Page 1
Installation Instructions
Page 2100-S-1“400”, “200” OVENPAK® Burners
General Instructions
Important: Do not discard packing material until
all loose items are accounted for.
To prevent damage in transit, the spark ignitor,
discharge sleeve, mounting gaskets, flame rod and
connecting linkage components may be packed
separately and shipped loose with your new Maxon
OVENPAK® Burner.
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 gas train as might be used with
OVENPAK® gas fired burners.
Piping Layout as sometimes required by
insurance and standards groups
Block and Bleed gas train arrangement illustrated
with Model “400” OVENPAK
Model “400” OVENPAK
supply (except for EB versions, which require a
separate combustion air blower). They also serve as
a fuel flow control and fuel/air mixing device. Model
“200” OVENPAK® Burners serve as a mixing device
and usually have an externally-mounted gas control
valve.
Burner should not be exposed to direct radiant
heat or positioned where it might draw in inert gases.
If such conditions exist, consider filters, relocation
and/or use of the EB version and external air supply.
Electrical service must match the voltage, phase
and cycle of all electrical system components and be
®
Burner
®
Burners provide the air
compatible with burner nameplate ratings. Insure that
all normal control safeguards are satisfied. Combustion air blower should continue to run after shutdown
to allow burner to cool.
Gas supply piping must be large enough to
maintain the required fuel pressures cataloged for the
particular burner size used with burner operating at
full rated capacity.
Anything more than minimal distance or piping
turns may necessitate oversizing piping runs to keep
pressure drops within acceptable ranges.
Inlet pipe leading to any burner should be at least
four pipe diameters in length. If multiple burners are
fed from a single gas train, care should be taken to
minimize pressure drop and give maximum uniformity.
Clean fuel lines are essential to prevent blockage
of pipe train components or burner gas ports.
Main Shut-Off Cock should be upstream of both
the main gas regulator and pilot line take-off. Use it to
shut off fuel to both pilot and main burner during shutdown periods of more than a few hours.
The fuel throttling valve contained within a Maxon
burner is not intended for tight shut-off.
Main gas regulator is essential to maintain a
uniform system supply pressure. If one pipe train
supplies multiple burners, provide a separate regulator in the branch leading to each burner system.
Size the regulator for full system capacity at the
required pressure, carefully considering pipe train
losses. Follow the instructions attached to the regulator during installation and be sure to remove any
shipping pin or block.
Pilot take-off should be upstream of the main gas
regulator, but downstream of the main gas cock. It
should normally include its own pilot gas regulator, a
solenoid valve and shut-off cock. A pilot adjustable
orifice at the pilot inlet simplifies adjustment.
Pilot piping must be large enough to provide for
the full flow and pressures shown in the catalog for
your particular burner size.
Fuel Shut-Off Valves (when properly connected to
a control system) shut the fuel supply off when a
hazardous operating condition is sensed. Manual
reset valves require operator attendance each time
the system is started up (or restarted after a trip-out).
Motorized shut-off valves permit automatic startrestart when used with an appropriate control system.
Test connections are essential for burner adjustment. They should be provided immediately downstream of the regulator and are included in the burner
itself. Test connections must be plugged except
when readings are being taken.
4/98
Maxon practices a policy of continuous product improvement. It reserves the right to alter specifications without prior notice.
INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES
m
CORPORATION
MUNCIE, INDIANA, USA
Page 2
Page 2100-S-2
“400”, “200” OVENPAK® Burners
Installation Instructions
Horizontal mounting is preferred, but burner may
be mounted in any position suitable for automatic
control motor and UV scanner (if used).
OVENPAK
through an oven wall or insulated air duct. Cut opening approximately 1" larger in diameter than discharge
sleeve to allow for thermal expansion of sleeve.
Burner mounting requires four studs and a flat
mounting surface perfectly centered on the discharge
sleeve.
After placing burner in position over studs, add lock
washers and nuts, then draw up hand-tight only.
Check that burner is seated evenly all around the
flange, filling any gaps to prevent air leakage, then
tighten all nuts firmly.
For proper performance of any burner, air inlet and
motor should be surrounded by clean, fresh, cool air.
Burner and pipe manifold support will be required to support weight of the burner and connected
pipe train components. Air control motors, in particular, require additional support. Maxon connecting
base and linkage assemblies are designed to position
the control motors to work with the burner, not to
support their weight.
The Packaged Model “400” OVENPAK
requires external auxiliary support provided by the
user. The support configuration may be similar to the
leg support or knee bracket support illustrated below.
®
Burners will typically be installed
®
Burner
Additional burner support may be required in
conjunction with a stiffener plate when mounting
OVENPAK® Burner (weighing 100-350 pounds)
through typical thin wall of heater/oven panels.
For push-through systems, use Maxon special
back pressure gasket between stiffener plate and
discharge sleeve flange and use (2) ring gaskets
between discharge sleeve flange and burner casting
to prevent back flow of high temperature air. Fill area
D (see sketch below) with no more than 2" of high
temperature packing (too little will overheat mounting;
too much will overheat sleeve).
Typical discharge sleeve mounting
recommendations
“400”
OVENPAK
Burners
®
Suggested supporting arrangements for
Packaged Model “400” OVENPAK
®
Burners:
For pull-through systems, spacers may be
installed on stud bolts and area D left empty to admit
cooling air past the sleeve.
WARNING: Welding of burner flange to stiffener
plate may cause warpage of burner flange and
require additional seal material to prevent
leakage.
Four lock screws permit centering of mixing cone
within burner body and sleeve.
m
CORPORATION
MUNCIE, INDIANA, USA
Maxon practices a policy of continuous product improvement. It reserves the right to alter specifications without prior notice.
INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES
Page 3
“400”, “200” OVENPAK® Burners
Installation Instructions
Page 2100-S-3
For “400” OVENPAK® Burners: Lock screws
should be drawn up hand-tight, then backed out onehalf turn to allow for cone expansion. They must be
re-checked after start-up, and loosened if necessary
to prevent deformation of cone. See start-up instructions for details. Over-tightening lock screws can
lead to cone distortion and greatly reduce cone
and discharge sleeve life.
Discharge sleeve must be flush with, or extend
beyond, interior wall. Maxon can supply a special 12"
long discharge sleeve, but higher noise levels may
result, particularly when firing on propane.
An external viewing port should be provided for
flame observation, preferably in such a position that
burner pilot and main flame can both be seen.
Flame sensing can be accomplished by either
flame rod or UV scanner. When UV scanner is used,
it should be kept as close to burner as feasible. Heat
block, if used, may affect signal strength with some
brands of scanners.
For “400” OVENPAK® Burners, field conversion
from a flame rod version to a UV scanner version and
vice versa may require additional parts in the burner.
Contact Maxon for requirements.
Alternate fuels may require correction of supply
pressures.
If OVENPAK® Burner is equipped with Maxon Hi/Lo
Control Motor, low-fire start wiring can be accomplished as shown in the sketch below.
Maxon assumes no responsibility for the use or
misuse of the layouts shown. Specific piping
and wiring diagrams should always be submitted to the appropriate agencies for approval on
each application.
Multi-burner installations require special consid-
erations if supplied by a common pipe train and/or air
supply. Air and Gas Balancing Valves should be
used for improved heating uniformity; Gas Swing-
Check Valves should be installed as close as possible to each burner inlet for dependable lightoff (gas
manifold may otherwise act as a reservoir, preventing
lightoff during trial-for-ignition period).
Control system’s circuitry must not allow main
Fuel Shut-Off Valve to be opened unless combustion
air is on, and must de-energize valve upon loss of
combustion air pressure, along with the other usual
system interlocks. Motor starter is to be interlocked
with valve, whether or not a combustion air pressure
switch is used.
4/98
Maxon practices a policy of continuous product improvement. It reserves the right to alter specifications without prior notice.
INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES
m
CORPORATION
MUNCIE, INDIANA, USA
Page 4
Page 2100-S-4
“400”, “200” OVENPAK® Burners
Start-Up Instructions
Read complete instructions before proceeding,
and familiarize yourself with all the system's equipment components. Verify that your 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/safety circuitry, and
with knowledge of the overall installation.
Instructions provided by the company and/or
individuals responsible for the manufacture
and/or overall installation of complete system
incorporating Maxon burners take precedence
over these provided by Maxon. If Maxon
instructions conflict with any codes or regulations, contact Maxon Corporation before
attempting start-up.
For initial OVENPAK
1. Close all burner fuel valves and cocks. Make
preliminary adjustments to fuel gas regulators.
Remove pilot and main gas regulator’s adjusting
screw covers. Turn adjusting screw down (clockwise) to approximately mid-position. Close pilot
gas adjustable orifice screw by turning in clockwise until it stops. (Do not over-tighten.) Then
back out the adjustable orifice (counter-clockwise)
approximately 2-3 turns.
2. Check all electric circuitry. Verify that all control
devices and interlocks are operable and functioning within their respective settings/ranges. Be
sure all air and gas manifolds are tight and that
test ports are plugged if not being used.
3. Check that all duct and chamber dampers are
properly positioned and locked into operating
positions.
4. Disconnect the automatic control motor’s
linkage from the “400” OVENPAK
operating crank arm by loosening the control
motor’s connecting rod from the burner’s toggle
linkage.
®
Burner start-up:
®
Burner’s
For Model EB-MRV and Model “200”
OVENPAK® Burners, the connecting linkage on
the separate control valve must be similarly
loosened and disconnected. Refer to specific
adjusting procedures relating to control valve
adjustment in Maxon catalog.
Initial start-up adjustment should only be
accomplished during a manual burner control
mode.
5. Start all system-related fans and blowers.
Check for proper motor rotation and impeller
direction. Verify that all control interlocks are
working. Allow air handling equipment to run for
adequate purge of your manifolds and combustion chamber plenums. With main gas shut off,
manually advance burner to high fire position so
that air only flows through burner and combustion
chamber.
CAUTION: Do not by-pass control panel timers
typically controlling sequential operations.
For EB OVENPAK® Burners only (step 6)
6. Verify differential air pressure. With combustion
air blower on, all volume air fans operating, and
burner at high fire position, connect a manometer
between the air test connection on backplate of
OVENPAK® Burner and your combustion chamber
static pressure test connection. This will give a
direct differential air pressure reading.
m
CORPORATION
MUNCIE, INDIANA, USA
Maxon practices a policy of continuous product improvement. It reserves the right to alter specifications without prior notice.
INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES
Page 5
“400”, “200” OVENPAK® Burner
Start-Up Instructions
Page 2100-S-5
Determine your differential air pressure reading
by taking an additional reading with manometer
connected between the burner’s air pressure test
port and atmosphere with the burner at high fire
position, fuel valves closed, and all air handling
systems running. Subtract the combustion
chamber static pressure obtained above from this
air pressure reading to give you differential air
pressure reading.
For Model “200” OVENPAK® Burner only
(steps 6A-6C)
6A. Cross-connect manometer to upstream ① and
downstream ② air pressure test connections on
Model “200” OVENPAK® Burner’s main housing.
6B. Start air handling system and adjust louvers,
dampers, etc. to desired setting to establish cold
suction design conditions.
6C. Transfer manometer connection from upstream
air pressure test ① to gas pressure test connection
③. This is the differential air pressure reading for a
Model “200” OVENPAK® Burner.
For “400” OVENPAK® Burners: The differential air
pressure setting determines the burner’s capacity and
performance capabilities. Model EB and MA manual
air OVENPAK® Burners, with their external air control
valve(s), provide for the manual setting of this differential air pressure to the burner. Refer to specific
adjusting procedures relating to MICRO-RATIO® and
control valve adjustment in Maxon product line
catalog. MA OVENPAK
locknut adjustment on the end of the air butterfly
®
Burners have an external
control valve. This lets you limit and set the differential
pressure to the OVENPAK
specification tables in the catalog for the differential
air settings required for your specific OVENPAK
Burner capacity.
7. Determine the required differential gas pres-
sure using this differential air pressure reading
obtained from step 6. If your combustion chamber
does not have a static pressure test connection,
then you must measure combustion chamber
static pressure by connecting a manometer
between the gas pressure test port on the
burner’s backplate and to atmosphere with the
burner at low fire position, fuel valves closed, and
all air handling systems running. High fire pressures are provided in Maxon product line catalog
literature and/or read data stamped into burner
nameplate.
8. Verify that spark ignitor is properly positioned
and lines up with the appropriate dimensions
required for your specific burner. (Refer to appropriate Maxon catalog specification table.) Check
that spark ignitor arcs at the end of your properly
positioned ignitor.
9. Return burner control valve (or crank) to low
fire position when purge of system is complete.
10. Open main and pilot gas cocks, then attempt
spark ignition to light pilot while slowly turning
pilot gas regulator spring clockwise and/or
adjustable orifice screw counter-clockwise to
increase fuel flow. Repeat procedure as necessary until pilot ignites as air might have to be bled
out of fuel supply lines before reliable pilot flame
is established. Pilot gas regulator should normally
be set for as low a pressure as possible, using
fuller opening of pilot gas adjustable orifice (if
used).
11. After ignition, adjust pilot flame for good stable
flame shape. A rule of thumb is that any pilot over
a tennis ball size is probably too large. This
assumes you have visual access to the pilot
flame. If this is not possible, then adjust pilot to
give the strongest and most stable flame signal
through your flame safety circuit. This signal
strength can be read with a micro-amp meter. The
signal strength (or range) will be determined by
the specific type of flame safeguard instrument
you have with your burner system.
®
Burner. Refer to Maxon
®
4/98
Maxon practices a policy of continuous product improvement. It reserves the right to alter specifications without prior notice.
INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES
m
CORPORATION
MUNCIE, INDIANA, USA
Page 6
Page 2100-S-6
“400”, “200” OVENPAK® Burners
Start-Up Instructions
12. Re-check pilot ignition by closing pilot gas cock
or otherwise causing pilot outage. Re-light and
refine pilot gas adjustment as necessary to get
ignition within a second or two. The flame safeguard relays should now power your main fuel
Shut-Off Valve(s).
CAUTION: After completing steps above, recheck all interlocking safety components and
circuitry to prove that they are properly installed, correctly set, and fully operational. If in
doubt, shut the system down, close pilot cock
and contact responsible individual before
proceeding further.
13. Establish main flame. With burner at low fire
position, back out main gas pressure regulator
adjusting screw (counter-clockwise) to get lowest
outlet pressure possible. Open all manual fuel
shut-off valves (automatic fuel shut-off valve
should already be open) so gas flows to burner
inlet. There should be little, if any, change in
flame appearance. Turn main regulator adjust-
ing screw in (clockwise) to obtain outlet pressure
of about 4"-6" wc higher than combustion chamber pressure (2"-4" wc for propane, considerably
higher for some EB versions). Main flame should
now appear larger than pilot-only flame.
14. Establish high fire setting by slowly moving
burner toward high fire position while observing
gas pressure at burner gas test connection.
Refine main gas regulator adjustment as necessary to provide correct differential pressure
(gauge to combustion chamber, see step 7) at
high fire. If pressure cannot be adjusted low
enough, a different regulator or regulator spring
may be necessary, or a limiting orifice valve (such
as Maxon's Series “BV”) should be added. Do
not, however, exceed 4" wc pressure drop
between regulator outlet and burner inlet.
CAUTION: If burner(s) go out, close shut-off
valve or shut main gas cock at once. Return to
minimum setting, re-light pilots if necessary,
then turn main gas on again. Check carefully
that every burner is lit before proceeding.
Cycle burner from minimum to maximum
and refine adjustment, if necessary.
For operation with interrupted pilot (as
recommended), shut off pilots and cycle burner
from minimum to maximum and back several
times to verify the flame is maintained.
15. When burner performance is satisfactory and
stable throughout the firing range, reconnect
control motor.
For “400” OVENPAK® Burners: Reconnect
linkage to control motor. Control linkage travel
must be such that burner crank is moved throughout its complete travel, or cataloged capacities
and turndowns will not be achieved. If less than
full-rated burner capacity is required, linkage can
be adjusted to limit maximum output.
With interrupted pilot, it may be necessary to
set control for somewhat higher than minimum
burner setting to permit hold-in of flame detection
system without pilot.
CAUTION: Internal drive mechanism within the
control motor may be damaged if linkage is
adjusted so as to cause binding with burner in
high or low fire position.
16. Re-check differential gas pressure with unit at
operating temperature. Refine high fire setting if
necessary, considering differential pressure,
flame length, and appearance. Natural gas flame
should normally be predominantly clear blue but
possibly with semi-luminous tips. Dust or contaminants in the air stream may affect flame appearance.
17. For “400” OVENPAK
contact between mixing cone and top-most
centering screw after system has reached
maximum operating temperature. If set screw
touches cone, back off an additional 1/8 turn on
top and both side set screws.
18. Plug all test connections not in use to avoid
dangerous fuel leakage. Replace equipment
cover caps and tighten linkage screws.
®
Burners: Check for
m
CORPORATION
MUNCIE, INDIANA, USA
Maxon practices a policy of continuous product improvement. It reserves the right to alter specifications without prior notice.
INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES
Page 7
Start-Up Instructions
Page 2100-S-7“400”, “200” OVENPAK® Burners
19. Check out overall system operation by cycling
through light-off at minimum, interrupting pilot,
and allowing temperature control system to cycle
burner from minimum to maximum and return.
Recheck all safety system interlocks for proper
setting and operation.
NOTE: Typical gas firing control sequence for Maxon
burner is provided
provided by complete system manufacturer incorporating Maxon burners take precedence.
For gas firing Model “400” OVENPAK
Light-off: Shut-down:
1. Close cocks, shut-off valve(s) 1. Close main &
2. Verify burner at low fire pilot gas cocks
3. Start recirculating/exhaust fans 2. Keep combustion
4. Start burner blower air blower running
5. Purge at least 4 air changes after shut-down long
6. Open pilot & main gas cocks enough to allow
only as a guide. Instructions
®
Burner
burner to cool
WARNING: Test every UV installation for
dangerous spark excitation from ignitors and
other possible sources of direct or reflected UV
radiation. Use only gas-tight scanner
connections.
20. Before system is placed into full service,
instruct operator personnel on proper start-up
operation with shut-down of system, establishing
written instructions for their future reference.
4/98
Maxon practices a policy of continuous product improvement. It reserves the right to alter specifications without prior notice.
INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES
m
CORPORATION
MUNCIE, INDIANA, USA
Page 8
Page 2100-S-8
“400”, “200” OVENPAK® Burners
Notes
m
CORPORATION
MUNCIE, INDIANA, USA
Maxon practices a policy of continuous product improvement. It reserves the right to alter specifications without prior notice.
INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES
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