Forney MAXFire 100 Series User manual

MAXFire®Series 100 Gas Igniters Manual
Publication 372001-04 Rev. C

MAXFire®Series 100 Gas Igniters Manual
372001-04 Rev. C
ii
INTRODUCTION
This manual contains information for the MAXFire®Series 100 Igniter from Forney Corporation, 16479
North Dallas Parkway, Suite 600 Addison, TX 75001.
All personnel should become thoroughly familiar with the contents of this manual before
attempting to install, operate or maintain the MAXFire®Igniter system. Because it is virtually
impossible to cover every situation that might occur during operation and maintenance of the
equipment described in this publication, personnel are expected to use good engineering judgment
when confronted with situations that are not specifically mentioned herein.
The user should update this manual whenever significant changes are made to the system. To be of value,
the manual must always reflect the latest configuration of the equipment. It should be noted, however,
that Forney Corporation will furnish updated pages only if Forney authorizes a modification and
accomplished under Forney supervision.
PROPRIETARY NOTICE
The contents of this publication are proprietary data of Forney Corporation. Reproduction or use of any
part of the publication for purposes other than the support of the equipment for which it is published is
permissible only if expressly authorized in writing by Forney.
Additional copies of this publication may be purchased from Forney. When ordering or
requesting cost information, refer to the publication number appearing on the title page. Address
to the attention of the Sales Department, Forney Corporation, 16479 North Dallas Parkway, Suite
600 Addison, TX 75001.
Revisions
Revision
Date
Comments
A
05/04/2010
Initial Release
B
10/25/2010
Updated Capacity Rating for MAXFire 135
C
02/09/2015
Update logos, contact info, Spec table-MaxFire35 gas supply

MAXFire®Series 100 Gas Igniters Manual
372001-04 Rev. C
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Table of Contents
Section 1 Description....................................................................................................1
1.1 Spark Ignition Source.......................................................................................................................2
1.2 View Port..........................................................................................................................................2
1.3 Mount Tube......................................................................................................................................2
Section 2 Specifications...............................................................................................3
Section 3 Safety ............................................................................................................4
Section 4 Installation ....................................................................................................5
4.1 Mount Tube / Guide Tube................................................................................................................5
4.2 Fuel and Air Piping...........................................................................................................................6
Section 5 Commissioning ............................................................................................7
5.1 Igniter Flame Detection....................................................................................................................7
Section 6 Troubleshooting...........................................................................................8
Section 7 Maintenance..................................................................................................9
7.1 Guide Tube ......................................................................................................................................9
7.2 Igniter ...............................................................................................................................................9
Section 8 Storage........................................................................................................10
Section 9 Return or Repair Service ...........................................................................10
Section 10 Spare Parts ...............................................................................................11
Table of Figures
Figure 1-1 MAXFire® Gas Igniter AssemblyGuide Tube Assembly........................................................1
Figure 1-2 Typical MAXFire® Mount Tube Assembly..............................................................................2
Figure 4-1 Igniter Tip Arrangement..........................................................................................................5
Figure 4-2 Typical Fuel Piping Arrangement ...........................................................................................6
List of Tables
10-1 Recommended Spare Parts List....................................................................................................11

MAXFire®Series 100 Gas Igniters Manual
372001-04 Rev. C
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Section 1 Description
The MAXFire®gas igniter is a versatile and reliable source of ignition energy for oil, coal, or natural gas
burners. It is a self-contained unit that features a stable and clean-burning flame, repeatable fuel ignition,
low maintenance (no moving parts), and low combustion/cooling air requirements.
Depending on the burner capacity, the MAXFire®gas igniter may be sized for use as an NFPA-rated
Class 1, Class 2, or Class 3 igniter. Class 1 igniters are used for burner light off and support. Class 2
igniters are used for light off and support under prescribed light off conditions. Class 3 igniters are used
for light off only and are not intended for warm-up or support.
MAXFire® igniters are available in a variety of hardware configurations to fit the customer’s installation
requirements and operating preferences. In addition to the standard assemblies, other capacities can be
provided on request.
The major components of the igniter assembly are a guide tube, ignition source, and view port. Figure
1-1 illustrates a typical arrangement of the MAXFire®igniter assembly.
Figure 1-1 MAXFire® Gas Igniter AssemblyGuide Tube Assembly
Guide tube lengths are available from 14 to 180 inches in 2-inch increments. The guide tube assembly
houses the following major parts of the igniter:
Gas tube
Spark Ignition Source
Orifice tube assembly

MAXFire®Series 100 Gas Igniters Manual
372001-04 Rev. C
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1.1 Spark Ignition Source
The igniter port of MAXFire®igniter can be fitted with:
Forney High Energy Spark Igniter (HESI Series 90 or Series 90EC for European applications)
High Tension Spark Igniter (HTSI)
Refer to the service manual for the HESI Series 90, HESI Series 90EC or HTSI for more detailed
information.
1.2 View Port
The standard MAXFire®igniter includes an integral view port through the igniter head.
CAUTION: Forney does not recommend the use of the view port for flame detector sighting. If this
location is utilized, Forney’s initial start-up procedure should be adhered to in its entirety. Reference
Section 5 Commissioning.
1.3 Mount Tube
In most applications, the MAXFire®igniter is mounted on a burner through a mount tube.
The mount tube (Figure 1-2) is welded to the burner front-plate and supports the igniter assembly. The
igniter guide tube slides into the mount tube and is secured in place by a split clamping ring (squeeze
collar) that is bolted or welded to the mount tube. The squeeze collar also serves as a packing gland
follower.
Figure 1-2 Typical MAXFire® Mount Tube Assembly
MAXFire®
Model
Mount Tube Outside
Diameter
110
2.13”
130
3.5”
135
4.0”
140
4.5”
150
5.5”

MAXFire®Series 100 Gas Igniters Manual
372001-04 Rev. C
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Section 2 Specifications
Specifications for each MAXFire Igniter are defined below:
MAXFire
110
MAXFire
130
MAXFire
135
MAXFire
140
MAXFire
150
Fuel
Natural gas
Fuel heating value
1000 Btu/ft3
Guide tube OD
1 7/8”
2 7/8”
3 ½”
4”
5”
Capacity rating
0.3 to 0.5
MMbtu/hr @
2 psig
0.2 to 1.5
Mbtu/hr @
10 to 15 psig
1.5 to 6
MMbtu/hr @
10 to 25 psig
(orifice size
dependent)
5 to 10
MMBtu/hr @
10 psig
11 to 15
MMBtu/hr @
15 to 20 psig
5, 10, and 15
MMBtu/hr @
15 psig
20 and 25
MMBtu/hr @
25 psig
25 to 50
MMBtu/hr @
15 to 25 psig
Gas inlet port
½” NPT
¾” NPT
1 ½” NPT
1 ½” NPT
2 ½” NPT
Cooling/combustion
air
23 scfm
45 scfm
50 scfm
80 scfm
120 scfm
Cooling/combustion
air pressure
3.0 to 6.0 inches w.c. above wind box pressure measured at the sight
port/scanner
Air inlet port
¾” NPT
¾” NPT
female
1 ½” NPT
1 ½” NPT
female
2” NPT
female
Ignition source
HESI, Series 90;
HESI, Series 90EC; or
HTSI
NFPA Class
1, 2, or 3
Recommended gas
supply hose size
¾” ID
1” ID
1 ½” ID
1 ½” ID
2 ½” ID
Gas line strainer
0.033 inch NPT female

MAXFire®Series 100 Gas Igniters Manual
372001-04 Rev. C
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Section 3 Safety
Forney makes every effort to include personnel safety as a basic design element of the MAXFire® igniter.
However, safety is the responsibility of each individual who installs, operates or maintains Forney
equipment. Observe the following safety instructions prior to performing installation, operation, or
maintenance instructions:
1. Use this equipment for its intended purpose only.
2. Follow the installation, operation, and maintenance procedures discussed in this publication and on
appropriate drawings.
CAUTION: The igniter should be sized, arranged, and tested per NFPA 85. Job-specific installation
instructions, arrangement and installation drawings are available as an option.
3. Ensure that all electrical tools are in good working order and has been calibrated correctly.
4. Do not disconnect grounding cables/wires while equipment is energized.
5. Do not perform modifications to the equipment.
6. Before opening the HESI power unit, disconnect the electrical supply from the power source. Allow
at least 2 minutes for the capacitor to discharge. Exercise extreme care when the power unit is
open. Refer to the HESI Service Manual for safety instructions for HESI equipment.
7. Ensure that no voltage is present prior to disconnecting any terminations.
8. Close the manual fuel shutoff valves before performing maintenance or troubleshooting procedures.
9. On pressurized furnace applications take precautions prior to removing the igniter to ensure hot
furnace gases do not escape from the boiler possibly creating a hazard. Forney recommends use of
aspirators on all igniters installed on pressurized furnaces.
10. Test all fuel pipe connections for leaks before placing system into service.
11. Ensure the igniter assembly and the HESI power unit or the HTSI transformer are connected to a
common ground.
12. When removing the igniter assembly from an operating furnace, wear protective clothing and
insulated gloves. While observing the igniter flame through an open observation port, wear a face
shield and protective clothing.
WARNING: Only knowledgeable and qualified technicians should be allowed access to this system or
its components. The installation, maintenance, and operation of the electrical equipment involve several
elements of danger. Carelessness can result in serious injury or death from electrical shock, falls, or
improper use of tools and test equipment.

MAXFire®Series 100 Gas Igniters Manual
372001-04 Rev. C
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Section 4 Installation
4.1 Mount Tube / Guide Tube
Typically, the mount tube is fixed permanently to the burner front plate and supports the igniter assembly.
The design of the MAXFire®igniter allows the user to weld the guide tube directly to the burner front plate,
if desired.
1. Cut a hole through the burner front plate in the location desired or as indicated on the installation
drawing. The diameter of the hole should be slightly larger than the outside diameter of the mount
tube.
2. Insert the mount tube through the front plate and into the burner area. Support the mount tube at the
position and penetration angle required or indicated on the optional installation drawing. During
retrofit or replacement applications, insert the MAXFire®igniter to the same location as the
previous igniter. As a general rule, the tip of the igniter should be 3 inches (± 1/8”) behind a vertical
plane through the position of the main burner fuel nozzle.
3. Seal-weld the mount tube to the burner front plate. On some older installations where cast iron
plates must be penetrated, a steel flange or cover plate can be bolted to the cast iron, so that the
mount tube can be welded to that flange or plate. When installing the guide tube, avoid contact with
internal burner parts, such as air vanes or burner sleeves. Occasionally, air vanes may have to be
trimmed in order to provide clearance for the mount tube.
4. Before tightening the mount tube squeeze collar, rotate the guide tube to accept flexible hose
connection for cooling/combustion air. Tighten the nuts of the squeeze collar to hold the guide tube
securely in position.
5. Before inserting the guide tube into the mount tube, inspect the primary combustion region for
cleanliness and check the position of the spark rod tip. Figure 4-1 illustrates the correct position of
the spark rod tip.
Figure 4-1 Igniter Tip Arrangement
Baffle Plate
Igniter Guide
Tube
Orifice Tube
Spark Rod Tip
Spark rod tip positioned 1/16”
through the baffle plate
Igniter Firing
Tip
Fuel Transport
Tube

MAXFire®Series 100 Gas Igniters Manual
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4.2 Fuel and Air Piping
Forney recommends using the following general guidelines regarding fuel and air piping.
NOTE: In applications for boilers with multiple igniters and burners, equal air and gas flow distribution
to each igniter are important for reliable and efficient operation. Care should be exercised in the design of
fuel and air headers to obtain uniform distribution under all flow conditions.
1. To prevent contamination of the igniter, ensure that all fuel and air piping and hoses have been
blown free of debris and moisture. During installation, tap off the gas header from the top or side to
help prevent contamination.
2. Install gas pressure regulators in the gas headers to ensure that the specified pressure is maintained
at the igniter. Ensure that the selected regulator has the required turndown capacity and response
time capability needed for this application. Install strainers upstream to protect regulator from
debris.
CAUTION: Install flexible hoses between the rigid supply headers to the igniter that allow adequate
length for maximum thermal expansion of the boiler.
3. Position igniter as needed to accept the flexible hose from air and gas supply. Ensure that all bends
in the flexible hose are in the same plane. Figure 4-2 illustrates a typical piping arrangement.
Figure 4-2 Typical Fuel Piping Arrangement

MAXFire®Series 100 Gas Igniters Manual
372001-04 Rev. C
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Section 5 Commissioning
Before commissioning the MAXFire®igniter, complete all steps in the Installation section of this manual.
Use the following checklist to ensure that the MAXFire®igniter is ready for initial operation.
_________ The mounting tube adequately supports the igniter assembly.
_________ The igniter assembly has been checked for clearance within the burner and does not
interfere with dampers, vanes, or any other moving parts.
_________ Adequate igniter assembly removal distance exists.
_________ The muffle area and gas orifices have been inspected and are free of dirt / debris.
_________ The HESI spark trip is in the correct location (Figure 3).
_________ All fuel and air piping have been blown clean and free of debris and moisture.
_________ The HESI was independently tested and works properly.
_________ All wiring and logic interlocks have been field-tested for proper operation.
_________ Adjust the cooling/combustion air manual valve to supply proper airflow. (reference
Specifications section of this manual).
_________ Adjust the pressure regulator on the igniter gas header to obtain the necessary
pressure at the igniter inlet.
5.1 Igniter Flame Detection
The igniter flame can be detected by a flame detector or flame rod located on the rear of the igniter or
separately mounted flame detector on the burner front. The igniter should always be started by qualified
personnel to test the igniter for proper light off, reliability, and compliance to NFPA 85 Code.
New igniters MUST always be started on a cold furnace to ensure all design parameters are correct and
the flame propagates to the fuel dump tube properly. It is highly recommended that a Forney Field
service engineer perform the initial startup to ensure safety and reliability of this product.
CAUTION: For Class 1, 2, or 3 igniters detecting flame down the guide tube of the igniter solely from
the back of the igniter may or may not be sufficient to prove an igniter flame. The application must be
proven at start-up. The purchaser is responsible to test as appropriate to satisfy NFPA.