Maxon RadMax 13 Installation manual

m
CORPORATION
INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES
Maxon practices a policy of continuous product improvement. It reserves the right to alter specifications without prior notice.
MUNCIE, INDIANA, USA
RadMax™ Burners Page 1400-S-1
11/03
Start-up Instructions
Read complete instructions before proceeding and
familiarize yourself with all the system’s equipment and
components. Verify that all equipment has been
installed in accordance with the original manufacturer’s
current instructions.
CAUTION: Initial adjustment and light-off should be
undertaken only by trained and experienced
personnel familiar with combustion systems, with
control/flame safeguard circuitry and with knowledge
of the overall installation. Equipment installation
and operating procedures should comply with all
applicable international, federal, state, local codes
and standards.
Initial RadMax™ Burner start-up:
1. Close all burner fuel valves and gas cocks.
Make preliminary adjustment to fuel gas
regulator(s) to establish adequate fuel pressure.
2. Check all electric circuitry. Verify that all control
devices, flame safeguard, and interlocks are
operable and functioning within their respective
settings/ranges.
3. Check that all duct and chambers are clear and
that their dampers operate freely. Adjust all
dampers to their proper start-up positions. Open
the manual pet-cock valves on all burner Direct-
Spark/Flame-Sensing Ports.
4. Start process fan(s) and combustion blower(s)
and purge the entire unit in accordance with the
appropriate codes and standards.
5. Adjust combustion air pressure to establish the
proper burner manifold pressure per the “Capacities
and Specifications” table on page 1400-S-2. A test
connection is provided on the burner manifold for
set-up adjustment purposes. Required manifold
pressures are differential pressures relative to the
firing chamber. For on/off (single firing rate)
operation, adjust air to establish the proper
manifold differential pressure required for the
desired firing rate. For variable firing rate opera-
tion, refer to the following procedure:
A. Set low fire combustion air flow. Position
combustion air flow control device to establish
burner manifold pressure required for the
desired minimum firing rate (per table on Page
1400-S-2). Manifold differential pressure
should never be less than 2.0” w.c.
B. Set high fire combustion air flow. Position
combustion air flow control device to establish
burner manifold pressure required for the
desired maximum firing rate (per the table on
Page 1400-S-2.) Manifold differential pressure
should not exceed 6.0” w.c.
C. Return air flow control device to minimum.
6. Adjust fuel/air mixing device to the recommended
initial settings. Refer to the appropriate start-up
instructions provided by the manufacturer for this
equipment.
7. Ignite the burner. (Direct spark applications only;
refer to appropriate manufacturers instructions for
piloted systems.)
A. Verify combustion air blower is running.
B. Set air flow control device to minimum.
C. Open main gas shut-off valve(s).
D. Initiate trial for ignition sequence and verify
spark ignitor is arcing properly.
E. If burner does not ignite, close main gas shut-
off valve(s) and re-purge unit before attempting
to ignite the burner again.
8. Adjust burner minimum firing rate. Allow
burners to come up to stable operating temperature.
With the air flow control device at minimum, adjust
the fuel flow to establish the desire operating
temperature within the range stated in the “Capaci-
ties and Specifications” table on Page 1400-S-2. If
a slight blue haze is present on the face of the
burner, this is an indication that the mixture is too
lean. To correct, increase fuel flow until the blue
haze is no longer present. If you notice a yellow
blanket of flame on the burner surface, this is an
indication the mixture is too rich. To correct,
decrease fuel flow until the yellow haze is no longer
present.
9. Adjust burner maximum firing rate. Slowly
increase combustion air flow and fuel flow in small
increments as allowed by the fuel/air ratio controller.
Hold at each step and allow the burner to come up
to a stable operating temperature. Make adjust-
ments to fuel flow as necessary to establish the
desired operating temperature within the range
stated in the “Capacities and Specifications” table.
Continue to increase the fuel/air ratio controller in
small increments and make adjustments at each
step until the desired high firing rate is established.
10.Verify settings. After establishing high and low fire
settings, cycle the burner from high to low fire
several times to confirm the repeatability of fuel/air
settings. Shut down the burner and re-ignite to
confirm reliability of ignition system and light-off
settings. Check all safety interlocks and limits and
confirm proper settings and operation.
11.Verify temperatures. Confirm desired face tem-
perature is achieved. Also, confirm oven/chamber
temperature does not exceed 500°F.Verify that
sufficient process circulation exists to prevent
localized hot spots in excess of 500°F on burner
bodies.

m
CORPORATION
MUNCIE, INDIANA, USA
INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES
Maxon practices a policy of continuous product improvement. It reserves the right to alter specifications without prior notice.
Start-up Instructions
Page 1400-S-2 RadMax™ Burners
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NOTE: Most systems are
designedtonominal
capacities.Reducedor
extendedcapacitiesare
possible.RadMax™should not
beinstalledinovens/chambers
above500°F.ContactMaxon
formoreinformation.
Face Temperature Range for Various Firing Rates
1000
1100
1200
1300
1400
1500
1600
1700
10 12 14 16 18 20 22 24 26 28 30
Fuel Flow - Natural Gas (SCFH)
Tile Temperature (F)
2"w.c. Manifold Pressure
3"w.c. Manifold Pressure
4"w.c. Manifold Pressure
4.5"w.c. Manifold Pressure
5"w.c. Manifold Pressure
6"w.c. Manifold Pressure
Capacities and Specifications

m
CORPORATION
INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES
Maxon practices a policy of continuous product improvement. It reserves the right to alter specifications without prior notice.
MUNCIE, INDIANA, USA
Gasket
Bottom
Clamp
M8Washer
M8 Lock
M8 Screw
Manifold
Assembly
Burner Head
Direct Spark/Flame Sensing
Port Connection (4 Places)
Direct Spark/Flame
Sensing Port
Rivet
3/8" Corrugated Stainless Steel
Tubing with 1/4" NPT Male
Connectors
1/4" NPT ControlValve
Page 1400-S-3RadMax™ Burners
Upon receipt of your Maxon RadMax™ Burner, it may
be necessary to install the burner heads to the burner
manifold.Theburnerheadsareshippedcompletely
assembledandonlyrequiretwo fasteners per head to
attach them to the burner manifold.
Assembly Instructions
Followingtheillustrationsbelow,mounttheburnerhead
to the manifold:
1. Place the gasket on the air/gas inlet on the under-
side of the burner head. This gasket is used to help
provide a gas tight seal and must be installed.
2. Place the head on the manifold such that the plug
mates up with the hole in the manifold.
3. Use two M8 screws and two M8 washers (provided)
to attach the bottom clamp against the manifold and
securely fasten the head. Alternate the tightening of
the bolts to ensure an even clamping force.
4. Repeat for the remainder of the burner heads. Make
sure the “face” or tile sides of the heads are rela-
tively flush with each other before final tightening of
the fasteners to 3-5 foot-lbs.
Gasket
Detail of Gasket Installation
9/02

m
CORPORATION
MUNCIE, INDIANA, USA
INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES
Maxon practices a policy of continuous product improvement. It reserves the right to alter specifications without prior notice.
RadMax™ Burners
Maintenance Instructions
Figure 1
Installing Replacement Burner Tiles
– Step 1
Coat the tile support face of the body casting with a
thin film of gasket adhesive.
Figure 2
– Step 3
Place tile retainer frame face down on a flat surface.
Install 3 burner tiles into tile retainer, making sure that
no gaps exist between tiles and that tiles are properly
centeredintileretainer.
Figure 3
Page 1400-S-4
– Step 2
Install the burner body gasket. Be careful to ensure
gasket is installed squarely and use care to avoid
tearing gasket material. Allow gasket to set for 5-10
minutes before installing tiles.

m
CORPORATION
INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES
Maxon practices a policy of continuous product improvement. It reserves the right to alter specifications without prior notice.
MUNCIE, INDIANA, USA
Page 1400-S-5
Maintenance Instructions
Figure 4
– Step 4
Place burner body casting face down into tile retainer
frame, with burner body gasket resting on top of burner
tiles (along inside edge of tile retainer frame).
Figure 5
– Step 5
Install spring clips to secure the tile retainer frame.
RadMax™ Burners
9/02

m
CORPORATION
MUNCIE, INDIANA, USA
INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES
Maxon practices a policy of continuous product improvement. It reserves the right to alter specifications without prior notice.
RadMax™ Burners
Page 1400-S-6
Notes