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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.
Stir up the heat in your furnace with exit velocities up to 275 ft/sec (185 MPH) to promote
workload heat penetration and better temperature uniformity
Operate on-ratio, with excess fuel, or with excess air to meet the specific demands of your
combustion process needs
Burn most clean, low pressure gaseous fuels or #2 light oil with only 8-16 ounce
combustion 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 to
8,400,000 Btu/hr per burner
Lower fuel consumption by using preheated combustion air up to 800F (427C) Lightweight refractory-less burner with stainless steel combustion sleeve for air heating
applications
CORPORATION
201 East 18th Street, P.O. Box 2068, Muncie, Indiana, 47307-0068. Phone: (765) 284-3304. FAX (765) 286-8394
Page 4202
KINEMAX Burners
Principle of Operation
With Series G KINEMAX Burners, combustion air enters the burner body and is swirled out into the burner block (or sleeve) through the internal air orifice plate. Low pressure gas enters the burner body and exits to the block through machined ports in the gas nozzle. The gas and air are intimately mixed in the cast burner block tunnel. The spark ignitor is positioned to intersect the fuel/air mixture directly in front of the nozzle face. Pilot gas is introduced directly behind the gas ports in the gas nozzle and essentially flows through to the burner block through the same ports as does the main gas. The pilot capacity is the minimum firing rate of the KINEMAX Burner. With Series C KINEMAX Burners, combustion air enters the burner body and is swirled out into the burner block (or sleeve) through the air orifice plate. Low pressure gas enters the body and exits to the block/sleeve through the gas tube and nozzle. For light oil firing, the #2 oil enters through the strainer and oil tube going to the oil spinner nozzle where the stream of liquid oil is atomized by the atomizing air directly in front of the spark ignitor. Gas for the pilot comes in through a separate inlet in the gas body and flows down the gas tube where it spins out the face of the gas nozzle in front of the spark ignitor.
KINEMAX Burners provide a higher velocity stream of hot combustion gases that promote circulation within your furnace or lehr, improving both temperature uniformity and workload penetration. When used in conjunction with Maxons MICRORATIO Control Valves, a KINEMAX Burner may be adjusted to fire on-ratio throughout the firing range or
set to give a choice between on-ratio and excess air, or excess fuel firing. As high as 4700% excess air is possible at minimum capacity. Maxon catalog bulletin 7000 describes MICRORATIO Control Valves which throttle air and fuel volumes to the KINEMAX Burner.
1/95
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
Seal and support assemblies reinforce burner blocks in thin wall construction, such as fiber wall furnaces and air heating installations. Their larger area mounting plate and metallic cylinder surround a heavier round cast block, providing additional strength and support. Carbon steel seal and support assembly is suitable for return air temperatures across the burner of up to 600F (316C) and/or downstream temperatures up to 900F (482C). Stainless steel seal and support assembly provides for return air temperatures of up to 1000F (538C) and/or downstream temperatures up to 1500F (816C). KINEMAX Burners are available in three configurations:
Standard version with refractory block for installation in refractory walls Complete with block sleeve to provide additional block support in chamber walls of softwall construction Complete with stainless steel combustion sleeve offering lightweight refractory-less burner for use in air heating applications. Maximum upstream temperature is 1000F (538C) and maximum downstream temperature for this configuration is 1500F (816C).
Typical applications include kilns, forge furnaces, annealing furnaces, lehrs, and other applications that require heating uniformity and broad ratio control.
A complete KINEMAX Burner system includes gas train, air/fuel proportioning equipment, pressure blower, and a control panel. Your Maxon representative can help you choose from the broad range available.
1/95
Page 4204
KINEMAX Burners
Capacity/Selection Data
All KINEMAX Burners can be fired on-ratio, excess fuel, or with excess air. They include built-in test port connections for simplified start-up and adjustments, spark ignitor and a raw gas nozzlemixing pilot. Performance data is provided in the tables below and on the following page. Raw gas nozzle-mixing pilot requires natural gas be regulated separately and supplied to the pilot gas inlet connection at 3-4" wc differential gas pressure. Pilot capacity is that which gives reliable light-off with 3" wc natural gas pressure and a combustion air differential pressure of 0.1" wc. To light off with full excess air requires considerably higher gas pressures. Minimums are based on an air differential of 0.1" wc and include excess air. Minimums increase if onratio adjustment is required, or if the burner is to be ignited with full excess air. Performance limits show the maximum excess air ratio possible at minimum firing rate. Maximum capacity is a function of differential air pressure supplied to the burner air inlet as read between air test connection and combustion chamber. Combustion air blower rating must be sized to allow for manifolding pressure losses. Fuel supply differential pressures (read between gas 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 Burners refractory block at lower firing rates. The flame geometry shown is measured from the end of burner block at maximum rated capacity.
Capacities / Specifications for 1.5" - 6" Series G (gas only) KINEMAX Burners
Burner Size Performance Factors Combustion air differential pressure Maximum Maximum with 800F preheated combustion air Capacities On-ratio pilot/minimum (1000's Btu/hr) Pilot/minimum with approximately 75% excess air Turndown ratio with 75% excess air Performance Limits with full excess air Minimum capacity to light burner (1000's Btu/hr) Percent excess air Turndown ratio with full excess air 27.5:1 35 osi inch wc 1.5" Series G 15 26 550 355 11 19 470 305 7 12 2" Series G 15 26 11 19 7 12 3" Series G 15 26 11 19 7 12 4" Series G 15 26 11 19 7 12 6" Series G 15 26 8000 5200 300 200 40:1 500 3900 16:1 1470 6.2 2.4 48 36
700 2400 2000 1600 4000 3400 2700 455 1560 1300 1040 2600 2205 1750 40 25 96:1 50 50 30 133:1 100
2600 2200 1800 3900 3400 2700 4700 3900 3100 3900 3300 2600 16:1 13:1 11:1 29:1 25:1 20:1 48:1 40:1 32:1 40:1 34:1 27:1 92 4.2 1.7 8 6 79 3.1 1.3 6 5 63 2 0.8 4 4 167 4.2 1.7 14 6 147 3.2 1.3 10 5 117 2.1 0.8 8 4 400 3.8 1.5 24 12 334 2.8 1.1 18 10 267 1.8 0.7 12 8 667 3.2 1.3 40 15 567 2.3 0.9 30 12 450 1.5 0.6 24 10
Combustion air volume required (SCFM) for maximum capacity (no excess air) Differential gas pressure required for maximum capacity Flame geometry Natural gas (inches w.c.) Propane gas (inches w.c.) Length (inches) Diameter (inches)
KINEMAX Burners
Page 4205
Capacity/Selection Data
Capacities / Specifications for 2" and 6" Series C (gas/oil) KINEMAX Burners
KINEMAX Burner Performance Factors Combustion air differential pressure inch w.c. Btu/hr Maximum GPH #2 oil Btu/hr On-ratio pilot or main minimum [3] Capacities Pilot or main minimum [3] with approximately 75% excess air GPH #2 oil Btu/hr GPH #2 oil .45 40,000 .3 28.6:1 210,000 1.5 535% 5.3:1 167 20 4.2 10 36 8 5.5 525,000 3.75 16:1 840,000 6 1100% 10:1 1470 70 6.2 13 96 24 7.15 62,000 60 775,000 26 1,000,000 26 8,400,000 osi 2" Series C (on #2 oil) 15 6" Series C (on #2 oil) 15
Turndown ratio with 75% excess air Performance Limits (throttling fuel only) with full excess air (full excess air defined as 15 osi differential pressure measured at the burner) Air volume (SCFM) required for maximum capacity Differential fuel supply pressure for maximum capacities Flame Geometry Diameter (inches Btu/hr Minimum capacity to light burner GPH #2 oil Percent excess air [1] Turndown ratio with full excess air Combustion air @ 15 osi Atomizing air @ 15 osi [2] Natural gas (in inches w.c.) #2 oil (in PSIG) Length (inches)
[1] Excess air based on minimum capacity required for ignition. Slight smoke possible, depending on air temperature and fuel oil quality. [2] When gas firing on Series C burner, a 1/2" diameter by-pass line is necessar y to keep atomizing air passage purged. [3] Minimum capacity will be twice rating shown if pilot is not interrupted.
11/95
Page 4206
KINEMAX Burners
Accessory Options
Refractory Block Test Connection Kit
Mounting Plate Gasket
Adjustable Orifice Test Connection Kit Alternate UV Scanner Port Spark Ignitor
1-1/2" Series G KINEMAX Burner with standard refractory block, spark ignitor assembly, optional pilot gas adjustable orifice, and two optional test connection kits. Optional pilot gas adjustable orifice simplifies pilot adjustments. Optional test connection kits simplify manometer hook-up for air and/or gas pressure readings during burner start-up and adjustment. They include 1/8" brass hose barb and 1/8" test cock. Kit must be removed and the test connections plugged during normal burner operation. Note alternate UV scanner port located on all KINEMAX Burners. Gas Check Valves should be installed in multi-burner jobs as close as possible to each burner inlet for dependable light-off (gas manifold may otherwise act as a reservoir, preventing lightoff during trial-for-ignition period). Valve should be installed horizontally or vertically with flow in upward direction. Do not install laying on side. Air and Gas Balancing Valves may be used on multi-burner installations for improved heating uniformity.
4" Series G KINEMAX Burner with stainless steel combustion sleeve, optional mounting plate gasket, and customers UV scanner. Optional mounting plate gasket provides burner/wall sealing when special mounting flange is used.
Combustion Sleeve Optional Pilot Gas Adjustable Orifice
Oil Tube
Spark Ignitor
6" Series C KINEMAX Burner shown with stainless steel combustion sleeve for lightweight, refractory-less burner used in various air heating applications.
KINEMAX Burners
Page 4207
Adjustable Orifice
for all burner sizes
Flame Rod
Spark Ignitor
A 6.06
B 2.75
dia. D 8.62
DD 4 4.25
G 11
H 11
HH 8.19
J 4.12
L 3.38
M 3.69
N 4.12
O 4.31
P 8.19
T 5.5
U 5.5
Stainless Steel Standard Block Z (min.) 2 Z (max.) 7.25 Extended Block Z (min.) 3.5 Z (max.) 11.5
11
11.75 5.88
5.12
2.25
3/96
Page 4208
KINEMAX Burners
Flame Rod
Spark Ignitor
A 7.38 8.56
B 3.31 4.06
Dia. D 10.12 11
DD 5.38 6.85
G 15 16
H 14 15
HH 11.62 12.38
J 5.81 6.19
L 4.19 4.5
M 4.44 4.81
N 3.31 3.62
O 6.38 7
P 6.62 7.19
R 6.69 7.19
SS
TT 3.25 2.81
T 7.5 8
U 7 7.5
Y 5.88 6.31
C.S. S.S. S.S. Carbon Steel Std. Blk. Std. Blk. Ext. Blk. Sleeve CC CC 7.25 CC 10 Z (min.) 7
Stainless Steel Std. Blk. Ext. Blk. Z (min.) Z (max.) Z (min.) Z (max.) 2 7.25 3.5 11.5
2.25
KINEMAX Burners
Page 4209
Stainless Steel Standard Block Z (min.) 2.0 Z (max.) 7.25 Extended Block Z (min.) 3.5 Z (max.) 11.5
Spark Ignitor
5/03
Page 4210
KINEMAX Burners
Spark Ignitor
Burner arrangement (as shipped) is shown on dimensional drawing. Gas body (see sketch above) can be rotated in 60 increments to reposition gas and pilot inlets plus sight glass. Atomizing air body (gas/oil burners only) can be rotated in 90 increments to reposition atomizing air inlet except that inlet cannot be aligned with gas inlet because of clearance needs. NOTE: Be sure to remove spark ignitor from assembly before attempting any repositioning of air or gas body to avoid cracking ignitor porcelain.
KINEMAX Burners
Page 4211
Component Identification
Series G KINEMAX Burners (gas only)
Nameplate
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Page 4212
KINEMAX Burners
Notes
KINEMAX Burners
Page 4200-S-1
7/94
Maxon practices a policy of continuous product improvement. It reserves the right to alter specifications without prior notice.
m
MUNCIE, INDIANA, USA
CORPORATION
Page 4200-S-2
KINEMAX Burners
Installation Instructions
General Instructions
The burner itself is normally only a part of your complete combustion system. Additional pipe train accessories and control components will be required for a complete system installation. The sketch below shows a typical pipe train system as might be used with gas-fired KINEMAX Burners. Important: Do not discard packing material until all loose items are accounted for. To prevent damage in transit, the control valves, pipe trains, spark ignitor, mounting gaskets, flame rod and connecting linkage components may be packed separately and shipped loose with your new Maxon KINEMAX Burner. KINEMAX Burners can fire in any direction, but the scanner manufacturer may impose limitations. Avoid orientations which might permit flame supervision port to collect debris and/or moisture. Include observation ports in your combustion chamber design to provide a view of both main and pilot flame area. This will simplify start-up and adjustment procedures.
Burner block and casting failure is frequently the result of external stresses and strains transmitted to the burner through the piping. Flexible connections are recommended in all piping to reduce piping stresses and alignment/shifting problems. Installation of such connectors at certain key spots in the air or gas manifolding can prevent damage to the burners from uneven thermal expansion.
Maxon assumes no responsibility for the use or misuse of the piping layout shown. Specific piping and wiring diagrams should always be submitted to the appropriate agencies for approval on each application.
m
MUNCIE, INDIANA, USA
Maxon practices a policy of continuous product improvement. It reserves the right to alter specifications without prior notice.
CORPORATION
KINEMAX Burners
Page 4200-S-3
4/91
Maxon practices a policy of continuous product improvement. It reserves the right to alter specifications without prior notice.
m
MUNCIE, INDIANA, USA
CORPORATION
Page 4200-S-4
KINEMAX Burners
m
MUNCIE, INDIANA, USA
Maxon practices a policy of continuous product improvement. It reserves the right to alter specifications without prior notice.
CORPORATION
KINEMAX Burners
Page 4200-S-5
Maxon practices a policy of continuous product improvement. It reserves the right to alter specifications without prior notice.
m
MUNCIE, INDIANA, USA
CORPORATION
Page 4200-S-6
KINEMAX Burners
Maxon offers a test connection kit accessory which provides a convenient means of connecting plastic tubing to the burner test port connections. Kit should be removed after initial start-up and the test ports plugged for normal burner operations. General: To achieve rated capacities, a KINEMAX Burner must be adjusted to give the specific air and gas differential pressures as indicated in the charts shown 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 is initially established with the air valve only. Disconnect the linkage between the air valve and fuel valve(s) on the MICRO-RATIO Valve assembly. Loosen to separate air valve
movement from fuel valve(s) travel
8. Establish the maximum combustion air differential pressure by moving MICRO-RATIO Valve assembly toward the higher numbered positions until the desired air differential (in accordance with burner specifications) is reached. Again, mark red air valve dial opposite crank pointer (refer to Chart 2 on page 4200-S-9). For example: A combustion system may need the air valve to only be 15 open for the minimum setting and the maximum requirements are satisfied with the air valve open to 60. By marking these points on the air valves indicating strip, you are ready to reconnect the SYNCHRO Fuel Valves linkage to the air valve. 9. Reconnect the SYNCHRO Fuel Valve linkage to the MICRO-RATIO assemblys air valve. Having marked the MICRO-RATIO air control valves settings for both minimum and maximum firing positions, you may adjust the linkage and travel of the SYNCHRO gas valves stroke (see sketch below).
m
MUNCIE, INDIANA, USA
Maxon practices a policy of continuous product improvement. It reserves the right to alter specifications without prior notice.
CORPORATION
KINEMAX Burners
Page 4200-S-7
12. To light and adjust KINEMAX Burner on gas: With gas pilot established and flame supervision system operational, opening the main fuel shut-off valve(s) will allow fuel flow to the SYNCHRO Fuel Control 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 the burner block at rated minimums. (Higher minimums might possibly extend flames beyond burner block.) NOTE: At this point, it is more important to get any kind of a flame as soon as possible. The flame geometry can be adjusted and refined as needed later. 14. Adjust main gas regulator (as necessary to maintain required burner differential). Re-adjust minimum screw if necessary. If pilots are to be interrupted, shut them off at this point and verify that main flame remains lit and holds in flame detectors. Re-adjust if necessary.
4/91
Maxon practices a policy of continuous product improvement. It reserves the right to alter specifications without prior notice.
m
MUNCIE, INDIANA, USA
CORPORATION
Page 4200-S-8
KINEMAX Burners
Chart 1
m
MUNCIE, INDIANA, USA
Maxon practices a policy of continuous product improvement. It reserves the right to alter specifications without prior notice.
CORPORATION
KINEMAX Burners
Page 4200-S-9
4/91
Maxon practices a policy of continuous product improvement. It reserves the right to alter specifications without prior notice.
m
MUNCIE, INDIANA, USA
CORPORATION
Page 4200-S-10
KINEMAX Burners
m
MUNCIE, INDIANA, USA
Maxon practices a policy of continuous product improvement. It reserves the right to alter specifications without prior notice.
CORPORATION
KINEMAX Burners
Page 4200-S-11
4/91
Maxon practices a policy of continuous product improvement. It reserves the right to alter specifications without prior notice.
m
MUNCIE, INDIANA, USA
CORPORATION
Page 4200-S-12
KINEMAX Burners
Notes
m
MUNCIE, INDIANA, USA
Maxon practices a policy of continuous product improvement. It reserves the right to alter specifications without prior notice.
CORPORATION
KINEMAX Burners
Page 4200-A/P-1
Assembly Numbers
For these products, please order the following product numbers:
(configured products are those with alphanumeric text)
KINEMAX Burners Complete Burner Assemblies [1] 1.5" 1.5 KM 2" 2 KM Series G Gas Only 3" 3 KM 4" 4 KM 6" 6 KM Series C Gas/Oil 2" 2C KM 6" 6C KM
[1] Refer to Product Data Sheet 9000-1 & 2 for alternate materials at net extra charge
50431
8/03
Maxon practices a policy of continuous product improvement. It reserves the right to alter specifications without prior notice.
m
MUNCIE, INDIANA, USA
CORPORATION
Page 4200-A/P-2
KINEMAX Burners
Assembly Numbers
KINEMAX Burners Replacement flame rod assembly with rubber cover Replacement & Spark ignitor sub-assembly with rubber cover Spare Parts Rubber cover (R) Observation glass (R) Standard block Extended block Rated for Standard block & C.S. 2600F combustion sleeve maximum Standard block & S.S. combustion sleeve Extended block & S.S. combustion sleeve Standard block Extended block Replacement Burner Block SubAssemblies 35000 35904 35956 35957 35958 35002 35905 35959 35960 35961 35004 35906 35962 35963 35964 Series G Gas Only 1.5" 51423 34042 2" 3" 51425 4" 51426 6" --Series C Gas/Oil 2" --37160 6" ---
39782 18722 19284 35006 35907 35965 35966 35967 37034 ----37058 ---
1037288 1037342 1037371 1037386 1037464 1037356 1037464 1037290 1037344 1037373 1037388 --1037358 ---
Rated for Standard block & C.S. 1037292 1037346 1037375 1037390 --1037360 --2800F combustion sleeve maximum Standard block & S.S. 1037294 1037348 1037377 1037392 1037466 1037362 1037466 combustion sleeve Extended block & S.S. 1037296 1037350 1037379 1037394 combustion sleeve Standard block Extended block 1037291 1037345 1037374 1037389 --1037364 ---
Rated for Standard block & C.S. 1037293 1037347 1037376 1037391 --1037361 --3000F combustion sleeve maximum Standard block & S.S. 1037295 1037349 1037378 1037393 1037467 1037363 1037467 combustion sleeve Extended block & S.S. 1037297 1037351 1037381 1037395 combustion sleeve --1037365 ---
m
MUNCIE, INDIANA, USA
Maxon practices a policy of continuous product improvement. It reserves the right to alter specifications without prior notice.
CORPORATION