ②in toggle ④ . Move the toggle in universal camassembly slot towards the center of rotation sothat gas valve can rotate from its minimum tomaximum position, while the air valve swingsbetween the established (and marked) minimumand maximum settings.

Place air valve on pre-determined “minimum”position and rotate gas valve to its “minimum” set-ting position. Tighten down set screw ① and bindingscrew ② with both valves set at “minimum”.

Establish set screw ① as minimum-end adjust-ment point and binding screw ② as maximum-endadjustment point. (Note: It doesn’t matter which ismaximum or minimum, as long as you identify andkeep the same reference points for the nextadjustment steps.

Now rotate MICRO-RATIO® Valve to “maximum”position. The air valve maximum setting waspreviously determined. Loosen binding screw ②and adjust pointer and linkage to correct just halfof the distance required to make the air valvepointer indicate the maximum air valve setting.

Re-tighten binding screw ② and return theMICRO-RATIO® Valve to the “minimum” airsetting.

This time, loosen set screw ① and again correctfor just half of the distance required to make the airvalve pointer indicate the minimum air valvesetting.

Re-tighten set screw ① and again return theMICRO-RATIO® Valve to its maximum position.

Similarly, correct one half the distance withbinding screw ② for the maximum setting, etc.

Continue this adjustment procedure untilthe gas and air valves reach their minimumand maximum positions simultaneously.Normally, this is accomplished within sevenadjustments.

10. To prepare Maxon MICRO-RATIO® Valve forinitial fuel firing adjustment:

Remove coverplate from screwcarrier cam assem-bly and turn alladjusting screwscounter-clockwiseuntil flush with outersurface of casting(new equipment isshipped this way).



If multiple fuel arrangement, adjust linkagerods and toggle arrangements between SYN-CHRO Fuel Control Valve(s) so that all fuelcontrol valves travel together (from minimum tomaximum positions). Leave MICRO-RATIO®

Valve(s) at “minimum” position, as shown bypointer on position indicator strip.

11. To light and adjust gas pilot: Check to insurecombustion air supply is flowing to burner. Pilotgas regulator should initially be set at approxi-mately midpoint of its adjustment range. With pilotgas solenoid closed, open main fuel gas and pilotgas cock. Energize spark ignitor and pilot gassolenoid. Turn pilot gas adjustable orifice screwout (counter-clockwise) several turns from its fullyseated position. Observe ignition of pilot gasthrough sight port of burner assembly and/or byviewing flame signal metered from flame safe-guard relay circuit.

Refine pilot gas setting for a hard blue flame(and/or strongest flame signal) by adjusting gasflow through pilot orifice and/or pilot regulator.

Shut off pilot gas cock to extinguish pilot fire.Reopen and confirm easy re-ignition severaltimes. The flame safeguard relays should nowpower the main fuel shut-off valves.

Verify all safety interlocks are operational beforeopening any main and/or individual burner valves.

12. To light and adjust KINEMAX® Burner on gas:With gas pilot established and flame supervisionsystem operational, opening the main fuel shut-offvalve(s) will allow fuel flow to the SYNCHRO FuelControl Valve of MICRO-RATIO® Valve assembly.

13. Turn minimum adjusting screw in (clockwise)to open gas valve until gas is ignited at burners.Several turns of the screw may be necessary.Flame should normally be confined back in theburner block at rated minimums. (Higher mini-mums might possibly extend flames beyondburner block.)

NOTE: At this point, it is more important to get any kindof a flame as soon as possible. The flame geometry canbe adjusted and refined as needed later.14. Adjust main gas regulator (as necessary to

maintain required burner differential). Re-adjustminimum screw if necessary.

If pilots are to be interrupted, shut them off at thispoint and verify that main flame remains lit and holdsin flame detectors. Re-adjust if necessary.

4/91

Adj. Screws(under cover)

Handle forManual

OperationPositionIndicatorPointer

Locking Screwfor manualoperation



15. Once your flame is established and refined atthis position, and without advancing the screwcarrier quadrant higher, screw all remainingscrews down to at least the same level as yourfirst adjusted screw.

NOTE: A preliminary setting can be established with allthe remaining adjusting screws. Generally, each suc-ceeding screw needs to be screwed in approximatelyone full turn deeper than its preceding screw. A smooth“stair-step” gradient pre-set at this point from low to highwill simplify the remaining adjustment steps.16. With allen wrench engaged in second screw,

slowly move MICRO-RATIO® Valve to #1position, adjusting as necessary to maintainignition and the type of flame desired. Flamelength should increase slightly, burning with ablue center and yellow tips, and a steady combus-tion noise.

If firing into an uncured refractory chamber,allow system to run at this setting for thedryout period recommended by the furnace orrefractory manufacturer, then continue adjust-ment of the MICRO-RATIO® Valve.

17. Turn all remaining adjustment screws inslightly further than the second screw, thenwith allen wrench inserted in third screw, slowlymove MICRO-RATIO® Valve toward #2 position,adjusting as necessary.

CAUTION: If flame is extinguished, immediatelyshut off gas and return MICRO-RATIO® Valve tominimum position. Verify that pilots are stillburning then reopen gas valve and turn screwlast adjusted in slightly further before returningto that firing position. Refine adjustment ifnecessary.

18. Progressively work your way up through eachadjusting screw position, developing a smoothprogression slope from your first screw to the“maximum” position.

NOTE: To adjust the flame at any position, you mustmove the SYNCHRO Valve to the number you desireto adjust. This aligns the adjusting screw directly ontop of the fuel valve plunger. A resulting adjustment ofthe screw is directly applied to the fuel valve plungerand its interconnected valve body linkage.

If high temperature limit trips before adjust-ment is completed, cycle back to minimum andhold there until the system cools down beforeattempting further adjustment.



19. Note gas supply pressure while continuingwith adjustment. If it falls off below acceptablerange, it may be necessary to re-adjust theregulator. If so, lower firing positions will needrechecked and if necessary, re-adjusted beforeproceeding.

20. When all screws have been adjusted, recheckdifferential pressures with unit at operatingtemperature. Refine “high fire” setting if neces-sary, considering differential pressure, flamelength, and appearance.

Flame should be blue with yellow tails and adistinct “wrapping” characteristic, with steadycombustion noise. Dust or contaminants in the airstream may affect flame appearance.

The charts below and on the next page showspecific differential gas (Chart 1) and air (Chart 2)pressure readings at various firing rates. Thisdata may be used to refine your KINEMAX®

Burner adjustments.

Chart 1



21. If system will operate with interrupted pilot(considered good practice), shut pilots off nowand cycle MICRO-RATIO® Valve slowly fromminimum to maximum and back, with all convec-tion system dampers in operating position or withfurnace door closed.

22. When burner performance is satisfactory andstable throughout the firing range, reconnectlinkage from control motor to MICRO-RATIO®

Valve.23. Check out overall system operation on all fuels

by cycling through light-off at minimum, interrupt-ing pilot, and allowing temperature control systemto cycle burner from minimum to maximum andreturn. Recheck all safety system interlocks forproper setting and operation.

CAUTION: Test every UV installation for dan-gerous spark excitation from ignitors, and otherburners, direct or reflected UV radiation.

24. Shut system down, closing all fuel valves andallowing an approved post-purge period beforeshutting down fans and combustion air blower.Remove test connections and plug openings, thenreplace all equipment covers and caps andtighten all linkage set screws.

25. Instruct operator on proper start-up, operationand shutdown of system. Establish writteninstructions for reference.



4/91

Chart 2




Light Oil Firing Start-Up Instructions

To light and adjust KINEMAX®

Burner on light oil:26. All preliminary adjustments as outlined for gas

firing (steps #1 through #25) must have beencompleted.

Verify all safety interlocks are operational beforeopening any main and/or individual burner fuelvalve.

27. With gas pilot established and UV flamesupervision system operational, opening themain oil shut-off valve(s) will allow #2 oil to flowto the SYNCHRO Oil Control Valve of theMICRO-RATIO® Valve assembly.

CAUTION: Oil flames are highly radiant. Useeye protection and avoid prolonged viewing.

28. Turn MICRO-RATIO® Valve to minimumposition and, using the allen wrench suppliedwith MICRO-RATIO® Valve, turn minimumadjusting screw of oil valve in (clockwise) topermit oil flow to the burner(s). Continue turninginward slowly until minimum oil fire ignites.

CAUTION: Shut off oil quickly if there is anoticeable drop in oil pressure or if ignitiondoes not occur within a few seconds.

29. Check that pressure downstream of oilpressure regulator is sufficient to meet burnerrequirement plus piping losses. Readjust oilpressure regulator if necessary.

Failure of “some” burners on a multiple burnerjob to ignite would generally indicate line scale ordirt obstructions in the oil valve, oil tube and/or oiltip. Disassemble, inspect and clean if necessary.

30. Once ignition occurs, turn minimum screw in(for more fuel) or out (for less) until a yellow-white flame is produced without smoke or browntips. When properly adjusted, it should bepossible now to shut off pilots with the flamedetection system (if used), holding in on mainflame only.

31. Once your flame is established and refined atthis position, and without advancing the screwcarrier quadrant higher, screw all remainingscrews down to at least the same level as yourfirst adjusted screw.

NOTE: A preliminary setting can be established withall the remaining adjusting screws. Generally, eachsucceeding screw needs to be screwed in approxi-mately one full turn deeper than its preceding screw.A smooth “stair-step” gradient pre-set at this pointfrom low to high will simplify the remaining adjustmentsteps.32. With allen wrench engaged in second screw,

slowly move MICRO-RATIO® Valve to #1position, adjusting as necessary to maintainignition and the type of flame desired. Flamelength should increase slightly, with a steadycombustion noise.

Flame appearance should remain yellow-whitewith no brown tips and exhibit a distinct “wrap-ping” shape throughout the cataloged firing rate.

33. If firing into an uncured refractory chamber,allow system to run at this setting for the dryoutperiod recommended by the furnace or refractorymanufacturer, then continue adjustment of theMICRO-RATIO® Valve.

34. Turn all remaining adjustment screws inslightly further than second, then with allenwrench inserted in the third screw, slowly moveMICRO-RATIO® Valve toward #2 position,adjusting as necessary.

CAUTION: If flame is extinguished, immediatelyshut off oil and return MICRO-RATIO® Valve tominimum position. Verify that pilots are stillburning then reopen oil valve and turn screwlast adjusted in slightly further before returningto that firing position. Refine adjustment ifnecessary.

35. Progressively work your way up through eachadjusting screw position, developing a smoothprogression slope from your first screw to the“maximum” position.

NOTE: To adjust the flame at any position, you mustmove the SYNCHRO Valve to the number you desireto adjust. This aligns the adjusting screw directly ontop of the fuel valve plunger. A resulting adjustment ofthe screw is directly applied to the fuel valve plungerand its interconnected valve body linkage.

If high temperature limit trips before adjust-ment is completed, cycle back to minimum andhold there until the system cools down beforeattempting further adjustment.



36. Note oil supply pressure while continuingwith adjustment. If it falls off below acceptablerange, it may be necessary to readjust theregulator. If so, lower firing positions will needrechecked and if necessary, readjusted beforeproceeding.

37. When all screws have been adjusted, allowsystem to reach operating temperature thenrecheck minimum and maximum differential airpressures. Readjust linkage between air and fuelvalves if necessary. If any change is made, refinegas adjusting screw settings, always adjustingonly that screw corresponding to the position atwhich valve is then set.

When adjusting for firing at maximum posi-tions, take care that adjusting screws slopegradually toward that setting.

38. If system will operate with interrupted pilot(as recommended), shut pilots off now and cycleMICRO-RATIO® Valve slowly from minimum tomaximum and back, with all convection systemdampers in operating position or with furnacedoor closed.

39. When burner performance is satisfactory andstable throughout the firing range, reconnectlinkage from control motor to MICRO-RATIO®

Valve.40. Check out overall system operation on all

fuels by cycling through light-off at minimum,interrupting pilot, and allowing temperaturecontrol system to cycle burner from minimum tomaximum and return. Recheck all safety systeminterlocks for proper setting and operation.

CAUTION: Test every UV installation for dan-gerous spark excitation from ignitors, and otherburners, direct or reflected UV radiation.

41. Shut system down, closing all fuel valves andallowing an approved post-purge period beforeshutting down fans and combustion air blower.Remove test connections and plug openings,then replace all equipment covers and caps andtighten all linkage set screws.

42. Instruct operator on proper start-up, operationand shutdown of system. Establish writteninstructions for reference.


Light Oil Firing Start-Up Instructions (continued)

4/91




Notes

mMaxon practices a policy of continuous product improvement. It reserves the right to alter specifications without prior notice.

CORPORATIONMUNCIE, INDIANA, USAINDUSTRIAL COMBUSTION EQUIPMENT AND VALVES

KINEMAX® Burners Page 4200-A/P-1

8/03

Assembly Numbers

For these products, please order the following product numbers:(configured products are those with alphanumeric text)

XAMENIK ® srenruB ylnOsaGGseireS liO/saGCseireS

etelpmoCrenruB

]1[seilbmessA

"5.1 "2 "3 "4 "6 "2 "6

MK5.1 MK2 MK3 MK4 MK6 MKC2 MKC6

Segment choices are as follows for configured products:• Combustion Air Inlet Flange• Air Connection Type• Gas Connection Type• Pilot Orifice• Flame Detection• Block Material• Block Length• Seal and Support• Mounting Ring

XAMENIK ® SRENRUBylnOsaGGseireS liO/saGCseireS

"5.1 "2 "3 "4 "6 "2 "6

tikdoremalFemalfdnadordnuorgsedulcni

)A(ylbmessa-busdor72415 82415 92415 03415 --- --- ---

teksagegnalfydobelzzoN)egnalfrenrub&llawneewteb(

34653 44653 54653 73073 34653 73073

htiwdesu(etalpgnitnuoMkcolbdnaeveelsnoitsubmoc

]2[)ylno73243 83243 93243 --- 73243 ---

rofteksagetalpgnitnuoMevoba

19343 29343 39343 --- 19343 ---

tesegnalfdedaerht#521)ylnosrenrub"6(

--- 77635 --- 77635

tiknoitcennoctset"8/1 73143

*evlavkcehcgniwssaGC)ezis( v wolf

)"4/3(81653Cv 1.12=

)"1(91653Cv 43=

)"2/1-1(02653Cv 76=

)"2(12653Cv 08=

86983)"3(

)"1(91653Cv 43=

86983)"3(

"VB"seireSgnicnalaB

*sevlaVC)ezis( v wolf

riaroF)"2/1-1(22191

Cv 08=)"2(32191

Cv 831=)"3(52191

Cv 562=--- ---

)"2(32191Cv 831=

---

sagroF)"4/3(91191

Cv 11=)"1(02191

Cv 81=)"2/1-1(22191

Cv 08=)"2(32191

Cv 831=---

)"1(02191Cv 81=

---

ecifiroelbatsujdasagtoliP 13405

[2] Specify dimension Z location for welding

*Must be ordered as loose items.

Spare Parts and Accessories for KINEMAX® Burners

[1] Refer to Product Data Sheet 9000-1 & 2 for alternate materials at net extra charge

• Mounting Ring Gasket• Test Connection Kit (Combustion Air)• Test Connection Kit (Fuel)• Orifice Plate (3" & 4" gas only)• Oil Tip Connection (2" gas/oil only)• Atomizing Air Connection (6" gas/oil only)• Nozzle Body Flange Gasket

m Maxon practices a policy of continuous product improvement. It reserves the right to alter specifications without prior notice.

CORPORATIONMUNCIE, INDIANA, USA INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES

Page 4200-A/P-2 KINEMAX® Burners

Assembly Numbers

XAMENIK ® srenruBylnOsaGGseireS liO/saGCseireS

"5.1 "2 "3 "4 "6 "2 "6

&tnemecalpeRstraPerapS

doremalftnemecalpeRrevocrebburhtiwylbmessa

32415 52415 62415 --- --- ---

ylbmessa-busrotingikrapSrevocrebburhtiw

24043 28793 06173

)R(revocrebbuR 22781

)R(ssalgnoitavresbO 48291

tnemecalpeRkcolBrenruB

-buSseilbmessA

rofdetaRF°0062mumixam

kcolbdradnatS 00053 20053 40053 60053 43073 40105 43073

kcolbdednetxE 40953 50953 60953 70953 --- 83105 ---

.S.C&kcolbdradnatSeveelsnoitsubmoc

65953 95953 26953 56953 --- 93105 ---

.S.S&kcolbdradnatSeveelsnoitsubmoc

75953 06953 36953 66953 85073 04105 85073

.S.S&kcolbdednetxEeveelsnoitsubmoc

85953 16953 46953 76953 --- 14105 ---


kcolbdradnatS 8827301 2437301 1737301 6837301 4647301 6537301 4647301

kcolbdednetxE 0927301 4437301 3737301 8837301 --- 8537301 ---


2927301 6437301 5737301 0937301 --- 0637301 ---


4927301 8437301 7737301 2937301 6647301 2637301 6647301


6927301 0537301 9737301 4937301 --- 4637301 ---


kcolbdradnatS 9827301 3437301 2737301 7837301 5647301 7537301 5647301

kcolbdednetxE 1927301 5437301 4737301 9837301 --- 9537301 ---


3927301 7437301 6737301 1937301 --- 1637301 ---


5927301 9437301 8737301 3937301 7647301 3637301 7647301


7927301 1537301 1837301 5937301 --- 5637301 ---

Documents

4200 Kinemax