Honeywell Maxon OT FHR User manual

Dual fuel burners - OXY-THERM®FHR
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combustion systems for industry
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Model number
OXY-THERM®FHR gas burners
Burner
model
Burner
size
Burner
type Fuel Fuel flow Block material
Burner
block
Oil
conversion
kit
Tagging
OT FHR S G N 36 M Y N N
Burner model
OT FHR - OXY-THERM®FHR burner
Burner size
S -Small
M - Medium
L - Large
XL - Extra large
Burner type
G - Gas
Fuel
N - Natural gas
X - Special gas (see Engineering)
Fuel flow
For OT FHR S G burners:
36 - 36 cubic meters/h
43 - 43 cubic meters/h
50 - 50 cubic meters/h
56 - 56 cubic meters/h
65 - 65 cubic meters/h
82 - 82 cubic meters/h
For OT FHR M G burners:
81 - 81 cubic meters/h
103 - 103 cubic meters/h
113 - 113 cubic meters/h
124 - 124 cubic meters/h
161 - 161 cubic meters/h
For OT FHR L G burners:
170 - 170 cubic meters/h
187 - 187 cubic meters/h
204 - 204 cubic meters/h
266 - 266 cubic meters/h
339 - 339 cubic meters/h
For OT FHR XL G burners:
281 - 281 cubic meters/h
365 - 365 cubic meters/h
466 - 466 cubic meters/h
566 - 566 cubic meters/h
667 - 667 cubic meters/h
Block material
M - MFZ-6 Mullite
Burner block
Y - Yes
N - No
Oil conversion kit
For OT FHR S G burners:
N - None
41 - 41 liters/h
58 - 58 liters/h
68 - 68 liters/h
For OT FHR M G burners:
N - None
99 - 99 liters/h
134 - 134 liters/h
193 - 193 liters/h
For OT FHR L G burners:
N - None
217 - 217 liters/h
251 - 251 liters/h
313 - 313 liters/h
358 - 358 liters/h
For OT FHR XL G burners:
N - None
462 - 462 liters/h
500 - 500 liters/h
569 - 569 liters/h
Tagging
N - None
ALW - Aluminum (wire-on)
SSW - Stainless steel (wire-on)

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E-i-5/13 Dual fuel burners - OXY-THERM®FHR
OXY-THERM®FHR oil burners
Burner
model
Burner
size
Burner
type Fuel Fuel flow Block material
Burner
block
Gas
conversion
kit
Tagging
OT FHR S O L 41 M Y N N
Burner model
OT FHR - OXY-THERM®FHR burner
Burner size
S - Small
M - Medium
L - Large
XL - Extra large
Burner type
O - Oil
Fuel
L - Light fuel oil
H - Heavy fuel oil
Fuel flow
For OT FHR S O burners:
41 - 41 liters/h
58 - 58 liters/h
68 - 68 liters/h
For OT FHR M O burners:
99 - 99 liters/h
134 - 134 liters/h
193 - 193 liters/h
For OT FHR L O burners:
217 - 217 liters/h
251 - 251 liters/h
313 - 313 liters/h
358 - 358 liters/h
For OT FHR XL O burners:
462 - 462 liters/h
500 - 500 liters/h
569 - 569 liters/h
Block material
M - MFZ-6 Mullite
Burner block
Y - Yes
N - No
Gas conversion kit
For OT FHR S O burners:
N - None
36 - 36 cubic meters/h
43 - 43 cubic meters/h
50 - 50 cubic meters/h
56 - 56 cubic meters/h
65 - 65 cubic meters/h
82 - 82 cubic meters/h
For OT FHR M O burners:
N - None
81 - 81 cubic meters/h
103 - 103 cubic meters/h
113 - 113 cubic meters/h
124 - 124 cubic meters/h
161 - 161 cubic meters/h
For OT FHR L O burners:
N - None
170 - 170 cubic meters/h
187 - 187 cubic meters/h
204 - 204 cubic meters/h
266 - 266 cubic meters/h
339 - 339 cubic meters/h
For OT FHR XL O burners:
N - None
281 - 281 cubic meters/h
365 - 365 cubic meters/h
466 - 466 cubic meters/h
566 - 566 cubic meters/h
667 - 667 cubic meters/h
Tagging
N - None
ALW - Aluminum (wire-on)
SSW - Stainless steel (wire-on)

Dual fuel burners - OXY-THERM®FHR
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Specifications
Capacities
OXY-THERM®FHR gas burners
(See Application Engineering Data Sheet for OXY-THERM®FHR burners for specific oxygen pressure information.)
OXY-THERM®FHR oil burners
(See Application Engineering Data Sheet for OXY-THERM®FHR burners for specific oil pressure information.)
Typical burner data
Fuel: natural gas at 60°F with 1000 Btu/ft3 (st) HHV - sg = 0.6 [1]
propane at 60°F with 2500 Btu/ft3HHV - sg 1.57 [1]
Stated pressures are indicative. Actual pressures are a function of air humidity, altitude, type of fuel and gas quality.
OXY-THERM®FHR gas burners OXY-THERM®FHR gas burner size
Small (S) Medium (M) Large (L) Extra Large (XL)
Maximum capacity range MBtu/h 1.0 - 3.2 2.9 - 6.3 6.0 - 13.1 10.0 - 24.0
Turndown 3 to 1
Pressures required to
burner inlet for maximum
capacities
Oxygen (@ 50% staged) < 1.0 psig < 1.0 psig < 1.0 psig < 1.4 psig
Natural gas psig 1.2
Propane psig 2.5
Typical oxygen to fuel
volumetric ratios
To natural gas 2.05 to 1
To propane 5.1 to 1
Approximate flame size Length See graphs on page 3-18.4-9
[1] sg (specific gravity) = relative density to air (density air = 0.0763 lb/ft3(st) )
OXY-THERM®FHR oil burners (LFO) = Light Fuel Oil; (HFO) = Heavy Fuel Oil [1]
Housing size Small (S) Medium (M) Large (L) Extra Large (XL)
Oil nozzle 115 125 156 188 218 250 281 312 328 344 391 422 438
Maximum flow gallons/hr 10.8 15.4 17.9 26.2 35.3 50.9 57.4 66.4 82.7 94.6 122.2 132.2 150.3
Fuel oil pressure @
maximum (LFO) psig 75
Fuel oil pressure @
maximum (HFO) psig 95 0
Turndown 3 to 1
Atomizing pressure
(LFO) psig 60
Atomizing pressure
(HFO) psig 80
Flame length range
@ maximum feet 4-5.5 4-5.5 4.5-6 5-6.5 5-6.5 8-10 10-12 10-12 11-13 12-14 13-15 14-16 15-17
[1] Heavy fuel oils require heating to obtain proper viscosity (less than 100 SSU or 21 cs) for optimal atomization. Temperature of HFO should be
measured at burner inlet, not HFO storage tank or oil heater outlet.
Burner fuel oil insert and oil piping near the fuel inlet should be purged with compressed air after shut down
to clear any remaining fuel oil. Failure to do so may cause plugging of oil atomizer and nozzle, and cause
poor or improper performance.

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E-i-5/13 Dual fuel burners - OXY-THERM®FHR
Materials of construction
Burner part Material
Burner housing 304 stainless steel
Block MFZ-6 Mullite
Gas nozzle 446 stainless steel
Oil nozzle 446 stainless steel
Mounting gasket MICA composite 710-1

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Intended service and typical application
Application details
OXY-THERM®FHR burners can be used in furnaces and melters, steel reheat furnaces, linear hearth furnaces, rotary hearth
furnaces, reverberatory furnaces, and other high temperature applications.
OXY-THERM®FHR burners have a unique design which allows fuel interchangeability and easy maintenance. They are able to
operate on fuel gas, light fuel oils or heavy fuel oils. Each fuel requires the use of separate nozzle inserts. Following plant safety
procedures, the burner fuel inserts can be removed while the furnace is still in operation. In some cases, fuel oils may be atomized
by fuel gases allowing simultaneous firing of two fuels.
OXY-THERM®FHR fuel inserts are custom designed for specific flame sizes and capacities. Contact MAXON with information on
your furnace dimensions, process, and capacity requirements.
.
Fuels
OXY-THERM®FHR burners are designed for firing on any clean fuel gas or light and heavy fuel oils.
Process flows and oxygen content
OXY-THERM®FHR burner requires no additional oxygen for complete, clean combustion beyond the oxygen fed through the
burner oxygen connection.
Process temperatures
OXY-THERM®FHR burners may be applied to furnace temperatures up to 3050°F with standard block materials. For higher
temperatures, please contact MAXON regarding special block materials.
Cooling flow, either clean, dry air or oxygen, must be used whenever the burner assembly is in a high temperature atmosphere and
is not firing. See installation and operating instructions for more details.
Burner blocks
MFZ-6 Mullite burner blocks are used with gas firing and oil firing. Burner blocks are available in standard lengths. See
“Dimensions and weights” on pages 3-18.4-10 and 11.
WARNING: Consult the installation and operation manual for safe removal of burner inserts. Use caution
as hot furnace gases will be present around typical burner installations.
Staged oxygen control valve must be placed in position #11 as shown on page 3-18.4-8 to provide optimal
cooling to the burner.
Block material
Type MFZ-6 Mullite
Maximum temperature 3050°F

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E-i-5/13 Dual fuel burners - OXY-THERM®FHR
Ratio control requirements
Correct fuel/oxygen ratio control valves should be selected. Trims should be selected to enable use with oxygen. For accurate ratio
control, MAXON SMARTLINK®MRV valves are recommended. Calibrated flowmeters in the fuel and the oxygen lines are
required for establishing accurate volumetric flow rates.
Emission performance
OXY-THERM®FHR burners utilize a patented oxygen staging technology to reduce the formation of NOx in high temperature
furnaces. Through deep staging of the oxidant flow, NOx is controlled to levels typically lower than less advanced oxy-fuel burners.
Best results are achieved in furnaces which are sealed tight from ambient air infiltration or running a slight positive pressure to
prevent the infiltration of nitrogen compounds. Results can vary widely by application. Contact MAXON for estimates and
consultation on best practice.
Exact emissions performance may vary in your application. Contact MAXON for installation-specific estimates and guaranteed
values. No guarantee of emissions is intended or implied without specific, written guarantee from MAXON.
Combustion oxygen and cooling flow
OXY-THERM®FHR burners may be adjusted to operate on ratio, with excess oxygen (oxidizing environment) or with excess fuel
(reducing environment). Typical applications will operate with 1-2% excess oxygen.
If burners are shut down while the furnace remains hot, it is recommended to continue a small flow of oxygen for cooling of the
burner. Alternatively, blower or fan air or can be used for burner cooling during burner shut down. Total elimination of cooling flow in
hot furnaces can result in damage to burner fuel inserts and other parts. For extended shut downs in hot furnaces, it is
recommended that the fuel insert be removed and cooling flow maintained through the burner housing.
Staging ratio control
OXY-THERM®FHR burners feature an adjustable staged oxygen design to optimize heat transfer, flame volume and emissions.
Increasing the staged oxygen produces higher radiative heat flux, larger flame volume and lower NOx emissions; decreasing
staged oxygen produces lower radiative heat flux, smaller flame volume and higher NOx emissions. The numbered hole positions
(1-11) shown on the drawing below correspond with the hole positions indicated on the primary/staged oxygen valve adjustment
graphs available from your MAXON sales representative.
Oxy-fuel burners cannot be set up and operated properly using only pressure measurements for
adjustment. Fully metered oxygen and fuel control systems are required for safe and optimum
performance.
1) Increasing staged
oxygen = higher
radiative heat flux
2) Decreasing staged
oxygen = lower
radiative heat flux
1
2
3
4
5
6
7
8
9
10
11
1
2

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Flame length - gas burners
Flame lengths shown are typical for burners sized and operating at maximum design conditions. Flame lengths per unit of heat
input will vary from these values when burners are operated below maximum design.

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combustion systems for industry
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E-i-5/13 Dual fuel burners - OXY-THERM®FHR
Dimensions and weights
OXY-THERM®FHR gas burners
1) 1/4” NPT
oxygen
pressure tap
2) Furnace wall
exterior
3) Fuel inlet
4) Oxygen inlet
View AA View BB
Dimensions in inches unless stated otherwise
Size A B C D [1] E F G H J K
S 23.7 2.72 12.28 14.12 5.96 9.41 13.47 10.0 4.26 2.62
M 26.54 2.82 14.28 14.62 8.21 10.22 14.0 13.25 4.73 2.93
L 30.17 3.56 14.28 15.12 11.71 13.12 16.5 15.75 5.26 2.73
XL 33.23 4.22 14.28 16.5 15.65 14.75 18.95 21.75 6.66 3.85
Size L M N P Q R S
NPT
T
NPT
Burner
weight
lbs
Block
weight
lbs
S 3.03 6.0 6.0 1.81 3.78 3.48 1-1/2 2 80 55
M 3.16 7.5 7.5 2.1 4.4 4.02 1-1/2 2 135 100
L 4.03 9.0 9.0 2.61 6.2 4.64 2 3 195 130
XL 4.62 11.88 11.88 2.93 7.57 6.66 3 4 335 245
[1] Clearance required to remove nozzle
D
1
2
A
BC
H
F
G
E
AA
BB
J
K
L
M
3
4
S
T
N
P
R
Q

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combustion systems for industry
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OXY-THERM®FHR oil burners
1) 1/4” NPT
oxygen
pressure tap
2) Furnace wall
exterior
3) 1/2” NPT
atomizing air
connection
4) 1/2” NPT oil
connection
5) Oxygen inlet
View AA View BB
Dimensions in inches unless stated otherwise
Size A B C D [1] E F G H J K
S 29.11 7.84 12.28 19.5 5.96 2.72 14.17 10.0 4.27 2.63
M 31.63 8.34 14.28 21.5 8.21 2.82 14.7 13.25 3.54 4.11
L 34.15 10.84 14.28 24.0 11.71 3.56 17.25 15.75 5.27 2.74
XL 35.46 12.16 14.28 24.5 15.65 4.22 18.56 21.75 --- ---
Size L M N P Q R S
NPT
Burner
weight
lbs
Block
weight
lbs
S 3.03 6.0 6.0 1.81 3.78 .90 2 85 55
M 3.16 7.5 7.5 2.1 4.4 1.19 2 140 100
L 4.03 9.0 9.0 2.61 6.20 1.38 3 200 130
XL 4.62 11.88 11.88 2.93 7.57 1.67 4 335 245
[1] Clearance required to remove nozzle
A
BC
H
1
2
3
F
G
E
D
AA
BB
J
K
L
M
N
P
4
5
S
Q
R

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E-i-5/13 Dual fuel burners - OXY-THERM®FHR
Installation instructions
Storage
OXY-THERM®FHR burners shall be stored dry (inside). Burner blocks have been cured carefully before shipment and shall be
kept dry. Wetting of the blocks could result in premature failures.
Handling
OXY-THERM®FHR burners are shipped as complete units. Handle burners with care, using proper equipment, during unpacking,
transport, lifting and installation. Any impact on the burner could result in damage.
Burner mounting
The views on the next page show two possible methods for mounting and holding an OXY-THERM®FHR burner block and frame
assembly in place.
Please read the operating and mounting instructions before using the equipment. Install the equipment in
compliance with the prevailing regulations.
Bedrijfs- en montagehandleiding voor gebruik goed lezen! Apparaat moet volgens de geldende voorschriften
worden geïnstalleerd.
Lire les instructions de montage et de service avant utilisation! L’appareil doit imperativement être installé selon
les règlementations en vigueur.
Betriebs- und Montageanleitung vor Gebrauch lesen! Gerät muß nach den geltenden Vorschriften installiert
werden.

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Typical burner mounting arrangement
Alternate burner mounting arrangement
1) Furnace wall
2) Melter wall
3) By others
4) Piping support
by others
1) By others
1
2
3
4
1
1

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E-i-5/13 Dual fuel burners - OXY-THERM®FHR
Burners should not be installed in a down-fired position.
The primary objective is to seal the burner block in the wall of the furnace and support the weight of any system piping.
The burner block sits on the sill or wall. The block must rest flat on the sill or wall without rocking to allow weight to be equally
distributed. Failure to do so could result in cracking and/or block failure. If burner port holes are too large, appropriate material
shims may be used to align the burner.
Burner block failure could result from external forces and stresses transmitted to the burner through the piping. Under no
circumstances should burner be the only support for 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 oxygen or gas
manifolding can prevent damage to the burners from uneven thermal expansion.
The opening of the furnace wall should provide a minimum of 1/16” clearance on all sides. High temperature furnace sealant or
other appropriate material should be used between burner block and furnace wall.
Burner installation procedure
Read the entire installation procedure before proceeding with the installation of oxygen-fuel burners.
To prevent damage in transit, the fuel inserts, mounting gaskets and burner housing may be packed separately. In most cases, the
burner will be shipped assembled. The housing may be removed from the burner block mounting plate to allow installation of the
block/mounting plate assembly only into the furnace wall.
For maximum burner life, burner housing and associated parts must be protected from hot gases.
Failure to follow the proper installation sequence noted below could result in damage or destruction of
vital burner components. Cooling oxygen or air flows should be present at all times when the burner
housing and metal components are mounted to a hot furnace.
NOTE: A 3/4” (or 12 mm) socket wrench is required for mounting nuts. A manual speed wrench is
recommended for quick and easy mounting of the burner housing.

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If fuel insert is shipped inside burner housing, remove the fuel insert and set aside in a protected area.
Install service plate over housing flange and secure plate to housing using T-bolts provided.
Pre-pipe quick-connect devices to the combustion oxygen, fuel and atomizing connections (if required) on the burner housing
and burner fuel inserts.
Install block/plate/housing assembly into furnace wall.
Establish cooling flow of air or oxygen through the housing during furnace heat up.
View port
A view port to observe burner flame is essential to inspect flame aspect. Locate the view port downstream of the flame, looking
back to the burner block. Make sure the complete flame can be evaluated.
Support burner oxygen and gas piping
The OXY-THERM®FHR burner shall not be used as support for the piping to the burner. Gas and oxygen piping shall be supported
in such a way that no additional loads will be created on the burner. Unsupported piping puts stresses on the block/housing
assembly.
Flexible connections are typically recommended for all OXY-THERM®FHR installations for both fuel and oxygen to prevent
transferring mechanical loads or vibrations to the burner’s ceramic parts. Quick connect/disconnect devices are recommended on
the oxygen and fuel connections to ease fuel nozzle switching.
Staged oxygen control valve must be placed in position #11 as shown on page 3-18.4-8 to provide optimal
cooling to the burner.
1) Service plate
2) Cooling flow
3) Staged oxygen
control valve (set to
position #11 for
optimal cooling)
1
23

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E-i-5/13 Dual fuel burners - OXY-THERM®FHR
Operating instructions
Instructions provided by the company or individual responsible for the manufacture and/or overall installa-
tion of a complete system incorporating MAXON burners take precedence over the installation and operat-
ing instructions provided by MAXON. If any of the instructions provided by MAXON are in conflict with local
codes or regulations, please contact MAXON before initial start-up of equipment.
Start-up
Typical ignition sequence
Checks during and after start-up
During and after start-up, check the integrity of the system. Check all bolted connections after first firing (first time on temperature)
and retighten if necessary.
Burner adjustment and control
Oxygen-fuel burners require accurate control of both fuel and oxygen for optimum performance. Piping to individual burners
should include control valves for both oxygen and fuel. In addition, flow meters for oxygen and fuel capable of local or remote
readout are required for proper burner adjustment.
Oxy-fuel burners cannot be set up and operated properly using only pressure requirements for adjustment. Fully metered oxygen
and fuel control systems are required for safe and optimum performance.
Read the combustion system manual carefully before initiating the start-up and adjustment procedure.
Verify that all of the equipment associated with and necessary to the safe operation of the burner system
has been installed correctly, that all pre-commissioning checks have been carried out successfully and
that all safety-related aspects of the installation are properly addressed.
OXY-THERM®FHR burners do not include means for self ignition. Burner ignition procedure is the
responsibility of the end user, according to applicable local, state and national codes. Burner ignition
should only be attempted at minimum firing rates (see capacity charts or contact MAXON) to prevent
pressure surge in the fired chamber.
CAUTION: Oxygen should only be used with approved materials, properly cleaned pipe and equipment,
and specially designed systems. Ordinary materials can be extremely flammable in the presence of oxygen
and air enriched with oxygen.

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Maintenance instructions
Safety requirements
Regular inspection, testing and recalibration of combustion equipment according to the installation manual is an integral part of its
safety. Inspection activities and frequencies shall be carried out as specified in the installation manual.
Perform the following activities at least annually as part of a recommended preventative maintenance routine:
Inspect burner internal parts for wear and oxidation.
Inspect associated control instruments and devices for function with particular attention to all safety permissive switches.
Perform leak tests on fuel shut-off valves according to any schedule established by the authority having jurisdiction.
Visual inspections
Regular visual inspection of all connections (air and fuel piping to the burner, bolting of the burner to the block) and burner flame
size and aspect are essential.
Recommended spare parts
Keep local stock of operationally critical parts. Contact MAXON for a complete list of recommended spare parts for your specific
application.
The OXY-THERM®FHR burner is provided with quick release clamps to allow for rapid change-over
between gas and oil firing. Customer-specific procedures for shut down and blocking of fuel gas and
oxygen supply to the burner must be developed and adhered to prior to attempting removal and changing
of fuel inserts. Only trained and qualified service and maintenance personnel should perform this
operation.