YOKOI KIKAI KOSAKUSHO HOPE CJ-1 User manual

HG0G046E
HOPE CJ
CERAMIC JET GAS BURNER
HANDLING MANUALS
YOKOI KIKAI KOSAKUSHO CO., LTD.
Head Office:
2720-1, Oboraguchi, Nakashidami, Moriyama-ku, Nagoya 463, Japan
Tel: [phone]
Fax: [phone]

TABLE OF CONTENTS
(Page)
1) Inspection of Product and Accessories,
and Outline and Specifications of Product
・・・・1
2) Matters to be attended for safety ・・・・2
3) Read without fail ・・・・3
4) Installation ・・・・4
5) Piping ・・・・5
6) Flow sheet ・・・・5
7) Operation（Preparing・Igniting・Adjusting・Extinguishing） ・・・・6,7
8) Inspection (Burner Nozzle, Ceramic Tube) ・・・・7
9) Warning Plate ・・・・7
10) Troubleshooting ・・・・8
11) Structural drawing ・・・・9,10

- 1 -
1) Inspection of Product and Accessories, and Outline and Specifications of Product
Thank you for your selection of HOPE CERAMIC JET GAS BURNER type CJ. Please carefully read this
instruction manual in order for you to be fully satisfied with the performance of this burner and to secure
the safety in operation, maintenance and inspection. Also, please be sure to deliver this instruction
manual to the end u-ser, as well as to the constructor.
Inspection
Check to confirm whether or not the product is exactly in accordance with your order by referring to
the nameplate and the specification table given below. Also check for damage and other irregularities
caused by and during transportation.
Outline
HOPE CJ TYPE CERAMIC JET GAS BURNER is a direct ignition, nozzle mixing type gas burner using
a light-weight, compact ceramic tube. As this burner uses no burner tile, its installation in furnace
bodies, maintenance and others are easy. Flames, which are stirred in the furnace by high-speed
combustion gas of 130m/sec, make the distribution of in-furnace temperature homogeneous. This
burner can also be used for hot air of 300℃. Thus, this gas burner can be used widely as a gas burner for
various heat treatment furnaces, heating furnaces and the like.
Specification
Type Capacity
kW (kcal/h)
Connection (Rc) Mass
(Kg)
Air Gas
CJ-1 58 (50,000) 1 1/2 1/2 16
CJ-2 140 (120,000) 2 3/4 16
CJ-3 233 (200,000) 2 1/2 1 26
CJ-4 372 (320,000) 3 1 1/2 29
※Standard Pressure：Gas 3～10kPa Air 6kPa

- 2 -
2) Matters to be attended for safety
Before installing, trial- operating, maintaining or inspecting this burner, please learn the inside of this
burner, information of safety and other matless to be attended by reading this instruction manual and all
of attached documents.
The rank of the matters .to be attended is classified to "Top danger"
"Danger "and "Caution" in this instruction manual.
In case of wrong operating, it is predicted that serious
dangerous situation will happen and the operator or other
people.
May die or may be seriously injured.
In case of wrong operating, it is predicted that dangerous
situation will happen and operator or other people may die or
may be seriously injured.
In case of wrong operating, it is predicted that dangerous
situation will happen and the operator or other people will be
injured or only material described.
NOTE, Even the matters classified to CAUTION have a possibility of causing serious results. Then,
never fail to abide by matters described.
Meaning of the mark Example
Compulsion
This symbol indicates the contents that force or direct an action.
Specific contents of such action are given nearby.
Be sure to do!
Prohibition
This symbol indicates the contents that prohibit an action. Specific
contents of such action are given nearby.
Don’t touch!
Precaution
This symbol indicates the contents that call attention. Specific
contents of such attention calling are given nearby. Be careful. It’s
hot!

- 3 -
3) Read without fail
Be sure to do!
Never foil to exhaust the air in the furnace (pre-purge) before
igniting. Repeated ignitions may cause explosion due to the gas
stagnated in the furnace, please install safety devices like a flame
supper visor.
Electric-shock
Caution
Never fail to cut the electricity of transformer when you take off
the ignition plug in order to check the spark of it.
Prohibited
Never fail to take off the site-hole when igniting or on-fire the
burner.
※flame in the furnace may blow out.
Don’t touch!
Never touch the mounting plate of the burner and fitting parts of
the burner, Ceramic-tube-base, Air-body.
These area are high temperature when the burner is burning.
Packings
1. Do not use the attached gasket for sealing this burner.
2. Put the replaced old gaskets pouch and there away them according to the waste disposal
regulation or the waste cleaning regulation. Never burn up them.

- 4 -
4) Installation
1. Be very careful not to make an impact on the ceramic tube, or the burner may be damaged.
2. Install the burner in such a way that it is free from any up/down, right/left excessive force.
3. Do not cover the ceramic tube directly with any insulating material or the like as shown in the
burner installation drawing.
4. Cover the metallic portion of the combustion tube base with flexible refractory, such as ceramic
fiber. (Refer to the burner installation drawing.)
Burner installation drawing
Dimension sheet
型式 A B φC φD φE φF PCD(□)G φ(□)H φJ L
CJ-1 24 80
＞D
=F
or
>(E+30)
88 138 PCD172 φ200 15 250
CJ-2 24 80 88 138 PCD172 φ200 15 250
CJ-3 24 80 110 160 PCD206 φ240 15 300
CJ-4 12 100 139 189 □190 □220 15 285
※If the furnace wall length is longer than the combustion tube length L, provide a taper that is
greater than φC.

- 5 -
5) Piping
1. Direct good care to the inside of the pipe not to leave seal tape fractions, bond, cutting chips, etc.
2. In connecting the pipes, provide pipe support in proper positions to prevent the application of any
excess force.
3. Provide a straight pipe part of about 6 times as large in diameter as the pipe before and behind the
orifice flow meter
6) Flow sheet
(1) Pressure balance Valve Method
(2) Connection Method

- 6 -
7) Operation（Preparing・Igniting・Adjusting・Extinguishing）
Preparing
1. Check to confirm that all the gas cocks have been closed.
2. Check for in-pipe gas leakage with air or nitrogen.
3. Check to confirm that each component unit of the air and gas lines are in normal operation.
4. Check to confirm that gas is being supplied under the specified pressure and that the inside of the
pipe has been subjected to replacement purge.
5. Start the blower, and confirm that the rotational direction is correct and the exit pressure is as
prespecified.
6. Set the pressure to the pressure in the maximum combustion (6KPa) and to the pressure of the
minimum combustion (0.1~0.5 KPa) by using the damper.
7. Fully open the control damper, and air-purge the inside of the furnace. (Use approx. 5 times as
much as the furnace volume as the reference volume of air-purge.)
8. Set the control damper to the position for the minimum combustion.
Igniting
9. Check to confirm that the cock, solenoid valve and limiting valve located immediately before the
burner have fully been closed.
10. Fully open the cock and solenoid valve located immediately before the burner, slowly open the
regulating cock, and check to confirm that the main burner has exactly been ignited. (Be sure to
check them visually or by using a flame detector.)
Adjusting
11. Read the air quantity referring to the burner air quantity characteristic table (burner PQ
characteristic table)
12. Calculate the necessary gas quantity, and adjust the gas quantity by using an orifice flow meter
(MO) or other flow meter and manipulating the limiting valve until the specified excess air ratio is
obtained.
13. When the equalizing valve method is used, slowly open the control damper to the position for the
maximum combustion while checking the combustion state, and check to confirm the flowrates of
gas and air.
14. When a safety circuit has been incorporated into the flame detector, also check to conform the
flame current value.
15. After setting the excess air ratio, return the control damper to the position for the minimum
combustion.
16. When the control motor is used, joint the control damper to the specified position.

- 7 -
Extinguishing
17. Fully close the cock and solenoid valve located immediately before the burner, and check to
confirm that the fire has been extinguished.
※Stop the blower after the in-furnace temperature lowers to below 500℃ to protect the nozzle.
8) Inspection (Burner Nozzle, Ceramic Tube)
1. Confirm that the shut-off valve, the solenoid valve and the combustion blower are powered OFF.
2. Loosen the union and others of the gas piping.
3. Loosen the “hexagon headed bolts”⑰[⑯] fixing the “Air body”⑥[⑤] and the “Gas body”⑦[⑥].
4. Hold the “gas body” firmly, and pull out “burner nozzle”⑧[⑦], “gas pipe”⑨[⑧], “Ignition plug”
⑩[⑨] slowly and simultaneously.
5. Remove the union or the flange from the air piping.
6. Loosen the nuts fixing the burner to the furnace body.
7. Remove the “Air body” and “ceramic tube”① very carefully from the furnace body.
8. The “Ceramic tube” is removed after removing the “air body”. (If an excessive force has to be
applied, be very careful not to break the “ceramic tube”, “ceramic receive packing”④[③] and
“ceramic Support Packing”⑤[④].)
9. If the insulator or the like of the ignition plug has irregularities, such as crack, replace it
immediately (or ignition failure will be caused).
10. To replace the “burner nozzle” by a new one, loosen the “hexagon socket setscrew”⑮[⑭].
11. Check the ceramic tube on the state of the inside and outside. If the combustion tube is broken,
contact us for consultation as combustion may often be hampered.
12. Reassemble the burner by reversing the order of the above steps.
※Inspect and clean the burner and its accessories from time to time according to the operational
conditions.
※Please refer to the structural drawing for the numbers. [ ] is number of CJ-4.
9) Warning Plate
When the installation construction has been completed, check
to confirm that the warning plate shown below is firmly
attached to the burner body. If the warning plate is lost,
immediately contact our sales department for instructions.

- 8 -
10) Troubleshooting
※Before inspecting the burner and its peripheral
units, carefully read the instruction manual
attached to each equipment.
Do not ignite.
Gas supply and air
supply are normal?
The sequence is in
normal operation?
The burner nozzle
is clogged?
Flame fails?
NO
NO
NO
NO
YES
YES
YES
YES
YES
YES
Inspect the following items:
Are the ultravision frame rod and
the protect relay are in normal
operation?
Is there a heavy fluctuation in air
pressure and gas pressure?
※If there is any questions, contact our sale department.
Air
Gas
Inspect the blower and each
component unit of the air line.
Inspect each component unit
the gas line.
Inspect the sequence, the
electric wire, etc.
Inspect the burner nozzle.
Does the ignition plug
emit sparks exactly?
Check the ignition plug and the
ignition transformer.

- 9 -
11) Structural drawing
CJ-1～3
NO. PARTICULARS QUAN
1 Ceramic Tube 1
2 Ceramic Tube Base 1
3 Receiving Ring 1
4 Receiving Packing 1
5 Support Packing 1
6 Air Body 1
7 Gas Body 1
8 Burner Nozzle 1
9 Gas Pipe 1
10 Ignition Plug 1
11 Air Packing 2
12 Orifice Plate 1
13 Air Flange 1
14 Hexagon Headed Bolt (With Nut) 4
15 Hexagon Socket Screw 4
16 Hexagon Socket Head Cap Screw 4
17 Hexagon Headed Bolt 4
18 Plug R1/4 2
19 Plug R1/8 2(1)
20 Sight Hole 1
21 Ultra Adapter 1

- 10 -
CJ-4
NO. PARTICULARS QUAN
1 Ceramic Tube 1
2 Ceramic Tube Base 1
3 Receiving Packing 1
4 Support Packing 1
5 Air Body 1
6 Gas Body 1
7 Burner Nozzle 1
8 Gas Pipe 1
9 Ignition Plug 1
10 Air Packing 2
11 Orifice Plate 1
12 Air Flange 1
13 Hexagon Headed Bolt (With Nut) 4
14 Hexagon Socket Screw 4
15 Nut 4
16 Hexagon Headed Bolt 4
17 Plug R1/4 2
18 Plug R1/8 2
19 Sight Hole 1
20 Ultra Adapter 1