Catalog MAXON

Bulletin 1100
Maxon Burner Nozzles

STICKTITE™ & PILOTPAK™
Air/gas premixing
Flame Retention Nozzles equipment used to provide
for open-port firing thorough blending of
air/gas mixture to
PREMIX® Blower Mixers

(see catalog bulletin 3100)
Provides positive flame retention and stable clean burning, while

directing the torch-shaped flame onto or through open ports to your
heat processes. (Photo: “SP” PILOTPAK™ Nozzle with flame rod)
MULTI-RATIO® Mixers
Series “SN” Sealed Nozzles (see catalog bulletin 3200)
with refractory tunnel block for sealed-port firing
Series “HG” Mixing Tubes

Series “LG” Mixing Tubes

Improve higher temperature operating efficiency and atmosphere

control by mounting the Sealed Nozzle assembly into your oven or
furnace wall, effectively sealing out any secondary air introduction. VENTITE™ Inspirator Mixers
(Photo: Series “SNF” Sealed Nozzle with pilot and seal & support (see catalog bulletin 3300)
housing)
CORPORATION 201 East 18th Street, P.O. Box 2068, Muncie, Indiana, 47307-0068. Phone: (765) 284-3304. FAX (765) 286-8394
Page 1102

Principle of Operation Series “SN” Sealed Nozzles are tunnel-type,
STICKTITE™ and PILOTPAK™ Nozzles are refractory block, closed-port burners for firing of
designed for direct-fired air heating and/or open-port air/gas premixtures without secondary air. They are
firing into a furnace, duct, or immersion tube. The designed to be installed into refractory, thin-wall, or
single torch-like flame creates a venturi effect that soft-wall combustion chambers and fed by almost any
pulls secondary air in around the burner nozzle and air/gas premixing system.
provides necessary cooling of the cast metal nozzle. The air/gas mixture manifold from your premixing
The burner nozzle is threaded onto the feed system is threaded into the Series “SN” Sealed
manifold from your air/fuel premixing device. This Nozzle assembly. This premixture is directed out
premixture is directed out through the nozzle’s main through the nozzle body’s main port into the stepped-
port. A small portion of the premixture is channeled tunnels of the refractory burner block.
out through the smaller ignitor ports that surround the A pilot port tunnel and a flame supervision port (not
large main port. The gas/air mixture is ignited by a shown in sketch below) intersect the main tunnel
spark ignitor or separate pilot assembly. directly in front of the nozzle body’s main port. At this
The eddy currents created on the face of the three-way tunnel intersection, the flame safeguard
nozzle provide positive flame retention of the torch (flame rod or UV scanner) monitors the pilot flame
flame emitted out of the main port. The flames from and/or main burner flame.
the tiny ignitor ports are protected from outside air Once the air/gas premixture is ignited by a
turbulences and surround the base of main flame to separate mounted pilot and spark ignitor, the flame
continually ignite the premixture being forced out of front progressively steps out through the burner
the nozzle by the mixture pressure from your mixing block’s tunnels. The “hot” refractory and the eddy-
device. currents created at each one of the steps within the
tunnel serve to provide positive flame retention of the
burner flame at all firing rates.
Typical STICKTITE™ Nozzle Construction
Typical Series “SN” Sealed Nozzle
Construction
4/92
Burner Nozzles Page 1103
Design and Application Details

Burner nozzle designations STICKTITE™ Nozzles
All Maxon burner nozzles are identified with a 3-
part designation. This code identifies (1) the type of
nozzle, (2) the inlet pipe size, and (3) the main gas
port diameter.
Example: SPA – 2-1/2" – 27
SP = PILOTPAK™ Nozzle Main gas

SPA = PILOTPAK™ Nozzle port
with adjustable orifice diameter “HD” STICKTITE™ Nozzles (available in 1/2"
HD = STICKTITE™ Nozzle (in 16ths of through 8" sizes) are cast iron burners used for
(for higher drafts) an inch) immersion tubes or for “open-port” furnace operations
BP = STICKTITE™ Nozzle (with slight “draft”, normally less than -0.5" wc static
(for back pressures) Inlet pipe pressure). Nozzle is also used where differential
HV = STICKTITE™ Nozzle size (NPT) air/gas mixture pressures exceed 7" wc, regardless of
(for radiant temperatures) the application. The nozzle’s eight ignitor ports
SN = Sealed Nozzle provide flame retention under higher draft conditions.
SNF = Sealed Nozzle with “BP” STICKTITE™ Nozzles (available in 1/2"
provision for flame through 4" sizes) are cast iron burners used for “open-
safeguard device port” furnace applications (with “balanced or slightly
positive”, normally up to +0.25" wc static pressure),
providing the differential air/gas mixture pressures do
Maxon burner nozzles are offered in different no exceed 7" wc. The nozzle’s four ignitor ports
types, each type optimized for a specific type of provide cooler operation and longer service life.
application. All require a full air/gas premixture from a “HV” STICKTITE™ Nozzles (available in 2"
premixing device. The air/gas premixing equipment through 8" sizes) are cast iron burner bodies with a
sections of your Maxon catalog include specific stainless steel retention ring. They are used for “open-
capacities for single and multiple nozzle applications port” firing of higher temperature applications (up to
with the various types of premixing equipment: 2400°F/1316°C) or where the nozzle might be
exposed to high radiant heat and/or sting-out from the
PREMIX® Blower Mixers – section 3100
firing port.
Mixing Tubes & MULTI-RATIO® Mixers – section 3200
VENTITE™ Inspirators – section 3300
A complete burner nozzle system will also include
gas train, proportioning and mixing equipment,
combustion air supply and a combustion control
panel. Your Maxon representative can help you select
from the broad range available.
5/03
Page 1104 Burner Nozzles

PILOTPAK™ Nozzles Series “SN” Sealed Nozzles
Type “SP” PILOTPAK™ Nozzles (available in Series “SN” Sealed Nozzles (available in 3/4"
1-1/2" through 6" sizes) are special packaged “HD” through 1" sizes) consist of a threaded nozzle, cast
STICKTITE™ Nozzles. Their cast iron bodies and iron frame and a refractory burner block. “SN” Sealed
gray iron ignition rings provide a built-in pilot, 10mm Nozzles do not include any provision for mounting a
spark ignitor, pilot gas tubing, pilot shut-off cock and flame safeguard device.
provision for mounting a flame sensing device (flame Series “SNF” Sealed Nozzles (available in
rod or UV scanner). 1-1/4" through 3" sizes) are the same as “SN” Sealed
Type “SPA” PILOTPAK™ Nozzles are the same Nozzles, but incorporate a flame safeguard port
as “SP” nozzles and include a pilot gas adjustable through which a flame rod or a UV scanner can be
orifice in lieu of the pilot shut-off cock. mounted.
PILOTPAK™ Nozzles may be applied on any All Sealed Nozzle assemblies include a pilot port
application suitable for the “HD” STICKTITE™ tunnel and provision for mounting of a broad range of
Nozzles. They may also be mounted directly in a duct accessory pilots.
or housing of recirculated air as long as air tempera- NOTE: Every Sealed Nozzle burner must be
tures do not exceed 600°F (316°C). ordered either with an appropriate pilot assembly
Direct spark ignited STICKTITE™ Nozzles or with optional pilot port cover kit. If a pilot
(available in 1/2" through 4") are “HD” assembly is not ordered, a pilot port cover kit (see
STICKTITE™ Nozzles drilled and tapped to mount a photo below) must be used to prevent the possibility
spark ignitor directly in the outer ignition ring of the of flame and/or hot combustion gases escaping out of
“HD” burner nozzle. This provides an economical the burner’s “open” pilot port tunnel, or to prevent
alternative to those applications when the separate infiltration of secondary air on “un-piloted”
pilot portion of the PILOTPAK™ Nozzle may not be installations.
required. Standard burner block material is suitable for
operating temperatures up to 2600°F (1427°C). The
maximum operating temperature limit may be
downrated to 2400°F (1316°C) if the Sealed Nozzle
Burner is operating under the following conditions:
– burner is installed in a furnace with fiber wall
construction
– frequent cycling inducing thermal shock and
stresses
“SP” PILOTPAK™ Optional refractory block materials are available
Nozzle to extend maximum operating temperature limits as
follows:
– up to 2800°F (1538°C); or
– up to 3000°F (1649°C)
These higher temperature material options are
available at net extra cost and may extend normal
delivery schedules.
“SN” Sealed Nozzle

with hinged lighter
port cover
Capacity/Selection Data
All Maxon Burner Nozzles provide
positive flame retention and clean,
complete, stable combustion when
supplied with a 100% air/gas
premixture. Their heat release is
directly related to the differential
mixture pressure developed by that
supply system.
Capacities in 1000’s Btu/hr are
plotted (on the charts on this page and
the following page) against the
differential mixture pressures for each
of the nozzle sizes.
Discharge area for each nozzle
size is also shown.
Any reference to a “pressure”
must relate to the “effective dis-
charge area” through which the
volume of gas or air/gas premixture
is passing. When selecting premixing
equipment systems, the maximum
and minimum mixture pressures must
be evaluated relative to the quantity
and/or size of the nozzle(s). The ratio
between these two factors dictates the
turndown capabilities of the overall
system.
Multiple nozzle combinations
may be considered for a given heat
release with a specific premixing
device, but the total discharge areas
of all the multiple nozzles must not
exceed the effective discharge area of
the specified single nozzle size.
A minimum differential mixture
pressure of +0.25" wc must be
maintained to minimize the
potential for backfiring.
8/01
Accessory Options
for Series “SN” Sealed Nozzles
All Sealed Nozzle sizes include provision for Flame

mounting of a broad range of accessory pilots. Rod
WARNING: Optional pilot port cover kit must be

used to seal opening if no pilot is installed.
If the optional flame rod is specified, standard

arrangement is as shown in Sketch 1 incorporating a
“Rajah” connector.
Optional electrode cover (shown in Sketch 2)

offers protection for electrode and connector.
Optional cooling tee shown in Sketch 3 allows Typical

pressurizing of flame rod port with cooling air for Pilot
improved performance, particularly on strong back Assembly
pressure applications.
Standard: Sketch 1
With Cover: Sketch 2
With Cooling Tee: Sketch 3
5/03
Accessory Options
for STICKTITE™ and PILOTPAK™ Nozzles
Tuyere Blocks
Provides uniform firing ports for
STICKTITE™ or PILOTPAK™
Nozzles used on furnaces
constructed of fire-brick (up to
2600°F/1427°C).
Tuyere Block dimensions (in inches)

Nozzle Size
3/4 & 1 1-1/4 1-1/2 2 2-1/2 & 3 4 5 6 8
(in inches)
A 1.75 2.12 2.72 3.5 4.75 6 8.75 12
B 4 6 8 10.5 15 18
C 1.5 1.75 2.5 3 4
H 5 7.5 10.25 13 18 22
L 4.5 7 9 13 18
W 5 7.5 10.25 13 18 22
Flame Rods for PILOTPAK™ Nozzles 10mm Spark Ignitor

7-1/2" long flame rod is normally furnished from stock. Furnished with all PILOTPAK™ Nozzles and required
If ordered with the nozzle, it is cut to correct length. If for any 1/2" through 3" direct sparked STICKTITE™
ordered separately, it must be cut to specified length Nozzle
(shown in table below) to fit your PILOTPAK™ Nozzle.
PILOTPAK™
18mm Spark Ignitor
1-1/2" & 2" 2-1/2" 3" 4" & 5" 6"
Nozzle Size Required for direct sparked 4" STICKTITE™ Nozzle
Dimension "L"
1.88 2 2.62 2.75 6
(in inches)
Accessory Options
for STICKTITE™ and PILOTPAK™ Nozzles
Nozzle Support Nozzle Spacing

Bracket assures STICKTITE™ and PILOTPAK™ Nozzles are de-
proper alignment signed for open-port firing into a furnace, oven, heater box
between a or immersion tube. The burner flame creates a venturi
STICKTITE™ or effect that pulls secondary air in around the burner nozzle
PILOTPAK™ Nozzle and provides necessary cooling.
and a firing port or To minimize nozzle deterioration, burner must
immersion tube. be centered within the
Nozzle Support opening of a tuyere
Brackets for Nozzle Size Dimension "E"
block or immersion tube (in inches) (in inches)
STICKTITE™ and the clearances 1/2
Nozzles include provision for pilot and flame rod indicated in table at right 3/4
mounting. For PILOTPAK™ Nozzles, the nozzle must be maintained. .5
1
bracket merely supports and positions the nozzle
1-1/4
itself.
Typical for Solution Heating Applications Nozzle Support Bracket dimensions (in inches)
E
Nozzle Size A B C D
Nozzle spacing
1-1/2" 3.5 1-1/8
4.25 4.19 [1] 7/16
2" 2.5 1-5/16 to 1-1/2
2-1/2" 1-5/8 to 2-1/2
5.25 5.75 4.88
3" 1-5/8 to 2-5/8
9/16
4" 6.88 1-1/2 to 2-3/4
6.44 6.88
5" 1-3/8 to 3
9
6" 9 8 11/16 1-1/2 to 2-1/2
[1] Actually grips inlet pipe, not nozzle as shown
Typical for
Furnace Pipe threads on this page conform to NPT
Applications (ANSI Standard B2.1)
4/92
Dimensions (in inches)

STICKTITE™ Nozzles
“HD” and “BP” STICKTITE™ Nozzles “HV” STICKTITE™ Nozzles

also for direct sparked “HD” Nozzles
NOTE: “BP” Nozzles have (4) ignitor ports; all others have
(8) ignitor ports
Nozzle dimensions (in inches)

Main Port diameter Discharge Area A
Nozzle Size B C D E
(inches) (in2) (NPT)
1/2"-5 5/16 0.77 1/2 1.44 1.44 --- ---
3/4"-6 3/8 .110 --- ---
3/4 1.56 1.56
3/4"-7 7/16 .150 --- ---
1"-8 1/2 .196 --- ---
1 2 2
1"-9 9/16 .248 --- ---
1-1/4"-10 21/32 .338 --- ---
1-1/4"-12 3/4 .442 1-1/4 2.38 2.38 --- ---
1-1/4"-14 7/8 .601 --- ---
1-1/2"-16 1 .785 --- ---
1-1/2 2.69 2.69
1-1/2"-18 --- ---
1-1/8 .994
2"-18 --- ---
2"-21 1-5/16 1.35 2 3.25 3.25
3.25 3.25
2"-24 1-1/2 1.77
2-1/2"-27 1-11/16 2.24 2-1/2 3.88 3.88 3.88 3.88
3"-30 1-7/8 2.76 3 4.56 4.56 4.56 4.56
4"-34 2-18 3.55
4 5.88 5.88 5.88 5.88
4"-41 2-9/16 5.16
5"-50 3-1/8 7.67 5 5.5 6.62 7.12 7.12
6"-60 3-3/4 11.04 6 8.5 8.5 8.25 8.25
8"-84 5-1/4 21.65 --- --- 10.75 10.75
8
8"-88 5-1/2 23.76 11.38 11.38 --- ---
Pipe threads on this page conform to NPT (ANSI Standard B2.1)


PILOTPAK™ Nozzles
NOTE: Typical of
NOTE: Typical of SPA-6-60 PILOTPAK™ Nozzle only
1-1/2" through 5"
PILOTPAK™
Nozzles
Nozzle dimensions (in inches)

Main Port diameter Discharge Area A
Nozzle Size B C D E F
(inches) (in2) (NPT)
1/2"-5 5/16 .07 1/2 1.44 1.44 --- --- ---
3/4"-6 3/8 .110 --- --- ---
3/4 1.56 1.56
3/4"-7 7/16 .150 --- --- ---
1"-8 1/2 .196 --- --- ---
1 2 2
1"-9 9/16 .248 --- --- ---
1-1/4"-10 21/32 .338 --- --- ---
1-1/4"-12 3/4 .442 1-1/4 2.38 2.38 --- --- ---
1-1/4"-14 7/8 .601 --- --- ---
1-1/2"-16 1 .785 --- ---
1-1/2 2.69 2.69 4.25
1-1/2"-18 --- ---
1-1/8 .994
2"-18 --- ---
2"-21 1-5/16 1.35 2 3.25 3.25 4.62
3.25 3.25
2"-24 1-1/2 1.77
2-1/2"-27 1-11/16 2.24 2-1/2 3.88 3.88 3.88 3.88 4.88
3"-30 1-7/8 2.76 3 4.56 4.56 4.56 4.56 5.25
4"-34 2-1/8 3.55
4 5.88 5.88 5.88 5.88 6
4"-41 2-9/16 5.16
5"-50 3-1/8 7.67 5 5.5 6.62 7.12 7.12 6.38
6"-60 3-3/4 11.04 6 8.5 8.5 8.25 8.25 6.88
5/03

Series “SN” Sealed Nozzles
“Basic” Series “SN” Sealed Nozzles (shown with optional flame rod & pressure pilot assemblies)
NOTE: Optional pilot port cover must be used to seal

pilot tunnel if no pilot is installed. (Order pilot port
cover set, pilot assembly, and/or flame rod separately)
Flame Rod
Optional cooling tee sets
10mm Spark Ignitor

Optional pilot mounting
bracket for
open port pilots
F AA BB
Burner Size A B C D G H J L M P R S V W X Y
NPT [1] [2]
3/4"-5, -7 3/4"
--- --- --- --- --- --- --- --- ---
1"-9 2.44 .31 7.5 5 1" 6.38 8.75 3.75 .28 .88
1-1/4"-12, -14 1-1/4" 2.56 3.62 4.88 3.75 11 8.06 .12 3.62 7
1-1/2"-16, -18 3.31 1-1/2" 3.5
2"-20 3.44 3.62
.38 9 7. 5 2" 9 12.12 5.25 3.94 5.12 .34 1 5.25 14.5 11.62 4.12 6.44
2"-24 4.19 4.38
.19
2-1/2"-27 4.69 2-1/2" 4.88
7.94
3"-33 5.75 .5 9.5 9 3" 11.5 13.88 6 5.94 3.68 6.12 .41 1.25 6.25 16.5 13.56 5.62
[3]
[1] Without cooling tee [2] With cooling tee [3] 12" long flame rod is normally furnished from stock. If ordered with the nozzle, it is cut to
correct length. If ordered separately, it must be cut to specified length (shown in table above) to fit your SN Sealed Nozzle.
Burner Nozzles Page 1100-S-1
Installation Instructions
STICKTITE™ / PILOTPAK™ Nozzles
STICKTITE™ and PILOTPAK™ Nozzles are Table 1: Clearances

designed for open-port firing into a furnace, oven,
heater box or immersion tube. The burner flame Inlet Pipe Size (in inches) "A" Dimension (in inches)
creates a venturi effect that pulls secondary air in 1/2
around the burner nozzle and provides necessary 3/4
cooling. 1/2
To minimize nozzle deterioration, burner must 1
be centered within the opening of a tuyere block 1-1/4
or immersion tube and the clearances indicated in 1-1/2 1-1/8
Table 1 at right must be maintained.
Optional nozzle support brackets shown in the 2 1-5/16 to 1-1/2
illustrations below insure permanent alignment of 2-1/2 1-5/8 to 2-1/2
nozzle with firing port. They should be lag-bolted 3 1-5/8 to 2-5/8
securely to furnace or tank shell, or to brickwork.
4 1-1/2 to 2-3/4
5 1-3/8 to 3
6 1-1/2 to 2-1/2
8 2
For Furnaces For Solution Heating
4/92 Maxon practices a policy of continuous product improvement. It reserves the right to alter specifications without prior notice.
INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES

mCORPORATION
MUNCIE, INDIANA, USA
Page 1100-S-2 Burner Nozzles
STICKTITE™ / PILOTPAK™ Nozzles
General Start-up Instructions 4. Orientate nozzle for best performance. When

Start-up procedures should follow the instructions firing horizontally, rotate to position pilot, spark
provided for the specific premixing equipment used. ignitor and flame rod /sensor on top. This provides
For PILOTPAK™ Nozzles, consider the following better ignition and flame sensing.
additional instructions: If normal thread make-up doesn’t give this
1. Pilot design requires some combustion air flow orientation, rotate cast iron ignition ring (in 90°
through main nozzle orifice. (It is a nozzle-mixing increments) by first loosening the four set screws
pilot relying on air flow through the main burner as holding it to the main body. If position is changed,
its source of combustion air.) check that set screws register with holes in the
If powered mixing equipment is used (such main body, then retighten securely.
as PREMIX® Blower Mixer) this would typically be 5. Firing port dimensions should be no smaller
accomplished by insuring (through the control than those of the optional tuyere block which
system) that mixer is operating and at low fire Maxon offers for use with your particular nozzle
position before pilot ignition sequence is begun. size.
If non-powered mixing equipment is used WARNING: Test every UV installation for
(such as VENTITE™ Inspirator), PILOTPAK™ dangerous spark excitation from ignitors and
Nozzle must be located in an air velocity of at least other burners, as well as other possible
500 fpm or subject to at least 0.2" wc draft. In such sources of direct or reflected UV radiation.
applications, the inspirator should be in a direct
line with the nozzle (not at right angles) and air
flow and/or draft pull should parallel nozzle Maintenance Instructions
centerline. Periodic inspection of STICKTITE™ and
2. Pilot gas pressure should be regulated to 2-4" PILOTPAK™ Burner nozzles is suggested, although
wc. Use two-stage regulation if necessary. no formal maintenance procedure is necessary. As a
Unusually high air velocities or draft conditions minimum:
may require slightly higher pilot gas pressures. 1. Check that required nozzle clearance is main-
3. Protect against over-heating. Excessive sting- tained (piping can move or sag).
out from firing port or high radiant heat loads can 2. Check for nozzle deterioration (generally due to
damage both nozzle and flame rod-detector. overheating). Replace before performance is
Burner nozzle main body should not exceed 900°F seriously affected.
during operation. 3. Check for nozzle-plugging (generally noticeable as
distorted flame and/or poor flame retention) and
correct if necessary.
mCORPORATION
Maxon practices a policy of continuous product improvement. It reserves the right to alter specifications without prior notice.

General Instructions
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 pipe train system as might be used
with Sealed Nozzle Burners.
Important: Do not discard packing material until
all loose items are accounted for.
To prevent damage in transit, the control valves,
pipe trains, spark ignitor, mounting gaskets, flame rod
and connecting linkage components may be packed The use of a monolithic seal of castable refractory
separately and shipped loose with your new Maxon around each Sealed Nozzle Burner (as shown above)
Sealed Nozzle Burner. will lessen the chance of shearing off the block
Series “SNF” Sealed Nozzle Burners can fire in because of unequal expansion of the refractory and
any direction, but the scanner manufacturer may the furnace shell.
impose limitations. Avoid orientations which might Excessive maintenance on the burner blocks and
permit pilot and/or flame supervision ports to collect castings is frequently the result of external stresses
debris and/or moisture. and strains transmitted to the burner through the
Include observation ports in your combustion piping. On large installations, consider the use of
chamber design to provide a view of both main and flexible piping connectors to provide “give-and-take” in
pilot flame area. Start-up and adjustment procedures both length and alignment. Installation of such con-
will be greatly simplified. nectors at certain key spots in the air or gas
Flexible connections are recommended in all manifolding can prevent damage to the burners from
piping to reduce piping stresses and alignment/ uneven thermal expansion.
shifting problems.
Typical of Series “LG” or “HG” Mixing Tubes, Maxon MICRO-RATIO® Valve and
Series “SNF” Sealed Nozzle Burner
Maxon assumes no responsibility for the use or misuse of the piping layout
shown. Specific piping and wiring diagrams should always be submitted to the
m
appropriate agencies for approval on each applications.
CORPORATION
INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES MUNCIE, INDIANA, USA
Burner Mounting In either case, size the opening in your refractory

In a refractory wall, bolt burner directly to the wall to give a 3" gap around the burner, then ram with
furnace shell as shown in Sketch 1 or, if there is no castable refractory such as A.P. Green Kast-Set,
shell, use angle irons extended between buckstays as B & W Kaolin Base Castable or equal, following
shown in Sketch 2. manufacturer’s instructions. Allow sufficient dry-out
time before firing burner, and cure slowly at start-up.
Note: Slotted holes in the burner mounting
Sketch 1 frame are intended to allow for lateral
expansion of furnace. Tighten mounting bolts
only enough to hold the burner in position.
General Start-up Instructions

Start-up procedures should follow the instructions
provided for the specific premixing equipment used.
Sketch 2
mCORPORATION

Installation and Maintenance Instructions

Block Replacement 7. Put main body into position and bolt finger-tight.
If the refractory block of your Sealed Nozzle Burner 8. Remove any excess refractory cement that is
requires replacement, Maxon can supply replacement forced out between body and burner block.
block and frame sub-assemblies. 9. Tighten nozzle body firmly into position and clean
throat with a narrow, wet brush to insure a
To install a new block and frame assembly: smooth path for air and gas.
1. Shut off system and allow to cool. 10. Allow re-assembled burner to stand at least 48
2. Disconnect piping, etc., and remove “SNF” hours so that refractory cement will set.
Sealed Nozzle burner from installation. Failure to do so may result in a weak bond and
3. Unscrew the bolts which fasten the nozzle body early deterioration.
to the mounting frame, set aside and remove
body (tapping lightly if necessary to break bond). 11. Re-install burner, following installation
4. Clean all old refractory from main body to insure instructions.
a proper seal when re-assembling. 12. Dry refractory thoroughly by running burner at
5. Prepare a refractory cement mixture (preferably low fire for at least 15 minutes.
A.P. Green ‘Sairset’) mixed to the consistency of 13. Reconnect controls, etc., restoring burner to
thin peanut butter. service following manufacturer’s instructions.
6. Apply a generous coating of the refractory
cement to those surfaces of the new block which
will mate with the burner main body when it is
installed.

mCORPORATION
Notes
m
CORPORATION

Burner Nozzles Page 1100-A/P-1
Assembly Numbers
STICKTITE™ Burner Nozzles
To order a combination of the following, order a STICKTITE configured product.
STICKTITE® STICKTITE® Nozzle Type
Nozzle Segment BP DSHD HD HV

Size Choice ANSI ISO ANSI ISO ANSI ISO ANSI ISO
1/2" - 5 .55 06650 (0.5) 06650 (0.5) 36640 (0.5) --- 06651 (0.5) 06651 (0.5) --- ---
3/4" - 6 .756 06652 (0.5) 21225 (0.5) 36641 (0.5) --- 06653 (0.5) 21226 (0.5) --- ---
3/4" - 7 .757 06654 (0.5) 21227 (0.5) 36642 (0.5) --- 06655 (0.5) 21228 (0.5) --- ---
1" - 8 18 06656 (1) 21232 (1) 36643 (1) --- 06657 (1) 21231 (1) --- ---
1" - 9 19 06658 (1) 21230 (1) 36644 (1) --- 06659 (1) 21229 (1) --- ---
1-1/4" - 10 1.2510 12982 (2) 21792 (2) 36645 (2) --- 12981 (2) 21793 (2) --- ---
1-1/4" -12 1.2512 06660 (2) 21233 (2) 36646 (2) --- 06661 (2) 21234 (2) --- ---
1-1/4" - 14 1.2514 06662 (2) 21236 (2) 17139 (2) --- 06663 (2) 21235 (2) --- ---
1-1/2" - 16 1.516 06664 (3) 21240 (3) 36647 (3) --- 06665 (3) 21239 (3) --- ---
1-1/2" - 18 1.518 06666 (3) 21238 (3) 15400 (3) --- 06667 (3) 21237 (3) --- ---
2" - 18 218 --- --- --- --- 14827 (4) 21248 (4) --- ---
2" - 21 221 06668 (4) 21318 (4) 37919 (4) --- 06669 (4) 21243 (4) 16388 (3) 44148 (3)
2" - 24 224 06670 (4) 21242 (4) 37920 (4) --- 06671 (4) 21241 (4) 05765 (3) 44122 (3)
2-1/2" - 27 2.527 06672 (6) 21038 (6) 37921 (6) --- 06673 (6) 21039 (6) 05766 (5) 44123 (5)
3" - 30 330 06674 (10) 21040 (10) 37922 (10) --- 06675 (10) 21041 (10) 05767 (8) 44124 (8)
4" - 34 434 06676 (17) 21044 (17) 37923 (17) --- 06677 (17) 21042 (17) 16389 (16) 44149 (16)
4" - 41 441 06678 (16) 21045 (16) 37924 (16) --- 06679 (16) 21043 (16) 05768 (15) 44127 (15)
5" - 50 550 --- --- --- --- 09518 (20) --- 05769 (26) ---
6" - 60 660 --- --- --- --- 00103 (50) 32752 (50) 05770 (42) 44128 (42)
8" - 84 884 --- --- --- --- --- --- 05771 (81) ---
8" - 88 888 --- --- --- --- 01825 (110) --- --- ---
Miscellaneous Replacement and/or Spare Parts

18110 10mm spark ignitor
18118 18mm spark ignitor
18117 Flame rod (L = 7.125")
18722 Cover for flame rod or spark ignitor
m
Approximate net weight (in pounds) shown in parentheses
CORPORATION
Page 1100-A/P-2 Burner Nozzles
Assembly Numbers
STICKTITE® PILOTPAK™ Nozzle Types [1] Nozzle Support Bracket

Flame Rods for Refractory
SP SPA PILOTPAK For For Tuyere
Nozzle Segment
(cut to length "L") STICKTITE PILOTPAK Blocks
Size Choice ANSI ISO ANSI ISO Nozzle Nozzle
1/2" - 5 .55 --- --- --- --- --- --- ---
3/4" - 6 .756 --- --- --- --- --- --- ---
T-10
3/4" - 7 .757 --- --- --- --- --- --- --- 02046
(8)
1" - 8 18 --- --- --- --- --- --- ---
1" - 9 19 --- --- --- --- --- --- ---
1-1/4" - 10 1.2510 --- --- --- --- --- --- ---
T-11
1-1/4" - 12 1.2512 --- --- --- --- --- --- --- 01871
(8)
1-1/4" - 14 1.2514 --- --- --- --- --- --- ---
1-1/2" - 16 1.516 16270 (4) 44146 (4) 20311 (5) 44158 (5) T-15
19568 20247
1-1/2" - 18 1.518 16271 (3) 44147 (3) 20312 (4) 44159 (4) (23)
59162
2" - 18 218 14831 (5) 44145 (5) 20317 (6) 44160 (6) 11148
L = 1.875" T-22
2" - 21 221 14571 (5) 44143 (5) 20318 (5) 44161 (5) 14856 01872
(25)
2" - 24 224 14292 (5) 44141 (5) 20319 (5) 44162 (5)
47743
2-1/2" - 27 2.527 14293 (6) 44142 (6) 20320 (7) 44163 (7) T-33
L = 2"
11149 14857 01873
59164 (59)
3" - 30 330 14190 (9) 44139 (9) 20321 (9) 44164 (9)
L = 2.625"
4" - 34 434 14572 (15) 44144 (15) 20322 (15) 44165 (15) T-44
59165 11150 14858 29291
4" - 41 4 41 14191 (14) 44140 (14) 20323 (15) 44166 (15) (100)
L = 2.75"
5" - 50 550 14192 (21) --- 20324 (15) --- T-66
59166 11798 14859 29298
6" - 60 660 15230 (52) 59167 (52) 20327 (52) 59168 (52) (255)
L = 6"
8" - 84 884 --- --- --- ---
--- --- --- ---
8" - 88 888 --- --- --- ---
[1] Includes #18110 spark ignitor
mCORPORATION

Burner Nozzles Page 1100-A/P-3
Assembly Numbers
Pilots for STICKTITE™ Burner Nozzles (see catalog pages 9505 & 9521 for more details)
Pressures required
Normal Pilot Assembly includes:
Pilot to pilot mixer
Capacity
Assembly Pilot Description Gas
Combustion 1000's Pilot Spark
Number Natural Gas Adjustable
Air Btu/hr Mixer Ignitor
Orifice*
04572 (3) Open por t atmospheric pilot 8-27" wc 30 12326
---
06868 (4) ---
Open por t venturi pilot 4-6" wc 15 12457
06969 (4) 18110
10849 (3) 39294 ---
10901 (3) 8-27" wc 30 12326
Open por t atmospheric pilot ---
10904 (3) 18110
13919 (4) 6-8" wc 25 12457
18886 (4) ---
Open por t venturi pilot 2-15 PSIG --- 30 18885 39295
18887 (4) 18110
09300 (2) ---
10237 (2) Open por t pressure pilot
4-7" wc 8-16 oz. 20 11680 38579
10895 (2) 18110
10899 (2) Pressure pilot/spark ignited
*Included in Pilot Mixer Assembly
Series SN Sealed Nozzles

Segment choices are as follows for configured products:
• Mixture Connection Type • Cooling Tee
• Pilot • Block Material
• Flame Detection
(Note: Not all configured products have all segment choices)
Spare Parts
Sealed Nozzle
Configured Flame Rods
Burner Size &
Item Number If used with Pilot Port Cover Set Cooling Tee Set
Designation If used alone
cooling tee set
SN- 3/4" -5 .75 5 SN
SN- 3/4" -7 .75 7 SN --- --- ---
SN- 1" -9 1 9 SN 32376
SNF- 1-1/4" -12 1.25 12 SN 59173 47746
27548
SNF- 1-1/4" -14 1.25 14 SN L = 3.725 L=7
SNF- 1-1/2" -16 1.5 16 SN
SNF- 1-1/2" -18 1.5 18 SN
59174 59176
SNF- 2" -20 2 20 SN
L = 4.125 L = 6.438
SNF- 2" - 24 2 24 SN 32377 27549
SNF- 2-1/2" -27 2.5 27 SN
59175 59177
SNF- 3" -33 3 33 SN
L = 5.625 L = 7.938
m
Approximate net weight (in pounds) are shown in parentheses
CORPORATION
Page 1100-A/P-4 Burner Nozzles
Assembly Numbers
Spare Parts
Pilots for Series ‘‘SNF’’ Sealed Replacement Block and Frame Assemblies
Nozzle Burners (see catalog pages 9505-9521
Sealed Nozzle Burner Size Replacement Block & Frame
for more details) & Assembly
Pilot Designation For basic burner [1]
Assembly Description SN- 3/4" -5
Number
SN- 3/4" -7 28851
Open port venturi pilot [1]
SN- 1" -9
for 4-6" wc natural gas @ 30,000 Btu/hr,
06868 SNF- 1-1/4" -12
includes: #12457 mixer & #39294 adjustable 28853
orifice SNF- 1-1/4" -14
Open port venturi pilot [1] w/ignitor SNF- 1-1/2" -16
for 4-6" wc natural gas @ 30,000 Btu/hr, SNF- 1-1/2" -18 28855
06969
includes: #12457 mixer, #39294 adjustable
SNF- 2" -20
orifice & #18110 ignitor
SNF- 2" -24 28857
Sealed port venturi pilot
10240 for 2-5 PSIG natural gas @ 20,000 Btu/hr, SNF- 2-1/2" -27 28859
all except 3" includes: #18885 mixer, #39295 adjustable SNF- 3" -33 28863
orifice & #18110 ignitor [1] Refer to Product Data Sheet 9000-1 & 2 for alternate
Sealed port venturi pilot refractor y materials at net extra charge
10243 for 2-5 PSIG natural gas @ 20,000 Btu/hr,
3" only includes: #18885 mixer, #39295 adjustable
Sealed port pressure pilot (for SNF-2-1/2"-
27 & smaller): for 4-7" wc natural gas & 8-16
11681 osi combustion air @ 25,000 Btu/hr, includes:
#11680 mixer, #38579 adjustable orifice &
#18110 ignitor
Sealed port pressure pilot (for SNF-3"-30 &
larger): for 4-7" wc natural gas & 8-16 osi
11684 combustion air @ 40,000 Btu/hr, includes:
#11683 mixer, #38579 adjustable orifice &
#18110 ignitor
Open port venturi pilot [1]
for 2-15 PSIG natural gas @ 30,000 Btu/hr
18886
includes: #18885 mixer & #39295 adjustable
orifice
Open port venturi pilot [1] w/ignitor
for 2-15 PSIG natural gas @ 30,000 Btu/hr,
18887
includes: #18885 mixer, #38579 adjustable
[1] Requires #43372 pilot mounting assembly (order
separately)
mCORPORATION

Bulletin 1200
Premix-type Line Burners

Style A, B & C LINOFLAME® Burners
Short, ribbon-type flames are
produced by modular-designed sections
with “customized” drillings. These
modular sections can provide burner
elements that most nearly match your
application’s heat and/or flame
distribution requirements.
Heat releases up to 525,000 Btu/hr
per lineal foot of burner and turndown
ratios up to 7:1 are possible from the
three different styles of LINOFLAME®
Burners. Each style is designed with
over 25 popular sections to maximize
the application flexibility of this type of
line burner. Let Maxon help you design
the burner element to meet your needs.
Type “VF” LINOFLAME® Burners

Like the Style A, B & C line burners
above, the Type “VF” LINOFLAME®
Burners also provide a ribbon of fire, but
in a wider and V-shaped pattern. Cast
iron, V-faced, modular sections
incorporate standardized drillings for
interchangeability.
Heat releases up to 600,000 Btu/hr
per lineal foot of burner and turndown
ratios up to 10:1 are produced from two
different types of LINOFLAME® Burners:
“VFL” (V-faced, low capacity) and “VFH”
(V-faced, high capacity).
Positive flame retention and constant
cross-ignition are provided without
separate ignition rails. Maintenance and
cleaning are easy.
“VF” LINOFLAME® Burners make
Manufactured under U.S. Patent #3,511,589; European patents stable operations possible in fresh still
granted and pending. air, highly inert air streams, or with air
velocities up to 4000 SFPM.
Page 1202
Premix-type Line Burners
INFRAWAVE® Burners
A high-intensity infra-red energy radiates from the high
face temperatures of the ceramic refractory grids of an
INFRAWAVE® Burner.
Their design produces a low forward velocity air move-
ment, minimizing disturbances of granular or powder
products.
Modular-designed sections permit tailoring total heat
release and radiant pattern to your particular application
requirements.
Two versions of INFRAWAVE® Burners (“SG” single grid
or “DG” double grid) provide the application flexibility that
dramatically boosts production speeds by concentrating
heating into small areas and/or onto fast-moving products.
Typical applications for INFRAWAVE® Burners are:
• Direct spot heating
• Direct heating/drying on a conveyer
• Oven process heating or drying
• Moving web heating/drying processes
Manufactured under U.S. Patents RE 24,405 and 3,588,301
Air/gas premixing equipment used to provide thorough blending

of air/gas mixture to Maxon Line Burners
MULTI-RATIO® Mixers
VENTITE™ Inspirator Mixers

PREMIX® Blower Mixers (see catalog bulletin 3300)
Series “HG” Series “LG”
Mixing Tubes Mixing Tubes
6/92
Premix-type Line Burners Page 1203

Principle of Operation Capacities of LINOFLAME® Burner assemblies

These LINOFLAME® Burners consist of a cast are established by the minimum and maximum
iron air-gas manifold, incorporating a drilled face and differential mixture pressures developed by the air/
flame retention ignition rails. When supplied with a full gas premixing equipment. Refer to the appropriate
air/gas premixture, they provide a “ribbon” flame catalog section of Maxon premixing devices for the
pattern. capacity and turndown range of the complete system.
Three styles of LINOFLAME® Burner sections
are offered. All styles (sizes) incorporate cast iron
burner bodies and are available with cast iron or alloy
ignition rails. The alloy ignition rails offer extended life
in difficult service conditions and are recommended
for propane-fired applications or those involving
temperatures above 400°F (204°C). Ambient airstream
temperatures passing over the burner
should not exceed 600°F.
Style A LINOFLAME® Burners
offer the highest heat release
potential per lineal foot. They are
available in 36 and 72 holes per foot
drilling patterns. Normal maximum
capacities are up to 525,000 Btu/hr
per lineal foot at 7.5" wc differential
mixture pressure.
12" straight Style LBA-12 LINOFLAME® Burner section
shown with optional direct spark ignition rail arrangement Style B LINOFLAME® Burners
provide medium heat release poten-
tial per lineal foot and are available in
The replaceable ignition rail design forms a 24, 36, 72 and 96 holes per foot
zipper channel on the face of the burner which drilling patterns. Normal maximum
provides positive flame retention and quick, reliable capacities are up to 250,000 Btu/hr
cross-ignition throughout the entire burner assembly. per lineal foot at 13" wc differential
Over 200 modular sections are available in mixture pressure. (Main drillings for
various shapes and configurations. These sections 24 hole pattern do not need to be
may be assembled into virtually any desired shape in specified.)
order to match flame and heat distribution to your job
requirements. Style C LINOFLAME® Burners
Customized drilled sections are also available. provide the lowest heat release per
The LINOFLAME® Burner’s discharge area must be lineal foot. These burners are offered
matched to the air/gas premixing equipment being in 24 holes per foot drilling pattern
used. By specifically sizing each drill pattern to the job only. Normal maximum capacities
specification, a truly unique burner element can be are up to 25,000 Btu/hr per lineal foot
created that is tailored to meet your exact heating at 2.5" wc differential mixture
requirements. They are cataloged for the matching pressure.
premixing equipment with several of the most popular Direct spark ignition rails are available in most
drilling options. LINOFLAME® sections that provide a means of direct
The short ribbon-type flame widely distributes the mounting an 18mm spark ignitor onto the face of the
desired heat release for greater temperature unifor- burner. This allows a constant source of spark to
mity. They provide stable operation in still, fresh air ignite the air/gas premixture coming out of the main
and/or in highly inert air stream atmospheres. and/or ignitor ports of the LINOFLAME® Burner
section.
7/03
Page 1204 Premix-type Line Burners
LINOFLAME® Burner Designations

Each LINOFLAME® Burner section is identified with
a designation code that identifies the specific type,
shape, size, drilling pattern, and drill sizes of the main
and ignitor ports.
For example: L B A – 12 – 96 – 36 – 43
L = LINOFLAME® Burner
Style of LINOFLAME® Burner Drill size of

A = Style A ignitor ports*
B = Style B
C = Style C
Type of ignition rail Drill size of main ports

A = with alloy rails none = no main ports
(blank) = with cast iron rails
Specific Section Number of holes/lineal foot

-3 = 3" straight 24
-6 = 6" straight 36
-8 = 8" straight 72
-12 = 12" straight 96
-12S = 12" straight with bossed side inlet
-12B = 12" straight with bossed back inlet
-3B = 3" straight with bossed back inlet * The maximum drill size for ignitor ports
-TS = 12" tee section with side inlet is .188" diameter.
-TB = 12" tee section with bottom inlet
-TX = 12" cross ignition
-E3 = 3" elbow
-E6 = 6" elbow
In the example above, we have described a 12"
straight section of Style B LINOFLAME® Burner with
alloy ignition rails and a 96 hole drilling pattern. The
main ports are drilled with #36 drill and the ignitor
ports are #43 drilled.
Total heat release and LINOFLAME® Burner Avoid continuous straight runs longer than 7 feet
footage are normally selected from the tables given in of LINOFLAME® Burner. Beyond that length, the burner
the various premixing equipment sections of the should be broken into separately-fed, shorter lengths
Maxon catalog: (connected by cross ignition end plate sets) to mini-
PREMIX® Blower Mixers ................... Bulletin 3100 mize burner distortion and stresses during alternate
Series LG & HG Mixing Tubes, heating and cooling cycles.
MULTI-RATIO™ Mixers ..................... Bulletin 3200 Use alloy ignition rails whenever burner is to be
VENTITE™ Inspirator Mixers ........... Bulletin 3300 fired on propane, or when application involves tempera-
Based on capacity information given in these tures above 400°F (204°C).
catalog sections, and within the constraints of duct Do not use side inlet tees if air velocities across the
size and air volume flows, a LINOFLAME® Burner LINOFLAME® Burner assembly exceed 1000 SFPM
assembly is designed utilizing the available sections because of the air stream turbulence created.
shown on the following pages. To center-feed Style C LINOFLAME® Burner
When ordering a burner assembly made up from assemblies, use a Style B bottom inlet section and two
these available module components, be sure to provide LBC-3 reducing sections.
an assembly sketch of the complete burner (as viewed
Warning: Discharge areas of this or any premix-
from the back, or upstream, side) including locations of
type burner are carefully matched to the equip-
all accessories and/or individual component sections.
ment supplying air/gas premixture. Increasing
Start-up and operating procedures will be greatly
the discharge area by adding to the burner or
simplified if observation ports are provided and posi-
enlarging burner ports could result in ignition
tioned to allow direct visual inspection of both pilot and
within the burner or backfire during operation.
main flame.
All “open” ends of burner assembly must be closed
off with one of the end closures or pilot assemblies
shown on the following pages. Any end plate ports not
used must be plugged. Burner duct area displacement
Burner inlet feed piping must be adequate to For purposes of calculating operating air velocities
provide a well-distributed flow of air/gas throughout the and resulting static pressure drops across the burner
burner assembly. assembly, use the following equivalent displacements:
Inlet flanges bolt directly to burner body casting and Velocity of air flowing past a LINOFLAME®
accept threaded NPT piping.
Do not exceed the capacity feed limitations shown Section Description Displacement Area
in the table below. 3" straight sections (-3) .064 ft2
6" straight sections (-6) .117 ft2
8" straight sections (-8) .152 ft2
Inlet feed capacity limitations 12" straight & back inlet sections (-12) .223 ft2
Burner inlet flange Maximum Btu/hr Tee section, bottom inlet (-TB) .300 ft2
Tee section, side inlet (-TS) .359 ft2
1-1/2" end inlet (LFE- 1-1/2") [1]
350,000 Tee section, cross ignition (-TX) .270 ft2
1-1/2" back inlet (LFB- 1-1/2")
3" elbow section (E-3) .176 ft2
2" end inlet (LFE- 2") [1] 6" elbow section (E-6) .175 ft2
600,000
2" back inlet (LFB- 2")
Burner assembly used for air heating is determined by
2-1/2" back inlet (LFB- 2-1/2") 850,000
dividing SCFM of air passing over the burner by the net
3" back inlet (LFB- 3") 1,250,000 area (in ft2) of the cross-section of the duct surrounding
[1] Do not end-feed straight rows of LINOFLAME® Burner if the burner. This net area is determined by subtracting
capacity exceeds 600,000 Btu/hr (150,000 Btu/hr for Style C). The the space displaced by the LINOFLAME® Burner from
effect of velocity pressure in such instances will prevent uniform the gross area of the duct itself.
heat distribution.
7/03

Style “A” LINOFLAME® Burner Sections
6" Straight 12" Straight Inlet Feed Section

LA-6, LAA-6 LA-12, LAA-12
12" Back Inlet Tee LA-TB, LAA-TB
End View Typical 6" Elbow Section

of All Style A LAA-E6
LINOFLAME®
Burner Straight Back inlet tee
Sections section requires a
back inlet flange set
from below
Inlet flange set options Back Inlet Flange Set

for back inlet tee section
ANSI Flange NPT Pipe Dimension
Identification Thread* "A"
LFB- 1-1/2" 1-1/2"
0.88
LFB- 2 2"
LFB- 2-1/2 2-1/2"
1.25
LFB- 3 3" *
Typical Cross Sec- Typical Cross Sectional
tional View of Style A View of Style A
LINOFLAME® Burner LINOFLAME® Burner with End Inlet Flange Set
with alloy ignition rails cast iron ignition rails End inlet flange set
ANSI Flange NPT Pipe
Designation Thread*
1-1/2" LFE 1-1/2"
2" LFE 2"
Cross Ignition *
End Plate Set
LX-EP, LXA-EP
(normally supplied in pairs)
LEP Plain End Plate EP-FR End Plate LDP Division Plate
* ISO threaded flanges available; contact Maxon.


Style “B” LINOFLAME® Burner Sections
Burner Sections Bossed Inlet Feed Sections

3" Straight 6" Straight 8" Straight
LB-3, LBA-3 LB-6, LBA-6 LB-8, LBA-8
12" Straight End view typical of all

LB-12, LBA-12 Style B LINOFLAME® Bossed 12" Back Inlet Section
Burner straight sections LB-12B, LBA-12B
Bossed 12" Side Inlet Section

LB-12S, LBA-12S
3" Elbow Section 6" Elbow Section
LB-E3, LBA-E3 LB-E6, LBA-E6
Bossed 3" Back Inlet Section

LB-3B, LBA-3B
Typical Cross Section Typical Cross Section View

View of Style B of Style B LINOFLAME®
LINOFLAME® Burner with Burner with cast iron
alloy ignition rails ignition rails
* ISO threaded manifolds available as loose parts;

contact Maxon.
7/03

Style “B” LINOFLAME® Burner Sections
Inlet Tee Feed Sections 3" Midget Section End inlet flange set
LM-3-72 ANSI Flange NPT Pipe
Designation Thread*
12" Back Inlet Tee 1-1/2" LFE 1-1/2"
LB-TB, LBA-TB 2" LFE 2"
End Inlet Flange Set
Tee section with back

inlet requires a back inlet
flange set from below
12" Side Inlet Tee

LB-TS, LBA-TS
Tee section with side inlet

requires a back inlet
flange set from below
Universal Support
Back Inlet Flange Set Inlet flange set options Bracket
for inlet tee sections above (normally ordered
ANSI Flange NPT Pipe Dimension in pairs).
Identification Thread "A"
Carbon steel and
LFB- 1-1/2" 1-1/2"
0.88 stainless steel versions
LFB- 2 2" available.
LFB- 2-1/2" 2-1/2"
1.25
LFB- 3 3" Cross Ignition End Plate Set
LX-EP, LXA-EP
LDP Division Plate LEP Plain End Plate EP-FR End Plate
* ISO threaded flanges available; contact Maxon.


Style “C” LINOFLAME® Burner Sections
12" Straight 9" Straight Typical Cross Section view of

LC-12, LCA-12 LC-9, LCA-9 Style C LINOFLAME® Burner with
alloy ignition rails
Typical Cross Section view of

Cross Ignition End B to C Reducing Section Style C LINOFLAME® Burner with
Plate Set LBC-3-24 cast iron ignition rails
LX-EP, LXA-EP
Flame Rod Holder

LEP Plain End Plate 1-1/4" LFC End Inlet Flange*
Typical mounting
of flame rod
holder and/or
LDP Division Plate
pilot mounting
bracket
* ISO threaded flanges available;

contact Maxon.
7/03
Pilot Capacities/Specifications/Dimensions (in inches)

for Style A, B & C LINOFLAME® Burners
End-mounted LINOPAK Pilots for Style A, B, & C LINOFLAME® Burners

Sketch Pressures required Nominal Pilot Assembly Includes:
Number Pilot Description to pilot mixer Capacity Pilot Gas Adjustable Spark
(below) Natural Gas Combustion Air 1000's Btu/hr Mixer Orifice Cock Ignitor
3 Iner t air LINOPAK pilot No Yes
Fresh air LINOPAK pilot
1 8-27" wc --- 30 Yes No
Fresh air LINOPAK pilot (w/vane)
Yes 18 mm
3 Iner t air LINOPAK pilot (w/vane) No Yes
Pressure type LINOPAK pilot
2 4-7" wc 8-16 osi 15 Yes No
Pressure type LINOPAK pilot (w/vane)
1 2
Optional/Replacement Parts
Optional Flame Rod
3
18mm Spark Ignitor
Optional electrode
cover protects porce-
lain insulator and
electrical connection
from dirt and moisture. May be used for
ambient temperatures up to 450°F (232°C).
Pilot Capacities/Specifications/Dimensions (in inches)

for Style A, B & C LINOFLAME® Burners
Side-mounted pilots for Style A, B, & C LINOFLAME® Burners
Sketch Pressures required Nominal Pilot Assembly Includes:
Number Pilot Description to pilot mixer Capacity Pilot Gas Adjustable Spark
(below) Natural Gas Combustion Air 1000's Btu/hr Mixer Orifice Cock Ignitor
Fresh air type LINOPAK pilot
1 Yes No
Fresh air type (with vane) 8-27" wc --- 30
18 mm
4 Recirculating type (with vane) No Yes
3 Pressure type pilot (with vane) 4-7" wc 8-16 oz. 15
Yes
No
4-7" wc 15
Yes No 10 mm
2 Open por t venturi pilot ---
No
2-15 PSIG 30
10mm
Fresh Air Type Pressure Type Inert Air Type
1 3 4
Open Port Type
Optional/Replacement Parts
18mm Spark Ignitor 10mm Spark Ignitor
NOTE: Sketch 2 shows pilot mounting

bracket mounted to side of a LINOFLAME®
Burner section. Pilot assembly and mount-
ing bracket must be ordered separately.
6/92

Principle of Operation Turndown ratios of 10:1 are common with both

®
Type “VF” LINOFLAME Burners consist of a cast “VFL” and “VFH” LINOFLAME® Burner assembly
iron air/gas manifold incorporating a V-shaped drilled applications.
burner face. When supplied with a full air/gas Capacities of Type “VF” LINOFLAME® Burners
premixture, they provide a wide ribbon flame pattern. depend on both mixture pressure and air velocity
The “VF” V-faced burner design provides excellent over the burner.
flame retention and constant cross ignition with Nominal ratings are shown in the graph below which
differential mixture pressures up to 10 inches w.c. plots mixture pressure (in inches wc) against heat release
without separate flame ignition rails. per lineal foot of burner. Graph is based on firing in still air
or in air streams with velocities with less than 1500 fpm
for VFL, 2000 fpm for VFH Burner.
VFH-12" section
Maintenance and cleaning are easier, due to the

larger drilled ports on the face and the absence of
flame ignition rails on the “VF” LINOFLAME® Burner.
As with other premix-type line burners, the “VF”
LINOFLAME® Burner is assembled using modular
component sections. Over 23 modular shapes may
be assembled to most any desired shape, matching
flame and heat distribution to your heating require-
Minimum capacities must be increased to those
ments.
figures shown in Table 1 below if velocity exceeds
Standard drilled sections permit matching the
those outlined above. Do not exceed 3000 SFPM
discharge area to the specific premixing equipment
velocity with VFL (4000 SFPM velocity for VFH).
used by simply controlling the total burner assembly
Maximum ratings require 10" wc mixture pressure,
footage.
but must be reduced by 5% if firing into a highly inert
Two varieties of “VF” LINOFLAME® Burners are
atmosphere.
available:
“VFH” (V-faced, high capacity) is normally rated Table 1: Minimum firing rate (1000's Btu/hr per
up to 600,000 Btu/hr per lineal foot of burner with 10" lineal foot) for various velocities (SFPM)
wc mixture pressure. Burner Type Still Air 1500 2000 2500 3000 4000
“VFL” (V-faced, low capacity) is rated up to
VFL 30 30 34 37 40 ---
300,000 Btu/hr per lineal foot of burner with 10" wc
VFH 60 60 60 65 70 80
mixture pressure.
dividing SCFM of air passing over the burner by the

Temperature limitations net area (in ft2) of the cross section of the duct
Ambient and/or return air stream temperatures surrounding the burner. This net area is determined
passing over the burner should not exceed 800°F by subtracting the space displaced by the
(427°C). Downstream temperature should not exceed LINOFLAME® Burner from the gross area of the duct
1000°F (538°C) for recirculated air streams, 1200°F itself.
(649°C) for all fresh air. Total heat release and “VF” LINOFLAME® Burner
Burner inlet feed piping must be adequate to footage are normally selected from the tables given in
provide a well-distributed flow of air/gas throughout the various premixing equipment sections of the
the burner assembly. In regards to capacity, there is Maxon catalog.
no penalty for either an oversized header or too many Series LG & HG Mixing Tubes,
inlet feeds on the burner assembly. MULTI-RATIO™ Mixers .............. Bulletin 3200
Inlet flanges bolt directly to burner body casting VENTITE™ Inspirators ............... Bulletin 3300
and accept threaded NPT piping. Based on capacity information given in these
Do not exceed the capacity feed limitations shown catalog sections, and within the constraints of duct
in the table below. size and air volume flows, a “VF” LINOFLAME®
Burner assembly is designed utilizing the available
Burner duct area displacement sections shown on the following pages.
For purposes of calculating operating air velocities Warning: Discharge areas of this or any premix-
and resulting static pressure drops across the burner type burner are carefully matched to the equip-
assembly, use the equivalent displacements given in ment supplying air/gas premixture. Increasing
the table below. the discharge area by adding to the burner
Velocity of air flowing past a LINOFLAME® Burner length could result in ignition within the burner
assembly used for air heating is determined by or backfire during operation.
Inlet Feed Capacity Limitations

Type "VFH" LINOFLAME® Burner Type "VFL" LINOFLAME® Burner
Feed Location Flange Designation Maximum Feet Maximum Feet Flange Designation Maximum Feet Maximum Feet
Used per Leg [1] per Feed Used per Leg [1] per Feed
End of straight VFH- 2 EF 2 VFL- 1-1/2 EF 2 2
12" back inlet VFH- 3 BF 5 VFL- 2 BF 4
2 1.5
12" x 12" back VFH- 3 XF 6 VFL- 3 XF 8
inlet cross VFH- 4 XF 10 --- --- ---
[1] A "leg" is defined as the additional burner sections attached to any one end of the section containing the inlet.
Burner Duct Area Displacement

Type "VFH" LINOFLAME® Burner Type "VFL" LINOFLAME® Burner
Section Description
2
Designation Displacement Area (ft ) Designation Displacement Area (ft2)
3" straight VFH-3 0.1 VFL-3 0.05
6" straight VFH-6 0.1 VFL-6 0.1
12" straight VFH-12 VFL-12
0.4
12" back inlet straight VFH-12B VFL-12B 0.2
6" elbow ---- --- VFL-L
12" x 6" tee VFH-T 0.5 VFL-T 0.28
12" x 12" cross VFH-X VFL-X
0.6 0.36
12" x 12" back inlet cross VFH-XB VFL-XB
6/92
When making premix-type line burner compari- “VF” Burner face temperatures are essentially
sons, the discharge areas and capacity equivalents constant (850°F) at their maximum firing rates. At this
may be shown as follows: temperature, the theoretical linear expansion is 0.06
inches/lineal foot. (Example: A 5' center-fed bar of
1' of VFL = 1/2' of VFH = 1' of Style B-96-36-43
“VF” LINOFLAME® Burner will deflect approximately
0.75" at 850°F and the deflection commences at the
When ordering a burner assembly made up from
ends of its feed section.)
the available module components, be sure to provide
With or without inlet feed flexible connectors in the
an assembly sketch of the complete burner (as
air/gas premixture line(s), the maximum linear
viewed from the back, or upstream, side) including
distance recommended between cross-ignition
locations of all accessories and/or individual compo-
end plates or between an end plate and a cross-
nent sections.
ignition end plate is 10 ft.
All “open” ends of burner assembly must be
Avoid continuous straight runs longer than 7
closed off with one of the end closures or pilot
feet of LINOFLAME® Burner. Beyond that length, the
assemblies shown on the following pages. Any end
burner should be broken into separately-fed, shorter
plate ports not used must be plugged.
lengths (connected by cross ignition end plate sets) to
Ignition may be either direct spark (utilizing special
minimize burner distortion and stresses during
flame rod and spark ignitor end closures offered) or
alternate heating and cooling cycles.
more typically, by incorporating one of the available
Burner support methods provide support to your
LINOPAK® pilots (offered for both low- and high-
inlet feed manifolds and bolt the “VF” burner assem-
pressure gas supplies and in your choice of atmo-
bly to the inlet flanges. If Universal Support Brackets
spheric and pressure types).
(USB) are used, locate them nearer to the inlet feed
sections, and not at the extreme ends of the burner.
Burner expansion and bowing Start-up and operating procedures will be greatly
Due to the increased mass of “VF” LINOFLAME® simplified if observation ports are provided and
Burner casting, special consideration must be made positioned to allow direct visual inspection of both
to allow for the additional linear expansion. pilot and main flame.
End-mounted LINOPAK Pilots for VF LINOFLAME® Burners

Selection Paramenters Normal Pilot Assembly Includes:
VFH LINOFLAME® VFL LINOFLAME®
Available Type of Capacity 18mm
Burner LINOPAK Burner LINOPAK Pilot Adjustable
Natural Gas Pilot Mixer Flame (1000's Spark
Pilot Pilot Mixer Gas Orifice
Pressures Safeguard Btu/hr) Ignitor
UV scanner VFH-LO-V-UV VFL-LO-V-UV 20
Venturi-type No
Low Gas Flame rod VFH-LO-V-FR VFL-LO-V-FR 20
Pressures Pressure-type UV scanner VFH-LO-P-UV VFL-LO-P-UV 25
(4-7" wc) (requires 4-16 osi Yes
Yes Yes
combustion air) Flame rod VFH-LO-P-FR VFL-LO-P-FR 25
Medium Gas UV scanner VFH-M-A-UV VFL-M-A-UV 25
Pressures Atmospheric-type No
(8-27" wc) Flame rod VFH-M-A-FR VFL-M-A-FR 25
UV scanner --- --- --- --- --- ---
Venturi-type
Higher Gas Flame rod VFH-HI-V-FR VFL-HI-V-FR 75 No
Pressures Pressure-type UV scanner VFH-HI-P-UV VFL-HI-P-UV 75 Yes Yes
(1-2 PSIG) (requires 4-16 osi Yes
combustion air) Flame rod VFH-HI-P-FR VFL-HI-P-FR 75

“VFH” LINOFLAME® Burner Sections
VFH straight sections VFH-T 12" x 6" tee VFH-X 12" x 12" cross
Straight Section Dimension "L"

VFH-12 12"
VFH-6 6"
VFH-3 3"
Inlet Feed Sections

VFH-12B 12" back inlet VFH-XB
12" x 12" back inlet cross
Typical cross sectional view of

VFH LINOFLAME® section
VFH-12B requires inlet flange set

below (order separately)
VFH-3BF back inlet flange set

for 12B inlet section
VFH-XB requires one of the inlet

flange sets shown below (order
separately)
(XB) back inlet

NPT Pipe Dimension
cross inlet
Size "A"
flange sets
VFH-3XF 3" 1
* ISO threaded flanges available; VFH-4XF 4" 1.31
contact Maxon.
7/03

“VFH” LINOFLAME® Burner Sections
End Closures End Inlet Sets
VFH-EC Typical for all VFH VFH-2EF

end closures
VFH-2EF-FR
VFH-EC-FR
Optional flame rod

(order separately)
VFH-2EF-SI
VFH-EC-SI
10 mm spark ignitor (included)
14mm spark ignitor

(included)
VFH-XEP Expansion end plate set
VFH-HREP
Hi-recirc end plate

VFL LINOFLAME® Burner Sections
VFL straight sections VFL-X 12" x 12" cross VFL-T 12" x 6" tee
Straight Section Dimension "L"

VFL-12 12"
VFL-6 6"
VFL-3 3" VFL-L 6" elbow section
Inlet Feed Sections

VFL-XB VFL-12B 12" back inlet
12" x 12" back inlet cross
VFL-12B requires inlet flange set

below (order separately)
VFL-2BF back inlet flange set

for 12B inlet section
Typical cross sectional view of
VFL LINOFLAME® section
VFL-XB requires one of the inlet

flange sets shown below (order
separately)
VFL-3XF inlet flange set for XB section
* ISO threaded
flanges available;
contact Maxon.
7/03

VFL LINOFLAME® Burner Sections
End Closures End Inlet Sets

VFL-EC VFL- 1-1/2" -EF
VFL-EC-FR
VFL-XEP expansion end plate set
Optional flame rod

(order flame rod separately)
VFL-EC-SI
VFL-HREP
hi-recirc end plate
10mm spark ignitor

(included)

LINOPAK Pilots with VF LINOFLAME® Burners
LINOPAK Pilots (using UV scanner) with VF LINOFLAME® Burners

VFH-LO-P-UV VFH-HI-P-UV VFH VFL
VFL-LO-P-UV VFL-HI-P-UV
low pressures higher pressures
Typical for the LINOPAK pilots at left
LINOPAK Pilots (using flame rods) with VF LINOFLAME® Burners

VFH-LO-V-FR VFH-LO-P-FR VFH-HI-P-FR
VFL-LO-V-FR VFL-LO-P-FR VFL-HI-P-FR
low pressures low pressures higher pressures
venturi type
Typical for all of the above LINOPAK pilots
7/03

18mm spark ignitor included with all LINOPAK pilots Universal Support Brackets (USB)
(normally ordered in pairs)
(12 gauge mild steel) for VF LINOFLAME® Burners
Stainless steel versions available.
Used with VFL

LINOFLAME® Burners
Optional flame rod for LINOPAK pilots
Used with VFH

LINOFLAME® Burners
Air-Gas Pilot Mixers for all LINOPAK Pilots

Atmospheric type Pressure type
Low pressures
venturi type Medium pressures High pressures Low pressures
External Mounting Assemblies for all LINOPAK Pilots

Description Side View Mtg. Plate Dim. Opening Dimension
Includes Mounting Plate

with two (2) feed-through
insulators for internal
mounting of spark ignitor
and flame rod
Includes Mounting Plate with

feed-through insulator for
internal spark ignitor and
provision for external UV
scanner


INFRAWAVE® Burners
Principle of Operation Alloy

Deflector Plate
®
INFRAWAVE Burners utilize air-gas premixtures Refractory Grid
supplied to a ductile iron burner body/manifold. Drilled

burner body ports and alloy deflector rails provide
flame retention, direction, and reliable cross-ignition Grid
Support
throughout the entire length of the modular designed Grid
Clamp
burner assembly. Because the air-gas premixture
passes through drilled ports in the burner body and
Burner
not through a porous refractory, the problems of Body
plugging caused by dirty/contaminated combustion air Ductile
Iron
are virtually eliminated. Manifold
Small fingers of flame are deflected down between
the ribs of the high-temperature refractory grids where Heating intensity can be further varied by adjust-
the grids are rapidly heated to radiant temperatures. ing burner-to-product distances, since radiant heating
The average refractory face temperature (with 10" wc intensity and effectiveness depend on the total
mixture pressure) is up to 2000°F (1093°C) and even radiating surface area. Misalignment or geometrical
at minimum capacities, this face temperature typically positioning of the workpiece with respect to an
remains at 900°F (482°C). INFRAWAVE® Burner can reduce its ability to absorb
The INFRAWAVE® Burner’s higher face tempera- radiant energy.
tures provide a very high intensity infrared radiation
source. The radiant power from a 2000°F face Typical INFRAWAVE® Burner mounting on a
temperature is approximately 2.4 times the radiant web/conveyor process
power potential of the burner face temperature at only
1500°F.
Face temperatures, and thus the radiant power
(capacity) effect of INFRAWAVE® Burners, increase
from minimum capacities up to approximately 10" wc
mixture pressures. Above that pressure, fingers of
flame extend forward from the outer edge of the slots
in the refractory grids. These hot products of combus-
tion exit with a very low forward velocity after traveling
along and between the refractory grid ribs. They can
provide additional convection heating for overall
increased system efficiencies.
Total heat release and INFRAWAVE® Burner DG Burners should normally be installed to fire
footages are normally selected from the tables given directly at the work. Efficiency of SG burners is
in the various premixing equipment sections of the improved by angling at approximately 45°. (See
Maxon catalog: sketch above.)
PREMIX® Blower Mixers ............. Bulletin 3100 Burner face to product distance
Series LG/HG Mixing Tubes INFRAWAVE® Burners discharge products of
and MULTI-RATIO™ Mixers ....... Bulletin 3200 combustion with a low forward velocity. This mini-
INFRAWAVE® Burners are offered in two (2) mizes the disturbance of granules and powders, but
versions: does not permit convection heating effect to cross
“DG” – high capacity double grid, or large gaps. Side-fired and down-fired burners
“SG” – lower capacity single grid. should generally be spaced 2-6" from product.
Larger spacings are possible with upward firing.
Modular design permits tailoring total heat release The gap will normally be kept uniform along the
and radiant pattern to your particular application. entire burner length, with the distance field-adjustable
to optimize performance.
6/92
Capacity/ Specification Data

INFRAWAVE® Burners
INFRAWAVE® Burner capacities as a function of differential mixture pressures
Select all premixing equipment and control Radiant Heat Input Calculations
valves based on the “gross” fuel flow capacity Consider mass and specific heat of system
curves shown on chart above. through-put, latent heat of vaporization and/or fusion,
Radiant power flow curves reflect the infrared radiation and exhaust losses.
heat output in radiant energy and do not take into Check that adequate product area is exposed to
consideration any convected heat available from the radiant heating. A 12" length of “DG” INFRAWAVE®
hot combustion products. Burner has approximately 1.56 ft2 of radiating surface
CAUTION: Emissivity of the product and/or geo- area.
metric positioning of the workpiece will affect the
infrared energy absorption rates.
Typical product emissivity factors (@ 100°F)

Brick, red 0.93 Paint, black 0.98
Cloth 0.75 - 0.9 Paint, white 0.91
Concrete 0.94 Paper 0.95
Glass, window 0.93 Plaster 0.91
Gypsum 0.91
INFRAWAVE® Burner Application Considerations

DG Burners should normally be installed to fire At high fire (8" wc mixture pressure) small points of
directly at the work. Transfer efficiency of SG burners amber-tipped flame should be visible protruding from
is improved by angling at approximately 45°. (See the ends of grid slots. Complete grid area should be
sketch below.) radiant.
Mixture pressures above 8" wc will provide no
further radiant increase, but will give flame extension
from grid slot ends and an increased volume of hot
convection gases.
Maximum infrared radiation, at any firing rate, is
produced by the air-fuel ratio giving brightest refractory
glow.
Physical damage to burner. Avoid mounting
burner where work or other foreign material will fall or
bump against it. Take care during storage and handling
not to damage the refractory grid sections.
Required burner type, footage and configuration.
Web stoppage may cause problems from residual In general, plastics and dry flammables cannot
heat, even with automatic burner shut-off. It may be withstand the intense radiation of double-grid (DG)
necessary to use pillow blocks, air cylinder and lever burner at high mixture pressures. Even single grid (SG)
arm to rotate the burner automatically out of the way at full fire may be too much for solvent evaporation.
upon deliberate or accidental web stoppage. Mixing equipment and combustion air pressure should
Spacing between rows. Because of burner face be selected to achieve only the required mixture
contours, the effective area of coverage is about pressure.
double that of the actual physical size. The width of web, conveyor or product will generally
Adjacent rows of burner should be spaced far determine maximum heat input from a single row of SG
enough apart to allow dispersion of hot gases into or DG burner. From this, total heat input will give you
the diluting ambient. As a rule-of-thumb: side- or up- the required number of rows of burner and minimize the
firing burners should not be closer than 15" on center. risk of longitudinal hot streaks.
Down-firing burners should not be closer than 18" on Flame supervision. INFRAWAVE® Burners
center. include provision for flame rod or UV scanner
If firing from both sides of a product, stagger detection. Main flame pick-up is difficult below about
burner rows to minimize heat concentration. 0.5" wc mixture pressure, so for lowest possible
Hot combustion product/convection gases are minimum capacity (and maximum turndown),
always hotter than the lowest grid temperature. They interrupted pilots or direct spark ignition should be
may reach 2000°F (1093°C). If not collected, these avoided. Flame rods sensing a pressure pilot may
gases disperse into the diluting ambient air and can require cooling tees if porcelain is subject to
have harmful effects on exposed equipment and temperatures exceeding 400°F (204°C) (as with down-
components. The situation is particularly noticeable fired burners).
with down-fired burners where spark electrode and UV scanners generally will require remote mounting
flame rod leads may require special insulation material. and air cooling to survive the ambient temperatures
Main flame characteristics. At minimum fire (0.2" encountered at the burner.
wc mixture pressure) approximately a 1/8" long blue
Warning: Test every UV flame sensing
knife-edge flame should be visible beneath the
installation for dangerous spark excitation from
deflector rails. There should be virtually no sound, and
ignitors, other burners and other possible
only very slight radiance visible on the refractory grids
sources of direct or reflected UV radiation.
near burner ports.
6/92

INFRAWAVE® Burners
Standard 6" and 12" straight sections

6" DG 12" DG Typical end & top views,
double grid (DG)
NOTE: All INFRAWAVE® Burner sections

use ISO standard (metric) fasteners
6" SG 12" SG Typical end & top views,

single grid (SG)
Single-grid (SG) burners may be

specified with grid position #1 or #2 as
viewed from the pilot end of an assembly
and shown at left. (If side-mounted
accessories are used, grids will always
be assembled on the same side as
accessories.)

INFRAWAVE® Burners
Standard 6" and 12" Straight Sections with Side-mounted Accessories
With spark ignitor With pressure pilot,

and provision for spark ignitor, adjustable
FR/UV orifice with provision for
mounting a UV scanner
Right: Plain SG-12"
straight with Right: DG-12" straight
optional flame rod section shown with end
closure set
With spark ignitor only (for direct

ignition) or with provision for FR/UV With pressure pilot
Inlet Feed Sections for INFRAWAVE® Burner assemblies

NOTE: Do not use 2" inlet flanges to feed more than 16' of SG burner (8' of DG). 3" inlet flanges may be used to
feed a maximum of 32' of SG burner (16' of DG).
12" DG 12" DG
Bottom Inlet Side Inlet
NOTE: See photo

above of DG-12"
straight section
showing end
closure set
mounted to close
off the burner body/
manifold cavity
Typical end view of side inlet section (with optional accessories)
2/96

INFRAWAVE® Burners
End-mounting Accessories for ALL Sections

End-mounted pilot and bracket for “SG” burner End-mounted pilot and bracket
for “DG” burner
6" DG straight
shown with end
mounted pilot,
bracket, flame
rod (optional)
and end closure
Caution: Be sure to kit (optional) on
specify refractory grid body manifold
position on SG
INFRAWAVE® Burner.
UV scanner/flame rod
must be located on Universal Support Bracket (normally supplied in pairs)
refractory grid side of
burner element.
Flange and End Closure Plate Sets

2" ANS Inlet Flange ➀ 3" ANS Inlet Flange ➀ End Closure Plate
➀ DIN threaded flange sets are also available upon request
Optional Flame Rods Replacement Spark Ignitors

Plain With Cooling Tee 10mm Spark Ignitor 14mm Spark Ignitor
Flame rod length "L" (in inches) 18mm Spark Ignitor

INFRAWAVE® Section With cooling tee Without tee
For all 6" & 12" SG or DG
6-13/16 4-1/2
burner sections
For end mounted pilot
4-13/16 2-1/2
assemblies
Component Identification
INFRAWAVE® Burners
➀ INFRAWAVE® Burners shipped prior

to 8/91 used ANS fasteners. After 8/91,
all INFRAWAVE® Burner assemblies
use ISO standard (metric) fasteners.
Suggested spare parts 3. Remove broken grid section and any remaining
• Deflector rail(s) • Refractory baffle grid(s) fragments as shown in Sketch 2.
• Grid clamp(s) • Manifold gaskets 4. Insert replacement grid and return grid clamp to
• Grid support(s) original position holding grid firmly against grid
support.
Gaskets 5. Center grids on each grid clamp section so they do
Unless specified otherwise, burners are shipped not overlap, then retighten grid clamp screws firmly.
from the factory with manifold and body/manifold joints
sealed with Keypaste.
For field replacements or sections shipped loose, NOTICE: INFRAWAVE® Burner grids must be
high temperature gaskets should be ordered and cured before being taken to high fire.
installed between manifolds and between body and This curing process must take place on initial firing
manifold. and is to include at least a 15 minute slow bring-up
time where the grid is fired low and brought up through
To replace refractory baffle grids: the firing rate at even increments over the 15 minute
1. Apply penetrating oil to grid clamp screws and let period.
stand for a few minutes. If still tight, tap with a After this process has taken place, the refractory
hammer to loosen. grids may be fired in the normal manner without
2. Unscrew grid clamp screws sufficiently so that grid negative side effects.
clamp may be tilted back to clear refractory grids as Failure to cure the refractory grids in this manner
shown in Sketch 1. may result in cracking and quick erosion of the grids,
which results in shortened burner life.
7/03
Notes
Premix-type Line Burners Page 1200-S-1
for Style A, B, C LINOFLAME® Burners
Important: Do not discard packing material until Maintain smooth, even air flow over the burner by
all loose items are accounted for. designing supports to provide minimum interference,
deflection and turbulence. Flat strap iron (with its
General width parallel to the direction of movement) is prefer-
LINOFLAME® Burner assemblies must be able to angle iron or channel supports.
adequately supported and positioned. For small or In horizontal air streams, the preferred support
simple burners, gas supply manifold may provide all methods depend on the type of burner configuration.
the support needed. Small assemblies (up to 5' with one center-fed
In most cases, however, additional supports will be inlet, up to 10' with two inlets) can usually be
required. Avoid rigid mounting. Burner assembly supported from the gas piping only.
expands and contracts with temperature variations, If horizontal rows of straight burner sections
and rigid mounting creates severe stresses within the predominate, choose one of the two alternatives
burner itself, its fastenings and/or supports. shown in Sketches 4 and 5.
Supports
If burner fires in still air:
Sketch 1 below illustrates a typical upward-firing
position. It is only necessary to supply sufficient
support to hold burner weight. In some circum-
stances, the manifolding itself may provide adequate
support particularly if inlets occur every 4' or less.
Use cross-ignition end plates to sectionalize longer
burner assemblies exceeding 7' in length.
Burner location should be chosen to minimize possi-

bility of plugging burner ports due to dirt, sand or other
foreign matter being dropped onto the burner face.
To protect burner, a supply of fresh cooling
secondary air should be provided, possibly as shown
in Sketch 2.
Sketch 4 shows the burner suspended from a

strap iron frame using USB (universal support brack-
ets) supplied by Maxon. Note that rigid mounting is
avoided by the 3/4" bracket hole which slips loosely
over a 1/2" bolt or steel rod attached to the support.
Gas piping would need independent support.
If burner fires into an air stream: Sketch 5 shows the burner assembly resting upon
Burners must be angle iron brackets and not attached to them in any
mounted so they fire way. Gas manifolding would be independently sup-
parallel to and in the ported and prevent forward movement of the burner.
same direction as the
movement of the air
which is being heated.
m
(See Sketch 3 at right.)
CORPORATION
Page 1200-S-2 Premix-type Line Burners
for Style A, B, C LINOFLAME® Burners
If vertical rows of straight burner sections pre- be moved back from the burner, thus minimizing any
dominate, small assemblies (up to 10' of burner) can airstream turbulence or diversion that it might cause.
be supported from the gas manifold. For larger Sketch 10 shows an alternate arrangement which
assemblies, see the examples below. offers the advantage of more controlled positioning.
This arrangement is especially good if the burner is to
be installed in a heater which must be shipped to
another location.
Pilots
Sketch 6 shows angle iron used to support the LINOPAK Pilots bolt directly onto the burner in
burner. Note that narrow edge of angle faces air flow. place of an end plate, already in proper position.
Sketch 7 shows how gas manifolding may be used “Patch-on” pilots, when not factory-installed,
to support the burner. If there are multiple inlets, you must be mounted as shown in Sketch 11 below, at a
must avoid rigid connection by using the oversize location suitable to you.
U-bolt (loosely drawn-up) illustrated. To mount flame rod, insert it in the flame rod
In vertical air streams, avoid upward-firing bracket. Position bracket on burner side as shown
arrangements wherever possible. The increased below so that flame rod passes directly over a main
chance of dirt falling into the burner (especially during burner port and mark the two mounting holes. Then
a shut-down) can seriously affect performance and drill 5/32" holes, tap them #10-24 and bolt flame rod
reliability. If unavoidable, however, support as shown bracket in place.
in Sketch 8. To mount pilot hood, position it as shown below
(off-setting slightly to clear flame rod if ground vane is
present), mark mounting holes and drill 13/64" holes,
tap 1/4"-20 threads and bolt pilot hood in place.
Support for down-fired burners

can be accomplished as shown in
the illustration at right. Always
avoid rigid mounting. See also the gas train installation and start-up
Sketch 9 shows USB (universal instructions for the particular proportioning and mixing
support brackets) used to support equipment used in your system.
the burner from an overhead angle
iron. One advantage this provides
is that the support mechanism may
mCORPORATION

Premix-type Line Burners Page 1200-A/P-1
Assembly Numbers
Style A, B & C LINOFLAME® Burners with cast iron ignition rails
LINOFLAME® Burner Designation Style "A" Style "B" Style "C"
Section Description (Code) LA-(*)-36 LA-(*)-72 LB-(*)-24 LB-(*)-36 LB-(*)-72 LB-(*)-96 LC-(*)-24
Configured Item Number [2] LA36 LA72 LB24 LB36 LB72 LB96 LC24
24135 24155 24195
3" straight section --- --- --- ---
(3) (3) (3)
(-3)
3" straight section with #18118 53818 53827 53843
--- --- --- ---
spark ignitor & rail (3) (3) (3)
24110 24117 24133 24153 24174 24193
6" straight section ---
(7) (7) (6) (6) (6) (6)
(-6)
6" straight section with #18118 53802 53806 53817 53826 53834 53842
---
spark ignitor & rail (7) (7) (6) (6) (6) (6)
24132 24152 24192
(8) (8) (8)
(-8)
--- --- --- ---
26631
9" straight section (-9) --- --- --- --- --- ---
(5)
24109 24116 24131 24151 24172 24191 26630
12" straight section
(10) (10) (9) (9) (9) (9) (6)
(-12)
12" straight section with #18118 53801 53805 53815 53824 53833 53840 53896 [1]
spark ignitor & rail (10) (10) (9) (9) (9) (9) (6)
12" straight section (1-1/2" NPT) 24137 24157 24197
--- --- --- ---
bossed side inlet (13) (13) (13)
12" straight section (1-1/2" NPT) (-12S)
53820 53829 53845
bossed side inlet with #18118 --- --- --- ---
(13) (13) (13)
spark ignitor & rail
--- --- --- ---
bossed back inlet (13) (13) (13)
12" straight section (1-1/2" NPT) (-12B)
53819 53828 53844
bossed back inlet with #18118 --- --- --- ---
(13) (13) (13)
3" straight section (1" NPT) 24140 24160 24200
--- --- --- ---
3" straight section (1" NPT) (-3B)
53821 53830 53846
(3) (3) (3)
24141 24161 24182 24201
12" tee section side inlet --- --- ---
(14) (14) (14) (14)
(-TS)
12" tee section side inlet with 53822 53831 53839 53847
--- --- ---
#18118 spark ignitor & rail (14) (14) (14) (14)
24112 24118 24142 24162 24202
12" tee section back inlet --- ---
(18) (18) (14) (14) (14)
(-TB)
12" tee section back inlet with 53803 53807 53823 53832 53848
--- ---
#18118 spark ignitor & rail (18) (18) (14) (14) (14)
[1] Style C LINOFLAME® section requires 10mm spark ignitor #18110
[2] To order line burner arrangements, order the appropriate configured item number. To order burner sections loose,
order individual burner section assembly numbers.
Size and number of drilled ports for all LINOFLAME® Burner sections must be specified on order

mCORPORATION
Page 1200-A/P-2 Premix-type Line Burners
Assembly Numbers
Style A, B & C LINOFLAME® Burners with cast iron ignition rails

LINOFLAME® Burner Designation Style "A" Style "B" Style "C"
Section Description (Code) LA36 LA72 LB24 LB36 LB72 LB96 LC24
1-1/2" NPT LFB- 1-1/2" 04123 (3) ---
Bottom & Side Inlet Flange 2" NPT LFB- 2" 04122 (3) ---
for (-TS) & (-TB) sections 2-1/2" NPT LFB- 2-1/2" 18694 (4) ---
3" NPT LFB- 3" 00295 (3) ---
1-1/4" NPT 1-1/4" -LFC --- --- --- --- --- --- 04916
End Inlet Flange 1-1/2" NPT 1-1/2" -LFE 03917 (2) ---
2" NPT 2" -LFE 03433 (2) ---
24143 24163 24203
12" cross ignition section (-TX) --- --- --- ---
(11) (11) (11)
24144 24164 24204
3" elbow section (-E3) --- --- --- ---
(4) (4) (4)
24148 24168 24208
6" elbow section (-E6) --- --- --- ---
(8) (8) (8)
3" midget section LM-3-72 [1] --- --- --- --- 26635 --- ---
24170 24170
B to C reducing section LBC-3 --- --- --- --- ---
(3) (3)
01860 05400
End plate (plain) LEP
(2) (1)
16680
End plate (flame rod) LEP-FR ---
(2)
24115 26634
End plate cross ignition LXEP
(3) (2)
03921
Division plate LDP ---
(1)
Universal suppor t bracket (order in pairs) USB 23577 (CS) / 39940 (SS)
Flame rod holder 2LFBR 16309
Flame rod L= 7-1/2" (with cover) --- 1037597
[1] Suggested drilling for LM-3-72 is #44 mains and #44 ignitors (maximum ignitor por t drill size is #44)

m
CORPORATION

Assembly Numbers
Style A, B & C LINOFLAME® Burners with alloy ignition rails
LINOFLAME® Burner Section Designation Style "A" Style "B" Style "C"
Description (Code) LAA-(*)-36 LAA-(*)-72 LBA-(*)-24 LBA-(*)-36 LBA-(*)-72 LBA-(*)-96 LCA-(*)-24
Configured Item No. [1] LAA36 LAA72 LBA24 LBA36 LBA72 LBA96 LCA24
24213 24232 24252 24271
3" straight section --- --- ---
(3) (3) (3) (3)
(-3)
3" straight section with #18118 53852 53860 53868 53877
--- --- ---
spark ignitor & rail (3) (3) (3) (3)
24121 24128 24211 24230 24250 24269
6" straight section ---
(7) (7) (6) (6) (6) (6)
(-6)
---
24210 24229 24268
(8) (8) (8)
(-8)
--- --- --- ---
26633
9" straight section (-9) --- --- --- --- --- ---
(5)
24120 24127 24209 24228 24248 24267 26632
12" straight section
(10) (10) (9) (9) (9) (9) (6)
(-12)
---
--- --- --- ---
bossed side inlet (13) (13) (13)
12" straight section (1-1/2" NPT) (-12S)
53853 53862 53879
bossed side inlet with #18118 --- --- --- ---
(13) (13) (13)
--- --- --- ---
12" straight section (1-1/2" NPT) (-12B)
53804 53861 53878
(13) (13) (13)
3" straight section (1" NPT) 24218 24237 24276
--- --- --- ---
3" straight section (1" NPT) (-3B)
53854 53863 53880
(3) (3) (3)
24219 24238 24277
12" tee section side inlet --- --- --- ---
(14) (14) (14)
(-TS)
12" tee section side inlet with 53855 53864 53881
--- --- --- ---
#18118 spark ignitor & rail (14) (14) (14)
24123 24129 24220 24239 24259 24278
12" tee section back inlet ---
(18) (18) (14) (14) (14) (14)
(-TB)
12" tee section back inlet with 53810 53814 53856 53865 53873 53882
---
#18118 spark ignitor & rail (18) (18) (14) (14) (14) (14)
[1] To order line burner arrangements, order the appropriate configured item number. To order burner sections loose,
order individual burner section assembly numbers.


m
CORPORATION
Assembly Numbers
Style A, B & C LINOFLAME® Burners with alloy ignition rails

LINOFLAME® Burner Section Designation Style "A" Style "B" Style "C"
Description (Code) LAA36 LAA72 LBA24 LBA36 LBA72 LBA96 LCA24
1-1/2" NPT LFB- 1-1/2" 04123 (3) ---
Bottom & Side Inlet 2" NPT LFB- 2" 04122 (3) ---
Flange Set
for (-TS) & (-TB) sections 2 - 1 / 2 " N PT L F B- 2-1/2" 18694 (4) ---
3" NPT LFB- 3" 00295 (3) ---
1-1/4" NPT 1-1/2" -LFC --- --- --- --- --- --- 04916
End Inlet Flange Set 1-1/2" NPT 1-1/2" -LFE 03917 (2)
2" NPT 2" -LFE 03433 (2)
24221 24240 24279
12" cross ignition section (-TX) --- --- --- ---
(11) (11) (11)
24222 24241 24280
3" elbow section (-E3) --- --- --- ---
(4) (4) (4)
24124 24130 24226 24245 24284
6" elbow section (-E6) --- ---
(9) (9) (8) (8) (8)
01860 05400
End plate (plain) LEP
(2) (1)
16680
End plate (flame rod) LEP-FR ---
(2)
24126 26634
End plate cross ignition LXAEP
(3) (2)
03921
Division plate LDP ---
(1)
Universal suppor t bracket
USB 23577
(order in pairs)
Flame rod holder 2LFBR 16309
Pilot mounting bracket --- 06950 (1)
Flame rod L= 7-1/2" --- 18117

m
CORPORATION

Assembly Numbers
Spare Parts
End-mounted LINOPAK Pilots Side-mounted pilots
for Style A, B & C LINOFLAME® Burners for Style A, B & C LINOFLAME® Burners
Pilot Assembly Includes: Pilot Pilot Assembly Includes:
Pilot
Assembly Pilot Description Assembly Pilot Description Pilot Gas Adjustable Spark
Pilot Gas Adjustable Spark
Number Number Mixer Orifice Cock Ignitor
Mixer Orifice Cock Ignitor
05140 Fresh air type
15214 Iner t air
33107 --- 15726 (3) LINOFLAME® pilot
(9) LINOPAK pilot 12326 39294 ---
10847 Fresh air type
15216 Fresh air LINOPAK (3) (with vane)
(5) pilot 18118
12326 39294 --- 12150 Recirculating type
15218 Fresh air LINOPAK 33107 --- 15726
(8) (with vane)
(5) pilot (w/vane)
10848 Pressure type pilot
15220 Iner t air LINOPAK 18118 11680 38579 ---
33107 --- 15726 (3) (with vane)
(9) pilot (w/vane)
06868
---
15215 Pressure type (4)
(4) LINOPAK pilot 12457 39294 ---
06969
18110
Pressure type 11680 38579 --- (4) Open por t
15219
LINOPAK pilot 18886 venturi pilot
(4) ---
(w/vane) (4)
18885 39295 ---
18887
18110
(4)
Miscellaneous Optional Accessories
18mm spark ignitor (R) 18118
10mm spark ignitor (R) 18110
Electrode cover for flame rod or spark ignitor (A) 18722
Miscellaneous Optional Accessories

Style B Only (ISO threaded flanges)
24 36 72 96
12" (1.5" NPT bossed
side inlet) straight 38304 24806 --- 34246
section
side inlet) straight 38304 34806 --- 34246
section w/ SI
back inlet) straight 38303 24805 --- 34245
section
back inlet) straight 383030 24805 --- 34245
section w/ SI
3" (1" NPT bossed back
38299 38300 38301 38302
inlet) straight section
3" (1" NPT bossed back
inlet) straight section w/ 38299 38300 38301 38302
SI

mCORPORATION
Assembly Numbers
VF LINOFLAME® Burners
VF LINOFLAME® Burner Sections

Configured Item Number [1] VFH VFL
VFH LINOFLAME® VFL LINOFLAME®
Item Section Description Assembly Assembly
Designation Designation
Number Number
3" straight VFH-3 34297 (11) VFL-3 34289 (4)
6" straight VFH-6 34298 (7) VFL-6 34290 (5)
Burner 12" straight VFH-12 34299 (13) VFL-12 34291 (8)
Sections 6" elbow --- --- VFL-L 34293 (8)
12" x 6" tee VFH-5 34302 (16) VFL-T 34294 (11)
12" x 12" cross VFH-X 34303 (20) VFL-X 34295 (15)
Back Inlet Feed 12" x 12" back inlet cross VFH-XB 34304 (24) VFL-XB 34296 (15)
Sections
(each requires an inlet
flange from below) 12" back inlet straight VFH-12B 34300 (17) VFL-12B 34292 (9)
2" NPT --- --- VFL-2BF 34333 (1)

For (12B) back inlet sections
ANS Back Inlet Flange 3" NPT VFH-3BF 34338 (3) --- ---
Options 3" NPT VFH-3XF 34339 (4) VFL-3XF 34334 (4)
For (XB) back inlet cross sections
4" NPT VFH-4XF 34340 (6) --- ---
2" ISO --- --- VFL-2BF 24531
For (12B) back inlet sections
ISO Back Inlet Flange 3" ISO VFH-3BF 21049 --- ---
Option 3" ISO VFH-3XF 21048 VFL-3XF 24532
For (XB) back inlet sections
4" ISO VFH-4XF 21046 --- ---
End cap set-plain VFH-EC 34335 (3) VFL-EC 34330 (2)
End cap set with provision for flame rod (order
VFH-EC-FR 34336 (3) VFL-EC-FR 34331 (2)
End Cap Sets #18117 flame rod separately)
End closure set with spark ignitor (includes #18110
VFH-EC-SI 23993 (3) VFL-EC-SI 24105 (2)
spark ignitor)
High recirculation end plate
VFH-HREP 25079 VFL-HREP 25120
(use with end cap set or end inlet flange set)
End Plate Sets
Expansion end plate set (includes (2) end closures
VFH-XEP 23190 (5) VFL-XEP 24308 (7)
with necessary expansion joint fasteners)
1-1/2" NPT --- --- VFL-1-1/2-EF 34332 (2)
End inlet flange set
2" NPT VFH-2-EF 34377 (3) --- ---
ANS End Inlet End inlet flange set w/provision for

Flange Options flame rod (order #8117 flame rod 2" NPT VFH-2EF-FR 24514 (3) --- ---
separately)
End flange set w/spark ignitor
2" NPT VFH-2EF-SI 24515 (3) --- ---
(includes #23739 spark ignitor)
1-1/2" ISO --- --- VFL- 1-1/2 -EF 24530
2" ISO VFH-2-EF 24534 --- ---
ISO End Inlet End inlet flange set w/provision for

Flange Options flame rod (order #18117 flame rod 2" ISO VFH-2EF-FR 44167 --- ---
separately)
End inlet flange set w/spark ignitor
2" ISO VFH-2EF-SI 44168 --- ---
(includes #23739 spark ignitor)
[1] To order line burner arrangements, order the appropriate configured item number. To order loose items, order individual assembly
numbers.
mCORPORATION

Assembly Numbers
“VF” LINOFLAME® Burners
End-mounted LINOPAK Pilots for "VF" LINOFLAME® Burners

Selection Parameters: "VFH" "VFL" Pilot Assembly Includes:
Available Type of LINOFLAME® LINOFLAME®
Burner Burner Adjustable 18mm Spark
Natural Gas Pilot Mixer Flame Pilot Mixer
Gas Orifice Ignitor
Pressures Safeguard LINOPAK Pilot LINOPAK Pilot
23218 (5) 24102 (5)
Venturi-type Flame Rod 23229 ---
VFH-LO-V-FR VFL-LO-V-FR
Low Gas
23995 (5) 24287 (5)
Pressures Pressure-type UV Scanner 18118
VFH-LO-P-UV VFL-LO-P-UV
(4-7" wc) (requires 4-16 osi 11680 38579
combustion air) 22737 (5) 24100 (5)
Flame Rod
VFH-LO-P-FR VFL-LO-P-FR
UV Scanner --- --- --- ---
Venturi-type 23219 (5) 24101 (5) ---
Flame Rod 23230
High Gas VFH-HI-V-FR VFL-HI-V-FR
Pressures 28240 (6) 28241 (6)
(1-2 PSIG) Pressure-type UV Scanner 18118
VFH-HI-P-UV VFL-HI-P-UV
(requires 4-16 osi 25006 38577
combustion air) 27709 (6) 27708 (6)
Flame Rod
VFH-HI-P-FR VFL-HI-P-FR
Fasteners for flanges ordered loose

VFH VFL
Description NPT ISO Part Part Part Part
Qty. Qty. Qty. Qty.
Number Number Number Number
2" NPT 2" ISO --- --- --- --- 40276 4 --- ---
Back inlet flange for (12B) back inlet section
3" NPT 3" ISO 40284 6 --- --- 40279 4 --- ---
3" NPT 3" ISO 40292 6 --- --- --- --- --- ---
Back inlet flange for (XB) back inlet cross section
4" NPT 4" ISO 40299 6 --- --- --- --- --- ---
1-1/2" NPT 1-1/2" ISO --- --- --- --- 40266 4 40019 4
2" NPT 2" ISO 40281 4 40023 4 --- --- --- ---
Miscellaneous Accessories and/or

Replacement Parts
Flame rod (L = 4.5") 1061849
10mm 18110
Spark ignitor 14mm 23739
18mm 18118
Universal Suppor t Bracket (USB) 23577 (CS)
(normally furnished in pairs) 39940 (SS)
Rubber cover 18722

m CORPORATION
Assembly Numbers
INFRAWAVE® Burners
INFRAWAVE® Burner Sections Note: All INFRAWAVE® Burner sections use ISO standard (metric) fasteners
Configured Item Number [1] INFRA SG INFRA DG
Section Type Description "SG" Single Grid "DG" Double Grid
Plain 6 S SG (16) 6 S DG (20)
With pilot, includes side-mounted pressure pilot #25906 which
includes #11680 pilot mixer, #18110 spark ignitor, #38579 adjustable 6 SP SG (18) 6 SP DG (22)
6" straight pilot gas orifice, with provision for mounting a UV scanner
sections With SI and FR, includes side-mounted #23739 spark ignitor,
(I.S.O. opposite of provision for mounting a flame rod (order #18117 flame --- 6 SSF DG (21)
assemblies) rod, if used, separately)
With SI, includes side-mounted #23739 spark ignitor 6 SS SG (16) 6 SS DG (20)
With FR-SCAN, includes provision for side-mounting a UV scanner or
6 SFU SG (16) 6 SFU DG (20)
flame rod (order #18117 flame rod, if used, separately)
Plain 12 S SG (32) 12 S DG (40)
includes #11680 pilot mixer, #18110 spark ignitor, #38579 adjustable 12 SP SG (30) 12 SP DG (37)
12" straight pilot gas orifice, with provision for mounting a UV scanner
sections With SI and FR, includes side-mounted #23739 spark ignitor,
(I.S.O. opposite of provision for mounting a flame rod (order #18117 flame 12 SSF SG (32) 12 SSF DG (40)
assemblies) rod, if used, separately)
With SI, includes side-mounted #23739 spark ignitor 12 SS SG (30) 12 SS DG (37)
With FR-SCAN, includes provision for side-mounting a UV scanner or
12 SFU SG (32) 12 SFU DG (40)
flame rod (order #18117 flame rod, if used, separately)
[1] To order burner arrangements, order the appropriate configured item number.
NOTE: 6” and 12” sections include the following segments:
• Grid Material
• Grid Clamp Material
• Body Gasket
• Maximum Airstream Temperature
mCORPORATION

Assembly Numbers
INFRAWAVE® Burners
INFRAWAVE® Burner Sections Note: All INFRAWAVE® Burner sections use ISO standard (metric) fasteners
Configured Item Number [1] INFRA SG INFRA DG
Section Type Description "SG" Single Grid "DG" Double Grid
Plain 6 BI SG (15) 6 BI DG (19)
6" bottom inlet With pilot, includes side-mounted pressure pilot, #25906 which
sections includes #11680 pilot mixer, #18110 spark ignitor, #38579
6 BI SP SG (17) 6 BI SP DG (21)
(I.S.O. adjustable pilot gas orifice, with provision for mounting a UV
assemblies) scanner
NOTE: Select With SI and FR, includes side-mounted #23739 spark ignitor,
optional inlet opposite of provision for mounting a flame rod (order #18117 --- 6 BI SSF DG (19)
flange set flame rod, if used, separately)
separately from With SI, includes side-mounted #23739 spark ignitor 6 BI SS SG (15) 6 BI SS DG (19)
listing on following
page With FR-SCAN, includes provision for side-mounting of a UV
scanner or flame rod (order #18117 flame rod, if used, 6 BI SFU SG (15) 6 BI SFU DG (19)
separately)
Plain 12 BI SG (28) 12 BI DG (36)
With pilot, includes side-mounted pressure pilot, #25906 which
12" bottom inlet includes #11680 pilot mixer, #18110 spark ignitor, #38579
sections (I.S.O. adjustable pilot gas orifice, with provision for mounting a UV 12 BI SP SG (31) 12 BI SP DG (38)
assemblies) scanner
NOTE: Select
With SI and FR, includes side-mounted #23739 spark ignitor,
optional inlet 12 BI SSF SG 12 BI SSF DG
opposite of provision for mounting a flame rod (order #18117
flange set (29) (37)
flame rod, if used, separately)
separately from
listing on following ith SI, includes side-mounted #23739 spark ignitor
W 12 BI SS SG (28) 12 BI SS DG (36)
page With FR-SCAN, includes provision for side-mounting of a UV
12 BI SFU SG 12 BI SFU DG
scanner or flame rod (order #18117 flame rod, if used,
(29) (36)
separately)
Plain 12 SI SG (28) 12 SI DG (35)
12" side inlet includes #11680 pilot mixer, #18110 spark ignitor, 338579
sections 12 SI SP SG (30) 12 SI SP DG (38)
adjustable pilot gas orifice, with provision for mounting a UV
(I.S.O. scanner
assemblies)
With SI and FR, includes side-mounted #23739 spark ignitor,
NOTE: Select 12 SI SSF SG 12 SI SSF DG
opposite of provision for mounting a flame rod (order #18117
optional inlet (29) (36)
flange set
separately from With SI, includes side-mounted #23739 spark ignitor 12 SI SS SG (28) 12 SI SS DG (36)
listing below With FR-SCAN, includes provision for side-mounting a UV
12 SI SFU SG 12 SI SFU DG
scanner or flame rod (order #18117 flame rod, if used,
(29) (36)
separately)
[1] To order burner arrangements, order the appropriate configured item number.

m CORPORATION
Assembly Numbers
INFRAWAVE® Burners
INFRAWAVE® Burner End Plate Sets, Accessory Options and Spare Parts
INFRA SG INFRA DG
Description
"SG" single grid "DG" double grid
End Mounted Pilot
Assembly End mounted pressure pilot and mounting bracket, includes
NOTE: Select an end plate pressure pilot #24922 which includes #11680 pilot mixer, #18118
27405 (5) 27404 (5)
set from below to close off spark ignitor, #38579 adjustable pilot gas orifice with provision to
the end of the burner mount a flame rod (order #18117 flame rod, if used, separately)
assembly
Bottom & Side Inlet 2" NPT (ANS) 27465 (2)
Flange Sets 3" NPT (ANS) 27466 (2)
Bottom & Side Inlet 2" ISO 35915 + (4) 54630
Flanges 3" ISO 32721 + (4) 54630
2" NPT (ANS) 27462 (2)
End Inlet Flange Sets
3" NPT (ANS) 27463 (2)
2" ISO 35915 + (4) 54630 + (4) 42534
End Inlet Flanges
3" ISO 32721 + (4) 54630 + (4) 40023
End plate set - end closure 27461 (3)
End Closure Sets
End plate set - bottom and side closure 27464 (3)
Flame rod (L - 7-1/2") (A/R) 18117
10mm 18110
Spark Ignitor (R) 14mm 23739
18mm 18118
Electrode protective cover (A/R) for flame rod or spark ignitor 18722
zinc plated, good up
23577
Universal support bracket (A) to 750°F
USB normally furnished in pairs stainless steel, good
39940
up to 1600°F
Miscellaneous Accessory Flame rod cooling tee (A) 27549
Options and Spare Parts
Standard 1056792
Refractory baffle grid (R) Drilled for pilot 1056793
Drilled for ignitor 1056794
Manifold gasket (R) for field assembly 31796
Manifold gasket, 6" body (R) 35358
Manifold gasket, 12" body (R) 35359
#310SS grid clamp (R) 28341
#310SS deflector rail (R) 28340
Deflector rail, cross ignition (R) 34329
Maximum airstream temperature: 450°F (rubber boot limit); 600°F (burner limit if up-fired, 400°F if down-fired)
m CORPORATION

Bulletin 1350
Maxon-P/S Radiant II Burners
Type 50 (side-to-side) assembly Type 25 (end-to-end) assembly
• High radiant output. Up to 33,000 Btu/sq. ft./hr (104 kw/m2) of radiant face area when
operated at 1650°F (900°C).
• Ease of maintenance. Each row of Maxon-P/S Radiant II Burner consists of individual

burner heads mounted along a common manifold. The burner heads can be removed easily
from the manifold and repaired or replaced with a minimum of downtime.
• Rapid heat up and cool down, eliminating the need to rotate burner heads away from your
product.
• Maxon-P/S Radiant II Burner tiles are not subject to water damage and require no
additional cooling or sealing air.
• No wire screens are required to stabilize combustion on the face of the burner.
• High surface temperatures at reasonable fuel inputs.
• Designed for operation in both horizontal and vertical applications.
• Low manifold pressures for normal operation: 4.5" - 5" wc nominal (11.2 – 12.5 mbar).
• Manifolds can be modified to allow for multi-width operation of burner sections.
CORPORATION 201 East 18th Street, P.O. Box 2068, Muncie, Indiana, 47307-0068. Phone (765) 284-3304. Fax (765) 286-8394.
Page 1352
Maxon-P/S Radiant II Burners

Maxon-P/S Radiant II Burners are designed to
deliver uniform, high intensity radiant energy for
moisture removal in textile and paper ovens, paint
drying, and powder coating, as well as many pre-heat,
plastic forming, heat treating and annealing
operations.
Benefits Rear view – Type 50 (side-to-side) assembly

Maxon-P/S Radiant II Burners allow you to eco-
nomically increase production rates, reduce seconds
and defects caused by improper or uneven heating or
drying and reduce down time and maintenance costs
when the need for service or repairs arises.
Side view – Type 13 assembly
Specifications
Front view – Type 13 assembly 1. Maxon-P/S Radiant II Burners are full premix and
will operate on both natural and propane gas.
Manifold mixture pressures at the burner range
from 4.5" – 5" wc (11.2 – 12.5 mbar).
2. The three-tile 25 and 50 series burner heads have
a maximum heat input of 25,000 Btu/hr (7.3 kw);
Type 13 has a maximum heat input of 19,500 Btu/
hr (5.7 kw).
3. Normal operating face temperatures range from
Front view – Type 25 (end-to-end) assembly 1250°F – 1650°F (675°C – 900°C).
4. Burner heads are fabricated of 304 stainless.
5. Burner tiles are high efficiency, high emissivity tiles.
6. All Maxon-P/S Radiant II Burner heads have a
quick connect feature which allows you to remove
and replace individual burner heads without
removing the whole manifold assembly from the
oven.
7. Tiles in the burner head are held in place by twist
lock retainers. There are no bolts or nuts to be
Type 50 burner with flame rod and spark ignitor removed if tiles need to be replaced.
8. Type 25 and Type 50 utilize the same burner
heads. Type 25 are asembled end-to-end; Type 50
are assembled side-to-side.
7/99
CORPORATION 201 East 18th Street, P.O. Box 2068, Muncie, Indiana, 47307-0068. Phone (765) 284-3304. Fax (765) 286-8394.
Maxon-P/S Radiant II Burners Page 1353
Specifications / Design Details

Radiant Energy - source and transfer
The quantity of radiant energy the P/S Radiant For example, if we assume the work temperature is
Burner system is capable of supplying is a function of 200°F and its emissivity is 0.80, the energy transfer
the surface area, emissivity and temperature of the rates per square foot at various tile temperatures are
burner tile(s). The effective surface area of a Type 25, as illustrated below.
Type 50 or Type 13 burner tile is 0.37 ft2 (0.034 m2).
Emissivity is defined as the measure of the ability of a P/S Radiant Burner tile temperature = 1400°F
material to radiate energy. It is expressed as a From the table below, we determine
number from 0.0 – 1.0. The nominal emissivity for the the heat flux to be 18,600 Btu/ft2/hr x 0.80 emissivity
P/S Radiant Burner tile is 0.92 @ 1500°F (815°C) or
0.94 at room temperature. The maximum operating = 14,880 Btu/ft2/hr
temperature for the P/S Radiant Burner tile is 1650°F
(900°C).
To determine the radiant heat transfer or heat flux P/S Radiant Burner tile temperature = 1600°F
from the P/S Radiant Burner system to the work, the From the table below, we determine
temperature and emissivity of the work must be the heat flux to be 28,000 Btu/ft2/hr x 0.80 emissivity
known. Refer to the following table to determine the
maximum heat flux between one square foot of P/S = 22,400 Btu/ft2/hr
Radiant Burner and the work at a given temperature.
You must correct for the emissivity of the work by
multiplying the value from the table by the work's Metric table appears on next page.
emissivity. ( The table is corrected for the burner tile's
emissivity.)
Radiant Heat Transfer Rate (in 1000's Btu/ft2/hr)

Temperature Temperature of P/S Radiant Burner Tile (° F) (Emissivity corrected for temperature)
of Work ° F [1] 1100 1150 1200 1250 1300 1350 1400 1450 1500 1550 1600 1650
0 9.4 10.6 12.0 13.5 15.1 16.9 18.8 20.9 23.2 25.6 28.2 31.0
100 9.3 10.5 11.9 13.4 15.0 16.8 18.8 20.8 23.1 25.5 28.1 30.9
200 9.1 10.4 11.8 13.3 14.9 16.7 18.6 20.7 22.9 25.4 28.0 30.8
300 8.9 10.2 11.5 13.0 14.7 16.5 18.4 20.5 22.7 25.1 27.8 30.6
400 8.6 9.8 11.2 12.7 14.3 16.1 18.0 20.1 22.4 24.8 27.4 30.2
500 8.1 9.3 10.7 12.2 13.9 15.6 17.6 19.7 21.9 24.3 26.9 29.7
600 7.4 8.7 10.1 11.6 13.2 15.0 16.9 19.0 21.3 23.7 26.3 29.1
700 6.6 7.8 9.2 10.7 12.3 14.1 16.0 18.1 20.4 22.8 25.4 28.2
800 5.4 6.7 8.1 9.6 11.2 13.0 14.9 17.0 19.3 21.7 24.3 27.1
900 4.0 5.3 6.6 8.1 9.8 11.6 13.5 15.6 17.9 20.3 22.9 25.7
1000 2.2 3.5 4.8 6.4 8.0 9.8 11.7 13.8 16.1 18.5 21.1 24.0
1100 --- 1.3 2.7 4.2 5.8 7.6 9.6 11.7 13.9 16.4 19.0 21.8
1200 --- --- --- 1.5 3.2 5.0 6.9 9.0 11.3 13.7 16.4 19.2
1300 --- --- --- --- --- 1.8 3.8 5.9 8.1 10.6 13.2 16.0
1400 --- --- --- --- --- --- --- 2.1 4.4 6.8 9.5 12.3
1500 --- --- --- --- --- --- --- --- --- 2.5 5.1 7.9
1600 --- --- --- --- --- --- --- --- --- --- --- 2.8
[1] Emissivity = 1.0
7/99
Page 1354 Maxon-P/S Radiant II Burners

Radiant Energy - source and transfer (continued)
To determine the radiant heat transfer or heat flux For example, if we assume the work temperature is
from the P/S Radiant Burner system to the work, the 93°C and its emissivity is 0.80, the energy transfer
temperature and emissivity of the work must be rates per square foot at various tile temperatures are
known. Refer to the following table to determine the as illustrated below.
maximum heat flux between one square meter of P/S
Radiant Burner and the work at a given temperature. P/S Radiant Burner tile temperature = 760°C
You must correct for the emissivity of the work by From the table below, we determine
multiplying the value from the table by the work's the heat flux to be 58 kw/m2 x 0.80 emissivity
emissivity. ( The table is corrected for the burner tile's
emissivity.) = 46.6 kw/m2
P/S Radiant Burner tile temperature = 870°C

From the table below, we determine
the heat flux to be 87.6 kw/m2 x 0.80 emissivity
= 70 kw/m2
Radiant Heat Transfer Rate (in kw/m2)

Temperature Temperature of P/S Radiant Burner Tile (° C) (Emissivity corrected for temperature)
of Work ° C [1] 600 625 650 675 700 725 750 775 800 825 850 875 900
0 30.4 34.0 37.9 42.2 46.8 51.7 57.1 62.8 68.9 75.5 82.5 89.9 97.9
50 30.1 33.7 37.7 41.9 46.5 51.4 56.8 62.5 68.6 75.2 82.2 89.7 97.6
100 29.7 33.3 37.2 41.5 46.1 51.0 56.3 62.0 68.2 74.7 81.7 89.2 97.2
150 29.0 32.6 36.5 40.8 45.4 50.3 55.7 61.4 67.5 74.1 81.1 88.6 96.5
200 28.0 31.7 35.6 39.9 44.4 49.4 54.7 60.4 66.6 73.1 80.1 87.6 95.6
250 26.7 30.4 34.3 38.5 43.1 48.1 53.4 59.1 65.3 71.8 78.9 86.3 94.3
300 25.0 28.6 32.6 36.8 41.4 46.4 51.7 57.4 63.6 70.1 77.1 84.6 92.6
350 22.7 26.4 30.3 34.6 39.2 44.1 49.5 55.2 61.3 67.9 74.9 82.4 90.4
400 19.9 23.5 27.4 31.7 36.3 41.3 46.6 52.3 58.5 65.0 72.1 79.6 87.5
450 16.3 19.9 23.8 28.1 32.7 37.7 43.0 48.8 54.9 61.5 68.5 76.0 84.0
500 11.8 15.5 19.4 23.7 28.3 33.3 38.6 44.4 50.5 57.1 64.2 71.7 79.7
550 6.4 10.1 14.1 18.4 23.0 28.0 33.3 39.1 45.2 51.8 58.9 66.4 74.4
600 --- 3.7 7.6 11.9 16.6 21.6 26.9 32.7 38.9 45.5 52.5 60.0 68.1
650 --- --- --- 4.3 9.0 14.0 19.3 25.1 31.3 37.9 45.0 52.5 60.5
700 --- --- --- --- --- 5.0 10.4 16.2 22.4 29.0 36.1 43.7 51.7
750 --- --- --- --- --- --- --- 5.8 12.0 18.7 25.8 33.3 41.4
800 --- --- --- --- --- --- --- --- --- 6.7 13.8 21.4 29.4
850 --- --- --- --- --- --- --- --- --- --- --- 7.6 15.7

Absorption Charts and Wave Length
A second important consideration in any radiant to be heated. The water absorption chart below will
application is the wave length of radiation gener- give you a graphic view of those wave lengths of
ated. As your heater surface temperature in- infrared that will be most readily absorbed by water.
creases, the wave length of the radiant energy As you can see from the absorption curve, there are
generated decreases. To get the most efficiency two ranges of wave length that fall under the maxi-
from your radiant dryer, you need to generate a wave mum portion of the curve. The first range includes
length of infrared that will be absorbed by the product radiation from 5.3 to 7 microns in length and an
to be heated. It does little or no good to increase your emitter surface temperature range from 280°F to
generator surface temperature in order to get more 530°F (140°C to 270°C). The second range of maxi-
energy released per square foot and generate wave mum efficiency is 2.55 to 2.9 microns in wave length
lengths of radiation that passes through your product and 1330°F to 1600°F (720°C to 870°C).
much like light passes through a window glass. Many try to increase drying capacity by increasing
Select the proper range of wave lengths by the burner input and face temperature. As the chart
using a radiation absorption chart for the product indicates, system efficiency could drop by over 70%
when going above 1600°F (870°C).
7/99

NOx and Flame Temperature vs. Excess Air
This chart represents the relationship between NOx
emissions and flame temperature versus percent of
excess air. Actual readings may vary according to
operating conditions.
°F °C
980
930
870
820
Flame Temperature
760
700
650
590
540
480
420

Sample Calculations
The following is a sample set of calculations to show Step 7) Assuming an emissivity of 0.5, our design
the steps required to determine the number of burner radiant density is (2,228 Btu/ft2)/0.5 = 4,456 Btu/ft2
heads and burner rows in a given application. This is the radiant density required to heat our mate-
rial from 65o F to 200o F in one minute.
Typical Application for Maxon P/S-II Radiant
Burner Step 8) If we multiply this radiant density by the area
Material to be heated: Steel Sheet Metal, 16 Ga. of the material we get:
Dimensions: 10 ft. x 10 ft.
Temperature Requirements: 65o F = initial temp (4,456 Btu/ft2)x(10 ft)x(10 ft) = 445,600 Btu/hr
200o F = final temp
Time to reach final temp: 1 minute We then divide by the radiant energy transfer (from
Belt Speed: 20 feet/minute Step 2) to get:
Step 1) Select operating temperature of Maxon P/S (445,600 Btu/hr) / (24,900 Btu/ft2 hr) = 17.9 ft2 of
Radiant burner of 1500o F. (The P/S Radiant oper- burner required per side
ates between 1200o and 1650o F. Selecting 1500o F
allows for a good “mid-range” should the operating To determine the number of burner heads required,
temperatures require adjustment after installation.) simply divide the total area per side by the area of the
burner head, which is 0.37 ft2.
Step 2) Determine the radiant energy transfer for the
operating temperatures in Btu/ft2 hr. According to the (17.9 ft2) / (0.37 ft2/burner head) = 48.4 burner heads
chart on page 1353, for a product temperature of 200o
F and an emitter temperature of 1500o F, the radiant Step 9) Determine and identify the zoning of the
energy transfer is 24,900 Btu/ft2 hr. Keep in mind that burner system, if any.
this energy transfer is for only one side of the product.
Step 10) Select the burner type (i.e., type 13, 25, or
Step 3) Determine the weight per square foot of the 50). For this particular application we choose (3)
material. For 16 gauge (.0598”) cold rolled steel rows of the 17-50 PS-II Radiant burner. This provides
sheet, this value is 2.50 lb/ft2. us with 51 burner heads at a length of approximately
108 inches per row (see page 1359).
Step 4) Determine the specific heat of the product.
For steel, cp = 0.11 Btu/lb oF. Step 11) Determine the fuel input to the burners.
Step 5) From the above information, we can now (51 burner heads)x(25,000 Btu/hr burner head) =
determine the heating capacity per square foot.
1,275,000 Btu/hr
(2.50 lb/ft2)(0.11 Btu/lb oF)(200o F - 65o F) =
This is the input required to the burner. Select an
37.13 Btu/hr ft2 appropriate premix system to provide this heat input.
Step 6) Applying the heat-up time of 1 minute we get:
37.13 Btu/hr ft2 x 60 min/hr = 2,228 Btu/ft2
This is based on an emissivity of 1.0, or 100% of the

energy absorbed.
7/99
Capacities and Specifications

Type 13 P/S Radiant II Burners
Type 13 (end-to-end) Assembly
Inlet Number of Capacity
Size Burner Heads (Btu/hr) Face Width
Designation
(in inches)
1" 2 39,000 3 - 13 31.83

3 58,500 4.5 - 13 47.77
1-1/2" 4 78,000 6 - 13 63.70
5 97,500 7.5 - 13 79.64
6 117,000 9 - 13 95.58
2" 7 136,500 10.5 - 13 111.52
8 156,000 12 - 13 127.45
9 175,500 13.5 - 13 143.39
2-1/2"
10 195,000 15 - 13 159.33
Type 25 and Type 50 P/S Radiant II Burners

Type 25 (end-to-end) Assembly Type 50 (side-to-side) Assembly
Inlet Number of Capacity
Size Burner Heads (Btu/hr) Face Width Face Width
(in inches) (in inches)
1" 3 75,000 3 - 25 33.69 3 - 50 16.69
4 100,000 4 - 25 44.94 4 - 50 22.27
5 125,000 5 - 25 56.19 5 - 50 27.85
1-1/2" 6 150,000 6 - 25 67.44 6 - 50 33.42
7 175,000 7 - 25 78.69 7 - 50 39.00
8 200,000 8 - 25 89.94 8 - 50 44.58
9 225,000 9 - 25 101.19 9 - 50 50.16
10 250,000 10 - 25 112.44 10 - 50 55.74
2" 11 275,000 11 - 25 123.69 11 - 50 61.31
12 300,000 12 - 25 134.94 12 - 50 66.89
13 325,000 13 - 25 146.19 13 - 50 72.47
14 350,000 14 - 25 157.44 14 - 50 78.05
15 375,000 15 - 25 168.69 15 - 50 83.63
2-1/2" 16 400,000 --- --- 16 - 50 89.20
17 425,000 --- --- 17 - 50 94.78
18 450,000 --- --- 18 - 50 100.36
19 475,000 --- --- 19 - 50 105.94
20 500,000 --- --- 20 - 50 111.52
21 525,000 --- --- 21 - 50 117.09
22 550,000 --- --- 22 - 50 122.67
3"
23 575,000 --- --- 23 - 50 128.25
24 600,000 --- --- 24 - 50 133.83
25 625,000 --- --- 25 - 50 139.41
26 650,000 --- --- 26 - 50 144.98

Type 25 Burner
A 0.5
1.0
3.25
6.5 7.5
.38 (3/8")
dia. thru holes
8 places
1.0
2.0
G 5.53
11.19
3.69 4.04
B
C
0.25
9.25 11.25 10.41

Box Centers ANSI 1/4" NPT Steel Pipe Coupling 4.88
Both Ends
F E Threaded
D Pipe Coupling
Both Ends
E
Burner Size A B C D F G
NPT ISO
3 - 25 37.5 45.38 1" ISO 7/1 R 1" 23.5 33.69
4 - 25 47.75 56.75 26.13 44.94
5 - 25 60.0 68.0 34.75 56.19
5.29 7.48
6 - 25 71.25 79.25 1-1/2" ISO 7/1 R 1-1/2" 37.38 67.44
7 - 25 82.5 90.5 46.0 78.69
8 - 25 93.75 101.75 48.63 89.94
9 - 25 105.0 116.5 57.25 101.19
10 - 25 116.25 127.75 59.88 112.44
11 - 25 127.5 139.0 2" ISO 7/1 R 2" 68.5 123.69
12 - 25 138.75 5.79 8.48 150.25 71.31 134.94
13 - 25 150.0 161.5 79.75 146.19
14 - 25 161.25 174.75 82.38 157.44
2-1/2" ISO 7/1 R 2-1/2"
15 - 25 172.5 186.0 91.0 168.69
7/99

Type 50 Burner
A
0.5
1.0
3.25
7.5
6.5
.38 (3/8")
dia thru holes
8 places
1.0
2.0
G 5.53
11.19
3.69 4.04
B
0.25
C
6.75 5.58 4.88

Both Ends Box Centers ANSI 1/4" NPT Steel Pipe Coupling 10.41
F
D
E Threaded Pipe Coupling
Both Ends
E
NPT ISO
3 - 50 21.16 29.03 1" ISO 7/1 R 1" 15.33 16.69
4 - 50 26.73 34.73 15.12 22.27
5 - 50 32.31 40.31 20.91 27.85
5.29 7.48
6 - 50 37.89 45.89 1-1/2" ISO 7/1 R 1-1/2" 20.70 33.42
7 - 50 43.47 51.47 26.48 39.00
8 - 50 49.05 57.05 26.27 44.58
9 - 50 54.62 66.12 32.06 50.16
10 - 50 60.20 71.70 31.85 55.74
11 - 50 65.78 5.79 8.48 77.28 2" ISO 7/1 R 2" 37.64 61.31
12 - 50 71.36 82.70 37.43 66.89
13 - 50 76.94 88.44 43.22 72.47
14 - 50 82.51 96.01 43.01 78.05
15 - 50 88.09 101.59 48.80 83.63
16 - 50 93.67 6.29 9.48 107.17 2-1/2" ISO 7/1 R 2-1/2" 48.59 89.20
17 - 50 99.25 112.75 54.37 94.78
18 - 50 104.83 118.33 54.16 100.36
19 - 50 110.40 124.15 59.95 105.94
20 - 50 115.98 129.73 59.74 111.52
21 - 50 121.56 135.31 65.53 117.09
22 - 50 127.14 140.89 65.32 122.67
6.79 10.48 3" ISO 7/1 R 3"
23 - 50 132.72 146.74 71.11 128.25
24 - 50 138.29 152.04 70.90 133.83
25 - 50 143.87 157.62 76.69 139.41
26 - 50 149.45 163.20 76.48 144.98

Type 13 Burner
A
0.5
1.0
3.25
7.5
6.5
.38 (3/8")
dia thru holes
8 places
1.0
G 2.0
3.97
3.69 4.04
B
.25
C
15.94
12.0 Box Centers ANSI 1/4" NPT Steel Pipe Coupling 3.31
Both Ends
F E Threaded
D Pipe Coupling
Both Ends
E
NPT ISO
3 - 13 36.44 44.31 1" ISO 7/1 R 1" 19.97 31.83
4.5 - 13 52.38 60.38 30.94 47.77
5.29 7.48
6 - 13 68.31 76.31 1-1/2" ISO 7/1 R 1-1/2" 35.91 63.70
7.5 - 13 84.25 92.25 46.88 79.64
9 - 13 100.19 111.69 51.84 95.58
10.5 - 13 127.63 5.79 8.48 127.63 2" ISO 7/1 R 2" 62.81 111.52
12 - 13 132.06 143.56 67.78 127.45
13.5 - 13 148.00 161.50 78.75 143.39
6.29 9.48 2-1/2" ISO 7/1 R 2-1/2"
15 - 13 163.94 177.44 83.72 159.33
7/99
Notes
Maxon-P/S Radiant II Burners Page 1350-S-1
Start-up Instructions
The following steps should be followed in the initial established, other pilots supplied by a single mixer
start-up of Maxon-P/S II Burners using mixers and can be adjusted in height using the 1/4" input ball
regulators to supply the proper air/gas mixture. valves. If it is determined that all pilots are too
The following procedures may be modified for small or too large, their size can be regulated by
different types of mixing systems. either increasing or decreasing the mixture pres-
sure. This is done by opening or closing the
1. Open all butterfly or ball valves (located on each manual air inlet valve on the entry of each pilot
main burner air gas manifold) to the full open mixer. There should be no additional changes
position. made to the gas supply.
2. Open each 1/4" ball valve on each pilot burner to 12. Once all pilot flames have been established, the
the full open position. pilot flame signal strength can be checked using
3. Close all manual gas valves on the main gas the flame signal meter located in the face of the
control train, as well as at each air/gas mixer main control panel. Slight changes in flame height,
location where there are valves installed. This position or mixture may be required to obtain the
prevents main burner ignition prior to proper set maximum flame signal.
up. 13. Main burners can now be started. Using the same
4. Start the combustion blower. method of adjustment as used on the pilot air/gas
5. Burner systems having a mixer per burner row; mixers, open the manual gas ball valve on the
Open the butterfly valves on the air entry to each mixer being set up. Back out on the gas adjustor
main burner air/gas mixer until a manifold pres- screw until the main burner lights off full width.
sure, using combustion air only, is 4.5" - 5" w.c. Note: Some burner systems come with a rich light-
(11.5 - 12.7 mbar) minimum. For burners in- off system. This system consists of a 3-way load
stalled face down, the minimum pressure should solenoid tied to a 10 sec. light-off timer. This
be set at 5"-5.5" w.c. (12.7 - 14 mbar). system puts a load signal on the regulator, causing
6. If more than one burner row or outboard zone it to open beyond the normal run setting. After a 10
is being supplied by a single air/gas mixer, the sec. light off period, the timer returns the regulator
manifold pressure in each row should be set using to its normal run setting.
the butterfly or ball valve installed on the manifold 14. Allow the main burner to come up to the normal
entry end to the proper manifold start-up setting. operating temperature. If a slight blue haze is
Some valves may need to be open more than present on the face of the burner, this is an indica-
others due to variations in pipe loss in each tion that the mixture is too lean. To correct the
manifold. problem, open the gas adjustment setting until the
7. After all manifold pressures have been checked blue haze is no longer present. If you notice a
and balanced, go through the same procedure for yellow blanket of flame on the burner surface, this
each pilot air/gas mixer. All 1/4" ball valves should is an indication that the mixture is too rich. To
be in the full open position. Using the inlet air valve correct this problem, screw in on the gas adjust-
on each mixer, set the mixer downstream pressure ment screw until the yellow blanket of flame is no
at 3-3.5" wc.(7.5 - 9 mbar). longer present. After all adjustments have been
8. Screw all gas adjustment screws on all pilot and made, cycle the burner several times to be sure
main air/gas mixers down to the full closed there are no problems lighting full width.
position. 15. After all main burners have been started and
9. At this time, check and set all air and gas safety adjusted, you can further fine tune individual
and limit switches prior to trying to fire and adjust burner rows for brightness and uniformity using the
the pilots. ball valves or butterfly valves installed on the inlet
10. Prior to starting any pilots, be sure to check to see of each manifold or zone. For best results and
that all manual gas valves on each main air/gas burner life, the burner operating surface tempera-
mixer are in the full closed position. This will ture should be set in the 1500°-1525°F (815° -
prevent accidental firing of any main burners when 830°C) range using a radiation temperature non-
the last pilot in any zone proves. contact gun.
11. With the flame safeguard in the ignition cycle, This completes the basic system start-up. Remove the
slowly open the gas adjustment screw on each manual ignition card in your flame safeguard and
pilot mixer until a pilot flame is established. The return the system to the automatic operating mode.
pilot should have a slight yellow tip when the
m
proper air/gas mixture is present. Once a pilot is
CORPORATION
Page 1350-S-2 Maxon-P/S Radiant II Burners
Assembly Instructions
Upon receipt of your Maxon P/S Radiant II Burner, it 2. Place the head on the manifold such that the plug
may be necessary to install the burner heads to the mates up with the hole in the manifold.
burner manifold. The burner heads are shipped
completely assembled and only require two fasteners 3. Use two M8 screws and two M8 washers (provided)
per head to attach them to the burner manifold. to attach the bottom clamp against the manifold and
securely fasten the head. Alternate the tightening of
Following the illustrations below, mount the burner the bolts to ensure an even clamping force.
head to the manifold as follows:
4. Repeat for the remainder of the burner heads. Make
1. Place the o-ring in the groove of the plug on the sure the “face” or tile side of the heads are relatively
underside of the burner head. This o-ring is used to flush with each other before final tightening of the
help provide a gas tight seal and must be installed. fasteners to 3-5 foot-lbs.
O-Ring
Detail of O-Ring Installation
O-Ring
Standard
Head
Pilot Head
(Note bracket
mounting tabs)
Bottom
Clamp
M8 Washer
M8 Screw
Manifold
Assembly
mCORPORATION

Maxon-P/S Radiant II Burners Page 1350-S-3
Repair Instructions
Installing Ledge Gaskets Figure 1
– Figures 1 & 2
Spread a bead of adhesive around the entire length of
the tile support ledge. Place the ledge gasket on the
adhesive, taking care to press the gasket flat (no high
spots) when installed. The adhesive should be allowed
to cure for at least 30 minutes before installing the tile.
Figure 2
Installing Gasket Tape Figure 3

– Figure 3
Install a single strip of gasket tape as shown. The tape
should form a double thickness across one short end
of the burner box. It is important to push the gasket
material into the corners as the tape is being installed.
If the tape does not extend into the corners squarely,
the tape may stretch and tear the gasket material
when the burner tiles are installed.

mCORPORATION
Page 1350-S-4 Maxon-P/S Radiant II Burners
Repair Instructions
Installing Burner Tiles Figure 4
– Figures 4 & 5
Once the tape is installed, put the outer two burner
tiles in place on the tile support ledge. Check to see
that the gasket tape around the outer edge of the tile
is in place and seated against the ledge gasket. The
middle tile can then be pressed into place by raising
the center edge of either outside tile to form a tent with
the middle tile. Press downward on the two raised
edges until the tile snaps into place. If one or more
burner tiles are uneven, do not attempt to push
individual tiles into place. This can result in cracked or
broken tiles. The burner tile will be leveled in the next
step.
Figure 5
Installing Tile Retainers Figure 6

– Figure 6
When the burner tiles are in place, insert the two long
tile retainers between the inside of the burner box and
the tape until the tabs extend through the tab openings
in the burner box. Next, using a small pair of channel
locks, press all of the tile retainers down lightly to level
the burner tile. Do not tighten any of the tabs while
using the channel locks to seat the tile. This could
result in broken tiles. Once both retainers have been
pressed down and the tiles have been seated, press
the retainers hand-tight and twist the tabs a quarter-
turn to lock the tile into place.
mCORPORATION

Maxon-P/S Radiant II Burners Page 1350-A/P-1
Assembly Numbers
Burner Assemblies - Type 25 and Type 50 Burner Assemblies - Type 13
Type 25 (end-to-end) Type 50 (side-to-side) Type 13 (end-to-end)
Assembly Assembly Assembly
Designation Designation Designation
Number Number Number
3 - 25 325 PSR2 3 - 50 350 PSR2 3 - 13 313 PSR2
4 - 25 425 PSR2 4 - 50 450 PSR2 4.5 - 13 4513 PSR2
5 - 25 525 PSR2 5 - 50 550 PSR2 6 - 13 613 PSR2
6 - 25 625 PSR2 6 - 50 650 PSR2 7.5 - 13 7513 PSR2
7 - 25 725 PSR2 7 - 50 750 PSR2 9 - 13 913 PSR2
8 - 25 825 PSR2 8 - 50 850 PSR2 10.5 - 13 10513 PSR2
9 - 25 925 PSR2 9 - 50 950 PSR2 12 - 13 1213 PSR2
10 - 25 1025 PSR2 10 - 50 1050 PSR2 13.5 - 13 13513 PSR2
11 - 25 1125 PSR2 11 - 50 1150 PSR2 15 - 13 1513 PSR2
12 - 25 1225 PSR2 12 - 50 1250 PSR2
Segment choices are as follows for
13 - 25 1325 PSR2 13 - 50 1350 PSR2
configured products:
14 - 25 1425 PSR2 14 - 50 1450 PSR2
• Manifold Connection
15 - 25 1525 PSR2 15 - 50 1550 PSR2
--- --- 16 - 50 1650 PSR2 • Manifold Material
--- --- 17 - 50 1750 PSR2 • Head Type
--- --- 18 - 50 1850 PSR2 • Ignition/Flame Detection(Inlet End)
--- --- 19 - 50 1950 PSR2 • Ignitor Position (Inlet End)
--- --- 20 - 50 2050 PSR2 • Ignition/Flame Detection Position (Plugged End)
--- --- 21 - 50 2150 PSR2 • Ignitor Position (Plugged End)
--- --- 22 - 50 2250 PSR2
• Constant Pilot (Inlet End)
--- --- 23 - 50 2350 PSR2
• Constant Pilot (Plugged End)
--- --- 24 - 50 2450 PSR2
--- --- 25 - 50 2550 PSR2
--- --- 26 - 50 2650 PSR2
Descriptions of segment choices and
available options are listed on page
1350-A/P-2
Ignitors
Assembly
Description
Number
Ignitor Assembly w/flame rod 1042678
Ignitor Assembly w/blast pilot 1042593

mCORPORATION
Page 1350-A/P-2 Maxon-P/S Radiant II Burners
Assembly Numbers
Segment Choice Detail
Segment Choices
Segment Name Segment Description Segment Choice Description
(DEFAULT is shaded)
ANSI_THRD ANSI Thread
MANIFOLD CONNECTION Type of thread on the premix inlet
ISO–THRD ISO (European) Thread
MANIFOLD MATERIAL Manifold material CS Steel
Burner tile and gasket materials Standard
STD
and options
HEAD TYPE
Rigidized tiles are cleaned and
dipped to reduce dusting STDR Standard with rigidized tile
BP Blast pilot
Type of ignition and flame BPFR Blast pilot and flame rod
detection on the inlet end of the FR With flame rod
IGN/FLAME DETECT (INLET END) burner
NONE No flame detection or ignitor
SI 3-prong spark ignitor
SIFR 3-prong ignitor with flame rod
END End mounted
Ignitor position for the inlet end of LH Left hand (viewed from inlet end)
IGN POSITION ( INLET END)
the burner NONE No ignitor chosen
RH Right hand (viewed from inlet end)
BP Blast pilot
Type of ignition and flame BPFR Blast pilot and flame rod
detection on the plugged end of FR With flame rod
IGN/FLAME DETECT (PLUGGED END) the burner
NONE No flame detection or ignitor
SI 3-prong spark ignitor
SIFR 3-prong ignitor with flame rod
END End mounted
Ignitor position for the plugged LH Left hand (viewed from inlet end)
IGN POSITION (PLUGGED END)
end of the burner NONE No ignitor chosen
RH Right hand (viewed from inlet end)
Ignition pilot location on inlet end NO Do not include with order

CONSTANT PILOT (INLET END)
of burner YES Include with order
Ignition pilot location on plugged NO Do not include with order

CONSTANT PILOT (PLUGGED END)
end of burner YES Include with order
mCORPORATION

Maxon-P/S Radiant II Burners Page 1350-A/P-3
Assembly Numbers
Replacement Parts
Assembly Number
Description
Ridgidized Tile Plain (or Std.)
Type 25 or 50 burner head 1040701 1038539
Burner Type 25 or 50 burner head (w/pilot mounting tabs) 1040699 1037762
Heads Type 13 burner head 1040697 1039397
Type 13 burner head (w/pilot mounting tabs) 1040695 1039401
Burner Tiles 25/50 burner tile (11-3/16" box - standard) 1040648 1059788
325-825 Std 1040686 1039627
325-825 Pilot Std 1040675 1039629
925-1325 Std 1040687 1039631
Type 25/50 925-1325 Pilot Std 1040676 1039633
Combination 1450-1850 Std 1040688 1039635
Burner
1450-1850 Pilot Std 1040678 1039637
Head
Replacement 1950-2650 Std 1040689 1039639
Kits 1950-2650 Pilot Std 1040679 1039641
(w/clamps, o-ring
313-7513 Std 1040669 1039560
and fasteners)
313-7513 Pilot Std 1040663 1039563
913-1213 Std 1040670 1039567
Type 13
913-1213 Pilot Std 1040664 1039569
13513-1513 Std 1040671 1039571
13513-1513 Pilot Std 1040665 1039573
Pressure pilot (required for blast pilots) 11680
25/50 tile retainer 44949
13 tile retainer 1039393
Replacement gasket kit for 25/50 box
Miscellaneous 45769
(consists of (1) #44942 tape gasket and (1) #45679 tile/box gasket)
Replacement
Items Replacement gasket kit for 13 box
1039865
(consists of (1) #1039391 tape gasket and (1) #1039390 tile/box gasket)
High temperature sealant - 3 oz. tube 45766
Fenwal spark ignitor 57586
90 deg mini flame rod 1041550
Note: 325-825 represents 3-25, 4-25, 5-25, 6-25, 7-25 and 8-25 sizes
313-7513 represents 3-13, 4.5-13, 6-13 and 7.5-13 sizes

mCORPORATION
Page 1350-A/P-4 Maxon-P/S Radiant II Burners
Notes
m
CORPORATION

Maxon Product Information Sheet
Product: P/S Radiant II Burners Page: 1350-1 Date: 4/00
Maxon Corporation, PO Box 2068, Muncie, IN 47307-0068. Phone (765) 284-3304. FAX (765) 286-8394.
Selection Guide – Maxon Series "LG" Mixing Tubes with North American
Limiting Orifice Valves for Air & Gas Inlets
P/S Premixing Guide P/S Burner Heads Capacity 1,000 North American
Series "LG" Mixing Tubes per "LG" Mixer Btu/hr Limiting Orifice Valve Size
Designation Assembly Number Series 13 Series 25/50 (maximum) Air Inlet Gas Inlet
LG-75-19 12165 2 2 50
LG-75-22 12166 3 2 65
LG-75-25 12167 3 3 70
LG-100-22 12168 3 3 70
LG-100-25 12169 3 3 70
LG-100-28 12170 4 3 90
1-1/4" 1/2"
LG-100-31 12171 4 3 90
LG-125-28 12172 4 3 90
LG-125-31 12173 5 4 110
LG-125-37 12174 7 6 150
LG-125-41 12175 9 8 195
LG-125-46 12176 12 10 240
LG-150-46 12177 12 10 240
LG-150-51 12178 12 10 240 3/4"
LG-150-56 12179 15 12 310
LG-150-63 12180 19 15 380
LG-200-56 12181 19 15 380
2"
LG-200-62 12182 19 15 380
LG-200-66 12183 19 15 380 1"
LG-200-70 12184 23 19 475
LG-200-73 12185 27 22 555
LG-200-80 12186 34 27 680
LG-300-78 12187 34 27 680
LG-300-84 12188 34 27 680
LG-300-92 12189 34 27 680
3" 1-1/2"
LG-300-98 12190 41 33 825
LG-300-106 12191 41 33 825
LG-300-116 12192 41 33 825
LG-400-98 12193 41 33 825
LG-400-106 12194 49 39 980
LG-400-116 12195 60 48 1200 4"
2"
LG-400-124 12196 72 58 1450 (not available)
LG-400-136 12197 87 70 1750
LG-400-142 12198 100 80 2000
Part Numbers for North American Limiting Orifice Valves Note: The Maxon LG Mixer size is based on a
Size Maxon Part Number minimum combustion air inlet pressure at the mixer
.5" 1040910 inlet of 7 osi. The minimum inlet pressure (air) to the
.75" 1033928 North American Limiting Orifice valve is 10 osi to
1" 1033934 supply the maximum Btu capacity noted. Normal
1.25" 1030339 inlet pressure to the North American Limiting Orifice
1.5" 1035023 on the gas inlet is 8” w.c. A 16 osi combustion
2" 1030338 blower is recommended for all systems to insure
2.5" 1040337 sufficient inlet pressures.
3" 1040335
Product: P/S Radiant II Burners Page: 1350-2 Date: 4/00
Dimensions & Component Arrangement – Maxon Series "LG" Mixing

Tubes with North American Limiting Orifice Valves for Air & Gas Inlets
Dimensions in inches
Maxon
A Wt.
Assembly
Pipe B C D E F (lb.)
Number
Size
1040910 .50 1.69 3.38 2.34 .88 1.75 1.5
1033928 .75 1.69 3.38 2.34 1.0 2.0 1.75
1033934 1 2.12 4.25 2.66 1.16 2.31 2.75
1030339 1.25 2.44 4.88 2.88 1.44 2.88 4.25
1035023 1.5 2.62 5.25 3.19 1.62 3.25 5.5
1030338 2 2.94 5.88 3.69 1.88 3.75 7.5
1040337 2.5 3.88 7.75 4.22 2.44 4.88 12.5
1040335 3 4.88 9.75 5.56 2.94 5.88 20.0
LG Mixing H J K
A B C D E F G M N O R
Tube gas inlet air inlet outlet
LG-75 8.88 3/4
LG-100 9.88 --- --- 1.44 1.69 2.38 --- 1/2 1-1/4 1 --- --- --- ---
LG-125 10.88 1-1/4
LG-150 12.25 5 1.5 1-1/2
5.75 1.5 2.25 3.25 1 2 1.81 1.5
LG-200 13.25 6 1.69 2 .44 .5
LG-300 17.5 9.25 6.84 1.41 4.38 1.81 1-1/2 3 3 1.94 1.75
LG-400 22.5 12 2.88 2.31 4 2.38 2
8.44 2.06 5.38 2 4 .56 .62
LG-500 26.5 16 2.38 5 2.62 2.25
Bulletin 1400
RadMax™ Burners
• Durable, industrial-quality cast iron body construction with stainless steel tile retainers
• Direct spark/flame sensing port for simple, reliable ignition and flame detection
• Easy tile replacement — spring clip assembly requires no tools for removal
• Radiant face temperatures from 1050°F to 1650°F deliver uniform heat for a variety of processes
• Rapid heat up and cool down eliminates the need to rotate burner heads away from product
• Low profile design operates in horizontal or vertical applications to accommodate limited space
applications
• No wire screens required to stabilize combustion on the burner face
• Low manifold pressures for normal operation: 4.5" - 5" wc nominal (11.2 – 12.5 mbar)
• Manifolds can be arranged to allow for multi-width/multi-length operation of burner

sections
• Retrofit Maxon P/S Radiant II applications by installing RadMax™ on existing

manifolds
CORPORATION 201 East 18th Street, P.O. Box 2068, Muncie, Indiana, 47307-0068. Phone (765) 284-3304. Fax: (765) 286-8394
Page 1402
RadMax™ Burners
RadMax™ Burners are designed to deliver uniform,
high intensity radiant energy for moisture removal in
textile and paper ovens, paint drying, and powder
coating, as well as many pre-heat, plastic forming,
heat treating and annealing operations.
Benefits
RadMax™ Burners can economically increase Rear view – Type 50 assembly
production rates, reduce seconds and defects caused
by improper or uneven heating or drying, and reduce
down time and maintenance costs when the need for
service or repair arises.
Side view – Type 25 assembly
Front view – Type 13 assembly

Specifications
1. RadMax™ Burners are full premix fuel/air and will
operate on both natural and propane gas. Manifold
mixture pressures at the burner range from 1" – 6"
wc (2.5 – 15 mbar).
2. The three-tile burner heads have a nominal heat
input of 25,000 Btu/hr (7.3 kW).
Front view – Type 25 (end-to-end) assembly
NOTE: Most systems are designed to nominal
capacities. Reduced or extended capacities are
possible. Contact Maxon for more information.
3. Normal operating face temperatures range from
1050°F – 1650°F (565°C – 900°C).
4. Burner heads are cast iron bodies with stainless
steel tile retainers.
5. Burner tiles are high efficiency, high emissivity tiles.
6. RadMax™ Burner heads have a quick connect
feature to remove and replace individual burner
heads without removing the whole manifold assem-
bly from the oven.
7. Tiles in the burner head are held in place by spring
clip retainer frames. There are no bolts or nuts to
Front view – Type 50 (side-to-side) assembly with direct
spark/flame sensing ports be removed if tiles need to be replaced.
8. Type 25 and Type 50 utilize the same burner heads.
Type 25 are assembled end-to-end; Type 50 are
assembled side-to-side.
9/02
RadMax™ Burners Page 1403

Radiant Energy - source and transfer
The quantity of radiant energy the RadMax™ Burner For example, if we assume the work temperature is
system is capable of supplying is a function of the 200°F and its emissivity is 0.80, the energy transfer
surface area, emissivity and temperature of the burner rates per square foot at various tile temperatures are
tile(s). The effective surface area of a Type 25, Type as illustrated below.
50 or Type 13 burner tile is 0.37 ft2 (0.034 m2). Emis-
sivity is defined as the measure of the ability of a RadMax™ Burner tile temperature = 1400°F
material to radiate energy. It is expressed as a number From the table below, we determine
from 0.0 – 1.0. The nominal emissivity for the the heat flux to be 18,600 Btu/ft2/hr x 0.80 emissivity
RadMax™ Burner tile is 0.92 @ 1500°F (815°C) or 0.94
at room temperature. The maximum operating tempera- = 14,880 Btu/ft2/hr
ture for the RadMax™ Burner tile is 1650°F (900°C).
To determine the radiant heat transfer or heat flux
from the RadMax™ Burner system to the work, the RadMax™ Burner tile temperature = 1600°F
temperature and emissivity of the work must be From the table below, we determine
known. Refer to the following table to determine the the heat flux to be 28,000 Btu/ft2/hr x 0.80 emissivity
maximum heat flux between one square foot of
RadMax™ Burner and the work at a given temperature. = 22,400 Btu/ft2/hr
Correct for the emissivity of the work by multiplying the
value from the table by the work’s emissivity. (The
table is corrected for the burner tile’s emissivity.) Metric table appears on next page.
Radiant Heat Transfer Rate (in 1000's Btu/ft2/hr)

Temperature Temperature of RadMax™ Burner Tile (°F) (Emissivity corrected for temperature)
of Work °F [1] 1100 1150 1200 1250 1300 1350 1400 1450 1500 1550 1600 1650
0 9.4 10.6 12.0 13.5 15.1 16.9 18.8 20.9 23.2 25.6 28.2 31.0
100 9.3 10.5 11.9 13.4 15.0 16.8 18.8 20.8 23.1 25.5 28.1 30.9
200 9.1 10.4 11.8 13.3 14.9 16.7 18.6 20.7 22.9 25.4 28.0 30.8
300 8.9 10.2 11.5 13.0 14.7 16.5 18.4 20.5 22.7 25.1 27.8 30.6
400 8.6 9.8 11.2 12.7 14.3 16.1 18.0 20.1 22.4 24.8 27.4 30.2
500 8.1 9.3 10.7 12.2 13.9 15.6 17.6 19.7 21.9 24.3 26.9 29.7
600 7.4 8.7 10.1 11.6 13.2 15.0 16.9 19.0 21.3 23.7 26.3 29.1
700 6.6 7.8 9.2 10.7 12.3 14.1 16.0 18.1 20.4 22.8 25.4 28.2
800 5.4 6.7 8.1 9.6 11.2 13.0 14.9 17.0 19.3 21.7 24.3 27.1
900 4.0 5.3 6.6 8.1 9.8 11.6 13.5 15.6 17.9 20.3 22.9 25.7
1000 2.2 3.5 4.8 6.4 8.0 9.8 11.7 13.8 16.1 18.5 21.1 24.0
1100 --- 1.3 2.7 4.2 5.8 7.6 9.6 11.7 13.9 16.4 19.0 21.8
1200 --- --- --- 1.5 3.2 5.0 6.9 9.0 11.3 13.7 16.4 19.2
1300 --- --- --- --- --- 1.8 3.8 5.9 8.1 10.6 13.2 16.0
1400 --- --- --- --- --- --- --- 2.1 4.4 6.8 9.5 12.3
1500 --- --- --- --- --- --- --- --- --- 2.5 5.1 7.9
1600 --- --- --- --- --- --- --- --- --- --- --- 2.8
9/02
Page 1404 RadMax™ Burners

Radiant Energy - source and transfer (continued)
To determine the radiant heat transfer or heat flux For example, if we assume the work temperature is
from the RadMax™ Burner system to the work, the 93°C and its emissivity is 0.80, the energy transfer
temperature and emissivity of the work must be rates per square foot at various tile temperatures are
known. Refer to the following table to determine the as illustrated below.
maximum heat flux between one square meter of
RadMax™ Burner and the work at a given temperature. RadMax™ Burner tile temperature = 760°C
Correct for the emissivity of the work by multiplying the From the table below, we determine
value from the table by the work’s emissivity. (The the heat flux to be 58 kW/m2 x 0.80 emissivity
table is corrected for the burner tile’s emissivity.)
= 46.6 kW/m2
RadMax™ Burner tile temperature = 870°C

From the table below, we determine
the heat flux to be 87.6 kW/m2 x 0.80 emissivity
= 70 kW/m2
Radiant Heat Transfer Rate (in kW/m2)

Temperature Temperature of RadMax™ Burner Tile (°C) (Emissivity corrected for temperature)
of Work °C [1] 600 625 650 675 700 725 750 775 800 825 850 875 900
0 30.4 34.0 37.9 42.2 46.8 51.7 57.1 62.8 68.9 75.5 82.5 89.9 97.9
50 30.1 33.7 37.7 41.9 46.5 51.4 56.8 62.5 68.6 75.2 82.2 89.7 97.6
100 29.7 33.3 37.2 41.5 46.1 51.0 56.3 62.0 68.2 74.7 81.7 89.2 97.2
150 29.0 32.6 36.5 40.8 45.4 50.3 55.7 61.4 67.5 74.1 81.1 88.6 96.5
200 28.0 31.7 35.6 39.9 44.4 49.4 54.7 60.4 66.6 73.1 80.1 87.6 95.6
250 26.7 30.4 34.3 38.5 43.1 48.1 53.4 59.1 65.3 71.8 78.9 86.3 94.3
300 25.0 28.6 32.6 36.8 41.4 46.4 51.7 57.4 63.6 70.1 77.1 84.6 92.6
350 22.7 26.4 30.3 34.6 39.2 44.1 49.5 55.2 61.3 67.9 74.9 82.4 90.4
400 19.9 23.5 27.4 31.7 36.3 41.3 46.6 52.3 58.5 65.0 72.1 79.6 87.5
450 16.3 19.9 23.8 28.1 32.7 37.7 43.0 48.8 54.9 61.5 68.5 76.0 84.0
500 11.8 15.5 19.4 23.7 28.3 33.3 38.6 44.4 50.5 57.1 64.2 71.7 79.7
550 6.4 10.1 14.1 18.4 23.0 28.0 33.3 39.1 45.2 51.8 58.9 66.4 74.4
600 --- 3.7 7.6 11.9 16.6 21.6 26.9 32.7 38.9 45.5 52.5 60.0 68.1
650 --- --- --- 4.3 9.0 14.0 19.3 25.1 31.3 37.9 45.0 52.5 60.5
700 --- --- --- --- --- 5.0 10.4 16.2 22.4 29.0 36.1 43.7 51.7
750 --- --- --- --- --- --- --- 5.8 12.0 18.7 25.8 33.3 41.4
800 --- --- --- --- --- --- --- --- --- 6.7 13.8 21.4 29.4
850 --- --- --- --- --- --- --- --- --- --- --- 7.6 15.7

Absorption Charts and Wave Lengths
A second important consideration in any radiant heated. The water absorption chart below will provide a
application is the wave length of radiation generated. graphic view of those wave lengths of infrared that will
As the heater surface temperature increases, the be most readily absorbed by water. As seen from the
wave length of the radiant energy generated de- absorption curve, there are two ranges of wave length
creases. To get the most efficiency from the radiant that fall under the maximum portion of the curve. The
dryer, generate a wave length of infrared that will be first range includes radiation from 5.3 to 7 microns in
absorbed by the product to be heated. It does little or length and an emitter surface temperature range from
no good to increase the generator surface temperature 280°F to 530°F (140°C to 270°C). The second range of
in order to get more energy released per square foot maximum efficiency is 2.55 to 2.9 microns in wave
and generate wave lengths of radiation that passes length and 1330°F to 1600°F (720°C to 870°C).
through the product much like light passes through a Many try to increase drying capacity by increasing
window glass. the burner input and face temperature. As the chart
Select the proper range of wave lengths by using indicates, system efficiency could drop by over 70%
a radiation absorption chart for the product to be when going above 1600°F (870°).
9/02

NOx and Face Temperature vs. Excess Air
This chart represents the relationship between NOx
emissions and face temperature versus percent of
excess air. Actual readings may vary according to
°F °C
NOx Emissions (ppm, corrected to 3% oxygen)
980
930
870
820
Face Temperature
760
700
650
590
540
480
420
% Excess Air
NOx Face Temp

Sample Calculations
The following is a sample set of calculations to show Step 7
the steps required to determine the number of burner Assuming an emissivity of 0.8, our design radiant
heads and burner rows in a given application. density is (5,528 Btu/ft2)/0.5 = 6,910 Btu/ft2
This is the radiant density required to heat our material
Typical application for Maxon RadMax™ Burner is from 65o F to 400o F in one minute.
preheating material for powder coating.
Material to be heated: Steel Sheet Metal, 10 Ga. Step 8
Dimensions: 4 ft. x 10 ft. If we multiply this radiant density by the area of the
Temperature Requirements: 65o F = initial temp material we get:
400o F = final temp
Time to reach final temp: 1 minute (6,910 Btu/ft2)x(4 ft)x(10 ft) = 276,400 Btu/hr
Belt Speed: 20 feet/minute
We then divide by the radiant energy transfer (from
Step 1
Step 2) to get:
Select operating temperature of Maxon RadMax™
Burner of 1500o F. (The RadMax™ operates between (276,400 Btu/hr) / (22,400 Btu/ft2 hr) = 12.3 ft2 of burner
1050o and 1650o F. Selecting 1500o F allows for a required per side
good “mid-range” should the operating temperatures
require adjustment after installation.) To determine the number of burner heads required,
simply divide the total area per side by the area of the
Step 2
burner head, which is 0.37 ft2.
Determine the radiant energy transfer for the operating
temperatures in Btu/ft2 hr. According to the chart on
(12.3 ft2) / (0.37 ft2/burner head) = 33.2 burner heads
page 1403, for a product temperature of 400o F and an
per side
emitter temperature of 1500o F, the radiant energy
transfer is 22,400 Btu/ft2 hr. Keep in mind that this
Step 9
energy transfer is for only one side of the product.
Determine and identify the zoning of the burner sys-
Step 3 tem, if any.
Heating the material the thickness of 16 gauge only,
determine the weight per square foot of the material. Step 10
For 16 gauge (.0598”) cold rolled steel sheet, this value Select the burner type (i.e., type 13, 25, or 50). For
is 2.50 lb/ft2. this particular application we choose (7) rows of the
5-25 RadMax™ Burner per side. This provides us with
Step 4 35 burner heads at a length of approximately 56 inches
Determine the specific heat of the product. For steel, per row (see page 1409).
cp = 0.11 Btu/lb oF.
NOTE: Powder coating requires material to be
Step 5 heated approximately the thickness of 16 gauge per
From the above information, we can now determine the side.
heating capacity per square foot.
(2.50 lb/ft2)(0.11 Btu/lb oF)(400o F - 65o F) = Step 11

Determine the fuel input to the burners.
92.13 Btu/hr ft2
Step 6 (35 burner heads)x(25,000 Btu/hr burner head) =
Applying the heat-up time of 1 minute we get:
875,000 Btu/hr per side x 2 = 1,750,000 Btu/hr
92.13 Btu/hr ft2 x 60 min/hr = 5,528 Btu/ft2
This is the input required to the burner. Select an
This is based on an emissivity of 1.0, or 100% of the appropriate premix system to provide this heat input.
energy absorbed.
9/02
RadMax™ Type 13/25/50 Burner Head

Manifold Pressure "w.c. 2 3 4 4.5 (nominal) 5 6
Combustion Air Flow SCFH 205 252 291 308 326 357
Maximum Capacity Btu/hr 17,800 20,700 23,500 24,925 26,200 28,500
Fuel Flow at Maximum SCFH 17.8 20.7 23.5 24.9 26.2 28.5
Minimum Capacity Btu/hr 10,800 14,100 16,600 18,000 19,300 21,700
Fuel Flow at Minimum SCFH 10.8 14.1 16.6 18.0 19.3 21.7
Face Temperature Range °F 1050-1483 1110-1537 1130-1569 1150-1590 1173-1611 1200-1659
Direct Spark/Flame Sensor Port

RadMax™ Type 13/25/50 Burner Head (metric data)

Manifold Pressure mbar 5.0 7.5 10.0 11.2 (nominal) 12.4 14.9
Combustion Air Flow (n)m3/hr 5.80 7.15 8.25 8.72 9.23 10.12
Maximum Capacity kW 5.2 6.1 6.9 7.3 7.7 8.4
Fuel Flow at Maximum (n)m3/hr 0.50 0.59 0.67 0.71 0.74 0.81
Minimum Capacity kW 3.2 4.1 4.9 5.3 5.7 6.4
Fuel Flow at Minimum (n)m3/hr 0.31 0.40 0.47 0.51 0.55 0.61
Face Temperature Range °C 566-806 599-836 610-854 621-866 634-877 649-904

Face Temperature Range for Various Firing Rates

1700
2"w.c. Manifold Pressure
1600
NOTE: Most systems are 3"w.c. Manifold Pressure
Tile Temperature (F)
1500
designed to nominal
capacities. Reduced or 1400 4"w.c. Manifold Pressure
extended capacities are
possible. Contact Maxon 1300 4.5"w.c. Manifold Pressure
for more information.
1200 5"w.c. Manifold Pressure

1000
10 12 14 16 18 20 22 24 26 28 30
Fuel Flow - Natural Gas (SCFH)
Type 13 RadMax™ Burners

Type 13 (end-to-end) Assembly
Number of Nominal
Inlet Manifold Size
Burner Capacity Face Width
Size Designation (in inches)
Heads (Btu/hr) (in inches)
2 50,000 2 - 13 31.62
3 75,000 3 - 13 47.46
4 100,000 4 - 13 63.31
1-1/2" 5 125,000 5 - 13 79.15 2x2
6 150,000 6 - 13 94.99
7 175,000 7 - 13 110.84
8 200,000 8 - 13 126.68
9 225,000 9 - 13 142.53
2" 2x3
10 250,000 10 - 13 158.37
Type 25 and Type 50 RadMax™ Burners

Number of Nominal Type 25 (end-to-end) Assembly Type 50 (side-to-side) Assembly
Inlet Manifold Size
Burner Capacity Face Width Face Width
Size Designation Designation (in inches)
Heads (Btu/hr) (in inches) (in inches)
3 75,000 3 - 25 33.57 3 - 50 16.64
4 100,000 4 - 25 44.82 4 - 50 22.27
5 125,000 5 - 25 56.07 5 - 50 27.89
1-1/2" 2x2
6 150,000 6 - 25 67.32 6 - 50 33.52
7 175,000 7 - 25 78.57 7 - 50 39.14
8 200,000 8 - 25 89.82 8 - 50 44.77
9 225,000 9 - 25 101.07 9 - 50 50.39
10 250,000 10 - 25 112.32 10 - 50 56.02
2" 11 275,000 11 - 25 123.57 11 - 50 61.64 2x3
12 300,000 12 - 25 134.82 12 - 50 67.27
13 325,000 13 - 25 146.07 13 - 50 72.89
14 350,000 14 - 25 157.32 14 - 50 78.52
15 375,000 15 - 25 168.57 15 - 50 84.14
2-1/2" 16 400,000 --- --- 16 - 50 89.77 2x4
17 425,000 --- --- 17 - 50 95.39
18 450,000 --- --- 18 - 50 101.02
19 475,000 --- --- 19 - 50 106.64
20 500,000 --- --- 20 - 50 112.27
21 525,000 --- --- 21 - 50 117.89
22 550,000 --- --- 22 - 50 123.52
3" * 2x5
23 575,000 --- --- 23 - 50 129.14
24 600,000 --- --- 24 - 50 134.77
25 625,000 --- --- 25 - 50 140.39
26 650,000 --- --- 26 - 50 146.02
* Maximum inlet size for bottom inlet is 2-1/2" NPT
9/02

Type 13 RadMax™ Burner
A B C
Position #2 Position #1 Position #10 Position #9
Position #8
Position #3
3.81
D
Position #4 Position #5 Position #6 Position #7 4.06 Threaded Pipe
NPS Half Coupling
Each End
15.84 15.78
Burner Centers
2.25
E
SIDE INLET
H G
F
Threaded Pipe - NPS Half Coupling
I
BOTTOM INLET

B H
F G
# of
Burner Bottom Bottom
A C D E Inlets I
Size Extended Inlet Inlet
Standard (Bottom
Length Only Only
Inlet)
2-13 31.62 4.42 5.42 1.19 1-1/2" NPT 27.63 0.00 2.06 1 25.38
3-13 47.46 4.42 5.42 1.19 1-1/2" NPT 43.47 7.92 2.06 1 41.22
4-13 63.31 4.42 5.42 1.19 1-1/2" NPT 59.31 0.00 2.06 1 57.06
5-13 79.15 4.42 5.42 1.19 1-1/2" NPT 75.16 7.92 2.06 1 72.91
6-13 94.99 4.42 5.42 1.19 1-1/2" NPT 91.00 15.84 2.06 2 88.75
7-13 110.84 4.42 5.42 1.19 1-1/2" NPT 106.84 23.77 2.06 2 104.59
8-13 126.68 4.42 5.42 1.19 1-1/2" NPT 122.69 31.69 2.06 2 120.44
9-13 142.53 4.92 5.92 1.69 2" NPT 138.66 39.61 2.62 2 136.28
10-13 158.37 4.92 5.92 1.69 2" NPT 154.50 47.53 2.62 2 152.13

A
Position #2 Position #1
POS. 1
Position #10 Position #9 B C
Position #3
Position #8
5.39
D
Position #4 Position #5 Position #6 Position #7 Threaded Pipe
NPS Half Coupling
Each End
11.25 11.07
Burner Centers
2.25
E
SIDE INLET
F
I
BOTTOM INLET

B H
F G
# of
A C D E Inlets I
Standard (Bottom
Length Only Only
Inlet)
3-25 33.57 4.42 5.42 1.19 1-1/2" NPT 31.50 5.63 2.06 1 29.25
4-25 44.82 4.42 5.42 1.19 1-1/2" NPT 42.75 0.00 2.06 1 40.50
5-25 56.07 4.42 5.42 1.19 1-1/2" NPT 54.00 5.63 2.06 1 51.75
6-25 67.32 4.42 5.42 1.19 1-1/2" NPT 65.25 0.00 2.06 1 63.00
7-25 78.57 4.42 5.42 1.19 1-1/2" NPT 76.50 16.88 2.06 2 74.25
8-25 89.82 4.42 5.42 1.19 1-1/2" NPT 87.75 22.50 2.06 2 85.50
9-25 101.07 4.92 5.92 1.69 2" NPT 99.13 28.13 2.62 2 96.75
10-25 112.32 4.92 5.92 1.69 2" NPT 110.38 22.50 2.62 2 108.00
11-25 123.57 4.92 5.92 1.69 2" NPT 121.63 28.13 2.62 2 119.25
12-25 134.82 4.92 5.92 1.69 2" NPT 132.88 33.75 2.62 2 130.50
13-25 146.07 4.92 5.92 1.69 2" NPT 144.13 39.38 2.62 2 141.75
14-25 157.32 5.42 6.42 2.19 2-1/2" NPT 158.63 33.75 3.75 2 153.00
15-25 168.57 5.42 6.42 2.19 2-1/2" NPT 169.88 39.38 3.75 2 164.25
9/02

A
Position #1 Position #8 B C
11.07
D
Threaded Pipe
NPS Half Coupling
Position #4 Position #5 Each End
2.25
5.62
Burner
Centers 5.39
E
SIDE INLET
F
I
BOTTOM INLET
See Page 1413 for additional dimensions


B H
F G
# of
A C D E Inlets I
Standard (Bottom
Length Only Only
Inlet)
3-50 16.64 4.42 5.42 1.19 1-1/2" NPT 16.31 2.81 2.06 1 14.06
4-50 22.27 4.42 5.42 1.19 1-1/2" NPT 21.94 0.00 2.06 1 19.69
5-50 27.89 4.42 5.42 1.19 1-1/2" NPT 27.56 2.81 2.06 1 25.31
6-50 33.52 4.42 5.42 1.19 1-1/2" NPT 33.75 0.00 2.06 1 30.94
7-50 39.14 4.42 5.42 1.19 1-1/2" NPT 38.81 2.81 2.06 1 36.56
8-50 44.77 4.42 5.42 1.19 1-1/2" NPT 44.44 0.00 2.06 1 42.19
9-50 50.39 4.92 5.92 1.69 2" NPT 50.19 2.81 2.62 1 47.81
10-50 56.02 4.92 5.92 1.69 2" NPT 55.81 0.00 2.62 1 53.44
11-50 61.64 4.92 5.92 1.69 2" NPT 61.44 2.81 2.62 1 59.06
12-50 67.27 4.92 5.92 1.69 2" NPT 67.06 16.88 2.62 2 64.69
13-50 72.89 4.92 5.92 1.69 2" NPT 72.69 19.69 2.62 2 70.31
14-50 78.52 5.42 6.42 2.19 2-1/2" NPT 81.56 16.88 3.75 2 75.94
15-50 84.14 5.42 6.42 2.19 2-1/2" NPT 87.19 19.69 3.75 2 81.56
16-50 89.77 5.42 6.42 2.19 2-1/2" NPT 92.81 22.50 3.75 2 87.19
17-50 95.39 5.42 6.42 2.19 2-1/2" NPT 98.44 25.31 3.75 2 92.81
18-50 101.02 5.42 6.42 2.19 2-1/2" NPT 104.06 28.13 3.75 2 98.44
19-50 106.64 5.92 6.92 2.69 3" NPT* 111.81 25.31 3.75 2 108.06
20-50 112.27 5.92 6.92 2.69 3" NPT* 117.44 28.13 3.75 2 113.69
21-50 117.89 5.92 6.92 2.69 3" NPT* 123.06 30.94 3.75 2 119.31
22-50 123.52 5.92 6.92 2.69 3" NPT* 128.69 33.75 3.75 2 124.94
23-50 129.14 5.92 6.92 2.69 3" NPT* 134.31 30.94 3.75 2 130.56
24-50 134.77 5.92 6.92 2.69 3" NPT* 139.94 33.75 3.75 2 136.19
25-50 140.39 5.92 6.92 2.69 3" NPT* 145.56 36.56 3.75 2 141.81
26-50 146.02 5.92 6.92 2.69 3" NPT* 151.19 33.75 3.75 2 147.44
*Maximum inlet size for bottom inlet is 2-1/2" NPT
9/02
Notes
RadMax™ Burners Page 1400-S-1
Read complete instructions before proceeding and desired maximum firing rate (per the table on
familiarize yourself with all the system’s equipment and Page 1400-S-2.) Manifold differential pressure
components. Verify that all equipment has been should not exceed 6.0” w.c.
installed in accordance with the original manufacturer’s C. Return air flow control device to minimum.
current instructions. 6. Adjust fuel/air mixing device to the recommended
initial settings. Refer to the appropriate start-up
CAUTION: Initial adjustment and light-off should be
instructions provided by the manufacturer for this
undertaken only by trained and experienced
equipment.
personnel familiar with combustion systems, with
7. Ignite the burner. (Direct spark applications only;
control/flame safeguard circuitry and with knowledge
refer to appropriate manufacturers instructions for
of the overall installation. Equipment installation
piloted systems.)
and operating procedures should comply with all
A. Verify combustion air blower is running.
applicable international, federal, state, local codes
B. Set air flow control device to minimum.
and standards. C. Open main gas shut-off valve(s).
D. Initiate trial for ignition sequence and verify
Initial RadMax™ Burner start-up: spark ignitor is arcing properly.
1. Close all burner fuel valves and gas cocks. E. If burner does not ignite, close main gas shut-
Make preliminary adjustment to fuel gas off valve(s) and re-purge unit before attempting
regulator(s) to establish adequate fuel pressure. to ignite the burner again.
2. Check all electric circuitry. Verify that all control 8. Adjust burner minimum firing rate. Allow
devices, flame safeguard, and interlocks are burners to come up to stable operating temperature.
operable and functioning within their respective With the air flow control device at minimum, adjust
settings/ranges. the fuel flow to establish the desire operating
3. Check that all duct and chambers are clear and temperature within the range stated in the “Capaci-
that their dampers operate freely. Adjust all ties and Specifications” table on Page 1400-S-2. If
dampers to their proper start-up positions. Open a slight blue haze is present on the face of the
the manual pet-cock valves on all burner Direct- burner, this is an indication that the mixture is too
Spark/Flame-Sensing Ports. lean. To correct, increase fuel flow until the blue
4. Start process fan(s) and combustion blower(s) haze is no longer present. If you notice a yellow
and purge the entire unit in accordance with the blanket of flame on the burner surface, this is an
appropriate codes and standards. indication the mixture is too rich. To correct,
5. Adjust combustion air pressure to establish the decrease fuel flow until the yellow haze is no longer
proper burner manifold pressure per the “Capacities present.
and Specifications” table on page 1400-S-2. A test 9. Adjust burner maximum firing rate. Slowly
connection is provided on the burner manifold for increase combustion air flow and fuel flow in small
set-up adjustment purposes. Required manifold increments as allowed by the fuel/air ratio controller.
pressures are differential pressures relative to the Hold at each step and allow the burner to come up
firing chamber. For on/off (single firing rate) to a stable operating temperature. Make adjust-
operation, adjust air to establish the proper ments to fuel flow as necessary to establish the
manifold differential pressure required for the desired operating temperature within the range
desired firing rate. For variable firing rate opera- stated in the “Capacities and Specifications” table.
tion, refer to the following procedure: Continue to increase the fuel/air ratio controller in
A. Set low fire combustion air flow. Position small increments and make adjustments at each
combustion air flow control device to establish step until the desired high firing rate is established.
burner manifold pressure required for the 10. Verify settings. After establishing high and low fire
desired minimum firing rate (per table on Page settings, cycle the burner from high to low fire
1400-S-2). Manifold differential pressure several times to confirm the repeatability of fuel/air
should never be less than 2.0” w.c. settings. Shut down the burner and re-ignite to
B. Set high fire combustion air flow. Position confirm reliability of ignition system and light-off
combustion air flow control device to establish settings. Check all safety interlocks and limits and
burner manifold pressure required for the confirm proper settings and operation.

mCORPORATION
Page 1400-S-2 RadMax™ Burners
RadMax™ Type 13/25/50 Burner Head
Minimum Capacity Btu/hr 10,800 14,100 16,600 18,000 19,300 21,700
Fuel Flow at Minimum SCFH 10.8 14.1 16.6 18.0 19.3 21.7
Face Temperature Range °F 1050-1483 1110-1537 1130-1569 1150-1590 1173-1611 1200-1659

RadMax™ Type 13/25/50 Burner Head (metric data)

3
Combustion Air Flow (n)m /hr 5.80 7.15 8.25 8.72 9.23 10.12
Minimum Capacity kW 3.2 4.1 4.9 5.3 5.7 6.4
Fuel Flow at Minimum (n)m3/hr 0.31 0.40 0.47 0.51 0.55 0.61
Face Temperature Range °C 566-806 599-836 610-854 621-866 634-877 649-904

Face Temperature Range for Various Firing Rates

1700
2"w.c. Manifold Pressure
NOTE: Most systems are 1600
designed to nominal 3"w.c. Manifold Pressure
Tile Temperature (F)
1500
capacities. Reduced or
extended capacities are 1400 4"w.c. Manifold Pressure
possible. Contact Maxon for
more information. 1300 4.5"w.c. Manifold Pressure

1000
m
10 12 14 16 18 20 22 24 26 28 30
Fuel Flow - Natural Gas (SCFH)
CORPORATION
MUNCIE, INDIANA, USA INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES
Assembly Instructions
Upon receipt of your Maxon RadMax™ Burner, it may Following the illustrations below, mount the burner head
be necessary to install the burner heads to the burner to the manifold:
manifold. The burner heads are shipped completely
assembled and only require two fasteners per head to 1. Place the gasket on the air/gas inlet on the under-
attach them to the burner manifold. 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
Gasket
Direct Spark/Flame Burner Head

Sensing Port
Direct Spark/Flame Sensing

Port Connection (4 Places)
Bottom
Rivet Clamp
M8 Washer
M8 Lock
Manifold M8 Screw
Assembly
1/4" NPT Control Valve
3/8" Corrugated Stainless Steel

Tubing with 1/4" NPT Male
Connectors

mCORPORATION
Maintenance Instructions
Installing Replacement Burner Tiles Figure 1
– Step 1
Coat the tile support face of the body casting with a
thin film of gasket adhesive.
– Step 2 Figure 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.
– Step 3 Figure 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
centered in tile retainer.
mCORPORATION

– Step 4 Figure 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).
– Step 5 Figure 5
Install spring clips to secure the tile retainer frame.

m CORPORATION
Notes
mCORPORATION

RadMax™ Burners Page 1400-A/P-1
Assembly Numbers
Burner Assemblies - Type 13 Burner Assemblies - Type 25 and Type 50
Type 13 (end-to-end) Assembly Type 25 (end-to-end) Type 50 (side-to-side)
Burner Configured Item Assembly Assembly
Designation Number Configured Configured
Burner Burner
2 - 13 213 RM Item Item
Number Number
3 - 13 313 RM
3 - 25 325 RM 3 - 50 350 RM
4 - 13 413 RM
4 - 25 425 RM 4 - 50 450 RM
5 - 13 513 RM
5 - 25 525 RM 5 - 50 550 RM
6 - 13 613 RM
7 - 13 713 RM 6 - 25 625 RM 6 - 50 650 RM
8 - 13 813 RM 7 - 25 725 RM 7 - 50 750 RM
9 - 13 913 RM 8 - 25 825 RM 8 - 50 850 RM

10 - 13 1013 RM 9 - 25 925 RM 9 - 50 950 RM
SPECIAL RM SPL 10 - 25 1025 RM 10 - 50 1050 RM
11 - 25 1125 RM 11 - 50 1150 RM
12 - 25 1225 RM 12 - 50 1250 RM
13 - 25 1325 RM 13 - 50 1350 RM
14 - 25 1425 RM 14 - 50 1450 RM
15 - 25 1525 RM 15 - 50 1550 RM
--- --- 16 - 50 1650 RM
Approximate Shipping Weight (in pounds) --- --- 17 - 50 1750 RM
RadMax Burner Type > Type 13 Type 25 Type 50 --- --- 18 - 50 1850 RM
Burner Head Weight 9.1 8.8 8.8 --- --- 19 - 50 1950 RM

--- --- 20 - 50 2050 RM
2" x 2" manifold 5.7 4.1 2.0
--- --- 21 - 50 2150 RM
Manifold 2" x 3" manifold 7.4 5.2 2.6
Weight --- --- 22 - 50 2250 RM
(per head) 2" x 4" manifold 9.1 6.4 3.2
--- --- 23 - 50 2350 RM
2" x 5" manifold 10.8 7.6 3.8
--- --- 24 - 50 2450 RM
--- --- 25 - 50 2550 RM
--- --- 26 - 50 2650 RM
SPECIAL RM SPL SPECIAL RM SPL

mCORPORATION
Page 1400-A/P-2 RadMax™ Burners
Assembly Numbers
Segment Choice Detail - Type 13 and Type 25 RadMax Burners
Segment Choices
(DEFAULT is shaded)
EXT Extended height to match PSR2
BURNER HEIGHT Box distance above manifold
STD Standard height
BOX TYPE Machining options STD Standard box
BI Back inlet feed
MANIFOLD TYPE Inlet connection location
EF End feed
NONE No flame sensing / direct spark
POS1 Position 1
POS10 Position 10
POS2 Position 2
Location of direct spark / flame
POS3 Position 3
sensing por t
DIR SPRK/FLM SENS PORT CHOICE 1 POS4 Position 4
Refer to drawings on pages 1410
POS5 Position 5
& 1411 for locations
POS6 Position 6
POS7 Position 7
POS8 Position 8
POS9 Position 9
DIR SPRK/FLM SENS PORT CHOICE 2 sensing por t - same segment POS8 Position 8
choices as above
DIR SPRK/FLM SENS PORT CHOICE 3 sensing por t - same segment NONE No flame sensing / direct spark
choices as above
choices as above
BOTH Heads and sensors loose
Level of burner assembly prior to COMPLETE Completely assembled

ASSEMBLY INSTRUCTIONS
shipment FSLOOSE Flame sensors loose
HEADSLOOSE Burner heads loose
Burner assembly mounting NO Do not include with order

INCLUDE U-BOLTS
hardware YES Include with order
m CORPORATION

Assembly Numbers
Segment Choice Detail - Type 50 RadMax Burners

Segment Choices
(DEFAULT is shaded)
EXT Extended height to match PSR2
BURNER HEIGHT Box distance above manifold
STD Standard height
BOX TYPE Machining options STD Standard box
BI Back inlet feed
MANIFOLD TYPE Inlet connection location
EF End feed
NONE No flame sensing / direct spark
POS1 Position 1
POS2 Position 2
POS3 Position 3
sensing por t
DIR SPRK/FLM SENS PORT CHOICE 1 POS4 Position 4
Refer to drawings on page 1412
POS5 Position 5
for locations
POS6 Position 6
POS7 Position 7
POS8 Position 8
DIR SPRK/FLM SENS PORT CHOICE 2 sensing por t - same segment POS7 Position 7
choices as above
choices as above
choices as above
BOTH Ship heads and sensors loose
Level of burner assembly prior to COMPLETE Ship completely assembled

SHIPPING INSTRUCTIONS
shipment FSLOOSE Ship flame sensors loose
HEADSLOOSE Ship burner heads loose
Burner assembly mounting NO Do not include with order

INCLUDE U-BOLTS
hardware YES Include with order

m CORPORATION
Assembly Numbers
Configured Spare Parts - RM RSP
Spare Parts
Configured Item Description Default Value Assembly Number
Number
RM BRNR HEAD RSP
Burner head 0 (see page 1400-A/P-5
for segment choices)
Ceramic tile (3 tiles per burner box required) 0 1059788
Direct Spark/Flame Sensing Por t Assembly with Bracket 0 1057903
Spark Ignitor/Flame Rod 0 1058544
CSST Corrugated Tubing 1/4" I.D. x 18" Long 0 1060048
Gasket - Fuel Inlet 0 1056590
Gasket - Burner Body - Type 25/50 0 1057352
Gasket - Burner Body - Type 13 0 1057681
Adhesive - Body Gasket - 5 oz. Tube 0 1060688
Diffuser - Type 25/50 0 1057351
Diffuser - Type 13 0 1057679

RM RSP Tile Retainer - Type 25/50 0 1057359
Tile Retainer - Type 13 (2 required) 0 1057683
Fuel Inlet (Standard) 0 1056590
Fuel Inlet (Extended Length) 0 1057999
Spring Clip - Type 25/50 (2 required per burner head) 0 1057384
Spring Clip - Type 13 (2 required per burner head) 0 1057734
Bottom Clamp 0 1058011
Box Clamp (included w/ head assemblies) 0 1057917

Fastener Kit for 2" x 2" and 2" x 3" Manifold (includes bolts, flat
0 1060692
washers, lock washers)
Fastener Kit for 2" x 4" and 2" x 5" Manifold (includes bolts, flat
0 1060693
washers, lock washers)
Valve for Direct Spark/Flame Sensing Por t 0 1062304
mCORPORATION

Assembly Numbers
Configured Spare Parts - RM BRNR HEAD RSP

Segment Choices
(DEFAULT is shaded)
13 Type 13 burner head
TYPE Type of burner head 25 Type 25 burner head
50 Type 50 burner head
EXT Extended height
BURNER HEIGHT Height of burner head
STD Standard height
NONE No flame sensing por t desired
POS1 Position 1
POS2 Position 2
Position of direct spark/flame
DIR SPRK/FLM SENS PORT POS3 Position 3
sensing por t
POS4 Position 4
POS5 Position 5
POS6 Position 6
Spark ignitor / flame rod option, NONE No spark ignitor/flame rod

SPARK IGNITOR/FLAME ROD
if desired YES Spark ignitor/flame rod wanted

m CORPORATION
Notes
m
CORPORATION

Bulletin 2100
Maxon Model “400” OVENPAK® Gas Burners
Model 415 OVENPAK® Burner

with connecting base and linkage
assembly to adapt customer's automatic
electric control motor
• Burns any clean fuel gas

• Fires into passing air streams
• Requires only low pressure gas
• Provides clean combustion with low NOx levels
• Compact burner design provides quick and easy installation
• Simple field adjustment and maintenance
Model “400” OVENPAK® Burner applications have included:

Air heating in ovens and dryers, paint finishing lines, paper and textile machines,
food baking ovens, coffee roasters, grain dryers, and fume incinerators. Manufactured under
U.S. patent #3,574,508; Canadian and European patents granted and pending.
CORPORATION 201 East 18th Street, P.O. Box 2068, Muncie, Indiana, 47307-0068. Phone: (765) 284-3304. Fax (765) 286-8394
Page 2102
Maxon Model “400” OVENPAK® Gas Burners
Provide application flexibility with:

• 40:1 turndown or more
• Over 90 different styles and sizes
• Heat releases to 16,500,000 Btu/hr
• Cost-effective external blower (EB) version
Model EB-3 OVENPAK® Burner with

connecting base and linkage assembly
Typical piping layout with “Block and Bleed” gas train arrangement
Page 2103
Maxon Pre-Assembled Package

Model “400” OVENPAK® Gas Burner System
Model 435
OVENPAK®
Burner with pre-
assembled “Block
& Bleed” pipe
train and pre-
wired into
package system
• A complete “packaged burner” system for maximum efficiency
• Pre-assembled system includes:

– High turndown Model “400” OVENPAK® Burner
– Completely assembled and pre-wired pipe train package
• Fast and easy installation with your choice of mounting options:

– Arranged for mounting onto your existing duct;
– Or mounted by Maxon in a pre-fabricated combustion heater/duct
Page 2104
Maxon Packaged Heater/Duct Sections

for Pre-Assembled OVENPAK® Gas Burner Systems
Model 425
OVENPAK® Burner
pre-assembled
package system,
installed and mounted
onto a Maxon pre-
fabricated heater/duct
section
• Reduce your fabrication time and costly design details

• Easy mounting provided by flanged duct connection joints
• Application flexibility offered by:
– Three duct sizes
– Five capacity options
– Optional return/inlet duct opening positions
• Discharge air volumes up to 12,000 SCFM
• Handles discharge air temperatures up to 600°F (316°C)
12/89
Model “400” OVENPAK® Gas Burner Page 2105

OVENPAK® Burners are nozzle-mixing gas burners
for many industrial direct-fired applications where
clean combustion and high turndown are required.
They are simple and versatile for use on a variety of
heating applications.
The Model “400” OVENPAK® Burner (shown at
right) includes a combustion air blower with non-
sparking paddle wheel-type impeller, pilot, spark
ignitor, stainless steel discharge sleeve, mixing cone,
self-contained internal air and gas proportioning
valves, and provision for your flame safeguard
sensor.
Right: Model 415 OVENPAK® Gas Burner with optional:

• combustion air filter
• connecting base and linkage assembly
• electrical control motor (by others)
Principle of operation (illustrated at left)

The OVENPAK® Burner is designed for industrial
air heating applications. It is available in two basic
versions: 1) packaged with integral combustion air
blower, or 2) for use with an external blower. Both
versions include a gas and air valve, internally linked
together to control the gas-air ratio over the full
operating range. The gas flows through the nozzle,
then along the inside of the burner cone where
combustion air is progressively and tangentially mixed
with the gas. This produces a very wide turndown
range and a highly stable flame under a variety of
Cross sectional view of a Model “400” OVENPAK® Gas

Burner
10/92
Page 2106 Model “400” OVENPAK® Gas Burners

Model “EB” (external blower) OVENPAK® Burners
(shown at right), like all OVENPAK® Burner assem-
blies, are designed to deliver heat through a patented
mixing cone and stainless steel sleeve.
Flanged burner body design on all OVENPAK®
Burner assemblies simplifies mounting and installa-
tion on your application. Burner can be installed in
any position that does not conflict with your control
motor or flame detector requirements.
Minimal torque requirements permit use of most view into
electric or air operators in conjunction with the op- cone of
tional (Maxon supplied) connecting base and linkage EB version
assemblies.
Model EB-3 OVENPAK® Burner arranged for external
blower source with connecting base and linkage assembly
to adapt customer's automatic control motor
“400-MA” and “EB-MA” versions

Model “400-MA” versions include a combustion air
blower in your choice of the voltages shown on page
2107, but provide constant combustion air volumes.
They differ from “standard” versions by use of a
slotted adjustable air butterfly locking device as
shown in photo at left. Internally, the linkage normally
cross-connecting air and gas butterflies is omitted.
In normal operation, the air butterfly is set to the
desired air differential pressure, and the fuel only is
throttled by a separate control valve. Maximum
capacities match those cataloged for “standard”
burners of equivalent size. Minimum capacities with
full air flow will be higher than those of “standard”
Model “EB-MA” OVENPAK® Burner with discharge sleeve burner.
and optional manual gas control
“EB-MRV” versions (photo at right)

“EB-MRV” versions of OVENPAK® Burners permit
air/fuel ratio control via a Maxon MICRO-RATIO®
control valve throughout the firing range. They differ
from standard “EB” burners in that internal gas and air
butterflies and the related shafts and linkages are
omitted.
In normal operation, air and fuel will be propor-
tioned by an external Maxon MICRO-RATIO® Control
valve.
Maximum capacities match those cataloged for
“EB” burners of equivalent size and differential air
pressure. Minimum capacity and air differential
pressure will vary with your application. Model “EB-MRV” OVENPAK® Burner with optional 12"
discharge sleeve
Model “400” OVENPAK® Gas Burners Page 2107
Capacities and Specifications – 60 Hertz

Standard Model “400” OVENPAK® Burner in-
60 Hz Motor Voltages Available
cludes a combustion air blower with motor.
115/208- 208-
Maximum capacity of Model “400” OVENPAK® Horsepower Type 575/3/60
230/1/60 230/460/3/60
Burner is affected by the static pressure within the
Totally
combustion chamber. Data shown assumes firing in 1/3 & 1/2
Enclosed
X X X
the open, or into an airstream with enough oxygen to
Totally
complete the combustion process. If burner is fired into 3/4 & 1 X X X
Enclosed
an oxygen-starved chamber or airstream, capacities Totally Not
may be reduced as much as 25-30%. Do not attempt 1-1/2, 2 & 3 X X
Enclosed Available
to operate beyond the duct static pressure range
shown. For higher back pressure applications, select
from Model “EB” or “EB-MRV” OVENPAK® Burner
options.
All gas pressures are differential pressures and
are measured at the gas pressure test connection on
the backplate of each OVENPAK® Burner. Differential
pressures shown are approximate.
Capacities and Operating Data – Model 405 through 422M

Burner Model 405 407M 408 408M 412M 413M 415 422M
Motor Horsepower: 1/3 1/2 1/3 3/4 1/2 3/4 1/3 3/4
Specification Frame Number: 48 48 48 56 48 56 48 56
-5.0 to 550 880 1650
--- -- --- --- ---
-0.5" wc 2.8" 3.4" 1.7"
D 500 750 800 790 1200 1300 1500 2150

±0" wc
U 2.3" 2.5" 2.8" 2.7" 2.8" 3.3" 1.4" 2.9"
C 475 700 760 750 1100 1190 1425 2000
Maximum T +1.0" wc
2.1" 2.2" 2.6" 2.5" 2.4" 2.8" 1.3" 2.5"
Capacities
S 450 600 720 640 925 1100 1350 1725
(1000's Btu/hr) +2.0" wc
T 1.9" 1.6" 2.3" 1.8" 1.7" 2.4" 1.1" 1.9"
with Natural Gas A
Pressures ("wc) T 510 550 800 1000 1610
+3.0" wc --- --- ---
I 1.1" 1.3" 1.3" 2.0" 1.6"
C 450 495 750 900 1500
S +4.0" wc --- --- ---
0.9" 1.1" 1.1" 1.6" 1.4"
475 800 1420
+5.0" wc --- --- --- --- ---
1.0" 1.3" 1.3"
Minimum Main plus pilot 15 20 37
Capacities
(1000's Btu/hr) Pilot only 10 15 20
Required natural gas differential
3.0 3.5 4.1 4.5 5.2 4.2 7.2
pressure to burner inlet ("wc)
Approximate flame length 1 to 2-1/2 to 1-1/2 to
1/2 to 1 ft. 1/2 to 1 ft. 1 to 2-1/2 ft.
in still air 1-1/2 ft. 3-1/2 ft. 2 ft.
5/93
Capacities and Operating Data – Model 425 through 487M

Burner Model 425 432M 435 442M 445 456M 470M 487M
Motor Horsepower : 3/4 3/4 3/4 1 1 1-1/2 2 3

Specification Frame Number : 56 56 56 56 56 143T 145T 182T
-5.0 to 2750 3850 5175 6400 8050 10060
--- ---
-0.5" wc 2.7" 2.2" 3.4" 3.6" 3.7" 4.6"
2500 3200 3500 4150 4500 5600 7000 8700
±0" wc
2.2" 3.6" 1.8" 2.5" 2.6" 2.8" 2.8" 3.4"
D
U 2375 3000 3325 4000 4280 5340 6570 8400
+1.0" wc
C 2.0" 3.2" 1.6" 2.4" 2.3" 2.5" 2.5" 3.2"
Maximum T
2250 2800 3150 3800 4125 5200 6300 8200
Capacities +2.0" wc
S 1.8" 2.8" 1.4" 2.1" 2.2" 2.4" 2.3" 3.0"
(1000's Btu/hr)
T 2650 3650 5000 5500 7500
with Natural Gas A +3.0" wc --- --- ---
Pressures ("wc) 2.5" 1.9" 2.2" 1.7" 2.5"
T
I 2500 3500 4600 5000 6200
C +4.0" wc --- --- ---
2.2" 1.8" 1.9" 1.4" 1.7"
S
2250 3300 4100 4500 5500
+5.0" wc --- --- ---
1.8" 1.6" 1.5" 1.2" 1.4"
3500 5000
+6.0" wc --- --- --- --- --- ---
0.7" 1.1"
Minimum Main plus pilot 60 87 110 125 150 175
Capacities
(1000's Btu/hr) Pilot only 35 45 90 105 115 117
3.6 4.9 3.8 4.9 4.5 5.1 5. 2 7.6
Approximate flame length 3-1/2 to
2-1/2 to 3-1/2 ft. 4 to 5 ft. 4 to 6 ft. 5 to 7 ft. 6 to 8 ft. 8 to 10 ft.
in still air 5 ft.

Standard Model “400” OVENPAK®
50 Hz Motor Voltages Available (possible net extra cost)
Burner includes a combustion air blower
with motor. Horsepower Type 190-200/1/50 380-415/3/50 500/3/50
Maximum capacity of Model “400” 1/3 & 1/2
Totally
X X X
OVENPAK® Burner is affected by the static Enclosed
pressure within the combustion chamber. Totally
3/4 & 1 X X X
Enclosed
Data shown assumes firing in the open, or
into an airstream with enough oxygen to Totally
1-1/2, 2 & 3 X X X
Enclosed
complete the combustion process. If burner
is fired into an oxygen-starved chamber or
airstream, capacities may be reduced as
much as 25-30%. Do not attempt to operate
beyond the duct static pressure range
shown. For higher back pressure applica-
tions, select from Model “EB” or “EB-MRV”
OVENPAK® Burner options.
All gas pressures are differential
pressures and are measured at the gas
pressure test connection on the backplate
of each OVENPAK® Burner. Differential
pressures shown are approximate.
Capacities and Operating Data - Model 405 through 422M

Burner Model 405 407M 40 8 408M 412M 413M 415 422M
Motor Horsepower: 1/3 1/2 1/3 3/4 1/2 3/4 1/3 3/4
Specification Frame Number: 48 48 48 56 48 56 48 56
460 735 1375
D -5.0" wc --- --- --- --- ---
U 2.0" 2.4" 1.2"
C 460 735 1375
Maximum T -3.0" wc --- --- --- --- ---
2.0" 2.4" 1.2"
Capacities
S 415 625 670 660 1000 1080 1250 1800
(1000's Btu/hr) T
±0" wc
1.6" 1.7" 2.0" 1.9" 2.0" 2.5" 1.0" 2.0"
with Natural Gas A
Pressures ("wc) T 390 585 630 625 920 990 1190 1670
+1.0" wc
I 1.4" 1.5" 1.7" 1.7" 1.7" 2.4" 0.9" 1.8"
C 920 1440
S +2.0" wc --- --- --- --- --- ---
1.7" 1.3"
Minimum Main plus pilot 15 20 15 20 37
Capacities
(1000's Btu/hr) Pilot only 10 15 20
2.2 2. 3 3.0 2.6 3. 5 4.1 2.9 5.6
Approximate flame length 1 to 1-1/2 to 2 to
1/2 to 1 ft. 1/2 to 1 ft. 1 to 2 ft.
in still air 1-1/2 ft. 2 ft. 2-1/2 ft.
8/00
Capacities and Operating Data - Model 425 through 487M

Burner Model 425 432M 435 442M 445 456M 470M 487M
Motor Horsepower: 3/4 3/4 3/4 1 1 1-1/2 2 3

Specification Frame Number: 56 56 56 56 56 143T 145T 182T
2300 2920 4325 5350 6700 8400
-5.0" wc --- ---
1.9" 1.3" 2.4" 2.5" 2.6" 3.2"
D
U 2300 2920 4325 5350 6700 8400
-3.0" wc --- ---
C 1.9" 1.3" 2.4" 2.5" 2.6" 3.2"
Maximum T
2090 2670 2780 3460 3760 4670 5850 7250
Capacities ±0" wc
S 1.6" 2.5" 1.1" 1.8" 1.8" 1.9" 2.0" 2.3"
(1000's Btu/hr) T
with Natural Gas 1970 2340 3340 4450 5500 7050
A +1.0" wc --- ---
Pressures ("wc) 1.4" 2.0" 1.6" 1.8" 1.7" 2.1"
T
I 3220 4340 5250 6850
C +2.0" wc --- --- --- ---
1.5" 1.7" 1.6" 2.1"
S
6250
+3.0" wc --- --- --- --- --- --- ---
1.7"
Minimum Main plus pilot 60 87 110 125 150 175
Capacities
(1000's Btu/hr) Pilot only 35 45 90 105 115 117
2.5 3.8 2.2 3.8 3.1 3.6 5.0 5.0
Approximate flame length 3 to 3-1/2 to
2 to 3 ft. 4 to 5 ft. 5 to 6 ft. 7 to 8 ft.
in still air 4-1/2 ft. 4 ft.

External Blower (EB) versions
Combustion and Differential Air Pressure ("wc) 3 4 5 6 8 9 10 11
Cooling Air
required Volume (SCFM) 150 170 190 210 240 255 270 280
Maximum Capacity 460 580 715 780 870 910 960 1000
EB-1 Heat Releases
Minimum & pilot 60 60 60 60 60 60 60 60
OVENPAK® (1000's Btu/hr)
Pilot only 45 45 45 45 45 45 45 45
Burner
Natural Gas At burner inlet 2.1 3.4 5.1 6.1 7.6 8.3 9.2 10.0
differential
pressures ("wc) At burner gas test connection 2.0 3.1 4.7 5.6 7.0 7.6 8.5 9.2
Flame Lengths In still air 4" to 15" beyond end of discharge sleeve

Cooling Air
EB-2 Heat Releases
Minimum & pilot 60 60 60 60 70 70 75 80
Pilot only 25 25 25 25 30 30 35 35
Burner
Natural Gas At burner inlet 3 5.2 7.8 9.5 11.3 12.1 12.9 13.8
differential

Cooling Air
EB-3 Heat Releases
Minimum & pilot 90 95 105 115 130 140 150 155
Pilot only 45 45 50 55 65 70 75 75
Burner
differential
Flame Lengths In still air 2 to 3 feet beyond end of discharge sleeve

Cooling Air
EB-4 Heat Releases
Minimum & pilot 100 115 130 140 160 170 180 190
Pilot only 40 40 40 45 50 55 55 60
Burner
differential
Flame Lengths In still air 2-1/2 to 3-1/2 feet beyond end of discharge sleeve
12/92


Cooling Air
EB-5 Heat Releases
Minimum & pilot 155 180 200 220 255 270 285 300
Pilot only 25 30 35 35 40 45 50 50
Burner
differential

Cooling Air
Heat Releases
EB-6 (1000's Btu/hr)
Minimum & pilot 335 390 490 575 695 735 815 850
OVENPAK® Pilot only 100 100 100 115 140 145 165 170
Burner
differential
3 to 8 feet beyond end of 8 to 12 feet beyond end of
Flame Lengths In still air
discharge sleeve discharge sleeve

Cooling Air
Heat Releases
EB-7 (1000's Btu/hr)
Minimum & pilot 335 390 490 575 695 735 815 850
OVENPAK® Pilot only 100 100 100 115 140 145 165 170
Burner
differential
Accessory Options
Air filter assemblies and silencers
dB(A) sound levels Sound Level dB(A)
from actual tests con- Burner
Model Standard with
ducted at full-rated 60 Hz Burner Silencer
capacity are shown in table 405 84 75
at right. Measurement point 407M 83 77
is shown in sketch below. 408M 84 75
(Meter was set to A-scale, 408 87 78
412M 81 73
slow response.) 82
413M 72
Operation on 50 Hz 415 89 77
power results in lower 422M 88 79
rotational speed of blower, 425 89 78
and so reduces air output, 432M 88 80
435 87 78
capacity, and resulting 89
442M 80
noise levels. 50 Hz noise 445 89 81
levels should not exceed 456M 90 83
the above data measured 470M 92 83
on 60 Hz operation. 487M 94 85
Air filter assemblies help to trap airborne particu-
late matter. They are offered with washable replaceable
filter elements or with permanent metallic elements (as
shown in photograph above). Filters mount onto
OVENPAK® Burner's blower housing (or silencer
housing of burners so equipped) and surround the
blower motor and combustion air inlet.
Filter silencers help reduce noise levels. They

mount onto OVENPAK® Burner's blower housing and
enclose the blower motor and combustion air inlet (as
shown in above photograph). They can be furnished in
conjunction with a permanent or replaceable filter
element assembly described above.
6/96
Accessory Options
Universal Joint Arrangements (for all Auxiliary Switches
versions except EB-MRV) allow control of as many as Maxon offers 4 types, all cam-actuated by the
5 burners by a single control motor. Torque require- burner main operating shaft. (If Universal Joint Ar-
ment is 10 in-lbs for EACH burner driven. Primary rangements are used, switch must mount on furthest
burner should drive no more than 2 Secondary burners left burner.) Field installation MAY require burner
to either side of itself. modification per instructions provided in Product
Miniature universal joints simplify burner alignment. Information Sheet 2000-7/8.
Aluminum connecting rod can be cut to fit actual Low Fire Start Switch Assembly (SPDT) opens
burner spacing. (Allowable distance between adjacent the circuit when burner leaves minimum position. Also
burner centerlines is 21" – 33" for 422M and smaller, available in Weatherproof and Hazardous Location/
23.5" – 36" for larger burners.) Weatherproof versions.
High and Low Fire Position Switch Assembly
includes 2 SPDT switches. One switch may be field-
set to activate at high fire position, while other is set to
activate at low fire position. Switch assemblies are
also available in a weatherproof version.
To order, specify:
1. Primary and secondary burners
2. Any other accessories desired
3. Required quantity of Universal Joint Assemblies
Low Fire Start Switch shown
Manual Handle Kit permits setting and locking

air and fuel valves at a constant firing rate. See photo Discharge Sleeve Mounting Gaskets
below. Standard discharge sleeve gasket provides
adequate sealing in most applications.
High Back Pressure Gasket Kit includes 2 addi-
tional gaskets to provide sealing against back pres-
sures as shown in sketch below.
Standard With
Arrangement High Back Pressure Kit
Accessory Options
Hi/Lo Control Motor Sets for high or low firing. Discharge Sleeves are available in 3 versions:
Optional set includes 2-position unidirectional 11- – Standard sleeve is 8" long, made of #310 SS, and
second 120v 50/60 Hz motor and connecting base with is suitable for downstream temperatures up to
mounting linkage. See table below for dimensions 1000°F (538°C).
which differ from standard burner.
– For higher velocities, specify 12" long sleeve made
of #310 SS for downstream temperatures up to
1000°F (538°C).
– For higher downstream temperatures between
1000°F (538°C) and 1500°F (816°C), specify 8" long,
#RA 330 SS sleeve.
Dimensions in Inches
Burner Model
P R T
EB-1, 2 405 - 413M 10.25 17.63 7.75
EB-3 415 - 422M 10.19 17.56 7.75
EB-4, 5 425 to 442M 11.69 19.06 8.75
EB-6, 7 445 - 487M 16.69 24.06 8.75
9/94
Dimensions (in Inches)

Model “400” and “400-MA” OVENPAK® Burners
NOTE: Use of auxiliary switches will add to dimension D.
Model A B* C D E F G H J K L M N CC DD EE FF GG HH JJ KK
405 8.81 11.37 14 3.66 17.81 14.37 17.06
17.31
407M 15.25 15.87 18 4.69 19.69 21.69 18.62
408 8.81 11.37 14 3.66 19.12 17.81 14.37 17.06
3.75 1 6.62 8.87 10.30 8.44 6.31 8.44 3.62
408M
5.44 13.19 4.37 0.25 17.31
412M 15.25 15.87 18 4.69 19.69 21.69 18.62
413M 19.12
415 8.81 11.37 14 17.75 14.37 17.06
4.75 1-1/4 7.69 8.81 10.25 10.37 8.25 10.37 4.44 3.59 17.31
422M 15.25 15.87 19.56 21.69 18.62
425 1-1/2 12.12 14.44 3.94 20.5 20.25 19.75
432M 15.25 15.87 2.81 21.25 23.56 29.62
5.75 10.06 11.88 14.69 12.50 5.44 10.25 12.5 5.62 18.25
435 12.12 14.44 18 3.94 20.5 20.25 19.75
442M 2 2.81 21.25 23.56
6.06 8.62 0.37
445 15.25 15.87 22.5
25 23.5
456M 29.62
6.81 14.38 16.88 19.31 14.62 6.5 12.25 14.75 6.69 5.37
470M 24
3 17.75 17.79 19 26.81 25.94
487M
*Main fuel gas inlet NPT


Model EB, EB-MA, and EB-MRV OVENPAK® Burners
NOTE: Use of auxiliary switches will add to dimension D.
Model A B C D E F G H J K L M N U V W X Y AA BB
EB-1
3.75 6.62 8.44 6.31 8.44 3.62 5.44
EB-2 1-1/4 5.44 8.87 10.31 13.19 4.37 0.25 7.25 8.62 6.37 0.44 5.44 4
EB-3 4.75 7.69 10.37 8.25 10.37 4.44 5.38
EB-4
5.75 2 10.06 11.88 14.69 12.5 5.44 10.25 12.5 5.62 9.25 10.62 8.87 7.75 6 6
EB-5
6.06 8.62 0.37 0.56
EB-6 11.7-
6.81 3 14.38 16.88 19.31 14.62 6.5 12.25 14.75 6.69 9.62 11.12 10.25 8.5 8
EB-7 5
1/98
Accessory Dimensions (in Inches)

Filter with silencer for Model “400” OVENPAK® Burner
Model JJ LL MM NN PP RR SS TT UU
405 14.4 12.4 19.3 10.4 23.2 29.9 33.6
407M 21.7 15.1 21.9 7.8 24.7 31.4 35.1
408 14.4 12.4 19.3 10.4 23.2 29.9 33.6
23.2
408M
412M 21.7 15.1 16 21.9 7.8 24.7 31.4 35.1
413M
415 14.4 12.4 19.3 10.4 23.2 29.9 33.6
23.1
422M 21.7 15.1 7.8 24.7 31.4 35.1
21.9
425 20.2 14.5 8.3 24 25.9 32.6 36.3
432M 23.6 18.1 22 24.9 10.8 24.9 31.9 38.5 42.3
435 20.25 14.5 16 21.4 8.3 24 25.9 32.6 36.3
442M 23.6 24.9
445 18.1 22 24.9 10.8 31.9 38.5 42.3
23.5 28.6
456M
470M
25.9 20.2 24 29.2 12.8 29.6 33.9 42.7 44.3
487M

Suggested spare parts Nameplate

– Spark Ignitor – Discharge Sleeve and Gasket
– Flame Rod, if used – Motor
– Filter Elements, if used – Impeller
– Mixing Cone – Gas/Air Valve Linkage Kit
To order parts for an existing OVENPAK® Burner assembly, list:
1. Name(s) of part(s) from above illustration
2. Quantity of each required
3. OVENPAK® Burner nameplate information:
• size and model number of burner
• assembly number
• date of manufacture
• if available, serial number of Maxon fuel shut-off valve in-line to OVENPAK®
Burner (This serial number is on Maxon valve's nameplate.)
9/03
Suggested Maintenance/Inspection Procedures

Discharge sleeve and cone alignment Flame Rod
Centering of the mixing cone provides a small
annular opening for the flow of some cooling combus-
tion air along the discharge sleeve wall. We SUGGEST
periodic inspection from the discharge side of the
burner to assure that this alignment is maintained.
Caution: Tightening can lead to cone distortion
and greatly reduce cone and discharge sleeve
life. Cone should be free to move and allow for
thermal expansion. NOTE: 1/2" x 1" adapter bushing supplied by others
If re-adjustment is necessary, back out the four lock
nuts and re-center mixing cone with adjusting screws Table 1: Flame rod and spark ignitor dimensions
handtight. Back each screw out one-half turn before re- for all Model “400” OVENPAK® Burners
locking. This allows for thermal expansion as cone manufactured after 1/1/91 ①
gets hot.
Filters should be inspected regularly and cleaned, Spark Ignitor Flame Rod
using a vacuum to remove loose/dry accumulations, Burner Model Dimensions Dimensions
then washing and/or degreasing as appropriate for the X Y X Y Z
filter type used. 405
To replace flame rod or spark ignitor: 407M
1. Check Table 1 at right for dimension “Y” and cut tip 408M
EB-1
to length shown. 1.3 .4
EB-2 408
2. Insert 1/2" NPT collar into burner and snug into .4 6 2.9
position. 412M
3. Insert insulator through collar into burner. 413M
4. Check table for dimension “X”, position accordingly,
and tighten locking bushing until insulator is held 415
EB-3 1.5 .4
firmly. 422M
WARNING: Over-tightening locking bushing may 425

damage insulator. 432M
EB-4
1.2 .4 .8 10.8 3.5
EB-5 435
NOTE: A full-wave 6000 volt spark ignition transformer
is suggested for use with Maxon burner equipment. 442M
445
EB-6 456M
1.3 .4 .4 12.8 2.9
EB-7 470M
487M
① Manufactured date is stamped on metal nameplate

of Model “400” OVENPAK® Burner. For specifics
relative to units manufactured prior to 1/1/91, see
Product Information Sheet 2100-3.
Maxon Pre-Assembled Package

Model “400” OVENPAK® Gas Burner System
425 OVENPAK®
package system
installed and
mounted onto a
Maxon
pre-fabricated
heater/duct section
Save time and reduce your installation costs with a All pre-assembled package systems include a
completely assembled and pre-wired burner and pipe Model “400” OVENPAK® Burner and pipe train. The
train “package”. pipe trains are available with “Block and Bleed” ar-
All system components have been carefully se- rangement options only.
lected to match the high performance characteristics of Additional application flexibility is provided with five
the Model “400” OVENPAK® Gas Burner. different sized systems, all with 40:1 turndown
The compact design of this “packaged system” capacity ranges.
makes mounting to your duct fast and easy. Connect Packaged OVENPAK® Burner systems may also be
to the gas line and bring in electricity. It's wired and mounted in a pre-fabricated combustion heater/duct
piped, ready to go. section by Maxon. This option is value-engineered to
give you the most for your dollar spent.
6/03
Design / Application Summary

Five Model "400" OVENPAK® pre-assembled package options:
OVENPAK® Burner Model > 405 408 415 425 435

Horsepower 1/3 3/4
Totally Enclosed Blower Motor
Frame Number 48 56
Maximum Capacity (Btu/hr) 500,000 800,000 1,500,000 2,500,000 3,500,000
Minimum Capacity (Btu/hr) main plus pilot 15,000 20,000 37,000 60,000 87,000
Minimum natural gas pressure required at pipe train inlet 6" wc 10" wc 9" wc 14" wc
Inlet pipe train size NPT 1.25" 1.5"
Approximate overall envelope dimensions 42" long x 40" high x 24" wide
Pre-assembled pipe train “package” Factory pre-wiring includes the following

includes the following components: components for 115 volts 60 hertz AC:
– Burner gas shut-off cock – Low fire start switch
– Main inlet gas shut-off cock – Combustion air pressure switch
– Pilot gas train consisting of: – Combination high and low gas pressure switch
• Pilot gas shut-off cock – Pilot gas solenoid valve
• Pilot gas pressure regulator (maximum 1 PSIG – Normally-open vent solenoid valve (when used)
natural gas inlet pressure) – Spark ignition transformer
• Pilot gas solenoid valve, 115/60VAC – Maxon “main” and/or “blocking” gas shut-off valve(s)
– Main gas pressure regulator (maximum 1 PSIG – NEMA type 12 and 13 junction box with terminal
natural gas inlet pressure) wiring strip
– Combustion air pressure switch, automatic reset,
Field wiring is required:
NEMA 1, 115/60VAC
– To the packaged system's junction box wiring strip
– Combination high and low gas pressure switch,
– To the Model “400” OVENPAK® Burner's combustion
manual reset, NEMA 1, 115/60VAC
air blower motor
– Spark ignition transformer, 6000 volts, NEMA 1, 115/
– Between your flame safeguard relay and the
60VAC
OVENPAK® Burner's flame sensor
– NEMA type 12 and 13 junction box with terminal
NOTE: A flame rod may be furnished by Maxon; UV
wiring strip
detector is a part of the control package when
– Normally open vent solenoid valve, 115/60VAC
supplied by Maxon or may be supplied by others.
A complete packaged system also includes: – Other field wiring connections may be required if your
• Maxon Model “400” OVENPAK® Burner assembly control circuit includes high/low temperature limits,
– Connecting base and linkage assembly to adapt automatic temperature controller, and/or other
customer-supplied automatic control motor miscellaneous safety limit switches.
(optional)
– Low fire start switch (mounted to OVENPAK®
Burner)
– Air filter assembly
• Maxon main gas shut-off valve, position “L”, 115/
60VAC
• Maxon main gas “blocking” shut-off valve, position
“L”, 115/60VAC00000000

Reduce your fabrication time with a complete Application flexibility is offered by three sizes of
combustion heater/duct including the prewired and ducts. All sizes can be fabricated to have return/inlet
prepiped Model “400” OVENPAK® Burner system opening at any 90° increment position (viewing from
package. the back of the OVENPAK® Burner). Continuous welds
Easy installation is provided by flanged duct on all joint seals permit duct section installation on
connection joints. Burner is mounted to a .312" mild pressure-side or suction-side applications.
steel wall, lined with 6" thick fiber insulation. The other
16 gauge aluminized steel heater/duct walls are ready
for your insulation.
Approximate duct section dimensions (in inches)

Model A B (inside) C D (inside) E F G H J (inside) K
405 - 408 12 24 5 10 36 48 12.62 26.62 7.5 37
415 15 30 6 12 42 60 14.62 32.62 9.5 48
425 - 435 18 36 8 16 48 72 18.62 38.62 11.5 58
6/03

Maximum discharge temperature 600°F (316°C)
Duct static pressures may range between +2" wc and -5" wc
Optimum design parameters permit up to 3000 feet per minute air velocity through return/inlet duct.
Recommended maximum discharge air volumes

Model "400" OVENPAK® Burner 405 408 415 425 435
Maximum discharge air volume in SCFM 5000 7500 12,000
To select your packaged system, specify:
1. Quantity ________
2. Model “400” OVENPAK® Gas Burner Assembly _________, for natural gas
– Arranged for UV detector, or with flame rod
– Furnished with blower motor for ___________ AC
– With low fire start switch _________ , General Purpose, 115/60 AC
– With combustion air filter assembly ____________ (optional)
– With connecting base and linkage assembly ____________ to adapt customer's automatic electric
control motor. Specify/select which one of these electric operators will be used:
– Barber-Colman #EA51–58, also with prefix MC, MP or MF
– Honeywell #M644, #M744, #M941, or #M944
– Penn/Johnson #M-80 or #M81
3. Arranged into pre-assembled and wired pipe train package, 115/60VAC,

– With Block and Bleed arrangement assembly ______________.
4. With _______ 1-1/4" or 1-1/2" Maxon Series __________ Automatic Reset, Manual Reset
Shut-Off Valve(s), for natural gas, in top assembly position “L” for 115/60VAC
– With electrical terminal block (option)
– With 6 second, or 2.5 second opening time (automatic reset valve(s) only)
– With ______________ auxiliary signal switch(es) (optional)
NOTE: Specify which switch(es) go in main valve and which switch(es) in blocking valve, if different.
5. With heater/duct section assembly ____________ (optional)

with return/inlet duct positioned on top, right, bottom, or left
Model “200” OVENPAK® Burners

Model “200” OVENPAK® Gas Burners
provide a broad range of heat without a
combustion blower by firing through-the-wall
into your combustion chamber on the suction
side of the circulating fan. An internal mixing
cone blends air drawn through the burner (by
chamber suction) with fuel gas delivered
through its central gas nozzle. The Model
“200” OVENPAK® Burner is designed for
applications involving suction-side firing from -
0.2" to -1.6" wc static chamber conditions.
They provide:
– low initial and operating cost
– easy installation
Model “200” OVENPAK®
Burner arranged with air inlet – simple adjustment
guard and optional UV scanner – heavy duty cast iron construction in a
compact burner configuration
Performance data
NOTE: Maximum capacity varies with the range of suction provided at operating temperature
Maximum capacities (1000's Btu/hr) with corresponding fuel gas differential

Performance data
pressures at specific combustion chamber static pressure conditions
Combustion chamber suction ("wc) -0.2 -0.3 -0.4 -0.5 -0.6 -0.7 -0.8 -0.9 -1.0 -1.6
Maximum capacity (1000's Btu/hr) 100 190 275 360 450 540 625 700 800 1000
Minimum capacity (1000's Btu/hr) 10 12 13 14 15 17 18 19 20 25
Combustion air volume required (SCFM) 65 80 90 95 110 120 130 135 145 184
Natural gas differential pressure required ("wc) 0.1 0.4 0.7 1.2 1.9 2.7 3.7 4.6 6.0 9.4
Propane gas differential pressure required ("wc) --- --- 0.3 0. 5 0.8 1.1 1.5 1.8 2.4 3.8
Approximate flame lengths beyond end of
0-3 6-9 12 - 18 15 - 21 18 - 24 21 - 27 24 - 30 24 - 26
discharge sleeve (inches)
Air volumes shown are for burners without damper, Typical pipe train
or with damper in full-open position. If damper is used
to restrict air flow, maximum capacity will be similarly
reduced.
Pilot flame issues from the same gas ports as
main flame, so proof of pilot gas ignition assures
ignition of main gas supply.
Flame sensing can be either by flame rod or UV
scanner when natural gas is the fuel, but only with UV
scanner if propane is the fuel.
Installation is simple, utilizing the built-in, direct-
mounting flange provided.
A complete combustion system utilizing Model
“200” OVENPAK® Burners also includes gas train,
fuel-throttling valve and control system. Your Maxon
representative can help you choose from the broad
range of options available.
12/89

Differential gas pressures in inches water column Suction (shown in inches wc) should be that
(" wc) for both natural gas and propane are those that available at operating temperature. It can be deter-
should be measured by connecting a manometer mined by a two-step procedure: First, measure cold
between test points shown in the photo below. suction (chamber to atmosphere). Second, multiply
that reading by the correction factor shown in Graph
"A" for your desired operating temperature.
Model “208” OVENPAK® Burner shown with air damper

and flame rod For example, if you anticipate running the system at 600°F,
follow that dotted line to the right until it intersects curve,
then read downward to a correction factor of 0.5. Therefore,
if you read a cold suction of 1" wc, your expected suction
“at temperature” would be 1" x 0.5 = 0.5" wc.
Burner
Assembly
Flame Rod Assembly

“400”, “200” OVENPAK® Burners Page 2100-S-1
General Instructions compatible with burner nameplate ratings. Insure that
all normal control safeguards are satisfied. Combus-
Important: Do not discard packing material until tion air blower should continue to run after shutdown
all loose items are accounted for. to allow burner to cool.
To prevent damage in transit, the spark ignitor, Gas supply piping must be large enough to
discharge sleeve, mounting gaskets, flame rod and maintain the required fuel pressures cataloged for the
connecting linkage components may be packed particular burner size used with burner operating at
separately and shipped loose with your new Maxon full rated capacity.
OVENPAK® Burner. Anything more than minimal distance or piping
The burner itself is normally only a part of your turns may necessitate oversizing piping runs to keep
complete combustion system. Additional pipe train pressure drops within acceptable ranges.
accessories and control components will be required Inlet pipe leading to any burner should be at least
for a complete system installation. The sketch below four pipe diameters in length. If multiple burners are
fed from a single gas train, care should be taken to
shows a typical gas train as might be used with
minimize pressure drop and give maximum uniformity.
OVENPAK® gas fired burners.
Clean fuel lines are essential to prevent blockage
of pipe train components or burner gas ports.
Piping Layout as sometimes required by Main Shut-Off Cock should be upstream of both
insurance and standards groups the main gas regulator and pilot line take-off. Use it to
shut off fuel to both pilot and main burner during shut-
Block and Bleed gas train arrangement illustrated
down periods of more than a few hours.
with Model “400” OVENPAK® Burner
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 regula-
tor 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 regula-
tor 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
Model “400” OVENPAK® Burners provide the air hazardous operating condition is sensed. Manual
supply (except for EB versions, which require a reset valves require operator attendance each time
separate combustion air blower). They also serve as the system is started up (or restarted after a trip-out).
a fuel flow control and fuel/air mixing device. Model Motorized shut-off valves permit automatic start-
“200” OVENPAK® Burners serve as a mixing device restart when used with an appropriate control system.
and usually have an externally-mounted gas control Test connections are essential for burner adjust-
valve. ment. They should be provided immediately down-
Burner should not be exposed to direct radiant stream of the regulator and are included in the burner
heat or positioned where it might draw in inert gases. itself. Test connections must be plugged except
If such conditions exist, consider filters, relocation when readings are being taken.
and/or use of the EB version and external air supply.
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Electrical service must match the voltage, phase
and cycle of all electrical system components and be
CORPORATION
Page 2100-S-2 “400”, “200” OVENPAK® Burners
Horizontal mounting is preferred, but burner may Additional burner support may be required in
be mounted in any position suitable for automatic conjunction with a stiffener plate when mounting
control motor and UV scanner (if used). OVENPAK® Burner (weighing 100-350 pounds)
OVENPAK® Burners will typically be installed through typical thin wall of heater/oven panels.
through an oven wall or insulated air duct. Cut open- For push-through systems, use Maxon special
ing approximately 1" larger in diameter than discharge back pressure gasket between stiffener plate and
sleeve to allow for thermal expansion of sleeve. discharge sleeve flange and use (2) ring gaskets
Burner mounting requires four studs and a flat between discharge sleeve flange and burner casting
mounting surface perfectly centered on the discharge to prevent back flow of high temperature air. Fill area
sleeve. D (see sketch below) with no more than 2" of high
After placing burner in position over studs, add lock temperature packing (too little will overheat mounting;
washers and nuts, then draw up hand-tight only. too much will overheat sleeve).
Check that burner is seated evenly all around the
flange, filling any gaps to prevent air leakage, then
tighten all nuts firmly. Typical discharge sleeve mounting
For proper performance of any burner, air inlet and recommendations
motor should be surrounded by clean, fresh, cool air.
Burner and pipe manifold support will be re-
“400”
quired to support weight of the burner and connected
OVENPAK®
pipe train components. Air control motors, in particu-
Burners
lar, 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® Burner
requires external auxiliary support provided by the
user. The support configuration may be similar to the
leg support or knee bracket support illustrated below.
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.
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For “400” OVENPAK® Burners: Lock screws If OVENPAK® Burner is equipped with Maxon Hi/Lo
should be drawn up hand-tight, then backed out one- Control Motor, low-fire start wiring can be accom-
half turn to allow for cone expansion. They must be plished as shown in the sketch below.
re-checked after start-up, and loosened if necessary
Maxon assumes no responsibility for the use or
to prevent deformation of cone. See start-up instruc-
misuse of the layouts shown. Specific piping
tions for details. Over-tightening lock screws can
and wiring diagrams should always be submit-
lead to cone distortion and greatly reduce cone
ted to the appropriate agencies for approval on
and discharge sleeve life.
each application.
Discharge sleeve must be flush with, or extend
beyond, interior wall. Maxon can supply a special 12" Multi-burner installations require special consid-
long discharge sleeve, but higher noise levels may erations if supplied by a common pipe train and/or air
result, particularly when firing on propane. supply. Air and Gas Balancing Valves should be
An external viewing port should be provided for used for improved heating uniformity; Gas Swing-
flame observation, preferably in such a position that Check Valves should be installed as close as pos-
burner pilot and main flame can both be seen. sible to each burner inlet for dependable lightoff (gas
Flame sensing can be accomplished by either manifold may otherwise act as a reservoir, preventing
flame rod or UV scanner. When UV scanner is used, lightoff during trial-for-ignition period).
it should be kept as close to burner as feasible. Heat Control system’s circuitry must not allow main
block, if used, may affect signal strength with some Fuel Shut-Off Valve to be opened unless combustion
brands of scanners. air is on, and must de-energize valve upon loss of
For “400” OVENPAK® Burners, field conversion combustion air pressure, along with the other usual
from a flame rod version to a UV scanner version and system interlocks. Motor starter is to be interlocked
vice versa may require additional parts in the burner. with valve, whether or not a combustion air pressure
Contact Maxon for requirements. switch is used.
Alternate fuels may require correction of supply
pressures.

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Start-Up Instructions
Read complete instructions before proceeding, For Model EB-MRV and Model “200”
and familiarize yourself with all the system's equip- OVENPAK® Burners, the connecting linkage on
ment components. Verify that your equipment has the separate control valve must be similarly
been installed in accordance with the original manu- loosened and disconnected. Refer to specific
facturer's current instructions. adjusting procedures relating to control valve
adjustment in Maxon catalog.
CAUTION: Initial adjustment and light-off Initial start-up adjustment should only be
should be undertaken only by trained and accomplished during a manual burner control
experienced personnel familiar with combus- mode.
tion systems, with control/safety circuitry, and 5. Start all system-related fans and blowers.
with knowledge of the overall installation. Check for proper motor rotation and impeller
Instructions provided by the company and/or direction. Verify that all control interlocks are
individuals responsible for the manufacture working. Allow air handling equipment to run for
and/or overall installation of complete system adequate purge of your manifolds and combus-
incorporating Maxon burners take precedence tion chamber plenums. With main gas shut off,
over these provided by Maxon. If Maxon manually advance burner to high fire position so
instructions conflict with any codes or regula- that air only flows through burner and combustion
tions, contact Maxon Corporation before chamber.
attempting start-up.
CAUTION: Do not by-pass control panel timers
typically controlling sequential operations.
For initial OVENPAK® Burner start-up: For EB OVENPAK® Burners only (step 6)
1. Close all burner fuel valves and cocks. Make 6. Verify differential air pressure. With combustion
preliminary adjustments to fuel gas regulators. air blower on, all volume air fans operating, and
Remove pilot and main gas regulator’s adjusting burner at high fire position, connect a manometer
screw covers. Turn adjusting screw down (clock- between the air test connection on backplate of
wise) to approximately mid-position. Close pilot OVENPAK® Burner and your combustion chamber
gas adjustable orifice screw by turning in clock- static pressure test connection. This will give a
wise until it stops. (Do not over-tighten.) Then direct differential air pressure reading.
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 function-
ing 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® Burner’s
operating crank arm by loosening the control
motor’s connecting rod from the burner’s toggle
linkage.
mCORPORATION

“400”, “200” OVENPAK® Burner Page 2100-S-5
Determine your differential air pressure reading control valve. This lets you limit and set the differential
by taking an additional reading with manometer pressure to the OVENPAK® Burner. Refer to Maxon
connected between the burner’s air pressure test specification tables in the catalog for the differential
port and atmosphere with the burner at high fire air settings required for your specific OVENPAK®
position, fuel valves closed, and all air handling Burner capacity.
systems running. Subtract the combustion
7. Determine the required differential gas pres-
chamber static pressure obtained above from this
sure using this differential air pressure reading
air pressure reading to give you differential air
obtained from step 6. If your combustion chamber
pressure reading.
does not have a static pressure test connection,
then you must measure combustion chamber
For Model “200” OVENPAK® Burner only static pressure by connecting a manometer
(steps 6A-6C) 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 pres-
sures 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 appro-
priate 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
6A. Cross-connect manometer to upstream ① and spark ignition to light pilot while slowly turning
downstream ② air pressure test connections on pilot gas regulator spring clockwise and/or
Model “200” OVENPAK® Burner’s main housing. adjustable orifice screw counter-clockwise to
6B. Start air handling system and adjust louvers, increase fuel flow. Repeat procedure as neces-
dampers, etc. to desired setting to establish cold sary until pilot ignites as air might have to be bled
suction design conditions. out of fuel supply lines before reliable pilot flame
6C. Transfer manometer connection from upstream is established. Pilot gas regulator should normally
air pressure test ① to gas pressure test connection be set for as low a pressure as possible, using
③. This is the differential air pressure reading for a fuller opening of pilot gas adjustable orifice (if
Model “200” OVENPAK® Burner. used).
11. After ignition, adjust pilot flame for good stable
For “400” OVENPAK® Burners: The differential air
flame shape. A rule of thumb is that any pilot over
pressure setting determines the burner’s capacity and a tennis ball size is probably too large. This
performance capabilities. Model EB and MA manual assumes you have visual access to the pilot
air OVENPAK® Burners, with their external air control flame. If this is not possible, then adjust pilot to
valve(s), provide for the manual setting of this differ- give the strongest and most stable flame signal
ential air pressure to the burner. Refer to specific through your flame safety circuit. This signal
adjusting procedures relating to MICRO-RATIO® and strength can be read with a micro-amp meter. The
control valve adjustment in Maxon product line signal strength (or range) will be determined by
catalog. MA OVENPAK® Burners have an external the specific type of flame safeguard instrument
locknut adjustment on the end of the air butterfly you have with your burner system.

mCORPORATION
Cycle burner from minimum to maximum
12. Re-check pilot ignition by closing pilot gas cock
and refine adjustment, if necessary.
or otherwise causing pilot outage. Re-light and
For operation with interrupted pilot (as
refine pilot gas adjustment as necessary to get
recommended), shut off pilots and cycle burner
ignition within a second or two. The flame safe-
from minimum to maximum and back several
guard relays should now power your main fuel
times to verify the flame is maintained.
Shut-Off Valve(s).
15. When burner performance is satisfactory and
CAUTION: After completing steps above, re- stable throughout the firing range, reconnect
check all interlocking safety components and control motor.
circuitry to prove that they are properly in- For “400” OVENPAK® Burners: Reconnect
stalled, correctly set, and fully operational. If in linkage to control motor. Control linkage travel
doubt, shut the system down, close pilot cock must be such that burner crank is moved through-
and contact responsible individual before out its complete travel, or cataloged capacities
proceeding further. and turndowns will not be achieved. If less than
full-rated burner capacity is required, linkage can
13. Establish main flame. With burner at low fire
be adjusted to limit maximum output.
position, back out main gas pressure regulator
With interrupted pilot, it may be necessary to
adjusting screw (counter-clockwise) to get lowest
set control for somewhat higher than minimum
outlet pressure possible. Open all manual fuel
burner setting to permit hold-in of flame detection
shut-off valves (automatic fuel shut-off valve
system without pilot.
should already be open) so gas flows to burner
inlet. There should be little, if any, change in CAUTION: Internal drive mechanism within the
flame appearance. Turn main regulator adjust- control motor may be damaged if linkage is
ing screw in (clockwise) to obtain outlet pressure adjusted so as to cause binding with burner in
of about 4"-6" wc higher than combustion cham- high or low fire position.
ber pressure (2"-4" wc for propane, considerably
higher for some EB versions). Main flame should 16. Re-check differential gas pressure with unit at
now appear larger than pilot-only flame. operating temperature. Refine high fire setting if
14. Establish high fire setting by slowly moving necessary, considering differential pressure,
burner toward high fire position while observing flame length, and appearance. Natural gas flame
gas pressure at burner gas test connection. should normally be predominantly clear blue but
Refine main gas regulator adjustment as neces- possibly with semi-luminous tips. Dust or contami-
sary to provide correct differential pressure nants in the air stream may affect flame appear-
(gauge to combustion chamber, see step 7) at ance.
high fire. If pressure cannot be adjusted low 17. For “400” OVENPAK® Burners: Check for
enough, a different regulator or regulator spring contact between mixing cone and top-most
may be necessary, or a limiting orifice valve (such centering screw after system has reached
as Maxon's Series “BV”) should be added. Do maximum operating temperature. If set screw
not, however, exceed 4" wc pressure drop touches cone, back off an additional 1/8 turn on
between regulator outlet and burner inlet. top and both side set screws.
18. Plug all test connections not in use to avoid
CAUTION: If burner(s) go out, close shut-off dangerous fuel leakage. Replace equipment
valve or shut main gas cock at once. Return to cover caps and tighten linkage screws.
minimum setting, re-light pilots if necessary,
then turn main gas on again. Check carefully
that every burner is lit before proceeding.
m CORPORATION

19. Check out overall system operation by cycling WARNING: Test every UV installation for
through light-off at minimum, interrupting pilot, dangerous spark excitation from ignitors and
and allowing temperature control system to cycle other possible sources of direct or reflected UV
burner from minimum to maximum and return. radiation. Use only gas-tight scanner
Recheck all safety system interlocks for proper connections.
setting and operation.
NOTE: Typical gas firing control sequence for Maxon 20. Before system is placed into full service,
burner is provided only as a guide. Instructions instruct operator personnel on proper start-up
provided by complete system manufacturer incorpo- operation with shut-down of system, establishing
rating Maxon burners take precedence. written instructions for their future reference.
For gas firing Model “400” OVENPAK® Burner
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
burner to cool

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Notes
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Model “400” OVENPAK® Burners Page 2100-A/P-1
Assembly Numbers
For these products, please order per the following product numbers:
(configured products are those with alphanumeric text)
Size Packaged Burner Packaged Manual Air Packaged Automotive UL Listed Burners
405 405 OP (70) 405MA OP (49) 405AM OP (70)
407M 407M OP (83) 407MMA OP (74) 407MAM OP (86)
408 408 OP (70) 408MA OP (49) 408AM OP (70)
408M 408M OP (84) 408MMA OP (75) 408MAM OP (88)
412M 412M OP (83) 412MMA OP (74) 412MAM OP (85)
413M 413M OP (84) 413MMA OP (75) 413MAM OP (88)
415 415 OP (72) 415MA OP (75) 415AM OP (73)
422M 422M OP (94) 422MMA OP (73) 422MAM OP (98)
425 425 OP (107) 425MA OP (74) 425AM OP (111) 54391 (120)
432M 432M OP (118) 432MMA OP (78) 432MAM OP (122) 54392 (131)
435 435 OP (107) 435MA OP (74) 435AM OP (111) 54393 (120)
442M 442M OP (122) 442MMA OP (81) 442MAM OP (125) 54394 (135)
445 445 OP (157) 445MA OP (149) 445AM OP (161) 54395 (174)
456M 456M OP (169) 456MMA OP (161) 456MAM OP (205) 54396 (186)
470M 470M OP (191) 470MMA OP (195) 470MAM OP (224) 54397 (208)
487M 487M OP (219) 487MMA OP (224) 487MAM OP (249) 54398 (236)
Size EB EB Manual Air EB MRV UL Listed Burners

EB-1 EB1 OP (45) EB1MA OP (26) EB1MRV OP (44)
EB-4 EB4 OP (79) EB4MA OP (52) EB4MRV OP (78) 54402 (93)
Segment choices are listed on pages 2100-A/P-2 through 4.
Approximate ship weight (in pounds) shown in parentheses.

Configured choices may cause some deviation in weights shown.

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CORPORATION
Page 2100-A/P-2 Model “400” OVENPAK® Burners
Assembly Numbers
Segment Choices
(DEFAULT is shaded)
ANSI ANSI threaded
BACKPLATE Type of threads on backplate
ISO ISO threaded
NONE No spark ignitor
Type of spark ignitor,
SPARK IGNITOR STD Standard spark ignitor
if desired
UL UL recognized spark ignitor
HIGH_CAP High capacity adjustable orifice
Type of adjustable orifice,
ADJUSTABLE ORIFICE NONE No adjustable orifice
if desired
STD Standard adjustable orifice
HIGH_TEMP High temp observation glass
STD Standard observation glass
OBSERVATION GLASS Type of observation glass
UV Tapped adapter for UV scanner
UV_HT Tapped adapter w/sightglass
FLAME_ROD Flame rod
Type of flame detection, NONE No flame detection device

FLAME DETECTION
if desired UV UV scanner provision
UV_HT UV scanner provision for high temp
BUT Butane gas
BUT_SS Butane gas with SS linkage
NAT Natural Gas
FUEL Type of fuel
NAT_SS Natural Gas w/SS linkage
PROP Propane Gas
PROP_SS Propane Gas w/SS linkage
SS Stainless steel mixing cone
MIXING CONE Mixing cone material
STD Standard mixing cone
NONE No discharge sleeve
12HBP 12" 310SS hi back pressure discharge sleeve
12RA330 12" RA330 discharge sleeve
Type of discharge sleeve, 1231022 12"310SS hi back pressure sleeve

DISCHARGE SLEEVE
if desired 8HBP 8" 310SS hi back pressure sleeve
8RA330 8" RA330 discharge sleeve
8REFLN 8" refractory lined discharge sleeve
8310SS 8" 310SS discharge sleeve
NONE Do not include with order
OVEN WALL GASKET If desired
YES Include with order
mCORPORATION

Assembly Numbers
Segment Choices
Segment Name Segment Description Segment Choice Descriptions
(DEFAULT is shaded)
IEC 230 / 400-3-50 IEC 34-7
NONE No motor
Selection of motor voltage, 115_230160 115 / 230-1-60 TEFC

MOTOR
if desired 190_415350 190 / 380-415-3-50 TEFC
230_460360 230 / 460-3-60 TEFC
575360 575-3-60 TEFC
BARB_COL Barber-Colman electric CB&L
CUST Customer installed CB&L
FOX_JORDAN Foxboro/Jordan electric CB&L
FOX_P25 Foxboro P-25 air CB&L
HW_ACTION Honeywell Actionator electric CB&L
HW_AIR Honeywell air actuated CB&L
CONNECTING BASE & HW_MOD Honeywell Modutrol electric CB&L

Type of CB&L, if desired
LINKAGE JOHN_CONT Johnson Controls air CB&L
LEEDS-NOR Leeds & Nor thrup electric CB&L
NONE No CB&L
PENN_JOHN Penn/Johnson electric CB&L
SMARTLINK SMARTLINK CB&L
TAYLOR Taylor air CB&L
120V_CONT 120V Maxon control motor kit
240V_CONT 240V Maxon control motor kit
MOD Modutrol control motor
Type of control motor,
CONTROL MOTOR MOD_WP Modutrol weather proof control motor
if desired
NONE No control motor
CX2HPSLPS Mswitch explosion-proof weather proof hi/lo pos
CS4HPSLPS Msw explosion-proof weather proof 2hi/2low pos
MSHPSLPSWP M'switch weather proof hi/low position
MSLPSWP M'switch weather proof low position
Choice of switches, MSLPSWPEP M'switch explosion-proof weather proof low pos

SWITCH
if desired NONE No position switch
OMHPSLPS Omron hi/low position
OMLPS Omron low position
TLHPSLPSWP T'mecanique weather proof hi/low position
TLLPSWP T'mecanique weather proof low position

mCORPORATION
Assembly Numbers
Segment Choices
(DEFAULT is shaded)
FLTR Air (foam) filter
FLTRSLNCR1 Air (foam) filter/silencer position 1
NONE No filter or silencer
Filter and/or silencer and PERMFILTR Air (permanent) filter
FLTR &/O SILENCER &
guard position,
GUARD POS PERMSLNCR1 Air (permanent) filter/silencer position 1
if desired
PERMSLNCR2 Air (permanent) filter/silencer position 2
PERMSLNCR3 Air (permanent) filter/silencer position 3
SLNCR1 Silencer, guard position 1
UNIVERSAL JOINT NONE No Universal Joint

If desired
ASSEMBLY YES 20216 Universal Joint needed
MANUAL Manual handle included
MANUAL HANDLE If desired
NONE No handle included
1000 1000F (538C) maximum stream temperature
MAX AIRSTREAM TEMP (F) Choice of temperature
1500 1500F (816C) maximum stream temperature
CS Carbon steel
Choice of material for guide CSTEC Carbon steel customer specific

GUIDE TUBE
tube 303SS 303 stainless steel
316SS 316 stainless steel
CUSTOMER NUMBER Specify 0 Enter value
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CORPORATION

Assembly Numbers
Spare Parts
Configured Spare Parts Kits Each configured product listed at left

has the following segments &
Burner Configured choices:
Description
Size Item Number
Segment Choices
405 405 OP RSP 405 OVENPAK Burner Recommended Spares
Spark ignitor None or Yes
407M 407M OP RSP 407M OVENPAK Burner Recommended Spares
Rubber boot None or Yes
Flame rod None or Yes
High/Low Control Motor Assembly None or Yes
High/Low Control Motor (only) None or Yes
Discharge sleeve None or Yes
Loose gasket (only) None or Yes
Gasket kit None or Yes
Switch assembly None or Yes
Switch (only) None or Yes
Filter element None or Yes
Internal linkage kit None or Yes
Connecting Base & Linkage None or Yes
Miscellaneous Accessories None or Yes
Specify
487M 487M OP RSP 487M OVENPAK Burner Recommended Spares Replacement Blower Kit [1]
Quantity
EB1 EB1 OP RSP EB1 OVENPAK Burner Recommended Spares Replacement Blower Motor [1] None or Yes
EB2 EB2 OP RSP EB2 OVENPAK Burner Recommended Spares Repl. Automotive Blower Motor [1] None or Yes
EB3 EB3 OP RSP EB3 OVENPAK Burner Recommended Spares [1] Not applicable to EB versions
EB4 EB4 OP RSP EB4 OVENPAK Burner Recommended Spares
NOTES:
• The flame rod assemblies already include a rubber boot
• The internal linkage kits include air butterfly connecting links (which will be extra parts for MA versions)
• The filter element segment does not appear in the EB configured spare parts
• The cone centering fasteners that appear under Misc. Accessories should be specified in multiples of 4
• After a selection of “yes”, the quantity of items is to be specified at the next level

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CORPORATION
Assembly Numbers
Spare Parts
Configured Item Numbers (by segment)

Segment Name 405 OP RSP 407M OP RSP 408 OP RSP 408M OP RSP 412M OP RSP
Spark Ignitor 405 SI RSP
Rubber Boot 405 BOOT RSP
Flame Rod 405 FR RSP
Hi/Lo Control Motor
405 MTR ASY RSP
Assembly
Hi/Lo Control Motor
405 MTR RSP
Only
Discharge Sleeve 405 SLV RSP
Loose Gasket (only) 405 GSKT RSP
Gasket Kit 405 GSKT KIT RSP
Switch Assembly 405 SW ASY RSP
Switch Only 405 SW RSP
Element 405 ELMNT RSP 407M ELMNT RSP 405 ELMNT RSP 407M ELMNT RSP
Internal Linkage Kit 405 LNKG RSP 407M LNKG RSP 405 LNKG RSP 407M LNKG RSP
Connecting Base &
405 CBL RSP
Linkage
Replacements
405 ACSY RSP 407M ACSY RSP 408 ACSY RSP 407M ACSY RSP 412M ACSY RSP
/Accessories
Replacement Blower
405 RBK 407M RBK 405 RBK 408M RBK 407M RBK
Kits
Replacement Blower
405 BLWR MTR RSP 407M BLWR MTR RSP 405 BLWR MTR RSP 408M BLWR MTR RSP 407M BLWR MTR RSP
Motor
Replacement Blower 407MAM BLWR MTR 408MAM BLWR MTR 407MAM BLWR MTR
405AM BLWR MTR RSP 405AM BLWR MTR RSP
Motor (automotive) RSP RSP RSP
Configured Item Numbers (by segment) - continued

Segment Name 413M OP RSP 415 OP RSP 422M OP RSP 425 OP RSP 432M OP RSP 435 OP RSP
Flame Rod 405 FR RSP 425 FR RSP
Hi/Lo Control Motor
405 MTR ASY RSP 425 MTR ASY RSP
Assembly
Hi/Lo Control Motor
405 MTR RSP
Only
Discharge Sleeve 405 SLV RSP 415 SLV RSP 425 SLV RSP
Loose Gasket (only) 405 GSKT RSP 415 GSKT RSP 425 GSKT RSP
Gasket Kit 405 GSKT KIT RSP 415 GSKT KIT RSP 425 GSKT KIT RSP
Switch Assembly 405 SW ASY RSP 425 SW ASY RSP
Element 407M ELMNT RSP 405 ELMNT RSP 407 ELMNT RSP 432M ELMNT RSP 407M ELMNT RSP
Internal Linkage Kit 407M LNKG RSP 405 LNKG RSP 407M LNKG RSP 425 LNKG RSP 432M LNKG RSP 425 LNKG RSP
Connecting Base &
405 CBL RSP
Linkage
Replacements /
412M ACSY RSP 415 ACSY RSP 425 ACSY RSP 432M ACSY RSP 435 ACSY RSP
Accessories
Replacement Blower
408M RBK 405 RBK 422M RBK 425 RBK 432M RBK 425 RBK
Kits
Replacement Blower
405 BLWR MTR RSP 405 BLWR MTR RSP 408M BLWR MTR RSP
Motor
Replacement Blower
405AM BLWR MTR RSP 405AM BLWR MTR RSP 408MAM BLWR MTR RSP
Motor (automotive)
m
CORPORATION

Assembly Numbers
Spare Parts
Configured Item Numbers (by segment) - continued

Segment Name 442M OP RSP 445 OP RSP 456M OP RSP 470M OP RSP 487M OP RSP
Flame Rod 425 FR RSP 445 FR RSP
Hi/Lo Control Motor
425 MTR ASY RSP
Assembly
Hi/Lo Control Motor
405 MTR RSP
Only
Discharge Sleeve 425 SLV RSP 445 SLV RSP
Loose Gasket (only) 425 GSKT RSP 445 GSKT RSP
Gasket Kit 425 GSKT KIT RSP 445 GSKT KIT RSP
Switch Assembly 425 SW ASY RSP 445 SW ASY RSP
Element 432M ELMNT RSP 470M ELMNT RSP
Internal Linkage Kit 442M LNKG RSP 445 LNKG RSP 470M LNKG RSP
Connecting Base &
405 CBL RSP
Linkage
Replacements /
435 ACSY RSP 445 ACSY RSP 456M ACSY RSP 470M ACSY RSP 487M ACSY RSP
Accessories
Replacement Blower
442M RBK 445 RBK 456M RBK 470M RBK 487M RBK
Kits
Replacement Blower
442M BLWR MTR RSP 456M BLWR MTR RSP 470M BLWR MTR RSP 487M BLWR MTR RSP
Motor
Replacement Blower 470MAM BLWR MTR 487MAM BLWR MTR
442MAM BLWR MTR RSP 456M BLWR MTR RSP
Motor (automotive) RSP RSP
Configured Item Numbers (by segment) - EB versions

Segment Name EB1 4OP RSP EB2 4OP RSP EB3 4OP RSP EB4 4OP RSP EB5 4OP RSP EB6 4OP RSP EB7 4OP RSP
Flame Rod 405 FR RSP 425 FR RSP 445 FR RSP
Hi/Lo Control Motor
405 MTR ASY RSP 425 MTR ASY RSP
Assembly
Hi/Lo Control Motor
405 MTR RSP
Only
Discharge Sleeve 405 SLV RSP 415 SLV RSP 425 SLV RSP 445 SLV RSP
Loose Gasket (only) 405 GSKT RSP 415 GSKT RSP 425 GSKT RSP 445 GSKT RSP
415 GSKT KIT
Gasket Kit 405 GSKT KIT RSP 425 GSKT KIT RSP 445 GSKT KIT RSP
RSP
Switch Assembly 405 SW ASY RSP 425 SW ASY RSP 445 SW ASY RSP
Internal Linkage Kit 405 LNKG RSP 425 LNKG RSP EB6 LNKG RSP
Connecting Base &
405 CBL RSP
Linkage
Replacements /
405 ACSY RSP 408 ACSY RSP 415 ACSY RSP 425 ACSY RSP 435 ACSY RSP 456M ACSY RSP 487M ACSY RSP
Accessories

mCORPORATION
Assembly Numbers
Spare Parts
Item Numbers (by size)

405, 407M, 408, 425, 432M, 445, 456M,
Segment Description Segment Choices 415, 422M
408M, 412M, 413M 435, 442M 470M, 487M
Standard 47232
Spark Ignitor
UL 54376
Rubber Boot Standard 18722
Flame Rod Standard 27729 27731 27732
Hi/Lo Control Motor
115v 50/60 or 230v 50/60 59599 59600
Assembly
Hi/Lo Control Motor
115v 50/60 or 230v 50/60 59601
only
8" 310SS 32730 32731 32732 32733
12" 310SS 27019 27020 27021 27022
8" RA330 34660 34661 34662 34663
Discharge Sleeve 12" RA330 47339 47346 47353 47360
8" Refractory Lined 38291 38292 38293 38294
8" High Back Pressure 34022 34023 34024 34025
Housing Flange 28475 28476 28477 28478
Std. Sleeve 33975 33976 33977 33978
Loose Gasket (only)
HBP Sleeve 34018 34019 34020 34021
Refractory Lined Sleeve 1050556 1050557 1050558 1050559
Gasket Kit Housing Flange & Std. Sleeve 34027 34028 34029 34030
CX2 High Position/Low Position 1043935 1043935 1043936
MS High Position/Low Position 30460 30460 30460
MS WP High Position/Low Position 37178 37178 37178
MS Low Position 20118 20118 20118
Switch Assembly MS WP Low Position 35610 35610 35610
MS WP EP Low Position 35944 35944 35948
Omron High Position/Low Position 46646 46567 46567
Omron Low Position 46645 46564 46564
TM WP High Position/Low Position 44358 44358 44358
TM WP Low Position 44357 44357 44357
CX2 High Position/Low Position 33502
MS High Position/Low Position 25836
MS WP High Position/Low Position 35598
MS Low Position 25836
Switch Only MS WP Low Position 35598
MS WP EP Low Position 33502
Omron High Position/Low Position 46560
Omron Low Position 46560
TM WP High Position/Low Position 54673
TM WP Low Position 54673
mCORPORATION

Assembly Numbers
Spare Parts
Item Numbers (by size)

408M
Segment 445 470M
Segment Choices 405 407M 408 412M 415 422M 425 432M 435 442M
Description 456M 487M
413M
Foam Filter 29758 28045 29758 28045 29758 28045 28047 28045 28047 24337
Element Permanent Filter 34651 34652 34651 34652 34651 34652 34654 34652 34654 34655
Foam Filter (Silencer) 31062 31062 31062 31062 31062 31062 31062 31062 31062 31051
Standard 33628 33629 33628 33629 33628 33632 33630 33633 33630 33633 33634 33635
Internal Linkage Stainless Steel 44988 44989 44988 44989 44988 44990 44991 44992 44991 44992 44994 44995
Kit Standard (butane) 33628 33629 33628 33629 33628 33632 33630 33633 33630 33633 33634
Stainless Steel (butane) 44988 44989 44988 44989 44988 44990 44991 44992 44991 44992 44994
Foxboro P25 (air) 24066
Honeywell (air) 20685
Johnson Control (air) 25187
Taylor (air) 22929
Connecting Base
Barber-Colman (electric) 19866
& Linkage
Foxboro/Jordan (electric) 34468
Honeywell Modutrol (electric) 19680
Honeywell Actionator (electric) 22009
Leeds & Nor thrup (electric) 24009
Penn/Johnson (electric) 19680

mCORPORATION
Assembly Numbers
Spare Parts
Item Numbers (by size) - Replacements / Accessories

412M 415 435
Segment Choices 405 407M 408 408M 425 432M 445 456M 470M 487M
413M 422M 442M
Automatic Operating Crank 45627
Toggle/Clamp Set 30510
Manual Handle Set 31990
Universal Joint Assembly 20216
Balancing Valve 19120 19121 19122 19123 19125
Swing Check Valve 35619 35937 35620 35621 38968
Pilot Adjustable Orifice 38009 50431
Pilot Adjustable Orifice
50431 --- --- --- --- --- --- ---
(high cap.)
Natural Gas Nozzle 51287 51295 51285 51286 51288 51289 51290 51291 51292 51293
Natural Gas Nozzle (coated) 47300 47301 47302 47303 47304 47305 47306 47307 47308 47309
Propane Gas Nozzle 51297 51294 51295 51296 51298 51299 51300 51301 51302 51303
Propane Gas Nozzle (coated) 47310 47311 47312 47313 47314 47315 47316 47317 47318 47319
ANSI CS Guide Tube 1053042 51304 51305 51306
ANSI SS Guide Tube 1053044 47291 47292 47293
ANSI 316SS Guide Tube 1053047 1034890 1034888 1034889
ISO CS Guide Tube 1053043 1049090 1049092 1049094
ISO SS Guide Tube 1053045 1049091 1049093 1049095
DI Natural Gas Mixing Cone 53755 53756 53755 53756 53757 53758 53759 53760
DI Natural Gas Mixing Cone
--- --- --- --- 53765 53766 53767 53768
(xs air)
SS Natural Gas Mixing Cone 38119 38120 38119 38120 38121 38122 38123 53771
DI Propane Gas Mixing Cone 53755 53756 53755 53756 53757 53758 53759 53760
DI Propane Gas Mixing Cone
--- --- --- --- 53765 53766 53767 53768
(xs air)
SS Propane Gas Mixing Cone 38119 38120 38119 38120 38121 38122 38123 53771
DI Butane Gas Mixing Cone 53799 53764 53799 53764 53763 53762 46471 53761
SS Butane Gas Mixing Cone --- --- --- --- 47230 --- --- ---
Cone Centering Screw [1] 40705
Nut (for cone centering
40019
screws) [1]
[1] Four (4) needed per cone
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CORPORATION

Assembly Numbers
Spare Parts
Item Numbers (by size) - Replacement Blower Kits and Motors

Segment
Segment Choices 405 407M 408 408M 412M 413M 415 422M
Description
.125" Hollow Pipe Plug 20410 (1)
Air Inlet Flange 19312 (1) 24645 (1) 19312 (1) 24645 (1) 19312 (1) 24645 (1)
Guard 33647 (1) 44825 (1) 33647 (1) 44825 (1) 33647 (1) 44825 (1)
1/4"-20 Plated Hex Nut 40019 (4)
1/4"-20x . 75" Hex Head Cap
40264 (4)
Screw
5/16"-18x .312" Socket Set Screw 40520 (1) 40520 (2) 40520 (1) 40520 (2) 40520 (1) 40520 (2)
#10x .5" Plated Round Head
40548 (11) 40548 (12) 40548 (11) 40548 (12) 40548 (11) 40548 (12)
Replacement Screw
Blower Kits Gasket 50556 (1) 50560 (1) 50556 (1) 50560 (1) 50556 (1) 50561 (1)
Impeller - ANSI 19314 (1) 24646 (1) 19314 (1) 24647 (1) 24646 (1) 24647 (1) 19314 (1) 24648 (1)
Impeller - ISO 25454 (1) 24708 (1) 25454 (1) 24709 (1) 24708 (1) 24709 (1) 25454 (1) 24710 (1)
Impeller - 7E 34710 (1) 34711 (1) 34710 (1) 24647 (1) 34711 (1) 24647 (1) 34710 (1) 24648 (1)
Housing - Standard 27536 (1) 27538 (1) 27536 (1) 27538 (1) 27536 (1) 27537 (1)
Housing - Manual Air 30490 (1) 30487 (1) 30490 (1) 30487 (1) 30490 (1) 30488 (1)
.125" Waste Nut - Aluminum 18098 (1)
.125" Waste Nut - Gray Iron 43423 (1)
115/230-1-60 17446 17785 17446 14535 17785 14535 17446 14535
190/380-415-3-50 47239 47240 47239 --- 47240 --- 47239 ---
Replacement 220/440-3-60 --- --- --- 47238 --- 47238 --- 47238
Blower
Motor 230/460-3-60 20636 20642 20636 20632 20642 20632 20636 20632
575-3-60 20637 20643 20637 20633 20643 20633 20637 20633
200/400-3-50 (IEC) 47561 47562 47561 47563 47562 47563 47561 47563
Replacement
230/460-3-60 34704 34705 34704 34706 34705 34706 34704 34706
Blower
Motor
460-3-60 --- --- --- --- --- --- --- ---
(automotive)
Number in parentheses represents quantity (if no value is shown, default quantity is 1).

m
CORPORATION
Assembly Numbers
Spare Parts
Item Numbers (by size) - Replacement Blower Kits and Motors (continued)
Segment
Segment Choices 425 432M 435 442M 445 456M 470M 487M
Description
.125" Hollow Pipe Plug 20410 (1)
Air Inlet Flange 19414 (1) 24062 (1) 19414 (1) 24062 (1) 24063 (1)
Guard 33648 (1) 33649 (1) 33648 (1) 33649 (1) 1049451 (1)
1/4"-20 Plated Hex Nut 40019 (4) 40019 (2)
1/4"-20x . 75" Hex Head Cap
40264 (4) 40264 (2)
Screw
5/16"-18x .312" Socket Set Screw 40520 (2)
#10x .5" Plated Round Head
40548 (11) 40548 (12) 40548 (11) 40548 (12)
Replacement Screw
Blower Kits Gasket 50562 (1) 50559 (1) 50562 (1) 50559 (1) 50558 (1)
Impeller - ANSI 19417 (1) 24649 (1) 19417 (1) 24650 (1) 23961 (1) 24371 (1) 24372 (1) 36892 (1)
Impeller - ISO 25455 (1) 24943 (1) 25455 (1) 24712 (1) 24543 (1) 24544 (1) 24545 (1) 24546 (1)
Impeller - 7E 19417 (1) 24649 (1) 19417 (1) 24650 (1) 23961 (1) 24371 (1) 24372 (1) 36892 (1)
Housing - Standard 27460 (1) 27540 (1) 27460 (1) 27540 (1) 27541 (1) 27539 (1)
Housing - Manual Air 30493 (1) 30489 (1) 30493 (1) 30489 (1) 30491 (1) 30492 (1)
.125" Waste Nut - Aluminum 18098 (1)
.125" Waste Nut - Gray Iron 43423 (1)
115/230-1-60 14535 32987 --- --- ---
190/380-415-3-50 --- --- --- --- --- --- --- ---
Replacement 220/440-3-60 47238 47236 47241 47242 47237
Blower
Motor 230/460-3-60 20632 17447 21060 21061 19296
575-3-60 20633 20635 39359 39360 20640
200/400-3-50 (IEC) 47563 47564 47565 47566 47567
Replacement
230/460-3-60 34706 34707 --- --- ---
Blower
Motor
460-3-60 --- --- --- --- --- 22773 22774 22775
(automotive)
Number in parentheses represents quantity (if no value is shown, default quantity is 1).
mCORPORATION

Assembly Numbers
Spare Parts - EB Versions
Item Numbers (by size) - for EB Versions

Segment Description Segment Choices EB1 EB2 EB3 EB4 EB5 EB6 EB7
Standard 47232
Spark Ignitor
UL 54376
Flame Rod Standard 27729 27731 1042698
Hi/Lo Control Motor
115v 50/60 or 230v 50/60 59599 59600
Assembly
Hi/Lo Control Motor
115v 50/60 or 230v 50/60 59601
Only
8" 310SS 32730 32731 32732 32733
12" 310SS 27019 27020 27021 27022
8" RA330 34660 34661 34662 34663
Discharge Sleeve 12" RA330 47339 47346 47353 47360
8" Refractory Lined 38291 38292 38293 38294
Housing Flange 28475 28476 28477 28478
Std. Sleeve 33975 33976 33977 33978
Loose Gasket (only)
HBP Sleeve 34018 34019 34020 34021
Refractory Lined Sleeve 1050556 1050557 1050558 1050559
Gasket Kit Housing Flange & Std. Sleeve 34027 34028 34029 34030
MS High Position/Low Position 30460 30460 30460
MS WP High Position/Low Position 37178 37178 37178
MS Low Position 20118 20118 20118
Switch Assembly MS WP Low Position 35610 35610 35610
MS WP EP Low Position 35944 35944 35948
Omron High Position/Low Position 46646 46567 46567
Omron Low Position 46645 46564 46564
TM WP High Position/Low Position 44358 44358 44358
TM WP Low Position 44357 44357 44357
MS High Position/Low Position 25836
MS WP High Position/Low Position 35598
MS Low Position 25836
Switch Only MS WP Low Position 35598
MS WP EP Low Position 33502
Omron High Position/Low Position 46560
Omron Low Position 46560
TM WP High Position/Low Position 54673
TM WP Low Position 54673
Standard 33628 33630 33631
Internal Linkage Kit Stainless Steel 44988 44991 44993
[1] Standard (butane) 33628 33630
Stainless Steel (butane) 44988 44991
[1] Bills-of-material include air butterfly connecting links (which will be extra for MA versions).

m CORPORATION
Assembly Numbers
Spare Parts - EB Versions
Item Numbers (by size) - for EB Versions

Segment Description Segment Choices EB1 EB2 EB3 EB4 EB5 EB6 EB7
Taylor (air) 22929
Connecting Base &
Barber-Colman (electric) 19866
Linkage
Automatic Operating Crank 45627
Toggle/Clamp Set 30510
Manual Handle Set 31990
Universal Joint Assembly 20216
Balancing Valve 19121 19123 19125
Swing Check Valve 35937 35621 38968
Pilot Adjustable Orifice 38009 50431
Pilot Adjustable Orifice (high cap.) 50431 --- --- --- ---
Natural Gas Nozzle 51287 51295 51286 51288 51289 51291 51293
Natural Gas Nozzle (coated) 47300 47301 47303 47304 47305 47307 47309
Propane Gas Nozzle 51297 51294 51296 51298 51299 51301 51303
Propane Gas Nozzle (coated) 47310 47311 47313 47314 47315 47317 47319
ANSI CS Guide Tube 1053042 51304 51305 51306
Replacements /
ANSI SS Guide Tube 1053044 47291 47292 47293
Accessories
ANSI 316SS Guide Tube 1053047 1034890 1034888 1034889
ISO CS Guide Tube 1053043 1049090 1049092 1049094
ISO SS Guide Tube 1053045 1049091 1049093 1049095
DI Natural Gas Mixing Cone 53755 53757 53758 53760
DI Natural Gas Mixing Cone (xs air) --- 53765 53766 53768
SS Natural Gas Mixing Cone 38119 38121 38122 53771
DI Propane Gas Mixing Cone 53755 53757 53758 53760
DI Propane Gas Mixing Cone (xs air) --- 53765 53766 53768
SS Propane Gas Mixing Cone 38119 38121 38122 53771
DI Butane Gas Mixing Cone 53799 53763 53762 53761
SS Butane Gas Mixing Cone --- 47230 --- ---
Nut (for cone centering screws) [1] 40019
[1] Four (4) needed per cone
m
CORPORATION

Assembly Numbers
Spare Parts - UL Versions
Item Numbers (by size) - for UL Versions

Segment Description Segment Choices 425 432M 435 442M 445 456M 470M 487M
Spark Ignitor UL 54376
PCI UV Scanner 40768
PCI Flame Rod 40769 --- --- --- ---
Flame Detection Kit
Fireye UV Scanner 40770
Honeywell Mini-Peeper 40771
7256-B10NRH (pci) 37386
Flame Safeguard ECA 70D40 (Fireye) 50335
R7795A1001 (Honeywell) 37415
PCI UV Scanner 37387
Scanner Fireye UV Scanner 50338
Honeywell Mini-Peeper 31088
Flame Rod PCI Flame Rod 54527
Relay SS100a Flame-Pak (PCI) 50251
Amplifier ECA 72CUVS4 (Fireye) 50336
ECA 60-1386-2 (Fireye) 50337
Base
Q795A1004 (Honeywell) 37417
Discharge Sleeve 8" 310SS 32732 32733
Housing Flange 28477 28478
Loose Gasket (only)
Std. Sleeve 33977 33978
Gasket Kit Housing Flange & Std. Sleeve 34029 34030
Differential Pressure 1.5"-5"wc Low Differential 54378 --- --- --- ---
Switch 3"-22"wc Low Differential --- --- --- --- 54379
Internal Linkage Kit
Standard 1063116 1063117 1063116 1063117 43096 43097 43098 43099
[1]
Taylor (air) 22929
Connecting Base &
Linkage Barber-Colman (electric) 19866
Pilot Adjustable Orifice 50431
Natural Gas Nozzle 51288 51289 51290 51291 51292 51293

Replacements /
ANSI CS Guide Tube 43085 43086
Accessories
DI Natural Gas Mixing Cone 53758 53759 53760
Nut (for cone centering screw) [2] 40019
Replacement Blower
Standard Housing w/GI Waste Nut 1063124 1063125 1063126 1063127 1063128 1063129 1063130 1063131
Kits
[1] Bills-of-material includes air butterfly connecting links (which will be extra for MA versions)
[2] Four (4) needed per cone.

m
CORPORATION
Assembly Numbers
Maxon Pre-Assembled Model “400” OVENPAK® Gas Burner Systems
Pre-assembled pipe train package includes all components for natural gas or propane gas:
• Burner gas shut-off cock
• Main inlet gas shut-off cock
• Pilot gas train consisting of:
– Pilot gas shut-off cock
– Pilot gas pressure regulator
– Pilot gas solenoid valve – 115/60v AC
• Main gas pressure regulator
• Combustion air pressure switch – automatic reset, NEMA 1, 115/60v AC
• Combination high and low gas pressure switch – manual reset, NEMA 1, 115/60v AC
• Spark ignition transformer – 5000 volts, NEMA 1, 115/60v AC
• NEMA 12 & 13 junction box with terminal wiring strip
• Normally open vent solenoid valve – 115/60v AC (Block and Bleed arrangements only)
• Maxon Model “400” OVENPAK® Burner assembly
• Maxon main gas shut-off valve – position “L”, 115/60v AC
• Maxon main gas blocking shut-off valve – position “L”, 115/60v AC (Block and Bleed arrangements only)
To order:
– Select appropriate Model “400” OVENPAK® Burner system from below
– Configure system (which includes the burner and valve(s) – refer to catalog page 2124)
For burner CB & L’s:
(1) Specify from Honeywell: WITH #7616BR crank arm
(2) Specify from Penn/Johnson: WITH #LVR27A-601 crank arm
Model "400" OVENPAK® Burner 405 408 408MA 415 425 435
Pre-Assembled
Block & Bleed w/Hi Lo Switch 405HL BB 408HL BB 408MAHL BB 415HL BB 425HL BB 435HL BB
Packaged System

• Fuel
• Low pressure gauge kit
• High pressure gauge kit
• Duct section
m
CORPORATION

Assembly Numbers
Model “200” OVENPAK® Burners
To order this configured product, enter: 208OP
Replacement Items
28637
Flame Rod with rubber cover
(1)
28548
Spark Ignitor
(1)
30126
Spark Ignitor Boot with 48" of spark ignition wire
(.5)
Manometer (0-8" wc range) 21757
Approximate net weight (in pounds) shown in

parentheses

m
CORPORATION
Product: Model “EB” OVENPAK® Burners Page: 2100-1 Date: 10/92
Suggested spare parts

– Spark Ignitor
– Flame Rod, if used
– Gas/Air Valve Linkage Kit
– Mixing Cone
– Discharge Sleeve and Gasket
To order parts for an existing OVENPAK®
Burner assembly, list:
3. OVENPAK® Burner nameplate information:
• size and model number of burner
• assembly number
• if available, serial number of Maxon fuel
shut-off valve in-line to OVENPAK® Burner
(This serial number is on Maxon valve’s
nameplate.)
Product Data Sheet Product: Model “400” OVENPAK Burners ®
Page: 2100-1 Date: 3/98

(for Maxon Personnel only)
Do Not Reproduce
Model “400” OVENPAK® Gas Burner Nozzle Drillings

– Each nozzle has eight gas ports drilled per chart NOTE: – The use of nozzle drilled for propane
below. increases gas pressure required with
– Each packaged OVENPAK® Burner assembly propane to the same as pressures re-
includes standard (natural gas) nozzle. quired for natural gas.
– K Factor for orifice is 0.77
– For propane firing: LESS natural gas nozzle, and
WITH propane nozzle.
Standard Natural Gas Optional Propane Gas

Model "400" OVENPAK® Burners Nozzle MTD [1] Drill Size Nozzle MTD [1] Drill Size
Assembly No. (decimal equivalent) Assembly No. (decimal equivalent)
405 --- EB-1 51287 11/64 (.1718) 51297 #29 (.1360)
408 407M, 408M EB-2 51295 #5 (.2055) 51294 #20 (.1610)
--- 412M, 413M --- 51285 1/4 (.2500) 51295 #5 (.2055)
415 422M EB-3 51286 23/64 (.3593) 51296 Let. "I" (.2720)
425 432M EB-4 51288 13/32 (.4060) 51298 5/16 (.3125)
435 442M EB-5 51289 33/64 (.5156) 51299 Let. "X" (.3970)
445 --- --- 51290 17/32 (.5312) 51300 13/32 (.4060)
--- 456M EB-6 51291 19/32 (.5937) 51301 29/64 (.4531)
--- 470M --- 51292 21/32 (.6562) 51302 33/64 (.5156)
--- 487M EB-7 51293 23/32 (.7187) 51303 35/64 (.5468)
[1] MTD = Manufacturers Twist Drill
“Normal” Maximum Combustion Air Pressures (at back plate air pressure test connection)
When firing against positive pressures, combustion

air readings will be higher, with the increase depend-
ing upon specific burner size and chamber pressure.
Size 405 408 415 425 435 407M 408M 412M 413M 422M 432M 442M 445 456M 470M 487M
"wc 3.1 3.3 2.3 3.1 2.6 4.9 4.5 4.7 5.4 4.8 4.8 4.8 2.9 3.7 4.9 6.1
Bulletin 2150
Model “400” OVENPAK® -II Gas Burners
Model 415 OVENPAK®-II

Burner shown with
customer’s UV scanner
mounted
• Burns any clean fuel gas

• Fires into passing air streams
• Requires only low pressure gas
• Provides clean combustion with low NOx levels
• New modular burner design provides easier installation
• Simple field adjustment and maintenance
Model “400” OVENPAK®-II Burner applications include:

Air heating in ovens and dryers, paint finishing lines, paper and textile machines,
food baking ovens, coffee roasters, grain dryers, and fume incinerators. Manufactured under
U.S. patent #3,574,508; Canadian #873,695; and European patent granted and pending.
Page 2152
Model “400” OVENPAK®-II Gas Burners

• 40:1 turndown or more
Model EB-3 OVENPAK®-II shown with

customer’s UV scanner mounted
Typical piping layout with “Block and Bleed” gas train arrangement
1/93
Model “400” OVENPAK®-II Gas Burner Page 2153

OVENPAK®-II Burners are nozzle-mixing gas
burners for many industrial direct-fired applications
where clean combustion and high turndown are
required. They are simple and versatile for use on a
variety of heating applications.
The Model “400” OVENPAK®-II Burner (shown at
right) includes a face-mounted motor, blower with
non-sparking paddle wheel-type impeller, pilot, spark
ignitor, stainless steel discharge sleeve, mixing cone,
self-contained internal air and gas proportioning
valves, and provision for your flame safeguard
sensor.
The blower housing can be rotated and mounted in
three alternate locations in 90° increments around the
burner air inlet center line. Control motor and low fire
start switches may be mounted on either the right or
left hand side of burner body.
Principle of operation (illustrated below)
The OVENPAK®-II Burner is designed for industrial
air heating applications. It is available in two basic
versions: 1) packaged with integral combustion air Model 415 OVENPAK®-II Gas Burner with optional
combustion air filter, high and low fire position switch set,
blower, or 2) for use with an external blower. Both spark ignitor, provision for customer’s UV scanner and with
versions include a gas and air valve, internally linked connecting base and linkage for electrical control motor
operating range. The gas flows through the nozzle,
then along the inside of the burner cone where
combustion air is progressively and tangentially mixed
with the gas. This produces a very wide turndown
range and a highly stable flame under a variety of
Cross-sectional views of a Model “400” OVENPAK®-II Gas Burner
9/91
Page 2154 Model “400” OVENPAK®-II Gas Burners

Model “EB” (external blower) OVENPAK®-II Burners
(shown in photos), like all OVENPAK® Burner assem-
blies, are designed to deliver heat through a patented
mixing cone and stainless steel sleeve.
Flanged burner body design on all OVENPAK®
Burner assemblies simplifies mounting and installa-
tion on your application. Burner can be installed in
any position that does not conflict with your control
motor or flame detector requirements.
Minimal torque requirements permit use of most
electric or air operators in conjunction with the
optional (Maxon supplied) connecting base and
linkage assemblies.
View into metallic cone of Model EB-3 OVENPAK®-II

Burner, arranged for external blower source, with
connecting base and linkage assembly to adapt customer's
automatic control motor, and optional low fire start switch
arrangement. Inlet air piping uses flexible connector set.
Model EB-3 OVENPAK®-II Burner with large viewing port,

spark ignitor, standard pilot gas adjustable orifice, optional
low fire start switch arrangement, and connecting base and
linkage for mounting customer’s control motor
Model “400” OVENPAK®-II Gas Burners Page 2155

Standard Model “400” OVENPAK®-II Burner Motor Voltages Available (60 Hz & 50Hz)
includes a combustion air blower with face-mounted 60 115/208- 208-
motor. 575/3/60
Hz 230/1/60 230/460/3/60
Maximum capacity of Model “400” OVENPAK®-II Horsepower Type
50 190-
Burner is affected by the static pressure within the 380-415/3/50 500/3/50
Hz [1] 200/1/50
combustion chamber. Data shown assumes firing in 1/3 Totally Enclosed X X X
the open, or into an airstream with enough oxygen to 3/4 & 1 Totally Enclosed X X X
complete the combustion process. If burner is fired into Not
an oxygen-starved chamber or airstream, capacities 1-1/2, 2, & 3 Totally Enclosed X X
Available
may be reduced as much as 25-30%. Do not attempt [1] Possible net extra cost
to operate beyond the duct static pressure range
shown. For higher back pressure applications, select For operation on 50 Hz, reduce OVENPAK®-II
from Model “EB” OVENPAK®-II Burner options. Burner capacities by 83% and pressures to 70% of
All gas pressures are differential pressures and those shown.
are measured at the gas pressure test connection on
the backplate of each OVENPAK®-II Burner. Differen-
tial pressures shown are approximate.
Capacities and Operating Data

OVENPAK®-II Burner Model 405 408 415 425 435 445 456 470 487
Motor Horsepower: 1/3 1/3 1/3 3/4 3/4 1 1-1/2 2 3
Specification Frame Number: 56C 56C 56C 56C 56C 56C 143TC 145TC 145TC
-5.0 to 550 880 1650 2750 3850 5175 6400 8050 10060
-0.5" wc 2.8" 3.4" 1.7" 2.7" 2.2" 3.4" 3.6" 3.7" 4.6"
500 800 1500 2500 3500 4500 5600 7000 8700
±0" wc
2.3" 2.8" 1.4" 2.2" 1.8" 2.6" 2.8" 2.8" 3.4"
475 760 1425 2375 3325 4280 5340 6570 8400
+1.0" wc
2.1" 2.6" 1.3" 2.0" 1.6" 2.3" 2.3" 2.5" 3.2"
Maximum Capacities 450 720 1350 2250 3150 4125 5200 6300 8200
(1000's Btu/hr) +2.0" wc
Duct 1.9" 2.3" 1.1" 1.8" 1.4" 2.2" 2.4" 2.3" 3.0"
with Natural Gas
Statics 5000 5500 7500
Pressures +3.0" wc --- --- --- --- --- ---
("wc) 2.2" 1.7" 2.5"
4600 5000 6200
+4.0" wc --- --- --- --- --- ---
1.9" 1.4" 1.7"
4100 4500 5500
+5.0" wc --- --- --- --- --- ---
1.5" 1.2" 1.4"
3500 5000
+6.0" wc --- --- --- --- --- --- ---
0.7" 1.1"
Minimum Capacities Main plus pilot 15 37 60 87 110 125 150 175
(1000's Btu/hr) Pilot only 10 20 35 45 90 105 115 117
Required natural gas differential pressure to
2.8 3.3 3.0 2.4 2.7 3.5 5.1 5.2 7.6
burner inlet ("wc)
3-1/2 to 8 to
Approximate flame length in still air 1/2 to 1 ft. 2-1/2 to 3-1/2 ft. 4 to 6 ft. 5 to 7 ft. 6 to 8 ft.
5 ft. 10 ft.
3/96

Combustion Differential Air Pressure ("wc) 3 4 5 6 8 9 10 11
and Cooling Air
Required Volume (SCFM) 150 170 190 210 240 255 270 280
EB-1 Heat Releases
Minimum & pilot 60 60 60 60 60 60 60 60
OVENPAK®-II (1000's Btu/hr)
Pilot only 45 45 45 45 45 45 45 45
Burner
Differential
Pressures ("wc) At burner gas test connection 2.0 3.1 4.7 5.6 7.0 7.6 8.5 9.2

and Cooling Air
EB-2 Heat Releases
Minimum & pilot 60 60 60 60 70 70 75 80
Pilot only 25 25 25 25 30 30 35 35
Burner
Natural Gas At burner inlet 3 5.2 7.8 9.5 11.3 12.1 12.9 13.8
Differential

and Cooling Air
EB-3 Heat Releases
Minimum & pilot 90 95 105 115 130 140 150 155
Pilot only 45 45 50 55 65 70 75 75
Burner
Differential

and Cooling Air
EB-4 Heat Releases
Minimum & pilot 100 115 130 140 160 170 180 190
Pilot only 40 40 40 45 50 55 55 60
Burner
Differential
Flame Lengths In still air 2-1/2 to 3-1/2 feet beyond end of discharge sleeve

and Cooling Air
EB-5 Heat Releases
Minimum & pilot 155 180 200 220 255 270 285 300
Pilot only 25 30 35 35 40 45 50 50
Burner
Differential

and Cooling Air
Heat Releases
EB-6 Minimum & pilot 335 390 490 575 695 735 815 850
(1000's Btu/hr)
OVENPAK®-II Pilot only 100 100 100 115 140 145 165 170
Burner
Differential

and Cooling Air
Heat Releases
EB-7 Minimum & pilot 335 390 490 575 695 735 815 850
(1000's Btu/hr)
OVENPAK®-II Pilot only 100 100 100 115 140 145 165 170
Burner
Differential
9/95
Accessory Options
Air filter assemblies and silencers
Air filter assemblies help to trap airborne particu-
late matter. They are offered with washable replace-
able filter elements or with permanent metallic ele-
ments. Filters mount onto OVENPAK®-II Burner's
blower housing and surround the combustion air inlet.
Filter silencers help reduce noise levels. They
physically become a part of the OVENPAK®-II
Burner's filter housing and enclose the combustion air
inlet (as shown in photograph at right). They must be
furnished in conjunction with a filter element assembly
described above.
Sound levels from actual Burner Sound Level
tests conducted at full-rated Size (dBA)
60 Hz capacity are shown in 405 80
table at right. Measurements 408 83
are the average maximum at 415 84
high fire for standard burner 425 86
(natural gas, 8" discharge 435 86
sleeve). 445 90
456 90
470 93
487 93 Model 415 OVENPAK®-II Burner assembly with combustion
air filter assembly (including replaceable foam filter
element). Permanent metallic filter element may be
substituted for standard foam filter element at extra cost.
When accessories and/or options are added, use
the following guidelines to calculate sound levels.
Filter (permanent) add 2 dB (3dB)
Silencer (with permanent filter) subtract 2 db (1 dB)
12" discharge sleeve add 2 dB
50 Hz motor – 83% capacity subtract 2 dB
Propane gas add 4 dB
Combine the adds and subtracts for net change
when calculating sound levels with more than one of
these options/accessories. (Example: A burner with
silencer and operating on propane would be 2 dB
louder.)
Silencer includes filter element as standard.
NOTE: Background may affect on-site
measurements.
Accessory Options
Auxiliary Switches Discharge Sleeves are available in 3 versions:
Low Fire (or Set Position) Switch Assembly
– Standard sleeve is 8" long, made of #310 SS, and
includes one cam-actuated switch (2 SPST circuits)
is suitable for downstream temperatures up to
which can be set to open a circuit when burner leaves
1000°F (538°C).
minimum (or set) position. It meets NEMA #4/IP665
standards for weatherproof, outdoors, non-hazardous – For higher velocities, specify 12" long sleeve
locations. made of #310 SS for downstream temperatures up
High and Low Fire Position Switch Assembly to 1000°F (538°C).
includes 2 cam-actuated switches (each with 2 SPST
– For higher downstream temperatures between
circuits). One switch may be field-set to activate at
1000°F (538°C) and 1500°F (816°C), specify 8"
high fire position, while the other is set to activate at
long, #RA 330 SS sleeve.
low fire position.
Oven Wall Adapter Plate provides a means

of mounting an OVENPAK®-II Burner in place of an
older style Model “400” OVENPAK® Burner.
Optional high and low fire position switch set shown on Oven wall adapter plate dimensions (in inches)
OVENPAK®-II Burner assembly
Discharge sleeve
6" 8" 10" 12"
diameter
Air Butterfly Position Switch Set provides one A 3.62 4.44 5.62 6.69
switch (2 SPST circuits) to monitor physical move-
B 5.12 6.12 6.69 8.25
ment and/or position of OVENPAK®-II Burner’s air
C 10.25 12.25 13.38 16.50
butterfly control valve.
D 7.28 9.34 11.25 13.25
E 8.75 10.50 12.31 14.75
3/95
OVENPAK®-II Burner Configurations

Maxon OVENPAK®-II Burner provides additional application flexibility with multiple
component arrangements. The standard configuration illustrated in the center of this
page may easily be switched to any of these other configurations to accomodate field-
site space requirements.
Standard Configuration
(as shipped from factory)
Figure 1 Figure 2
Blower scroll case to Combustion air filter
LEFT with control motor housing to LEFT with
on RIGHT control motor on RIGHT
Figure 3 Figure 4
Blower scroll case to Combustion air filter
RIGHT with control housing to RIGHT with
motor on RIGHT control motor on LEFT
NOTE: Optional switch sets are always on

opposite side from mounted control motor

Model “400” OVENPAK®-II Burners
Model A B C D E F G H J K L M N P
405
1 6.25 10.0 9.38 10.38
408 15.25 7.88 7.25 18.62 19.75 11.75 11.19 8.0 4.00
415 1-1/4 8.31 12.0 9.31 10.31
425 1-1/2
16.25 7.81 7.88 23.3 27.4 17.25 11.44 7.85 10.25 13.31 10.94 6.06 11.94
435
445 14.44 2
26.7 30.0
456 15.38
15.06 6.69 6.81 17.38 7.62 12.25 16.25 15.56 6.44 16.56
470 16.44
28.9 31.2 3
487 17.31
Model R S T U V W X Y Z BB CC DD EE FF
405
8.25 8.75 5.31 3.12
408 8.81 6.81 7.25 5.88 13.06 14.0 8.5 2.81 1.62 3.31
415 7.5 10.5 5.25 3.88
425
8.81 7.81 12.31 7.19 5.31 4.31 7.88 8.31 17.62 23.2 11.31 6.06 4.31
435
445
6.38 13.44 5.5 .75
456
10.56 9.69 14.75 8.88 3.69 6.81 9.88 23.6 25.1 4.69
470
6.94 17.38 4.31
487
NOTE: All OVENPAK®-II Burners use ISO standard (metric) fasteners

7/95

Model “EB” OVENPAK®-II Burner
Model A B C E H J K L M N P R S
EB-1
1 6.25 10.0 9.38 10.38 8.25
EB-2 15.25 7.88 7.25 11.5 8.0 4.06 8.81
EB-3 1-1/4 8.31 12.0 9.31 10.31 7.5
EB-4 1-1/2
16.25 7.81 7.88 15.5 7.85 10.25 13.31 10.94 6.06 11.94 8.81 7.81
EB-5
2
EB-6
15.06 6.69 6.81 16.56 7.62 12.25 16.25 15.56 6.44 16.56 10.56 9.69
EB-7 3
Model T U V W X Y Z EE FF GG HH JJ KK
EB-1
8.75 5.31 3.12
EB-2 6.81 7.25 5.88 13.06 1.62 3.31 6.69 7mm 6.25 4.5
EB-3 10.5 5.25 3.88
EB-4
12.31 7.19 5.31 4.31 7.88 8.31 17.62 4.31 8.50 8.25 6.62
EB-5
.75 12mm
EB-6 6.38
14.75 8.88 3.69 6.81 9.88 23.6 4.69 9.50 10.25 8.62
EB-7 6.94
NOTE: All OVENPAK®-II Burners use ISO standard (metric) fasteners


– Spark Ignitor – Discharge Sleeve
– Flame Rod, if used – Oven Wall Gasket
– Motor – Filter Elements, if used
– Impeller – Mixing Cone
– Gas/Air Valve Linkage Kit
To order parts for an existing OVENPAK®-II Burner assembly, list:
3. OVENPAK®-II Burner nameplate information:
• size of burner
• assembly number and date
• Factory Order number
5/96

Discharge sleeve and cone alignment WARNING: Over-tightening locking bushing
The mixing cone is self-centering within the burner may damage ceramic insulator.
housing and discharge sleeve to provide a small
annular opening for the flow of some cooling
combustion air along the discharge sleeve wall. We
SUGGEST periodic inspection from the discharge
side of the burner to assure that this clearance is
maintained.
Blockage of the annular opening will lessen
burner service life.
Filters should be inspected regularly and
cleaned, using a vacuum to remove loose/dry
accumulations, then washing and/or degreasing as
appropriate for the filter type used.
Table 1: Flame rod and spark ignitor dimensions
To replace flame rod or spark ignitor: for all Model “400” OVENPAK®-II Burners
1. Check Table 1 at right for dimension Y and cut tip
to length shown. Spark Ignitor Flame Rod
2. Insert 1/2" NPT collar into burner and snug into Dimensions Dimensions
Burner Model (in inches) (in inches)
position.
X Y W X Y Z
3. Insert insulator through collar into burner.
4. Check table for dimension X, position accordingly, EB-1 405
2
and tighten locking bushing until insulator is held EB-2 408 5.5 .9 6 3.2
firmly. EB-3 415 1.2
EB-4 425
1.8 6.5 .9 10.8 3.2
EB-5 435 0.4
445
EB-6 456
2.4 8.25 1.0 11.75 ---
EB-7 470
487
OVENPAK®–II Burners Page 2150-S-1
General Instructions Gas supply piping must be large enough to
maintain the required fuel pressures cataloged for the
Important: Do not discard packing material until particular burner size used with burner operating at
all loose items are accounted for. full rated capacity.
To prevent damage in transit, the spark ignitor, Anything more than minimal distance or piping
discharge sleeve, mounting gaskets, flame rod and turns may necessitate oversizing piping runs to keep
connecting linkage components may be packed pressure drops within acceptable ranges.
separately and shipped loose with your new Maxon Inlet pipe leading to any burner should be at least
OVENPAK®-II Burner. four pipe diameters in length. If multiple burners are
The burner itself is normally only a part of your fed from a single gas train, care should be taken to
complete combustion system. Additional pipe train minimize pressure drop and give maximum uniformity.
accessories and control components will be required Clean fuel lines are essential to prevent blockage
for a complete system installation. The sketch below of pipe train components or burner gas ports.
Main Shut-Off Cock should be upstream of both
shows a typical gas train as might be used with
the main gas regulator and pilot line take-off. Use it to
OVENPAK®-II gas fired burners.
Piping Layout as sometimes required by The fuel throttling valve contained within a Maxon
insurance and standards groups burner is not intended for tight shut-off.
Block and Bleed gas train arrangement
Fuel Shut-Off Valves (when properly connected to
OVENPAK®-II Burners provide the air supply hazardous operating condition is sensed. Manual
(except for EB versions, which require a separate reset valves require operator attendance each time
combustion air blower). They also serve as a fuel flow the system is started up (or restarted after a trip-out).
control and fuel/air mixing device. Motorized shut-off valves permit automatic start-
Burner should not be exposed to direct radiant restart when used with an appropriate control system.
heat or positioned where it might draw in inert gases. Test connections are essential for burner adjust-
If such conditions exist, consider filters, relocation ment. They should be provided immediately down-
and/or use of the EB version and external air supply. stream of the regulator and are included in the burner
Electrical service must match the voltage, phase itself. Test connections must be plugged except
and cycle of all electrical system components and be when readings are being taken.
compatible with burner nameplate ratings. Insure that
tion air blower should continue to run after shutdown
to allow burner to cool.

mCORPORATION
Page 2150-S-2 OVENPAK®–II Burners
be mounted in any position suitable for automatic conjunction with a stiffener plate when mounting
control motor and UV scanner (if used). OVENPAK®-II Burner (weighing 100-350 pounds)
OVENPAK®-II Burners will typically be installed through typical thin wall of heater/oven panels.
through an oven wall or insulated air duct. Cut open- For push-through systems, use Maxon oven wall
ing approximately 1" larger in diameter than discharge gasket (E) between stiffener plate and burner body
sleeve to allow for thermal expansion of sleeve. flange. Fill area D (see sketch below) with no more
Burner mounting requires eight studs and a flat than 2" of high temperature packing (too little will
mounting surface perfectly centered on the discharge overheat mounting; too much will overheat sleeve).
sleeve.
After placing burner in position over studs, add lock Typical discharge sleeve mounting
washers and nuts, then draw up hand-tight only.
recommendations Oven
Check that burner is seated evenly all around the Wall
flange, filling any gaps to prevent air leakage, then
E
tighten all nuts firmly. D
For proper performance of any burner, air inlet and A
Burner and pipe manifold support will be required
to support weight of the burner and connected pipe Burner Discharge B C
Sleeve
train components. Air control motors, in particular,
require additional support. Maxon connecting base and
linkage assemblies are designed to position the control
D
motors to work with the burner, not to support their A
A Perimeter weld thimble
weight. end to inner panel OR Oven Inner panel
use flashing "A" Wall surface
Typically
B Discharge sleeve diameter
Suggested supporting arrangements for (in inches)
4-6"
OVENPAK®-II Burners C Discharge sleeve diameter Typically

plus 1" (min.) 8"
Note: It is important that no insulation or flashing come in

Oven contact with the discharge sleeve beyond "D."
Wall

OVENPAK®-II WARNING: Welding of burner flange to stiffener

Burner plate may cause warpage of burner flange and
leakage.
Leg Support
Knee
Bracket
Four lock screws permit centering of mixing cone
Support within burner body and sleeve.
m CORPORATION

Discharge sleeve and cone alignment Flame sensing can be accomplished by either
Cone self centering is achieved by using fixed flame rod or UV scanner. When UV scanner is used,
length cone screws. This eliminates the need to it should be kept as close to burner as feasible. Heat
adjust for cone alignment. Cone screws should be block, if used, may affect signal strength with some
tight against the housing to ensure proper cone brands of scanners.
spacing and cone security. Field conversion from a flame rod version to a UV
scanner version and vice versa is possible without
CAUTION: Loose cone screws can cause the any additional burner parts.
following: cone overheating, spark electrode Alternate fuels may require correction of supply
damage, cone ejection. pressures.
The mixing cone is centered in the burner housing Maxon assumes no responsibility for the use or
and discharge sleeve to provide a small annular misuse of the layouts shown. Specific piping
opening for the flow of cooling air along the discharge and wiring diagrams should always be submit-
sleeve wall. We SUGGEST periodic inspection of ted to the appropriate agencies for approval on
cone screws for tightness in the housing and from the each application.
discharge side of the burner to insure that annular
opening is maintained.
Multi-burner installations require special consid-
Blockage of the annular opening will lessen erations if supplied by a common pipe train and/or air
burner service life. supply. Air and Gas Balancing Valves should be
used for improved heating uniformity; Gas Swing-
Discharge sleeve must be flush with, or extend
Check Valves should be installed as close as pos-
beyond, interior wall. Maxon can supply a special 12"
sible to each burner inlet for dependable lightoff (gas
long discharge sleeve, but higher noise levels may
manifold may otherwise act as a reservoir, preventing
result, particularly when firing on propane.
lightoff during trial-for-ignition period).
An external viewing port should be provided for
Control system’s circuitry must not allow main
flame observation, preferably in such a position that
Fuel Shut-Off Valve to be opened unless combustion
burner pilot and main flame can both be seen.
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.

mCORPORATION
Installation of control motor mounting bracket
Model 425, 435, 445, 487, EB-4, EB-5, EB-6 and Both holes are located on the same side as the
EB-7 OVENPAK®-II Burners require the control motor operating shaft elliptical hole. Refer to Figure 2
mounting bracket to be installed as follows, based on below.
the type of control motor being used. 2. Mount the control motor bracket with two M6X20
To mount the bracket, follow the procedure outlined hex head screws so the chosen holes align with
below. the bolt flanges located above the operating shaft.
3. Attach the stand off spacers between the control
1. Determine which holes to use: motor bracket and the burner with two M6X80 hex
– All Barber Coleman control motors use the head bolts. Mount the bolts through the narrow
holes stamped with the number 2. slots located below holes 2 and 3. Refer to Figures
– All Honeywell Modutrol control motors use the 1 and 2.
holes stamped with the number 3.
mCORPORATION

Read complete instructions before proceeding, For Model EB-MRV Burners, the connecting
and familiarize yourself with all the system's equip- linkage on the separate control valve must be
ment components. Verify that your equipment has similarly loosened and disconnected. Refer to
been installed in accordance with the original manu- specific adjusting procedures relating to control
facturer's current instructions. valve adjustment in Maxon catalog.
Initial start-up adjustment should only be
CAUTION: Initial adjustment and light-off accomplished during a manual burner control
should be undertaken only by trained and mode.
experienced personnel familiar with combus- 5. Start all system-related fans and blowers.
tion systems, with control/safety circuitry, and Check for proper motor rotation and impeller
with knowledge of the overall installation. direction. Verify that all control interlocks are
Instructions provided by the company and/or working. Allow air handling equipment to run for
individuals responsible for the manufacture adequate purge of your manifolds and combus-
and/or overall installation of complete system tion chamber plenums. With main gas shut off,
incorporating Maxon burners take precedence manually advance burner to high fire position so
over these provided by Maxon. If Maxon that air only flows through burner and combustion
instructions conflict with any codes or regula- chamber.
tions, contact Maxon Corporation before
attempting start-up. CAUTION: Do not by-pass control panel timers
For EB OVENPAK®-II Burners only (step 6)

®
For initial OVENPAK -II Burner start-up: 6. Verify differential air pressure. With combustion
1. Close all burner fuel valves and cocks. Make air blower on, all volume air fans operating, and
preliminary adjustments to fuel gas regulators. burner at high fire position, connect a manometer
Remove pilot and main gas regulator’s adjusting between the air test connection on backplate of
screw covers. Turn adjusting screw down (clock- OVENPAK® -II Burner and your combustion
wise) to approximately mid-position. Close pilot chamber static pressure test connection. This will
gas adjustable orifice screw by turning in clock- give a direct differential air pressure reading.
wise until it stops. (Do not over-tighten.) Then
positions.
coupler from the OVENPAK® -II Burner’s shaft by
loosening the set screw and sliding the coupler
halves apart and removing the rubber coupler.
Make sure that the coupler fingers will rotate
without hitting.

mCORPORATION
Determine your differential air pressure reading through your flame safety circuit. This signal
by taking an additional reading with manometer strength can be read with a micro-amp meter. The
connected between the burner's air pressure test signal strength (or range) will be determined by
port and atmosphere with the burner at high fire the specific type of flame safeguard instrument
position, fuel valves closed, and all air handling you have with your burner system.
systems running. Subtract the combustion 12. Re-check pilot ignition by closing pilot gas cock
chamber static pressure obtained above from this or otherwise causing pilot outage. Re-light and
air pressure reading to give you differential air refine pilot gas adjustment as necessary to get
pressure reading. The differential air pressure ignition within a second or two. The flame safe-
setting determines the burner’s capacity and guard relays should now power your main fuel
performance capabilities. Shut-Off Valve(s).
sure using this differential air pressure reading CAUTION: After completing steps above, re-
obtained from step 6. If your combustion chamber check all interlocking safety components and
does not have a static pressure test connection, circuitry to prove that they are properly in-
then you must measure combustion chamber stalled, correctly set, and fully operational. If in
static pressure by connecting a manometer doubt, shut the system down, close pilot cock
between the gas pressure test port on the and contact responsible individual before
burner’s backplate and to atmosphere with the proceeding further.
burner at low fire position, fuel valves closed, and
all air handling systems running. High fire pres-
sures are provided in Maxon product line catalog
literature and/or read data stamped into burner
nameplate.
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 cham-
positioned ignitor.
9. Return burner control valve (or crank) to low
higher for some EB versions). Main flame should
fire position when purge of system is complete.
now appear larger than pilot-only flame.
14. Establish high fire setting by slowly moving
spark ignition to light pilot while slowly turning
burner toward high fire position while observing
pilot gas regulator spring clockwise and/or
gas pressure at burner gas test connection.
adjustable orifice screw counter-clockwise to
Refine main gas regulator adjustment as neces-
increase fuel flow. Repeat procedure as neces-
sary to provide correct differential pressure
sary until pilot ignites as air might have to be bled
(gauge to combustion chamber, see step 7) at
out of fuel supply lines before reliable pilot flame
high fire. If pressure cannot be adjusted low
is established. Pilot gas regulator should normally
enough, a different regulator or regulator spring
be set for as low a pressure as possible, using
may be necessary, or a limiting orifice valve (such
fuller opening of pilot gas adjustable orifice (if
as Maxon's Series “BV”) should be added. Do
used).
not, however, exceed 4" wc pressure drop
11. After ignition, adjust pilot flame for good stable
between regulator outlet and burner inlet.
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
mCORPORATION

18. Check out overall system operation by cycling
CAUTION: If burner(s) go out, close shut-off
through light-off at minimum, interrupting pilot,
valve or shut main gas cock at once. Return to
and allowing temperature control system to cycle
burner from minimum to maximum and return.
Recheck all safety system interlocks for proper
NOTE: Typical gas firing control sequence for Maxon
burner is provided only as a guide. Instructions
provided by complete system manufacturer incorpo-
rating Maxon burners take precedence.
from minimum to maximum and back several For gas firing OVENPAK®-II Burner
times to verify the flame is maintained. Light-off: Shut-down:
15. When burner performance is satisfactory and 1. Close cocks, shut-off valve(s) 1. Close main &
stable throughout the firing range, reconnect 2. Verify burner at low fire pilot gas cocks
control motor. 3. Start recirculating/exhaust fans 2. Keep combustion
With interrupted pilot, it may be necessary to 4. Start burner blower air blower running
set control for somewhat higher than minimum 5. Purge at least 4 air changes after shut-down long
burner setting to permit hold-in of flame detection 6. Open pilot & main gas cocks enough to allow
system without pilot. burner to cool
CAUTION: Internal drive mechanism within the WARNING: Test every UV installation for
control motor may be damaged if linkage is dangerous spark excitation from ignitors and
adjusted so as to cause binding with burner in other possible sources of direct or reflected UV
high or low fire position. radiation. Use only gas-tight scanner
connections.
16. Re-check differential gas pressure with unit at
operating temperature. Refine high fire setting if 19. Before system is placed into full service,
necessary, considering differential pressure, instruct operator personnel on proper start-up
flame length, and appearance. Natural gas flame operation with shut-down of system, establishing
should normally be predominantly clear blue but written instructions for their future reference.
possibly with semi-luminous tips. Dust or contami-
nants in the air stream may affect flame appear-
ance.
dangerous fuel leakage. Replace equipment
cover caps and tighten linkage screws.

mCORPORATION
Notes
m
CORPORATION

Model “400” OVENPAK®-II Burners Page 2150-A/P-1
Assembly Numbers
For these products, please order the following product numbers:
Size Packaged Burner Size EB EB MRV

405 405 OP2 (105) EB1 EB1 OP2 (73) EB1MRV OP2 (72)
470 470 OP2 (270)
487 487 OP2 (283)
Segment choices are as follows for the above configured products:
Segment choices Packaged EB EBMRV

Gas Inlet Flange X X X
Ignitor X X X
Adjustable Orifice X X X
Flame Detection X X X
Fuel X X X
Mixing Cone X X X
Discharge Sleeve X X X
Adapter Plate X X X
Motor X
Motor Position X
CB & L's X X
Switches X X
Filters/Silencers X
CB & L Position X X
Switch Position X X
Air Butterfly Position Switch
X X
Location
Maximum Airstream
X X X
Temperature (°F)
Guide Tube X X X
Customer Number X X X
Approximate net weight (in pounds) shown in parentheses.

Configured choices may cause some deviation in weights shown.

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CORPORATION
Page 2150-A/P-2 Model “400” OVENPAK®-II Burners
Assembly Numbers
Miscellaneous Accessories – Model “400” and EB OVENPAK®-II Burners
These items can be ordered loose with configured products or end product assemblies. They can also be ordered
as replacement items, if necessary.
Balancing and Swing Check Valves (sized for burner inlet pipe size)
Pipe Size (NPT) > 1" 1-1/4" 1-1/2" 2"
Model "400" and EB 415 425 435, 445, 456
405, 408
OVENPAK®-II Burners EB 1, 2, 3 EB 4 EB-5
Balancing Cv Flow Factor 5 42 80 138
Valves Valve Assembly Number 19120 (3) 19121 (4) 19122 (4) 19123 (6)
Miscellaneous Spare Parts

405, 408 415 425, 435 445, 456, 470, 487
Model "400" and EB OVENPAK®-II Burners
EB-1, EB-2 EB-3 EB-4, EB-5 EB-6, EB-7
Pilot Gas Adjustable Orifice 38009 (2) 50431 (3)
Air Inlet Flexible Connector Set 31248 31249 31250
Low Fire or Set Point
"Weatherproof"
Start Switch
NEMA 1,3,3R,4,12, & 13, IP 665 40820 (1) 40821 (1) 41340 (1)
1 switch with (2) SPST
(outdoors, non-hazardous locations)
circuits
High & Low Fire
"Weatherproof"
Position Switch
NEMA 1,3,3R,4,12, & 13 IP665 40822 (4) 40823 (4) 41341 (4)
2 switches each with (2)
SPST circuits
Air Butterfly Position
"Weatherproof"
Switch Set
NEMA 1,3,3R,4,12, & 13 IP665 40803 40804 40805
1 switch with (2) SPST
circuits
Discharge Diameter (in inches) 6" 8" 10" 12"
8" long sleeve (#310SS) 53925 53926 53927 53928
12" long sleeve (#310SS) 40773 40777 40779 40781
Discharge Sleeve and 8" long sleeve (RA330) 40774 40776 40778 40780
Mounting Gasket 12" long sleeve (RA330) 47513 47514 47515 47516
Options 8" Refractory Lined Sleeve Assembly 1050806 1050808 1050809 1050810
Oven Wall Gasket (Ref. lined) 1050556 1050557 1050558 1050559
Oven Wall Gasket (SS) 54502 54503 54506 54507
Oven Wall Adapter Plate 54468 54469 54470 54471
Replacement Rubber Cover
Miscellaneous
for flame rod/spark ignitor 18722 (0.5)
Accessories
m
CORPORATION

Model “400” OVENPAK®-II Burners Page 2150-A/P-3
Assembly Numbers
Gas Nozzles
Model "400" and EB 405 408 415 425 435 456 487
445 470
OVENPAK® -II Burners EB-1 EB-2 EB-3 EB-4 EB-5 EB-6 EB-7
Natural gas nozzle 54038 54039 54040 40849 40850 40944 40840 41430 41429
Propane/butane nozzle 54041 54042 54043 40851 40852 40839 41428 41437 41438
Coated natural gas
47319 47320 47321 47322 47323 47324 47325 47326 47327
nozzle
Coated propane/butane
47328 47329 47330 47331 47332 47333 47334 47335 47336
nozzle
Spark Electrode and Flame Rod Assemblies

405, 408 415 425, 435 445, 456, 470, 487
Model "400" and EB OVENPAK®-II Burners
EB-1, EB-2 EB-3 EB-4, EB-5 EB-6, EB-7
Spark Electrode 47232 34042 39782
Flame Rod Assembly (includes rubber cover) 1059939
43078 43079
Cut rod length extending beyond porcelain to 1062022 (EB only)
length = 6" length = 10.8"
dimension given at right for appropriate burner size length = 18.75"
Internal Linkage Repair Kits

Model "400" and EB 405, 408, 415 425, 435 445, 456, 470, 487
OVENPAK®-II Burners EB-1, EB-2, EB-3 EB-4, EB-5 EB-6, EB-7
Linkage Repair Kit 40824 (3) 40825 (4) 40836 (4)
Combustion Air Filters and Silencers

Model "400" OVENPAK®-II Burner 405, 408, 415 425, 435 445, 456 470, 487
Standard Air Filter Assembly
40826 (12) 40827 (12) 40828 (27) 41507
includes (1) replaceable element
Filter/Silencer Assembly includes filter
40832 40833 40834 41508
assembly with (1) replaceable element
Standard Air Filter Assembly
47520 47521 47522 47523
includes (1) permanent element
Filter/Silencer Assembly includes filter
47524 47525 47526 47527
assembly with (1) permanent element
Replaceable filter element for above 40933 40934 40935
Permanent Filter Element 40829 (2) 40830 (4) 40831 (6)

mCORPORATION
Page 2150-A/P-4 Model “400” OVENPAK®-II Burners
Assembly Numbers
Connecting Base & Linkage Assemblies

This listing shows only a sampling of the more popular control motors. We may be able to furnish Connecting
Base & Linkage Assemblies for other operators not cataloged (supply manufacturer’s name and model number).
Maxon Connecting Base & Linkage Assembly Number

Type Manufacturer Model Number Models 405 – 415, Models 425 – 435, Models 445 – 487,
EB-1 to EB-3 EB-4 & EB-5 EB-6 & EB-7
A 01-9/861M
I Honeywell 01-11/861P 41435 41436 40791
R 03-8/863T
EA51-58
Barber-Colman also with prefix 40785 40786 40792
MC, MP, or MF
E M6181, M6184, M6191,
L M6194, M6281, M6284,
E M6294,M7184, M7281,
C M7284, M7384, M7385, 1051009 1051010 1051011
T Honeywell M7984, M9181, M9184,
R M9191, M9194, M9481,
I M9484, M9491, M9494
C M640A
40789 40790 41331
M940A
M80
Penn/Johnson 40787 40788 40793
M81
Customer Installed CB&L 45627 (crank arm) & 40711 (spring pin)
m
CORPORATION

Bulletin 2200
Maxon Series “67” TUBE-O-FLAME® Gas Burners
Illustration of Series “67”

TUBE-O-FLAME® Burner and flame
pattern in typical solution heating application
(burner shown with optional automatic control
motor and pilot adjustable orifice)
• Nozzle-mixing, refractory-less burners for tube firing

• Burns any clean, low pressure fuel gas
• Increases heat transfer efficiencies with long, swirling flame pattern
• Promotes faster bring-up times with 20:1 turndown capabilities
• Easy installation due to flange-mounted compact design
• Simple start-up and field adjustments
• Low horsepower requirements reduce initial and operating costs
• Produces low levels of NOx in combustion products
• Generates less noise than open-port tube firing
Series “67” TUBE-O-FLAME® Burner applications have included:

Indirect air heating on bake ovens, and solution heating; such as spray washers, cleaning,
pickling or quench tanks, dye becks, salt baths, snow melting pits, rendering vats, and
asphalt kettles
Page 2202
Maxon Series “67” TUBE-O-FLAME® Gas Burners

• Over 36 different styles
• Sizes for 6" through 14" diameter tubes
• Optional 2-position (Hi/Lo) electric control

motor
Series “67” LB TUBE-O-FLAME® Burner • Cost effective external blower (LB) version
showing version less blower for those
applications requiring multiple burner zones
from common combustion air source
Typical TUBE-O-FLAME® Burner System Arrangement
11/90
Series “67” TUBE-O-FLAME® Gas Burners Page 2203

Maxon TUBE-O-FLAME® Burners are nozzle- Series “67”
mixing, gas-fired, refractory-less burners specifically 8" TUBE-O-FLAME®
designed for firing into an immersion tube. Typical Gas Burner
with optional
applications have included various industrial solution
hi/lo Maxon
heating jobs such as dip tanks, spray washers, control motor set
pickling or quench tanks, dye becks, salt baths,
asphalt kettles, indirect air heaters and bakery ovens.
Standard Series “67” TUBE-O-FLAME® Burner
package (shown at right) includes a combustion air
blower with a non-sparking aluminum paddle-wheel-
type impeller. A pilot and spark ignitor is included in
the cast iron burner body, as well as the ductile iron
mixing disc, internally-connected air and gas control
valves, gas nozzle and provisions for your flame
safeguard sensor.
Principle of operation (illustrated below)
Model LB (less blower) Series “67” TUBE-O-

FLAME® Burners (shown below), like all TUBE-O-
FLAME® Burner assemblies, are designed to deliver
heat efficiently into your immersion tube.
Flanged burner body design on all Series “67”
TUBE-O-FLAME® assemblies simplifies mounting and
installation on your application. Most manufacturers’
control motors require operating shaft in horizontal
plane.
Minimal torque requirements permit use of
virtually any electric or air operator. Maxon can supply
connecting base and linkage assemblies for mounting
most temperature control operators.
Series “67” 8" LB

TUBE-O-FLAME®
Burner with optional
The TUBE-O-FLAME® Burner is available in two Maxon hi/lo control
basic versions: 1) packaged with integral low horse- motor set and burner
power combustion air blower, or 2) LB (less blower) mounting ring
for use with an external combustion blower source.
Both versions incorporate a gas and air valve linked
throttling range of the burner. Gas flows out through
the gas nozzle where it mixes with the swirled com-
bustion air coming through the mixing disc. This
results in a long, swirling flame that spins down the
firing tube, scrubbing the internal tube walls and
promoting higher heat transfer efficiencies.
2/96
Page 2204 Series “67” TUBE-O-FLAME® Gas Burners

Any clean commercial fuel gas can be used, with
adjustment provided by simply setting inlet gas
pressure to the Series “67” TUBE-O-FLAME® Burner.
The burner can be mounted either straight, through
the tank wall, or angled downward. If more than one
pipe diameter of tube length is not solution-backed,
overheating and deterioration of tube may occur.
NOTICE: Burner performance can be drastically
affected by tube configuration.
Tube design should consist of Schedule #40 pipe
or lighter in the same size as burner. It is suggested
that the first straight pass of tube consist of at least 10 Exhaust considerations
pipe diameters in length and not end in a single-mitre
Immersion tubes are usually vented to the out-
elbow turn. Burner capacity may be reduced if tube
doors, except for those in highly ventilated areas such
layout has multiple single-mitre turns. Firing tube
as a plating room with continuous high-volume
length and resulting wetted tube surface area deter-
exhaust. An exhaust fan may be required if the
mines combustion transfer efficiency.
building is under negative pressure. Exhaust is
normally diluted to avoid the need for high-tempera-
Tube length and configuration ture fans, but adequate make-up air must be avail-
able.
This diluting can be done with an open tee installed
in a vertical run (or in a horizontal run with the open
end down), but such a system mixes slowly.
An adjustable hood (shown in sketch below) offers
much better performance. In all cases, care must be
taken that all products of combustion are exhausted
from the building.
An exhaust stack damper must be used, suit-
able for 1000°F, and designed to prevent full
stack closure.
Many factors affect overall system efficiency. Tube

length is the most important. The graph above shows
approximate tube length required to attain a given
efficiency. Typical installations run in the 70% – 75%
range. Space considerations (including tube displace-
ment) may limit possible tube lengths and so reduce
efficiency. Above 85% efficiency, there is a risk of
condensation-caused tube damage.

Series “67” TUBE-O-FLAME® Burners are offered “Packaged” TUBE-O-FLAME® Burner internal
both in a standard version (including a combustion air components include Rulon bearings which have a
blower in your choice of the voltages listed below) and maximum temperature limit of +500°F (260°C) and a
in an “LB” version to use with a separate combustion Plexiglass observation glass with a temperature limit
air supply. of +175°F (80°C).
“LB” TUBE-O-FLAME® Burners (less blower)
TUBE-O-FLAME® 6-08 10-30 versions do not have motor temperature limits. They
10-25 14-50
Burner model 8-15 12-38 can be equipped with a “high temperature kit” to
Horsepower 1/3 HP 3/4 HP 1-1/2 HP 2 HP replace observation glass and flange gasket to raise
115/208-230/1/60 X X N/A N/A maximum combustion air temperature limit to +500°F
208-230/460/3/60 X X X X
(260°C).
575/3/60 X X X X Multiple burner arrangement
190-200/3/50* X X X X A universal joint assembly permits cross-linking
380-415/3/50* X X X X of two Series “67” TUBE-O-FLAME® Burners for
500/3/50* X X X X control by a single operator. Additional universal joint
* 50 her tz motor option at net extra charge
assemblies may be used to link as many as five
burners to a single control motor. Each assembly
Typical Basic Burner System Arrangement includes a 7/16" x 22" aluminum rod and two (2)
miniature universal joints. Precise burner alignment is
unnecessary, and rod may be cut in field as required.
No more than two burners can be controlled to each
side of “Primary” burner. Ten inch-pounds of torque is
required for each burner driven.
Distance between burner center lines should not
exceed 30", nor be less than 13.5" for 6" or 8" burner,
15.5" for 10" or 12" burner, or 22.5" for 14" burner.
Take steps to insure equal gas pressure at each
burner, then install individual ignition systems.
To order this accessory, specify:

1. Desired automatic burner
Temperature limitations 2. Desired manual (secondary) burners
Motor manufacturers recommend maximum 3. Required universal joint assemblies
ambient temperature of +140°F (+40°C). Temperature NOTE: Multiple burner installations fed by a single
limits can vary with the type of motor and insulation pipe train should incorporate a “balancing valve” and
used. Such special motors are available at net extra a “swing check valve” installed as close as possible to
charge and with extended deliveries. each burner gas inlet for improved heating uniformity
Control motor manufacturers normally establish a and more dependable light-off. Otherwise, gas
maximum ambient temperature for their operators at manifold may act as a reservoir, preventing reliable
+125°F (52°C). light-off during trial-for-ignition period of your control
panel sequence.
12/89

Automatic control Regardless of the type of automatic control (high-
low or modulating), Series “67” TUBE-O-FLAME®
Burners should be at or very near the Low firing
position for pilot ignition and main flame light-off.
The built-in air and gas flow control valves are
mechanically linked together. At Low, the air valve is
cracked open but the gas valve is practically closed.
If some higher firing rate is selected for low fire on
High-Low installations, both valves will be opened
wider. The increased combustion air will necessitate
more gas for pilot ignition. If carried too far, this
increase can cause the main flame to be too rich.
Two-position control, then, results in what essen-
tially is on-off control, down to just a little more than
pilot. Burners can be ordered with Maxon-supplied
Automatic burner with Maxon hi/lo control motor
Hi/Lo Control Motor or with a Connecting Base &
(available for 120/60 or 240/60 AC)
Linkage assembly to accept most operators.
With either Hi/Lo or modulating control, high-fire
can be set at any desired point within burner range.
Optional Low-Fire Start Switch includes cam
actuator on burner operating shaft to make contact at
or near low fire position. Properly wired in series with
pilot gas valve, switch can assure low-fire light-off. If
used on multiple burner installation with universal joint
Typical Low-Fire Start
arrangements, switch must mount on farthest left
wiring
burner.
Field installation of these switches on equipment
not originally furnished with them may require minor
drilling modifications as outlined in Product Informa-
tion Sheet 2000-7/8, shipped with the 'loose' switch
assembly.

Standard 6-08 8-15 10-25 10-30 12-38 14-50
TUBE-O-FLAME® Burner Model
Less blower 6-LB 8-LB 10-LB --- 12-LB 14-LB
Capacities Maximum 800 1500 2500 3000 3800 5000

(1000's Btu/hr) Pilot & minimum 55 80 145 180 195 300
Natural gas pressure required At gas inlet 3.2" wc 6.3" wc 3.9" wc 6.5" wc 10.5" wc 14.0" wc
(at maximum flow condition) At burner gas test connection 2.0" wc 2.0" wc 2.0" wc [2] 3.1" wc 4.9" wc 4.3" wc
Propane gas pressure required At gas inlet 1.3" wc 2.5" wc 3.1" wc 4.1" wc 7.5" wc 5.6" wc
(at maximum flow condition) At burner gas test connection 0.8" wc 0.8" wc 2.3" wc [1] 3.35" wc [1] 5.3" wc [1] 1.7" wc
Required air pressure at burner air inlet connection 3.0" wc 2.0" wc 3.0" wc 5.1" wc 5.0" wc 5.0" wc
Maximum combustion air volume required (SCFM) 140 260 435 522 660 870
Tube length (in feet, sized for 30% flue loss) 30 ft. of 6" 40 ft. of 8" 50 ft. of 10" 55 ft. of 10" 60 ft. of 12" 70 ft. of 14"
and diameter (Schedule #40 or lighter) diameter diameter diameter diameter diameter diameter
Complete burner totally enclosed 1/3 HP 1/3 HP 3/4 HP 1-1/2 HP 1-1/2 HP 2 HP
motor horsepower and frame number FR# 48 FR# 48 FR# 56 FR# 143T FR# 143T FR# 145T
Complete burner sound levels Burner only 81 81 84 88 88 92

dB(A) Burner with silencer 74 74 76 80 80 84
[1] With propane nozzle only
[2] With standard nozzle; higher if propane nozzle is used
NOTE: For operation on 50 Hz power, reduce capacities to 83% of those shown,

pressures to 70%.
10/95

60 Hz capacity and specification information for Main gas train including regulator should be sized
both standard burners (including blower) and LB to give no more than 2" wc pressure drop, less if firing
burners (requiring separate air supply) are given in propane with 6" and 8" burner sizes.
the table on page 2207. Measured sound levels and Pilot piping and regulator should be sized
motor information provided apply only to standard carefully for the full pilot and minimum capacity shown
burners. and selected to insure 2-4" wc pressure is supplied to
For operation on 50 Hz power, reduce capacities pilot inlet connection after any piping losses (7-16" wc
to 83% of those shown, pressures to 70%. depending on size, if optional adjustable orifice cock
is used).
CAUTION: Burner performance can be drasti-
Self-piloting feature of burner allows pilot gas to
cally affected by tube configuration.
by-pass internal gas control valve and issue from
Air pressure readings at test connection reflect main gas nozzle ports. We suggest use of continuous
those that may be expected prior to light-off and may pilot arrangement. If interrupted pilot is used, adjust
vary as a result of tube and exhaust configurations. burner to prevent reaching full minimum position.
Inlet air pressures and flows must not exceed Minimum capacity will be increased.
those given in the table. DO NOT OVERSIZE blowers Low-fire start: Main flame light-off is possible at
feeding LB Burners. If a blast gate or similar device is higher capacities, but larger pilots will be required and
used to limit air pressure at an LB burner, air pressure turndown will be sacrificed.
at the burner will rise as firing rate is reduced until the
blower's rated pressure is reached. This will result in
increased pilot and minimum capacities, as well as
increased excess air at lower firing rates.

Series “67” TUBE-O-FLAME® Burner (automatic version)
Model A B C D* E H P R T CC DD EE FF GG HH JJ KK
6-08 3.75 1 6 8.62 8.44 6.62
5.44 17.44 7.75 8.81 11.37 14 16.5 17.5 14.5 17.06
8-15 4.75 1-1/4 7 8.56 10.37 7.69 3.5
10-25 1-1/2 12.12 14.44 19 20.25 19.75
10-30 5.75 8 9.69 12.5 18.87 8.62 18 21
6.06 8.75 15.25 15.87 2.5 20 23.5 30.37
12-38 2
14-50 6.81 9 14 14.62 23.62 9.69 17.75 17.69 19 5 23 26.4 26 29.62
*Use of auxiliar y switches will add up to 1" to dimension D
4/95

“LB”–67 TUBE-O-FLAME® Burner (automatic version)
Model A B C D* E G H J T U V W X Y AA BB
6-LB 3.75 1 6 8.62 8.44 6.62 5.19
5.44 13 4.37 7.25 8.31 6.37 0.44 5.44 3
8-LB 4.75 1-1/4 7 8.56 10.37 7.69 5.12
10-LB 1-1/2 9 10.69 5.62 4
5.75 8 9.69 14.5 12.5 8.62 8.87 7.75
12-LB 2 6.06 5.44 10.37 11.75 0.56 5.06 6
14-LB 6.81 2 9 14 9 14.62 9.69 9.62 11.12 11.75 10.25 8.19 8
*Use of auxiliary switches will add up to 1" to dimension D
Accessory Dimensions (in inches)

Filter with silencer for “67” TUBE-O-FLAME® Burner
Model JJ LL MM NN PP RR SS TT UU
6-08
14.37 12.44 19.31 10.44 22.91 23.16 29.88 33.56
8-15 16
10-25 14.38 14.56 21.44 8.32 23.62 25.86 32.7 36.26
10-30
23.56 18.06 22 24.94 10.82 29.62 31.88 38.7 42.28
12-38
14-50 25.94 20.25 24 29.25 12.75 35.25 33.88 42.9 47.9
11/95

TUBE-O-FLAME® Burner Mounting Ring Flame Rod
Burner Model
"L"
Standard LB
6-08 6-LB 2"
8-15 8-LB 3"
10-25 10-LB 4"
10-30 --- 7"
12-38 12-LB 7"
14-50 14-LB 4"
Burner Model WW XX YY A
6-08 6-LB 8.5 6.13 3.75
Spark Ignitor
8-15 8-LB 10.38 8.13 4.75
10-25 10-LB 3/8
12.5
10-30 --- 10.14 5.75
12-38 12-LB 14.62
14-50 14-LB 18 12.13 7/16 6.81
Burner Size "L"
6" with flame rod 2.5"
6" with UV scanner 3.5"
8" through 14" 3.5"
Suggested spare parts TUBE-O-FLAME® Burner nameplate

– Spark Ignitor – Motor
– Flame Rod, if used – Impeller
– Filter Elements, if used – Gas/Air Valve Linkage Kit
To order parts for an existing TUBE-O-FLAME® Burner assembly,
specify:
3. Series “67” TUBE-O-FLAME® Burner nameplate data:
• size and/or model number of burner
• assembly number of burner
• if available, serial number of Maxon shut-off valve controlling fuel to
TUBE-O-FLAME® Burner (This serial number is on Maxon valve's
nameplate)
12/89

In normal operation, little more is required than Flame rod
periodic checking to see that control motor linkage
has not slipped from adjustment and that burner
remains tightly mounted to the firing tube.
Burner should be shielded from splashing and
physical abuse.
Inspect impeller for proper rotation, speed, and dirt
build-up which might reduce air flow. If your system Burner Model
includes an air filter, schedule maintenance as "L"
Standard LB
required for your plant environment.
Combustion air filters 6-08 6-LB 2"
Always keep air filters clean for optimum system 8-15 8-LB 3"
performance. 10-25 10-LB 4"
Vacuum as needed to remove any dry accumula-
tions. To remove oil and dirt, wash elements in hot 10-30 --- 7"
water and detergent as necessary. 12-38 12-LB 7"

Replaceable elements can be wrung gently and 14-50 14-LB 4"
allowed to air dry before returning to service. Perma-
nent elements should generally be blown dry after
rinsing, and if desired, a light coating of suitable oil
applied.
Spark ignitor
To avoid interruption to service, you may wish to
order a spare element “set”.
Flame rods and spark ignitors are critical to
safety and reliability of operation and start-ups. Be
sure flame rod is properly sized and installed to fit
your specific burner model. (Refer to dimension “L” at
right.) Burner Size "L"
Similarly, the spark ignitor must be the right length 6" with flame rod 2.5"
(dimension “L”) for reliable ignition. 6" with UV scanner 3.5"
Burner mounting position is limited only by those
8" through 14" 3.5"
restrictions imposed by UV scanner or control motor
manufacturers.
WARNING: Test every UV flame sensing instal-

lation for dangerous spark excitation from
ignitors, other burners and other possible
Field Service Tips

If performance of a Series “67” TUBE-O-FLAME® – Determine differential air pressure at burner
Burner has changed, review the following list. backplate air test port.
1. Shut system down, close main and pilot cocks.
Symptoms: 2. Connect manometer between burner air test port
and to atmosphere.
“Tube or exhaust stack is sooty or smoky”
3. Restart exhaust fans and burner blower with fuel
“Burner produces rumbling or chugging noise”
gas cocks closed and burner at "high-fire"
“Reduced capacity – not enough heat”
position. Record air test port reading.
Corrective Actions: Burner Model 6-08 8-15 10-25
10-30
14-50
12-38
– Isolate burner fuel supply and confirm actual
capacity being consumed. Air pressure ("wc) 3.0 2.0 3.0 5.0 5.0
– Check burner blower motor rotation.
– Check control motor linkage to insure burner 4. Chart above shows normal “balanced tube” static
crank is going to full “high-fire” position. condition readings.
– Check gas pressure regulator for proper func- 5. If your reading exceeds the “normal” readings,
tioning. Insure gas pressure and volume to burner you have a “back pressure” in your tube.
inlet matches burner nameplate data. 6. If your readings are “lower” than the normal
– Check immersion tube for leaks, blockages, or balanced readings, you have an “exhaust suc-
insulating layers of dirt inside or on outside of tube. tion” on the tube.
NOTICE: Burner performance can be drastically 7. Adjust exhaust fan and/or stack damper to create
affected by tube configuration and static burner air pressure test port readings as close as
conditions within tube created by exhaust fans possible to those shown for “normal” balanced
and dampers in exhaust stack. conditions to maximize system's thermal transfer
efficiency.
– Determine static condition of tube (draft or
suction).
Excessive suction can cause chugging and
implies hot combustion products are being drawn
out of tube too fast, reducing thermal transfer
efficiency. High tube suction also may affect differ-
ential gas pressure settings. Too high of a suction
may lower inlet gas pressures so that low gas
pressure switches cannot be adjusted.
Excessive back pressure can cause smoke and
may restrict firing capacity of burner.
12/89
Notes
Series “67” TUBE-O-FLAME® Gas Burners Page 2200-S-1
General Instructions Gas supply piping must be large enough to
Important: Do not discard packing material until particular burner size used with burner operating at
all loose items are accounted for. full rated capacity.
To prevent damage in transit, the spark ignitor, Anything more than minimal distance or piping
mounting ring, flame rod and connecting linkage turns may necessitate oversizing piping runs to keep
components may be packed separately and shipped pressure drops within acceptable ranges.
loose with your new Maxon TUBE-O-FLAME® Burner. Inlet pipe leading to any burner should be at least
The burner itself is normally only a part of your four pipe diameters in length. If multiple burners are
complete combustion system. Additional pipe train fed from a single gas train, care should be taken to
accessories and control components will be required minimize pressure drop and give maximum uniformity.
for a complete system installation. The sketch below Clean fuel lines are essential to prevent blockage
shows a typical gas train as might be used with a of pipe train components or burner gas ports.
Series “67” TUBE-O-FLAME® gas fired burner.
Piping Layout as sometimes required by shut off fuel to both pilot and main burner during shut-
insurance and standards groups
Block and Bleed gas train arrangement illustrated Main gas regulator is essential to maintain a
with Series “67” TUBE-O-FLAME® Burner uniform system supply pressure. If one pipe train
The 3/8" pilot connection of the Series “67” TUBE-
O-FLAME® Burner is adequate for the pilot gas flows
shown, but care must be taken to assure that the
required gas pressure is available at pilot inlet. To
avoid excessive drop through solenoid and upstream
TUBE-O-FLAME® Burner provides the air supply valves and cocks, follow these guidelines:
(unless it is an LB version, which requires a separate
combustion air blower). It also serves as a fuel flow Suggested Pilot Natural Gas Flow
control and fuel/air mixing device. Burner Model
Pipe Size (cfh)
Burner should not be exposed to direct radiant 6-08 3/8" 55
heat or positioned where it might draw in inert gases.
8-15 3/8" 80
If such conditions exist, consider filters, relocation,
10-25 1/2" 145
and/or use of the LB version and external air supply.
Electrical service must match the voltage, phase, 10-30 1/2" 180
and cycle of all electrical system components and be 12-38 1/2" 195
compatible with burner nameplate ratings. Insure that 14-50 3/4" 300
m
CORPORATION
Page 2200-S-2 Series “67” TUBE-O-FLAME® Gas Burners
Fuel Shut-Off Valves (when properly connected to Suggested supporting arrangements
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 start or
restart when used with an appropriate control system.
Test connections are essential for burner adjust-
ment. They should be provided immediately down-
stream of the regulator and are included in the burner
itself. Test connections must be plugged except
when readings are being taken.
Exhaust stack dampers are necessary to the
proper operation of an immersion tube burner system.
They should be lockable, suitable for 1000ºF and
designed to prevent full stack closure.
Horizontal mounting is preferred. Most manufac-
turers’ control motors require operating shaft in a
horizontal plane.
Burner mounting requires four studs and a flat Exhaust Considerations
mounting surface perfectly centered on the firing tube. Immersion tubes are usually vented to the outdoors,
Burner can be mounted directly on tank wall using except for those in highly ventilated areas such as a
four welded studs, but the more common practice plating room with continuous high volume exhaust. An
utilizes an optional mounting ring (complete with exhaust fan may be required if the building is under
studs) welded to tank wall, end of tube, or other negative pressure. Exhaust is normally diluted to avoid
mounting surface. If the application calls for position- the need for high temperature fans, but adequate make-
ing the burner in other than its normal upright position, up air must be available.
be sure to align studs appropriately. This diluting can be done with an open tee installed
After placing burner in position over studs, add lock in a vertical run (or in a horizontal run with the open
washers and nuts, then draw up all four hand-tight end down), but such a system mixes slowly.
only. Check that burner is seated evenly around the An adjustable hood (shown in sketch below) offers
flange, filling any gaps to prevent air leakage, then much better performance. In all cases, care must be
tighten all nuts firmly. taken that all products of combustion are exhausted
For proper performance of any burner, air inlet and from the building.
motor should be surrounded by clean, fresh, cool air. An exhaust stack damper must be used, suit-
Burner and pipe manifold support may be able for 1000°F, and designed to prevent full
required to support weight of the burner and con- stack closure.
nected pipe train components. Air control motors, in
particular, require additional support. Maxon connect-
ing base and linkage assemblies are designed to
position the control motors to work with the burner,
not to support their weight.
The Series “67” TUBE-O-FLAME® Burner may
require external auxiliary support provided by the
user. The support configuration may be similar to the
leg support or knee bracket support illustrated.
Additional burner support may be required in
conjunction with a stiffener plate when mounting
TUBE-O-FLAME® Burner (weighing 100-350 pounds)
onto tube or thin tank walls.
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Series “67” TUBE-O-FLAME® Gas Burners Page 2200-S-3
Protective covers for burner should be added in Field conversion from a flame rod version to a UV
the field if exposure to dripping condensate, splashing scanner version and vice versa may require additional
flux, exhaust steam, etc. is unavoidable. parts in the burner. Contact Maxon for requirements.
Sketches below illustrate some possible arrange- Alternate fuels may require correction of supply
ments. Any cover used should be removable to pressures.
provide access to burner and should not interfere with If TUBE-O-FLAME® Burner is equipped with
control linkage motion or observation port viewing. Maxon Hi/Lo Control Motor, low-fire start wiring can
be accomplished as shown in the sketch below.

each application.
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 pos-
sible to each burner inlet for dependable lightoff (gas
lightoff during trial-for-ignition period).
WARNING: Welding of burner flange to a Control system's circuitry must not allow main
stiffener plate or firing tube may cause warpage Fuel Shut-Off Valve to be opened unless combustion
of burner flange and require additional seal air is on, and must de-energize valve upon loss of
material to prevent leakage. combustion air pressure, along with the other usual
Flame sensing can be accomplished by either
flame rod or UV scanner. When UV scanner is used,
switch is used.
it should be kept as close to burner as feasible. Do
not use cooling air to scanner port: sighting is
through gas cavity. Heat block, if used, may affect
signal strength with some brands of scanners.

mCORPORATION
Read complete instructions before proceeding, Initial start-up adjustment should only be
and familiarize yourself with all the system's equip- accomplished during a “manual” burner
ment components. Verify that your equipment has control mode.
been installed in accordance with the original manu- 5. Start all system-related fans and blowers.
facturer's current instructions. Check for proper motor rotation and impeller
direction. Verify that all control interlocks are
CAUTION: Initial adjustment and light-off working. Allow air handling equipment to run for
should be undertaken only by trained and adequate purge of your manifolds and immersion
experienced personnel familiar with combus- tubes. With main gas shut off, manually advance
tion systems, with control/safety circuitry, and TUBE-O-FLAME® Burner's operating crank to
with knowledge of the overall installation. “high fire” position so that air only flows through
Instructions provided by the company and/or burner and firing tube.
individuals responsible for the manufacture
and/or overall installation of complete system CAUTION: Do not by-pass control panel timers
incorporating Maxon burners take precedence typically controlling sequential operations.
over these provided by Maxon. If Maxon
instructions conflict with any codes or regula-
Series “67”
attempting start-up. TUBE-O-FLAME®
Burners
For initial TUBE-O-FLAME® Burner start-up:

1. Close all burner fuel valves and cocks. Make
preliminary adjustments to fuel gas regulators.
Remove pilot and main gas regulators' adjusting
screw covers. Turn adjusting screw down (clock-
wise) to approximately mid-position. Close pilot
gas adjustable orifice screw by turning in clock-
3. Check that the immersion tube stack damper 6. Determine static condition of tube (draft or
is properly positioned and locked into operating suction) and verify differential air pressure at
position. burner backplate air test port.
4. Disconnect the automatic control motor's Measure your air pressure reading with
linkage from your TUBE-O-FLAME® Burner's manometer connected between the burner's air
operating crank arm by loosening the control pressure test port and atmosphere with the burner
motor's connecting rod from the burner's toggle at “high fire” position, fuel valves closed, and all
linkage. air handling systems running.
m CORPORATION

Series “67” TUBE-O-FLAME® Burners Page 2200-S-5
Record air test port reading. Chart below shows 11. Open main and pilot gas cocks, then attempt
normal balanced tube static condition readings. spark ignition to light pilot while slowly turning
pilot gas regulator clockwise and/or adjustable
10-30 orifice screw counter-clockwise to increase fuel
Burner Model 6-08 8-15 10-25 14-50
12-38 flow. Repeat procedure as necessary until pilot
Air Pressure ("wc) 3.0 2.0 3.0 5.0 5.0 ignites, as air might have to be bled out of fuel
supply lines before reliable pilot flame is estab-
If your reading exceeds these normal readings, lished. Pilot gas regulator should normally be set
you have a back pressure in your tube. for as low a pressure as possible, using fuller
If your readings are lower than the normal opening of pilot gas adjustable orifice (if used).
balanced readings, you have an exhaust suction 12. After ignition, adjust pilot flame for good stable
in your tube. flame shape. A rule of thumb is that any pilot over
Excessive suction can cause chugging and a tennis ball size is probably too large. This
implies hot combustion products are being drawn assumes you have visual access to the pilot
out of the tube too fast, reducing thermal transfer flame. If this is not possible, then adjust pilot to
efficiency. High tube suction also may affect give the strongest and most stable flame signal
differential gas pressure settings. Too high of a through your flame safety circuit. This signal
suction may lower inlet gas pressures so that low strength can be read with a micro-amp meter. The
gas pressure switches cannot be adjusted. signal strength (or range) will be determined by
Excessive back pressure can cause smoke the specific type of flame safeguard instrument
and may restrict firing capacity of burner. you have with your burner system.
NOTE: The differential air pressure setting deter-
mines the burner's capacity and performance capabili-
ties.
7. Adjust exhaust fan and/or stack damper to guard relays should now power your main fuel
create burner air pressure test port readings as Shut-Off Valve(s).
close as possible to those shown for normal
balanced conditions to maximize system's thermal CAUTION: After completing steps above, re-
transfer efficiency. check all interlocking safety components and
circuitry to prove that they are properly in-
NOTICE: Burner performance can be drastically stalled, correctly set, and fully operational. If in
affected by tube configuration and static doubt, shut the system down, close pilot cock
conditions within tube created by exhaust fans and contact responsible individual before
and dampers in exhaust stack. proceeding further.
sure using this differential air pressure reading
obtained from step 6. High fire pressures are
provided in Maxon product line catalog literature
and/or read data stamped into burner nameplate.
flame appearance. Turn main regulator adjust-
ing screw in (clockwise) to obtain outlet pressure
of about 4"-6" wc higher than combustion cham-
positioned ignitor.
10. Return burner control valve/crank to low fire
higher for some LB versions). Main flame should
position when purge of system is complete.
now appear larger than pilot-only flame.

mCORPORATION
15. Establish high fire setting by slowly moving 17. Re-check differential gas pressure with unit at
burner crank toward high fire position while operating temperature. Refine high fire setting if
observing gas pressure at burner gas test con- necessary, considering differential pressure,
nection. Refine main gas regulator adjustment as flame length, and appearance. Dust or contami-
necessary to provide correct differential gas nants in the air stream may affect flame appear-
pressure at high fire. If pressure cannot be ance.
adjusted low enough, a different regulator or 18. Plug all test connections not in use to avoid
regulator spring may be necessary, or a limiting dangerous fuel leakage. Replace equipment
orifice valve (such as Maxon's Series “BV”) cover caps and tighten linkage screws.
should be added. Do not, however, exceed 4" wc 19. Check out overall system operation by cycling
pressure drop between regulator outlet and through light-off at minimum, interrupting pilot,
burner inlet. and allowing temperature control system to cycle
CAUTION: If burner(s) go out, close shut-off NOTE: Typical gas firing control sequence for
valve or shut main gas cock at once. Return to Maxon burner is provided only as a guide. Instruc-
minimum setting, re-light pilots if necessary, tions provided by complete system manufacturer
then turn main gas on again. Check carefully incorporating Maxon burners take precedence.
For gas firing Series “67”
TUBE-O-FLAME® Burner
and refine adjustment, if necessary. Light-off: Shut-down:
For operation with interrupted pilot (as 1. Close cocks, shut-off valve(s) 1. Close main &
from minimum to maximum and back several 4. Start burner blower air blower running
times to verify the flame is maintained. 5. Purge at least 4 air changes after shut-down long
16. When burner performance is satisfactory and burner to cool
stable throughout the firing range, reconnect
linkage to control motor. Recheck all safety system interlocks for proper
Control linkage travel must be such that burner setting and operation.
crank is moved throughout its complete travel, or
cataloged capacities and turndowns will not be WARNING: Test every UV installation for danger-
achieved. ous spark excitation from ignitors and other pos-
If less than full-rated burner capacity is re- sible sources of direct or reflected UV radiation.
quired, linkage can be adjusted to limit maximum Use only gas-tight scanner connections.
output. With interrupted pilot, it may be neces-
sary to set control for somewhat higher than 20. Before system is placed into full service,
minimum burner setting to permit hold-in of flame instruct operator personnel on proper start-up
detection system without pilot. operation with shut-down of system, establishing
written instructions for their future reference.
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.
m CORPORATION

Series “67” TUBE-O-FLAME® Burners Page 2200-A/P-1
Assembly Numbers
Size Packaged Burner Segment choices are as follows for

6-08 608 TOF (62) configured products:
8-15 815 TOF (67)
• Backplate
10-25 1025 TOF (98)
• Adjustable orifice
10-30 1030 TOF (117)
• Observation glass
12-38 1238 TOF (117) • Flame detection
14-50 1450 TOF (166) • Fuel
• Mounting Ring
• Motor (and/or adapter flange for LB)
Size LB • CB & L's
6" LB 6LB TOF (43) • Switches
8" LB 8LB TOF (49) • Filters/Silencers (Packaged burners only)
10" LB 10LB TOF (80) • Control Motor
• Universal Joint Assembly
12" LB 12LB TOF (74)
• Manual Handle Set
14" LB 14LB TOF (104)
Spare Parts – Series “67” TUBE-O-FLAME® Burners

Burner Size > 6-08 8-15 10-25 10-30, 12-38 14-50
39833 39834 39835 39836 39837
Linkage Repair Kit
(3) (3) (4) (4) (4)
Automatic Operating Crank
(required on any burner assembly to connect to a 16334 (0.5)
Miscellaneous customer-supplied connecting base & linkage)
Items Connecting Linkage, Toggle, Clamp Set 30510 (1)
Manual Handle Set (except MRV versions) 31990 (2)
Rubber Cover for flame rod/spark ignitor 18722 (0.5)
Universal Joint Assembly 20216 (4)
Balancing and Swing Check Valves (sized for burner inlet pipe size)
Pipe Size (NPT) > 1" 1-1/4" 1-1/2" 2"
®
Series “67” TUBE-O-FLAME Burners 6-08, 6LB 8-15, 8LB 10-25, 10LB 10-30, 12-38, 14-50, 12LB, 14LB

mCORPORATION
Page 2200-A/P-2 Series “67” TUBE-O-FLAME® Burners
Assembly Numbers
Spare Parts
6-08 8-15 10-25 12-38 14-50
Series “67” and LB TUBE-O-FLAME® Burners 10-30
6LB 8LB 10LB 12LB 14LB
16476 19330 27307 29469
Burner Mounting Ring 16477 (4)
(4) (4) (8) (12)
Flame Rod Assembly 47743 47744 47745 47746 47745
Replacement Spark Ignitor
24699* 19407 (1)
*For 6-08 TUBE-O-FLAME® arranged for flame rod only.
L = 2.5" L = 3.5"
If UV scanner is used, select #19407 (L = 3.5")
UV Scanner Adapter Plate 37430 (.5)
120v
Control Motor Set (includes 59599 (10) 59600 (10)
50/60Hz
control motor, enclosure, mounting
High-Low base & linkage components) 240v
59599 (10) 59600 (10)
Automatic 50/60 Hz
Control 120v
Motor Set 59601 (8)
Replacement Motor only from 50/60 Hz
above set 240v
59601 (8)
50/60 Hz
Pilot Adjustable Orifice 38009 (2) 50431 (3)
High Capacity Pilot Adjustable Orifice 50431 (3) N/A
General Purpose NEMA 1
20118 (1)
(indoors, non-hazardous locations)
Low Fire Weatherproof
Start Switch NEMA 1,3,3R,4,12, & 13 35610 (1)
(1 SPDT) (outdoors, non-hazardous locations)
Hazardous Duty/Weatherproof
NEMA 1,3,3R,4,7,9,12, & 13 35944 (1)
(outdoors, hazardous duty locations)
High & Low
Fire
Position 30460 (4)
Switch
(2 SPDT)
Replacement Gas Nozzles

Series “67” TUBE-O-FLAME® Burner 6-08 8-15 10-25 10-30 12-38 14-50
Natural gas nozzle 19329 19311 19416 28065 28065 19424
Propane gas nozzle Not Available 31036 31037 31037 Not available
Natural gas nozzle w/ guide tube 1055080 1055081 1055082 1055083 1055083 1055084
Propane gas nozzle w/ guide tube Not available 1062920 1062921 1062921 Not available
Guide tube - NPT threaded 1055075 1055076 1055077 1055078 1055078 1055079
Guide tube - ISO threaded 1063804 1063805 1063806 1063807 1063807 1063808
m
CORPORATION

Series “67” TUBE-O-FLAME® Burners Page 2200-A/P-3
Assembly Numbers
Spare Parts

Series “67” TUBE-O-FLAME® Burner 6-08, 8-15 10-25 10-30, 12-38 14-50
Standard Air Filter Assembly 21772 24672 24334 24335
includes (2) replaceable elements (12) (12) (27) (35)
29758 28045 28047 24337
Replaceable filter elements for above
(.5) (.5) (1) (1)
Air Filter Assembly
Air 50826 50827 50833 50834
with (2) permanent elements
Filters
Permanent Filter Elements for direct
replacement providing burner originally
supplied with permanent elements 34651 34652 34654 34655
NOTE: See Product Information Sheet (2) (4) (6) (8)
2000-3 for details involving field
modifications
Air Inlet Silencer Assembly 31242 31243 31244 31245
includes housing and inlet guard (32) (35) (100) (100)
Air Inlet Filter Assembly for Silencer
29742 29743
Assembly above
(3) (6)
includes (1) replaceable element
Silencers
Replaceable Filter Element for 31062 31051
Silencer/Filter Assembly above (2) (4)
Air Inlet Filter Assembly for Silencer
35567 35568
Assembly above
(15) (20)
includes (1) permanent element
Approximate net weight (in pounds) shown in parentheses.

m
CORPORATION
Page 2200-A/P-4 Series “67” TUBE-O-FLAME® Burners
Assembly Numbers
Spare Parts
Connecting Base and Linkage Assemblies

This listing of CB & L Assemblies shows only a sampling of the more popular control motors. We may be able to
furnish CB & L for other operators not cataloged (supply manufacturer's name and model number).
Type Manufacturer Model Number Maxon CB & L Assembly Number

24066
P-25 [1]
(15)
Foxboro
27104
P-50 [2]
(15)
019/861M [3]
20685
Air Honeywell 01-11/861P [3]
(10)
03-8/863T [3]
D-3153 25187
Johnson
D-3151 (10)
22929
Taylor 40VF6
(10)
19866
Barber-Colman EA51-58, also with prefix MC, MP, or MF
(6)
34468
Foxboro/Jordan SM1510
(10)
M644 [4]
M744 [4] 19680
M941 [4] (8)
Honeywell M944 [4]
Electric
M640A 22009
M940A (6)
10261
10262 24009
Leeds & Northrup
10264 (10)
10266
M80 [5] 19680
Penn/Johnson
M81 [5] (8)
[1] Specify from Foxboro: [2] Specify from Foxboro: [3] Model cannot be used
WITH #B6301-LR yoke WITH #B6301-WR yoke on TUBE-O-FLAME®
WITH #B6301-KY connection assembly WITH #B6301-TY connection assembly Burner with UV scanner
LESS indicating pointer LESS indicating pointer option due to physical size
LESS travel indicator scale LESS travel indicator scale limitations
LESS stem locknuts LESS stem locknuts
[4]Specify from Honeywell: [5] Specify from Penn/Johnson:

WITH #7616BR crank arm WITH #LVR27A-601 crank arm
mCORPORATION

Product Data Sheet Product: Series “67” TUBE-O-FLAME® Burners
Page: 2200-1 Date: 5/03

Do Not Reproduce
Standard Nozzle Drillings for Series “67” TUBE-O-FLAME® Burners
Standard
TUBE-O-FLAME® Drill Size UV_TUBE
Number of Holes Fuel Gas Nozzle Part
Burner Model (in inches) Nozzle Part Number
Number
6 - 08 8 1/4 Natural or Propane 19329 1055080
7/16 Natural 19416 1055082
10 - 25 8
21/64 Propane 31036 1062920
7/16 Natural 28065 1055083
10 - 30 8
21/64 Propane 31037 1062921
7/16 Natural 28065 1055083
12 - 38 8
21/64 Propane 31037 1062921

Bulletin 2300
Maxon Model “500-SP” OVENPAK® Gas/Oil Burners
Model 515-SP OVENPAK® Burner

with connecting base and linkage
assembly and automatic electric
control motor
• Burns clean fuel gases, light oils, or both simultaneously

• Provides stand-by or alternate fuel capabilities
• Gas-only version converts easily to combination fuel firing
• Low horsepower requirements reduce initial and operating costs
• Uses compressed air for oil atomization
• Clean combustion with low NOx levels
• Compact design for easy installation and maintenance
Model “500-SP” OVENPAK® Burner applications have included:

Air heating in ovens and dryers, paint finishing lines, paper and textile machines, food bak-
ing ovens, coffee roasters, grain dryers, and fume incinerators. Manufactured under U.S.
patent #3,574,508; Canadian and European patents granted and pending.
Page 2302
Maxon Model “500-SP” OVENPAK® Gas/Oil Burners
Provides application flexibility with:

• Turndown up to 20:1
• Pre-assembled pipe train accessory options
for easy installation and start-up
Model EBC-4-SP OVENPAK® Combina-
tion Gas/Oil Burner with automatic electric
control motor
Typical pipe train components required for combination fuel firing

of Model “500-SP” OVENPAK® Burner system
1/90
Model “500-SP” OVENPAK® Gas/Oil Burners Page 2303

Maxon OVENPAK® Burners are nozzle-mixing
burners specifically designed for direct-fired applica-
tions in ovens and dryers where clean combustion is
required.
Typical applications for Model “500” OVENPAK®
Burners include air heating in ovens and dryers, paint
lines, paper and textile machines, food-baking ovens,
coffee roasters, grain dryers and fume incinerators.
Principle of operation
Model “500” OVENPAK® Burners are available in
gas-only (500-G) and combination gas/oil (500-SP)
versions. Both incorporate a fuel and air valve linked
together to control the fuel-air ratio over the full
operating range.
The combination (500-SP) burner also has an
integrated oil control valve mounted into the burner
body. All valves work together. The choice of fuels is
up to you: gas, oil, or both at the same time.
Both gas-only and combination burners are avail-
able in two basic versions: 1) packaged with integral
combustion air blower, or 2) for use with an external
blower (EB versions).
When firing on oil, compressed air provides good
atomization. The oil flow pattern inside the mixing cone
Model "515-SP" OVENPAK® Gas/Oil Burner
results in intimate mixing with the combustion air.
In combination fuel firing, gas is introduced
around the patented oil nozzle and both gas and oil
are controlled in conjunction with the air damper.
“EB-MRV” versions of OVENPAK® Burners permit
air/fuel ratio control via an externally-mounted Maxon
MICRO-RATIO® control valve throughout the firing
range. They differ from standard “EB” (external blower)
versions in that internal gas and air butterflies and the
related shafts and linkages are omitted.
Cross sectional view of a Model “500-SP” OVENPAK® Burner
Model "EBC-4 SP" OVENPAK® Gas/Oil Burner
5/02
Page 2304 Model “500-SP” OVENPAK® Gas/Oil Burners

The standard Model “500-SP” OVENPAK® NOTE: Since the maximum capacity of the
Burner package includes a combustion air blower OVENPAK® Burner is affected by the static pressure
with motor in a variety of voltages. You may select within the duct or combustion chamber, do not
from: attempt to operate a Model “500” OVENPAK® Burner
beyond this static pressure range. For higher back
Horsepower Type 115/230/1/60 230/460/3/60 575/3/60
pressure applications, select from Model “EBC”,
3/4 HP Totally “EBG”, or “EB-MRV” OVENPAK® Burner options.
X X X
& 1 HP Enclosed
Capacity data for gas or oil firing of Model “500-SP”
1-1/2 HP, Totally Not
X X OVENPAK® Burners is based on use of #2 fuel oil
2 HP & 3 HP Enclosed Available
with a maximum viscosity of 40-50 SSU, a heating
value of approximately 140,000 Btu per gallon, and/or
Capacities and operating data are summarized in natural gas at 1000 Btu per cubic foot, .6 specific
the table below and on page 2305. gravity.
Broad operating flexibility allows firing against NOTE: All fuel supply pressures are differential
positive chamber pressures of 1" wc or less (higher pressures as measured at the fuel pressure test
for EB versions) or with as much as 5" wc suction. Air connection on the backplate of the burner. Differential
stream velocities of up to 2000 fpm (firing across flow) pressures shown are approximate.
or 3000 fpm (firing parallel to air flow) are tolerated. Propane firing requires fuel pressures at the test
connection that are 40% of those given for natural gas.
Use only UV flame sensor systems for oil firing.
Capacities for 60 hertz applications
Burner Model Number 508-SP 515-SP 525-SP 535-SP 550-SP
Motor Horsepower and 3/4 HP 3/4 HP 1 HP 1-1/2 HP 3 HP
Frame Number FR #56 FR #56 FR #56 FR #143T FR #182T
Maximum capacity 1000's Btu/hr 800 1500 2500 3500 5000
Cubic feet per hour natural gas 800 1500 2500 3500 5000
Fuel flow volumes
Gallons per hour #2 fuel oil 5.7 11 18 25 36
Minimum capacity (1000's Btu/hr) Natural gas pilot (only) 18 38 40 50 70
with compressed air off Natural gas main (only) 40 75 100 175 250
Natural gas pilot (only) 72 114 125 200 250
Minimum capacity (1000's Btu/hr)
with compressed air on #2 fuel oil (only) 224 280 224 238 406
Gallons per hour 1.6 2.0 1.6 1.7 2.9
Compressed air required Pressure (PSIG) 60 60 60 60 60
(for oil firing only) Volume (SCFM) 5.2 7.8 8.0 8.0 12.6
Differential natural gas pressure At burner inlet 2.4 6.2 3.1 4.9 3.8
required ("w.c.) At burner test connection 2.0 3.0 2.4 3.8 3.0
#2 oil pressure required At control valve (PSIG) 35 40 55 60 60
Burner Only - Natural Gas 84 85 87 90 95
Sound level Burner w/ silencer - Natural Gas 76 76 75 79 85
dB(A) Burner Only - #2 Oil 85 85 87 91 96
Burner w/ silencer - #2 Oil 78 76 77 79 85
Flame Length Inches, in still air 20 56 58 60 60

A standard Model “500-SP” OVENPAK® Burner Since maximum capacity of Model “500-SP”
includes a combustion air blower with motor in a variety OVENPAK® Burner is affected by the static pres-
of voltages. You may select from: sure within the combustion chamber, do not
attempt to operate beyond the duct static pressure
50 Hz Motor Voltages Available (possible net extra cost) range shown on page 2304. For higher back
pressure applications, select from Model “EBC”,
Horsepower Type 190-200/1/50 380-415/3/50 500/3/50
“EBG”, or “EB-MRV” OVENPAK® Burner options.
3/4 HP Totally All fuel pressures are differential pressures
X X X
& 1 HP Enclosed
and are measured at the fuel pressure test connec-
1-1/2 HP, Totally
2 HP & 3 HP Enclosed
X X X tion on the backplate of each OVENPAK® Burner.
Differential pressures shown are approximate.
Capacities for 50 hertz applications

Burner Model Number 508-SP 515-SP 525-SP 535-SP 550-SP
Motor Horsepower and 3/4 HP 3/4 HP 1 HP 1-1/2 HP 3 HP
Frame Number FR #56 FR #56 FR #56 FR #143T FR #182T
Maximum capacity 1000's Btu/hr 670 1250 2100 2900 4200
Cubic feet per hour natural gas 670 1250 2100 2900 4200
Fuel flow volumes
Gallons per hour #2 fuel oil 4.8 9 15 21 30
Minimum capacity (1000's Btu/hr) Natural gas pilot (only) 18 38 40 50 70
with compressed air off Natural gas main (only) 40 75 100 175 250
Natural gas pilot (only) 72 114 125 200 250
Minimum capacity (1000's Btu/hr)
with compressed air on #2 fuel oil (only) 224 280 224 238 406
Gallons per hour 1.6 2.0 1.6 1.7 2.9
Compressed air required Pressure (PSIG) 60 60 60 60 60
(for oil firing only) Volume (SCFM) 5.2 7.8 8.0 8.0 12.6
Differential natural gas pressure At burner inlet 1.7 4.3 2.2 3.4 2.6
required ("wc) At burner test connection 1.4 2.1 1.7 2.6 2.1
#2 oil pressure required At control valve (PSIG) 35 40 55 60 60
Burner Only - Natural Gas 84 85 87 90 95
Sound level Burner w/ silencer - Natural Gas 76 76 75 79 85
dB(A) Burner Only - #2 Oil 85 85 87 91 96
Burner w/ silencer - #2 Oil 78 76 77 79 85
Flame Length Inches, in still air 20 56 58 60 60
5/02

External Blower versions
Model EBC-2 and EBC-3 OVENPAK® Burners

Combustion and Differential air pressure ("wc) 2 4 6 8 10 12 14
cooling air required Volume (SCFM) 85 120 147 170 190 208 225
Maximum capacity 1000's Btu/hr 499 706 864 998 1116 1222 1320
Cubic feet per hour natural gas 499 706 864 998 1116 1222 1320
Fuel flow volumes
Gallons per hour #2 fuel oil 3.6 5.0 6.2 7.1 8.0 8.7 9.4
Minimum capacity Natural gas pilot (only) 25 35 40 50 60 80 100
(1000's Btu/hr)
with compressed air off Natural gas main (only) 40 56 63 75 82 88 93
EBC-2 Natural gas pilot (only) 50 70 80 90 100 120 140
OVENPAK® Minimum capacity
Burner (1000's Btu/hr) #2 fuel oil (only) 175 175 175 175 175 175 175
with compressed air on Gallons per hour 1.25 1.25 1.25 1.25 1.25 1.25 1.25
Compressed air Pressure (PSIG) 60 60 60 60 60 60 60
required
(for oil firing only) Volume (SCFM) 5.3 5.2 5. 2 5.2 5.2 5.2 5.2
Differential natural gas At burner inlet 1.1 2.3 3.4 4.6 5.7 6.9 8.0
pressure required ("w.c.) At burner test connection 0.9 1.7 2.6 3.4 4.3 5.1 6.0
#2 oil pressure required At control valve (PSIG) 35 35 35 35 35 35 35
Flame length Inches, in still air 14 22 25 26 28 29 30
Combustion and Differential air pressure ("wc) 6 7 8 9 10 11 12

cooling air required Volume (SCFM) 460 496 531 563 593 622 650
Maximum capacity 1000's Btu/hr 2065 2230 2384 2529 2666 2796 2920
Cubic feet per hour natural gas 2065 2230 2384 2529 2666 2796 2920
Fuel flow volumes
Gallons per hour #2 fuel oil 14.7 15.9 17.0 18.1 19.0 20.0 20.9
Minimum capacity Natural gas pilot (only) 75 83 99 100 102 168 240
(1000's Btu/hr)
with compressed air off Natural gas main (only) 90 100 119 120 122 202 288
EBC-3 Natural gas pilot (only) 104 106 108 120 140 175 280
OVENPAK® Minimum capacity
Burner (1000's Btu/hr) #2 fuel oil (only) 350 350 350 350 350 350 350
with compressed air on Gallons per hour 2.5 2.5 2.5 2.5 2.5 2.5 2.5
Compressed air Pressure (PSIG) 60 60 60 60 60 60 60
required
(for oil firing only) Volume (SCFM) 7.7 7.7 7.7 7.7 7.6 7.6 7.6
Differential natural gas At burner inlet 9.6 11.2 12.8 14.4 16.0 17.6 19.2
pressure required ("w.c.) At burner test connection 4.8 5.6 6.4 7.2 8.0 8.8 9.6
#2 oil pressure required At control valve (PSIG) 50 50 50 50 50 50 50
Flame length Inches, in still air 35 37 40 42 44 46 48

Model EBC-4 and EBC-5 OVENPAK® Burners

Combustion and Differential air pressure ("wc) 6 8 10 12 14 16 18 20
cooling air required Volume (SCFM) 489 565 632 692 747 799 847 893
Maximum capacity 1000's Btu/hr 2539 2931 3277 3590 3878 4146 4397 4635
Cubic feet per hour natural gas 2539 2931 3277 3590 3878 4146 4397 4635
Fuel flow volumes
Gallons per hour #2 fuel oil 18.1 20.9 23.4 25.6 27.7 29.6 31.4 33.1
Minimum capacity Natural gas pilot (only) 150 200 220 260 280 290 300 310
(1000's Btu/hr)
with compressed air off Natural gas main (only) 200 230 255 277 297 315 332 345
Natural gas pilot (only) 180 200 250 285 300 320 330 340
EBC-4 Minimum capacity
OVENPAK® (1000's Btu/hr) #2 fuel oil (only) 252 252 252 252 252 252 252 252
Burner with compressed air on
Gallons per hour 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8
Compressed air Pressure (PSIG) 70 70 70 70 70 70 70 70
required
(for oil firing only) Volume (SCFM) 7.8 7.8 7.7 7.7 7.7 7.6 7.6 7.6
Differential natural gas At burner inlet 2.9 3.9 4.9 5.9 6.9 7.8 8.8 9.8
pressure required
("w.c.) At burner test connection 2.3 3.1 3.9 4.7 5.5 6.2 7.0 7.8
#2 oil pressure
At control valve (PSIG) 70 70 70 70 70 70 70 70
required
Flame length Inches, in still air 32 36 38 42 42 44 48 52

Maximum capacity 1000s Btu/hr 3499 4517 4948 5345 5714 6060 6388 6700
Fuel flow volumes
(1000's Btu/hr)
EBC-5 Natural gas pilot (only) 300 305 310 320 330 340 375 400
Minimum capacity
Gallons per hour 1.9 1.9 1.9 1.9 1.9 1.9 1.9 1.9
required
pressure required
#2 oil pressure
required
5/02

Model EBC-6 OVENPAK® Burner

Maximum capacity 1000's Btu/hr 5505 6356 7106 7785 8408 8989 9534 10050
Fuel flow volumes
(1000's Btu/hr)
EBC-6 Natural gas pilot (only) 300 310 320 330 340 370 400 410
Minimum capacity
Gallons per hour 2.9 2.9 2.9 2.9 2.9 2.9 2.9 2.9
required
pressure required
#2 oil pressure
required

Model “500-SP” and “500-G” OVENPAK® Burners
(shown with optional filter assembly)
Burner Model A B C D E F H K L M
508-SP 3.75 1 6.62 12.31 8.44 6.31 8.44 3.62
5.06 8.87
515-SP 4.75 1-1/4 7.69 12.25 10.37 8.25 10.37 4.44
525-SP 1-1/2
5.75 10.06 13.87 12.5 10.25 12.5 5.62
535-SP 2 5.69 8.62
550-SP 6.81 3 14.38 18.87 14.75 12.25 14.75 6.69
Burner Model N S CC DD EE FF GG HH JJ KK
508-SP 4.69 18.5
0.25 8.69 15.75 20 22 19
515-SP 15.25 3.5 17.5
15.87
525-SP 18.5
17.62 2.81 22 24
535-SP 0.37 9.31 20 30
550-SP 17.75 17.69 18.87 5.37 24.5 27 26
5/96

Model EBC and EBG OVENPAK® Burners
(common dimensions for EBC-MRV and EBG-MRV versions)
Burner Model A B C D E F H J K L
EB-2 3.75 1 6.62 12.31 8.44 6.31 8.44
5.06 8.87 4.37
EB-3 4.75 1-1/4 7.69 12.25 10.37 8.25 10.37
EB-4 1-1/2
5.75 10.06 13.87 12.5 5.44 10.25 12.5
EB-5 2 5.69 8.62
EB-6 6.81 3 14.38 18.87 14.62 6.5 12.25 14.75
Burner Model M N S U V W X Y AA BB
EB-2 3.62 6
0.25 8.69 8.5 9.94 6.37 0.44 5.44 4
EB-3 4.44 5.37
EB-4
5.62 10.37 11.87 8.87 7.75 5.5 6
EB-5 0.37 9.31 0.56
EB-6 6.69 9.62 11.12 11.75 10.25 8.69 8

Filter with silencer for Model “500” OVENPAK® Burners
➀ NOTE: Sight glass replaced by

UV Scanner Adapter Plate,
1/2", if used (optional)
Burner Model LL MM NN PP RR SS TT UU VV
508-SP
15 16 22 8 24 25 32 36 3/8
515-SP
525-SP
18 22 15 11 32 39 42
535-SP 25 1/2
550-SP 20.25 24 30 13 34 43 48
Spark Ignitor
1.375" .19"
1.20"
5/02

3/8" NPT Pilot Gas Train
for Model 508, 515, EBC-2, and EBC-3 OVENPAK® Burners
Pipe train pressure rating: 5 PSIG
Includes: (1) 3/8" ball valve
(1) 3/8" pilot gas regulator (R400S)
(1) 3/8" pilot gas solenoid (120/60 AC)
⇐ Flow
1/2" NPT Pilot Gas Train

for Model 525, 535, 550, EBC-4, EBC-5, and EBC-6 OVENPAK® Burners
(1) 3/4" pilot gas regulator (R500S)
(1) 1/2" pilot gas solenoid (120/60 AC)
1/4" NPT Compressed Air Pipe Train

for all Model “500” and “EBC” OVENPAK® Burners
(1) 1/4" air filter (5 micron)
(1) 1/4" air pressure regulator
⇐ Flow
1/4" NPT Compressed Air Pipe Train

Pipe train pressure rating: 140 PSIG for #27084
90 PSIG for #27085
(1) 1/4" air filter (5 micron)
(1) 1/4" air solenoid valve (120/60 AC) ⇐
(1) 1/4" air pressure regulator Flow

3/8" NPT Light Oil Pipe Train options
No solenoid valve option includes:
(1) 3/8" ball valve
(1) 3/8" oil filter (20 micron) ⇐ Flow
(1) oil pressure gauge
(1) 3/8" oil pressure regulator
One solenoid valve option includes:

(1) 3/8" ball valve
(1) 3/8" oil filter (20 micron)
(1) oil pressure gauge ⇐ Flow
(1) 3/8" oil pressure regulator
(1) 3/8" oil solenoid (120/60 AC)
Double solenoid valve option includes:

(1) 3/8" ball valve
(1) 3/8" oil filter (20 micron)
(1) oil pressure gauge ⇐
(1) 3/8" oil pressure regulator Flow
(2) 3/8" oil solenoid valves (120/60 AC)
4/95
Flowmeter Piping Options

All gas/oil combination burner assemblies include a If necessary, the flowmeter mounting arrangement
direct-reading oil flowmeter. This flowmeter must be can be altered in the field by changing the upper and/or
mounted vertically. lower flowmeter tubing arrangement. Optional flowme-
Standard burner assemblies are equipped with the ter piping sets provide for this re-positioning.
flowmeter mounted in the proper position for horizon- Optional solenoid piping sets provide necessary
tal-firing of the OVENPAK® Burner. piping hardware to position an additional solenoid valve
For down-firing or up-firing of the OVENPAK® up as close as possible to the burner control valve.
Burner, alternate mounting of the flowmeter is required. This reduces the residual volume of oil between the
If an up-firing or down-firing application is specifed shut-off valve and the oil nozzle tip at time of shut-
when ordering, the burner assembly will be equipped down.
with the flowmeter in the proper vertical position. An optional solenoid valve may also be re-posi-
tioned for down-firing and up-firing burner applications.
Typical arrangement for all Model “500” Typical arrangement for all Model “500”
down-firing OVENPAK® Burners up-firing OVENPAK® Burners
To order replacement parts: For new oil nozzle sub-assembly:

1. Specify parts by name from accompanying For burners built before 5/13/02, contact Maxon with
sketches and indicate quantity desired. assembly number and date of manufacture (stamped
2. SEE BURNER NAME- into nameplate). A new mixing cone may also be
PLATE: required.
– Indicate burner size Complete internal linkage replacement kits are also
and assembly available.
number
– Indicate date of
manufacture
stamped to right of
assembly number
(Some older burners
may have date stamped into bottom or left edge
of nameplate, or no date. REPORT ANY OF
THESE VARIATIONS.)
3. Indicate serial number stamped on nameplate of
Maxon Shut-Off Valve controlling fuel to burner.
NOTE: Older versions of this burner may include
slightly different oil nozzle sub-assemblies, mixing
cones and discharge sleeves. Current components
may be used as replacements and will provide the
same or superior performance.
7/03

Discharge sleeve and cone alignment WARNING: If burner is run on oil, but subject to
Centering of the mixing cone provides a small long intervals of gas-only firing, the oil line,
annular opening for the flow of some cooling combus- components and piping should be blown clear
tion air along and inside the discharge sleeve wall. We at shutdown to prevent start-up difficulties
suggest periodic inspection from the discharge side of during later oil light-off.
the burner to assure this critical alignment is main-
tained. Filter maintenance
Inside inspections (from discharge end of burner) Filters MUST be kept clean for optimum burner
can spot possible mixing cone or discharge sleeve performance. They should be inspected regularly
deterioration before performance is drastically affected. (experience will dictate the required frequency) and
Check specifically that mixing cleaned as needed.
cone is centered within burner To clean washable/replaceable elements, remove
body and discharge sleeve, so from burner, then vacuum to remove dry accumula-
as to give the intended flow of tions. Wash in warm soapy water, wring gently and dry
cooling air along the sleeve. If before replacing in filter assembly.
necessary, re-adjust by loosen- To clean permanent elements, remove from
ing the four lock nuts (see burner, vacuum or blow clean of excess dirt, then wash
sketch) and turning the four in soap and water (or solvent, if necessary), dry, re-
adjusting screws to center cone within the opening. coat (if desired) and re-install.
Back each screw off 1/4 turn (to allow for thermal
To replace spark ignitor
expansion of hot mixing cone) then hold in position and
1. Check table below for dimension “Y” and cut tip if
turn all four lock nuts down snugly.
necessary.
CAUTION: OVER-TIGHTENING ADJUSTING 2. Insert 1/2" NPT collar into burner and snug into
SCREWS CAN GREATLY REDUCE CONE AND position.
DISCHARGE SLEEVE LIFE. 3. Insert insulator through Spark
Shield
collar into burner,
Critical check points in oil line: Mixing
rotating if necessary, to Cone
1. Pump (wear, lubrication)
engage in burner cone. 1/8"
2. By-pass valve (loose packing)
Insert spark ignitor until
3. Strainer (filled with scale, etc.)
insulator bottoms in
4. Filters (plugged)
spark shield then retract 1/8" to establish proper
5. Regulator (not bottomed)
gap.
6. Viscosity no higher than 50 SSU (about 45°F with
4. Tighten locking bushing until insulator is held in
#2 oil)
place.
Critical check points in compressed air line:
1. Compressor (lubrication, water accumulation) WARNING: Over-tightening locking bushing will
2. Filters (plugged) damage ceramic insulator.
3. Water traps (full)
4. Regulator (set to give desired pressure)
Critical check points on burner:
1. Oil control valve (working smoothly)
2. Oil nozzle stem (clean, no nicks or scratches,
or pluggage)
3. Oil nozzle mix chamber (not plugged)
Y = 0.19"
4. Universal screw carrier snug on operating shaft
5. Set collar tight and snug on operating shaft
6. Set screws holding cone backed off 1/4 turn and
locked
7. Cone mounted concentrically in housing
8. Cam strips and/or plunger cap wear

To clean oil nozzle sub-assembly:
1. Disconnect the oil and compressed air lines at 7. Spacer bushing [8] should be tightly held between
burner and remove the four socket head cap nozzle body [6] and tube retainer [1]. If adjust-
screws holding tube retainer [1] to burner. ment is necessary, loosen Allen screw [9] and
2. Carefully withdraw the oil nozzle sub-assembly. cap screw [10], then slide tube retainer [1]
Save the gasket [2]. towards nozzle body [6] as far as possible. Re-
3. If a new nozzle sub-assembly is to be installed, tighten Allen screw [9] and cap screw [10].
replace gasket [2] and reverse steps 1 and 2. If 8. Re-install stem [7], mix chamber [11], and nozzle
the nozzle itself is to be changed or cleaned, cap [4] on the body [6]. A drag will be felt when
loosen the set screw [3]. the nozzle contacts O-ring. Continue to screw the
4. Unscrew nozzle cap [4] from nozzle sub-assem- nozzle onto the body until mix chamber [11] is
bly. Be careful not to damage the O-ring [5], stem contacted. Torque to 125 ft-lbs. Do not use pipe
[7], or mix chamber [11]. Remove the O-ring [5] dope, permatex, etc. on threads.
and save if undamaged. 9. Tighten set screw [3]; it must not protrude from
5. Clean nozzle cap [4], stem [7], and mix chamber nozzle.
[11]. Do not nick or dent edges or surfaces. Use 10. Insert oil nozzle sub-assembly in burner. Make
compressed air or a solvent that will remove all sure gasket [2] is in place, then re-install and
foreign particles. Do not use an abrasive. tighten the four socket head cap screws, holding
6. Re-install VITON O-ring [5] or replace if dam- tube retainer [1] in place.
aged. For a replacement, use a VITON O-ring, 11. Reconnect the oil and compressed air lines, then
size #122 (1-1/8" x 3/32") on 508, 515, EBC-2, fire burner and check compressed air pressure
and EBC-3 burners (including older versions). On and oil flow to insure that nothing has changed.
larger burners, such as the 525, 535, 550, EBC-5, Following established light-off procedure, check
and EBC-6, use size #126 (1-3/8" x 1-9/16" x pressures, oil flow, main flame, etc.
3/32").
1 6 5
11
10
7
8 4
9 3
5/02
Notes
®
Model “500-SP” OVENPAK Burners Page 2300-S-1
General Instructions Electrical service must match the voltage, phase
Important: Do not discard packing material until compatible with burner nameplate ratings. Insure that
all loose items are accounted for. all normal control safeguards are satisfied. Combus-
To prevent damage in transit, the oil flowmeter, tion air blower should continue to run after shutdown
spark ignitor, discharge sleeve, mounting gaskets, to allow burner to cool.
flame rod and connecting linkage components may be Gas supply piping must be large enough to
packed separately and shipped loose with your new maintain the required fuel pressures cataloged for the
Maxon OVENPAK® Burner. particular burner size used with burner operating at
The burner itself is normally only a part of your full-rated capacity. Gas piping pressure drops to the
complete combustion system. Additional pipe train gas regulator should not exceed 1/2" wc at full flow for
accessories and control components will be required supply pressures of 8 oz. or less (10% of initial
for a complete system installation. The sketch below pressure if supply is higher than 1/2" PSIG).
shows a typical pipe train as might be used with a gas- Anything more than minimal distance or piping
fired Model “500-G” OVENPAK® Burner. turns may necessitate “oversizing” piping runs to keep
pressure drops within acceptable ranges.
Piping Layout as sometimes required by Oil and air piping should be sized for the pressure
insurance and standards groups and volume requirements of the burner, with supply
pressures high enough to permit subsequent regulation
“Block and Bleed” gas train arrangement illus- at each burner. Oil and compressed air should be avail-
trated with Model “500-G” OVENPAK® Burner able to the inlet of the train at 100 PSIG, with oil heated
if necessary so that viscosity does not exceed 50 SSU.
Clean fuel lines are essential to prevent blockage
supplies multiple burners, provide a separate regulator
in the branch leading to each burner system. Care
should be taken to minimize pressure drop and give
maximum uniformity.
losses. Follow the instructions attached to the regulator.
Burner provides the air supply (unless it is “EB” regulator, but downstream of the main gas cock. It
version, which requires a separate combustion air should normally include its own pilot gas regulator, a
blower). It also serves as a fuel flow control and fuel/ solenoid valve and shut-off cock. A pilot adjustable
air mixing device. orifice at the pilot inlet simplifies adjustment.
It should not be exposed to direct radiant heat or Pilot piping must be large enough to provide for
positioned where it might draw in inert gases. If the full flow and pressures shown in the catalog for
problems exist, consider filters, relocation and/or use your particular burner size.
of the “EB” version and external air supply.

mCORPORATION
®
Page 2300-S-2 Model “500-SP” OVENPAK Burners
Fuel Shut-Off Valves (when properly connected to Oil pipe train should be located reasonably close
a control system) shut the fuel supply off when a to the burner and below the burner inlet. The oil
hazardous operating condition is sensed. Manual solenoid valve must be interlocked with the low
reset valves require operator attendance each time pressure compressed air switch. The oil flowmeter
the system is started up (or restarted after a trip-out). (included with the burner) must be installed with flow
Motorized shut-off valves permit automatic start- vertically upward.
restart when used with an appropriate control system. Use only UV flame sensor systems for oil firing.
Test connections are essential for burner adjust- Flame rods may be used ONLY with specially adapted
ment. They should be provided immediately down- GAS-ONLY burners.
stream of the regulator and are included in the burner Control systems should provide all normally
itself. Test connections must be plugged except recommended interlocks (including operation of fuel
when readings are being taken. shut-off valves). Sequencing Control Systems are
Blower location must deliver a reasonably clean available from Maxon that include provision for post-
and cool air supply. Inlet filters and silencers are purge pilots during all but emergency shut-downs.
available as options. Where external blowers are This sequencing is essential to minimize risk of smoke
used, care must be taken to keep pressure drops to a during oil-fired shut-down.
minimum and to independently support the weight of Always re-establish pilot before shutting off oil.
air piping. For gas and oil combination firing, valves for
Gas pipe train should be located reasonably close both fuels must operate simultaneously on light-off
to the burner. As much as 4" wc pressure drop at full and on shut-down.
flow is acceptable, but pressure increase at low fire For gas or oil firing, interlock fuel valves electri-
will cause increased minimum and reduced turndown. cally so only one or the other can be used, not both
Compressed air train should be located reason- together.
ably close to the burner. A union is necessary to Low fire start and interrupted pilot are essential to
permit withdrawal of the oil nozzle sub-assembly. For obtain cataloged minimums.
proper operation, a low air pressure switch interlocked
with the oil shut-off valve should be installed down-
stream of the air regulator, with no valving between
the switch and the burner itself.
Typical pipe train components

required for combination fuel
firing of Model “500”
OVENPAK® Burner system
Compressed Air
Pipe Train
Gas Pipe Train
Oil Pipe Train
mCORPORATION

®
be mounted in any position suitable for automatic conjunction with a “stiffener plate” when mounting
control motor and UV scanner. OVENPAK® Burner (weighing 100-350 pounds)
OVENPAK® Burner will typically be installed through typical thin wall of heater/oven panels.
through an oven wall or insulated air duct. Cut opening For push-through systems, use Maxon special
approximately 1" larger in diameter than discharge back pressure gasket between stiffener plate and
sleeve to allow for thermal expansion of sleeve. discharge sleeve flange and use (2) ring gaskets
Burner mounting requires four studs and a flat between discharge sleeve flange and burner casting
mounting surface perfectly centered on the discharge to prevent back flow of high temperature air. Fill area
sleeve. After placing burner in position over studs, add D (see sketch below) with no more than 2" of high
lock washers and nuts, then draw up all four hand- temperature packing (too little will overheat mounting;
tight only. Check that burner is seated evenly all too much will overheat sleeve).
around the flange, filling any gaps to prevent air
leakage, then tighten all nuts firmly. Typical discharge sleeve mounting recommendations
For proper performance of any burner, air inlet and for Model “500” & “EB” OVENPAK® Burner applications
pipe train components. Air control motors, in particu-
lar, 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 Model “500” OVENPAK® Burner requires
external auxiliary support provided by the user. The
support configuration may be similar to the leg support
or knee bracket support illustrated below.
Suggested supporting arrangements

for Model “500” OVENPAK® Burners:

WARNING: Welding of burner flange to stiffener

plate may cause warpage of burner flange and
leakage.

mCORPORATION
®
Four lock screws permit centering of mixing cone Flame sensing of oil must be accomplished by UV
within burner body and sleeve. They should be drawn scanner and should be mounted as close to burner as
up hand-tight, then backed out 1/4 turn to allow for feasible. Do not use cooling air to scanner port:
cone expansion. They must be re-checked after sighting is through gas cavity. Heat block, if used, may
start-up, and loosened if necessary to prevent affect signal strength with some brands of scanners.
deformation of cone. See start-up instructions for Alternate fuels may require correction of supply
details. pressures.
Over-tightening lock screws can lead to cone Specific piping and wiring diagrams should
distortion and greatly reduce cone and dis- always be submitted to the appropriate agen-
charge sleeve life. cies for approval on each application.
Discharge sleeve must be flush with, or extend Multi-burner installations may require special
beyond, interior wall. Maxon can supply a 12" long piping considerations, if supplied by a common pipe
discharge sleeve, but higher noise levels may result, train and/or air supply, to provide equal supply pres-
particularly when firing on propane. sures to each burner.
An external viewing port should be provided for Control system's circuitry must not allow main
flame observation, preferably in such a position that fuel shut-off valve to be opened unless combustion air
burner pilot and main flame can both be seen. is on, and must de-energize valve upon loss of
switch is used.
mCORPORATION

®
Procedure required to convert gas-only Model “500-G” and “EB-G” OVENPAK® Burner
to combination fuel version (Model “500-SP” and “EB-SP”)
Oil conversion kits for Model “500-G” or “EB-G” 6. Insert the oil nozzle sub-assembly into the back
OVENPAK® Burners include the components shown plate and bolt into place firmly with four #10-24 x
below. 5/8" socket head cap screws. Be sure the oil line
(line with 90° reducing elbow) is closest to the fan
Adjustable Oil Control and the compressed air line (line with the pipe tee)
Quadrant Valve is closest to the oil control valve.
7. Connect the end of the oil tube to the oil control
valve with a brass oil tube connector and the other
end to the 90° reducing elbow with a brass oil tube
connector, making sure that the flowmeter is right
side up and in vertical position. Be sure these
connector fittings are made up tight.
8. Verify the oil control valve plunger is inserted in
Oil Flowmeter the oil control valve and that it will depress into the
Note: Current versions may vary in Sub-Assembly oil control valve approximately 3/4".
appearance from illustration 9. Loosen the set screw in the operating shaft
set collar so that the set collar is loose on the
operating shaft. DO NOT REMOVE THE SET
COLLAR.
10. Slide the spacer onto the operating shaft on
the end from which the control crank was re-
moved.
11. Slide the screw carrier onto the operating
Nozzle
Sub-Assembly shaft and tighten the set screws in the screw
carrier onto the “flat” on the operating shaft. Move
the shaft back and forth if necessary to locate the
To make the conversion: “flat” and the set screws.
1. Disconnect the automatic control linkage from 12. Turn the screw carrier to the minimum posi-
operating crank. Save the toggle, bolt, washer, tion (indicator arrow pointing to “LO”) and push
nut, etc. the screw carrier firmly against the brass spacer.
2. Loosen set screw in operating crank. Remove Slide the set collar into the burner until it is snug
crank from operating shaft and discard. against the burner and tighten the set screw.
3. Remove the four #10-24 x 5/8" socket head cap Operate the screw carrier a few times between
screws from the retainer and cover plate. minimum and maximum to assure smooth opera-
4. Remove the gas nozzle sub-assembly com- tion. If the set collar is not snug or the screw
pletely from the back plate and discard. Gas carrier is not firmly mounted, repeat step 12.
nozzle sub-assembly is comprised of: 13. Connect the automatic control linkage to the
a. Retainer and cover plate screw carrier using the toggle, bolt, etc. from step 1.
b. Gas nozzle 14. Connect the compressed air line to the 1/8"
c. Gasket pipe tee on the oil nozzle sub-assembly.
d. All thread support rod 15. Double check all oil line connections to make
e. 1/4" – 20 hex nuts (2) sure they are tight.
5. Mount oil control valve sub-assembly to the 16. Adjust oil firing of the burner per catalog start-up
boss on main housing, using four 1/4" – 20 x 5/8" instructions and curves.
hex head cap screws.

mCORPORATION
®
Read complete instructions before proceeding, control valve must be similarly loosened and
and familiarize yourself with all the system's equip- disconnected. Refer to specific adjusting proce-
ment components. Verify that your equipment has dures relating to control valve adjustment in
been installed in accordance with the original manu- Maxon catalog.
facturer's current instructions. Initial start-up adjustment should only be
accomplished during a “manual” burner
CAUTION: Initial adjustment and light-off control mode.
should be undertaken only by trained and 5. Start all system-related fans and blowers.
experienced personnel familiar with combus- Check for proper motor rotation and impeller
tion systems, control/safety circuitry, and with direction. Verify that all control interlocks are
knowledge of the overall installation. Instruc- working. Allow air handling equipment to run for
tions provided by the company and/or indi- adequate purge of your manifolds and combustion
viduals responsible for the manufacture and/ chamber plenums. With main gas shut off, manu-
or overall installation of complete system ally advance OVENPAK® Burner's operating crank
incorporating Maxon burners take precedence to “high fire” position so that air only flows through
over these provided by Maxon. If Maxon burner and combustion chamber.
tions, contact Maxon Corporation before CAUTION: Do not by-pass control panel timers
attempting start-up. typically controlling sequential operations.
6. Verify differential air pressure. With combustion

air blower “on”, all volume air fans operating, and
burner at “high fire” position, connect a manome-
ter between the air test connection on backplate of
For initial OVENPAK® Burner gas-firing OVENPAK® Burner and your combustion chamber
start-up: static pressure test connection. This will give a
1. Close all burner fuel valves and cocks. Make direct differential air pressure reading.
Remove pilot and main gas regulators' adjusting Model “500”
®
screw covers. Turn adjusting screw down (clock- OVENPAK
wise) to approximately mid-position. Close pilot
Burners
gas adjustable orifice screw by turning in clock-
ing within their respective settings/ranges. Be sure
all air and gas manifolds are tight and that test
ports are plugged if not being used.
If the combustion chamber does not have a
positions.
static pressure test connection, measure combus-
4. Disconnect the automatic control motor's
tion chamber static pressure by connecting a
linkage from your OVENPAK® Burner's operating
manometer between the gas pressure test port on
crank arm by loosening the control motor's
the OVENPAK® Burner's backplate and to atmo-
connecting rod from the burner's toggle linkage.
sphere with the burner at “low fire” position, fuel
For Model “EBG-SP-MRV” OVENPAK®
valves closed, and all air handling systems
Burners, the connecting linkage on the separate
running. Determine differential air pressure
reading by taking an additional reading with
mCORPORATION

®
manometer connected between the burner's air pilot ignites, as air might have to be bled out of
pressure test port and atmosphere with the burner fuel supply lines before reliable pilot flame is
at high fire position, fuel valves closed, and all air established. Pilot gas regulator should normally be
handling systems running. Subtract the combus- set for as low a pressure as possible, using fuller
tion chamber static pressure obtained above from opening of pilot gas adjustable orifice (if used).
this air pressure reading to determine the differ- 11. After ignition, adjust pilot flame for good stable
ential air pressure reading. flame shape. A rule of thumb is any pilot over a
tennis ball size is probably too large. This as-
NOTE: The differential air pressure setting determines
sumes visual access to the pilot flame. If this is
the burner's capacity and performance capabilities.
not possible, then adjust pilot to give the strongest
Model EB and MA manual air OVENPAK® Burners,
and most stable flame signal through your flame
with their external air control valve(s), provide for the
safety circuit. This signal strength can be read
manual setting of this differential air pressure to the
with a micro-amp meter. The signal strength (or
burner. Refer to specific adjusting procedures relating
range) will be determined by the specific type of
to MICRO-RATIO® and control valve adjustment in
flame safeguard instrument used with your burner
Maxon product line catalog. MA OVENPAK® Burners
system.
have an external locknut adjustment on the end of the
air butterfly control valve. This lets you limit and set
the differential pressure to the OVENPAK® Burner.
Refer to Maxon specification tables in the catalog for
the differential air settings required for your specific
guard relays should now power the main fuel
OVENPAK® Burner capacity.
Shut-Off Valve(s).
sure using this differential air pressure reading CAUTION: After completing steps above, re-
obtained from step 6. High fire pressures are check all interlocking safety components and
provided in Maxon product line catalog literature circuitry to prove that they are properly in-
and/or read data stamped into burner nameplate. stalled, correctly set, and fully operational. If in
8. Verify that spark ignitor is properly positioned doubt, shut the system down, close pilot cock
and lines up with the appropriate dimensions and contact responsible individual before
required for your specific burner. proceeding further.
a. Insert insulator To this point, gas firing and oil firing start-up
Spark
through collar into Shield procedures are identical. The gas-fired pilot that is
burner, rotating if Mixing required for both operating modes has been estab-
necessary, to Cone
1/8" lished.
engage in burner To continue adjusting for main gas firing only,
cone. Insert spark follow steps 13 through 20. To adjust for combination
ignitor until insula- oil firing, follow steps 13 through 33. If OVENPAK®
tor bottoms in spark shield then retract 1/8" to Burner is to fire with a gas pilot and oil only main
establish proper gap. fuel, proceed to steps 21 through 33.
b. Tighten locking bushing until insulator is held in
place. For main gas firing only (steps 13 through 20)
Check that spark ignitor arcs at the end of your 13. Establish main gas flame. With burner at low fire
properly positioned ignitor. position, open all manual fuel shut-off valves
9. Return burner control valve/crank to low fire (automatic fuel shut-off valve should already be
position when purge of system is complete. open) so gas flows to burner inlet. There should
10. Open main and pilot gas cocks, then attempt be little, if any, change in flame appearance.
spark ignition to light pilot while slowly turning pilot
gas regulator spring cap clockwise and/or adjust-
able orifice screw counter-clockwise to increase
m
fuel flow. Repeat procedure as necessary until
CORPORATION
®
Turn main regulator adjusting screw in (clock- 16. Re-check differential gas pressure with unit at
wise) to obtain outlet pressure of about 4"-6" wc operating temperature. Refine high fire setting if
higher than combustion chamber pressure (2"-4" necessary, considering differential pressure, flame
wc for propane, considerably higher for some EB length, and appearance. Natural gas flame should
versions). Main flame should now appear larger normally be predominantly clear blue, but possibly
than pilot-only flame. with semi-luminous tips. Dust or contaminants in
14. Establish high fire setting on gas by slowly the air stream may affect flame color.
moving burner crank toward high fire position 17. Check for contact between mixing cone and
while observing gas pressure at burner gas test top-most centering screw after system has
connection. Refine main gas regulator adjustment reached maximum operating temperature. If set
as necessary to provide correct differential gas screw touches cone, back off an additional 1/8
pressure (gauge to combustion chamber, see step turn on top and both side set screws.
7) at high fire. If pressure cannot be adjusted low 18. Plug all test connections not in use to avoid
enough, a different regulator or regulator spring dangerous fuel leakage. Replace equipment
may be necessary, or a limiting orifice valve (such cover caps and tighten linkage screws.
as Maxon's Series BV) should be added. Do not, 19. Check out overall system operation by cycling
however, exceed 4" wc pressure drop between through light-off at minimum, interrupting pilot, and
regulator outlet and burner inlet. allowing temperature control system to cycle
CAUTION: If burner(s) go out, close shut-off Recheck all safety system interlocks for proper
valve or shut main gas cock at once. Return to setting and operation.
minimum setting, re-light pilots if necessary, NOTE: Typical gas firing control sequence for Maxon
then turn main gas on again. Check carefully burners is provided only as a guide. Instructions
that every burner is lit before proceeding. provided by complete system manufacturer incorpo-
rating Maxon burners take precedence.
For gas firing Model “500-G” OVENPAK® Burner
For operation with interrupted pilot (as Light-off:
recommended), shut off pilots and cycle burner 1. Close cocks, shut-off valve(s)
from minimum to maximum and back several 2. Verify burner at low fire
times to verify the flame is maintained. 3. Start recirculating/exhaust fans
15. When burner gas firing performance is satis- 4. Start burner blower
factory and stable throughout the firing range, 5. Purge system per appropriate NFPA standards
reconnect linkage to control motor. and/or other applicable codes and standards
Control linkage travel must be such that burner 6. Open pilot & main gas cocks
crank is moved throughout its complete travel, or Shut-down:
cataloged capacities and turndowns will not be 1. Close main & pilot gas cocks
achieved. 2. Keep combustion air blower running after shut-
If less than full-rated burner capacity is re- down long enough to allow burner to cool
quired, linkage can be adjusted to limit maximum
output. With interrupted pilot, it may be neces- WARNING: Test every UV installation for danger-
sary to set control for somewhat higher than ous spark excitation from ignitors and other pos-
minimum burner setting to permit hold-in of flame sible sources of direct or reflected UV radiation.
detection system without pilot. Use only gas-tight scanner connections.
CAUTION: Internal drive mechanism within the 20. Before system is placed into full service,
control motor may be damaged if linkage is instruct operator personnel on proper start-up
adjusted so as to cause binding with burner in operation with shut-down of system, establishing
high or low fire position. written instructions for their future reference.
mCORPORATION

®
For initial OVENPAK® Burner oil firing 25. Refine main burner adjustment, if necessary,
start-up: using the flow/position curves shown below.
Complete steps 1 through 12 to establish gas-fired Determine need by advancing linkage slowly from
pilot and steps 13 through 20 for main gas firing (if low-fire position while viewing main flame for
combination fuel firing is to be used). satisfactory characteristics and the complete
absence of smoke, soot, odor, or unvaporized oil.
21. Prepare for initial oil firing start-up by checking Certain firing conditions may require significantly
that all the burner valves are closed, the combus- higher or lower flows for optimal combustion.
tion chamber purged, combustion air is estab-
lished, oil and compressed air is supplied at 90- Model “500-SP” OVENPAK® Burner
125 PSIG, fuel selector switch is set for oil, control
motor linkage is disconnected, and OVENPAK® 40
Burner is set to “low fire” position. 60 Hz 550
35
22. Set compressed air pressure (using the regula- only
tor and gauge furnished as part of the pipe train) 30
to the figure shown for your burner size in the
Gallons/Hour - #2 Oil
table below. Re-adjust pilot gas if necessary. 25 535
20
Required Pressures 525
Compressed Air #2 Oil Pressure 15
Burner Model
(PSIG) [1] (PSIG)
515
10
500-SP EBC-SP 500-SP EBC-SP 500-SP EBC-SP
508
508-SP EBC-2SP 35 5
60
515-SP EBC-3SP 50
0
525-SP EBC-4SP 60 35-60 70 Lo
1 2 3 4 5 6 7 8 9 10 11 Hi
12
Firing Position
535-SP EBC-5SP 70
80 For 50 Hz
550-SP EBC-6SP operation, 30 550
these burners 50 Hz
[1] Varies with air differential pressure are downrated 25 only
as shown in the
23. Adjust low compressed air pressure switch to chart at right. 535
Gallons/Hour - #2 Oil
20
break at about 5 PSIG below the desired supply
pressure. (It should be electrically interlocked with 15 525
the oil solenoid valve.)
10
NOTE: All Model “500-SP” OVENPAK® Burners are 515
adjusted and test-fired in the open at our factory 5 508

before shipment, so simple setting of oil pressure
regulator is normally sufficient to establish main flame 0
1
Lo 2 3 4 5 6 7 8 9 10 11 12
Hi
once the manual oil valve is opened. Significant re- Firing Position
adjustment will normally be required only in cases of
high back pressure or suction.
CAUTION: If burner(s) go out, close shut-off
24. Open manual oil valve. When the burner lights, valve or main fuel cock at once. Return to
set the oil pressure (using the regulator and gauge minimum setting, re-light pilots if necessary,
furnished as part of the pipe train) to the figure then turn main oil on again. Check carefully that
shown for your burner size in the table above. every burner is lit before proceeding.
CAUTION: Oil flames are highly radiant. Use eye

protection and minimize viewing.

m
CORPORATION
®
26. Cycle burner from minimum to maximum and 31. Check out overall system operation by cycling
refine adjustment, if necessary. through light-off at minimum, interrupting pilot, and
For operation with interrupted pilot (as allowing temperature control system to cycle
recommended): Test burner operation by cycling burner from minimum to maximum and return.
to low fire position and turning off oil, then pilot. 32. Re-check all safety system interlocks for proper
Re-light pilot and main flame, then cycle burner setting and operation.
through its firing range while checking for suitable NOTE: Typical oil firing control sequence for Maxon
flame signal. Repeat as necessary. burners is provided only as a guide. Instructions
27. Set low oil pressure switch (if used) to break provided by complete system manufacturer incorpo-
just below the established oil pressure at the rating Maxon burners take precedence.
sensing point. (It should be a manual reset switch,
®
on the low pressure side of the oil pressure For oil firing Model “500-SP” OVENPAK Burners
regulator). Light-off:
28. When burner performance is satisfactory and 1. Purge system per appropriate NFPA standards
stable throughout the firing range, reconnect and/or other applicable codes and standards
linkage to control motor. 2. Combustion air on
Control linkage travel must be such that burner 3. Burner at low fire
crank is moved throughout its complete travel, or 4. Gas pilot lit
cataloged capacities and turndowns will not be 5. Compressed air on
achieved. 6. Oil on main flame lit
If less than full-rated burner capacity is re- 7. Pilot gas off
quired, linkage can be adjusted to limit maximum 8. Firing rate controlled to need
output. With interrupted pilot, it may be neces-
Shut-down:
sary to set control for somewhat higher than
1. Cycle to low fire
minimum burner setting to permit hold-in of flame
2. Re-establish pilot
detection system without pilot.
3. Main oil off
CAUTION: Internal drive mechanism within the 4. Compressed air off
control motor may be damaged if linkage is 5. Pilot gas off
adjusted so as to cause binding with burner in 6. Cool down oven
high or low fire position. 7. Combustion air off
29. Check for contact between mixing cone and WARNING: Test every UV installation for danger-
top-most centering screw after system has ous spark excitation from ignitors and other pos-
reached maximum operating temperature. If set sible sources of direct or reflected UV radiation.
screw touches cone, back off an additional 1/8 Use only gas-tight scanner connections.
turn on top and both side set screws.
33. Before system is placed into full service,
instruct operator personnel on proper start-up
dangerous fuel leakage. Replace equipment
operation with shut-down of system, establishing
cover caps and tighten linkage screws.
m CORPORATION

Model “500-SP” OVENPAK® Gas/Oil Burners Page 2300-A/P-1
Assembly Numbers
Packaged Packaged Packaged Packaged

Size Gas Only Gas Only Combination Combination
Burner Automotive Burner Automotive
508 508G OP (91) 508AMG OP (95) 508C OP (98) 508AMC OP (102)
EB EB EBMRV EBMRV
Size
Gas Only Combination Gas Only Combination
EB2 EB2G 5OP (52) EB2C 5OP (60) EB2MRVG 5OP (46) EB2MRVC 5OP (48)

configured products:
• Backplate
• Spark Ignitor
• Adjustable orifice
• Observation glass
• Flame detection
• Fuel/Linkage
• Mixing Cone
• Flowmeter Piping (Combination burners only)
• Discharge Sleeve
• Oven wall gasket
• Motor (and/or adapter flange for EB)
• CB & L's
• Switches
• Filters/Silencers (Packaged burners only)
• Max Airstream Temp (°F)

m
CORPORATION
Page 2300-A/P-2 Model “500-SP” OVENPAK® Gas/Oil Burner
Assembly Numbers
Configured Pipe Trains

Pipe Trains
Configured Compressed Air Light Oil
Burner No. Pilot Gas w/o solenoid w/ solenoid w/o solenoid w/ 1 solenoid w/ 2 solenoid
valve valve valve valve valves
508C OP 508C PGPT 27086 508C CAPT 31322 508C OPT1 508C OPT2
EB2C 5OP 508C PGPT 27086 508C CAPT 31322 508C OPT1 508C OPT2
Configured Solenoid Valve Kits Configured Replacement Blower Kits

Configured Solenoid Valve Kits Configured Replacement Blower
Burner Size
Burner No. Kit No.
Up Down Horizontal
535 535 RBK
508C OP 508C USVK 508C DSVK 508C HSVK
550 550 RBK
EB2C 5OP 508C USVK 508C DSVK 508C HSVK
m
CORPORATION
Assembly Numbers
Spare Parts
Combination 508-SP 515-SP 525-SP 535-SP 550-SP
Model "500" OVENPAK® Burner
Gas Only 508G-SP 515-G-SP 525-GSP 535G-SP 550-GSP
Combination EBC-2SP EBC-3SP EBC-4SP EBC-5SP EBC-6SP
Model EB-SP OVENPAK® Burner
Gas Only EBG-2SP EBG-3SP EBG-4SP EBG-5SP EBG-6SP
Pilot Gas Adjustable Orifice 38009 (2) 50431 (3)
Replacement Oil Nozzle Assembly 36545 (5) 36546 (5) 36547 (7) 36548 (10) 36549 (10)
for 500G-SP versions 36555 36556 36557 36558 36559
Oil Conversion Kit
for EBG-SP version 36550 36551 36552 36553 36554
with 29362
EBC-SP with 29362 upper tube upper tube with 29362 upper tube
versions with 29361 lower tube with 31602 with 31603 lower tube
for up-firing lower tube
applications with 29362 with 29362 with 29362
500-SP with 29362 upper tube upper tube upper tube upper tube
versions with 29361 lower tube with 31602 with 31602 with 29363
Flowmeter Piping lower tube lower tube lower tube
Option with 28984 with 28984 with 28984
EBC-SP lower tube lower tube lower tube with 28984 lower tube
versions with 28985 with 28986 with 31547 with 31548 upper tube
for down-firing upper tube upper tube upper tube
applications with 28984 with 28984 with 28984
500-SP with 28984 lower tube lower tube lower tube lower tube
versions with 28985 upper tube with 28986 with 31547 with 28987
upper tube upper tube upper tube

m
CORPORATION
Page 2300-A/P-4 Model “500-SP” OVENPAK® Gas/Oil Burners
Assembly Numbers
Spare Parts
Combination 508-SP 515-SP 525-SP 535-SP 550-SP
Model "500" OVENPAK® Burners
Gas Only 508G-SP 515G-SP 525G-SP 535G-SP 550G-SP
Combination EBC-2SP EBC-3SP EBC-4SP EBC-5SP EBC-6SP
Model EB-SP OVENPAK® Burners
Gas Only EBG-2SP EBG-3SP EBG-4SP EBG-5SP EBG-6SP
Low Fire 27106
Start
Switches Hazardous Duty/Weatherproof
(1 SPDT) NEMA 1,3,3R,4,7,9,12, & 13 35949 35950
(outdoors, hazardous duty locations)
High and General Purpose NEMA 1
Low Fire 29878 29883
Position
Switch Weatherproof NEMA 1,3,3R,4,12, & 13
35616 35617
(2 SPDT) (outdoors, non-hazardous locations)
Replacement Spark Ignitor 47663
Alternate UV Scanner Adapter Plate 30321
Discharge Diameter (in inches) 6" 8" 10" 12"
8" long sleeve (#310SS) 32730 32731 32732 32733 [1]
12" long sleeve (#310SS) 27019 27020 27021 27022
8" long sleeve (RA330) 34660 34661 34662 34663 [2]
12" long sleeve (RA330) 47339 47346 47353 47360
8" long high back pressure sleeve
34022 34023 34024 34025 [3]
(#310SS)
12" long high back pressure sleeve
Discharge 47337 47344 47351 47358
(#310SS)
Sleeve and
Mounting 8" long refractor y lined sleeve 38291 38292 38293 38294
Gasket 6" long sleeve (#310SS) --- --- --- 29860
Options
6" long sleeve (RA330) --- --- --- 34664
Standard housing flange gasket 28475 28476 28477 28478
Standard flange discharge sleeve gasket
34027 34028 34029 34030
set
Standard discharge sleeve gasket 33975 33976 33977 33978
6" long HBP sleeve (#310SS) --- --- --- 34026
HBP discharge sleeve gasket 34018 34019 34020 34021
Refractor y lined discharge sleeve gasket 1050556 1050557 1050558 1050559
Linkage Maintenance Kits 33636 33637 33638 33639
[1] For propane or propane air ser vice with 500-SP or EB-SP OVENPAK® Burners, use #29860 discharge sleeve (length 6")
[2] For propane or propane air ser vice (as above), use #34664 (length 6")
[3] For propane or propane air ser vice (as above), use #34026 (length 6")
m
CORPORATION

Assembly Numbers
Spare Parts
Connecting base and linkage assemblies CB & L
Type Manufacturer Model No.
This listing of CB & L assemblies shows only a Assembly
sampling of the more popular control motors. We may EA51-58, also
28560
be able to furnish CB & L for other operators not Barber-Colman with prefix MC,
MP, or MF (7)
cataloged (supply manufacturer’s name and model
number). M6184D, A, F
M6194D, B, E
M9184D
Type Manufacturer Model No. CB & L Assembly M7384A
M7184A
P-25 [1] 28436
Foxboro M7984D
P-50 [2] 28437 M7284A, C, Q
28562
M9484D, E
01-11/861P Honeywell (8)
M9494D
Honeywell 03-3/863T 28442 Electric M6284F
Air 01-9/861M M9184D, A, F
D-3153 M9484E, F, D
Johnson 29265 M6294D, B
D-3151
M6284A, D, F
28440 M9194D, E
Taylor 40VF6
(18) M640A, M940A 28563 (9)
[1] Specify from Foxboro: [2] Specify from Foxboro: 10261
WITH #B6301-LR yoke WITH #B6301-WR yoke Leeds & 10262 28564
WITH #B6301-KY conn. asby. WITH #B6301-TY conn. asby. Northrup 10264 (9)
LESS indicating pointer LESS indicating pointer 10266
LESS travel indicator scale LESS travel indicator scale Penn/Johnson M-80, M-81 28562 (8)
LESS stem locknuts LESS stem locknuts

508-SP, 508G-SP, 525-SP, 525G-SP, 550-SP,
Model "500" OVENPAK® Burner>
515-SP, 515G-SP 535-SP, 535G-SP 550G-SP
A Standard Air Filter Assembly includes (2) replaceable elements 24672 (12) 24334 (27) 24335 (35)
I
R
Replaceable filter elements for above 28045 (.5) 28047 (1) 24337 (1)
F
Air Filter Assembly with (2) permanent elements 50827 50833 50834
I
L
T Permanent Filter Elements for direct replacement providing
E burner originally supplied with permanent elements.
34652 (4) 34654 (6) 34655 (8)
R NOTE: See Product Information Sheet 2000-3 for details involving
S field modifications
S Air Inlet Silencer Assembly includes housing and inlet guard 31243 (35) 31244 (100) 31245 (100)
I
L Air Inlet Filter Assembly for Silencer Assembly above
29742 (3) 29743 (6)
E includes (1) replaceable element
N Replaceable Filter Element for Silencer/Filter Assembly
C 31062 (2) 31051 (4)
above
E
R Air Inlet Filter Assembly for Silencer Assembly above
35567 (15) 35568 (20)
S includes (1) permanent element

m CORPORATION
Page 2300-A/P-6 Model “500-SP” OVENPAK® Gas/Oil Burners
Notes
m
CORPORATION

Bulletin 2600
MEGAFIRE® Gas/Oil Burners
15M MEGAFIRE® Burner firing on natural gas with 10:1 turndown ratio capabilities
• Provides clean burning of #2 oil, natural, or propane gas

• Easy installation due to compact design
• Quiet operation with exceptionally low horsepower requirements
• In-line blower (IB) version includes energy-efficient centaxial direct-drive
combustion air blower
• Provides application flexibility with:
– Heat releases to 45,000,000 Btu/hr
– High turndown capabilities
10:1 on #2 oil
15:1 on natural gas
– Nine different styles and three different sizes
MEGAFIRE® Burner applications have included:

Boilers, rotary dryers (for sand, gravel, minerals, and chemicals), municipal solid waste incinerators,
indirect air heaters, heater/treaters for the petroleum industry, food process dryers, fertilizer dehydration,
rendering plant operations, gypsum board dryers, and fluidized bed installations for power plants
Page 2602
MEGAFIRE® Gas/Oil Burners
• Fires gas, #2 oil, or both simultaneously
• Atomizes oil with steam or compressed air
• Clean products of combustion with low emission levels
• Stand-by or alternate fuel capabilities
• Cost-effective external blower (EB) version for back pressure applications
• Economical operation and low noise levels
• Easy installation and start-up when supplied with pre-assembled controls

and pipe train accessory options
1/99
CORPORATION 201 East 18th Street, P.O. Box 2068, Muncie, Indiana, 47307-0068. Phone: (765) 284-3304. Fax (765)286-8394
MEGAFIRE® Gas/Oil Burners Page 2603
Performance and Selection Data

Packaged Internal Construction Basic MEGAFIRE® Burners include an air control
shutter, fuel nozzles, mixing cone, pilot and provision
for UV scanner in one compact package.
“EB” External Blower version Combustion air is provided by either an integral
centaxial (IB) in-line blower or via an (EB) external
Combustion
Air Inlet blower. A differential air pressure (see page 2604)
1/4" NPT Lifting Lug
Comb. Air must be provided for cataloged capacities. IB version
1/2" NPT
Oil Inlet
Test Conn. is used for negative to balanced combustion chamber
pressures. For back pressure or over-fire applications,
use EB version and external blower.
5/8" (.625) dia.

Observation Mounting Holes
Port
Main Stainless Steel

Gas Access Discharge Sleeve
Inlet Plate Pilot
3/4" NPT Inlet
Atomizing Plate
Media Inlet
Alternate Air
Inlet Positions
“IB” In-Line Blower version
End View Into
Lifting Lifting Lug
Lug 1/2" NPT
Oil Inlet
Face of Burner
Stainless Steel
Combustion Castable
Air Inlet Refractory
Same Mtg.
as
Discharge
Sleeve
Optional Block/Seal &

Main Access 1/4" NPT Stainless Steel Support Assembly
Gas Plate Comb. Air Discharge Sleeve
Inlet Test Conn.
3/4" NPT Pilot Inlet Plate
Atomizing
Media Inlet
Flame discharge is through a stainless steel Suitable fuels include natural gas, propane, or #2
combustion sleeve (1100°F (593°C) maximum oil at 50 SSU viscosity or less. Atomizing steam or air
chamber temperature) or a refractory block (1600°F is required at 60 PSIG for oil firing. Simultaneous gas
(870°C) maximum chamber temperature) complete and oil firing is possible, up to the total rated capacity
with seal and support housing. of a MEGAFIRE® Burner.
Piloting is by an independent, spark-ignited, raw A complete system utilizing MEGAFIRE® Burners
gas pilot. also includes gas, oil, and atomizing media pipe trains
Burner mounting uses an integral mounting and a control panel.
flange, but additional support MUST be provided.
Combustion air control is accomplished with a
built-in air shutter, connected via control cable, to a
fuel control valve (Maxon MICRO-RATIO® Valve). The
“XC” version utilizing external control of air and fuel is
also available.
8/97
Page 2604 MEGAFIRE® Gas/Oil Burners

MEGAFIRE® Burners 15M 30M 45M
Maximum Capacity (Btu/hr) Natural Gas, Propane, or #2 Oil 15,000,000 30,000,000 45,000,000
Natural Gas or Propane 15 to 1 15 to 1 15 to 1
Turndown Ratios
#2 Oil 10 to 1 10 to 1 10 to 1
Natural Gas 22" wc 26" wc 38" wc
Fuel Pressures
#2 Oil 70 psig 70 psig 60 psig
required at burner inlet
Propane 8.8" wc 10.4" wc 15.2" wc
Pilot Gas Inlet Pressure (range) 100k – 300 kBtu/hr 0.5 – 5" wc
Combustion Air (SCFM) [1] 2750 6000 9500
Combustion Air Differential Pressure
@ test connection upstream of air shutter 2.9" wc 2.9" wc 3.3" wc
(IB and EB versions)
Total Combustion Air Pressure
@ EB transition inlet 4.4" wc 5.1" wc 9.9" wc
Required (EB version only)
Atomizing Media SCFM Air @ 60 psig 20 37 72
(for oil firing option) lbs/hr Steam @ 60 psig 58 109 207
IB Blower Horsepower Direct Drive 230/460/3/60 3 5 10
Length (in feet) 9 15 21
Approximate Flame Dimension
Diameter (in feet) 3.5 4 4
Force (pounds) required to open air shutter with combustion air on (refer to
40 lbs. 50 lbs. 60 lbs.
Bulletin 7000-Control Valves for torque required to operate control valve set
Noise Levels (IB burner only) [2] dBA 87 88 89
[1]The SCFM shown is based on the IB fan cur ves at the known differential through the burner with the air shutter fully open. For
both IB and EB versions, combustion air must be provided at differential pressure (burner over combustion chamber) for
cataloged burner capacities.
[2] Silencers are available to reduce noise levels to below 80 dBA
To select your MEGAFIRE® Burner, specify: – Electrical specification for motor

– For “EB” version:
1. Quantity – Electrical specification for motor
2. Size – Blower discharge position
– 15M = 15,000,000 Btu/hr (maximum) – Blower volume and pressure
– 30M = 30,000,000 Btu/hr (maximum) – For “XC” version (EB only):
– 45M = 45,000,000 Btu/hr (maximum) – Verify that control of combustion air/fuel gas
3. Fuel and atomizing media and/or fuel oil is specified
– Gas: If other than natural or propane gas, 6. Discharge options
provide: – #310 stainless steel discharge sleeve, or
Specific fuel and/or analysis; – Refractory block with seal and support housing
Specific gravity, calorific value, and 7. Control valve options
available pressure – Standard cam version
– Oil: If other than #2 oil, provide: – Packaged control valve arrangement:
Specific fluid and/or analysis; Right-hand assembly, or
Specific gravity, calorific value, viscosity, Left-hand assembly
temperature and available pressure 8. Assembly arrangement options
– Atomizing media: – Gas inlet position (Note: pilot/scanner always
Air – Volume and pressure opposite side from gas inlet)
Steam – Volume, temperature and – Air inlet position
pressure 9. Accessory options
4. Combustion chamber static pressure – Connecting base & linkage for specific
condition automatic control motor
5. In-Line (IB) or External (EB) Blower version – Atomizing air train
– For “IB” version: – Atomizing steam train
– Light oil train
– Gas train
– Shut-off valve(s)
– Control panel

Performance Curves
15M MEGAFIRE® – Natural Gas

25 16000
14000
Natural Gas Flow, cubic feet / hour

20
Natural Gas Pressure, inches w.c.
12000
10000
15
Flow 8000
10
Pressure
6000
4000
5
2000
0 0
Min
0 1 2 3 4 5 6 7 8 9 10 Max
11
Fuel Gas Control Valve Position
NOTE: The fuel gas pressures shown are measured at the fuel gas test connection downstream of the control valve at the gas
manifold inlet flange.
NOTE: The fuel gas control valve, represented on the x-axis of the above graph is a Maxon 3 inch
“-M” style control valve. This valve is supplied in the 15M, 30M and 45M MEGAFIRE® pre-assembled control
valve/pipe train package.
15M MEGAFIRE® – #2 Fuel Oil

70 120
60
100
Fuel Oil Flow, gallons / hour
50
Fuel Oil Pressure, psig
80
40
Pressure 60
30
Flow 40
20
20
10
0 0
0
Min 1 2 3 4 5 6 7 8 9 10 11
Max
Fuel Oil Control Valve Position
NOTE: The fuel oil control valve, represented on the x-axis of the above graph is a Maxon 1/2" – O – 100 SYNCHRO
oil valve. This valve is supplied in the 15M MEGAFIRE® pre-assembled control valve/pipe train package.
8/97

Performance Curves
30M MEGAFIRE® – Natural Gas

25 30000
25000
Natual Gas Flow, cubic feet / hour

20
20000
15
15000
Flow
10
Pressure 10000
5
5000
0 0
0
Min
Min 1 2 3 4 5 6 7 8 9 10 Max
11
Fuel Gas Valve Position
NOTE: The fuel gas control valve, represented on the x-axis of the above graphs is a Maxon 3 inch
30M MEGAFIRE® – #2 Fuel Oil

60 250
50
200
40
Pressure 150
30
Flow 100
20
50
10
0 0
Min
0
Min 1 2 3 4 5 6 7 8 9 10 11
Max
Fuel Oil Control Valve Position
NOTE: The fuel oil control valve, represented on the x-axis of the above graph is a Maxon 3/4" – O – 200 SYNCHRO

Performance Curves
45M MEGAFIRE® – Gas

30 45000
40000
25
Natural gas Flow, cubic feet / hour

35000
20 30000
Flow
25000
15
20000
Pressure
10 15000
10000
5
5000
0 0
0
Min 1 2 3 4 5 6 7 8 9 10 11
Max
Max
Fuel Gas Valve Position
NOTE: The fuel gas control valve, represented on the x-axis of the above graphs is a Maxon 3 inch
45M MEGAFIRE® – Oil

60 350
300
50
250
40
Flow 200
30
150
Pressure
20
100
10
50
0 0
0
Min 1 2 3 4 5 6 7 8 9 10 Max
11
Max
Fuel Oil Valve Position
NOTE: The fuel oil control valve, represented on the x-axis of the above graph is a Maxon 1" – O – 400 SYNCHRO
8/97
Dimensions
15M EB MEGAFIRE® Combination Burners – Right Hand Arrangement

48.44
36.63
Combustion 30.0
1/4" NPT
Air Inlet 16.5 Lifting
Comb. 5/8" (.625) dia.
1/2" NPT Air Test Lug Mounting
Oil Inlet Conn. 28.69 Holes
7.13 19.44
9.88
15.0 21.03 27.656 dia.

dia. 19.28 29.656 dia.
dia.
Observation
Port 16.76
Main
Gas 2.0 Stainless Steel
Access Discharge Sleeve
Inlet Plate Pilot 22˚ 22˚
3/4" NPT Inlet Alternate Air
Atomizing Plate Inlet Positions
Media Inlet
15M EB MEGAFIRE® Combination Burners – Left Hand Arrangement

48.44
36.63 Combustion
Air Inlet
30.0
Lifting
Lug 16.5
1/4" NPT
5/8" (.625) dia. 28.69 Access Comb. Air 7.0
Mounting Holes Plate Test Conn.
19.44 9.88
27.656 dia. 15.0
29.656 dia. 21.03

19.28 dia.
dia.
Observation
16.76
Port
Stainless Steel Main Gas Inlet
Alternate 22˚ 22˚ Discharge Sleeve 2.0

1/2" NPT
Air Inlet Oil Inlet
Positions Gas Pressure
Pilot Inlet 3/4" NPT Atomizing
Test Connection Media Inlet
Plate
17.0 dia.
22
15˚
15˚
19.0 dia.
4" ANSI raised face 150# slip-on welding
9/16" (.562) dia. flange w/2.688 lg. 4" NPT Sch. 40 pipe
12.0 dia.
12 holes
outside Bolt holes to straddle centerline
Combustion Air Inlet Main Gas Inlet

Dimensions
15M IB MEGAFIRE® Combination Burners – Right Hand Arrangement
56.94
36.63 28.69 5/8" (.625) dia.
Mounting Holes
30.0 19.44
16.5 Lifting
Lifting Lug
1/2" NPT
Lug 27.656 dia.
Oil Inlet
9.88 29.656 dia.
Combustion
Air Inlet
16.76
24.03 19.28
dia. dia.
22˚ 22˚
Main Gas Inlet Access 1/4" NPT Stainless Steel

Plate Comb. Air Discharge Sleeve
2.0
3/4" NPT Test
Atomizing Conn.
Media
Inlet Pilot Inlet Plate
15M IB MEGAFIRE® Combination Burners – Left Hand Arrangement

56.94
36.63
30.0
Access 16.5
Plate Lifting
1/4" NPT Lug
Lifting
Comb. Air
Lug
9.88 Test Conn.
5/8" (.625) dia. 28.69
Mounting Holes Combustion
19.44 Air Inlet
27.656 dia. 19.28 24.03

29.656 dia. dia. dia.
16.76
Stainless Steel Main Gas Inlet

Discharge Sleeve 1/2" NPT 3/4" NPT Atomizing 2.0
22˚ 22˚ Pilot Inlet Oil Inlet Media Inlet
Plate
Gas Pressure
Test Connection
22˚

flange w/2.688 lg. 4" NPT Sch. 40 pipe
Bolt holes to straddle centerline
Main Gas Inlet
8/97
Dimensions
58.94
Combustion
Air Inlet 36.63
30.0 35.5 5/8" (.625) dia.
Lifting Mounting Holes
10.9 16.5 15.5 26.25
Lug
3/4" NPT
Oil Inlet
42.31 dia.
19.0
33.63
dia. 27.06
dia.
Observation
Port
23.08
40.31 dia.
Main Stainless Steel
1/4" NPT
Gas Discharge Sleeve
Comb. Air Access Pilot
Inlet Test Conn. 2.0 Plate Inlet
22˚ Alternate
3/4" NPT Plate 22˚
Air Inlet
Atomizing Positions
Media Inlet

58.94
36.63
30.0 Combustion
Air Inlet
35.5 16.5
5/8" (.625) dia.
Mounting Holes 26.25 Lifting 1/4" NPT
15.5 Comb. Air 10.9
Lug
Test Conn.
42.31 dia.
19.0
27.06
dia. 33.63
dia.
23.08
Stainless Steel
Discharge Sleeve Access Plate
3/4" NPT Main Gas Inlet
Pilot Inlet Oil Inlet
Alternate Air Plate 2.0
3/4" NPT
Inlet Positions 22˚ 22˚ Atomizing
Gas Pressure Media Inlet
Test Connection
21.25 dia.
22˚
11˚
11˚

flange w/2.688 lg. 4" NPT Sch. 40 pipe 23.5 dia.
16.0 dia.
9/16" (.562) drill thru outside
16 holes
Main Gas Inlet
Combustion Air Inlet
Dimensions
61.94
36.63
30.0 35.5
Lifting 5/8" (.625) dia.
16.5 Lug 26.25 Mounting Holes
15.5
3/4" NPT
Oil Inlet
Combustion
Air Inlet
42.21 dia.
36.63 27.06
dia. dia.
23.08
Stainless Steel 40.31 dia.

Main Gas Inlet Discharge Sleeve
Access
1/4" NPT Plate Pilot Inlet
2.0
Comb. Air Plate
Test Conn. 22˚ 22˚
3/4" NPT Atomizing
Media Inlet

61.94
36.63
30.0
35.5 16.5 Lifting
5/8" (.625) dia. Lifting 1/4" NPT
Mounting Holes 26.25 Lug
15.5 Lug Comb. Air
Test Conn.
Combustion
42.31 dia. Air Inlet
27.06 36.63
dia. dia.
23.08
40.31
Stainless Steel
Discharge Sleeve
Main Gas Inlet
3/4" NPT Access
22˚ 22˚ Pilot Inlet Plate
Oil Inlet Plate 2.0
3/4" NPT
Gas Pressure Atomizing
22˚

Main Gas Inlet
8/97
Dimensions
60.94
Combustion 36.63
Air Inlet 3.0
Access Plate
16.5
Lifting 37.49
1" NPT Lug
28.25 5/8" (.625) dia.
12.9 Oil Inlet 15.5 Mounting Holes
46.78 dia.
21.48
31.43
37.59
dia.
dia.
Observation
23.38
Port
44.78 dia.
Stainless Steel Alternate Air

Main Gas Inlet 22˚ 22˚
Discharge Sleeve Inlet Positions
2.0 Pilot Inlet Plate
3/4" NPT 1/4" NPT
Atomizing Comb. Air
Media Inlet Test Conn.

60.94
36.63 Combustion
30.0 Air Inlet
Access 16.5
Plate
37.49
Lifting 1/4" NPT
5/8" (.625) dia. Lug Comb. Air
Mounting Holes
28.25 15.5 12.9
Test Conn.
46.78 dia.
21.48
31.3
dia. 37.59
dia.
Observation
Port
25.38
44.78 dia.
Stainless Steel
Discharge Sleeve Main Gas Inlet
Alternate Air 22˚ 22˚
Inlet Positions Pilot Inlet 2.0
Plate
Gas Pressure
3/4" NPT Atomizing
Test Connection
Media Inlet
25.0 dia.
22˚
9˚
9˚
27.5 dia.
20.0 dia.
9/16" (.562) drill thru flange w/2.688 lg. 4" NPT Sch. 40 pipe
20 holes Bolt holes to straddle centerline
Combustion Air Inlet Main Gas Inlet

Dimensions
65.94
36.63
30.0
Lifting 37.49
16.5 Lifting
Lug 28.25 5/8" (.625) dia.
1" NPT Lug
15.5 Mounting Holes
Combustion OIl Inlet
Air Inlet
46.78 dia.
41.59 31.43
dia. dia.
25.38
44.78 dia.
Stainless Steel
Main Gas Inlet 1/4" NPT Discharge Sleeve
Access Plate Comb. Air Pilot Inlet Plate 22˚ 22˚
2.0
Test Conn.
3/4" NPT Atomizing
Media Inlet

65.94
36.63
30.0
37.49 1" NPT Lifting
5/8" (.625) dia. Lifting
28.25 Oil Inlet 1/4" NPT Lug
Mounting Holes Lug Comb. Air
15.5 Test Conn.
Combustion
Air Inlet
46.78 dia.
41.59
31.3 dia.
dia.
25.38
44.78 dia. Stainless Steel

Discharge Sleeve Main Gas Inlet
Pilot Inlet Access 2.0
22˚ 22˚
Plate Plate 3/4" NPT Atomizing
Gas Pressure
22˚

Bold holes to straddle centerline
Main Gas Inlet
8/97
Dimensions
Oil Gun Assembly Name
R
39255B
Combustion Air
COMBUSTION AIR TEST

Lifting lugs to be in Test Connection
upright (or 12 o'clock) position
regardless of air, oil
or gas inlet rotation
FLAME
DETECTOR
Blower PILOT
SPARK IGN.
Lifting
Lug
See pilot
detail below
MAIN GAS
Main
Gas
OIL
ATOMIZING MEDIA
Mounting feet to be in
Atomizing Oil
down (6 o' clock) position
Air/Steam
regardless of air, oil or
gas inlet rotation
MEGAFIRE® Raw Gas Pilot
No Gaps
Sight Pilot Gas
Port Connection
Note: Oil gun assembly must seat
solidly against mixing cone
UV Scanner
Connection
Spark
Ignitor
Suggested Block Mounting

for Seal & Support Blocks
Refractory
Metal Cast or Block
Wall Fiber Blanket
Wrapping Block
1" minimum
Burner Block Maximum chamber temperature ratings for

with Stainless
discharge options:
Support Sleeve
SS discharge sleeve – 1100°F (593°C)
Refractory block discharge – 1600°F (870°C)
Dimensions
Refractory Block/Seal & Support Assembly
15M MEGAFIRE® Burner

ENG
ITEM
NO.
1 SEA
5/8" (.625)
2 BUR
3 HEX
4 FLA
16 holes
27.656 dia.
25.0
5.875
9.875
29.656 dia.
34.0
42.312 dia.
40.312 dia.
12.0
5/8" (.625) 16.0
16 holes
8/97
Dimensions
Refractory Block/Seal & Support Assembly
5/8" (.625) holes

16 required
38.5
46.781 dia.
11.5
44.781 dia. 15.5
MEGAFIRE® Burner Accessories

(Dimensions in Inches)
#2 Light Oil Pipe Train 6

7 7
8
4 5
1 3 1
Inlet → Flow →
2
Assembly includes: 6 Low pressure switch (5-150 PSIG)

1 3/4" ball valves 7 3/4" Series 8730 shut-off valves
2 1" filter (ordered separately; assembled into pipe train
3 3/4" oil pressure regulator as shown)
4 1/4" needle valve 8 High pressure switch (5-150 PSIG)
5 Oil pressure gauge (0-160 PSIG)
Atomizing Air Pipe Train
1 3 1
Inlet → Flow →
Assembly includes:
1 3/4" ball valves
2 3/4" air filter
3 3/4" air regulator with (0-160 PSIG) gauge
4 Low pressure switch (5-150 PSIG)
5 3/4" solenoid valve
8/97
MEGAFIRE® Burner Accessories

(Dimensions in Inches)
Atomizing Steam Pipe Trains (maximum temperature 300°F)

Note: Field site insulation will be required.
5
3
8
7
6
4
1 1
2
Inlet → Flow →
Assembly includes:
1 1" ball valves
2 1" strainer
3 Thermometer (30-300°F)
4 1" pressure regulator
5 Low pressure switch (50-150 PSIG)
6 1" solenoid valve
7 1/4" needle valve
8 Steam pressure gauge (0-100 PSIG)
Pipe Train Size Length Height Depth Minimum Inlet Pressure Maximum Inlet Pressure
#2 Light Oil 3/4" 76" 23" 13" 75 PSIG
Atomizing Steam 1" 56" 22" 8" 100 PSIG 150 PSIG
Atomizing Air 3/8" 38" 22" 5" 75 PSIG
MEGAFIRE® Gas/Oil Burners Page 2600-S-1
General Instructions Main gas regulator is essential to maintain a
Important: Do not discard packing material until supplies multiple burners, provide a separate regula-
all loose items are accounted for. tor in the branch leading to each burner system.
To prevent damage in transit, the control valves, Size the regulator for full system capacity at the
pipe trains, spark ignitor, combustion sleeve, mount- required pressure, carefully considering pipe train
ing gaskets and connecting linkage components may losses. Follow the instructions attached to the regula-
be packed separately and shipped loose with your tor during installation and be sure to remove any
new Maxon MEGAFIRE® Burner. shipping pin or block.
The burner itself is normally only a part of your Pilot take-off should be upstream of the main gas
complete combustion system. Additional pipe train regulator, but downstream of the main gas cock. It
accessories and control components will be required should normally include its own pilot gas regulator, a
for a complete system installation. solenoid valve, and shut-off cock. A pilot adjustable
IB MEGAFIRE® Burner provides its own combus- orifice at the pilot inlet simplifies adjustment.
tion air supply (“EB” version requires a separate Pilot piping must be large enough to provide for
combustion air blower). Both nozzle mixing burners the full flow and pressures shown in the catalog for
serve as their own fuel/air mixing device. your particular burner size.
Burner should not be exposed to direct radiant heat Fuel Shut-Off Valves (when properly connected to
or positioned where it might draw in inert gases. If a control system) shut the fuel supply off when a
problems exist, consider relocation and/or use of the hazardous operating condition is sensed. Manual
“EB” version and external air supply. reset valves require operator attendance each time
Electrical service must match the voltage, phase the system is started up (or restarted after a shut-
and cycle of all electrical system components and be down). Motorized shut-off valves permit automatic
compatible with burner nameplate ratings. Insure that start-restart when used with an appropriate control
all normal control safeguards are satisfied. Combus- system.
tion air blower should continue to run after shutdown Test connections are essential for burner adjust-
to allow burner to cool. ment. They should be provided immediately down-
Gas supply piping must be large enough to stream of the regulator and are included in the burner
maintain the required fuel pressures cataloged for the itself. Test connections must be plugged except
particular burner size used with burner operating at when readings are being taken.
full-rated capacity. Blower location must deliver a reasonably clean
Anything more than minimal distance or piping and cool air supply. Where external blowers are used,
turns may necessitate “oversizing” piping runs to keep care must be taken to keep pressure drops to a
pressure drops within acceptable ranges. minimum and to independently support the weight of
If multiple burners are fed from a single gas train, air piping.
care should be taken to minimize pressure drop and Gas, oil, and air piping should be located rea-
give maximum uniformity. sonably close to the burner and sized for the pressure
Clean fuel lines are essential to prevent blockage and volume requirements of the burner, with supply
of pipe train components or burner gas ports. pressures high enough to permit subsequent regula-
Main Shut-Off Cock should be upstream of both tion at each burner. Gas piping drops should not
the main gas regulator and pilot line take-off. Use it to exceed 10% of initial supply pressure.
shut off fuel to both pilot and main burner during shut- NOTE: To prevent dripping of oil at shut-down, oil
down periods of more than a few hours. piping should include a means to purge the oil gun of
The fuel throttling MICRO-RATIO® Valve with a unburned oil after firing. This can be accomplished
Maxon MEGAFIRE® Burner is not intended for tight with a steam or air atomizing purge sequence. Oil
shut-off. shut-off should be located as close as possible to the
burner oil inlet.

mCORPORATION
Page 2600-S-2 MEGAFIRE® Gas/Oil Burners
For proper operation, atomizing train should Burner mounting requires 16 studs and a flat
include a low pressure switch, interlocked with the oil mounting surface perfectly centered on the combus-
shut-off valve, installed downstream of the regulator, tion sleeve.
with no valving between that tap and the burner itself. After placing burner in position over studs, add lock
Oil pipe train should be located below the burner washers and nuts, then draw up all 16 hand-tight only.
inlet. The oil solenoid valve must be interlocked with Check that burner is seated evenly all around the
the low pressure atomizing air switch. flange, filling any gaps to prevent air leakage, then
Control systems should provide all normally tighten all nuts firmly.
recommended interlocks (including operation of fuel For proper performance of any burner, air inlet and
shut-off valves). Sequencing Control Systems are motor should be surrounded by clean, fresh, cool air.
available from Maxon that include provision for post- Additional burner support will be required in
purge pilots during all but emergency shut-downs. conjunction with a “stiffener plate” when mounting
This sequencing is essential to minimize risk of MEGAFIRE® Burner (weighing 650-1000 pounds)
smoke during oil-fired shutdown. through typical thin wall of heater/oven panels.
Always re-establish gas pilot before shutting Combustion sleeve must be flush with, or extend
off oil. beyond, interior wall.
For gas-and-oil combination firing, valves for An external viewing port should be provided for
both fuels must operate simultaneously on light-off flame observation, preferably in such a position that
and on shut-down. burner pilot and main flame can both be seen.
For gas or oil firing, interlock fuel valves electri- Flame sensing must be accomplished by UV
cally so only one or the other can be used, not both scanner. UV scanner should be kept as close to
together. burner as feasible. Heat block, if used, may affect
signal strength with some brands of scanners.
Oil shut-off valves should be installed as close as
possible to burner for dependable light off. If not, oil
pressures.
may not reach the burner nozzle before flame
safeguard “times-out”. Maxon assumes no responsibility for the use or
Low fire start and interrupted pilot are essential to
obtain cataloged minimums.
each application.
pipe train components. Air control motors, in particu- Multi-burner installations require special consid-
lar, require additional support. Maxon connecting erations if supplied by a common pipe train and/or air
base and linkage assemblies are designed to position supply. Air Balancing Valves and separate burner
the control motors to work with the burner, not to gas pressure regulators should be used for improved
support their weight. heating uniformity; Gas Swing Check Valves should
Horizontal mounting is preferred, but burner may be installed as close as possible to each burner inlet
be mounted in any position suitable for automatic for dependable light-off (gas manifold may otherwise
control motor and UV scanner. act as a reservoir, preventing light-off during trial-for-
MEGAFIRE® Burner will typically be installed ignition period).
through a refractory wall or insulated air duct. Cut Control system’s circuitry must not allow main
opening at least 2" larger in diameter than combustion Fuel Shut-Off Valve to be opened unless combustion
sleeve to allow for thermal expansion of sleeve. air is on, and must de-energize valve upon loss of
The MEGAFIRE® Burner requires external auxiliary combustion air pressure, along with the other usual
support provided by the user. Lifting lugs are provided system interlocks. Motor starter is to be interlocked
on the burner to assist in lifting and the alignment with valve, whether or not a combustion air pressure
mounting of the MEGAFIRE® Burner. switch is used.
mCORPORATION

Read complete instructions before proceeding, and 6. Prepare Maxon SYNCHRO Control Valve(s) for
familiarize yourself with all the system’s equipment initial fuel firing adjustment. (See catalog pages
components. Verify that your equipment has been 7000-S-1 through 4.) Remove screw carrier cover
installed in accordance with the original manu- plate(s) from top of fuel control valve(s) exposing
facturer's current instructions. multiple adjusting screws. If multiple fuel arrange-
ment, adjust linkage rods and toggle arrange-
CAUTION: Initial adjustment and light off ments between SYNCHRO Fuel Valves, so that
should be undertaken only by trained and all fuel control valves travel together (from mini-
experienced personnel familiar with combus- mum to maximum positions). Leave SYNCHRO
tion systems, with control/safety circuitry, Fuel Valve(s) at minimum position, as shown by
and with knowledge of the overall installa- pointer on the position indicator strip.
tion. Instructions provided by the company 7. Temporarily shut down MEGAFIRE® Burner
and/or individuals responsible for the manu- blower and remove the access hatch cover
facture and/or overall installation of com- entrance into your MEGAFIRE® Burner housing.
plete system incorporating Maxon burners This permits observing the internally mounted air
take precedence over these provided by shutter. Adjust length of the flexible operating
Maxon. If Maxon instructions conflict with cable by screwing the rod end bearings on either
any codes or regulations, contact Maxon end of the cable to insure that when the fuel valve
Corporation before attempting start-up. is at minimum position, the air control shutter is
completely closed. At maximum setting position
for the fuel valve(s), the air control shutter must
have been pulled to its full open position.
For initial system start-up: Once the air control shutter positions are
1. Close all burner fuel valves and/or cocks. Make confirmed with regard to the fuel valves' minimum
preliminary adjustments to fuel regulators and oil and maximum positions, the access hatch
back pressure relief valves. Check oil supply cover(s) must be replaced. Restart MEGAFIRE®
system to be free from air entrainment. Burner's combustion air blower.
2. Check all electric circuitry. Verify that all safety 8. Verify differential air pressure setting. With
devices and interlocks are operable and function- combustion air blower on and all volume air fans
ing within their respective settings/ranges. Be operating, connect a manometer between the 1/4"
sure all manifolds are tight and that test ports are diameter air test connection on MEGAFIRE®
plugged if not being used. Burner and your combustion chamber static
3. Check that all duct and chamber dampers are pressure connection. This differential pressure
properly positioned and locked into operating reading (burner over combustion chamber) should
positions. be set per values on page 2604. Obtain this
4. Start all system-related fans and blowers. Check setting by either adjusting inlet air control valve
for proper motor rotations and impeller direction. (on EB MEGAFIRE® Burner) or combustion
Verify safety interlocks are working. Allow air chamber shutters involved with IB MEGAFIRE®
handling equipment to run for adequate purge of Burner applications.
manifold and combustion chamber plenums. 9. With combustion air fan on, pilot gas regulator
should initially be set at approximately midpoint of
CAUTION: Do not by-pass control panel timers its adjustment range (range equals 0.5–5 inches
typically controlling sequential operations. wc). With pilot gas solenoid closed, open pilot gas
cock. Energize spark ignitor and pilot gas sole-
5. Using 3/16" allen wrench, disconnect the auto- noid. Observe pilot ignition through sight port of
matic control motor(s) linkage from Maxon pilot assembly and/or by viewing micro-amp
SYNCHRO Control Valve by loosening the control signal metered from flame safeguard relay circuit.
motor's connecting rod from the valve's toggle
linkage. Initial start-up adjustment should only be
accomplished during a manual control mode.

mCORPORATION
Start-Up Instructions (cont'd.)

MEGAFIRE® Raw Gas Pilot 12. To establish full range of burner's gas capacity:
With gas flowing to burner, the first adjusting
Sight Pilot Gas
Connection
screw on your SYNCHRO gas valve is ready for
Port
adjusting.
UV Scanner 13. To adjust SYNCHRO Fuel Control Valve(s):
Connection Turn SYNCHRO Valve to minimum. Open
Spark upstream fuel cock. Using the allen wrench
Ignitor provided, turn that adjusting screw down (clock-
wise) to permit fuel to flow to your MEGAFIRE®
Burner. The gas will come out of the radial
spokes inside your burner assembly. The oil
flows out the nozzle in the center of the burner
cone.
NOTE: At this point, it is more important to get
any kind of a flame as soon as possible. The
flame geometry can be adjusted and refined as
needed later.
Once your flame is established and refined at
this position, and without advancing the screw
Refine pilot setting for a hard blue flame (and/ carrier quadrant higher, screw all remaining
or strongest micro-amp signal) by adjusting gas screws down to at least the same level as your
flow through pilot regulator. first adjusted screw.
Shut off pilot gas cock to extinguish pilot fire. NOTE: A preliminary setting can be established
Reopen and confirm easy re-ignition several with all the remaining adjusting screws. Generally,
times. The flame safeguard relays should now each succeeding screw needs to be screwed in
power the main fuel Shut-Off Valves. approximately one full turn deeper than its
10. To light and adjust MEGAFIRE® burner on oil: preceeding screw. A smooth "stair-step" gradient
With gas pilot established and flame supervision pre-set at this point from low to high will simplify
system operational, the atomizing flow (either the remaining adjustment steps.
compressed air or steam) must be introduced to
the burner's atomizing inlet. Verify that pressure CAUTION: Oil flames are highly radiant. Use
and volume of atomizing media is being supplied eye protection and avoid prolonged viewing.
to the burner inlet per catalog specifications. Prepare to shut off oil quickly if there is a
Verify that oil supply pump is on. Verify all noticeable drop in oil pressure or if ignition
safety interlocks are operational before opening does not occur.
any main and/or individual burner oil valves.
With manual oil valve open, oil will flow to the 14. Without advancing the SYNCHRO Valve quad-
Oil SYNCHRO Valve which is on minimum and rant, screw down on #2 screw (one or two turns).
the air control shutter is closed. Then slowly advance the SYNCHRO Valve
NOTE: The oil start-up procedure can advance to quadrant to the #2 position. Adjust flame appear-
step #14. ance at this new position #2.
11. To light and adjust MEGAFIRE® Burner on gas: NOTE: If firing chamber is of refractory construc-
With gas pilot established and flame supervision tion, allow your MEGAFIRE® Burner system to
system operational, opening the main fuel Shut- operate at this low setting for the necessary dry/
Off Valve(s) will allow fuel flow to the SYNCHRO cure-out time period recommended by the cham-
Fuel Control Valve. ber or refractory manufacturer. Then continue
NOTE: At this point, refer to pages 2605-2607 for adjustments of SYNCHRO Valve.
pressure settings versus valve position for each
size MEGAFIRE®, oil and gas.
mCORPORATION


Again, without moving SYNCHRO Valve, bring SYNCHRO SYNCHRO
#3 and all remaining adjusting screws down to the Poppet Oil
same level as #2 screw.
NOTE: If approximate pre-set gradient was made
earlier, the remaining screws will already be at or
below appropriate levels.
Progressively work your way up through each
adjusting screw position, developing a smooth
progression slope from your first screw to the
"maximum" position.
NOTE: To adjust the flame at any position, you
must move the SYNCHRO Valve to the number
you desire to adjust. This aligns the adjusting
screw directly on top of the fuel valve plunger. A
resulting adjustment of the screw is directly
applied to the fuel valve plunger and its intercon-
nected valve body linkage.
15. Cycle burner from minimum to maximum and Legend
refine adjustment, if necessary. Always set Item Description
SYNCHRO Valve to the numbered position you 1 Adjusting Screws
wish to adjust. 2 Cam Springs
For operation with interrupted pilot (as recom- 3 Plunger/Cap Assembly
mended), shut off pilot and cycle burner from 4 Plunger Bushing
minimum to maximum and back several times to 5 Set Collar
verify the flame is maintained. 6 Operating Crank
16. Reconnect linkage to control motor, plug all test 7 Upper Spring Retainer
8 Gas Valve Spring
connections, replace equipment cover caps and
9 Spring Return Shaft
tighten linkage screws. 10 Shaft Retainer
17. Check out overall system operation on all fuels by 11 Lower Spring Retainer
cycling through light-off at minimum, interrupting 12 Packing Collar
pilot, and allowing temperature control system to 13 O-Rings
cycle burner from minimum to maximum and 14 Operating Shaft
return. Recheck all safety system interlocks for 15 Valve Disc
proper setting and operation. 16 Valve Body
17 Valve Disc Spring
CAUTION: Test every UV installation for dan- 18 Valve Disc Guide
gerous spark excitation from ignitors, and 19 Valve Stem
20 Spring Support Plug
other burners, direct or reflected UV radiation.
21 Stud Bolt
22 Bushing
18. Before system is placed into full service, instruct 23 Locking Screw
operator personnel on proper start-up operation
with shutdown of system, establishing written CAUTION: If flame is extinguished, immedi-
instructions for their future reference. ately return SYNCHRO Valve to minimum
position and shut off fuel (if flame safeguard
has not already done so). Turn in slightly on
adjusting screw at point where ignition was
lost, then return SYNCHRO Valve to mini-
mum position, re-establish pilots, open fuel
valve and verify ignition.

mCORPORATION
Notes
m
CORPORATION

MEGAFIRE® Gas/Oil Burners Page 2600-A/P-1
Assembly Numbers
MEGAFIRE® Gas/Oil Burners Pre-assembled Control Valve/Pipe Train
Packages
Assembly
Designation MEGAFIRE® Burner Size 15M 30M 45M
Number
Burner Type IB / EB IB / EB IB / EB
46476 15M IB-COMBO MEGAFIRE ASBY
Gas Only Burners 46683 46682 46468
46482 15M IB-GAS MEGAFIRE ASBY
Oil Only Right Hand 57298 57296 57294
57364 15M IB-OIL MEGAFIRE ASBY
Burners Left Hand 57299 57297 57295
57508 15M EB-GAS-XC MEGAFIRE ASBY
Combination Right Hand 46681 46679 46467
57518 15M EB-OIL-XC MEGAFIRE ASBY
Gas/Oil
57522 15M EB-COMBO-XC MEGAFIRE ASBY Burners Left Hand 46680 46678 46677
57360 30M IB-OIL MEGAFIRE ASBY Discharge Sleeve/Refractory Block
57520 30M EB-GAS-XC MEGAFIRE ASBY
Options
Assemblies at left must be equipped with one of
57521 30M EB-OIL-XC MEGAFIRE ASBY
these options for a complete MEGAFIRE®
57504 30M EB-COMBO-XC MEGAFIRE ASBY assembly.
57362 45M IB-OIL MEGAFIRE ASBY MEGAFIRE® Burner Size 15M 30M 45M
57511 45M EB-GAS-XC MEGAFIRE ASBY 310SS Discharge Sleeve 57237 57236 57235
57517 45M EB-OIL-XC MEGAFIRE ASBY Refractor y Block and Seal with
46461 46462 46463
57519 45M EB-COMBO-XC MEGAFIRE ASBY Suppor t Housing
Position Switches*
XC = External Control
NOTE: This version does not include the air control shutter Assembly
Description
or air control cable. External control of combustion air/fuel Number
gas and/or fuel oil is required. Maxon carries a complete Microswitch Low (MSLPS) 14309
line of control valves suitable for this version.
Omron Low (OMLPS) 14316
Microswitch High / Low (MSHPSLPS) 18189

Pre-Assembled Pipe Trains Microswitch Weather proof Low
35614
Description Assembly Number (MSLPSWP)
Atomizing Steam Train 37175 Microswitch ExPrf High/Low
35945
(MSHPSLPSEP)
#2 Fuel Oil Pipe Train 48186
Microswitch W'Proof High/Low
Atomizing Air Pipe Train 48185 39508
(MSHPSLPSWP)
*A control valve pipe train is required.

m
CORPORATION
Bulletin 2750
Maxon TUBE-O-THERM® Gas Burners
3" TUBE-O-THERM® Burner package with customer’s control motor mounted
• Fires directly into small-bore immersion tubes
• Burner-to-tube direct firing system allows uniform heat transfer, eliminates “hot spots,” and
produces faster bring-up times.
• Economical and efficient package design with integral low-horsepower blower costs
less and saves energy (external blower models also available).
• No-hassle installation and easy maintenance access with wall or tube mounted design.
• Burns natural, propane or butane gas and produces reduced levels of NOx and CO.
• UV flame scanner capability for all sizes
Manufactured under U.S. Patents 5,399,085 and 5,520,537; Canadian Patent 2,138,783
Patents pending in Europe, Japan, Mexico and South Korea
Page 2752
Maxon TUBE-O-THERM® Gas Burners

• Four models sized for 3", 4", 6" and 8" diameter tubes
• Heat releases up to 5,300,000 Btu/hr
• Cost-effective external blower (EB) version available

for applications requiring multiple burner zones from a common
combustion air source
• UV flame scanner capability for all sizes
3" TUBE-O-THERM® Burner external

blower version with customer’s control
motor mounted
Typical piping layout with Block and Bleed gas train arrangement
10/99
TUBE-O-THERM® Gas Burners Page 2753

Maxon TUBE-O-THERM® Burners are nozzle- Model EB (external blower) TUBE-O-THERM®
mixing, gas fired, refractory-less burners specifically Burners (shown below), like all TUBE-O-THERM®
designed for firing into a small bore tube. Typical Burner assemblies, are designed to deliver heat
applications are industrial solution heating jobs such efficiently into your fired tube application.
as dip tanks, spray washers, pickling or quench tanks,
salt baths, indirect air heaters and bakery ovens.
TUBE-O-THERM® Burners are available in two
basic versions: 1) packaged with integral low horse-
power combustion air blower in your choice of the 3" EB
voltages listed below, or 2) EB (external blower) for TUBE-O-THERM®
use with an external combustion air source. Burner with control
motor
TUBE-O-THERM® 3" 4" 6" 8"
Burner Model Pkd. Pkg. Pkg. Pkg.
Horsepower 1/2 HP 1/2 HP 2 HP 3 HP
208-230/460/3/60 (std.) X X X X
115/230/1/60 X X X NA
190-380/3/50* X X X X Wall or tube stub mounting options simplify
installation on your application. Mounting dimensions
575-3-60 X X X X
for tube stub option correspond to standard ANSI
*50 her tz motor option at extra charge
150# flange sizes.
Low torque requirements permit use of virtually
Standard TUBE-O-THERM® Burner package
any electric operator. Maxon supplies connecting
(shown below) includes a combustion air blower with
base and linkage assemblies for mounting most
a non-sparking aluminum impeller. A built-in pilot and
temperature control operators.
spark ignitor is included in the cast iron burner body,
as well as the air and gas control valves, gas nozzle,
pilot adjustable orifice and provisions for your flame Principle of operation (illustrated below)
scanner. Burner design permits blower to be rotated
at 90° intervals around centerline for application
flexibility.
3" TUBE-O-THERM®
Gas Burner with
customer’s control
motor and UV scanner
mounted
Both versions incorporate a gas and air valve

linked together to control the gas-air ratio over the full
throttling range of the burner. Gas flows out through
the gas nozzle where it mixes with the combustion air.
Natural gas, propane or butane can be used.
10/99
Page 2754 TUBE-O-THERM® Gas Burners
Design and Application Details (continued)

Horizontal mounting of the burner is preferred, but Small bore immersion tubes can be sized for efficien-
it may be mounted in any position suitable for auto- cies lower than 80% if tank space is limited or if complete
matic control motor and UV scanner. Do not directly freedom from tube condensation is desired.
insulate tube length outside of tank or overheating NOTE: Schedule 40 pipe should be used for at
and deterioration of tube may occur. The installer least the first 2 feet of tube length.
should take precautions to prevent personnel from
coming into contact with the hot section of the tube. Temperature limitations
See restrictions in the “Wall Mounting Option” section Blower motor manufacturers recommend maxi-
on page 2755. mum ambient temperature of +140°F (+40°C).
NOTICE: Burner performance can be affected Temperature limits can vary with the type of motor
by tube configuration. (See page 2755.) and insulation used. Such special motors are avail-
able at net extra charge and with extended deliveries.
Check blower motor nameplate for temperature limits
Tube length and configuration on EB TUBE-O-THERM® Burners.
Tube design should consist of a specified length of Control motor manufacturers normally establish a
Schedule #40 pipe or lighter (see note below) in the maximum ambient temperature for their operators at
same size as burner. It is possible to fire TUBE-O- +125°F (+52°C).
THERM® Burners into tube diameters larger than the TUBE-O-THERM® Burner internal components
size designation. Contact your Maxon representative include Rulon bearings which have a maximum
for further information. temperature limit of +500°F (+260°C).
Maxon suggests that the first straight pass of tube
consist of the minimum length shown below for each Automatic control
tube size and not end in a single-miter elbow turn. Regardless of the type of automatic control (high-
Burner capacity may be reduced if tube layout has low or modulating), TUBE-O-THERM® Burners should
multiple single-miter turns. be at or very near the low firing position for pilot
Firing tube length and resulting wetted tube surface ignition and main flame light-off.
area determines combustion transfer efficiency. The built-in air and gas flow control valves are
Refer to efficiency vs. tube length chart on page mechanically linked together. At low, the air valve is
2756 for proper length. cracked open but the gas valve is practically closed.
If some higher firing rate is selected for low fire on
Many factors affect overall system efficiency. high-low installations, both valves will be opened
Typical installations run in the 70% to 80% range. wider. The increased combustion air will necessitate
Space considerations (including tube displacement) more gas for pilot ignition. If carried too far, this
may limit possible tube lengths and reduce efficiency. increase can cause the main flame to be too rich.
Above 80% efficiency, there is a risk of condensation- Two position control, then, results in what essen-
caused tube damage. tially is high-low control, down to minimum capacity.
With either high-low or modulating control, high fire
can be set at any desired point within burner range.
(See notes on instruction page 2750-S-1 for set up of
high-fire points less than rated high fire).
The TUBE-O-THERM® Burner was designed to
accept the following electric control motors: Barber-
Colman (EA51-58; also with prefix MC, MP, or MF),
Honeywell Modutrol (M644, M744, M941, M944,
M640A, or M940A), and Penn/Johnson (M80 or M81).
The motor mounting bracket and linkage included with
TUBE-O-THERM® Burners will accept any of these
motors; additional CB & L parts are not required.
Flame safeguard
The TUBE-O-THERM® Burner will operate with a
variety of UV scanners for all burner sizes.

Wall mounting option so, the diluting atmospheric air will depress the
dewpoint temperature of the combustion products so
The TUBE-O-THERM® Burner was designed to
that they may exhaust out of the plant without undue
transfer heat to your process as efficiently as possible.
condensation.
As a result, your process tube, which bolts to the
If the dilution tee option is chosen, there must be
outlet of the TUBE-O-THERM® Burner, can become hot
safeguards to ensure that the diluting air is not re-
during the burner’s operation. The inlet portion of this
stricted or blocked. If this were to occur, condensation
tube will overheat if it extends too far outside the tank.
inside the stack could result, with condensate flowing
The maximum recommended length for the inlet portion
downward to the low point in the tube, possibly block-
of your process tube outside the tank is shown as
ing the tube and causing burner instability.
Dimension C in the drawings labeled “Stub mounted
versions” on pages 2759-2761. Because of the high firing rates possible with this
burner and the low cross-sectional area of the tubes,
For most applications, the wall mounting option
no draft or chimney effect should be designed for, or
is recommended. Use of the wall mounting option
expected, if the exhaust stack diameter is equal to
will support the burner off of the tank, instead of
the fired tube diameter.
supporting the burner with the tube. Maxon also
suggests using a burner support independent of the Immersion tubes are usually vented to the outdoors,
flange, which will allow for some expansion during except for those in highly ventilated areas such as a
firing. Consult your Maxon representative for more plating room with continuous high-volume exhaust. An
information. exhaust fan may be required if the building is under
negative pressure. Exhaust is normally diluted to avoid
Tube exhaust requirements the need for high-temperature fans, but adequate
make-up air must be available.
WARNING: Failure to follow the recommended This diluting can be done with an open tee installed
exhaust considerations could result in poor burner in a vertical run (or in a horizontal run with the open
performance and/or corrosion of the fired tube due to end down), but such a system mixes slowly.
condensation. An adjustable hood (shown in sketch below) offers
much better performance. In all cases, care must be
Historically, conventional immersion tube burners
taken that all products of combustion are exhausted
were sized for 70% efficiency, since this percentage
from the building.
provided a compromise between operating fuel
economy and tube length.
Small-bore tubes require less space than conven-
tional tubes. Therefore, small-bore tubes can be made
longer to provide efficiencies of 80% or more.
Tubes sized for 80% efficiency will have low
exhaust temperatures, causing condensation to form in
them during start-up or during long idling periods. This
condensation will normally evaporate after the burner
has run at high fire for a brief period of time. If ex-
tended idling periods are expected, a condensate drain
should be provided at the low point nearest the exhaust
and the immersion tube should be pitched towards the
exhaust.
If the immersion tube will operate at efficiencies of
75% or lower, the exhaust leg can exit through the
liquid surface in the tank without designing for conden-
sation. However, the length of the exhaust tube must
also be considered in the design as explained below.
These considerations also extend to the exhaust
Cross-sectional area of the exhaust hood should be
lengths after the tube exits the liquid surface. An
a minimum of 1.5 times the fired tube cross-
exhaust tube exiting the tank will continue to transfer
heat and cool the products of combustion to their sectional area.
condensation point. Therefore, an atmospheric break or
dilution tee (shown at right) should be used. By doing
4/99

Immersion Tube Sizing – 60 Hz
8" EB (5.3M Btu/hr)

80
75
8" Pkg. (3.5M Btu/hr)
70
65
6" EB (3M Btu/hr)
60
6" Pkg. (2M Btu/hr)
55
Wetted Tube Length (feet)
50
45
4" EB (1.35M Btu/hr)
4" Pkg. (900K Btu/hr)
40 3" EB (750K Btu/hr)
3" Pkg. (500K Btu/hr)
35
30
25
Above 80%
Design for
20
Condensation
15
10
65 70 75 80 85
Immersion Tube Efficiency (percent)
Design Notes due to increased maximum firing rate.
1. Systems sized for 80% efficiencies or higher need to Indirect Firing
account for condensation during extended idling Tube sizing chart above is applicable only to liquid-
periods. Refer to Design and Application Details on backed immersion tubes. Indirect-fired applications (non-
page 2755. liquid backed fired tubes) could require additional length
2. Curves shown are for 60 Hz applications only. depending on the specific application. For indirect firing in
3. Curves above are not parallel due to small differences in moving air streams, use the above chart and multiply
excess combustion air at maximum design rate. All the specified tube length by 1.75 to obtain the same
TUBE-O-THERM®Burners operate in a range of 2% to efficiency.
4% excess oxygen at maximum firing rate. Recommended air stream velocity across fired tubes
4. Use the centerline lengths of elbows when computing is 1500+ FPM.
total tube length.
5. Note that longer tube lengths are required to achieve the
same efficiency on external blower (EB) versions. This is

60 Hz capacity and specification information for Main gas train should be sized to give no more
both standard burners (including blower) and EB than 6" wc pressure drop to obtain catalog minimums.
burners (requiring separate air supply) are given in the It is recommended to size the regulator for at least
table on page 2758. Measured sound levels and motor 120% of the full system capacity at the required
information apply only to standard burners. pressure, carefully considering pipe train losses.
For operation on 50 Hz power, reduce capacities Pilot piping and regulator should be sized
to 83% of those shown. Refer to 50Hz capacities and carefully for the full pilot and capacity shown on Page
specifications on Product Information Sheet 2750-2 for 2758. Pilot regulator pressure range should match the
pressure range used for the main gas regulator. This
proper operating pressures.
will eliminate the possibility of chattering in the pilot
Air pressure readings at test connection reflect
regulator when the main gas (higher pressure) is at
those that may be expected during high fire operation high fire and the burner operates with continuous pilot.
and may vary as a result of tube and exhaust configu- If burner controls are set to operate with interrupted
rations. pilot, chattering would not be a concern.
Inlet air pressures and flows must not exceed NOTE: Most regulator manufacturers include an
those given in table. DO NOT OVERSIZE blowers internal relief valve in their standard regulators. These
feeding EB Burners. If a blast gate or similar device is relief valves will begin to vent when the downstream
used to limit air pressure at an EB Burner, air pressure pressure is somewhere around 7 inches w.c. greater
at the burner will rise as firing rate is reduced until the than the regulator set pressure. Regulators can be
blower’s rated pressure is reached. This will result in ordered without an internal vent. The best option is to
increased pilot and minimum capacities, as well as run the pilot interrupted. If the pilot is not interrupted,
increased excess air at lower firing rates. catalog minimums cannot be obtained.
For optimum performance, the use of Maxon FG Refer to Page 2758 for the proper pilot gas pressure
Blowers is recommended. as measured at the burner gas test port. The
adjustable orifice inside the pilot can be used to
NOTE: The required combustion air blower for establish the required pressure (5/32" hex wrench
each individual EB-style burner is given below: required). Pilot solenoid should be located within 5 feet
3" Burner C-1450-12 (1-1/2 HP) of burner to allow gas to reach burner before flame
safeguard “times-out”.
4" Burner C-1450-12 (1-1/2 HP)
Self-piloting feature of burner allows pilot gas to
6" Burner C-3480-12 (3 HP) bypass internal gas control valve and issue from main
8" Burner C-7020-16 (7-1/2 HP) gas nozzle ports. Most insurance authorities agree that
Blower curves for these burners are shown on an interrupted pilot is a more reliable method of
monitoring an industrial combustion system.
Low-fire start: Main flame light-off is possible
The TUBE-O-THERM® Burner combustion air and above minimum fire position, but larger pilot will be
fuel gas controls are linked and characterized to required and turndown will be sacrificed.
provide proper air/fuel ratios at specific supply
pressures. Use of blowers which do not match the
Maxon FG Blower performance curves shown on
Product Information Sheet 2750-3 could result in
burner instability, excessive rumbling and unsatis-
factory overall performance.
Transfer Efficiencies
Transfer Efficiency % Btu/hr, ft2 (avg.) wetted tube surface
(based on tube length) 3" Pkg. 3" EB 4" Pkg. 4" EB 6" Pkg. 6" EB 8" Pkg. 8" EB
65 35,480 35,480 24,830 31,040 23,810 31,240 26,514 32,461
70 23,160 27,290 21,220 28,150 21,530 28,500 23,086 29,340
75 17,800 22,330 18,790 25,810 19,660 26,210 21,137 27,506
80 14,800 19,440 17,220 24,120 18,270 24,720 19,683 25,723
85 12,890 17,400 15,840 22,650 17,200 23,340 18,048 24,631
9/03

Size 3" 4" 6" 8"
TUBE-O-THERM® Burner External External External External
Description Pkgd. Pkgd. Pkgd. Pkgd.
Blower Blower Blower Blower
Maximum 500,000 750,000 900,000 1,350,000 2,000,000 3,000,000 3,500,000 5,300,000
Capacities
Pilot Only 50,000 75,000 90,000 135,000 130,000 200,000 350,000 530,000
(Btu/hr)
Minimum(main only) 50,000 75,000 90,000 135,000 160,000 240,000 350,000 470,000
To burner
Gas pressure required 35.3" wc 66.0" wc 29.5" wc 65.3" wc 36.5" wc 76.4" wc 37.0" wc 76" wc
gas inlet
for main burner (at
maximum capacities) To burner
32.1" wc 59.0" wc 25.8" wc 56.9" wc 29.2" wc 62.1" wc 33.0" wc 72" wc
gas test por t
Pilot gas pressure To burner
Natural Gas 0.6" wc 1.2" wc 0.5" wc 1.0" wc 0.3" wc 0.6" wc 0.6" wc 1.3" wc
required gas test por t
Requirements
At burner air
6.1" wc 18.3" wc 7.2" wc 16.7" wc 9.8" wc 18.6" wc 10.0" wc 24.8" wc
inlet
Combustion air
pressure required Differential
air pressure 1.5" wc 2.8" wc 1.3" wc 2.8" wc 2.1" wc 3.9" wc 1.4" wc 2.7" wc
[1]
To burner
Gas pressure required 15.0" wc 32.0" wc 14.5" wc 31.7" wc 18.0" wc 41.0" wc 18.2" wc 44" wc
gas inlet
for main burner (at
maximum capacities) To burner
13.6" wc 29.0" wc 12.9" wc 28.4" wc 15.4" wc 33.7" wc 16.5" wc 37" wc
gas test por t
Pilot gas pressure To burner
Propane Gas 0.5" wc 1.1" wc 0.3" wc 0.8" wc 0.4" wc 0.8" wc 0.6" wc 1.3" wc
required gas test por t
Requirements
At burner air
Combustion air 6.1" wc 18.3" wc 7.2" wc 17.0" wc 9.8" wc 18.6" wc 10.0" wc 24.8" wc
inlet
pressure required (at
high fire position with no Differential
fire) air pressure 1.5" wc 2.8" wc 1.3" wc 2.8" wc 2.1" wc 3.9" wc 1.4" wc 2.7" wc
[1]
100 155 180 270 415 600 675 1015
Maximum combustion air volume required
SCFM SCFM SCFM SCFM SCFM SCFM SCFM SCFM
Tube length (in feet, sized for 80% efficiency) and 30 ft. of 34 ft. of 36 ft. of 38 ft. of 50 ft. of 56 ft. of 64 ft. of 73 ft. of
diameter (Schedule #40 pipe or lighter) 3" dia. 3" dia. 4" dia. 4" dia. 6" dia. 6" dia. 8" dia. 8" dia.
Packaged burner and/or combustion air blower
1/2 HP [2] 1/2 HP [2] 2 HP [2] 3 HP [3]
horsepower required
Packaged burner sound levels dB(A) at 3 feet
85 N/A 86 N/A 88 N/A 89 N/A
(no silencer)
[1] Setting differential air pressure is described in Service Tips on pages 2750-S-5 and 2750-S-6.
[2] 12 osi blower required [3] 16 osi blower required (See suggested blower selection on page 2757.)
Blower curves are shown on Product Information Sheet 2750-3.
50 Hz performance data shown on Product Information Sheet 2750-1


3" Packaged TUBE-O-THERM® Burners 3" flange mount
45˚
2.375 2.375
.375
13.375
9.5
6.75
C Air Inlet w/o
control motor 6.75
6.0
5.25
90˚
4.5
3.0
dia.
10.0
dia.
.75 dia
Continuous weld 4 req'd.
B
H L mounting plate
This dimension is
critical for proper to tank wall
(see page 2750-S-3)
Spark Ignitor
G operation & must be held
+.031 3" stub mount
Combustion Air Location -.031
45˚
Test Connection 1/2" NPT
10.5 Mounting
1/8" NPT Req'd. dim. 2.375 2.375
MAXON
R%%135
.375
TUBE-O-THERM
MAXIMUM
GAS BURNER
USE
WITH
FIRING
TUBE
MILLION
R%%135
for ignitor Plate

removal
CAPACITY BTU/HR
Pilot Gas Inlet

ASBY
FUEL
NO.
F.O. NO.
MAXON CORPORATION
MUNCIE,INDIANA,U.S.A.
3/8" NPT
80
70
60
50 40 30
20
10
0.5
90
0
PI L O T GAS Max stub
Gas Inlet MAXON
length
extending 6.75
from 6.0
5.25
tank wall
S TA L L
IN
D
FLAME
DETECTOR
H E
R E
90˚
Main Gas Inlet
Air Test 1/2" NPT
1/8" NPT 3.0 dia.
Connection Scanner Location 4.5
1/8" NPT E 2.5 3/4" NPT Gas Test I Centerline of control motor
6.0 dia.
F Connection
J
K M16 studs
4 req'd.
Burner Size B* C D E F G H I J K L
3" Pkg. 13.113
4.0 4.875 5.75 19.62 19.0 26.5 6.5 15.75 18.75 4.188
3" EB 13.59
*This dimension is factory-set
Foam Filter Foam Filter/Silencer Stub mounted versions (optional)

20.34 20.34
Tank Wall
A (inside)
C
7.03 11.82 Tank Wall (outside)
dia. dia. B
Hex Nut
TUBE-O-THERM®
Burner Immersion Tube
EB (external blower) TUBE-O-THERM® Burners
Dimensions for the EB version are the same as
those shown above for the Packaged version with the
Dim. A Dim. B Dim. C
exception of a dimension for the air inlet required for an
Burner Thickness Burner Flange
external blower.
flange to of to inside of tank
Air inlet sizes for EB versions are as follows:
end of stud hex nut wall (max.)
3" EB – 4" dia.
Air inlet adapter flange assemblies are provided by 3" Burner 1.807" 0.512" 2.5"
Maxon.
NOTE: Do not exceed Dimension C. The inlet
portion of the tube will overheat if it extends too far
outside the tank.
8/03

45˚
2.375 2.375 .375

13.375
9.5
6.75
C Air Inlet w/o
control motor 7.5
6.75
5.9
90˚
4.0 dia.
5.5
11.5 dia.
B Continuous weld
H L mounting plate
This dimension is
critical for proper to tank wall
G operation & must be held (see page 2750-S-3) 4" stub mount
Spark Ignitor +.031
22.5˚ ˚
Combustion Air Location -.031

Test Connection 1/2" NPT
10.5 Mounting
1/8" NPT Req'd. dim. 45˚ 2.375
MAXON
R%%135
2.375 .375
TUBE-O-THERM
MAXIMUM
GAS BURNER
USE
WITH
FIRING
TUBE
MILLION
R%%135
for ignitor Plate

removal
CAPACITY BTU/HR
Pilot Gas Inlet

ASBY
FUEL
NO.
F.O. NO.
MAXON CORPORATION
3/8" NPT
80
70
60
50 40 30
20
10
0.5
90
PI L O T GAS Max stub

Gas Inlet MAXON
length
extending 7.5
from 6.75
5.9
tank wall
S TA L L
IN
D
FLAME
DETECTOR
H E
R E
Main Gas Inlet

Air Test 1/2" NPT 4.0 dia
Connection Scanner Location 1/8" NPT
1/8" NPT E 2.5 3/4" NPT Gas Test I Centerline of control motor 5.5
F Connection 7.5 dia
J
K
M16 studs
8 required
Burner Size B* C D E F G H I J K L
4" Pkg. & EB 14.5 5.0 6.0 6.5 20.38 21.0 29.5 8.0 17.5 23.0 4.062
*This dimension is factory-set

20.34 20.34
Tank Wall
A (inside)
C
7.03 11.82 Tank Wall (outside)
dia. dia. B
Hex Nut
TUBE-O-THERM®
Dim. A Dim. B Dim. C
Burner Thickness Burner Flange
external blower.
flange to of to inside of tank
Air inlet sizes for EB versions are as follows:
end of stud hex nut wall (max.)
4" EB – 4" dia.
4" Burner 1.829" 0.512" 2.5"
Air inlet adapter flange assemblies are provided by
Maxon.
outside the tank.

45˚
13.375 9.50 .375

6.00 dia. Air Inlet 8.20
w/o control motor
9.44
90˚
6.0 dia.
1.0 dia.
5.500 15.625 dia.

This dimension is
36.38 critical for proper
Spark Ignitor
operation and must
Location be held.
1/2" NPT
Combustion
15.234 +.031
-.031 6" stub mount
Air Test Connection 22.5˚
26.12 15.00 Mounting Plate
1/8" NPT MAXON
R%%135
Required dimension
TUBE-O-THERM
GAS BURNER
USE
WITH
FIRING
TUBE
R%%135
for ignitor removal

.375
MAXIMUM MILLION
45˚
CAPACITY BTU/HR
ASBY
FUEL
NO.
F.O. NO.
MAXON CORPORATION
50 40 30
60 20
70
10
80
90
0
PI L O T
Gas GAS
Air Test Inlet

MAXON
Connection 9.44
1/8" NPT S TA L L
IN
FLAME
DETECTOR
7.750 H E
R E
1/4" NPT
Gas Test 6.0 dia.
Main Gas Inlet Connection
8.2 3/4"NPT 8.50
2.500
24.31 20.50
3/4" NPT 9.5 dia.
23.38
M20 studs
8 req'd.

27.6 27.6
Tank Wall
9.03
A (inside)
dia.
16.35 C
dia.
B Tank Wall (outside)
Hex Nut
TUBE-O-THERM®
external blower. Dim. A Dim. B Dim. C
Air inlet sizes for EB versions are as follows: Burner Thickness Burner Flange
6" EB – 6" dia. flange to of to inside of tank
Air inlet adapter flange assemblies are provided by end of stud hex nut wall (max.)
Maxon. (See page 2763.) 6" Burner 2.180" 0.63" 2.5"

outside the tank.
8/03

45˚
15.875 14.25
7.0 dia. 10.38 19.5
Air Inlet w/o control motor dia.
90˚
5.375 1.0
dia.
This dimension is Continuous weld mounting
critical for proper plate to tank wall
operation & (see page 2750-S-3)
Spark Ignitor
must be held
Location 8.0 dia.
1/2" NPT 18.324 (Pkg.)
39.9
18.5 (EB)
Combustion Air
Test Connection
1/8" NPT
+.031 / -0.31
Mounting
Plate
8" stub mount
29.8 14.0
MAXON
TUBE-O-THERM
GAS BURNER
R%%135
R%%135
Req'd. dimension
22.5˚
USE FIRING
WITH TUBE
MAXIMUM MILLION
for ignitor removal

CAPACITY BTU/HR
ASBY
FUEL
NO.
F.O. NO.
MAXON CORPORATION
Pilot Gas Inlet

50 40 30
60 20
70
10
3/8" NPT
80
90
PI L O T 45˚
Gas
Inlet
S TA L L
IN
FLAME
DETECTOR
H E
R E
9.10
1/4" NPT
Main Gas Inlet
Gas Test
1-1/4" NPT Connection
E3%%136
E1%%136
Air Test Scanner Location 8.5 Centerline of control motor

Connection 9.1 4.0 3/4" NPT
M20 studs
1/8" NPT 23.75 8 req'd.
27.8
26.62
11.75 dia.
8.0 dia.

27.6 27.6
Tank Wall
A (inside)
C
9.03
16.35
dia.
dia. B Tank Wall (outside)
Hex Nut
TUBE-O-THERM®

exception of a dimension for the air inlet required for an Dim. A Dim. B Dim. C
external blower. Burner Thickness Burner Flange
Air inlet sizes for EB versions are as follows: flange to of to inside of tank
8" EB – 6" dia. end of stud hex nut wall (max.)
Air inlet adapter flange assemblies are provided by 8" Burner 2.272" 0.63" 3"
Maxon.
outside the tank.

Replacement Spark Ignitor Replacement Pilot Gas Adjustable Orifice
Burner Size X Y
3" & 4" 8.75 9.0
6" & 8" 12.25 12.5
EB Adapter Flange
Burner Size A B C
3" & 4" 5.58 4.0 7.0
6" & 8" 7.5 5.79 9.19
Suggested Spare Parts:

– Spark ignitor and protective cover
– Pilot gas adjustable orifice
8/03
Notes
TUBE-O-THERM® Gas Burners Page 2750-S-1
General Instructions Clean fuel lines are essential to prevent blockage
Important: Do not discard packing material until Main shut-off cock should be upstream of both
all loose items are accounted for. the main gas regulator and pilot line take-off. Use it to
To prevent damage in transit, the spark ignitor, shut off fuel to both pilot and main burner during shut-
mounting gaskets, and connecting linkage compo- down periods of more than a few hours.
nents may be packed separately and shipped loose The fuel throttling valve contained within a
with your new Maxon TUBE-O-THERM® Burner. Maxon burner is not intended for tight shut-off.
complete combustion system. Additional pipe train Main gas regulator is essential to maintain a
accessories and control components will be required uniform system supply volume and pressure. If one
for a complete system installation. pipe train supplies multiple burners, provide a sepa-
TUBE-O-THERM® Burner provides the air supply rate regulator in the branch leading to each burner
(unless it is EB version, which requires a separate system.
combustion air blower). It also serves as a fuel flow It is recommended that the regulator be sized for at
control and fuel/air mixing device. least 120% of full system capacity at the required
Burner should not be exposed to direct radiant heat pressure, carefully considering pipe train losses.
or positioned where it might draw in inert gases. If Follow the instructions attached to the regulator
such conditions exist, consider filters, relocation, and/ during installation. Refer to page 2758 for burner inlet
or use of the EB version and external air supply. pressure requirements.
Electrical service must match the voltage, phase, Pilot take-off should be upstream of the main gas
and cycle of all electrical system components and be regulator, but downstream of the main gas cock. It
compatible with burner nameplate ratings. Insure that should normally include its own pilot gas regulator, a
all normal control safeguards are satisfied. Combus- solenoid valve and shut-off cock. The pilot adjustable
tion air blower should continue to run after shutdown orifice at the pilot inlet simplifies adjustment.
to allow burner to cool. NOTE: Most regulator manufacturers include an
internal relief valve in their standard regulators. These
NOTE: Burners supplied with standard blower relief valves will begin to vent when the downstream
motors have dual voltage capability (230/460v/ pressure is somewhere around 7 inches w.c. greater
3 Ph/60 Hz; 115/230v/3 Ph/60 Hz; 190/380v/3 Ph/ than the regulator set pressure. Regulators can be
50 Hz). Failure to connect plant voltage to proper ordered without an internal vent. The best option is to
fan wiring will result in poor burner performance. run the pilot interrupted. If the pilot is not interrupted,
Refer to wiring diagram on fan motor. catalog minimums cannot be obtained.
Gas supply piping must be large enough to Pilot piping must be large enough to provide for
maintain the required fuel pressures cataloged for the the full flow and pressures shown in the catalog for
particular burner size used with burner operating at your particular burner size. Pilot solenoid should be
full-rated capacity. located within 5 feet of burner to allow gas to reach
Anything more than minimum distance or piping burner before flame safeguard “times-out”.
turns may necessitate oversizing piping runs to keep The 3/8" pilot connection of the TUBE-O-THERM®
pressure drops within acceptable ranges. Burner is adequate for the pilot gas flows shown, but
Inlet pipe leading to any burner should be at least care must be taken to assure that the required gas
four pipe diameters in length. If multiple burners are pressure (8-12" wc) and flow are available at pilot
fed from a single gas train, care should be taken to inlet.
minimize pressure drop and give maximum uniformity. Fuel Shut-Off Valves (when properly connected to
NOTE: Multiple burner installations fed by a single a control system) shut the fuel supply off when a
pipe train should incorporate a balancing valve and a hazardous operating condition is sensed. Manual
swing check valve installed as close as possible to reset valves require operator attendance each time
each burner gas inlet for improved heating uniformity the system is started up (or restarted after a shut-
and more dependable light off. Otherwise, gas down). Motorized shut-off valves permit automatic
manifold may act as a reservoir, preventing reliable start-restart when used with an appropriate control
system.
m
light off during trial for ignition period of your control
panel sequence.
CORPORATION
Page 2750-S-2 TUBE-O-THERM® Gas Burners
Test connections are essential for burner adjust- Air and Gas Balancing Valves should be used for
ment. They should be provided immediately down- improved heating uniformity; Gas Swing-Check
stream of the regulator and are included in the burner Valves should be installed as close as possible to
itself. each burner inlet for dependable light-off (gas mani-
fold may otherwise act as a reservoir, preventing light-
Test connections must be plugged except when
off during trial-for-ignition period).
readings are being taken.
Horizontal mounting of the burner is preferred, Fuel Shut-Off Valve to be opened unless combustion
but burner may be mounted in any position suitable air is on, and must de-energize valve upon loss of
for automatic control motor and UV scanner. combustion air pressure, along with the other usual
Burner mounting requires a standard 150# flange system interlocks. Motor starter is to be interlocked
to fit the burner’s studs (four studs for 3" burner, eight with valve, whether or not a combustion air pressure
studs for 4", 6" and 8" burners). Burner mounting switch is used.
gasket is a standard 150# flange gasket (supplied by
Because of the high firing rates possible with this
Maxon). Although the mounting uses standard ANSI
burner and the low cross-sectional area of the
dimensions, metric bolts are used for the burner
tubes, no draft or chimney effect should be de-
mounting. Therefore, Maxon will supply metric nuts
signed for, or expected, if the exhaust stack
with the burner. Customer should apply an anti-seize
diameter is equal to the fired tube diameter.
thread lubricant to mounting bolts before installing
burner onto flange connection. Immersion tubes are usually vented to the
After placing burner in position, add lock washers outdoors, except for those in highly ventilated areas
and nuts, then draw up hand-tight only. Check that such as a plating room with continuous high volume
burner is centered, then tighten all nuts firmly. exhaust. An exhaust fan may be required if the
For proper performance of any burner, air inlet and building is under negative pressure. Exhaust is
motor should be surrounded by clean, fresh, cool air. normally diluted to avoid the need for high
Burner and pipe manifold support will be re- temperature fans, but adequate make-up air must be
quired to support weight of the burner and connected available.
pipe train components. Air control motors, in particu- This diluting can be done with an open tee installed
lar, require additional support. Maxon connecting in a vertical run (or in a horizontal run with the open
base and linkage assemblies are designed to position end down), but such a system mixes slowly.
the control motors to work with the burner, not to An adjustable hood (shown in sketch below) offers
support their weight. much better performance. In all cases, care must be
The TUBE-O-THERM® Burner may require external taken that all products of combustion are exhausted
auxiliary support provided by the user. Additional from the building.
burner support may be required in conjunction with a
stiffener plate when mounting TUBE-O-THERM®
Burner onto tube or thin tank walls.
Protective covers for burner should be added in
the field if exposure to dripping condensate, splashing
flux, exhaust steam, etc. is unavoidable. Any such
cover should be removable to provide access to
burner and should not interfere with control linkage
motion, observation port viewing or air inlet.
Flame sensing is accomplished by a UV scanner.
Keep scanner as close to burner as feasible. Do not
use cooling air to scanner port. Heat block, if used,
may affect signal strength with some brands of
scanners.
pressures.
erations if supplied by a common pipe train and/or air Cross-sectional area of the exhaust hood should
supply. be a minimum of 1.5 times the fired tube cross-
m
sectional area.
CORPORATION
Wall mounting installation (recommended) and stub mounting
The TUBE-O-THERM® Burner was designed to For most applications, the wall mounting option
transfer heat to your process as efficiently as pos- is recommended. Use of the wall mounting option
sible. As a result, your process tube, which bolts to will support the burner off of the tank, instead of
the outlet of the TUBE-O-THERM® Burner, can supporting the burner with the tube. Maxon also
become hot during the burner’s operation. suggests using a burner support independent of the
flange, which will allow for some expansion during
On optional stub mounted versions, the inlet
firing. Consult your Maxon representative for more
portion of this tube will overheat if it extends too
information.
far outside the tank.
The maximum recommended length for the initial
To install the wall mounting:
portion of your process tube outside the tank is 1. Insert the immersion tube through the tank wall,
shown: making sure that it extends no more than 1/2" past
Burner flange to inside of tank wall (maximum): the outside of the wall (the tube should be as flush
Dimension “C” 3” burner 2.5” as possible with the Wall Mounting Plate once it is
Dimension “C” 4” burner 2.5” installed).
Dimension “C” 6” burner 2.5” 2. Weld the immersion tube to the tank wall.
Dimension “C” 8” burner 3” 3. Slip the Wall Mounting Plate over the immersion
tube (with the screw heads facing the tank wall)
Stub mounted installation and seal weld the I.D. to the tank wall.
Tank Wall
A (inside) Optional: Continuous weld the O.D. of the mount-
C
ing plate. If I.D. is seal welded, O.D. should be
B Tank Wall (outside)
intermittant welded for rigidity and strength.
Hex Nut
TUBE-O-THERM® 4. Attach the burner to the mounting bolts.
Wall mounted installation

Tank Wall (customer’s)
TUBE-O-THERM® Burner
immersion tube should extend no more than 1/2" past this outside wall
Wall Mounting Plate (Maxon) (to be welded to customer’s tank)
Gasket (Maxon) high temperature RTV applied between burner body and gasket only
Existing Weld - tank wall/tube
Immersion Tube (customer’s)
I.D. of Maxon supplied mounting plate is 3/4" larger

than O.D. of tube. This is to allow a gap for weld
m
As an option to seal welding the O.D. of the mounting
clearance where the tube welds to the tank wall
plate, customer can seal weld the I.D. to prevent leakage
of hot products of combustion.
CORPORATION
Read complete instructions before proceeding, Initial start-up adjustment should only be
and familiarize yourself with all the system's equip- accomplished during a manual burner control
ment components. Verify that your equipment has mode.
been installed in accordance with the original manu- 6. Start all system-related fans and blowers.
facturer's current instructions. Check for proper motor rotation and impeller
CAUTION: Initial adjustment and light-off working. Allow air handling equipment to run for
should be undertaken only by trained and adequate purge of your manifolds and immersion
experienced personnel familiar with combus- tubes. With main gas shut off, manually advance
tion systems, with control/safety circuitry, and TUBE-O-THERM®Burner's operating crank to
with knowledge of the overall installation. high-fire position (90) so that air only flows
Instructions provided by the company and/or through burner and immersion tube.
and/or overall installation of complete system CAUTION: Do not bypass control panel timers
incorporating Maxon burners take precedence typically controlling sequential operations.
7. Determine the required gas pressure from
chart on page 2758.
attempting start-up. NOTE: Gas pressures (shown on page 2758) are
under actual high-fire conditions, once proper
differential air pressure has been established.
For initial TUBE-O-THERM®Burner start-up:
1. Close all burner fuel valves and cocks. Make and bottoms out inside the burner air plate.
Remove pilot and main gas regulators' adjusting NOTE: Field experience shows that a full-wave
screw covers. Turn adjusting screw down (clock- spark ignition transformer provides a reliable
wise) to approximately mid-position. Close pilot ignition source.
gas adjustable orifice screw by turning in clock- 9. Return burner control valve/crank to low-fire
wise until it stops. (Do not over-tighten.) Then position when purge of system is complete.
back out the adjustable orifice (counter-clockwise) 10. Open main and pilot gas cocks, activate spark
approximately 2-3 turns. ignition transformer and pilot gas solenoid valve,
2. Check all electric circuitry. Verify that all control then attempt pilot ignition to light pilot while slowly
devices and interlocks are operable and function- turning pilot gas regulator and/or adjustable orifice
ing within their respective settings/ranges. Be screw counter-clockwise to increase fuel flow.
sure all air and gas manifolds are tight and that Repeat procedure as necessary until pilot ignites,
test ports are plugged if not being used. as air might have to be bled out of fuel supply
3. Check that the immersion tube stack damper lines before reliable pilot flame is established.
is fully open and locked into position. Stack Pilot gas regulator should normally be set for as
dampers not required and can block exhaust even low a pressure as possible, using fuller opening of
if open. pilot gas adjustable orifice.
4. Check that air and gas pressure switches are 11. After ignition, adjust pilot to provide pilot gas
not marginally set to prevent troublesome system pressure as specified on page 2758. Use a pilot
shutdown during start-up. Set pressure switches gas pressure regulator that provides 8-12" wc gas
with some cushion for start-up and re-adjust pressure to the pilot gas inlet.
during final system tuning.
5. Disconnect the automatic control motor's
linkage from your TUBE-O-THERM®Burner's
operating crank arm by loosening the control
motor's connecting rod from the burner's linkage.
mCORPORATION

12. Re-check pilot ignition by closing pilot gas cock Cycle burner from minimum to maximum
or otherwise causing pilot outage. Re-light and and refine adjustment, if necessary.
refine pilot gas adjustment as necessary to get For operation with interrupted pilot, shut off
ignition within a second or two. The flame safe- pilots and cycle burner from minimum to maxi-
guard relays should now power your main fuel mum and back several times to verify the flame is
Shut-Off Valve(s). maintained.
CAUTION: After completing previous steps, re- stable throughout the firing range, reconnect
check all interlocking safety components and linkage to control motor.
circuitry to prove that they are properly in- Control linkage travel must be such that burner
stalled, correctly set, and fully operational. If in crank is moved throughout its complete travel, or
doubt, shut the system down, close pilot cock cataloged capacities and turndowns will not be
and contact responsible individual before achieved.
proceeding further. 16. If attempts to start-up burner have been
unsuccessful to this point, refer to Service Tips on
13. Establish main flame. With burner at low-fire
pages 2750-S-6 and 7.
adjusting screw (counter-clockwise) to get lowest NOTICE: If less than full-rated burner capacity is
outlet pressure possible. Open all manual fuel required, adjust control motor and/or motor/gas
shut-off valves (automatic fuel shut-off valve shaft linkage to limit maximum output. Do not
should already be open) so gas flows to burner adjust gas/air linkage.
flame appearance. Turn main regulator adjust- CAUTION: Do not limit capacity by adjusting gas
ing screw in (clockwise) until gas pressure at the pressure to the burner inlet. The internal gas
burner inlet (upstream of the burner) is as speci- valve is characterized to the air butterfly valve
fied on page 2758. Main flame should now and is based on the specified inlet gas pressures.
appear larger than pilot-only flame. Operation outside of these specifications will
result in unsatisfactory burner performance.
At cold start-up, some rumbling will occur as the
tube warms up. To reduce or prevent this rumbling, With interrupted pilot, it may be necessary to
a low-fire time period of approximately 2 minutes set control for somewhat higher than minimum
before continuing on to high fire is recommended. burner setting to permit hold-in of flame detection
system without pilot.
14. Establish high-fire setting by slowly moving
burner crank toward high fire position while CAUTION: Internal drive mechanism within the
observing gas pressure at burner gas test inlet. control motor may be damaged if linkage is
Refine main gas regulator adjustment as neces- adjusted so as to cause binding with burner in
sary to provide correct differential gas pressure at high or low fire position.
high fire. If pressure cannot be adjusted high
enough, a different regulator or regulator spring 17. Re-check differential gas pressure with unit at
may be necessary. Do not, however, exceed operating temperature. Refine high-fire setting if
6" wc pressure drop between regulator outlet and necessary, considering differential pressure,
burner inlet. flame stability, and appearance. Dust or contami-
nants in the air stream may affect flame appear-
CAUTION: If burner(s) go out, close shut-off ance.
valve or shut main gas cock at once. Return to 18. Plug all test connections not in use to avoid
minimum setting, re-light pilots if necessary, dangerous fuel leakage. Replace equipment
then turn main gas on again. Check carefully cover caps and tighten linkage screws.

mCORPORATION
19. Check out overall system operation by cycling Recheck all safety system interlocks for
through light-off at minimum, interrupting pilot, proper setting and operation.
burner from minimum to maximum and return. WARNING: Test every UV installation for
NOTE: Typical gas firing control sequence for dangerous spark excitation from ignitors and
Maxon burner is provided only as a guide. Instruc- other possible sources of direct or reflected UV
tions provided by complete system manufacturer radiation. Use only gas-tight scanner
incorporating Maxon burners take precedence. connections.
For gas firing 20. Before system is placed into full service,
TUBE-O-THERM®Burner instruct operator personnel on proper start-up
Light-off: Shut-down: operation with shut-down of system, establishing
1. Close cocks, shut-off valve(s) 1. Close main & written instructions for their future reference.
4. Start burner blower air blower running
5. Purge at least 4 air changes after shut-down long
burner to cool
Service Tips
On occasions during cold start-up, a rumbling will TUBE-O-THERM®
occur in the tube until thermal equilibrium is estab- Burners
lished. This is normal and should disappear within a
few minutes. A low-fire time period of approximately 2
minutes is recommended prior to high-fire operation.
If, after several minutes of high-fire operation the
rumbling has not decreased or the burner exhibits
flame instability, shut off the burner and perform the
following checks:
1. Start all system-related fans and blowers to
duplicate conditions from step 6 of start-up
instructions on page 2750-S-4. Advance burner
operating crank to high-fire position.
2. Determine and verify differential air pressure
at burner backplate test ports.
Connect a manometer between the gas test
port and the air test port. With the burner
operating crank at high-fire position, fuel valve(s)
closed, air handling systems and combustion air
blower on, the manometer will read the differen-
tial combustion air pressure.
Air test port should be connected to the (+)
end of the manometer as it will have the higher
pressure over the gas test port.
mCORPORATION

Service Tips (continued)

NOTE: The chart below shows normal differential NOTE: The differential air pressure setting
combustion air pressure readings in a no-fire determines the burner's capacity and perfor-
condition. These readings will increase when mance capabilities.
burner is firing. The fuel gas pressures shown are
at high fire condition. NOTICE: Burner performance can be drastically
Size 3" 4" 6" 8" affected by tube configuration and static
Burner conditions within tube created by dampers in
Model Pkg EB Pkg EB Pkg EB Pkg EB
exhaust stack.
Differential Air
1.5 2.8 1.3 2.8 2.1 3.9 1.4 2.7
Pressure ("wc) 3. All TUBE-O-THERM® Burners are shipped with
Natural Gas
32.1 59 25.8 56.9 29.2 62.1 33.0 72.0 the air/gas linkage factory set. Check centerline to
Pressure ("wc) [1] centerline dimensions on the air/gas linkage to
Propane Gas
13.6 29 12.9 28.4 15.4 33.7 16.5 37.0 determine that it is the proper length per dimen-
Pressure ("wc) [1] sion B shown on pages 2759-2761. The linkage is
[1] at burner gas test por t fabricated as a turnbuckle-style link. To adjust,
simply loosen the locknut and twist the arm
If your reading is higher than these cold air
clockwise to shorten, or counter-clockwise to
pressure readings, you have a suction in your tube.
lengthen the linkage.
This condition should not be a problem.
4. If air/gas linkage dimension is correct per dimen-
If your reading is lower than the cold air
sions shown on pages 2759-2761, check wiring
differential pressure reading, you have a back
diagram to blower motor to determine that dual
pressure in your tube.
voltage motor has been wired properly. Failure to
If an exhaust stack damper is used, check that it do so will result in differential air pressure read-
is fully open and locked in place. ings that are out of specification. Correct wiring
Excessive back pressure can cause high CO errors as necessary.
emissions, smoke and carbon in firing tube and will 5. If stack damper is used in error, make certain it is
restrict firing capacity of burner. full open and locked (may need to be removed).
Additional Service Tips

Problem Cause(s)
Pilot fails to light. 1. On initial start-up, gas line may be filled with air. Repeat ignition
trial several times to purge.
2. No power to ignition transformer or pilot solenoid.
3. Open circuit between ignition transformer and ignitor plug.
4. Pilot gas cock adjusting screw closed.
5. Insufficient gas pressure into or out of pilot regulator.
Main flame fails to light or goes out 1. Insufficient pressure into or out of main gas regulator.
as burner cycles to high fire. 2. Marginal air pressure switch setting.
3. Marginal gas pressure switch setting.
4. Incorrect combustion air pressure.
Burner is unstable or produces 1. Gas/air ratio out of adjustment. Adjust fuel pressures and/or air
soot, smoke or excessive carbon linkage as instructed under Service Tips.
monoxide. 2. Air filter to combustion air fan is plugged or dirty. Replace or clean.
3. Exhaust stack damper is closed or partially closed, or another
restriction exists in the fired tube system.

mCORPORATION
Notes
mCORPORATION

TUBE-O-THERM® Gas Burners Page 2750-A/P-1
Assembly Numbers
Size Packaged & EB Burners
3" 3 TOT (79)
Approximate ship weight
4" 4 TOT (85) (in pounds) are shown in
6" 6 TOT (125) parentheses
8 TOT (184)
8"
8HC TOT* (105)
*EB only.
Segment Choice Detail - TUBE-O-THERM® Burners

Segment Choice
(DEFAULT is shaded)
Type of thread connections ANSI ANSI threaded
BACKPLATE
on burner backplate ISO ISO threaded
Selection of adjustable NONE No adjustable orifice
ADJUSTABLE ORIFICE
orifice, if desired STD Standard adjustable orifice
Selection of flame detection NONE No flame detection device
FLAME DETECTION
device, if desired UV UV scanner
BUT Butane gas
FUEL Type of fuel NAT Natural gas
PROP Propane gas
STUB Stub mount
MOUNTING
Type of mounting desired WALL Wall mount
ARRANGEMENT
WALL_NOFLG Wall mount without mounting plate
EB EB Burner (less blower)
BLOWER SELECTION Selection of blower, if desired
PKGD Packaged Burner
CONNECTING BASE & Type of Connecting Base & HW_MOD Honeywell Modutrol electric CB&L
LINKAGE Linkage (CB&L), if desired NONE No CB&L
NONE No position switch
Type of position switch, if
SWITCH TLHPSLPSWP Termecanique weather-proof hi/low position switch
desired
TLLPSWP Termecanique weather-proof low position switch
FLTR Filter kit
Selection of filter kit or
FLTR &/O SILENCER FLTRSLNCR Filter/silencer assembly
filter/silencer, if desired
MOD Modutrol control motor
MOD_WP Modutrol weather-proof control motor
Type of control motor,
CONTROL MOTOR NONE No control motor
if desired
120V_CONT 120V Maxon control motor
240V_CONT 240V Maxon control motor
Selection of flex connector, NONE No flex connector

FLEX CONNECTOR
if desired YES Flex connector included

m
CORPORATION
Page 2750-A/P-2 TUBE-O-THERM® Gas Burners
Assembly Numbers
TUBE-O-THERM® Burner Spare Parts
Burner Size > 3" 4" 6" 8" 8"HC
Spark ignitor assembly 42256 (2) 42148 (2) 42148
Pilot gas adjustable orifice 50431 (1) 50431
Combustion air fan filter kits 1042561 (3) 1042405 (3) 1042406 (7) 1042407 (7)
Filter / Silencer 1042560 1042401 1042402 1042403
Replacement foam filter element 1042393 1042393 1042394 1042394
---
44234 (Pkgd.)
Linkage repair kit 44235 44236 44237
45245 (EB)
Hi/Lo position switch assembly 44345 44346 45575 45576
NOTE: Approximate net ship weight (in pounds) shown in parentheses
Replacement Blowers
Burner Size > 3" 4" 6" 8" 8"HC
115/230/1/60 43217 43218 43216 --- ---
230/460/3/60 42126 42259 42201 43491 ---
380/3/50 43743 43744 43745 43746 ---
575/3/60 44390 44391 44392 44393 ---
mCORPORATION

Product: TUBE-O-THERM® Gas Burners Page: 2750-3 Date: 2/98
Maxon Corporation, PO Box 2068, Muncie, IN 47307-0068. Phone (765) 284-3304. FAX 1-765-286-8394.
Performance Curves
for Maxon FG Blowers used with EB versions of TUBE-O-THERM® Burners
For 3" and 4" TUBE-O-THERM® Burners
C-1450-12
(1-1/2 HP)
For 6" TUBE-O-THERM® Burners
C-3480-12
(3 HP)
For 8" TUBE-O-THERM® Burners
C-7020-16
(7-1/2 HP)
Bulletin 2800
Maxon Packaged & EBMRV CYCLOMAX®

Low NOx Burner
Packaged Version EBMRV Version
• Provides clean combustion with NOx emission levels below 25 ppm (50 mg/m3) and CO
levels less than 75 ppm (90 mg/m3) at 3% O2. Lower emissions possible based on specific
application. Contact your Maxon sales representative for more information.
• Nozzle-mixing gas burner for use with natural gas or propane
• Packaged version available in 5 sizes – up to 3,700,000 Btu/hr (1100 kW)
• EBMRV version available in 4 sizes – up to 7,400,000 Btu/hr (2200 kW)
• Packaged version operates on low gas pressure – 16" w.c. (40 mbar) or less
• Simple installation, adjustment and start-up
• Turndown averages 15:1 (10:1 on smaller sizes)
• Designed specifically for oven-type applications with cross velocities up to 4000 fpm (20
m/s)
• Packaged version handles oven conditions from 2" w.c. (5 mbar) suction to 2" w.c. (5 mbar)
back pressure
• EBMRV version offers good performance with a much wider range of suction or back
pressure applications
Page 2802
Maxon Packaged & EBMRV CYCLOMAX®

Low NOx Burner
Principle of Operation
The clean-burning design of the Maxon Packaged The EBMRV versions are field-adjusted to the
and EBMRV CYCLOMAX® Low NOx Burners produce proper air-fuel ratios by using a Maxon MICRO-
extremely low emissions of both NOx and CO. RATIO® Valve.
The patented burner nozzle creates a swirling The flame is almost completely contained inside the
flame within the combustion sleeve. The recirculation combustion sleeve. The gases exiting the sleeve are
pattern allows the burner to produce very low levels of essentially those of complete combustion.
CO and unburned hydrocarbons. EBMRV versions use Maxon FG Blowers and
On the Packaged versions, the air/fuel shaft MICRO-RATIO® Valves, and are capable of doubling
maintains the proper air-fuel ratio for low emissions the capacity of the Packaged versions.
throughout the firing range. For best results, the fuel
pressures upstream of the burner should not change
by more than 3" w.c. (7.5 mbar) as the burner throttles
from high to low fire. Blower
Filter/Silencer
Gas Inlet Body

Packaged Version
Gas Bypass (0.4M & 0.8M only)
Air Inlet Body
Nozzle
Gas Bridge
GAS SS
Pilot
Spark
Ignitor
Combustion Sleeve
Back Plate
Main Pilot Scanner
Gas Manifold Housing Pipe
Tube
Main Housing
Air Inlet Adapter
EBMRV Version Nozzle Back
Plate
Threaded
Gas Inlet
Pilot
Spark
Ignitor
Combustion Sleeve Gas Pilot Scanner

Manifold Tube Pipe
9/03
Packaged & EBMRV CYCLOMAX® Burners Page 2803
Burner Application Details

Packaged Versions
CYCLOMAX® Burners were designed for low to To adjust the Packaged burner, set the gas
moderate temperature oven-type applications only. pressure according to the values shown in the table
They may be used in any oven whose combustion below. During adjustment, observe the flame if
chamber temperature is 800°F (427°C) or less. possible. The flame should be blue and it should be
totally contained inside the combustion sleeve,
NOTE: CYCLOMAX ® Burners should not be used
especially at low firing rates. Blue flame outside of the
in any application where there is a static (no
combustion sleeve is caused by combustion that is
moving air) condition.
either too rich or too lean and will result in high levels
Packaged CYCLOMAX® Burners include a low of CO. Yellow or orange flames are normally an
horsepower combustion air blower in your choice of indicator of a too-rich flame. Higher oven suction will
the voltages listed below. require higher gas pressure to the burner for optimum
performance. Higher back pressure will require less
Packaged gas pressure to the burner for optimum performance.
CYCLOMAX® 0.4M 0.8M 1.6M 2.7M 3.7M The values listed in the table below are for a near
Burner Model
balanced condition.
Horsepower 1/2 HP 1/2 HP 3/4 HP 2 HP 3 HP
IMPORTANT: The pilot must be interrupted in
208-230/460/3/60 1/2 HP 1/2 HP 3/4 HP 2 HP 3 HP
order to obtain the emissions listed in the
575/3/60 1/2 HP 1/2 HP 3/4 HP 2 HP 3 HP following table. Continuous pilot is not
recommended.
IMPORTANT: The combustion air blower must be
in operation any time the air stream temperature is
above 200°F (93°C). If not, damage to the blower,
burner and piping is possible.
Packaged CYCLOMAX® – Natural Gas Capacities and Specifications (60 Hz)

Burner Size 0.4M 0.8M 1.6M 2.7M 3.7M
Recommended Gas Pressure "w.c. 15.5 11.5 14.2 11.0 10.0
Maximum Capacity (1000's Btu/hr) 425 850 1600 2700 3700
Minimum Capacity (1000's Btu/hr) 30 - 45 56 - 70 107 - 133 180 - 225 247 - 308
Pilot Capacity (1000's Btu/hr) 15 - 35 60 - 70 50 - 100 70 - 150 100 - 150
Turndown Up to 10:1 Up to 10:1 Up to 15:1 Up to 15:1 Up to 15:1
Emission Turndown based on high fire 15:1 15:1 3.5:1 6:1 4:1
Maximum Air Pressure "w.c. 5.5 5 5 8 8
Air Flow SCFM (Maximum) 105 210 400 670 930
NOx (corrected to 3% oxygen) 25 25 25 25 25
CO (corrected to 3% oxygen) 75 75 75 75 75
Sound Level (without silencer) dB(A) 83 - 89 83 - 89 83 - 89 86 - 90 86 - 90
Flame Length (ft) 0.5 0.5 1.0 2.0 1.5
NOTE: On the packaged unit, gas pressure is

measured at the pressure tap on the gas valve body
(not the backplate). The backplate pressure tap is for
the EBMRV version.
9/03
Page 2804 Packaged & EBMRV CYCLOMAX® Burners

EBMRV Versions
Maxon CYCLOMAX® Burners are available in four piping. Set the MICRO-RATIO® Valve to obtain the
external blower versions. By using the specified gas and air pressures shown on the graphs on pages
external blower, it is possible to double the capacity of 2805 - 2808. The following table lists the recom-
the burner over the Packaged version. Emissions are mended MICRO-RATIO® Valve and FG Blower
similar to the burner operating with a packaged fan. selections.
With the EBMRV versions, there is slightly more flame The values in the table below are guidelines. To
outside of the can and this makes the burner more meet your capacity and turndown needs, pressures
sensitive to cross velocity. must be set to match the graphs on pages 2805 -
The external blower versions are very similar to the 2808.
packaged versions except they do not include gas or IMPORTANT: The EBMRV versions, like the
air internal control devices. A threaded EB Air Adapter packaged versions, should be operated with inter-
allows the MICRO-RATIO® Valve to be mounted. rupted pilot. Emissions can be 20% higher if the pilot
The recommended (minimum) FG Blower is shown is left on continuously and combustion sleeve life is
in the chart below. If you use a butterfly style gas reduced.
valve on the MICRO-RATIO® Valve, turndown could IMPORTANT: Whenever the combustion chamber
be affected. Poppet style gas valves should be used. temperature is above 200°F (93°C), air should be
If your air piping is unusually long and/or contains flowing through the burner. If not, damage to gaskets
many fittings, please review your blower size to in the burner could result and increase the chance for
compensate for higher pressure drops through the air leaks.
Burner Size EB2MRV CM EB3MRV CM EB4MRV CM EB5MRV CM

Maximum Capacity (Btu/hr) 1,600,000 3,200,000 5,400,000 7,400,000
®
MICRO-RATIO Valve 1"–P x M–3" 1.5"–P x M–4" 2.5"–P x M–6" 2.5"–P x M–6"
Minimum FG Blower Recommended C-2370-16 C-4520-16 C-9180-24 C-11220-24
CYCLOMAX® EB Versions – Natural Gas Capacities and Specification (60 Hz)

Burner Size EB2MRV CM EB3MRV CM EB4MRV CM EB5MRV CM
Maximum Capacity (Btu/hr) 1,600,000 3,200,000 5,400,000 7,400,000
Minimum Capacity (Btu/hr) 100,000 180,000 200,000 180,000
Pilot Capacity (Btu/hr) 100,000 150,000 180,000 200,000
Gas Pressure at Maximum Firing Rate ("w.c.) 34 40 38.5 35.5
Air Pressure at Maximum Firing Rate ("w.c.) 15 15 28.5 30
Turndown 15:1 15:1 15:1 15:1
Emission Turndown based on high fire 15:1 13:1 15:1 12:1
Air Flow at Maximum (SCFM) 400 800 1350 1850
Typical Gas Pressure Upstream of MICRO-RATIO® Valve (psi) 1.5 to 2 2 to 3 2 to 2.5 2.5 to 3.5
Typical NOx 3% O2 (low cross velocity) <25 <25 <25 <25
Typical CO 3% O2 (low cross velocity) <75 <75 <75 <75
Typical NOx 3% O2 (high cross velocity) <25 <25 <25 <25
Typical CO 3% O2 (high cross velocity) <100 <100 <200 <100
Flame Length (ft) 1.0 1.5 2.0 1.5
NOTE: Operation above the recommended gas pressure for a given air pressure will result in higher NOx and
lower CO. Operation below the recommended gas pressure curves will result in lower NOx and higher CO. Use of
propane as a fuel will result in higher emissions. Oven cross velocities and back pressures have a slight affect on
the optimum pressures to set.

EB2MRV - Natural Gas
40 KBtu/hr
35 1600
30
Gas Pressure "wc
25
20 1200
15
10 800
5
400
0
0 2 4 6 8 10 12 14 16 18
Air Pressure "wc
EB2MRV - Propane KBtu/hr
16 1600
14
12
Gas Pressure "wc
10 1200
4 800
2
400
0
0 2 4 6 8 10 12 14 16
Air Pressure "wc
10/99

EB3MRV - Natural Gas
50 KBtu/hr
45
40 3200
35
Gas Pressure "wc
30
25 2500
20
2000
15
10 1500
5 1000
0
0 2 4 6 8 10 12 14 16 18
Air Pressure "wc
EB3MRV - Propane
KBtu/hr
25
20 3200
Gas Pressure "wc
15
2500
10
2000
5 1500
1000
0
0 5 10 15 20
Air Pressure "wc

EB4MRV - Natural Gas KBtu/hr
40 5400
35
30
4500
25
4000
20
15
3000
10
2000
5
1000
0
0 5 10 15 20 25 30
Air Pressure "wc
EB4MRV - Propane
25 KBtu/hr
5400
20
4500
15
4000
10
3000
5
2000
1000
0
0 5 10 15 20 25 30
Air Pressure "wc
10/99

EB5MRV - Natural Gas KBtu/hr
35 7400
30
25 6000
20
5000
15
4000
10
3000
5
2000
1000
0
0 5 10 15 20 25 30
Air Pressure "wc
EB5MRV - Propane
25 KBtu/hr
7400
20
6000
15
5000
10
4000
5 3000
2000
1000
0
0 5 10 15 20 25 30
Air Pressure "wc

Dimensions – Packaged Versions
S
M
L
1/4" NPT Gas Pressure
T dia.
Test Connection
dia. Foam Filter Hi Fire Switch Position
K Foam Silencer/Filter (optional)
1/4" NPT Hi/Lo Pressure B
Switch Connection 5/8" (.625) dia. burner
mounting holes
P N
8 holes equally spaced
Main Gas Inlet
M A X O N
CYCLOMAX
R
R
Pilot Gas 3/8" NPT
A
LOW NOX GAS BURNER PATENT PENDING
SIZE ASBY#
FACTORY ORDER#
MAXON CORPORATION
MUNCIE IN.USA
Spark Ignitor 1/2" NPT

WARNING!
E R Scanner 3/4" NPT

dia. Rdia. C rad.
dia.
D dia.
Observation Port
0.375 H 22˚
J 45˚
G
F

N
Burner Size A B C D E F G H J K L M P R S T
NPT
0.4M 10.03 3.06 6.32 13.66 8.90 19.88 13.47 2.66 4.65 26.95 7.03 9.88 1" .937 10.3 20.27 11.82
0.8M 10.03 3.06 6.32 13.66 8.90 19.88 13.47 2.66 4.65 26.95 7.03 9.88 1" .937 10.3 20.27 11.82
1.6M 10.03 3.06 6.32 13.66 8.90 19.88 13.47 2.66 4.65 26.95 7.03 9.88 1" .937 10.3 20.27 11.82
2.7M 13.02 3.40 7.73 16.5 11.72 18.47 20.21 3.67 11.64 34.0 9.03 14.12 1-1/2" .930 13.25 27.52 16.38
3.7M 13.02 3.40 7.73 16.5 11.72 28.57 20.21 3.67 11.64 34.0 9.03 14.12 1-1/2" .930 13.25 27.52 16.38
10/99

Dimensions – EBMRV Version
EB2MRV & EB3MRV 4" NPT

Combustion
Air Inlet
1/4" NPT Air Pressure 3.06

Test Connection
9.6 5.05
0.93
1-1/2" NPT 9.52 SIZE
CYCLOMAX
M A X O N
LOW NOX GAS BURNER
ASBY#
R
PATENT PENDING
Main Gas
FACTORY ORDER#
MAXON CORPORATION
MUNCIE IN.USA
WARNING!
Inlet Pilot Gas

13.66 PILOT
10.5 dia. 3/8" NPT

8.9 EB TEST CONN
dia. dia. SPARK IGN.
1/4" NPT Gas Pressure

Test Connection IN
FLAME
S TA L
DETECTOR
H E RE
L
Spark Ignitor
22.0 1/2" NPT
6.32 rad.
Spark Ignitor Scanner
Removal 3/4" NPT
Clearance 5/8" (.625) dia.
0.38 Burner Mtg. Holes 22˚
Observation
19.88 15.88 Port
45˚
EB4MRV & EB5MRV 6" NPT

Combustion
Air Inlet
3.38
1/4" NPT Air Pressure 15.32 6.78
Test Connection
0.93 2" NPT

Main Gas Inlet
10.88 M A X O N
R
R
CYCLOMAX
LOW NOX GAS BURNER PATENT PENDING
SIZE ASBY#
FACTORY ORDER#
MAXON CORPORATION
MUNCIE IN.USA
WARNING!
4.199 16.48 dia.

11.72 13.25 EB TEST CONN
dia. dia.
Observation
1/4" NPT
Port
Gas Pressure
Test Connection IN
FLAME
S TA L
DETECTOR
H E RE
L
SPARK IGN.
PILOT
Pilot Gas
3/8" NPT
22.0 Spark Ignitor 1/2" NPT
0.38 Spark Ignitor 7.73 rad.
A Removal 22˚ 5/8" (.625) dia.
Clearance Scanner 3/4" NPT Burner Mtg. Holes
23.46 45˚
Dimension "A" 18.47 for EB4MRV

28.57 for EB5MRV
Packaged & EBMRV CYCLOMAX® Burners Page 2800-S-1
Packaged Versions
Please read all installation and start-up instructions Electrical service must match the voltage, phase
before working with the burner. and cycle of all electrical system components and be
compatible with burner nameplate ratings.
IMPORTANT: Do not discard packing material
Gas and air supply piping must be large enough
until all loose items are accounted for.
to provide for the full flow and pressures shown in the
Some components may be shipped separately from catalog for your particular burner when it is operating at
your Packaged CYCLOMAX® Burner to prevent its full-rated capacity.
damage in transit. Do not discard packing until you Clean fuel lines are essential to preventing the
have accounted for all loose items. blockage of burner gas ports and pipe train compo-
The burner is only a part of your complete combus- nents. Dirty fuel lines may require special filters.
tion system. Additional pipe train accessories and Main shut-off cock should be upstream of both the
control components will be required for a complete main gas regulator and pilot take-off line.
system installation. The sketch below shows a typical Main gas regulator is essential to maintaining a
gas train as might be used with the burner. uniform system supply pressure. If one pipe train
supplies multiple burners, provide a separate regulator
in the branch leading to each burner system.
losses. If the regulator has more than 3” wc (7.5 mbar)
of droop*, two-stage regulation is recommended.
Follow the instructions attached to the regulator and be
sure to remove any shipping pin or block.
*Droop is defined as the increase in gas pressure
(due to imperfections in a gas pressure regulator) as
the burner is throttled from high fire where the desired
gas pressure is set.
regulator, but downstream of the main gas shut-off
cock. It normally includes its own pilot gas regulator, a
orifice at the pilot inlet simplifies adjustment. The pilot
must be interrupted in order to obtain low emission
Packaged CYCLOMAX® Burner comes complete
levels. Continuous pilot is not recommended.
with its own combustion air blower. The burner also
NOTE: The 0.4m size burner is lit on main gas. It
provides fuel flow control and a fuel/air mixing device.
does not have a separate pilot.
The Packaged CYCLOMAX® Burner should not be
exposed to direct radiant heat or positioned where it Plumbing and electrical wiring must allow the
might draw in inert gases. If such conditions exist, pilot to be interrupted. Pilot take-off should be
consider filters, relocation, and/or use of the EBMRV upstream of the main gas regulator.
CYCLOMAX® Burner with an external air supply.
Pilot piping must be large enough to provide for the
CAUTION: Installation should be undertaken full flow and pressures shown in the catalog for your
only by trained personnel familiar with combus- particular burner size.
tion systems, with control/safety circuitry, and External support of the gas piping is recommended.
with knowledge of the overall installation. Fuel shut-off valves (when properly connected to a
Instructions provided by the company or indi- control system) shut the fuel supply off when a
viduals responsible for the manufacture and hazardous operating condition is sensed. Manual reset
overall installation of the complete system valves require operator attendance each time the
incorporating Maxon burners take precedence system is started up (or restarted after a trip-out).
over these provided by Maxon. If there are any Motorized shut-off valves permit automatic start-
conflicts in these instructions, contact Maxon restart when used with an appropriate control system.
before proceeding.

mCORPORATION
Page 2800-S-2 Packaged & EBMRV CYCLOMAX® Burners
Packaged Versions
Test connections are essential for proper burner The Packaged CYCLOMAX® Burner can be
adjustment and operation and are included in the mounted in several positions. Some accessories,
Packaged CYCLOMAX® Burner. Test connections such as control motors, can limit the mounting op-
must be plugged except when readings are being tions. Burners are typically installed through an
taken. insulated wall that could be several inches thick. The
Burner mounting requires a stud pattern on a flat mounting hole diameter should be approximately 1 to
surface that matches the mounting holes on the main 1-1/2 inches (25,4 to 38,1 mm) larger than Dimension
housing of the CYCLOMAX® Burner (see dimension “R” on page 2809.
drawing on page 2809). After placing the burner in If the combustion air fan is supplied with a filter, the
position, add lock washers and nuts. Tighten se- filter must be kept clean. A dirty air filter can result in
curely. Connect the gas supply to the burner at the inadequate combustion air flow to the burner and
threaded inlet on the gas valve body. Recommended higher emissions. Decreased air pressure could
gas pressure at the burner is shown below for each indicate that the filter is becoming plugged.
burner size. NOTE: To make the burner lighter and easier to
handle, the blower can be removed before the burner
is mounted.
Recommended Gas Pressure "wc
A 5000-volt full-sine-wave spark ignition trans-
Burner Size 0.4M 0.8M 1.6M 2.7M 3.7M former should be used. Make sure the spark ignitor is
Natural 60 Hz 15.5 11.5 14.2 11.0 10.0 in the proper position by loosening the ignitor nut and
Gas 50 Hz 9.9 8.0 8.5 7.0 6.4 pushing the ceramic insulator as far in as possible.
Hold the insulator in place as the nut is retightened.
Improper positioning of the ignitor will result in diffi-
Recommended Gas Pressure mbar culty in lighting the burner.
Burner Size 0.4M 0.8M 1.6M 2.7M 3.7M Connect all remaining electrical and mechanical
components.
Natural 60 Hz 38.6 28.6 35.4 27.4 24.9
Gas 50 Hz 23.2 19.9 21.2 17.4 15.9
If it is ever necessary to remove the fuel shaft from
the burner, be sure to use anti-seize lube or a light
grease on the fuel shaft during reassembly.
Apply the grease to the O-rings only – do not
apply it to the cutout area. Too much grease
can plug the area in the fuel shaft that affects
the gas flow.
m CORPORATION

Packaged Versions
Read all instructions before proceeding and 3. Check that all duct and chamber dampers are
familiarize yourself with the system’s components. properly positioned and locked into operating
Verify that your equipment has been correctly positions.
installed. 4. Start all system related fans and blowers.
Check for proper motor rotation and impeller
CAUTION: Initial adjustment and light-off
direction. Verify that all safety interlocks are
should be undertaken only by trained
working. Allow air handling equipment to run for
personnel familiar with combustion systems,
an adequate purge of manifolds and combustion
with control/safety circuitry, and with
chamber plenums.
knowledge of the overall installation.
5. Initial start-up adjustment can more easily be
Instructions provided by the company or
accomplished in a manual control mode.
Disconnect the automatic control motor’s linkage
and overall installation of a complete system
from the burner’s control valve by loosening the
incorporating Maxon burners take precedence
control motor’s connecting rod from the valve’s
toggle linkage.
instructions conflict with any rules or
6. Once the burner is installed and all safety devices
regulations, contact Maxon before attempting
are in place, the burner is ready to be fired.
start-up.
Position the burner at its minimum firing rate. Do
The integral air-fuel shaft keeps the air-fuel ratio in not exceed minimum (overtravel), as the gas and
the proper range throughout the firing range. air valves will start to re-open. The 0.4M size does
not have a pilot; it is lit on main gas. For other
Proper air-fuel ratio control depends on a constant
sizes, pilot pressure can be as low as 6 to 12" wc
pressure upstream of the shaft. Regulators with
(14.9 to 29.9 mbar) under ideal conditions, but a
less than 3" wc (7.5 mbar) droop should be used.
higher pilot pressure will facilitate start-up under
A pneumatic or electric control motor can be stubborn lighting conditions. Maxon recommends
mounted to the air-fuel shaft and establish firing rates that the pilot take-off be upstream of the main gas
according to system demands. regulator. Ideal pilot flow ranges from about 70
Gas pressure test connections are essential for SCFH (0.02 m3/min) on the 800,000 Btu/hr (117
burner adjustment and are provided in the burner. Do kW) size to about 120 SCFH (0.06 m3/min) on the
not attempt to use test connections in pipe elbows or largest size (for natural gas).
tees, as internal turbulence can give erroneous 7. If the burner fails to light, it could be due to
readings. Test connections not being used must be trapped air in the gas line. Keep trying until the
plugged. gas purges the air. If the burner fails to light after
repeated attempts, check to see if the spark
For initial system start-up ignitor is pushed all the way in. For the 0.4M
1. Close all burner fuel valves and/or cocks. burner, adjust the gas bypass until a stable
Make preliminary adjustments to regulators. minimum flame at a gas pressure close to (or
Remove pilot regulator adjusting screw cover and slightly higher than) what is desired at high fire is
turn screw down to near mid-range condition. achieved. If working with a 0.4M burner and it is lit
Close pilot gas adjustable orifice screw by turning and stable on main gas at minimum, proceed to
it clockwise until it stops, and then back it out Step 10.
(counterclockwise) 2 to 3 turns. 8. Confirm that the pilot is lit before proceeding to
2. Check all electric circuitry and verify that all the next step.
safety devices and interlocks are functioning
within their respective settings/ranges. Marginally-
set pressure switches can result in numerous
nuisance trips and can delay start-up. Be sure all
manifolds are tightly sealed and that test ports are
plugged if not being used.

mCORPORATION
Packaged Versions
9. With burner at minimum position, turn on the
main gas. The 0.4M and 0.8M sizes have a gas
bypass with an adjustable orifice which can be
adjusted to allow more gas to flow around the fuel
shaft at minimum. Shut off the pilot and confirm
that the burner is still lit. Adjust the main gas
regulator to 3" wc (7.5 mbar) more than the
recommended value.
10. Slowly increase the firing rate. As firing rate
increases, the pressure upstream of the burner
may decrease somewhat because of regulator
droop.
11. Bring the burner up to high fire, increasing
regulator pressure if necessary.
12. Readjust the regulator to the recommended gas
pressure upstream of the burner (see page 2800-
S-2).
NOTE: Do not overtravel when going up to high
fire.
13. Once the burner is lit and has been fired
throughout the range, slowly bring it down to
minimum and verify that the gas pressure does not
increase by more than 3" wc (7.5 mbar) as the
burner is throttled down. High suction applications
can require higher gas pressures to the burner
because more air is pulled through the system.
High back pressure conditions can require that the
gas pressure be set lower than the values listed on
page 2800-S-2.
m CORPORATION

EBMRV Versions
Please read all installation and start-up instructions has shown that with three 90° elbows and 10 feet (3048
before working with the burner. mm) of straight pipe, rated capacities can be obtained
with these sizes.
IMPORTANT: Do not discard packing material
Gas supply piping should be the same size (or
larger) than the size of the poppet gas valve:
Some components may be shipped separately 1” (25.4 mm) for EB2MRV
from your EBMRV CYCLOMAX® Burner to prevent 1.5” (38 mm) for EB3MRV
damage in transit. Do not discard packing until you 2.5” (63 mm) for EB4MRV and EB5MRV
have accounted for all loose items. Pipe/duct the MICRO-RATIO® Valve to the air inlet
The burner is only a part of your complete combus- and attach the gas line from the MICRO-RATIO®
tion system. Additional pipe train accessories and Valve to the threaded gas inlet on the burner back
control components will be required for a complete plate. Smaller gas piping can be used, but will require
system installation. MICRO-RATIO® Control Valve higher gas pressure to compensate for the additional
(Style “P” gas valve and M- style butterfly air valve) pressure drop.
and FG Blower must be ordered separately. See Clean fuel lines are essential to prevent the
CYCLOMAX® (section 2800) and FG Blower (section blockage of burner gas ports and pipe train
9250) catalog literature for selection guidelines for components.Dirty fuel lines may require special filters.
choosing the appropriate blower for your burner and If an uneven flame is observed (dark spots on the
capacity requirements. sleeve, no flame in a particular region, etc.), one or
Do not position the EBMRV CYCLOMAX® Burner more of the gas ports may be plugged. An uneven
or the FG Blower where they will be exposed to direct flame will cause higher emissions. Good flame
radiant heat or the blower could draw in inert gases. If uniformity allows for optimum performance of the
such conditions exist, consider filters or relocation. burner.
Main shut-off cock should be upstream of the
CAUTION: Installation should be undertaken
main gas regulator and the pilot line take-off.
only by trained personnel familiar with
Main gas regulator is essential to keep the
combustion systems, with control/safety
pressure upstream of the MICRO-RATIO® Valve
circuitry, and with knowledge of the overall
constant once the burner is set to the recommended
installation. Instructions provided by the
gas pressure versus air pressure curve. If one pipe
company or individuals responsible for the
train supplies multiple burners, provide a separate
manufacture and overall installation of a
regulator to the MICRO-RATIO® Valve of each burner
complete system incorporating Maxon burners
system. Size the regulator for full system capacity at
take precedence over these provided by Maxon.
the required pressure upstream of the MICRO-
If there are any conflicts in these instructions,
RATIO® Valve. Pressure to the MICRO-RATIO® Valve
contact Maxon before proceeding.
should be 1 psi (69 mbar) higher than the high fire
Electrical service must match the voltage, phase gas pressure at the burner. Follow the instructions
and cycle of all electrical system components and attached to the regulator and be sure to remove any
must be compatible with burner nameplate ratings. shipping pin or block.
Gas and air supply piping must be large enough Pilot take-off should be upstream of the main gas
to provide for the full flow and pressures shown in the regulator but downstream of the main gas shut-off
catalog for your particular burner when it is operating cock. It normally includes a pilot gas regulator,
at its full rated capacity. solenoid valve, and shut-off cock. A pilot adjustable
Attempt to minimize the pressure drop from the orifice at the pilot inlet simplifies adjustment.
blower to the burner. If air supply piping is unusually
Plumbing and electrical wiring must allow the
long and/or incorporates many fittings through which
pilot to be interrupted.
large pressure drops could occur, choose a higher
capacity blower. Do not use air piping smaller than 3”
(76 mm) on the EB2MRV 4” (102 mm) on EB3MRV, or
6” (152 mm) on the EB4MRV and EB5MRV. Testing

mCORPORATION
EBMRV Versions
Pilot piping must be large enough to provide the Burner mounting requires a stud pattern on a flat
full flow and pressures required for lighting the burner. surface that matches the mounting holes on the main
Pilots will light over a wide range of pressures. housing of the CYCLOMAX® Burner (see dimensional
Compensate for higher pressures by closing the drawings on pages 2809 and 2810). Place the burner
adjustable orifice. Unless available pilot pressure is in position and add lock washers and nuts. Tighten
significantly higher than the burner operating securely.
pressure, use the following guidelines for sizing the Connect the air valve of the MICRO-RATIO®
pilot gas piping: Valve assembly to the threaded inlet of the EBMRV
• EB2MRV & EB3MRV – use at least 1/2” (12.7 mm) adapter on the burner. Connect the gas valve of the
dia. pilot piping MICRO-RATIO® Valve assembly to the threaded inlet
• EB4MRV & EB5MRV – use at least 3/4” (19 mm) on the back plate of the burner. Adjust the linkage of
dia. pilot piping the MICRO-RATIO® Valve to achieve reliable light-off
External support of both the air and gas piping is and adequate air to support both the pilot and main
recommended. flames.
Fuel shut-off valves (when properly connected to The air valve should be set at 5 to 10 degrees open
a control system) shut the fuel supply off when a when the gas valve is at minimum to get reliable
hazardous operating condition is sensed. Manual lighting.
reset valves require operator attendance each time Connect the FG Blower to the inlet of the MICRO-
the system is started up (or restarted after a trip-out). RATIO® air valve. Minimize the piping between the
Motorized shut-off valves permit automatic start- blower, valve and burner to reduce pressure drop.
restart when used with an appropriate control system. The EBMRV CYCLOMAX® Burner can be mounted
in a variety of positions, but is most conveniently
The control valves which may be used with the
mounted with both inlets facing upward on the side of
EBMRV CYCLOMAX® Burner are not intended
an oven. Downfiring is permitted. Burners are typically
for tight shut-off.
installed through an insulated wall. The mounting hole
Flame sensing can be accomplished only with a diameter should be approximately 1 to 1-1/2 inches
UV scanner. Cooling air to the UV scanner should not (25,4 to 38,1 mm) larger than Dimension “R” on page
be required. 2809.
Test connections are essential for proper set-up If using a filter with the FG Blower, check
of the EBMRV CYCLOMAX® Burners. The two test periodically to see if the filter is becoming plugged. If
connections for the EBMRV version are located on a drop in air pressure or change in flame appearance
the burner back plate (gas pressure) and on the is observed, the filter may be plugged. Inadequate air
circumference of the burner main housing (air flow to the burner can result in higher emissions.
pressure). Test connections must be plugged except A 5000 volt, full-wave spark ignition transformer
when readings are being taken. should be used. Verify that the spark ignitor is in the
Include observation ports in the combustion proper position by loosening the ignitor nut and
chamber design to provide a view of the flame. This pushing the ceramic in as far as possible. Keep
will simplify start-up and adjustment procedures. forward pressure on the ceramic as the nut is being
re-tightened. Improper positioning of the ignitor will
cause difficulty in lighting the burner. Connect all
remaining electrical and mechanical components.
m CORPORATION

EBMRV Versions
Read all instructions before proceeding and 5. Initial start-up adjustment should only be
familiarize yourself with the system’s components. done in a manual control mode. Disconnect any
Verify that the equipment has been correctly installed. control motors from the MICRO-RATIO® Valve
linkage using an allen wrench to disconnect the
control motor’s connecting rod from the valve’s
should be undertaken only by trained
toggle linkage.
NOTE: The EBMRV CYCLOMAX® Burners are
with control/safety circuitry, and with
designed to be used with Maxon MICRO-RATIO®
knowledge of the overall installation.
Valves. The gas valve has a multiple screw adjusting
cam which is used to adjust the gas pressure at each
setting to correspond with the appropriate air pressure
and overall installation of a complete system
for each position. The numbers on the external
position indicating strip correspond to a series of
adjusting screws which should be initially set to give
instructions conflict with any rules or
the desired contour to the cam.
regulations, contact Maxon before attempting
Control valves are easily adapted to automatic
start-up.
operation with an electric or pneumatic control
Gas and air pressure test connections are essential motor.
for proper burner adjustment. Test connections must Maxon offers a broad range of CB & L
be plugged except when readings are being taken. (connecting bracket and linkage) assemblies
to properly position and align the control motors
For initial system start-up: when used with Maxon control valves. Maxon
CB & L assemblies are designed to position
1. Close all burner fuel valves and/or cocks. the control operator, not to support its weight.
Make preliminary adjustments to regulators. User must provide auxiliary support in the form of
Remove pilot regulator adjusting screw cover and wall brackets, floor stands, turnbuckle hangers,
turn screw down to near mid-range position. Turn etc., to support the weight and size of the
pilot gas adjustable orifice screw clockwise until it operator.
closes, then turn screw counter-clockwise two or 6. Measure air pressure by connecting a
three turns. manometer to the air pressure test connection
2. Check all electric circuitry. Verify that all safety which is located on the burner’s main housing
devices and interlocks are operable and approximately 4” (102 mm) back from the burner
functioning within their respective ranges. Be sure mounting flange.
all manifolds are tight and verify that test 7. Measure gas pressure by connecting a
connections are plugged if not being used. manometer to the gas pressure test connection
3. Check that all duct and chamber dampers are on the back plate of the burner.
properly positioned and locked into operating NOTE: Maxon offers a test connection kit which
positions. provides a convenient means of connecting plastic
4. Start all system-related fans and blowers. tubing to the burner test port connections. Kit should
Check for proper motor rotation and impeller be removed after intial start-up and the test ports
direction. Verify that all safety interlocks are should be plugged for normal operations.
working. Allow air handling equipment to run for a 8. Open the MICRO-RATIO® air valve slightly to
sufficient purge time. provide enough air to support reliable light-off.

mCORPORATION
EBMRV Versions
9. Establish the maximum combustion air 16. Slowly move the MICRO-RATIO® Valve to next
pressure by moving the air valve crank assembly position. Adjust as necessary to maintain ignition
toward the higher positions until the desired air and the type of flame desired. Flame should be a
pressure is reached. This occurs around 90 steady blue color and should only fill
degrees, unless the burner and/or blower are approximately 25% of the can at lower firing rates.
greatly oversized. Observe the air pressure and adjust gas pressure
10. Reconnect the fuel valve to the air valve. to appropriate value shown in charts/graphs.
Having marked the minimum and maximum 17. Repeat Step 16
Adj. Screws
settings, adjust the linkage and travel of the with the (under cover)
stroke. Set the air and gas pressures throughout remaining
the entire range. adjustment Handle for
Manual
11. Re-check and verify that air handling devices screws until high Operation
are still operating. fire position is Position
Indicator
reached. If a Pointer
CAUTION: If flame is extinguished any time
flameout occurs,
during steps 12 through 18, immediately shut- Locking Screw
allow purge time for manual
off gas and return MICRO-RATIO® Valve to operation
and return to Step
minimum position. Allow adequate purge time
12 in the adjustment procedure. At each setting,
for safety reasons. Re-light the pilot (if
use the adjustment screw to set the gas pressure
necessary) and reopen gas valve and turn
to the appropriate value corresponding to air
screw last adjusted in slightly further before
pressure reading. Refer to charts and graphs in
returning to that firing position. Refine
this catalog section.
adjustment if necessary.
18. Cycle the burner to verify that pressures are
12. Light the pilot. With pilot gas solenoid (or within the recommended ranges. The position
manual cock) closed, open the main fuel supply of each screw on the MICRO-RATIO® Valve
valve(s). Energize spark ignitor and open pilot gas affects the adjacent screws. It can take two or
solenoid (or manual cock). Observe ignition of three passes through the ranges to get the burner
pilot. Pilot should be set at the minimum gas flow gas pressures set to the desired values with
which will support reliable ignition. Adjust pilot repeatability. When high fire position is reached
using adjustable orifice and/or pilot gas regulator. with the MICRO-RATIO® Valve, slowly move the
13. Shut off the spark ignition and pilot and valve to the position immediately below high fire,
confirm easy re-ignition several times. read the air pressure, observe the gas pressure,
14. With pilot gas on and spark ignition off, turn on and adjust the appropriate screw if necessary.
the main gas. With the main gas flowing, verify Move the valve down to the next setting and
that flame is visible all around the burner nozzle. repeat this procedure with each of the remaining
If not, adjust the minimum adjusting screw of the adjustment screws until minimum fire is reached.
MICRO-RATIO® Valve until flame appears stable.
After the initial adjustment pass, adjust only the
Shut off pilot.
screw corresponding to the actual position of the
15. With the burner still set at minimum, adjust all
MICRO-RATIO® Valve and the NEXT adjacent
other screws on the cam to form a smooth ramp.
screw to be adjusted (either up or down the ramp).
NOTE: A preliminary setting can be established with
If possible, do not adjust the previous screw. Two
all the remaining adjusting screws. Generally, each
passes through the firing range is enough. Some
succeeding screw needs to be screwed in
sensitive applications may require three passes
approximately one full turn deeper than its preceding
with adjustments to get the ramp smooth enough to
screw. A smooth “stair-step” gradient pre-set at this
produce repeatable gas pressures at each setting.
point from low to high will simplify the remaining
adjustment steps.
m CORPORATION

EBMRV Versions
CAUTION: If high temperature limit trips before 21. System should have an interrupted pilot. Verify
adjustment is complete, cycle burner back to that pilot is shut-off. Operation with the pilot on
minimum and allow the system to cool down before causes flame non-uniformity, significantly higher
attempting to make any further adjustment. emissions and can shorten can life.
22. When burner performance is satisfactory,
19. Observe the gas supply pressure during reconnect the linkage from the control motor to
adjustment. As firing rate is increased, the gas the MICRO-RATIO® gas valve.
supply pressure will drop off and could go below 23. Check out overall system operation by cycling
recommended levels. It may be necessary to the burner, observing the air and gas pressures,
adjust the regulator. If so, all positions on the re-igniting the burner, etc. Recheck all safety
screw carrier of the MICRO-RATIO® Valve will interlocks for proper setting and operation. After
need to be re-adjusted. air and gas pressures have been verified and are
Flame Appearance: While increasing the burner within recommended ranges, shut the burner
setting, continue to make adjustments to keep the down, remove all fittings and tubing from the test
flame stable. A flame that is too lean will be connections and plug the test ports with pipe
transparent and will lift away from the nozzle. A plugs.
flame that is too rich will be yellow and will burn on CAUTION: Test every UV installation for
the outside of the can. A rich flame looks lazy. It dangerous spark excitation from ignitors, other
will be darker than a lean flame and appear purple burners, and direct or reflected UV radiation.
in color. When adjusted properly, the flame will
appear bright blue in color. At low oven 24. Shut system down and close all fuel valves.
temperatures, the can color should be visible as a Allow an approved post-purge period before
slight glowing effect. At moderate to high oven shutting down all fans. Replace all equipment
temperatures, the can should appear as a uniform covers and caps and tighten all linkage set
medium red in color. Generally, a too lean flame screws.
condition creates high CO and low NOx, and a too 25. Instruct operating personnel on proper start-up,
rich flame condition will create lower CO but higher operation and shut-down of system. Establish
NOx. The best reference for CO and NOx levels is written instructions for reference.
the charts on pages 2803 and 2804. The optimum NOTE: It is good practice to check the air and gas
pressures can vary according to the characteristics pressures regularly. If the gas supply to the
of the natural gas used as well as furnace back MICRO-RATIO® Valve changes significantly, the
pressure or suction conditions. adjusting screws will need to be re-adjusted. If a
20. When all screws have been adjusted and filter is becoming plugged, a routine check of the
initial repeatability is verified, re-check air and gas pressures can uncover problems
pressures with unit at operating temperature. before they become serious. Poor burner
Refine settings if outside of the recommended performance will result if pressures are set
ranges shown on the graphs. incorrectly.

mCORPORATION
Notes
m
CORPORATION

Packaged & EBMRV CYCLOMAX® Burners Page 2800-A/P-1
Assembly Numbers
Packaged Version - 60 Hz
For these products, please order per the Connecting Base & Linkage (CB & L)
following product numbers: Spare Parts
NOTE: This listing of CB & L assemblies shows a sampling
(configured products are those with alphanumeric
of the more popular control motors. P
text)
Manufacturer CB & L
Operator
Maximum Capacity Assembly
Configured Type Name Model Number Number
Btu/hr kW Packaged Burners
P-25 24383
400,000 125 0.4M CM Foxboro
P-50 24384
800,000 250 0.8M CM 01-11/861P
17376
1,600,000 470 1.6M CM Honeywell 03-8/863T
Air
2,700,000 800 2.7M CM 01-9/861M 17711
3,700,000 1100 3.7M CM D-3153
Johnson 17867
D-3151
NOTE: For 50 Hz operation, performance will be Taylor 40VF6 17708
downrated to approximately 83% of 60 Hz capacity. EA51-58, also
Barber-Colman with prefix MC, 17377
MP or MF
M6184D,A,F
configured products: M6194D,B,E
• Fuel M9184D, M7384A
• Motor (Combustion air fan) M7184A, M7984D
• CB & L’s M7284A,C,Q
Electric M9484D,E
• High and Low Fire Switches Honeywell 17372
M9494D, M6284F
• Filters/silencers M9184D,A,F
M9484E,F,D
See Segment Choice Descriptions on M6294D,B
page 2800-A/P-3 M6284A,D,F
M9194D,E
M-80
Penn/Johnson 17372
M-81

mCORPORATION
Page 2800-A/P-2 Packaged & EBMRV CYCLOMAX® Burners
Assembly Numbers
EBMRV Version
For these products, please order per the Segment choices are as follows for
following product numbers: configured products:
(configured products are those with alphanumeric • Fuel (natural gas or propane)
text) • Thread choice (ANSI or ISO)
Maximum Capacity Configured

See Segment Choice Descriptions on
Btu/hr kW EB CYCLOMAX® Burner page 2800-A/P-3
1,600,000 468 EB2MRV CM
3,200,000 937 EB3MRV CM
5,400,000 1581 EB4MRV CM
7,400,000 2167 EB5MRV CM
MICRO-RATIO® Valves and FG Blowers must be ordered separately.

Guidelines are listed below. For additional information, see Maxon catalog literature for MICRO-RATIO® Valves
(Section 7000) and FG Blowers (Section 9250).
Minimum size Gas Valve Size Air Valve Size

CYCLOMAX® Burner MICRO-RATIO® Valve
FG Blower inches DN inches DN
EB2MRV CM C2370 MP MRV 1 25 3 75
EB3MRV CM C4520 MP MRV 1.5 40 4 100
EB4MRV CM C9180 MP MRV 2.5 65 6 150
EB5MRV CM C11220 MP MRV 2.5 65 6 150
Other styles of MICRO-RATIO® Valves (MM MRV OR MA MRV) can be used, but turndown may suffer. Use a
higher capacity and/or a higher pressure blower if a significant pressure drop between the blower and burner is
present.
If a different blower will be used, see the table below.

Minimum Air Flow and Pressure Requirements
Air Flow Required Pressure Required
CYCLOMAX® Burner
3
SCFM M (st)/hr oz. mbar
EB2MRV CM 400 680 16 69
EB3MRV CM 800 1360 16 69
EB4MRV CM 1350 2290 24 103
EB5MRV CM 1850 3145 24 103
mCORPORATION

Packaged & EBMRV CYCLOMAX® Burners Page 2800-A/P-3
Assembly Numbers
Segment Choice Detail - Packaged CYCLOMAX® Burners
Segment Choice
(DEFAULT is shaded)
Type of fuel used for burner NAT Natural Gas

FUEL
operation PROP Propane Gas
230_460360 230/460-3-60 TEFC

MOTOR Combustion air motor voltage
575360 575-3-60 TEFC
HW_AIR Honeywell air actuated CB&L
HW_MOD Honeywell Modutrol electric CB&L
Type of connecting base &
CONNECTING
linkage assembly (CB&L), if HW_MOD+MTR Honeywell Modutrol CB&L + Honeywell Control Motor
BASE & LINKAGE
desired
HW_01986M Honeywell 019861M air actuated CB&L
JOHN_CONT Johnson Controls air CB&L
NONE No CB&L
BOTH Both Hi & Lo switches chosen

SWITCH Type of position switch required
TMECHHI Termecanique switch (Hi Pos)
TMECHLO Termecanique switch (Lo Pos)
FLTR Filter kit
FLTR &/O SILENCER Air filter and/or silencer required FLTRSLNCR Filter/silencer kit
Segment Choice Detail - EBMRV CYCLOMAX® Burners

Segment Choice
(DEFAULT is shaded)
Type of fuel used for burner NAT Natural Gas

FUEL
operation PROP Propane Gas
Type of thread on inlet ANSI ANSI Threads

THREADED INLETS
connections ISO ISO Threads

m CORPORATION
Page 2800-A/P-4 Packaged & EBMRV CYCLOMAX® Burners
Assembly Numbers
Spare Parts for Packaged CYCLOMAX® Burners
Packaged CYCLOMAX® Burners 0.4M CM 0.8M CM 1.6M CM 2.7M CM 3.7M CM
Combustion air fan [1] 42259/44391 42259/44391 44883/47821 42201/44392 43491/44393
Spark ignitor [2] 44889 44889 44889 44892 44892
Rubber cover [2] 18722 18722 18722 18722 18722
Combustion sleeve [1] 43478 43478 43478 45986 45034
Combustion sleeve gasket [1] 44882 44882 44882 45057 45057
Foam filter kit [3] 1042405 1042405 1042405 1042406 1042407
Replacement foam filter element [1] 1042393 1042393 1042393 1042394 1042394
Pilot protection plate [1] 1042297 --- --- --- ---
Pilot protection plate fasteners [1] Qty 2 43768 --- --- --- ---
High or low fire switch assembly [3]
44884 44884 44884 44884 44884
(order 2 for both high and low)
Silencer/Filter assembly [3] 1042401 1042401 1042401 1042402 1042403
[1] Replacement par t [2] Suggested spare par t [3] Accessor y – must be ordered separately
Spare Parts for EBMRV CYCLOMAX® Burners

EBMRV CYCLOMAX® Burners EB2MRV CM EB3MRV CM EB4MRV CM EB5MRV CM
Spark ignitor [2] 44889 44889 44892 44892
Rubber cover [2] 18722 18722 18722 18722
Combustion sleeve [1] 43478 43478 45986 45034
Combustion sleeve gasket [1] 44882 44882 45057 45057
Pilot protection plate [1] 1051588 1051590 1051591 1051592
Pilot protection plate fasteners [1] Qty 2 43768 43768 43768 43768
[1] Replacement par t [2] Suggested spare par t [3] Accessor y – must be ordered separately
m CORPORATION

Product: Packaged CYCLOMAX® Burners Page: 2800-1 Date: 9/03
Effect of regulator droop on burner emissions

Regulator droop can cause NOx levels to increase.
The following table shows the effect of droop.
Maximum NOx level shown is that which occurs from
30 or 40 percent open to maximum.
Droop = (gas pressure at minimum) – (gas pressure at maximum)
400,000 and 800,000 Btu/hr burner:
Droop Maximum NOx Level Turndown

0" wc 25 10:1
3" wc 28 9:1
6" wc 42 8:1
1,600,000 Btu/hr burner:

0 – 2" wc 25 15:1
2.6" wc 27 13.5:1
5" wc 34 12.6:1

0 – 4.5" wc 25 15:1
5.5" wc 30 (burner noisy with droop) 12:1

0 – 2" wc 25 15:1
3.5" wc 40 14.2:1
7" wc 50 12.5:1
Regulator droop will cause the CO emissions to be

lower. Note that the 0.4M, 0.8M and 2.7M sizes are
the most forgiving of regulator droop. All values
shown are for natural gas running on 60 Hz power.
On propane, the effect of droop may be even more
dramatic.
Bulletin 2900
Maxon APX® Burners
• Eliminates leakage with single-piece, aluminum extrusion body design
• Cooler oven walls due to deeper penetration and shorter flame lengths
• Corrosion-resistant main gas/air body and durable stainless steel mixing plates
• Standard burner designed for use with low pressure natural gas, propane or butane
• Up to 40:1 turndown
• Capacities up to 1MMBtu/hr/ft
• Packaged units up to 15 feet in length
CORPORATION 201 East 18th Street, P.O. Box 2068, Muncie, Indiana, 47307-0068. Phone: (765) 284-3304. Fax: (765) 286-8394
Page 2902
Maxon APX® Burners

Design and Application Details Principle of Operation
Maxon APX® Burners are packaged nozzle mixing The design of the APX® Burner allows for high
line burners designed for fresh or low temperature turndown ratio without premixing fuel and air at low
recirculated air heating applications. firing rates. Low emissions are maintained through
The APX® Burner is a value engineered design precise aeration of the flame along its length. This
utilizing a single aluminum extrusion for both its air and progressive aeration of the flame is achieved with the
fuel manifolds. Its single-piece, joint-less body design advanced mixing plate design of Maxon’s NP AIRFLO®
eliminates burner leakage. Line Burner.
Standard packaged units are available in 0.5 to 15 Air is supplied by a low horsepower paddle wheel
foot lengths. Maximum firing rate is 1 MMBtu/hr/ft. blower mounted directly to the back of the main burner
The APX® Burner has two wall mounting options: extrusion. Paddle wheel blowers resist particle build-
flange mounted on suction side of recirculating fan or up and provide higher air pressure. The higher air
slot fired. The burner may also be mounted within a pressure allows for increased flame turbulence as well
duct for fresh air heating applications or low tempera- as uniform air distribution across the length of the
ture recirculating applications. burner. The increased turbulence shortens the flame,
The APX® Burner throttles gas only while obtaining providing resistance to cross flows.
up to 40:1 turndown. Gas and air are fed from the The APX® Burner is designed so that the flame
back. A variety of pilots and end plates are available exits the mixing chamber more than six inches down-
for application flexibility. stream from the mounting flange for suction applica-
tions. APX® enables the use of up to 6 inch oven
panels without a costly mounting adapter or without
risking damage to oven structure from flame
impingement.
Back view of APX Burner View from pilot end plate
4/02
Maxon APX® Burners Page 2903

For a slot mounted or continuous flange mounted The APX® Burner can be applied in a wide variety of
APX® Burner located on the suction side of a air heating applications. Typical operating environ-
circulating fan, a suction of up to 2 inches w.c. is ments, limits on their variables, and notes concerning
permissible. operation of the burner are listed below.
Contact Maxon for applications in which the burner
fires into suction higher than 2 inches w.c.
Differential Differential
Differential Nominal
Burner Gas Pressure Gas Pressure Maximum Heat Minimum Flame Blower
Air Air
Burner Length Standard Low Pressure Release Heat Release Length Horsepower
Pressure Volume
Size (inches) Drilling Drilling (Btu/hr) (Btu/hr) (Inches) (Qty.)
(in. w.c.) (scfm)
(in. w.c.) (in. w.c.)
0.5 6 -- 5.5 400,000 1.5 80 12,500 30-40 1/12
1.0 12 21 11 1,000,000 4 200 25,000 30-40 1/2
1.5 18 21 11 1,500,000 4 300 37,500 30-40 1/2
2.0 24 21 11 2,000,000 4 400 50,000 30-40 3/4
2.5 30 21 11 2,500,000 4 500 62,500 30-40 1
3.0 36 21 11 3,000,000 4 600 75,000 30-40 1
3.5 42 21 11 3,500,000 4 700 87,500 30-40 1-1/2
4.0 48 21 11 4,000,000 4 800 100,000 30-40 1-1/2
5.0 60 21 11 5,000,000 4 1000 125,000 30-40 3
6.0 72 21 11 6,000,000 4 1200 150,000 30-40 1 (2)
7.0 84 21 11 7,000,000 4 1400 175,000 30-40 1-1/2 (2)
8.0 96 21 11 8,000,000 4 1600 200,000 30-40 1-1/2 (2)
9.0 108 21 11 9,000,000 4 1800 225,000 30-40 3 (2)
10.0 120 21 11 10,000,000 4 2000 250,000 30-40 3 (2)
11.0 132 21 11 11,000,000 4 2200 275,000 30-40 3 (2)
12.0 144 21 11 12,000,000 4 2400 300,000 30-40 3 (3)
13.0 156 21 11 13,000,000 4 2600 325,000 30-40 3 (3)
14.0 168 21 11 14,000,000 4 2800 350,000 30-40 3 (3)
15.0 180 21 11 15,000,000 4 3000 375,000 30-40 3 (3)
Variable Minimum Maximum

Inlet combustion air temperature (°F) Ambient 125
Air stream cross velocity (ft/min) (1) 400 1750
Air stream parallel velocity (ft/min) 400 4000
Upstream air temperature (°F) Ambient 500
Downstream air temperature (°F) N/A 650
Oven pressure (inches w.c. DP, oven to ambient) Balanced 2 inch w.c. suction (2)
(1) Cross velocity defined as velocity perpendicular to burner
(2) Suction side applications only
8/03
Page 2904 Maxon APX® Burners

0.5 ft. APX® Burner
10.2 11.5 4.5

1.2 7.7
6.5 2.2
RIGHT
LEFT 3.3
3.3
Flame Rod
1/4" NPT
Threads Spark Ignitor
10.5 14mm Threads
Distance req'd for removal 1.2
1.8
11.2
Main Gas Inlet Flange

1" NPT
1" NPT Nipple

Supplied by Customer
9.3 7.1
3.1 8.1
LEFT RIGHT
6.0
.438 x .750
Mounting Slots
Qty. 4
7.8
4.0 4.7
dia. dia.
3.9
7.0
wall
opening 7.9 10.1
9.0
1.3 1.3
8.6
Wall Opening


Blower Dimensions Burner Size
# of
A B C
Blowers
A 1 1 12.7 15.2 14.4
3.3 3.3
1.5 1 12.7 15.2 14.4
2 1 16.4 19.0 14.6
6.5 2.5 1 16.4 19.0 14.6
11.5 3 1 16.4 19.0 14.6
2.2 3.5 1 16.4 19.0 14.6
4 1 16.4 19.0 14.6
5 1 16.4 19.0 14.6
6 2 16.4 19.0 14.6
7 2 16.4 19.0 14.6
8 2 16.4 19.0 14.6
9 2 16.4 19.0 14.6
B 10 2 16.4 19.0 14.6
11 2 16.4 19.0 14.6
12 3 16.4 19.0 14.6
13 3 16.4 19.0 14.6
14 3 16.4 19.0 14.6
15 3 16.4 19.0 14.6
Left end Right end Blower Notes:

plate/pilot plate/pilot
U.V. Mount/Flame Rod

1" NPT Blower is capable of 90°
mounting increments.
10.5
Dist. req'd for removal
In 6 ft. through 15 ft.
1.5" NPT nipple Pilot Gas burners, aligning blowers
supplied by
customer equipped with filter
Spark Ignitor
silencer will cause
interference.
Foam Filter Exact motor apt to change

based on availability; size
Foam Silencer / Filter will not exceed
dimensions shown.
C
U.V. Mount/Flame Rod

1" NPT
10.5
Dist. req'd for removal
1.5" NPT nipple

supplied by
customer
Pilot Gas
Spark Ignitor
4/02

1 ft. through 5 ft. APX® Burners
For wall opening (cut-out)
Air Test Centerline see Page 2908
Connection of Burner Wall Mount Pilot RG
2.0 A
FR End Plate
Air Shutter Gas Inlet Spark Ignitor
U.V. Mount / Flame Rod
2.5 1" NPT
7.0
5.0
Wall
Opening
Pilot Gas
A
7.0
Burner Length (see below)
Burner Size 1 1.5 2 2.5 3 3.5 4 5

Burner Length 13.5 19.5 25.5 31.5 37.5 43.5 49.5 61.5
6 ft. and 7 ft. APX® Burners

Centerline For wall opening (cut-out)
Air Test Connection of Burner see Page 2908
FR End Plate 2.0 Wall Mount Pilot RG
Air Shutter A Gas Inlet 2.0
Spark Ignitor
7.0 2.5
Wall 5.0
Opening U.V. Mount / Flame Rod
1" NPT
A
18.0 Pilot Gas
11.0
25.0 18.0
8 ft. through 11 ft. APX® Burners

Air Test Connection For wall opening Wall Mount Pilot RG
FR End Plate (cut-out) see Page 2908
2.0 Gas Air Spark Ignitor
Inlet Shutter Centerline of Burner A 2.0
7.0 2.5
Wall 5.0
Opening U.V. Mount / Flame Rod
1" NPT
29.0 29.0
A
(24.9 for 9' APX) (24.0 for 9' APX) Pilot Gas
36.0 36.0
Burner Size 6 7 8 9 10 11
Burner Length 73.5 85.5 97.5 109.5 121.5 133.5 3.1 1.5" NPT
Mounting Surface
1.5" NPT Nipple
Supplied by customer
SECTION A-A


12 ft. APX® Burners
Air Test Connection For wall opening Wall Mount Pilot RG
(cut-out) see Page 2908 Centerline
FR End Plate 2.0 Gas Inlet Air Shutter of Burner 2.0
A Spark Ignitor
U.V. Mount / Flame Rod
7.0 2.5 1" NPT
Wall 5.0
Opening
Pilot Gas
A
18.0 18.0
47.0 47.0
54.0 54.0
145.5 Burner Length
13 ft. and 14 ft. APX® Burners

Spark Ignitor
For wall opening
Air Test Connection (cut-out) see Page 2908 Centerline Wall Mount Pilot RG
FR End Plate 2.0 of Burner 2.0
Gas Inlet Air Shutter A
7.0 2.5
Wall 5.0
Opening
18.0 11.0 A
47.0 18.0 Pilot Gas
54.0 54.0 U.V. Mount /
61.0 Flame Rod
1" NPT
Burner Length
(see below)
13 14
Burner
Length
157.5 169.5
15 ft. APX® Burners

Spark Ignitor
FR End Plate Wall Mount Pilot RG
For wall opening
Air Test Gas (cut-out) see Page 2908
2.0 Connection Inlet Air Shutter 2.0
7.0
2.5 Wall
5.0
Opening
12.0 21.0 Pilot Gas

21.0 56.0
56.0 63.0 U.V. Mount / Flame Rod
63.0
1" NPT
181.5 Burner Length

3.1 1.5" NPT
Mounting Surface
1.5" NPT Nipple
Supplied by customer
SECTION A-A
8/03

Wall Opening
Pilot Fig. #
Wall Opening = Burner Footage + XL + XR from pages 2909-2910
Example: Wall Opening = 24" burner + 2.15 + 1.35 (for a 2 ft. burner with Fig. 1 & Fig. 2 end plates)
Fig. # X
Wall Opening
Fig. 1 2.15
XL Burner Footage XR
Fig. 2, 3, 5, 6 1.35
Fig. 4 3.00*
*Use of Fig. 4 pilot will
require a special wall
opening shape if full seal is
required. Contact Maxon for
details.
Mounting Flanges Slot Mounting Tabs

A
6.0
2.1 Typ.
1.0
.438
4.5
3.9 2.7
CL
3.9 2.7 3.375

4.5
A = 4.0 square (1 ft. - 1.5 ft. burners) 2.0
A = 5.4 square (2 ft. - 15 ft. burners)

1.0
.375
Universal Mounting Bracket
Recommend 1 bracket per 5 feet of burner for horizontal orientations.
In vertical installations, use 1 bracket per 3 feet of burner and install 2.25
brackets on both sides of the burner.
(This face to burner)
7.5
Additional support tabs suggested for

burners longer than 4 feet. These tabs
may be mounted at various locations
on 6" spacings.
6.5
.375
dia.
1.346
1.875
1.875
1.0


Pilot End Plate Options
FIG 1 - WALL MOUNT PILOT BYPASS

1.9
Mounting
1.1 Surface
2.5
.4 dia. 3.4 6.0
10.8 * Dist. req'd for removal
* Dist. req'd for removal
18110
Spark Ignitor 1.8
10mm 3.6 .8 Pilot Air
Bleed Orifice
3.2 U.V. Mount / Flame Rod
1" NPT 9.4
Pilot Gas
3/8" NPT with adapter
FIG 2 - 0.25" FR END PLATE

1.1
.4 dia.
Mounting 5.0
1.1 Surface
2.5
.4 dia. 9.3
*Dist. req'd for removal
Flame Rod
1/4" NPT Gas Test Port 1.5
18117 1.8 1/8" NPT Optional Sight Glass
3.6 (Not available on all configurations)
6.9
*Dist. req'd for removal
FIG 3 - 14mm SI END PLATE 1.1
.4 dia.
Mounting 5.0
1.1 Surface
2.5
3.3
.4 dia. *Dist. req'd for removal
1.8 Gas Test Port
23739
Spark Ignitor 1/8" NPT
3.6 1.5
14mm
2.7
* Distance required for
*Dist. req'd for removal removal dimensions is
not to scale
4/02

Pilot End Plate Options (continued)
FIG 4 - WALL MOUNT PILOT - RAW GAS

2.75
Mounting
1.1 Surface
.4 dia.
Spark Ignitor 10.7
47232 * Dist req'd for removal Pilot Gas
1.8
1/2"-14 UNC 3.6 18117 3/8" NPT
Flame Rod & .8
U.V. Mount
1/4" NPT
7.9
* Dist req'd for removal
FIG 5 - INDUCT PILOT END PLATE

47789 1.1
Spark Ignitor
14MM
Pilot Gas Inlet

3/8" NPT 2.5
.6 1.5 Mounting
.5 5.0
1.1 Surface
1.4
.4 dia. 9.3
18117 .8 Gas Test Port
Flame Rod 1.8 1/8" NPT .4 dia.
1/4" NPT 3.6 1.5
6.9
FIG 6 - INDUCT FEED THRU PILOT
3/4"-10 UNC 1.1

Feed-thru Ignitors and Flame Rods
Ignitor Feed Thru (Order separately from burner)
.4 dia.
Feed
FR-Thru Feed-thru Feed-thru
Length
U.V.-Thru Ignitors Flame Rods
3/4"-10 UNC
12" 44652 47631
Mounting 5.0
1.1 Surface
1.4 2.5 18" 44653 47632
9.2
.4 dia. * Dist. req'd for removal 24" 44653 or 44654 46580
Gas Test Port
Pilot Gas .8 1/8" NPT
1/4" NPT 1.8 30" 44654 or 44655 47635
1.5
3.6
36" 44655 or 44656 47637
7.0
* Distance required for

removal dimensions is
not to scale


Flame Rod #18117
16mm Hex
1/4" -18 Thread
8mm Hex Nut
7.125
MAXON
.59 dia.
.394 dia.
.197
1.27 dia.
.75 .75
1.77
10.01
Spark Ignitors
14mm Thread
#18110 #23739 1.36
.28
MAXON
23739
.47
.89 .51 .08
1.8 1.02
1.87
4.09
#47232 #47789 14mm thread

7.27
1.25
.375
47789
.32
MAXON
.47
.56 dia.
.080
1/2 - 14 Threads .89 .512 .559

#11 Rajah
Connector 24mm Hex 1.8
5.51 3.3
Quartz Ignitor #47489

6.5
7/8" Hex 3/4 - 16 UNF Thread
0.472
dia.
3.5 1.25 3.6
8.4
4/02

Filters/Silencers Filter/Silencer Dimensions
Burner A B C D E
Size dia. dia. dia. dia. dia.
1 11.8 7.0 17.8 2.5 1.9
1.5 11.8 7.0 17.8 2. 5 1.9
2 11.8 7.0 17.8 2.7 2.1
2.5 16.4 9.0 25.1 2.7 2.1
3 16.4 9.0 25.1 2.7 2.1
B A 4 16.4 9.0 25.1 2.7 2.1
dia. dia.
5 16.4 9.0 25.1 2.7 2.1
Filter
6 16.4 9.0 25.1 2.7 2.1
Filter / Silencer
7 16.4 9.0 25.1 2.7 2.1
.9 8 16.4 9.0 25.1 2.7 2.1
12.5 C 9 16.4 9.0 25.1 2.7 2.1
E D
10 16.4 9.0 25.1 2.7 2.1
11 16.4 9.0 25.1 2.7 2.1
12 16.4 9.0 25.1 2.7 2.1
13 16.4 9.0 25.1 2.7 2.1
14 16.4 9.0 25.1 2.7 2.1
15 16.4 9.0 25.1 2.7 2.1
Optional Control Valve Package
9.8
14.3
Typical control motor
(Honeywell
Modutrol shown)
5.5
2.8
2.0 2.1
6.0
6.1 2.3
Optional Control Valve Package (continued)
Direct Coupled Actuator (GP only)

1.5 CV shown
1/2" NPT conduit connection

12' motor cable standard
1.80
1.80 .22
3.89
0.830" dia. hole 2.41 5.54

to accept 1/2"
conduit fittings
by others for
LFS connection
(optional)
5.18
1.31
Actuator Specifications
Torque 35 in/lbs
Power 24 VAC
Signal 4-20 mAmp
Position
2-10 VDC
Feedback
Optional LFS Switch

Specifications
Power 120 VAC
Signal 15 Amp
Switch SPDT
7/02
Notes
Maxon APX® Burners Page 2900-S-1
Please read all installation and start-up Filters for both fuel and air may be required in some
instructions prior to working with the burner. environments to prevent plugging of gas and/or air
View ports providing a clear view of the flame are ports.
recommended. The APX® Burner can be slot mounted or mounted
with a continuous mounting flange. Dimensional data
Do not discard packing material until all parts
for all mounting options for all sizes can be found on
have been identified. (Some parts are shipped
page 2904 through 2910.
loose with the burner.)
The APX® Burner may also be mounted within a
The burner accounts for a portion of the total fresh or recirculating air stream. The packaged
combustion system (see typical piping schematic combustion air fan may be utilized within the duct for
below). The sizing and installation instructions for fresh air applications and can be mounted with an air
other components such as valves, control motors, control damper on the outer wall for recirculating
blowers, gas pressure regulators, pressure switches, applications. In-duct applications will require additional
etc. can be found in the corresponding sections of the support for piping and air duct work.
Maxon Catalog. A typical pipe train is shown below.
The APX® Burner utilizes a combustion air blower
to supply combustion air. The combustion fan should
Installation Options:
not be positioned where inert gases could be drawn For UV scanner flame supervision, use of a UV
into the combustion air intake. Electrical service must scanner adapter will allow use of full phase ignitor
match the voltage, phase, and cycle of the combustion transformer. This will prevent spark excitation from the
fan as well as all other electrical system components. spark ignitor. This is the recommended installation for
a UV scanner. Half-wave spark transformers may
alternately be used without the UV scanner adapter.
Typical APX® Burner piping layout

mCORPORATION
Page 2900-S-2 Maxon APX® Burners
Read complete instructions before proceeding and CAUTION: Do not bypass control panel timers
familiarize yourself with all components of the com- typically controlling sequential operations.
bustion system. Verify that the system has been
installed in accordance with the original 6. Set burner to low fire position. Main combus-
manufacturer’s current instructions. tion air blower should be on.
7. Adjust the combustion air shutter such that the
CAUTION: Initial adjustment and light-off should combustion air differential corresponds to the
be undertaken only by trained and experienced chart on page 2903. Turn pilot gas pressure
personnel familiar with combustion systems, regulator spring in approximately 40% and open
with control/safety circuitry, and with knowledge pilot adjustable orifice 2 turns from fully seated
of the overall installation. Instructions provided position.
by the company and/or individuals responsible For direct spark ignition, proceed to step #10.
for the manufacture and/or overall installation of 8. Open main and pilot gas cocks. Energize spark
the complete system incorporating Maxon ignition transformer and pilot gas solenoid valve,
burners take precedence over these provided by then attempt pilot ignition. If necessary, slowly
Maxon. If Maxon instructions conflict with any increase pilot flow through adjustment of pilot gas
codes or regulations, contact Maxon Corporation pressure regulator or pilot gas cock. For burner
before attempting start-up. with Fig. 1 pilot, a pilot air shutter is also provided
to tune the pilot bypass air. Repetition of this
procedure may be necessary as ignition will occur
only when air trapped in the pilot line has been
For initial start-up of Maxon APX® Burner: bled. Pilot should be no larger than tennis ball size.
If an APX Burner is equipped for direct spark
1. Close all burner fuel valves and cocks. Make ignition, adjust main gas control valve so that
preliminary adjustment to the fuel gas pressure minimum flame is a complete ribbon of uniform
regulators. flame in the trough of the burner.
2. Check all electrical circuitry. Verify that all 9. Shut off pilot gas flow and re-ignite several
control devices and interlocks are operable and times. The flame safeguard relays should now
functioning within their respective settings/ranges. power main fuel shut-off valves.
Be sure all air and gas manifolds are tight and 10. Light the APX® Burner. With pilot flame estab-
that test connections are plugged if not in use. lished and flame supervision operational, opening
3. Check that air and gas pressure switches are the main fuel shut-off valve will allow fuel flow to
not marginally set. Set pressure switches with a the burner.
large enough range to prevent system shutdown 11. Adjust main gas pressure regulator to maintain
during initial adjustment. During final system required differential gas pressure.
tuning, the pressure switches should be re- 12. If pilot is interrupted as recommended, turn off
adjusted. pilot and verify that flame supervision is opera-
4. Disconnect any automatic control motor tional.
linkage from the burner control valve. Initial 13. Slowly cycle the APX® Burner from light-off to
start-up should only be accomplished in a manual minimum through maximum and back to ensure
burner control mode. that the burner functions satisfactorily throughout
5. Start all system related fans and blowers. the operating range. Refine adjustment if neces-
Check for proper rotation of motors and impellers. sary.
Verify that all control interlocks are operating. 14. When burner performance is satisfactory and
Allow air handling equipment to adequately purge stable throughout the operating range, re-
combustion chamber. connect the control linkage and allow unit to
operate in automatic control mode.
15. Shut system down, closing all fuel valves.
Disconnect and plug all test connections. Re-
place all equipment covers and caps. Tighten all
linkage set screws.
m CORPORATION

Maxon APX® Burners Page 2900-A/P-1
Assembly Numbers
Burner Description Configured Product Number Burner Description Configured Product Number
0.5 ft. APX Lineburner .5 APX 7 ft. APX Lineburner 7 APX
1 ft. APX Lineburner 1 APX 8 ft. APX Lineburner 8 APX
1.5 ft. APX Lineburner 1.5 APX 9 ft. APX Lineburner 9 APX
6 ft. APX Lineburner 6 APX
Segment Choice Detail - APX® Burners

Segment Choices
(DEFAULT is shaded)
BUT Butane Gas
FUEL Type of fuel gas NAT Natural Gas
PROP Propane Gas
DRILLING LP Low pressure drilling

Type of drilling pattern
(not valid for 0.5 ft. APX) STD Standard drilling
CONT Continuous flange burner mounting
MOUNTING OPTION Type of burner mounting INDUCT In-duct burner mounting
SLOT Slot fired burner mounting
ANSI ANSI threaded
GAS FLANGE Type of threads on gas flange
ISO ISO threaded
FLAME DETECTION FR Flame rod

Type of flame detection system
(not valid for 0.5 ft. APX) SCANNER UV Scanner provision
EB External blower
NONE No fan (for Shanghai only)
BLOWER VOLTAGE SELECTION Type of blower desired
230_460360 230/460-3-60 Combustion air fan
575360 575-3-60 Combustion air fan
FLTR Air filter
FILTER &/OR SILENCER
Add air filter or silencer, if desired FLTSLNCR Filter / silencer
(not valid for 0.5 ft. APX)
Segment Choice Detail continued on page 2900-A/P-2

m CORPORATION
Page 2900-A/P-2 Maxon APX® Burners
Assembly Numbers
Segment Choice Detail - APX® Burners
Segment Choices
(DEFAULT is shaded)
NONE None selected
PILOT ORIFICE Type of pilot orifice, if desired 38009_HC High capacity orifice
50431_VHC Very high capacity orifice
SLOT FIRED MOUNTING TABS Number of tabs required 0 Specify value
UNIVERSAL MOUNTING
Number of brackets required 0 Specify value
BRACKETS (not valid for 0.5 ft. APX)
FIG1_FR Standard air bypass with flame rod
FIG1_UV Standard air bypass with UV scanner provision
FIG2_FR Flame rod end plate with flame rod
FIG2_PLN Flame rod end plate plain
FIG2_SG Flame rod end plate with sight glass
LEFT END PLATE/PILOT
FIG3_SIEP Spark ignitor end plate
(See Page 2905 for left/right Pilot end plate options- left end
orientation) FIG4_FR Raw gas with flame rod
FIG4_UV Raw gas with UV provision
FIG5_FR In-duct end plate with flame rod
FIG5_UV In-duct end plate with UV provision
FIG6_FR Feed thru end plate with flame rod
FIG6_UV Feed thru end plate with UV provision
FIG1_FR Standard air bypass with flame rod
FIG1_UV Standard air bypass with UV scanner provision
FIG2_FR Flame rod end plate with flame rod
FIG2_PLN Flame rod end plate plain
FIG2_SG Flame rod end plate with sight glass
RIGHT END PLATE/PILOT
Pilot end plate options - right FIG3_SIEP Spark ignitor end plate
(See Page 2905 for left/right
end
orientation) FIG4_FR Raw gas with flame rod
FIG4_UV Raw gas with UV provision
FIG5_FR In-duct end plate with flame rod
FIG5_UV In-duct end plate with UV provision
FIG6_FR Feed thru end plate with flame rod
FIG6_UV Feed thru end plate with UV provision
NONE None selected
CV valve with direct coupled motor and LFS
W_BEL_LFS
(GP)
W_BEL_MTR CV valve with direct coupled motor (GP)
CONTROL MOTOR
Type of control motor if desired W_CB_L CV valve with CB&L
(not valid for 0.5 ft. APX)
W_CB_L_LFS CV valve with CB&L and LFS
W_MOD_LFS CV valve with mod motor and LFS
W_MOD_MTR CV valve with CB&L and mod motor
m CORPORATION

Maxon APX® Burners Page 2900-A/P-3
Assembly Numbers
Replacement Items & Accessories
0.5 ft. 1 ft. through 2 ft. 2.5 ft. through 15' ft.
Burner Size
.5 APX 1 APX - 2 APX 2.5 APX - 15 APX
Air Filter --- 1042405 1042407
Filter/Silencer --- 1042401 1042403
Replacement Foam Filter Element --- 1042393 1042394
ISO Flange 48342 48341
UV Adapter (wall mount) 47157
For Fig. 1 pilot 18110
Spark For Fig. 3 pilot 23739

Ignitors For Fig. 5 pilot 47489
For Fig. 4 pilot 47232
Spark Ignitor (prior to 2/15/02) - quar tz 47489
12" 44652
Feed-thru Spark Ignitors 18" 44653
For Fig. 6 - INDUCT FEED
24" 44653 or 44654
THRU PILOT
(order separately from burner) 30" 44654 or 44655
36" 44655 or 44656
Flame Rod Fig. 1, 2, 4 & 5 18117
12" 47631
Feed-thru Flame Rods 18" 47632
For Fig. 6 - INDUCT FEED
24" 46580
THRU PILOT
(order separately from burner) 30" 47635
36" 47637
HC 38009
Adjustable Orifice
VHC 50431
NOTE: Spark ignitor, flame rod and adjustable orifice included (shipped loose)

m CORPORATION
Page 2900-A/P-4 Maxon APX® Burners
Assembly Numbers
Replacement Blowers
240/480/3/60 575/3/60
APX Burner Size
Blower(s) Blower(s)
.5 APX 47386 48370
1 APX 47145 47387
1.5 APX 47146 47388
2 APX 47147 47389
2.5 APX, 3 APX 47148 47390
3.5 APX, 4 APX 47149 47391
5 APX 47150 47392
6 APX 47148 (2) 47390 (2)
7 APX, 8 APX 47149 (2) 47391 (2)
9 APX, 10 APX, 11 APX 47150 (2) 47392 (2)
12 APX 47149 (3) 47391 (3)
13 APX, 14 APX, 15 APX 47150 (3) 47392 (3)
mCORPORATION

Product Data Sheet Product: APX™ Burners
Page: 2900-1 Date: 3/97

Do Not Reproduce
Make-up Air
The Maxon APX™ burner can be utilized for make-up air applications. The burner is particularly useful when the
make-up air system has variable air flow. Several system variables need to be defined so that the APX™ burner
can be properly applied. These include:
• Process airflow turndown.

• Maximum temperature rise of the system.
• Required emissions.
A process air turndown of 2:1 will affect make-up air in two ways. At half the process air flow, only half the
dilution air is present. Also, only the lower half of the firing rate would be utilized as the maximum temperature
rise remains constant. The APX™ Burner can achieve a 5 ppm CO make-up air rating at 100oF temperature rise
without process air turndown. Like NP AIRFLO® Burner, the peak CO levels occur near 25% of firing capacity.
In order to obtain the best emissions throughout the highest turndown, the fuel and air should be controlled with
an MRV. Fuel and air should be throttled on ratio through a 2 - 3:1 turndown. From that point and below, fuel
only should be throttled. The air flow (not pressure drop because APX™ takes a drop across a distribution
plate) setting at 2 - 3:1 turndown would be equivalent to the air flow of NP-I with approximately .4 to .55 in wc
pressure drop.
The chart below demonstrates that the APX™ will deliver make-up quality air when fired in-duct. The chart
depicts CO emissions for APX™ with constant combustion air and APX™ with throttled combustion air. The
secondary y-axis demonstrates the effect of cutting the process air, and thus dilution air, by a factor of two. The
burner still generates the same amount of CO at a given firing rate on a “pounds” or “ppm at 3%” level, but
changing the amount of process air will change the “as read” levels.
APX CO Emissions vs Gas Flow

6 (100 Deg F Max Temp Rise) 12
5 10
CO (ppm as read, 1/2

APX w/ 100 Deg F Max Rise at
4 8
process flow)
Constant Air Full Process Flow, 200
Deg F Max Rise at 1/2
3 Process Flow 6
2 APX w/ 4
Throttled Air
1 2
0 0
0 100 200 300 400 500 600 700 800 900 1000
Gas Flow (scfh/ft)
Note that only the lower half of the firing rate would be used when the process air is cut in half. In other words,
half process air would only require half the firing rate to obtain the same temperature rise as full firing rate at full
process flow. This is the reason variable process air flow systems require such large burner turndown.
Product Data Sheet Product: APX™ Burners
Page: 2900-2 Date: 3/97

Do Not Reproduce
Alternate Fuel Consideration
The APX™ Burner with the standard drilling can accomodate Natural Gas, Propane and Butane. The APX™
For fuels other than natural gas, special consideration should be given to the application.
Propane:
• Protect flame against cross-flow above 750,000 Btu/ft.

• Maintain full air pressure - may require downrating of burner to 900,000 Btu/ft if flame length is critical.
• Increased CO - requires reducing max temperature rise to 80oF for make-up air rating of 5 ppm CO as read.
Butane:
• Protect flame against cross-flow.

• Maintain full air pressure - downrate burner to 800,000 Btu/ft.
• Turndown limited to 25:1
• Increased CO - not recommended for make-up air applications requiring less than 10 ppm CO as read with
maximum temp rise of 90oF.
• UV scanner recommended.
Butylene and Propylene (more than 15% of volume of fuel gas is butylene and propylene combined)
• Protect flame against cross-flow.

• Maintain full air pressure - downrate burner to 750,000 Btu/ft
• Turndown may be limited to 20:1
• UV scanner only.
• Increased CO - not recommended for make-up air.
• Maximum of 60% combined C3H6 + C4H8 in fuel mixture.
50 Hz consideration
The APX™ burner can be applied for 50 hz applications. For natural gas, either downrate the burner to
accomodate the loss of airflow or order the next size blower to restore full firing capacity. For other fuels, the
airflow must be equivalent to 60 hz applications. Minimum differential air pressure at the burner connection is
3.5 in wc for alternate fuels, though the 4.0 in w.c. displayed in the catalog is preferred. To restore the burner to
60 hz equivalent on balanced ovens, modify the order as follows:
• 1.0 APX™ - less 47145, with 47146.

• 1.5 APX™ - less 47146, with 42259. In this one case, an SER is required. When using the 42259 (from
packaged Tube-O-Therm), the mounting flange of the blower must be modified from round to square to
accomodate the air control slide gate.
• 2.0 APX™ - less 47147, with 47148.
• 3.0 APX™ - less 47148, with 47149.
• 4.0 APX™ - less 47149, with 47150.
• 5.0 APX™ - EB only.
Bulletin 3100

Premix Burner
Systems
SN Sealed Nozzles
PREMIX® Blower Mixer shown with electric control motor (by others),
STICKTITE® Nozzles
optional connecting base and linkage assembly, and combustion air
filter assembly
• Mechanical device for producing an air/gas mixture using

most clean, low pressure fuel gases
• Air/gas ratio control at all firing rates Style A & B

• Includes electric motor and non-loading paddle-wheel impeller in LINOFLAME® Burners
cast iron blower case
• Integral ratio valve provides thorough air/gas mixing

• Optional stand-by fuel arrangement allows changeover to
alternate gaseous fuels
• Single point firing rate control to single or multiple burners VFL & VFH
• Low initial and operating costs through use of lower LINOFLAME® Burners
horsepower motor
• Application flexibility provided with over 70 different models and

sizes
INFRAWAVE® Burners
Page 3102

Principle of Operation Stand-by fuel
arrangement (using
PREMIX® Blower Mixers consist of a ratio valve Series “Q” Control
and blower. Air for combustion is drawn in through the Valve) provides a
ratio valve where it can be throttled. means to easily use
That same ratio valve includes a gas butterfly valve alternate fuel without re-
cross linked to the air valve. A multiple-screw cam adjustment.
design permits fuel flow to be matched to air flow at
each firing position.
This gives excellent control and allows on-ratio
firing. If the application calls for it, ratio may be made
oxidizing or reducing at any point within the burner
firing range.
PREMIX® Blower Mixer

with stand-by fuel
arrangement
Series “M” Miniature PREMIX® Blower Mixers

provide a low cost alternative for smaller heating
applications requiring “on-off” firing.
The mixer must be matched to the discharge areas

and mixture pressure requirements of the burners
used.
Any clean gaseous fuel (500-3200 Btu/ft3) can be
used. Only 2" to 8" wc supply pressure is necessary
at the mixer.
Combustible mixture may be piped to single or
multiple burners, but should not be throttled down-
stream of the mixer.
Typical applications for PREMIX® Blower Mixer

systems have included: M-100 Miniature PREMIX® Blower Mixer
• metal melting in pots and crucibles
• solution heating
• grain dryers Miniature PREMIX® Blower Mixers consist of an
• direct flame polishing of glassware adjustable fuel orifice and blower. Air for combustion
• miscellaneous air heating applications in nearly is drawn in through an adjustable air shutter.
every industrial marketplace An adjustable gas orifice valve permits fuel flow to
Earlier versions of the PREMIX® Blower Mixer have be matched to air flow for on-ratio firing. The ratio may
been in use since 1917. be made oxidizing or reducing within the firing limits of
the particular burner type used.
7/90
PREMIX® Blower Mixers Page 3103
Typical Piping Layouts

for PREMIX® Blower Mixer Systems
Block & Bleed system is frequently
required by insurance authorities.
Maxon assumes no responsibility for the

use or misuse of these layouts. Specific
piping and wiring diagrams should be
submitted to the appropriate agencies for
approval on each application.
Stand-by fuel arrangements permit quick

changeover to alternate fuels.
Maxon Series “Q”
Flow Control Valves
described in catalog
Bulletin 7000 provide the
additional flow control
point for the stand-by fuel
arrangements.
A single control operator (rated for at least 150
inch-pounds torque) operates both the ratio valve
furnished as part of the PREMIX® Blower Mixer and
an additional Series “Q” Control Valve (ordered
separately). Typical piping arrangement is shown at
right. Maxon does not supply the piping shown.
When this arrangement is used, the PREMIX®
Blower Mixer is first adjusted for the primary fuel A complete burner system utilizing a PREMIX®
(usually natural gas), then the “Q” Valve is adjusted Blower Mixer will also include gas train, burner
to provide proper alternate fuel flow. assembly and control panel. Your Maxon
range available.
11/92
Page 3104 PREMIX® Blower Mixers
General Designations of PREMIX® Blower Mixers

PREMIX® Blower Mixer designations consist of two
The capacity of a PREMIX® Blower Mixer is
parts. The first half of the designation represents the
determined by the size, type, and number of burners
mixer type. For “M”, “PL”, “PM” and “PH” Mixers,
or nozzles, and by the field conditions under which it
this is followed by their maximum capacity (in
operates. Choose carefully from the capacities/
thousands of Btu/hr) when firing a single
selection tables for the combination of mixer, burner
STICKTITE™ Nozzle against balanced conditions.
and operating conditions for your application.
Slight variations in combustion chamber pressure, Example: PM-525 PREMIX® Blower Mixer has a
draft conditions, or the availability of secondary air maximum capacity of 525,000 Btu/hr when
can affect ratings and performance. firing a single HD- 2" -21 STICKTITE™
Each blower mixer must be matched to total Nozzle in open air or against a balanced
discharge areas and mixture pressure requirements combustion chamber static pressure
of the specific burners used. Four types of blower condition.
mixers are available: M, PL, PM and PH. An M-500 Miniature PREMIX® Blower
Miniature PREMIX® Blower Mixers are for “on-off” Mixer has a capacity of 500,000 Btu/hr with
firing applications and do not include a ratio valve. a HD - 2-1/2" -27 STICKTITE™ Nozzle in
PL Mixers use smaller motors and develop less similar conditions.
mixture pressure than PM Mixers. PH Mixers develop
the highest mixture pressures.
Each PREMIX® Blower Mixer assembly includes a totally enclosed electric motor. You may select from a
variety of available voltages:
60 Hertz Options 50 Hertz Options (possible net extra cost)

Horsepower 208 - 230/460/3/60
115/208 - 230/1/60 575/3/60 190 - 200/1/50 380 - 415/3/50 500/3/50
(standard motor)
1/6 √ Not Available Not Available √ Not Available Not Available
1/3 & 1/2 √ √ √ √ √ √
3/4 & 1 √ √ √ √ √ √
1-1/2, 2, 3 & 5 Not Available √ √ Not Available √ √
®
PREMIX Blower Mixers with STICKTITE™ Nozzles
This page provides sizing and capacity information Table 1: Percent of capacity reduction
for systems using PREMIX® Blower Mixers and Back Pressure +.1" wc +.15" wc +.2" wc +.25" wc
STICKTITE™ and/or PILOTPAK™ Burner Nozzles.
PL 3 6 9 12
Capacities (in 1000’s Btu/hr) shown in Tables 3, 4, Percent
and 5 are based on firing through appropriately-sized PM 2-1/2 5 7-1/2 10
Reduction
Series “T” Tuyere Blocks into a combustion chamber PH 2 4 6 8
whose internal pressure does not exceed +0.05".
Higher back pressures reduce capacities by the
percentages shown in Table 1 at right. Table 2: Percent of capacity increase
Suction conditions with adequate secondary air Application Oven & Furnace Immersion Tube
may allow capacity increases by the percentages
Suction -.05" wc -.1" wc -.05" wc -1" wc
shown in Table 2.
To select a mixer and burner combination, PL 6 12 12 24
determine required maximum capacity. Use tables Percent
PM 5 10 10 20
below to find nozzle size and mixer designation. Increase
PH 4 8 8 16
Multiple nozzles can be used, but the actual
capacities will depend upon the type, size, and quan-
tity of nozzles selected for your application.
PREMIX® Blower Mixer Capacities (1000’s Btu/hr) with STICKTITE™/PILOTPAK™ Nozzle

firing into balanced combustion chamber pressure (0 to +0.05" wc static pressure)
Table 3: "PL" Blower Mixers Table 4: "PM" Blower Mixers Table 5: "PH" Blower Mixers
Mixer Nozzle Mixer Nozzle Mixer Nozzle
Size Size Max:Min Size Size Max:Min Size Size Max:Min
PL-80 1" -9 80:25 PM-200 1-1/4" -12 200:40 PH-190 1-1/4" -10 190:30
PL-130 1-1/4" -12 130:40 PM-260 1-1/4" -14 260:60 PH-250 1-1/4" -12 250:40
PL-165 1-1/4" -14 165:60 PM-350 1-1/2" -16 350:75 PH-330 1-1/4" -14 330:60
PL-195 1-1/2" -16 195:75 PM-525 2" -21 525:110 PH-400 1-1/2" -16 400:75
PL-380 1-1/2" -18 380:100 PM-690 2" -24 690:170 PH-500 1-1/2" -18 500:100
PL-490 2" -21 490:110 PM-920 2-1/2" -27 920:200 PH-700 2" -21 700:110
PL-540 540:170 PM-1080 3" -30 1080:240 PH-900 2" -24 900:170
2" -24
PL-630 630:170 PM-1200 4" -34 1200:275 PH-1220 2-1/2" -27 1220:200
PL-750 2-1/2" -27 750:200 PM-2000 4" -41 2000:450 PH-1400 3" -30 1400:240
PL-850 3" -30 850:240 PM-3200 5" -50 3200:700 PH-1650 4" -34 1650:275
PL-1000 4" -34 1000:275 PH-2350 4" -41 2350:450
PL-1350 1350:450
PL-1440 4" -41 1440:450
PL-1700 1700:450
PL-2650 5" -50 2650:700
PL-3500 3500:1100
PL-4250 6" -60 4250:1100
PL-4600 4600:1100
11/92
Miniature PREMIX® Blower Mixers with STICKTITE™ Nozzles
The table below provides performance data for 500 unit is fired against +0.15" wc to +0.75" wc back
Miniature PREMIX® Blower Mixers used with pressure (+0.15" wc to +0.5" wc for other sizes). Do
STICKTITE™ Burner Nozzles. All minimum capacities not use against higher back pressures.
are based on natural gas firing at 0.25" wc differential The rich maximum capacity shown requires at
mixture pressure. least 6" wc gas pressure at blower mixer inlet, and is
Two maximum capacities are shown. The “on- attainable only when firing in open air.
ratio” maximum is attainable when firing against Data given for single STICKTITE™ Nozzles lists
balanced pressure conditions and requires 3" wc the flame length that may be expected under rich
natural gas pressure at blower mixer inlet. Maximum maximum firing conditions. Flame will be shorter under
capacities will be reduced by 5 to 50% when the M- all other circumstances.
Capacity (1000's Btu/hr) STICKTITE™ Nozzle

Maximum
Mixer Approximate
On-Ratio Mixture Pressure
Designation Minimum Rich Maximum Size Flame Length
Maximum (inches wc)
(in inches)
18 39 50 1.3 HD-3/4" -7 8
21 44 70 1.25 HD -1" -8 10
25 54 120 1.2 HD -1" -9 12
M-100
31 65 130 1.1 HD -1-1/4" -10 14
40 85 140 1 HD -1-1/4" -12 16
60 98 150 0.75 HD -1-1/4" -14 18
75 150 270 1.1 HD -1-1/2" -16 38
M-250 100 180 370 1 HD -1-1/2" -18 50
110 225 450 0.9 HD -2" -21 60
170 360 600 1.35 HD -2" -24 54
200 500 820 1.6 HD -2-1/2" -27 60
M-500
240 580 1000 1.5 HD -3" -30 65
275 670 1200 1.4 HD -4" -34 65
®
PREMIX Blower Mixers with Series “SN” Sealed Nozzles
This page provides sizing and capacity information Table 1: Percent of capacity reduction
for systems using PREMIX® Blower Mixers and “SN”
Back Pressure +.1" wc +.15" wc +.2" wc +.25" wc
Sealed Nozzles. Data is based on balanced conditions
PL 2-1/2 5 7-1/2 10
or less than +0.05" wc combustion chamber pressure. Percent
Suctions or drafts of up to 0.1" wc will have no PM 2 3 4 5
Reduction
appreciable affect on capacity since these are sealed PH 2 3 4 5
burners. Higher back pressures reduce capacities by
the percentages shown in Table 1 at right.
To select a mixer and burner combination,
determine required maximum capacity. Use tables
below to find nozzle size and mixer designation.
Multiple nozzles can be used but the actual
capacities will depend upon the type, size and quantity
of nozzles selected for your application.
PREMIX® Blower Mixer Capacities (1000’s Btu/hr) with “SN” Sealed Nozzles
firing into balanced combustion chamber pressure (0 to +0.05" wc static pressure)
Table 2: "PL" Blower Mixers Table 3: "PM" Blower Mixers Table 4: "PH" Blower Mixers
Mixer Nozzle Mixer Nozzle Mixer Nozzle
Size Size Max:Min Size Size Max:Min Size Size Max:Min
PL-80 1" -9 80:25 PM-200 1-1/4" -12 200:40 PH-190 1" -9 190:25
PL-130 1-1/4" -12 130:40 PM-260 1-1/4" -14 260:60 PH-250 1-1/4" -12 250:40
PL-165 1-1/4" -14 165:60 PM-350 1-1/2" -16 350:75 PH-330 1-1/4" -14 330:60
PL-195 1-1/2" -16 195:75 PM-525 2" -20 525:160 PH-400 1-1/2" -16 400:75
PL-380 1-1/2" -18 380:100 PM-690 2" -24 690:170 PH-500 1-1/2" -18 500:100
PL-490 2" -20 490:155 PM-920 920:200 PH-700 2" -20 700:160
2-1/2" -27
PL-540 540:170 PM-1080 1080:200 PH-900 2" -24 900:170
2" -24
PL-630 630:170 PM-1200 3" -33 1200:360 PH-1220 1220:200
2-1/2" -27
PL-750 750:200 PM-2000 2000:560 PH-1400 1400:200
2-1/2" -27 4" -42
PL-850 850:200 PM-3200 3200:560 PH-1650 3" -33 1650:360
PL-1000 3" -33 1000:360 PH-2350 4" -42 2350:560
PL-1350 1350:560
PL-1440 4" -42 1440:560
PL-1700 1700:560
PL-2650 4" -45 2650:720
PL-3500 3500:1100
PL-4250 6" -60 4250:1100
PL-4600 4600:1100
5/93
PREMIX Blower Mixers with Style “A” or “B” LINOFLAME® Burners
®
Information is provided on this page and page 3109 To select a mixer and burner combination,
for systems using PREMIX® Blower Mixers and Style determine your required maximum capacity. When you
“A” or “B” LINOFLAME® Burners firing in still air. locate suitable capacities, read the required PREMIX®
Capacities shown in the tables are based on 100% Mixer size from left side of the table. Choose any of
air/gas premixture through the burner and on minimal the burner footage/drilling combinations shown to the
use of secondary air. Maximum capacity may be right of capacity columns, matching the footage to your
reduced as much as 10% if fresh air is restricted. space available and heat distribution needs.
These tables are also based on balanced pressure LINOFLAME® Burner assemblies can be shaped to
conditions and the use of a regulated supply of natural meet the needs of your particular application (for
gas at 2" -7" wc (measured at blower mixer inlet). additional burner information, see Maxon catalog
Low-fire start is recommended for all such section pertaining to LINOFLAME® Burners).
applications, and particularly with Type “PH” Mixers,
because of the higher mixture pressures developed.
Table 1: Capacities (1000's Btu/hr) with "PL" Blower Mixers and indicated footage of Style "A" or "B"
LINOFLAME® Burner in still air applications [1]
Style "A" or "B" LINOFLAME® Burner assembly length
Blower Mixer Capacities (1000's Btu/hr)
(feet-inches of indicated type and drillings)
Designation
Maximum Minimum B-36-42-42 B-96-50-50 B-96-44-44 B-96-36-43 A-72-17-33 A-72-C-33
PL-80 80 20 1' --- --- --- --- ---
PL-130 130 45 1' 10" 1' 6" 1' 3" 1' --- ---
PL-165 165 66 2' 6" 2' 3" 2' 1' 3" --- ---
PL-195 195 78 3' 4" 2' 8" 2' 3" 1' 8" 1' ---
PL-380 380 105 4' 3' 6" 2' 8" 2' 1' 6" 1'
PL-490 490 165 6' 3" 5' 6" 4' 3" 3' 2' 1' 6"
PL-540 540 175 7' 6" 6' 3" 5' 3' 8" --- ---
PL-630 630 185 6' 10" 5' 10" 4' 6" 3' 3" 2' 1'6"
PL-750 750 210 8' 8" 7' 4" 5' 8" 4' 2' 8" 2'
PL-850 850 285 11' 3" 9' 6" 7' 4" 5' 4" 3' 6" 2' 6"
PL-1000 1000 330 13' 3" 11' 8' 6" 6' 3" 4' 3'
PL-1350 1350 450 18' 15' 12' 8' 6" 5' 8" 4'
PL-1440 1440 465 18' 4 " 15' 8" 12' 8' 8" 6' 4'
PL-1700 1700 520 20' 3" 17' 4" 13' 4" 10' 6' 6" 4' 6"
PL-2650 2650 730 29' 24' 3" 19' 13' 8" 9' 6' 6"
PL-3500 3500 1130 45' 38' 29' 8" 21' 6" 14' 10'
PL-4250 4250 1200 43' 4" 37' 28' 6" 20' 8" 14' 10'
PL-4600 4600 1200 44' 9" 37' 6" 27' 8" 21' 6" 14' 10'
[1] LINOFLAME® Burner located in fresh air and subject only to normal convection currents
®
Table 2: Capacities (1000's Btu/hr) with "PM" Blower Mixers and indicated footage of Style "A" or "B"
LINOFLAME® Burner in still air applications [1]
Designation
Maximum Minimum B-36-42-42 B-96-50-50 B-96-44-44 B-96-36-43 A-72-17-33 A-72-C-33
160 39 1' 6" 1' 3" 1' --- --- ---
PM-200
200 45 2' 1' 6" 1' 8" 1' 2" --- ---
PM-260 260 60 2' 6" 2' 1' 8" 1' 2" --- ---
PM-350 350 88 3' 6" 2' 10" 2' 4" 1' 8" 1' ---
PM-690 690 190 7' 6" 6' 4" 5' 3' 9" 2' 6" ---
PM-920 800 190 7' 6" 6' 4" 5' 3' 8" 2' 6" ---
PM-1080 1050 265 10' 4" 8' 8" 6' 10" 5' --- 2' 6"
PM-1200 1200 310 12' 4" 10' 4" 8' 3" 6' 4' 3'
PM-2000 2000 510 20' 16' 8" 13' 6" 9' 10" 6' 6" 4' 6"
PM-3200 3200 700 27' 4" 23' 4" 18' 4" 13' 4" 9' 6' 6"
Table 3: Capacities (1000's Btu/hr) with "PH" Blower Mixers and indicated footage of Style "A"
or "B" LINOFLAME® Burner in still air applications [1]
Designation
Maximum Minimum B-36-42-42 B-96-50-50 B-96-44-44 B-96-36-43 A-72-17-33
PH-190 190 35 1' 4" 1' 2" 1' 9" ---
PH-250 250 48 1' 10" 1' 8" 1' 3" 1' ---
PH-330 330 68 2' 8" 2' 3" 1' 9" 1' 3" ---
PH-400 400 82 3' 4" 2' 2' 3" 1' 6" ---
PH-500 500 108 4' 4" 3' 8" 3' 2' 2" 1' 6"
PH-700 700 130 5' 4' 3" 3' 4" 2' 4" ---
PH-900 900 180 7' 6' 4' 10" 3' 6" ---
PH-1220 1200 225 8' 6" 7' 4" 5' 8" 4' 3" ---
PH-1400 1400 280 10' 8" 9' 3" 7' 3" 5' 3" ---
PH-1650 1750 390 15' 6" 13' 6" 10' 6" 7' 8" 5'
2300 480 19' 16' 12' 6" 9' 6'
PH-2350
2800 750 29' 3" 24' 8" 19' 4" 14' 9' 6"
5/93
®
Style “A” or “B” LINOFLAME® Burners may be Capacities of LINOFLAME® Burner assemblies
used in air heating applications with uniform air will vary from “still air” capacities when installed
stream velocities across burner in the range of 500- for air heating applications. Still air capacities will be
1500 SFPM and return air temperatures not to exceed increased by 5% when operating in an air stream of 0
500°F (260°C). A regulated supply of natural gas at 2- to +2.0" wc static pressure. An increase of 10% will be
7" wc is required to the blower mixer inlet. experienced when operating in an air stream with a
At least 25 SCFM fresh make-up air must be suction of -1.0 to 0" wc static pressure.
available to the recirculated system for each
100,000 Btu/hr of maximum capacity. If not
available, use capacities from “still air” tables shown
on pages 3108 and 3109.
Miniature PREMIX® Blower Mixer with Style “A” or “B” LINOFLAME® Burners
Table 1 below provides capacity data for 500 unit is fired against +0.15 to +0.75" wc back
LINOFLAME® Burner/Miniature PREMIX® Systems. pressure (+0.15 to +0.50" wc for other sizes). Do not
Two maximum capacities are shown. The on-ratio use against higher back pressures.
maximum is based on 3" wc natural gas pressure at The rich maximum capacity shown requires at
mixer inlet and balanced pressure firing conditions. least 6" wc gas pressure at blower mixer inlet and is
Capacities will be reduced by 5% to 50% when the M- attainable only when firing in open air.
Table 1: Capacities (1000's Btu/hr) with Miniature PREMIX Blower Mixers and indicated footage of Style "A" and "B"
LINOFLAME® Burners firing into balanced combustion chamber pressure (0 to +0.05" wc static pressure)
Maximum Style "A" or "B" LINOFLAME® Burner assembly length
Blower Capacities (1000's Btu/hr)
Mixture (feet-inches of indicated type and drillings)
Mixer
O n- Ra ti o R i ch Pressure
Designation Minimum B-36-42-42 B-96-50-50 B-96-44-44 B-96-36-43 A-72-17-33 A-72-C-33
Maximum Maximum (" wc)
20 39 50 1.3 1' 8" 4" 3" --- ---
30 44 70 1.25 1' 3" 9" 6" 4" --- ---
40 54 120 1.2 1' 6" 1' 8" 6" --- ---
M-100
45 65 130 1.1 2' 1' 4" 1' 8" 6" ---
60 85 140 1 2' 6" 1' 10" 1' 3" 1' --- ---
75 98 150 0.75 3' 6" 2' 6" 1' 8" 1' 3" 1' 6"
80 150 270 1.1 4' 8" 3' 3" 2' 1' 8" 1' ---
M-250 120 180 370 1 6' 4' 2' 8" 2' 1' 6" ---
175 225 450 0.9 8' 5' 6" 3' 8" 2' 8" 2' 1' 6"
210 360 600 1.7 10' 9" 7' 3" 4' 9" 3' 9" 2' 6" 1' 9"
300 500 820 1.6 13' 6" 9' 3" 6' 4' 6" 3' 3" 2'
M-500
310 580 1000 1.5 16' 9" 11' 3" 7' 6" 5' 9" 4' 2' 6"
475 670 1200 1.4 21' 6" 14' 6" 9' 6" 7' 6" 5' 3' 4"
PREMIX Blower Mixers with INFRAWAVE® Burners
®
Capacities and necessary burner footage for If additional turndown range is required, see
INFRAWAVE® Burner assemblies used with Type Table 2 providing similar information for Type “PH”
“PM” PREMIX® Blower Mixers are shown in Table 1 PREMIX® Blower Mixers which develop slightly higher
below. Follow the maximum capacity column mixture pressures.
downward until your desired capacity is reached, then
read across to the required burner footage and mixer
size.
Table 1: Capacities with "PM" PREMIX® Blower Mixer Table 2: Capacities with "PH" PREMIX® Blower Mixer
Mixer Lineal Feet Lineal Feet Capacity (1000's Btu/hr) Mixer Lineal Feet Lineal Feet Capacity (1000's Btu/hr)
Size "SG" "DG" Minimum Maximum Size "SG" "DG" Minimum Maximum
1 1/2 10 55 1 1/2 10 65
2 1 20 105 2 1 16 130
3 1-1/2 30 150 3 1-1/2 25 195
4 2 40 200 4 2 33 260
PM-200 PH-190
5 2-1/2 50 245 5 2-1/2 40 315
6 3 60 295 6 3 48 375
7 3-1/2 65 320 7 3-1/2 55 420
8 4 72 360 8 4 60 500
7 3-1/2 70 340 7 3-1/2 60 440
8 4 75 375 8 4 65 525
9 4-1/2 83 415 PH-330 9 4-1/2 75 585
PM-350
10 5 92 465 10 5 82 650
11 5-1/2 100 510 11 5-1/2 86 675
12 6 110 540 11 5-1/2 92 715
18 9 175 885 PH-500
12 6 100 785
20 10 185 925 12 6 110 800
PM-920 22 11 200 1020 14 7 110 845
24 12 215 1110 16 8 120 960
26 13 230 1175 PH-700
18 9 135 1080
24 12 235 1150
20 10 150 1200
26 13 250 1200
PM-2000 22 11 165 1280
28 14 260 1295
20 10 160 1275
30 15 275 1390
PH-900 22 11 170 1320
32 16 290 1440
24 12 175 1360
36 18 375 1800
24 12 190 1375
PM-3200 40 20 410 2000
26 13 200 1430
44 22 445 2200
PH-1220 28 14 210 1475
48 24 485 2400
30 15 225 1565
32 16 240 1650
36 18 270 1980
40 20 300 2200
PH-1650
44 22 330 2420
48 24 360 2640
7/93

Miniature PREMIX® Blower Mixers
M-100 M-250 M-500
All Sizes
Available
Discharge Positions
#1 is supplied unless
otherwise specified
Mini-PREMIX
A B Outlet D E F G H J K L M N
Designation
M-100 4.56 2.25 1 4 9.12 13 5.19 2.25 4.06 2.21
3.19 3.94
M-250 4.81 1.94 1-1/2 4.25 6.75 9.44 14.62 5.38 2.56 5.31 3.44
M-500 4 2.75 2-1/2 6.5 4.69 4.69 10.12 13.5 8.19 3.25 3.75 ---


“PL” PREMIX® Blower Mixers
Sec. A-A
Discharge and ratio valve quadrant position must be specified. Discharge

For PL-1350 positions 1-6 normally require ratio valve quadrant position “A”. Discharge positions 7-
& smaller For all others 12 normally require “B”. #1-A discharge is supplied unless otherwise specified.
Dimensions - "PL" Blower Mixers

A F L
Mixer B C D E G H J K M N O R S T U V W Y Z
[1] size size
PL-80
PL-130
10.88 9.81 1-1/2 1 8.12 3.69 6.31 5.31 5.31 3.94 2.6 15.25
PL-165
PL-195 4.69 11 12.5 4.62 10.5 8.38 10.5
PL-380
PL-490 11.12 10.06 2 8.88 4.69 7.69 6.5 6.5 4.19 1.81 15.5
4.19
PL-540 0.44 0.12
PL-630
1-1/4
PL-750 3 11.31 7.81
PL-850 4.38 15.31 12.5
11.69 12.06 4.75 12 14 5.75 13 5.88 10.62 7.75 7.19 1.62
PL-1000
PL-1350 13.19 10.06
4
PL-1440 5 18.69
PL-1700 12.5 11.94 5.38 13.5 15.5 6 14 12.81 6.75 12.12 8.44 8.88 8 4.88 1.06 18.06
PL-2650 5.75 2 18.5
15.5 12.44 16.75 16.75 9.75 10.19 9.25 5.38 1.12 18.56
PL-3500 0.56 0.44
5.06 6 6.5 15 15.25 7.94 13
PL-4250 15.88 13.12 6.06 19.25
17.88 19.88 9.62 10.25 9.31 1
PL-4600 14.88 14 7.12 3 5.69 23.6 23.8
[1] According to information supplied by motor manufacturer. May var y.
5/03

“PM” PREMIX® Blower Mixers
Sec. A-A
Discharge and ratio valve quadrant position must be specified.

Discharge positions 1-6 normally require ratio valve quadrant position
For PM-690 “A”. Discharge positions 7-12 normally require “B”. #1-A discharge is
& smaller For all others supplied unless otherwise specified.
Dimensions - "PM" Blower Mixers

A F L
[1] size size
PM-200
PM-260 11.25 10.06 3.69 2 11 12.5 4.62 8.88 4.69 8.38 7.69 6.5 6.5 4.19 1.81 15.5 10.5
1-1/4
PM-350 4.19 0.44 10.5 0.12
PM-525 11.69 12.06 4.38 15.31 12.5
4.75 3 12 14 5.75 11.31 5.88 10.62 7.81 7.75 7.19 1.62
PM-690 11.12 10.06 5 18.69
PM-920 5.75
PM-1080 12.5 11.94 4.19 5.38 13.5 15.5 6 14 2 12.81 6.75 12.12 8.44 8.88 8 0.44 4.88 1.06 18.06 18.5
4
PM-1200 0.56
5.75
PM-2000 15.5 12.44 16.75 18.75 15.06 10.06 10.19 9.22 0.12 5.38 1.12 18.56
5.06 6.5 15 7.94 13
PM-3200 15.88 14 7.12 6 17.88 19.88 3 15.25 9.62 10.25 9.31 0.44 5.69 1 23.6 23.8
[1] According to information supplied by motor manufacturer.


“PH” PREMIX® Blower Mixers
Sec. A-A
Discharge and ratio valve quadrant position must be specified. Discharge positions 1-6
normally require ratio valve quadrant position “A”. Discharge positions 7-12 normally require
“B”. #1-A discharge is supplied unless otherwise specified.
Dimensions - "PH" Blower Mixers

A F L
[1] size size
PH-190
PH-250
10.69 10.5
PH-330 10.31 3.62 2 12.5 14.5 5.5 13 14.75 6.88 10.5 11.69 9 9 4.81 1.31 15.44
PH-400 4.19 1-1/4
PH-500 12
PH-700 0.56 0.44 12.5
12.83 16.75
PH-900
3 17.94 15.88
PH-1220
14.94 5.12 13.5 15.5 6 14 7.38 12.5 9.94 9.94 5.19 1.75
PH-1400
12.75 5.75 2 18.88 18.5
PH-1650
4 18.75 16.38
PH-2350
[1] According to information supplied by motor manufacturer
11/92

Stand-by Fuel Arrangement utilizing a Maxon Optional Inlet Air Filter Assemblies are shown in
Series “Q” Control Valve is illustrated below and Sketch 3. See tables for dimensions which apply to
dimensions given in accompanying tables. See your mixer size with appropriate filter.
Sketch 1 for positions 1-A through 6-A. See Sketch 2
for positions 7-A through 12-A.
1 2
3
"PL" & "PM" Blower Mixers

With "Q" Valve With Filter Assembly
Mixer
Size X Y Z A B C D E F
PL-80
PL-130
3.25 9.5
PL-165
PL-195 3.13 7.13 11.5 10.5 16.75 3
PL-380
PL-490 3.5 9.75
6.56
PL-540 1
PL-630
PL-750
PL-850 3.69 9.94 3.38 6.13 13.5 12.5 19.75 4
PL-1000
PL-1350
PL-1440 5.06 11.94
PL-1700 4.44 10.69 "PH" Blower Mixers
7.38
PL-2650 1-1/4 5.06 8.31 18.44 18.5 27.75 5 With "Q" Valve With Filter Assembly
4.94 11.19 Mixer
PL-3500
Size X Y Z A B C D E F
PL-4250 5.62 11.88 8
1-1/2 PH-190
PL-4600 6 12.25 9 7.81 12.31 23.69 23.75 35.56 7
PH-250
PM-200 3.13 7.13 11.5 10.5 16.75 3
PH-330 4 10.25 6.56
PM-260 3.5 9.75 3.13 7.13 11.5 10.5 16.75 3
6.56 PH-400
PM-350
PH-500
PM-525 3.69 9.94 3.38 6.13 13.5 12.5 19.75 4 1
1 PH-700 3.38 6.13 13.5 12.5 19.75 4
PM-690 5.06 11.31 4.5 10.75
PM-920 PH-900
PM-1080 4.44 10.69 7.38 5.06 8.31 18.44 18.5 27.75 5 PH-1220
7.38
PM-1200 PH-1400
5.25 11.5 5.06 8.31 18.44 18.5 27.75 5
PM-2000 4.94 11.19 PH-1650
1-1/4
PM-3200 6 12.25 8.38 7.81 12.31 23.69 23.75 35.56 7 PH-2350 1-1/4
To order replacement parts, specify: Nameplate

1. Mixer type and assembly number (from nameplate)
2. Part names (from illustration above)
3. Quantity for each
Suggested spare parts:

– Cam springs
– Gas valve plunger and cap
7/90

To replace Air Filter Element
Refer to photo at right, then:
1. Insert finger through each lock ring, then rotate
from back to front by pulling against force of spring.
2. Swing hinged cover upward out of the way.
3. Withdraw dirty filter element for cleaning or replace-
ment. If you clean rather than replace filter element,
wash in a strong detergent, warm water solution, or
steam clean. Dry thoroughly in warm air not to
exceed 200°F (93°C) before replacing.
4. Insert new or cleaned filter element into cage.
Check that it has extended onto air inlet sleeve
providing positive closure at that point.
5. Lower hinged cover to closed position and lock in
place with lock rings.
Warning: The filter material used is approved by
UL as Class II (fire retardant). Hot welding beads
or direct flame can ignite filter material.
To replace Cam Springs or Plunger & Cap Assembly

Shut system down electrically and close gas cocks, 7. To re-assemble unit, slide quadrant back over
then: shaft ⑥ , taking care that set screws ⑩ line up with
1. Identify components from Sketches 1 and 2 at and seat properly in the two recesses 12 in shaft
right, then remove air filter assembly or inlet cover ⑥. Check that alignment marks match, then
guard ① , quadrant cover nameplate ② , indicator tighten set screws ⑩.
plate ③ , and control motor linkage ④ . 8. Replace control motor linkage, indicator plate,
2. Rotate quadrant ⑤ counter-clockwise to minimum quadrant cover nameplate, and inlet cover guard or
position. Add an alignment mark across shaft ⑥ air filter assembly removed in step 1.
and quadrant hub ⑦ as shown in Sketch 1 if mark 9. Check burner adjustment and refine.
does not already exist. 10. Place system back in service.
3. Identify brake ⑧ and spring from Sketch 2 and
make a note to avoid losing them when removing
quadrant.
4. Insert Allen wrench (provided with replacement
1 2
cam springs) through holes ⑨ and loosen set
screws ⑩ , then slide quadrant off shaft carefully.
5. To replace cam springs, remove screws 11 then
lift off and replace with new cam springs and
retighten screws 11.
6. To replace plunger and cap assembly (see
component identification drawing on page 3117),
grasp cap and lift assembly out of ratio valve.
Insert new plunger and cap sub-assembly carefully
and check that it slides freely.
PREMIX® Blower Mixers Page 3100-S-1
General Instructions 2. Electrical service must match the voltage,
phase, and cycle of all electrical system
Important: Do not discard packing materials components and be compatible with burner
until all loose items are accounted for. nameplate ratings. Insure that all normal control
safeguards are satisfied. Blower mixer air should
To prevent damage in transit, spark ignitors, flame continue to run after shutdown to allow burner to
rods, connecting linkage components, and filter cool.
housings/elements may be packed separately and 3. Gas supply piping must be large enough to
shipped loose with your new Maxon PREMIX® Blower maintain required fuel pressures (approximately
Mixer. 2" - 8" wc) at the ratio valve inlet while burner is
The blower mixer itself is normally only a part of operating at full capacity. The use of non-
your complete combustion system. Additional pipe standard gases or long, complicated piping may
train accessories and control components may be necessitate “oversizing” piping runs to keep
required for a complete combustion system pressure drops within acceptable ranges.
installation. 4. Clean fuel lines are essential to prevent
The sketch below shows a typical gas train as blockage of pipe train components or burner gas
might be used with a PREMIX® Blower Mixer. ports. All dirt, scale and pipe dope should be
Typical Piping Layout blown out of any new gas line before actually
connecting to the burner system.
5. Main shut-off cock should be upstream of both
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
ratio valve of your PREMIX® Blower Mixer is
not intended for tight shut-off.
6. Main gas regulator is essential to maintain a
uniform system supply pressure. A separate
regulator should be provided in the branch
leading to each mixer if more than one is served
by a common main. Size regulator for full system
capacity at required pressure, including pipe train
losses. Follow the instructions attached to the
regulator during installation.
7. Pilot take-off should be upstream of the main
gas regulator, but downstream of the main gas
Maxon assumes no responsibility for the use or cock. It should normally include its own pilot gas
misuse of the piping layouts shown. Specific regulator, a solenoid valve and shut-off cock. A
piping and wiring diagrams should always be pilot adjustable orifice at the pilot inlet simplifies
submitted to the appropriate agencies for adjustment.
approval on each application. 8. Pilot piping must be large enough to provide for
the full flow and pressures shown in the catalog
1. PREMIX® Blower Mixer provides the air supply to for your particular burner size.
your combustion system and is essential to the
inspiration and mixing of fuel gas. It should be
located in the coolest, cleanest position that you
can find near the burner itself. It must not be
exposed to direct radiant heat or positioned where
it might draw in inert gases or hot air rising from a
furnace or oven. If such conditions exist, consider
filters, relocation and/or ducting of an outside air
supply.

mCORPORATION
Page 3100-S-2 PREMIX® Blower Mixers
9. Fuel shut-off valves (when properly connected New Filter Assembly Installation
to a safety control system) are designed to shut
the fuel supply off when a hazardous operating To install a new filter assembly, refer to the
condition is sensed. Manual reset valves require photos below, then:
operator attendance each time the system is 1. Remove existing air inlet guard, saving screws
started up (or restarted after a trip-out). removed.
Motorized shut-off valves permit automatic 2. Place sleeve of new filter assembly over the open
start/restart when used with appropriate control end of mixer air inlet, turning so that filter suction
system. switch connection is opposite ratio valve
10. Ratio valve (part of mixer) controls burner heat quadrant.
release by throttling air and gas flows. It includes 3. Align holes in filter sleeve with those in mixer air
provision for an adjustable minimum and throttling inlet, then secure filter assembly in place with
over a turndown range that matches burner screws removed in step 1.
capabilities. 4. Check position of filter assembly cover hinge. If it
11. Downstream piping from blower mixer to burner is not at top, remove sheet metal screws holding
should be kept as short as possible. wire cage to filter sleeve and rotate as necessary,
12. Inlet pipe leading to any burner should be at then re-fasten. Three unused holes must be
least four pipe diameters in length. If the mixer is plugged with remaining sheet metal screws.
supplying multiple burners or multiple inlets to a Warning: The filter material used is approved
single burner element, care should be taken so by UL as Class II (fire retardant). Hot welding
that air/gas mixing piping gives minimal pressure beads or direct flame can ignite filter material.
drop and maximum uniformity. Do not install any
shut-off device in the air/gas mixture line.
13. Test connections are essential for burner
adjustment. They should be provided (at a
minimum) downstream of the mixer and at each Air Inlet
Guard
burner inlet. Test connections in elbows or tees
should be avoided. Test connections must be
plugged except when readings are being taken.
14. Vent dampers and pressure controllers should
be used to maintain balanced or slightly positive
furnace or chamber pressures (0.0" to 0.5" wc) for
maximum efficiency. Excessive back pressure will Ratio Valve
Quadrant
reduce burner capacity. Negative pressures allow
infiltration of secondary air and will affect
efficiency and temperature uniformity.
Cover Hinge
Cage
Filter
Suction Switch Filter
Connection Sleeve
mCORPORATION

Premixed Air/Gas Manifolding Suggestions
1. Always design air/gas manifold piping for uniform Sketch 1 shows four burners fed from one end-fed
distribution to multiple-feed or multiple-burner header. Note that full mixer size is continued past all
systems. Select manifold piping sizes by starting burner take-offs, and outlet extended and capped one
at the burner/nozzle end and working backward to pipe diameter length beyond last take-off. Always
the blower mixer outlet. keep blower mixer a minimum of four pipe diameters
2. Always make sure that any distribution header is in length from first take-off.
greater in cross-sectional area than the total
cross-sectional area(s) of any and all pipes being
fed.
3. Never install a throttling or shut-off device in any
air/gas mixture line between the blower mixer and
its burner(s).
4. If necessary to have a smaller size manifold, use
alternate discharge flanges available from Maxon
for most PREMIX® Blower Mixers.
The chart below gives typical pipe data for use
in designing air/gas distribution manifolds.
General Pipe Data

Inside Outside
Nominal Pipe Inside Area
Diameter Diameter
Diameter (square inches)
(inches) (inches)
0.269 0.405 0.057
Sketch 2 shows a system with the two side
1/8
manifolds sized so their total combined cross-
1/4 0.364 0.54 0.104 sectional areas do not exceed that of blower mixer
3/8 0.493 0.675 0.191 outlet. If a manifold must be center-fed, then
1/2 0.622 0.84 0.304
provisions may be required to connect both ends of
the side manifolds together to form a complete looped
3/4 0.824 1.05 0.533 distribution header to insure uniform distribution to the
1 1.049 1.315 0.864 multiple burners.
1-1/4 1.38 1.66 1.496
1-1/2 1.61 1.9 2.036
2 2.067 2.375 3.356
2-1/2 2.469 2.875 4.788
3 3.068 3.5 7.393
3-1/2 3.548 4 9.887
4 4.026 4.5 12.73
5 5.047 5.563 20.006
6 6.065 6.625 28.89
8 7.981 8.625 50.027
10 10.02 10.75 78.854
12 12 12.75 113.097

mCORPORATION
Bringing in outside combustion air to blower mixers
In exceptionally dirty locations, or where a local Outside Air Supply Duct Sizes
code or plant regulation requires external-source
Blower Mixer Type Maximum Duct Footage
combustion air, a separate supply duct from outside
the room or building may be necessary. Standard
PL PM PH Oversize
Size
The air inlet of a PREMIX® Blower Mixer is sized to
3" dia. 4" dia.
accept round sheet metal ducting for this purpose.
The accompanying table lists all available PREMIX® PL-8-
Blower Mixers together with a suggested maximum PL-130 PM-200 PH-190
duct run that will allow development of full-rated mixer PL-165 PM-260 PH-250 30 ft. ---
capacity. PL-195 PH-330
Two columns are shown: a standard size which PH-400
matches the PREMIX® Blower Mixer inlet diameter, PM-350 20 ft.
and an oversize column which reflects the length
PL-380 18 ft. 30 ft.
made possible by enlarging the entire duct one size.
A sheet metal transition could reduce duct to the PL-490 11 ft.
standard size at ratio valve air inlet. PL-540 4-1/2 ft. 19 ft.
Because of the additional friction involved in duct 4" dia. 5" dia.
elbows, treat each turn in direction as if it added PH-500
an additional 10 pipe diameters in length. 30 ft. ---
PM-525 PH-700
PL-630 PH-900 28 ft.
PL-750 20 ft.
30 ft.
PL-850 16 ft.
PL-1000 11 ft.
PL-1350 3 ft. 10 ft.
5" dia. 7" dia.
PH-1220
PM-690 PH-1400
30 ft. ---
PM-920 PH-1650
PM-1080
PM-1200 24 ft.
PL-1700 12 ft.
PH-2350 9-1/2 ft. 30 ft.
PL-1440 9 ft.
PM-2000 8-1/2 ft.
PL-2650 5 ft. 25 ft.
PL-3500 3 ft. 15 ft.
PL-4250 2 ft. 10 ft.
7" dia. 10" dia.
PM-3200 27 ft.
PM-4000 18 ft.
PL-4600 13 ft. 30 ft.
PM-4800 12 ft.
PM-5750 11 ft.
PL-8500
2-1/2 ft. 15 ft.
m
PL-10500
CORPORATION
Read complete instructions before proceeding, and 5. Start all system-related fans and blowers.
familiarize yourself with all the system’s components. Check for proper motor rotation and impeller
Verify that your equipment has been installed in direction. Verify that all control interlocks are
accordance with the manufacturer’s current working. Allow air handling equipment to run for
instructions. adequate purge of your manifolds and
combustion chamber plenums. With main gas
shut off, manually advance blower mixer’s screw
should be undertaken only by trained and
carrier to “high fire” position so that air only flows
experienced personnel familiar with combus-
through burner and combustion chamber.
tion systems, with control/safety circuitry, and
with knowledge of the overall installation. CAUTION: Do not by-pass control panel timers
Instructions provided by the company and/or typically controlling sequential operations.
6. Determine minimum differential mixture
and/or overall installation of complete system
pressure. Depending on the type of burner and
its application, a method must be developed to
over these provided by Maxon. If Maxon in-
connect a manometer between the combustion
structions conflict with any codes or regula-
chamber static pressure and into a straight
manifold going to the burner (at a point farthest
from the PREMIX® Blower Mixer).
This method must take into consideration all of
the frictional pressure drops in the distribution
For initial PREMIX® Blower Mixer start-up: manifolding. You must maintain at least +0.25" wc
1. Check all electric circuitry. Verify that all control differential mixture pressure (with natural gas)
devices and interlocks are operable and between the burner and the combustion chamber
functioning within their respective settings/ranges. to avoid potential backfire conditions. (For VF
Be sure all air and gas manifolds are tight and LINOFLAME® Burners, differential mixture
that test ports are plugged if not being used. pressure should be +0.1" wc.)
2. Close all burner fuel valves and cocks. Do not try to take a differential mixture
Remove pilot and main gas regulators’ adjusting pressure reading from a test port at or near an
screw covers. Turn adjusting screw down elbow in the piping manifolds due to potentially
(clockwise) to approximately mid-position. Close erroneous readings caused by turbulence set up
pilot gas adjustable orifice screw by turning in within the pipe by such pipe fittings. Measure in a
clockwise until it stops. (Do not over-tighten.) straight manifold with at least four pipe diameters
Then back out the adjustable orifice (counter- in length before and after the test port location.
clockwise) approximately 2-3 turns. 7. Set minimum differential mixture pressure with
3. Check that all duct and chamber dampers are minimum stop screw located on the side of the
properly positioned and locked into operating screw carrier quadrant of blower mixer ratio valve
positions. (see sketch below).
linkage from your blower mixer’s screw carrier by
loosening the control motor’s connecting rod from
the toggle linkage.
control mode.

mCORPORATION
This minimum stop screw creates a mechanical Turning in the adjusting screws ⑤ (clockwise)
block which prohibits the screw carrier quadrant gives a contour to flexible steel cam strips (see
and its direct-connected air butterfly valve from Sketch 2). These cam strips bear on a plunger
closing completely. Thus a “minimum” volume of and cap assembly ⑦ that determines opening of
air is allowed in through the ratio valve to be the gas butterfly valve. Cam strips serve to
delivered down the distribution manifold(s) to the provide a continuous gradient.
burner(s). This air is used to establish the
minimum differential pressure.
Screwing in (clockwise) on the minimum stop
screw through its lock nut will open up the air
butterfly and increase the minimum differential
pressure.
Once your manometer readings confirm the
minimum differential mixture readings, lock the
minimum stop screw in that position so the ratio
valve cannot be moved back below this minimum
firing position. Regardless of what numerical
value the indicator strip shows, this becomes the
As shown in Sketch 3, the plunger and cap
minimum firing position for your specific system in
assembly ⑦ acts upon a roller/crank ⑧ to rotate a
this application.
valve shaft ⑨ to which the gas butterfly is
8. Adjusting the ratio valve of your PREMIX®
attached.
Blower Mixer: The heart of each PREMIX®
Turning adjusting screw in until it is flush with
Blower Mixer is its ratio valve. The description
quadrant opens gas butterfly fully. Do not
and accompanying sketches summarize its
attempt to force screw further.
operation.
A quadrant (shown in Sketch 1) is rotated either
manually or by a control operator to change firing
rate as indicated by a position indicator strip ① and
position pointer ②. A minimum stop screw ③ limits
rotation and establishes a minimum air flow.
Removing a cover strip ④ reveals a numbered
series of adjusting screws ⑤ which bear on a set
of cam strips beneath the quadrant.
Directly connected to the quadrant by a shaft ⑩

extending through its point of rotation is the air
control butterfly 11 , also shown in Sketch 3. Note
that at #1 position of quadrant, air butterfly may
be “closed” but deliberately undersized to provide
a required minimum air flow. Air butterfly is fully
open with quadrant at highest numbered position.
(Number varies with mixer size.)
mCORPORATION

9. Prepare to adjust the ratio valve by removing 14. Light main burners at minimum, as follows:
the cover plate from the quadrant screw carrier First, make sure ratio valve is at its minimum
and turn all adjusting screws out until they are all setting (which may be at position 1 or 2 after
flush with the outer surface of the screw carrier completing step 6). With gas pilot established and
casting. (New equipment is shipped from factory flame supervision system operational, opening
with all screws already backed out to this level.) the main fuel Shut-Off Valve(s) will allow fuel flow
10. Return blower mixer quadrant to “low fire” to the blower mixer’s ratio valve. Turn
position when air purge of system is complete. corresponding screw in (clockwise) until flame
11. Open main and pilot gas cocks, then attempt ignites at all burner nozzles. (This may take
to light burner pilot while slowly turning pilot gas several turns of the screw.)
regulator and/or adjusting orifice screw to NOTE: At this point, it is more important to get
increase fuel flow. Repeat procedure as any kind of a flame as soon as possible. The
necessary until pilot ignites as air might have to flame geometry can be adjusted and refined as
be bled out of fuel supply lines before reliable pilot needed later.
flame is established. Pilot gas regulator should Continue turning in slowly until flame becomes
normally be set for as low a pressure as possible, noticeably rich (usually purple or green with a
using fuller opening of pilot gas adjustable orifice slight yellow tip). Then slowly back the screw out
(if used.) until the flame becomes bright blue.
12. After ignition, adjust pilot flame for good stable 15. Once your flame is established and refined at this
flame shape. A “rule of thumb” is that any pilot position, and without advancing the screw carrier
over a tennis ball size is probably too large. This quadrant higher, screw all remaining screws down
assumes you have visual access to the pilot to at least the same level as your first adjusted
flame. If this is not possible, then adjust pilot to screws.
give the strongest and most stable flame signal NOTE: A preliminary setting can be established
through your flame safety circuit. The signal with all the remaining adjusting screws. Generally,
strength (or range) will be determined by the each succeeding screw needs to be screwed in
specific type of flame safeguard instrument you approximately one additional full turn from the
have with your burner system. preceding screw. A smooth “stair step” gradient
13. Re-check pilot ignition by closing pilot gas cock pre-set at this point from low to high will simplify
or otherwise causing pilot outage. Re-light and the remaining adjustment steps.
refine pilot gas adjustment as necessary to get 16. Without advancing the ratio valve quadrant, screw
reliable ignition. The flame safeguard relays down on #2 screw (one or two turns). Then slowly
should now power your main fuel Shut-Off advance the ratio valve quadrant to the #2
Valve(s). position. Adjust flame appearance at this new
position #2.
CAUTION: After completing steps above, re-
NOTE: If firing chamber is of refractory
check all interlocking safety components and
construction, allow your burner system to operate
circuitry to prove that they are properly
at this low setting for the necessary dry/cure out
installed, correctly set, and fully operational. If
time period recommended by the chamber or
in doubt, shut the system down, close pilot
refractory manufacturer. Then continue
cock and contact responsible individual before
adjustment of ratio valve.
proceeding further.
Again, without moving ratio valve, bring #3 and
all remaining adjusting screws down to the same
level as #2 screw.
NOTE: If approximate pre-set gradient was
made earlier, the remaining screws will already be
at or below appropriate levels.

mCORPORATION
Progressively work your way up through each 20. When burner performance is satisfactory and
adjusting screw position, developing a smooth stable throughout the firing range, reconnect
progression slope from your first screw to the linkage to control motor.
“maximum” position. As each is adjusted, you Control linkage travel must be such that burner
must turn the remaining unadjusted screws in at quadrant is moved throughout its complete travel,
least that far to prevent possible damage to or cataloged capacities and turndowns will not be
flexible cam strips inside the ratio valve. achieved.
NOTE: To adjust the flame at any position, you If less than full-rated burner capacity is
must move the ratio valve to the number you required, linkage can be adjusted to limit
desire to adjust. This aligns the adjusting screw maximum output. With interrupted pilot, it may
directly on top of the fuel valve plunger. A be necessary to set control for somewhat higher
resulting adjustment of the screw is directly than minimum burner setting to permit hold-in of
applied to the fuel valve plunger and its flame detection system without pilot.
interconnected valve body linkage. Always
adjust only the screw corresponding to the
position at which the ratio valve has been set.
CAUTION: If flame is extinguished, immediately high or low fire position.
return ratio valve to minimum position and shut
off fuel (if flame safeguard has not already done
fuel leakage. Replace equipment cover caps and
so). Turn in slightly on adjusting screw at point
tighten linkage screws.
where ignition was lost, then return ratio valve
22. Check out overall system operation by cycling
to minimum position, re-establish pilots, open
through light-off at minimum, interrupting pilot,
fuel valve and verify ignition.
17. Refine main gas regulator adjustment (if burner from minimum to maximum and return.
necessary) to give the required pressure. If a 23. Recheck all safety system interlocks for proper
major adjustment is made, you may then need to setting and operation.
re-adjust the screw(s) just set.
WARNING: Test every UV installation for
18. After adjusting through the full range, allow
dangerous spark excitation from ignitors and
furnace or oven to reach operating temperature
other possible sources of direct or reflected UV
and refine adjustment as needed for hot
radiation. Use only gas-tight scanner
conditions.
connections.
19. Cycle burner from minimum to maximum and
refine adjustment, if necessary. 24. Before system is placed into full service,
For operation with interrupted pilot (as instruct operator personnel on proper start-up,
recommended), shut off pilots and cycle burner operation, and shut-down of system. Establish
from minimum to maximum and back several written instructions for their future reference.
times to verify the flame is maintained. When
satisfied with adjustment, replace ratio valve
cover plate.
mCORPORATION

Miniature PREMIX® Blower Mixers
Before proceeding, verify that all system equipment
has been installed in accordance with the general
instructions found on pages 3100-S-1 and 2.
Initial adjustment and light-off should be
control/safety circuitry, and overall installation.
M-100/M-100-U M-500
individual responsible for the overall
M-250
installation of complete system take
precedence over those provided by Maxon. If
Maxon instructions conflict with local codes or
regulations, contact us before start-up. 4. Light pilot(s) at the burner nozzle(s).
5. Open main gas cock and the adjustable orifice
cock (where applicable).
For initial system start-up: 6. Turn gas adjusting screw slowly “out” (counter-
1. Start blower mixer and check for proper impeller clockwise) until ignition occurs, then refine setting
rotation. Correct if necessary. as necessary. You will find most adjustment
2. Close mixer fuel port. For M-100 and M-250 occurs within the first three turns of gas adjusting
sizes, see illustration above, then remove cap ① screw.
and lightly turn orifice screw “in” (clockwise) until it Allow time for remaining air to bleed out of gas
seats. line, but if ignition does not occur with reasonable
For the M-500, see sketch above. Insert 5/16" promptness, close the gas cock and check for:
Allen wrench through slot ② and turn gas adjusting A. Insufficient gas supply, possibly due to gas
screw “in” (clockwise) until it bottoms. regulator incorrectly installed, closed gas cock,
3. Open air shutter fully. Verify burner differential etc.
air pressure is at least +0.25" wc. Verify that it B. Too much gas as a result of turning the
meets required minimum for that specific burner adjusting screw too fast or too far.
nozzle(s). C. Improper piloting or insufficient spark.

mCORPORATION
Notes
m
CORPORATION

PREMIX® Blower Mixers Page 3100-A/P-1
Assembly Numbers
for Blower Mixers, Inlet Filters and Replacement Filter Elements
PL, PM and PH PREMIX® Blower Mixers are Table 2: Assembly numbers for PM Mixers, Filters
listed in Tables 1 through 3, as well as the optional PREMIX® Blower Mixer Approx. Filter Numbers
filter assemblies and replacement elements to be Ship
Assembly Weight Assembly Elements
used with them. Designation HP-Frame
No. (pounds) (A) (R)
To order any blower mixer, specify:
PM-200 19374
1. Mixer size and assembly number
PM-260 19375 105 17411 25292
2. Electrical specification
3. Discharge position and ratio valve arrangement PM-350 1/3 -48 19376
4. Assembly number and quantity of accessory items: PM-525 19378 110 17412 25293
– Combustion air filter assembly PM-690 19380 130
– Connecting base and linkage assembly PM-920 19381
– Low fire start switch PM-1080 3/4 -56 19382 190 17413 25294
– Stand-by fuel arrangement PM-1200 19383
PM-2000 1 -56 19384 235
Table 1: Assembly numbers for PL Mixers, Filters
PM-3200 1-1/2 -56 19612 300 17414 25295
PREMIX® Blower Mixer Approx. Filter Numbers
Ship
Assembly Weight Assembly Elements
Designation HP-Frame Table 3: Assembly numbers for PH Mixers, Filters
No. (pounds) (A) (R)
PL-80 18543 PREMIX® Blower Mixer Approx. Filter Numbers
Ship
PL-130 18545 Assembly Weight Assembly Elements
100 Designation HP-Frame
PL-165 18546 No. (pounds) (A) (R)
PL-195 18547 17411 25292 PH-190 19385

PL-380 19361 PH-250 19386
17411 25292
PL-490 19362 105 PH-330 1/3 -48 19387 135
PL-540 1/3 -48 19363 PH-400 19388
PL-630 19364 PH-500 19389
PL-750 19365 110 PH-700 19390 17412 25293
165
PL-850 19366 17412 25293 PH-900 3/4 -56 19391
PL-1000 19367 PH-1220 19392 195
130
PL-1350 19368 PH-1400 19393
1 -56 200 17413 25294
PL-1440 19369 140 PH-1650 19394
PL-1700 3/4 -56 19370 190 PH-2350 1-1/2 -56 19395 205
PL-2650 19371 17413 25294
1 -56 235
PL-3500 19372
PL-4250 1-1/2 -56 19373 285
PL-4600 2 -56 19616 315 17414 25295
Miniature PREMIX® Blower Mixers Table 4: Miniature PREMIX® Blower Mixers

Table 4 (right) provides assembly numbers for
(stock assemblies - Position 1 only)
Miniature PREMIX® Blower Mixers plus motor horse-
Blower Mixer Approximate
power. Each unit includes totally enclosed motor. All Assembly
Designation Motor HP Shipping Weight
three mixers may be specified for either 115 or 230 Number
(Position 1 only) (pounds)
volt single-phase power supply.
To order a Miniature PREMIX® Blower Mixer in M-100 51201 25
positions other than Position 1, use the following
M-250 1/6 51203 30
assembly numbers. Specify position in the text line of
M-500 53505 35
the item.
M-100 #44353
m
M-250 #44354
M-500 #44355
CORPORATION
Page 3100-A/P-2 PREMIX® Blower Mixers
Accessory Assembly Numbers

Optional Low Fire Start Switches are shown in Optional Connecting Base and Linkage
Table 5. Enter table from the left on the line corre- (CB & L) Assemblies to mount and position
sponding to your mixer type, reading across to the customer’s electric control motor or air operator are
column which includes your specific mixer size and listed in Table 7 below.
appropriate switch assembly number. NOTE: Control motor must provide at least 50 in-lbs
of torque for use with a PREMIX® Blower Mixer.
This listing of CB & L assemblies shows only a
Table 5: NEMA 1 Low Fire Start Switches sampling of the more popular control motors. We may be
(for indoor, general purpose/non-hazardous duty locations)
able to furnish a CB & L for other operators not cataloged
Blower Mixer Type/Designation Low Fire Start Switch (supply manufacturer’s name and model number).
PL PM PH Assembly Number
80-195 --- --- 1056557
Table 7: Connecting Base & Linkage Assemblies
380-540 200-350 190-400 1056558
Type Manufacturer Model No. Assembly No.
630-1350 525 500-900 1056559
P-25 [1] 24383
--- 690 --- 1056560 Foxboro
P-50 [2] 24384
1440-4250 920-2000 1220-2350 1056561
01-11/861 P [3]
4600 3200 --- 1056562 17376
Honeywell 03-3/863 T
For example: PM-920 Mixer uses #18719 LFS switch Air
01-9/861 M 17711
D3153
Alternate Discharge Flanges (required only if the Johnson 17867
D3151
blower mixer outlet is to be piped smaller than stan- Taylor 40VF6 [3] 17708
dard discharge pipe size) are listed in Table 6 below. EA 51-58, also
Barber-
with prefix MC, 17377
Colman
Table 6: Alternate Discharge Flanges for MP, or MF
reduced outlet manifold sizes M644 [4]

M744 [4]
Standard Alternate Reduced Alternate Flange 17372
M941 [4]
Discharge Discharge Pipe M944 [4]
Pipe Size Size PL & PM Mixers PH Mixer Electric
Honeywell
1-1/2" 05387 12117 M640A (Discontinued)
17378
M940A (Discontinued)
2" 1-1/4" 10907 12216
1" --- --- Herculine 1066900
2-1/2" 18694 12218 Penn/ M-80 [5]
3" 17372
2" 04122 12217 Johnson M-81 [5]
[1] Specify from Foxboro:

WITH #B6301-LR yoke
WITH #B6301-KY connection assembly
LESS indicating pointer
LESS travel indicator scale
LESS stem locknuts
WITH #B6301-WR yoke
WITH #B6301-TY connection assembly
LESS stem locknuts
[3] Dimensional interference prevents use with discharge
position #3A. For position #11-A, order WITH #15983
spacer
[4] Specify from Honeywell: WITH #7616BR crank arm
[5] Specify from Penn/Johnson: WITH #LVR27A-601 crank
m
arm
CORPORATION
Bulletin 3200
Maxon Premixing Equipment

Premix Burner
Systems
MULTI-RATIO ™ Mixers Maxon-P/S Radiant Burners
Style A & B
LINOFLAME® Burners
• Air/gas mixing devices for use with all Maxon premix burner
systems to provide thorough blending of air/gas mixture VFL & VFH
LINOFLAME® Burners
• Uses most clean fuel gases
• May be used with single or multiple burner systems
• Series “LG” Mixing Tubes and MULTI-RATIO™ Mixers are
designed for use with low pressure gas
• Series “HG” Mixing Tubes use kinetic energy of higher gas
INFRAWAVE® Burners
pressures to thoroughly blend the air/gas mixture
Page 3202
MULTI-RATIO™ Mixers
Maxon MULTI-RATIO™ Mixers are air/fuel proportioning They provide air/gas ratio control throughout
devices designed for use with all Maxon premix burner the firing range by incorporating an “LG” Mixing
systems, including both single and multiple burner systems. Tube and adjustable gradient air/fuel control
valve in one compact unit.
MULTI-RATIO™ Mixers are suited for use
Adjusting Screws
Air Oriface Plate
with most clean, low pressure gases.
Combustion air at 6 to 16 osi is used to entrain
the low pressure gas.
Mixture Built-in adjusting screws permit tailoring
Outlet Combustion
Air Inlet
burner performance to your specific needs.
Single point control simplifies adjustment.
Characterized air port and gas valve disc are
Gas Valve Disc carefully matched to achieve desired heat
Gas Inlet
release using most clean gases of 500 to 3200
Btu/ft3 heating value.
The unit delivers air/fuel mixture to premix
burners at mixture pressures as high as 13" wc
when using a 16 oz. pressure blower.
The MULTI-RATIO™ Mixer’s capacity can
MULTI-RATIO™ Mixer
be modified in the field by replacing compatible
air orifice plates.

Series “LG” Mixing Tubes provide thorough Balancing among multiple mixing tubes is accomplished with a
blending of the air/gas mixture for all Maxon built-in gas shading disc.
premix burner systems. Capacity can be modified in the field by replacing compatible
Most clean, low pressure gases may be air orifice plates.
used. When combined with a combustion air
blower and Maxon MICRO-RATIO® control Air Orifice Plate
valve, the “LG” Mixing Tube can offer localized

mixing of pre-proportioned air and fuel to single
or multiple burner systems.
A wide range of capacities provides
application flexibility.
Mixture Outlet
Combustion air at 6-16 osi from a pressure
blower is forced through an air orifice plate, Combustion
drawing fuel gas into a mixing tube throat. Air Inlet
Capacity is determined by fuel characteristics,

Gas Inlet
air pressure and air orifice plate size. Gas Shading Disc
Most clean fuel gases of 500-3200 Btu/ft3
can be used at supply pressures of 3" wc to 8
osi at the inlet of the proportioning device. Series “LG” Mixing Tube
Page 3203

Using the kinetic energy of higher gas pressures, Principle of Operation
the Series “HG” Mixing Tube provides a thoroughly Series “HG” Mixing Tubes distribute fuel gas through
blended air/gas mixture. a chamber surrounding the combustion air stream.
The higher gas pressure allows use of a lower Multiple gas ports (drilled for the specific gas type and
pressure combustion air blower. In combination with a combustion air pressure used) allow the higher pres-
Maxon MICRO-RATIO® control valve and combustion sure gas to be injected into the lower pressure com-
air blower, the “HG” Mixing Tube can provide localized bustion air stream.
mixing of air and fuel to single or multiple burner This means very low combustion air pressure drops.
systems. As little as 6 ounces air differential at the mixing tube
Adjustment is simple through single point inlet can produce as much as 10" wc mixture pressure
proportioning. at the mixing tube outlet.
Like the MULTI-RATIO™ Mixers and Series “LG” Compared to the 14 ounce differential required to
Tubes, they can be used with all Maxon premix burner achieve similar performance using typical low gas
systems. pressure mixing systems, substantial savings are
In addition, Series “HG” Mixing Tubes can be sized possible in both initial and operating costs.
for partial premixing of air/gas ratios to Maxon Gas must be supplied at pressures of 2 PSIG or
AIRFLO® burner systems, including: higher. Each gas orifice is field-accessible through an
external plugged hole which may also be used as a
COMBUSTIFUME® gas pressure test connection.
LO-NOX®
“66” AIRFLO®
“LV” AIRFLO®
Gas Orifice Port
Combustion
Gas Chamber Air Inlet
Mixture
Outlet
Gas inlet
Series “HG” Mixing Tube
Maxon catalog bulletin 7000 describes MICRO-

RATIO ® control valves which throttle air and
gas volumes to the Series “LG” Mixing Tube
and Series “HG” Mixing Tube
Page 3204
Typical Applications
The following illustrations show Maxon MULTI- One mixing device may be used to feed single or
RATIO™ Mixers and Series “LG” or “HG” Mixing Tubes multiple burner elements, or separate mixers may be
used in typical furnace applications. Both systems used for each unit or zone of a multi-stage system.
include a central combustion air supply and multiple A complete burner system will also include burner,
Sealed Nozzle Burners. This arrangement would be gas train, pressure blower and control panel. In addition,
similar for installations using other Maxon premix an “LG” or “HG” Mixing Tube system will require an air/
burners. gas control valve, such as the Maxon MICRO-RATIO®
Valve shown below.
Series “LG” or “HG” Mixing Tubes (with Maxon MICRO-RATIO ® Valve)
11/95
Premixing Equipment Page 3205
Series “LG” Mixing Tubes and MULTI-RATIO™ Mixers
General Maximum Capacity

(1000's Btu/hr) at differential
Minimum Mixer HD
Capacity Designation
The capacity of an “LG” Mixing Tube or combustion air pressures STICKTITE®
(measured at mixer inlet) 1000's MR=MULTI-RATIO®
MULTI-RATIO™ Mixer is determined by LG=LG Mixing Tube
Nozzle Size
Btu/hr
15 osi 11 osi 7 osi 5 osi
its physical size, by the size, type, and
number of burners or nozzles through MR
95 80 65 55 13 -75-22 3/4"-6
LG
which it fires, and by the field conditions
MR
under which it operates. 105 90 70 60 17
LG
-75-25 3/4"-7
Choose from the following capacity/
MR
selection tables for the combination of 130 110 90 75 21 -100-28 1"-8
LG
mixer, burner and operating conditions of MR
your application. 160 135 110 95 26 -100-31 1"-9
LG
Slight variations in combustion MR
210 180 150 125 32 -125-37 1-1/4"-10
chamber pressure, draft conditions or the LG
availability of secondary air can affect MR
280 240 195 165 44 -125-41 1-1/4"-12
capacity and performance. LG
MR
340 300 240 210 60 -125-46 1-1/4"-14
LG
With STICKTITE™ Burner Nozzles
MR
Capacities and nozzle sizing 450 380 310 265 75 -150-56 1-1/2"-16
LG
information are provided at right for MR
burner systems utilizing these mixers with 560 430 380 325 100 -150-63 1-1/2"-18
LG
STICKTITE™ Burner Nozzles. The left MR
690 580 475 400 -200-70
side of the table deals with capacities, LG
120 2"-21
and is based on natural gas firing against MR
800 690 555 475 -200-73
balanced or slightly positive combustion LG
chamber pressures. 990 855 680 580 160
MR
-200-80 2"-24
Maximum capacities are cataloged LG
for four different air differential pressures MR
1190 1010 825 700 -300-98
LG
(measured at inlet to the mixer). 210 2-1/2"-27
Back pressures of +.15" wc will MR
1420 1210 980 830 -300-106
LG
reduce capacities by 5%; back pressures
MR
of +.25" wc by 15%. 1760 1490 1200 1000 245
LG
-300-116 3"-30
Draft conditions will permit some
MR
degree of overfiring if secondary air is 2090 1780 1450 1200 290 -400-124 4"-34
LG
available around the burner and if MR
additional flame length can be tolerated. 2550 2180 1750 1480 -400-136
LG
To select a mixing tube and burner 460 4"-41
3040 2580 2000 1660 MR
combination, determine required heat -400-142
3160 2650 2080 1685 LG
release and your available air differential 3620 3100 2500 2050 MR
pressure as measured at the mixer inlet. -500-157
3910 3350 2600 2100 LG
Read downward in the appropriate 720 5"-50
4160 3520 2850 2400 MR
column to the desired maximum heat -500-166
4850 4020 3200 2600 LG
release. Then read across that line to find
the mixer designation and the “HD” Nomenclature – Both MULTI-RATIO™ Mixers and Series “LG”
STICKTITE™ Nozzle size. Mixing Tubes are identified by a 3-part designation.
Multiple nozzles can be used, but the For example: MR-75-22 or LG-75-22
actual capacities will depend upon the “LG” or “ MR” indicates mixer type; -75 indicates discharge pipe
type, size and quantity of nozzles size in inches (75 = 3/4", 150 = 1-1/2", etc.); -22 indicates throat
selected for your application. diameter of air orifice plate in 64ths of an inch (22 = 22/64" air port
diameter)
5/03
Page 3206 Premixing Equipment
Series “LG” Mixing Tubes and MULTI-RATIO™ Mixers with Sealed Nozzles
Capacities and nozzle sizing Maximum Capacity

Minimum Mixer
information is provided at right for systems (1000's Btu/hr) at differential
Capacity
"SN"
combustion air pressures Designation Sealed Nozzle
utilizing these mixers with SEALED (measured at mixer inlet) 1000's MR=MULTI-RATIO®
Size
NOZZLES. The left side of the table deals 15 osi 11 osi 7 osi 5 osi
Btu/hr LG=LG Mixing Tube
with capacities, and is based on natural
MR
gas firing against balanced or slightly 95 80 65 55 13
LG
-75-22 3/4"-5
positive combustion chamber pressures. MR
Maximum capacities are cataloged for 105 90 70 60 17 -75-25 3/4"-7
LG
four different air differential pressures MR
(measured at inlet to mixer). Be sure to 130 110 90 75 -100-28
LG
allow for piping losses from combustion air 26 1"-9
MR
160 135 110 95 -100-31
blower. LG
Back pressures of +.15" wc will reduce MR
210 180 150 125 -125-37
capacities by 5%; back pressure of +.25" LG
44 1-1/4"-12
wc by 15%. MR
280 240 195 165 -125-41
To select a mixer and burner LG
combination, determine required heat 340 300 240 210 60
MR
1-1/4"-14
-125-46
release and your available air differential LG
pressure. Read downward in the 450 380 310 265 75
MR
-150-56 1-1/2"-16
appropriate column to the desired LG
maximum heat release. Then read across MR
560 430 380 325 100 -150-63 1-1/2"-18
LG
that line to find the mixer designation and
the SEALED NOZZLE size. MR
690 580 475 400 150 -200-70 2"-20
LG
Multiple nozzles can be used, but the
actual capacities will depend upon the MR
800 690 555 475 -200-73
LG
type, size and quantity of nozzles selected 160 2"-24
MR
for your application. 990 855 680 580 -200-80
LG
MR
1190 1010 825 700 -300-98
LG
MR
1420 1210 980 830 210 -300-106 2-1/2"-27
LG
MR
1760 1490 1200 1000 -300-116
LG
MR
2090 1780 1450 1200 360 -400-124 3"-33
LG
MR
2550 2180 1750 1480 -400-136
LG
560 ---
3040 2580 2000 1660 MR
-400-142
3160 2650 2080 1685 LG
3620 3100 2500 2050 MR
-500-157
3910 3350 2600 2100 LG
720 ---
4160 3520 2850 2400 MR
-500-166
4850 4020 3200 2600 LG
with Style A or B LINOFLAME® Burners
Sizing and capacity information for systems To determine velocity, make a trial burner
using these mixers and Style A or B LINOFLAME® selection, calculate displacement at .20 ft2 per lineal
Burners is shown on page 3208. foot of burner, subtract from duct cross-sectional area
This information is applicable for natural gas or and divide into total air flow.
propane gas firing, with fuel supply being regulated in Recirculated air systems must include at least 25
the range of 3" wc to 8 osi. SCFM of fresh air for each 100,000 Btu/hr of
If burners will be firing in still air, use the maximum capacity.
information in the table on page 3208, which is based To select a mixer and burner combination,
on balanced pressures in combustion chamber and determine your available air differential pressure at
on 100% premixture (on-ratio firing). the mixer inlet and read downward under the
If burners are to be used to heat an air stream, appropriate column to your desired maximum
follow the guidelines given below the table for suction- capacity. Read across that line to the resulting
side or pressure-side firing. This information is based minimum capacity available.
on gas-rich firing, using part of the air stream as When you are satisfied with the indicated maximum
secondary air to complete combustion. and minimum firing rates, read across to the
Very high degrees of recirculation with resulting low appropriate mixer designation. On that same line,
oxygen content may reduce attainable maximum you will find six possible burner lengths.
capacities to those illustrated in the table. Choose the one that will best fit your space
Air velocities must be maintained in the range of requirements. Arrange a burner assembly using that
500-1500 SFPM, and return air temperature across total footage, then specify it with the drilling indicated
the burner in recirculating systems must not exceed at the top of that column.
500°F (260°C). For special application requirements, contact
your Maxon representative for possible “customized”
burner drillings based on total discharge area per
lineal foot.
8/90
with Style A or B LINOFLAME® Burners
LINOFLAME® Burners in still air applications

Maximum Capacity
(1000's Btu/hr) at differential Minimum Mixer Designation Style "A" or "B" LINOFLAME® Burner assembly length
combustion air pressures Capacity (feet of indicated type and drillings)
MR=MULTI-RATIO®
(measured at mixer inlet) 1000's
LG=LG Mixing Tube
Btu/hr
15 osi 11 osi 7 osi 5 osi B-36-4242 B-96-5050 B-96-4444 B-96-3643 A-72-1733 A-72-C-3 [1]
MR
114 95 83 68 22 -100-28 1 .75 .5 --- --- ---
LG
MR
160 118 100 86 27 -100-31 1.5 1 .75 .5 --- ---
LG
MR
190 160 138 115 29 -125-37 2.25 1.5 1 .75 .5 ---
LG
MR
250 210 180 150 40 -125-41 3 2 1.5 1 .75 ---
LG
MR
320 270 212 189 57 -125-46 4 2.5 2 1.25 1 .5
LG
MR
410 345 284 240 71 -150-56 5 3.5 2.5 1.75 1.25 .75
LG
MR
510 395 350 295 92 -150-63 6.5 4.5 3 2.25 1.5 1
LG
MR
620 525 405 360 124 -200-70 8 5.5 4 2.75 2 1.25
LG
MR
730 620 490 427 136 -200-73 9 6.25 4.5 3 2.25 1.5
LG
MR
890 750 600 525 145 -200-80 11 7.75 5.5 3.75 2.5 1.75
LG
MR
1060 890 760 630 163 -300-98 14 9.5 6.75 5 3.5 2
LG
MR
1280 1080 865 750 182 -300-106 16 11 7.25 5.5 4 2.5
LG
MR
1550 1310 1110 900 250 -300-116 18 12.5 8.5 6 5 3
LG
MR
1900 1620 1270 1080 340 -400-124 22 15 11 7.5 5.5 3.5
LG
MR
2300 1960 1610 1330 420 -400-136 26 18 12 9 6.5 4.5
LG
2780 2180 1910 1585 510 MR
-400-142 32 23 16 11 8 5.5
2850 2410 1910 1550 510 LG
3300 2800 2400 1930 590 MR
-500-157 40 28 20 14 10 6.5
3500 3040 2400 1930 590 LG
3800 3250 2620 2160 660 MR
-500-166 45 32 22 17 12 7.5
4400 3660 2940 2400 660 LG
[1] Maximum capacity not to exceed 525,000 Btu/hr per lineal foot with these drillings
Suction-side applications (up to -1.0" wc suction): capacities will increase approximately 30% over
still air capacities listed above
Pressure side applications (up to +2.0" back pressure): capacities will increase approximately
20% over still air capacities listed above
with “VF” LINOFLAME® Burners
Capacities for Type “VF” LINOFLAME® Burners To select equipment, determine required heat
used with these mixers are shown in the table below. release and your available air differential pressure.
These capacities are based on natural gas firing and a Read downward in the appropriate column to the
minimum differential mixture pressure of 0.10" wc. desired maximum capacity. Opposite that data you will
Increased minimums may be necessary in air find the recommended size of mixing device and a
stream. summary of burner footage required for either “VFL” or
Maximum capacities are a function of the available “VFH” LINOFLAME® Burners.
air differential pressure and are shown for four different
ranges of air differential pressure. Consider pressure
drops carefully when sizing blower.
Maximum Capacity (1000's Btu/hr) Lineal feet of VF LINOFLAME® Burner

at differential combustion air pressures Minimum Mixer Designation
(measured at mixer inlet) Capacity MR=MULTI-RATIO®
1000's Btu/hr LG=LG Mixing Tube Type VFL Type VFH
MR
145 130 105 90 15 -125-31 .5 .25
LG
MR
285 255 200 170 30 -125-41 1 .5
LG
MR
585 525 430 335 60 -150-63 2 1
LG
MR
855 760 600 510 90 -200-80 3 1.5
LG
MR
1160 1040 820 720 120 -300-84 4 2
LG
MR
1450 1300 1050 910 150 -300-98 5 2.5
LG
MR
1720 1590 1320 1180 180 -300-106 6 3
LG
2050 1830 1500 1300 210 MR 7 3.5
-300-116
2300 2100 1750 1500 240 LG 8 4
MR
2900 2650 2200 1950 300 -400-136 10 5
LG
MR
3400 3050 2550 2250 360 -400-142 12 6
LG
MR
3950 3600 3050 2650 420 -500-157 14 7
LG
4400 3900 3400 3000 480 MR
-500-157 16 8
4500 4100 3550 3100 480 LG
4650 4200 3700 3250 540 MR
-500-166 18 9
5200 4850 4000 3500 540 LG
5700 5300 4400 3850 600 LG -500-166 20 10
8/90
with INFRAWAVE® Burners
Capacities and required burner footage for Consider pressure drops carefully when sizing
INFRAWAVE® Burner systems fed by “LG” Mixing blower, so that the required differential is available.
Tubes or MULTI-RATIO™ Mixers are summarized in Once the mixing device has been sized for the
the table below. All capacity information given is for desired capacity, check the right side of the table for
natural gas firing. required burner footage of single grid or double grid
Minimum is based on approximately 0.25" wc INFRAWAVE® Burners.
differential mixture pressure in the burner. The
maximum capacities are obtainable when the indicated
air differential pressure is available at “LG” tube or
MULTI-RATIO™ Mixer inlet.
Maximum Capacity (1000's Btu/hr) Lineal feet of INFRAWAVE® Burner

at differential combustion air pressures Minimum Mixer Designation
(measured at mixer inlet) Capacity MR = MULTI-RATIO® Type SG Type DG
1000's Btu/hr LG = LG Mixing Tube Single Grid Double Grid
11 osi 7 osi 5 osi
MR
120 100 75 15 -125-31 2 1
LG
MR
240 200 150 30 -125-41 4 2
LG
MR
480 400 300 60 -150-63 8 4
LG
MR
720 600 450 90 -300-78 12 6
LG
MR
960 800 600 120 -300-84 16 8
LG
MR
1200 1000 750 150 -300-98 20 10
LG
MR
1440 120 0 900 180 -300-106 24 12
LG
1680 1400 1050 210 MR 28 14
-300-116
1920 1600 1200 240 LG 32 16
MR
2400 2000 1500 300 -400-136 40 20
LG
MR
2880 2400 1800 360 -400-142 48 24
LG
3 360 2800 2100 420 MR 56 28
-500-157
3840 3200 2400 480 LG 64 32
4320 3600 2700 540 MR 72 36
-500-166
4800 4000 3000 600 LG 80 40
General Gas Orifice Drillings

The capacity of a Series “HG” Mixing Tube is Each Series “HG” Mixing Tube will have a specific
determined by its physical size, air pressures, the number and size of gas orifices drilled in the venturi
size, type and number of burner nozzles fired, and by throat of the mixer. The size of the gas orifice is
the field conditions under which it operates. stamped into the metal casting on the outside of each
Choose from the following capacity/selection tables mixing tube body.
for the combination of mixing tube, burners, and Refer to the table below for the suggested drillings.
operating conditions for your application. Nomenclature
Slight variations in combustion chamber pressure,
draft conditions or the availability of secondary air can All Series “HG” Mixing Tubes are identified by pipe
affect capacity ratings and performance. size.
Example: 3" Series “HG” Mixing Tube
(3" is the inlet air pipe connection and the mixture
discharge pipe size)
Gas Orifice Drillings for Series “HG” Mixing Tubes

NOTE: Drillings below based on 2 PSIG inlet gas pressure (measured at “HG” Mixing Tube gas inlet)
For fully premixed systems For partially premixed systems
Size of "HG"
Gas orifice drillings
Combustion Air Mixing Tube Combustion Air Gas orifice drillings
for Series "SN" and STICKTITE Nozzles,
Pressure Pressure for Series "66" AIRFLO and
Style A, B & VF LINOFLAME,
measured at air (number of measured at air COMBUSTIFUME Burners
INFRAWAVE and LO-NOX Burners
inlet of "HG" gas orifices in inlet of "HG"
Mixing Tube for for for parentheses) Mixing Tube for for for
Natural Gas Propane Gas Butane Gas Natural Gas Propane Gas Butane Gas
8 osi 11/64" 9/64" #29
12 osi 7/32" #16 #18 2" HG 21/64" I F
(4)
16 osi 15/64" #11 #14
8 osi 3/16" #23 #27
12 osi 13/64" #18 #22 3" HG 21/64" I F
(6)
16 osi 7/32" #15 #18
8 osi A #12 #15
12 osi F #3 #8 4" HG 6&8
7/16" T R
(8) osi
16 osi J #1 3/8"
8 osi F #4 #8
12 osi K #1 7/32" 6" HG 29/64" 3/8" T
(12)
16 osi N D A
8 osi S 9/32" 17/64"
12 osi 13/32" U 11/32" 8" HG 35/64" 29/64" 7/16"
(12)
16 osi 15/32" U 11/32"
11/92
Series “HG” Mixing Tubes with STICKTITE™ Burner Nozzles
Maximum and minimum capacities that may be negligible pressure drop between the “HG” Mixing Tube
expected from “HG” Mixing Tubes when firing through a outlet and STICKTITE™ Nozzle, and on 100% premix
single STICKTITE™ Nozzle of the indicated size are firing into a chamber with slight positive pressure.
shown in the table below. Multiple nozzles can be used, but the actual
The combustion air blower must be selected to allow capacities will depend upon the type, size and quantity
for whatever drop exists between it and the “HG” of nozzles selected for your application.
Mixing Tube inlet. All figures below are based on
Single STICKTITE™ Nozzle capacities at various air pressures

Minimum Maximum Capacity in 1000's Btu/hr
"HG" Mixing STICKTITE™ at indicated differential air pressures (measured at mixing tube inlet)
Capacity
Tube size Nozzle size
1000's Btu/hr 4 osi 6 osi 8 osi 10 osi 12 osi 14 osi
2" HD-2"-24 160 850 1000 1150 1280 1400 1480
3" HD-3"-30 240 1150 1400 1550 1700 1850 2000
4" HD-4"-41 450 2200 2600 3000 3300 3600 3900
6" HD-6"-60 1000 5000 6000 7000 7900 8500 9200
8" HD-8"-88 2400 11000 13500 15000 16500 18000 19500
Series “HG” Mixing Tubes with Series “SN” Sealed Nozzle Burners
Capacities and nozzle sizing information are mixer). Be sure to allow for piping losses from
provided below for systems utilizing “HG” Mixing Tubes combustion air blower.
with Sealed Nozzles. The right side of the table deals Back pressures of +0.15" wc will reduce capacities
with capacities, and is based on natural gas firing by 5%; back pressures of 0.25" wc by 15%.
against balanced or slightly negative combustion Multiple nozzles can be used, but the actual
chamber pressures. capacities will depend upon the type, size and quantity
Maximum capacities are cataloged for three of nozzles selected for your application.
different air differential pressures (measured at inlet to
Single Series “SN” Sealed Nozzle capacities at various combustion air pressures
Maximum Capacity in 1000's Btu/hr
"HG" Mixing Tube Series "SN" Sealed Minimum Capacity at indicated differential air pressure (measured at mixing tube inlet)
Size Nozzle Burner 1000's Btu/hr
4 osi 6 osi 10 osi
2" SN-2"-20 160 690 840 1100
3" SN- 2-1/2" -27 260 1300 1500 1950
4" SN-4"-42 560 2200 2700 3350
6" SN-6"-60 1000 4350 5250 6700
Series “HG” Mixing Tubes with Style A or B LINOFLAME® Burners
Sizing and capacity information for systems under the appropriate column to your desired maximum
using “HG” Mixing Tubes and Style A or B capacity, then across that line to the resulting
LINOFLAME® Burners is shown in Table 1 below and minimum capacity available.
Table 2 on the following page. When you are satisfied with the indicated maximum
If burners will be firing in still air, use Table 1 and minimum firing rates, read across to the
(below). appropriate mixer designation. On that same line, you
Table 1 is based on balanced pressures in the will find five possible burner lengths.
combustion chamber and on 100% premixture (on-ratio Choose the one that will best fit your space
firing). requirements. Arrange a burner assembly using that
Both tables apply for natural gas, propane and total footage, then specify it with the drilling indicated
butane gas firing, with fuel supply being regulated to at the top of that column.
the range of 2 PSIG. For special application requirements, contact
To select a mixer and burner combination, your Maxon representative for possible “customized”
determine required heat release and your available air burner drillings based on total discharge area per lineal
differential pressure at mixer inlet. Read downward foot.
Table 1: LINOFLAME® Burners in still air applications

Maximum Capacity (1000's Btu/hr) at
Minimum Lineal feet of LINOFLAME® Burner
indicated differential combustion air "HG" Mixing
Capacity in (feet of indicated type and drillings)
pressures (measured at mixer inlet) Tube Size
1000's Btu/hr
8 osi 6 osi B-36-4242 B-96-5050 B-96-4444 B-96-3643 A-72-1733
865 755 140 2" HG 11 7 5 3.75 2.5
1600 1360 230 3" HG 16 11 8 6 4
2730 2410 395 4" HG 30 20 14.5 10.5 7
5450 4750 850 6" HG 65 42 30 22 15
8200 7150 1260 8" HG 97 63 45 33 22
5/96
Series “HG” Mixing Tubes with Style A or B LINOFLAME® Burners
If burners are to be used to heat an air stream, To determine velocity, make a trial burner
see Table 2 (below). selection, calculate displacement at .20 ft2 per lineal
Table 2 is based on gas-rich firing, using part of the foot of burner, subtract from duct cross-sectional area
air stream as secondary air to complete combustion. and divide into total air flow.
Very high recirculation may reduce attainable Recirculated air systems must include at least 25
maximum capacities to those illustrated in Table 1 SCFM of fresh air for each 100,000 Btu/hr of maximum
(page 3213). capacity.
Air velocities must be maintained in the range of
500-1500 SFPM, and return air temperature across the
burner in recirculating systems must not exceed 500°F
(260°C).
Table 2: LINOFLAME® Burners for air heating applications

Assuming uniform velocity from 500 to 1500 sfpm (and a return air temperature not to exceed 500°F (260°C), if system is recirculating)
Maximum Capacity
Lineal feet of LINOFLAME® Burner
in 1000's Btu/hr at differential combustion air Minimum (feet of indicated type and drillings)
pressures (measured at mixer inlet) Minimum SCFM fresh HG
On pressure side On suction side Capacity air required Mixing
of fan of fan in 1000's to secure Tube
(back pressures (suctions ranging Btu/hr maximum Size B-36-4242 B-96-5050 B-96-4444 B-96-3643 A-72-1733
u p to +2" w c ) to -1" wc) capacities [1]
925 770 1000 840 170 250-285 2" HG 7.5 6.5 5 3.75 2.5
1650 1430 1800 1550 290 450-500 3" HG 12 10 8 6 4
2900 2420 3200 2650 630 800-870 4" HG 21 19 14.5 10.5 7
5700 4750 6250 5200 880 1500-1750 6" HG 45 38 30 22 15
8550 7150 9350 7800 1350 2250-2620 8" HG 67 57 45 33 22
[1] The smaller figure indicates SCFM fresh air which must be introduced into the system for the maximum burner capacity shown in the 4
osi column, and the larger figure the amount required for the 6 osi capacity. Amounts for other capacities may be interpolated.
Series “HG” Mixing Tubes with “VF” LINOFLAME® Burners
Capacities of Type “VF” LINOFLAME® Burner Maximum capacities are shown for three
assemblies supplied by “HG” Mixing Tubes are shown differential combustion air pressures.
in the table below. To size a system, determine required heat release
Minimum capacity is based on 0.10" wc differential and available air differential pressure at the mixer inlet.
mixture pressure in the “VF” burner. Air stream Read downward in the appropriate column to the
velocities higher than 1500 SFPM and larger burner desired maximum capacity. Opposite that figure you
assemblies may require increased minimums. will find the required “HG” Mixing Tube size, expected
minimum capacity, and the required burner footage.
Maximum Capacity Lineal feet of "VF" LINOFLAME® Burner

"HG" Minimum (1000's Btu/hr) at differential air pressures
Mixing Tube Capacity (measured at mixer inlet) VFL LINOFLAME® VFH LINOFLAME®
Size 1000's Btu/hr Burner Burner
4 osi 6 osi 10 osi
60 --- 600 --- 2 1
2"
120 850 1000 1200 4 2
120 --- 1200 --- 4 2
180 1400 1650 1800 6 3
3"
240 1750 2100 2400 8 4
300 2050 2400 --- 10 5
240 --- 2400 --- 8 4
300 --- --- 3000 10 5
360 2600 3250 3600 12 6
4"
420 2950 3800 4200 14 7
480 3250 4000 4800 16 8
540 3400 4400 --- 18 9
480 --- 4800 --- 16 8
540 --- --- 5400 18 9
600 4500 5600 6000 20 10
660 4900 6100 6600 22 11
6" 720 5300 6600 7200 24 12
840 6100 7500 8400 28 14
960 6800 8400 9600 32 16
1080 7600 9400 --- 36 18
1200 8100 --- --- 40 20
840 --- 8400 --- 28 14
1080 --- --- 10800 --- 18
1200 --- 10000 1200 --- 20
1320 9600 11900 13200 --- 22
8"
1440 10400 12900 14400 --- 24
1560 10900 13500 15600 --- 26
1680 11400 14300 16800 --- 28
1800 12000 15100 18000 --- 30
8/90
Series “HG” Mixing Tubes with INFRAWAVE® Burners
Capacity and burner footage suggestions for To size a system, determine required heat release
systems utilizing Series “HG” Mixing Tubes and and available air differential pressure, then read
INFRAWAVE® Burners are summarized in the table downward in the appropriate column to the desired
below. capacity. Opposite that figure, you will find the required
Minimum capacities shown are based on “HG” Mixing Tube size and burner footage
approximately 0.25" wc differential mixture pressure in recommendations.
the burner. The three maximums shown are based on
the indicated combustion air differential pressure at the
inlet to the “HG” Mixing Tube.
Maximum Capacity Lineal feet of INFRAWAVE® Burner

"HG" Minimum (1000's Btu/hr) at differential air pressures
Mixing Tube Capacity (measured at mixer inlet) Type "SG" Type "DG"
Size 1000's Btu/hr Single Grid Double Grid
4 osi 6 osi 10 osi
2" 120 720 865 960 16 8
180 1080 1295 1440 24 12
3" 240 1440 1730 1920 32 16
300 1800 2160 2400 40 20
360 2160 2580 2880 48 24
420 2520 3025 3360 56 28
4"
480 2880 3450 3840 64 32
540 3240 3890 4320 72 36
600 3600 4320 4800 80 40
660 3960 4750 5280 88 44
720 4320 5185 5760 96 48
6" 840 5040 6050 6720 112 56
960 5760 6915 7680 128 64
1080 6480 7776 8640 144 72
1200 7200 8640 9600 160 80
Series “HG” Mixing Tubes with Series “66” AL5 AIRFLO® Burners
For firing in recirculated air streams, see table at Recirculated air with Series “66” AL5
right for the capacities available from various lengths AIRFLO® Burner
of AL5 AIRFLO® Burner assemblies when used with
“HG” Mixing Tubes. Data is based on 2 PSIG natural Capacity Primary Combustion Air
"AL5" "HG"
1000's required [1] through
gas supply pressure at the mixer and 2600-3500 SFPM Btu/hr
Footage Size
"HG" Mixing Tube (SCFM)
air stream velocity across the burner. 325 1/2 18
Turndown ratios of 15:1 are possible using natural 2"
650 1 37
gas. Uneven and/or turbulent air flows, or the use of
975 1-1/2 55
propane, will give higher minimums and reduce
turndown. 1300 2 73
The capacities shown are based on a minimum 1625 2-1/2 92
3"
of 80 SCFM of fresh air being added for each 1950 3 110
100,000 Btu/hr of heat input. Lower fresh air volumes, 2275 3-1/2 128
the presence of exceptionally high moisture, or other 2600 4 147
combustion-retarding or inert components may require 2925 4-1/2 165
special consideration. 3250 5 183
Differential air pressure of 5.2" wc is required for
3900 6 4" 220
all of these combinations and is measured between
4550 7 256
burner inlet and duct/chamber static pressure.
5200 8 293
Multiple “HG” Mixing Tubes may be used with a
single MICRO-RATIO® Valve, but remember to size 5850 9 330
blower for the combined SCFM required and allow for 6500 10 367
piping losses. 7150 11 403
6"
7800 12 44 0
8450 13 47 7
9100 14 513
9750 15 550
10400 16 587
11050 17 623
11700 18 660
12350 19 697
13000 20 733
13650 21 770
8"
14300 22 807
14950 23 844
15600 24 880
16250 25 917
16900 26 954
17550 27 990
18200 28 1027
[1] Approximately 1/3 of total required at maximum capacity.
Balance from air stream.
2/93
Series “HG” Mixing Tubes with Types 5CF-5 & 4CF-5 COMBUSTIFUME® Burners
Effluent air streams with oxygen Table 1: Design Parameters

levels of 12 to 16% may be heated with Percent of oxygen in effluent: 12 to 12.9 13 to 13.9 14 to 15.9
COMBUSTIFUME® Burners supplied Required increase in gross heat release (Btu/hr) 10% 7.5% 5%
with a partial premixture of air and
Maximum heat release per lineal foot of burner
natural or propane gas. (Btu/hr)
700,000 1,000,000
A complete burner system to (COMBUSTIFUME® Burner with 5 rows of #36
handle these difficult applications would drilled holes = 120 holes per foot)
include a COMBUSTIFUME® Burner Maximum footage

5 6
of COMBUSTIFUME® Burner per inlet feed
assembly, Series “HG” Mixing Tube,
Minimum heat release
MICRO-RATIO® Control Valve and a (Btu/hr) per lineal foot of burner
75,000
combustion air blower. Your Maxon Combustion air required through Series "HG"
representative can help you select from 47 41 34
Mixing Tube (SCFM per lineal foot of burner)
the broad range of options available. Differential air pressure required (inches water
column) as measured between burner inlet and 8 6.4 5.5
duct/chamber static pressure
General Selection Procedure:
1. Determine available oxygen level in air stream to be
heated.
2. Enter Table 1 under column with specific oxygen Table 2: Series "HG" Mixing Tube Selection
level for parameters of your application. Available "HG" SCFM combustion air volume required
oxygen level dictates primary air and extra heat Mixing Tube Size at maximum through "HG" Mixing Tube
requirements for additional primary air flows. 2" 0 to 190
3. Calculate gross heat requirement. 3" 90 to 260
4. Determine burner footage and inlet feed require- 4" 175 to 500
ments. 6" 400 to 1167
5. Select “HG” Mixing Tube size from Table 2 based 8" 880 to 2500
upon the volume of air required.
Example:
– Required heat release of 7,000,000 Btu/hr
– For system measured with 13.5% oxygen in air
stream D. 11 ft. x 41 SCFM/ft = 451 SCFM primary air
with differential pressure = 6.4" wc
From Table 1 (13 to 13.9%, middle column)
From Table 2 (301 - 520 SCFM)
A. Gross heat required
7,000,000 x 1.075 = 7,525,000 Btu/hr E. Select 6" HG Mixing Tube with
12 each 29/64 gas orifices per catalog page 3211
7,525,000 Btu F. Select MICRO-RATIO® Control Valve
B. = 10.75 ft. = 11 ft. of burner
700,000 Btu/ft – for 451 SCFM air = (27060 SCFH)
– for 7525 SCFH natural gas
11 ft
C. = 2 inlets
6 ft/inlet
Series “HG” Mixing Tubes with LO-NOX™ Burners
Fresh and recirculated air streams may be heated Table 1: Design Parameters
with LO-NOX™ Burners supplied with a full premixture
Differential mixture
of air and natural or propane gas. Maximum Combustion air
pressure (inches
capacity required through HG
A complete burner system to handle these difficult w.c.) as measured
heat release Btu/hr Mixing Tube
applications would include a LO-NOX™ Burner assem- between burner inlet
per lineal foot of (SCFM per lineal foot
and duct/chamber
bly, Series “HG” Mixing Tube, MICRO-RATIO® Control LO-NOX™ Burner of LO-NOX™ Burner)
static pressure
Valve and a combustion air blower. Your Maxon
200,000 40 2.5
representative can help you select from the broad
range of options available. 300,000 60 3.5
400,000 80 6.5
General Selection Procedure: 500,000 100 10
1. Calculate gross heat requirement.
550,000 120 11
2. Determine burner footage and inlet feed require-
ments.
3. Enter Table 1 under column with your capacity Table 2: Series "HG" Mixing Tube Selection
needs for parameters of your application. HG Mixing SCFM combustion air volume required at
4. Select “HG” Mixing Tube size from Table 2 based Tube Size maximum through HG Mixing Tube
upon the volume of air required. 2" 0 to 190
3" 90 to 260
Example: 4" 175 to 500
– Required heat release of 7,000,000 Btu/hr 6" 400 to 1167
8" 880 to 2500
From Table 1
A. Gross heat required: 7,000,000 Btu/hr
7,000,000 Btu
B. = 14 ft
500,000 Btu/ft
C. 14 ft x 100 SCFM/ft = 1400 SCFM primary air

with differential mixture pressure = 14" wc
From Table 2
D. Since single 8" HG Mixing Tube is rated for a

maximum of 2500 SCFM, this requires (1) 8" HG
Mixing Tube with gas orifices per catalog page
3211
E. Select MICRO-RATIO® Control Valve

– For 1400 SCFM air = (84,000 SCFH)
– For 7000 SCFH natural gas
12/91

2", 3", 4" Sizes
6", 8" Sizes
Size A B C D E outlet F gas inlet G air inlet

2" 10 4.25 2.75 2.5 2" 1" 2"
3" 15 6.38 3.88 3.19 3" 1-1/4" 3"
4" 20 11.19 3.44 3.81 4" 1-1/2" [1] 4"
6" 14.5 4.5 5 5.63 6" 2" [1] 6"
8" 19.5 4.63 5.25 5.88 8" 2-1/2" [1] 8" [1]
[1] Connection is threaded flange. All others threaded body.


View AA
LG Mixing H J K
A B C D E F G M N O R
Tube gas inlet air inlet outlet
LG-75 8.88 3/4
LG-100 9.88 --- --- 1.44 1.69 2.38 --- 1/2 1-1/4 1 --- --- --- ---
LG-125 10.88 1-1/4
LG-150 12.25 5 1.5 1-1/2
5.75 1.5 2.25 3.25 1 2 1.81 1.5
LG-200 13.25 6 1.69 2 .44 .5
LG-300 17.5 9.25 6.84 1.41 4.38 1.81 1-1/2 3 3 1.94 1.75
LG-400 22.5 12 2.88 2.31 4 2.38 2
8.44 2.06 5.38 2 4 .56 .62
LG-500 26.5 16 2.38 5 2.62 2.25
3/94

MULTI-RATIO™ H J K
A B C D E F G L M N O P R
Mixer Size gas inlet air inlet outlet
MR-75 9.38 3/4
MR-100 10.38 --- 1.75 3.19 2.31 5.62 2.88 3/4 1-1/4 1 .56 --- --- --- --- ---
MR-125 11.38 1-1/4
MR-150 12.38 1-1/2 1.5
7.38 1.88 5.19 2.69 6.56 3.06 1-1/4 2 .69 3.62 1.5
MR-200 13.38 2 1.69 .44 .5
MR-300 17.75 8.5 4 3 3 1.81 3.88 1.75
MR-400 21.75 2.94 6.75 8.06 3.94 2 4 .56 4.75 2
9.75 4.12 4 2.62 .56 .62
MR-500 25.75 5 5.25 2.25

Suggested spare parts: Nameplate

– Cam springs
– Plunger and cap assembly
– O-Ring assembly
To order replacement parts:

1. Specify parts by the names shown in the sketch above
2. Indicate quantity desired
3. Indicate burner size and assembly number from burner nameplate (sample
at right),
4. If available, indicate serial number stamped on nameplate of Maxon Shut-
Off Valve used with this mixer
8/90

for MULTI-RATIO™ Mixers
Preventive maintenance will help your MULTI-
RATIO™ Mixer maintain the accurate air/fuel ratio Adjusting
control it is designed to provide. To overcome the dirt, Flexible Screw
grease or scale accumulations that may build up Cam Strips
internally, we suggest you establish a periodic Screw

maintenance schedule based on experience and the Plunger Carrier
severity of your operating conditions, and perform Cap Air Valve
periodic air/valve cleaning as outlined below: Top Plate
1. Shut down combustion system both electrically Plunger Mixer
and mechanically (by closing gas cocks, etc.). Body
Plunger
2. Disconnect control motor linkage at the mixer Guide
screw carrier (so that adjustment will be
unchanged after re-assembly).
3. Remove the four screws which hold air valve top
plate onto mixer body. (To reach all four, screw
carrier must be rotated from one extreme position
Characterized Air Port
to the other.) in Air Sleeve
4. Lift screw carrier and air valve out of mixer body,
exposing plunger and cap assembly.
5. Clean accumulated dirt from air valve sleeve and 8. Turn screw carrier over and inspect the cam
mixer body. springs mounted inside. Replace the cam springs
if they are not smooth and free of scratches or
WARNING: A surface lubricant such as spray
gouges. If they are in good condition, lubricate
graphite must coat surfaces of air valve and
with light grease or petroleum jelly.
body for smooth operation. After cleaning parts
9. Return screw carrier and air valve assembly to
thoroughly, apply spray graphite and allow at
mixer body, then replace the four hold-down
least 10-15 minutes drying before re-assembling.
screws and tighten air valve top plate securely.
DO NOT USE PETROLEUM BASE LUBRICANTS.
10. Observe several operating cycles for proper firing.
6. Remove, clean and inspect plunger and cap Refine adjustment of adjusting screws if
assembly. If cap is missing or does not swivel necessary.
freely, replace entire plunger and cap assembly. 11. Reconnect automatic control linkage and place
7. Re-insert plunger and cap into plunger guide and system back in operation.
check for free movement. If operation is erratic or
plunger sticks, replace plunger and cap assembly.
Premixing Equipment Page 3200-S-1
General Instructions Piping Layouts as sometimes required by
insurance and standards groups
MULTI-RATIO™ Mixer System
To prevent damage in transit, connecting linkage
components may be packed separately and shipped
loose with your new Maxon MULTI-RATIO™ Mixer,
“LG” or “HG” Mixing Tube system.
The mixer itself is normally only a part of your
for a complete system installation. The sketches at
right show typical gas trains as might be used with
“LG”/“HG” Mixing Tubes or MULTI-RATIO™ Mixers.
1. Combustion air blower provides the air supply
to your combustion system and is essential to the
mixing of fuel gas. It should be located in the
coolest, cleanest position that you can find near “LG” Mixing Tube System
the burner itself. It must not be exposed to direct
radiant heat or positioned where it might draw in
the inert gases or hot air rising from a furnace or
oven. If problems exist, consider filters, relocation
and/or ducting of an outside fresh air supply.
2. Electrical service must match the voltage,
phase and cycle of all electrical system compo-
nents and be 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.
3. Gas supply piping must be large enough to “HG” Mixing Tube System
maintain the required fuel pressures cataloged
for the particular burner size used with burner
operating at full-rated capacity.
Natural gas pressures generally required (as
measured at the mixer gas inlet) are 3" wc to 8
osi for “LG” Mixing Tubes and MULTI-RATIO™
Mixers, or 1 PSIG higher than air pressure for
“HG” Mixing Tubes.
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 Maxon assumes no responsibility for the use or
burners are fed from a single gas train, care misuse of the piping layouts shown. Specific
should be taken to minimize pressure drop and piping and wiring diagrams should always be
give maximum uniformity. submitted to the appropriate agencies for

mCORPORATION
Page 3200-S-2 Premixing Equipment
4. Clean fuel lines are essential to prevent 9. Minimums: The MULTI-RATIO™ Mixer includes
blockage of pipe train components or burner gas a minimum air valve adjusting screw on the side
ports. All dirt, scale and pipe dope should be of the screw carrier for setting the minimum
blown out of any new gas line before actually differential mixture pressures.
connecting to the burner system. See specific start-up and adjusting instructions
5. Main gas shut-off cock should be upstream of for systems involving Maxon MICRO-RATIO®
both main gas regulator and pilot line take-off. Control Valves to set minimums.
Use it to shut off fuel to both pilot and main 10. Minimize combustion air pressure drop
burner during shutdown periods of more than a between blower and mixer. Keep a minimum
few hours. Maxon Control Valves, such as the straight run of four pipe diameters into the mixer
MULTI-RATIO™ Mixer and MICRO-RATIO® air inlet. Downstream piping from mixer to burner
Valve, are not intended for tight shut-off. should be kept as short as possible.
6. Main gas regulator is essential to maintain a 11. Inlet pipe leading to any burner should be at
uniform system supply pressure. A separate least four pipe diameters in length. If the mixer is
regulator should be provided in the branch supplying multiple burners or multiple inlets to a
leading to each burner system if more than one is single burner element, care should be taken so
served by a common main. Size regulator for full that air/gas mixture piping gives minimum
system capacity at required pressure, including pressure drop and maximum uniformity. Do not
pipe train losses. Follow the instructions attached install any shut-off device in the air/gas
to the regulator during installation. mixture line.
7. Pilot take-off should be upstream of main gas 12. Test connections are essential for burner
regulator but downstream of main gas cock. It adjustment. At a minimum, they should be
should normally include its own pilot gas provided downstream of the mixing tube and at
regulator (selected to meet pilot flow and each burner inlet. Test connections should never
pressure needs), a solenoid valve and shut-off be installed in elbows or pipe tees. Test
cock. An adjustable gas orifice at the pilot inlet connections must be plugged except when
simplifies adjustment. readings are being taken.
Appropriate pilots should be provided which 13. Vent dampers and pressure controllers should
are compatible with the type of burner and be used to maintain balanced or slightly positive
control system being used. furnace pressures (0.0" to 0.5" wc) for maximum
8. Fuel shut-off valves (when properly connected efficiency. Excessive back pressure can damage
to a safety control system) shut the fuel supply furnace and/or reduce burner capacity. Negative
off when a hazardous operating condition is pressures allow infiltration of secondary air and
sensed. Manual reset valves require operator can seriously affect efficiency and temperature
attendance each time the system is started up (or uniformity.
restarted after a trip-out). Motorized shut-off
valves permit automatic start/restart when used
with appropriate control system.
mCORPORATION

Read complete instructions before proceeding, and are working. Allow air handling equipment to run
familiarize yourself with all the system’s equipment for adequate purge of your manifolds and
components. Verify that your equipment has been combustion chamber plenums. With main gas
installed in accordance with the original shut off, manually advance MULTI-RATIO™
manufacturer’s current instructions. Mixer or MICRO-RATIO® Control Valve’s
operating crank to “high fire” position so that air
CAUTION: Initial adjustment and light off
only flows through burner and combustion
chamber.
experienced personnel familiar with
combustion systems, with control/safety CAUTION: Do not by-pass control panel timers
circuitry, and with knowledge of the overall typically controlling sequential operations.
6. Check minimum mixture pressure at burners
company and/or individuals responsible for the
by turning the MULTI-RATIO™ Mixer or MICRO-
manufacture and/or overall installation of
RATIO® Control Valve to its minimum position
and reading differential air pressure only at each
burner with a water column manometer. Any
If Maxon instructions conflict with any codes or
reading below 0.25" wc differential (natural gas),
regulations, contact Maxon Corporation before
or 0.10" wc for VF LINOFLAME® Burners,
requires re-adjustment as described below.
6A. Setting minimum mixture pressure with
MULTI-RATIO™ Mixer system:
For initial burner start-up: If minimum mixture pressure must be
1. Close all burner fuel valves and cocks. Make increased, open the MULTI-RATIO™ Mixer
preliminary adjustments to fuel gas regulators. slowly (by turning toward the higher-numbered
Remove pilot and main gas regulators’ adjusting positions) until the required minimum differential
screw covers. Turn adjusting screw down air pressure is reached. Mark air valve dial at the
(clockwise) to approximately mid-position. Close position opposite pointer and note the numbered
pilot gas adjustable orifice screw by turning in position on screw carrier cam assembly which is
clockwise until it stops. (Do not over-tighten.) opposite index pointer (see sketch below).
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.
positions.
linkage from your MICRO-RATIO® Control Valve
or MULTI-RATIO™ Mixer’s operating crank arm
by loosening the control motor’s connecting rod
from the toggle linkage.
Initial start-up adjustment should only be accom-
plished during a “manual” burner control mode.
5. Start all system-related fans and blowers.
Check for proper blower motor rotation and
impeller direction. Verify that all control interlocks

mCORPORATION
Screw in on the minimum air stop screw on the Continue opening the MICRO-RATIO® air valve
side of the screw carrier cam. This makes a while watching the manometer connected into
physical “stop” that prohibits the screw carrier the burner’s air/gas mixture manifold. Determine
from going all the way down to the minimum the point at which further opening of the air valve
firing positions. Screw down until the established gives no appreciable increase in air pressure
minimum differential air pressure readings at within the manifold/burner. Mark the air valve dial
each burner are above the minimum mixture at this position opposite the air valve pointer. This
pressure settings described in step 6. point will become the maximum air setting for
Tighten down on the locking nut on the your MICRO-RATIO® Valve mixing tube system.
minimum air stop screw to lock the MULTI- Having marked and/or recorded the MICRO-
RATIO™ Mixer at the minimum air mixture RATIO® Control Valve’s air valve settings for both
pressure setting. minimum and maximum firing positions, you may
6B. Setting minimum mixture pressure with a adjust the linkage and travel of the gas valve’s
MICRO-RATIO® Control Valve and Series “LG” stroke (see sketch below).
or “HG” Mixing Tube system:
If minimum mixture pressure must be
increased, open the MICRO-RATIO® air valve
slowly (by turning toward higher-numbered
positions) until the required differential air
(mixture) pressure is reached, then mark air
valve dial at the position opposite pointer. This
point will become the minimum air setting for
your MICRO-RATIO® Valve mixing tube system
(see sketch below).
Loosen Allen set screw “A” and binding screw

“B” in toggle “C”. Move the toggle in universal
cam assembly slot towards the center of rotation
so that gas valve can rotate from its minimum to
maximum position, while the air valve swings
between the established (and marked) minimum
and maximum settings.
Place air valve on pre-determined “minimum”
position and rotate gas valve to its “minimum”
setting position. Tighten down set screw “A” and
binding screw “B” with both valves set at
“minimum”.
Establish set screw “A” as minimum-end
adjustment point and binding screw “B” as
maximum-end adjustment point. (Note: It doesn’t
matter which is maximum or minimum, as long as
you identify and keep the same reference points
for the next adjustment steps.)
Now rotate MICRO-RATIO® Valve to
“maximum” position. The air valve maximum
setting was previously determined. Loosen
binding screw “B” and adjust pointer and linkage
to correct just half of the distance required to
make the air valve pointer indicate the maximum
m
air valve setting.
CORPORATION
Re-tighten binding screw “B” and return the NOTE: At this point, it is more important to get
MICRO-RATIO® Valve to the “minimum” air any kind of a flame as soon as possible. The
setting. flame geometry can be adjusted and refined as
This time, loosen set screw “A” and again needed later.
correct for just half of the distance required to Continue turning in slowly until flame becomes
make the air valve pointer indicate the minimum noticeably rich (usually purple or green with a
air valve setting. slight yellow tip). Then slowly back the screw out
Re-tighten set screw “A” and again return the until the flame becomes bright blue.
MICRO-RATIO® Valve to its maximum position. 10. Once your flame is established and refined at this
Similarly, correct one half the distance with position, and without advancing the screw carrier
binding screw “B” for the maximum setting, etc. quadrant higher, screw all remaining screws
Continue this adjustment procedure until the down to at least the same level as your first
gas and air valves reach their minimum and adjusted screw.
maximum positions simultaneously. Normally, NOTE: A preliminary setting can be established
this is accomplished within seven adjustments. with all the remaining adjusting screws.
7. Remove cover plate from screw carrier cam Generally, each succeeding screw needs to be
assembly and turn all adjusting screws counter- screwed in approximately one full turn more
clockwise until flush with outer surface of casting (clockwise) than its preceding screw. A smooth
(new equipment is shipped this way). “stair-step” gradient pre-set at this point from low
8. Open main and pilot gas cocks and light first to high will simplify the remaining adjustment
burner pilot following instructions appropriate for steps.
that burner and pilot type. If multiple pilots are
CAUTION: If flame is extinguished, immediately
used, open individual cocks and adjust each in
return MICRO-RATIO® Control Valve or MULTI-
turn.
RATIO™ Mixer to minimum position and shut
To light and adjust gas pilot: Check to insure
pilot combustion air supply is flowing to any
pressure pilot mixer. Pilot gas regulator should
where ignition was lost, then return valve/mixer
initially be set at approximately midpoint of its
adjustment range. With pilot gas solenoid closed,
open main fuel gas and pilot gas cock. Energize
spark ignitor and pilot gas solenoid. Observe pilot 11. Without advancing the valve/mixer quadrant,
ignition through sight port of pilot assembly and/ screw down clockwise on #2 screw (one or two
or by viewing micro-amp signal metered from turns). Then slowly advance the screw carrier
flame safeguard relay circuit. quadrant to the #2 position. Adjust flame
Refine pilot setting for a hard blue flame (and/ appearance at this new position #2.
or strongest micro-amp signal) by adjusting gas NOTE: If firing chamber is of refractory
flow through pilot orifice and/or pilot regulator. construction, allow your burner system to operate
Shut off pilot gas cock to extinguish pilot fire. at this low setting for the necessary dry/cure-out
Re-open and confirm easy re-ignition several time period recommended by the chamber or
times. The flame safeguard relays should now refractory manufacturer. Then continue
power the main fuel shut-off valves. adjustments of valve/mixer.
9. Light main burners at minimum as follows:
First, turn MICRO-RATIO® Valve or MULTI-
RATIO™ Mixer to its minimum setting (which
may be at position 1 or 2 after completing step
6), then open fuel shut-off valve and turn
corresponding screw in (clockwise) until flame
ignites at all burner nozzles. (This may take
several turns of the screw.)

mCORPORATION
12. Again, without moving valve/mixer, bring #3 and CAUTION: After completing previously listed
all remaining adjusting screws down to the same steps, check all interlocking safety components
level as #2 screw. and circuitry to prove that they are properly
NOTE: If approximate pre-set gradient was made installed, correctly set, and fully operational. If
earlier, the remaining screws will already be at or in doubt, shut the system down, close main and
below appropriate levels. pilot cocks and contact responsible individual
Progressively work your way up through each before proceeding further.
progression slope from your first screw to the 14. Reconnect linkage to control motor, plug all test
“maximum” position. connections, replace equipment cover caps and
As each is adjusted, you must turn the tighten linkage screws.
remaining unadjusted screws in at least that far 15. Check out overall system operation by cycling
to prevent possible damage to flexible cam strips through light-off at minimum, interrupting pilot,
inside the screw carrier cam assembly. and allowing temperature control system to cycle
Turning a screw in “clockwise” gives more gas burner from minimum to maximum and return.
at that setting; turning it out gives less. Re-check all safety system interlocks for
NOTE: To adjust the flame at any position, you proper setting and operation.
must move the valve quadrant to the number you WARNING: Test every UV installation for
desire to adjust. This aligns the adjusting screw dangerous spark excitation from ignitors and
directly on top of the fuel valve plunger. A other possible sources of direct or reflected UV
resulting adjustment of the screw is directly radiation. Use only gas-tight scanner
applied to the fuel valve plunger and its connections.
interconnected valve body linkage.
13. Cycle burner from minimum to maximum and 16. Before system is placed into full service,
refine adjustment, if necessary. instruct operator personnel on proper start-up,
For operation with interrupted pilot (as operation and shut-down of system. Establish
recommended), shut off pilots and cycle burner written instructions for their future reference.
from minimum to maximum and back several
mCORPORATION

Premixing Equipment Page 3200-A/P-1
Assembly Numbers
Series "LG" Mixing Tubes and MULTI-RATIO™ Mixers

Mixer assemblies include
Series "LG" Mixing Tubes MULTI-RATIO™ Mixers
air orifice plate
Assembly Approx. Ship Air Orifice Plate Assembly Assembly Approx. Ship
Number Weight (lbs) Designation Number Number Weight (lbs.)
LG-75-19 12165 A-19 11867 MR-75-19 11981
LG-75-22 12166 6 A-22 11910 MR-75-22 11982 10
LG-75-25 12167 A-25 11865 MR-75-25 11983
LG-100-28 12170 A-28 11842 MR-100-28 11986
7
LG-100-31 12171 A-31 11866 MR-100-31 11987
LG-125-31 12173 A-31 11866 MR-125-31 11989
20
LG-125-37 12174 A-37 11933 MR-125-37 11990
10
LG-125-41 12175 A-41 11934 MR-125-41 11991
LG-125-46 12176 A-46 11935 MR-125-46 11992
LG-150-46 12177 B-46 12131 MR-150-46 11993
LG-150-56 12179 12 B-56 11909 MR-150-56 11995 30
LG-150-63 12180 B-63 11868 MR-150-63 11996
LG-200-56 12181 B-56 11909 MR-200-56 11997
LG-200-62 12182 B-62 12133 MR-200-62 11998
LG-200-70 12184 15 B-70 11936 MR-200-70 12000 35
LG-200-73 12185 B-73 11937 MR-200-73 12001
LG-200-80 12186 B-80 11869 MR-200-80 12002
LG-300-78 12187 C-78 12135 MR-300-78 12003
LG-300-84 12188 C-84 12136 MR-300-84 12004
LG-300-92 12189 C-92 11911 MR-300-92 12005
23 70
LG-300-98 12190 C-98 11938 MR-300-98 12006
LG-300-106 12191 C-106 11897 MR-300-106 12007
LG-300-116 12192 C-116 11939 MR-300-116 12008
LG-400-124 12196 C-124 11940 MR-400-124 12012
LG-400-136 12197 30 C-136 11941 MR-400-136 12013 75
LG-400-142 12198 C-142 12138 MR-400-142 12014
LG-500-157 12201 C-157 11942 MR-500-157 12017
35 80
LG-500-166 12202 C-166 11943 MR-500-166 12018
Series "HG" Mixing Tubes

Approx. Ship
Designation Assembly Number [1]
Weight (lbs.)
2" HG 12139 4
3" HG 12140 18
4" HG 21535 36
6" HG 15673 55
8" HG 02821 100
m
[1] Gas orifice drillings must be designated on order
CORPORATION
Page 3200-A/P-2 Premixing Equipment
Assembly Numbers
Connecting Base & Linkage Assemblies for use with MULTI-RATIO™ Mixers
This listing of CB & L Assemblies shows only a NOTE: MULTI-RATIO™ Mixers M-200 and smaller
sampling of the more popular control motors. We may require operators capable of 90 in-lbs torque.
be able to furnish CB & L for other operators not MR-300 and larger require 120 in-lbs torque.
number).
MULTI-RATIO™ Mixer Size

Type Manufacturer Model Number
MR-200 & smaller MR-300 & larger
P-25 [1] 24427 24429
Foxboro
A P-50 [2] 24428 24430
I Honeywell
01-11/861P
17274 17275
R 03-8/863T
Taylor 40VF6 --- 12883
EA51-58, also with
Barber-Coleman 15165 15166
prefix MC, MP, or MF
M644 [3]
E M744 [3]
16240 16241
M941 [3]
L M944 [3]
Honeywell
E
C M940A (Discontinued)
14525 14526
T Herculine 1066899 1066872
R
10261
I 10262
Leeds & Nor thrup 14126 14127
C 10264
10266
M-80 [4]
Penn/Johnson 16240 16241
M-81 [4]
[1] Specify from Foxboro: [3] Specify from Honeywell:

WITH #B6301-LR yoke WITH #7616BR crank arm
WITH #B6301-KY connection assembly
LESS indicating pointer [4] Specify from Penn/Johnson:
LESS travel indicator scale WITH #LVR27A-601 crank arm
LESS stem locknuts

WITH #B6301-WR yoke
LESS stem locknuts
mCORPORATION

Bulletin 3300
Premix Burner
Systems
SN Sealed Nozzles
• Use kinetic energy of higher gas pressures to

provide air/gas mixture for all Maxon premix-type burner
systems
• Uses most clean fuel gases 500-3200 Btu/ft3

• Low initial cost
• Maintenance-free design
• Easy to adjust and operate
• Maximum application flexibility offered with 10 Style A & B

different sizes LINOFLAME® Burners
• Provides for partial premixing of air/gas ratios to

Maxon AIRFLO® type burner systems
VFL & VFH

LINOFLAME® Burners
Partial Premix
Burner Systems
‘66’ AIRFLO® Burner
Page 3302

Principle of Operation Air Shutter
VENTITE™ Inspirators provide a low-cost means Spud

Venturi Tube
of supplying air/gas mixture to premix-type gas
burners. Thumb
Gaseous fuel under high pressure is introduced Lock
Screw
(not visible)
through a drilled spud orifice into the venturi throat,
pulling in a proportional amount of combustion air.
The air and gas are mixed and may be used to supply
most premix-type burner nozzles.
Spud is easily replaceable in the field, so different
fuels can be readily accommodated. (Spud orifice Spud Orifice
drilling varies with gas characteristics and available
inlet pressures.)
Air shutter is adjustable to accommodate draft VENTITE™ Inspirator
requirements of installation and includes a thumb lock
screw. A complete VENTITE™ Inspirator system will also
Control can be manual, as by the firing cock; include gas train, burner, throttling equipment, and a
automatic, using a control motor to throttle fuel flow control panel. Your Maxon representative can help
through Maxon’s Series “CV”, “Q”, or Synchro Gas you choose from the broad range available.
Valves; or on/off firing using a solenoid valve. Typical applications include air heaters, grain
dryers, ceramic kilns, incinerators, solution heating,
metal melting, refinery heater/treaters, and many
other direct flame applications.
Flow Aluminum hand torches are specialized alumi-

Control num VENTITE™ Inspirators with a cast iron HD-2-24
STICKTITE™ Nozzle.
Valves These lightweight units (only 9 pounds) are easy to
handle and are totally portable, requiring only flexible
gas and/or air connections.
Series “CV” Valve Application flexibility is provided with six different
options available for high or low gas pressure installa-
tions.
Typical applications include foundry floor mould
drying, ladle drying, core drying, die preheating,
brazing, preheating for welding and ore car thawing
operations.
Series “Q” Valve SYNCHRO Valve
Aluminum Hand Torch
9/90
VENTITE™ Inspirators Page 3303
General To select the appropriate Inspirator/STICKTITE™
Capacity of a burner system incorporating Nozzle combination, determine your expected
VENTITE™ Inspirators is determined by the size, type negative pressure conditions and available gas
and number of burners or nozzles through which it pressure.
fires, and by the field conditions under which it Catalog data extends only to 30 PSIG. Higher
operates. Select from the following capacity/selection pressures are possible, but noise frequently becomes
tables for the combination of mixer, burner and a consideration.
operating conditions of your application. Locate your available gas pressure in the
Even slight variations in combustion chamber appropriate table and scan downward in that column
pressure, draft conditions or the availability of to the fuel and heat release required. Separate data is
secondary air can affect ratings and performance provided for 1000 Btu/ft3 natural gas and 2500 Btu/ft3
drastically. propane.
Designations of VENTITE™ Inspirators are based Identify VENTITE™ Inspirator size and spud
on outlet pipe size. For example: A 1-1/2" orifice drilling by following across the line showing
VENTITE™ Inspirator will discharge the air/gas your desired fuel, pressure and heat release.
mixture through a 1-1/2" standard threaded pipe Select and order the matching “HD”
connection. A specific spud orifice drilling must STICKTITE™ Nozzle from the information given in
always be designated when ordering a VENTITE™ the STICKTITE™ Nozzle catalog section.
Inspirator.
Open-port firing with STICKTITE™ Nozzles

VENTITE™ Inspirators may be used as shown at
right to supply air/gas mixture to STICKTITE™ Burner
Nozzles being fired out in the open, into immersion
tubes, or firing through a chamber wall with the use of
a Maxon tuyere block.
STICKTITE™ Nozzle may be threaded directly
onto VENTITE™ Inspirator outlet or optional 90°
elbow arrangement may be specified as shown at
right. Support clamp is standard on 3" and larger
VENTITE™ Inspirators and available as optional
accessory on 2" and 2-1/2" versions.
Capacities and nozzle sizing information are
provided on pages 3304-3306 for burner systems
utilizing VENTITE™ Inspirators with STICKTITE™
Burner Nozzles. Data is based on the use of a single,
full-sized STICKTITE™ Nozzle threaded directly onto
the outlet of a VENTITE™ Inspirator or arranged for
right-angle firing with a single elbow and close nipple.
Use only the “HD” STICKTITE™ Nozzle size
indicated for each VENTITE™ Inspirator.
Your actual choice of an appropriate VENTITE™
Inspirator and STICKTITE™ Nozzle combination will
be based on combustion chamber back pressure or
draft and the available pressure and heating value of
the fuel gas being used.
9/03
Page 3304 VENTITE™ Inspirators
VENTITE™ Inspirator and STICKTITE™ Nozzle
SCFH natural gas capacities when firing into balanced combustion chamber pressure
(0 to -0.05" wc static pressure) – Under these firing conditions, approximately 80% primary air inspiration is
expected. Do not fire on propane gas with these conditions.
VENTITE™ Inspirator Inspirator's Spud Natural Gas [1] Pressures (PSIG) measured at VENTITE™ Inspirator Inlet
Size Orifice Drill Size
with single STICKTITE™ area of spud orifice in 1
2 3 4 5 6 8 10 12 15 20 25 [2] 30 [2]
Nozzle size square inches Min.
1" #56
24 33 39 45 50 54 62 69 74 83 94 104 114
HD- 1" -9 .00169
1-1/4" #51
39 54 66 76 86 92 105 119 130 143 165 185 200
HD- 1-1/4" -14 .00353
1-1/2" #36
85 118 144 167 183 203 235 267 285 320 370 405 425
HD- 1-1/2" -18 .0089
2" #33
114 157 187 213 237 258 299 335 368 416 490 565 638
HD- 2" -24 .01003
2-1/2" #30
146 200 241 275 304 333 384 430 470 530 620 720 810
HD- 2-1/2" -27 .01297
3" 9/64"
172 238 284 324 360 393 454 508 560 631 743 855 968
HD- 3" -30 .01553
4" 13/64"
360 495 592 673 750 818 945 1060 1170 1317 1550 1780 2020
HD- 4" -41 .03241
5" 17/64"
610 840 1005 1140 1275 1380 1605 1790 1980 2240 2635 3030 3425
HD- 5" -50 .05542
6" 19/64"
765 1055 1260 1435 1590 1740 2005 2250 2500 2800 330 3800 4300
HD- 6" -60 .06922
8" 13/32"
1360 1870 2240 2550 2830 3100 3575 4000 4400 4980 5860 6750 7600
HD- 8" -88 .1296
[1] Gross heating value of natural gas assumed to be 1000 Btu/ft3 and specific gravity 0.60.
[2] Inlet gas pressures above 20 PSIG on a VENTITE™ Inspirator often result in higher noise levels.
Aluminum Hand Torches When ordering, specify spud orifice drilled #33
These are specialized aluminum VENTITE™ Inspira- for natural gas firing or #43 spud orifice for
tors with cast iron HD-2"-24 STICKTITE™ Nozzles and propane gas.
provisions for simple air/gas adjustments.
Three styles are offered (as illustrated at right):
straight type, 45° elbow type, and 90° elbow type.
Each style may also be specified in two (2) versions
(based upon available gas pressure). 90˚ Elbow Type
Low pressure gas version requires 0.2" wc to 8
osi natural gas pressure and a compressed air supply (Low Pressure Gas Version)
at 5-60 PSIG (2-3 SCFM flow) and is rated at Straight Type

210,000-475,000 Btu/hr. High gas pressure version
requires natural gas supply at 5-25 PSIG capacity and
is rated at 250,000-500,000 Btu/hr.
These lightweight units (only 9 pounds) are easy to (High Pressure Gas Version)
handle, requiring only flexible gas and/or air connections
for portability. You need only connect to your gas supply
(and compressed air lines for low pressure versions).
45˚ Elbow Type
Light-off is normally manual in most applications,
without flame supervision.
Note: Tees and elbows may not be
in the orientation shown.
VENTITE™ Inspirator and STICKTITE™ Nozzle
SCFH gas capacities when firing into slightly negative combustion chamber pressure
(-0.05 to -0.15" wc static pressure) – Under these firing conditions, approximately 65% primary air inspiration is expected.
VENTITE™ Gas Pressures (PSIG) measured at VENTITE™ Inspirator Inlet

Inspirator's Spud
Inspirator Size Fuel Gas
Orifice Drill Size
with single Type [1]
area of spud orifice 1
STICKTITE™ (SCFH) 2 3 4 5 6 8 10 12 15 20 25 [2] 30 [2]
in square inches Min.
Nozzle Size
#55
Natural 30 41 49 56 62 67 78 87 95 106 123 140 156
1" .00212
HD- 1" -9 #59
Propane 12 16 20 22 24 27 31 35 38 42 49 56 62
.00132
#46
Natural 59 81 98 112 124 135 156 175 192 215 252 287 320
1-1/4" .00515
HD- 1-1/4" -14 #52
Propane 24 32 39 45 50 54 62 70 77 86 101 115 128
.00317
#31
Natural 122 169 203 232 257 283 327 367 400 450 528 600 660
1-1/2" .01131
HD- 1-1/2" -18 #41
Propane 50 68 81 93 103 113 131 147 160 180 211 240 264
.00724
#27
Natural 188 259 309 352 391 425 493 552 607 687 808 930 1050
2" .01629
HD- 2" -24 #32
Propane 75 104 124 141 156 170 197 221 243 275 323 372 420
.01057
#19
Natural 238 325 393 448 497 542 625 700 770 875 1030 1185 1335
2-1/2" .02164
HD- 2-1/2" -27 #29
Propane 95 130 154 180 199 217 250 280 308 350 412 475 534
.01453
#13
Natural 294 404 484 552 613 669 772 864 955 1075 1265 1450 1650
3" .02688
HD- 3" -30 #25
Propane 118 162 194 221 245 267 310 346 382 430 506 580 660
.01755
17/64"
Natural 605 835 1000 1135 1265 1375 1595 1780 1965 2220 2610 3000 3400
4" .05542
HD- 4" -41 #3
Propane 242 335 400 455 508 550 638 712 790 890 1040 1200 1360
.03563
#Q
Natural 938 1295 1545 1750 1960 2125 2465 2755 3040 3440 4050 4650 5260
5" .08657
HD- 5" 50 17/64"
Propane 375 518 620 700 785 850 985 1100 1215 1375 1620 1860 2100
.05542
3/8"
Natural 1155 1590 1900 2170 2400 2620 3025 3390 3750 4225 4975 5725 6460
6" .11045
HD- 6" -60 #N
Propane 462 636 760 870 960 1050 1210 1330 1500 1690 1990 2300 2580
.07163
17/32"
Natural 2130 2935 3500 4000 4440 4850 5600 6260 6900 7800 9180 10600 11900
8" .2217
HD- 8" -88 27/64"
Propane 850 1170 1400 1600 1780 1940 2240 2500 2760 3120 3670 4240 4760
.1398
[1] Gross heating value of natural gas assumed to be 1000 Btu/ft3 and specific gravity 0.060; propane gas to be 2500 Btu/ft3 with specific
gravity of 1.55
5/03
VENTITE™ Inspirators and STICKTITE™ Nozzle
SCFH capacities when firing into high negative combustion chamber pressure
(-0.15 to -0.3" wc static pressure) – Under these firing conditions, approximately 50% primary air inspiration is expected.
VENTITE™ Gas Pressures (PSIG) measured at VENTITE™ Inspirator Inlet

Inspirator's Spud
Inspirator Size Fuel Gas
Orifice Drill Size
with single Type [1]
area of spud orifice 1
STICKTITE™ (SCFH) 2 3 4 5 6 8 10 12 15 20 25 [2] 30 [2]
in square inches Min.
Nozzle Size
#53
Natural 35 48 58 66 73 80 93 104 115 129 152 175 198
1" .00278
HD- 1" -9 3/64"
Propane 14 19 23 26 29 32 37 42 45 51 61 70 79
.00173
#42
Natural 78 108 129 147 161 178 206 230 254 286 338 388 440
1-1/4" .00687
HD- 1-1/4" -14 #49
Propane 31 43 52 59 64 71 82 92 101 114 135 155 176
.00419
#29
Natural 159 219 262 296 331 362 418 467 516 581 685 790 895
1-1/2" .01453
HD- 1-1/2" -18 7/64"
Propane 64 87 105 118 131 145 168 186 206 233 274 316 358
.0094
11/64"
Natural 262 360 430 490 545 592 686 768 846 958 1125 1295 1465
2" .0232
HD- 2" -24 #29
Propane 105 144 172 196 218 237 274 306 338 383 450 518 586
.01453
#10
Natural 330 450 545 620 690 750 865 970 1070 1220 1440 1650 1860
2-1/2" .02941
HD- 2-1/2" -27 #23
Propane 132 180 217 247 276 300 346 388 428 487 575 660 742
.01863
7/32"
Natural 415 570 683 779 865 945 1090 1220 1350 1520 1790 2050 2325
3" .03758
HD- 3" -30 #17
Propane 166 228 274 311 346 378 436 487 540 608 715 820 930
.02351
5/16"
Natural 850 1175 1400 1600 1775 1935 2240 2500 2760 3120 3670 4225 4785
4" .0767
HD- 4" -41 1/4"
Propane 340 470 560 640 710 770 890 1000 1100 1245 1465 1690 1915
.04909
25/64"
Natural 1265 1745 2085 2365 2640 2875 3325 3720 4100 4640 5465 6275 7100
5" .1198
HD- 5" -50 5/16"
Propane 508 700 830 950 1050 1150 1330 1495 1640 1850 2180 2500 2840
.0767
7/16"
Natural 1540 2125 2540 2900 3215 3500 4050 4530 5000 5650 6650 7650 8625
6" .15033
HD- 6" 60 #S
Propane 615 850 1010 1160 1285 1400 1620 1810 2000 2260 2660 3060 3450
.09511
5/8"
Natural 2900 4000 4760 5440 6050 6600 7625 8520 9400 10625 12500 14400 16250
8" .3068
HD- 8" -88 1/2"
Propane 1160 1600 1910 2170 2420 2640 3050 3410 3760 4250 5000 5760 6600
.19635
[1] Gross heating value of natural gas assumed to be 1000 Btu/ft3 and specific gravity 0.060; propane gas to be 2500 Btu/ft3 with specific
gravity of 1.55
VENTITE™ Inspirator and Series “SN” Sealed Nozzle
Where sealed-port firing is preferred for Capacities and nozzle sizing information are
atmosphere control or energy conservation, provided below and on the following page for burner
VENTITE™ Inspirators may be used to supply air/gas systems utilizing VENTITE™ Inspirators with Sealed
mixture to Series “SN” Sealed Nozzles as shown in Nozzles.
sketch below. The elimination of secondary air reduces To select the appropriate Inspirator/Sealed Nozzle
capacities somewhat from open-port or ribbon-firing combination, determine your expected back pressure
applications, but multiple inspirators and nozzles may conditions and available gas pressure. Catalog data
be used to achieve extends only to 30 PSIG. While higher pressures may
virtually any desired be used, higher noise levels must be expected.
heat input. Do not use Locate your available gas pressure in the
against back appropriate table and scan downward in that column to
pressures exceeding the heat release required. Identify the VENTITE™
0.20" wc or for Inspirator size and spud orifice drilling required by
propane or butane following across the line showing your desired pressure
fuels. and heat release. Select and order a matching SN
Sealed Nozzle from the information given in the
Sealed Nozzle catalog section.
SCFH natural gas capacities when firing against combustion chamber back pressures
(0 to +0.1" wc static pressure)
Inspirator's Spud Natural Gas [1] Pressures (PSIG) measured at VENTITE™ Inspirator inlet
VENTITE™ Inspirator Size
Orifice Drill Size
with single Series "SN" 1
area of spud orifice 2 3 4 5 6 8 10 12 15 20 25 [2] 30 [2]
Sealed Nozzle Burner size Min.
in square inches
1" #61
17 24 28 32 36 39 45 50 54 61 70 78 85
SN- 1" 9 .00113
1-1/4" #53
31 43 52 59 67 72 82 93 102 113 132 149 164
SN- 1-1/4" -14 .00278
1-1/2" #41
69 96 116 13 4 147 162 188 212 229 258 300 335 363
SN- 1-1/2" -18 .00724
2" #37
96 133 158 180 200 218 253 283 311 351 414 477 540
SN- 2" -20 .00849
2-1/2" #32
123 169 203 231 256 280 323 361 398 448 523 605 685
SN- 2" -24 .01057
3" #30
198 205 245 279 310 338 390 437 482 543 641 737 834
SN- 2-1/2" -27 .01297
[1] Gross heating value of natural gas assumed to be 1000 Btu/hr3 and specific gravity to be 0.60.
11/92
VENTITE™ Inspirator and Series “SN” Sealed Nozzle
SCFH natural gas capacities when firing against combustion chamber back pressures
(+0.1 to +0.2" wc static pressure)
Inspirator's Spud Natural Gas [1] Pressures (PSIG) measured at VENTITE™ Inspirator inlet
VENTITE™ Inspirator Size
Orifice Drill Size
with single Series "SN" 1
area of spud orifice 2 3 4 5 6 8 10 12 15 20 25 [2] 30 [2]
Sealed Nozzle Burner size Min.
in square inches
1" #70
10 14 17 19 22 24 27 31 34 38 45 52 59
SN- 1" 9 .00057
1-1/4" #56
23 31 37 42 47 52 59 67 74 83 98 113 128
SN- 1-1/4" -14 .00169
1-1/2" #48
53 74 88 100 111 121 140 156 172 195 230 265 300
SN- 1-1/2" -18 .00454
2" #42
78 108 129 147 163 178 206 230 254 286 338 388 440
SN- 2" -20 .00687
2-1/2" #36
100 137 164 187 208 227 262 292 325 365 425 490 555
SN- 2" -24 .00890
3" #31
124 171 205 233 259 282 325 365 404 455 538 618 700
SN- 2-1/2" -27 .01131
[1] Gross heating value of natural gas assumed to be 1000 Btu/hr3 and specific gravity to be 0.60.
VENTITE™ Inspirators and Style “A” & “B” LINOFLAME® Burners
Where wide distribution of heat is required, feeding two LINOFLAME® Burner assemblies in a still
VENTITE™ Inspirators may be used to supply air/gas air oven heating application. Some secondary air
mixture to LINOFLAME® Burner assemblies. should normally be supplied around the burner, possi-
Heat releases are affected by available gas pres- bly through secondary air ports as shown.
sures, air velocity, percent recirculation, and firing The sketch below shows one possible arrangement
chamber pressure conditions.
Capacities and burner selection information are
provided on pages 3310-3313 for burner systems
utilizing VENTITE™ Inspirators and Style “A” and “B”
LINOFLAME® Burners.
To select the appropriate Inspirator/LINOFLAME®
Burner combination, determine your expected operating
conditions and the available fuel and pressure. Catalog
data extends only to 30 PSIG. Higher pressures are
possible, but higher noise levels will be experienced.
Locate your available gas pressure in the appro-
priate table and scan down that column to the heat
release required, then read across to identify the
necessary VENTITE™ Inspirator size and its spud
orifice drilling for your fuel gas (spud orifice drillings are
of the burner assembly mounted in an airstream to be
shown for 1000 Btu/ft3 natural gas or 2500 Btu/ft3
heated. For heat releases in excess of those in
propane).
capacity tables, multiple VENTITE™ Inspirators may
In the “burner length” section on the right side of the
table, you will find six possible LINOFLAME® Burner be used as shown and the LINOFLAME® Burner
footages and drillings which might be selected. assembly divided into separate sections by division
Identify the footage which best fits your applica- plates.
tion needs then, at the top of that column, read the
indicated LINOFLAME® type and drilling pattern.
Style “A” or “B” LINOFLAME® Burner heat
release must NOT exceed 525,000 Btu/hr per
lineal foot of burner.
Air stream applications require a minimum flow of
fresh make-up air, with the actual amount based on
heat release. Minimum fresh air (SCFM) columns
shown at the right of tables 2, 3 and 4 indicate a range
corresponding to the 5 PSIG through 30 PSIG maxi-
mum capacities. Minimum fresh air requirements for
intermediate pressures may be interpolated.
See “A” & “B” LINOFLAME® Burner catalog section
for additional burner information.
The sketch below shows VENTITE™ Inspirators
9/90
Table 1: LINOFLAME® Burners in still air applications

with VENTITE™ Inspirator located in fresh air and LINOFLAME® Burner subject only to normal convection currents
Capacities (1000's Btu/hr) at indicated Spud Orifice

natural gas pressures (PSIG) Drill Size Style "A" or "B" LINOFLAME® Burner Length
measured at VENTITE™ Inspirator inlet Size Area of spud (feet of indicated type and drillings)
Maximum orifice in
Minimum square inches B-36-4242 B-96-5050 B-96-4444 B-96-3643 A-72-1733 A-72-C33
30 [1] 20 15 10 5
#56
105 86 75 63 46 23 1" 1.5 1 .5 --- --- ---
.00169
#52
185 150 130 108 78 60 1-1/4" 3.25 2.5 1.5 1.25 1 ---
.00317
#38
385 335 290 245 168 85 1-1/2" 5.5 4 2.5 2 1.25 1
.00809
7/64"
575 445 336 305 215 170 2" 9.5 6.5 4.5 3.5 2.5 1.5
.0094
1/8"
730 560 475 38 0 270 215 2-1/2" 12 8.75 5.5 4.25 3 2
.0122
#29
880 675 570 470 330 250 3" 15 10 7 5.25 3.75 2.5
.01453
#10
1850 1410 1200 970 680 475 4" 29 20 13 10 7 4.5
.02941
#F
3100 2400 2050 1630 1170 675 5" 42 30 20 15 10 7
.05187
9/32"
3100 2400 2050 1630 1170 1025 6" 62 44 27 22 15 10
.06213
[1] Inlet gas pressures above 20 PSIG on a VENTITE™ Inspirator often result in high noise levels
For air heating applications

with air stream velocities across burner in the range of
500 to 1500 FPM and return air temperatures not to
exceed 500°F (260°C), if in a recirculating system
Table 2: LINOFLAME® Burners on pressure or suction side of volume air fan

with VENTITE™ Inspirator inside of duct parallel to direction of air flow
Capacities (1000's Btu/hr) at

indicated gas pressures Inspirator's Spud Minimum
(PSIG) Orifice Drill Size Fresh Air
Style "A" or "B" LINOFLAME® Burner Length
measured at VENTITE™ Area of spud Required
(feet of indicated type and drillings)
Inspirator inlet Size orifice in square (SCFM) at
inches indicated duct
Maximum
static pressure
30 Mi n. Natural Propane A-72-C33 conditions
20 15 10 5 B-36-4242 B-96-5050 B-96-4444 B-96-3643 A-72-1733
[1] Gas Gas [2]
#55 #59
142 118 105 87 63 25 1" 1.25 1 --- --- --- --- 63 - 142
.00212 .00132
#49 #53
250 206 179 150 108 65 1-1/4" 3 2.5 1.5 1.25 1 --- 108 - 250
.00419 .00278
#31 #41
530 465 400 335 230 95 1-1/2" 5 4 2.5 2 1.25 1 230 - 530
.01131 .00724
1/8" #39
800 615 480 420 300 175 2" 8.5 6.5 4.5 3.5 2.5 1.5 300 - 800
.01227 .00777
#28 #34
1000 775 660 535 380 200 2-1/2" 10.5 8.75 5.5 4.25 3 2 380 - 1000
.0155 .00968
#22 1/8"
1200 930 790 640 450 275 3" 13 10 7 5.25 3.75 2.5 450 - 1200
.01936 .01227
#1 #14
2550 1950 1650 1325 940 560 4" 24 20 13 10 7 4.5 940 - 2500
.04083 .02602
19/64" #B
4300 3300 2800 2240 1600 725 5" 35 30 20 15 10 7 1600 - 4300
.06922 .04449
#Q 17/64"
5400 4000 3500 2820 2000 1000 6" 50 44 27 22 15 10 2000 - 5400
.08657 .05542
[1] Inlet gas pressures above 20 PSIG on a VENTITE™ Inspirator often result in high noise levels.
[2] Do not use when maximum capacity divided by lineal feet of LINOFLAME® Burner exceeds 525,000 Btu/hr per foot
9/90
Table 3: LINOFLAME® Burners on suction side of volume air fan

(0 to -0.1" wc duct static pressures) with VENTITE™ Inspirator outside of duct in fresh air

Maximum
static pressure
30 Min . Natural Propane A-72-C33 conditions
20 15 10 5 B-36-4242 B-96-5050 B-96-4444 B-96-3643 A-72-1733
[1] Gas Gas [2]
#55 #59
142 118 105 87 63 25 1" 1.25 1 -- - --- --- --- 17 - 35
.00212 .00132
#49 #53
250 206 179 150 108 65 1-1/4" 3 2.5 1.5 1.25 1 --- 30 - 60
.00419 .00278
#31 #41
530 465 400 335 230 95 1-1/2" 5 4 2.5 2 1.25 1 60 - 130
.01131 .00724
1/8" #39
800 615 480 420 300 175 2" 8.5 6.5 4. 5 3.5 2.5 1.5 115 - 320
.01227 .00777
#28 #34
1000 775 660 535 380 200 2-1/2" 10.5 8.75 5.5 4.25 3 2 130 - 320
.0155 .00968
#22 1/8"
1200 930 790 640 450 275 3" 13 10 7 5.25 3.75 2.5 150 - 390
.01936 .01227
#1 #14
2550 1950 1650 1325 940 560 4" 24 20 13 10 7 4.5 260 - 700
.04083 .02602
19/64" #B
4300 3300 2800 2240 1600 725 5" 35 30 20 15 10 7 400 - 1000
.06922 .04449
#Q 17/64"
5400 4000 3500 2820 2000 1000 6" 50 44 27 22 15 10 550 - 1400
.08657 .05542
Table 4: LINOFLAME® Burner on suction side of volume air fan

(-0.11 to -0.5" wc duct static pressures) with VENTITE™ Inspirator outside of duct in fresh air

Maximum
static pressure
30 Mi n. Natural Propane A-72-C33 conditions
20 15 10 5 B-36-4242 B-96-5050 B-96-4444 B-96-3643 A-72-1733
[1] Gas Gas [2]
#53 #56
170 140 125 103 75 34 1" 1.25 1 --- --- --- --- 29 - 63
.00278 .00169
#46 #51
300 250 215 180 130 88 1-1/4" 3 2.5 1.5 1.25 1 --- 52 - 110
.00515 .00353
#29 #36
640 550 480 400 275 130 1-1/2" 5 4 2.5 2 1.25 1 105 - 240
.01453 .0089
#28 7/64"
960 730 620 500 350 235 2" 8.5 6.5 4.5 3.5 2.5 1.5 165-385
.0155 .0094
#23 #31
1200 930 800 650 450 270 2-1/2" 10.5 8.75 5.5 4.25 3 2 200 - 520
.01863 .01131
11/64" #29
1450 1100 950 760 540 375 3" 13 10 7 5.25 3.75 2.5 240 - 640
.0232 .01453
1/4" #8
3000 2300 1950 1600 1150 760 4" 24 20 13 10 7 4.5 470 -1150
.04909 .0311
21/64" #G
5300 3950 3350 2700 1900 1000 5" 35 30 20 15 10 7 700 - 2000
.08456 .0535
#U #L
6400 5000 4200 3350 2400 1350 6" 50 44 27 22 15 10 950 - 2400
.1064 .06605
9/90
VENTITE™ Inspirators and Type “VF” LINOFLAME® Burners
Capacities of Type “VF” LINOFLAME® Burner Increased minimums may be necessary for
assemblies fed by VENTITE™ Inspirators are shown higher air stream velocities.
in the tables below and on page 3315. End bell of VENTITE™ Inspirator must be
To select, identify the appropriate application (still located in fresh air, even though Type “VF”
air or air stream), then check in the column showing LINOFLAME® Burners themselves may be installed in
available fuel supply pressure to locate your desired the recirculating air stream of a pull-through heater.
capacity.
Within that same application section of the tables,
you will also find the minimum capacity, the
VENTITE™ spud orifice drill size, the VENTITE™
Inspirator size and the necessary burner footage.
Table 1: Type “VF” LINOFLAME® Burner in still air applications
Maximum Capacities (1000's Btu/hr) at Minimum Type "VF" LINOFLAME®

VENTITE™ Inspirator's Spud Orifice Drill Size
indicated gas pressures (PSIG) Capacity Burner Length
Inspirator Area of spud orifice in square inches
measured at VENTITE™ Inspirator inlet (1000's (feet of indicated type)
Size
20 15 10 5 Btu/hr) Natural Gas Propane Gas VFL VFH
#70 #74
45 38 31 22 5 1" .5 .25
.00062 .0004
#56 #61
98 83 67 47 45 1-1/4" 1.5 .75
.00169 .0012
#48 1/16"
230 195 156 111 90 1-1/2" 3 1.5
.00454 .00307
#42 #48
338 286 230 163 120 2" 4 2
.00687 .00454
#36 #44
425 365 292 208 150 2-1/2" 5 2.5
.0089 .00581
#31 #40
538 455 365 259 180 6 3
.01131 .00754
3"
#28 #32
680 570 480 360 240 8 4
.0155 .01057
5/32" #31
860 740 585 430 300 10 5
.01917 .01131
4"
#19 #29
1035 880 705 500 360 12 6
.02164 .01453
VENTITE™ Inspirators and Type “VF” LINOFLAME® Burners
For air heating applications with air stream For fresh (non-recirculating) air heating appli-
velocities across burner less than 1500 SFPM for cations, “VF” Burners can be located on pressure or
“VFL” or less than 2000 SFPM for “VFH”, ambient suction side of volume air fan with VENTITE™
and/or return air stream temperatures over the burner Inspirator located inside of duct parallel to direction of
should not exceed 800°F (437°C). Downstream air flow.
temperatures should not exceed 1000°F (538°C) for For recirculating air heating applications, “VF”
recirculating air streams and 1200°F (649°C) for all Burner must be located on suction side of volume air
fresh air applications. fan with VENTITE™ Inspirator located outside of duct
in fresh air.
Table 2: Type “VF” LINOFLAME® Burners for air stream heating applications
with VENTITE™ Inspirator located in fresh air outside of duct while “VF” burner installed in the passing air stream
Maximum Capacities (1000's Btu/hr) at Minimum Type "VF" LINOFLAME®

VENTITE™ Inspirator's Spud Orifice Drill Size
indicated gas pressures (PSIG) Capacity Burner Length
Inspirator Area of spud orifice in square inches
measured at VENTITE™ Inspirator inlet (1000's (feet of indicated type)
Size
20 15 10 5 Btu/hr) Natural Gas Propane Gas VFL VFH
#56 #60
94 83 69 50 15 1" .5 .25
.00169 .00126
#51 #54
165 143 119 86 45 1-1/4" 1.5 .75
.00353 .00238
#36 #44
370 320 270 185 90 1-1/2" 3 1.5
.0089 .00581
#33 #42
490 416 335 237 120 2" 4 2
.01003 .00687
#30 #37
620 530 430 304 150 2-1/2" 5 2.5
.01297 .00849
9/64" #33
743 631 508 360 180 6 3
.01553 .01003
3"
#19 #30
930 800 635 470 240 8 4
.02164 .01297
3/16" #28
1220 1040 850 600 300 10 5
.02761 .0155
4"
13/64" #19
1550 1317 1060 750 360 12 6
.03241 .02164
9/90
VENTITE™ Inspirators and Series “66” AIRFLO® Burners
Air heating applications with Series “66” AIRFLO® Burner

Capacity and burner footage information are Minimum capacity attainable with inspirator
provided below for burner systems utilizing combination is shown in the right side of the table,
VENTITE™ Inspirators and Series “66” AIRFLO® corresponding to various air stream velocities. Table
Burners. Data is based on the use of Type AL5 shows corresponding AL5 Series “66” AIRFLO®
AIRFLO® Burner and a natural gas supply pressure of Burner footage.
4-1/2 PSIG measured at the inspirator’s inlet. Higher Higher air velocities give shorter flame lengths
inlet pressures are not recommended. and result in increased pressure drop across the
The VENTITE™ Inspirator must be mounted burner and profile plate.
directly in the air stream being heated and must feed For additional burner details, see catalog section
directly into a burner back inlet as shown in sketch for Series “66” AIRFLO® Burners.
below.
NOTE: This combination is not suitable for
Typical Piping Layout
make-up air supply heating.
To select the appropriate Inspirator/Series “66”
AIRFLO® Burner combination, determine your
required maximum capacity.
For recirculated process air heating, maximum
capacity is 600,000 Btu/hr per lineal foot. Minimum
capacity is determined by air stream velocity across
the burner, which must be maintained in the range of
2200-3000 SFPM. Fresh make-up air must be added
to the recirculated air stream at the rate of 100 SCFM
per 100,000 Btu/hr heat release (introduced so as to
pass effectively through and over the burner).
Approximate flame lengths shown in the table
vary with air stream velocity and are measured from
discharge end of burner mixing plates (i.e. from
profile).
In the table below, scan downward to the maximum
capacity required for your application, then read to the
left for the required VENTITE™ Inspirator size and
spud orifice drill size.
Table 1: Recirculated Process Air Heating
Inspirator's Spud Orifice Series "66" Type AL-5 Maximum Minimum Capacities (1000's Btu/hr) at
VENTITE™ indicated air stream velocities (SFPM)
Area AIRFLO® Burner length Capacity
Inspirator Size Drill Size
(square inches) (feet) (1000's Btu/hr) 2200 2600 3000
1-1/2" 9/64" .01553 .5 300 45 50 55
2" 13/64" .03241 1 600 90 100 110
9/32" .06213 2 1200 180 200 220
3"
11/32" .09281 3 1800 270 300 330
4" 25/64" .1198 4 2400 360 400 440
Approximate turndown range at indicated velocities 6.7:1 6:1 5.5:1
Approximate flame length at indicated velocities 15" - 18" 12" - 15" 11" - 14"

Standard VENTITE™ Inspirators
1" – 1-1/2" Sizes (with primary air shutter) 1" Size (without primary air shutter)
2" – 2-1/2" Sizes 3" – 8" Sizes
Elbow Type (any size)
Accessories
90° firing arrangements are available to reduce
space requirements by mounting VENTITE™
Inspirator parallel to chamber wall.
Support clamps are included as part of 3" and
larger VENTITE™ Inspirators. They are optional for 2"
and 2-1/2" sizes.
VENTITE™ Inspirator Size D E F (gas) G H J K L N [3] O

2.25 [1]
1" 8.62 9.69 1.06
4.44 [2]
--- 1/2 --- --- --- ---
1-1/4" 10.56 11.69 1.31
4.44
1-1/2" 12.38 13.75 1.5
2" 17.31 12.81 18.88 1.81
3/4 6.5 1.69 1.5 3.62
2-1/2" 19.56 13 .44 21.38 2.12
3" 16.5 13.56 1.88 1.12 2.88 18.56 2.56
1 7.88
4" 18 14.38 2.12 2 3.38 20.75 3.12
5" 2.38 .56 24.38 3.75
21.06 15.94 11.5 2.25 4.75
6" 1-1/2 2.62 25 4.38
8" 28.5 22 15 3.25 .69 3 5 33.88 5.69
[1] Assembly without primar y air shutter. [2] Assembly with primar y air shutter
[3] VENTITE™ Inspirator size is outlet pipe size. Dimension "N" is based on typical thread engagement and may var y.
Pipe threads on this page conform to ANSI Standard B2.1.
9/90

Aluminum Hand Torches
includes aluminum VENTITE™ Inspirator and cast iron HD-2-24 STICKTITE™ Nozzle
Pipe threads on this page conform to ANSI Standard B2.1.

VENTITE™ Inspirators Page 3300-S-1
General Alternate operating modes are illustrated below: for
VENTITE™ Inspirators are only a part of a manual operation, see sketch 2; for on-off
complete combustion system. operation, see sketch 3 (solid lines); for high-low
Sketch 1 below summarizes the additional operation, see sketch 3 (including dotted lines).
components that might typically be part of a complete 1. Electrical service must match the voltage, phase
modulated system. Use this sketch and the following and cycle of all electrical system components.
comments as a check list prior to actual installation. 2. Gas supply piping must be large enough to
maintain required fuel pressures (as high as 30
PSIG depending on application) at the
inspirator’s inlet while burner is operating at full
capacity. Anything more than minimum distance
or piping turns may necessitate “oversizing”
piping runs to keep pressure drops within
acceptable ranges.
3. Clean fuel lines are essential to prevent
blockage of pipe train components and inspirator
Maxon assumes no responsibility for the use or burner gas ports. All dirt, scale and pipe dope
misuse of the piping layouts shown. Specific should be blown out of any new gas line before
piping and wiring diagrams should always be actually connecting to the burner system.
submitted to the appropriate agencies for 4. Main shut-off cock ② should be upstream of both
approval on each application. 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.
5. Main gas regulator ③ is essential to maintain a
leading to each burner system if more than one is
served by a common main. Size regulator for full
system capacity at required pressure, including
pipe train losses. Follow the instructions attached
to the regulator for installation.

mCORPORATION
Page 3300-S-2 VENTITE™ Inspirators
6. Pilot take-off ④ should be upstream of main gas 8. Fuel Control Valve controls burner heat
regulator but downstream of main gas cock. It release by throttling gas flow to it. It should
should normally include its own pilot gas include provision for an adjustable minimum and
regulator, a solenoid valve and a shut-off cock. throttling over a turndown range that matches
An adjustable orifice gas cock at the pilot inlet burner capabilities. In manual systems, it may be
simplifies adjustment. an indicating cock. Maxon Control Valves are not
Suitable pilots should be provided for the type intended for tight shut-off.
of burner and control system being used. 9. Minimize pressure drop between inspirator and
7. Fuel shut-off valve(s) ⑤ (when properly burner(s). Inlet pipe leading to any burner should
connected to a safety control system) are be a straight run of at least four pipe diameters in
designed to shut the fuel supply off when a length. If the VENTITE™ Inspirator is supplying
hazardous operating condition is sensed. Manual multiple burners or multiple inlets to a single
reset valves require operator attendance each burner element, care should be taken so that air/
time the system is started up (or restarted after a gas mixing piping gives minimal pressure drop
trip-out). Motorized shut-off valves permit and maximum uniformity.
automatic start-restart when used with an
Do not install any shut-off device in the air/gas
appropriate control system.
mixture line.
10. Test connections are essential for burner
adjustment. They should be provided
downstream of the main regulator and at each
burner inlet. Test connections must be plugged
except when readings are being taken.
m CORPORATION

VENTITE™ Inspirators Page 3300-S-3
Before proceeding, verify that all equipment has 7. Adjust inspirator air shutter opening (if
been installed in accordance with the general necessary) to obtain desired flame character.
instructions found in the preceding pages. Shutter will normally be wide open if spud orifice
has been correctly sized.
Initial adjustment and light-off should be
8. Cycle system off and re-light several times.
When burner performance is satisfactory and
control/safety circuitry and overall installation.
control valve linkage to control motor.
If Maxon instructions conflict with local codes
Control linkage travel must be such that control
or regulations, contact Maxon before start-up.
valve is moved throughout its complete travel, or
cataloged capacities and turndowns will not be
For initial system start-up: achieved.
1. Disconnect control motor from flow control If less than full-rated burner capacity is
valve (if applicable). Initial start-up should only be required, linkage can be adjusted to limit
accomplished during a “manual” burner control maximum output. With interrupted pilot, it may
mode. be necessary to set control for somewhat higher
2. Purge furnace or oven. Furnace doors, vents than minimum burner setting to permit hold-in of
and flues should all be wide open and the flame detection system without pilot.
purging allowed to continue until all possible
accumulation of explosive vapors is dispersed.
Twenty minutes or more may be necessary on
adjusted so as to cause binding.
large installations.
9. Re-check differential gas pressure with unit at
operating temperature. Refine “high fire” setting if
necessary, considering differential pressure,
3. Bleed air out of gas line leading to main gas flame length, and appearance. Dust or
cock, taking care not to allow accumulation of contaminants in the air stream may affect flame
flammable vapors. appearance.
4. Open main and pilot gas cocks and light pilots 10. Plug all test connections not in use to avoid
following instructions appropriate for the burner dangerous fuel leakage. Replace equipment
and pilot type. If multiple pilots are used, open cover caps and tighten linkage screws.
individual cocks and adjust each in turn. 11. Check out overall system operation by cycling
5. Install manometer to read mixture pressure at through light-off at minimum, interrupting pilot,
burner and to establish required minimum. With and allowing temperature control system to cycle
pilots burning, open fuel shut-off valve(s) and burner from minimum to maximum and return.
advance fuel control valve slowly from minimum Re-check all safety system interlocks for
setting until ignition of main flame occurs. proper setting and operation.
Refine main gas regulator setting, if necessary,
and verify control valve setting which gives
required minimum mixture pressure. Adjust
minimum stop of control valves as needed (if
applicable).
connections.
6. Advance control valve (or indicating firing cock)
manually to high fire position (adjusting if 12. Before system is placed into full service,
necessary), observing burner performance. instruct operator personnel on proper start-up,
operation, and shut-down of system. Establish
CAUTION: If burners go out, close shut-off
valve or shut main gas cock at once. Return to
that every burner nozzle is lit before
m
proceeding.
CORPORATION
Page 3300-S-4 VENTITE™ Inspirators
For Low Pressure Gas Hand Torches
To start-up: To shut-down, close the gas valve first, then the air
1. Open air valve to the desired degree. valve.
2. With an ignition source at the hand torch nozzle, CAUTION: Always observe good judgement
open gas valve until flame is established. and common sense when operating a portable
3. Adjust gas valve for the desired flame with sharp hand torch.
well-defined structure. A flame with long weak
structure indicates a rich mixture and too much
gas. A short light flame with hissing noise
indicates a lean mixture with too little gas.
4. If higher or lower heat release is desired, re-
adjust air valve first, then refine gas valve setting.
The Venturi tube and air shutter of the VENTITE™ Burner nozzles should be regularly inspected for
Inspirator should be kept clean to assure normal possible deterioration and replaced if necessary.
operation. Generally, the higher the operating temperature, the
more frequent the inspections should be.
mCORPORATION

VENTITE™ Inspirators Page 3300-A/P-1
Assembly Numbers
Assembly numbers for standard Standard VENTITE™ Inspirators and Accessories
VENTITE™ Inspirators and accessories
VENTITE™ Inspirator Spare Parts
are shown in table at right. Note that two
versions of the 1" size are shown. Approximate
90° Firing Support
Item No. Size Shipping Wt.
Optional 90° firing arrangement (pounds)
Arrangement Clamp Set
consists of an elbow and nipple in the
1" [1] 3
appropriate size to allow right-angle firing. 23191
Optional support clamp set (2" and 1" [2] Not
5
1.25" 23192 Available
2.5" sizes only) simplifies mounting of the
VENTITE™ Inspirator. 1.5" 6 23193
When ordering VENTITE™ Inspirators, 2" 14 23194
the desired spud orifice drill size must be 21494
VENTITE 2.5" 16 23195
specified. 3" 23196
40
4" 23197
5" 55 23198 Included
configured products: 6" 60 23199
• Tube Size
8" 100 23200
• Thread Type
[1] Without primar y air shutter
• Spud Orifice Size
[2] With air shutter
• 90° Firing Arrangement
• Support Clamp Set
Assembly numbers for standard VENTITE™ and NOZZLE Combinations

VENTITE™ and Nozzle combinations
Item No. Size
are shown at right.
1 VENTITE/NZL 1"
1.25 VENTITE/NZL 1.25"
configured products: 2 VENTITE/NZL 2"
• VENTITE
• Shutter (1" only)
3 VENTITE/NZL 3"
• Elbow
• Nozzle 4 VENTITE/NZL 4"
• Nozzle Support Bracket (1.5" 5 VENTITE/NZL 5"
through 6") 6 VENTITE/NZL 6"
• Support Clamp Set (2" and 2.5") 8 VENTITE/NZL 8"
• Pilot Type
Aluminum hand torch assembly

numbers are shown in table at right. Low Aluminum Hand Torches [1]
gas version requires .2" wc to 8 osi Assembly Numbers
natural gas pressure. High gas version Hand Torch Style Low Gas Pressure High Gas Pressure
requires 5-25 PSIG gas supply. For Version Version
natural gas firing (high gas version only),
Straight 12902 12598
specify “with #33 spud orifice”; for propane
with 40° Elbow 12903 12599
firing (high gas version only), specify “with
#43 spud orifice”. with 90° Elbow 12904 12600
Approximate shipping weight is 10 [1] Includes HD-2-24 STICKTITE™ Nozzle
pounds for any hand torch version.

mCORPORATION
m
CORPORATION

Bulletin 4100
WIDE-RANGE® Gas Burners
3" WIDE-RANGE® Burners: At right, basic burner assembly with UV scanner (supplied by customer), optional pressure pilot
assembly and its spark ignitor. Burner with optional seal and support assembly is shown at left.
• Burns most low-pressure gaseous fuels, including low-Btu waste gases and
hydrogen
• Flame retention at all firing rates with multi-stage stepped-tunnel refractory block design
• Faster bring-up times without temperature override with 40:1 turndown capability
• Maximum application flexibility provided with eight sizes and capacities up to

13,500,000 Btu/hr
• On-ratio firing over a broad range of operating conditions
• Alternate refractory block materials for temperatures up to 3000°F (1649°C) gives

maximum cost effectiveness
Page 4102
WIDE-RANGE® Burners
Principle of Operation Optional refractory block materials are available
Combustion air enters the burner body, surrounds to extend maximum operating temperature limits as
the gas insert nozzle, and exits through the air ports follows:
on the face of the gas insert nozzle. – up to 2800°F (1538°C); or
Low pressure gas enters the gas insert nozzle and – up to 3000°F (1649°C)
is directed out the gas ports (not shown), where it is These higher temperature material options are
intimately mixed with the combustion air in the multi- available at net extra cost and may extend normal
stage burner block tunnel. delivery schedules.
A pilot port tunnel and a flame supervision port Seal and support assemblies reinforce burner
intersect the main burner tunnel directly in front of the blocks in thin wall construction and air heating instal-
nozzle face. At this three-way tunnel intersection, the lations. Their larger area mounting plate and metallic
flame safeguard (flame rod or UV scanner) monitors cylinder surround a heavier round cast block, provid-
the pilot flame and/or main burner fire. ing additional strength and support.
Carbon steel seal and support assembly, when
Material temperature limits used in air heating applications, is suitable for return
Standard burner block material is suitable for temperatures across the burner of up to 600°F
operating temperatures up to 2600°F (1427°C). The (316°C) and/or downstream temperatures of up to
maximum operating temperature limit may be 900°F (482°C).
downrated to 2400°F (1316°C) if the WIDE-RANGE® Stainless steel seal and support assembly
Burner is operating under the following conditions: provides for return air temperatures of up to 1000°F
– burner is installed in a furnace with fiber wall (538°C) and/or downstream temperatures up to
construction 1500°F (816°C).
– frequent cycling inducing thermal shock and
stresses
Typical WIDE-RANGE® Burner construction
11/93
WIDE-RANGE® Gas Burners Page 4103
Capacity ratings of WIDE-RANGE® Burners vary Minimum capacity is more directly a function of
with the combustion air supply pressure and with operating conditions. The minimum capacities shown
operating conditions. below reflect actual main burner flame minimums (i.e.
Maximum capacity is a function of differential air when pilot is interrupted, minimum flame must hold in
and gas pressure supplied to the burner inlets. flame safeguard).
Combustion air blower rating should be at least 2 Natural gas pressure for rated maximum
ounces higher than burner air inlet requirements to capacities should be approximately 5" wc differential
allow for manifolding pressure losses. measured at burner gas inlet (2" wc for propane gas).
WIDE-RANGE® Burner Size > 1.25" 1.5" 2" 2.5" 3" 4" 6" 8"
14 225 450 675 1050 1800 3000 7500 13500
(24) (7 x 35) (9 x 52) (9 x 55) (12 x 65) (13 x 72) (16 x 101) (22 x 130) (30 x 156)
Maximum Capacities 12 210 420 620 1000 1700 2850 7050 12500
(1000's Btu/hr) (21) (7 x 30) (8 x 45) (9 x 47) (11 x 57) (12 x 63) (14 x 87) (21 x 112) (28 x 136)
Inlet 10 190 380 565 930 1600 2650 6600 11500
and
Air (17) (6 x 30) (7 x 40) (8 x 40) (10 x 50) (11 x 60) (13 x 80) (20 x 110) (26 x 125)
Pressures
Approximate Flame Shape 8 170 340 520 850 1450 2450 5900 10200
in ounces
(diameter x length in inches) [1] (14) (6 x 25) (7 x 36) (8 x 36) (10 x 48) (11 x 55) (13 x 73) (19 x 106) (24 x 118)
(in inches)
at various combustion air 6 150 300 450 750 1300 2250 5250 8850
differential pressures (osi) (10) (5 x 20) (7 x 30) (7 x 30) (9 x 41) (10 x 47) (12 x 60) (18 x 92) (20 x 102)
4 120 250 375 640 1100 1950 4400 7250
(7) (4 x 15) (6 x 22) (6 x 22) (7 x 32) (9 x 38) (11 x 43) (17 x 58) (18 x 66)
Minimum Capacity (1000's Btu/hr) 15 25 30 40 60 100 250 340
[1] Flame geometry is in non-airflow condition to atmosphere
Nomenclature
WIDE-RANGE® Burners are designated with a Every WIDE-RANGE® Burner must be ordered
three-part identification code: either with appropriate pressure pilot assembly or
with optional pilot port cover kit. If a pilot assembly
Example: WR F – 1.5"
is not ordered, it is recommended that a pilot port
WR = WIDE-RANGE® Burner cover kit be used to prevent the possibility of flame
F = Arranged for flame supervision by flame rod and/or hot combustion gases escaping through the
or UV scanner burner’s open pilot port tunnel.
All WIDE-RANGE® Burners are drilled and
1.5" = Burner size (also air inlet pipe size)
tapped 3/4" NPT to accept a flame supervision
The type of gas must be specified when order- device. When shipped, the flame supervision port is
ing any WIDE-RANGE® Burner. All nozzle inserts for plugged with a face bushing and a pipe plug. Flame
WRF burners must be specifically drilled to match the rod must be ordered separately or UV scanner
fuel gas to be fired. The WRF Burner will be drilled for supplied by others. Remove the pipe plug and/or the
natural gas unless specified differently on order. face bushing to mount your flame supervision device.
Air inlet arrangement “D” will be furnished (see
page 4106 ) unless specified otherwise.
11/93
Page 4104 WIDE-RANGE® Gas Burners
Accessory Options
Flame Rod
Refractory Block
Cooling Tee
Assembly UV Scanner
(supplied by customer)
Observation
Tee Assembly Pressure Pilot
Hinged Lighter Assembly
Port Cover Seal & Support
Housing
Basic burner with refractory block, optional pressure
3" WIDE-RANGE® Burner with seal and support assembly, pilot and its spark ignitor, and pilot adjustable orifice.
optional hinged lighter port cover, optional observation tee UV scanner (supplied by customer) is mounted in flame
assembly, optional flame rod and cooling tee assembly supervision port of burner.
Every WIDE-RANGE® Burner must be ordered

either with the appropriate pressure pilot or with
the optional pilot port cover.
The basic burner includes a refractory burner block
which has been cast into a cast iron burner frame and
equipped with a flame supervision port. Flame rod may be
ordered separately.
Other versions of the burner include a seal and
support housing of carbon steel (CS) or stainless steel
(SS).
Observation tee assembly (for 3" through 8" burners
only) permits viewing of flame through what would
normally be the gas inlet. Note that the inlet is turned 90°
with this option.
Cooling tee arrangements provide connection for a
purge air supply to UV scanner/flame rod connection.
1.25" through 2.5" WIDE-RANGE® Burners

Basic Burner Burner with Seal & Support Assembly
3" WIDE-RANGE® Burners


Burner Size A B C D E F G H J M O P R S V W X Y
1.25" 2.12 3 7.5 5.0 1-1/4" 3/4" 6.38 8.75 3.75 3.5 4.88 9/32" .88 3.75 11.0 8.06 .12
2.0
1.5" 2.31 1-1/2"
4.5 9.0 7.5 1" 9.0 12.12 5.25 3.75 5.12 5/8" 1.0 5.25 14.5 11.62
2" 2.5 2" 2.38
.19
2.5" 2.94 4.0 9.5 2-1/2" 1-1/4" 3.0
9.0 11.5 13.88 6.0 3.5 6.12 3/4" 1.25 6.25 16.5 13.56
3" 3.31 4.75 9.44 3" 1-1/2" 4.12
4" 4.19 5.56 11.5 11.5 4" 2" 13.5 16.0 7.0 4.56 5.0 6.56 3/4" 1.0 7.75 20.5 17.12 .25
5/96

Burner Size A B C D E F G H J K M O P R S V W X Y
6" 5.94 10.69 10.5 16.38 6" 3" 20.5 --- 9.75 16 6.0 7.19 --- 9/16" --- 9.62 --- 17.12 ---
Air Inlet
Flange Set
(for 8" burners only)
Available Air Inlet Arrangements
WIDE-RANGE® Burners can be shipped in any of the piping
configurations shown. Arrangement “D” is always furnished unless
specified otherwise.
Entire burner may be rotated to suit piping, but positions which would
allow dirt or debris to block flame supervision port should be avoided.
For burners with pilot and flame rod
For burners with hinged lighter port cover set or UV scanner mounting
Arrangement Arrangement Arrangement Standard

"R" "L" "U" Arrangement
"D"

Inlet Flange Gasket

(WR-3", 4", & 6")
Inlet Flange Gasket (WR-3", 4", & 6")

1. Specify parts by the names shown in the sketches above
3. Indicate burner size from numbers cast on side of nozzle
body and/or pipe size of air inlet connection
4. If ordering gas nozzle insert, identify gas or letter code
stamped on gas inlet: “N” or “P”
5. If ordering refractory block sub-assemblies, identify
refractory material code stamped on block frame near
cast Maxon name
5/03
Notes
WIDE-RANGE® Burners Page 4100-S-1

Available Air Inlet Arrangements
WIDE-RANGE® Burners can be shipped in any of Entire burner may be rotated to suit piping but
the piping configurations shown below. Arrangement positions which would allow dirt or debris to block
“D” is always furnished unless specified otherwise. flame supervision port should be avoided.
For burners with pilot and flame

rod or UV scanner mounting For burners with hinged lighter port cover set
To rotate burner body

WIDE-RANGE® Gas Burners can be ordered in any 3. Clean main body of any refractory which remains
of the piping arrangements shown above. If it attached and remove any loose chips from mating
becomes necessary to alter orientation for installation, block surface.
burner main body may be rotated by referring to 4. Prepare a refractory cement mixture (preferably
component identification drawing below, then A.P. Green ’Sairset) mixed to the consistency of
following this procedure: thin peanut butter.
5. Apply a coating of cement to those block surfaces
which will mate with the burner body when it is
reinstalled.
6. Rotate main body to desired position, set in place
and bolt finger-tight.
7. Remove any excess refractory cement that is
forced out between body and burner block.
Observe the alignment illustration on page 4100-
S-2 and reposition body if necessary.
8. Tighten main body firmly into position and clean
throat with a narrow brush to insure smooth path
for air and gas. Replace burner insert and tighten
set screw.
9. Allow reassembled burner to stand at least 48
hours so that refractory cement will set.
Failure to do so may result in a weak bond and
early deterioration.
1. Loosen socket head screw then remove gas
nozzle insert from main body.
2. Unscrew the bolts which fasten main body to
mounting frame, set aside and remove body
(tapping lightly, if necessary to break refractory
cement seal).

mCORPORATION
Page 4100-S-2 WIDE-RANGE® Burners

Block Replacement 9. Tighten main body firmly into position and clean
throat with a narrow wet brush to insure a smooth
If the refractory block of your WIDE-RANGE® path for air and gas. Replace burner insert and
Burner ever requires replacement, Maxon can supply tighten set screw.
replacement block and frame sub-assemblies. To 10. Allow reassembled burner to stand at least 48
replace a burner with Seal and Support Housing, a hours so that refractory cement will set.
complete frame/block/seal and support is available.
Failure to do so may result in a weak bond and
To install a new block and frame assembly: early deterioration.
1. Shut off system and allow to cool. 11. Reinstall burner, following installation instructions.
2. Disconnect piping etc. and remove WIDE- 12. Dry refractory thoroughly by running burner at low
RANGE® Burner from installation. fire for at least 15 minutes.
3. Loosen socket set screw and remove burner 13. Reconnect controls, etc., restoring burner to
insert, then unscrew the bolts which fasten the service following manufacturer’s instructions.
main body to the mounting frame, set aside and
remove body (tapping lightly if necessary to break
bond).
4. Clean all old refractory from main body to insure a
proper seal when reassembling.
5. Prepare a refractory cement mixture (preferably
A.P. Green ’Sairset) mixed to the consistency of
thin peanut butter.
6. Apply a generous coating of the refractory cement
to those surfaces of the new block which will mate
with the burner main body when it is installed.
7. Put main body into position and bolt finger-tight.
8. Remove any excess refractory cement that is
forced out between body and burner block.
Observe the accompanying alignment diagrams
and reposition body if necessary.
Replacement frame/block/seal and support sub-assembly

for WR-3" WIDE-RANGE® Burner
mCORPORATION

with gas-fired WIDE-RANGE® Burners.
and connecting linkage components may be packed Flexible connections are recommended in all piping
separately and shipped loose with your new Maxon to reduce piping stresses and alignment/shifting
WIDE-RANGE® Burner. problems.
WIDE-RANGE® Burners can fire in any direction, The use of a monolithic seal of castable refractory
but the scanner manufacturer may impose limitations. around each WIDE-RANGE® Gas Burner (as shown
Avoid orientations which might permit pilot and/or above) will lessen the chance of shearing off the block
flame supervision ports to collect debris and/or because of unequal expansion of the refractory and
moisture. the furnace shell.
If burner piping arrangement does not meet your Excessive maintenance on the burner blocks and
installation requirements, see page 4100-S-1 for castings is frequently the result of external stresses
available alternatives and rotate burner body (if and strains transmitted to the burner through the
necessary) following instructions provided. piping. On large installations, consider the use of
Include observation ports in your combustion flexible piping connectors to provide “give-and-take” in
chamber design to provide a view of both main and both length and alignment. Installation of such
pilot flame area. Start-up and adjustment procedures connectors at certain key spots in the air or gas
will be greatly simplified. manifolding can prevent damage to the burners from
uneven thermal expansion.
Typical installation diagram of WIDE-RANGE® Burner system
Maxon assumes no responsibility for the use or misuse of the piping layout
shown. Specific piping and wiring diagrams should always be submitted to
m
the appropriate agencies for approval on each application.
CORPORATION
Installation Instructions (continued)

WIDE-RANGE® Burner requires a separate Fuel shut-off valves (when properly connected to
combustion air blower. The nozzle mixing burners a control system) are designed to shut the fuel supply
serve as their own fuel/air mixing device. off with a loss of electrical power. Manual reset
The blower should not be exposed to direct radiant valves require operator attendance each time the
heat or positioned where it might draw in inert gases. system is started up (or restarted after a shut-down).
If problems exist, consider relocation. Motorized shut-off valves permit automatic start-
Electrical service must match the voltage, phase restart when used with an appropriate control system.
and cycle of all electrical system components and be Test connections are essential for burner
compatible with burner nameplate ratings. Insure that adjustment. They should be provided immediately
all normal control safeguards are satisfied. Combus- upstream of the burner and an air test connection is
tion air blower should continue to run after shutdown included in the burner itself. Test connections must
to allow burner to cool. be plugged except when readings are being taken.
Gas supply piping must be large enough to Blower location must deliver a reasonably clean
maintain the required fuel pressures cataloged for the and cool air supply. Care must be taken to keep air
particular burner size used with burner operating at manifold pressure drops to a minimum and to
full-rated capacity. independently support the weight of air piping.
Anything more than minimal distance or piping Gas and air piping should be located reasonably
turns may necessitate “oversizing” piping runs to keep close to the burner and sized for the pressure and
pressure drops within acceptable ranges. volume requirements of the burner, with supply
If multiple burners are fed from a single gas train, pressures high enough to permit subsequent
care should be taken to minimize pressure drop and regulation at each burner. Gas piping drops should
give maximum uniformity. not exceed 10% of initial supply pressure.
Clean fuel lines are essential to prevent blockage Control systems should provide all normally
of pipe train components or burner gas ports. recommended interlocks (including operation of fuel
Main shut-off cock should be upstream of both shut-off valves). Sequencing control systems are
the main gas regulator and pilot line take-off. Use it to available from Maxon that include provision for post-
shut off fuel to both pilot and main burner during shut- purge pilots during all but emergency shut-downs.
down periods of more than a few hours. Control system’s circuitry must not allow main
fuel shut-off valve to be opened unless combustion air
The fuel throttling MICRO-RATIO® Valve with a
is on, and must de-energize valve upon loss of
Maxon WIDE-RANGE® Burner is not intended for
tight shut-off.
Main gas regulator is essential to maintain a with valve, along with a combustion air pressure
uniform system supply pressure. If one pipe train switch.
supplies multiple burners, provide a separate Flame sensing may be accomplished by UV
regulator in the branch leading to each burner system. scanner or flame rod. UV scanner should be kept as
Size the regulator for full system capacity at the close to burner as feasible. Heat block, if used, may
required pressure, carefully considering pipe train affect signal strength with some brands of scanners.
losses. Follow the instructions attached to the Low fire start and interrupted pilot are essential to
regulator during installation. obtain cataloged minimums.
Pilot take-off should be upstream of the main gas Burner and pipe manifold support will be
regulator, but downstream of the main gas cock. It required to support weight of the burner and any
should normally include its own pilot gas regulator, a connected pipe train components. Air control motors,
solenoid valve, and shut-off cock. A pilot adjustable in particular, require additional support. Maxon
orifice at the pilot inlet simplifies adjustment. connecting base and linkage assemblies are
Pilot piping must be large enough to provide for designed to position the control motors to work with
the full flow and pressures shown in the catalog for the control valve, not to support their weight.
your particular burner size. Multi-burner installations require special
considerations if supplied by a common pipe train
and/or air supply. Air and Gas Balancing Valves
may be used for improved heating uniformity.
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Burner Mounting In either case, size the opening in your refractory
wall to give a 3" gap around the burner, then ram with
In a refractory wall, bolt burner directly to the castable refractory such as A.P. Green Kast-Set, B &
furnace shell as shown in Sketch 1 or, if there is no W Kaolin Base Castable or equal, following
shell, use angle irons extended between buckstays as manufacturer’s instructions. Allow sufficient dry-out
shown in Sketch 2. time before firing burner, and cure slowly at start-up.
Sketch 1 Note: Slotted holes in the burner mounting

frame are intended to allow for lateral expan-
sion of furnace. Tighten mounting bolts only
enough to hold the burner in position.
In thin-wall or soft-wall construction, where

burner should be equipped with Seal and Support
Housing, cut an opening 1" larger (diameter) than
Seal and Support. Weld four studs to shell and mount
as shown in Sketch 3, then pack with soft insulation
fiber.
Sketch 3
Sketch 2

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Read complete instructions before proceeding, For initial system start-up:
and familiarize yourself with all the system’s equip- 1. Close all burner fuel valves and/or cocks.
ment components. Verify that your equipment has Make preliminary adjustments to fuel regulators.
been installed in accordance with the original 2. Check all electric circuitry. Verify that all safety
manufacturer’s current instructions. devices and interlocks are operable and function-
CAUTION: Initial adjustment and light-off ing within their respective settings/ranges. Be
should be undertaken only by trained and sure all manifolds are tight and that test ports are
experienced personnel familiar with combus- plugged if not being used.
tion systems, with control/safety circuitry, and 3. Check that all duct and chamber dampers are
with knowledge of the overall installation. properly positioned and locked into operating
Instructions provided by the company and/or positions.
individuals responsible for the manufacture Vent dampers and pressure controllers
and/or overall installation of complete system should be used to maintain balanced or
incorporating Maxon burner take precedence slightly positive furnace pressures (0.0" to
over these provided by Maxon. If Maxon in- 0.05" wc) for maximum efficiency. Excessive
structions conflict with any codes or regula- back pressure can damage furnace and/or reduce
tions, contact Maxon Corporation before burner capacity. Negative pressures allow infiltra-
attempting start-up. tion of secondary air and can seriously affect
NOTE: The following instructions assume use of 4. Start all system-related fans and blowers.
piloted burners and Standard Cam MICRO-RATIO® Check for proper motor rotation and impeller
Valves: direction. Verify that all safety interlocks are
The photograph below shows a MICRO-RATIO® working. Allow air handling equipment to run for
Valve assembly consisting of an air butterfly valve to adequate purge of manifold and combustion
control combustion air flow and an adjustable-gradiant chamber plenums.
SYNCHRO gas flow control valve. The latter is CAUTION: Do not by-pass control panel timers
mechanically linked to the air valve and a series of typically controlling sequential operations.
adjusting screws permits setting of a desired air/fuel
ratio throughout the burner firing range. A pneumatic 5. Initial start-up adjustment should only be
or electric control motor will normally be mounted to accomplished during a “manual” control
this MICRO-RATIO® mode.
Valve assembly and Using a 3/16" allen wrench, disconnect the
establish firing rates in automatic control
accordance with system motor’s linkage from
demands. Maxon MICRO-RATIO®
Control Valve by
Additional data on loosening your control
Maxon MICRO-RATIO® motor’s connecting rod
Valves is provided in from the valve’s toggle
catalog bulletin 7000. linkage.

Disconnect this
ment. Each WIDE-RANGE® Burner includes air test linkage from
connections, but an additional fuel test connection MICRO-RATIO® Valve
should be provided (at minimum) upstream of the
burner.
Do not attempt to use test connections in pipe
elbows or tees, as internal turbulence can give
erroneous readings. Test connections must be
mCORPORATION

Start-Up Instructions (continued)

6. See appropriate catalog dimensional page for 8. Establish the maximum combustion air
test connection locations, then cross-connect a differential pressure by moving MICRO-RATIO®
manometer between burner air test connection Valve assembly toward the higher numbered
and a piece of tubing inserted into the combustion positions until the desired air differential (in
chamber at a point that will reflect chamber accordance with burner specifications) is reached.
pressure. This will provide a direct-reading of Again, mark red air valve dial opposite crank
differential air pressures. pointer.
In similar fashion, cross-connect a manometer
For example: A combustion system may need the
between inlet manifold gas test port and combus-
air valve to only be 15° open for the “minimum”
tion chamber to directly read differential gas
setting and the “maximum” requirements are
pressures.
satisfied with the air valve open to 60°. By marking
General: To achieve rated capacities, a WIDE- these points on the air valve’s indicating strip, you
RANGE® Burner must be adjusted to give the are ready to reconnect the SYNCHRO Fuel Valve’s
specific air and gas differential pressures indicated linkage to the air valve.
on catalog page 4103.
9. Reconnect the SYNCHRO Fuel Valve linkage
7. Set minimum air differential pressure at 0.1" w.c. to the MICRO-RATIO® assembly’s air valve.
With MICRO-RATIO® Valve combinations of air Having marked the MICRO-RATIO® air control
and fuel valves, the minimum differential setting is valve’s settings for both minimum and maximum
initially established with the air valve only. firing positions, you may adjust the linkage and
Disconnect the linkage between the air valve travel of the SYNCHRO gas valve’s stroke (see
and fuel valve(s) on the MICRO-RATIO® Valve sketch below).
assembly.
Loosen to separate air valve
movement from fuel valve(s) travel
Rotate the air valve while watching the

manometer for the minimum air differential Loosen Allen set screw ① and binding screw ②
pressure of 0.1" wc. (Note: This is a very small in toggle ④. Move the toggle in universal cam
increment on a normal manometer. Readings/ assembly slot towards the center of rotation so
settings above 0.1" wc will lessen turndown ratio that gas valve can rotate from its minimum to
of burner system.) Mark red air valve dial (see maximum position, while the air valve swings
sketch below) opposite crank pointer. between the established (and marked) minimum
position and rotate gas valve to its “minimum” set-
ting position. Tighten down set screw ① and binding
screw ② with both valves set at “minimum”.
Establish set screw ① as minimum-end adjust-
ment point and binding screw ② as maximum-end
adjustment point. (Note: It doesn’t matter which is
maximum or minimum, as long as you identify
and keep the same reference points for the next
adjustment steps).

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Now rotate MICRO-RATIO® Valve to “maxi- solenoid. Turn pilot gas adjustable orifice screw
mum” position. The air valve maximum setting out (counter-clockwise) several turns from its fully
was previously determined. Loosen binding screw seated position. Observe ignition of pilot gas
② and adjust pointer and linkage to correct just half through sight port of burner assembly and/or by
of the distance required to make the air valve viewing flame signal metered from flame safe-
pointer indicate the maximum air valve setting. guard relay circuit.
Re-tighten binding screw ② and return the Refine pilot gas setting for a hard blue flame
MICRO-RATIO® Valve to the “minimum” air (and/or strongest flame signal) by adjusting gas
setting. flow through pilot orifice and/or pilot regulator.
This time, loosen set screw ① and again correct Shut off pilot gas cock to extinguish pilot fire.
for just half of the distance required to make the air Reopen and confirm easy re-ignition several
valve pointer indicate the minimum air valve times. The flame safeguard relays should now
setting. power the main fuel shut-off valves.
Re-tighten set screw ① and again return the
Verify all safety interlocks are operational
MICRO-RATIO® Valve to its maximum position.
before opening any main and/or individual
Similarly, correct one half the distance with
burner valves.
binding screw ② for the maximum setting, etc.
Continue this adjustment procedure until 12. To light and adjust WIDE-RANGE® Burner on
the gas and air valves reach their minimum gas: With gas pilot established and flame supervi-
and maximum positions simultaneously. sion system operational, opening the main fuel
Normally, this is accomplished within seven shut-off valve(s) will allow fuel flow to the SYN-
adjustments. CHRO Fuel Control Valve of MICRO-RATIO®
10. To prepare Maxon MICRO-RATIO® Valve for Valve assembly.
initial fuel firing adjustment: 13. Turn minimum adjusting screw in (clockwise)
Remove cover to open gas valve until gas is ignited at burners.
Adj. Screws
plate from screw (under cover) Several turns of the screw may be necessary, but
carrier cam assem- Handle for
flame should normally be confined back in the
bly and turn all Manual burner block at rated minimums.
Operation
adjusting screws Position
NOTE: At this point, it is more important to get any kind
counter-clockwise Indicator of a flame as soon as possible. The flame geometry can
Pointer
until flush with outer be adjusted and refined as needed later.
Locking Screw
surface of casting for manual 14. Adjust main gas regulator (as necessary to
(new equipment is operation maintain required burner differential). Re-adjust
shipped this way). minimum screw if necessary.
If multiple fuel arrangement, adjust linkage If pilots are to be interrupted, shut them off at this
rods and toggle arrangements between SYN- point and verify that main flame remains lit and holds
CHRO Fuel Control Valve(s) so that all fuel in flame detectors. Re-adjust if necessary.
control valves travel together (from minimum to 15. Once your flame is established and refined at
maximum positions). Leave MICRO-RATIO® this position, and without advancing the screw
Valve(s) at “minimum” position, as shown by carrier quadrant higher, screw all remaining
pointer on position indicator strip. screws down to at least the same level as your
11. To light and adjust gas pilot: Check to insure first adjusted screw.
combustion air supply is flowing to burner. Pilot NOTE: A preliminary setting can be established with all
gas regulator should initially be set at approxi- the remaining adjusting screws. Generally, each suc-
mately midpoint of its adjustment range. With pilot ceeding screw needs to be screwed in approximately
gas solenoid closed, open main fuel gas and pilot one full turn deeper than its preceding screw. A smooth
gas cock. Energize spark ignitor and pilot gas “stair-step” gradient pre-set at this point from low to high
will simplify the remaining adjustment steps.
mCORPORATION


16. With allen wrench engaged in second screw, 20. When all screws have been adjusted, recheck
slowly move MICRO-RATIO® Valve to #1 differential pressures with unit at operating
position, adjusting as necessary to maintain temperature. Refine “high fire” setting if neces-
ignition and the type of flame desired. Flame sary, considering differential pressure, flame
length should increase slightly, burning with a length, and appearance.
blue center and yellow tips, and a steady combus- Natural gas flame should be bright blue with
tion noise. very slight yellow tails and the burner will have a
If firing into an uncured refractory chamber, steady combustion noise. Dust or contaminants in
allow system to run at this setting for the the air stream may affect flame appearance.
dryout period recommended by the furnace or 21. If system will operate with interrupted pilot
refractory manufacturer, then continue adjust- (considered good practice), shut pilots off now
ment of the MICRO-RATIO® Valve. and cycle MICRO-RATIO® Valve slowly from
17. Turn all remaining adjustment screws in minimum to maximum and back, with all convec-
slightly further than the second screw, then tion system dampers in operating position or with
with allen wrench inserted in the third screw, furnace door closed.
slowly move MICRO-RATIO® Valve toward #2 22. When burner performance is satisfactory and
position, adjusting as necessary. stable throughout the firing range, reconnect
linkage from control motor to MICRO-RATIO®
Valve.
shut off gas and return MICRO-RATIO® Valve to
23. Check out overall system operation on all fuels
minimum position. Verify that pilots are still
by cycling through light-off at minimum, interrupt-
burning then reopen gas valve and turn screw
ing pilot, and allowing temperature control system
last adjusted in slightly further before returning
to cycle burner from minimum to maximum and
to that firing position. Refine adjustment if
return. Recheck all safety system interlocks for
necessary.
proper setting and operation.
18. Progressively work your way up through each
CAUTION: Test every UV installation for dan-
gerous spark excitation from ignitors, and other
burners, direct or reflected UV radiation.
“maximum” position.
NOTE: To adjust the flame at any position, you must 24. Shut system down, closing all fuel valves and
move the SYNCHRO Valve to the number you desire allowing an approved post-purge period before
to adjust. This aligns the adjusting screw directly on shutting down fans and combustion air blower.
top of the fuel valve plunger. A resulting adjustment of Remove test connections and plug openings, then
the screw is directly applied to the fuel valve plunger replace all equipment covers and caps and
and its interconnected valve body linkage. tighten all linkage set screws.
If high temperature limit trips before adjust- 25. Instruct operator on proper start-up, operation
ment is completed, cycle back to minimum and and shutdown of system. Establish written
hold there until the system cools down before instructions for reference.
attempting further adjustment.
19. Note gas supply pressure while continuing
with adjustment. If it falls off below acceptable
range, it may be necessary to re-adjust the
regulator. If so, lower firing positions will need
rechecked and if necessary, re-adjusted before
proceeding.

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Notes
m
CORPORATION

WIDE-RANGE® Gas Burners Page 4100-A/P-1
Assembly Numbers
WIDE-RANGE® Burner Size > 1.25" 1.5" 2" 2.5" 3" 4" 6" 8"
Configured Item Number > 1.25 WR 1.5 WR 2 WR 2.5 WR 3 WR 4 WR 6 WR 8 WR

Segment Choices
Segment Name Segment Choice Description
(DEFAULT is shaded)
ANSI_THRD ANSI threaded connection
AIR CONNECTION TYPE
ISO_THRD ISO threaded connection
D Down position
L Left position
AIR INLET POSITION
R Right position
U Up position
ANSI_THRD ANSI threaded connection
GAS CONNECTION TYPE
ISO_THRD ISO threaded connection
BUT Nozzle drilled for butane gas
NAT Nozzle drilled for natural gas
FUEL NONE Blank nozzle (customer drilled)
PROP Nozzle drilled for propane gas
600 Nozzle drilled for low Btu (600) gas
NO No pilot chosen
PILOT YES Pilot only chosen
YES_C Pilot with cover chosen
NO Choice not selected
OBSERVATION TEE (3" through 8" only)
YES Choice selected
FR Flame rod
FR_C Flame rod with cover
FLAME DETECTION
NONE No device chosen
UV UV scanner
COOLING TEE
YES Choice selected
2600 2600F maximum block temperature limit
BLOCK MATERIAL 2800 2800F maximum block temperature limit
3000 3000F maximum block temperature limit
CS Carbon steel seal and suppor t
SEAL AND SUPPORT NONE No seal and suppor t
SS Stainless steel seal and suppor t
GROUND ROD (1.25" through 4" only)
YES* Choice selected
* No longer a standard and is available as a SPECIAL only.

m
CORPORATION
Page 4100-A/P-2 WIDE-RANGE® Gas Burners
Assembly Numbers
Spare Parts for WIDE-RANGE® Gas Burners

Burner Size > 1.25" 1.5" 2" 2.5" 3" 4" 6" 8"
Pilot por t cover kit 32376 32377 ---
Pressure pilot assembly 11681 11684 included
Obser vation tee assembly Not available 14724 14725 14726 18380
Flame rod (cut to length L in inches) 59235 59174 59175 18117 18117 59236
L=3.6 L=4.1 L=5.6 L=7.1 L=7.125 L=5.5
Flame rod for cooling tee set 47746 59176 59177 59237 59238
---
(cut to length L in inches) L=7 L=6.4 L=7.9 L=9.4 L=9.8
For UV scanner 30854 32878
Air cooling tee set
For flame rod 27548 27549 ---
Rubber cover for flame rod and/or spark ignitor 18722
Burner block & frame sub-assembly 28853 28859 28861 28863 28865 28871 28873 29045
Burner block & frame sub-assembly with
28973 29013 29017 29021 29025 29037 29041 29211
carbon steel seal & suppor t
Burner block & frame sub-assembly with
28974 29014 29018 29022 29026 29038 29042 29212
stainless steel seal & suppor t
Ignitor 18110 39790
Ignition Wire --- 19300
mCORPORATION

Bulletin 4200
KINEMAX® Gas or Oil Burners
1-1/2" Series G KINEMAX® Burners with spark ignitor, optional pilot gas adjustable orifice, and arranged for UV scanner mounting.
Standard refractory block is shown in background and burner equipped with seal and support assembly in foreground.
• Stir up the heat in your furnace with exit velocities up to 275 ft/sec (185 MPH) to promote
workload heat penetration and better temperature uniformity
• Operate on-ratio, with excess fuel, or with excess air to meet the specific demands of your
combustion process needs
• Burn most clean, low pressure gaseous fuels or #2 light oil with only 8-16 ounce
combustion air pressures
• 48:1 turndown capability promotes faster bring-up times without temperature override
• Maximum application flexibility provided with seven different sizes and capabilities up to
8,400,000 Btu/hr per burner
• Lower fuel consumption by using preheated combustion air up to 800°F (427°C)
• Lightweight refractory-less burner with stainless steel combustion sleeve for air heating
applications
• Alternate refractory block materials for chamber temperatures up to 3000°F (1649°C)
Page 4202
KINEMAX® Burners
Principle of Operation Series G KINEMAX® Burners
for gas only firing
With Series G KINEMAX® Burners,
combustion air enters the burner body and
is swirled out into the burner block (or
sleeve) through the internal air orifice plate.
Low pressure gas enters the burner
body and exits to the block through
machined ports in the gas nozzle.
The gas and air are intimately mixed in
the cast burner block tunnel. The spark
ignitor is positioned to intersect the fuel/air
mixture directly in front of the nozzle face.
Pilot gas is introduced directly behind the
gas ports in the gas nozzle and essentially
flows through to the burner block through
the same ports as does the main gas. The
pilot capacity is the minimum firing rate of
the KINEMAX® Burner.
With Series C KINEMAX® Burners,
combustion air enters the burner body and
is swirled out into the burner block (or Series C KINEMAX® Burners
sleeve) through the air orifice plate. Low for gas/oil firing
pressure gas enters the body and exits to
the block/sleeve through the gas tube and
nozzle.
For light oil firing, the #2 oil enters
through the strainer and oil tube going to the
oil spinner nozzle where the stream of liquid
oil is atomized by the atomizing air directly in
front of the spark ignitor.
Gas for the pilot comes in through a
separate inlet in the gas body and flows
down the gas tube where it spins out the
face of the gas nozzle in front of the spark
ignitor.
KINEMAX® Burners provide a higher velocity set to give a choice between on-ratio and excess air,
stream of hot combustion gases that promote circula- or excess fuel firing. As high as 4700% excess air is
tion within your furnace or lehr, improving both possible at minimum capacity.
temperature uniformity and workload penetration. Maxon catalog bulletin
When used in conjunction with Maxon’s MICRO- 7000 describes MICRO-
RATIO® Control Valves, a KINEMAX® Burner may be RATIO® Control Valves which
adjusted to fire on-ratio throughout the firing range or throttle air and fuel volumes
to the KINEMAX® Burner.
1/95
KINEMAX® Burners Page 4203

Material temperature limits Seal and support assemblies reinforce
burner blocks in thin wall construction, such as fiber
Standard burner block material is suitable for
wall furnaces and air heating installations. Their larger
operating temperatures up to 2600°F (1427°C). The
area mounting plate and metallic cylinder surround a
maximum operating temperature limit may be
heavier round cast block, providing additional strength
downrated to 2400°F (1316°C) if the KINEMAX®
and support.
Burner is operating under the following conditions:
Carbon steel seal and support assembly is
– burner is installed in a furnace with fiber wall
suitable for return air temperatures across the burner
construction
of up to 600°F (316°C) and/or downstream
– frequent cycling is present, inducing thermal shock
temperatures up to 900°F (482°C).
and stresses
Stainless steel seal and support assembly
Optional refractory block materials are available
provides for return air temperatures of up to 1000°F
to extend maximum operating temperature limits as
(538°C) and/or downstream temperatures up to
follows:
1500°F (816°C).
– up to 2800°F (1538°C); or
– up to 3000°F (1649°C) KINEMAX® Burners are available in
These higher temperature material options are three configurations:
delivery schedules. – Standard version with refractory block for
Preheated combustion air up to 800°F (427°C) installation in refractory walls
can be accommodated by standard burner. – Complete with block sleeve to provide additional
block support in chamber walls of softwall
construction
– Complete with stainless steel combustion
sleeve offering lightweight refractory-less burner for
use in air heating applications. Maximum upstream
temperature is 1000°F (538°C) and maximum
downstream temperature for this configuration is
1500°F (816°C).
Typical KINEMAX® Burner Installation
Typical applications include kilns, forge furnaces, A complete KINEMAX® Burner system includes
annealing furnaces, lehrs, and other applications that gas train, air/fuel proportioning equipment, pressure
require heating uniformity and broad ratio control. blower, and a control panel. Your Maxon
range available.
1/95
Page 4204 KINEMAX® Burners
All KINEMAX® Burners can be fired on-ratio, ratio adjustment is required, or if the burner is to be
excess fuel, or with excess air. They include built-in ignited with full excess air.
test port connections for simplified start-up and Performance limits show the maximum excess air
adjustments, spark ignitor and a raw gas nozzle- ratio possible at minimum firing rate.
mixing pilot. Maximum capacity is a function of differential air
Performance data is provided in the tables below pressure supplied to the burner air inlet as read
and on the following page. between air test connection and combustion
Raw gas nozzle-mixing pilot requires natural gas chamber. Combustion air blower rating must be sized
be regulated separately and supplied to the pilot gas to allow for manifolding pressure losses.
inlet connection at 3-4" wc differential gas pressure. Fuel supply differential pressures (read between
Pilot capacity is that which gives reliable light-off with gas test connection and combustion chamber) are
3" wc natural gas pressure and a combustion air shown for both natural gas and propane.
differential pressure of 0.1" wc. To light off with full Flame geometry is also shown in tables. Flame
excess air requires considerably higher gas remains within the KINEMAX® Burner’s refractory
pressures. block at lower firing rates. The flame geometry shown
Minimums are based on an air differential of 0.1" is measured from the end of burner block at
wc and include excess air. Minimums increase if on- maximum rated capacity.
Capacities / Specifications for 1.5" - 6" Series G (gas only) KINEMAX® Burners
Burner Size 1.5" Series G 2" Series G 3" Series G 4" Series G 6" Series G
Performance
Combustion air osi 15 11 7 15 11 7 15 11 7 15 11 7 15
Factors
differential pressure inch wc 26 19 12 26 19 12 26 19 12 26 19 12 26
Maximum 550 470 375 1000 880 700 2400 2000 1600 4000 3400 2700 8000
Maximum with 800°F preheated
355 305 245 650 570 455 1560 1300 1040 2600 2205 1750 5200
combustion air
Capacities On-ratio pilot/minimum 30 40 50 300
(1000's Btu/hr) Pilot/minimum with approximately
20 25 30 200
75% excess air
Turndown ratio with 75% excess
27.5:1 50:1 96:1 133:1 40:1
air
Minimum capacity to light
35 50 100 500
Performance burner (1000's Btu/hr)
Limits with Percent excess air 2600 2200 1800 3900 3400 2700 4700 3900 3100 3900 3300 2600 3900
full excess air Turndown ratio with full excess
16:1 13:1 11:1 29:1 25:1 20:1 48:1 40:1 32:1 40:1 34:1 27:1 16:1
air
Combustion air volume required (SCFM) for
92 79 63 167 147 117 400 334 267 667 567 450 1470
maximum capacity (no excess air)
Differential
gas pressure Natural gas (inches w.c.) 4.2 3.1 2 4.2 3.2 2.1 3.8 2.8 1.8 3.2 2.3 1.5 6.2
required for
maximum Propane gas (inches w.c.) 1.7 1.3 0.8 1.7 1.3 0.8 1.5 1.1 0.7 1.3 0.9 0.6 2.4
capacity
Flame Length (inches) 8 6 4 14 10 8 24 18 12 40 30 24 48
geometry Diameter (inches) 6 5 4 6 5 4 12 10 8 15 12 10 36
Capacities / Specifications for 2" and 6" Series C (gas/oil) KINEMAX® Burners
2" Series C 6" Series C
KINEMAX® Burner
(on #2 oil) (on #2 oil)
Performance Factors osi 15 15
Combustion air differential pressure
inch w.c. 26 26
Btu/hr 1,000,000 8,400,000

Maximum
GPH #2 oil 7.15 60
Btu/hr 62,000 775,000

On-ratio pilot or main minimum [3]
Capacities GPH #2 oil .45 5.5
Pilot or main minimum [3] with Btu/hr 40,000 525,000

approximately 75% excess air GPH #2 oil .3 3.75
Turndown ratio with 75% excess air 28.6:1 16:1
Performance Limits Btu/hr 210,000 840,000

(throttling fuel only) Minimum capacity to light burner
GPH #2 oil 1.5 6
with full excess air Percent excess air [1] 535% 1100%
(full excess air defined as 15 osi differential
pressure measured at the burner) Turndown ratio with full excess air 5.3:1 10:1
Air volume (SCFM) Combustion air @ 15 osi 167 1470

required for maximum capacity Atomizing air @ 15 osi [2] 20 70
Differential fuel supply pressure Natural gas (in inches w.c.) 4.2 6.2
for maximum capacities #2 oil (in PSIG) 10 13
Length (inches) 36 96
Flame Geometry
Diameter (inches 8 24
[1] Excess air based on minimum capacity required for ignition. Slight smoke possible, depending on air temperature and fuel oil quality.
[2] When gas firing on Series C burner, a 1/2" diameter by-pass line is necessar y to keep atomizing air passage purged.
[3] Minimum capacity will be twice rating shown if pilot is not interrupted.
KINEMAX® Burner Designation

All KINEMAX® Burners are drilled and tapped to When ordering a KINEMAX® Burner, the following
accept flame rod or UV scanner. Use flame rod information must be specified:
option only with Series G (gas only) burners. – Burner size (air inlet pipe size)
KINEMAX® Burners are designated by size (air
– Burner series (Series G or Series C)
inlet pipe size) and either Series G (for gas only) or
Series C (for gas/oil firing). – Block or sleeve arrangement
Example: – For flame rod or UV scanner
6" Series C KINEMAX® assembly If burner is to be used with a flame rod, an
with block optional flame rod kit must also be ordered.
11/95
Accessory Options
Refractory Block
Mounting Plate
Test Gasket
Connection
Kit
UV Scanner UV Scanner
(supplied by (supplied by
customer) customer)
Stainless Steel
Adjustable Combustion Sleeve
Orifice
Spark 4" Series G KINEMAX® Burner with stainless steel
Test Connection Alternate Ignitor combustion sleeve, optional mounting plate
Kit UV Scanner Port gasket, and customer’s UV scanner. Optional
mounting plate gasket provides burner/wall sealing
1-1/2" Series G KINEMAX® Burner with standard when special mounting flange is used.
refractory block, spark ignitor assembly, optional
pilot gas adjustable orifice, and two optional test
Combustion Sleeve
connection kits. Optional pilot gas adjustable orifice
simplifies pilot adjustments. Optional test connection Optional Pilot Gas
kits simplify manometer hook-up for air and/or gas Adjustable Orifice
pressure readings during burner start-up and adjust-
ment. They include 1/8" brass hose barb and 1/8" test
cock. Kit must be removed and the test connections
plugged during normal burner operation. Note
alternate UV scanner port located on all KINEMAX® Oil
Tube
Burners.
Gas Check Valves should be Spark

Ignitor
installed in multi-burner jobs as
close as possible to each burner
inlet for dependable light-off
UV Scanner
(gas manifold may otherwise act (supplied by customer)
as a reservoir, preventing light-
off during trial-for-ignition 6" Series C KINEMAX® Burner shown with stain-
period). Valve should be in- less steel combustion sleeve for lightweight,
stalled horizontally or vertically refractory-less burner used in various air heating
with flow in upward direction. Do not applications.
install laying on side.
Air and Gas Balancing Valves

may be used on multi-burner
installations for improved heating
uniformity. Replacement spark ignitor sub-assembly includes
ignitor and rubber cover.

1.5" – 2" Series “G” KINEMAX® Burners
Adjustable Orifice Test Connection Kit

for all burner sizes for all burner sizes
Flame Rod Spark Ignitor
Burner dia. NPT NPT

A B DD G H HH J L M N O P T U
Size D E F
1.5" 4 1-1/2" 3/4"
6.06 2.75 8.62 11 11 8.19 4.12 3.38 3.69 4.12 4.31 8.19 5.5 5.5
2" 4.25 2" 1"
C.S. Std. S.S. Std. S.S. Ext. Stainless Steel

Burner Carbon Steel Sleeve
V W X Y Blk. Blk. Blk. Standard Block Extended Block
Size
CC CC CC Z (min.) Z (max.) Z (min.) Z (max.) Z (min.) Z (max.)
1.5"
11 11.75 5.88 5.12 2.25 7.25 10 2 7.25 2 7.25 3.5 11.5
2"
3/96

3" – 4" Series “G” KINEMAX® Burners
Flame Rod
Spark Ignitor
Burner Dia. NPT NPT

A B DD G H HH J L M N O P R S SS
Size D E F
3" 7.38 3.31 10.12 5.38 3" 1-1/2" 15 14 11.62 5.81 4.19 4.44 3.31 6.38 6.62 6.69 13.38 2.38
4" 8.56 4.06 11 6.85 4" 2" 16 15 12.38 6.19 4.5 4.81 3.62 7 7.19 7.19 14.38 1.75
C.S. S.S. S.S. Carbon Steel Stainless Steel

Burner Std. Blk. Std. Blk. Ext. Blk. Sleeve
TT T U V W X Y Std. Blk. Ext. Blk.
Size
CC CC CC Z (min.) Z (min.) Z (max.) Z (min.) Z (max.)
3" 3.25 7.5 7 14.38 13.25 6.62 5.88
2.25 7.25 10 7 2 7.25 3.5 11.5
4" 2.81 8 7.5 16 14.12 7.06 6.31


2" Series C KINEMAX® Burners
C.S. S.S. S.S. Stainless Steel

Carbon Steel Sleeve
Burner Size Std. Block Std. Block Ext. Block Standard Block Extended Block
CC CC CC Z (min.) Z (max.) Z (min.) Z (max.) Z (min.) Z (max.)
2" - C 2.25 7.25 10.0 7.0 7.25 2.0 7.25 3.5 11.5
Spark Ignitor
Pipe threads on this page conform to NPT

(ANSI Standard B2.1)
5/03

6" KINEMAX® Burners
*Dimension is 16" if refractory block is chosen.
Spark Ignitor Burner arrangement (as shipped) is shown on

dimensional drawing. Gas body (see sketch above)
can be rotated in 60° increments to reposition gas
and pilot inlets plus sight glass. Atomizing air body
(gas/oil burners only) can be rotated in 90° incre-
ments to reposition atomizing air inlet except that inlet
cannot be aligned with gas inlet because of clearance
needs. NOTE: Be sure to remove spark ignitor from
assembly before attempting any repositioning of air or
gas body to avoid cracking ignitor porcelain.
Series G KINEMAX® Burners (gas only)

1. Specify parts by the names shown in the sketches
3. Indicate burner size from numbers cast on side of
nozzle body and/or pipe size of air inlet connection
4. If ordering refractory block sub-assemblies,
identify refractory material code stamped on block
frame near cast Maxon name
Series C KINEMAX® Burners (gas/oil) Nameplate
1/95
Notes
KINEMAX® Burners Page 4200-S-1

Air Inlet Arrangement
KINEMAX® Burners are furnished in standard
position illustrated at right. Since burner block is
round, the entire burner assembly may be installed
and rotated when mounting into combustion chamber
wall. This will permit matching up to field site piping.
Positions which would allow dirt or debris to fall down
and block flame supervision port should be avoided.
Air inlet down is standard
Burner Block Replacement

If the refractory block of your KINEMAX® Burner To install a new block sub-assembly:
ever requires replacement, Maxon can supply 1. Secure heat processing equipment from operation
replacement block and frame sub-assemblies. following manufacturer’s instructions.
When ordering refractory block/frame sub- 2. Disconnect piping, etc. and remove KINEMAX®
assemblies, identify refractory block material code Burner from installation.
stamped on the bolt heads of your existing KINEMAX® 3. Loosen and remove the nuts holding the burner
Burner. body to the burner block.
4. Remove old block assembly and remount new
block assembly. Be sure gasket between block and
body is in place between the components.
Replacement Block & Frame

Sub-Assembly

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Page 4200-S-2 KINEMAX® Burners
with gas-fired KINEMAX® Burners.
and connecting linkage components may be packed
separately and shipped loose with your new Maxon
Burner block and casting failure is frequently the
KINEMAX® Burner.
result of external stresses and strains transmitted to
KINEMAX® Burners can fire in any direction, but
the burner through the piping. Flexible connections
the scanner manufacturer may impose limitations.
are recommended in all piping to reduce piping
Avoid orientations which might permit flame supervi-
stresses and alignment/shifting problems. Installation
sion port to collect debris and/or moisture.
of such connectors at certain key spots in the air or
Include observation ports in your combustion
gas manifolding can prevent damage to the burners
chamber design to provide a view of both main and
from uneven thermal expansion.
pilot flame area. This will simplify start-up and adjust-
ment procedures.
Typical installation diagram of Series “G” KINEMAX® Burner system
Maxon assumes no responsibility for the use or misuse of the piping

layout shown. Specific piping and wiring diagrams should always be
submitted to the appropriate agencies for approval on each application.
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KINEMAX® Burner requires a separate combus- valves require operator attendance each time the
tion air blower. The nozzle mixing burners serve as system is started up (or restarted after a trip-out).
their own fuel/air mixing device. Motorized shut-off valves permit automatic start-
The blower should not be exposed to direct radiant restart when used with an appropriate control system.
heat or positioned where it might draw in inert gases. Blower must deliver a reasonably clean and cool
If problems exist, consider relocation. air supply. Care must be taken to keep air manifold
Electrical service must match the voltage, phase pressure drops to a minimum and to independently
and cycle of all electrical system components and be support the weight of air piping.
compatible with nameplate ratings. Insure that all Gas and air piping should be located reasonably
normal control safeguards are satisfied. Combustion close to the burner and sized for the pressure and
air blower should continue to run after shutdown to volume requirements of the burner, with supply
allow burner to cool. pressures high enough to permit subsequent regula-
Gas supply piping must be large enough to tion at each burner. Gas piping drops should not
maintain the required fuel pressures cataloged for the exceed 10% of initial supply pressure.
particular burner size used with burner operating at Control systems should provide all normally
full-rated capacity. recommended interlocks (including operation of fuel
Anything more than minimal distance or piping shut-off valves).
turns may necessitate “oversizing” piping runs to keep Control system’s circuitry must not allow main
pressure drops within acceptable ranges. fuel shut-off valve to be opened unless combustion air
If multiple burners are fed from a single gas train, is on, and must de-energize valve upon loss of
care should be taken to minimize pressure drop and combustion air pressure, along with the other usual
give maximum uniformity. system interlocks. Motor starter is to be interlocked
Clean fuel lines are essential to prevent blockage with valve, whether or not a combustion air pressure
of pipe train components or burner gas ports. switch is used.
Main shut-off cock should be upstream of both Flame sensing may be accomplished by UV scan-
the main gas regulator and pilot line take-off. Use it to ner or flame rod. UV scanner should be kept as close
shut off fuel to both pilot and main burner during shut- to burner as feasible. Heat block, if used may affect
down periods of more than a few hours. signal strength with some brands of UV scanners. Flame
rod sensing must not be used with oil firing.
Low fire start is essential to obtain cataloged
Maxon KINEMAX® Burner is not intended for tight
minimums.
shut-off.
Burner and pipe manifold support will be
Main gas regulator is essential to maintain a required to support weight of the burner and any
uniform system supply pressure. If one pipe train connected pipe train components. Air control motors,
supplies multiple burners, consider a separate in particular, require additional support. Maxon
regulator in the branch leading to each burner system. connecting base and linkage assemblies are
Size the regulator for full system capacity at the designed to position the control motors to work with
required pressure, carefully considering pipe train the control valve, not to support their weight.
losses. Follow the instructions attached to the regula- Multi-burner installations require special consid-
tor during installation. erations if supplied by a common pipe train and/or air
Pilot take-off should be upstream of the main gas supply. Air and Gas Balancing Valves may be used
regulator, but downstream of the main gas cock. It for improved heating uniformity; Gas Swing Check
should normally include its own pilot gas regulator, a Valves should be installed in horizontal pipe and as
solenoid valve, and shut-off cock. A pilot adjustable close as possible to each burner inlet for dependable
orifice at the pilot inlet simplifies adjustment. light-off (gas manifold may otherwise act as a reser-
Pilot piping must be large enough to provide for voir, preventing light-off during trial-for-ignition pe-
the full flow and pressures shown in the catalog for riod).
your particular burner size. If burners are opposite and firing toward each
Fuel shut-off valves (when properly connected to other, use alternate UV scanner connection on
a control system) are designed to shut the fuel supply KINEMAX® Burner to lessen chance of direct or
off with a loss of electrical power. Manual reset reflected UV radiation.

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Burner Mounting
In a refractory wall (sketch 1), basic burner may be Check visually that no obstructions exist in front of
used with castable refractory rammed into the space the burner, then prepare a shell opening up to 1"
around burner, supported with angle iron and retained larger than burner diameter (2" larger through refrac-
by mastic-coated anchors. The remaining gap should tory part of wall). Attach studs to furnace shell or weld
be packed with ceramic fiber insulation. angle iron from buckstay to buckstay if additional
support is required, checking location carefully for
appropriate burner arrangement.
sion of furnace. Tighten mounting bolts only NOTE: Discharge face of burner should be flush
enough to hold the burner in position. with inner furnace wall for maximum recirculation
effectiveness. Entire burner may be rotated about
In a “soft” wall (sketch 2), burner should be
its centerline to mount in any position.
specified with optional burner block sleeve and
wrapped tightly in fiber blanket. Remaining space Mount burner in position and draw up mounting
should be packed with ceramic fiber insulation. bolts to provide support. Overtightening will prevent
For maximum burner life, burner frame and furnace lateral expansion of the furnace plate and can cause
shell must be protected from hot gas flows. Use high destructive stresses.
temperature gasketing between burner mounting
flange and furnace shell.
1 2
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Gas Firing Start-Up Instructions

ment components. Verify that your equipment has Make preliminary adjustments to regulators.
establish firing rates automatic control motor’s linkage from Maxon
in accordance with MICRO-RATIO® Control
system demands. Valve by loosening your
control motor’s con-
Additional data necting rod from the
on Maxon MICRO- valve’s toggle linkage.
RATIO® Valves is
provided in catalog
bulletin 7000.
Disconnect this
Test connections are essential for burner adjust- linkage from
ment. Each KINEMAX® Burner includes air and fuel MICRO-RATIO® Valve
test connections but additional connections should be
provided (at minimum) downstream of the regulator
and MICRO-RATIO® Valve.
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CORPORATION
Gas Firing Start-Up Instructions (continued)

6. See appropriate catalog dimensional page for Rotate the air valve while watching the
test connection locations, then cross-connect a manometer for the minimum air differential
manometer between burner air test connection pressure of 0.1" wc. (Note: This is a very small
and a piece of tubing inserted into the combustion increment on a normal manometer. Readings/
chamber at a point that will reflect chamber settings above 0.1" wc will lessen turndown ratio
pressure. This will provide a direct-reading of of burner system.) Then mark red air valve dial
differential air pressures. (see sketch below) opposite crank pointer.
In similar fashion, cross-connect a manometer
between burner’s gas test port and combustion
chamber to read differential gas pressures.
8. Establish the maximum combustion air

differential pressure by moving MICRO-RATIO®
Valve assembly toward the higher numbered
positions until the desired air differential (in
accordance with burner specifications) is reached.
Again, mark red air valve dial opposite crank
pointer (refer to Chart 2 on page 4200-S-9).
Maxon offers a “test connection kit” accessory
which provides a convenient means of connecting For example: A combustion system may need the
plastic tubing to the burner test port connections. air valve to only be 15° open for the “minimum”
Kit should be removed after initial start-up and the setting and the “maximum” requirements are
test ports plugged for normal burner operations. satisfied with the air valve open to 60°. By marking
these points on the air valve’s indicating strip, you
General: To achieve rated capacities, a KINEMAX®
are ready to reconnect the SYNCHRO Fuel Valve’s
Burner must be adjusted to give the specific air and
linkage to the air valve.
gas differential pressures as indicated in the charts
shown on pages 4200-S-8 and 9. 9. Reconnect the SYNCHRO Fuel Valve linkage
to the MICRO-RATIO® assembly’s air valve.
7. Set minimum air differential pressure at 0.1" w.c.
Having marked the MICRO-RATIO® air control
With MICRO-RATIO® Valve combinations of air
valve’s settings for both minimum and maximum
and fuel valves, the minimum differential setting is
firing positions, you may adjust the linkage and
initially established with the air valve only.
travel of the SYNCHRO gas valve’s stroke (see
Disconnect the linkage between the air valve
sketch below).
and fuel valve(s) on the MICRO-RATIO® Valve
assembly. Loosen to separate air valve
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Loosen Allen set screw ① and binding screw ② If multiple fuel arrangement, adjust linkage
in toggle ④. Move the toggle in universal cam rods and toggle arrangements between SYN-
assembly slot towards the center of rotation so CHRO Fuel Control Valve(s) so that all fuel
that gas valve can rotate from its minimum to control valves travel together (from minimum to
maximum position, while the air valve swings maximum positions). Leave MICRO-RATIO®
between the established (and marked) minimum Valve(s) at “minimum” position, as shown by
and maximum settings. pointer on position indicator strip.
Place air valve on pre-determined “minimum” 11. To light and adjust gas pilot: Check to insure
position and rotate gas valve to its “minimum” set- combustion air supply is flowing to burner. Pilot
ting position. Tighten down set screw ① and binding gas regulator should initially be set at approxi-
screw ② with both valves set at “minimum”. mately midpoint of its adjustment range. With pilot
Establish set screw ① as minimum-end adjust- gas solenoid closed, open main fuel gas and pilot
ment point and binding screw ② as maximum-end gas cock. Energize spark ignitor and pilot gas
adjustment point. (Note: It doesn’t matter which is solenoid. Turn pilot gas adjustable orifice screw
maximum or minimum, as long as you identify and out (counter-clockwise) several turns from its fully
keep the same reference points for the next seated position. Observe ignition of pilot gas
adjustment steps. through sight port of burner assembly and/or by
Now rotate MICRO-RATIO® Valve to “maximum” viewing flame signal metered from flame safe-
position. The air valve maximum setting was guard relay circuit.
previously determined. Loosen binding screw ② Refine pilot gas setting for a hard blue flame
and adjust pointer and linkage to correct just half (and/or strongest flame signal) by adjusting gas
of the distance required to make the air valve flow through pilot orifice and/or pilot regulator.
pointer indicate the maximum air valve setting. Shut off pilot gas cock to extinguish pilot fire.
Re-tighten binding screw ② and return the Reopen and confirm easy re-ignition several
MICRO-RATIO® Valve to the “minimum” air times. The flame safeguard relays should now
setting. power the main fuel shut-off valves.
This time, loosen set screw ① and again correct
for just half of the distance required to make the air Verify all safety interlocks are operational before
opening any main and/or individual burner valves.
valve pointer indicate the minimum air valve
setting. 12. To light and adjust KINEMAX® Burner on gas:
Re-tighten set screw ① and again return the With gas pilot established and flame supervision
MICRO-RATIO® Valve to its maximum position. system operational, opening the main fuel shut-off
Similarly, correct one half the distance with valve(s) will allow fuel flow to the SYNCHRO Fuel
binding screw ② for the maximum setting, etc. Control Valve of MICRO-RATIO® Valve assembly.
Continue this adjustment procedure until 13. Turn minimum adjusting screw in (clockwise)
the gas and air valves reach their minimum to open gas valve until gas is ignited at burners.
and maximum positions simultaneously. Several turns of the screw may be necessary.
Normally, this is accomplished within seven Flame should normally be confined back in the
adjustments. burner block at rated minimums. (Higher mini-
10. To prepare Maxon MICRO-RATIO® Valve for mums might possibly extend flames beyond
initial fuel firing adjustment: burner block.)
Remove cover NOTE: At this point, it is more important to get any kind
Adj. Screws
plate from screw (under cover)
of a flame as soon as possible. The flame geometry can
carrier cam assem- be adjusted and refined as needed later.
Handle for
bly and turn all Manual 14. Adjust main gas regulator (as necessary to
adjusting screws Operation maintain required burner differential). Re-adjust
Position
counter-clockwise Indicator minimum screw if necessary.
Pointer If pilots are to be interrupted, shut them off at this
until flush with outer
Locking Screw
surface of casting for manual
point and verify that main flame remains lit and holds
(new equipment is operation in flame detectors. Re-adjust if necessary.
shipped this way).

mCORPORATION

15. Once your flame is established and refined at 19. Note gas supply pressure while continuing
this position, and without advancing the screw with adjustment. If it falls off below acceptable
carrier quadrant higher, screw all remaining range, it may be necessary to re-adjust the
screws down to at least the same level as your regulator. If so, lower firing positions will need
first adjusted screw. rechecked and if necessary, re-adjusted before
NOTE: A preliminary setting can be established with all proceeding.
the remaining adjusting screws. Generally, each suc- 20. When all screws have been adjusted, recheck
ceeding screw needs to be screwed in approximately differential pressures with unit at operating
one full turn deeper than its preceding screw. A smooth temperature. Refine “high fire” setting if neces-
“stair-step” gradient pre-set at this point from low to high sary, considering differential pressure, flame
will simplify the remaining adjustment steps. length, and appearance.
16. With allen wrench engaged in second screw, Flame should be blue with yellow tails and a
slowly move MICRO-RATIO® Valve to #1 distinct “wrapping” characteristic, with steady
position, adjusting as necessary to maintain combustion noise. Dust or contaminants in the air
ignition and the type of flame desired. Flame stream may affect flame appearance.
length should increase slightly, burning with a The charts below and on the next page show
blue center and yellow tips, and a steady combus- specific differential gas (Chart 1) and air (Chart 2)
tion noise. pressure readings at various firing rates. This
If firing into an uncured refractory chamber, data may be used to refine your KINEMAX®
allow system to run at this setting for the Burner adjustments.
dryout period recommended by the furnace or
refractory manufacturer, then continue adjust-
ment of the MICRO-RATIO® Valve.
Chart 1
17. Turn all remaining adjustment screws in
slightly further than the second screw, then
with allen wrench inserted in third screw, slowly
move MICRO-RATIO® Valve toward #2 position,
adjusting as necessary.
necessary.
18. Progressively work your way up through each
“maximum” position.
NOTE: To adjust the flame at any position, you must
move the SYNCHRO Valve to the number you desire
to adjust. This aligns the adjusting screw directly on
top of the fuel valve plunger. A resulting adjustment of
the screw is directly applied to the fuel valve plunger
and its interconnected valve body linkage.
If high temperature limit trips before adjust-
ment is completed, cycle back to minimum and
hold there until the system cools down before
attempting further adjustment.
mCORPORATION


Chart 2 21. If system will operate with interrupted pilot
(considered good practice), shut pilots off now
and cycle MICRO-RATIO® Valve slowly from
minimum to maximum and back, with all convec-
tion system dampers in operating position or with
furnace door closed.
Valve.
24. Shut system down, closing all fuel valves and
allowing an approved post-purge period before
shutting down fans and combustion air blower.
Remove test connections and plug openings, then
replace all equipment covers and caps and
tighten all linkage set screws.
25. Instruct operator on proper start-up, operation
and shutdown of system. Establish written
instructions for reference.

mCORPORATION
Light Oil Firing Start-Up Instructions

To light and adjust KINEMAX® NOTE: A preliminary setting can be established with
Burner on light oil: succeeding screw needs to be screwed in approxi-
26. All preliminary adjustments as outlined for gas mately one full turn deeper than its preceding screw.
firing (steps #1 through #25) must have been A smooth “stair-step” gradient pre-set at this point
completed. from low to high will simplify the remaining adjustment
steps.
Verify all safety interlocks are operational before 32. With allen wrench engaged in second screw,
opening any main and/or individual burner fuel slowly move MICRO-RATIO® Valve to #1
valve. position, adjusting as necessary to maintain
27. With gas pilot established and UV flame ignition and the type of flame desired. Flame
supervision system operational, opening the length should increase slightly, with a steady
main oil shut-off valve(s) will allow #2 oil to flow combustion noise.
to the SYNCHRO Oil Control Valve of the Flame appearance should remain yellow-white
MICRO-RATIO® Valve assembly. with no brown tips and exhibit a distinct “wrap-
ping” shape throughout the cataloged firing rate.
CAUTION: Oil flames are highly radiant. Use 33. If firing into an uncured refractory chamber,
eye protection and avoid prolonged viewing. allow system to run at this setting for the dryout
28. Turn MICRO-RATIO® Valve to minimum period recommended by the furnace or refractory
position and, using the allen wrench supplied manufacturer, then continue adjustment of the
with MICRO-RATIO® Valve, turn minimum MICRO-RATIO® Valve.
adjusting screw of oil valve in (clockwise) to 34. Turn all remaining adjustment screws in
permit oil flow to the burner(s). Continue turning slightly further than second, then with allen
inward slowly until minimum oil fire ignites. wrench inserted in the third screw, slowly move
MICRO-RATIO® Valve toward #2 position,
CAUTION: Shut off oil quickly if there is a adjusting as necessary.
noticeable drop in oil pressure or if ignition
does not occur within a few seconds. CAUTION: If flame is extinguished, immediately
shut off oil and return MICRO-RATIO® Valve to
29. Check that pressure downstream of oil minimum position. Verify that pilots are still
pressure regulator is sufficient to meet burner burning then reopen oil valve and turn screw
requirement plus piping losses. Readjust oil last adjusted in slightly further before returning
pressure regulator if necessary. to that firing position. Refine adjustment if
Failure of “some” burners on a multiple burner necessary.
job to ignite would generally indicate line scale or
dirt obstructions in the oil valve, oil tube and/or oil 35. Progressively work your way up through each
tip. Disassemble, inspect and clean if necessary. adjusting screw position, developing a smooth
30. Once ignition occurs, turn minimum screw in progression slope from your first screw to the
(for more fuel) or out (for less) until a yellow- “maximum” position.
white flame is produced without smoke or brown NOTE: To adjust the flame at any position, you must
tips. When properly adjusted, it should be move the SYNCHRO Valve to the number you desire
possible now to shut off pilots with the flame to adjust. This aligns the adjusting screw directly on
detection system (if used), holding in on main top of the fuel valve plunger. A resulting adjustment of
flame only. the screw is directly applied to the fuel valve plunger
31. Once your flame is established and refined at and its interconnected valve body linkage.
this position, and without advancing the screw If high temperature limit trips before adjust-
carrier quadrant higher, screw all remaining ment is completed, cycle back to minimum and
screws down to at least the same level as your hold there until the system cools down before
first adjusted screw. attempting further adjustment.
m CORPORATION

Light Oil Firing Start-Up Instructions (continued)

36. Note oil supply pressure while continuing 39. When burner performance is satisfactory and
with adjustment. If it falls off below acceptable stable throughout the firing range, reconnect
range, it may be necessary to readjust the linkage from control motor to MICRO-RATIO®
regulator. If so, lower firing positions will need Valve.
rechecked and if necessary, readjusted before 40. Check out overall system operation on all
proceeding. fuels by cycling through light-off at minimum,
37. When all screws have been adjusted, allow interrupting pilot, and allowing temperature
system to reach operating temperature then control system to cycle burner from minimum to
recheck minimum and maximum differential air maximum and return. Recheck all safety system
pressures. Readjust linkage between air and fuel interlocks for proper setting and operation.
valves if necessary. If any change is made, refine
gas adjusting screw settings, always adjusting
only that screw corresponding to the position at
which valve is then set.
When adjusting for firing at maximum posi- 41. Shut system down, closing all fuel valves and
tions, take care that adjusting screws slope allowing an approved post-purge period before
gradually toward that setting. shutting down fans and combustion air blower.
38. If system will operate with interrupted pilot Remove test connections and plug openings,
(as recommended), shut pilots off now and cycle then replace all equipment covers and caps and
MICRO-RATIO® Valve slowly from minimum to tighten all linkage set screws.
maximum and back, with all convection system 42. Instruct operator on proper start-up, operation
dampers in operating position or with furnace and shutdown of system. Establish written
door closed. instructions for reference.

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CORPORATION
Notes
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CORPORATION

KINEMAX® Burners Page 4200-A/P-1
Assembly Numbers
For these products, please order the following product numbers:
KINEMAX® Burners Series G Gas Only Series C Gas/Oil
Complete 1.5" 2" 3" 4" 6" 2" 6"
Burner
Assemblies [1] 1.5 KM 2 KM 3 KM 4 KM 6 KM 2C KM 6C KM
[1] Refer to Product Data Sheet 9000-1 & 2 for alternate materials at net extra charge

• Combustion Air Inlet Flange • Mounting Ring Gasket
• Air Connection Type • Test Connection Kit (Combustion Air)
• Gas Connection Type • Test Connection Kit (Fuel)
• Pilot Orifice • Orifice Plate (3" & 4" gas only)
• Flame Detection • Oil Tip Connection (2" gas/oil only)
• Block Material • Atomizing Air Connection (6" gas/oil only)
• Block Length • Nozzle Body Flange Gasket
• Seal and Support
• Mounting Ring
Spare Parts and Accessories for KINEMAX® Burners

Series G Gas Only Series C Gas/Oil
KINEMAX® BURNERS
1.5" 2" 3" 4" 6" 2" 6"
Flame rod kit
includes ground rod and flame 51427 51428 51429 51430 --- --- ---
rod sub-assembly (A)
Nozzle body flange gasket
35643 35644 35645 37037 35643 37037
(between wall & burner flange)
Mounting plate (used with
combustion sleeve and block 34237 34238 34239 --- 34237 ---
only) [2]
Mounting plate gasket for
34391 34392 34393 --- 34391 ---
above
125# threaded flange set
--- 53677 --- 53677
(6" burners only)
1/8" test connection kit 34137
Gas swing check valve* 35618 (3/4") 35619 (1") 35620 (1-1/2") 35621 (2") 38968 35619 (1") 38968
(size) Cv flow Cv = 21.1 Cv = 34 Cv = 67 Cv = 80 (3") Cv = 34 (3")
Series "BV" 19122 (1-1/2") 19123 (2") 19125 (3") 19123 (2")
For air --- --- ---
Balancing Cv = 80 Cv = 138 Cv = 265 Cv = 138
Valves* 19119 (3/4") 19120 (1") 19122 (1-1/2") 19123 (2") 19120 (1")
(size) Cv flow For gas --- ---
Cv = 11 Cv = 18 Cv = 80 Cv = 138 Cv = 18
Pilot gas adjustable orifice 50431
[2] Specify dimension Z location for welding
*Must be ordered as loose items.

mCORPORATION
Page 4200-A/P-2 KINEMAX® Burners
Assembly Numbers
Series G Gas Only Series C Gas/Oil
KINEMAX® Burners
1.5" 2" 3" 4" 6" 2" 6"
Replacement flame rod
51423 51425 51426 --- --- ---
assembly with rubber cover
Replacement & Spark ignitor sub-assembly 34042 39782 37160
Spare Parts with rubber cover
Rubber cover (R) 18722
Observation glass (R) 19284
Standard block 35000 35002 35004 35006 37034 50104 37034
Extended block 35904 35905 35906 35907 --- 50138 ---
Rated for Standard block & C.S.
35956 35959 35962 35965 --- 50139 ---
2600°F combustion sleeve
maximum Standard block & S.S.
35957 35960 35963 35966 37058 50140 37058
combustion sleeve
Extended block & S.S.
35958 35961 35964 35967 --- 50141 ---
combustion sleeve
Standard block 1037288 1037342 1037371 1037386 1037464 1037356 1037464
Extended block 1037290 1037344 1037373 1037388 --- 1037358 ---
Replacement Rated for Standard block & C.S.
1037292 1037346 1037375 1037390 --- 1037360 ---
Burner Block 2800°F combustion sleeve
Sub- maximum Standard block & S.S.
Assemblies 1037294 1037348 1037377 1037392 1037466 1037362 1037466
combustion sleeve
1037296 1037350 1037379 1037394 --- 1037364 ---
combustion sleeve
Standard block 1037289 1037343 1037372 1037387 1037465 1037357 1037465
Extended block 1037291 1037345 1037374 1037389 --- 1037359 ---
Rated for Standard block & C.S.
1037293 1037347 1037376 1037391 --- 1037361 ---
3000°F combustion sleeve
maximum Standard block & S.S.
1037295 1037349 1037378 1037393 1037467 1037363 1037467
combustion sleeve
1037297 1037351 1037381 1037395 --- 1037365 ---
combustion sleeve
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Bulletin 4300
RAMFIRE® Burners
1-1/2" RAMFIRE® Burners: At right, burner assembly with UV scanner (supplied by customer), spark ignitor and optional
mounting plate. Basic burner with standard refractory block and seal and support assembly is shown at left.
• Improve your furnace temperature uniformity and work penetration with rapid circulation
from RAMFIRE® Burner’s high exit velocities, up to 550 ft/sec (375 MPH)
• Increase furnace loading and reduce flame impingement potential with RAMFIRE® Burner’s
short flame length. Let the high velocity stream of hot combustion gases stir-up your furnace’s heat.
• Maintenance and/or field inspection is simple with burner’s removable backplate, giving direct and
easy access to the gas nozzle and refractory block
• 20:1 turndown capability promotes faster bring-up times without temperature override
• Operate “on-ratio” or with “excess air” to meet specific demands of your process requirements
• Clean burning with natural or propane gases to produce lower NOX levels
• Requires low pressure combustion air for heat releases up to 800,000 Btu/hr in two popular sizes
for maximum cost effectiveness
Page 4302
RAMFIRE® Burners
Combustion air enters the burner
body and is swirled out into the burner
block through the air orifice plate. Gas
enters the burner body and exits to the
block through ports in the gas nozzle.
Gas and air are mixed on the face of
the nozzle directly in front of the spark
ignitor where it is ignited.
The pilot gas is introduced through
the side of the burner body and into the
gas nozzle.
The ignited gas/air flame front passes
down the refractory block tunnel to exit
through its reduced area discharge. This
helps to develop the short flame length
extending from the block and promotes
the very high exit velocities characteris-
tic of the RAMFIRE® Burner.
Each RAMFIRE® Burner includes a seal and Material temperature limits
support housing to insure block integrity, spark
ignitor, a sight glass, and four test connections to Standard burner block material is suitable for
simplify start-up and adjustment. operating temperatures up to 2200°F (1204°C). The
When used in conjunction with Maxon’s MICRO- maximum operating temperature limit may be
RATIO® Control Valves, a RAMFIRE® Burner may be downrated if the RAMFIRE® Burner is operating under
adjusted throughout the firing range to fire “on-ratio” the following conditions:
or with “excess air”. As high as 2100% excess air is – burner is installed in a furnace with fiber wall
possible at minimum capacity. construction
Maxon catalog bulletin – frequent cycling is present, inducing thermal shock
7000 describes MICRO- and stresses
RATIO® Control Valves which Seal and support assemblies reinforce burner
throttle air and gas volumes blocks in thin soft wall construction.
to the RAMFIRE® Burner. Carbon steel seal and support assembly is
Typical applications include suitable for chamber temperatures of up to 900°F
kilns, forge furnaces, annealing (482°C).
furnaces, lehrs, and other applications that require Stainless steel seal and support assembly
heating uniformity. provides for chamber temperatures up to 1500°F
Provision is made for a UV scanner to monitor both (816°C).
built-in raw gas pilot and main flame. Direct spark
ignition of burner is possible if sequencing incorpo-
rates low-fire start.
4/91
RAMFIRE® Burners Page 4303
All RAMFIRE® Burners can be fired “on-ratio” or Maximum capacity is a function of differential air
with “excess air”. They include built-in test port pressure to the burner air inlet connections as read
connections for simplified start-up and adjustments, a between A1 test connection and combustion chamber.
spark ignitor and a gas pilot. Combustion air must be available at 15 osi at the
Performance data is provided in table below. burner inlet. Combustion air blower rating should be
Gas pilot requires separately regulated natural gas at least 2 ounces higher than burner air inlet require-
differential pressure of 5-6" wc to the inlet of (optional) ments to allow for manifolding pressure losses.
pilot gas adjustable orifice. Combustion air flows show two figures: the first is
Cataloged minimums require an air differential of the flow (in SCFM) required at maximum rated
0.1" wc for 1-1/2" burner size and 0.2" wc for 2" capacity. The second set of numbers, denoted “for
burners. This translates to 35% excess air for the sizing”, indicates the actual flow rate that will be
1-1/2" burner and 75% for the 2" at rated minimum. If encountered in starting up a “cold” burner. If combus-
on-ratio minimum is required, output will be consider- tion blower is to be used to purge combustion cham-
ably higher. ber, blower must be sized for the larger air volumes to
Performance limits show the maximum “excess prevent possible blower motor overloading. The lower
air” ratio possible at minimum firing rate. figure at maximum rated capacity is the result of back
Fuel supply differential pressures (read between pressure developed within the burner while firing.
G1 test connection and combustion chamber) are Flame geometry is also shown in the table below.
shown for natural gas. To achieve cataloged maxi- Flame remains within the burner’s refractory block at
mum, natural gas must be supplied at 10 osi (18" wc) most firing rates. The flame length shown is mea-
at the burner inlet. sured from the end of burner block at maximum rated
capacity. The diameter shown is the greatest that may
be expected over entire capacity range.
Series "G" RAMFIRE® Burner Size 1.5" 2"

measured between burner inlet and 26 inches w.c.
Required combustion air chamber static condition (15 osi)
differential pressures
for maximum capacities measured across burner air test 12 inches w.c.
Performance Factors connections A1 and A2 (6.9 osi)
measured between burner inlet and 18 inches w.c.
Required natural gas chamber static condition (10.4 osi)
differential pressure
for maximum capacity measured across burner gas test 9 inches w.c.
connections G1 and G2 (5.2 osi)
Maximum 400,000 800,000
Capacities "On-ratio" pilot / minimum 40,000 120,000
(Btu/hr) 20,000 50,000
Pilot / minimum with (percent) excess air
(35%) (75%)
Minimum capacity to light burner (Btu/hr) 20,000 50,000
Performance limits with
(maximum 15 osi) Percent excess air 2100% 1660%
combustion air Turndown ratio 20:1 16:1
Combustion air volume [1] SCFM required for maximum capacity 67 134
required for maximum capacity SCFM required for blower sizing 80 160
Length (inches) 14" 20"
Flame geometry
Diameter (inches) 2" 3"
[1] Note explanation at top of page regarding "combustion air flows"
9/93
Page 4304 RAMFIRE® Burners
Accessory Options
The photo below shows a RAMFIRE® Burner pressure readings during burner start-up and
with seal and support assembly, standard refrac- adjustment. Each kit includes 1/8" brass hose barb
tory block and spark ignitor assembly. Standard and 1/8" test cock. Kit must be removed and the
air inlet position is shown. test connections plugged during normal burner
Standard refractory material permits operation at operation.
firing chamber temperatures of up to 2200°F • Optional pilot gas adjustable orifice to simplify
(1204°C). pilot adjustments
The following accessories are also shown: • Optional mounting plate and gasket. Mounting
• Optional test connection kit. Test connection kit plates and gaskets attach to furnace or kiln wall and
simplifies manometer hook-up for air and/or gas provide desired location relative to inner wall face.
Refractory Block
Mounting Plate
(optional)
Pilot Gas
Adjustable Orifice
Spark
Ignitor
Test Connection Kit

UV Scanner (optional)
(supplied by customer)
Gas check valves should be

horizontally installed in multi-
burner applications as close as
Spark ignitors are used to ignite pilot or for direct possible to each burner inlet for
burner light-off. dependable light-off (gas mani-
fold may otherwise act as a
A complete Series “G” RAMFIRE® Burner system reservoir, preventing light-off
will also include gas train, air/fuel proportioning during trial-for-ignition period).
equipment, pressure blower, and a combustion
control panel. Your Maxon representative can help Air and gas balancing valves
you choose from the broad range available. may be used on multi-burner
installations for improved heating
uniformity.
RAMFIRE® Burners Page 4305
10/92
Page 4306 RAMFIRE® Burners
To order replacement parts: Nameplate

1. Specify parts by the names shown in the sketch
above
3. Indicate burner size from numbers cast on side of
refractory material code stamped on block frame
bolt heads
RAMFIRE® Burners Page 4300-S-1

RAMFIRE® Burners are furnished in standard
and/or rotated when mounting into combustion
chamber wall. This will permit matching up to field site
piping. Positions which would allow dirt or debris to
fall down and block flame supervision port should be
avoided.
Air inlet down is standard

If the refractory block of your RAMFIRE® Burner To install a new block sub-assembly:
ever requires replacement, Maxon can supply re- 1. Secure heat processing equipment from operation
placement block and frame sub-assemblies. following manufacturer’s instructions.
When ordering refractory block/frame sub-assem- 2. Disconnect piping, etc. and remove RAMFIRE®
blies, identify refractory block material code stamped Burner from installation.
on the bolt heads of your existing RAMFIRE® Burner. 3. Loosen and remove the nuts holding the burner
body to the burner block.
4. Remove old block assembly and remount new
block assembly. Be sure gasket between block and
body is in place between the components.
5. Secure the block to the body by retightening the
nuts onto the block studs.
6. Re-install burner, following installation instructions.

Sub-Assembly

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Page 4300-S-2 RAMFIRE® Burners
with RAMFIRE® Burners.
pipe trains, spark ignitor, mounting gaskets, and
connecting linkage components may be packed
separately and shipped loose with your new Maxon Burner block and casting failure is frequently the
RAMFIRE® Burner. result of external stresses and strains transmitted to
RAMFIRE® Burners can fire in any direction, but the burner through the piping. Flexible connections
the scanner manufacturer may impose limitations. are recommended in all piping to reduce piping
Avoid orientations which might permit flame supervi- stresses and alignment/shifting problems. Installation
sion ports to collect debris and/or moisture. of such connectors at certain key spots in the air or
Include observation ports in your combustion gas manifolding can prevent damage to the burners
chamber design to provide a view of both main and from uneven thermal expansion.
pilot flame area. This will simplify start-up and adjust- Gas check valves should be horizontally installed
ment procedures. in multi-burner applications as close as possible to
each burner inlet for dependable light-off. (Gas
light-off during trial-for-ignition period.)
Typical installation diagram of RAMFIRE® Burner system

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RAMFIRE® Burner requires a separate combus- Motorized shut-off valves permit automatic start-
tion air blower. The nozzle mixing burners serve as restart when used with an appropriate control system.
their own fuel/air mixing device. Test connections are essential for burner adjust-
The blower should not be exposed to direct radiant ment. They should be provided immediately upstream
heat or positioned where it might draw in inert gases. of the burner and are included in the burner itself.
If problems exist, consider relocation. Test connections must be plugged except when
Electrical service must match the voltage, phase readings are being taken.
and cycle of all electrical system components and be Blower location must deliver a reasonably clean
compatible with burner nameplate ratings. Insure that and cool air supply. Care must be taken to keep air
all normal control safeguards are satisfied. Combus- manifold pressure drops to a minimum and to inde-
tion air blower should continue to run after shutdown pendently support the weight of air piping.
to allow burner to cool. Gas and air piping should be located reasonably
Gas supply piping must be large enough to close to the burner and sized for the pressure and
maintain the required fuel pressures cataloged for the volume requirements of the burner, with supply
particular burner size used with burner operating at pressures high enough to permit subsequent regula-
full-rated capacity. tion at each burner. Gas piping drops should not
Anything more than minimal distance or piping exceed 10% of initial supply pressure.
turns may necessitate oversizing piping runs to keep Control systems should provide all normally
pressure drops within acceptable ranges. recommended interlocks (including operation of fuel
If multiple burners are fed from a single gas train, shut-off valves). Sequencing control systems are
care should be taken to minimize pressure drop and available from Maxon that include provision for post-
give maximum uniformity. purge pilots during all but emergency shut-downs.
Clean fuel lines are essential to prevent blockage Control system’s circuitry must not allow main
of pipe train components or burner gas ports. fuel shut-off valve to be opened unless combustion air
Main shut-off cock should be upstream of both is on, and must de-energize valve upon loss of
the main gas regulator and pilot line take-off. Use it to combustion air pressure, along with the other usual
shut off fuel to both pilot and main burner during shut- system interlocks. Motor starter is to be interlocked
down periods of more than a few hours. with valve, along with a combustion air pressure
switch.
Flame sensing is accomplished by UV scanner.
Maxon RAMFIRE® Burner is not intended for tight
UV scanner should be kept as close to burner as
shut-off.
feasible. Heat block, if used, may affect signal
Main gas regulator is essential to maintain a strength with some brands of scanners.
uniform system supply pressure. If one pipe train Low fire start and interrupted pilot are essential to
supplies multiple burners, provide a separate regula- obtain cataloged minimums.
tor in the branch leading to each burner system. Burner and pipe manifold support will be re-
Size the regulator for full system capacity at the quired to support weight of the burner and any
required pressure, carefully considering pipe train connected pipe train components. Air control motors,
losses. Follow the instructions attached to the regula- in particular, require additional support. Maxon
tor during installation. connecting base and linkage assemblies are de-
Pilot take-off should be upstream of the main gas signed to position the control motors to work with the
regulator, but downstream of the main gas cock. It control valve, not to support their weight.
should normally include its own pilot gas regulator, a Multi-burner installations require special consid-
solenoid valve, and shut-off cock. A pilot adjustable erations if supplied by a common pipe train and/or air
orifice at the pilot inlet simplifies adjustment. supply. Air and Gas Balancing Valves should be
Pilot piping must be large enough to provide for used for improved heating uniformity; Gas Swing
the full flow and pressures shown in the catalog for Check Valves may be installed in horizontal pipe and
your particular burner size. as close as possible to each burner inlet for depend-
Fuel shut-off valves (when properly connected to able light-off (gas manifold may otherwise act as a
a control system) are designed to shut the fuel supply reservoir, preventing light-off during trial-for-ignition
off with a loss of electrical power. Manual reset period).
valves require operator attendance each time the
system is started up (or restarted after a shut-down).

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Burner Mounting Check visually that no obstructions exist in front of
the burner, then prepare a shell opening up to 1" larger
Prepare burner mounting as follows: than burner diameter (2" larger through refractory part
In a refractory wall (sketch 1), basic burner may be of wall). Attach studs to furnace shell or weld angle
used with castable refractory rammed into the space iron from buckstay to buckstay if additional support is
around burner, supported with angle iron and retained required, checking location carefully for appropriate
by mastic-coated anchors. The burner block should be burner arrangement.
coated with a mortar for good adhesion between it and
the castable refractory material. The remaining gap NOTE: Discharge face of burner should be flush
should be packed with ceramic fiber insulation. with inner furnace wall for maximum recirculation
In a soft wall (sketch 2), burner should be specified effectiveness. Entire burner may be rotated about
with optional burner block sleeve and wrapped tightly in its centerline to mount in any position.
fiber blanket. Remaining space should be packed with Mount burner in position and draw up mounting
ceramic fiber insulation. bolts to provide support. Overtightening will prevent
For maximum burner life, burner frame and furnace lateral expansion of the furnace plate and can cause
shell must be protected from hot gas flows. Use high destructive stresses.
1 2
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establish firing rates automatic control motor’s
in accordance with linkage from Maxon
system demands. MICRO-RATIO® Control
Valve by loosening your
Additional data control motor’s connect-
on Maxon MICRO- ing rod from the valve’s
RATIO® Valves is toggle linkage.
provided in catalog
bulletin 7000.
Disconnect this
linkage from
Test connections are essential for burner adjust- MICRO-RATIO® Valve
ment. Each RAMFIRE® Burner includes air and fuel

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6. Series “G” RAMFIRE® Burners include built-in test General: To achieve rated capacities, a RAMFIRE®
connections both upstream and downstream of Burner must be adjusted to give the specific air and
internal fuel and air orifices. To achieve rated gas differential pressures as indicated in the charts
capacities, adjust MICRO-RATIO® Control Valve shown on pages 4300-S-9.
to give the differential pressures indicated on
charts on page 4300-S-9. 7. Set minimum air differential pressure at 0.1" w.c.
Gas differential pressures read across With MICRO-RATIO® Valve combinations of air
burner’s built-in gas test connections G1 and G2 and fuel valves, the minimum differential setting is
(shown in photo below) are shown in Chart 1. initially established with the air valve only.
Note that natural gas flows are in standard cubic Disconnect the linkage between the air valve
feet/hour and are gas differential readings across and fuel valve(s) on the MICRO-RATIO® Valve
burner gas test connections (not inlet gas supply) assembly.
pressure in inches w.c. Loosen to separate air valve
For propane firing, these differential gas movement from fuel valve(s) travel
pressure readings would be 40% of these indi-

cated for the equivalent natural gas heat releases.
Test connections are

shown with optional
test connection kits
G1
Rotate the air valve while watching the
manometer for the minimum air differential
A1 G2 pressure of 0.1" wc. (Note: This is a very small
increment on a normal manometer. Readings/
settings above 0.1" wc will lessen turndown ratio
of burner system.) Then mark red air valve dial
(see sketch below) opposite crank pointer.
A2
Combustion air differential pressures read

across burner’s built-in air test connections A1 and
A2 (shown in photo above) are shown in Chart 2.
Note that graph for 2" RAMFIRE® begins at 0.2"
wc differential. This is required minimum for 2"
size.
Maxon offers a “test connection kit” accessory
which provides a convenient means of connecting
plastic tubing to the burner test port connections. 8. Establish the maximum combustion air
Kit should be removed after initial start-up and the differential pressure by moving MICRO-RATIO®
test ports plugged for normal burner operations. Valve assembly toward the higher numbered
positions until the desired air differential (in
accordance with burner specifications) is reached.
Again, mark red air valve dial opposite crank
pointer (refer to Chart 2 on page 4300-S-9).
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For example: A combustion system may need the Re-tighten binding screw [2] and return the
air valve to only be 15° open for the “minimum” MICRO-RATIO® Valve to the “minimum” air
setting and the “maximum” requirements are setting.
satisfied with the air valve open to 60°. By marking This time, loosen set screw [1] and again
these points on the air valve’s indicating strip, you correct for just half of the distance required to
are ready to reconnect the SYNCHRO Fuel Valve’s make the air valve pointer indicate the minimum air
linkage to the air valve. valve setting.
Re-tighten set screw [1] and again return the
9. Reconnect the SYNCHRO Fuel Valve linkage MICRO-RATIO® Valve to its maximum position.
to the MICRO-RATIO® assembly’s air valve. Similarly, correct one half the distance with
Having marked the MICRO-RATIO® air control binding screw [2] for the maximum setting, etc.
valve’s settings for both minimum and maximum Continue this adjustment procedure until
firing positions, you may adjust the linkage and the gas and air valves reach their minimum
travel of the SYNCHRO gas valve’s stroke (see and maximum positions simultaneously.
sketch below). Normally, this is accomplished within seven
adjustments.
10. To prepare Maxon MICRO-RATIO® Valve for
initial fuel firing adjustment:
Remove cover Adj. Screws
bly and turn all Manual
Operation
Indicator
counter-clockwise Pointer
until flush with outer Locking Screw
Loosen Allen set screw [1] and binding screw surface of casting for manual
[2] in toggle [4]. Move the toggle in universal cam (new equipment is
operation
assembly slot towards the center of rotation so shipped this way).

that gas valve can rotate from its minimum to If multiple fuel arrangement, adjust linkage
maximum position, while the air valve swings rods and toggle arrangements between
between the established (and marked) minimum SYNCHRO Fuel Control Valve(s) so that all fuel
and maximum settings. control valves travel together (from minimum to
Place air valve on pre-determined “minimum” maximum positions). Leave MICRO-RATIO®
position and rotate gas valve to its “minimum” set- Valve(s) at “minimum” position, as shown by
ting position. Tighten down set screw [1] and binding pointer on position indicator strip.
screw [2] with both valves set at “minimum”. 11. To light and adjust gas pilot: Check to insure
Establish set screw [1] as minimum-end combustion air supply is flowing to burner. Pilot
adjustment point and binding screw [2] as maxi- gas regulator should initially be set at approxi-
mum-end adjustment point. (Note: It doesn’t matter mately midpoint of its adjustment range. With pilot
which is maximum or minimum, as long as you gas solenoid closed, open main fuel gas and pilot
identify and keep the same reference points for the gas cock. Energize spark ignitor and pilot gas
next adjustment steps.) solenoid. Turn pilot gas adjustable orifice screw
Now rotate MICRO-RATIO® Valve to “maxi- out (counter-clockwise) several turns from its fully
mum” position. The air valve maximum setting seated position. Observe ignition of pilot gas
was previously determined. Loosen binding screw through sight port of burner assembly and/or by
[2] and adjust pointer and linkage to correct just viewing flame signal metered from flame safe-
half of the distance required to make the air valve guard relay circuit.
pointer indicate the maximum air valve setting.

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Refine pilot gas setting for a hard blue flame If firing into an uncured refractory chamber,
(and/or strongest flame signal) by adjusting gas allow system to run at this setting for the
flow through pilot orifice and/or pilot regulator. dryout period recommended by the furnace or
Shut off pilot gas cock to extinguish pilot fire. refractory manufacturer, then continue adjust-
Reopen and confirm easy re-ignition several ment of the MICRO-RATIO® Valve.
times. The flame safeguard relays should now 17. Turn all remaining adjustment screws in
power the main fuel shut-off valves. slightly further than the second screw, then
Verify all safety interlocks are operational before
move MICRO-RATIO® Valve toward #2 position,
adjusting as necessary.
12. To light and adjust RAMFIRE® Burner on gas:
With gas pilot established and flame supervision
system operational, opening the main fuel shut-off
valve(s) will allow fuel flow to the SYNCHRO Fuel
Control Valve of MICRO-RATIO® Valve assembly.
13. Turn minimum adjusting screw in (clockwise)
to open gas valve until gas is ignited at burners.
necessary.
Several turns of the screw may be necessary.
Flame should normally be confined back in the 18. Progressively work your way up through each
burner block at rated minimums. (Higher mini- adjusting screw position, developing a smooth
mums might possibly extend flames beyond progression slope from your first screw to the
burner block.) “maximum” position.
NOTE: At this point, it is more important to get any kind NOTE: To adjust the flame at any position, you must
of a flame as soon as possible. The flame geometry can move the SYNCHRO Valve to the number you desire
be adjusted and refined as needed later. to adjust. This aligns the adjusting screw directly on
14. Adjust main gas regulator (as necessary to top of the fuel valve plunger. A resulting adjustment of
maintain required burner differential). Re-adjust the screw is directly applied to the fuel valve plunger
minimum screw if necessary. and its interconnected valve body linkage.
If pilots are to be interrupted, shut them off at this If high temperature limit trips before adjust-
point and verify that main flame remains lit and holds ment is completed, cycle back to minimum and
in flame detectors. Re-adjust if necessary. hold there until the system cools down before
15. Once your flame is established and refined at attempting further adjustment.
this position, and without advancing the screw 19. Note gas supply pressure while continuing
carrier quadrant higher, screw all remaining with adjustment. If it falls off below acceptable
screws down to at least the same level as your range, it may be necessary to re-adjust the
first adjusted screw. regulator. If so, lower firing positions will need
NOTE: A preliminary setting can be established with all rechecked and if necessary, re-adjusted before
the remaining adjusting screws. Generally, each suc- proceeding.
ceeding screw needs to be screwed in approximately 20. When all screws have been adjusted, recheck
one full turn deeper than its preceding screw. A smooth differential pressures with unit at operating
“stair-step” gradient pre-set at this point from low to high temperature. Refine “high fire” setting if neces-
will simplify the remaining adjustment steps. sary, considering differential pressure, flame
16. With allen wrench engaged in second screw, length, and appearance.
slowly move MICRO-RATIO® Valve to #1 Flame should be blue with yellow tails and
position, adjusting as necessary to maintain with a steady combustion noise. Dust or contami-
ignition and the type of flame desired. Flame nants in the air stream may affect flame appear-
length should increase slightly, burning with a ance.
blue center and yellow tips, and a steady combus-
tion noise.
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The charts at right show specific differential Chart 1
gas (Chart 1) and air (Chart 2) pressure readings
at various firing rates. This data may be used to
refine your RAMFIRE® Burner adjustments.
21. If system will operate with interrupted pilot
(considered good practice), shut pilots off now
and cycle MICRO-RATIO® Valve slowly from
Valve.
24. Shut system down, closing all fuel valves and
allowing an approved post-purge period before Chart 2
shutting down fans and combustion air blower.
Remove test connections and plug openings, then
replace all equipment covers and caps and
tighten all linkage set screws.
25. Instruct operator on proper start-up, operation

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Notes
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CORPORATION

RAMFIRE® Burners Page 4300-A/P-1
Assembly Numbers
Series "G" Gas only

RAMFIRE® Burners
1.5" 2" 3" 4"
Complete Burner Assemblies 1.5 RF 2 RF 3 RF 4 RF

• Air Connection Type
• Gas Connection Type
• Pilot Orifice
• Flame Detection
• Block Material
• Seal and Support
• Mounting Ring
• Mounting Ring Gasket
• Test Connection Kit (Combustion Air)
• Test Connection Kit (Fuel)
• Backplate Connection
Spare Parts for RAMFIRE® Burners

RAMFIRE® Burners 1.5" 2" 3" 4"
Complete Burner Assemblies 1.5 RF 2 RF 3 RF 4 RF
Mounting plate (A) [1] 34237 34238 34239
Mounting plate gasket (A) [1] 34391 34392 34393
Pilot gas adjustable orifice (A/R) 50431
1/8" test connection kit (A) 34137
Spare Parts &
Accessory Items 35618 (3/4") 35619 (1")
Gas swing check valve (size) Cv flow (A)* --- ---
Cv = 21.2 Cv = 34
19122 (1-1/2") 19123 (2")
For air --- ---
Series "BV" balancing valves Cv = 80 Cv = 138
(size) CV flow (A)* 19119 (3/4") 19120 (1")
For gas --- ---
Cv = 11 Cv = 18
Spark ignitor sub-assembly includes
34042 39782
rubber cover (R)
Replacement
& Spare Parts Rubber cover (R) 18722
Obser vation glass (R) 19284
Replacement Burner Standard block with C.S. sleeve (R) 33853 33855 33857 33859
Block & Sleeve
Sub-Assemblies Standard block with S.S. sleeve (R) 33854 33856 33858 33860
[1] Mounting plates and gaskets are required options. Mounting plate is normally welded in place at assembly to give
desired block placement relative to inner firing chamber wall. If you do not specify a desired mounting plate location, it will be
shipped “loose,” requiring welding at installation.
*Must be ordered as loose items

m CORPORATION
Bulletin 4400
VORTIFLARE® Radial Flame Burners
1-1/2" Series “G” VORTIFLARE® Burner assembly with seal and support, and optional pilot and mounting ring shown on left.
On right is 1-1/2" Series “G” VORTIFLARE® Burner assembly with basic refractory block.
• Gas/oil flexibility in a radial flame pattern

• Burn most clean, low pressure gaseous fuels or #2 fuel oil with only 8-16 osi combustion
air pressures
• Operate on-ratio or with excess air to meet the specific demands of your combustion process
• Eliminate flame impingement and reduce hot spotting
• Short radial flame pattern permits larger loadings of your furnace and lehrs
• Achieve better temperature control without temperature override with 25:1 turndown on
gas or 12:1 turndown on #2 oil
• Series “G” (gas only) version permits future conversion to oil firing
• Mounting flexibility allows you to install VORTIFLARE® Burners in side wall or roof, through thick
or thin soft wall refractory construction
Page 4402
VORTIFLARE® Radial Flame Burners

Principle of Operation Series “G” VORTIFLARE® Burners
for gas only firing
With Series “G” VORTIFLARE® Burners,
combustion air enters the burner body and is swirled
out into the burner block through the nozzle ports.
These ports create the spinning radial flame
characteristic of the VORTIFLARE® Burners.
Low pressure gas enters the burner body and
exits to the block through machined ports in the
nozzle.
Pilot gas and air enter the burner body from a
separate pilot mixer assembly (not shown in sketch at
right) and passes down a refractory tunnel to intersect
the main air and gas path, just in front of the burner
nozzle.
With Series “C” VORTIFLARE® Burners,

combustion air enters the burner body and is swirled
out into the burner block through the nozzle ports.
Low pressure gas is introduced to the burner
body and exits to the block through the nozzle ports.
Light oil enters through the strainer and oil tube. It
passes through the oil nozzle where the stream of
liquid oil is atomized directly in front of the gas pilot
tunnel by the atomizing air.
VORTIFLARE® Burners provide a low forward Series “C” VORTIFLARE® Burners

velocity radial spot of hot combustion gases that for gas or oil firing
permit larger loadings within your furnace or lehr,
improving both temperature uniformity and
economical production results.
When used in conjunction with Maxon’s MICRO-
RATIO® Control Valves, a VORTIFLARE® Burner may
be adjusted to fire on-ratio throughout the firing range
or set to give a choice between “on-ratio” or “excess
air” firing. As high as 200% excess air is possible at
minimum capacity.
Maxon catalog bulletin

7000 describes MICRO-
RATIO® Control Valves which
throttle air and gas volumes
to the VORTIFLARE® Burner.
5/91
VORTIFLARE® Radial Flame Burners Page 4403

Material Temperature Limits Seal and support assemblies reinforce burner
blocks in thin wall construction installations. Their
Standard burner block material is suitable for metallic cylinder surrounds the round cast block,
operating temperatures up to 2200°F (1204°C). The providing additional strength and support.
maximum operating temperature limit may be Stainless steel seal and support assembly
downrated if the VORTIFLARE® Burner is operating provides for chamber temperatures up to 1500°F
under the following conditions: (816°C).
– burner is installed in a furnace with fiber wall VORTIFLARE® Burners are available in two
construction configurations:
– frequent cycling is present, inducing thermal shock – Standard version with refractory blocks for
and stresses installation in refractory walls
– Standard with stainless steel seal and support
to provide additional block support in chamber walls
of softwall construction
Typical Series “G” VORTIFLARE® Burner Installation
Typical applications include kilns, forge furnaces, A complete VORTIFLARE® Burner system may
galvanizing tanks, annealing furnaces, lehrs, sinter include gas and/or oil trains, air/fuel proportioning
furnaces, and other applications requiring heating equipment, pressure blower, and a combustion
uniformity and broad ratio control. control panel. Your Maxon representative can help
you choose from the broad range available.
5/91
Page 4404 VORTIFLARE® Radial Flame Burners
Capacities/Selection Data
Capacities/Specifications for Series “G” (gas only) and Series “C” (gas/oil) VORTIFLARE® Burners
Capacities and operating data shown in the table Atomizing air is required at 14 osi for oil firing,
below is based on firing with .65 Sp. Gr. natural gas optional for gas firing, with two capacity ranges
(1000 Btu/ft3) and #2 fuel oil (34.2 SSU viscosity at shown. Shutting off atomizing air on Series “C”
100°F) at approximately 140,000 Btu/gal. VORTIFLARE® Burners for gas firing gives lower
Gas pressures shown are “differential” (firing minimum capacities and slightly reduced maximums.
chamber to burner test connections). Propane gas Gas pilots require 25 CFH natural gas supply at
requires approximately 40% of the pressure shown for about 2" wc (at inlet) and 11" wc differential pilot air
natural gas. supply.
Oil supply must be regulated to the pressure Series “G” VORTIFLARE® Burner air/fuel ratios
indicated at the inlet to burner Y-strainer, and must be may be adjusted for up to 10% excess gas at maxi-
maintained at 40°F or higher (50 SSU minimum mum firing rate, up to 200% excess air at minimum
viscosity). firing rate or both if Maxon’s MICRO-RATIO® Control
Other light distillate fuels such as #1, #2, JP4, Valves are used. Data in the table below is based
etc. may be used. Do not use #4 or heavier oils. on “on-ratio” firing.
Series "G" Series "C"

Series >
VORTIFLARE® Burner (on natural gas) (on #2 oil)
Performance Factors Size > 1.5" 2" 2"
osi 14
Combustion Air Differential Pressure
inch w.c. 24
1000's Btu/hr Maximum 500 750 ---
(without atomizing air) Minimum 20 30 ---
1000's Btu/hr Maximum --- 840
Capacities
(with atomizing air) Minimum --- 100 70
Gallon/hr #2 oil Maximum --- --- 6
(with atomizing air) Minimum --- --- 0.5
Air Volume Combustion air (SCFM) 85 140
Requirements Atomizing air (SCFM) --- 14 [1] 14
Natural Gas Differential Pressure (inches w.c.) 3" wc 3" wc ---
Fuel Requirements [2]
#2 oil pressure (PSIG) --- --- 7.5
Without atomizing air 25:1 25:1 ---
Turndown Ratio
With atomizing air --- 8:1 12:1
Flame Geometry Diameter (inches) x Length (inches) 15" x 2" 20" x 4"
[1] If atomizing air is used with gas firing
[2] Differential: Firing chamber to burner gas test connection, or to burner oil inlet at Y-strainer on oil tube
Accessory Options
Pilot Assembly
Seal & Support
Housing Mounting Ring
Mounting Clip
1-1/2" Series “G” VORTIFLARE® Burner basic block 1-1/2" Series “G” VORTIFLARE® Burner with seal and
with pilot assembly and mounting clips support assembly and mounting ring
Mounting
Pilot Assembly Ring
Provision for UV Scanner
with cooling air
Spark Ignitor
Eye Bolt Set

includes (4) eye bolts
Oil Tube Sub-assembly
Seal & Support

Housing
2" Series “C” VORTIFLARE® Burner with seal and VORTIFLARE® Burner with optional eye bolt set to
support, pilot assembly, and provision for UV scanner enable supporting of burner weight while mounting into
cooling air chamber wall
Optional adjustable mounting bracket assembly

(left) permits adjusting burner to match chamber wall
Adjustable thickness. VORTIFLARE® Burners are mounted with
Mounting Bracket
Assembly face of block flush with internal chamber wall.
5/03

1.5" Series “G” VORTIFLARE® Radial Flame Burner
Available Air Inlet Positions
Common items for all size VORTIFLARE® Burners Dimension “X” must be
specified on order. Burners
with seal and support housing
may be specified with an
optional mounting ring which
is welded in place at
assembly to give desired
block placement relative to
inner firing chamber wall. If
you do not specify a desired
mounting ring location
(Dimension “X”), it will be
shipped “loose”, requiring
welding at installation.

2" Series “G” (gas only) VORTIFLARE® Burner
2" Series “C” (gas/oil) VORTIFLARE® Burner
Dimension “X” must be specified Available Air Inlet Positions

on order. Burners with seal and
support housing may be specified
with an optional mounting ring which
is welded in place at assembly to
give desired block placement
relative to inner firing chamber wall.
If you do not specify a desired
mounting ring location (Dimen-
sion “X”), it will be shipped
“loose”, requiring welding at
installation. Pipe threads on this page conform to NPT (ANSI Standard B2.1)
5/91
1.5" Series “G” VORTIFLARE® Burner To order replacement parts:
1. Specify parts by the names shown in the sketches
3. Indicate burner size from number cast on side of
refractory material code stamped on block frame
near cast Maxon name
Replacement parts orders should always specify

the date and assembly number stamped on the
nameplate (see below) of the particular burner for which
they are intended.
2" Series “C” VORTIFLARE® Burner 2" Series “G” VORTIFLARE® Burner
VORTIFLARE® Radial Flame Burners Page 4400-S-1

VORTIFLARE® Burners are furnished in standard
and rotated when mounting into combustion chamber
wall. This will permit matching up to field site piping.
Positions which would allow dirt or debris to fall down
and block flame supervision port should be avoided.
Air inlet “down” is standard

If the refractory block of your VORTIFLARE® To install a new block sub-assembly:
Burner ever requires replacement, Maxon can supply 1. Secure heat processing equipment from operation
replacement block and frame sub-assemblies. following manufacturer’s instructions.
When ordering refractory block/frame sub- 2. Disconnect piping, etc. and remove VORTIFLARE®
assemblies, identify refractory block material code Burner from installation.
stamped on the bolt heads of your existing 3. Loosen and remove the nuts holding the burner
VORTIFLARE® Burner. body to the burner block.
Burners with seal and support housing may be 4. Remove old block assembly and remount new
specified with an optional mounting ring which is block assembly. Be sure gasket between block and
welded in place at assembly to give desired block body is in place between the components.
placement relative to inner firing chamber wall. If you 5. Secure the block to the body by retightening the
do not specify a desired mounting ring location, it will nuts onto the block studs.
be shipped “loose”, requiring welding at installation. 6. Re-install burner, following installation instructions.

Sub-Assembly

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Page 4400-S-2 VORTIFLARE® Radial Flame Burners
with gas-fired VORTIFLARE® Burners.
and connecting linkage components may be packed
separately and shipped loose with your new Maxon
VORTIFLARE® Burner.
VORTIFLARE® Burners can fire in any direction, but Burner block and casting failure is frequently the
the scanner manufacturer may impose limitations. result of external stresses and strains transmitted to
Avoid orientations which might permit pilot and/or flame the burner through the piping. Flexible connections
supervision port to collect debris and/or moisture. are recommended in all piping to reduce piping
Include observation ports in your combustion stresses and alignment/shifting problems. Installation
chamber design to provide a view of both main and of such connectors at certain key spots in the air or
pilot flame area. This will simplify start-up and adjust- gas manifolding can prevent damage to the burners
ment procedures. from uneven thermal expansion.
Typical installation diagram of Series “G” VORTIFLARE® Burner system

mCORPORATION


VORTIFLARE® Burner requires a separate Test connections are essential for burner adjust-
combustion air blower. The nozzle mixing burners ment. They should be provided immediately down-
serve as their own fuel/air mixing device. stream of the regulator and are included in the burner
Electrical service must match the voltage, phase itself. Test connections must be plugged except
and cycle of all electrical system components and be when readings are being taken.
compatible with nameplate ratings. Insure that all Blower must deliver a reasonably clean and cool
normal control safeguards are satisfied. Combustion air supply. Care must be taken to keep air manifold
air blower should continue to run after shutdown to pressure drops to a minimum and to independently
allow burner to cool. support the weight of air piping.
Gas supply piping must be large enough to The blower should not be exposed to direct radiant
maintain the required fuel pressures cataloged for the heat or positioned where it might draw in inert gases.
particular burner size used with burner operating at If problems exist, consider relocation.
full-rated capacity. Gas and air piping should be located reasonably
Anything more than minimal distance or piping close to the burner and sized for the pressure and
turns may necessitate “oversizing” piping runs to keep volume requirements of the burner, with supply
pressure drops within acceptable ranges. pressures high enough to permit subsequent regula-
If multiple burners are fed from a single gas train, tion at each burner. Gas piping drops should not
care should be taken to minimize pressure drop and exceed 10% of initial supply pressure.
give maximum uniformity. Control systems should provide all normally
Clean fuel lines are essential to prevent blockage recommended interlocks (including operation of fuel
of pipe train components or burner gas ports. shut-off valves). Sequencing control systems are
Main shut-off cock should be upstream of both available from Maxon that include provision for post-
the main gas regulator and pilot line take-off. Use it to purge pilots during all but emergency shut-downs.
shut off fuel to both pilot and main burner during shut- Control system’s circuitry must not allow main
down periods of more than a few hours. fuel shut-off valve to be opened unless combustion air
Maxon VORTIFLARE® Burner is not intended for
tight shut-off.
Main gas regulator is essential to maintain a switch is used.
uniform system supply pressure. If one pipe train Flame sensing may be accomplished by UV
supplies multiple burners, consider a separate scanner or flame rod. UV scanner should be kept as
regulator in the branch leading to each burner system. close to burner as feasible. Heat block, if used may
Size the regulator for full system capacity at the affect signal strength with some brands of UV scan-
required pressure, carefully considering pipe train ners. Flame rod sensing must not be used with oil
losses. Follow the instructions attached to the regula- firing.
tor during installation. Low fire start is essential to obtain cataloged
Pilot take-off should be upstream of the main gas minimums.
regulator, but downstream of the main gas cock. It Burner and pipe manifold support will be
should normally include its own pilot gas regulator, a required to support weight of the burner and any
solenoid valve, and shut-off cock. A pilot adjustable connected pipe train components. Air control motors,
orifice at the pilot inlet simplifies adjustment. in particular, require additional support. Maxon
Pilot piping must be large enough to provide for connecting base and linkage assemblies are
the full flow and pressures shown in the catalog for designed to position the control motors to work with
your particular burner size. the control valve, not to support their weight.
Fuel shut-off valves (when properly connected to Multi-burner installations require special consid-
a control system) are designed to shut the fuel supply erations if supplied by a common pipe train and/or air
off with a loss of electrical power. Manual reset supply. Air and Gas Balancing Valves may be used
valves require operator attendance each time the for improved heating uniformity.
system is started up (or restarted after a trip-out).
Motorized shut-off valves permit automatic start-
m
restart when used with an appropriate control system.
CORPORATION

Burner Mounting
Burner mounting should be such that discharge Flame sensing: Burner design incorporates UV
face of block is either flush with internal wall or scanner port suitable for supervision of both pilot and
protrudes a maximum of 1". Do not recess block main flames. Use of purge/cooling air is recom-
into wall. Center-to-center mounting distance be- mended.
tween burners should never be less than the maxi-
NOTE: Discharge face of burner must be flush
mum flame diameter of VORTIFLARE® Burner.
with inner furnace wall for maximum effective-
The opening in furnace shell should normally
ness. Entire burner may be rotated about its
provide 1/2" clearance on all sides. High-temperature
centerline to mount in any position.
gasketing should be used between burner mounting
flange and furnace shell. For maximum burner life, Test connections are essential for burner adjust-
burner frame and furnace shell must be protected ment. Each VORTIFLARE® Burner includes air and
from hot gas flows. fuel test connections but additional connections
Multiple burner installations should be provided should be provided (at a minimum) downstream of the
with balancing valves in the fuel and air lines to each regulator and MICRO-RATIO® Valve. Do not attempt
individual burner (located as close to the burner as to use test connections in pipe elbows or tees, as
possible) to equalize flows and (if necessary) to internal turbulence can give erroneous readings.
increase the upstream pressures required. Test connections must be plugged except when
In a refractory wall or roof (sketch 1), basic readings are being taken.
burner may be used (with castable refractory rammed Include observation ports in your chamber
into a 3" clearance left around burner and the remain- design to provide a view of both main and pilot flame
ing gap packed with ceramic fiber insulation), sup- areas. This will simplify start-up and adjustment
ported with angle iron and retained by mastic-coated procedures.
anchors. Run all oil piping below the burner centerline
In a “soft” wall or roof (sketch 2), burner should wherever possible. On down-firing jobs, this means
be specified with seal and support housing and getting the oil piping down below Y-strainer level and,
wrapped tightly in fiber blanket. Remaining space if possible, over the side of the furnace.
should be packed with ceramic fiber insulation. Use
high temperature gasketing between burner mounting
mCORPORATION


this MICRO-RATIO® mode. Using a 3/16" allen wrench, disconnect
Valve assembly and the automatic control
establish firing rates motor’s linkage from
in accordance with Maxon MICRO-RATIO®
system demands. Control Valve by loosen-
ing your control motor’s
Additional data connecting rod from the
on Maxon MICRO- valve’s toggle linkage.
RATIO® Valves is
provided in catalog
bulletin 7000.
Disconnect this
linkage from
Test connections are essential for burner adjust- MICRO-RATIO® Valve
ment. Each VORTIFLARE® Burner includes air and
fuel test connections but additional connections
should be provided (at minimum) downstream of the
regulator and MICRO-RATIO® Valve.
m
CORPORATION

6. See appropriate catalog dimensional page for General: To achieve rated capacities, a
test connection locations, then cross-connect a VORTIFLARE® Burner must be adjusted to give the
manometer between burner air test connection specific air and gas differential pressures as
and a piece of tubing inserted into the combustion indicated on catalog capacity page 4404.
chamber at a point that will reflect chamber
pressure. This will provide a direct-reading of 7. Set minimum air differential pressure at 0.1" w.c.
differential air pressures. With MICRO-RATIO® Valve combinations of air
In similar fashion, cross-connect a manometer and fuel valves, the minimum differential setting is
between burner’s gas test port and combustion initially established with the air valve only.
chamber to read differential gas pressures. Disconnect
Maxon offers a “test connection kit” accessory the linkage Loosen to separate air valve
which provides a convenient means of connecting between the
plastic tubing to the burner test port connections. air valve and
Kit should be removed after initial start-up and the fuel valve(s) on
test ports plugged for normal burner operations. the MICRO-
RATIO® Valve
assembly.
Typical
test connection locations
for Series “G”
VORTIFLARE® Burner
Typical
test connection locations
for Series “C”
VORTIFLARE® Burner
mCORPORATION


Rotate the air valve while watching the Loosen Allen set screw [1] and binding screw
manometer for the minimum air differential [2] in toggle [4]. Move the toggle in universal cam
pressure of 0.1" wc. (Note: This is a very small assembly slot towards the center of rotation so
increment on a normal manometer. Readings/ that gas valve can rotate from its minimum to
settings above 0.1" wc will lessen turndown ratio maximum position, while the air valve swings
of burner system.) Then mark red air valve dial between the established (and marked) minimum
(see sketch below) opposite crank pointer. and maximum settings.
position and rotate gas valve to its “minimum” set-
ting position. Tighten down set screw [1] and binding
screw [2] with both valves set at “minimum”.
Establish set screw [1] as minimum-end
adjustment point and binding screw [2] as maxi-
mum-end adjustment point. (Note: It doesn’t matter
which is maximum or minimum, as long as you
identify and keep the same reference points for the
next adjustment steps.
Now rotate MICRO-RATIO® Valve to “maxi-
mum” position. The air valve maximum setting
8. Establish the maximum combustion air was previously determined. Loosen binding screw
differential pressure by moving MICRO-RATIO® [2] and adjust pointer and linkage to correct just
Valve assembly toward the higher numbered half of the distance required to make the air valve
positions until the desired air differential (in pointer indicate the maximum air valve setting.
accordance with burner specifications) is reached. Re-tighten binding screw [2] and return the
Again, mark red air valve dial opposite crank MICRO-RATIO® Valve to the “minimum” air
pointer. setting.
This time, loosen set screw [1] and again
correct for just half of the distance required to
air valve to only be 15° open for the “minimum”
make the air valve pointer indicate the minimum air
valve setting.
Similarly, correct one half the distance with
binding screw [2] for the maximum setting, etc.
9. Reconnect the SYNCHRO Fuel Valve linkage Continue this adjustment procedure until
to the MICRO-RATIO® assembly’s air valve. the gas and air valves reach their minimum
Having marked the MICRO-RATIO® air control and maximum positions simultaneously.
valve’s settings for both minimum and maximum Normally, this is accomplished within seven
firing positions, you may adjust the linkage and adjustments.
travel of the SYNCHRO gas valve’s stroke (see 10. To prepare Maxon MICRO-RATIO® Valve for
sketch below). initial fuel firing adjustment:
Remove cover
Adj. Screws
bly and turn all Manual
Operation
Indicator
counter-clockwise Pointer
until flush with outer Locking Screw
for manual
surface of casting operation
(new equipment is
shipped this way).

mCORPORATION

If multiple fuel arrangement, adjust linkage If pilots are to be interrupted, shut them off at this
rods and toggle arrangements between SYN- point and verify that main flame remains lit and holds
CHRO Fuel Control Valve(s) so that all fuel in flame detectors. Re-adjust if necessary.
control valves travel together (from minimum to 15. Once your flame is established and refined at
maximum positions). Leave MICRO-RATIO® this position, and without advancing the screw
Valve(s) at “minimum” position, as shown by carrier quadrant higher, screw all remaining
pointer on position indicator strip. screws down to at least the same level as your
11. To light and adjust gas pilot: Check to insure first adjusted screw.
combustion air supply is flowing to burner. Pilot NOTE: A preliminary setting can be established with all
gas regulator should initially be set at approxi- the remaining adjusting screws. Generally, each suc-
mately midpoint of its adjustment range. With pilot ceeding screw needs to be screwed in approximately
gas solenoid closed, open main fuel gas and pilot one full turn deeper than its preceding screw. A smooth
gas cock. Energize spark ignitor and pilot gas “stair-step” gradient pre-set at this point from low to high
solenoid. Turn pilot gas adjustable orifice screw will simplify the remaining adjustment steps.
out (counter-clockwise) several turns from its fully 16. With allen wrench engaged in second screw,
seated position. Observe ignition of pilot gas slowly move MICRO-RATIO® Valve to #1
through sight port of burner assembly and/or by position, adjusting as necessary to maintain
viewing flame signal metered from flame safe- ignition and the type of flame desired. Flame
guard relay circuit. length should increase slightly, burning with a
Refine pilot gas setting for a hard blue flame blue center and yellow tips, and a steady combus-
(and/or strongest flame signal) by adjusting gas tion noise.
flow through pilot orifice and/or pilot regulator. If firing into an uncured refractory chamber,
Shut off pilot gas cock to extinguish pilot fire. allow system to run at this setting for the
Reopen and confirm easy re-ignition several dryout period recommended by the furnace or
times. The flame safeguard relays should now refractory manufacturer, then continue adjust-
power the main fuel shut-off valves. ment of the MICRO-RATIO® Valve.
Verify all safety interlocks are operational before
slightly further than the second screw, then
12. To light and adjust VORTIFLARE® Burner on move MICRO-RATIO® Valve toward #2 position,
gas: With gas pilot established and flame supervi- adjusting as necessary.
sion system operational, opening the main fuel
shut-off valve(s) will allow fuel flow to the SYN-
CHRO Fuel Control Valve of MICRO-RATIO®
Valve assembly.
13. Turn minimum adjusting screw in (clockwise)
to open gas valve until gas is ignited at burners.
Several turns of the screw may be necessary.
necessary.
Flame should normally be confined back in the
burner block at rated minimums. (Higher mini- 18. Progressively work your way up through each
mums might possibly extend flames beyond adjusting screw position, developing a smooth
burner block.) progression slope from your first screw to the
NOTE: At this point, it is more important to get any kind “maximum” position.
of a flame as soon as possible. The flame geometry can NOTE: To adjust the flame at any position, you must
be adjusted and refined as needed later. move the SYNCHRO Valve to the number you desire
14. Adjust main gas regulator (as necessary to to adjust. This aligns the adjusting screw directly on
maintain required burner differential). Re-adjust top of the fuel valve plunger. A resulting adjustment of
minimum screw if necessary. the screw is directly applied to the fuel valve plunger
mCORPORATION


If high temperature limit trips before adjust- 22. When burner performance is satisfactory and
ment is completed, cycle back to minimum and stable throughout the firing range, reconnect
hold there until the system cools down before linkage from control motor to MICRO-RATIO®
attempting further adjustment. Valve.
19. Note gas supply pressure while continuing 23. Check out overall system operation on all fuels
with adjustment. If it falls off below acceptable by cycling through light-off at minimum, interrupt-
range, it may be necessary to re-adjust the ing pilot, and allowing temperature control system
regulator. If so, lower firing positions will need to cycle burner from minimum to maximum and
rechecked and if necessary, re-adjusted before return. Recheck all safety system interlocks for
proceeding. proper setting and operation.
20. When all screws have been adjusted, recheck
differential pressures with unit at operating
temperature. Refine “high fire” setting if neces-
sary, considering differential pressure, flame
length, and appearance. 24. Shut system down, closing all fuel valves and
Flame should be blue in color and relatively allowing an approved post-purge period before
short and flat, with a distinct “vortex” characteristic shutting down fans and combustion air blower.
and a steady combustion noise. Dust or contami- Remove test connections and plug openings, then
nants in the air stream may affect flame appear- replace all equipment covers and caps and
ance. tighten all linkage set screws.
21. If system will operate with interrupted pilot 25. Instruct operator on proper start-up, operation
(considered good practice), shut pilots off now and shutdown of system. Establish written
and cycle MICRO-RATIO® Valve slowly from instructions for reference.

mCORPORATION

To light and adjust VORTIFLARE® 31. Once your flame is established and refined at
Burner on light oil: carrier quadrant higher, screw all remaining
26. All preliminary adjustments as outlined for gas screws down to at least the same level as your
firing (steps #1 through #25) must have been first adjusted screw.
completed. NOTE: A preliminary setting can be established with
Verify all safety interlocks are operational before succeeding screw needs to be screwed in approxi-
opening any main and/or individual burner fuel mately one full turn deeper than its preceding screw.
valve. A smooth “stair-step” gradient pre-set at this point
27. Establish proper pressure of atomizing air. from low to high will simplify the remaining adjustment
Pilot gas may have to be increased. steps.
With gas pilot established and UV flame 32. With allen wrench engaged in second screw,
supervision system operational, opening the slowly move MICRO-RATIO® Valve to #1
main oil shut-off valve(s) will allow #2 oil to flow position, adjusting as necessary to maintain
to the SYNCHRO Oil Control Valve of the ignition and the type of flame desired. Flame
MICRO-RATIO® Valve assembly positioned at length should increase slightly, with a steady
minimum. combustion noise.
Flame appearance should remain yellow-white
CAUTION: Oil flames are highly radiant. Use with no brown tips, relatively short and flat, and
eye protection and avoid prolonged viewing. exhibit a distinct “vortex” shape throughout the
28. Turn MICRO-RATIO® Valve to minimum cataloged firing rate.
position and, using the allen wrench supplied 33. If firing into an uncured refractory chamber,
with MICRO-RATIO® Valve, turn minimum allow system to run at this setting for the dryout
adjusting screw of oil valve in (clockwise) to period recommended by the furnace or refractory
permit oil flow to the burner(s). Continue turning manufacturer, then continue adjustment of the
inward slowly until minimum oil fire ignites. MICRO-RATIO® Valve.
CAUTION: Shut off oil quickly if there is a slightly further than second, then with allen
noticeable drop in oil pressure or if ignition wrench inserted in the third screw, slowly move
does not occur within a few seconds. MICRO-RATIO® Valve toward #2 position,
29. Check that pressure downstream of oil adjusting as necessary.
pressure regulator is sufficient to meet burner CAUTION: If flame is extinguished, immediately
requirement plus piping losses. Readjust oil shut off oil and return MICRO-RATIO® Valve to
pressure regulator if necessary. minimum position. Verify that pilots are still
Failure of “some” burners on a multiple burner burning then reopen oil valve and turn screw
job to ignite would generally indicate line scale or last adjusted in slightly further before returning
dirt obstructions in the oil valve, oil tube and/or oil to that firing position. Refine adjustment if
tip. Disassemble, inspect and clean if necessary. necessary.
30. Once ignition occurs, turn minimum screw in
(for more fuel) or out (for less) until a yellow- 35. Progressively work your way up through each
white flame is produced without smoke or brown adjusting screw position, developing a smooth
tips. When properly adjusted, it should be progression slope from your first screw to the
possible now to shut off pilots with the flame “maximum” position.
detection system (if used), holding in on main
flame only.
mCORPORATION


NOTE: To adjust the flame at any position, you must 38. If system will operate with interrupted pilot
move the SYNCHRO Valve to the number you desire (as recommended), shut pilots off now and cycle
to adjust. This aligns the adjusting screw directly on MICRO-RATIO® Valve slowly from minimum to
top of the fuel valve plunger. A resulting adjustment of maximum and back, with all convection system
the screw is directly applied to the fuel valve plunger dampers in operating position or with furnace
and its interconnected valve body linkage. door closed.
36. Note oil supply pressure while continuing 40. Check out overall system operation on all
with adjustment. If it falls off below acceptable fuels by cycling through light-off at minimum,
range, it may be necessary to readjust the interrupting pilot, and allowing temperature
regulator. If so, lower firing positions will need control system to cycle burner from minimum to
rechecked and if necessary, readjusted before maximum and return. Recheck all safety system
proceeding. interlocks for proper setting and operation.
37. When all screws have been adjusted, allow
system to reach operating temperature then
recheck minimum and maximum differential air
pressures. Readjust linkage between air and fuel
valves if necessary. If any change is made, refine 41. Shut system down, closing all fuel valves and
gas adjusting screw settings, always adjusting allowing an approved post-purge period before
only that screw corresponding to the position at shutting down fans and combustion air blower.
which valve is then set. Remove test connections and plug openings,
When adjusting for firing at maximum posi- then replace all equipment covers and caps and
tions, take care that adjusting screws slope tighten all linkage set screws.
gradually toward that setting. 42. Instruct operator on proper start-up, operation

m
CORPORATION
Notes
m
CORPORATION

Bulletin 4500
MULTIFIRE® Dual Fuel Burners

for gas or oil firing
Right: 2" MULTIFIRE® II Dual Fuel Burner with spark ignited pilot assembly and provision for UV scanner (scanner by others).
Left: 2" MULTIFIRE® II Burner with seal and support assembly.
• Clean burning of light distillate fuel oils or most gaseous fuels with low combustion air
pressures
• Wide turndown capabilities on oils or gases promote faster bring-up times without temperature
override
• Maximum application flexibility provided with five different sizes and “on-ratio” capacities up to
17,500,000 Btu/hr per burner
• 6" HO MULTIFIRE® Burner capable of firing #6 heavy oil (maximum viscosity of 90 SSU)
• Operate “on-ratio” or with “excess air” to meet the specific demands of your combustion
process. For air heating applications, most MULTIFIRE® Burners may be “overfired” without
increasing burner size providing lower costs per Btu.
• Alternate refractory block materials for temperatures up to 3000°F (1649°C) to provide
maximum cost effectiveness
Page 4502
MULTIFIRE® Dual Fuel Burners

MULTIFIRE® Burners incorporate a nozzle-mix
refractory block design capable of “on-ratio” firing over
a broad range of operating conditions.
The dual fuel capability indicates that
MULTIFIRE® Burners can fire on either gas or
oil, but not both fuels at the same time.
The illustration at right shows the combustion air
being introduced through the burner body, surround-
ing the nozzle, and spinning out into the refractory
block tunnel through machined air orifice ports on the
face of the burner nozzle.
On gas firing, the gas enters the burner body and
travels down through the inside of the gas nozzle. As Typical for 2" – 8" size
the gas passes through the nozzle face, it is spun out MULTIFIRE® Burners
into the refractory block tunnel where it is thoroughly
mixed with the combustion air.
On oil firing, the oil is brought through the oil Since MULTIFIRE® Dual Fuel Burners offer
strainer into the oil tube/nozzle tip. either the gas firing option or an oil firing alterna-
Atomizing air enters the burner body through the tive, the manifolding to the burner normally incorpo-
same opening that supplies gas for the gas firing rates a manual 3 way-2 port selector cock to simplify
option. The atomizing air attacks the stream of liquid switch-over to the alternate fuel firing. Automatic or
oil at the face of the oil tube/nozzle tip. remote operations have involved use of electric or
In both the gas firing and oil firing options, a pneumatic selector valves.
spark ignited gas pilot provides a stable pilot flame When used in conjunction with Maxon’s MICRO-
down through its own pilot tunnel in the refractory RATIO® Control Valves, a MULTIFIRE® Burner may
block to intersect and ignite the fuel/air mixtures be adjusted to fire “on-ratio” or with “excess air”
coming out of the nozzle face. throughout the firing range.
Provision is made for a single UV scanner to Maxon catalog bulletin
monitor both gas pilot and main flame. 7000 describes MICRO-
RATIO® Control Valves which
throttle air and gas volumes
to the MULTIFIRE® Burner.
5/91
MULTIFIRE® Dual Fuel Burners Page 4503

A complete MULTIFIRE® Burner system may Typical applications include kilns, industrial
include gas and/or oil trains, air/fuel proportioning furnaces and ovens, grain dryers, metal melting, fume
equipment, pressure blower, and a control panel. incinerators and other applications requiring heating
Your Maxon representative can help you choose from uniformity.
the broad range available.
Typical MULTIFIRE® Dual Fuel Burner installation for gas and light oil
Typical installation drawing above is schematic illustration. For clarity purposes, the oil piping is shown coming down to
burners; however, in actual installation, oil piping should always be piped below and go up to burners.
Material temperature limits

Standard burner block material is suitable for Seal and support assemblies reinforce burner
operating temperatures up to 2600°F (1427°C). The blocks in thin wall construction and air heating appli-
maximum operating temperature limit may be cations.
downrated to 2400°F (1316°C) if the MULTIFIRE® Carbon steel seal and support assembly is
Burner is operating under the following conditions: suitable for return air temperatures across the burner
– burner is installed in a furnace with fiber wall of up to 600°F (316°C) and/or downstream tempera-
construction tures of up to 900°F (482°C).
– frequent cycling is present, inducing thermal shock Stainless steel seal and support assembly
and stresses provides for return air temperatures of up to 1000°F
Optional refractory block materials are available (538°C) and/or downstream temperatures up to
to extend maximum operating temperature limits as 1500°F (816°C).
follows:
– up to 2800°F (1538°C); or
– up to 3000°F (1649°C)
These higher temperature material options are
delivery schedules.
7/94
Page 4504 MULTIFIRE® Dual Fuel Burners
Capacities/specifications in the following charts Normal minimum and on-ratio minimum shown on
are based on natural gas (0.65 specific gravity and chart assume minimal excess air volume.
1000 Btu/ft3 calorific value); #2 fuel oil (140,000 Example: Normal minimum on #6 oil of 2,500,000
Btu/gal); and #6 heavy oil (150,000 Btu/gal). Btu/hr with 6" HO MULTIFIRE® Burner assumed to
Other gaseous or distillate fuels such as pro- have approximately 10% excess air in combustion
pane, #1, kerosene and JP-4 may be used in all reaction. On-ratio minimum for 3" MULTIFIRE® II
MULTIFIRE® Burners, but #4 or heavier oils may only Burner on gas at 140,000 Btu/hr assumed to deliver
be fired in 6" HO MULTIFIRE® Burner. Propane gas 2% oxygen in combustion products (or 10% excess
may be fired at approximately 40% of the differential air).
gas pressure shown for natural gas. #6 heavy oil Maximum capacities are given for two alternate
must be heated to maintain a viscosity of 90 SSU or application conditions:
less to the burner inlet of 6" HO MULTIFIRE® Burner. • Nominal closed chamber maximum is based on
Air differential pressure readings are measured firing with no available secondary air (0 to 0.1" wc
between burner inlet (or burner test port connection) static pressure in combustion chamber). This would
and combustion chamber static pressure. be typical of applications with higher temperature
MULTIFIRE® Burners are 3-pipe burners with furnaces, etc.
gas and atomizing air flows using the same inlet • For air heating applications, extended capacities
connection. To achieve the on-ratio minimum capaci- are possible only if fresh secondary air is available
ties shown for gas firing, the differential combustion from passing air stream. Burners can fire across a
air pressure must not exceed 0.3" wc. fresh air stream at velocities of 1000 SFPM or less, or
In the oil firing chart (page 4505), operations with fire into a parallel fresh air stream up to 4000 SFPM.
excess air at minimum firing rates provide the lower
NOTE: If burners fire into a high moisture, inert,
minimum capacities shown as absolute minimum.
or recirculated air stream, maximum capacities
may decrease approximately 10% from those
shown for closed chamber maximums.
Capacities / specifications on natural gas (1000 Btu/ft3 and 0.65 specific gravity)
6" HO 6" HC MULTIFIRE® III
MULTIFIRE® II Burners
Burner Size & Type MULTIFIRE® MULTIFIRE® Burners
2" 3" 4" Burners Burners 6" 8"
Combustion air differential pressures 14 osi 18 osi 14 osi 18 osi 14 osi 18 osi 14 osi 22 osi 14 osi 22 osi 14 osi 14 osi
(inches w.c.) (25) (32) (25) (32) (25) (32) (25) (38) (25) (38) (25) (25)
For closed chamber
firing with no secondary
680 735 1450 1600 2825 3000 7500 9000 7500 9000 7500 16,000
Maximum air (0 to +0.1" wc back
capacity pressures)
(1000's Btu/hr) For air heating
applications with fresh 740 850 1850 1925 2858 3000 16,000 23,000 16,000 23,000 11,250 24,000
secondary air available
Minimum
capacity On-ratio minimum 60 140 420 200 200 500 1000
(1000's Btu/hr)
SCFM combustion air required
114 123 242 267 471 500 1250 1500 1250 1500 1250 2667
for closed chamber maximum
Nominal turndown ratio 11.3:1 12.3:1 10.4:1 11.4:1 6.7:1 7:1 37.5:1 45:1 37.5:1 45:1 15:1 16:1
Differential natural gas pressure
22 27 13 15 26 30 -0.2 1 -0.2 1 20 30
(inches w.c.)
Flame Diameter (inches) 9" 12" 16" 24" 30" 24" 30" 24" 30"
geometry
(in still air) Length (feet) 3 ft. 4 ft. 5 ft. 10 ft. 12 ft. 10 ft. 12 ft. 8 ft. 16 ft.
For oil firing minimums, the air control valve must For dual fuel operations and to gain full turndown
be fully closed, thus utilizing only atomizing air. A ratio on either fuel, a by-pass arrangement around
separate oil control valve is required for each burner the fully closed air control valve is necessary.
in a multiple burner installation, if cataloged oil-fired
minimum is to be achieved.
Capacities / specifications on #2 light oil [1] (at 34.2 SSU viscosity @100°F, 140,000 Btu/gal)
6" HC MULTIFIRE® III
MULTIFIRE® II Burners
Burner size & type 6" HO MULTIFIRE® Burners MULTIFIRE® Burners
2" 3" 4" Burners 6" 8"
Fuel oil #2 oil #2 oil #2 oil #2 oil #6 oil #2 oil #2 oil #2 oil
Combustion air
14 osi 18 osi 14 osi 18 osi 14 osi 18 osi 14 osi 22 osi 14 osi 22 osi 14 osi 22 osi 14 osi 14 osi
differential pressures
(25) (32) (25) (32) (25) (32) (25) (38) (25) (38) (25) (38) (25) (25)
(inches w.c.)
For closed chamber
firing with no
Maximum secondary air 725 740 1450 1600 2835 2950 9300 10,700 10,000 11,500 9500 11,500 8000 17,500
capacity (0 to +0.1" wc back
(1000's pressures)
Btu/hr) For air heating
applications with fresh 798 1095 1824 1958 2835 2950 9300 10,700 10,000 11,500 21,470 26,000 12,000 26,250
secondary air available
Minimum Normal minimum 96 125 170 200 255 295 2500 2500 2000 2500 775 1400
capacity
(1000's
Bt/hr) Absolute minimum 56 72 126 149 170 197 1200 1200 1385 530 980
Turndown Nominal 7.4:1 5.9:1 8.5:1 8:1 11:1 10:1 3.7:1 4.3:1 4:1 4.6:1 4.8:1 4.6:1 10.3:1 12.5:1
ratios Maximum [2] 12.9:1 10.3:1 11.5:1 10.7:1 16.7:1 15:1 7.8:1 8.9:1 8.3:1 9.6:1 6.9:1 8.3:1 15:1 17.9:1
SCFM combustion air required
121 124 242 267 473 492 1250 1500 1250 1500 1250 1500 1250 2667
for closed chamber maximum
Volume (SCFM) 14 16 27 31 54 61 417 417 334 417 128 175
Atomizing
air Differential pressure
14 osi 18 osi 14 osi 18 osi 14 osi 18 osi 22 osi 22 osi 14 osi 22 osi 14 osi 14 osi
(osi)
Oil inlet pressure (PSIG)
5.5 6 20 24 16 18 5 8 5 8 4 5 17 10
required at burner oil inlet
Flame Diameter 9" 12" 16" 34" 36" 34" 36" 34" 36" 30" 36"
geometry
(in still air) Length 3 ft. 4 ft. 6 ft. 8 ft. 10 ft. 8 ft. 10 ft. 9 ft. 11 ft. 10 ft. 16 ft.
[1] Shaded area indicates #6 oil
[2] Based on absolute minimum and closed chamber maximums
3/96
Accessory Options
UV Scanner
(supplied by others)
Flame Rod/
UV Scanner
Port
Refractory
Block
Spark Ignitor
Seal & Support

Assembly
Optional Pressure
Pilot Assembly
Pilot
Assembly
2" MULTIFIRE® II Burner with standard refractory 2" MULTIFIRE® II Burner with optional seal and
block, optional pressure pilot with spark ignitor, support assembly and pilot. Flame rod/UV scanner
and UV scanner (supplied by others). port shown with pipe plug (as shipped).
Flame Rod
Replacement spark ignitor
Hinged Lighter
Port Cover
2" MULTIFIRE® II Burner with hinged lighter port

and flame rod with cooling tee. Cooling tee set
lessens nuisance shutdowns by keeping flame
safeguard port clean of inerts and reducing tempera-
tures at flame rod/UV scanner.
Accessory Options
Air By-pass System required for full turndown capabilities on oil firing
MULTIFIRE® Burners are normally used as part of Typical schematic illustration
a combustion system including MICRO-RATIO® Air/ for air by-pass system
Fuel Control Valves. For gas firing of the burner, the
air valve must be adjusted so that at its minimum
position, sufficient combustion air passes to allow
operation at minimum gas-firing capacity.
When firing on oil, the required minimum combus-
tion air is supplied as atomizing air, and the flow
through the partially open air valve which was neces-
sary for gas firing now becomes “excess” air, requir-
ing that the minimum oil firing rate be increased.
If the full turndown range of the burner is
required on oil, then the air valve must be closed at
minimum firing position, and an air by-pass system
installed to provide the minimum combustion air
required for gas firing (see sketch at right). Control
sequencing should be such that the air by-pass
solenoid valve is open for gas firing, and the balanc-
ing valve set for the desired minimum capacity.
Suggested by-pass solenoid valve sizes are included
in table below.
Air By-Pass
BV Balancing Valve
Burner Size Solenoid Valve
Size CV Flow Size CV Flow Maxon assumes no responsibility for the use or
2" MULTIFIRE® II 1/2" -BV 5 1/2" 5 misuse of the piping layouts shown. Specific
®
3" MULTIFIRE II 1" -BV 18 1" 21
piping and wiring diagrams should always be
4" MULTIFIRE® II
& larger sizes
1-1/4" -BV 42 1-1/4" 32 approval on each application.
MULTIFIRE® Burner air inlet Standard Air Inlet Position “D”

arrangements
MULTIFIRE® Burners can be shipped in
various piping configurations (illustrated on
following dimensional pages).
Air inlet position “D” will be fur-
nished as standard unless specified
differently. Position “D” (air inlet “down”) on
6" and smaller burners may require use of
flexible connection or street elbow in the
gas/atomizing air inlet to avoid potential
dimensional interference with some UV
scanner models.
6/91

2" through 4" MULTIFIRE® II Burners
2" - 4" MULTIFIRE® Burners

Burner K
A B C D E F G H J L O P R S T U V W X Y
Size rad.
2" 7.62 4.5 9 7.5 2" 1" 9 5.25 4.44 5.56 2.06 5.12 1 11.88 5.25 14.5 11.56
13.88 11/16" 1/4" .19
3" 8.81 5 11.25 9 3" 1-1/2" 11.5 6 6.88 6.38 2.56 6.12 1.25 14.25 6.25 16.5 13.56
4" 8.38 5.62 11.5 11.5 4" 2" 13.5 16 7 8.19 7.44 3 6.56 13/16" 1 14.81 3/8" 7.75 20.5 17.12 .25


6" HO & 6" HC MULTIFIRE® Burners
6" MULTIFIRE® III Burners
Available Inlet Positions
Pipe threads on this page conform to

NPT (ANSI Standard B2.1)
8/00

8" MULTIFIRE® III Burner
Available Inlet Positions
Pipe threads on this page conform to

NPT (ANSI Standard B2.1)
MULTIFIRE® Dual Fuel Burners Page 4500-S-1
with MULTIFIRE® Dual Fuel Burners.
pipe trains, spark ignitor, mounting gaskets, and
connecting linkage components may be packed
separately and shipped loose with your new Maxon the burner through the piping. Flexible connections
MULTIFIRE® Burner. are recommended in all piping to reduce piping
MULTIFIRE® Burners can mount and fire in any stresses and alignment/shifting problems. Installation
direction, but the scanner manufacturer may impose of such connectors at certain key spots in the air or
limitations. Avoid orientations which might permit gas manifolding can prevent damage to the burners
flame supervision port to collect debris and/or from uneven thermal expansion.
moisture. Burner and pipe manifold support will be re-
Include observation ports in your combustion quired to support weight of the burner and any
chamber design to provide a view of both main and connected pipe train components. Air control motors,
pilot flame area. This will simplify start-up and adjust- in particular, require additional support. Maxon
ment procedures. connecting base and linkage assemblies are de-
Burner block and casting failure is frequently the signed to position the control motors to work with the
result of external stresses and strains transmitted to control valve, not to support their weight.
Typical installation diagram of MULTIFIRE® Dual Fuel Burner system
Typical installation drawing above is schematic illustration. For clarity purposes, the oil piping is shown coming down to
burners; however, in actual installation, oil piping should always be piped below and go up to burners.

m
CORPORATION
Page 4500-S-2 MULTIFIRE® Dual Fuel Burners

MULTIFIRE® Burner requires a separate combus- Flame sensing: Burner design incorporates a
tion air blower. The nozzle mixing burners serve as single UV scanner port suitable for supervision of both
their own fuel/air mixing device. pilot and main flames. Use of purge/cooling air is
The blower should not be exposed to direct radiant recommended. UV scanner should be kept as close
heat or positioned where it might draw in inert gases. to burner as feasible. Heat block, if used, may affect
If problems exist, consider relocation. signal strength with some brands of scanners.
Electrical service must match the voltage, phase Main shut-off cock should be upstream of both
and cycle of all electrical system components and be the main gas regulator and pilot line take-off. Use it to
compatible with nameplate ratings. Insure that all shut off fuel to both pilot and main burner during shut-
normal control safeguards are satisfied. Combustion down periods of more than a few hours.
air blower should continue to run after shutdown to
allow burner to cool.
Maxon MULTIFIRE® Burner is not intended for tight
Gas supply piping must be large enough to
shut-off.
particular burner size used with burner operating at Main gas regulator is essential to maintain a
full-rated capacity. uniform system supply pressure. If one pipe train
Anything more than minimal distance or piping supplies multiple burners, consider a separate
turns may necessitate “oversizing” piping runs to keep regulator in the branch leading to each burner system.
pressure drops within acceptable ranges. Size the regulator for full system capacity at the
If multiple burners are fed from a single gas train, required pressure, carefully considering pipe train
care should be taken to minimize pressure drop and losses. Follow the instructions attached to the regula-
give maximum uniformity. Gas piping drops should tor during installation.
not exceed 10% of initial supply pressure. Use gas Pilot take-off should be upstream of the main gas
balancing valves and install gas cocks near each regulator, but downstream of the main gas cock. It
burner on multiple burner jobs. Close them during oil should normally include its own pilot gas regulator, a
firing to prevent recycling of oil vapors between solenoid valve, and shut-off cock. A pilot adjustable
burners. orifice at the pilot inlet simplifies adjustment.
Oil Piping: Use oil balancing valves (located as Pilot piping must be large enough to provide for
close to the burner as possible) to equalize flows on the full flow and pressures shown in the catalog for
multiple-burner installations and (if necessary) to your particular burner size.
increase the upstream pressures required. Piloting: Gas pilot should be interrupted, whether
Run all oil piping below the burner centerline the main flame is gas or oil. If operation calls for oil
wherever possible. On down-firing jobs this means firing only, pilot may be fed by bottled gas.
getting the oil piping down below Y-strainer level and, Fuel shut-off valves (when properly connected to
if possible, over the side of the furnace. a control system) are designed to shut the fuel supply
Warning: If burner is to be fired on gas only off with a loss of electrical power. Manual reset
(with the provision for future oil firing), oil tube valves require operator attendance each time the
inlet MUST be capped. system is started up (or restarted after a shut-down).
Clean fuel lines are essential to prevent blockage Motorized shut-off valves permit automatic start-
of pipe train components or burner gas ports. restart when used with an appropriate control system.
Air Piping: Install and use main and atomizing air Test connections are essential for burner adjust-
balancing valves as outlined above for oil. Size air ment. They should be provided immediately down-
piping carefully to give the full flows and pressures stream of the gas regulator and are included in the
needed. burner itself. Test connections must be plugged
mCORPORATION


Blower location must deliver a reasonably clean If the full turndown range of the burner is
and cool air supply. Care must be taken to keep air required on oil, then the air valve must be closed at
manifold pressure drops to a minimum and to inde- minimum firing position, and an air by-pass system
pendently support the weight of air piping. installed to provide the minimum combustion air
Multi-burner installations require special consid- required for gas firing (see below). Control sequenc-
erations if supplied by a common pipe train and/or air ing should be such that the air by-pass solenoid valve
supply. Air and Gas Balancing Valves may be used is opened for gas firing, and the balancing valve set
for improved heating uniformity. for the desired minimum capacity. Suggested by-pass
Control systems should provide all normally solenoid valve sizes are included on catalog page
recommended interlocks (including operation of fuel 4507.
shut-off valves). Combustion control systems are
available from Maxon that include provision for post- Typical schematic illustration of
purge pilots during all but emergency shut-downs. air bypass system
fuel shut-off valve to be opened unless combustion air
switch is used.
Low fire start and interrupted pilot are essential to
obtain cataloged minimums.
MICRO-RATIO® Fuel Control Valve controls heat
release by throttling gas, air and oil flows to burner. It
should include provision for an adjustable minimum
and throttling over a turndown range that matches
burner capabilities.
Air by-pass system is required for full turndown
capabilities on light oil firing.
MULTIFIRE® Burners are normally used as part of
a combustion system including MICRO-RATIO® Air/
Fuel Control Valves. For gas firing of the burner, the
air valve must be adjusted so that at its minimum
position sufficient combustion air passes to allow
operation at minimum gas-firing capacity. Maxon assumes no responsibility for the use or
When firing on oil, the required minimum combus- misuse of the piping layouts shown. Specific
tion air is supplied as atomizing air, and the flow piping and wiring diagrams should always be
through the partially open air valve which was neces- submitted to the appropriate agencies for
sary for gas firing now becomes “excess” air, requir- approval on each application.
ing that the minimum oil firing rate be increased. Vent dampers and pressure controllers should
be used to maintain balanced or slightly positive
furnace pressures (0.0" to 0.05" wc) for maximum
efficiency. Excessive back pressure can damage
furnace and/or reduce burner capacity. Negative
pressures allow infiltration of secondary air and can
seriously affect efficiency and temperature uniformity.

mCORPORATION

Burner Mounting
angle iron from buckstay to buckstay if additional
support is required, checking location carefully for
appropriate burner arrangement.
sion of furnace. Tighten mounting bolts only
In a refractory wall (sketch 2), basic burner may
enough to hold the burner in position.
be used (with castable refractory rammed into a 3"
In a “soft” wall (sketch 1), burner should be clearance left around burner and the remaining gap
specified with burner seal and support and wrapped packed with ceramic fiber insulation), supported with
tightly in fiber blanket. Remaining space should be angle iron and retained by mastic-coated anchors.
packed with ceramic fiber insulation.
NOTE: Discharge face of burner should be flush
For maximum burner life, burner frame and furnace
with inner furnace wall for maximum recirculation
shell must be protected from hot gas flows. Use high
effectiveness. Entire burner may be rotated about
its centerline to mount in any position.
Check visually that no obstructions exist in front of Mount burner in position and draw up mounting
the burner, then prepare a shell opening up to 1" bolts to provide support. Overtightening may prevent
larger than burner diameter (2" larger through refrac- lateral expansion of the furnace plate and can cause
tory part of wall). Attach studs to furnace shell or weld destructive stresses.
1 2
m CORPORATION


Read complete instructions before proceeding, At minimum firing rate, all the combustion air
and familiarize yourself with all the system’s equip- required for oil firing is furnished as atomizing air. To
ment components. Verify that your equipment has avoid introducing unnecessary excess air, the
been installed in accordance with the original MICRO-RATIO® Air Valve will normally be closed at
manufacturer’s current instructions. minimum.
Since atomizing air is not used for gas firing, the
combustion air necessary at minimum firing rate could
be supplied through a by-pass arrangement around
the closed MICRO-RATIO® Air Valve.
tion systems, with control/safety circuitry, and
As an alternate, this by-pass can be eliminated and
with knowledge of the overall installation.
the MICRO-RATIO® Air Valve opened enough to
Instructions provided by the company and/or
supply the combustion air necessary for gas firing at
minimum, but the minimum firing rate on oil will be
increased from the figure cataloged.
incorporating Maxon burner take precedence
Additional data on Maxon MICRO-RATIO®
Valves is provided in catalog bulletin 7000.
ment. Each MULTIFIRE® Burner includes air and fuel
NOTE: The following instructions assume use of
piloted burners and standard cam MICRO-RATIO®
Valves:
The photograph below shows a typical Triplex
MICRO-RATIO® Valve assembly consisting of an air
butterfly valve to control combustion air flow, plus
adjustable-gradiant SYNCHRO gas and oil flow
control valves. The latter two are mechanically linked For initial system start-up:
to the air valve and a series of adjusting screws 1. Close all burner fuel valves and/or cocks.
permits setting of a desired air/fuel ratio throughout Make preliminary adjustments to gas regulators.
the burner firing range. A pneumatic or electric control 2. Check all electric circuitry. Verify that all safety
motor will normally be mounted to this MICRO- devices and interlocks are operable and function-
RATIO® Valve assembly and establish firing rates in ing within their respective settings/ranges. Be
accordance with system demands. sure all manifolds are tight and that test ports are
plugged if not being used.
Air Gas Oil properly positioned and locked into operating
positions.
direction. Verify that all safety interlocks are
adequate purge of manifold and combustion
chamber plenums.

mCORPORATION

5. Initial start-up adjustment should only be Maxon offers a “test connection kit” accessory
accomplished during a “manual” control which provides a convenient means of connecting
mode. plastic tubing to the burner test port connections.
Using a 3/16" allen wrench, disconnect the Kit should be removed after initial start-up and the
automatic control test ports plugged for normal burner operations.
motor’s linkage from
General: To achieve rated capacities, a MULTIFIRE®
Maxon MICRO-RATIO®
Burner must be adjusted to give the specific air and
Control Valve by
gas differential pressures as indicated in the capacity
loosening your control
tables on pages 4504 and 4505.
motor’s connecting rod
from the valve’s toggle 7. Set minimum air differential pressure at 0.1" wc.
linkage. With MICRO-RATIO® Valve combinations of air
Disconnect this
and fuel valves, the minimum differential setting is
linkage from initially established with the air valve only.
MICRO-RATIO® Valve
Disconnect the linkage between the air valve
and fuel valve(s) on the MICRO-RATIO® Valve
assembly.
Loosen to separate air valve
6. Close all fuel hand valves and properly position

three-way cocks to supply gas to burner(s).
See appropriate catalog dimensional page
for test connection locations, then cross-
connect a manometer between burner air test
connection and a piece of tubing inserted into the
combustion chamber at a point that will reflect Rotate the air valve while watching the
chamber pressure. This will provide a direct- manometer for the minimum air differential
reading of differential air pressures. pressure of 0.1" wc. (Note: This is a very small
In similar fashion, cross-connect a manometer increment on a normal manometer. Readings/
between burner’s gas test port and combustion settings above 0.1" wc will lessen turndown ratio
chamber to read differential gas pressures. of burner system.) Then mark red air valve dial
(see sketch below) opposite crank pointer.
If burner is also to be adjusted for the cata-

loged oil minimum and a by-pass has been
installed around the MICRO-RATIO® Air Valve,
close MICRO-RATIO® Air Valve and open by-
m
pass line (usually with a solenoid valve).
CORPORATION

Set manual adjusting valve in by-pass line so Place air valve on pre-determined “minimum” po-
a positive differential of .15" to 0.3" wc (as re- sition and rotate gas valve to its “minimum” setting
quired by burner) is established. position. Tighten down set screw [1] and binding
If a higher minimum on oil is acceptable and screw [2] with both valves set at “minimum”.
by-pass has not been installed, move MICRO- Establish set screw [1] as minimum-end
RATIO® Valve assembly off minimum position adjustment point and binding screw [2] as maxi-
until the required air differential of 0.15" to 0.3" wc mum-end adjustment point. (Note: It doesn’t matter
is obtained, then mark this position on the red air which is maximum or minimum, as long as you
valve dial also. If minimum input is not critical, air identify and keep the same reference points for the
valve may be opened even further for minimum. next adjustment steps.)
8. Establish the maximum combustion air Now rotate MICRO-RATIO® Valve to “maxi-
differential pressure by moving MICRO-RATIO® mum” position. The air valve maximum setting
Valve assembly toward the higher numbered was previously determined. Loosen binding screw
positions until the desired air differential (in [2] and adjust pointer and linkage to correct just
accordance with burner specifications) is reached. half of the distance required to make the air valve
Verify that the required atomizing air pressure is pointer indicate the maximum air valve setting.
still available at this setting and mark dial. Re-tighten binding screw [2] and return the
MICRO-RATIO® Valve to the “minimum” air
setting.
air valve to be only 15° open for the “minimum”
This time, loosen set screw [1] and again
correct for just half of the distance required to
make the air valve pointer indicate the minimum air
valve setting.
9. Reconnect the SYNCHRO Fuel Valve linkage Similarly, correct one half the distance with
to the MICRO-RATIO® assembly’s air valve. binding screw [2] for the maximum setting, etc.
Having marked the MICRO-RATIO® air control Continue this adjustment procedure until
valve’s settings for both minimum and maximum the gas and air valves reach their minimum
firing positions, you may adjust the linkage and and maximum positions simultaneously.
travel of the SYNCHRO gas valve’s stroke (see Normally, this is accomplished within seven
sketch below). adjustments.
NOTE: If multiple fuel arrangement, adjust
linkage rods and toggle arrangements between
SYNCHRO Fuel Control Valve(s) so that all fuel
control valves travel together (from minimum to
maximum positions). Leave MICRO-RATIO®
Valve(s) at “minimum” position, as shown by
pointer on position indicator strip.
10. To prepare Maxon MICRO-RATIO® Valve for
initial gas firing adjustment:
Remove cover
Adj. Screws
Loosen Allen set screw [1] and binding screw carrier cam assem- Handle for
[2] in toggle [4]. Move the toggle in universal cam bly and turn all Manual
Operation
assembly slot towards the center of rotation so adjusting screws Position
that gas valve can rotate from its minimum to counter-clockwise Indicator
Pointer
maximum position, while the air valve swings until flush with outer Locking Screw
between the established (and marked) minimum surface of casting for manual
operation
and maximum settings. (new equipment is
shipped this way).

mCORPORATION
Page 4500-S-8 MULTIFIRE® Burners

11. To light and adjust gas pilot: Check to insure NOTE: At this point, it is more important to get any kind
combustion air supply is flowing to burner. of a flame as soon as possible. The flame geometry can
Turn three-way cock (if necessary) to introduce be adjusted and refined as needed later.
atomizing air to burner, then rotate MICRO- 14. Adjust main gas regulator (as necessary to
RATIO® Valve to its maximum position. Purge maintain required burner differential). Re-adjust
system completely with air. minimum screw if necessary.
Return MICRO-RATIO® Valve to minimum and If pilots are to be interrupted, shut them off at
open main and pilot gas cocks. this point and verify that main flame remains lit and
Open individual pilot air valves and adjust if holds in flame detectors. Re-adjust if necessary.
necessary to allow 8-16 oz. differential air pres- 15. Once your flame is established and refined at
sure to the pilots. Higher pressures greatly this position, and without advancing the screw
increase the sensitivity of pilot gas adjustment. carrier quadrant higher, screw all remaining
Pilot gas regulator should initially be set at screws down to at least the same level as your
approximately midpoint of its adjustment range. first adjusted screw.
With pilot gas solenoid closed, open main fuel gas NOTE: A preliminary setting can be established with all
and pilot gas cock. Energize spark ignitor and the remaining adjusting screws. Generally, each suc-
pilot gas solenoid. Turn pilot gas adjustable orifice ceeding screw needs to be screwed in approximately
screw out (counter-clockwise) several turns from one full turn deeper than its preceding screw. A smooth
its fully seated position. Observe ignition of pilot “stair-step” gradient pre-set at this point from low to high
gas through sight port of burner assembly and/or will simplify the remaining adjustment steps.
by viewing flame signal metered from flame 16. With allen wrench engaged in second screw,
safeguard relay circuit. slowly move MICRO-RATIO® Valve to #1
12. Refine pilot gas setting for a hard blue flame (and/ position, adjusting as necessary to maintain
or strongest flame signal) by adjusting gas flow ignition and the type of flame desired. Flame
through pilot orifice and/or pilot regulator. length should increase slightly, burning with a
Shut off pilot gas cock to extinguish pilot fire. blue center and yellow tips, and a steady combus-
Reopen and confirm easy re-ignition several tion noise.
times. The flame safeguard relays should now If firing into an uncured refractory chamber,
power the main fuel shut-off valves. allow system to run at this setting for the
dryout period recommended by the furnace or
Verify all safety interlocks are operational
refractory manufacturer, then continue adjust-
before opening any main and/or individual
ment of the MICRO-RATIO® Valve.
burner valves.
To light and adjust MULTIFIRE® Burner on slightly further than the second screw, then
gas: with allen wrench inserted in third screw, slowly
13. With gas pilot established and flame supervi- move MICRO-RATIO® Valve toward #2 position,
sion system operational, opening the main fuel adjusting as necessary.
shut-off valve(s) will allow gas flow to the SYN- CAUTION: If flame is extinguished, immediately
CHRO Fuel Control Valve of MICRO-RATIO® shut off gas and return MICRO-RATIO® Valve to
Valve assembly. minimum position. Verify that pilots are still
Turn minimum adjusting screw in (clock- burning then reopen gas valve and turn screw
wise) to open gas valve until gas is ignited at last adjusted in slightly further before returning
burners. Several turns of the screw may be to that firing position. Refine adjustment if
necessary. Flame should normally be confined necessary.
back in the burner block at rated minimums.
(Higher minimums might possibly extend flames
beyond burner block.)
m CORPORATION


18. Progressively work your way up through each When adjusting for firing at maximum
adjusting screw position, developing a smooth positions, take care that adjusting screws slope
progression slope from your first screw to the gradually toward that setting.
“maximum” position. 21. If system will operate with interrupted pilot (as
NOTE: To adjust the flame at any position, you must recommended), shut pilots off now and cycle
move the SYNCHRO Valve to the number you desire MICRO-RATIO® Valve slowly from minimum to
to adjust. This aligns the adjusting screw directly on maximum and back, with all convection system
top of the fuel valve plunger. A resulting adjustment of dampers in operating position or with furnace
the screw is directly applied to the fuel valve plunger door closed.
and its interconnected valve body linkage. 22. When burner performance is satisfactory and
If high temperature limit trips before adjust- stable throughout the firing range, reconnect
ment is completed, cycle back to minimum and linkage from control motor to MICRO-RATIO®
hold there until the system cools down before Valve.
attempting further adjustment. 23. Check out overall system operation on all fuels
19. Note gas supply pressure while continuing by cycling through light-off at minimum, interrupt-
with adjustment. If it falls off below acceptable ing pilot, and allowing temperature control system
range, it may be necessary to re-adjust the to cycle burner from minimum to maximum and
regulator. If so, lower firing positions will need return. Recheck all safety system interlocks for
rechecked and if necessary, re-adjusted before proper setting and operation.
proceeding.
20. When all screws have been adjusted, recheck
differential pressures with unit at operating
temperature. Refine “high fire” setting if neces-
sary, considering differential pressure, flame 24. Shut system down, closing all fuel valves and
length, and appearance. If any change is made, allowing an approved post-purge period before
refine gas adjusting screw settings, always shutting down fans and combustion air blower.
adjusting only that screw corresponding to Remove test connections and plug openings, then
the position at which flame is then set. replace all equipment covers and caps and
Flame should be blue with yellow tails and tighten all linkage set screws.
with a steady combustion noise. Dust or contami- 25. Instruct operator on proper start-up, operation
nants in the air stream may affect flame appear- and shutdown of system. Establish written
ance. instructions for reference.

mCORPORATION

To light and adjust MULTIFIRE® 31. Once your flame is established and refined at
Burner on light oil: carrier quadrant higher, screw all remaining
26. All preliminary adjustments as outlined for gas screws down to at least the same level as your
firing (steps #1 through #25) must have been first adjusted screw.
completed. NOTE: A preliminary setting can be established with
Verify all safety interlocks are operational before succeeding screw needs to be screwed in approxi-
opening any main and/or individual burner fuel mately one full turn deeper than its preceding screw.
valve. A smooth “stair-step” gradient pre-set at this point
Close all fuel hand valves and properly from low to high will simplify the remaining adjustment
reposition three-way cock to supply the atomizing steps.
air to burner(s). 32. With allen wrench engaged in second screw,
27. With gas pilot established and UV flame slowly move MICRO-RATIO® Valve to #1
supervision system operational, opening the position, adjusting as necessary to maintain
main oil shut-off valve(s) will allow #2 oil to flow ignition and the type of flame desired. Flame
to the SYNCHRO Oil Control Valve of the length should increase slightly, with a steady
MICRO-RATIO® Valve assembly. combustion noise.
Flame appearance should remain yellow-white
CAUTION: Oil flames are highly radiant. Use with no brown tips and exhibit a distinct “wrap-
eye protection and avoid prolonged viewing. ping” shape throughout the cataloged firing rate.
28. Turn MICRO-RATIO® Valve to minimum 33. If firing into an uncured refractory chamber,
position and, using the allen wrench supplied allow system to run at this setting for the dryout
with MICRO-RATIO® Valve, turn minimum period recommended by the furnace or refractory
adjusting screw of oil valve in (clockwise) to manufacturer, then continue adjustment of the
permit oil flow to the burner(s). Continue turning MICRO-RATIO® Valve.
inward slowly until minimum oil fire ignites. 34. Turn all remaining adjustment screws in
slightly further than second, then with allen
CAUTION: Shut off oil quickly if there is a wrench inserted in the third screw, slowly move
noticeable drop in oil pressure or if ignition MICRO-RATIO® Valve toward #2 position,
does not occur within a few seconds. adjusting as necessary.
29. Check that pressure downstream of oil CAUTION: If flame is extinguished, immediately
pressure regulator is sufficient to meet burner shut off oil and return MICRO-RATIO® Valve to
requirement plus piping losses. Re-adjust oil minimum position. Verify that pilots are still
pressure regulator if necessary. burning then reopen oil valve and turn screw
Failure of “some” burners on a multiple burner last adjusted in slightly further before returning
job to ignite would generally indicate line scale or to that firing position. Refine adjustment if
dirt obstructions in the oil valve, oil tube and/or oil necessary.
tip. Disassemble, inspect and clean if necessary.
30. Once ignition occurs, turn minimum screw in 35. Progressively work your way up through each
(for more fuel) or out (for less) until a yellow- adjusting screw position, developing a smooth
white flame is produced without smoke or brown progression slope from your first screw to the
tips. When properly adjusted, it should be “maximum” position.
possible to shut off pilots with the flame detection NOTE: To adjust the flame at any position, you must
system (if used), holding in on main flame only. move the SYNCHRO Valve to the number you desire
to adjust. This aligns the adjusting screw directly on
top of the fuel valve plunger. A resulting adjustment of
the screw is directly applied to the fuel valve plunger
mCORPORATION


36. Note oil supply pressure while continuing 40. Check out overall system operation on all
with adjustment. If it falls off below acceptable fuels by cycling through light-off at minimum,
range, it may be necessary to re-adjust the interrupting pilot, and allowing temperature
regulator. If so, lower firing positions will need control system to cycle burner from minimum to
rechecked and if necessary, re-adjusted before maximum and return. Recheck all safety system
proceeding. interlocks for proper setting and operation.
37. When all screws have been adjusted, allow
system to reach operating temperature then
recheck minimum and maximum differential air
pressures. Readjust linkage between air and fuel
valves if necessary. If any change is made, refine 41. Shut system down, closing all fuel valves and
gas adjusting screw settings, always adjusting allowing an approved post-purge period before
only that screw corresponding to the position at shutting down fans and combustion air blower.
which valve is then set. Remove test connections and plug openings,
When adjusting for firing at maximum posi- then replace all equipment covers and caps and
tions, take care that adjusting screws slope tighten all linkage set screws.
gradually toward that setting. 42. Instruct operator on proper start-up, operation
38. If system will operate with interrupted pilot and shutdown of system. Establish written
(as recommended), shut pilots off now and cycle instructions for reference.
MICRO-RATIO® Valve slowly from minimum to
maximum and back, with all convection system
dampers in operating position or with furnace
door closed.

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CORPORATION
Notes
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CORPORATION

MULTIFIRE® Dual Fuel Burners Page 4500-A/P-1
Assembly Numbers
Complete Burner Assemblies [1] arranged for UV scanner mounting
2" 3" 4" 6" 8"

6" HO 6" HC
MULTIFIRE® Burners MULTIFIRE® MULTIFIRE® MULTIFIRE® MULTIFIRE® MULTIFIRE®
MULTIFIRE® MULTIFIRE®
II II II III III
Configured Item
2 MF 3 MF 4 MF 6 HO MF 6 HC MF 6 MF 8 MF
Number
[1] Refer to Product Data Sheet 9000-1 and -2 for alternate refractory materials at net extra charge

• Combustion Air Inlet Flange (8" only) • Cooling Tee
• Air Connection Type • Block Material
• Air Inlet Position • Seal and Support
• Gas Connection Type • Test Connection Kit (Combustion Air)
• Gas Drilling • Test Connection Kit (Fuel)
• Pilot
• Flame Detection
Spare Parts for MULTIFIRE® Dual Fuel Burners
2" 3" 4" 6" 8"

MULTIFIRE® 6" HO 6" HC
MULTIFIRE® MULTIFIRE® MULTIFIRE® ® ® MULTIFIRE
®
MULTIFIRE®
Burners MULTIFIRE MULTIFIRE
II II II III III
Gas Sealed pressure type pilot

11684 18639
pilot assembly (A)
assembly Hinged lighter por t
[2] 32377
cover (A)
Scanner cooling tee set (A) 30854 32878
Combustion air inlet flange kit (A) --- --- --- --- --- --- 21120
1/8" test connection kit (A) 34137
120/60 AC air by-pass solenoid 27600 28845 28846
valve (A) 1/2", Cv = 5 1", Cv = 21 1-1/4", Cv = 32
BV balancing valve for air 19118 19120 19121
by-pass line (A) 1/2", Cv = 5 1", Cv = 18 1-1/4", Cv = 42
Block & frame sub-assembly for basic
28336 28351 28355 30757 28446 32010
burner (R)
Block & frame sub-assembly with
carbon steel seal & suppor t 28337 28460 28461 30755 28462 31790
assembly (R)
Block & frame sub-assembly with
stainless steel seal & suppor t 28463 28464 28465 30756 28466 31791
assembly (R)
Nozzle block gasket (R) 32722 32723 32724 --- --- --- ---
Replacement spark ignitor (R) 18110
Pilot gas adjustable orifice (R) 38579
[2] Pilot assembly or hinged lighter port is required

m
CORPORATION
Bulletin 4600
OXY-THERM® Gas or Oil Burners
OXY-THERM® Oil Burner OXY-THERM® Gas Burner
• Provide clean combustion with low NOx levels, even with on-site generated oxygen
(approximately 90% purity) units. OXY-THERM® Burners use oxygen for the combustion reaction,
removing the major source of nitrogen available for the formation of NOx.
• Quickly convert between gas and oil service by changing the burner nozzle. Provides stand-by or
alternate fuel capabilities. Fuel oil capability ranges from light to heavy fuel oils.
• Designed for easy installation and maintenance. OXY-THERM® Burner nozzles can be removed
during furnace operation, eliminating costly downtime.
• Achieve higher flame temperatures by burning fuels with oxygen. OXY-THERM® Burners eliminate
the need for costly combustion air preheaters, regenerators or recuperators.
• Substantially improve the product quality by eliminating the flow reversals found in regenerative
melters. Oxygen-fuel firing reduces flue gas volume, resulting in less turbulence in the melter
atmosphere.
• Quickly change burner capacity by replacing the thread-on burner nozzle (gas burners only).
• Improve heat transfer, leading to better homogenization and fining of the melt. Hence, lower seed
counts, higher pull rates and better selections.
• Eliminate the need for water cooling and related water piping and maintenance.
• Provide application flexibility with 5:1 turndown range.
Gas OXY-THERM® manufactured under U.S. Patent #4690635,
Canadian Patent #1260378, U.K. Patent #2192982,
German Patent P3722446.8 and French Patent #8704742.
Oil OXY-THERM® Burner manufactured under U.S. Patent #5092760.
Additional patents pending in Canada, Europe, Japan, South Korea and Mexico.
CORPORATION 201 East 18th Street, P.O. Box 2068, Muncie, Indiana, 47307-0068. Phone: (765) 284-3304. FAX: 765-286-8394
Page 4602
OXY-THERM® Gas or Oil Burners

Flow control and shut-off valves (available from
Principle of Operation Maxon) need to conform with the appropriate codes
With OXY-THERM® Burners, oxygen for and standards for oxygen service.
combustion enters the burner body, mixes with the Two refractory block materials are available for
fuel and exits the burner block. OXY-THERM® Burners. Zedmul-20 burner blocks
For oil firing, oil enters through the nozzle, is are to be used for gas firing only, and should be
atomized and combines with the combustion oxygen checked for compatibility with your process. Zirconia
as it exits the burner block. burner blocks may be used with gas firing and are
The ignited oxygen-fuel flame discharges through required for oil firing due to the highly radiant nature
the refractory block tunnel and develops a luminous, of the flame.
soft, but tightly-wrapped flame pattern with low exit
velocities. Capacities
Pilots are generally not required for oxygen-fuel Gas OXY-THERM® Burners provide maximum
applications. Contact your Maxon representative outputs that range from 200 MBtu/hr (59kW) to 7.5
about specific piloting questions. MMBtu/hr (2.2MW). Oil OXY-THERM® Burners
Typical applications in the glass industry include provide maximum outputs that range from 2.7
tunnel-type ceramic kilns, converted regenerative- MMBtu/hr (790 kW) to 15 MMBtu/hr (4.4 MW).
type glass melters, and unit melters. NOTE: In the Imperial System, “M” refers to 103, “MM”
refers to 106.
OXY-THERM®
Oil Burner
(cutaway view)
OXY-THERM®
Gas Burner
(cutaway view)
4/94
OXY-THERM® Burners Page 4603
Design Guidelines
Applications using oxygen-fuel burner technology (see diagram at right). 3-way Valve
can vary greatly. Therefore, Maxon is providing Block cooling air/
general information which should guide users and oxygen (or other air Cooling Air
designers of furnaces that use oxygen-fuel burners. source) connects to the
NOTE: Premium-quality materials have been used valve, in addition to
➤
on the OXY-THERM® Burner, but metal components combustion oxygen.
can be destroyed by high furnace temperatures if the The cooling source ➤ To
burner is misused or left unprotected from cooling should not be com- Burner
➤
flows. Because most oxygen-fuel burner applications pressed air, since
operate at very high temperatures, these guidelines compressed air could
focus on enhancing burner performance and contain oils which Oxygen
longevity. contaminate oxygen-
clean components.
Design Guidelines A 3-way valve is recommended. The valve
1. Whenever the gas or oil insert is installed in the should offer 180° operation, with shut-off at 90°.
burner housing, cooling flow should be Every component that comes in contact with
established through the combustion oxygen oxygen must be cleaned for oxygen service.
connection (see item 4 for recommended piping). 5. Quick-connect devices for the combustion
Cooling flow may be either air or oxygen, but not oxygen, atomizing air/oxygen and fuel will
compressed air. An example of a cooling air facilitate hook-up and installation, especially
source would be the block cooling air on a glass when switching from fuel gas to fuel oil. Quick-
melter. Minimum recommended cooling air/ connect devices also limit the amount of time that
oxygen flows are 15 scfm for Series 600 OXY- burner components are exposed to furnace
THERM® Burners and 30 scfm for Series 900 temperatures without cooling flow. This is helpful
OXY-THERM® Burners. during hot conversions or when replacing existing
2. If the burner will not be fired for an extended burners.
period (over 24 hours), then the gas or oil insert 6. Burner and piping should be supported as shown
should be withdrawn from the housing. The in the installation instructions. Unsupported
service nut should be installed in its place, and piping puts stress on the block/frame assembly. If
cooling air/oxygen flow established (see item 1 enough stress is present, the burner block could
for recommended flow rates). This cooling flow crack, affecting performance and burner life.
will extend gasket life and retard the collection of 7. The Zedmul 20-C block is recommended for fuel
particulate material inside the burner block gas fired applications. It provides an economical,
opening. As an alternative to cooling flow, the high-quality burner block material, and is familiar
burner housing may be removed, if desired, to users throughout industry. Zedmul 20-C burner
leaving the block/frame assembly mounted to the blocks have been used on applications such as
furnace wall. container glass, sodium silicate and fiberglass
3. On oil fired burners, reduced pressure atomizing furnaces.
air/oxygen should be maintained when the 8. The Zirconia block is required for all fuel oil fired
burner is not firing. Without atomizing flow, some applications. Even if fuel oil is anticipated only as
residual oil can communicate through the atom- a back-up fuel, the Zirconia block must be used.
izer holes and into oxygen clean components in The Zirconia block may also be used for gas
the oil insert. The atomizing flow will also serve to firing if the user has concerns about the compat-
cool the oil nozzle (10 psig atomizing pressure ibility of the Zedmul 20-C block with his or her
would be sufficient). Required safety practice is process.
that any time atomizing flow is shut off, oil inserts 9. All liquids and atomizing air/oxygen should be
are to be removed and re-cleaned to prevent any filtered. A 100-mesh duplex fuel oil filter is
fuel oil residue and oxygen from coming into recommended for oil fired OXY-THERM®
contact with each other. Burners. Filtering the atomizing air/oxygen will
4. To provide cooling flow to the burner housing, help prevent debris from plugging the atomizing
Maxon recommends installing a 3-way ball valve holes.
immediately upstream from the combustion 10. OXY-THERM® fuel gas burners should be specified
oxygen connection on the burner at or near expected design capacity. For
6/94
Page 4604 OXY-THERM® Burners
Design Guidelines (continued)

applications requiring maximum flame length, the for example, a 300-liter-per-hour burner was
burners should be sized or specified for the true specified, but operated at 200 liters per hour, the
expected maximum capacity. Maxon sizes and flame length would be significantly shorter than if
fabricates fuel gas burner nozzles according to the 200-liter-per-hour burner was specified and
customer specifications. The design of the OXY- used. See below for nominal and maximum
THERM® allows quick changing of the threaded capacities for fuel oil inserts.
gas nozzle in those cases where burners may need 12. For proper atomization, fuel oils should be
more capacity than expected, or if future furnace supplied to the burner inlet at a viscosity of 100
loads are expected to increase. SSU (20 centistokes) or less. A typical #6 fuel oil
11. OXY-THERM® fuel oil burners should also be would need to be heated to approximately 220°F
specified at or near expected design capacity. If, to obtain the proper viscosity.
Capacity / Selection Data

All Maxon gas OXY-THERM® Burners are custom oil is anticipated only as a back-up fuel, the Zirconia
drilled to meet your specific application requirements. block must be used. The Zirconia block may also be
This helps assure that you get the best possible used for gas firing if the user has concerns about the
burner – selected, sized and drilled – to meet your compatibility of the Zedmul 20-C block with his or her
specific job’s requirements. process. Both materials have shown excellent results
in operations with no reports of failures after five
NOTE: A calibrated flow meter in the gas and the
years of operation and several campaigns.
oxygen line is recommended for establishing
accurate volumetric flow rates.
Gas OXY-THERM® Burner Series 600 Series 900
Maxon oil OXY-THERM® Burners are available in
two block sizes and six oil insert sizes – 70, 100, 150, 200 1250
Maximum capacity range
to to
200, 300 and 400 liters per hour (maximum capacities in 1000's Btu/hr
2,000 7,500
2.7 MMBtu/hr through 17.6 MMBtu/hr). Minimum capacity 1/5 of maximum capacity
The maximum capacities shown in the
Oxygen see cur ves on page 4605
accompanying charts are a range of heat releases. Required pressures
to burner inlet for Natural gas 8 psig
The minimum capacity will be 1/5 of the specific maximum capacities
maximum capacity selected. Your specified maximum Propane 20 psig
capacity dictates the individualized fuel drilling used in Typical oxygen to To natural gas 2.1 to 1
fuel volumetric
the manufacture of the burner’s gas insert. ratios* To propane 5.2 to 1
The Zedmul 20-C block is recommended for fuel
18" 30"
gas fired applications. It provides an economical, Approximate Diameter
maximum maximum
high-quality burner block material and is familiar to flame geometry
Length 1.5 ft per MMBtu/hr
users throughout industry. The Zirconia block is
*Exact calorific values should be checked and oxygen/fuel ratio
required for all fuel oil fired applications. Even if fuel adjusted accordingly.
Series Series 600 or 900 Series 900

Oil OXY-THERM® Burners
Size 70 100 150 200 300 400
Maximum fuel flow (liters/hr) 80 115 173 230 345 460
Maximum output (MMBtu/hr) 3.06 4.40 6.61 8.81 13.21 17.62
Nominal fuel flow (liters/hr) 70 100 150 200 300 400
Minimum with 5:1 turndown (MMBtu/hr) 0.61 0.88 1.32 1.76 2.64 3.52
Atomizing oxygen/air flow (scfh) at 50 psig 434 519 646 784 1205 1591
Oxygen pressure to burner inlet ("wc) See cur ves on page 4606
Fuel pressure to burner inlet (psig) at nominal 18.1 25.7 38.6 51.5 77.1 102.7
Approximate flame diameter (inches) 18 18 24 24 30 36
Approximate flame length (feet) 3.0 4.0 6.0 7.5 11.5 15.5
NOTE: In the Imperial System, "MM" refers to 106.
Gas OXY-THERM® Burners

Combustion Oxygen Pressure Curves
Series 600
10,000
Oxygen Flow (scfh)
1,000
200
0.1 1 10 50
Oxygen Pressure (inches w.c.)
Series 900
50,000
Oxygen Flow (scfh)
10,000
1,000
500
0.05 0.1 1 10 100
12/95

Series 600 (70 lph)

10,000
1,000
1 10 100
Series 900 (70, 100, 150, 200 lph)

20,000
Oxygen Flow (scfh)
10,000
1,000
0.1 1 10 100

Series 900 (300, 400 lph)
5/96

Atomizing Oxygen/Air Flow vs. Pressure
Each line represents a particular oil
nozzle nominal rating, e.g., “400”
represents the 400 liter per hour oil
nozzle.
NOTES:
• If oxygen is used for atomizing, its
volume should be factored in when
establishing the excess oxygen
requirements for each application. If air is
used for atomizing, the volume of oxygen
contained in the air is so small that it
represents an insignificant amount of the
oxygen required for combustion.
Therefore, it should not be factored into
the operating fuel/oxygen ratios.
• The volume of atomizing flow for cooling
as described on page 4603, item 3,
would equal approximately 20 percent of
the atomizing volume at 50 psig shown
on the chart.

Fuel Oil Flow vs. Pressure
Each line represents a particular

oil nozzle nominal rating, e.g.,
“400” represents the 400 liter per
hour oil nozzle
Dimensions

Series 600 Series 900

Series 600
Series 900
2/95
Dimensions
Optional Pilot Arrangements
Series 600 Series 900
Adjustable Pilot Gas Orifice Spark Ignitor

(included in pilot) (included in pilot)
Pressure-type
sealed port pilot
(optional)
2/95
Notes
OXY-THERM® Burners Page 4600-S-1
The burner is normally only a part of your complete Possible Burner Mounting Configurations
combustion system. Additional pipe train accessories
and control components will be required for a com-
plete system installation.
To prevent damage in transit, the burner insert and
mounting gaskets may be packed separately and
shipped loose.
OXY-THERM® Burners can fire in all directions
except downward. Avoid orientations which might
permit an idle burner to collect debris.
Include observation ports in your design to provide
a view of the flame area. This will simplify start-up and
adjustment procedures.
Burner block failure could result from external
stresses and strains transmitted to the burner through
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.
Burner Mounting
The sketches at right show two possible methods
of mounting and holding an OXY-THERM® Burner
block and frame assembly in place. Alternate support
methods are possible.
The primary focus is to compress the frame against
the wall of the melter and to support the weight of any
system piping.
The burner block sits on the sill or wall. The burner
block and frame weight should be supported and
equally distributed. If burner port holes are too large,
shims may be used to align the burner.
The opening in the furnace shell should normally
provide 1/16" clearance on all sides. High tempera-
ture furnace sealant or gasketing should be used
between burner mounting flange and furnace shell.
For maximum burner life, burner frame and furnace
shell must be protected from hot gas flows.

m
CORPORATION
Page 4600-S-2 OXY-THERM® Burners
Hot Installation Procedure for Materials commonly used in valves and burners for
Zedmul 20-C Burner Blocks ordinary service have ignition temperatures in gas-
eous oxygen that are above normal flowing tempera-
Over the last 20 years, the following procedure has tures. These may include organic materials such as
been used to install Zedmul 20-C burner blocks “on Neoprene, Viton, Teflon, lubricants and sealing
the fly” in glass operations. Most of the experience compounds. Therefore, the danger of combustion
has been in float and container glass operations with exists in materials being ignited not by the normal
hot face temperatures between 1425°C (2600°F) and flowing temperatures, but rather by localized higher
1675°C (3050°F). temperatures resulting from such conditions as:
1. All moisture within the burner block should be 1. Adiabatic Compression
removed before starting installation. This is Rapidly opening a valve may result in an abnor-
accomplished by placing the burner on the crown mally high gas temperature caused by adiabatic
of the furnace or under the port area for a day. compression of a low pressure gas at the valve
2. Where the new block will contact older, hot outlet.
materials, Fiberfrax paper should be used as a 2. Dirt or Foreign Particle Impingement
thermal buffer. A foreign particle that is being carried in a high
3. Remove the old block and clean the opening. velocity gas stream and which strikes the burner or
4. Insert the new block into the furnace. a valve body wall may transform its kinetic energy
5. Permit the new block to heat-up to near ambient into heat sufficient to raise the impinging particle or
temperatures (usually about one half to three the material it strikes to its respective ignition
quarters of an hour). temperature.
6. Resume normal operations. 3. Ignition by Stray Static Electricity Sparks
A valve, for example, that has already been heated
Burner Adjustment and Control
up by friction may transmit sufficient heat to ignite
Oxygen-fuel burners require accurate control of other surrounding metallic materials from static
both fuel and oxygen for optimum performance. electricity sparks.
Piping to individual burners should include control 4. Excessive Friction
valves for both oxygen and fuel. In addition, flow Heat generated by friction between two surfaces
meters for oxygen and fuel capable of local or remote may raise the temperature of one or both of the
readout are required for proper burner adjustment. surfaces to the ignition point of a substance within
Flame sensing may be accomplished by UV an oxygen atmosphere.
scanner. Burner design can incorporate a UV scan- Organic materials have ignition temperatures
ner port suitable for supervision of both pilot and main below that of metals. Therefore, use of organic
flames. UV scanner, if used, should be kept as close materials in contact with oxygen should be avoided as
to burner as feasible. Heat block, if used, may affect much as possible. The best material is one with the
signal strength with some brands of UV scanners. highest ignition temperature and lowest specific heat
Electrical service must match the voltage, phase that possesses the necessary mechanical properties
and cycle of all electrical system components and be for the application.
compatible with nameplate ratings. Ensure that all Lubricants and sealing compounds should be
normal control safeguards are satisfied. used sparingly and should be a material that is
CAUTION: Oxygen should only be used with suitable for oxygen service. Common petroleum
approved materials, properly cleaned pipe and lubricants are not satisfactory and are particularly
equipment, and specially designed systems. hazardous because of their high heat of combustion
Ordinary materials can be extremely flammable and high rate of reaction.
in the presence of oxygen and air enriched with O-rings should be lubricated with Series 25-10M
oxygen. Halocarbon or Fluoramics Lox 8 grease or equal. Pipe
threads should be sealed with Fluoramics Lox 8 pipe
All organic and many inorganic materials will joint paste or equal.
react with gaseous oxygen at particular temperature
and pressure conditions. Fire and/or an explosion
may result from this reaction.
m
CORPORATION

OXY-THERM® Burners Page 4600-S-3
Other Materials and Precautions Main fuel regulator is essential to maintain a
• Brass or copper pipe should be used in any pipe uniform system supply pressure.
carrying oxygen. Size the regulator for full system capacity at the
• Do not use Buna-N in any equipment that contacts required pressure, carefully considering pipe train
oxygen. losses. Follow the instructions attached to the regula-
• Packings, such as for valves, should be Viton or tor during installation.
Teflon. If used, pilot take-off should be upstream of the
• All accessory and pipe train components such main gas regulator, but downstream of the main gas
as regulators, solenoid valves, gauges, pressure cock. It should normally include its own pilot gas
switches, etc., must be oxygen service regulator, a solenoid valve, and shut-off cock. A pilot
compatible. adjustable orifice at the pilot inlet simplifies
Fuel supply piping must be large enough to adjustment.
maintain the required fuel pressures cataloged for the Pilots do not use oxygen.
particular burner size used with burner operating at
full rated capacity. Pilot piping must be large enough to provide for
Anything more than minimal distance or piping the full flow and pressures shown in the catalog for
turns may necessitate oversizing piping runs to keep your particular burner size.
pressure drops within acceptable ranges. Fuel shut-off valves (when properly connected to
If multiple burners are fed from a single fuel train, a control system) are designed to shut the fuel
care should be taken to minimize pressure drop and supply off with a loss of electrical power. Manual
give maximum uniformity. reset valves require operator attendance each time
Clean atomizing oxygen/air lines are essential to the system is started up (or restarted after a shut-
prevent plugging of critical atomizing ports in the oil down). Motorized shut-off valves permit automatic
insert. start-restart when used with an appropriate control
Clean fuel lines are essential to prevent blockage system.
of pipe train components or burner fuel ports. Any test connections must be plugged except
Fuel and oxygen piping should be located when readings are being taken.
reasonably close to the burner and sized for the Control systems should provide all normally
pressure and volume requirements of the burner. recommended interlocks (including operation of fuel
Main shut-off cock should be upstream of the shut-off valves). Sequencing control systems are
main fuel regulator and pilot (if supplied) line take-off. available from Maxon that include provision for post-
Use it to shut off fuel during shut-down periods of purge pilots during all but emergency shut-downs.
more than a few hours. Control system’s circuitry must not allow main
fuel shut-off valve to be opened unless oxygen is
A fuel throttling control valve is not intended on, and must de-energize valve upon loss of oxygen
for tight shut-off. pressure, along with the other usual system inter-
locks.
Start-up instructions are specific to each applica-
tion. Contact your Maxon representative for instruc-
tions for your particular application.

m
CORPORATION
Page 4600-S-4 OXY-THERM® Burners
Notes
m
CORPORATION

OXY-THERM® Burners Page 4600-A/P-1
Assembly Numbers
Gas OXY-THERM® Burners Oil OXY-THERM® Burners
Burner Series Configured Item Number Burner Series Configured Item Number
Series 600 600 OT Series 607 607 OT
Series 900 900 OT Series 907 907 OT

Series 910 910 OT
Series 915 915 OT
Series 920 920 OT
Series 930 930 OT
Series 940 940 OT
Segment Choice Detail – Gas OXY-THERM® Burners

Segment Choice
(DEFAULT is shaded)
NAT Natural Gas
FUEL Type of fuel
PROP Propane Gas
Type of material used for burner ZED Zedmul
BLOCK MATERIAL
block ZIRC [1] Zirconia
NO No pilot chosen
PILOT Optional pilot
YES Pilot chosen
[1] Zirconia block required when back-up fuel is oil
Segment Choice Detail – Oil OXY-THERM® Burners

Segment Choice
(DEFAULT is shaded)
FUEL Type of fuel OIL Fuel Oil
BLOCK MATERIAL
block ZIRC Zirconia
NO No pilot chosen
YES Pilot chosen
Ordering Designations (oil burners only)

Series 607 = Series 600 (6" x 6" block), 70 lph Example:
Series 907 = Series 900 (9" x 9" block), 70 lph
Series 910 = Series 900, 100 lph Series 6 0 7
Series 915 = Series 900, 150 lph
Series 920 = Series 900, 200 lph 6" x 6" block 70 lph
Ordering Designations (gas burners only)
Series 600
Gas port sized according to firing rate
Series 900 by Maxon Sales personnel

mCORPORATION
Product: OXY-THERM® Burners Page: 4600-1 Date: 2/96
Removing the gas insert Reinstalling the gas insert

NOTE: This procedure can be done by hand without 1. Remove the service nut (solid cap) from the back
the use of tools. of the burner housing.
1. Shut off the gas flow to the burner. 2. Carefully slide the gas insert into the burner
housing, keeping the tip centered within the block.
2. Reduce the oxygen flow or switch to bypass air.
Push until the gas insert is in the block far enough
This will keep the housing cool while removing the
for the first O-ring to disappear within the burner
gas insert.
housing. You should feel the nozzle tip seat into
3. Remove the gas line from the burner at the quick the nozzle body insert, indicating that the gas
disconnect between the burner and the flex hose. insert is centered.
4. Unscrew the insert nut from the burner housing. If 3. Slide the insert nut onto the end of the gas insert
installed properly, this can be done by hand and begin to tighten it onto the burner housing.
without the use of tools. The action of tightening the nut will draw the
second O-ring into the housing. When the nut is
5. Remove the gas insert from the burner housing
hand-tight and the nozzle is seated properly (no
by gently rocking it from side to side while pulling
further forward movement), there should be a
outward.
small gap between the end of the nut and the rim
6. Screw the service nut (solid cap) onto the threads of the housing. Once the nut is hand-tight, back it
of the burner housing. This will prevent inspirated off 1/4 turn (it should turn freely). This will be its
air from entering the furnace and protect from final position (do NOT retighten).
stingout during the time that the gas insert is
4. Reconnect the gas line to the back of the gas
removed. Do NOT tighten.
insert.
7. Inspect or replace the gas insert as necessary. If
5. Shut off the bypass air (if it was on) and turn the
the nozzle tip is to be replaced, do NOT use any
oxygen valve back to its fully open position.
tools to tighten. It is sealed by an O-ring and
should be hand-tight. 6. Open the gas valve to its fully open position. A
faint “pop” will be heard indicating that the burner
NOTE: The nozzle tip opening should be round and
is lit.
free from any obstruction or debris.
7. Visually inspect the flame to ensure ignition and
8. Inspect the two O-rings to ensure that they are
proper flame appearance.
not cracked or damaged. Make sure that they are
well lubricated with an oxygen-compatible lubri-
cant before reinstalling.
Product Data Sheet Product: OXY-THERM® Burners
Page: 4600-1 Date: 3/98

Do Not Reproduce
Running all capacity through a single port might

Our burners work with all available oxygen
lead you to believe that the OXY-THERM® burner
source technology. Because on-site generated
produces a high velocity / high momentum flame. On
oxygen is common, it is important that users
the contrary, when you consider that momentum =
understand that our burners work with the low
mass x velocity, you will see that the low-velocity
pressure supplied by such units. Refer to the
dynamics of the oxygen dominate the flame shape.
combustion oxygen curves on pages 4605-
The oxygen has double the mass of the natural gas
4607 and 4656-4658.
(molecular weight of O2= 32 versus 16 for natural
gas), and has at least two times the volumetric flow
Burner Application rate of natural gas. Therefore, the oxygen dynamics
prevail. This results in a low momentum non-lofting
Glass engineers (or others) are typically inter- flame pattern. The positive effect of the high-velocity
ested in the following information when considering fuel is that the OXY-THERM® flame does not tend to
oxy-fuel burners (this information can be found in the loft as competitors’ burners do. This keeps the flame
catalog): off of the crown, even at turndown. Our competition
angles their burners downward to compensate for the
1. Block size lofting. In many instances, however, this causes
2. Flame length hard impingement on the glass surface, which
3. Connection sizes creates a hot spot that the unmelted batch material
4. Block composition moves away from. This usually results in poorer
5. Utilities / pressure required glass quality and lower selection rates.
6. Capacities / turndown
7. Oxy-fuel ratios Additional Information
8. Cooling flows
9. Maintenance required
1. Many of our competitors, especially oxygen
companies, talk about the number of oxy-fuel
Some glass engineers also want to know where the
conversions they’ve been involved with. When
burners should be mounted in the furnace wall. For
you ask them about it, however, you’ll find
existing applications of the Series 900 OXY-THERM®
they’ve only supplied the oxygen, not the burn-
burner, the distance from the centerline of the burner
ers. Maxon has been the dominant burner
to the batch surface has ranged from 10 to 18 inches.
supplier for glass melters that have been con-
Most often this distance was between 12 and 14
verted to oxy-fuel technology.
inches. The burner block can extend out of the wall 1
inch or recess back into the wall a maximum of 3
2. Comparisons to the OXY-THERM® in our com-
inches. Also, burners are mounted and fired parallel
petitors’ advertising focus on the burner that we
to the batch surface.
developed in the early 80’s, not the burner that
To process an order for a gas OXY-THERM®
we have on the market today. Maxon pioneered
burner, total Btu requirement per burner needs to be
the use of non-water-cooled oxy-fuel burners. As
specified on the order.
with any new technology, the first efforts were
All gas nozzles are custom drilled per order. It is
improved upon. We’ll readily admit that some of
not uncommon to have several different maximum
those first burners had problems in certain
capacities specified for the same burner size on a
applications, but we’ve continuously improved
single order. This is because, for a single glass
the burner and solved its shortcomings. Our
furnace, various burner locations may have different
competitors still focus on our early development
capacity requirements. To size the gas port, the
problems.
following information is required:
3. Maxon has installed more than 600 oxy-fuel
1. Fuel (heating value and specific gravity)
burners in more than 60 furnaces worldwide.
2. Maximum heat release required
Nobody else has as much oxy-fuel burner
experience in the glass industry. Nobody even
comes close.
Product Data Sheet Product: OXY-THERM® Burners
Page: 4600-2 Date: 3/98

Do Not Reproduce
4. Maxon is independent. We do not sell oxygen 6. The user can decide how to control the oxygen
and we do not design furnaces. We do not tell and fuel flow to the burner. Our burners have
glass engineers how to do what they already worked with a wide range of control schemes.
know how to do. We sell combustion equipment.
That’s our expertise. 7. The same burner is used to fire both gas and oil.
A mere change to the nozzle and you can
5. In numerous comparison tests where change from one fuel to the other in less than 5
competitor’s burners were fired in the same minutes - FLEXIBILITY.
furnace, Maxon burners have been chosen every
time. There have been lots of comparisons made In summary, Maxon offers users the freedom of
on paper, but we have won the ones that count choice: choice of furnace designer / consultant,
due to lower emissions and better quality glass choice of oxygen supplier, choice of control sche-
production. matic. Maxon has no obligations or ties to any of the
above suppliers of equipment and services. The
OXY-THERM® burner can be used with anyone’s
oxygen, with anyone’s controls and with anyone’s
engineering services.
Bulletin 4620
Maxon Series 300 OXY-THERM® Burners
Maxon Series 300 OXY-THERM® Burner with square block and optional self-ignition feature
• Capacities up to 300,000 Btu/hr (88 kW) with choice of two block shapes.
• Burns any gaseous fuel, including poor quality fuels that may be unstable using air for combustion.
• Clean combustion with low NOx levels. OXY-THERM® Burners use oxygen for the combustion
reaction, removing atmospheric nitrogen as a source of NOx emissions.
• Easy installation and maintenance. OXY-THERM® Burner nozzles can be removed during furnace
operation, eliminating costly downtime.
• Dramatically increase available heat by producing higher flame temperatures from burning fuels
with oxygen. OXY-THERM® Burners eliminate the need for costly combustion air preheaters,
regenerators or recuperators.
• Substantially reduce the size of exhaust gas handling equipment. Oxygen-fuel firing can reduce
flue gas volume and exhaust gas treatment requirements by 75% or more.
• Improve heat transfer with increased flame temperature and luminosity.
• Self-cooling design eliminates the need for water cooling and related water piping and
maintenance.
• Simple, robust design and high operational turndown provides application flexibility.
Patents: Manufactured under U.S. Patent

#6,345,979. Additional patents pending.
Page 4622
Maxon Series 300 OXY-THERM® Burners

Principle of Operation Typical applications include converted
regenerative-type furnaces and melters, unit melters,
With Series 300 OXY-THERM® Burners, oxygen laboratory furnaces, non-ferrous melting and recovery,
for combustion enters the burner body, mixes with and various special applications requiring high
the fuel at the nozzle and exits the burner block. temperatures with focused flame profiles.
The flame discharges through the refractory block Flow control and shut-off valves (available from
tunnel and develops a luminous, tightly-wrapped flame Maxon) need to conform with the appropriate codes
pattern. and standards for oxygen service.
The Series 300 OXY-THERM® Burner features a
self-ignition option. Contact your Maxon representative Capacities
about specific ignition/piloting questions. Series 300 OXY-THERM® Burners provide a
maximum output of 300,000 Btu/hr (88 kW). Minimum
capacity is 5,000 Btu/hr (60:1 turndown).
Series 300 round block (bottom) and round block with Series 300 square block (bottom) and square block with
optional self-ignition feature (top) optional self-ignition feature (top)
6/03
Series 300 OXY-THERM® Burners Page 4623
Installation and Operation Guidelines

Applications using oxygen-fuel burner technology 7. The burner block should be slightly recessed inward
can vary greatly. Maxon provides the following from the inner furnace wall, and can be recessed by
general guidelines for burner installation and as much as 3 inches (76mm).
operation. Furnace designers will provide design
8. OXY-THERM® Burners can fire in any direction.
specifics for individual furnaces.
However, avoid orientations which might permit an
Note: Premium-quality materials have been used idle burner to collect debris.
in the Series 300 OXY-THERM® Burner, but metal
9. Furnace observation ports should be located to
components can be destroyed by high furnace
provide a view of the flame. This will simplify
temperatures if the burner is misused or
burner start-up and adjustment.
disconnected from cooling flows. Because most
oxygen-fuel burner applications operate at very high
temperatures, these guidelines focus on enhancing Ignition (for burners with the self-ignition feature)
burner performance and longevity. Maxon recommends the use of a 6000-volt full-
wave spark ignition transformer for use with Series
1. Every component that comes in contact with 300 OXY-THERM® Burners that are equipped with the
oxygen must be cleaned for oxygen service. self-ignition feature. A standard .250" female spade
connector should be used on the ignition transformer
2. Cooling flow, either clean-dry air or oxygen, must be connection. The #58375 Insulator Block (or optional
used whenever the burner assembly is in a high #1048182 UV Scanner Adapter) prevents stray
temperature atmosphere and is not firing. Typical voltages from damaging any sensitive electronic
compressed air systems contain lubrication equipment, and must not be removed (except as
oils, which will contaminate oxygen-clean outlined in the Hot Installation Procedures).
environments and cannot be used for cooling
flows without special treatment. Cooling air Installation & Start-up
provided by plant process air fans is one possible Take care not to damage the burner parts when
source. making the fuel connection. On burners using the self-
3. To provide cooling flow to the burner assembly, ignition option, the 3/16" compression fitting on the
Maxon recommends installing a 3-way ball valve Insulator Block can be removed for 1/8" NPT
immediately upstream from the combustion oxygen connection. The compression nut should only be
connection on the burner. Connect cooling source tightened 3/4 of a turn from finger-tight.
and combustion oxygen source to the valve. Refer to the Capacity and Specification chart for
recommended pressures and flow rates. Spark
4. Use care when connecting fuel tubing/piping to the transformer should be energized only until the burner
burner fuel connection (3/16" O.D. tubing and/or 1/8" lights. Cooling oxygen or clean, dry air should be
NPT). Fuel connection is not designed to support provided when the burner is installed in a high
fuel piping. Tubing and compression fittings are temperature atmosphere and the burner is not
recommended over standard piping. firing.
5. Burners, piping, and UV scanners (if burner The proper sequence for igniting the Series 300
mounted) should be supported to relieve stress to OXY-THERM® Burner with the self-ignition feature is;
burner components. Unsupported equipment will Oxygen on, Spark on, Fuel on (Ignition occurs), Spark
cause damage to the burner. Flexible connections off.
are recommended in all piping to relieve stress and
to account for thermal expansion.
6. The material used in the refractory block is an
alumina/zirconia/silica composition. It is the
responsibility of the user to assure its compatibility
with the user’s process.
6/03
Page 4624 Series 300 OXY-THERM® Burners
Capacity and Selection Data

Maxon Series 300 OXY-THERM® Burners are NOTE: A calibrated flow meter in both the fuel gas
available in four versions. An alumina/zirconia/silica and oxygen line is recommended for establishing
(AZS) composition refractory block is available in both accurate volumetric flow rates. Exact calorific
3" square and 3" round (approximately 2.8" dia.) values and oxygen purity should be checked and
versions. The burner is also offered with or without a oxygen/fuel ratio should be adjusted accordingly.
spark-ignition feature.
OXY-THERM® Burners Series 300

Maximum 300,000 Btu/hr (88 kW)
Capacity
Minimum [1] 5,000 Btu/hr (9 kW) (60:1 turndown)
Oxygen 630 scfh at approx. 2.9" w.c.
Required pressures to burner inlet for maximum capacities Natural gas [2] 6.2 psig (.43 bar)
Propane [2] 2.5 psig (.17 bar)
To natural gas 2.1 to 1
Typical oxygen to fuel volumetric ratios*
To propane 5.2 to 1
Approximate flame size Diameter 1" to 6" (15.2 cm)

(visible flame length firing in open air) Length 36" (91.4 cm)
*Exact calorific values and oxygen purity should be checked and oxygen/fuel ratio should be adjusted accordingly.
[1] Lower minimums are possible, but require review by Maxon engineering. [2] Lower maximum pressures are possible if
spark ignition feature is not required.
Approximate Flame Lengths - Series 300 OXY-THERM® Burner
40
35
30
25
Inches
20
15
10
0
0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300
CFH Gas
Dimensions
Series 300 OXY-THERM® Burner with square block
16.5" (41.9 cm)

removal clearance
Exterior Furnace Wall
6.5"
45˚ (16.5 cm) 0.8"
ref. Gas Inlet 10.0" (25.4 cm)
(1/8"NPT) M6 x 1.0 Thd.
OXY-THERM
3"
R
R
SERIES BURNER
URNER
DATE
TE FO NUMBER
MAXON
MAXON CORPORATION
CORPORATION
MUNCIE, INDIANA U.S
U.S.A.
.A. sq.
1.2"
3/4" NPT 0.2"

3.0" Oxygen Inlet
sq. 3.0"
(7.6 cm) (7.6 cm)
Series 300 OXY-THERM® Burner with round block
16.5" (41.9 cm)

removal clearance
6.5"
45˚ (16.5 cm) 0.8"
(1/8" NPT) M6 x 1.0 Thd.
OXY
XY-THERM
-THERM R
2.8"
R
SERIES BURNER
URNER
DATE
TE FO NUMBER
dia.
MAXON
MAXON CORPORATION
CORPORATION
MUNCIE, INDIANA U.S
U.S.A.
.A.
1.2" (7.1 cm)
3/4" NPT 0.2"

3.0" Oxygen Inlet
sq. 3.0"
(7.6 cm) (7.6 cm)
6/03
Dimensions
Series 300 OXY-THERM® Burner with square block & self-ignition feature
19.5" (49.5 cm)

removal clearance
9.5"
45˚ (24.1 cm)
(3/16" O.D. tube) M6 x 1.0 Thd.
OXY-THERM
-THERM
3"
R
R
SERIES BURNER
URNER
DATE
TE FO NUMBER
MAXON
MAXON CORPORA
CORPORATION
MUNCIE, INDIANA U
U.S
TION
.S.A.
.A. sq.
1.2"
3/4" NPT
NOTE:
3.0" Oxygen Inlet
sq. Compression fitting
can be removed for 3.0"
(7.6 cm)
1/8" NPT inlet (7.6 cm)
Series 300 OXY-THERM® Burner with round block & self-ignition feature
19.5" (49.5 cm)

removal clearance
9.5"
45˚ (24.1 cm)
ref Gas Inlet 10.0" (25.4 cm)
(3/16" O.D. tube) M6 x 1.0 Thd.
OXY-THERM R
2.8"
R
SERIES BURNER
URNER
DATE FO NUMBER
dia.
MAXON
MAXON CORPORATION
CORPORATION
MUNCIE, INDIANA U.S
U.S.A.
.A.
1.2" (7.1 cm)
3/4" NPT
3.0 NOTE:
Oxygen Inlet
sq. Compression fitting
can be removed for 3.0"
(7.6 cm)
1/8" NPT inlet (7.6 cm)
Fully engage burner assembly (Item 2)
against inside lip of refractor block (Item 1),
then apply spring loaded set screw (Item 7)
as directed.
OXY-THERM R%%135
SERIES BURNER
DATE FO NUMBER
MAXON CORPORATION
MUNCIE, INDIANA U.S.A.
5 6 7 2 3 4 1
Use Loctite Threadlocker MP-9210,

screw in spring loaded set screw until it
completely bottoms out, then back-out
1/8th of a turn.
Item No. Description

1 Block & Frame Assembly
2 Burner Inser t Assembly
3 Backplate
4 Backplate Gasket
5 M6 x 1.0 Hex Nut
6 M6 Plated Washer
7 Spring Plunger
6/03
Notes
Series 300 OXY-THERM® Burners Page 4620-S-1
General Instructions The burner is only a part of your complete
• Fuel and oxygen piping must be supported to combustion system. Additional pipe train accessories
prevent undue stress and damage to burner block and control components will be required for a complete
and components. system installation.
• Fuel and oxygen supply piping must be large Important: Do not discard packing material until
enough to maintain the required fuel pressure all loose items are accounted for.
cataloged for the particular burner size used with
burner operating at full rated capacity.
• Fuel and oxygen piping should be located reason- Cold Installation Procedure
ably close to the burner and sized for the pressure Read the entire installation procedure before
and volume requirements of the burner. proceeding with the installation of oxygen-fuel burners.
• Anything more than minimal distance or piping turns
Failure to follow the proper installation
may necessitate oversizing piping runs to keep
sequence noted below could result in damage or
pressure drops within acceptable ranges.
destruction of vital burner components. Cooling
• If multiple burners are fed from a single fuel train,
oxygen or airflows should be present at all times
care should be taken to minimize pressure drop and
when the burner housing and metal components
give maximum uniformity.
are mounted to a hot furnace.
• Clean fuel lines are essential to prevent blockage of
pipe train components or burner fuel ports. 1. Visually inspect the burner. The burner is shipped
• Main shut-off cock should be upstream of the main fully assembled, and is designed for installation as a
fuel regulator. Use it to shut off fuel during shutdown complete unit.
periods of more than a few hours. 2. Confirm that cooling air or oxygen is available at the
• A fuel throttling control valve is not intended for tight individual burner ports and control stations before
shut-off. installing the burner.
• Main fuel regulator is essential to maintain a uniform 3. Install the burner assembly into the furnace wall.
system supply pressure. Refer to the information at right for Hot Installation
• Size the regulator for full system capacity at the Procedures. Refer to page 4620-S-2 for Burner
required pressure, carefully considering pipe train Mounting instructions.
losses. Follow the instructions attached to regulator 4. Complete connections for fuel, oxygen and electrical
during installation. (if burner is supplied with spark ignition feature).
• Fuel shut-off valves (when properly connected to a 5. Verify flow of clean-dry cooling air if the furnace will
control system) are designed to shut the fuel supply be heated up with another burner. Improper flows or
off with a loss of electrical power. Manual reset no cooling flows could damage or destroy the burner
valves require operator attendance each time the during heat-up.
system is started up (or restarted after a shut- 6. The UV scanner must be field-supported if the UV
down). Motorized shut-off valves permit automatic scanner is connected to the OXY-THERM® Burner.
start-restart when used with an appropriate control 7. Burner installation is complete.
system. 8. Other system safeguards and approvals must be
• Any test connections should be plugged except completed before the burner can be lit. These
when readings are being taken. safeguards include but are not limited to:
• Control systems should provide all normally recom- – Furnace operating temperature at the burner
mended interlocks (including operation of fuel shut- location must exceed the ignition temperature of
off valves). the fuel being used (for burners without the self-
• Control system's circuitry must not allow main fuel igniting feature).
shut-off valve to be opened unless oxygen is on, – Oxygen/fuel control must be functional and
and must de-energize valve upon loss of oxygen characterized to provide the proper oxygen/fuel
pressure, along with the other system interlocks. ratio to the burner.

mCORPORATION
Page 4620-S-2 Series 300 OXY-THERM® Burners
Start-up instructions are specific to each application. Burner Mounting
Contact your Maxon representative for instructions for
your particular application. The primary objective is to seal all openings
between the burner and furnace wall, and to support
Hot Installation Procedure the weight of any system piping. The burner block
Read the entire Cold Installation Procedure (as a sits on the sill or wall.
reference) before proceeding with the installation of The block must rest flat on the sill or furnace wall
oxygen-fuel burners. without rocking to allow the weight to be evenly
Failure to follow the proper installation sequence distributed. Failure to do so could result in cracking or
noted below could result in damage or block failure. If burner/furnace openings are too large,
destruction of vital burner components. Cooling shims may be used to align the burner.
oxygen or air-flows should be present at all times The opening of the furnace should provide a
when the burner housing and metal components minimum 1/16" clearance on all three sides. High
are mounted to a hot furnace. temperature furnace sealant or gasketing should be
used between the burner and furnace wall.
1. Temporarily remove the spark-insulation block from
burners that have the self-ignition feature. Failure to Burner Adjustment and Control
do so could cause the insulator to melt. It should be Oxygen-fuel burners require accurate control of both
re-installed just prior to burner light off. fuel and oxygen for optimum performance. Maxon can
2. All moisture within the burner block should be supply state-of-the-art electronic or manual oxygen/fuel
removed before starting installation. Preheating ratio control valves. Piping to individual burners should
burner block to remove moisture and reduce thermal include control valves for both oxygen and fuel. In
shock is advised. addition, flow meters for oxygen and fuel capable of
3. Where the new burner block contacts older or hot local or remote readout are required for proper burner
materials, silica paper should be used as a thermal adjustment.
buffer. The furnace opening should be clean and free Flame sensing may be accomplished by use of a
of debris. UV scanner. The UV scanner must be field-supported
4. Insert the burner block into the furnace wall. if an adapter is used to mount the scanner to the
5. Attach burner assembly to block, ensuring cooling air burner assembly. Heat blocks, if used, may affect
or oxygen flows are established to protect metal signal strength with some brands of UV scanners.
components.
6. Allow the new burner block to heat up to near ambient
temperatures (usually about one half to three-quarters
of an hour). Start-up instructions are specific to each
7. Resume normal operations as described in Cold application. Contact your Maxon representative for
Installation Procedure. instructions for your particular application.
m CORPORATION

Series 300 OXY-THERM® Burners Page 4620-A/P-1
Assembly Numbers
Assembly Numbers Replacement Parts

OXY-THERM® Burners Square block & frame sub-assembly 1035017
Series 300 with square block 1035027 Round block & frame sub-assembly 1035450
Series 300 with round block 1035453 Rope gasket 1043970
Series 300 with square block & self-ignition 1035759 Spring plunger set screw 1043981
Series 300 with round block & self-ignition 1035717 Spark insulator 58375
Compression fitting 58417
Brass hex nut (2 required) 1034885
UV scanner adapter / spark insulator 1048182

m
CORPORATION
Bulletin 4650
OXY-THERM® LE Gas or Oil Burners
OXY-THERM® LE Oil Burner OXY-THERM® LE Gas Burner
• Lowest NOx levels of any oxygen/fuel burner, even with on-site generated oxygen. NOx levels up
to 70% lower than conventional oxy-gas, up to 50% lower than conventional oxy-oil.
• Low pressure oxygen requirements allow the use of any oxygen source.
• Gas or oil fuel capability. Quickly switch between gas and oil service by changing only the burner
nozzle. Fuel oil capability ranges from light to heavy fuel oils. Atomize with oxygen, air or steam.
• Increased flame volume and luminosity.
• Patented design eliminates flame lofting.
• Easy to change burner capacity by replacing simply the threaded burner nozzle (gas burners
only).
• Provides application flexibility with 5:1 turndown range.
• Three sizes available. Capacities up to 17.6 MMBtu/hr (5.2 MW) per burner in three size ranges.
• Designed for easy installation and service. OXY-THERM® LE Burner nozzles can be removed
during furnace operation, eliminating costly downtimes.
• Achieve higher flame temperatures by burning fuels with oxygen. OXY-THERM® LE Burners
eliminate the need for costly combustion air preheaters, regenerators or recuperators.
• Substantially improve the product quality by eliminating the flow reversals in regenerative
melters. Oxygen-fuel firing cuts flue gas volume, turbulence in the melter is reduced, as well as
exhaust gas treatment requirements.
Patents pending in U.S., Canada, Mexico, Europe, Japan and South Korea
Page 4652
OXY-THERM® LE Gas or Oil Burners

Principle of Operation Flow control and shut-off valves (available from
With OXY-THERM® LE Burners firing gas, Maxon) need to conform with the appropriate
oxygen for combustion enters the burner housing standards for oxygen service.
and exits the burner block where it mixes with the Two refractory block materials are available for
fuel. OXY-THERM® LE Burners. Zedmul 20-C burner
For oil firing, oil enters through the nozzle, is blocks are to be used for gas firing only, and should
atomized with your choice of oxygen, air or steam and be checked for compatibility with your process.
combines with the combustion oxygen as it exits the Zirconia burner blocks may be used with gas firing
burner block. and are required for oil firing due to the highly radiant
The ignited oxygen-fuel flame discharges through nature of the flame.
the refractory block tunnel and develops a luminous,
non-lofting, tightly-wrapped flame pattern with low Capacities
momentum. Gas OXY-THERM® LE Burners provide maximum
Pilots are generally not required for oxygen-fuel outputs that range from 200 MBtu/hr (59 kW) to
applications. Contact your Maxon representative 15 MMBtu/hr (4.4 MW). Oil OXY-THERM® LE
about specific piloting questions. Burners provide maximum outputs that range from
Typical applications in industry include tunnel- 3.0 MMBtu/hr (879 kW) to 17.6 MMBtu/hr (5.2 MW).
type ceramic kilns, converted regenerative-type glass
melters, unit melters, waste incinerators and smelters.
7/94
OXY-THERM® LE Burners Page 4653
Installation and Operation Guidelines

Applications using oxygen-fuel burner technology 5. To provide cooling flow to the burner housing,
can vary greatly. Maxon provides the following Maxon recommends installing a 3-way ball valve
general guidelines for burner installation and immediately upstream from the combustion
operation. Furnace designers will provide design oxygen connection on the burner
specifics for individual furnaces. (see diagram at right).
NOTE: Premium-quality materials have been used Connect cooling source 3-way Valve
in the OXY-THERM® LE Burner, but metal and combustion
components can be destroyed by high furnace oxygen source to the Cooling Air
temperatures if the burner is misused or left valve.
unprotected from cooling flows. Because most The cooling source
oxygen-fuel burner applications operate at very high should not be com-
temperatures, these guidelines focus on enhancing pressed air, since
To
burner performance and longevity. compressed air may Burner
contain oils which
Operation Guidelines contaminate oxygen-
Oxygen
1. Whenever the burner housing is installed, cooling clean components.
flow should be established through the The valve should offer 180° operation, with shut-
combustion oxygen connection (see item 4 for off at 90°. Every component that comes in
recommended piping). Cooling flow may be contact with oxygen must be cleaned for
either air or oxygen, but not compressed air. An oxygen service.
example of a cooling air source is the block 6. Quick-connect devices for the combustion
cooling air on a glass melter. Minimum oxygen, atomizing oxygen/air/steam and fuel will
recommended cooling air/oxygen flows are facilitate hook-up and installation, especially
15 scfm for Series 600 OXY-THERM® LE when switching from fuel gas to fuel oil. Quick-
Burners, 30 scfm for Series 900 and 45 scfm connect devices also limit the amount of time that
for Series 1200 OXY-THERM® LE Burners. burner components are exposed to furnace
2. If the burner will not be fired for an extended temperatures without cooling flow. This is helpful
period (over 8 hours), then the gas or oil insert during hot conversions or when replacing existing
should be withdrawn from the housing. The burners.
service nut should be installed in its place, and 7. Burner and piping should be supported as shown
cooling air/oxygen flow established (see item 1 in the installation instructions. Unsupported
for recommended flow rates). This cooling flow piping puts stresses on the block/frame assembly
will extend gasket life and retard the collection of which could crack the burner block.
particulate material inside the burner block Flexible connections are recommended in all
opening. As an alternative to cooling flow, the piping. Adding flexible connections at appropriate
burner housing may be removed, if desired, locations in the oxygen or gas manifolding can
leaving the block/frame assembly mounted to the prevent damage to the burners from piping
furnace wall. stresses or uneven thermal expansion.
3. On oil-fired burners, reduced pressure atomizing 8. The Zedmul 20-C block is available for most fuel
oxygen/air/steam should be maintained when the gas-fired applications. However, it is the respon-
burner is not firing. Continuous atomizing flow sibility of the user to assure that the Zedmul 20-C
cools the nozzle and prevents oil from touching material is compatible with the user’s process.
oxygen-clean components. Atomizing pressure of
10 psig is sufficient for oxygen/air, 50 psig for
steam.
4. Any time atomizing flow is shut off, oil inserts
should be removed and recleaned to prevent fuel
oil residue and oxygen from coming into contact
with each other.
7/94
Page 4654 OXY-THERM® LE Burners
Operation Guidelines (continued)
9. The Zirconia block is required for all fuel oil-fired 12. All OXY-THERM® LE Burners should be specified
applications, even if fuel oil will be used only as a so they run at or near design capacity. Maximum
back-up fuel. The Zirconia block may also be flame length occurs at maximum capacity. The
used for gas firing if the user has concerns about OXY-THERM® LE threaded gas nozzle can be
the compatibility of the Zedmul 20-C block with changed easily if more capacity is required in the
the process. future.
10. For oil-fired OXY-THERM® LE Burners, all liquids 13. OXY-THERM® Burners can fire in any direction
and atomizing oxygen/air/steam should be except straight down. Avoid orientations which
filtered. A 100-mesh duplex fuel oil filter is might permit an idle burner to collect debris.
recommended. 14. Observation ports which provide a view of the
11. For proper atomization, fuel oil should be flame will simplify burner start-up and adjust-
supplied to the burner inlet at a viscosity of 100 ment.
SSU (20 centistokes) or less. A typical #6 fuel oil 15. Burner block can be recessed into the inner
will normally be heated to approximately 220°F furnace wall by as much as 3 inches.
(105°C) to obtain proper viscosity.

Maxon gas OXY-THERM® LE Burners are The maximum capacities shown in the
available in three block sizes. Nozzles are custom accompanying charts for gas OXY-THERM® LE are a
drilled to meet your specific capacity requirements. range of heat releases. The minimum capacity for
This helps to assure that you get the best possible gas OXY-THERM® will be 1/5 of the maximum
burner – selected, sized and drilled – to meet your capacity selected.
specific job’s requirements. The Zedmul 20-C block is available for most fuel
gas-fired applications. However, it is the responsibility
NOTE: A calibrated flow meter in both the gas and
of the user to assure that the Zedmul 20-C material is
the oxygen lines is recommended for establishing
compatible with the user’s process. The Zirconia
accurate volumetric flow rates.
block is required for all fuel oil-fired applications,
Maxon oil OXY-THERM® LE Burners are even if fuel oil will be used only as a back-up fuel. The
available in three block sizes and six oil insert nominal Zirconia block may also be used for gas firing if the
sizes – 70, 100, 150, 200, 300 and 400 liters per hour user has concerns about the compatibility of the
(maximum capacities 3.0 MMBtu/hr through 17.6 Zedmul 20-C block with the process.
MMBtu/hr).
Gas OXY-THERM® LE Burner Series 600 Series 900 Series 1200

Maximum capacity range in 1000's Btu/hr 200 to 2,700 1,500 to 11,000 5,000 to 15,000
Minimum capacity 20% of maximum capacity (5:1 turndown)
Oxygen Refer to pressure curves
Pressures required to burner inlet
Natural gas 8 psig maximum
for maximum capacities
Propane 20 psig maximum
To natural gas 2.1 to 1
Typical oxygen to fuel volumetric ratios*
To propane 5.2 to 1
Diameter 18" maximum 30" maximum 36" maximum
Approximate flame size
Length 2.0 - 2.25 ft. per MMBtu/hr
*Exact calorific values should be checked and oxygen/fuel ratio adjusted accordingly
Series 600
Series Series 900 Series 1200
Oil OXY-THERM® LE Burners or 900
Size 70 100 150 200 300 300 400
Maximum fuel flow (liters/hr) 80 115 173 230 345 345 460
Maximum output (MMBtu/hr) 3.06 4.40 6.61 8.81 13.21 13.21 17.62
Nominal fuel flow (liters/hr) 70 100 150 200 300 300 400
Minimum with 5:1 turndown (MMBtu/hr) 0.61 0.88 1.32 1.76 2.64 2.64 3.52
Atomizing oxygen/air flow (scfh) at 50 psig 434 519 646 784 1205 1205 1591
Atomizing steam flow (scfh) at 70 psig (300°F) 568 679 846 1026 1577 1577 2082
Oxygen pressure to burner inlet ("wc) Refer to pressure cur ves on pages 4656-4658
Fuel pressure to burner inlet (psig) at nominal Refer to pressure cur ves on page 4660
Approximate flame diameter (inches) at maximum output 18 18 24 30 30 30 36
Approximate flame length (feet) at maximum output 6.0 8.0 11.5 13.5 17.5 17.5 20.0
12/95

Series 600 OXY-THERM® LE Burners
Combustion Oxygen Pressure vs. Flow – Series 600 Gas Burners
Combustion Oxygen Pressure vs. Flow – Series 600 Oil Burners
O2 Flow2
*For pressures not shown on the curve, use the following equation: P2 = ( )2 x P1
O2 Flow1
Use a reference off the above curves for O2 Flow1 and its corresponding P1.

O2 Flow2
*For pressures not shown on the curve, use the following equation: P = ( )2 x P1
2 O2 Flow2
7/94

O2 Flow2
*For pressures not shown on the curve, use the following equation: P2 = ( )2 x P1
O2 Flow1

Oil OXY-THERM® LE Burners
Atomizing Oxygen/Air Flow vs. Pressure
Each line represents a particular oil
nozzle nominal rating, e.g., “400”
represents the 400 liter per hour oil
nozzle.
NOTES:
• If oxygen is used for atomizing, its
volume should be taken into account
when establishing the excess oxygen
requirements for each application. If air is
used for atomizing, its oxygen volume
should not be taken into account. The
volume of oxygen in atomizing air is too
small to be significant.
• Steam atomization will shorten the flame
pattern by as much as 25% compared to
air or oxygen atomizing.

Atomizing Steam Flow vs. Pressure
Each line represents a particular

oil nozzle nominal rating, e.g.,
“400” represents the 400 liter per
hour oil nozzle.
7/94

Fuel Oil Flow vs. Pressure
Each line represents a

particular oil nozzle
nominal rating, e.g.,
“400” represents the
400 liter per hour oil
nozzle.
Dimensions
Pipe threads on this page conform to NPT (ANSI B2.1)
12/95
Dimensions
Pipe threads on this page conform to NPT (ANSI B2.1)

OXY-THERM® LE Burners Page 4650-S-1
The burner is only a part of your complete combus- NOTE: A 19 mm (or 3/4") socket is required for
tion system. Additional pipe train accessories and mounting nuts. A manual speed wrench is recom-
control components will be required for a complete mended for quick and easy burner mounting.
system installation. 1. If fuel insert is shipped inside burner housing,
remove the fuel insert and insert nut and set aside
Important: Do not discard packing material until in a protected area.
all loose items are accounted for. 2. Install service nut on the burner housing.
3. Remove burner housing from the block/frame
Burner Installation Procedure assembly. Use caution to prevent damage to the
Read the entire installation procedure before mounting gasket. The mounting gasket should be
proceeding with the installation of oxygen-fuel sandwiched between the burner housing and the
burners. nozzle body insert.
4. Install block/frame assembly into furnace wall.
Failure to follow the proper installation sequence
Refer to page 4650-S-3 for hot installation proce-
noted below could result in damage or destruction
dure for burner blocks.
of vital burner components. Cooling oxygen or air
5. Pre-pipe quick-connect devices to the combustion
flows should be present at all times when the
oxygen, fuel and atomizing connections on the
burner housing and metal components are
burner housing and burner fuel inserts.
mounted to a hot furnace.
6. Confirm that cooling air or oxygen is available at
To prevent damage in transit, the fuel inserts, the individual burner ports and control stations
mounting gaskets and burner housing may be packed before installing burner housing.
separately. In most cases, the burner will be 7. Confirm that mounting gasket is in good condition
shipped assembled but with the mounting nuts and that nozzle body insert is held firmly in place
only finger-tight. In either case, the burner block by the two spring pins.
and frame will need to be disassembled from the 8. Confirm that service nut is installed on the
rest of the burner to allow installation of the block housing (to prevent hot furnace gases from
into the furnace wall. blowing out of the housing).

m
CORPORATION
Page 4650-S-2 OXY-THERM® LE Burners
9. Mount housing to block/frame studs. 20. Other system safeguards and approvals must be
completed before burner can be lit. These
Use caution and work quickly once housing is in
safeguards include but are not limited to:
position to be mounted. Hot furnace gases can
– furnace operating temperature at the burner
deform or destroy the oxygen-compatible mounting
location must exceed the ignition temperature
gasket.
of the fuel being used (for burners with no
10. Install and snug the four corner mounting nuts pilot).
and washers only. – oxygen/fuel control must be functional and
11. Connect the cooling oxygen/air source to the characterized to provide the proper oxygen/
combustion oxygen connection on the burner fuel ratio to the burner.
housing and begin cooling flow. Start-up instructions are specific to each
12. Install and snug the remaining mounting washers application. Contact your Maxon representative for
and nuts. Do not overtighten the mounting nuts. instructions for your particular application.
13. Apply an oxygen compatible lubricant to the two
O-rings on the fuel insert. Burner Mounting
14. Remove service nut from housing. The sketch below shows one possible method of
15. Install the fuel insert into the housing. mounting and holding an OXY-THERM® LE Burner
Fuel oil burners: Push the insert into the housing block and frame assembly in place. Other methods
until both O-rings are inside and the machined are possible.
flange on the oil insert contacts the housing.
Fuel gas burners: The gas nozzle is designed to The primary objective is to compress the frame
lock into the nozzle body insert. Push the insert against the wall of the melter and to support the
into the housing until both O-rings are inside weight of any system piping.
housing. Once gas nozzle contacts the nozzle The burner block sits on the sill or wall. The block
body insert, wiggle the fuel gas insert while must rest flat on the sill or wall without rocking to
pushing forward at the same time. This should allow weight to be equally distributed. Failure to do so
ensure that the nozzle has locked into the nozzle could result in cracking and block failure. If burner
body insert. Unlike the fuel oil insert, there is no port holes are too large, shims may be used to align
machined stop on the fuel gas insert. the burner.
If the fuel gas nozzle is not locked into the nozzle The opening of the furnace wall should provide
body insert, poor burner performance and higher 1/16" clearance on all sides. High temperature
emissions will result. The resulting improper flows furnace sealant or gasketing should be used between
generated could destroy the gas nozzle. burner mounting flange and furnace wall.
16. Immediately confirm that cooling oxygen or air is
flowing. If not, remove fuel insert and establish For maximum burner life, burner frame must be
cooling flow through housing. protected from hot gases.
17. Thread the insert nut onto the housing until it
bottoms out against the fuel insert. The insert nut
can be used to push the fuel insert fully into the
Possible Burner Mounting Configuration
housing. Once the insert nut bottoms out, back
the nut off 1/16 of a turn. It is not necessary for
the insert nut to be tight.
18. Connect fuel supply and atomizing medium (fuel
oil firing) to the fuel insert.
19. Burner installation is complete.
mCORPORATION

OXY-THERM® LE Burners Page 4650-S-3
Hot Installation Procedure for Burner Adjustment and Control
Zedmul 20-C Burner Blocks Oxygen-fuel burners require accurate control of
Over the last 20 years, the following procedure has both fuel and oxygen for optimum performance.
been used to install Zedmul 20-C burner blocks Piping to individual burners should include control
without interrupting the glass operations. Most of the valves for both oxygen and fuel. In addition, flow
experience has been in float and container glass meters for oxygen and fuel capable of local or remote
operations with hot face temperatures between readout are required for proper burner adjustment.
1425°C (2600°F) and 1675°C (3050°F). Flame sensing may be accomplished by UV
1. All moisture within the burner block should be scanner. Burner design can incorporate a UV scanner
removed before starting installation. This is port suitable for supervision of both pilot and main
accomplished by placing the burner on the crown flames. UV scanner, if used, should be kept as close
of the furnace or under the port area for a day. to burner as feasible. Heat block, if used, may affect
2. Where the new block contacts older, hot signal strength with some brands of UV scanners.
materials, Fiberfrax paper should be used as a
thermal buffer. Start-up Instructions
3. Remove the old block and clean the opening. Start-up instructions are specific to each
4. Insert the new block into the furnace. application. Contact your Maxon representative for
5. Allow the new block to heat up to near ambient instructions for your particular application.
temperatures (usually about one half to three
quarters of an hour).
6. Resume normal operations.

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CORPORATION
Page 4650-S-4 OXY-THERM® LE Burners
• Fuel supply piping must be large enough to • If used, pilot take-off should be upstream of the
maintain the required fuel pressures cataloged for main gas regulator, but downstream of the main
the particular burner size used with burner gas cock. It should normally include its own pilot
operating at full rated capacity. gas regulator, a solenoid valve, and shut-off cock.
A pilot adjustable orifice at the pilot inlet simplifies
• Anything more than minimal distance or piping
adjustment.
turns may necessitate oversizing piping runs to
keep pressure drops within acceptable ranges. • Pilots do not use oxygen.
• If multiple burners are fed from a single fuel train, • Pilot piping must be large enough to provide for
care should be taken to minimize pressure drop the full flow and pressures shown in the catalog for
and give maximum uniformity. your particular burner size.
• Clean atomizing oxygen/air/steam lines are • Fuel shut-off valves (when properly connected to
essential to prevent plugging of critical atomizing a control system) are designed to shut the fuel
ports in the oil insert. supply off with a loss of electrical power.
Manual reset valves require operator attendance
• Clean fuel lines are essential to prevent blockage
each time the system is started up (or restarted
of pipe train components or burner fuel ports.
after a shut-down). Motorized shut-off valves
• Fuel and oxygen piping should be located permit automatic start-restart when used with an
reasonably close to the burner and sized for the appropriate control system.
pressure and volume requirements of the burner.
• Any test connections must be plugged except
• Main shut-off cock should be upstream of the when readings are being taken.
main fuel regulator and pilot (if supplied) line take-
• Control systems should provide all normally
off. Use it to shut off fuel during shut-down periods
recommended interlocks (including operation of
of more than a few hours.
fuel shut-off valves). Sequencing control systems
• A fuel throttling control valve is not intended are available from Maxon that include provision for
for tight shut-off. post-purge pilots during all but emergency shut-
downs.
• Main fuel regulator is essential to maintain a
uniform system supply pressure. • Control system’s circuitry must not allow main
fuel shut-off valve to be opened unless oxygen is
• Size the regulator for full system capacity at the
on, and must de-energize valve upon loss of
oxygen pressure, along with the other usual system
losses. Follow the instructions attached to the
interlocks.
regulator during installation.
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CORPORATION

OXY-THERM® LE Burners Page 4650-A/P-1
Assembly Numbers
Gas OXY-THERM® Burners Oil OXY-THERM® Burners
Burner Series Configured Item Number Burner Series Configured Item Number
Series 600 600 OT LE Series 607 607 OT LE
Series 915 915 OT LE
Segment Choice Detail – Gas OXY-THERM® Burners

Segment Choice
(DEFAULT is shaded)
NAT Natural Gas
FUEL Type of fuel
PROP Propane Gas
BLOCK MATERIAL
block ZIRC [1] Zirconia
NO No pilot chosen
YES Pilot chosen
[1] Zirconia block required when back-up fuel is oil
Segment Choice Detail – Oil OXY-THERM® Burners

Segment Choice
(DEFAULT is shaded)
FUEL Type of fuel OIL Fuel Oil
Type of material used for burner
BLOCK MATERIAL ZIRC Zirconia
block
NO No pilot chosen
YES Pilot chosen
Ordering Designations (oil burners only)

Series 607 = Series 600 (6" x 6" block), 70 lph Example:
Series 910 = Series 900, 100 lph Series 6 0 7
Series 920 = Series 900, 200 lph 6" x 6" block 70 lph
Ordering Designations (gas burners only)
Series 600
Series 900 Gas port sized according to firing rate
by Maxon Sales personnel
m
Series 1200
CORPORATION
Page 4650-A/P-2 OXY-THERM® LE Burners
Assembly Numbers
Replacement Parts
OXY-THERM® LE Series 600 Series 900 Series 1200

Burner Type Gas Oil Gas Oil Gas Oil
Block & Frame Zedmul 44336 --- 44000 --- 44376 ---
Sub-assembly Zirconia 44337 44337 44001 44001 44377 44377
Gasket 44318 44318 43873 43873 43873 43873
Mounting Nuts 43874 43874 43874 43874 43874 43874
Gas Nozzle 44321 [1] --- 43902 [1] --- 44368 [1] ---
44080 (70 lph)

44081 (100 lph)
Oil Insert 44084 (300 lph)
--- 44333 (70 lph) --- 44082 (150 lph) ---
Sub-assembly 44334 (400 lph)
44083 (200 lph)
44084 (300 lph)
O-rings (1) Viton 26471 32983 [2] 32984 32983 [2] 32984 32983 [2]
O-rings (2) Viton 38386 38386 30455 30455 30455 30455
O-rings (2) Viton --- 43359 [2] --- 43359 [2] --- 43359 [2]
Pilot Assembly 45422
[1] Maxon factor y order number required
[2] Inside oil inser t sub-assembly
m
CORPORATION

OXY-THERM® Accessories Page 4675
Maxon Oxy-pilot
Oxy-pilot Specifications
Fuel Flow Pressure Capacity
Natural Gas 25 CFH 2.25" wc
25,000
Propane 10 CFH 0.83" wc
Btu/hr
Oxygen 53 CFH 0.5" wc

12.25
(approximate)
1/2" NPT Clearance

for Removal
2.25
Natural
Gas Inlet
(3/16" O.D. Tube)
Ignition Transformer
Connection
Oxy
Inlet
NOTE: Swagelock fitting (1/2" NPT)
can be removed for
1/8" NPT attachment
3/99
Page 4676 OXY-THERM® Accessories
Maxon Oxy-pilot
Ignition
Maxon recommends the use of a 6000 volt full- The Insulator Block helps reduce stray voltages
wave spark ignition transformer for use with the Oxy- that may migrate back up the fuel line and/or damage
pilot. A standard .250" female spade connector should any sensitive electronic equipment and must not be
be used on the ignition transformer connection. removed.
Installation and Start-up

• The pilot is shipped “cleaned for oxygen service.” • Spark should be constant only until the pilot lights.
The spark gap is factory-set. Never attempt to • Pilot operation should always be interrupted when
disassemble the pilot. used with either the OXY-THERM® LE or Standard
• Install the pilot by the NPT threads in the burner OXY-THERM® Burners. Failure to do so will result
housing of the OXY-THERM® LE, or with the bolt- in imbalanced main burner flame and accelerated
on pilot adapter when used on the Standard OXY- degradation of the refractory block.
THERM®. • Cooling oxygen must be used when the pilot is
• When threading in the pilot, do not use a pipe installed in a high temperature atmosphere and
wrench on the tee section; use the stainless nipple the OXY-THERM® Burner is not firing.
instead. Take care not to damage the stainless fuel • The proper sequence for igniting the pilot is: Spark
tube when making the connection. on, Oxygen on, Fuel on (ignition occurs), Spark off.
• The 3/16" compression fitting can be removed for At this point, the main OXY-THERM® Burner can
1/8" NPT connection, if preferred. The Swagelock be ignited. If the burner is not going to be ignited
nut should only be tightened three-quarters of a within a few minutes, the pilot should be interrupted
turn from finger-tight. to extend refractory life.
• Refer to the Capacity and Specification chart on
the previous page for recommended pressures and
flow rates.
Assembly Numbers
Oxy-pilot Assembly Numbers
Maxon Oxy-pilot Assembly 58378
Compression Fitting 58417
Insulator Block 58375
Replacement Pilot Adapter (for use with
57815
Parts Standard OXY-THERM®)
Pilot Adapter Gasket 18850
Pilot Adapter Bolts (3 required) 40261
Bulletin 4700
KINEDIZER® Gas Burners
• Field proven low emissions. Adjustable for application flexibility.
• Rugged design for oxidizers, process heaters, kilns, furnaces, and other high-temperature
applications.
• Flow turndown as high as 40:1
• Available in a wide range of capacities.
• Nozzle mixing design.
• Burns natural gas, propane or other fuels.
• Provides excellent stirring and mixing with its medium velocity exhaust.
• Accepts preheated and vitiated combustion air.
• For use with cross velocities up to 3000 fpm (915 m/min).
Manufactured under U.S. Patent #6,238,206
Page 4702
KINEDIZER® Gas Burners

Principles of Design Low Emissions
®
The KINEDIZER Burner is a nozzle-mixing The KINEDIZER® Burner is capable of low NOx
medium-velocity design. Using advanced mixing when given excess air, typically 25-30% at high fire.
technology, the burner produces low emissions with The same burner, when adjusted for on-ratio opera-
very little excess air. Ruggedly built with a reinforced tion, will give low CO and high thermal efficiency. With
refractory block and steel burner body and nozzle, it flue gas recirculation, the emissions and efficiency
burns natural gas, propane or other fuels. can be further improved.
Combustion air is supplied with an external blower,
and accurate air and fuel modulation is accomplished
by the proven MICRO-RATIO® Valve (see catalog
sections 7000 and 7100). For more critical applica-
tions, mass flow control of fuel/air ratio can be at-
tained with the SMARTFIRE Intelligent Combustion
Control System. SMARTFIRE provides positive
assurance of minimized emissions, maximized
efficiency and the most repeatable, reliable and safe
control.
Combustion air can range from 21% O2 down to
17% O2 and from ambient temperature up to 800°F
(425°C). Maximum chamber temperature is 2000°F
(1090°C) with any cross velocity up to 3000 fpm (915
m/min). Flame length with 30% excess air is 4 in/
MBtu/hr (30 cm / MW) and with 5% excess air is 1 ft /
MBtu/hr (1 m / MW). Turndown is 40:1*. The
KINEDIZER® Burner can be overfired by up to 20%
simply by supplying higher combustion air and gas
pressures. Contact Maxon for details.
*The smallest (0.5M) burner turndown is 10:1. Larger
sizes offer turndown of more than 40:1.
Vent to Atmosphere
(outdoors)
Fuel Gas
Pilot Gas
Fuel Gas
Train
Combustion
Air Blower
KINEDIZER®
Low Nox Burner
MICRO-RATIO®
Control Valve
9/03
KINEDIZER® Gas Burners Page 4703
Main Flame - Natural Gas

10% Excess Air - Low Oxygen
Combustion Air 30% Excess Air - Low NOx
Environments
Nat. Gas Nat. Gas
Burner Recommended Fuel Shor t Block Fuel Shor t Block
Maximum Pressure Maximum Maximum
FG Blower, Pressure & Long Block Pressure &
Designation Flow (differential) Flow Flow
neutral chamber (differential) Heat Shield (differential) Heat Shield
(HHV basis) (HHV basis)
Maxon Length x Diameter Length x Diameter
SCFM "wc SCFH psi SCFH psi
Designation @ High Fire @ High Fire
0.5M C-2940 108 27.7 500 1.7 8" x 14" 12" x 6" 591 2.4 18" x 14"
2.5M C-5450 542 27.7 2500 2.2 12" x 16" 18" x 8" 2955 3.0 24" x 16"
5M C-7140 1083 27.7 5000 3.1 18" x 20" 24" x 10" 5909 4.3 24" x 20"
9M C-14880 1950 27.7 9000 3.0 36" x 26" 4' x 18" 10636 4.2 36" x 26"
18M C-30960 3900 27.7 18000 4.0 4' x 42" 6' x 3' 21273 5.6 4' x 42"
27M N/A 5850 27.7 27000 4.0 5' x 60" 9' x 4' 31909 5.6 5' x 60"
40M N/A 8666 17.8 40000 2.4 5' x 72" 13' x 5' 47269 3.4 8' x 72"
Pilot (Built-in) Turndown

Combustion Air Natural Gas Burner Full turndown with
Burner Pressure A/F Ratio Pressure Recommended Pipe Designation 30% excess air
Flow Flow
Designation (differential) at Light-off (differential) Size for < 50 ft. of Pipe 0.5M 10:1
SCFM "wc x:1 SCFH "wc "NPT 2.5M 15:1
0.5M 17 0.70 13 80 0.1 3/8 5M 40:1
2.5M 56 0.30 14 250 0.9 3/4 9M 40:1
5M 66 0.10 20 100 0.1 3/8 18M 40:1
9M 117 0.10 20 175 0.5 1/2 27M 40:1
18M 166 0.05 20 250 0.9 3/4 40M 32:1
27M 249 0.05 20 500 3.7 3/4
40M 585 0.10 30 1500 7.5 1.0
2/00
Page 4704 KINEDIZER® Gas Burners
To find the required fuel pressure at any firing rate, Example: If 18.5" wc is measured on the
multiply the measured air pressure by the constant combustion air pressure test port of a 9M
above corresponding to desired excess air setting. KINEDIZER®;
• Multiply 18.5" x 3.03 = 56.1" wc
• Set the fuel pressure measured at the burner gas
test port to 56.1" wc for 30% excess air
Natural Gas Flow Curves

Combustion Air Natural Gas Pressure ("wc)
Burner Air Pressure
Air Maximum Flow a factor b factor c factor d factor
Designation (differential)
SCFM "wc On Ratio 10% excess air 30% excess air 50% excess air
0.5M 108 27.7 2.87 2.37 1.70 1.27
2.5M 542 27.7 3.66 3.03 2.17 1.63
5M 1083 27.7 5.25 4.34 3.10 2.33
9M 1950 27.7 5.12 4.24 3.03 2.28
18M 3900 27.7 6.76 5.59 4.00 3.00
27M 5850 27.7 6.76 5.59 4.00 3.00
40M 8666 17.8 6.31 5.22 3.73 2.80
NOTES:
1. For propane fuels, specifiy on ordering. All main gas pressures remain identical to those above.
2. Contact your Maxon representative for information on other fuels or for operation outside the shaded region.
Dimensions
.5M & 2.5M KINEDIZER® Burners
60°
1/4" NPT
Chamber Test Connection .625 dia.
1/4" NPT mounting holes
AA 22.5° 22.5°
Air Test Connection Optional Air 8 req'd.
BB Inlet Flange 1/2" NPT Scanner
J dia. & Observation Port
B
View "A-A" Z
1/4" NPT
K dia. Purge Air
C dia. Connection
D
blk. iron
pipe
Y
M
1/4" NPT
M14 x .25 thd.
Gas Test Connection
(spark ignitor)
A
Pilot Gas
G Inlet L
E X Main Gas Inlet
F
A C D J K L Z
Size B E F G M X Y AA BB
NPT dia. pipe dia. dia. NPT* rad.
.5M 3/8" 1.97 3.5 3" 5.7 7.86 0.25 10.73 12.0 1/2" 4.69 3.562 3.62 5.28 3.956 2.981
2.5M 3/8" 3.12 6.625 6" 6.94 10.06 0.375 12.52 14.15 1-1/4" 6.19 4.49 4.63 6.049 3.831 2.856
* 1/2" NPT is female; 1-1/4" NPT is male
N N
R dia. P R S T
S no. of holes Size N
dia. dia. # of holes dia.
.5M 45° 7.5 .75 4 6.0
2.5M 22.5° 11.0 .875 8 9.5
P dia.
T dia.
View "A-A"
Optional Air Inlet Flange
Conforms to 150# ANS Flg. Pattern
Bolt holes to straddle burner vertical & horizontal centerline.
Material: .250" thk. carbon steel
9/03
Dimensions
5M through 40M KINEDIZER® Burners

1/4" NPT
Chamber Test Connection
H dia.
AA I # of holes
1/4" NPT
BB Optional Air 22 22
Air Test
Connection Inlet Flange J dia. Observation
B Port
A Spark Ignitor &
View "A-A" Pilot Gas Inlet
Pilot Gas Inlet
Z
CC 1" NPT
Scanner Port
K dia.
1/4" NPT Purge
C dia. Air Connection
D
blk. iron
pipe DD
M
M14 x .25 thd.
(spark ignitor)
1/4" NPT Gas Test Connection

G
E L
F
A C D H I J K L Z
Size B E F G M AA BB CC DD
NPT dia. pipe dia. # holes dia. dia. NPT rad.
5M 3/8" 3.85 8.625 8" 11.24 15.09 0.375 5/8" 8 15.12 16.75 1-1/2" 7.38 6.629 3.956 2.981 2.497 3.406
9M 1/2" 5.0 12.75 12" 14.75 19.75 0.5 5/8" 8 16.86 18.45 3" 12.5 7.685 3.956 2.981 3.303 4.607
18M 3/4" 7.2 12.75 12" 18.35 24.73 0.5 5/8" 8 18.82 20.45 3" 11.69 8.684 3.956 2.981 3.814 5.813
27M 3/4" 7.2 18.0 18" 23.84 29.71 0.5 5/8" 8 20.95 22.57 4"* 14.31 9.751 3.956 2.981 3.815 6.90
40M 3/4" 11.125 22.0 22" 37.09 48.21 0.5 5/8" 8 26.443 28.0 6"* 16.25 11.67 3.981 3.006 3.814 9.499
* 4" (27M) and 6" (40M) gas inlets are 150# raised face flanges, not NPT
N N
P dia.
R dia.
S # of holes
P R S T
Size N
dia. dia. # of holes dia.
5M 22.5° 13.5 .875 8 11.75
9M 15° 19.0 1.0 12 17.0
18M 15° 19.0 1.0 12 17.0
T dia. 27M 11.25° 25.0 1.25 16 22.75
40M 9° 25.75 .562 20 24.13
View "A-A"
Optional Air Inlet Flange
Conforms to 150# ANS Flg. Pattern*
Bolt holes to straddle burner vertical & horizontal centerline
Material: .250" thk. carbon steel
*NOTE: 40M air inlet flange does not follow ANSI bolt patterns
9M through 40M air inlet flanges have elongated holes
Options and Accessories

Block Options U
Four block options are available to suit many installa-
tion configurations. Alternate block materials are also
available for higher temperatures. Please contact your
Maxon representative for details. V
dia.
Standard (long) block

For installation in hard wall refractory or for upfired
applications in soft walled refractory. Good for tem-
peratures up to 2200°F. Block/Seal & Support Block Options
Seal and support block

For installations in soft wall or soft roof applications.
Good for temperatures up to 2200°F. V
dia.
Short block
For installations in soft wall insulation, hard wall
refractory, or insulated metal panels. Good for appli- 2.5
cation temperatures up to 2200°F. Short Block Option
NOTE: Short block use with applications over 1400°F
will produce high burner backplate temperatures.
W
Heat Shield
For installations in metal panels, ducts, or other non-
insulated areas. Good for application temperatures as V
dia.
high as 1000°F. The heat shield is provided hollow
and may be filled with board-type insulation for
additional protection.
Heat Shield Option
Size U V dia. W
.5M 9.518 8.562 2.155
2.5M 9.523 10.422 2.160
5M 9.523 12.994 2.16
9M 12.16 14.562 2.16
18M 12.16 16.562 2.16
27M 12.16 18.548 2.16
40M 12.03 23.913 2.15
9/03
Options and Accessories

Plug Shell (2.5M, 5M & 9M only)
For installation in insulated metal panels where
deeper burner penetration is desirable. The mounting
plug may be insulated to provide added protection
from application temperatures as high as 1800°F
16 slots
(insulation by others). 11.25°
.0625 dia.
29.134 dia.
27.480 dia.
1/4" NPT
Chamber
Pressure Tap
24.015
dia.
Sight Glass
0.375
9.860
KINEDIZER® Gas Burners Page 4700-S-1
Burner Protection SMARTFIRE Control System
1. The UV scanner must have a cooling air flow of 1 1. Consult the SMARTFIRE installation and
SCFM. This can be supplied by the combustion operation instructions. Only adequate regulator
air blower. It should be connected to the tee on adjustment will be required.
the UV scanner pipe nipple. (See pages 4705 &
4706.) An adjustable orifice can be used for fine Test Connections
control. 1. Install test fittings, tubes, and manometers or
– UV scanners generally cannot withstand more gauges at the air, gas and chamber pressure test
than 200°F (93°C). connections on the burner. (See pages 4705 &
– Note: The scanner and sight ports are 4706.)
interchangeable. 2. Air and gas pressures must be read differentially
2. The combustion air blower should remain on any against the system chamber pressure.
time the chamber temperature is above 800oF
(426°C). Mounting
1. Burner may be mounted at any orientation.
Pilot – Some automatic control motors require that the
1. The pilot solenoid should be located close to the control motor shaft be horizontal.
burner for quick ignition. – An upward-facing UV scanner can lose signal
2. An interrupted pilot is suggested; this maximizes over time as water and debris fall on the lens.
burner turndown. Interrupted pilot is required any 2. The block should be installed per the guidelines of
time the optional sealed pressure port pilot is page 4700-S-3.
used. Interrupted pilot is required for best
emissions. Combustion Air Supply
3. The pilot gas flow is 1/40 of maximum gas flow. 1. No air filtration is necessary for the KINEDIZER
®
Pilot flow and pressure requirements as well as Burner because of its open internal structure.
recommended pipe size for each burner are 2. Where outdoor air is used, temperature, i.e.,
®
shown in the KINEDIZER Capacities and density, must be considered.
Specifications chart (page 4703). – Air at 20oF (-7°C) is 21% denser than air at
4. An adjustable orifice is not required, but may 120oF (49°C).
afford fine tuning of pilots. – Cold air may extinguish a flame which was
® lean but stable on a hot day.
MICRO-RATIO Valve
1. Set a smooth ramp on the gas SYNCHRO valve
with the MAX screw about two turns from flush
with the quadrant face, i.e., from fully open and
the MIN screw just one or two turns in.
2. Adjust the automatic-actuator-to-control-valve
linkage until the valve travels from MIN to MAX as
the control output ranges from 0 - 100%.

mCORPORATION
Page 4700-S-2 KINEDIZER® Gas Burners
Air Inlet Via Elbow* Flue Gas Recirculation*
1. If an elbow is located in close proximity to the 1. Flue gas may be piped into the combustion air.
burner air inlet, the air butterfly valve should be – This can substantially reduce exhaust
immediately upstream of the elbow for maximum emissions while increasing thermal efficiency.
turndown. The butterfly should open as shown on – The O2 must remain above 17% at all times.
Product Information Sheet 4700-1. This improves – The temperature at the burner inlet must be
the burner air flow profile at lower firing rates. below 800oF (426°C).
2. If an elbow is used, a sight glass in that elbow is
recommended. The sight glass and burner
centerlines should coincide. (See Product *Indicates Optional Equipment or Mode of Operation
Information Sheet 4700-1.)
Multiple Burners Manifolded to a Single

Blower*
1. For good air distribution, the air manifold should
extend one diameter past the burner inlet with the
burner feeding from a tee rather than an elbow.
(See Product Information Sheet 4700-2.)
2. All burners fed from the same manifold should
cycle together.
3. For maximum flexibility, each burner should have
its own pilot and main gas regulators.
4. For maximum flexibility, each burner should have
®
its own MICRO-RATIO Valve.
5. Proper air manifold sizing using the equal area
method should be utilized. Conscientious
manifold design will allow maximum turndown and
best performance.
m CORPORATION

Burner Mounting In refractory installations, size the opening in your
refractory wall to give a 3" gap around the burner,
In a refractory wall, bolt burner directly to the then ram with castable refractory such as A.P. Green
furnace shell as shown in Sketch 1. In oven or Kast-Set, B & W Kaolin Base Castable or equal,
insulated panel construction, follow Sketch 2. following manufacturer’s instructions. Allow sufficient
dry-out time before firing burner, and cure slowly at
start-up.
Sketch 1
In thin-wall or soft-wall construction, where
burner should be equipped with Seal and Support
Furnace
Shell
Housing, cut an opening 1" larger (diameter) than
Seal and Support. Weld studs to shell and mount as
Furnace shown in Sketch 3, then pack with soft insulation fiber.
Wall
If the firing chamber is designed for radiant tempera-
tures, be certain the stainless steel of the Seal and
Support Housing is shielded from radiant energy.
Sketch 3
Insulation
Castable
Refractory Housing
Material
Gasket
(by others)
Sketch 2
Panel
Wall
Mounting Studs
Soft Insulating
Material

mCORPORATION
All instructions may be superceded by applicable NFPA codes or governing local codes.
Setting the MICRO-RATIO® Air Valve Span Adjusting the Gas SYNCHRO Control
1. * Close the main and pilot gas cocks. Valve
2. Start all process and combustion blowers. 1. Once the pilot is proven, the main gas cocks may
3. * Disconnect the automatic motor from the be opened. At this point, the burner is ready to
MICRO-RATIO® valves. transition to main flame.
4. With the gas SYNCHRO valve at MIN, loosen the – If firing into an uncured refractory chamber,
connecting rod between air and gas valves and follow the manufacturer's schedule for curing.
adjust the air valve until the differential air – The burner block, which is cured at the factory,
pressure (burner air test connection to chamber needs no burnout time.
test connection) reads 0.1" w.c. (7mm w.c.). 2. Once your flame is established and refined at
5. With the gas SYNCHRO valve at MAX, adjust the this position, and without advancing the screw
air valve until the differential air pressure (burner carrier quadrant higher, screw all remaining
air test connection to chamber test connection) screws down to at least the same level as your
reads the desired value for the maximum first adjusted screw.
anticipated firing rate. Refer to the operating NOTE: A preliminary setting can be established with all
®
chart for your size burner on the KINEDIZER the remaining adjusting screws. Generally, each suc-
Burner Capacities and Specifications page ceeding screw needs to be screwed in approximately
(4703). one full turn deeper than its preceding screw. A smooth
NOTE: The air pressures on page 4703 produce “stair-step” gradient pre-set at this point from low to high
the minimum light off capacity for maximum will simplify the remaining adjustment steps.
turndown. 3. With allen wrench engaged in second screw,
6. Reconnect the air-gas linkage so the differential slowly move MICRO-RATIO® Valve to #1
air pressure varies from 0.1" w.c. to the maximum position, adjusting as necessary to maintain
value as the gas valve travels from MIN to MAX. ignition and the type of flame desired. Flame
This may require iteration between MIN and MAX length should increase slightly, burning with a
until both are set properly. blue center. Yellow tips may become evident on
lower excess air settings.
Lighting the Pilot If firing into an uncured refractory chamber,
1. Find the pilot pressure required at the burner gas allow system to run at this setting for the
pressure test connection by referring to the pilot dryout period recommended by the furnace or
specification table for your size burner in the refractory manufacturer, then continue adjust-
®
KINEDIZER Burner Capacities and ment of the MICRO-RATIO® Valve.
Specifications chart (page 4703). 4. Turn all remaining adjustment screws in
2. * Drive the burner to minimum. slightly further than the second screw, then
3. * Confirm that the system has been purged. with allen wrench inserted in third screw, slowly
4. Open the pilot gas cocks. move MICRO-RATIO® Valve toward #2 position,
5. Reset the low gas pressure switch, if required. adjusting as necessary.
6. * Confirm that all interlocks are proven.
7. Energize the spark ignitor and pilot solenoid. If a
chamber sight port is available, confirm that the
spark ignitor is arcing inside the burner throat.
Also confirm that the pilot solenoid is opening.
8. Adjust the pilot gas pressure regulator until the
required pilot pressure is achieved. Repeated
necessary.
ignition trials may be needed at first to fill the pilot
pipe train with fuel.
9. At no time should any safety or permissive
device be jumpered or otherwise disabled.
mCORPORATION

All instructions may be superceded by applicable NFPA codes or governing local codes.
5. Progressively work your way up through each 7. When all screws have been adjusted, recheck
adjusting screw position, developing a smooth differential pressures with unit at operating
progression slope from your first screw to the temperature. Refine “high fire” setting if neces-
“maximum” position. sary, considering differential pressure, flame
NOTE: To adjust the flame at any position, you must length, and appearance.
move the SYNCHRO Valve to the number you desire 8. Complete final adjustment of the differential
to adjust. This aligns the adjusting screw directly on fuel pressure relative to the differential air
top of the fuel valve plunger. A resulting adjustment of pressure from the chart below.
the screw is directly applied to the fuel valve plunger – A lean low NOx flame is blue and short (4 in/
and its interconnected valve body linkage. MBtu/hr), while an on-ratio flame will have
If high temperature limit trips before adjust- yellow tips and a greater length (1 ft/ MBtu/hr).
ment is completed, cycle back to minimum and – Dust, powder, salt, etc. in the combustion air
hold there until the system cools down before will color the flame yellow or orange. Moisture
attempting further adjustment. will make it red. These colors are normal when
6. Note gas supply pressure while continuing the air carries such substances.
with adjustment. If it falls off below acceptable 9. * Plug all pressure test connections.
®
range, it may be necessary to re-adjust the 10. With the MICRO-RATIO Valve at minimum and
regulator. If so, lower firing positions will need automatic control output at 0%, reconnect the
®
rechecked and if necessary, re-adjusted before automatic control motor to the MICRO-RATIO
proceeding. Valve.
* Indicates a safety item.
Natural Gas Flow Curves

Combustion Air Natural Gas Pressure ("wc)
Burner Air Pressure
Air Maximum Flow a factor b factor c factor d factor
Designation (differential)
SCFM "wc On Ratio 10% excess air 30% excess air 50% excess air
0.5M 108 27.7 2.87 2.37 1.70 1.27
2.5M 542 27.7 3.66 3.03 2.17 1.63
5M 1083 27.7 5.25 4.34 3.10 2.33
9M 1950 27.7 5.12 4.24 3.03 2.28
18M 3900 27.7 6.76 5.59 4.00 3.00
27M 5850 27.7 6.76 5.59 4.00 3.00
40M 8666 17.8 6.31 5.22 3.73 2.80

mCORPORATION
Notes
m
CORPORATION

KINEDIZER® Gas Burners Page 4700-A/P-1
Assembly Numbers
For these products, please order the Segment choices are as follows for
following product numbers: configured products:
(configured products are those with alphanumeric • Plug shell option
text) (2.5M, 5M & 9M only)
• Air gas inlet body
Size Burner • Fuel
0.5M .5M KDZER • Block
2.5M 2.5M KDZER
5M 5M KDZER
9M 9M KDZER
18M 18M KDZER
27M 27M KDZER
40M 40M KDZER
Specials KDZER SPL

Segment Choices
(DEFAULT is shaded)
NO No plug shell option
PLUG SHELL OPTION For 2.5M, 5M & 9M sizes only
YES Plug shell option chosen
FLGD Flanged air gas inlet body
AIR GAS INLET BODY Type of inlet body
STD Standard air gas inlet body
NAT Natural gas
FUEL Type of fuel
PROP Propane
HTSHLD Heat shield
SHRT Shor t block
BLOCK Type of block desired
SLV Standard block with sleeve
STD Standard block
Spare Parts
Burner 0.5M 2.5M 5M 9M 18M 27M 40M
Spark ignitor 28548 28548 47789 47789 47789 47789 47789
Standard block 57453 57455 57456 57457 57458 57459 59824
Seal & support block 48812 48814 48815 48816 48817 48818 59823
Short block 59782 59783 59784 59785 59786 59787 59833
Heat shield 59764 59765 59766 59767 59768 59769 59831
Block gasket 48414 48424 48448 48434 48440 48446 59822
Plug shell gasket --- 59126 59127 59128 --- --- ---
Sight glass (1/2" NPT) 19284 ---
Sight glass (1" NPT) --- 37428

mCORPORATION
m
CORPORATION

Product: KINEDIZER® Burners Page: 4700-1 Date: 2/00
Recommended valve orientation for close coupling of valve and burner
Air Flow
Sight
Glass
Product: KINEDIZER® Burners Page: 4700-2 Date: 2/00
Recommended header piping for multiple burners
1 dia.
Air Flow
1 dia.
Product Data Sheet Product: KINEDIZER® Burners
Page: 4700-1 Date: 8/03
Do Not Reproduce
KINEDIZER® Burners may be applied to a variety of performance. Attempt to keep the block slightly
applications for low to ultra-low emissions. NOx may recessed to nearly flush with the interior wall and
be controlled by the advanced mixing pattern, excess avoid any dog house or recess. Short block should not
air use, internal flue gas recirculation, or by recircula- be used in chambers with any process velocities.
tion of flue gas back to the combustion air source.
Factors that affect the NOx level include application Heaters
temperature, type of block used, excess air used, KINEDIZER® Burners adapt well to firebox and cabin
and other application parameters. heaters. (See furnaces above.) Avoid using the
burner in firetube or waterbath heaters. Experience
The following are suggested uses with example shows fast mix, high-energy burners are not appro-
expected emissions: priate for tube firing due to noise and vibration. In
addition, tight firing tubes may impede the entrainment
Oxidizers of flue gas necessary to suppress NOx emissions. To
In oxidizers and incinerators up to 1650°F, expect maintain <30 ppm NOx, required excess air may climb
NOx emission <30 ppm corrected with long block. to as high as 70%.
Excess air must be set at 30%. NOx should hold
through 8:1 turndown. CO will not be present at more Air Heating
than 50 ppm as long as the oxidizer temperature KINEDIZER® Burners may be used for air heating
remains above 1400°F with adequate dwell time and where a high capacity, low emissions, single point
mixing. burner is required. Best performance requires that
the flame be contained in a firing sleeve or chamber
Furnaces for thermal destruction of CO. Short block, long
In furnaces up to 1650°F with stack oxygen of 4-5%, blocks or heat shield may be used. (See note [3]
NOx < 30 ppm is attainable with long blocks. If below.)
installation will allow use of the short block, NOx can
be suppressed to < 25-30 ppm with flue gas Firing sleeves should be kept as short as possible
recirculation. Excess air should be set at 30% and while containing the flame length. Sleeve diameters
only reduced if internal fgr takes adequate effect. should be sized for <10,000 Btu per cross sectional
Installation of the short block is critical to emissions square inch to avoid potential noise.
Sample Expected Emissions at High Fire [1]

Air heating, direct Oxidizers, furnaces, Furnaces, oxidizers,
Application [2] Air heating
contact water heating heaters incinerators
Temperature < 800°F < 1200°F < 1650°F < 1950°F
NOx <30 <30 <30 <45
Standard Block
CO <1000 <400 <50 <50
NOx <30 <30 <30 <45
Seal & Support Block
CO <1000 <400 <50 <50
NOx <30 <25-30 <25-30 <35
Short Block
CO <1000 <400 <50 <50
NOx <30 N/A N/A N/A
Heat Shield
CO <1000 N/A N/A N/A
[1] Emissions are specific to each application and may be influenced by installation, temperatures, and other factors outside the burners.
Please contact the appropriate Maxon personnel for more specific information.
[2] Air heating may require flame protection sleeves or isolated combustion chambers to be constructed.
[3] Cross velocities up to 3000 fpm only applies to the burner with standard block or seal and suppor t block. Use of the shor t block or heat
shield requires that the flame be protected from process air impingement.
Bulletin 4800
UNI-RAD®
Gas Fired Radiant Tube Burner System
The Maxon UNI-RAD® Burner System consists of two major components
UNI-RAD® Direct Spark Ignited Burner

MAX-SAVER® In-Situ Recuperator
When the above features are combined, they have shown:

• Fuel savings ranging from 30% to 50% combined with:
• Increased alloy life for decreased maintenance/rebuild costs
• Improved furnace temperature uniformity for better product quality
• Improved production quality
Page 4802
Features and Benefits

Maxon’s UNI-RAD® Radiant Tube Burner produces an extremely stable and luminous flame envelope profile that
maximizes heat transfer throughout the radiant tube. Flame ignition is maintained by a patented continuous spark
system that ensures ignition each and every time. Options are available to operate with preheated combustion air
to 1200°F (650°C) and the UNI-RAD® Burner fires on any clean fuel gas.
UNI-RAD® Features
Plasma Type Ignition Unlike most spark ignited burners, the UNI-RAD® Burner provides a zone of
ionized air enriched with a small quantity of combustion gas to provide high
energy ignition.
Annular Ignition Electrodes The UNI-RAD® Burner does not use a conventional spark plug; instead, the
primary air and gas inlet tubes provide the electrical path for the ignition spark.
This design feature provides many times the electrode area for extended life and
positive burner ignition.
Adjustable Flame Length The flame length may be tailored to your specific needs by changing the combus-
tion air to ignition air ratios. This simple adjustment allows the burner to obtain
optimum tube temperature uniformity over a wide range of firing rates and
preheated air temperatures.
Wide Input Range The unique design of the UNI-RAD® Burner allows it to operate over a large
range of fuel gas inputs. Stability is maintained and flame length is controllable
with firing rates ranging from as little as 80,000 Btu/hr input to as much as
700,000 Btu/hr.
Instantaneous Ignition The burner’s continuous plasma spark provides instantaneous ignition allowing
the burner to operate from the Duration Adjusting Type (DAT) output from a
Proportional, Integral, Derivative (PID) Control Loop. When controlled using the
appropriate valving, single point tube temperature variations may be reduced to
as little as plus or minus 4° F (2.2°C).
Flame Supervision The UNI-RAD® Burner may be used in conjunction with UV flame supervision
equipment.
Super Forced Cooling In applications requiring rapid cooling, the UNI-RAD® Burner has been used with
secondary cooling manifolds to provide high rates of heat removal using conven-
tional radiant tubes. The UNI-RAD® Burner can sustain radiant tube pressure in
excess of 10 PSIG (0.7 bars).
Radiant Tube Types The UNI-RAD® System is suitable for use on customer-supplied pressure
tubes, negative pressure tubes, and electrified radiant tubes.
Modes Of Operation
The UNI-RAD® Burner can be operated in the following control modes:
• Proportional control over the entire firing rate range
• High-Low
• ON-OFF
• Pulse-Fired
The Pulse-Fired control mode is recommended, as it produces the tightest temperature
control available while also maximizing furnace alloy life.
9/97
UNI-RAD® Radiant Tube Burners Page 4803
Burner Selection Criteria
Combustion Air
View Port/Optic
Flame Sensor Mount
Gas 3"- 4"

Inlet
Combustion
Radiant
Ignition Air Housing
Electrical Tube
Air Inlet
Ignition
Connection
Burner Selection
The UNI-RAD® Burner can be used with various The table at left gives typical maximum capacities for
radiant tube sizes, tube configurations, heat inputs, the conditions shown. The UNI-RAD® Burner has been
etc. The following information should be supplied to used with firing rates ranging from 80,000 Btu/hr to
assist Maxon in matching the correctly sized UNI- 700,000 Btu/hr, depending upon tube length and
RAD® Burner to your specific application: diameter.
1. Radiant tube inside and outside diameters
2. Radiant tube configuration Radiant Tube Life
3. Furnace or process temperature Competitive burner systems stress the fuel savings
4. Radiant tube length obtained by the use of combustion air preheated to
5. Radiant tube material 800° to 1000° from waste heat energy. The fact that
6. Method of mounting (standard flange, packing preheated air produces much higher flame tempera-
gland, etc.) tures, and consequently decreases furnace alloy life
7. Furnace wall thickness (see page 4800-S-1 for is generally ignored. The UNI-RAD® system over-
mounting instructions) comes this problem through the use of pulse firing
8. Requirement for heat recuperation (if used) and has consistently shown increases in the furnace
alloy life while saving fuel. An extensive number of
Typical Burner Firing Rates UNI-RAD® Burner users have increased their radiant
Housing Natural Gas Flow (CFH) Combustion tube life by as much as 300%.
Size and Btu/hr Capacity Air
(inches) x 1000 Btu/hr CFM UNI-RAD® Burners have also successfully been
4" 151 28 applied to silicon carbide tubes. These tubes can
handle higher operating temperatures than most alloy
4.5" 170 31
tubes, and allows for increased heat flux.
5" 188 35
6" 226 41
Construction
7" 264 48 The UNI-RAD® Burner is constructed of cast iron and
8" 302 55 carbon steel with internal components constructed of
stainless steel. The air inlet tube length must be
Note: Burner firing rate is based on: specified when ordering to provide for differences in the
1. 1000 Btu/CF Natural Gas furnace wall thickness.
2. 120" total "U" tube length within chamber
3. 2% excess oxygen and 0% combustibles
4. 100 Btu/sq.in. of tube surface area
6/01
Page 4804 UNI-RAD® Radiant Tube Burners
Burner Selection Criteria

Piping Primary ignition air is usually less than 7% of total
The gas and air piping for the UNI-RAD Burner is ® air to the burner. The custom drilled air orifice in the
simple and direct. As shown in the piping schematic ignition air pipe assembly sets the value. An LOV is
below, each UNI-RAD® Burner uses one fuel gas line, sometimes used as a trim device to field optimize the
one primary ignition air line, and one main combustion burner ignition. The primary air is never throttled. It is
air line. kept on at all times.
CAUTION: If main air ball valve is inadvertently
Gas Metering closed, raw gas may be delivered to the tube,
A custom drilled gas spud orifice on each burner possibly creating an explosive condition.
sets the desired capacity. Typical gas pressure
requirements at the burner range from 8" – 24" w.c.
depending upon customer requirements. In Conclusion
The UNI-RAD® Burner system has been successfully
Air Metering applied to a variety of furnaces. Its success is due not
Combustion airflow is metered with a Limiting Orifice only to the quality of our equipment, but also to a
Valve (LOV) located prior to the inlet of the careful evaluation of each application. We work with
recuperator. A minimum of supply air pressure of 10" our customers to assure that every aspect of their
w.c. at the inlet to the recuperator is usually required. combustion system is designed for optimum perfor-
Higher pressures may be necessary, depending upon mance. Please contact your local Maxon representa-
burner capacity, or how the recuperator is sized. tive for assistance.
Typical Piping Schematic

(Four Burners)
Zone Air
Proof-of-Opening
Switch
Main Air
MAX-SAVER® Ball
LOV
Recuperator Valve
M ain Ai r
UNI-RAD®
Burner
M ain Ai r
M a i n A i r H e a de r
I g n i t i on A i r
** Note:
Main Gas
Air Control
Valve
Main Gas
Main G as Main G as
Main Gas Control

Solenoid Valve
Maxon FG
Combustion From Zone Fuel Regulator
& Safety Valve Train
Air Blower
** Note: Optional Items.
Large multi-burner zones may balance easier
with individual main gas LOV's on each burner.
Ignition air can be set easier with individual
ignition air LOV 's on each burner.
MAX-SAVER®
U-Shaped In-Situ Recuperator
The Maxon UNI-RAD® Burner System consists of two When these features are combined, they provide the
major components: following advantages over existing systems:
• Fuel savings ranging from 25% to 50% over non-
– UNI-RAD® Direct Spark Ignited Burner recuperative systems
– MAX-SAVER® In-Situ Recuperator • Increased alloy life
• Improved furnace temperature uniformity
• Improved production quality
• Long recuperator life
Typical Burner / Recuperator Layout

Y
Radiant
Tube Air Inlet
(by others)
MAX-SAVER®
Recuperator
UNI-RAD®
Burner
Schd. 40
Piping
Y
Section Y-Y shown on page 4806
6/01
MAX-SAVER®
U-Shaped In-Situ Recuperator
Section View Y-Y
Exhaust Stack Eductor

Cold Combustion Air
(by others)
Draw Band
(by others)
Bulkhead Plate
(by others) Radiant Tube
(by others)
Optional
Exhaust
Cooling Pre-heated Combustion Air
Air
Draw Bands (by Maxon)

11.00" Dia.
9.50" Bolt Circle
7.00" O.Dia.
6.85" I.Dia.
Custom draw band designs are available
0.75" Hole
from Maxon by request.
0.25"
HRS
Section A - A
31.3"
Weld
304 SS
Recuperator #58065
Weld 1.5" REF: Drawing #SER_5287A

NPT
8.25"

UNI-RAD® Burners - used with metal tubes
Removal
Length
Overall
Length
A B 16.76
6.31
Sec. A
4.13
E NPT
F
D 1/2" NPT
Air Inlet
C
1/2" NPT
3/4" NPT
Gas Inlet
4 holes Air Inlet

3/4" dia. Tube Length
2.81 Nozzle
Protrusion
Sec. A 8.45 Length
3.02 7.83
Air Inlet
Section A-A Tube & Nozzle
0.47 Assembly Length
E F
Housing Size* A B C D
NPT I.D.
1.25 4 UR 3.38 6.25 3.38 5.19 1-1/4" 4.0
1.25 5 UR 3.38 6.25 3.38 5.19 1-1/4" 5.0
1.5 4 UR 3.38 6.23 3.38 5.19 1-1/2" 4.0
1.5 5 UR 3.38 6.23 3.38 5.19 1-1/2" 5.0
1.5 6 UR 3.38 6.23 3.38 5.19 1-1/2" 6.0
1.5 7 UR 3.38 6.23 3.38 5.19 1-1/2" 7.0
2 6 UR 3.63 6.25 3.63 7.19 2" 6.0
2 7 UR 3.63 6.25 3.63 7.19 2" 7.0
2 8 UR 3.63 6.25 3.63 7.19 2" 8.0
*Refers to size of burner housing; dimension "E" (NPT) and dimension "F" (inside diameter)
Air Inlet Nozzle Air Tube & Nozzle Gas Tube

Removal Length Overall Length
Tube Length Protrusion Length Assembly Length Assembly
4.0" 29.0" 20.2" 3.4" 9.25" 11.75"
7.0" 32.0" 23.2" 6.4" 12.25" 14.75"
9.5" 34.5" 25.7" 8.9" 14.75" 17.25"
11.5" 36.5" 27.7" 10.9" 16.75" 19.25"
13.5" 38.5" 29.7" 12.9" 18.75" 21.25"
15.5" 40.5" 31.7" 14.9" 20.75" 23.25"
17.5" 42.5" 33.7" 16.9" 22.75" 25.25"
6/01

UNI-RAD® Burners - used with silicon carbide tubes
Removal
Length
Overall
Length
18.83
A B
Sec. A 8.38
6.19
E NPT
F
D 1/2" NPT
C Air Inlet
1/2" NPT
3/4" NPT
Gas Inlet
4 holes
3/4" dia. Air Inlet Nozzle
2.81 Tube Length Protrusion
Sec. A Length
8.45
3.02 7.83
Air Inlet
Section A-A Tube & Nozzle
0.47
Assembly Length
Housing* E F
A B C D
Size NPT I.D.
1.25 4.5C UR 3.38 6.25 3.38 5.19 1-1/4" 4.5
1.5 6C UR 3.38 6.25 3.27 5.19 1-1/2" 6.0
*Refers to size of burner housing; dimension "E" (NPT) and dimension "F" (inside diameter)
Air Inlet Nozzle Air Tube & Nozzle Gas Tube

Removal Length Overall Length
Tube Length Protrusion Length Assembly Length Assembly
4.0" 31.0" 20.2" 1.3" 9.25" 11.75"
7.0" 34.0" 23.2" 4.3" 12.25" 14.75"
9.5" 36.5" 25.7" 6.8" 14.75" 17.25"
11.5" 38.5" 27.7" 8.8" 16.75" 19.25"
13.5" 40.5" 29.7" 10.8" 18.75" 21.25"
15.5" 42.5" 31.7" 12.8" 20.75" 23.25"
17.5" 44.5" 33.7" 14.8" 22.75" 25.25"

MAX-SAVER® Recuperator - 1.25"
28.0
3.94 *From 3.75"

to 5.5" dia.
10.38 2.13
3.0 3.0 3.0 3.0 7.0
1.25" NPT
1.66 dia.
2.25
MAX-SAVER® Recuperator - 1.5"

28.0
*From 3.5" to
3.10 10.0" dia.
6.0 12.0
10.38 4.15
6.0 6.0 9.0
1.5" NPT
1.9 dia.
*Baffle diameters are normally selected to be 0.25" smaller than the I.D. of the firing tube
6/01

MAX-SAVER® Recuperator - 2"
28.0
4.63
*5.5" to
10.0 dia.
6.0 12.0
14.35 5.1
6.0 6.0 9.0
2" NPT
2.38 dia.
*Baffle diameters are normally selected to be 0.25" smaller than the I.D. of the firing tube
UNI-RAD® Burner Component Identification

Y
A
F X
E
W
G
H V
D Z
C U
B I L O P
K M N
T
S
J
A AA CC
DD
BB EE
BB
FF HH
GG
R
JJ
Q
KK
Item Part Number Description Item Part Number Description

A 20410 .125" HLW PIPE PLUG T 57956 IGN ROD
B 19284 .5" NPT OBSVTN GL U 57968 .25" IDE INSL
C 57943 .5" MALL CR V 1050577 UNI-RAD BRNR GSKT
D 57942 .5" -27 SPUD HLDR W 57970 IGN INSL RETN FLG
E 20160 .75" CA-PLUG X 1039932 M8-PLN ISO 7089 WSHR CLS
F 57939 .75" X .125" STL HEX BSHG Y 1046010 M8X16 ISO4017 SS HEX HD
G 26284 .75" X .75" X .75" MALL TEE Z 53529 IGN TERM CAP
H 57940 .5" - 27 BR SPUD - MAIN GAS AA 1050671 .625" ID CRMC INSL
I 20443 .5" BLK STL CLS NPL BB 57947 GAS INLT HLDG CLR
J 21012 .5" X .125" STL HEX BSHG CC 57955 1.375" ID INSL
K 37072 1" X .5" STL HEX BSHG DD 57948 .875" ID INSL
L 54510 M8 X 25 ISO4017 PLTD HEX EE --- GAS INLT TB ASY
M 17318 1" FLG FF 57971 CRMC CNTRG SPDR
N 1050577 UNI-RAD BRNT GSKT GG --- AIR TUBE & NOZZLE ASY
O 54512 M8-1.25 PLTD FIN HEX NU HH 58030 BRNR CSTG GSKT
P 1039932 M8-PLN ISO 7089 WSHR CLS JJ --- AIR INLT GSKT
Q 1053385 UNI-RAD IGN AIR PIPE ASY KK --- BRNR AIR INLT HSG
R 1053397 M9X10 CONE PT SET SCR For part numbers of shaded items, see next page
S 1053214 BRNR HSG
6/01
UNI-RAD® Burner Component Identification

Air Inlet Nozzle
EE Tube
GG
"A"
JJ
"B"
KK
Item "EE" - Gas Inlet Tube Assembly Item "GG" - Air Tube & Nozzle Assembly
Dimension "A" Dimension "B"
Air Inlet Tube EE Air Inlet GG
Gas Inlet Tube Assembly Air Tube & Nozzle
Length GAS INLT TB ASY Tube Length AIR TUBE & NOZZLE ASY
Length Assembly Length
4.0" 11.75 58058 4.0" 9.25 58056
7.0" 14.75 57959 7.0" 12.25 57958
9.5" 17.25 58050 9.5" 14.75 58048
11.5" 19.25 58054 11.5" 16.75 58052
13.5" 21.25 1041716 13.5" 18.75 1053137
15.5" 23.25 1053155 15.5" 20.75 1053138
17.5" 25.25 1053156 17.5" 22.75 1053139
NOTE: Air tube and nozzle available only as an
Item "JJ" - Air Inlet Gasket assembly, not separate items
Housing Size
JJ Item "KK" - Burner Air Inlet Housing
AIR INLT GSKT for alloy tubes (pictured above)
1.25 4 UR 57975 KK
Housing Size
1.25 4.5C UR 57976 BRNR AIR INLT HSG
1.25 5 UR 57976 1.25 4 UR 1053164
1.5 4 UR 57975 1.25 5 UR 1053065
1.5 5 UR 57976 1.5 4 UR 1053166
1.5 6 UR 58286 1.5 5 UR 1053167
1.5 6C UR 58286 1.5 6 UR 1053068
1.5 7 UR 58283 1.5 7 UR 1053169
2 6 UR 1053360 2 6 UR 1053170
2 7 UR 1053360 2 7 UR 1053171
2 8 UR 1053360 2 8 UR 1053172
Item "KK" - Burner Air Inlet Housing

KK1 for silicon carbide tubes (pictured at left)
KK2 Tube KK1 KK2 KK3 KK4 KK5 KK6 KK7
KK3 Size Housing Screw Washer Ring Gasket Plg Gland Nut
KK4
KK5 4.5"C 1053173 54630 1039932 1053232 1053250 1053233 54512
KK6 1053174 54630 1039932 1053236 1053251 1053235 54512
6"C
KK7
UNI-RAD® Radiant Tube Burners Page 4800-S-1
All instructions may be superceded by appli- combustion air supply pressure or less. The burners
cable NFPA codes. are typically piped into multiple burner zones using
common air and gas manifolds. It is not uncommon to
control 5 to 10 burners on the same zone.
Important: Do not discard packing material Ignition Air
The UNI-RAD® Burner ignition air is a constant
To prevent damage in transit, some components
supply of air piped into the burner body and is typi-
may be packed separately and shipped loose with your
cally between 2% and 7% of the total air required to
new Maxon UNI-RAD® Burner.
complete combustion.
Ignition
for a complete system installation. The UNI-RAD® Burner ignition is provided by a
continuous plasma arc inside the burner. The electri-
cal energy to produce this arc is provided by a continu-
Mounting ous duty ignition transformer mounted near the burner
The UNI-RAD® Burner is mounted by bolting the air in a cool environment. The transformer is generally
housing to the furnace shell, with the combustion air turned on via an auxiliary contact in the safety shut-off
inlet nipple oriented for piping convenience. The burner valve, assuring that whenever gas is available to the
body is then bolted onto the air housing which can also burner, the ignition transformer is on.
be oriented for piping convenience. The UNI-RAD®
Burner is shipped with the air housing/burner body nuts Flame Safety
installed loosely. These should be hand-tight before
The UNI-RAD® Burner generally operates without
installation is complete.
flame safety, but in those situations where it is
required, UV and IR (infrared) scanners have been
Combustion Air Supply used successfully. Please contact Maxon for details.
Combustion air can be supplied either directly from
a blower or pre-heated up to 800°F. Higher pre-heat CAUTION: When connecting optic flame sensors
temperatures may be available. Contact Maxon for to gas tube/view port, a quartz isolation lens is
more information. The UNI-RAD® Burner is a low recommended between the gas tube and optic
pressure burner and typically requires 2 inches w.c. flame sensors.
Combustion Air
View Port/Optic
Flame Sensor Mount
Gas 3"- 4"

Inlet
Combustion
Radiant
Ignition Air Housing
Electrical Tube
Air Inlet
Ignition
Connection

mCORPORATION
Page 4800-S-2 UNI-RAD® Radiant Tube Burners
Read complete instructions before proceeding, 7. Set the high and low gas pressure switches on the
and familiarize yourself with all the system's equipment main fuel train to 5 inches w.c. above and below
components. Verify that your equipment has been the main gas pressure regulator, respectively.
installed in accordance with the original manufacturer's 8. Open the main gas cocks in the main fuel train
current instructions. (not pictured).
9. Open the safety shut-off valve and verify that the
CAUTION: Initial adjustment and light-off ignition transformer is energized and that the high
should be undertaken only by trained and voltage lead is properly installed on the burner.
experienced personnel familiar with combus- 10. Open the zone gas cock (not pictured).
tion systems, with control/safety circuitry, and 11. While looking into the burner sight glass, slowly
with knowledge of the overall installation. open the burner gas valve . Ignition commence-
Instructions provided by the company and/or ment should be immediate. Flame should be a light
yellow to yellow-orange in appearance. Using some
type of pressure measuring device, verify the gas
over these provided by Maxon. If Maxon pressure delivered to the burner spud.
instructions conflict with any codes or regula- 12. Look into the exhaust leg of the radiant tube and
tions, contact Maxon Corporation before look for the flame position. Open or close the
attempting start-up. limiting orifice valve in the combustion air line
until the flame length is maximized.
1. Close the main, zone and burner gas valves . Using an oxygen analyzer, adjust the combustion
2. Turn on the main power supply. air limiting orifice valve until 2-1/2% excess
3. Set the temperature control instrument to a oxygen is measured in the exhaust. The exhaust
sufficient set-point to ensure the burner is “on”. gas sample should be taken approximately halfway
4. Start the combustion air blower. Check impeller ®
up the MAX-SAVER Recuperator, or to the inside
rotation. edge of the refractory wall, if possible.
5. Verify that the combustion air pulse firing valve ®
If a MAX-SAVER Recuperator is being used, it is
is fully open and then set the proof-of-opening desirable for the flame to bend all the way around
switch so that the contact closes only when the the radiant tube and lick the end of the recuperator
air pulse firing valve is fully open. return bend when at operating temperature.
6. Open the burner air shut-off valve (ball valve or 13. Oxygen settings should always be confirmed at
equivalent) and main air limiting orifice valve to operating conditions. O2 readings will normally be
the fully open position. lower when taken during hot operating conditions
compared to cold start-up conditions.
Typical Piping Schematic (one burner shown) Ignition Transformer

18/2 SJO CORD
Combustion Air (ORDER SEPARATELY)
Proof -of-Opening
MAX-SAVER®
Recuperator
Switch
ó 120/60 IGN
Main Air POWER TRANS

LOV Air Cock
UNI-RAD®
POWER SUPPLY CONNECTION KIT
Burner
ö ì (INCLUDES PLUG SET & SJO CORD FERRULES)
** Note:
I g n i t i on A i r Air Control
Valve
** Note: ú From
Combustion
Air Blower
IGNITION WIRE
TO BE ORDERED SEPARATELY
Main Gas
** Note: Optional Items.

Large multi-burner zones may balance easier
with individual main gas LOV's on each burner.
Ignition air can be set easier with individual 10 KV IGNITION TRANSFORMER TERMINATION KIT
ignition air LOV 's on each burner. EPOXY (INCLUDES IGNITION TRANSFORMER AND
FILLED TWO IGNITION WIRE CONNECTORS)
120/60
m CORPORATION

UNI-RAD® Radiant Tube Burners Page 4800-A/P-1
Assembly Numbers
UNI-RAD® Burners
UNI-RAD Burners - configured assembly item numbers

Burner Size w/ 1.25 recuperator w/ 1.5 recuperator w/ 2.0 recuperator
w/4" housing metal tube 1.25 4 UR 1.5 4 UR ---
w/4.5" housing silicon carbide tube 1.25 4.5C UR --- ---
w/5" housing metal tube 1.25 5 UR 1.5 5 UR ---

metal tube --- 1.5 6 UR 2 6 UR
w/6" housing
silicon carbide tube --- 1.5 6C UR ---
w/7" housing metal tube --- 1.5 7 UR 2 7 UR
w/8" housing metal tube --- --- 2 8 UR
NOTE: Metal and silicon carbide tubes normally supplied by others, not by Maxon
Segment Choice Detail - UNI-RAD Burners

Segment Choices
(DEFAULT is shaded)
BUT Butane Gas
FUEL Type of fuel NAT Natural Gas
PROP Propane Gas
DRILLED HOUSING --- YES Drilled Mounting Flange
AIR HOUSING CONNECTION Type of connection ANSI ANSI Threaded
HOUSING FINISH Type of finish on housing STD Standard
MAXIMUM AIR INLET TEMP (F) Maximum air inlet temperature 800 800F (427C) Maximum
115 11.5" Long Air Tube
AIR INLET TUBE LENGTH (IN) Length of air inlet tube in inches 175 17.5" Long Air Tube
4 4" Long Air Tube
7 7" Long Air Tube
Continued on next page

mCORPORATION
Page 4800-A/P-2 UNI-RAD® Radiant Tube Burners
Assembly Numbers
UNI-RAD® Burners
Segment Choice Detail - UNI-RAD Burners (continued)

Segment Choices
(DEFAULT is shaded)
NOZZLE TYPE Type of nozzle STD Standard nozzle
IGNITION AIR ORIFICE DIA (IN) Diameter of ignition air orifice Specify value Select from drill sizes shown
GAS SPUD ORIFICE DIA (IN) Diameter of gas spud orifice Specify value Select from drill sizes shown
METERING VALVE --- NO None provided
NO Do not include with order
RECUPERATOR (shipped loose) Burner with recuperator
ANSI ANSI Threaded (shipped loose)
.75" GAS BALL VALVE Gas ball valve (shipped loose)
NO None provided
Ignition air ball valve (shipped ANSI ANSI Threaded (shipped loose)
.5" IGNITION AIR BALL VALVE
loose) NO None provided
MAIN AIR BALL VALVE Main air ball valve (shipped loose)
NO None provided
Main air limiting orifice valve ANSI ANSI Threaded (shipped loose)
MAIN AIR ORIFICE VALVE
(shipped loose) NO None provided
NONE None Selected
125 1.25" Connection
Size of main air limiting orifice 15 1.5" Connection

MAIN AIR ORIFICE VALVE SIZE
valve in inches 2 2" Connection
25 2.5" Connection
3 3" Connection
.125" SAMPLE COCKS (QTY 2) If desired; shipped loose
NO None provided
POWER SUPPLY CONNECTION NO Do not include with order

If desired; shipped loose
KIT YES Include with order
NONE None Provided
PRIMARY POWER SUPPLY If desired; shipped loose
115_60_1 115v 60 hz Single Phase
IGNITION TRANSFORMER NONE None Provided

If desired; shipped loose
OUTPUT 10000 10000v
IGNITION WIRE LENGTH (FT) Wire length in feet Specify value ---
18/2 SJO CORD LENGTH (FT) Cord length in feet Specify value ---
m
CORPORATION

Assembly Numbers
MAX-SAVER® Recuperators
MAX-SAVER Recuperators
(when purchasing recuperator only)
Recuperator
1.25 1.5 2.0
Size [1]
Item Number 1.25 UR RECUP 1.5 UR RECUP 2 UR RECUP
[1] Size refers to the recuperator NPT connections or the
equivalent O.D. to Sched. 40 black pipe
Segment Choice Detail - MAX-SAVER Recuperators

Segment Choices
(DEFAULT is shaded)
ANSI_THRD ANSI Threaded
CONNECTION Type of connection
ISO_THRD ISO Threaded
NONE No Baffle
BAFFLES (size) Size of baffles
Default Size See Below
Baffle Sizes (available in 1/8" increments from minimum to maximum)

Baffles [2]
Recuperator Size [1]
Minimum Size Available Maximum Size Available Default Size
1.25 3.75" (375) 5" (5) 375
1.5 5" (5) 10" (10) 5
2 5.5" (55) 10" (10) 55
[1] Size refers to the recuperator NPT connections, or the equivalent O.D. to Sched. 40 black pipe
[2] The correct baffle size (diameter) will be a nominal 0.250" smaller than the I.D. of the firing tube

mCORPORATION
Assembly Numbers
Spare Parts
UNI-RAD configured spare parts kits

(default quantities of spare parts are based on a
quantity of 10 burners)
Configured item number
UR RSP
Par t numbers and descriptions for individual
spare par ts are shown below
UNI-RAD, MAX-SAVER recommended spare parts kit

Default Value in each kit
Spare Parts Kit
Description (based on a quantity of 10 Part Number
Configured Item Number
burners)
.875" x 2.31" CERAMIC SPACER 2 57948
1.375" x 2.31" CERAMIC SPACER 1 57955
.25" x 2.31" CERAMIC SPACER 1 57968
CENTERING SPACER 3 57971
UR RSP .5" SIGHT GLASS 1 19284

IGN TRANS TERMINATION KIT 1 57974
125V POWER SUPPLY CONN KIT 1 58288
18/2 SJO CORD (FT) 5 58294
.125" TEST CONNECTION KIT 4 34137
#58294 18/2 SJO CORD

(ORDER SEPARATELY)
120/60 IGN
POWER TRANS
#58288 POWER SUPPLY CONNECTION KIT

(INCLUDES PLUG SET & SJO CORD FERRULES)
#32909 IGNITION WIRE

TO BE ORDERED SEPARATELY
10 KV #57974 IGN TRANS TERMINATION KIT

EPOXY (INCLUDES IGNITION TRANSFORMER AND
FILLED TWO IGNITION WIRE CONNECTORS)
120/60
m
CORPORATION

Assembly Numbers
Accessories
LOV - Limiting Orifice Valve Main Gas Control Solenoid Valves

Size Maxon Part Number Pressure Maxon Part
Size Flow (Gas) Drop
Rating Number
.5" 1040910
.375" 50 PSIG 28695 183 CFH 1"
.75" 1033928
.5" 50 PSIG 32826 240 CFH 1"
1.0" 1033934
.75" 50 PSIG 28697 248 CFH 1"
1.25" 1030339
.75" 25 PSIG 45945 580 CFH 1"
1.5" 1035023
2.0" 1030338 1.0" 25 PSIG 28845 1,119 CFH 1"
2.5" 1040337 1.25" 25 PSIG 28846 1,730 CFH 1"
3.0" 1040335 1.5" 25 PSIG 28847 1,900 CFH 1"

2.0" 25 PSIG 29400 3,251 CFH 1"
Main Air Control Valves 2.5" 5 PSIG 29401 5,821 CFH 1"
Size Maxon Part Number 3.0" 5 PSIG 29402 7,430 CFH 1"
1.5" 1054140
2.0" 1054141
2.5" 1054142 Pressure Gauges
3.0" 1037612 1/4" NPT, Bottom Connection 2-1/2" Dial
4.0" 58635 Pressure Range Maxon Part Number
Actuator w/o Dampening 1054147 0 - 15" wc 20202
Actuator w/Dampening 58634 0 - 35" wc 20203

0 - 60" wc 20204
0 - 5 PSIG 20199
Note: Shaded part numbers are included in 0 - 15 PSIG 20200

configurator 0 - 30 PSIG 20205
0 - 60 PSIG 20201
0 - 160 PSIG 30540
Protection Valve for above 30516
Lever Sample Cock 34516

m
CORPORATION
Assembly Numbers
Accessories
Manual Valves
Cast Iron Plug Cock Ball Valves for Air or Gas

Size Maxon Part Number Size Maxon Part Number
.75" 26180 .25" 33110
1.0" 26181 .375" 31046
1.25" 20194 .5" 31045
1.5" 20195 .75" 31047
2.0" 20196 1.0" 31081
2.5" 20197 1.25" 31080
3.0" 20198 1.5" 37925
4.0" 36881 2.0" 37926
DeZurick Fig. 425 w/handle Maxitrol BV250 / BV250T
Pressure Switches
Type of Switch Manufacturer's Description Maxon Part Number
Antunes JD2 Pressure Switch with red spring, .1-24" wc 1030337
Proof-of-Opening Pressure Switches ASCO Tripoint - Pressure Switch SA20D 1041818
ASCO Tripoint - Transducer TA20A11 1041819
Gas and Air Low Pressure Switch Honeywell #C437-F-1011, 0-26" wc 33224
Gas High Pressure Switch Honeywell #C437-D-1013, .5-5 PSIG 33591
Note: Shaded part numbers are included in configurator
m
CORPORATION

Bulletin 5100
Series “66” AIRFLO® Line Burners
• For direct-fired process air heating applications
• Burns clean and odor-free with low levels of NOx production
• Direct-firing optimizes heat transfer efficiencies. All available heat from the gaseous fuel is
released directly into the passing air stream.
• 15:1 turndown ratio provides application flexibility for all fresh or recirculated air stream heating
• Long service life and lower maintenance cost result from rust-resistant cast iron burner bodies
and the controlled expansion of mixing plate’s design
• Modular burner design permits shaping the burner element and total heat release to match your specific
application’s requirements. Basic building block concept provides infinite number of possible burner
configurations to meet your needs.
Covered by U.S. Patents #25,626, #3,297,259 and #4,573,907;

Canada #786,136 and #786,137; Great Britain #943,733
Page 5102

Principle of Operation Progressive
aeration
Series “66” AIRFLO® Burners consist of a rust- pattern
resistant cast iron body (which serves as an air/fuel
manifold), drilled to discharge the partially premixed
air/fuel mix between the diverging stainless steel
Mixing
mixing plates. plates
The entire burner assembly is mounted inside your
duct directly in the air stream being heated. The air Gussets
stream passes across the burner and through the for
strength
mixing plates and is used as additional combustion Manifold
for partial
air, particularly at the higher firing rates. Carefully air/gas
controlled mixing plate aeration patterns give premixture Rust-resistant
cast body
progressive mixing, superior cross-ignition and flame Flanged modular
retention across the entire burner assembly length. construction
Optimum performance demands that air

velocities be uniform across the entire burner
assembly. Series “66” AIRFLO® Line Burners are offered in
Air velocities are established by the use of three different types. Each type is optimized for a
customer-installed profile plates. Normal design specific type of application. All require a partial air/gas
operating velocities are in the range of 2600-3000 premixture and are intended for use in heating
SFPM, resulting in approximately 0.8" wc static process air in motion:
pressure drop across the profile opening. For special
applications, considerably higher or lower pressure • AL-4 AIRFLO® Burner with its aluminized steel
drops and velocities may be encountered. mixing plates is the most economical choice for all
Normal capacities vary widely with application. fresh air heating with natural gas.
Fuel used and design velocities affect turndown. • AL-4S AIRFLO® Burner incorporates #321
Modular design permits shape and total heat release stainless steel mixing plates for all fresh air
to match application needs. heating with natural or propane gases.
• AL-5 AIRFLO® Burner has #321 stainless steel
mixing plates and is designed for recirculated or
higher temperature applications.
3/92
Series “66” AIRFLO® Line Burners Page 5103

System components normally used in conjunction with a Maxon Series
“66” AIRFLO® Burner application
Typical piping layout using VENTITE™ Inspirators A complete Series “66” AIRFLO® Burner system
and Series “66” AIRFLO® Burners normally includes a gas train, proportioning/mixing
equipment, combustion air supply, and a combustion
control panel. Your Maxon representative can help

misuse of the piping layouts shown. Specific
3/92
Page 5104 Series “66” AIRFLO® Line Burners
Series “66” AIRFLO® Line Burners and Series “66” AIRFLO® Mixers for
fresh process air heating applications
Capacity in 1000's Btu/hr Nominal
Type of Gas and Type of Duct Static Pressure and per lineal foot of burner
Velocity SFPM Range of
Series "66" AIRFLO® Burner Series "66" AIRFLO® Mixer
Maximum Minimum Turndown
2600 650 43
0" to +2.0" wc
3000 750 50 15:1
FO-P
3500 900 60
2600 600 43
+2.1" to +4.0" wc 14:1
3000 700 50
FO-PX
Natural Gas 3500 800 60 13:1
with
AL-5 Burner 2200 550 35
0" to -1.0" wc
2600 650 43 15:1
FO-S
3000 750 50
2200 550 40 13:1
-1.1" to -4.0" wc
2600 675 47 14:1
FO-SX
3000 750 53 13:1
2600 600 43 14:1
0" to +2.0" wc
2800 650 47 13:1
FO-P
3000 700 50 14:1
2600 550 43
+2.1" to +4.0" wc 12:1
2800 600 47
FO-PX
Propane Gas 3000 650 50 13:1
with
AL-5 Burner 2600 600 43 14:1
0" to -1.0" wc
2800 650 47 13:1
FO-S
3000 700 50 14:1
2600 625 47
-1.1" to -4.0" wc
2800 675 50 13:1
FO-SX
3000 700 53
More selection data on fresh process air Flame length is approximately 22" to 26" on
heating with Series “66” FO-P, FO-PX, FO-S and natural gas (20"-24" on propane) measured from the
FO-SX AIRFLO® Mixers is available in Maxon forward edge of the mixing plates.
catalog bulletin 5300. Propane maximum capacities are reduced to avoid
overheating of the mixing plates; minimum capacities
differ due to velocity differences.
Series “66” AIRFLO® Line Burners and Series “66” AIRFLO® Mixers
for recirculated process air heating applications
Type of Gas and Type Duct Static Pressure Capacity in 1000's Btu/hr Nominal SCFM Fresh Air
Velocity per lineal foot of burner
of Series "66" AIRFLO® and Series Range of required per
SFPM
Burner "66" AIRFLO® Burner Maximum Minimum Turndown 100,000 Btu/hr
2200 550 35 60
0" to +2.0" wc
2600 650 43 15:1 80
R-P
3000 750 50 120
2200 450 35 60
+2.1" to +4.0" wc
2600 550 43 13:1 80
R-PX
Natural Gas 3000 650 50 120
with
AL-5 Burner 2200 550 35 60
0" to -1.0" wc
2600 650 43 15:1 80
R-S
3000 750 50 120
2200 550 40 13:1 60
-1.1" to -4.0" wc
2600 675 47 80
R-SX 14:1
3000 750 53 120
2600 600 43 70
0" to +2.0" wc
2800 650 47 14:1 80
R-P
3000 700 50 100
2600 500 43 70
+2.1" to +4.0" wc
2800 550 47 12:1 80
R-PX
Propane Gas 3000 600 50 100
with
AL-5 Burner 2600 600 43 70
0" to -1.0" wc
2800 650 47 80
R-S
3000 700 50 100
14:1
2600 625 43 70
-1.1" to -4.0" wc
2800 675 47 80
R-SX
3000 700 50 100
More selection data on recirculated process air Higher air velocities give shorter flame lengths
heating with Series “66” AIRFLO® Mixers and and result in increased pressure drop across the
AIRFLO® Burners is available in Maxon catalog burner and profile plate.
bulletin 5300. Minimum capacity is determined by air stream
Flame lengths are 26" to 30" on natural gas (24" velocity across the burner, which must be maintained
to 28" on propane), measured downstream from the in the range of 2200-3000 SFPM. Fresh make-up air
forward edges of the mixing plates. must be added to the recirculated air stream at
Capacities for natural gas and propane differ at the rate of 60-120 SCFM per 100,000 Btu/hr heat
minimum because the recommended air stream release (introduced so as to pass effectively through
velocities differ. and over the burner).
3/92
Series “66” AIRFLO® Line Burners and VENTITE™ Inspirators
Capacity in 1000's Btu/hr
Type of Gas and Type of Velocity per foot of lineal burner Nominal Range SCFM Fresh Air required
Series "66" AIRFLO® Burner SFPM of Turndown per 100,000 Btu/hr
Maximum Minimum
2200 90 6.7:1
Natural Gas with
2600 600 100 6:1 100
AL-5 Burner
3000 110 5.5:1
More selection data on recirculated process air Higher air velocities give shorter flame lengths
heating with VENTITE™ Inspirators and Series and result in increased pressure drop across the
“66” AIRFLO® Burners is available in Maxon burner and profile plate.
catalog bulletin 3300. For recirculated process air heating, maximum
Flame length is approximately 12" to 18" on capacity is 600,000 Btu/hr per lineal foot. Minimum
natural gas measured downstream from the forward capacity is determined by air stream velocity across
edge of the mixing plates. the burner, which must be maintained in the range of
The VENTITE™ Inspirator must be mounted 2200-3000 SFPM. Fresh make-up air must be
directly in the air stream being heated and must feed added to the recirculated air stream at the rate of
directly into a burner back inlet. A natural gas supply 100 SCFM per 100,000 Btu/hr heat release (intro-
pressure of 4-1/2 PSIG measured at the inspirator’s duced so as to pass effectively through and over the
inlet is required. Higher inlet pressures are not burner).
recommended.
Series “66” AIRFLO® Line Burners and Series “HG” Mixing Tubes
Capacity in 1000's Btu/hr
Type of Gas and Type of Velocity per foot of lineal burner Nominal Range SCFM Fresh Air required
Series "66" AIRFLO® Burner SFPM of Turndown per 100,000 Btu/hr
Maximum Minimum
2600 600 40
Natural Gas with
3000 650 43 15:1 80
AL-5 Burner
3500 700 47
More selection data on recirculated process air Turndown ratios of 15:1 are possible using
heating with Series “HG” Mixing Tubes and Series natural gas. Uneven and/or turbulent air flows, or the
“66” AIRFLO® Burners is available in Maxon use of propane, will give higher minimums and reduce
catalog bulletin 3200. turndown.
Capacity data is based on 2 PSIG natural gas The capacities shown are based on a minimum
supply pressure at the “HG” Mixing Tube and 2600- of 80 SCFM of fresh air being added for each
3500 SFPM air stream velocity across the burner. 100,000 Btu/hr of heat input. Lower fresh air
Differential combustion air pressure of 5.2" wc volumes, the presence of exceptionally high moisture,
is required at the mixing tube and is measured or other combustion-retarding or inert components
between burner inlet and duct/chamber static may require special consideration.
pressure.
Total heat release and AIRFLO® Burner footage Total duct area displaced by this burner assembly:
are normally selected from the tables given in the
(3 x 0.7 ft2) + (2 x 0.75 ft2) = 3.6 ft2
various mixer sections of the Maxon catalog:
Series “66” AIRFLO® Mixers .................. 5300 Volume (CFM)
Series “HG” Mixing Tubes ...................... 3200 Velocity (FPM) = Net Free
VENTITE™ Inspirators .......................... 3300 Area (ft2)
Based on capacity information given in these
catalog sections, and within the constraints of duct The net free area of the duct, and consequently the
size and air volume flows, a Series “66” AIRFLO® profile opening surrounding the burner element, can
Burner assembly is designed utilizing these available be determined by inserting the air volume and/or the
sections shown on the following pages. desired operating velocity into this formula. The
When ordering a burner assembly made up from burner displaces area in the duct and must be added
these available module components, be sure to to the air handling area to determine the appropriate
provide an assembly sketch of the complete burner profile dimensions.
(as viewed from the back, or upstream, side) including Air stream velocity and resulting static pressure
locations of all accessories and/or individual compo- drop affect performance and are achieved by means
nent sections. of a silhouette profile opening within the duct.
Start-up and operating procedures will be greatly A minimum profile plate width of 6" is required
simplified if observation ports are provided and surrounding all Series “66” AIRFLO® Burner
positioned to allow direct visual inspection of both assemblies.
pilot and main flame. Maintenance access should also
be provided upstream of burner. Burner inlet feed piping must be adequate to
All “open” ends of burner assembly must be closed provide a well-distributed flow of air/gas throughout
off with one of the end closures or pilot assemblies the burner assembly. Do not use more than 2-1/2 feet
shown on the following pages. Any end plate ports not of type “AL-4” or “AL-4S” burner in any direction from
used must be plugged. a burner section containing an inlet.
Do not use more than 2 feet of type “AL-5” burner
in any direction from a burner section containing an
Displacement area per section inlet.
For purposes of calculating operating air velocities Do not exceed the footage feed limitations shown
and resulting static pressure drops across the burner in the table below.
assembly and profile plate, use the following equiva-
lent displacements:
Each 6" straight section: 0.35 ft2 Inlet feed capacity limitations
Each 12" straight & 12B section: 0.7 ft2 Burner Inlet Flanges AL-4 & AL-4S AL-5
Each 12" x 6" tee section: 0.75 ft2 2" end inlet flange
2 ft. 1 ft.
Each 12" x 12" cross & BX section: 0.85 ft2 2" back inlet flange
Each 36" B (12" x 12" x 12" H) section: 1.5 ft2 2.5" back inlet flange 3 ft. 1-1/2 ft.
3" back inlet flange
For example:
A Series “66” AIRFLO® Burner assembly is made 4" back inlet flange 6 ft. 4 ft.
up of: 3" back inlet cross flange
(2) 12" straight section @0.7 ft2 displ. area 4" back inlet cross flange 12 ft. 8 ft.
(1) 12" back inlet straight @ 0.7 ft2 displ. area
(2) 12" x 6" tee section @ 0.75 ft2 displ. area Inlet flanges bolt directly to burner body casting
and accept threaded NPT piping. Chart above shows
maximum lineal feet of Series “66” AIRFLO® Burner
that may be fed by a given inlet flange.
3/92
Envelope Dimensions (in inches)

Modular Burner Sections
6" straight 12" straight 12" x 6" tee 12" x 12" cross
section section section section
Typical End Views
Straight Tee and

Sections Cross Sections

Modular Inlet Feed Burner Sections
12" x 12"
12" back inlet section 36" back inlet section back inlet cross
NOTE: 12B, 36B and XB back inlet sections must be ordered

with one of the back inlet flange sets shown below.
Back Inlet Flanges

Flange Sets for 12" & 36" Inlet flanges bolt directly to Flange Sets for 12" x 12"
Back Inlet Sections burner casting and accept Back Inlet Cross Sections
standard NPT threaded piping
of indicated size.
NOTE: Refer to page 5107
2" 2-1/2" 3" 4" for specific inlet feed capacity
LFB LFB LFB LFB limitations. 3" 4"
A (size) B
A (size)
2 0.88
3
2.5
1.25 4
3
4 3.5
10/93

End Closures and End Inlet Flange Sets
All open ends of a burner assembly must be closed off with one of these end closures,
or with a pilot end plate or pilot assembly as shown below and on page 5111.
Plain end 2" end

plate set flange
set
Plain end plate
closure includes
1/8" NPT test
connection
EP-FR-end plate set

UV scanner can be
mounted through straight-
in flame rod location. 1"
tap is bushed to 1/4" for
flame rod.
Alternate
flame rod
position
14mm spark ignitor and flame rod ( if used) must be

ordered separately with all end plate sets.
F2-FR-2" end inlet

flange set
UV scanner can be
flame rod.
Alternate
flame rod
NOTE: See catalog page position
5107 for specific inlet
feed capacity limitations.

Pilot Assemblies
Built-in pilot arrangements Built-in pilot detail

(6" straight sections only) (6" straight sections only)
Direct mounted version includes 14mm spark igni-
tor. Order electrode separately for externally mounted
version. Order flame rod (if used) separately.
6" straight section

with direct mounted built-in pilot set
With built-in pilot arrangement, a section of the 6"

straight burner body casting must be separated off to
form a cavity for pilot gas. Pilot flame emerges through
the main burner face.
Optional external mounting assemblies

shown on page 5113
AIRFLO-PAK pilot arrangements

(shown at right)
Direct mounted version includes 14mm spark
ignitor. Order electrode separately for externally
mounted version. Order flame rod (if used)
separately.
10/93

Pilot Assemblies
Optional air/gas pilot mixers for all Series “66” AIRFLO® pilot assemblies
Atmospheric type Atmospheric type Pressure type

with adjustable orifice with fixed orifice with adjustable orifice
External Mounting Plate Assemblies

External mounting plate details Positioning mounting plate in relation to
A plate is included with all assemblies shown on AIRFLO® Burner pilot location
page 5113
Mounting Plate with two

(2) feed-through insulators
for internal mounting of
spark ignitor and flame
rod. Same size external
mounting plate used in all
assemblies shown on
page 5113.
External mounting plate

dimensions
Through-wall
opening
required

As used with AIRFLO-PAK As used with built-in

Description pilot assemblies pilot assemblies

assembly for internal
spark ignitor & internal
flame rod

assembly for external UV
scanner & internal spark
ignitor


assembly for external
spark electrode &
external UV scanner
NOTE: Order spark

electrode sub-assembly
separately

ignitor
NOTE: Order spark electrode

and 24" flame rod
sub-assemblies separately
3/92

Profile Plate Bracket Division plate
Provides support for Provides isolation of burner
profile within closed burner feed(s) where desirable.
loop. On some
applications, it may be
necessary to restrict air
flow between adjacent Optional electrode cover
burner rows to achieve Protects porcelain insulator and
design operating velocities. This is done by installing electrical connection from dirt
customer-fabricated profile plates on profile mounting and moisture. May be used for
bracket(s). See sketch 1 below for use on square ambient temperatures up to
openings (formed by adjacent cross-sections of 450°F (232°C).
burner). Sketch 2 applies to rectangular opening.
14mm
1 Spark Ignitor
18"
Spark Electrode
2 Flame rod identification

For those burners using flame rods, most
applications are covered by one of three sizes
(specific number depends on nominal length “N” of
rod extension). These may need cut to dimension “L”
specified in tables on pages 9908 and 9908A before
use in your particular application.
N
7-1/2"
Universal support bracket
Normally used in pairs as shown below. Mount to 12"
burner assembly at any joint between sections.
24"
Two versions available: zinc plated for maximum
inlet temperature up to 750°F (399°C) or #304SS for
maximum inlet temperature up to 1600°F (871°C).
To order replacement parts: Item

Part Description
® Number
1. Identify specific AIRFLO Burner
1 Burner body
series/type from burner assembly
2 Back up bar (straight)
information plate on following page and 3 Gasket, body (straight)
visually confirm if your burner body 4 Back up bar (inside)
casting has 4 rows or 5 rows of holes. 5 Gasket, inside
2. Provide sketch of burner arrangement 6 Back up bar (outside)
as viewed from back (or casting side) of 7 Burner body gasket (between joints)
assembly. 8 Support bracket gasket 18 GA
For example: 9 6" mixing plate
10 Corner mixing plate
12 5/16" -18 x 1-1/4" hex head cap screw
13 5/16" -18 finished hex nut
14 #10 -24 FLEX-LOK hex nut
15 #10 -24 x 1/2" indented hex head machine screw
16 #10 -24 x 2-1/4" indented hex head machine screw
17 Washer
3. Specify quantity of each replacement 18 #10 -24 x 3/8" indented hex head machine screw
item required from drawings. For 19 3/8" -16 hex nut finished
20 3/8" -16 x 1-1/4" hex head cap screw
additional information, refer to Maxon
21 1/4" -20 x 3/4" hex head cap screw
3/92
There are two (2) types of fastener kits for Series “66” AIRFLO® Burner assemblies:
EP Fastener Kits (end plate fastener kit) provide Fastener Kit (mixing plate fastener kit) includes
an assortment of nuts, bolts, etc., that will mount any all the necessary nuts, bolts, etc., to fasten one
Maxon pilot, end plate, or end inlet flange to the open mixing plate to the adjoining mixing plate and to
end of an AIRFLO® Burner assembly. Depending mount any support bracket (gusset) or back-up bar
upon what specific end plate/pilot assembly you have, required. There may be some “excess” fasteners in
there may be some “excess” fasteners in the kit that the kit that may also be discarded, depending upon
can be discarded. There are enough fasteners to the specific mixing plate joint. These kits do not
secure the end plate/pilot to both side mixing plates include body casting flange joint bolts.
and to the end of the body casting flanges.
Example:
Series “66” AIRFLO® Burner Information Plate
Series “66” AIRFLO® Burners Page 5100-S-1
General Fuel shut-off valves (when properly connected to a
These mounting instructions for Series “66” safety control system) shut the fuel supply off with a
AIRFLO® Line Burners are in addition to the general loss of electrical power. Manual reset valves require
AIRFLO® Line Burner installation instructions operator attendance each time the system is started
published on Maxon catalog pages 5000-S-1 through up (or restarted after a shut-down). Motorized shut-
5000-S-10. off valves permit automatic start/restart when used
Specific instructions are also offered for other with appropriate control system.
Maxon component items:
– Shut-Off Valves (pages 6000-S-1 through S-14) ment. At a minimum, they should be provided down-
– Flow Control Valves (pages 7000-S-1 through S-4) stream of any mixing tube and at each burner inlet.
– Mixing Tubes (pages 3200-S-1 through S-6) Test connections should never be installed in elbows
Read complete instructions before proceeding, or pipe tees. Test connections must be plugged
and familiarize yourself with all the system’s equip- except when readings are being taken.
ment components. Verify that your equipment has
been installed in accordance with the original
manufacturer’s current instructions. Bolt Torque Tightening
Clean fuel lines are essential to prevent blockage 1. Apply Never-Seez (anti-seize and lubricating
of pipe train components or burner gas ports. All dirt, compound) to the threads of the bolts to improve
scale and pipe dope should be blown out of any new the pre-loading of the gasket.
gas line before actually connecting to the burner 2. Tighten the bolts to 1/2 the specified value (see
system. table below), starting at position 1 and working to
Main gas shut-off cock should be upstream of position 6.
both main gas regulator and pilot line take-off. Use it 3. Tighten the bolts to the full torque value, starting at
to shut off fuel to both pilot and main burner during position 1 and working to position 6.
shutdown periods of more than a few hours. MICRO- 4. Tighten the bolts again to the full value starting at
RATIO® Control Valves are not intended for tight position 1 and working to position 6.
shut-off.
uniform system supply pressure. A separate regulator
should be provided in the branch leading to each
burner system if more than one is served by a com-
mon main. Size regulator for full system capacity at
required pressure, including pipe train losses. Follow
the instructions attached to the regulator during
installation.
Pilot take-off should be upstream of main gas
regulator but downstream of main gas cock. It should
normally include its own pilot gas regulator (selected Torque Values
to meet pilot flow and pressure needs), a solenoid Bolt Size Bolt Material Torque Value Units
valve and shut-off cock. An adjustable gas orifice at M10 Plated steel 186 in lbs
the pilot inlet simplifies adjustment. M10 Stainless steel 248 in lbs
Appropriate pilots should be provided which are M10 High Alloy 45 ft lbs
compatible with the type of burner and control system
being used.

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Page 5100-S-2 Series “66” AIRFLO® Burners
1. Always design air/gas manifold piping for uniform Sketch below shows four inlets being fed from one
distribution to multiple-feed or multiple-burner end-fed header. Note that full premixture manifold
systems. Select manifold piping sizes by start- size is continued past all burner take-offs, and outlet
ing at the burner/nozzle end and working extended and capped one pipe diameter length
backward to the premixer discharge. beyond last take-off. Always keep premixer device a
2. Always make sure that any distribution header is minimum of four pipe diameters in length from first
greater in cross-sectional area than the total cross- take-off.
sectional area(s) of any and all pipes being fed.
air/gas mixture line between the premixing device
and its burner(s).
The chart below gives typical pipe data for use in
designing air/gas distribution manifolds.
General Pipe Data (Schedule 40)

Inside Outside
Diameter Diameter
(inches) (inches)
1/8 0.269 0.405 0.057
1/4 0.364 0.54 0.104
3/8 0.493 0.675 0.191
1/2 0.622 0.84 0.304
3/4 0.824 1.05 0.533
1 1.049 1.315 0.864
1-1/4 1.38 1.66 1.496
1-1/2 1.61 1.9 2.036
2 2.067 2.375 3.356
2-1/2 2.469 2.875 4.788
3 3.068 3.5 7.393
3-1/2 3.548 4 9.887
4 4.026 4.5 12.73
5 5.047 5.563 20.006
6 6.065 6.625 28.89
8 7.981 8.625 50.027
10 10.02 10.75 78.854
12 12 12.75 113.097
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A fully premixed air/gas mixture must be supplied to Natural gas pressure generally required (as mea-
your Series “66” AIRFLO® Burner to support proper sured at the mixer gas inlet) is 1 PSIG higher than air
combustion. With “fully-premixed” Series “66” AIRFLO® pressure for “HG” Mixing Tubes.
Burner systems, a Series “HG” Mixing Tube with Anything more than minimal distance or piping
MICRO-RATIO® Control Valve is often used to premix turns may necessitate “oversizing” piping runs to keep
gas and air prior to its introduction to the Series “66” pressure drops within acceptable ranges.
AIRFLO® Burner assembly. Inlet pipe leading to any burner should be at least
A typical “HG” Mixing Tube system piping four pipe diameters in length. If multiple burners are
layout is illustrated below. fed from a single gas train, care should be taken to
CAUTION: Do not install any shut-off device in
the air/gas mixture line.
For initial burner start-up of Series “66”

AIRFLO® premixed gas burner system:
CAUTION: Initial adjustment and light-off should

be undertaken only by trained and experienced
Maxon assumes no responsibility for the use or personnel familiar with combustion systems,
misuse of the piping layout shown. Specific with control/safety circuitry and with knowledge
piping and wiring diagrams should always be of the overall installation. Instructions provided
submitted to the appropriate agencies for by the company and/or individuals responsible
approval on each application. for the manufacture and/or overall installation of
Combustion air blower provides the air (oxygen) take precedence over these provided by Maxon.
supply to your combustion system and is essential to If Maxon instructions conflict with any codes or
the mixing of fuel gas. It should be located in the regulations, contact Maxon Corporation before
coolest, cleanest position that you can find near the attempting start-up.
burner itself. It must not be exposed to direct radiant
heat or positioned where it might draw in the inert 1. Close all burner fuel valves or cocks. Make
gases or hot air rising from a furnace or oven. If preliminary adjustments to fuel gas regulators.
problems exist, consider filters, relocation and/or Remove pilot and main gas regulators’ adjusting
ducting of an outside fresh air supply. screw covers. Turn adjusting screw down
Minimize combustion air pressure drop between (clockwise) to approximately mid-position. Close
blower and mixing tube. Keep a minimum straight run pilot gas adjustable orifice screw by turning in
of four pipe diameters into the mixer air inlet. Down- clockwise until it stops. (Do not over-tighten.)
stream piping from mixer to burner should be kept as Then back out the adjustable orifice (counter-
short as possible. clockwise) approximately 2-3 turns.
Electrical service must match the voltage, phase 2. Check all electric circuitry. Verify that all
and cycle of all electrical system components and be control devices and interlocks are operable and
compatible with burner nameplate ratings. Insure that functioning within their respective settings/
all normal control safeguards are satisfied. Combus- ranges. Be sure all air and gas manifolds are
tion air blower should continue to run after shutdown tight and that test ports are plugged if not being
to allow burner to cool. used.
Gas supply piping must be large enough to 3. Check that all duct and chamber dampers
maintain the required fuel pressures cataloged for the are properly positioned and locked into
particular burner size used with burner operating at operating positions.
full-rated capacity.

mCORPORATION
linkage from your MICRO-RATIO® Control
Valve’s operating crank arm (or from your
Maxon Control Valve) by loosening the control
motor’s connecting rod from the valve’s toggle
linkage. Manually set and secure control valve in
its “minimum” position.
impeller direction. Verify that all control inter-
locks are working. Allow air handling equipment
to run for adequate purge of your manifolds and
shut off, manually advance MICRO-RATIO®
Control Valve’s operating crank to “high fire”
position so that air only flows through burner and
combustion chamber.
by turning the MICRO-RATIO® Control Valve to
its minimum position and reading differential air
pressure only at each burner with a water Having marked and/or recorded the MICRO-
column manometer. Any reading below 0.10" wc RATIO® Control Valve’s air valve settings for
differential (natural gas) requires re-adjustment both minimum and maximum firing positions,
as described below. you may adjust the linkage and travel of the gas
Setting minimum mixture pressure with a valve’s stroke (see sketch below).
MICRO-RATIO® Control Valve and Series Loosen Allen set screw “A” and binding screw
“HG” Mixing Tube system: “B” in toggle “C”. Move the toggle in universal
If minimum mixture pressure must be in- cam assembly slot towards the center of rotation
creased, open the MICRO-RATIO® air valve so that gas valve can rotate from its minimum to
slowly (by turning toward higher-numbered maximum position, while the air valve swings
positions) until the required differential air between the established (and marked) minimum
(mixture) pressure is reached, then mark air and maximum settings.
your MICRO-RATIO® Valve mixing tube system.
Continue opening the MICRO-RATIO® air
valve while watching the manometer connected
into the burner’s air/gas mixture manifold.
Determine the point at which further opening of
the air valve gives no appreciable increase in air
pressure within the manifold/burner. Mark the air
valve dial at this position opposite the air valve
pointer. This point will become the maximum air
setting for your MICRO-RATIO® Valve mixing
tube system.
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Place air valve on pre-determined “minimum” Refine pilot setting for a hard blue flame
position and rotate gas valve to its “minimum” (and/or strongest micro-amp signal) by adjusting
setting position. Tighten down set screw “A” and gas flow through pilot orifice and/or pilot
binding screw “B” with both valves set at regulator.
“minimum”. Shut off pilot gas cock to extinguish pilot fire.
Establish set screw “A” as minimum-end Re-open and confirm easy re-ignition several
adjustment point and binding screw “B” as times. The flame safeguard relays should now
maximum-end adjustment point. (Note: It doesn’t power the main fuel shut-off valves.
matter which is maximum or minimum, as long 9. Light main burners at minimum as follows:
as you identify and keep the same reference First, turn MICRO-RATIO® Valve to its
points for the next adjustment steps.) minimum setting (which may be at position 1 or
Now rotate MICRO-RATIO® Valve to “maxi- 2 after completing step 6), then open fuel shut-
mum” position. The air valve maximum setting off valve and turn corresponding screw in
was previously determined. Loosen binding (clockwise) until flame ignites across burner
screw “B” and adjust pointer and linkage to face. (This may take several turns of the screw.)
correct just half the distance required to make NOTE: At this point, it is more important to get
the air valve pointer indicate the maximum air any kind of a flame as soon as possible. The
valve setting. flame geometry can be adjusted and refined as
Re-tighten binding screw “B” and return the needed later.
MICRO-RATIO® Valve to the “minimum” air A good minimum fire should provide uniform
setting. flame across the entire burner face, contained
This time, loosen set screw “A” and again within the zipper flame channel at the base of
correct for just half the distance required to burner mixing plates. Any thin spots or gaps
make the air valve pointer indicate the minimum indicate uneven air velocity over the burner
air valve setting. which must be corrected or a higher minimum
Re-tighten set screw “A” and again return the fire established by continuing to turn in on the
MICRO-RATIO® Valve to its maximum position. minimum stop screw.
Similarly, correct one half the distance with 10. Once your flame is established and refined at
binding screw “B” for the maximum setting, etc. this position, and without advancing the screw
Continue this adjustment procedure until the carrier quadrant higher, screw all remaining
gas and air valves reach their minimum and screws down to at least the same level as your
maximum positions simultaneously. Normally, first adjusted screw.
this is accomplished within seven adjustments. Once the gas is applied to the burner, you
7. Remove cover plate from screw carrier cam may find that a LOUD howling is set-up by the
assembly and turn all adjusting screws counter- duct system. This howling means that the burner
clockwise until flush with outer surface of casting is firing too rich. Back out on the gas screws and
(new equipment is shipped this way). the noise will stop. The burner is then adjusted
8. Open main and pilot gas cocks and light first so that the flame is lean. You will know you have
burner pilot following instructions appropriate for adjusted the burner too lean if the flame fails to
that burner and pilot type. If multiple pilots are cross ignite across the face.
used, open individual cocks and adjust each in NOTE: A preliminary setting can be established
turn. with all the remaining adjusting screws. Gener-
To light and adjust gas pilot: Check to ally, each succeeding screw needs to be
insure pilot combustion air supply is flowing to screwed in approximately one full turn more
any pressure pilot mixer. Pilot gas regulator (clockwise) than its preceding screw. A smooth
should initially be set at approximately midpoint “stair-step” gradient pre-set at this point from low
of its adjustment range. With pilot gas solenoid to high will simplify the remaining adjustment
closed, open main fuel gas and pilot gas cock. steps.
Energize spark ignitor and pilot gas solenoid.
Observe pilot ignition through sight port of pilot
assembly and/or by viewing micro-amp signal
m
metered from flame safeguard relay circuit.
CORPORATION
CAUTION: If flame is extinguished, immediately NOTE: Dust and/or chemicals entrained into
return MICRO-RATIO® Control Valve to passing air stream may affect physical color of
minimum position and shut off fuel (if flame flame. In this case, adjust burner for stable flame
safeguard has not already done so). Turn in shape and geometry.
slightly on adjusting screw at point where To measure mixture pressure, connect
ignition was lost, then return valve to minimum water column (manometer) to the test connec-
position, re-establish pilot, open fuel valve and tion in burner’s end plate. To determine air
verify ignition. velocity, use a velometer at the profile opening.
Correct velocities by increasing or decreasing
11. Without advancing the valve quadrant, screw profile opening size.
down clockwise on #2 screw (one or two turns). If flame is too short, gas pressure may be too
Then slowly advance the screw carrier quadrant low and should be increased, or velocities are
to the #2 position. Adjust flame appearance at too high and may need to be decreased.
this new position #2. NOTE: Air velocities should be measured only
NOTE: If firing chamber is of refractory construc- when the fan is handling air at the desired
tion, allow your burner system to operate at this control temperature.
low setting for the necessary dry/cure-out time 13. Cycle burner from minimum to maximum and
period recommended by the chamber or refrac- refine adjustment, if necessary.
tory manufacturer. Then continue adjustments of For operation with interrupted pilot (as
valve. recommended), shut off pilots and cycle burner
12. Again, without moving valve, bring #3 and all from minimum to maximum and back several
remaining adjusting screws down to the same times to verify the flame is maintained.
level as #2 screw.
NOTE: If approximate pre-set gradient was CAUTION: After completing previously listed
made earlier, the remaining screws will already steps, check all interlocking safety components
be at or below appropriate levels. and circuitry to prove that they are properly
Progressively work your way up through each installed, correctly set, and fully operational. If
adjusting screw position, developing a smooth in doubt, shut the system down, close main and
progression slope from your first screw to the pilot cocks, and contact responsible individual
“maximum” position. before proceeding further.
As each is adjusted, you must turn the 14. Reconnect linkage to control motor, plug all
remaining unadjusted screws in at least that far test connections, replace equipment cover caps
to prevent possible damage to flexible cam and tighten linkage screws.
strips inside the screw carrier cam assembly. 15. Check out overall system operation by cycling
Turning a screw in “clockwise” gives more through light-off at minimum, interrupting pilot,
gas at that setting; turning it out gives less. and allowing temperature control system to
NOTE: To adjust the flame at any position, you cycle burner from minimum to maximum and
must move the valve quadrant to the number return.
you desire to adjust. This aligns the adjusting Re-check all safety system interlocks for
screw directly on top of the fuel valve plunger. A proper setting and operation.
applied to the fuel valve plunger and its intercon- WARNING: Test every UV installation for
nected valve body linkage. dangerous spark excitation from ignitors and
Observe flame characteristics carefully. other possible sources of direct or reflected UV
Flame should remain a bright blue color with a radiation. Use only gas-tight scanner
length beyond the mixing plates as indicated in connections.
capacity/specification data. If flame becomes 16. Before system is placed into full service,
long and yellow, gas pressure is too high and/or instruct operator personnel on proper start-up,
air velocity is too low. operation and shut-down of system. Establish
mCORPORATION

Series “66” AIRFLO® Line Burners Page 5100-A/P-1
Assembly Numbers
AL4 AL4S AL5

Series "66" AIRFLO® Line Burner Gray iron bodies [1] Gray iron bodies [1] Gray iron bodies [1]
Material Specifications> with aluminized with #321 stainless with #321 stainless
steel mixing plates steel mixing plates steel mixing plates
Configured Item Number> AL4 AL4S AL5
Item Description Designation Designation Designation
6" straight AL-4-6 AL-4S-6 AL-5-6
1049727 1049728 1049723
6" straight (15) (15) (15)
AL-4-6P AL-4S-6P AL-5-6P
for use with built-in pilot assembly
1049734 1049735 1049733
Burner Sections 12" straight AL-4-12
(22)
AL-4S-12
(22)
AL-5-12
(22)
1049837 1049838 1049836
12" x 6" tee AL-4-T AL-4S-T AL-5-T
(30) (30) (30)
1049758 1049759 1049757
12" x 12" cross [1] AL-4-X AL-4S-X AL-5-X
(37) (37) (37)
Back Inlet Feed 12" back inlet straight 1049752 1049753 1049751
AL-4-12B AL-4S-12B AL-5-12B
Sections (31) (31) (31)
(each requires an 1049787 1049788 1049794
36" back inlet "H" [1] AL-4-36B AL-4S-36B AL-5-36B
inlet flange from (95) (95) (95)
options listed 1049831 1049832 1049830
below) 12" x 12" back inlet cross [1] AL-4-XB AL-4S-XB AL-5-XB
(42) (42) (42)
Cast iron 04122 (3) / 21380* for "12B" section
2" NPT
Ductile iron 20042 (3) / 25934* for "36B" section
For "12B" & 2-1/2"

Cast iron 18694 (4) / 21444* for "12B" section
"36B" back inlet NPT
A.N.S. Inlet
Flange Options sections Cast iron 00295 (5) / 21384* for "12B" section
(for back inlet feed 3" NPT
sections above) Ductile iron 20043 (5) / 25935* for "36B" section
4" NPT Cast iron 15348 (7) / 25949* for "12B" section
For 12" x 12" XB 3" NPT Ductile iron 18806 (6) / 24493*
back inlet cross
sections 4" NPT Ductile iron 18807 (7) / 22006*
AL-66-EP plain end plate set 1050142 (4)

End Plate & End AL-66-F2 2" NPT end inlet flange set 1050157 1050143
Inlet Flange Sets
2" NPT end inlet flange set w/ SQ
--- 1052134
Pipe Plug
AL-66-EP-FR-SI pilot end plate set
(order #18075 spark ignitor & #18117 1050144 (5)
Direct Sparked flame rod separately)
End Plate & End
Inlet Flange Sets AL-66-F2-FR-SI 2" end inlet pilot set
(order #18075 spark ignitor & #18117 1050145 (5)
flame rod separately)
[1] 12" x 12" cross, 12" x 12" back inlet cross, and 36" back inlet "H" sections include ductile iron body casting
* ISO threaded
NOTE: To order line burner arrangements, order appropriate configured item number. To order loose items,
order individual assembly numbers.
Approximate net ship weight (in pounds) shown in parentheses

m
CORPORATION
Page 5100-A/P-2 Series “66” AIRFLO® Line Burners
Assembly Numbers
AL4 AL4S AL5
Series "66" AIRFLO® Line Burner Gray iron Gray iron Gray iron
Material Specifications> bodies [1] with bodies [1] with bodies with
aluminized #321 stainless #321 stainless
Item Description steel mixing steel mixing steel mixing
plates plates plates
Built-in pilot and end plate set FR/SI for direct end-mounted
flame rod/UV scanner & spark ignitor (includes #18075 spark 1050158 (6)
Built-in Pilot Sets ignitor; order flame rod separately)
(use with 6"-P
sections only) Built-in pilot end plate set FR/SI for externally mounted flame
rod/UV scanner & spark electrode (order flame rod and/or spark 1050159 (6)
electrode with an external mounting assembly separately)
AIRFLO-PAK pilot set FR/SI for direct end-mounted flame
AIRFLO-PAK rod/UV scanner & spark ignitor (includes #18075 spark ignitor; 1050146 (8)
Pilot Sets (each order flame rod, if used, and pilot mixer, separately)
requires a pilot
mixer from options AIRFLO-PAK pilot set FR/SI for externally mounted flame
listed below) rod/UV scanner & spark electrode (order flame rod and/or spark 1050147 (8)
electrode, pilot mixer, and external mounting assembly separately)
Atmospheric pilot mixer 16948 (1)
Pilot Mixer
Options for Atmospheric pilot mixer includes shut-off cock, tubing, and
12326 (2)
AIRFLO-PAK pilot #39294 adjustable orifice
assemblies above
Pressure pilot mixer includes #38579 adjustable orifice 17082 (2)
For internal spark ignitor & external UV scanner 19561 (3)
For internal spark ignitor & internal flame rod 19225 (3)
External
Mounting Plate For external spark electrode & external UV scanner (order
36593 (3)
Assemblies spark electrode separately)
For external spark electrode & external flame rod (order spark
36594 (3)
electrode & flame rod separately)
Spark 14mm spark ignitor (for direct mounted assemblies) 18075 (0.5)
Ignitor/Electrode
Sub-Assemblies 18" long spark electrode (for external mounting assemblies) 36538 (1.5)
Flame Rod Flame rod L = 7-1/8" (for direct mounted assemblies) 18117 (0.5)
Sub-Assemblies Flame rod L = 24" (for externally mounted assemblies) 36537 (1.3)
zinc plated carbon steel,
Universal support bracket 23577 (0.2)
good up to 750°F
(order in pairs) (A)
#304SS, good up to 1600°F 39940 (0.2)
Plated 1050482
End Plate
Stainless Steel 1050483
Spare Fastener Kits
A-286 Hi Temp 1050484
Optional
Accessory and Division plate (A) 18891 (0.5)
Replacement
Items Profile plate bracket (A) 20223 (0.5)
Spark electrode L = 18" (R) 17426 (1)
Flame rod L = 24" (R) 18410 (1)
Electrode cover for flame rod/spark ignitor (A/R) 18722 (0.2)
Adjustable orifice 3/8" (for pressure pilot mixer) (R) 38579 (0.5)
Adjustable orifice (for atmospheric pilot mixer) (R) 39294 (0.5)

[1] 12" x 12" cross, 12" x 12" back inlet cross, and 36" back inlet "H" sections include ductile iron body castings
NOTE: To order line burner arrangements, order appropriate configured item
m
number. To order loose items, order individual assembly numbers.
CORPORATION
Series “66” AIRFLO® Line Burners Page 5100-A/P-3
Assembly Numbers
Configured Spare Parts Kits for Series "66" AIRFLO® Burners

Description AL4 AL4S AL5
Series "66" AIRFLO® Burners AL4 RSP LV3 RSP
Segment Choice Detail - Configured Spare Parts Kits for Series "66" AIRFLO® Burners
Configured Item Number Segment Name Segment Description
DIRECT MTD SPARK IGNITOR Direct mounted spark ignitor
DIRECT MTD FLAME ROD -7.125" Direct mounted flame rod (length = 7.125")
EXTERNAL MTD FLAME ROD -24" External mounted flame rod (length = 24")
SPARK ELECTRODE -18" Spark electrode (length = 18")
RUBBER COVER Rubber cover for flame rod or spark electrode
ADJUSTABLE ORIFICE (PRESS) Adjustable orifice (pressure)
BODY FLANGE GASKET Body flange gasket
BACK INLET FLANGE GSKT -STR Back inlet flange gasket - straight
AL4 RSP BACK INLET FLANGE GSKT -H Back inlet flange gasket - H
BACK INLET FLANGE GSKT -CROSS Back inlet flange gasket - cross
GASKET SEALANT Gasket sealant
STR FLANGE KIT 200F (MAX) Straight flange kit 200 degrees F (maximum)
STR BI FLANGE KIT 200F (MAX) Straight back inlet flange kit 200 degrees F (maximum)
36H BI FLANGE KIT 200F (MAX) 36H back inlet flange kit 200 degrees F (maximum)
CRSS BI FLANGE KIT 200F (MAX) Cross back inlet flange kit 200 degrees F (maximum)
ADJUSTABLE ORIFICE (ATMOS) Adjustable orifice (atmosphere)
SHUT-OFF COCK Shut-off cock
LV3 RSP BACK INLET FLANGE GSKT -H Back inlet flange gasket - H

mCORPORATION
Page 5100-A/P-4 Series “66” AIRFLO® Line Burners
Notes
m
CORPORATION

Bulletin 5300
Series “66” AIRFLO® Mixers
• Electro-mechanical device for producing a partial premixture for Series “66” AIRFLO®
Line Burners
• Air/gas ratio control at all firing rates using most clean, low pressure fuel gases
• Provides clean combustion with low levels of NOx
• Includes electric motor and non-loading paddle-wheel impeller in cast iron blower case
• Integral ratio valve provides thorough air/gas mixing
• Optional stand-by fuel arrangement allows changeover to alternate gaseous fuels
• Single point firing rate control for Series “66” AIRFLO® Line Burner assemblies
• Low initial and operating costs through use of lower horsepower motor
• Application flexibility provided with eight different models in 76 popular sizes
Manufactured under U.S. Patent #25626; Canadian and European

patents granted and pending.
Page 5302
Series “66” AIRFLO® Mixers

Series “66” AIRFLO® Mixers consist of a ratio valve
and blower. Air for combustion is drawn in through the
ratio valve where it can be throttled.
The same ratio valve also includes a gas butterfly
valve with cross linkage featuring multiple-screw cam
design that permits fuel flow to be matched to air flow
at each possible setting.
This provides excellent repeatability and ratio
control for lowest minimum and so, greatest turndown.
At higher firing rates, a progressively richer mixture is
developed, until at maximum firing rate a major
portion of the combustion air is supplied by the air
stream being heated (75-80% from fresh air streams,
60-70% from recirculated air streams containing a A complete burner system utilizing a Series “66”
minimum 80 cfm fresh air per 100,000 Btu/hr heat AIRFLO® Mixer will also include gas train, Series “66”
release); thus reducing horsepower requirement by as AIRFLO® Burner assembly and combustion control
much as 80% when compared to a full-premixed panel. Your Maxon representative can help you
system of equivalent heat release. choose from the broad range available.
Typical Piping Layouts

for Series “66” AIRFLO®
Mixer Systems
Basic AIRFLO® Burner system

with pilot and with block and bleed
pipe train system as frequently
required by insurance authorities

misuse of these layouts. Specific piping and wiring
diagrams should be submitted to the appropriate
agencies for approval on each application.
11/91
Series “66” AIRFLO® Mixers Page 5303
Capacities/Specifications
Series “66” AIRFLO® Mixers come in a broad range
of sizes and versions, and must be selected carefully
to match your specific application needs.
The mixer must be matched to discharge areas
and mixture pressure requirements of the burners
used. Eight series are available as outlined in table
below, in a total of 76 sizes:
Application Conditions Mixer Series Burner Type

Fresh Suction side FO-S, FO-SX AL5
Process Air Pressure side FO-P, FO-PX AL5
Series “66” AIRFLO® Mixer shown in discharge position #5A
Recirculated Suction side R-S, R-SX AL5 with optional air filter assembly, connecting base and
Oven Heating Pressure side R-P, R-PX AL5 linkage assembly, and with automatic control motor
(normally supplied by others)
Selection procedures Any clean, gaseous fuel (500-3200 Btu/ft3) can be

After the maximum capacity is determined, select used. Only 2" to 8" wc supply pressure is necessary
the appropriate AIRFLO® Mixer and corresponding at the mixer.
footage of Series “66” AIRFLO® Line Burner. Series “66” AIRFLO® Mixer designation is a
5-part identification code that is stamped into the
For example: nameplate of each unit.
Total Btu/hr required No. of Feet of
= Series “66” Designation Code
Cataloged Btu/ft AIRFLO® Burner 66 – FO – 2200 – P X
Then match AIRFLO® Mixer to this length of

X: if present, denotes design
AIRFLO® Burner. for higher duct static pressure
Refer to selection tables on pages 5304 and 5305 conditions
appropriate for your operating conditions and deter- P: pressure side application
mine the required mixer designation. ALWAYS USE S: suction side application
THE AIRFLO® MIXER CORRESPONDING TO THE
Nominal heat release (1000’s Btu/hr)
CHOSEN BURNER FOOTAGE.
For operation on 50 Hz power, reduce capacities FO: fresh process air heating
to 83% of those shown. R: recirculated process air heating
Series “66” AIRFLO® Mixer
Each AIRFLO® Mixer assembly includes a 3400 RPM totally enclosed motor. You may select from a variety of available voltages:
60 Hertz Options 50 Hertz Options (possible net extra cost)
Horsepower
115/208 - 230/1/60 208 - 230/460/3/60 575/3/60 190 - 200/1/50 380 - 415/3/50 500/3/50
1/3, 3/4 & 1 ✔ ✔ ✔ ✔ ✔ ✔
Optional mixer arrangement

Blower case may be specified in any of 12 different
discharge positions, and adjusting screw quadrant
positioned to left or right of air inlet for adjusting
convenience (see sketch 1). Both must be specified
when ordering the mixer, or it will be shipped in
arrangement #1A. (NOTE that illustrations are viewed
from the motor side of the mixer.)
11/91
Page 5304 Series “66” AIRFLO® Mixers
Series “66” AIRFLO® Mixers for recirculated air heating applications
These Series “66” AIRFLO® Mixers designed for Maximum capacities shown are based on
use in recirculated air heating applications are standard burner design velocities. Ratings may be
designated “R” type. reduced if air stream velocities are lower.
Capacity data, designations and motor Minimum capacities are different for natural gas
information are shown in the tables below, cross and propane due to the higher air stream velocities
referenced to a specific burner footage. required for propane firing.
NOTICE: ALWAYS SELECT AN AIRFLO® MIXER Be sure to choose the appropriate mixer column for
TO MATCH YOUR REQUIRED BURNER YOUR cold differential pressure conditions.
FOOTAGE.
Suction side recirculated air heating applications

For duct static conditions For duct static conditions Minimum capacity
0.0" wc to -1.0" wc -1.1" wc to -4.0" wc 1000's Btu/hr Lineal feet of Totally
Maximum [1] Maximum [1] Series "66" Enclosed
AIRFLO® Mixer AIRFLO® Mixer AIRFLO® Burner Motor
capacity capacity Natural Gas Propane Gas
designation designation
1000's Btu/hr 1000's Btu/hr
975 66-R-975-S 1015 66-R-1015-SX 65 71 1.5
1300 66-R-1300-S 1350 66-R-1350-SX 86 94 2
1625 66-R-1625-S 1685 66-R-1685-SX 108 118 2.5
1/3 HP
1950 66-R-1950-S 2025 66-R-2025-SX 129 141 3
FR #48
22 7 5 66-R-2275-S 2360 66-R-2360-SX 151 165 3.5
26 0 0 66-R-2600-S 2700 66-R-2700-SX 172 188 4
32 5 0 66-R-3250-S 3375 66-R-3375-SX 215 235 5
39 0 0 66-R-3900-S 4050 66-R-4050-SX 258 282 6 3/4 HP
52 0 0 66-R-5200-S 5400 66-R-5400-SX 344 376 8 FR #56
58 5 0 66-R-5850-S 6075 66-R-6075-SX 387 423 9 1 HP
6500 66-R-6500-S 6750 66-R-6750-SX 430 470 10 FR #56
[1] For operation on 50 Hz power, reduce capacities to 83% of those shown
Pressure side recirculated air heating applications

For duct static conditions For duct static conditions Minimum capacity
0.0" wc to +2.0" wc +2.1" wc to +4.0" wc 1000's Btu/hr Lineal feet of Totally
Maximum [1] Maximum [1] Series "66" Enclosed
AIRFLO® Mixer AIRFLO® Mixer AIRFLO® Burner Motor
capacity 1000's capacity 1000's Natural Gas Propane Gas
designation designation
Btu/hr Btu/hr
975 66-R-975-P 825 66-R-825-PX 65 71 1.5
1300 66-R-1300-P 1100 66-R-1100-PX 86 94 2
1625 66-R-1625-P 1375 66-R-1375-PX 108 118 2.5
3/4 HP
1950 66-R-1950-P 1650 66-R-1650-PX 129 141 3
FR #56
22 7 5 66-R-2275-P 1925 66-R-1925-PX 151 165 3.5
26 0 0 66-R-2600-P 2200 66-R-2200-PX 172 188 4
29 2 5 66-R-2925-P 2475 66-R-2475-PX 194 212 4.5
32 5 0 66-R-3250-P 2750 66-R-2750-PX 215 235 5
1 HPFR #56
39 0 0 66-R-3900-P 3300 66-R-3300-PX 258 282 6
Fresh air (non-recirculating) process air heating applications
These Series “66” AIRFLO® Mixers designed for reduced if air stream velocities are lower. Note that
use in fresh process air heating applications are maximum capacities are downrated when burning
designated “FO” type. propane (to reduce likelihood of overheating mixing
Capacity data, designations and motor plates with the faster-burning fuel).
information are shown in tables below, cross Minimum capacities are different for natural gas
referenced to a specific burner footage. and propane due to the higher air stream velocities
NOTICE: ALWAYS SELECT A MIXER TO required for propane firing.
MATCH YOUR REQUIRED BURNER FOOTAGE. Be sure to choose the appropriate mixer column for
Maximum capacities shown are based on YOUR cold differential pressure conditions.
standard burner design velocities. Ratings may be
Suction side fresh process air heating applications

Duct Static Conditions: 0.0" wc to -1.0" wc Duct Static Conditions: -1.1" wc to -4.0" wc
Lineal feet of
Minimum capacity Minimum capacity Totally
Maximum Maximum AIRFLO®
1000's Btu/hr AIRFLO® Mixer 1000's Btu/hr AIRFLO® Mixer Enclosed
capacity [1] capacity [1] Burner in
Motor
1000's Btu/hr Natural Propane designation 1000's Btu/hr Natural Propane designation assembly
Gas Gas Gas Gas
975 65 71 66-FO-975-S 1015 71 75 66-FO-1015-SX 1.5
1300 86 94 66-FO-1300-S 1350 94 100 66-FO-1350-SX 2
1625 108 118 66-FO-1625-S 1685 118 125 66-FO-1685-SX 2.5
1/3 HP
1950 129 141 66-FO-1950-S 2025 141 150 66-FO-2025-SX 3
FR #48
2275 151 165 66-FO-SS75-S 2360 165 175 66-FO-2360-SX 3.5
2600 172 188 66-FO-2600-S 2700 188 200 66-FO-2700-SX 4
3250 215 235 66-FO-3250-S 3375 235 250 66-FO-3375-SX 5
3900 258 282 66-FO-3900-S 4050 282 300 66-FO-4050-SX 6 3/4 HP
5200 344 376 66-FO-5200-S 5400 376 400 66-FO-5400-SX 8 FR #56
5850 387 423 66-FO-5850-S 6075 423 450 66-FO-6075-SX 9 1 HP
6500 430 470 66-FO-6500-S 6750 470 500 66-FO-6750-SX 10 FR #56
Pressure side fresh process air heating applications

Duct static conditions: 0.0" wc to +2.0" wc Duct static conditions: +2.1" wc to +4.0" wc
Natural gas Propane gas Natural gas Propane gas Lineal feet
Totally
capacity capacity AIRFLO® capacity capacity AIRFLO® of AIRFLO®
Enclosed
1000's Btu/hr 1000's Btu/hr Mixer 1000's Btu/hr 1000's Btu/hr Mixer Burner in
Motor
designation designation assembly
Maximum Maximum Maximum Maximum
Minimum Minimum Minimum Minimum
[1] [1] [1] [1]
1125 75 975 71 66-FO-1125-P 1050 75 900 71 66-FO-1050-PX 1.5
1500 100 1300 94 66-FO-1500-P 1400 100 1200 94 66-FO-1400-PX 2
3/4 HP
2625 175 2275 165 66-FO-2625-P 2450 175 2100 165 66-FO-2450-PX 3.5
FR #56
3000 200 2600 188 66-FO-3000-P 2800 200 2400 188 66-FO-2800-PX 4
3375 225 2925 212 66-FO-3375-P 3150 225 2700 212 66-FO-3150-PX 4.5
3750 250 3250 235 66-FO-3750-P 3500 250 3000 235 66-FO-3500-PX 5 1 HP
4500 300 3900 282 66-FO-4500-P 4200 300 3600 282 66-FO-4200-PX 6 FR #56
11/91

Stand-by Fuel Arrangement (using Series “Q” Control Valves)
To order, specify:
1. Type and size of AIRFLO® Mixer
2. Corresponding size of Series “Q” Valve (selected
from table below)
3. Arrangement per assembly #17714 for all sizes
4. Mixer discharge position (may be specified in any
discharge position except #4B and #10B)
See appropriate catalog pages for dimensions of
AIRFLO® Mixers and Series “Q” Valves.
Ratio Valve in Ratio Valve in

Arrangement “A” Arrangement “B”
Suction Side Mixers (-S, -SX) Pressure Side Mixers (-P, -PX)
AIRFLO® Mixer Dimensions AIRFLO® Mixer Dimensions
Q Valve size [1] Q Valve size [1]
Type Size X Y Z Type Size X Y Z
975 thru 1950 3.5 9.75
1" 1125 thru 1500 4 10.25 6.56
2275 and 2600 6.56
3.69 9.94 1"
3250
FO-S FO-P 2625 and 3000
3900 thru 5200 1.25" 4.44 10.69
7.38 4.5 10.75 7.38
5850
4.94 11.19 3375 thru 4500 1.25"
6500 1.5" 8
1015 thru 2025 3.5 9.75
1" 1050 thru 1400 4 10.25 6.56
2360 and 2700 6.56
3.69 9.94 1"
3375
FO-SX FO-PX 2450 and 2800
4050 thru 5400 1.25" 4.44 10.69
7.38 4.5 10.75 7.38
6075
4.94 11.19 3150 thru 4200 1.25"
6750 1.5" 8
975 thru 1950 3.5 9.75
1" 975 thru 1950 4 10.25 6.56
2275 and 2600 6.56
3.69 9.94 1"
3250
R-S R-P 2275 and 2600
3900 thru 5200 1.25" 4.44 10.69
7.38 4.5 10.75 7.38
5850
4.94 11.19 2925 thru 3900 1.25"
6500 1.5" 8
340 thru 2025 3.5 9.75
1" 275 thru 1650 4 10.25 6.56
2360 and 2700 6.56
3.69 9.94 1"
3035 and 3375
R-SX R-PX 1925 thru 2475
4050 thru 5400 1.25" 4.44 10.69
7.38 4.5 10.75 7.38
6075
4.94 11.19 2750 thru 3300 1.25"
6750 1.5" 8
[1] Based on 3" wc drop using propane gas

“R” AIRFLO® Mixers (for recirculated air heating)
Mixer Sketch 1 (4 bolt floor mounting) Sketch 2 (3 bolt floor mounting)

1300 2275 3900 5850
R-S 975 and 1950 and 3250 --- --- --- --- thru --- thru
1625 2600 5200 6500
1350 2360 4050 6500
R-SX 1015 and 2025 and 3375 --- --- --- --- thru --- thru
1685 2700 5400 6750
975 2275 3250
R-P --- --- --- --- --- and 1950 and 2925 --- and ---
1300 2600 3900
825 1925 2750
R-PX --- --- --- --- --- and 1650 and 2475 --- and ---
1100 2200 3300
A [1] 12 13.5 15 12.5 15.5
B 10 12 10.5 12 12.75
C 4.19 4.5 4.19 4.5 5.75 4.5 5.75
D dia. 7/16 9/16
E 3.69 5.31 4.75 5.62 5.12 5.38 5.12 5.06
F size 3" 4" 3" 4" 6"
G 11 12 13.5 16.75
H 12.5 14 15.5 18.75
J 4.62 5.75 6 6.5
K 10.5 13 14 15
L size 1" 1-1/4" 2" 1-1/4" 2" 3" 2" 3"
M 12.12 11.31 13.19 16.38 16.62 18.75 12.81 18.75 15.25
N 4.69 5.88 6.88 7.38 6.75 7.38 7.94
O 8.38 10.62 12.5 13
R 10.19 7.81 10.06 14.06 14.12 16.38 8.44 16.38 9.75
S 6.5 7.75 8.88 9.94 8.88 9.94 10.16
T 6.5 7.16 8.88 9.94 8 9.94 9.22
V 4.19 4.38 4.69 5.19 4.88 5.19 5.38
W 1.81 1.62 2.25 1.75 1.06 1.75 1.12
Y 15.5 15.5 16.44 18.06 16.75 18.56
Z 10.5 12.5 10.5 18.5
[1] According to latest information from motor manufacturer
11/91

“FO” AIRFLO® Mixers (for fresh process air heating)
Mixer Sketch 1 (4 bolt floor mounting) Sketch 2 (3 bolt floor mounting)

1300 2275 2925 3900 5850
FO-S 975 and 1950 and and --- --- --- --- thru --- thru
1625 2600 3250 5200 6500
1350 2360 3035 4050
FO-SX 1015 and 2025 and and --- --- --- --- thru --- 6750
1685 2700 3375 5400
1125 1875 2625 3750
FO-P --- --- --- --- --- and and and 3375 --- and ---
1500 2250 3000 4500
1050 1750 2450 3500
FO-PX --- --- --- --- --- and and and 3150 --- and ---
1400 2100 2800 4200
A [1] 12 13.5 15 12.5 15.5
B 10 12 11 12 13
C 4.25 4.5 4.25 4.5 5.75 4.5 5.75
D dia. .44 .56
E 3.69 5.94 4.75 5.62 5.12 5.38 5.12 5.06
F size 3" 4" 3" 4" 6"
G 11 12 13.5 16.75
H 12.5 14 15.5 18.75
J 4.62 5.75 6 6.5
K 10.5 13 14 15
L size 1" 1-1/4" 2" 1-1/4" 2" 3" 2" 3"
M 12.12 11.31 13.19 16.38 16.62 18.75 12.81 18.75 15.25
N 4.69 5.88 6.88 7.38 6.75 7.38 7.94
O 8.38 10.62 12.5 12.12 12.5 13
R 10.19 7.81 10.06 14.06 14.12 16.38 8.44 16.38 9.75
S 6.5 7.16 8.88 9.94 8.88 9.94 10.16
T 6.5 7.16 8.88 9.94 8.88 9.94 9.22
V 4.19 4.38 4.69 5.19 4.88 5.19 5.38
W 1.81 1.62 2.25 1.75 1.06 1.75 1.12
Y 15.5 15.5 16.5 18 16.75 19
Z 10.5 12.5 10.5 18.5 12.5 18.5
[1] According to latest information from motor manufacturer
Accessories
Stand-by Fuel Arrangement
(using Maxon Series “Q” Control Valve)
Stand-by fuel arrangements permit quick
changeover to alternate fuels.
Maxon Series “Q”
Flow Control Valves
described in catalog
Bulletin 7000 provide
the additional flow
control point for the
stand-by fuel arrange-
ments.
A single control operator (rated for at least 150
inch-pounds torque) operates both the ratio valve
furnished as part of the AIRFLO® Mixer and an
additional Series “Q” Control Valve (ordered sepa-
rately). Typical piping arrangement is shown below.
Maxon does not supply the piping shown.
When this arrangement is used, the AIRFLO®
Mixer is first adjusted for the primary fuel (usually Stand-by-by Fuel
natural gas), then the “Q” Valve is adjusted to provide
Arrangement
proper alternate fuel flow.
Series “66” AIRFLO® Mixer
shown in discharge
position #1A with Series
Alternate piping arrangements “Q” Gas Control Valve and
For discharge positions 1A to 12A connecting base and
linkage assembly
positioning customer’s air
control motor
Connecting base and linkage assemblies

Maxon offers a broad range of connecting base
and linkage assemblies to properly position and
For discharge positions 1B to 12B align customer’s operators for control of Maxon
AIRFLO® Mixers and/or flow control valves.
Proper position and alignment are essential for
smooth and trouble-free operation; however, Maxon
CB & L assemblies are designed to position
control operators, not to support them. User must
provide auxiliary support in the form of wall brackets,
floor stands, hangers, etc. to support the control
motor’s size and weight.
2/96
Accessories (continued)
Inlet Air Filters Accessory Switches
Optional inlet air filters should be installed where Several types of accessory switches are offered for
the air supply is dusty or foreign matter may be drawn Series “66” AIRFLO® Mixers.
into the system and will plug burner or mixer system NEMA 1 Low Fire Start Switches meet system
ports. requirements calling for the burner system to be at its
Easily installed on the air inlet, this filter assembly low-fire or minimum position before start-up can
includes a washable/replaceable foam filter element proceed. A typical arrangement is shown in photo
in a protective wire cage. The mounting collar in- below.
cludes a filter suction switch connection to allow Choose from the broad range of accessory
monitoring of filter condition. switches stocked as convenience items by Maxon.
Filter assemblies may be added in the field, or These switches are available with either a carbon
specified when ordering the mixer. steel or stainless steel air butterfly shaft.
Warning: Filter material is UL-rated as Class II
Fire Retardant (“when clean, burns moderately
when attacked by flame or emits moderate
amounts of smoke or both”). Hot welding beads
Low Fire
or direct flame can ignite filter material. Start Switch
Ducting of an outside air source may be advis-
able if the AIRFLO® Mixer must be located in an
exceptionally dirty location and filter maintenance
would be a problem. If so, contact Maxon for recom-
mendations regarding run and size limitations for Air Differential Switches can be used to prove
sheet metal ducting from an outside air source to the operation of the mixer blower. Mounted as shown in
inlet of mixer ratio valve. the photograph below (cross-connected between the
connections provided on ratio valve air inlet and near
Hinged
Cover mixer discharge), they require the pressure differential
developed by mixer operation to close a switch in the
Foam
control circuit. Setting should be as high as possible
Filter
Element Cage without nuisance shutdown.
AIRFLO®
Filter Suction Switch can be used to monitor filter
Mixer condition, and wired into an alarm circuit or in such a
way as to prevent system operation when suction on
the filter exceeds the preset .45" wc.
Differential
Pressure Switch Pressure
Connection
Suction to high side
Connection of switch
to low side
of switch
Series “66”
Air Inlet AIRFLO®
Lock Ring
Sleeve Mixer in
discharge
position #5B
with optional
air inlet filter
assembly
Filter
Sleeve
Filter
Suction Switch
Connection
To order replacement parts, specify: Nameplate

®
1. AIRFLO Mixer designation and assembly number
(from nameplate)
2. Part names (from illustration above)
3. Quantity for each
Suggested spare parts:

– Cam springs
– Gas valve plunger and cap
11/91
To replace Air Filter Element Hinged

Cover
Refer to photo at right, then:
1. Insert finger through each lock ring, then rotate Foam
from back to front by pulling against force of Filter
spring. Element Cage
2. Swing hinged cover upward out of the way. AIRFLO®
3. Withdraw dirty filter element for cleaning or Mixer
replacement. If you clean rather than replace filter
element, wash in a strong detergent, warm water
solution, or steam clean. Dry thoroughly in warm
air not to exceed 200°F (93°C) before replacing.
4. Insert new or cleaned filter element into cage.
Check that it has extended onto air inlet sleeve
providing positive closure at that point.
5. Lower hinged cover to closed position and lock in
place with lock rings.
Warning: The filter material used is approved
by UL as Class II (fire retardant). Hot welding
beads or direct flame can ignite filter material.
Air Inlet
Lock Ring
Sleeve
To replace Cam Springs or Plunger & Cap Assembly

Shut system down electrically and close gas 7. To re-assemble unit, slide quadrant back over shaft
cocks, then: [6], taking care that set screws [10] line up with and
1. Identify components from Sketches 1 and 2 at set properly in the two recesses [12] in shaft [6].
right, then remove air filter assembly or inlet cover Check that alignment marks match, then tighten
guard [1], quadrant cover nameplate [2], indicator set screws [10].
plate [3], and control motor linkage [4]. 8. Replace control motor linkage, indicator plate,
2. Rotate quadrant [5] counter-clockwise to minimum quadrant cover nameplate, and inlet cover guard
position. Add an alignment mark across shaft [6] or air filter assembly removed in step 1.
and quadrant hub [7] as shown in Sketch 1 if mark 9. Check burner adjustment and refine.
does not already exist. 10. Place system back in service.
3. Identify brake [8] and spring from Sketch 2 and
make a note to avoid losing them when removing
quadrant.
4. Insert Allen wrench (provided with replacement cam
springs) through holes [9] and loosen set screws ,
then slide quadrant off shaft carefully.
5. To replace cam springs, remove screws [11] then
lift off and replace with new cam springs and
retighten screws [11] .
6. To replace plunger and cap assembly (see
component identification drawing on page 5311),
grasp cap and lift assembly out of ratio valve.
Insert new plunger and cap sub-assembly care-
fully and check that it slides freely.
Series “66” AIRFLO® Mixers Page 5300-S-1
General Instructions 2. Electrical service must match the voltage,
phase and cycle of all electrical system compo-
nents and be compatible with mixer’s nameplate
Important: Do not discard packing materials
ratings. Insure that all normal control safeguards
are satisfied. AIRFLO® Mixer air should continue
To prevent damage in transit, spark ignitors, flame to run after shutdown to allow AIRFLO® Burner
rods, connecting linkage components, and filter to cool.
housings/elements may be packed separately and 3. Gas supply piping must be large enough to
shipped loose with your new Maxon AIRFLO® Mixer. maintain required fuel pressures (approximately
The AIRFLO® Mixer itself is normally only a part of 2" - 8" wc) at the ratio valve inlet while burner is
your complete combustion system. Additional pipe operating at full capacity. The use of non-
train accessories and control components may be standard gases or long, complicated piping may
required for a complete combustion system installa- necessitate “oversizing” piping runs to keep
tion. pressure drops within acceptable ranges.
The sketch below shows a typical gas train as 4. Clean fuel lines are essential to prevent
might be used with a Series “66” AIRFLO® Mixer. blockage of pipe train components or burner gas
ports. All dirt, scale and pipe dope should be
blown out of any new gas line before actually
Typical Piping Layout connecting to the AIRFLO® Burner system.
5. Main shut-off cock should be upstream of both
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 ratio valve of your AIRFLO® Mixer is not
intended for tight shut-off.
6. Main gas regulator is essential to maintain a
leading to each AIRFLO® Mixer if more than one
is served by a common main. Size regulator for
full system capacity at required pressure,
including pipe train losses. Follow the instruc-
misuse of the piping layouts shown. Specific
tions attached to the regulator during installation.
7. 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
1. AIRFLO® Mixer provides the air supply to your regulator, a solenoid valve and shut-off cock. A
combustion system and is essential to the pilot adjustable orifice at the pilot inlet simplifies
inspiration and mixing of fuel gas. It should be adjustment.
located in the coolest, cleanest position that you 8. Pilot piping must be large enough to provide for
can find near the AIRFLO® Burner itself. It must the full pilot flow and pressures shown in the
not be exposed to direct radiant heat or posi- catalog for your particular AIRFLO® Burner size.
tioned where it might draw in inert gases or hot
air rising from a furnace or oven. If such condi-
tions exist, consider filters, relocation and/or
ducting of an outside air supply.

mCORPORATION
Page 5300-S-2 Series “66” AIRFLO® Mixers
9. Fuel shut-off valves (when properly connected New Filter Assembly Installation
to a safety control system) are designed to shut
the fuel supply off with any interruption in the To install a new filter assembly, refer to the
electric current supply. Manual reset valves photos below, then:
require operator attendance each time the 1. Remove existing air inlet guard, saving screws
system is start-up (or restarted after a shut- removed.
down). Motorized shut-off valves permit 2. Place sleeve of new filter assembly over the open
automatic start/restart when used with appropri- end of mixer air inlet, turning so that filter suction
ate control system. switch connection is opposite ratio valve quadrant.
10. Ratio valve (part of AIRFLO® Mixer) controls 3. Align holes in filter sleeve with those in mixer air
burner heat release by throttling air and gas inlet, then secure filter assembly in place with
flows. It includes provision for an adjustable screws removed in step 1.
minimum and throttling over a turndown range 4. Check position of filter assembly cover hinge. If it
that matches AIRFLO® Burner capabilities. is not at top, remove sheet metal screws holding
11. Downstream piping from AIRFLO® Mixer to wire cage to filter sleeve and rotate as necessary,
burner could be kept as short as possible. then re-fasten. Three unused holes must be
12. Inlet feed manifold to any AIRFLO® Burner plugged with remaining sheet metal screws.
should be at least four pipe diameters in length. Warning: The filter material used is approved
If the AIRFLO® Mixer is supplying multiple inlets by UL as Class II (fire retardant). Hot welding
to a single burner element, care should be taken beads or direct flame can ignite filter material.
so that air/gas mixing piping gives minimal
pressure drop and maximum uniformity. Do not
install any throttling or shut-off device in the
air/gas mixture line.
Air Inlet
13. Test connections are essential for burner Guard
adjustment. They should be provided (at a
minimum) downstream of the AIRFLO® Mixer
and at each burner inlet. Do not attempt to use
test connections in pipe elbows or tees, as
internal turbulence can give erroneous readings.
Test connections must be plugged except when
Ratio Valve
readings are being taken. Quadrant
Cover Hinge
Cage
Filter
Suction Switch Filter
Connection Sleeve
mCORPORATION

1. Always design the size of your air/gas manifold The sketch below shows four inlets fed from one
piping for uniform distribution to multiple-feed end-fed header. Note that full mixer outlet size is
burner systems. Select manifold piping sizes by continued past all burner feed take-offs, and outlet
starting at the burner inlet end and working extended and capped one pipe diameter length
backward to the AIRFLO® Mixer discharge. beyond last take-off. Always keep AIRFLO® Mixer a
greater in cross-sectional area(s) of any and all take-off.
pipes being fed.
air/gas mixture line between the AIRFLO® Mixer
and the AIRFLO® Burner inlet(s).
General Pipe Data

Inside Outside
Diameter Diameter
(inches) (inches)
1/8 0.269 0.405 0.057
1/4 0.364 0.54 0.104
3/8 0.493 0.675 0.191
1/2 0.622 0.84 0.304
3/4 0.824 1.05 0.533
1 1.049 1.315 0.864
1-1/4 1.38 1.66 1.496
1-1/2 1.61 1.9 2.036
2 2.067 2.375 3.356
2-1/2 2.469 2.875 4.788
3 3.069 3.5 7.393
3-1/2 3.548 4 9.887
4 4.026 4.5 12.73
5 5.047 5.563 20.006
6 6.065 6.625 28.89
8 7.981 8.625 50.027
10 10.02 10.75 78.854
12 12 12.75 113.097

mCORPORATION
Read complete instructions before proceeding, and 5. Start all system-related fans and blowers.
familiarize yourself with all the system’s components. Check for proper motor rotation and impeller
Verify that your equipment has been installed in direction. Verify that all control interlocks are
accordance with the manufacturer’s current working. Allow air handling equipment to run for
instructions. adequate purge of your manifolds and
shut off, manually advance AIRFLO® Mixer’s
screw carrier to “high fire” position so that air only
experienced personnel familiar with
flows through burner and combustion chamber.
circuitry, and with knowledge of the overall CAUTION: Do not by-pass control panel timers
installation. Instructions provided by the typically controlling sequential operations.
6. Determine minimum differential pressure.
Depending on the type of AIRFLO® Burner and
its application, a method must be developed to
measure chamber static pressure by connecting
a manometer between the combustion chamber
and a straight manifold going to the burner (at a
point farthest distant from the AIRFLO® Mixer).
This method must take into consideration all
For initial Series “66” AIRFLO® Mixer of the frictional pressure drops in the distribution
start-up: manifolding. You should maintain at least +0.1"
wc differential mixture pressure (with natural gas)
1. Check all electric circuitry. Verify that all between the burner and the combustion chamber
control devices and interlocks are operable and static pressure to avoid potential backfire
functioning within their respective settings/ conditions.
ranges. Be sure all air and gas manifolds are Do not try to take a differential pressure
tight and that test ports are plugged if not being reading from a test port at or near an elbow in
used. the piping manifolds due to potentially
2. Close all burner fuel valves and cocks. erroneous readings caused by turbulence set up
Remove pilot and main gas regulators’ adjusting within the pipe by such pipe fittings. Measure in a
seal cap covers. Turn adjusting screw down straight manifold with at least four pipe diameters
(clockwise) to approximately mid-position. Close in length before and after the test port location.
pilot gas adjustable orifice screw by turning in 7. Set minimum differential pressure with
clockwise until it stops. (Do not over-tighten.) minimum stop screw located on the side of the
Then back out the adjustable orifice (counter- screw carrier quadrant of AIRFLO® Mixer ratio
clockwise) approximately 2-3 turns. valve (see Sketch 1 below).
positions.
linkage from your AIRFLO® Mixer’s screw carrier
by loosening the control motor’s connecting rod
from the toggle linkage.
control mode.
m CORPORATION

This minimum stop screw creates a gives a contour to flexible steel cam strips [8]
mechanical block which prohibits the screw (see Sketch 3). These cam strips bear on a
carrier quadrant and its direct-connected air plunger and cap assembly [7] that determines
butterfly valve from closing completely. Thus a opening of the gas butterfly valve. Cam strips
“minimum” volume of air is allowed in through the serve to provide a continuous gradient.
ratio valve to be delivered down the distribution
manifold(s) to the burner. This air is used to
establish the minimum differential pressure.
Screwing in (clockwise) on the minimum stop
screw through its lock nut will open up the air
butterfly and increase the minimum differential
pressure.
Once your manometer readings confirm the
minimum differential mixture readings, lock the
minimum stop screw in that position with the lock
nut so the ratio valve cannot be moved back
below this minimum firing position. Regardless of
what numerical value the indicator strip shows, As shown in Sketch 4, the plunger and cap
this becomes the minimum firing position for your assembly [7] acts upon a roller/crank to rotate a
specific system in this application. valve shaft [9] to which the gas butterfly is
8. Adjusting the ratio valve of your Series “66” attached.
AIRFLO® Mixer: The heart of each AIRFLO® Turning adjusting screw in until it is flush with
Mixer is its ratio valve. The description and quadrant opens gas butterfly fully. Do not attempt
accompanying sketches summarize its operation. to force screw further.
A quadrant (shown in Sketch 2) is rotated
either manually or by a control operator to
change firing rate as indicated by a position
indicator strip [1] and position pointer [2]. A
minimum stop screw [3] limits rotation and
establishes a minimum air flow.
Removing a nameplate [4] reveals a numbered
series of adjusting screws [5] which bear on a set
of cam strips [8] beneath the quadrant.
Turning in the adjusting screws [5] (clockwise)
Directly connected to the quadrant by a shaft

[10] extending through its point of rotation is the
air control butterfly [11], also shown in Sketch 4.
Note that at #1 position of quadrant, air butterfly
may be “closed” but deliberately undersized to
provide a required minimum air flow. Air butterfly
is fully open with quadrant at highest numbered
position.

mCORPORATION
9. Prepare to adjust the ratio valve by removing 14. Light main burners at minimum, as follows:
the cover plate from the quadrant screw carrier First, make sure ratio valve is at its minimum
and turn all adjusting screws out until they are all setting (which may be at position 1 or 2 after
flush with the outer surface of the screw carrier completing step 6). With pilot gas established
casting. (New equipment is shipped from factory and flame supervision system operational,
with all screws already backed out to this level.) opening the main fuel shut-off valve(s) will allow
10. Return AIRFLO® Mixer quadrant to “low fire” fuel flow to the AIRFLO® Mixer’s ratio valve. Turn
position when air purge of system is complete. corresponding screw in (clockwise) until flame
11. Open main and pilot gas cocks, then attempt ignites at burner. (This may take several turns of
to light burner pilot while slowly turning pilot gas the screw.)
regulator and/or adjusting orifice screw to NOTE: At this point, it is more important to
increase fuel flow. Repeat procedure as get any kind of a flame as soon as possible. The
necessary until pilot ignites as air might have to flame geometry can be adjusted and refined as
be bled out of fuel supply lines before reliable needed later.
pilot flame is established. Pilot gas regulator Continue turning in slowly until flame
should normally be set for as low a pressure as becomes noticeably rich (usually purple or green
possible, using fuller opening of pilot adjustable with a slight yellow tip). Then slowly back the
orifice (if used). screw out until the flame becomes bright blue.
12. After ignition, adjust pilot flame for good stable 15. Once your flame is established and refined at this
flame shape. A “rule of thumb” is that any pilot position, and without advancing the screw carrier
over a tennis ball size is probably too large. This quadrant higher, screw all remaining screws
assumes you have visual access to the pilot down to at least the same level as your first
flame. If this is not possible, then adjust pilot to adjusted screws.
give the strongest and most stable flame signal NOTE: A preliminary setting can be
through your flame safety circuit. The signal established with all the remaining adjusting
strength (or range) will be determined by the screws. Generally, each succeeding screw needs
specific type of flame safeguard instrument you to be screwed in approximately one additional full
have with your AIRFLO® Burner system. turn from the preceding screw. A smooth “stair
13. Re-check pilot ignition by closing pilot gas cock step” gradient pre-set at this point from low to
or otherwise causing pilot outage. Re-light and high will simplify the remaining adjustment steps.
refine pilot gas adjustment as necessary to get 16. Without advancing the ratio valve quadrant,
reliable ignition. The flame safeguard relays screw down on #2 screw (one or two turns). Then
should now power your main fuel shut-off slowly advance the ratio valve quadrant to the #2
valve(s). position. Adjust flame appearance at this new
position #2.
NOTE: If firing chamber is of refractory
construction, allow your AIRFLO® Burner system
to operate at this low setting for the necessary
dry/cure out time period recommended by the
chamber or refractory manufacturer. Then
continue adjustment of ratio valve.
proceeding further.
Again, without moving ratio valve, bring #3
and all remaining adjusting screws down to the
same level as #2 screw.
NOTE: If approximate pre-set gradient was
made earlier, the remaining screws will already
be at or below appropriate levels.
mCORPORATION

Progressively work your way up through each 20. When AIRFLO® Burner performance is
adjusting screw position, developing a smooth satisfactory and stable throughout the firing
progression slope from your first screw to the range, reconnect linkage to control motor.
“maximum” position. As each is adjusted, you Control linkage travel must be such that
must turn the remaining unadjusted screws in at AIRFLO® Mixer’s quadrant is moved throughout
least that far to prevent possible damage to its complete travel, or cataloged capacities and
flexible cam strips inside the ratio valve. turndowns will not be achieved.
NOTE: To adjust the flame at any position, If less than full-rated AIRFLO® Burner
you must move the ratio valve to the number you capacity is required, linkage can be adjusted to
desire to adjust. This aligns the adjusting screw limit maximum output. With interrupted pilot, it
directly on top of the fuel valve plunger. A may be necessary to set control for somewhat
resulting adjustment of the screw is directly higher than minimum burner setting to permit
applied to the fuel valve plunger and its hold-in of flame detection system without pilot.
interconnected valve body linkage. Always
adjust only the screw corresponding to the
position at which the ratio valve has been set.
CAUTION: If flame is extinguished, immediately high or low fire position.
return ratio valve to minimum position and shut
fuel leakage. Replace equipment cover caps
and tighten linkage screws.
where ignition was lost, then return ratio valve
22. Check out overall AIRFLO® Burner system
operation by cycling through light-off at
minimum, interrupting pilot, and allowing
17. Refine main gas regulator adjustment (if temperature control system to cycle AIRFLO®
necessary) to give the desired pressure. If a Burner from minimum to maximum and return.
major adjustment is made, you may then need to 23. Recheck all safety system interlocks for
re-adjust the screw(s) just set. proper setting and operation.
18. After adjusting through the full range, allow
oven to reach operating temperature and refine
adjustment as needed for hot conditions.
19. Cycle AIRFLO® Burner from minimum to
maximum and refine adjustment, if necessary.
connections.
recommended), shut off pilots and cycle 24. Before system is placed into full service,
AIRFLO® burner from minimum to maximum and instruct operator personnel on proper start-up,
back several times to verify the flame is operation, and shut-down of system. Establish
maintained. When satisfied with adjustment, written instructions for their future reference.
replace ratio valve cover plate.

mCORPORATION
Notes
m
CORPORATION

Series “66” AIRFLO® Mixers Page 5300-A/P-1
Assembly Numbers
To order any Series “66” AIRFLO® Mixer, specify:
1. AIRFLO® Mixer designation and assembly number
2. Electrical motor specification
3. Discharge position and ratio valve arrangement
4. Assembly number and quantity of accessory
items:
– Air filter assembly
– Connecting base & linkage assembly
– Low fire start switch
– Stand-by fuel arrangement
Series 66-R-xxxx-S and 66-R-xxxx-SX AIRFLO® Mixers

(for recirculated air stream on suction side applications)
Lineal feet of Series"66" AIRFLO® Mixer Approximate Motor Combustion Air Filter
Designations Assembly Numbers
Series"66" Ship Weights Horsepower &
Numbers
AIRFLO® Burner R-S Mixers R-SX Mixers (in pounds) Frame Size Assembly (A) Element (R)
1.5 66-R-975-S 66-R-1015-SX 18997
2 66-R-1300-S 66-R-1350-SX 18998 105
17411 25292
2.5 66-R-1625-S 66-R-1685-SX 18999
1/3 HP
3 66-R-1950-S 66-R-2025-SX 19000
FR #48
3.5 66-R-2275-S 66-R-2360-SX 19001
110
4 66-R-2600-S 66-R-2700-SX 19185 17412 25293
5 66-R-3250-S 66-R-3375-SX 19003
6 66-R-3900-S 66-R-4050-SX 19004 3/4 HP
170
8 66-R-5200-S 66-R-5400-SX 19006 FR #56
17413 25294
9 66-R-5850-S 66-R-6075-SX 1 HP
19007 235
10 66-R-6500-S 66-R-6750-SX FR #56
Series 66-R-xxxx-P and 66-R-xxxx-PX AIRFLO® Mixers

(for recirculated air stream on pressure side applications)
Series"66" Ship Weights Horsepower &
Numbers
AIRFLO® Burner R-P Mixers R-PX Mixers (in pounds) Frame Size Assembly (A) Element (R)
1.5 66-R-975-P 66-R-825-PX
19021 130
2 66-R-1300-P 66-R-1100-PX
3/4 HP
3.5 66-R-2275-P 66-R-1925-PX 17411 25292
19186 155 FR #56
4 66-R-2600-P 66-R-2200-PX
4.5 66-R-2925-P 66-R-2475-PX 19023 160
5 66-R-3250-P 66-R-2750-PX 19024 1 HP
170 17412 25293
6 66-R-3900-P 66-R-3300-PX 19025 FR #56

m
CORPORATION
Page 5300-A/P-2 Series “66” AIRFLO® Mixers
Assembly Numbers
Series 66-FO-xxxx-S and 66-FO-xxxx-SX AIRFLO® Mixers

(for fresh process air heating on suction side applications)
Series"66" Ship Weight Horsepower &
Numbers
AIRFLO® Burner R-S Mixers R-SX Mixers (in pounds) Frame Size Assembly (A) Element (R)
1.5 66-FO-975-S 66-FO-1015-SX 18997
2 66-FO-1300-S 66-FO-1350-SX 18998 105
17411 25292
2.5 66-FO-1625-S 66-FO-1685-SX 19099
1/3 HP
3 66-FO-1950-S 66-FO-2025-SX 19000
FR #48
3.5 66-FO-2275-S 66-FO-2360-SX 19001
110
4 66-FO-2600-S 66-FO-2700-SX 19185 17412 25293
5 66-FO-3250-S 66-FO-3375-SX 19003
6 66-FO-3900-S 66-FO-4050-SX 19004 3/4 HP
170
8 66-FO-5200-S 66-FO-5400-SX 19006 FR #56
17413 25294
9 66-FO-5850-S 66-FO-6075-SX 1 HP
19007 235
10 66-FO-6500-S 66-FO-6750-SX FR #56
Series 66-FO-xxxx-P and 66-FO-xxxx-PX AIRFLO® Mixers

(for fresh air process heating on pressure side applications)
Series"66" Ship Weight Horsepower &
Numbers
AIRFLO® Burner R-P Mixers R-PX Mixers (in pounds) Frame Size Assembly (A) Element (R)
1.5 66-FO-1125-P 66-FO-1055-PX
19121 130
2 66-FO-1500-P 66-FO-1400-PX
3/4 HP
3.5 66-FO-2625-P 66-FO-2450-PX 17411 25292
19186 150 FR #56
4 66-FO-3000-P 66-FO-2800-PX
4.5 66-FO-3375-P 66-FO-3150-PX 19023 160
5 66-FO-3750-P 66-FO-3500-PX 19024 1 HP
170 17412 25293
6 66-FO-4500-P 66-FO-4200-PX 19025 FR #56
mCORPORATION

Series “66” AIRFLO® Mixers Page 5300-A/P-3
Assembly Numbers
Optional Low Fire Start Switches are shown in the table below. There are two assemblies available. One
includes a carbon steel air butterfly shaft and the other includes a stainless steel shaft. With either selection, the
standard air butterfly shaft in the ratio valve assembly must be removed when a low fire start switch is
added.
NEMA #1 Low Fire Start Switch (S.P.D.T.) for indoor, general purpose/non-hazardous duty locations
Low Fire Start Switch
Assembly Number 18715/45708 18716/45709 18717/45710 18718/45711 18719/45712
(carbon steel/stainless steel)
66-R-xxxx-S 975 1300 - 1950 2275 - 3250 3900 - 4550 5200 - 6500
66-R-xxxx-SX 1015 1350 - 2025 2360 - 3375 4050 - 4725 5400 - 6750
66-R-xxxx-P --- 975 - 2925 3250 - 3900 --- ---
AIRFLO® 66-R-xxxx-PX --- 825 - 2475 2750 - 3300 --- ---
Mixer
Type 66-FO-xxxx-S 975 1300 - 1950 2275 - 3250 3900 - 4550 5200 - 6500
66-FO-xxxx-SX 1015 1350 - 2025 2360 - 3375 4050 - 4725 5400 - 6750
66-FO-xxxx-P --- 1125 - 3375 3750 - 4500 --- ---
66-FO-xxxx-PX --- 1050 - 3150 3500 - 4200 --- ---
Connecting Base & Linkage Assemblies Optional Connecting Base and Linkage
Type Manufacturer Model No. Assembly No. (CB & L) Assemblies to mount and position
P-25 [1] 24383
customer’s electric control motor or air operator are
Foxboro listed at left.
P-50 [2] 24384
NOTE: Control motor must provide at least 50 in-
01-11/861 P [3]
03-3/863 T
17376 lbs of torque for use with a Series “66” AIRFLO®
Honeywell
Air Mixer.
01-9/861 M 17711
This listing of CB & L assemblies shows only a
D3153
Johnson 17867 sampling of the more popular control motors. We may
D3151
Taylor 40VF6 [3] 17708 be able to furnish a CB & L for other operators not
EA 51-58, also
Barber- number).
with prefix MC, 17377
Colman
MP, or MF
M644 [4]
M744 [4]
17372
M941 [4]
Electric M944 [4]
Honeywell
17378
Herculine 1066900
Penn/ M-80 [5]
17372
Johnson M-81 [5]
[1] Specify from Foxboro: [3] Dimensional interference prevents use with discharge
WITH #B6301-LR yoke position #3A. For position #11A, order WITH #15983
WITH #B6301-KY connection assembly spacer
LESS indicating pointer [4] Specify from Honeywell: WITH #7616BR crank arm
LESS travel indicator [5] Specify from Penn/Johnson: WITH #LVR27A-601 crank
LESS stem locknuts arm
WITH #B6301-WR yoke
m
LESS stem locknuts
CORPORATION
Bulletin 5400
Series “LV” AIRFLO® Line Burners
3 ft. LV-3 assembly with

AIRFLO-PAK pilot, pilot
mixer and flame rod
• Series “LV” AIRFLO® Burners provide stable, efficient, raw-gas operations in air streams
with relatively low duct velocities. Duct static pressure drops may be as low as 0.2" wc.
• Produces clean and odor-free combustion with natural or propane gases
• Air stream temperatures approaching a Series “LV” AIRFLO® Burner can be up to 1050°F
(566°C)
• Air stream oxygen levels (as low as 12% by volume) can be tolerated without a need to add
primary combustion air to the system
• Modular burner design provides burner assembly configurations and total heat release for
maximum application flexibility
• 17 varieties of Series “LV” AIRFLO® Burners available, each optimized in materials and/or
performance factors to match your specific application requirements

Page 5402
Series “LV” AIRFLO® Burners are designed for
heating process air in motion and consist of a rust-
resistant gray iron, ductile iron, or aluminum bronze
body (which serves as the raw gas or air/fuel manifold),
drilled to discharge the fuel gas/mixture between
diverging stainless steel or Hastelloy-X mixing plates.
duct directly in the air stream being heated. The air
stream passes across the burner and through the
mixing plates and is used as additional combustion air,
particularly at the higher firing rates. Carefully con-
trolled mixing plate aeration patterns give progressive
mixing, superior cross-ignition and flame retention
across the entire burner assembly length. The Series
“LV” AIRFLO® Burner burns clean and odor-free with • LV-NP-1 AIRFLO® Burner with its gray iron body
low levels of NOx production. and #321 stainless steel mixing plates is the most
Air velocities and the resulting duct static economical choice for a raw gas burner system for
pressure drop are the key to successful operation. fresh air heating with low heat release per lineal foot.
They are established by the use of a customer-
• LV-3G AIRFLO® Burners also have gray iron bodies
installed profile within the duct.
and #321 stainless steel mixing plates. Four different
A minimum profile plate width of 6" is required
versions are available, either for raw gas burner
surrounding all Series “LV” AIRFLO® Burner
applications or those requiring a partial air/gas
assemblies.
premixture system and/or outlet temperatures up to
Optimum burner performance and maximum
1000°F (538°C).
service life demands that air stream velocities be
uniform across the entire burner assembly. • LV-4D AIRFLO® Burner has a ductile iron body and
Normal capacities vary widely with application and #310 stainless steel mixing plates as above for
duct pressures. Fuel used and design velocities affect applications with outlet temperatures up to 1500°F
turndown. Modular design permits shape and total heat (816°C).
release to match application needs.
• LV-5D AIRFLO® Burners compliment their ductile
Performance data varies depending upon tempera-
iron bodies with Hastelloy-X mixing plates for use in
ture of air upstream and downstream of burner assem-
applications with up to 1700°F (927°C) outlet tem-
bly, the percent of oxygen (by volume) in the passing
perature requirements.
air stream, and the allowable duct static pressure drop
(which relates to velocity of air) across the Series “LV” • LV-5B AIRFLO® Burners have an aluminum bronze
AIRFLO® Burner. body casting with Hastelloy-X mixing plates for use
Several varieties of Series “LV” AIRFLO® Burn- with applications requiring up to 1700°F (927°C)
ers are offered. Each type is optimized for a specific outlet temperatures.
type of application. All varieties can be used as raw
gas type systems or partial air/gas premixture is used
for heating process air-in-motion where higher up-
stream temperatures and/or lower oxygen levels are
involved.
9/03
Series “LV” AIRFLO® Line Burners Page 5403

Series “LV” AIRFLO® Burner Design Parameters
Series “LV” AIRFLO® Burners are designed for Flame supervision may be by flame rod or UV
stable, efficient, raw gas operations in air streams scanner with inlet temperatures below 600°F (316°C).
with relatively low duct velocities. Duct static Higher temperatures will require a UV scanner with
pressure drops may be as low as 0.2" wc or up to possible addition of some cooling or purge air.
2.5" wc. To properly select the appropriate Series
Elevated air stream temperatures approaching “LV” AIRFLO® Burner to meet your specific
the Series “LV” AIRFLO® Burner can be as high as
application requirements, these four factors must first
1050°F (566°C). Reduced oxygen levels as low as
be determined:
12% (by volume) are tolerated without a need to add
1. Percent (by volume) of oxygen remaining in air
primary combustion air. For applications with low
stream to be heated.
oxygen levels, a partial premixture must be added
2. Allowable duct static pressure drop, which is a
through the system.
direct relationship to the velocity of air across the
burner and/or profile plate.
Series "LV" AIRFLO® Burner Design Parameters
3. Air stream temperatures approaching and
Temperature Limits downstream of the burner.
Burner Minimum Capacity (at 1.0" wc
Series Maximum Maximum static pressure drop) 4. Type of fuel to be fired through the burner.
Inlet Outlet
The designation of each Series “LV”
LV-NP-1 600°F 1000°F 30,000 Btu/hr per lineal foot
(316°C) (538°C)
AIRFLO® Burner section identifies specifics about
LV-3G
that section, namely:
1500°F
LV-4D 1000°F (816°C)
• Specific type of AIRFLO® Burner
(538°C) 75,000 Btu/hr per lineal foot • Mixing plate material
LV-5D
1700°F • Section code
1050°F (927°C)
LV-5B
(566°C)
• Body material
• Number of drilled holes/lineal foot
Series “LV” AIRFLO® Burner Designation

Example: 12" x 12" BK INLET SECTION LV 5 – BX – D – 24
Section Description
LV = Series “LV” AIRFLO® Burner
Mixing Plate Material
3 = #321 stainless steel
5 = Hastelloy-X
Section Code
6 = 6" straight section
Body Material
G = gray iron body
D = ductile iron body
B = aluminum bronze body
T = 12" x 6" tee section
X = 12" x 12" cross section
Number of (#30) drilled holes per lineal foot
12B = 12" back inlet straight section
24 = 24 holes (0.3113 in2/ft) discharge area
BX = 12" x 12" back inlet cross section
BH = 36" back inlet “H” section
9/03
Page 5404 Series “LV” AIRFLO® Line Burners

Determine flammability limits and/or minimum oxygen content levels
Since oxygen content within the air stream is This will show graphically the flammability (or the
critical to the flammability range of a Series “LV” capability) of your air stream to support raw gas
AIRFLO® Burner, it also directly affects the maximum combustion. Any combination of temperatures and
capacity (Btu/hr per lineal foot) of the burner oxygen levels falling above the raw gas firing line
assembly. should support combustion with a raw gas Series “LV”
The chart below relates the incoming air stream AIRFLO® Burner system.
temperature (°F) and the measured percentage of Any combination of incoming temperature and
oxygen remaining in this air stream. measured percent of oxygen falling below the raw
gas line will normally require the designated
percentage of premixture through the Series “LV”
AIRFLO® Burner system.
Air Stream Flammability Chart For example:
For process air with 12% oxygen

and 600°F:
This combination needs 45%
primary air premixture.
For process air with 14% oxygen

and 800°F:
This combination could be handled
with a raw gas burner system.

Determine maximum heat release for Series “LV” AIRFLO® Burner sys-
tems when operating as raw gas
Once flammability level of the process air stream To calculate heat release per lineal foot of
has been determined from page 5404, the heat release Series “LV” AIRFLO® Burner, multiply a factor
per lineal foot of burner may be calculated. from each of the charts below that matches the
The Series “LV” AIRFLO® Burner performance is specific parameters of your application by the
affected by a combination of: constant (23,832) to get heat release in 1000’s Btu/
1. Percent (by volume) of oxygen remaining in the hr per foot.
process air stream to be heated
Note: This constant evolves from the orifice flow
2. Allowable duct static pressure drop, which is a
formula:
direct relationship to the velocity across the burner
and/or profile plate Pressure drop
1655 x K x A (area) X
3. Process air stream temperatures, approaching Specific gravity
and downstream of the burner element
K = orifice coefficient Factors in

A = mixing plate Charts C, D & E
discharge area (in2)
Chart C – Pressure Drop Factor
Differential Duct Pressure drop
Static Pressure Drop 0.2 0.4 0.6 0.8 1.0 1.2 1.5 2.0 2.5 factor =
(inches wc)
Pressure
Drop 0.45 0.63 0.77 0.89 1.0 1.1 1.22 1.4 1.58 ∆P
Factor C
Chart D – Temperature Factor

Temperature
Measured °F 200 300 400 500 600 700 800 900 1000 1100 1200
Incoming Air factor =
Temperature °C 93 149 204 260 316 371 427 482 538 593 649
Temperature 1.25 S.G.
1.12 1.04 0.98 0.93 0.88 0.84 0.81 0.78 0.75 0.73 0.71
Factor D
Chart E – Oxygen Content Factor

Measured Oxygen level
% Oxygen 12% 13% 14% 15% 16% 17% 18% 20% 20.8% factor =
Content
Oxygen
Level 0.06 0.065 0.07 0.075 0.08 0.085 0.09 0.1 0.104 % oxygen
Factor E (expressed as a decimal)
2
For example:
For 1" wc pressure drop with 700°F incoming Notice: When primary combustion air is supple-
temperature and 14% oxygen content: mented in the system, a corresponding work
C x D x E x 23,832 = load increase must be factored into the gross
1.0 x 0.84 x 0.07 x 23,832 = 1401 heating requirement to heat the fresh combus-
Under these conditions, the “LV” AIRFLO® Burner tion air being introduced.
should be selected at 1,400,000 Btu/hr per lineal foot.
5/94
Performance Selection Data

Maximum burner capacities are affected by air burner. It is not greatly affected by air stream oxygen
stream oxygen level, approach air temperature, and levels with Series “LV” AIRFLO® Burners.
duct static pressure drop as shown on the preceding Differential gas pressures and flame lengths
pages. shown are approximate since burner assembly configu-
Flame length data shown on chart below is a factor rations and varying velocities may affect actual
of burner firing rate and static pressure drop across the readings in field.
Performance Data for 24 hole/ft. – raw gas operation
NOTE: Continuous operation in shaded region should be avoided in general fume incineration applications.

Air stream velocity and resulting pressure drop To determine profile plate opening areas, add
affect performance of Series “LV” AIRFLO® Burners as burner displacement areas (Ft2/section) from Table 2
shown in previous charts. This velocity across and for your complete burner assembly to Net Free Area of
through your burner’s mixing plates must be kept your duct:
uniform by use of a silhouette profile plate through
which the burner fires. A minimum 6" profile plate Net Free Area of Duct (Ft2) = Fan Volume (SCFM)
should be installed surrounding the interior duct walls Velocity (SFPM)
at the leading edge of your burner’s mixing plates.
Optimum design operating velocity ranges are Net Free Area (Ft2) + Burner Displacement (Ft2)
shown in Table 1. The most accurate readings for = Profile Area (Ft2)
velocities (in SFPM) are as measured with a velometer
(or Pitot tube) directly in the duct at the plane of the Various duct size/profile area relationships may give
profile plate and leading edge of your burner mixing slightly different field site data than is shown in Table
plates. 2.
Since Series “LV” AIRFLO® Burners are installed in
such widely diversified applications, it is often difficult
to get into the chamber/duct and profile plate area to
obtain any velocity pressure readings described above. Table 2: Displacement area and equivalent
For this reason, a close approximation of operating footage per section
velocities may be made with a measurement of duct Section Displacement Equivalent
static pressure drop. Preferably, a static pressure Burner Section Area (ft2/section) Footage
Description
test point one duct diameter in distance upstream from LV-NP-1 Others All
the profile plate and one duct diameter length down-
6" straight 0.16 0.19 0.5
stream will give approximation of operating velocity
across the burner. These static pressure drops relate 12" straight & (BI) 0.32 0.38 1
to velocity as shown in Table 1. 18" straight 0.48 --- 1.5
CAUTION: Do not try to take a differential static
24" straight 0.64 --- 2
pressure reading from a test port at or near an
elbow in the duct or chamber due to potentially 12 x 6 tee --- 0.46 1.25
erroneous readings caused by turbulence set up within 12 x 12 cross & (BX) --- 0.57 1.5
the duct at such points. Measure in a straight duct 36-BH --- 0.92 2.5
with at least one diameter in length before and after the
test port location.
Table 1: Velocity (SFPM) relative to static pressure drop ("wc)

Approximate air stream velocity at
1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
burner profile plate (SFPM)
Duct static pressure drop through
0.1 0.2 0.4 0.6 0.9 1.2 1.6 2 2.5 3
profile opening ("wc) [1]
[1] Based on profile/burner plane K factor of 0.8. May vary with your specific duct size/profile area relationship
3/92
Page 5408 Series “LV” AIRFLO® Burners

Profiling for higher temperature applications To find duct static pressure drop over burner
When calculating profile dimensions for Series “LV”
AIRFLO® Burner assemblies in applications with higher
inlet air temperatures, greater temperature rise, and/or
variable air stream volumes, the air with elevated
temperature and densities must be considered.
Sample calculations
A sample procedure for determining maximum
presssure drop and calculating profile size is provided
below.
at maximum and minimum air flow rates
Given: Duct size = 6 ft. x 4 ft.
Maximum air flow rate = 10,000 SCFM [1] Procedure: To keep pressure drop to a minimum for
Minimum air flow rate = 3,600 SCFM high air flow condition, we’ll want the
Inlet air temperature = 1000°F lowest possible pressure drop at the low
air flow condition.
[1] SCFM = cubic feet/minute of air at STP (60°F and 14.7
PSIA pressure) – From page 5406, minimum pressure drop = 0.2" wc
Series “LV” AIRFLO® Burner arrangement
To find what pressure drop would result at high air
flow condition, we must first find the “net free area”
Net free duct area (ft2) required per 100 ACFM [1] required.
of flowing air volume – From table at left: 1000°F inlet air and 0.2" wc
Duct pressure drop requires 0.42 ft2 per 1000 ACFM
Static Inlet Temperature over Burner
– Since minimum air flow is given at 3600 SCFM, this
Pressure
figure must be converted to “actual” cubic feet per
Drop 70°F 200°F 400°F 600°F 800°F 1000°F 1200°F
("wc) minute.
0.2 0.70 0.63 0.55 0.50 0.46 0.42 0.40
Net area = “Factor” x
0.3 0.57 0.51 0.45 0.41 0.37 0.34 0.33 ACFM
0.4 0.50 0.44 0.39 0.35 0.32 0.30 0.28 1000
3600 x
0.5 0.45 0.40 0.35 0.31 0.29 0.27 0.25
(460 + 1000)
0.6 0.41 0.36 0.32 0.29 0.26 0.24 0.23 Net free area = 0.42 x (460 + 70)
0.7 0.38 0.34 0.30 0.27 0.24 0.23 0.21 1000
0.8 0.35 0.31 0.28 0.25 0.23 0.21 0.20 Net area = 4.16 ft2
0.9 0.33 0.30 0.26 0.23 0.21 0.20 0.19
For maximum flow condition of 10,000 SCFM, the
1.0 0.31 0.28 0.25 0.22 0.20 0.19 0.18
“net area” remains at 4.16 ft2, we can expect the
1.2 0.28 0.25 0.23 0.20 0.19 0.17 0.16 pressure drop to increase.
1.4 0.27 0.24 0.21 0.19 0.17 0.16 0.15 – To determine pressure drop for the maximum flow
1.6 0.25 0.22 0.20 0.18 0.16 0.15 0.14 condition, re-solve the equation for “factor”.
1.8 0.23 0.21 0.18 0.17 0.15 0.14 0.13
2.0 0.22 0.20 0.17 0.16 0.14 0.13 0.13 Net area = “Factor” x
ACFM
2.2 0.21 0.19 0.17 0.15 0.14 0.13 0.12
1000
2.4 0.20 0.18 0.16 0.14 0.13 0.12 0.12
2.6 0.20 0.18 0.15 0.14 0.13 0.12 0.11
10,000 x
(460 + 1000)
4.16 ft2 = “Factor” x
[1] ACFM = actual air volume in cubic feet per minute at a specific (460 + 70)
temperature 1000
Factor = 0.15
– From table at left: Under the 1000°F column, we find
0.15 factor. Go to left hand column to find expected
duct static pressure drop for high air flow condition
to be 1.6" wc.

Sample calculations (continued) Burner assembly layout should be symmetrical
with relation to the inlet feed sections.
To find required profile dimensions Burner feed piping must be adequate to provide a
Procedure: well-distributed flow of gas throughout the burner
Profile area = burner displacement + net free area assembly. Do not exceed the capacity feed
limitations shown in table below.
– From table on page 5407, find total burner
displacement area
Capacity limitations for inlet feed sections
(3) 36" H sections @ 0.92 ft2 = 2.76 ft2
(4) 6" straight sections @ 0.19 ft = 0.76 ft2
2 Series "LV" AIRFLO® Burner
Maximum Btu/hr
3.52 ft2 Inlet Pipe per inlet
Burner Section
Size (NPT)
Total “gross” profile area = 3.52 ft2 + 4.16 ft2 1-1/4" 1,500,000
= 7.68 ft2
1-1/2" End inlet flange set 2,400,000
Note: Use minimum 6" profile plate around duct. 3,500,000
2" 12" straight (12B)
To determine profile opening width 7,000,000
– If we add 2" clearance to each end of 4 ft. burner INCINO-PAK® (12B & 36BH)
assembly width: 36" back inlet (BH) 8,300,000
width = 4' + 2" + 2" = 4'4" = 4.33'
3" 12" straight (12B)
– Check for minimum of 6" profile. 10,000,000
6' – 4'4" = 20"
12" x 12" cross (BX)
20" 4" 12,000,000
= 10" on each side, so condition is met
2
Observation ports, provided and positioned to
provide direct visual inspection of both pilot and main
To determine profile height burner flames, simplify start-up and operating proce-
– Gross area = width x height dures. Maintenance access should also be provided
7.68 ft2 = 4.33 ft x height upstream of burner assembly.
height = 1.77 ft.
– Check for minimum of 6" profile.
4' – 1.77' - 2.23'
2.23'
= 1.12', so condition is met
2
– Therefore, profile size becomes:
4'4" x 21-1/4"
3/92

INCINO-PAK® Burner Inlet Feed Sections
INCINO-PAK® Burner sections are special con-

figurations of 12" or 36" back inlet feed sections.
They provide “outside-the-duct” access to pilot, ignitor,
and flame safeguard components, eliminating lateral
duct wall connections.
INCINO-PAK® Burner sections are designed to
feed Series “LV” AIRFLO® systems in end-fired
incinerators or preheaters with cylindrical combustion
chambers, or when burner is fired at an elbow in the
ductwork.
INCINO-PAK® Burner sections can be used alone
12" back inlet INCINO-PAK® Burner section shown with (2)
(with appropriate end plates and accessories added), or Series “LV” AIRFLO® end plates; includes spark ignitor,
as an inlet feed section in a larger Series “LV” pilot gas adjustable orifice, raw gas pilot, and arranged for
AIRFLO® Burner assembly. mounting customer’s UV scanner
All INCINO-PAK® Burner sections contain a 2"
(NPT) gas inlet connection which may be used to feed and 36B back inlet INCINO-PAK® Burner sections:
Series “LV” AIRFLO® Burner with a maximum capacity Series 600 = 600 millimeter (23.8") length
of 7,000,000 Btu/hr. Series 800 = 800 millimeter (31.5") length
Heat release and gas pressure requirements Series 1100 = 1100 millimeter (43.3") length
match those of the other Series “LV” AIRFLO® sec- This “manifold length” reflects the distance
tions. The raw gas pilot capacity is 25,000 Btu/hr. between the outside duct mounting wall and the
centerline of the lineburner casting. See catalog page
WARNING: Pilot gas should be interrupted once
5418 for specific dimensions.
main flame is established. UV sight tube must
Each INCINO-PAK® Burner section includes a spark
be sealed against any scanner cooling air used.
electrode, adjustable pilot gas orifice, body gasket, and
Three manifold lengths are offered in both the 12B provision for your UV scanner.
Typical installation Typical block & bleed piping layout for raw gas INCINO-PAK®
in cylindrical incinerator Burner system as frequently required by insurance authorities

submitted to the approproate agencies for approval on each applica-
tion.

Series LV-NP1 AIRFLO® Burner sections
9/03

Series LV-3, -4, and -5 AIRFLO® Burner sections
Series LV-3, -4, and -5 AIRFLO® Burner back inlet sections
Inlet flange options
A Size A
Size B 3" NPT 3
2" NPT 0.88 4" NPT 4
3" NPT 1.75

Pilots & end plate assemblies for Series LV-3, -4, & -5 AIRFLO® Burner
sections
Plain End Plate Set 2" End Inlet Set 2" Inlet Pilot Set
Built-in pilot assemblies must mount only where Series

“LV” AIRFLO® Burner sections provide for the segmented Pilot mixer options
gas chamber within the burner body casting. See sketches for Series “LV” AIRFLO-PAK
below relative to possible locations for built-in pilot assem- pilot sets (above)
blies.
With built-in pilot arrangement, a section of the burner
body casting is separated off to form a cavity for pilot gas.
Pilot flame emerges through the main burner face.
All straight 6" Aluminum bronze Ductile iron 12" x

sections, whether 12" x 6" tee 6" tee sections
gray iron, ductile section can accept can have built-in
Air-Gas Pilot Mixers – Pressure Type
iron, or aluminum built-in pilot only pilot assembly
bronze, can accept on right end of mounted on any
built-in pilots on straight 12" side end.
one end. (when viewed from NOTE: Gray iron
back side of the tee sections do
assembly). not accept built-in
pilot assemblies.
9/03



flame rod

ignitor


spark electrode & exter-
nal UV scanner
NOTE: Order spark

electrode sub-assembly
separately

assembly for external flame
rod & external spark ignitor
NOTE: Order spark electrode

and 24" flame rod
sub-assemblies separately

External mounting plate dimensions
External mounting plate details
A plate is included with all assemblies shown on
page 5414.
Mounting plate with two (2)

feed-through insulators for
internal mounting of spark
ignitor and flame rod. Same
size external mounting
plate used in all assem-
blies shown on page 5414.
Positioning mounting plate in relation to

“LV” -3, -4, & -5 AIRFLO® Burner pilot
location
Through-wall opening required
9/03

Provides support for profile Provides isolation
within closed burner loop. On of burner feed(s)
some applications, it may be where desirable.
necessary to restrict air flow
between adjacent burner rows
to achieve design operating
velocities. This is done by
Optional cover protects porcelain
installing customer-fabricated profile plates on profile
insulator and electrical connection
mounting bracket(s). See sketch 1 below for use on
from dirt and moisture. May be
square openings (formed by adjacent cross-sections of
used for ambient temperatures up
burner). Sketch 2 applies to rectangular opening.
to 450°F (232°C).
1
Direct Mounted
14mm
Spark Ignitors
2
Externally Mounted
Spark Electrodes
Dimension "A" 12 18 24 36
Dimension "B" 13.8 19.8 25.8 36.2
Universal support bracket For LV-4 & -5 AIRFLO® Burner

Normally used in pairs as shown below. Mount to
burner assembly at any joint between sections. Flame rod identification
Two versions available: Zinc plated carbon steel for For those Series “LV” AIRFLO® Burners using flame
maximum inlet temperature up to 750°F (399°C) or 304 rods, most applications are covered by one of two
SS for maximum inlet temperature up to 1600°F sizes (specific number depends on nominal length “N”
(871°C). of rod extension). These may need to be cut to
dimension “L” specified in tables on pages 9908 and
9908A before use in your particular application.
N
7-1/8"
24"
Series “LV” AIRFLO® Line Burners
Item
Part Description
To order replacement parts: Number
1. Identify specific Series “LV” AIRFLO® 1 Burner body
series/type from burner assembly informa- 2 Back up bar (straight)
tion plate pictured on page 5419. 3 Gasket, body (straight)
2. Provide sketch of burner arrangement, 4 Back up bar (inside)
5 Gasket, inside
as viewed from back (or casting side) of
6 Back up bar (outside)
assembly. For example:
7 Gasket, outside elbow
8 Support bracket gasket 18 GA
9 6" mixing plate
12 M10 - 1.5 x 45 hex head cap screw
13 M10 - 1.5 finished hex nut
3. Specify quantity of each replacement 16 #10 -24 x 2-1/4" indented hex head machine screw
item required from table at right. 17 Washer
19 M10 - 1.5 hex nut finished
9/03

INCINO-PAK® Burner Back Inlet Sections
Series “LV” AIRFLO® type 36" back inlet sections
Series “LV” AIRFLO® type 12" back inlet sections
Series A B L X
600 23.81 37.25 31.65 1.5 Pipe threads on this page conform to
800 31.5 45.25 39.34 1.75 NPT (ANSI Standard B2.1)
1100 43.31 56.25 51.15 1
INCINO-PAK® Burners
Nameplate located on Nameplate located on

INCINO-PAK® Burner body INCINO-PAK® Burner backplate
9/03
Notes
Series “LV” AIRFLO® Line Burners Page 5400-S-1
General Fuel shut-off valves (when properly connected to
a safety control system) shut the fuel supply off with a
These mounting instructions for Series “LV”
loss of electrical power. Manual reset valves require
AIRFLO® Burners are in addition to the general
operator attendance each time the system is started
AIRFLO® Line Burner installation instructions
up (or restarted after a shut-down). Motorized shut-
published on Maxon catalog pages 5000-S-1 through
off valves permit automatic start/restart when used
5000-S-10.
Specific instructions are also offered for other
ment. At a minimum, they should be provided down-
– Shut-Off Valves (pages 6000-S-1 through S-14)
stream of any mixing tube and at each burner inlet.
– Flow Control Valves (pages 7000-S-1 through S-4)
Test connections should never be installed in elbows
– Mixing Tubes (pages 3200-S-1 through S-6)
or pipe tees. Test connections must be plugged
Read complete instructions before proceeding,
and familiarize yourself with all the system’s equip-
ment components. Verify that your equipment has
shutdown periods of more than a few hours. MICRO- 4. Tighten the bolts again to the full value starting at
RATIO® Control Valves are not intended for tight position 1 and working to position 6.
shut-off.
installation.
to meet pilot flow and pressure needs), a solenoid Bolt Size Bolt Material Torque Value Units
valve and shut-off cock. An adjustable gas orifice at M10 Plated steel 186 in lbs
the pilot inlet simplifies adjustment. M10 Stainless steel 248 in lbs
Appropriate pilots should be provided which are M10 High Alloy 45 ft lbs
compatible with the type of burner and control system
being used.

mCORPORATION
Page 5400-S-2 Series “LV” AIRFLO® Line Burners
INCINO-PAK® Burner Sections

INCINO-PAK® Burner sections are special configu- INCINO-PAK® Burner sections mount through the
rations of 12" and 36" back inlet feed sections de- duct/chamber wall and extend the AIRFLO® Burner
signed to provide “outside-the-duct” access to the body and mixing plates out into the air stream. They
pilot, ignitor and flame safeguard components. must still be profiled in the duct, since velocity must
These sections are used in end-fired incinerators or be maintained just like all Maxon AIRFLO® Burners.
preheaters, or when burner is fired at an elbow in the The externally mounted burner body housing
ductwork. As such, the mounting and installation of remains on the outside of the duct/chamber.
INCINO-PAK® Burner sections differs slightly from the A typical INCINO-PAK® Burner system piping
other Maxon AIRFLO® Burners. layout is illustrated in the drawing below:

m CORPORATION

INCINO-PAK® Burner Mounting CAUTION: Prior to attempting burner separa-
tion, completely remove the spark ignitor from
the INCINO-PAK® Burner assembly. Replace
ignitor only after INCINO-PAK® section is
securely mounted.
Remove remaining (3) flange bolts from burner
inlet flange. (Instruction packet is attached to this
flange joint at time of manufacture.) Once the (4) body
inlet flange bolts are removed, the burner element can
be separated from the gas inlet tube sub-assembly by
pulling gas inlet body out of burner element.
NOTICE: The gas scanner
tube and spark ignitor tube
must align themselves with
the large holes in the burner
body casting face.
A typical method of through-wall mounting of
This alignment and the
INCINO-PAK® Burner is shown above. The
inlet flange joint integrity
INCINO-PAK® Burner’s back housing is normally
must be maintained when
mounted and secured onto a separate “wall plug” that
burner is re-assembled.
is large enough to allow the burner element to be
Place large body flange
inserted through the duct/chamber wall opening and
gasket (shipped loose) onto
center itself in the profile plate. The burner element’s
gas inlet tube to seal body
weight must be independently supported.
inlet flange and combustion
The “wall plug” is secured into the opening of the
chamber wall joint prior to
duct/chamber wall, positioning the burner element in
mounting burner element and/
the air stream, and providing a maintenance/inspec-
or gas inlet burner body into
tion access port for the burner and combustion
position on your combustion
chamber.
chamber.
The INCINO-PAK® Burner sections can be used
Provide a liberal coating of
alone (with appropriate end plates, etc.) or as an inlet
the high-temperature “Never-
feed section in a larger Series “LV” AIRFLO® Burner
Seez” gasket paste (shipped
assembly.
loose) on both metal flange
You must separate the INCINO-PAK® Burner
surfaces. Insert the 2" diam-
body housing and gas scanner tube sub-assem-
eter inlet flange gasket
bly from the AIRFLO® Burner element, then re-
(shipped loose) between
assemble it after mounting in your duct/chamber.
these surfaces prior to re-
assembling burner element
and inlet tube sub-assembly.
NOTE: Wooden alignment
dowels inserted through the
large holes of the burner
element face casting will help
to remount and align the gas
scanner tube and spark
ignitor tube when re-assem-
bling the burner assembly.

mCORPORATION
Raw Gas Burner 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.
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
Typical Electric Control Motor
with Series “CV” Control Valve
For initial burner start-up of raw Check for proper blower motor rotation and
gas burner system: are working. Allow air handling equipment to run
1. Close all burner fuel valves or cocks. Make for adequate purge of your manifolds and com-
preliminary adjustments to fuel gas regulators. bustion chamber plenums. With main gas shut
Remove pilot and main gas regulators’ adjusting off, manually advance MICRO-RATIO® Control
screw covers. Turn adjusting screw down Valve’s operating crank to “high fire” position so
(clockwise) to approximately mid-position. Close that air only flows through burner and combustion
pilot gas adjustable orifice screw by turning in chamber.
clockwise until it stops. (Do not over-tighten.)
Then back out the adjustable orifice (counter- CAUTION: Do not by-pass control panel timers
clockwise) approximately 2-3 turns. typically controlling sequential operations.
2. Check all electric circuitry. Verify that all 6. To light and adjust gas pilot: Pilot gas regula-
control devices and interlocks are operable and tor should initially be set at approximately mid-
functioning within their respective settings/ point of its adjustment range. With pilot gas
ranges. Be sure all air and gas manifolds are solenoid valve closed, open main fuel gas and
tight and that test ports are plugged if not being pilot gas cock. Energize spark ignitor and open
used. pilot gas solenoid. Turn adjustable orifice screw
3. Check that all duct and chamber dampers out (counter-clockwise) several turns from its
are properly positioned and locked into fully seated position. Observe pilot ignition
operating positions. through a sight port and/or by viewing micro-
Initial start-up adjustment should only be accom- amp signal metered from flame safeguard relay
plished during a “manual” burner control mode. circuit.
Refine pilot setting for a hard blue flame (and/
4. Disconnect the automatic control motor’s or strongest micro-amp signal) by adjusting gas
linkage from your MICRO-RATIO® Control flow through pilot orifice and/or pilot regulator.
Valve’s operating crank arm (or from your 7. Prepare to ignite main burner by adjusting
Maxon Control Valve) by loosening the control main gas regulator to approximately midpoint
motor’s connecting rod from the valve’s toggle of its adjustment range. Linkage arrangement for
linkage. Manually set and secure control valve in the use of Series “CV” Gas Control Valve is
its “minimum” position. illustrated above for a typical control motor.
Arrange accordingly.
m CORPORATION


8. With control valve at “minimum”, ignite main C. Once your flame is established and refined at
burner by opening main fuel shut-off valve. this position, and without advancing the
Adjust main gas regulator to give the desired screw carrier quadrant higher, screw all
outlet pressure. Refine pilot adjustment if it has remaining screws down to at least the same
been affected. Adjust burner “minimum” by level as your first adjusted screw.
turning in on the minimum stop screw of the gas NOTE: A preliminary setting can be estab-
control valve until stable flame appears in the lished with all the remaining adjusting
narrow zipper channel at the base of burner screws. Generally, each succeeding screw
mixing plates. needs to be screwed in approximately one
A good minimum fire should provide uniform full turn deeper than its preceding screw. A
flame across the entire burner face, contained smooth “stair-step” gradient pre-set at this
within the zipper flame channel at the base of point from low to high will simplify the re-
burner mixing plates. Any thin spots or gaps maining adjustment steps.
indicate uneven air velocity over the burner D. Without advancing the SYNCHRO Valve
which must be corrected or a higher minimum quadrant, screw down on #2 screw (one or
fire established by continuing to turn in on the two turns). Then slowly advance the
minimum stop screw. SYNCHRO Valve quadrant to the #2
NOTE: If your Maxon Series “LV” AIRFLO® position. Refine flame appearance at this
Burner was furnished with an adjustable gradi- new position #2.
ent type Series “Q” or SYNCHRO Control Valve E. Turn all higher-numbered screws in at least
instead of a Series “CV” Valve, proceed to step as far as the one last adjusted, then turn next
8A for specific instructions and differences in one in as necessary to achieve desired flame
adjustment procedures. while rotating valve mechanism to that
position on indicator strip.
Adj. Screws F. Repeat for each remaining screw.
(under cover) NOTE: To avoid possible damage to cam
strips, always turn all higher-numbered
Handle for
screws in as far as the one last adjusted.
Manual
Operation G. Refine adjustment as needed, always turning
Position valve so that position indicator matches
Indicator screw being adjusted. For more fuel, turn
Pointer screw in (clockwise); for less fuel, turn screw
out (counter-clockwise). If screws must be
Locking Screw
turned in flush with carrier casting, increase
for manual
operation fuel pressure and re-adjust by starting at
minimum over again.
H. Cycle system off and on, and through all
A. From step #5, the automatic control motor firing rates until satisfied with performance.
linkage has already been disconnected from I. Reconnect control motor linkage and check
your adjustable gradient type control valve that operator does not “bind” and that all
and the valve is at its “minimum” position. interlocks are performing properly.
B. Open fuel supply and begin adjustment of 9. Adjust burner “high fire” by slowly rotating
appropriate adjustable gradient valve by fuel control valve crank arm towards its
turning in minimum (or lowest numbered) maximum. Observe flame characteristics
screw until desired flame is achieved. (Main carefully. Flame should remain a bright blue
fuel regulator may need adjusted at this color with a length beyond the mixing plates as
point.) indicated in capacity/specification data. If flame
becomes too long and yellow, gas pressure is
too high and/or air velocity is too low.

mCORPORATION

NOTE: Dust and/or chemicals entrained into crank [4] to the previously-determined maximum
passing air stream may affect physical color of firing rate position. Tighten toggle clamp bolt [3],
flame. In this case, adjust burner for stable flame thus fixing clamp to motor crank.
shape and geometry. Cycle control motor back to minimum, watch-
To measure gas pressure, connect water ing carefully that it does not bind before reaching
column (manometer) to the test connection in minimum.
burner’s end plate. To determine air velocity, If it is stopped or if minimum is not reached,
use a velometer at the profile opening. Correct loosen toggle clamp screw [1] and move toggle
velocities by increasing or decreasing profile clamp along the connecting linkage so both
opening size. motor and valve can assume their minimum
If flame is too short, gas pressure may be too positions. Then retighten toggle clamp screw [1].
low and should be increased or velocities are Refine adjustment by cycling several times
too high and may need to be decreased. Note between low and high control motor position
that air velocities should be measured only when while re-adjusting toggle clamp bolt [3] as
the fan is handling air at the desired control necessary until control motor travels through its
temperature. full cycle while moving control valve crank arm
The desired maximum capacity may be from its minimum only up to the desired maxi-
achieved with less than full control valve open- mum previously determined.
ing. Mark with a pencil or scribe the point on 11. Relight burner and cycle control system from
valve crank arm where the desired maximum is low to high fire several times to observe
obtained, then return crank arm to low position performance. Refine adjustments of pilot and
and shut system off. main burner minimum if necessary.
10. Referring to illustration on page 5400-S-4,
Warning: Test every UV flame sensor system
reconnect control motor linkage (with control
for dangerous spark excitation from ignitors
motor in low or minimum position) by loosening
and other burners, as well as other possible
toggle clamp screw [1] and moving toggle clamp
[2] along the connecting linkage to a point where
toggle clamp bolt [3] can be placed at the 12. Check carefully that all interlocks and limits
outermost position of control motor crank slot. are in full operating condition and before
Then tighten toggle clamp screw [1], thus fixing system is placed into full service, instruct
clamp to linkage. operator personnel on proper start-up,
Allowing toggle clamp bolt [3] to slide in the operation and shut-down of system, estab-
crank arm slot, cycle control motor towards its lishing written instructions for reference.
maximum position and move fuel control valve
Raw Gas Firing Start-Up Instructions for INCINO-PAK® Burner Sections

INCINO-PAK® Burner
sections are started up in the
same manner as other AIRFLO®
Burners, except the designed
manifolding for the raw gas
brings all the components to the
“outside” of the duct.
Your control valve is adjusted
in the same manner with
INCINO-PAK® Burners as
described earlier for raw gas
burner start-up instructions.
m CORPORATION

Partial-Premixed Burner Start-Up Instructions

Series “LV” AIRFLO® Line Burners may also be Gas supply piping must be large enough to
installed in oxygen-starved air streams. In those maintain the required fuel pressures cataloged for the
applications, a full or partial premixed air/gas mixture particular burner size used with burner operating at
must be supplied to your AIRFLO® Burner to support full-rated capacity.
proper combustion. With “partial-premixed” AIRFLO® Natural gas pressure generally required (as
Burner systems, a Series “HG” Mixing Tube with measured at the mixer gas inlet) is 1 PSIG higher
MICRO-RATIO® Control Valve is often used to premix than air pressure for “HG” Mixing Tubes.
gas and air prior to its introduction to the AIRFLO® Anything more than minimal distance or piping
Line Burner assembly. turns may necessitate “oversizing” piping runs to keep
A typical “HG” Mixing Tube system piping pressure drops within acceptable ranges.
layout is illustrated below. Inlet pipe leading to any burner should be at least
four pipe diameters in length. If multiple burners are
For initial burner start-up of partial-

premixed burner system:
Start-up steps #1 through #5 are the same for
partial-premix and raw gas burner systems. See page
Maxon assumes no responsibility for the use or 5400-S-4 for first five start-up steps, then continue
misuse of the piping layout shown. Specific piping with step #6 below.
and wiring diagrams should always be submitted to 6. Check minimum mixture pressure at burners
the appropriate agencies for approval on each by turning the MICRO-RATIO® Control Valve to
application. its minimum position and reading differential air
pressure only at each burner with a water
Combustion air blower provides the air (oxygen)
column manometer. Any reading below 0.10" wc
supply to your combustion system and is essential to
differential (natural gas) requires re-adjustment
the mixing of fuel gas. It should be located in the
as described below.
coolest, cleanest position that you can find near the
Setting minimum mixture pressure with a
burner itself. It must not be exposed to direct radiant
MICRO-RATIO® Control Valve and Series
heat or positioned where it might draw in the inert
“HG” Mixing Tube system:
gases or hot air rising from a furnace or oven. If
If minimum mixture pressure must be in-
problems exist, consider filters, relocation and/or
creased, open the MICRO-RATIO® air valve
ducting of an outside fresh air supply.
slowly (by turning toward higher-numbered
Minimize combustion air pressure drop between
positions) until the required differential air
blower and mixing tube. Keep a minimum straight run
(mixture) pressure is reached, then mark air
of four pipe diameters into the mixer air inlet. Down-
stream piping from mixer to burner should be kept as
short as possible.
your MICRO-RATIO® Valve mixing tube system
Electrical service must match the voltage, phase
(see sketch on page 5400-S-8).

mCORPORATION

Having marked and/or recorded the MICRO-
RATIO® Control Valve’s air valve settings for
both minimum and maximum firing positions,
you may adjust the linkage and travel of the gas
valve’s stroke (see sketch below).

“minimum”.
Continue opening the MICRO-RATIO® air maximum-end adjustment point. (Note: It doesn’t
valve while watching the manometer connected matter which is maximum or minimum, as long
into the burner’s air/gas mixture manifold. as you identify and keep the same reference
Determine the point at which further opening of points for the next adjustment steps.)
the air valve gives no appreciable increase in air Now rotate MICRO-RATIO® Valve to “maxi-
pressure within the manifold/burner. Mark the air mum” position. The air valve maximum setting
valve dial at this position opposite the air valve was previously determined. Loosen binding
pointer. This point will become the maximum air screw “B” and adjust pointer and linkage to
setting for your MICRO-RATIO® Valve mixing correct just half the distance required to make
tube system. the air valve pointer indicate the maximum air
valve setting.
m
CORPORATION


Re-tighten set screw “A” and again return the Continue turning in slowly until flame be-
MICRO-RATIO® Valve to its maximum position. comes noticeably rich (usually purple or green
Similarly, correct one half the distance with with a slight yellow tip). Then slowly back the
binding screw “B” for the maximum setting, etc. screw out until the flame becomes bright blue.
Continue this adjustment procedure until the A good minimum fire should provide uniform
gas and air valves reach their minimum and flame across the entire burner face, contained
maximum positions simultaneously. Normally, within the zipper flame channel at the base of
this is accomplished within seven adjustments. burner mixing plates. Any thin spots or gaps
7. Remove cover plate from screw carrier cam indicate uneven air velocity over the burner
assembly and turn all adjusting screws counter- which must be corrected or a higher minimum
clockwise until flush with outer surface of casting fire established by continuing to turn in on the
(new equipment is shipped this way). minimum stop screw.
8. Open main and pilot gas cocks and light first 10. Once your flame is established and refined at
burner pilot following instructions appropriate for this position, and without advancing the screw
that burner and pilot type. If multiple pilots are carrier quadrant higher, screw all remaining
used, open individual cocks and adjust each in screws down to at least the same level as your
turn. first adjusted screw.
To light and adjust gas pilot: Check to NOTE: A preliminary setting can be established
insure pilot combustion air supply is flowing to with all the remaining adjusting screws. Gener-
any pressure pilot mixer. Pilot gas regulator ally, each succeeding screw needs to be
should initially be set at approximately midpoint screwed in approximately one full turn more
of its adjustment range. With pilot gas solenoid (clockwise) than its preceding screw. A smooth
closed, open main fuel gas and pilot gas cock. “stair-step” gradient pre-set at this point from low
Energize spark ignitor and pilot gas solenoid. to high will simplify the remaining adjustment
Observe pilot ignition through sight port of pilot steps.
return MICRO-RATIO® Control Valve to
Refine pilot setting for a hard blue flame
minimum position and shut off fuel (if flame
(and/or strongest micro-amp signal) by adjusting
safeguard has not already done so). Turn in
gas flow through pilot orifice and/or pilot
slightly on adjusting screw at point where
regulator.
ignition was lost, then return valve to minimum
Shut off pilot gas cock to extinguish pilot fire.
position, re-establish pilot, open fuel valve and
Re-open and confirm easy re-ignition several
verify ignition.
times. The flame safeguard relays should now
power the main fuel shut-off valves. 11. Without advancing the valve quadrant, screw
9. Light main burners at minimum as follows: down clockwise on #2 screw (one or two turns).
First, turn MICRO-RATIO® Valve to its Then slowly advance the screw carrier quadrant
minimum setting (which may be at position 1 or to the #2 position. Adjust flame appearance at
2 after completing step 6), then open fuel shut- this new position #2.
off valve and turn corresponding screw in NOTE: If firing chamber is of refractory construc-
(clockwise) until flame ignites at all burner tion, allow your burner system to operate at this
nozzles. (This may take several turns of the low setting for the necessary dry/cure-out time
screw.) period recommended by the chamber or refrac-
NOTE: At this point, it is more important to get tory manufacturer. Then continue adjustments of
any kind of a flame as soon as possible. The valve.
flame geometry can be adjusted and refined as
needed later.

mCORPORATION

12. Again, without moving valve, bring #3 and all CAUTION: After completing previously listed
remaining adjusting screws down to the same steps, check all interlocking safety components
level as #2 screw. and circuitry to prove that they are properly
NOTE: If approximate pre-set gradient was installed, correctly set, and fully operational. If
made earlier, the remaining screws will already in doubt, shut the system down, close main and
be at or below appropriate levels. pilot cocks, and contact responsible individual
progression slope from your first screw to the 14. Reconnect linkage to control motor, plug all
“maximum” position. test connections, replace equipment cover caps
As each is adjusted, you must turn the and tighten linkage screws.
to prevent possible damage to flexible cam through light-off at minimum, interrupting pilot,
strips inside the screw carrier cam assembly. and allowing temperature control system to
Turning a screw in “clockwise” gives more cycle burner from minimum to maximum and
gas at that setting; turning it out gives less. return.
NOTE: To adjust the flame at any position, you Re-check all safety system interlocks for
must move the valve quadrant to the number proper setting and operation.
you desire to adjust. This aligns the adjusting WARNING: Test every UV installation for
screw directly on top of the fuel valve plunger. A dangerous spark excitation from ignitors and
resulting adjustment of the screw is directly other possible sources of direct or reflected UV
applied to the fuel valve plunger and its intercon- radiation. Use only gas-tight scanner
nected valve body linkage. connections.
recommended), shut off pilots and cycle burner operation and shut-down of system. Establish
mCORPORATION

Series “LV” AIRFLO® Line Burners Page 5400-A/P-1
Assembly Numbers
Series “LV” AIRFLO® Line Burner Material Gray iron bodies [1] Ductile iron bodies with
Specifications> with #321 stainless steel mixing plates #310 stainless steel mixing plates
Configured Item Number> LVNP1 LV3G24 LV3G48 LV3G96 LV3G120 LV4D24 LV4D48 LV4D96 LV4D120
Old Style LV-NP1 LV-85 --- --- --- LV-4CF --- --- ---
Item Designations>
Current LVNP1 LV3G24 LV3G48 LV3G96 LV3G120 LV4D24 LV4D48 LV4D96 LV4D120
36721 1049732 1049729 1049730 1049731 1047315 1047322 1047329 1047336
6" straight (-6)
(8) (14) (14) (14) (14) (13) (13) (13) (13)
36722 1049742 1049736 1049737 1049738 1047316 1047323 1047330 1047337
12" straight (-12)
(13) (21) (21) (21) (21) (20) (20) (20) (20)
36724
18" straight (-18) --- --- --- --- --- --- --- ---
Burner (20)
Sections 36725
24" straight (24) --- --- --- --- --- --- --- ---
(25)
1049845 1049839 1049840 1049841 1047317 1047324 1047331 1047338
12" x 6" tee (-T) ---
(29) (29) (29) (29) (28) (28) (28) (28)
1049778 1049760 1049765 1049770 1047318 1047325 1047332 1047339
12" x 12" cross (-X) [1] ---
(36) (36) (36) (36) (35) (35) (35) (35)
Back Inlet 12" back inlet straight (-12B) [1] 36723 1049750 1049747 1049748 1049749 1047319 1047326 1047333 1047340
Feed (16) (30) (30) (30) (30) (29) (29) (29) (29)
Sections 1049825 1049810 1049815 1049820 1047320 1047327 1047334 1047341
(each 12" x 12" back inlet cross (BX) [1] ---
(41) (41) (41) (41) (40) (40) (40) (40)
requires an
inlet flange 1049805 1049789 1049795 1049800 1047321 1047328 1047335 1047342
from below)
36" back inlet “H” (-BH) [1] ---
(90) (90) (90) (90) (85) (85) (85) (85)
Description LV NP1 LV3 & LV4

1.5" NPT 1.5" Inlet Flange (12B, 36B) --- 1.5D BIF
2" NPT 20042
2" Inlet Flange (12B, 36B) 2D BIF
2" ISO 25934
For 12B & 36BH inlet
2.5" NPT 2.5" Inlet Flange (12B, 36B) --- 2.5D BIF
A.N.S. Inlet sections
3" NPT 20043
Flange Options 3" Inlet Flange (12B, 36B) 3D BIF
for ductile iron 3" ISO 25935
back inlet feed 4" NPT 4" Inlet Flange (12B, 36B) --- 4D BIF
sections above
3" NPT 18806
3" Inlet Flange (Cross) 3D XIF
For 12" & 12" 3" ISO 24493
(BX) back inlet cross
sections 4" NPT 18807
4" Inlet Flange (Cross) 4D XIF
4" ISO 22006
NOTE: To order line burner arrangements, order appropriate configured item number. To order loose
items, order individual assembly numbers.

mCORPORATION
Page 5400-A/P-2 Series “LV” AIRFLO® Line Burners
Assembly Numbers
Series "LV" AIRFLO® Line Burner Material Ductile iron bodies Aluminum bronze bodies
Specifications> with Hastelloy X mixing plates with Hastelloy X mixing plates
Configured Item Number> LV5D24 LV5D48 LV5D96 LV5D120 LV5B24 LV5B48 LV5B96 LV5B120
Old Style LV-5CF --- --- --- LV-6CF --- --- ---
Item Designations>
Current LV5D24 LV5D48 LV5D96 LV5D120 LV5B24 LV5B48 LV5B96 LV5B120
1047343 1047350 1047357 1047364 1047371 1047375 1047379 1047383
6" straight (-6)
(13) (13) (13) (13) (15) (15) (15) (15)
1047344 1047351 1047358 1047365 1047372 1047376 1047380 1047384
12" straight (-12)
Burner (20) (20) (20) (20) (20) (20) (20) (20)
Sections 1047345 1047352 1047359 1047366 1047373 1047377 1047381 1047385
12" x 6" tee (-T)
(28) (28) (28) (28) (30) (30) (30) (30)
1047346 1047353 1047360 1047367
12" x 12" cross (-X) --- --- --- ---
(35) (35) (35) (35)
1047347 1047354 1047361 1047368 1047374 1047378 1047382 1047386
Back Inlet Feed 12" back inlet straight (-12B) (29) (29) (29) (29) (31) (31) (31) (31)
Sections
1047348 1047355 1047362 1047369
(each requires an 12" x 12" back inlet cross (BX) --- --- --- ---
(40) (40) (40) (40)
inlet flange from
below) 1047349 1047356 1047363 1047370
36" back inlet “H” (-BH) --- --- --- ---
(85) (85) (85) (85)
Description All LV5D All LV5B

1.5" NPT 1.5" Inlet Flange (12B, 36B) 1.5D BIF 1.5B BIF
A.N.S. 2" NPT 2" Inlet Flange (12B, 36B) 2.0D BIF 2B BIF
Inlet For 12B & 36BH inlet
2.5" NPT 2.5" Inlet Flange (12B, 36B) 2.5D BIF 2.5B BIF
Flange sections
Options 3" NPT 3" Inlet Flange (12B, 36B) 3D BIF 3B BIF
for ductile iron
back inlet 4" NPT 4" Inlet Flange (12B, 36B) 4D BIF ---
feed sections
above For 12" & 12" 3" NPT 3" Inlet Flange (Cross) 3D XIF ---
(BX) back inlet cross
sections 4" NPT 4" Inlet Flange (Cross) 4D XIF ---
Segment Choice Detail –Configured Inlet Flanges for Back Inlet & Cross Sections
Configured Item Segment Choice
Number (DEFAULT is shaded)
FLANGE DI Ductile iron

1.5D BIF MATERIAL GI Gray iron
2D BIF
2.5D BIF GAS ANSI_THRD ANSI threaded
3D BIF CONNECTION ISO_THRD ISO threaded
4D BIF
1.5B BIF 1000 1000°F approach air temp (max)
2B BIF
2.5B BIF 1050* 1050°F approach air temp (max)
3B BIF MAX APPROACH
450 450°F approach air temp (max)
3D XIF AIR TEMP (F)
4D XIF 600 600°F approach air temp (max)
*Available for 1.5B, 2B, 2.5B and 3B BIF only
NOTE: All choices are not available NOTE: To order line burner arrangements, order appropriate configured
in some cases. item number. To order loose items, order individual assembly numbers.
m
CORPORATION
Assembly Numbers
Ductile iron Ductile iron Aluminum
Gray iron bodies with
Series "LV" AIRFLO® Line Burner bodies with bodies with bronze bodies
#321 stainless steel
Material Specifications> #310 SS Hastelloy X with Hastelloy X
mixing plates
mixing plates mixing plates mixing plates
LV3G24 - LV4D24 - LV5D24 - LV5B24 -
Configured Item Number> LVNP1
LV3G120 LV4D120 LV5D120 LV5B120
Old Style LV-NP1 LV-85 LV-4CF LV-5CF LV-6CF
LV3G24 (&
Item Designations> D24) thru LV4D24 thru LV5D24 thru LV5B24 thru
Current LV-NP1
LV3G120 LV4D120 LV5D120 LV5B120
(&D120)
PLAIN END PLATE SET
36713 (3) 1050134 (4) 1047723 (4) 1047730 (4) 1047737 (4)
Plain end plate set
End Plate &
2" END INLET SET
End Inlet --- 1050135 (4) --- --- ---
2" end inlet set
Flange Sets
1.25" END INLT FLG SET 36715 (4) --- --- --- ---
1-1/4" end inlet flange set
DIR SPRK SET W/ 18075 SI
Direct spark set (includes #18075 spark ignitor &
--- 1050136 (5) 1047724 (5) 1047731 (5) ---
provides for mounting a flame rod; order #18117
separately)
2" INLT DS SET W/ 18075 SI
Direct Spark 2" inlet direct spark set (includes #18075 spark
End Plate & --- 1050137 (5) 1047725 (5) 1047732 (5) ---
ignitor & provides for mounting a flame rod; order
End Inlet #18117 flame rod separately)
Flange Sets
2" END INLET FLANGE --- --- LV4D 2EIF LV5D 2EIF ---
NPF 1.25" FR-SI 2-PC DS SET
NPF- 1-1/4" FR-SI 2-piece direct spark set includes
36716 (4) --- --- --- ---
#23739 spark ignitor (order #18117 flame rod
separately)
BUILT-IN PILT SET (DIR MNT)
Built-in pilot set, for direct mounted flame rod/UV
scanner & spark ignitor, includes #18075 spark
--- 1050138 (6) 1047726 (6) 1047733 (6) 1047738 (6)
ignitor (order flame rod, if used, separately)
Built-in Pilot
Sets BUILT-IN PILT SET (EXT MNT)
Built-in pilot set, for externally mounted flame
rod/UV scanner & spark electrode (order flame rod, --- 1050139 (6) 1047727 (6) 1047734 (6) 1047739 (6)
if used, electrode, and external mounting assembly
separately)

mCORPORATION
Assembly Numbers
Material Specifications> #310 SS Hastelloy X with Hastelloy X
mixing plates
mixing plates mixing plates mixing plates
LV3G24 - LV4D24 - LV5D24 - LV5B24 -
LV3G120 LV4D120 LV5D120 LV5B120
Old Style LV-NP1 LV-85 LV-4CF LV-5CF LV-6CF
LV3G24 (&
Item Designations> D24) thru LV4D24 thru LV5D24 thru LV5B24 thru
Current LV-NP1
LV3G120 LV4D120 LV5D120 LV5B120
(&D120)
ATMOSPHERIC PILOT MIXER --- 16948 (1) 20103 (1) 20103 (1) [1]
Atmospheric pilot mixer
Pilot Mixer
ATMSPH PILT MXR W/ADJ ORIF, ETC
Options Atmospheric pilot mixer includes shut-off cock, --- 12326 (2) --- --- ---
for AIRFLO-PAK
tubing and #39294 adjustable orifice
pilot assemblies
above PRESSURE PILT MIXER W/ADJ ORIF
Pressure pilot mixer includes #38579 adjustable --- 17082 (2) 11680 (2) 11680 (2) [1]
orifice
AIRFLO-PAK PILT SET (DIR MNT)
AIRFLO-PAK pilot set, for direct mounted flame
rod/UV scanner & spark ignitor, includes #18075 --- 1050140 (8) 1047728 (8) 1047735 (8) 1047735 (8) [1]
spark ignitor (order flame rod, if used, and pilot
mixer separately)
AIRFLO-PAK PILT SET (EXT MNT)
AIRFLO-PAK pilot set, for externally mounted flame
rod/UV scanner & spark electrode (order flame rod, --- 1050141 (8) 1047729 (8) 1047736 (8) 1047736 (8) [1]
if used, spark electrode, pilot mixer, and external
mounting assembly separately)
AIRFLO Pilot
Sets NP MINI-PAK PILT ASY W/SI, ORIF
NP MINI-PAK pilot assembly, includes #23739 spark
36718 (3) --- --- --- ---
ignitor & #38577 adjustable orifice (order #18117
NP-PAK PILT SET W/SI, ETC
NP MINI-PAK pilot assembly, includes #23739 spark
ignitor, #38577 adjustable orifice, 5/16" shut-off cock 36719 (4) --- --- --- ---
& 24" of 5/16" dia. tubing (order #18117 flame rod, if
used, separately)
NP-PAK PILT SET W/ SI 36714 --- --- --- ---
NP-PAK pilot set w/ SI
[1] Uses ductile iron castings instead of aluminum-bronze castings. Lowers the maximum approach temperature to 1000°F.
m CORPORATION

Assembly Numbers
Material Specifications> #310 SS Hastelloy X with Hastelloy
mixing plates
mixing plates mixing plates X mixing plates
LV3G24 - LV4D24 - LV5D24 - LV5B24 -
LV3G120 LV4D120 LV5D120 LV5B120
EXT MTG PLT: INT SI & EXT UV --- 40907 (3) --- --- ---
For internal spark ignitor & external UV scanner
EXT MTG PLT: INT SI & INT FR --- 40908 (3) --- --- ---
External For internal spark ignitor & internal flame rod
Mounting EXT MTG PLT: EXT SPK ELEC & UV
Plate For external spark electrode & external UV scanner --- 36593 (3) 36544 (3)
Assemblies (order electrode sub-assembly separately)
EXT MTG PLT: EXT SPK ELEC & FR
For external spark electrode & external flame rod (order --- 36594 (3) --- --- ---
electrode & flame rod sub-assemblies separately)
DIRECT MOUNTED SPARK IGN: 14MM 23739 (0.5) 18075 (0.5) 18075 (0.5)
Direct mounted spark ignitor 14mm (R)
EXT MTD ELECTRODE: L=12" --- --- 36539
12" externally-mounted shrouded electrode
EXT MTD ELECTRODE: L=18" --- 36538 ---
Spark 18" externally-mounted electrode
Ignitor Sub-
Assemblies EXT MTD ELECTRODE: L=24" --- --- 36541
QUARTZ IGNITOR W/ DI END FLG * --- --- LV4DQIGN LV5DQIGN ---
Quar tz ignitor with DI flange
QUARTZ IGNITOR W/ AL-BZ ENG FLG * --- --- LV5BQIGN
Quar tz ignitor with AL-BZ flange
FR-DIRECT MOUNTED (L=7.125") 18117
Direct mounted flame rod sub-assembly (length=7.125")
Flame Rod FR-DRCT MNTDF (L=7.125") W/ RBR CVR
Sub- Direct mounted flame rod sub-assembly (length=7.125") 1037597
Assemblies with rubber cover
FR-EXTERNAL MOUNTED (L=24")
External mounted flame rod sub-assembly (length=24")
--- 36537 ---
*See Page 5400 A/P-7 for segment choices.

m
CORPORATION
Assembly Numbers
Material Specifications> #310 SS Hastelloy X with Hastelloy
mixing plates
mixing plates mixing plates X mixing plates
LV3G24 - LV4D24 - LV5D24 - LV5B24 -
LV3G120 LV4D120 LV5D120 LV5B120
UNIVERSAL SUPPORT BRKT: (CS)
Universal suppor t bracket, zinc plated, good up 23577
to 800°F (order in pairs) (A)
UNIVERSAL SUPPORT BRKT: #304SS
Universal suppor t bracket, #304SS, good up to 39940
1600°F (order in pairs)
DIVISION PLATE
18133 1048448
Division plate
Optional
Accessory PROFILE PLATE BRACKET
and 20967 36580
Profile plate bracket
Replacement
Items Electrode Cover for flame rod or spark ignitor,
18722
good for up to 450°F (R)
Flame rod L = 24" (R) --- 18410 (1) --- --- ---
BODY FLANGE KITS
1049624 or 1048207 or 1048206
Body flange kits (fastener kits for joining two --- 1050598
(depends on temperature)
burner bodies)
2" END INLET FLANGE (KIT)
--- --- LV4D 2EIF LV5D 2EIF LV5B 2EIF
End inlet flange kit (See table below)
Configured End Inlet Flange Kits - Segment Choices

Configured
Item Segment Choices Descriptions Segment Values
Number
2" NPT W/ .75"-10 THRD
For quar tz ignitors
2" ISO W/ .75"-10 THRD
2" NPT W/ 18075 (14MM) IGNITOR
Local internal ignitor
2" ISO W/ 18075 (14MM) IGNITOR
2" NPT W/ .62 DRILL-THRU
LV4D 2EIF For feed-through shrouded ignitors
LV5D 2EIF 2" ISO W/ .62 DRILL-THRU Specify quantities
LV5B 2EIF
600F BODY FLANGE KIT (STL) 600°F body flange fastener kit
800F BODY FLANGE KIT (SS) 800°F body flange fastener kit
High temperature body flange kit for
1000F BODY FLANGE KIT (718)
LV4D and LV5D
High temperature body flange
fastener kit for LV5B
mCORPORATION

Assembly Numbers
Segment Choice Detail – Quartz Ignitors
Configured Segment Choice
Item Number (DEFAULT is shaded)
12 12" long
18 18" long
20 20" long
24 24" long
LENGTH
30 30" long
36 36" long
42 42" long
LV4DQIGN 48 48" long

LV5DQIGN CS Carbon steel
MATERIAL
SS Stainless steel
MAX APPROACH AIR TEMP (F)
FLANGE KIT
YES Choice selected
12 12" long
18 18" long
24 24" long
LENGTH 30 30" long
36 36" long
42 42" long
48 48" long
LV5BQIGN MATERIAL SS Stainless steel
MAX APPROACH AIR TEMP (F) 450 450°F approach air temp (max)
FLANGE KIT
YES Choice selected

mCORPORATION
Assembly Numbers
Configured Spare Parts Kits for LV3 Burners

Description Gray iron bodies
LV AIRFLO® Line Burners LV3 RSP
Segment Choice Detail - Configured Spare Parts Kits for LV3 AIRFLO® Burners
LV3 RSP BACK INLET FLANGE GSKT -H Back inlet flange gasket - H
mCORPORATION

Assembly Numbers
Configured Spare Parts Kits for LV4 & LV5 AIRFLO® Burners
Description Aluminum bronze bodies Ductile iron bodies
LV AIRFLO® Line Burners LVB RSP LVD RSP
Segment Choice Detail - Configured Spare Parts Kits for LV4 & LV5 AIRFLO® Burners
Segment Choices
Aluminum Bronze Ductile Iron
DIRECT MTD SPARK IGNITOR Specify quantity No segment choices available
MOUNTED FLAME ROD Specify quantity No segment choices available
MTD FLAME ROD W/RUBBER COVER Specify quantity No segment choices available
12" SHROUDED ELECTRODE 12" spark electrode
CERAMIC IGNITOR
12" SHROUDED ELECTRODE 12" spark electrode with rubber cover
CERAMIC IGNITOR W/RUBBER CVR
12" QUARTZ IGNITOR 12" quar tz spark ignitor
QUARTZ IGNITOR
12" QUARTZ IGNITOR 12" quar tz spark ignitor with carbon steel tube
QUARTZ IGNITOR W/CS TUBE
12" QUARTZ IGNITOR 12" quar tz spark ignitor with stainless steel tube
QUARTZ IGNITOR W/SS TUBE
RUBBER COVER Specify quantity No segment choices available
ADJUSTABLE ORIFICE Not Available NONE Available only with ductile iron body assemblies
GASKET SEALANT Specify quantity No segment choices available
Continued on Page 5400 A/P-10

mCORPORATION
Assembly Numbers
Segment Choice Detail - Configured Spare Parts Kits for LV4 & LV5 AIRFLO® Burners (Continued)
Segment Name Segment Choices Secondary Segment Choices Segment Choice Description
FLANGE GASKET ONLY Includes flange gasket only
600F (MAX) GASKET KIT Gasket kit for up to 600°F
BODY FLANGE CHOICES
12" BACK INLET CHOICES
GASKET/FASTENER KITS
CROSS BACK INLET CHOICES
SEAL PLATE CHOICES
NOTE: Any secondary segment with multiple choices is also a configured item. The quantities must be specified at
this level as well.
mCORPORATION

Assembly Numbers
Optional Accessory and Replacement Items - Spark Ignitors

Aluminum
Ductile iron Ductile iron
Gray iron bodies with bronze
Series "LV" AIRFLO® Line Burner bodies with bodies with
#321 stainless steel bodies
Material Specifications > #310 SS Hastelloy X
mixing plates w/Hastelloy X
mixing plates mixing plates
mixing plates
LV3G24 - LV4D24 - LV5D24 - LV5B24 -
Configured Item Number > LVNP1
LV3G120 LV4D120 LV5D120 LV5B120
12" 24715
18" 21063
Ceramic ignitor
24" 21064
36" 35553
12" 36539
Ceramic ignitor 18" 36540
with rubber cover 24" 36541
36" 36542
12" 44665
18" 44666
20" 45716
24" 44667
Quartz ignitor
30" 44668
36" 44669
42" 44935
Spark 48" 44670
Not
Ignitors available
12" 44658
(R)
18" 44659
20" 45715
Quartz ignitor 24" 44660
with carbon steel tube 30" 44661
36" 44662
42" 44933
48" 44663
12" 44652
18" 44653
20" not available
with stainless steel tube 30" 44655
36" 44656
42" 44934
48" 44657

m
CORPORATION
Assembly Numbers
Optional Accessory and Replacement Items - Gasket/Fastener Kits

Aluminum
Ductile iron Ductile iron
Gray iron bodies with bronze
Series "LV" AIRFLO® Line Burner bodies with bodies with
#321 stainless steel bodies
Material Specifications > #310 SS Hastelloy X
mixing plates w/Hastelloy X
mixing plates mixing plates
mixing plates
LV3G24 - LV4D24 - LV5D24 - LV5B24 -
Configured Item Number > LVNP1
LV3G120 LV4D120 LV5D120 LV5B120
Flange Gasket Only 1047672
Body Flange 600°F (max) Gasket Kit 1049624
Choices 800°F (max) Gasket Kit 1048207
1050°F (max) Gasket Kit 1048206
12" Back Inlet 600°F (max) Gasket Kit 1049872
Gasket/ Flange Gasket Only 1047671 ---
Not available
Fastener Kits 36" Back Inlet 600°F (max) Gasket Kit 1049874 ---
Choices 800°F (max) Gasket Kit 1049874 ---
1050°F (max) Gasket Kit 1049875 ---
Flange Gasket Only 1047674 ---
Cross Back Inlet 600°F (max) Gasket Kit 1049896 ---
Choices 800°F (max) Gasket Kit 1049896 ---
1050°F (max) Gasket Kit 1049897 ---
Seal Plate
Seal Plate Gasket Only 1047669
Choices
Plated 600°F (max) 1068682
End Plate Spare
Stainless Steel 800°F (max) 1068684
Fastener Kit
A-286 High Temp 1050°F (max) 1068680
m CORPORATION

Assembly Numbers
Raw Gas INCINO-PAK® Burner Sections Segment choices are as follows for
(includes spark electrode & adjustable pilot gas orifice) configured products:
Ductile iron bodies Ductile iron bodies
Description with #310 stainless with Hastelloy X • Connection type
steel mixing plates mixing plates • Back inlet type
Series 600 LV • Section type
Series 800 LV LV4D IP LV5D IP
• Extension (location A)
• Extension (location B)
Series 1100 LV • Extension (location C)
NOTE: Each open end of these burner sections must be closed • Extension (location D)
off with an end plate from options listed on page 5400-A/P-3. • Max. Approach Air Temp (F)
Segment Choice Detail – INCINO-PAK® Burner Sections

Segment Choice
(DEFAULT is shaded)
ANSI_THRD ANSI threaded
CONNECTION TYPE Type of threaded connection
ISO_THRD ISO threaded
1100 43.3" (1100 mm) wall to body centerline
BACK INLET TYPE Type of back inlet 600 23.8" (600 mm) wall to body centerline
12B 12" B straight back inlet
SECTION TYPE Type of burner section
36H 36" H back inlet
NONE No additional section
EXTENSION (LOCATION A) Additional section 12 12" straight section
6 6" straight section
EXTENSION (LOCATION B) Additional section 12 12" straight section
EXTENSION (LOCATION C) Additional section 12 12" straight section
EXTENSION (LOCATION D) Additional section 12 12" straight section
Maximum approach air 450 450°F approach air temp (max)

MAX APPROACH AIR TEMP (°F)
temperature 600 600°F approach air temp (max)

m CORPORATION
Assembly Numbers
Configured Spare Parts Kits for LV INCINO-PAK® Burners
Description Ductile Iron Bodies
600 LV INCINO-PAK 600 IP RSP

Item Numbers (If ordered individually)
Segment Description Segment Choice
600 800 1100
SPARK IGNITOR Specify quantity 36934 36935 36936
ADJUSTABLE ORIFICE Specify quantity 15726
MOUNTING GASKET
Specify quantity 1047670
(10" diameter)
BODY GASKET (5.75" diameter) Specify quantity 1047672
INLET FLANGE GASKET Specify quantity 1047675
GASKET SEALANT (1/4 lb.) Specify quantity 39565
LV HIGH TEMPERATURE
FASTENER KIT
CF HIGH TEMPERATURE
FASTENER KIT *
*Intended for CF INCINO-PAK® Burners (refer to Catalog Section 5700)
mCORPORATION

Bulletin 5500
®
Series “NP” & “RG” AIRFLO Burners
48" Straight Bar Assembly Series NP-I AIRFLO® Burner
• For direct-fired fresh air heating applications

• Operates economically and installs easily
• Fits your duct with custom-built assemblies
• Burns clean and odor-free with most gaseous fuels
• Meets most application needs with high heat releases & wide turndown ratios
Covered by U.S. Patents 3,178,161 and 3,297,259
Page 5502

Maxon Series "NP" and "RG" AIRFLO® Burners Nominal capacities of 20,000 Btu per hour per foot
consist of rust-resistant cast iron bodies (which serve (minimum) to 500,000 Btu per hour per foot (maxi-
as the gas manifold) drilled to discharge the fuel mum) give 25:1 turndown. Fuel used and design
between diverging stainless steel mixing plates. velocities may result in higher or lower turndown.
Aluminum bodies are also available for applications in Modular design lets you match burner shape and total
corrosive or high moisture environments. heat release to your specific application needs.
The entire burner assembly is mounted directly in Several variations are offered, each optimized for a
the air stream being heated. The fresh air stream specific type of application as follows. All are raw-gas
passes through the mixing plates and mixes with the burners, intended for use in fresh air streams.
fuel as combustion air; thus all available heat from the
gaseous fuel is released directly into the air stream. For make-up air heating, NP-I and NP-II burner
types provide a nominal capacity of 500,000 Btu per
Carefully controlled aeration patterns provide hour per foot and turndowns of 25 to 1 or higher using
progressive mixing, superior cross-ignition, flame either natural gas or propane. Optimum air stream
retention and clean, odor-free combustion. velocity is 3000 standard feet per minute (SFPM).
Air velocities across the burner assemblies (the key For process air heating, NP-I and NP-II burners
to successful operation) are established by the use of may be used. If higher firing rates are desired, NP-III
profile plates. burner may be specified, providing a nominal capacity
of 1,000,000 Btu per hour per foot at an optimum air
Optimum performance demands that air veloci- stream velocity of 4000 SFPM, but with reduced
ties be uniform across the entire burner. turndown.
For 2-speed air handling systems, choose RG-IV

burner (for natural gas only) for a nominal capacity of
500,000 Btu per hour per foot at an optimum velocity
of 3000 SFPM.
Pilots are available in both built-in and add-on

configurations. They include spark ignitor and provi-
sions for adapting flame detection devices.
A complete "NP" or "RG" AIRFLO® Burner system

will also include gas train, fuel control valve and a
control panel. Your Maxon representative can help
Typical 36" straight bar assembly of Series RG-IV AIRFLO®

Burner
Page 5503
Typical Applications for Maxon Series “NP” and “RG”

®
AIRFLO Burners
Packaged Make-up Air Systems Packaged Make-up Air Systems
with 100% Outside Air with Partially Recirculated Air
NP/RG AIRFLO® Burner NP/RG AIRFLO® Burner
Fan Fan
Fresh
Air
Fresh
Air
Supply Supply Return

Air Air Air
Single-stage Burner Heated Paint Spray Humidity Controlled, 2-stage Burner

Booths with Re-heat Option Heated Paint Spray Booths
Air Intake Air Intake
Reheat
Preheat NP/RG AIRFLO® Burner Staged
NP/RG AIRFLO® Burner (If Required) NP/RG AIRFLO® Burner
Fan Fan
Bag Humidifier Supply Bag Humidifier Supply

Filters Air Filters Air
Drying, Baking & Curing Operations Grain Dryers
NP/RG AIRFLO® Burner

Filter Fan
Grain Bin
Hot Air
Fresh
Air Chamber
Heated NP/RG
Air AIRFLO® Burner
NP/RG AIRFLO® Burner

Filter
Fan
Fresh
Air Fan
Cooling
Heated
Air Chamber Intake
Air
2/01
Page 5504
Typical In-Duct Configuration of Series “NP-I” AIRFLO® Burner Assembly
At 500,000 Btu/hr per ft. Minimum at Nominal 20,000 Btu/hr per ft.
System components normally used in conjunction with a Maxon Series

“NP/RG” AIRFLO® Burner application
Legend:
Item
Description
Number
1 Outside ther mostat
2 Intake high temperature limit switch
3 Control valve
4 Vent valve
5 Strainer
6 Dr ip leg
Intake Louvers
7 Differential air switch
8 High temperature switch
Profile Plate
9 Discharge air ther mostat
10 Sequencing Control Panel
AIRFLO® Burner
1
Duct Walls
2
4
3
10
Bl
oc
k&
Bl
ee
dM n
ain rai
Ga asT
sT o tG
rai
n Pil
7
Main
8 Volume
5 6 9
Fan
2/01
Series "NP" & "RG" AIRFLO® Burners Page 5505
Operation in shaded area

requires special
considerations
rea
esign A
D
mum
Opti
Operation in shaded area

requires special
considerations
a
n Are
g
Desi
um
ptim
O
9/03
Page 5506 Series "NP" & "RG" AIRFLO® Burners
Performance Selection Data (cont'd.)
Area
n
esig
D
m
timu
Op
Airstream velocity across and through your burner's mixing Table 1: Burner Displacement (ft2/section)
plates must be kept uniform and within desired limits by use of a Section NP RG
silhouette profile plate through which the burner fires. A 6" (mini- 6" Straight 0.25 0.33
mum) profile plate should be installed surrounding the interior duct 12" Straight 0.50 0.66
walls at the leading edge of your burners mixing plates.
18" Straight 0.75 0.99
Optimum design ranges for the various burner types are shown
in the above graphs. Velocities (SFPM) are measured with a 24" Straight 1.00 1.32
velometer directly in the duct at the plane of the profile plate and 12" Back Inlet 0.50 0.66
leading edge of burner mixing plates. 36" Back Inlet 1.20 1.50
To determine profile opening areas, add burner displacement 12" x 6" Tee 0.60 0.75
areas (Ft2/section) from Table 1 for your complete burner assembly
6" x 6" Elbow 0.45 0.60
to "Net Free Area" of your duct:
Inlet Feed Limitations:
"Net Free Area" of Duct (Ft2) = Fan Volume (SCFM)
NP-I NP-II NP-III RG-IV
Velocity (SFPM)
1-1/4" end ≤4' ≤4' ≤2000 ≤4'
Net Free Area (Ft2) + Burner Displacement (Ft2) = Profile Area (Ft2)
inlet flange KBtu/hr
1-1/2" back ≤5' ≤5' ≤4500 ≤5'
Various duct size/profile area relationships may give slightly
different field site data than is shown in Table 2. Velocities should inlets* KBtu/hr
*Note: For 36 back inlet sections, not more than 6"
always be confirmed and established by use of a velometer on
off any one leg
actual field site installation.
Pilot Capacities: Nominally rated at
25,000 Btu/hr with natural gas differen-
Table 1: Velocity Factors tial pressures of 4-6" w.c.
Desired velocity across burner at profile plate opening (SFPM) 1600 1800 2000 2200 2400 2600 2800 3000 3250 3500 3750 4000 4500 5000
Appoximate velocity pressure reading at profile plate ("wc) 0.16 0.20 0.25 0.30 0.36 0.42 0.49 0.57 0.64 0.77 0.88 1.00 1.26 1.55
Series "NP" AIRFLO® Burners Page 5507
Approximate Envelope Dimensions

(Nominal, in Inches)
Burner Sections
(All burners shown are available in NP-I, II or III versions. Use one of these numbers (I, II or III) in place of asterisk (*) in
burner designation when ordering.)
NP- * -6 NP- * -12 or NP- * -18 NP- * -24

6" Straight NP- * -12B 18" Straight 24" Straight
or 6"P Pilot 12" Straight or 12B
Back Inlet
NP- * -L NP- * -T NP- * -36B

6" X 6" Elbow 12" X 6" Tee 36B Back Inlet
Typical End View
4/95
Page 5508 Series "NP" AIRFLO® Burners
Pilots, End Closures, and End Inlet Flange Sets

NOTE: All open ends of burner assembly must be closed off with one of these end closures or pilots.
One-piece cast end closures should not be used if temperature rise exceeds 300°F.
Plain End Closure Sets End Inlet & Pilot Flange Sets
NP-EC (1 pc) NP-EP (2 pc) NPF- 1-1/4" -FR-SI (1 NPF- 1-1/4"- EP NPF- 1-1/4"- FR-SI (2
End Closure Set End Plate Set pc) Pilot Set w/SI (2 pc) End Inlet pc) Pilot Set w/SI
Flange Set
Pilot End Plate Sets
NP-Pak Pilot Set NP-Pak Pilot Set NP-Pak Pilot Set NP-EC-SI-3/4"UV NP-EC-SI-1/2"-FR
w/SI w/Adj. Orifice/SI w/orifice/cock/tube/ (1 pc) Pilot Set w/ (1 pc) End Closure
SI SI Set w/SI
Common Dimensions (Nominal, in Inches) Pilot Assembly Section
Typical End View NP-6P Pilot Sec-
tion w/Built-in Pilot
includes end plate
pilot w/SI onto its
own special 6"
Series NP AIRFLO®
Burner assembly
PIpe threads on this page conform to NPT

Legend:
1 - 1/8" test connection
2 - 1/4" pilot gas connection
3 - 14mm spark ignitor connection
4 - 1/2" or 3/4" UV/FR connection
bushed to 1/4" for FR
5 - Alternate 1/4" angled FR location
7 - 1-1/4" NPT gas inlet
Series "RG" AIRFLO® Burners Page 5509
Approximate Envelope Dimensions

(Nominal, in Inches)
Burner Sections
RG-IV-6 RG-IV-12 or RG-IV-18 RG-IV-24
6" Straight or RG-IV-12B 18" Straight 24" Straight
6"P Pilot 12" Straight or 12B
Back Inlet
RG-IV-L RG-IV-T RG-IV-36B

6" X 6" Elbow 12" X 6" Tee 36B Back Inlet
Typical End View
5/88
Page 5510 Series "RG" AIRFLO® Burners
Pilots, End Closures, and End Inlet Flange Sets

NOTE: All "open" ends of burner assembly must be closed off with one of these end closures or pilots.
One piece cast end closures should not be used if temperature rise exceeds 300ºF.
Plain End Closure Sets End Inlet & Pilot Flange Sets
RG-EP (2 pc) RGF- 1-1/4" -FR-SI (1 RGF- 1-1/4"- EP RGF- 1-1/4"- FR-SI (2
End Plate Set pc) Pilot Set w/SI (2 pc) End Inlet pc) Pilot Set w/SI
Flange Set
Pilot End Plate Sets Pilot Assembly Section

RG-6P Pilot Sec-
tion w/Built-in Pilot
includes end plate
pilot w/SI and a
special 6" Series
RG AIRFLO® Burner
assembly
RG-Pak Pilot Set w/ RG-Pak Pilot Set w/ RG-Pak Pilot Set

SI Adj. Orifice/SI w/orifice/cock/tube/SI
Common Dimensions (Nominal, in Inches)

Typical End View
Legend:
1 - 1/8" test connection
3 - 14mm spark ignitor connection
4 - 1/2" UV/FR conn. bushed to 1/4" for FR
5 - Alternate 1/4" angled FR location
7 - 1-1/4" NPT gas inlet

"NP" & "RG" AIRFLO® Burners Page 5511
Accessories / Replacement Items

Dimensions, Nominal in Inches
14mm Spark Ignitor Profile Plate Bracket

Provides support for profile within closed burner loop.
1/4" dia.
Flame Rod (1/4" NPT)
Adjustable Orifice
Support Bracket
Normally used in pairs as shown here.
Mount to burner assembly at any joint.
Division Plate
Provides isolation of burner feed where desirable.
External Mounting Assembly

Frequently used to provide easy accessibility to spark ignitor and flame supervision components.
External Mounting Plate Used with typical pilot Opening Required

mounting of Spark Ignitor
and Flame Rod.
5/88
Page 5512 "NP" & "RG" AIRFLO® Burners
Notes
Series "NP" & "RG" AIRFLO® Burners Page 5500-S-1
General Sketch 2 shows the burner suspended from a strap
iron frame using Maxon USB support brackets. Note
Important: Do not discard packing material until that rigid mounting is avoided by the bracket hole
all loose items are accounted for. which slips loosely over a bolt or steel rod attached to
the support. Gas piping would need independent
Avoid bending or damaging the steel mixing plates support.
of your Series "NP" or "RG" AIRFLO® Burner during Sketch 3 shows the burner assembly resting upon
uncrating and installation. angle iron brackets and not attached to them in any
These burners are used way. Be sure the angle iron supports allow the burner
only for the heating of flanges to expand and contract. Gas manifolding
fresh air in motion and would be independently supported and prevent
should not be used in forward movement of the burner.
recirculating air systems.
Mount the burners so they
fire parallel to and in the
same direction as the
movement of the air (see
sketch 1 at right).
Velocity and flow of air
at operating temperature
must be uniform. Minimum
silhouette profile plates of 6" should be installed in
duct to completely surround burner assembly.
Supports
Series "NP" & "RG" AIRFLO® Burner assemblies
must be adequately supported and positioned.
Avoid rigid mounting. Burner assembly expands
and contracts with temperature variations.
Maintain smooth, even air flow over the burner by Sketch 4 shows simple strap iron used to support
designing supports to provide minimum interference, the burner. Note that narrow edge of strap faces air
deflection and turbulence. flow to avoid undue turbulence.
The sketches below show typical installation and Sketch 5 shows gas manifolding used to support
support methods: the burner. If there are
multiple inlets, you must
avoid rigid connection by
using the oversize U-bolt
(loosely drawn up) illustrated.
Support for down-fired
burners can be accomplished
as shown in the illustration at
right. Always avoid rigid
mounting.
Sketch 6 shows Maxon
USB support brackets
suspending the burner from
an overhead angle iron.
Sketch 7 shows an alter-
nate arrangement which
offers the advantage of more
controlled positioning.

mCORPORATION
Page 5500-S-2 Series "NP" & "RG" AIRFLO® Burners
Installation Instructions (cont'd.)

Gas Train tor and pilot solenoid valve. For pilot adjustment, an
See piping layout below to identify various typical adjustable orifice is recommended at or near the pilot
system components. gas inlet.
Pipe size of gas line must be large enough to Fuel shut-off valve, when properly wired to a
assure ample fuel pressure at maximum system safety control system, shuts the fuel supply off when a
capacity. Burner capacity is totally dependent on fuel hazardous operating condition is sensed by your
differential being maintained. (See capacity/specifica- control circuit. Manual reset valves require operator
tion data for the actual fuel pressure required at the attendence each time the system is started up (or
burner to achieve its rated capacity.) restarted after a trip-out). Motorized shut-off valves
Clean fuel lines are essential to prevent blockage permit automatic start/restart when used with appro-
of pipe train components or burner gas ports. All dirt, priate control system.
scale and pipe dope should be blown out of any gas Fuel control valve controls burner heat release by
line before actually connecting to the burner system. throttling gas flow to it. It should include provision for
Main shut-off cock should be upstream of both an adjustable minimum and throttling over a turndown
system regulator and pilot line take-off. Use it to shut range that matches burner capabilities. The illustra-
off fuel to both pilot and main burner during extended tion shows a Series "CV" Flow Control Valve; but
shutdown periods. Maxon Control Valves are not adjustable gradient Synchro® and/or "Q" Flow Control
intended for tight shutoff. Main system shut-off should Valves may be used.
always be accomplished with a manual fuel cock. Gas pressure test connections are provided in
Main gas regulator is essential to maintain a most Series "NP" and "RG" Burner end plate sets, but
uniform system supply pressure. A separate regulator it is also helpful to provide an additional test connec-
should be provided in the branch leading to each tion in the piping between main gas regulator and fuel
burner system if more than one is served by a com- control valve. All connections must be plugged unless
mon main. Size regulator for full system capacity at an actual pressure measuring device (gauge or
required pressure, including pipe train losses. manometer) is being used.
The gas train piping illustrated should be installed
as close to the burner as possible. Maxon assumes no responsibility for the use
Pilot take-off should be upsteam of main gas or misuse of the piping layouts shown.
regulator, but downstream of main gas cock. It Specific piping and wiring diagrams should
normally includes pilot shut-off cock, pilot gas regula- always be submitted to the appropriate
m CORPORATION

familiarize yourself with all the system's equipment
installed in accordance with the original manu-
facturer's current instructions.

6. To light and adjust gas pilot: Pilot gas regulator
should initially be set at approximately midpoint
For initial system start-up: of its adjustment range. With pilot gas solenoid
1. Close all burner fuel valves and/or cocks. Make valve closed, open main fuel gas and pilot gas
preliminary adjustments to fuel regulators. cock. Energize spark ignitor and open pilot gas
2. Check all electric circuitry. Verify that all safety solenoid. Turn adjustable orifice screw out
devices and interlocks are operable and func- (counter-clockwise) several turns from its fully
tioning within their respective settings/ranges. seated position. Observe pilot ignition through a
Be sure all manifolds are tight and that test ports sight port by viewing micro-amp signal metered
are plugged if not being used. from flame safeguard relay circuit.
3. Check that all duct and chamber dampers are Refine pilot setting for a hard blue flame (and/or
properly positioned and locked into operating strongest micro-amp signal) by adjusting gas
positions. flow through pilot orifice and/or pilot regulator.
4. Start main volume air fan. Check for proper 7. Prepare to ignite main burner by adjusting main
motor rotation and impeller direction. Verify all gas regulator to approximately midpoint of it's
safety interlocks are working. Allow air handling adjustment range. Linkage arrangement for the
equipment to run adequate purge of manifold use of Series "CV" Gas Control Valve is illus-
and combustion chamber plenums. Verify air trated above for a typical control motor. Arrange
volume and velocity across burner element to be accordingly.
within burner operating specifications. 8. With control valve at "minimum", ignite main
burner by opening main fuel shut-off valve.
CAUTION: Do not by-pass control panel timers Adjust main gas regulator to give the desired
typically controlling sequential operations. outlet pressure. Refine pilot adjustment if it has
been affected. Adjust burner "minimum" by
5. Disconnect the automatic control motor linkage turning in on the minimum stop screw of the gas
from your Maxon Control Valve by loosening the control valve until stable flame appears in the
control motor's connecting rod from the valve's narrow zipper channel at the base of burner
toggle linkage. Initial start-up adjustment should mixing plates.
only be accomplished during a "manual" control
mode. Manually set and secure control valve in
its "minimum" position.

mCORPORATION
Page 5500-S-4 Series "NP" & "RG" AIRFLO® Burners

A good minimum fire should provide uniform D. Without advancing the Synchro® Valve
flame across the entire burner face, contained quadrant, screw down on #2 screw (one or
within the zipper flame channel at the base of two turns). Then slowly advance the
burner mixing plates. Any thin spots or gaps Synchro® Valve quadrant to the #2 position.
indicate uneven air velocity over the burner Refine flame appearance at this new
which must be corrected or a higher minimum position #2.
fire established by continuing to turn in on the E. Turn all higher-numbered screws in at least
minimum stop screw. as far as the one just adjusted, then turn
NOTE: If your Maxon NP/RG AIRFLO® Burner next one in as necessary to achieve desired
was furnished with an adjustable gradient type flame while rotating valve mechanism to that
Series "Q" or Synchro® Control Valve instead of position on indicator strip.
a Series "CV" Valve, read ahead to step 8A for F. Repeat for each remaining screw.
specific instructions and differences in adjust- NOTE: To avoid possible damage to cam
ment procedures. strips, always turn all higher-numbered
5
screws in as far as the last one adjusted.
G. Refine adjustment as needed, always
7 turning valve so that position indicator
matches screw being adjusted.
For more fuel, turn screw in (clockwise). for
19
less fuel, turn screw out (counter-clockwise).
3 If screws must be turned in flush with carrier
casting, increase fuel pressure and readjust
by starting at minimum over again.
18
4 2 H. Cycle system off and on, and through all
11 10 6
16
12 firing rates until satisfied with performance.
17
13
14
I. Reconnect control motor linkage and check
1 that operator does not "bind" and that all
A. From step #5, the automatic control motor interlocks are performing properly.
linkage has already been disconnected from 9. Adjust burner "high fire" by slowly rotating fuel
your adjustable gradient type control valve control valve crank arm towards its maximum.
and the valve is at its "minimum" position. Observe flame characteristics carefully. Flame
B. Open fuel supply and begin adjustment of should remain a bright blue color with a length
appropriate adjustable gradient valve by beyond the mixing plates as indicated in capac-
turning in minimum (or lowest numbered) ity/specification data. If flame becomes long and
screw until desired flame is achieved. (Main yellow, gas pressure is too high and/or air
fuel regulator may need adjusted at this velocity is too low.
point.) NOTE: Dust and/or chemicals entrained into
C. Once your flame is established and refined passing air stream may effect physical color of
at this position, and without advancing the flame. In this case, adjust burner for stable flame
screw carrier quadrant higher, screw all shape and geometry.
remaining screws down to at least the same To measure gas pressure, connect water
level as your first adjusted screw. column (manometer) to the test connection in
NOTE: A preliminary setting can be estab- burner's end plate. To determine air velocity, use
lished with all the remaining adjusting a velometer at the profile opening. Correct
screws. Generally, each succeeding screw velocities by increasing or decreasing profile
needs to be screwed in approximately one opening size.
full turn deeper than its preceeding screw. A If flame is too short, gas pressure may be too
smooth "stair-step" gradient pre-set at this low and should be increased or velocities are
point from low to high will simplify the too high and may need to be decreased. Note
remaining adjustment steps. that air velocities should be measured only when
the fan is handling air at the desired control
m
temperature.
CORPORATION

The desired maximum capacity may be motor and valve can assume their minimum
achieved with less than full control valve open- positions. Then retighten toggle clamp screw 1.
ing. Mark with a pencil or scribe the point on Refine adjustment by cycling several times
valve crank arm where the desired maximum is between low and high control motor position
obtained, then return crank arm to low position while readjusting toggle clamp bolt 3 as neces-
and shut system off. sary until control motor travels through its full
10. Reconnect control motor linkage (with control cycle while moving control valve crank arm from
motor in low or minimum position) by loosening its minimum only up to the desired maximum
toggle clamp screw 1 and moving toggle clamp previously determined.
2 along the connecting linkage to a point where 11. Relight burner and cycle control system from low
toggle clamp bolt 3 can be placed at the outer- to high fire several times to observe perform-
most position of control motor crank slot. Then ance. Refine adjustments of pilot and main
tighten toggle clamp screw 1, thus fixing clamp burner minimum if necessary.
to linkage.
Allowing toggle clamp bolt 3 to slide in the crank Warning: Test every UV Flame Sensor
arm slot, cycle control motor towards its maxi- System for dangerous spark excitation from
mum position and move fuel control valve crank ignitors and other burners, as well as other
4 to the previously-determined maximum firing possible sources of direct or reflected UV
rate position. Tighten toggle clamp bolt 3, thus radiation.
fixing clamp to motor crank.
Cycle control motor back to minimum, watching 12. Check carefully that all interlocks and limits are
carefully that it does not bind before reaching in full operating condition and before system is
minimum. placed into full service, instruct operator person-
If it is stopped or if minimum is not reached, nel on proper start-up, operation and shut-down
loosen toggle clamp screw 1 and move toggle of system, establishing written instructions for
clamp along the connecting linkage so both reference.

mCORPORATION
Page 5500-S-6 Series "NP" AIRFLO® Burners
Maintenance and Component Identification/Spare Parts

5
4
18 2
11 10 6
12
16
17
13 Item No. Burner Body NP-I NP-II NP-III
14 6" Straight 18061 20700 20899
1
To order replacement parts: 12" 18070 20699 20900
1. See burner nameplate and indicate burner type. 18" 21840 21847 21848
2. Sketch burner arrangement (as viewed from casting side). 1 24" 21841 21851 21852
3. Specify replacement items required from sketch. 12" Back Inlet 18062 20548 20901
4. Specify quantity of each and assembly numbers from 36" Back Inlet 2008 20010 22011
tables below and at right: 12 x 6 Tee 18071 20547 21332
2 6 x 6 Elbow 18060 20549 21324
Quantity Required for Indicated Section

Item Asby.
Part Description
No. 6" Str. 12" 18" 24" 12" x 6" 6" x 6" 12" 36" No.
Str. Str. Str. Tee Elbow B.I. B.I.
3 2 4 6 8 2 2 4 4 42430 Mixing Plate
4 2 1 4 43062 Mixing Plate: Inside Corner
5 1 44263 Mixing Plate: Wedge
6 2 4 6 8 2 2 4 4 18049 Back Up Bar
7 2 4 6 8 4 4 4 8 30001 Gasket/Suppor t Bracket (Metal)
10 4 8 12 16 12 8 8 24 40487 #10-24 x 1-3/8" Round Head Mach. Screw "Sems"
11 12 24 36 48 29 22 24 48 40484 #10-24 x 1/2" Round Head Mach. Screw "Sems"
12 14 28 42 56 37 28 28 64 40014 #10-24 Hex Nut
13 2 2 2 2 4 2 2 4 40297 3/8"-16 z 1-1/2" Hex Head Cap Screw
14 2 2 2 2 4 2 2 4 40028 3/8"-16 Hex Nut
16 2 4 6 8 4 2 4 8 40617 10-24 x 3/8" Hex Head Mach. Screw
17 2 4 6 8 4 2 4 8 40616 Washer
18 4 2 8 18050 Back Up Bar (Inside)
mCORPORATION

Series "RG" AIRFLO® Burners Page 5500-S-7

5
19
3
18
4 2
11 10 6
12
16
17 Item No. Burner Body RG-IV
13
14 6" Straight 18061
1 12" 18070
To order replacement parts: 18" 21840
1. See burner nameplate and indicate burner type. 1 24" 21841
2. Sketch burner arrangement (as viewed from casting side). 12" Back Inlet 18062
3. Specify replacement items required from sketch. 36" Back Inlet 22008
4. Specify quantity of each and assembly numbers from tables below 12 x 6 Tee 18071
and at right: 2 6 x 6 Elbow 18060

Item Asby.
Part Description
No. 6" Str. 12" 18" 24" 12" x 6" 6" x 6" 12" 36" No.
Str. Str. Str. Tee Elbow B.I. B.I.
3 2 4 6 8 2 2 4 4 23731 Mixing Plate
6 2 4 6 8 2 2 4 4 18049 Back Up Bar
7 2 4 6 8 4 4 4 8 30090 Gasket/Suppor t Bracket (Metal)
10 4 8 12 16 12 8 8 24 40487 #10-24 x 1-3/8" Round Head Mach. Screw "Sems"
11 16 32 48 64 39 30 32 64 40484 #10-24 x 1/2" Round Head Mach. Screw "Sems"
12 18 36 54 72 47 36 36 80 40014 #10-24 Hex Nut
13 2 2 2 2 4 2 2 4 40297 3/8"-16 x 1-1/2" Hex Head Cap Screw
14 2 2 2 2 4 2 2 4 40028 3/8"x16 Hex Nut
16 2 4 6 8 4 2 4 8 40617 10-24 x 3/8" Hex Head Mach. Screw
17 2 4 6 8 4 2 4 8 40616 Washer
18 4 2 8 18050 Back Up Bar (Inside)
19 2 1 4 18066 Deflector Plate

m CORPORATION
Page 5500-S-8 Series “NP” & “RG” AIRFLO® Burners
Periodic maintenance will insure continued trouble- visually that no holes in the mixing plates are
free operation of your Series NP or RG AIRFLO® blocked. See Product Information Sheet 5500-3
Burner system. for inspection and maintenance instructions for
At least a yearly inspection is recommended for gas ports.
make-up air heating installations and more frequently
WARNING: Do not enlarge burner ports or
for process applications in year-round operation. Your
performance may be drastically affected.
own experience is the best guide in determining
frequency of inspection, but as a minimum the follow- If any mixing plates are loose or missing fasteners,
ing procedure should be followed: tighten/replace as necessary. Always use zinc plated
1. Shut the system down totally, disconnecting or or stainless fasteners.
locking out power supply so there can be no 3. Put system back into operation and, if possible,
accidental start-up during inspection. view from downstream side while cycling burner
2. Inspect the burners carefully, including upstream through full firing range. This will give a visual
and downstream sides of mixing plates as well as check for blocked burner ports.
burner body face. Any accumulation of scale or 4. Observe flame pattern and, if necessary, take
foreign material on either side of the mixing plates steps to correct velocity and/ or air distribution
should be removed with a wire brush. Check problems.
Repair / Replacement Procedures

If adverse operating conditions or accidental 3. Install new mixing plates, back up bars and plate
damage make it necessary to replace either individual support brackets to the new body castings. Be
mixing plates or complete burner sections, follow this careful not to damage gaskets that go between
procedure: mixing plates and burner body. They are cut to
1. Identify necessary replacement parts from overlap approximately 1/16" for tight air seal.
component identification drawing on preceding 4. If end plate sets must be installed, apply Key
page, then order required quantities of each. Paste to both sides of end plate at the areas that
Consider carefully the economics of installing a will contact the cast iron body and end flange or
complete replacement burner instead of replacing pilot. Then put in position between mixing plates
individual parts. Once exposed to actual flame and insert fasteners loosely. Do not tighten at this
temperatures, burner castings harden and the time.
removal and replacing of fasteners can be time 5. Tighten burner body bolts making sure that
consuming and difficult. Accessibility may also be mating cast iron flanges remain square and flush.
severely limited requiring removal of complete 6. Align mixing plates and check that gaskets are in
assembly in any case. position and properly aligned, then tighten all
2. When necessary parts have been received, mixing plate mounting screws and bolts.
remove damaged mixing plates or burner sec- 7. Double check that all fasteners are secure.
tions, taking care not to damage remaining 8. Return burner to operation, observing flame
portion of burner. If new burner bodies are being carefully at all firing rates.
installed, apply thin coat of Key Graphite Paste to
the mating flanges of loose cast iron bodies. (This
is necessary to provide a gas-tight seal after
assembly.) Insert new section into place, making
sure that both flanges are square and flush, then
bolt sections together.
mCORPORATION

Series “NP” & “RG” AIRFLO® Line Burners Page 5500-A/P-1
Assembly Numbers
Series NP/RG AIRFLO® Burners - cast iron bodies
NP-I NP-II NP-III RG-IV NP-V
Burner Type
#430SS mixing plates #430SS mixing plates #430SS mixing plates #321SS mixing plates #430SS mixing plates
Configured Item
NP1 NP2 NP3 RG4 NP5
Number
Assembly Assembly Assembly Assembly Assembly
Description Designation Designation Designation Designation Designation
Number Number Number Number Number
12" straight section NP-I-12 20865 (13) NP-II-12 20871 (13) NP-III-12 20904 (13) RG-IV-12 23677 (14) NP-V-12 34251
6" x 6" elbow section NP-I-L 20869 (12) NP-II-L 20875 (12) NP-III-L 21352 (12) RG-IV-L 23683 (13) NP-V-L 34253
12" x 6" tee section NP-I-T 20868 (19) NP-II-T 20874 (19) NP-III-T 21351 (19) RG-IV-T 23682 (20) NP-V-T 34254
12" back inlet
NP-I-12B 20867 (16) NP-II-12B 20873 (16) NP-III-12B 20905 (16) RG-IV-12B 23679 (17) NP-V-12B 34252
section
36" back inlet
NP-I-36B 22012 (41) NP-II-36B 22013 (41) NP-III-36B 22014 (41) RG-IV-36B 24096 (45) NP-V-36B 34257
section
6" pilot assembly
section includes
NP-I-6P 24874 (9) NP-II-6P 26670 (9) NP-III-6P 26671 (9) RG-IV-6P 24875 (10) NP-V-6P ---
built-in pilot & spark
ignitor
6" pilot assembly
section with built-in NP-I-6P 1020084 --- --- --- --- RG-IV-6P 1020085 --- ---
pilot only
m
CORPORATION
Page 5500-A/P-2 Series “NP” & “RG” AIRFLO® Line Burners
Assembly Numbers
Burner Type NP-I, NP-II, NP-III & NP-V RG-IV
Assembly Assembly
Description Designation Designation
Number Number
Plain End 1 piece end closure set NP-EC 36710 (4) --- ---
Closure Sets 2 piece end plate set NP-EP 20881 (3) RG-EP 21651 (4)
1 piece pilot set includes spark ignitor NPF- 1-1/4 -FR-SI 36712 (4) RGF- 1-1/4 - FR-SI 28365 (5)
End Inlet & 1 piece pilot set without spark ignitor NPF- 1-1/4 -FR 1063669 RGF- 1-1/4 - FR 1063671
Pilot Flange
Sets 2 piece pilot set includes spark ignitor NPF- 1-1/4 -FR-SI 20883 (3) RGF- 1-1/4 - FR-SI 21654 (4)
2 piece end inlet flange set NPF- 1-1/4 -EP 20882 (4) RGF- 1-1/4 - EP 21652 (5)
1 piece end closure set includes spark ignitor NP-ED-FR-SI 36711 (4) --- ---
1 piece end closure set w/out spark ignitor NP-ED-FR 1063668 --- ---
1 piece pilot set includes spark ignitor NP-ED-SI-3/4-UV 37004 (4) --- ---
Pilot End 1 piece pilot set without spark ignitor NP-ED-3/4-UV 1063670 --- ---
Plate Sets 2 piece pak-pilot set includes spark ignitor NP-PAK 23184 (3) RG-PAK 23183 (3)
2 piece pak-pilot set includes adjustable
NP-PAK 23185 (3) RG-PAK 23187 (3)
orifice & spark ignitor
2 piece pak-pilot set includes adjustable orifice,
NP-PAK 23186 (4) RG-PAK 23188 (4)
shut-off cock, tubing and spark ignitor
Flange to flange fastener kit 1053850 1053917
Fastener 1 piece end plate fastener kit 1053919 1053924
Kits 2 piece plain end plate fastener kit 1053920 1053925
2 piece pilot end plate fastener kit 1053921 1053926
Universal suppor t bracket (order in pairs) USB 23577(CS) / 39940(SS)
Rubber cover for flame rod or spark ignitor 18722
Flame rod (L = 7-1/8) 18117
Flame rod with rubber cover 1037597
Division plate 18133
Replacement
Profile plate bracket (NP) 20967
Items
Adjustable pilot gas orifice (3/8" NPT) 38009
External mounting plate (feed through) 40908
14mm spark ignitor 23739
Pilot gas adjustable orifice (for pak-pilots only) 38577
Gasket 1053686
mCORPORATION

Series “NP” & “RG” AIRFLO® Line Burners Page 5500-A/P-3
Assembly Numbers
Series NP/RG AIRFLO® Burners - aluminum bodies
NP-I-(AL) RG-IV-(AL)
Burner Type
#430 SS mixing plates #321 SS mixing plates
Configured Item Number NP1AL RG4AL
Assembly Assembly
Number Number
12" straight section NP-I-12 (AL) 45606 (9) RG-IV-12 (AL) 39800 (10)
6" straight section NP-I-6 (AL) 45605 (5) RG-IV-6 (AL) 39799 (5)
12" x 6" tee section NP-I-T (AL) 45608 (12) RG-IV-T (AL) 1034084 (13)
12" back inlet section NP-I-12B (AL) 45607 (13) RG-IV-12B (AL) 39801 (14)
36" back inlet section NP-I-36B (AL) 45609 (28) RG-IV-36B (AL) 1041513 (32)
Plain End
2 piece end plate set NP-EP 45612 [1] (3) RG-EP 51034 [1] (4)
Closure Sets
2 piece pak-pilot set includes spark ignitor NP-PAK 45610 [1] (3) RG-PAK 51029 [1] (3)
Pilot End
Plate Sets 2 piece pak-pilot includes adjustable orifice
NP-PAK 45611 [1] (3) RG-PAK 51032 [1] (3)
& spark ignitor
Flange to flange fastener kit 1053850 1053917
1 piece end plate fastener kit 1053919 1053924
Fastener Kits
2 piece plain end plate fastener kit 1053920 1053925
Universal suppor t bracket (order in pairs) USB 23577 (CS) / 39940 (SS)
Flame rod (L= 7.125) 18117
Flame rod & rubber cover 1037597
Replacement
Items
Pilot gas adjustable orifice (pak-pilots only) 38577
Gasket 1053686
[1] Electroless nickel plated

mCORPORATION
Page 5500-A/P-4 Series “NP” & “RG” AIRFLO® Line Burners
Assembly Numbers
Series NP/RG AIRFLO® Burners - aluminum bodies w/stainless steel fasteners and back up bars
NP-I-(ALSS) RG-IV-(ALSS)
Burner Type
#430 SS mixing plates #321 SS mixing plates
Configured Item Number NP1ALSS RG4ALSS
Assembly Assembly
Number Number
12" straight section NP-I-12 (AL) 1042278 RG-IV-12 (AL) 1042283
6" straight section NP-I-6 (AL) 1042277 RG-IV-6 (AL) 1042282
12" x 6" tee section NP-I-T (AL) 1042280 RG-IV-T (AL) 1042285
12" back inlet section NP-I-12B (AL) 1042279 RG-IV-12B (AL) 1042284
36" back inlet section NP-I-36B (AL) 1042281 RG-IV-36B (AL) 1042286
Plain End
2 piece end plate set NP-EP 45612 [1] (3) RG-EP 51034 [1] (4)
Closure Sets
2 piece pak-pilot set includes spark ignitor NP-PAK 45610 [1] (3) RG-PAK 51029 [1] (3)
Pilot End
Plate Sets 2 piece pak-pilot includes adjustable orifice
NP-PAK 45611 [1] (3) RG-PAK 51032 [1] (3)
& spark ignitor
Flange to flange fastener kits 1053851 1053918
Fastener Kits 2 piece plain end plate fastener kit 1053922 1053927
Universal suppor t bracket (order in pairs) USB 39940
Flame rod (L = 7.125) 18117
Flame rod & rubber cover 1037597
Replacement
Items
Pilot gas adjustable orifice (pak-pilots only) 38577
Gasket 1053686
[1] Electroless nickel plated
mCORPORATION

Bulletin 5550
Series NP-LE AIRFLO® Burners
• Designed for direct-fired make-up air and process applications
• Improved emissions performance over Maxon's standard NP AIRFLO® Burner, with

significantly lower levels of CO and NO2
• Higher capacity - up to 1,000,000 Btu/hr/ft
• Shorter flame length
• Easily meets ANSI/CSA standards
• Available in low pressure version and corrosion-resistant materials
mCORPORATION 201 East 18th Street, P.O. Box 2068, Muncie, Indiana, 47307-0068. Phone: (765) 284-3304. Fax (765) 286-8394
Page 5552
Specifications
Input Rating Up to 1,000,000 Btu/hr/ft
Airstream Profile Differential Pressure 0.3 to 1.0 "wc
Pilot Capacity 25,000 Btu/hr @ 4"-6" wc
Burner Turndown 30:1
Maximum Upstream Temperature 600°F cast iron; 450°F aluminum
Maximum Downstream Temperature 1000°F cast iron; 850°F aluminum
Maximum Temperature Rise 760°F
Minimum Upstream Oxygen 18% O2

NP1-LE Cast iron and aluminum
Burner Bodies
NP2-LE Cast iron
6" Straight
12" Straight
12" Straight with Back Inlet
Burner Section Configurations
6" x 12" Tee
6" x 6" Elbow (cast iron only)
36" Back Inlet (12" x 12" H-configuration)
Mixing Plates 430 Stainless Steel
NP1-LE:
- Standard - Cast Iron Body, Cast Iron End Plates
- AL - Aluminum Body, Cast Iron End Plates
Assembly Material Availability - ALSS - Aluminum Body & Back-up Bars, Nickle Plated End Plates, Stainless Steel Fasteners
NP2-LE:
- Standard - Cast Iron Body, Cast Iron End Plates
Spark Ignitor
UV Flame Scanner Connection
Flame Rod
Accessories
Adjustable Pilot Orifice
Division Plate
External Mounting Assemblies
CO Emissions Profile
NO2 Emissions Profile Nominal Conditions NP1-LE
Nominal Conditions CO vs. Temperature Rise
NP1-LE NO2 vs. Temperature Rise 5.0
0.70
4.5
0.60
4.0 Natural
NO2 ppm (as measured)
Gas
CO ppm (as measured)
Natural Gas
0.50 3.5 Propane
Propane
3.0
0.40
2.5
0.30 2.0
0.20 1.5
1.0
0.10
0.5
0.00 0.0
0 20 40 60 80 100 120 140 160 180 200 0 20 40 60 80 100 120 140 160 180 200
Temperature Rise (F) Temperature Rise (F)
Page 5553
Typical Applications for Maxon Series NP-LE

AIRFLO® Burners
Packaged Make-up Air Systems Packaged Make-up Air Systems

with 100% Outside Air with Partially Recirculated Air
NP-LE AIRFLO® Burner NP-LE AIRFLO® Burner
Fan Fan
Fresh
Air
Fresh
Air
Supply Supply Return

Air Air Air
Single-stage Burner Heated Paint Spray Humidity Controlled, 2-stage Burner

Booths with Re-heat Option Heated Paint Spray Booths
Air Intake Air Intake
Reheat
Preheat NP-LE AIRFLO® Burner Staged
NP-LE AIRFLO® Burner (If Required) NP-LE AIRFLO® Burner
Fan Fan
Bag Humidifier Supply Bag Humidifier Supply

Filters Air Filters Air
Drying, Baking & Curing Operations Grain Dryers
NP-LE AIRFLO® Burner

Filter Fan
Grain Bin
Fresh Hot Air
Air Chamber
Heated
Air NP-LE
AIRFLO® Burner

Filter
Fan
Fresh
Air Fan
Cooling
Heated Chamber Intake
Air
Air
Page 5554
System components normally used in conjunction with a Maxon NP-LE

AIRFLO® Burner application
Intake Louvers
Profile Plate
1
Duct Walls
2
4
3
10
Bl
oc
k&
Bl
ee
dM in
ain
s Tra
Ga
sT Ga
ot
rai
n Pil
7
Main
8 Volume
5 6 9
Fan
Legend:
Item
Description
Number
1 Outside ther mostat
2 Intake high temperature limit switch
3 Control valve
4 Vent valve
5 Strainer
6 Dr ip leg
7 Differential air switch
8 High temperature switch
9 Discharge air ther mostat
10 Sequencing Control Panel
m CORPORATION
1/01
201 East 18th Street, P.O. Box 2068, Muncie, Indiana, 47307-0068. Phone: (765) 284-3304. Fax (765) 286-8394
Series NP-LE AIRFLO® Burners Page 5555
Recommended Burner Capacities and Profile Dp

Air Velocity at Profile (SFPM)
1736 2005 2242 2456 2652 2836 3008 3170
1000
900
Heat Input (MBtu/hr/ft)
800
700
600
500
400 Natural Gas
Propane
300
200
0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
Profile Differential Pressure ("w.c)
k=1.6
Fuel Pressure Requirements
13
12
11
Differential Fuel Pressure ("w.c.)
10
9
8 Natural Gas - NP1-LE
7 Natural Gas - NP2-LE
6 Propane - NP1-LE
5 Propane- NP2-LE
4
3
2
1
0
0 100 200 300 400 500 600 700 800 900 1,000
12/01
Page 5556 Series NP-LE AIRFLO® Burners
NOx Emissions Profile

Profile Dp 0.7"w.c.
NP1-LE
140
120
NOx (ppmvd @ 3% O 2)
100
80
Natural Gas
60 Propane
40
20
0
0 100 200 300 400 500 600 700 800 900 1000
Heat Input (Mbtu/hr/ft)
CO Emissions Profile
Profile Dp 0.7" w.c.
NP1-LE
700
600
CO (ppmvd @ 3% O 2)
500
400
Natural Gas
300 Propane
200
100
0
0 100 200 300 400 500 600 700 800 900 1000
Heat Input (Mbtu/hr/ft)
Note: Emission performance is application specific and may vary.
NO2 Emissions Profile

Nominal Firing Rate
NP1-LE
0.70
0.60
NO2 ppm (as measured)
0.50
0.40
Natural Gas
Propane
0.30
0.20
0.10
0.00
0 20 40 60 80 100 120 140 160 180 200
Temperature Rise (F)
CO Em issions Profile
Nominal Operating Conditions
NP1-LE CO vs. T e mperature Rise
5.0
4.5
4.0
CO ppm (as measured)
3.5 Natural Gas

3.0 Propane
2.5
2.0
1.5
1.0
0.5
0.0
0 20 40 60 80 100 120 140 160 180 200
Te m pe ra ture Rise (F)
6/03
Flame Length
30
25
Flame Length (inches)
20
Profile ∆P
0.5"w .c.
15 0.7"w .c.
0.9"w .c
10
0
100 200 300 400 500 600 700 800 900 1,000
Pilot Capacities
Flow Pressure
Description Fuel
(SCFH) ("wc)
Natural
Cast Iron End Plate with 20-30 2-5
Gas
Fixed Orifice
Propane 8-12 1.4-3
Natural
LT End Plate Without Fixed 10-60 0.1-2
Gas
Orifice
Propane 4-24 0.1-1.0
Note: Excessive pilot fuel flow will lead to lighting difficulties and
ignitor failure.

Airstream velocity across and through your burner's mixing plates Figure 1: Profile Plate Positioning
must be kept uniform and within desired limits by use of a silhouette Edge of mixing plate
profile plate through which the burner fires. A 6" (minimum) profile
plate should be installed surrounding the interior duct walls. See 1.375" 1.375"
Figure 1 at right for specifications.
∆P x 144 x 2 x 32.2 x 3600
( ______________________ )
Profile Profile
Profile Design Velocity (SFPM)= Discharge Discharge
27.68 x 0.075 x 1.6
Example A Example B
Where ∆P = Profile Differential Pressure ("w.c.)
To determine profile opening areas, add burner displacement

areas (Ft2/section) from Table 1 (below) for your complete burner Note: Distance from end of the mixing plate to
assembly to "Net Free Area" of your duct: downstream edge of the profile should be 1.375"
Net Free Area of Duct (ft2) = Fan Volume (SCFM)/Design Velocity (SFPM)
Effective Burner Displacement (ft2) = Sum of Section Areas (per Table 1) – Effective Displacement Adjustment
Effective Displacement Adjustment (ft2) = Length of mixing plate adjacent to profile plate (inches) x 1.85/144
Example Calculation:
Mixing Eff. Displ. Adj. (ft2) = 2(24") x 1.85/144 = 0.6 (ft2)
Plate
Eff. Brnr. Displ. (ft2) = 2(1.8) – 0.6 = 3.0 (ft2)
24"
Profile Profile Area (ft2)

Opening = Table 1: NP1-LE & NP-2LE Burner
Net Free Area of Duct (ft2)
+ Displacement (ft2/section)
Effective Burner Displacement (ft2) Section Displacement (ft2) *
(2) 36" Back Inlet Sections
6" Straight 0.4
12" Straight 0.8
Various duct size/profile area relationships may give slightly
12" Back Inlet 0.8
different field site data than is shown in Table 2. Velocities should
always be confirmed and established by use of a velometer on 36" Back Inlet 1.8
actual field site installation. 12" x 6" Tee 0.9
Optimum design ranges for the various burner types are shown in 6" x 6" Elbow 0.7
the graphs on the preceding pages. Velocities (SFPM) are measured *Effective displacement is less when profiled as
with a velometer directly in the duct at the plane of the profile plate or recommended
can be calculated from profile differential pressure. Table 3: Inlet Feed Limitations
ρv2 (0.075 x V2 x 27.68) Burner > NP1-LE & NP2-LE
Profile Velocity Pressure (hv) = ______ = ______________________
2g (2 x 32.2 x 144 x 3600) equal to or
1-1/2" end inlet flange
less than 4 ft.
Profile Differential Pressure (∆P) = hv x k
equal to or
1-1/2" back inlets*
where V (SFPM) is velocity at profile opening. less than 5 ft.
k is resistance coef. of 1.6 for NP-LE. *Note: For 36 back inlet sections, not more than
6" off any one leg
Table 2: Velocity Factors (as measured with pitot tube K=1.0)
Desired velocity across burner at profile plate
1600 1800 2000 2200 2400 2600 2800 3000 3250 3500 3750 4000 4500 5000
opening (SFPM)
Approximate velocity pressure reading at
0.16 0.20 0.25 0.30 0.36 0.42 0.49 0.57 0.64 0.77 0.88 1.00 1.26 1.55
profile plate ("wc)
Approximate corresponding static pressure
0.26 0.32 0.40 0.48 0.58 0.67 0.78 0.91 1.02 1.23 1.41 1.60 2.02 2.48
drop across profile plate ("wc)
5/02
Dimensions
6" Straight 12" Straight 12" Back Inlet 18" Straight
12.0 6.0 12.0

6.0 12.0
1-1/2" NPT Inlet
24"
NP-LE End Profile 12.0 12.0
Straight
9.9
36" Back Inlet Section Tee Section Elbow Section
5.0 6.0 6.0 5.0 5.0 6.0 6.0 6.0
8.6 8.6
1.3
2.5
1-1/2" NPT Inlet
Dimensions
Plain Upper End Plate Pilot Upper End Plate
9.7
9.7
1" NPT 7.2

7.2 UV Scanner
Spark Flame Rod

Ignitor
1/4" NPT
Pilot Fuel/Air
2.7 2.7
2.5
1/8 NPT
1-1/2" NPT Fuel Press.
Test Conn.
3.8 3.8
Lower Fuel Inlet End Plate Plain Lower End Plate
Pilot 1" Angled Upper End Plate LT Pilot Upper End Plate
9.7 3.0
1/2" NPT
Flame Scanner
1" NPT Spark Ignitor 3.8
UV Scanner 7.2
Spark 1/4" NPT

Ignitor Pilot Fuel/Air
1/4" NPT
Pilot Fuel/Air
2.7
9/03
Dimensions
End Plate Assemblies
PLN PLN FI O/O FR PLN O/O FR FI
LT PLN LT PLN FI LT PILT PLN LT PILT FI
I/O FR PLN I/O FR FI 1" 15DEG PLN 1" 15DEG FI
PLN = Plain New Description Old Description

FI = Fuel Inlet PLN Plain EP
O = Outwardly extending flame rod. Away
PLN FI Upper Plain/Lower Fuel
from burner manifold.
I/O FR PLN Upper Pilot/ Lower Plain
I = Inwardly extending flame rod. Toward
burner manifold I/O FR FI Upper Pilot/Lower Fuel
FR = Flame rod
LT = Low temp applications
PILT = Pilot end plate
1" 15DEG = UV or FR port is 1" NPT angled 15
degrees toward burner manifold
Accessories/Replacement Items
Spark Ignitor Flame Rod
Adjustable Orifice Division Plate

1/4"
NPT 1.1 2.5
1/4"
NPT
0.90 2.4
1.3
1.2
3.2
3.8
4.6
Fixed Orifice (0.100")

Support Brackets
1/4" NPT
1/4" NPT
3.8
3/4"
hole
2.5
External Mounting Assembly

Frequently used to provide easy accessibility to spark ignitor and flame supervision components.
External Mounting Plate Used with typical pilot Opening Required

mounting of Spark
Ignitor and Flame Rod.
9/03
NP-1-LE
6
4
8 2
9
10
see
note
see below 17
7 note
5
below 11
1 see 7 1
5 note
below
1. See burner nameplate and indicate burner type.
2. Sketch burner arrangement (as viewed from casting side).
3. Specify replacement items required from diagrams above.
4. Specify quantity of each and assembly numbers from table below:
Item
Quantity Required for Indicated Section Part Description
No.
18" Str.
12" x 6" 6" x 6" 12" 36"
6" Str. 12" Str. 1050373 24" Str.
1 Tee Elbow B.I. B.I. Burner Body
1050373 1050376 + 1050376
1050387 1050389 1050385 1050390
1050376 Asby. No.
2 2 4 6 8 2 2 4 4 1049073 Mixing Plate
5 2 4 6 8 4 18049 Back Up Bar
6 2 2 4 1 2 2 4 1049071 Gasket/Shim (Metal)
7 4 20 24 48 18 20 20 48 1051567 M5 K-Nut Plated
8 12 12 24 6 12 12 24 1051583 M5 x 10 ISO 4017 Plated Hex Bolt
9 4 8 12 16 12 8 8 24 1051570 M5 x 45 ISO 4017 Plated Hex Bolt
10 2 2 4 1050679 Outside Corner Back Up Bar
11 4 2 8 1050672 Inside Corner Back Up Bar
NOTE: These items included with fastener kits. See pages 5567 & 5568 for fastener kit details.
NP-1-LE-AL
6
4
8 2
9
10
see
note
see below 17
7 note
5
below 11
1 see 7 1
5 note
below
Item
No.
12" x 6" 6" x 6" 12" 36"
6" Str. 12" Str.
1050375 1050384
1050388 --- 1050386 1050391 Asby. No.
2 2 4 2 4 4 1049073 Mixing Plate
3 2 4 1052004 Mixing Plate: Inside Corner
4 1049075 Mixing Plate: Wedge
5 2 4 4 18049 Back Up Bar
6 2 1 2 4 1049071 Gasket/Shim (Metal)
7 4 20 18 20 48 1051567 M5 K-Nut Plated
8 12 6 12 24 1051583 M5 x 10 ISO 4017 Plated Hex Bolt
9 4 8 12 8 24 1051570 M5 x 45 ISO 4017 Plated Hex Bolt
10 2 4 1050679 Outside Corner Back Up Bar
11 4 8 1050672 Inside Corner Back Up Bar
9/03
NP-1-LE-AL-SS
6
4
8
2
3
9
10
see see
note note
7 below
below 17
5
12 11
1
see 7 1
note
below
Item
No. Part Description
12" x 6" 6" x 6" 12" 36"
6" Str. 12" Str.
1050375 1050384
1050388 1050389 1050386 1050391 Asby. No.
2 2 4 2 4 4 1049073 Mixing Plate
5 2 4 4 45613 Back Up Bar (Aluminum)
6 2 1 2 4 1049071 Gasket/Shim (Metal)
7 4 20 18 20 48 1051566 M5 Nut Stainless Steel
8 12 6 12 24 54619 M5 x 10 ISO 4017 Hex Head Screw (Stainless Steel)
9 4 8 12 8 24 1051569 M5 x 45 Hex Head Screw Class A (Stainless Steel)
10 2 4 1050680 Outside Corner Back Up Bar (Aluminum)
11 4 8 1050673 Inside Corner Back Up Bar (Aluminum)
12 4 20 18 20 48 1051853 M5 Stainless Steel Lockwasher
NP-2-LE
6
4
8 2
9
10
see
note
see below 17
7 note
5
below 11
1 see 7 1
5 note
below
Item
No.
18" Str.
24" Str. 12" x 6" 6" x 6" 12" 36"
6" Str. 12" Str. 1051634
1 1051636 Tee Elbow B.I. B.I. Burner Body
1051634 1051636 +
(qty. 2) 1051640 1051644 1051638 1051642
1051636 Asby. No.
2 2 4 6 8 2 2 4 4 1049073 Mixing Plate
5 2 4 6 8 4 18049 Back Up Bar
6 2 2 4 1 2 2 4 1049071 Gasket/Shim (Metal)
7 4 20 24 40 18 20 20 48 1051567 M5 K-Nut Plated
9/03
Fastener Kits
Flange to Flange Fastener Kit
Shim
Gasket
M5 x 10
Hex Head Screw
M5 Nut
M5 Lock Washer
(SS only)
M10 x 1.5
Hex Nut
M10 x 40
Hex Head Screw M10 Lock Washer
Body Gasket
Assembly Numbers
Replacement Items
NP1LE NP1LEAL NP1LEALSS NP2LE
Flange to Flange Fastener Kit (includes gaskets) 1051879 1051879 1051880 1051879
Body Gasket 1050424 1050424 1050424 1050424
Metal Shim Gasket 1049071 1049071 1049071 1049071
Fastener Kits
End Plate to Flange Fastener Kit
End Plate
Gasket
Shim
Gasket
M5 x 20
(SS only)
M5 K-Nut
M10 x 1.5
Hex Nut
M10 Lock Washer
Body Gasket
Body Gasket
Assembly Numbers
Replacement Items
End Plate to Flange Fastener Kit (includes gaskets) 1051881 1051881 1051882 1051881
Body Gasket 1050424 1050424 1050424 1050424
Metal End Plate Gasket 1050423 1050423 1050423 1050423
LT Plain End Plate to Flange Fastener Kit 1057896 1057896 N/A 1057896
LT Pilot End Plate to Flange Fastener Kit 1057893 1057893 N/A 1057893
LT - Metal End Plate Gasket - Pilot 1056603 1056603 N/A 1056603
LT - Metal End Plate Gasket - Plain 1056604 1056604 N/A 1056604
9/03
Notes
Series NP-LE AIRFLO® Burners Page 5550-S-1
General Sketch 2 shows the burner suspended from a strap
iron frame using Maxon USB support brackets. Note
Important: Do not discard packing material until that rigid mounting is avoided by the bracket hole
all loose items are accounted for. which slips loosely over a bolt or steel rod attached to
the support. Gas piping would need independent
Avoid bending or damaging the steel mixing plates support.
of your Series NP-LE AIRFLO® Burner during Sketch 3 shows the burner assembly resting upon
uncrating and installation. angle iron brackets and not attached to them in any
These burners are used way. Be sure the angle iron supports allow the burner
for the heating of fresh air flanges to expand and contract. Gas manifolding
in motion. Mount the would be independently supported and prevent
burners so they fire parallel forward movement of the burner.
to and in the same direc-
tion as the movement of
the air (see sketch 1 at
right).
Velocity and flow of air
at operating temperature
must be uniform. Minimum
silhouette profile plates of
6" should be installed in
duct to completely surround burner assembly.
Supports
Series NP-LE AIRFLO® Burner assemblies must be
adequately supported and positioned.
Avoid rigid mounting. Burner assembly expands
and contracts with temperature variations.
Maintain smooth, even air flow over the burner by
designing supports to provide minimum interference, Sketch 4 shows simple strap iron used to support
deflection and turbulence. the burner. Note that narrow edge of strap faces air
The sketches below show typical installation and flow to avoid undue turbulence.
support methods: Sketch 5 shows gas manifolding used to support
Allow Space the burner. If there are
Strap Iron for Burner
Frame Expansion multiple inlets, you must
Maxon Air Air
Support Movement Movement avoid rigid connection by Angle
Iron
Brackets using the oversize U-bolt Support
(loosely drawn up) illustrated.
Support for down-fired
2
Rod
3 burners can be accomplished

Support
as shown in the illustration at Brackets
right. Always avoid rigid 3/4"
Hole
mounting.
Sketch 6 shows Maxon Air Air
USB support brackets Movement Movement
suspending the burner from

an overhead angle iron.
Sketch 7 shows an alter- 6
nate arrangement which
Bolt or Rod
Angle Iron
offers the advantage of more
Long enough to permit
controlled positioning.
m
Strap Iron Support
brackets to move with
Frame
burner expansion
CORPORATION
Page 5550-S-2 Series NP-LE AIRFLO® Burners

Gas Train tor and pilot solenoid valves. For pilot adjustment, a
See piping layout below to identify various typical fixed orifice, or adjustable orifice is recommended at or
system components. near the pilot gas inlet.
Pipe size of gas line must be large enough to Fuel shut-off valves, when properly wired to a
assure ample fuel pressure at maximum system safety control system, shuts the fuel supply off when a
capacity. Burner capacity is totally dependent on fuel hazardous operating condition is sensed by your
differential being maintained. (See capacity/specifica- control circuit. Manual reset valves require operator
tion data for the actual fuel pressure required at the attendence each time the system is started up (or
burner to achieve its rated capacity.) restarted after a trip-out). Motorized shut-off valves
Clean fuel lines are essential to prevent blockage permit automatic start/restart when used with appro-
of pipe train components or burner gas ports. All dirt, priate control system.
scale and pipe dope should be blown out of any gas Fuel control valve controls burner heat release by
line before actually connecting to the burner system. throttling gas flow to it. It should include provision for
Main shut-off cock should be upstream of both an adjustable minimum and throttling over a turndown
system regulator and pilot line take-off. Use it to shut range that matches burner capabilities. The illustra-
off fuel to both pilot and main burner during extended tion shows a Series "CV" Flow Control Valve; but
shutdown periods. Maxon Control Valves are not adjustable gradient SYNCHRO® and/or "Q" Flow
intended for tight shutoff. Main system shut-off should Control Valves may be used.
always be accomplished with a manual fuel cock. Gas pressure test connections are provided in
Main gas regulator is essential to maintain a most Series NP-LE Burner end plate sets, but it is
uniform system supply pressure. A separate regulator also helpful to provide an additional test connection in
should be provided in the branch leading to each the piping between main gas regulator and fuel
burner system if more than one is served by a com- control valve. All connections must be plugged unless
mon main. Size regulator for full system capacity at an actual pressure measuring device (gauge or
required pressure, including pipe train losses. manometer) is being used.
The gas train piping illustrated should be installed
as close to the burner as possible. Maxon assumes no responsibility for the use
Pilot take-off should be upsteam of main gas or misuse of the piping layouts shown.
regulator, but downstream of main gas cock. It Specific piping and wiring diagrams should
normally includes pilot shut-off cock, pilot gas regula- always be submitted to the appropriate
Strap Iron
Typical Piloted System
Frame
Support
Brackets
Air Air
Movement Movement
7
mCORPORATION

familiarize yourself with all the system's equipment
installed in accordance with the original manu-
facturer's current instructions.

6. To light and adjust gas pilot: Pilot gas regulator
should initially be set at 2-5” wc. With pilot gas
For initial system start-up: solenoid valves closed, open main fuel gas and
1. Close all burner fuel valves and/or cocks. Make pilot gas cock. Energize spark ignitor and open
preliminary adjustments to fuel regulators. pilot gas solenoid. Turn adjustable orifice screw
2. Check all electric circuitry. Verify that all safety out (counter-clockwise) several turns from its
devices and interlocks are operable and func- fully seated position or adjust regulator pressure
tioning within their respective settings/ranges. when fixed orifice is used. Observe pilot ignition
Be sure all manifolds are tight and that test ports through a sight port and/or by viewing micro-amp
are plugged if not being used. signal metered from flame safeguard relay circuit.
3. Check that all duct and chamber dampers are Refine pilot setting for a hard blue flame (and/or
properly positioned and locked into operating strongest micro-amp signal) by adjusting gas
positions. flow through pilot orifice and/or pilot regulator.
4. Start main volume air fan. Check for proper 7. Prepare to ignite main burner by adjusting main
motor rotation and impeller direction. Verify all gas regulator to approximately midpoint of its
safety interlocks are working. Allow air handling adjustment range. Linkage arrangement for the
equipment to run adequate purge of manifold use of Series "CV" Gas Control Valve is illus-
and combustion chamber plenums. Verify air trated above for a typical control motor. Arrange
volume and velocity across burner element to be accordingly.
within burner operating specifications. 8. With control valve at "minimum," ignite main
burner by opening main fuel shut-off valves.
CAUTION: Do not by-pass control panel timers Adjust main gas regulator to give the desired
typically controlling sequential operations. outlet pressure. Refine pilot adjustment if it has
been affected. Adjust burner "minimum" by
5. Disconnect the automatic control motor linkage turning in on the minimum stop screw of the gas
from your Maxon Control Valve by loosening the control valve until stable flame appears in the
control motor's connecting rod from the valve's narrow zipper channel at the base of burner
toggle linkage. Initial start-up adjustment should mixing plates.
only be accomplished during a "manual" control
mode. Manually set and secure control valve in
its "minimum" position.

m
CORPORATION

A good minimum fire should provide uniform remaining adjustment steps.
flame across the entire burner face, contained D. Without advancing the SYNCHRO® Valve
within the zipper flame channel at the base of quadrant, screw down on #2 screw (one or
burner mixing plates. Any thin spots or gaps two turns). Then slowly advance the
indicate uneven air velocity over the burner SYNCHRO® Valve quadrant to the #2
which must be corrected or a higher minimum position. Refine flame appearance at this
fire established by continuing to turn in on the new position #2.
minimum stop screw. (See drawing on page E. Turn all higher-numbered screws in at least
5550-S-2.) as far as the one just adjusted, then turn
NOTE: If your Maxon NP-LE AIRFLO® Burner next one in as necessary to achieve desired
was furnished with an adjustable gradient type flame while rotating valve mechanism to that
Series "Q" or SYNCHRO® Control Valve position on indicator strip.
instead of a Series "CV" Valve, refer to step F. Repeat for each remaining screw.
8A through 8I for specific instructions and NOTE: To avoid possible damage to cam
differences in adjustment procedures. strips, always turn all higher-numbered
For Series “CV” Valves, skip to step 9. screws in as far as the last one adjusted.
G. Refine adjustment as needed, always
Adj. Screws turning valve so that position indicator
(under cover)
matches screw being adjusted.
Handle for For more fuel, turn screw in (clockwise). for
Manual less fuel, turn screw out (counter-clockwise).
Operation
Position If screws must be turned in flush with carrier
Indicator casting, increase fuel pressure and readjust
Pointer by starting at minimum over again.
Locking Screw H. Cycle system off and on, and through all
for manual firing rates until satisfied with performance.
operation
I. Reconnect control motor linkage and check
that operator does not "bind" and that all
A. From step #5, the automatic control motor interlocks are performing properly.
linkage has already been disconnected from 9. Adjust burner "high fire" by slowly rotating fuel
your adjustable gradient type control valve control valve crank arm towards its maximum.
and the valve is at its "minimum" position. Observe flame characteristics carefully. Flame
B. Open fuel supply and begin adjustment of should remain a bright blue color with a length
appropriate adjustable gradient valve by beyond the mixing plates as indicated in capac-
turning in minimum (or lowest numbered) ity/specification data. If flame becomes long and
screw until desired flame is achieved. (Main yellow, gas pressure is too high and/or air
fuel regulator may need adjusted at this velocity is too low.
point.) NOTE: Dust and/or chemicals entrained into
C. Once your flame is established and refined passing air stream may effect physical color of
at this position, and without advancing the flame. In this case, adjust burner for stable flame
screw carrier quadrant higher, screw all shape and geometry.
remaining screws down to at least the same To measure gas pressure, connect water
level as your first adjusted screw. column (manometer) to the test connection in
NOTE: A preliminary setting can be estab- burner's end plate. To determine air velocity, use
lished with all the remaining adjusting a velometer at the profile opening. Correct
screws. Generally, each succeeding screw velocities by increasing or decreasing profile
needs to be screwed in approximately one opening size.
full turn deeper than its preceeding screw. A If flame is too short, gas pressure may be too
smooth "stair-step" gradient pre-set at this low and should be increased or velocities are
point from low to high will simplify the too high and may need to be decreased. Note
that air velocities should be measured only
m
when the fan is handling air at the desired
control temperature.
CORPORATION

The desired maximum capacity may be
achieved with less than full control valve open-
ing. Mark with a pencil or scribe the point on
valve crank arm where the desired maximum is
obtained, then return crank arm to low position
and shut system off.
10. If using Maxon Series “CV” Valve, reconnect
control motor linkage (with control motor in low
or minimum position) by loosening toggle clamp
screw 1 and moving toggle clamp 2 along the
connecting linkage to a point where toggle
clamp bolt 3 can be placed at the outermost
position of control motor crank slot. Then tighten
toggle clamp screw 1, thus fixing clamp to
linkage.
Allowing toggle clamp bolt 3 to slide in the crank
arm slot, cycle control motor towards its maxi-
mum position and move fuel control valve crank
4 to the previously-determined maximum firing
rate position. Tighten toggle clamp bolt 3, thus 11. Relight burner and cycle control system from
fixing clamp to motor crank. low to high fire several times to observe per-
Cycle control motor back to minimum, watching formance. Refine adjustments of pilot and main
carefully that it does not bind before reaching burner minimum if necessary.
minimum.
If it is stopped or if minimum is not reached, Warning: Test every UV Flame Sensor
loosen toggle clamp screw 1 and move toggle System for dangerous spark excitation from
clamp along the connecting linkage so both ignitors and other burners, as well as other
motor and valve can assume their minimum possible sources of direct or reflected UV
positions. Then retighten toggle clamp screw 1. radiation.
Refine adjustment by cycling several times
between low and high control motor position 12. Check carefully that all interlocks and limits are
while readjusting toggle clamp bolt 3 as neces- in full operating condition. Before system is
sary until control motor travels through its full placed into full service, instruct operator person-
cycle while moving control valve crank arm from nel on proper start-up, operation and shut-down
its minimum only up to the desired maximum of system. Establish written instructions for
previously determined. reference.

m
CORPORATION

NP-1-LE
6
4
8 2
9
10
see
note
see below 17
7 note
5
below 11
1 see 7 1
5 note
below
Item
No.
18" Str.
12" x 6" 6" x 6" 12" 36"
6" Str. 12" Str. 1050373 24" Str.
1050373 1050376 + 1050376
1050387 1050389 1050385 1050390
1050376 Asby. No.
2 2 4 6 8 2 2 4 4 1049073 Mixing Plate
5 2 4 6 8 4 18049 Back Up Bar
6 2 2 2 4 1 2 2 4 1049071 Gasket/Shim (Metal)
7 4 20 24 48 18 20 20 48 1051567 M5 K-Nut Plated
mCORPORATION


NP-1-LE-AL
6
4
8 2
9
10
see
note
see below 17
7 note
5
below 11
7
1 see 1
5 note
below
Item
No.
12" x 6" 6" x 6" 12" 36"
6" Str. 12" Str.
1050375 1050384
1050388 --- 1050386 1050391 Asby. No.
2 2 4 2 4 4 1049073 Mixing Plate
5 2 4 4 18049 Back Up Bar
6 2 2 1 2 4 1049071 Gasket/Shim (Metal)
7 4 20 18 20 48 1051567 M5 K-Nut Plated
8 12 6 12 24 1051583 M5 x 10 ISO 4017 Plated Hex Bolt
9 4 8 12 8 24 1051570 M5 x 45 ISO 4017 Plated Hex Bolt
10 2 4 1050679 Outside Corner Back Up Bar
11 4 8 1050672 Inside Corner Back Up Bar

m
CORPORATION

NP-1-LE-AL-SS
6
4
8
2
3
9
10
see see
note note
7 below
below 17
5
12 11
1 7
see 1
note
below
Item
No. Part Description
12" x 6" 6" x 6" 12" 36"
6" Str. 12" Str.
1050375 1050384
1050388 1050389 1050386 1050391 Asby. No.
2 2 4 2 4 4 1049073 Mixing Plate
5 2 4 4 45613 Back Up Bar (Aluminum)
6 2 2 1 2 4 1049071 Gasket/Shim (Metal)
7 4 20 18 20 48 1051566 M5 Nut Stainless Steel
8 12 6 12 24 54619 M5 x 10 ISO 4017 Hex Head Screw (Stainless Steel)
9 4 8 12 8 24 1051569 M5 x 45 Hex Head Screw Class A (Stainless Steel)
10 2 4 1050680 Outside Corner Back Up Bar (Aluminum)
11 4 8 1050673 Inside Corner Back Up Bar (Aluminum)
12 4 20 18 20 48 1051853 M5 Stainless Steel Lockwasher
mCORPORATION


NP-2-LE
6
4
8 2
9
10
see
note
see below 17
7 note
5
below 11
1 see 7 1
5 note
below
Item
No.
18" Str.
24" Str. 12" x 6" 6" x 6" 12" 36"
6" Str. 12" Str. 1051634
1 1051636 Tee Elbow B.I. B.I. Burner Body
1051634 1051636 +
(qty. 2) 1051640 1051644 1051638 1051642
1051636 Asby. No.
2 2 4 6 8 2 2 4 4 1049073 Mixing Plate
5 2 4 6 8 4 18049 Back Up Bar
6 2 2 2 4 1 2 2 4 1049071 Gasket/Shim (Metal)
7 4 20 24 40 18 20 20 48 1051567 M5 K-Nut Plated

m CORPORATION

Fastener Kits
End Plate Fastener Kit Body to Body Fastener Kit
End Plate
Gasket
Shim
Gasket
Shim
Gasket M5 x 10
Hex Head Screw
M5 Nut
M5 x 20
(SS only) M5 Lock Washer
(SS only)
M5 K-Nut
M10 x 1.5
Hex Nut
M10 x 1.5
Hex Nut
M10 Lock Washer
Body Gasket M10 x 40

Body Gasket Hex Head Screw M10 Lock Washer
Body Gasket
Assembly Numbers
Replacement Items
Flange to Flange Fastener Kit (includes gaskets) 1051879 1051879 1051880 1051879
End Plate to Flange Fastener Kit (includes gaskets) 1051881 1051881 1051882 1051881
Body Gasket 1050424 1050424 1050424 1050424
Metal End Plate Gasket 1050423 1050423 1050423 1050423
LT Plain End Plate to Flange Gasket Kit 1057896 1057896 N/A 1057896
LT Pilot End Plate to Flange Gasket Kit 1057893 1057893 N/A 1057893
LT - Metal End Plate Gasket - Pilot 1056603 1056603 N/A 1056603
LT - Metal End Plate Gasket - Plain 1056604 1056604 N/A 1056604
m CORPORATION

Periodic maintenance will insure continued trouble- visually that no holes in the mixing plates are
free operation of your Series NP-LE AIRFLO® Burner blocked. See next page (5550-S-12) for inspec-
system. tion and maintenance instructions for gas ports.
At least a yearly inspection is recommended for
make-up air heating installations and more frequently WARNING: Do not enlarge burner ports or
for process applications in year-round operation. Your
performance may be drastically affected.
own experience is the best guide in determining
frequency of inspection. As a minimum, the following If any mixing plates are loose or missing fasteners,
procedure should be followed: tighten/replace as necessary. Always use zinc plated
1. Shut the system down totally. Disconnect or lock or stainless metric fasteners.
out power supply so there can be no accidental 3. Put system back into operation and, if possible,
start-up during inspection. view from downstream side while cycling burner
2. Inspect the burners carefully, including upstream through full firing range. This will give a visual
and downstream sides of mixing plates as well as check for blocked burner ports.
burner body face. Any accumulation of scale or 4. Observe flame pattern and, if necessary, take
foreign material on either side of the mixing plates steps to correct velocity and/ or air distribution
should be removed with a wire brush. Check problems.
Repair / Replacement Procedures

If adverse operating conditions or accidental 3. Install new mixing plates, back up bars and plate
damage make it necessary to replace either individual support brackets to the new body castings.
mixing plates or complete burner sections, follow this 4. If end plate sets must be installed, put in position
procedure: between mixing plates and insert fasteners
1. Identify necessary replacement parts from loosely. Do not tighten at this time.
component identification drawings on preceding 5. Tighten burner body bolts making sure that
pages, then order required quantities of each. mating cast iron flanges remain square and flush.
Consider carefully the economics of installing a 6. Align mixing plates and check that body gaskets
complete replacement burner instead of replacing are in position and properly aligned. Tighten all
individual parts. Once exposed to actual flame mixing plate mounting screws and bolts.
temperatures, burner castings harden and the 7. Double check that all fasteners are secure.
removal and replacing of fasteners can be time 8. Return burner to operation, observing flame
consuming and difficult. Accessibility may also be carefully at all firing rates.
severely limited requiring removal of complete
assembly in any case.
2. When necessary parts have been received,
remove damaged mixing plates or burner sec-
tions, taking care not to damage remaining
portion of burner. If new burner bodies are being
installed, place body gasket on the mating
flanges of loose cast iron bodies. (This is neces-
sary to provide a gas-tight seal after assembly.)
Insert new section into place, making sure that
both flanges are square and flush, then bolt
sections together.

mCORPORATION
Inspection and Maintenance of Gas Ports

– Conduct initial inspection within the first month – Use of an electric drill motor is not suggested
after commissioning. Visually check the gas ports unless both Pin Vise and Drill (as shown below)
of new burner assemblies for any piping scale or can be chucked up in a vari-speed drill unit. Use
debris. Use Pin Vise with drill bit to remove. caution, because it is easy to snap the bits off in a
– Annual inspections are normally adequate once port when using a drill motor. Removal of broken
the initial piping debris is removed. The operating bits from the gas ports is difficult.
conditions of the burner will determine how – Contact your Maxon representative to answer
frequently maintenance is actually required. questions or address any problems.
Pin Vise
NP-LE AIRFLO®
Burner Body 1 inch
(Mixing Plates Not Shown)
Gas Ports
All are #43 Drill Size
(Exception is several #47
holes at the intersection of #47
12x6 tee's and 36 BI's) Holes #43
Here Holes
36" BI Sections 12" x 6" All Straight Sections

Tee Sections 6", 12", 18" & 24"
mCORPORATION

Series NP-LE AIRFLO® Burners Page 5550-A/P-1
Assembly Numbers
Series NP-LE AIRFLO® Burners

NP-1-LE
NP-1-LE NP-1-LE NP-2-LE
Aluminum body & back-up bars,
Burner Type Cast iron body, Aluminum body, Cast iron body,
nickle plated end plates,
cast iron end plates cast iron end plates cast iron end plates
stainless steel fasteners
Configured Item
Number
Assembly Assembly Assembly Assembly
Description Designation Designation Designation Designation
Number Number Number Number
6" straight section NP-I-LE-6 1051617 NP-I-LE-6 AL 1051650 NP-I-LE-6 AL W/SS 1051662 NP-II-LE-6 1051969
12" straight section NP-I-LE-12 1051616 NP-I-LE-12 AL 1051649 NP-I-LE-12 AL W/SS 1051661 NP-II-LE-12 1051968
18" straight section NP-I-LE-18 1051618 --- --- --- --- NP-II-LE-18 1052487
24" straight section NP-I-LE-24 1051619 --- --- --- --- NP-II-LE-24 1052488
6" x 6" elbow section NP-I-LE-L 1051620 ---- --- --- --- NP-II-LE-L 1051970
12" x 6" tee section NP-I-LE-T 1051621 NP-I-LE-T AL 1051651 NP-I-LE-T AL W/SS 1051663 NP-II-LE-T 1051971
12" back inlet section NP-I-LE-12B 1051622 NP-I-LE-12B AL 1051652 NP-I-LE-12B AL W/SS 1051664 NP-II-LE-12B 1051972
36" back inlet section NP-I-LE-36B 1051623 NP-I-LE-36B AL 1051653 NP-I-LE-36B AL W/SS 1051665 NP-II-LE-36B 1051973
Assembly Numbers
Description
Plain end plate 1052060 1052060 1052067 1052060
End Plate Upper pilot, lower plain end plate 1052057 1052057 1052064 1052057
Sets Upper pilot, lower fuel inlet end plate 1052058 1052058 1052065 1052058
Upper plain, lower fuel inlet end plate 1052059 1052059 1052066 1052059
with rubber cover 1052109 1052109 1052109 1052109
Spark ignitor without rubber cover 23739 23739 23739 23739
LT version 18075 18075 --- 18075
with rubber cover 1037597 1037597 1037597 1037597
Flame rod
without rubber cover 18117 18117 18117 18117
Adjustable orifice 38577 38577 38577 38577
Universal suppor t bracket (CS) 23577 23577 --- 23577
Replacement
Universal suppor t bracket (SS) 39940 39940 39940 39940
Items
Division plate 1049076 1049076 1049076 1049076
Flange to flange fastener kit (includes gaskets) 1051879 1051879 1051880 1051879
End plate to flange fastener kit (includes gaskets) 1051881 1051881 1051882 1051881
External mounting assembly 40908 40908 40908 40908
Body gasket 1050424 1050424 1050424 1050424
Metal shim gasket 1049071 1049071 1049071 1049071
Metal end plate gasket 1050423 1050423 1050423 1050423

m CORPORATION
Bulletin 5600
Maxon CROSSFIRE® Line Burner
• Operational flexibility
- High moisture air streams
- Low O2 air streams
- Highly inert air streams
- Parallel velocities up to 4000 fpm, cross velocities up to 3000 fpm
• Extremely low emissions - NOx levels of 25 ppm and CO levels of 250 ppm at 3% O2 are
possible. Contact your Maxon sales representative about your specific application.
• Temperature uniformity to enhance product quality
• Up to 25:1 turndown for process flexibility
• High firing capacity - up to 2,500,000 Btu/hr/ft (732 kW/ft)
• Nozzle-mixing line burner for use with low pressure natural gas firing
• Also available in stainless steel housings and nickel-plated body versions
Page 5602
Maxon CROSSFIRE® Line Burner

Design and Application Details Principle of Operation
Maxon CROSSFIRE® Burners are nozzle-mixing, The design of the CROSSFIRE® burner allows for
modular line burners designed for a variety of fresh and extremely low emissions of both NOx and CO.
recirculated air process heating applications. The Impingement of a series of jets containing a
burner is available in a variety of arrangements, substantially homogeneous mixture of fuel and air
including straight, grid and ladder sections. An creates stability and extremely short flame lengths.
external blower supplies combustion air. The high excess air translates into low NOx levels.
The CROSSFIRE® Burner is primarily used for in- The inherently stable design allows operation of the
duct firing. The CROSSFIRE® Burner can be designed burner in a fuel lean condition without creating high
within a system to allow for up to 2,500,000 Btu/hr/ft levels of CO.
(732 kW/ft). The maximum fuel pressures and air The burner performs optimally at a specific fuel/air
pressures required for varying maximum firing loads ratio throughout the firing range. Deviation from the
are described in the table below. optimum fuel/air ratio will result in trade-off between
NOx and CO emissions. For example, a fuel lean
setting (in reference to optimum fuel/air ratio) will result
Test Connection Pressures in lower NOx emissions but higher CO emissions.
Required Air Required Fuel Conversely, a fuel rich setting, again in reference to
Maximum Capacity
Pressure Pressure
MMBtu/hr/ft
(inches w.c.)* (inches w.c.)*
the optimum fuel/air ratio, will result in higher NOx
emissions with lower CO levels.
1.00 2.9 7.4
The fuel/air ratio is controlled by a Maxon MICRO-
1.25 4.5 11.4 ®
RATIO Valve throughout the operating range. The
®
1.50 6.2 16.4 MICRO-RATIO Valve allows for a variable fuel ramp
1.75 8.2 22.1 corresponding to the chosen maximum lineal firing
®
2.00 10.5 28.8 duty. The MICRO-RATIO Valve is sized according to
2.25 12.9 36.3 the fuel and air flow requirements for the entire
®
2.50 15.7 44.8 combustion system. For MICRO-RATIO Valve sizing
*Differential pressures measured at test connection. Air and gas information, see Sections 7000 and 7100 of the Maxon
DP is differential over system static pressure. product catalog.
For optimum performance and emissions control in
Test Connection Pressures (metric) applications with variable process flow, use Maxon's
Required Air Required Fuel SMARTFIRE™ Intelligent Combustion Control System.
Maximum Capacity See Maxon catalog section 7200 for more details.
Pressure Pressure
kW/ft
(mbar)* (mbar)*
300 7.2 18.4
375 11.2 28.4
450 15.4 40.9
525 20.4 55.0
600 26.2 71.7
660 32.1 90.4
732 39.1 111.6
*Differential pressures measured at test connection. Air and gas
DP is differential over system static pressure.
5/03
CROSSFIRE® Line Burner Page 5603
Performance Data
Lineal heat release at high fire Btu/hr/ft 1,000,000 1,250,000 1,500,000 1,750,000 2,000,000 2,250,000 2,500,000
Minimum lineal heat release Btu/hr/ft 100,000 100,000 100,000 100,000 100,000 100,000 100,000
Turndown ratio 10:1 12.5:1 15:1 17.5:1 20:1 22.5:1 25:1
Flame length inches [1] 12 16 20 24 28 32 36
Pilot pressure/heat release "w.c.* [2] / Btu/hr 5-8" w.c. / 40,000 Btu/hr
Combustion air flow SCFM 283 344 400 455 510 562 617
Air pressure at burner inlet ("w.c.) [3] 3.1 4.8 6.6 8.7 11.1 13.7 16.7
Air pressure at burner test
("w.c.)* 2.9 4.5 6.2 8.2 10.5 12.9 15.7
connection
Fuel pressure at burner inlet
("w.c. ) [3] 8.0 12.3 17.7 23.9 31.1 39.2 48.4
(natural gas)
Fuel pressure at burner test
("w.c.)* 7.4 11.4 16.4 22.1 28.8 36.3 44.8
connection (natural gas)
NOx emissions [4] ppm @ 3% O2 <25 ppm corrected to 3% O2 dry
CO emissions [4] ppm @ 3% O2 <250 ppm corrected to 3% O2 dry
[1] Flame lengths listed are at 50% excess air.
[2] At inlet of adjustable pilot orifice.
[3] Air and gas ÆP is differential over system static pressure.
[4] Emissions stated are not guaranteed. Actual emission performance may var y. Contact Maxon for specific application details.
*Differential pressures measured at burner test connections. Air and gas ÆP is differential over system static pressure.
Operating Environment The burner can operate in a variety of environ-

ments. Typical operating environments, limits on their
Variable Minimum Maximum
variables, and notes concerning operation of the
Inlet Combustion Air Temp. °F Ambient 400 burner are presented at left.
Inlet Combustion Air O2 Level % O2 20.8 20.8 It is important to note that inlet combustion vari-
Air Stream Cross Velocity ft/min 0 3000 ables such as O2 level and combustion air tempera-
Air Stream Axial Velocity ft/min 0 4000 ture will change air pressure requirements and/or
Upstream Air Temperature °F See Char t
maximum firing capacity.
Downstream Air Temperature °F Below
Process Air Stream O2 Level % O2 4 21
°F Temperature Operating Envelope

1350
Downstream Temperature
Consult
Maxon
1200
1025
Operating Envelope
850
100 250 500 750 °F
Upstream Temperature
Consult Maxon for operation in shaded region. Ability to operate in
shaded region is dependent upon operating conditions.
10/02
Page 5604 CROSSFIRE® Line Burner

Natural Gas Fuel/Air Settings
46
44
42
40
38
s
36
34 Lower CO
32
30
28
26
t
24
22 Lower NOx
20
18
16
14
12
10
8
6
4
2
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Differential Air Pressure ("w.c.)
NOTE: Pressure measured at burner test connections; refer to inlet pressure requirements for fan sizing
Propane Fuel/Air Settings

20
19 2 .50 M M B t u/hr /f t
18
17
16
15
s
2 .2 5 M M B t u/hr /f t
14 Lower CO
13
12 2 .0 M M B t u/hr /f t
11
t
10
9 Lower NOx 1.75 M M B t u/hr /f t
8
7 1.50 M M B t u/hr /f t
6
5 1.2 5 M M B t u/hr /f t
4
3 1.0 0 M M B t u/hr /f t
2
1
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Differential Air Pressure ("w.c.)
NOTE: Pressure measured at burner test connections; refer to inlet pressure requirements for fan sizing

Side View
(back inlet section shown)
13.35
16.6
17.8
3.2
4.6
Coupling required
for ISO connection
Bottom View Coupling required

for ISO connection 4.34
end inlet section
1-1/2 NPT Pipe

Fuel Inlet
10.8 mm dia.
Combustion Air Inlet Lifting Lugs
.5 ft. burner = 4" dia. Qty. specified on order
1 ft. & 1.5 ft. burners - 6" dia.
Bottom view Bottom view

back inlet section w/round air inlet back inlet section w/retangular air inlet
9.0 (Typ.) 6.0 9.0
3.45
6.5 6.9
10.8 mm dia. Gas Inlet Combustion 7.5

Gas Inlet 1-1/2" NPT
1-1/2" NPT Combustion Lifting Lugs Air Inlet
Air Inlet Qty. specified per order
8" dia.
Pilot End View

6.9 6.9 6.9
1.1 1.1 1.1
UV Scanner 4.3
3/4" NPT 5.9
6.4
Spark Ignitor
14mm 7.6
11.3
Gas Test
Connection 13.4
1/8" NPT
16.3 16.3
Pilot Fuel/Air
1/2" NPT 19.4
Combustion Air
Test Connection
1/8" NPT
Round air inlet Rectangular air inlet

4" & 6" dia. 6.5" W x 7.5" H
Round air inlet
8" dia.
10/02

Straight Burner Sections
.5 ft. burner - end inlet 1 ft. burner - end inlet 1.5 ft. burner - end inlet
4.2 4.2
2.8 8.9 2.8 14.9 4.2 20.9
6.2 12.2 2.8 18.2
3.1 6.1 9.1
3.6 3.6 3.6
7.2 7.2 7.2
2 ft. burner - back inlet 3 ft. burner - back inlet

26.9 38.9
24.2 36.2
12.1 18.1
9.0 9.0
3.6 3.6
7.2 7.2
4 ft. burner - back inlet

50.9
48.2
24.1
9.0 9.0
3.6
7.2

62.9
60.2
18.1 24.0
9.0 9.0
3.6
7.2

74.9
72.2
18.1 36.0
9.0 9.0
3.6
7.2

Straight Burner Sections

86.9
84.2
24.1 36.0
9.0 15.0 9.0
3.6
7.2

98.9
96.2
24.1 48.0
9.0 21.0 9.0
3.6
7.2

110.9
108.2
24.1 60.0
9.0 27.0 9.0
3.6
7.2
10/02

2 ft. back inlet grid sections
26.9 26.9
24.2 24.2
12.1
12.1
24.9
11.7 18.9 17.7
9.0
9.0
2 BI XF GRD with 12" span
26.9 26.9
24.2 24.2
12.1 12.1
11.9 36.9
14.9
23.7 30.9
29.7
9.0
9.0
26.9
24.2 26.9
24.2
12.1 12.1
54.9
17.9
23.9
35.7
9.0 47.7
42.9
9.0
9.0

9.0

38.9
38.9
36.2 36.2
18.1 18.1
11.9 18.9 24.9

17.7
9.0
9.0
3 BI XF GRD with 12" span 3 BI XF GRD with 18" span
38.9
36.2 38.9
36.2
18.1 18.1
30.9 36.9
11.9 14.9
23.7
29.7
9.0
9.0
38.9
36.2 38.9
36.2
18.1 18.1
54.9
42.9
17.9 23.9
35.7
9.0 47.7
9.0
9.0
3 BI XF GRD with 36" span 9.0

10/02

50.9 50.9
48.2 48.2
24.1
24.1
24.9
11.7 18.9
17.7
9.0

50.9 50.9
48.2 48.2
24.1 24.1
36.9
11.9 30.9 14.9
23.7 29.7
9.0
9.0
50.9
50.9
48.2
48.2
24.1 24.1
42.9 54.9
17.9
23.9
35.7
9.0 47.7
9.0
9.0

9.0


62.9
62.9
60.2
60.2
18.1
18.1
24.9
18.9
11.7 17.7
9.0 24.0 9.0 24.0
62.9 62.9
60.2 60.2
18.1 18.1
30.9
11.9 14.9 36.9
23.7 29.7
9.0 24.0
9.0 24.0
62.9 62.9
60.2
60.2
18.1 18.1
54.9
17.9 42.9 23.9
35.7
9.0 47.7
9.0
9.0 24.0
5 BI XF GRD with 36" span 9.0 24.0
10/02

74.9 74.9
72.2 72.2
18.1 18.1
18.9 24.9
11.7 17.7
9.0
36.0 9.0
36.0
74.9
74.9 72.2
72.2 18.1
18.1
36.9
14.9
11.9 30.9
29.7
23.7
9.0 9.0
36.0 36.0
74.9 74.9
72.2 72.2
18.1
18.1
42.9 54.9
17.9 23.9
35.7 47.7
9.0 9.0
9.0
36.0
9.0


86.9
86.9
84.2 84.2
24.1
24.1
24.9
18.9
11.7 17.7
9.0
9.0
36.0 36.0
86.9 86.9
84.2 84.2
24.1 24.1
30.9 36.9
11.9 14.9
23.7
29.7
9.0
36.0 9.0
36.0
86.9
86.9
84.2
84.2
24.1 24.1
17.9 42.9 23.9

54.9
35.7
9.0 47.7
9.0
9.0
36.0
9.0
36.0
10/02

98.9
98.9
96.2
96.2
24.1
24.1
24.9
18.9 17.7
11.7
9.0 9.0
48.0 48.0
98.9
98.9
96.2 96.2
24.1
24.1
30.9 14.9 36.9

11.9
23.7 29.7
9.0
48.0 9.0
48.0
98.9
98.9
96.2 96.2
24.1 24.1
54.9
17.9 23.9
35.7 47.7
9.0 9.0
42.9
9.0
48.0
9.0


110.9
110.9
108.2
108.2
18.1
18.1
18.9 17.7
11.7 24.9
9.0 9.0
36.0
36.0
72.0 72.0
110.9 110.9
108.2 108.2
18.1
18.1
11.9 14.9
23.7 29.7
30.9
36.9
9.0
36.0 9.0
36.0
72.0
72.0
110.9 110.9
108.2 108.2
18.1
18.1
17.9 23.9
35.7 47.7
9.0 9.0
42.9
54.9
9.0
36.0
9.0
72.0 36.0
72.0
10/02

Horizontal spacing of CROSSFIRE® ladders
62.9
48.0 7.5 typ.
4 ft. CROSSFIRE® Ladder
9.0 9.0
74.9
60.0 7.5 typ.
9.0 9.0
86.9
36.0 36.0 7.5 typ.
15.0 15.0
98.9
42.0 42.0 7.5 typ.

15.0 15.0
33.0 33.0
110.9
48.0 48.0 7.5 typ.
15.0 15.0
39.0 39.0
122.9
54.0 54.0 7.5 typ.
15.0 15.0
45.0 45.0

Vertical spacing of CROSSFIRE® ladders
Cross Member Dim. A Dim. B

Designation Description (inches) (inches)
Dim. A
112 Qty. 1 - 12" spacing 12 24
Dim. B
118 Qty. 1 - 18" spacing 18 36
124 Qty. 1 - 24" spacing 24 48
130 Qty. 1 - 30" spacing 30 60

Dim. A
212 Qty. 2 - 12" spacing 12 36
218 Qty. 2 - 18" spacing 18 54
Dim. B
224 Qty. 2 - 24" spacing 24 72
230 Qty. 2 - 30" spacing 30 90

Dim. A
312 Qty. 3 - 12" spacing 12 48
318 Qty. 3 - 18" spacing 18 72
324 Qty. 3 - 24" spacing 24 96
Dim. B 330 Qty. 3 - 30" spacing 30 120

Dim. A
412 Qty. 4 - 12" spacing 12 60
418 Qty. 4 - 18" spacing 18 90
424 Qty. 4 - 24" spacing 24 120
430 Qty. 4 - 30" spacing 30 150
Dim. B
See page 5616 for horizontal spacing of

CROSSFIRE® ladders
10/02
Notes
CROSSFIRE® Line Burner Page 5600-S-1
Please read all installation and start-up and air may be required in some environments to
instructions prior to working with the burner. A prevent plugging of gas and/or air ports.
view port providing a clear view of the entire flame is For CROSSFIRE® Burner assemblies four feet
strongly recommended. and over in length, multiple gas and air inlets are
Do not discard packing material until all parts utilized to ensure uniform distribution. As with all
have been identified. (Some parts are shipped loose combustion systems, proper manifolding practices
with the burner.) must be sufficient to feed each air and gas inlet with
equal flow. However, it is further recommended that
The burner accounts for a portion of the total
balancing dampers and air pressure taps be installed
combustion system (see typical piping
within each branch of the air manifold to facilitate
schematic below). The sizing and installation
equal distribution of the combustion air flow to each
instructions for other components such as
air inlet.
valves, control motors, blowers, regulators,
The pilot/ignition system requires air to be fed
switches, etc. can be found in the
from the combustion air piping (upstream of the
corresponding sections of the Maxon Catalog.
MICRO-RATIO® Valve) to the pilot gas mixer as
The CROSSFIRE® Burner requires an external shown in the piping schematic.
blower to supply combustion air. The combustion The burner may be mounted horizontally or
fan should not be positioned where inert gases could vertically within a duct. Additional support is
be drawn into the combustion air intake. Electrical required to support the weight of the burner and gas
service must match the voltage, phase, and cycle of piping. Care should be taken not to introduce any
the combustion fan as well as all other electrical additional stresses on the gas inlet(s) at the burner.
system components. Furthermore, burner and gas piping support should be
Gas and air are piped separately into the burner designed for thermal expansion.
assembly. The gas piping and air ducting should be Once the burner is installed within the duct, the
sufficiently large enough to flow the maximum ignitor and UV scanner tube can be installed.
capacity at the rated pressures. Filters for both fuel Separate conduit should be used for the wiring of the
scanner and ignitor.
Typical CROSSFIRE® Burner piping layout
Vent to Safe Location
Main Shut Maxon
Off Valve
Pilot Adj. Fuel
Blocking Pilot Adj. Air

Gas Pilot Pilot Valve
Inlet Regulator Solenoid Burner
Valves Maxon Maxon Pilot
Inlet
Air Pressure
Switch
Strainer
Burner
Gas Inlet
Burner
Combustion Air Manifold
Combustion
MICRO-RATIO Air Inlet
Valve
Oven
Low Gas High Gas Wall
MAXON Pressure Pressure
Switch Switch
*Air pressure switch located upstream of MRV. Locating switch downstream of MRV will
result in higher air flow than required by the burner at minimum.
Maxon assumes no responsibility for the use or misuse of the piping layout shown.
Specific piping and wiring diagrams should always be sumitted to the appropriate

m
CORPORATION
Page 5600-S-2 CROSSFIRE® Line Burner
The spark ignitor assembly utilized by
CROSSFIRE® Burners is designed to be fed through Caution:
the wall of the duct. Replacement of the ignitor is • Burner assembly and fuel piping must be
easily accomplished from outside of the duct. properly supported.
To initially install the ignitor, first carefully • Avoid external loads to fuel inlet(s).
remove the internal sub-assemblies and set aside.
Insert the outer tube through the opening in the duct • Do not overtighten fuel piping to burner
wall and thread into the pilot end plate. (Access connection.
covers and seal plates are available from Maxon to • Use back-up wrench when tightening inlet
facilitate installation.) piping.
• Flexible connection recommended to allow
UV scanner installation: for expansion.
A UV magnifying lens enhances pilot flame signal
and is recommended for scanner tube lengths greater • Do not lift burner assembly from fuel
than 24". inlet(s).
Optional Seal Plate Kit (shipped loose) Flame Scanner (not included)
Spark Ignitor (not included)
Fuel Pressure Tap (not included)

Pilot Fuel/Air (not included)
O-Rings Mounting Plate
Cover Plate
m CORPORATION

CROSSFIRE® Line Burner Page 5600-S-3
For initial start-up of Maxon CROSSFIRE® 7. Set burner to low fire position. Main combus-
Burner: tion air blower should be on.
8. Open manual and pilot gas cocks, activate
1. Close all burner fuel valves and cocks. Make spark ignition transformer and pilot gas
preliminary adjustment to the fuel gas regulators. solenoid valve, then attempt pilot ignition. If
Remove pilot and main gas regulators’ adjusting necessary, slowly increase pilot flow through
screw covers. Turn adjusting screw down (clock- adjustment of pilot regulator or pilot gas cock.
wise) to approximately mid-position. Close pilot Repetition of this procedure may be necessary as
gas adjustable orifice screw by turning clockwise ignition will occur only when air trapped in the
until it stops. (Do not over-tighten.) Then back pilot line has been bled. Adjust pilot gas pressure
out the adjustable orifice (counter-clockwise) 2-3 as specified.
turns. 9. After ignition, slowly open pilot bleed air to
2. Check all electrical circuitry. Verify that all shorten pilot flame. The pilot is not designed to
control devices and interlocks are operable and be a full premix pilot. The pilot bleed air will
functioning within their respective settings/ranges. prevent soot formation on spark electrode.
Be sure all air and gas manifolds are tight and 10. Shut off pilot gas flow and re-ignite several
that test ports are plugged if not in use. times (bleed air should be left in the open posi-
3. Check that air and gas pressure switches are tion). The flame safeguard relays should now
not marginally set. Set pressure switches with a power main fuel shut-off valves.
large enough range to prevent system shutdown 11. Light the CROSSFIRE® Burner. With pilot flame
during initial adjustment. During final system established and flame supervision operational,
tuning, the pressure switches should be re- opening the main fuel shut-off valve will allow fuel
adjusted. flow to the burner.
4. Disconnect the automatic control motor 12. Turn minimum adjusting screw on the MICRO-
linkage from the MICRO-RATIO® Valve. Initial RATIO® Valve “in” (clockwise) to increase gas
start-up should only be accomplished in a manual flow at minimum until burner ignites. Flame will
burner control mode. be blue at the base with yellow tips. Flame
5. Start all system related fans and blowers. should be continuous along its length.
Check for proper rotation of motors and impellers. 13. Adjust main regulator to maintain required
Verify that all control interlocks are operating. differential gas pressure. Re-adjust minimum
Allow air handling equipment to adequately purge adjusting screw.
combustion chamber. For an application with 14. If pilot is interrupted as recommended, turn off
variable process flow, set process flow to maxi- pilot and verify that flame supervision is opera-
mum. tional.
CAUTION: Do not bypass control panel timers 15. Progressively work your way up through each
or interlocks typically controlling sequential adjusting screw position as per Maxon catalog
operations. sections 7000 and 7100. Above minimum firing
rate, flame will transition to light blue in color. A
6. Refer to CROSSFIRE® Fuel/Air Settings graph flame that is too lean will exhibit voids along its
(on page 5604) to obtain maximum and minimum length. Adjust the flame at each adjusting screw
air and fuel pressure settings for the system’s so that it is as short as possible, light blue in
maximum heat release (up to 2,500,000 Btu/hr/ft). color, and without voids in the flame. Dust in the
Preliminarily set the stroke of the air and fuel combustion air stream or process stream may
valves in accordance with Maxon catalog sections cause yellow “sparklers”. The air and gas pres-
7000 and 7100. For maximum control, ensure that sures should be close to those presented in the
the fuel valve quadrant has a full stroke of 90°. Fuel/Air Settings chart. If high temperature limit
trips prior to completion of adjustment, cycle back
to low fire and allow the unit to cool before
continuing the adjustment process.

mCORPORATION
Page 5600-S-4 CROSSFIRE® Line Burner
Test Connection Pressures Operating Tips:
Required Air Required Fuel The minimum firing rate attainable is dependent
Maximum Capacity
Pressure Pressure
MMBtu/hr/ft
(inches w.c.)* (inches w.c.)* upon low firing rate control. Size the MICRO-RATIO®
Valve, both air and fuel valves, with at least 1-3 inches
1.00 2.9 7.4
w.c. pressure drop. Use the full stroke of both valves,
1.25 4.5 11.4
if possible. A butterfly disc or gate valve installed
1.50 6.2 16.4
upstream of the combustion air blower intake and/or
1.75 8.2 22.1 downstream of the combustion air outlet (prior to
2.00 10.5 28.8 MICRO-RATIO® Valve) will enable full stroke of the air
2.25 12.9 36.3 butterfly.
2.50 15.7 44.8 At minimum firing rate, only the tips of the flame
*Differential pressures measured at burner inlet. Air and gas DP is should be yellow. The base of the flame should still
differential over system static pressure. be light blue in color. Readjustment of the minimum
air setting and/or minimum MICRO-RATIO® Valve
Test Connection Pressures (metric) adjusting screw may be necessary. A flame that is
Required Air Required Fuel yellow at the base of the flame is deficient of air and
Maximum Capacity
kW/ft
Pressure Pressure may form soot on the face of the burner.
(mbar)* (mbar)* Variable process flow with greater than 4 inches
300 7.2 18.4 w.c. pressure swing will significantly affect the fuel/air
375 11.2 28.4 ratio of the flame and, subsequently, emissions.
450 15.4 40.9 Check burner operation from minimum to maximum
525 20.4 55.0 firing rates and at minimum and maximum process
600 26.2 71.7 flow to ensure proper flame at all operating condi-
660 32.1 90.4
tions.
For optimum performance and emissions control in
732 39.1 111.6
applications with variable process flow, use Maxon’s
*Differential pressures measured at burner inlet. Air and gas DP is
differential over system static pressure.
SMARTFIRE™ Intelligent Combustion Control System.
See Maxon catalog section 7200 for more details.
16. Slowly cycle the unit from light-off to minimum

through maximum and back to ensure that the
burner functions satisfactorily throughout the
operating range. Refine adjustment if necessary.
stable throughout the operating range, re-
connect the control linkage and allow unit to
operate in automatic control mode.
18. Shut system down, closing all fuel valves.
Disconnect and plug all test connections. Re-
place all equipment covers and caps. Tighten all
linkage set screws.
m CORPORATION

CROSSFIRE® Line Burner Page 5600-A/P-1
Assembly Numbers
Standard Burner Assemblies Segment choices are as follows for the
Configured Item Number Description configured item numbers:
.5 EI XF STR 6" straight CROSSFIRE, end inlet • Fuel
1 EI XF STR 1' straight CROSSFIRE, end inlet • Gas Connection
1.5 EI XF STR 1.5' straight CROSSFIRE, end inlet
• Body Material
• Housing Material
2 BI XF STR 2' straight CROSSFIRE, back inlet
• Air Connector
• Air Connector Material
4 BI XF STR 4' straight CROSSFIRE, back inlet • Cross Member Span (Grids only)
5 BI XF STR 5' straight CROSSFIRE, back inlet • Cross Member (Ladders only)
6 BI XF STR 6' straight CROSSFIRE, back inlet • End Plate
7 BI XF STR 7' straight CROSSFIRE, back inlet • Division Plate
8 BI XF STR 8' straight CROSSFIRE, back inlet • End Mounting Bracket
9 BI XF STR 9' straight CROSSFIRE, back inlet • Center Mounting Bracket
2 BI XF GRD 2' grid CROSSFIRE, back inlet
• Maximum Firing Rate
• To be used with SMARTFIRE
• Customer Number
• Burner Capacity
5 BI XF GRD 5' grid CROSSFIRE, back inlet • Lifting Lugs
8 BI XF GRD 8' grid CROSSFIRE, back inlet Descriptions of segment choices and
9 BI XF GRD 9' grid CROSSFIRE, back inlet available options are listed on pages
4 BI XF LDR 4' ladder CROSSFIRE, back inlet 5600-A/P-2 through 5600-A/P-4.
5 BI XF LDR 5' ladder CROSSFIRE, back inlet
Please furnish a sketch when ordering
any CROSSFIRE assembly. This includes
straight, grid, and ladder assemblies.
Indicate the position of the pilot end plate
on all assemblies. In addition, indicate
the position of the end gas inlet if order-
ing the 6”, 1’, or 1.5’ straight CROSSFIRE
assembly. Sample configurations appear
on pages 5600-A/P-5, 5600-A/P-6 and
5600-A/P-7.

m
CORPORATION
Page 5600-A/P-2 CROSSFIRE® Line Burner
Assembly Numbers
Segment Choice Details
Segment Choices
(DEFAULT is shaded)
BUT Butane Gas
FUEL Type of fuel NAT Natural Gas
PROP Propane Gas
GAS CONNECTION Type of gas inlet connection
CTD Coated
BODY MATERIAL Type of body material used
STD Standard
SS Stainless Steel
HOUSING MATERIAL Type of housing material used
STD Standard
No Connector (Customer
AIR CONNECTOR NONE
Supplied)
Square air inlet not available for Type, if any, of air connector
SQ 6.524" x 7.503" Square
.5', 1', and 1.5' sections.
RD 8" Round
NONE No Material
Type of material of air connector,
AIR CONNECTOR MATERIAL SS Stainless Steel
if any
STD Standard
1 12" Span
1.5 18" Span
CROSS MEMBER SPAN Spacing, in feet, between cross 2 24" Span - 1 Air
(GRID ONLY) member centerlines 2.5 30" Span - 1 Air
3 36" Span - 1 Air & Gas
4 48" Span - 1 Air & Gas
112 Qty 1 - 12" Spacing
CROSS MEMBER 418 Qty 4 - 18" Spacing
Quantity and centerline spacing,
(Quantity & Spacing)
in feet, of cross members 124 Qty 1 - 24" Spacing
(LADDER ONLY)
m CORPORATION

Assembly Numbers
Segment Choice Details (continued)
Segment Choices Segment Choice
Segment Name Segment Description
(DEFAULT is shaded) Description
PLN Plain End Plate
END PLATE (POS 1)* Type of end plate used in position 1
STD Standard Piloted End Plate
PLN Plain End Plate
PLN Plain End Plate
PLN Plain End Plate
NO No Division Plates
DIVISION PLATE (LOC A) Type of division plate used at location A
YES Division Plates
DIVISION PLATE (LOC B) Type of division plate used at location B
YES Division Plates
DIVISION PLATE (LOC C) Type of division plate used at location C
YES Division Plates
DIVISION PLATE (LOC D) Type of division plate used at location D
YES Division Plates
END MOUNTING BRACKET Number of end mounting brackets required (QUANTITY) (Optional)
CENTER MOUNTING BRACKET** Number of center mounting brackets required (QUANTITY) (Optional)
1 1 MMBtuh/ft
1.25 1.25 MMBtuh/ft
Maximum rate per foot at which burner 1.5 1.5 MMBtuh/ft
MAXIMUM FIRING RATE
operates 1.75 1.75 MMBtuh/ft
2 2 MMBtuh/ft
2.25 2.25 MMBtuh/ft
Is CROSSFIRE to be used with optional Maxon NO SMARTFIRE Not Used
TO BE USED WITH SMARTFIRE
SMARTFIRE? YES SMARTFIRE Used
CUSTOMER NUMBER Attach customer number to burner? (to be filled in) (Optional)
Capacity of burner (based on firing rate and
BURNER CAPACITY
burner length) (calculated) ---
(MMBTUH)
No user input required for this field
LIFTING LUGS Quantity and location to be specified on order (QUANTITY) (Optional)
*Denotes secondary segment choices involved (see next page)
**Available on End Inlet burners only.

m
CORPORATION
Assembly Numbers
Secondary Segment Choice Details for Standard Piloted End Plates
Segment Choices
(DEFAULT is shaded)
CTD Coated Gray Iron
MATERIAL Type of end plate material
STD Gray Iron
CONNECTION Type of connection for end plate
NO Choice Not Selected
GAS MIXER Optional gas mixer
YES Choice Selected
NO Choice Not Selected
PILOT ADJUSTABLE ORIFICE Optional adjustable orifice for pilot
YES Choice Selected
Feed Thru Ignitor w/SS Tube
FTISS
(available in 12", 18", 24", 30", 36", 42", 48")
IGNITOR Type of ignitor required NONE Ignitor Customer Provided
STD Std Ignitor w/o Feed Thru Plate
STDP Std Ignitor w/Feed Thru Plate
NONE No Detector Provided
FLAME DETECTION Type of flame detection required
UV Set Up For UV (Customer Provided)
SEAL PLATE KIT NO Choice Not Selected
Optional seal plate kit
(ship loose) YES Choice Selected
Secondary Segment Choice Details for Plain End Plates

Segment Choices
(DEFAULT is shaded)
SS Stainless Steel
MATERIAL End plate material
STD Carbon Steel
TYPE Type of end plate (no user choices available) PLN Plain
Miscellaneous Items & Accessories

Gas mixer sub-assembly 19298
Pilot adjustable orifice Air 15726
14mm x .875" spark ignitor 1046629
12" long 1050342
18" long 1050343
24" long 1050344
Long Shrouded
30" long 1050345
Ignitor
36" long 1050346
42" long 1050347
48" long 1050348
Ignition Adapter 1047215
m CORPORATION

Assembly Numbers
CROSSFIRE® – Straight Assembly
End Plate End Plate

Position 1 Position 2
Gas Inlet
Standard Burner Assemblies Segment choices are as follows for the

.5 EI EX STR 6" straight CROSSFIRE, end inlet • Fuel
1 EI XF STR 1' straight CROSSFIRE, end inlet • Gas Connection
1.5 EI XF STR 1.5' straight CROSSFIRE, end inlet • Body Material
• Air Connector
4 BI XF STR 4' straight CROSSFIRE, back inlet • End Plates
5 BI XF STR 5' straight CROSSFIRE, back inlet • End Mounting Bracket
6 BI XF STR 6' straight CROSSFIRE, back inlet • Center Mounting Bracket
7 BI XF STR 7' straight CROSSFIRE, back inlet • Maximum Firing Rate
8 BI XF STR 8' straight CROSSFIRE, back inlet • To be used with SMARTFIRE
9 BI XF STR 9' straight CROSSFIRE, back inlet • Customer Number
• Burner Capacity
• Lifting Lugs

straight assemblies.

m
CORPORATION
Assembly Numbers
CROSSFIRE® – Grid Assembly
3 ft. span between cross members, 1 air & gas
End Plate End Plate
Horizontal
Tee Housing Gas Inlet
Cross Members /
Vertical Tee
Housings
Horizontal
Tee Housing End Plate
End Plate
Position 2
Position 3
CROSSFIRE® Grid Assemblies Segment choices are as follows for the

2 BI XF GRD 2' grid CROSSFIRE, back inlet • Fuel
3 BI XF GRD 3' grid CROSSFIRE, back inlet • Gas Connection
• Body Material
• Air Connector
7 BI XF GRD 7' grid CROSSFIRE, back inlet • Cross Member Span
8 BI XF GRD 8' grid CROSSFIRE, back inlet • End Plates
9 BI XF GRD 9' grid CROSSFIRE, back inlet • Division Plates
• End Mounting Bracket
• Center Mounting Bracket
• Customer Number
• Burner Capacity
• Lifting Lugs

grid assemblies.
m
CORPORATION

Assembly Numbers
9 ft. CROSSFIRE® Ladder Back Inlet
with (2) cross members at 30” spacing
End Plate
Position 4
End Plate
Position 1
Outer Ladder Housing Division

Plate A

Division
Plate A
Division
Plate B
Vertical Ladder Cross Members /
Gas Inlet
Housing Inner Ladder
Division Housings
Plate B
Division
Plate C Vertical Ladder
Housing
Division Outer Ladder
Plate C Housing
End Plate End Plate

Segment choices are as follows for CROSSFIRE® Ladder Assemblies

ladder assemblies: Configured Item
Description
• Fuel Number
• Gas Connection 4 BI XF LDR 4' ladder CROSSFIRE, back inlet
• Body Material 5 BI XF LDR 5' ladder CROSSFIRE, back inlet
• Housing Material 6 BI XF LDR 6' ladder CROSSFIRE, back inlet
• Air Connector 7 BI XF LDR 7' ladder CROSSFIRE, back inlet
• Air Connector Material 8 BI XF LDR 8' ladder CROSSFIRE, back inlet
• Cross Member
• End Plates
• Division Plates NOTE: Larger burners may need to be ordered and/or
• End Mounting Bracket shipped in segments (for ladder assemblies only).
• Center Mounting Bracket Contact Maxon for details.
• Customer Number Please furnish a sketch when ordering
• Burner Capacity ladder assemblies.
• Lifting Lugs

mCORPORATION
Notes
m
CORPORATION

Bulletin 5700
COMBUSTIFUME® Line Burners
8 ft. Series CF5D COMBUSTIFUME® Burner assembly
• For direct-fired fume incineration and higher temperature process air heating applications
• Modular burner design provides burner assembly configurations and total heat release for maximum
application flexibility
• COMBUSTIFUME® Burner provides stable, efficient, raw gas operations in air streams with
oxygen levels as low as 16% (by volume), or with inlet temperatures up to 1050°F (566°C)
• Burns clean and odor-free with low levels of NOx production
• When air stream oxygen content is low, primary combustion air may be added through the
COMBUSTIFUME® Burner system to produce combustion of most clean gaseous fuels
• Fume incineration costs are minimized by direct firing COMBUSTIFUME® Burner in the effluent air
stream
• 12 different varieties of COMBUSTIFUME® Line Burners available, each optimized in

materials and/or performance factors to match your specific application requirements
Covered by U.S. Patents #25,626; #3,297,259 and #4,573,907;

CORPORATION 201 East 18th Street, P.O. Box 2068, Muncie, Indiana, 47307-0068. Phone: (765) 284-3304. FAX 765-286-8394
Page 5702

COMBUSTIFUME® Line Burners are designed for
heating high temperature process air in motion and
consist of a rust-resistant ductile iron or aluminum
bronze body (which serves as the raw gas or air/fuel
manifold), drilled to discharge the fuel/gas mixture
between diverging stainless steel or Hastelloy-X
mixing plates.
mixing plates and is used as additional combustion
air, particularly at the higher firing rates. Carefully
controlled mixing plate aeration patterns give
progressive mixing, superior cross-ignition and flame
retention across the entire burner assembly length. • CF4D COMBUSTIFUME® Burners have ductile
Air velocities and the resulting duct static iron bodies and #310 stainless steel mixing plates.
pressure drop are the key to successful opera- Four different versions are available, either for raw
tion. They are established by the use of a customer- gas burner applications, or for those requiring a
installed profile plate within the duct. A minimum partial air/gas premixture system and/or outlet
profile width of 6" is required surrounding all temperatures up to 1500°F (816°C).
COMBUSTIFUME® Burner assemblies. • CF5D COMBUSTIFUME® Burners complement
Optimum burner performance and maximum their ductile iron bodies with Hastelloy-X mixing
service life demand that air stream velocities be plates as above for applications with up to 1700°F
uniform across the entire burner assembly. (927°C) outlet temperature requirements.
Normal capacities vary widely with application. • CF5B COMBUSTIFUME® Burners have an
Fuel used and design velocities affect turndown. aluminum bronze body casting with Hastelloy-X
Modular design permits shape and total heat release mixing plates for use with applications requiring up
to match application needs. to 1700°F (927°C) outlet temperatures with
Performance data varies depending upon tem- incoming temperatures up to 1050°F (566°C).
perature of air upstream and downstream of burner
assembly, the percent of oxygen (by volume) in the Typical applications include:
passing air stream, and the allowable duct static Adhesive tape curing Brake lining ovens
pressure drop (which relates to velocity of air across Coffee roasters Coil-coating lines
the COMBUSTIFUME® Burner). Core ovens Cupola furnace stacks
Several varieties of COMBUSTIFUME® Burners Fat rendering Fiberglass curing
are offered. Each type is optimized for a specific type Lithographing ovens Meat smokehouses
of application. All varieties can be used when a partial Metal-coating ovens Operating room exhaust
Packing house effluents Paint-baking ovens
air/gas premixture is required and are intended for
Paint removal facilities Plastic curing ovens
use in heating process air-in-motion where high Printing presses Roofing paper machine hoods
temperatures and/or lower air stream oxygen content Solvent degreasing Textile dryers
are involved. Turbine exhaust reheat Varnish burn-off
Varnish kettles Vinyl sponge curing
Wire enameling
9/03
COMBUSTIFUME® Line Burners Page 5703
Design Considerations
To properly select the appropriate type Any combination of temperatures and oxygen levels
COMBUSTIFUME® Line Burner to meet your specific falling above the raw gas firing diagonal line should
application requirements, these four factors must first support combustion with a raw gas COMBUSTIFUME®
be determined: Burner system.
1. Percent (by volume) of oxygen remaining in air Any combination of incoming temperature and
stream to be heated measured percent of oxygen falling below the
2. Allowable duct static pressure drop, which is a diagonal line will normally require the designated
direct relationship to the velocity of air across the percentage of premixing through a
burner and/or profile plate COMBUSTIFUME® Burner system.
3. Air stream temperatures approaching and
Notice: When primary combustion air is
downstream of the COMBUSTIFUME® Burner
supplemented in the system, a corresponding work
4. Type of fuel to be fired through the burner
load increase must be factored into the gross
Oxygen content and temperature of effluent/air heating requirement to heat the fresh combustion
stream dictates how and which COMBUSTIFUME® air being introduced.
Line Burner must be applied. Flammability of a raw
gas burner is affected by oxygen content, air stream
temperature and moisture content. Since a typical
application for COMBUSTIFUME® Burners would
involve an air stream temperature of 700°F or higher,
air streams with measured oxygen levels above 16%
(by volume) will normally support combustion by a
raw gas burner and not require additional primary
combustion air. However, if measured oxygen content
in air stream is less than 16% or air stream
temperature is less than 500°F, a percentage of
partial premixed gas/air may be required to
supplement the lower oxygen levels in your system
for a complete combustion reaction to occur. Please
refer to the Air Stream Flammability Chart on this
page for the exact oxygen requirements of effluent/air
streams.
Elevated air stream temperatures approaching
a COMBUSTIFUME® Burner can be as high as
1050°F (566°C). This naturally causes changes in air
density and net air velocities, and results in an effect
on COMBUSTIFUME® Burner performance.
The combination effect of lower inlet
temperature and lower oxygen levels will normally
require a partial percentage of premixture be added
through the COMBUSTIFUME® Burner system.
This combination effect (or air stream flammability)
is graphically illustrated in the chart at right.
Since oxygen content within the air stream is
critical to the flammability range of a
COMBUSTIFUME® Burner, it also directly affects the
maximum capacity (Btu/hr per lineal foot) of the
burner assembly.
9/03
Page 5704 COMBUSTIFUME® Line Burners

General These static pressure drops relate to velocity
Air stream velocity and resulting pressure drop (in SFPM) as shown in Table 1 below.
affect performance of COMBUSTIFUME® Burner CAUTION: Do not try to take a differential static
systems. This velocity across and through your pressure reading from a test port at or near an elbow
burner’s mixing plates must be kept uniform and in the duct or chamber due to potentially erroneous
within desired limits by use of a (customer fabricated) readings caused by turbulence set up within the duct
silhouette profile plate through which the burner fires. at such points. Measure in a straight duct with at least
A minimum 6" profile plate should be installed one duct diameter in length before and after the
surrounding the interior duct walls at the leading edge profile opening.
of your burner’s mixing plates. For lower temperature rise applications,
Optimum design operating velocity ranges are determine profile opening area by adding burner
shown in preceding pages. The most accurate displacement area (ft2/section) from page 5705 to net
readings for velocities (in SFPM) are as measured free area of your duct:
with a velometer (or pitot tube) directly in the duct at
the plane of the profile plate and leading edge of your Fan volume (SCFM)
Net free area of duct (ft2) =
burner’s mixing plates. Velocity (SFPM)
Since COMBUSTIFUME® Burner systems are
installed in such widely diversified applications, it is
often difficult to get into the chamber/duct and profile NOTE: Various duct size/profile area relationships
plate area to obtain the velocity pressure readings may give slightly different field site data than is shown
described above. For this reason, a close in static pressure chart below.
approximation of operating velocities may be made
with a measurement of duct static pressure drop.
Preferably, a static pressure test point one duct
diameter in distance upstream from the profile plate
and one duct diameter length downstream will give
an approximation of operating velocity across the
burner.
Table 1: Velocity (SFPM) relative to static pressure drop ("wc)

Approximate air stream velocity at
1000 1500 2000 2500 3000 3500 4000
burner profile plate (SFPM)
Duct static pressure drop through
0.1 0.2 0.4 0.6 0.9 1.2 1.6
profile opening ("wc) [1]
[1] Based on profile/burner plane K factor of 0.8. May vary with your specific duct size/profile area relationship

COMBUSTIFUME® Line Burner Design Parameters
Maximum Thermal expansion due to the high operating
Maximum Maximum
COMBUSTIFUME®
Temperature Discharge
Static temperature of incineration units requires special
Burner Type Pressure care in manifold and combustion chamber design.
Limits Temperature
Drop
Flexible connections between manifold and burner
CF4D 1500°F 2" wc assembly inlets are recommended, and provision
1000°F (816°C) should be made in burner support to allow for growth
CF5D 2.5" wc
(538°C)
with temperature.
CF5D
1700°F
2" wc
Flame supervision by UV scanner is preferred,
1050°F (927°C)
CF5B and must be used whenever effluent inlet tempera-
(566°C)
tures exceed 600°F (316°C). Cooling or purge air to
Minimum capacity is 150,000 Btu/hr per lineal foot the scanner connection is recommended. Flame rods
of COMBUSTIFUME® Line Burner for “raw gas” can be mounted through pilot assembly, but are
burner systems. limited to 600°F (316°C) effluent inlet temperature.
Differential gas pressure (the difference between Observation and access are both important to a
gas pressure inside COMBUSTIFUME® Burner successful installation. Ability to view the flame from
manifold and the combustion chamber static pres- downstream of burner (particularly pilot location)
sure) required in burner at maximum firing rates is greatly simplifies start-up and operating procedures,
shown in table below. while access to upstream side of burner facilitates
eventual maintenance.
For raw gas firing in air streams where oxygen level
exceeds 16% (for 24 hole drilling pattern) Displacement area per section
Maximum Capacity For purposes of calculating operating air velocities
500 600 700 800 900 1000
1000's Btu/hr per lineal ft.
and resulting static pressure drops across the burner
Differential Gas Natural 2 2.9 4 5.2 6.6 8 assembly and profile plate, use the following
Pressures (inches wc) Propane 0.8 1.2 1.6 2.1 2.6 3.3 equivalent displacements:
Each 6" straight section: 0.35 ft2
Effluent air streams with oxygen levels of 12% Each 12" straight & 12B section: 0.7 ft2
to 16% may be heated with COMBUSTIFUME®
Each 12" x 6" tee section: 0.75 ft2
Burner supplied with a partial premixture of air and
natural or propane gas. Each 12" x 12" cross & BX section: 0.85 ft2
A complete burner system to handle these Each 36" B H section: 1.5 ft2
difficult applications would include a
COMBUSTIFUME® Burner assembly, Series “HG”
Mixing Tube, MICRO-RATIO® Control Valve and a
combustion air blower as shown below. Your Maxon
representative can help you select from the broad
range of options available.
“HG” Mixing Tube System for partial premixed COMBUSTIFUME® Burner system
Maxon assumes no responsibility for the use or misuse of

the piping layouts shown. Specific piping and wiring
diagrams should always be submitted to the appropriate
9/03

Series “HG” Mixing Tubes with partially premixed COMBUSTIFUME® Burner
system in 12 – 16% oxygen level air stream applications
General Selection Procedure: Table 1: Design Parameters
1. Determine available oxygen level in Percent of oxygen in effluent: 12 to 12.9 13 to 13.9 14 to 15.9
air stream to be heated.
Required increase in gross heat release
2. Enter Table 1 under column with (Btu/hr)
10% 7.5% 5%
specific oxygen level for parameters
Maximum heat release per lineal foot of
of your application. Available oxygen 700,000 1,000,000
burner (Btu/hr)
level dictates combustion air and Minimum heat release (Btu/hr) per lineal foot of
extra heat requirements for additional 75,000
burner
primary air flows. Combustion air required through Series "HG"
3. Calculate gross heat requirement. 47 41 34
Mixing Tube (SCFM per lineal foot of burner)
4. Determine burner footage and inlet Differential air pressure required (inches wc)
feed requirements. as measured between burner inlet and 8 6.4 5.5
5. Select “HG” Mixing Tube size from duct/chamber static pressure
Table 2 based upon the volume of
combustion air required.
Example: Table 2: Series "HG" Mixing Tube Selection

– Required heat release of 7,000,000 Btu/hr "HG" Mixing SCFM combustion air volume required at
– For system measured with 13.5% oxygen in air Tube Size maximum through "HG" Mixing Tube
stream 2" 0 to 190
3" 90 to 260
From Table 1 (13 to 13.9%, middle column) 4" 175 to 500
6" 400 to 1167
A. Gross heat required
8" 880 to 2500
7,000,000 x 1.075 = 7,525,000 Btu/hr
Table 3: Gas Orifice Drillings for Series "HG"
7,525,000 Btu Mixing Tubes
B. = 10.75 ft. = 11 ft. of burner NOTE: Drillings below based on 2 PSIG inlet gas pressure
700,000 Btu/ft
(measured at "HG" Mixing Tube gas inlet)
11 ft. For partially premixed systems
C. = 2 inlets
6 ft/inlet Size of "HG" Gas Orifice Drillings
Mixing Tube Combustion Air for Series "66" AIRFLO® and
(number of gas Pressure COMBUSTIFUME® Burners
D. 11 ft. x 41 SCFM/ft = 451 SCFM primary air with orifices in measured at air
inlet of "HG" for for for
differential pressure = 6.4" wc parentheses)
Mixing Tube Natural Propane Butane
Gas Gas Gas
From Table 2 (400 to 1167 SCFM) 2" HG
21/64" I F
(4)
E. Select 6" HG Mixing Tube with 3" HG
21/64" I F
12 each 29/64" gas orifices per Table 3 (6)
4" HG
6 & 8 osi 7/16" T R
F. Select MICRO-RATIO® Control Valve (8)
– for 451 SCFM air = (27060 SCFH) 6" HG
29/64" 3/8" T
(12)
– for 7525 SCFH natural gas
8" HG
35/64" 29/64" 7/16"
(12)

Raw gas firing of COMBUSTIFUME® Burners in air streams with 16+% oxygen levels
Profiling for higher temperature applications 7. Calculate maximum total heat required
When calculating profile dimensions for Btu/hr = SCFM x “K”
COMBUSTIFUME® Burner systems in applications (from step 2) (from chart below)
with higher inlet air temperatures, greater temperature
rises, and/or variable air stream volumes, the air with Multiply SCFM of air by multiplier (K), which
elevated temperatures and densities must be combines hypothetical available heat at 1500°F
considered. and a 1.08 composite air heating factor to give
the value in Btu required being “gross heating
Sample Calculations value” of fuel. Since multiplier (K) varies with
A sample procedure for designing a raw gas inlet and discharge air temperature, the various
COMBUSTIFUME® Burner system for a thermal fuel factors are graphically shown below:
incinerator (with 16+% oxygen level) is provided
below. For 1300°F, 1500°F and 1700°F
General Selection Procedure discharge temperatures
1. Determine available oxygen level in air stream
to be heated.
For a raw gas application, we will use 16+%
oxygen level.
2. Determine the SCFM of air through the
incinerator. Include any variations in this flow.
For our calculations, we will use a constant
volume air fan of 5000 SCFM.
3. Determine inlet temperature of effluent to
COMBUSTIFUME® Burner.
We will use inlet temperature of 700°F.
4. Determine outlet or discharge temperatures
from the incinerator.
For our example, we will design for 1500°F.
5. Determine the volume of any combustible
hydrocarbons in the effluent air stream.
We will use 20 gallons of evaporated solvent
per hour @ 110,000 Btu/gallon.
CFH gas
6. Determine available gas pressure and its Evolvement of “K” = x 1000
anticipated pressure drop through the control SCFM air
system’s piping and valves.
For this example, we will use 5 PSIG natural Enter chart at 700°F inlet temperature line
gas supply pressure available; 3" wc pressure (from step 3); follow across to intersect the
drop through control system; +3" wc static 1500°F discharge temperature sloped line,
pressure in combustion chamber; 8" wc then drop straight down to read the “K”
differential gas pressure required to burner and multiplier factor of 1150.
14" wc gas pressure required from main gas Therefore, maximum heat input required:
regulator (at maximum burner firing rate).
Btu/hr = 5000 SCFM x 1150 = 5,750,000
3/92

Design procedure and calculation example (continued)
8. Determine the COMBUSTIFUME® Burner 10. Determine total burner displacement area by
footage adding the displacement area of all the individual
Divide the maximum Btu/hr (calculated in step sections (see page 5705)
7) by 1,000,000 Btu/hr per lineal foot. Round-
Area displaced by this assembly:
up to the nearest whole foot (if necessary).
(2) 12" x 6" tee sections @ 0.75 = 1.50 ft2
Required 5,750,000 Btu/hr (from step 7) (3) 12" straight sections @ 0.7 = 2.10 ft2
=
Burner Footage 1,000,000 Btu/lineal foot Total Area = 3.60 ft2
Required burner footage = 5.7 lineal feet 11. Determine dimensions of profile plate opening
using these general guidelines:
= (round-off to 6 lineal ft.) A. Profile opening should be 1" longer than
9. Lay out a proposed burner assembly using nominal length of burner assembly (dimension
these general guidelines: X + 1" in the sketch below)
A. Use as few tee sections as possible to conform B. Edge of profile plate should be 6-1/2" from
to general shape of the combustion chamber. centerline of any “outside row” of castings
B. Minimize use of cross or back inlet cross “Typical Configuration” Example:
sections for general fume incineration
applications, since they do not provide the
same degree of exposure to the flame
achieved by straight or tee sections.
C. If multiple burner rows are used, they should
be placed on 12" centers to avoid need for
between-the-row profile plate baffles.
D. Do not exceed 3,500,000 Btu/hr capacity for
any 2" diameter end inlet flange.
E. 2" diameter back inlet flange and INCINO-
Example: 6 lineal feet assembly
PAK® inlet feed section should feed no more
than 7,000,000 Btu/hr capacity.
F. 3" diameter back inlet flange on “12B”
section can feed up to a maximum of
10,000,000 Btu/hr, or 8,300,000 Btu with any
36BH section.
G. Keep burner assembly balanced and as
symmetrical as possible around all inlet feeds.
NOTE: Several possible burner arrangements 12. Calculate gross area of profile plate opening
could be devised. For this example, we will
propose the burner layout illustrated below: Sq. ft. area = inches length x inches width
144 sq. in. / sq. ft.
Example: 6 lineal feet
If we assume a gross profile area of 13" x 61"
Gross area of opening in profile plate

= 13" x 61" = 5.51 sq. ft.
144 in2/ft2

13. Calculate the velocity of flow of the effluent 12-1/2" x 60", which would increase pressure drop
over the burner and through profile opening as follows:
Velocity = SCFM (from step 2)
Area = 12.5" x 60" = 5.21 ft2
(SFPM) Profile Area – Burner Displacement
144 in2/ft2
(from step 12) (from step 10)
SFPM = 5000 = 3200

Velocity of Effluent:
5.21 – 3.62
SFPM = 5000 SCFM = 2645 SFPM
2 2 Pressure drop = 1.9" wc
5.51 ft – 3.62 ft
14. Check the duct static pressure drop across the 15. Check the minimum Btu/hr per lineal foot
burner assembly and profile plate required
In Graph “B” below, check to see whether the Maximum heat – Btu/hr available
velocity determined in step 13 and the inlet Btu/hr (from step 1) from solvent
effluent temperature (step 3) result in a pressure per foot = (from step 5)
drop within the shaded (acceptable) area.
Footage of burner
Conditions in the shaded area are permissible.
(from step 8)
Minimum
Btu/hr per ft. = 5,750,000 – (20 gal. x 110,000)
6 ft.
= 591,667
If above figure falls below 150,000 Btu/hr per ft.,
burner footage must be reduced and/or a compromise
of other design parameters must be made. Our
example is well above the 150,000 limit, so the
turndown range of a standard COMBUSTIFUME®
Burner system should be adequate.
16. Select the proper type COMBUSTIFUME®
Burner from these general guidelines:
Type of COMBUSTIFUME® Burner: With inlet effluent
Maximum
Maximum Maximum
Optimum pressure should be in the 1 - 1.5" range. COMBUSTIFUME® Static
Inlet Discharge
Burner Type Pressure
– If the pressure drop is too high, the profile Temperature Temperature
Drop
opening must be increased.
CF4D 1500°F 2" wc
– If the pressure drop is too low, the profile
1000°F (816°C)
opening must be reduced. CF5D 2.5" wc
(538°C)
NOTE: Chart is based on tight profiling. If sizeable CF5D
gap is maintained around burner, pressure drop will be 1700°F
1050°F 2"
CF5B (927°C)
less than indicated in Graph “B”. (566°C)
Pressure drop across burner and profile plate temperature of 700°F, discharge temperature of
(refer to Graph “B”) 1500°F, and a pressure drop of approximately 1.9" wc
(2645 SFPM @ 700°F) = 1.1" wc drop for burner assembly selected:
Use Type CF4D COMBUSTIFUME® Burner
It would be better to change the opening to
9/03
Based on capacity information given in this catalog burner assembly. Burner assembly layout should be
section, and within the constraints of duct size and air symmetrical and balanced with relation to inlet feed
volume flows, a COMBUSTIFUME® Burner assembly sections.
is designed utilizing these available sections shown on Do not exceed the capacity feed limitations shown
the following pages. in the table below.
When ordering a burner assembly made up from
these available module components, be sure to provide
Raw gas firing capacity limitations for inlet feed
an assembly sketch of the complete burner (as viewed
sections
from the back, or upstream, side), including locations
of all accessories and/or individual component COMBUSTIFUME® Burner
Maximum
sections. Inlet Pipe Size
Burner Section Btu/hr per inlet
All open ends of burner assembly must be (NPT)
closed off with one of the end closures or pilot End inlet flange set 3,500,000
assemblies shown on the following pages. Any end 2" 12" straight (12B)
7,000,000
plate ports not used must be plugged. INCINO-PAK® (12B & 36B)
Air stream velocity and resulting static pressure 36" back inlet (BH) 8,300,000
drop affect performance and are achieved by means of 3" 12" straight (12B)
a silhouette profile plate within the duct. 10,000,000
12" x 12" cross (XB)
A minimum profile plate width of 6" is required 4" 12,000,000
surrounding all COMBUSTIFUME® Burner
assemblies. Inlet flanges bolt directly to burner body casting and
accept threaded NPT piping. Chart above shows
Burner inlet feed piping must be adequate to maximum lineal feet of COMBUSTIFUME® Burner that
provide a well-distributed flow of air/gas throughout the may be fed by a given inlet flange.
COMBUSTIFUME® Line Burner Designation
The designation Example: 12" x 12" bk inlet section CF 5 – BX – D – 24

of each
COMBUSTIFUME® Section Description
Burner section
identifies specifics CF = COMBUSTIFUME® Burner
about that section. IP-CF = INCINO-PAK® Burner

5 = Hastelloy-X
Section Code
6 = 6" straight section Body Material
12 = 12" straight section D = ductile iron body
T = 12" x 6" tee section B = aluminum bronze body
BH = 36" back inlet “H” section
48 = 48 holes (0.6226 in2/ft) discharge area [1]
[1] These drill patterns available for special applications such as
low Btu/fuels and partial premixing system

INCINO-PAK® Burner Inlet Feed Sections
INCINO-PAK® Burner sections are special

configurations of 12" or 36" back inlet feed sections.
They provide “outside-the-duct” access to the raw gas
pilot, ignitor, and flame safeguard components,
eliminating lateral duct wall connections.
INCINO-PAK® Burner sections are designed to
feed COMBUSTIFUME® Burner elements in end-fired
incinerators or preheaters with cylindrical combustion
chambers, or when burner is fired at an elbow in the
ductwork.
INCINO-PAK® Burner sections can be used alone 36" back inlet “H” INCINO-PAK® Burner section shown with (4)
(with appropriate end plates and accessories added), COMBUSTIFUME® Burner end plates; includes spark ignitor, pilot
or as an inlet feed section in a larger gas adjustable orifice cock, raw gas pilot, and arranged for
mounting of customer’s UV scanner
COMBUSTIFUME® Line Burner assembly.
All INCINO-PAK® Burner sections contain a 2"
Three manifold lengths are offered in both the 12B
(NPT) gas inlet connection which may be used to
and 36B back inlet INCINO-PAK® Burner sections:
feed up to a maximum capacity of 7,000,000 Btu/hr.
Series 600 = 600 millimeter (23.8") length
Heat release and gas pressure requirements
match those of the other COMBUSTIFUME® sections.
The raw gas pilot capacity is 25,000 Btu/hr.
This “manifold length” reflects the distance
WARNING: Pilot gas should be interrupted between the outside duct mounting wall and the
once main flame is established. UV sight tube centerline of the COMBUSTIFUME® Burner casting.
must be sealed against any scanner cooling air See catalog page 5712 for specific dimensions.
used. Each INCINO-PAK® Burner section includes a
spark electrode, adjustable pilot gas orifice, body
gasket, and provision for your UV scanner.
Typical block & bleed piping layout for raw gas INCINO-PAK® Typical installation
Burner system as frequently required by insurance authorities in cylindrical incinerator

submitted to the approproate agencies for approval on each application.
9/03

INCINO-PAK® Burner Back Inlet Sections
36" back inlet “H” section
12" back inlet “12B” section
Series A B L X
600 23.81 37.25 31.65 1.5
Pipe threads on this page conform to 800 31.5 45.25 39.34 1.75
NPT (ANSI Standard B2.1) 1100 43.31 56.25 51.15 1

Typical End Views
Straight Tee and

9/03

12" x 12"
12" back inlet section 36" back inlet section back inlet cross
NOTE: 12B, 36B and XB back inlet sections must be ordered

with one of the back inlet flange sets shown below.
Back Inlet Flanges

Flange Sets for 12" & 36" Inlet flanges bolt directly to Flange Sets for 12" x 12"
either standard NPT or
standard ISO threaded piping
of indicated size.
2" 3" NOTE: Refer to page 5710
LFB LFB for specific inlet feed capacity
3" 4"
limitations.
A (size) B A (size)
2 0.88 3
3 1.25 4

Plain end plate set

Plain end plate closure
includes 1/8" NPT test
connection
Pilot end plate set

UV scanner can be
flame rod.
Alternate
flame rod
position
Flame rods ( if used) must be

ordered separately with all pilot end plate sets.
Inlet pilot set
UV scanner can be
flame rod.
NOTE: See catalog page

9/03

Pilot Assemblies
Built-in pilot arrangements Built-in pilot detail

Direct mounted version includes 14mm spark
ignitor. Order electrode separately for externally
mounted version. Order flame rod (if used) sepa-
rately.
NOTE: Built-in pilot assemblies must mount only

where COMBUSTIFUME® Burner sections provide for
the segmented gas chamber within the burner body
casting. See sketches below relative to possible
locations for built-in pilot assemblies.
Optional external mounting assemblies

shown on page 5718
All 6" straight sections, Aluminum bronze 12" x Ductile iron 12" x 6" tee
whether gray iron, ductile 6" tee section can accept sections can have built-in
iron, or aluminum bronze, built-in pilot only on right pilot assembly mounted on
can accept built-in pilots on end of straight 12" side any end.
one end. (when viewed from back NOTE: Gray iron tee
side of the assembly). sections do not accept
built-in pilot assemblies.

Pilot Assemblies
AIRFLO-PAK pilot arrangements Optional air/gas pilot mixers

Direct mounted version includes 14mm spark for all COMBUSTIFUME® Burner AIRFLO-PAK pilot
ignitor. Order electrode separately for externally assemblies
mounted version. Order flame rod (if used) and pilot
mixer separately. Pressure type with adjustable orifice
Atmospheric type with fixed orifice

External mounting plate details – A plate is Positioning mounting plate in relation to
included with all assemblies shown on page 5718 AIRFLO® Burner pilot location
Mounting Plate with two

(2) feed-through insulators
for internal mounting of
spark ignitor and flame
assemblies shown on
page 5718.
External mounting Through-wall

plate dimensions opening required
9/03



flame rod

ignitor
Description

spark electrode &
external UV scanner
NOTE: Order optional

spark electrode sub-
assembly separately
Optional external
(shrouded) spark
electrode for above
External electrode 12" 18" 24" 36"

Dimension “A” 12 18 24 34.437
Dimension “B” 13.781 19.781 25.781 36.170

Provides support for profile Provides isolation of burner
within closed burner loop. On feed(s) where desirable.
some applications, it may be
necessary to restrict air flow
between adjacent burner
rows to achieve design Optional electrode cover
operating velocities. This is Protects porcelain insulator and
done by installing customer-fabricated profile plates electrical connection from dirt
on profile mounting bracket(s). See sketch 1 below and moisture. May be used for
for use on square openings (formed by adjacent ambient temperatures up to
cross-sections of burner). Sketch 2 applies to 450°F (232°C).
rectangular opening.
1 14mm
Spark Ignitor
Spark
Electrode

For those COMBUSTIFUME® Burners using flame
rods, most applications are covered by one of three
sizes (specific number depends on nominal length “N”
of rod extension). These may need cut to dimension
“L” specified in tables on page 9908A before use in
your particular application.
N
Universal support bracket 7-1/2"
Normally used in pairs as shown below. Mount to
12"
Two versions available: zinc plated carbon steel for 24"
maximum inlet temperature up to 750°F (399°C) or
#304SS for maximum inlet temperature up to 1600°F
(871°C).
9/03
INCINO-PAK® Burner Back Inlet Feed Section
Nameplate located on Nameplate located on

COMBUSTIFUME® Burner body INCINO-PAK® Burner gas inlet body
COMBUSTIFUME® Line Burners
To order replacement parts: Item

Part Description
® Number
1. Identify specific COMBUSTIFUME
1 Burner body
series/type from burner assembly 2 Back up bar (straight)
information plate pictured on page 5720. 3 Gasket, body (straight)
2. Provide sketch of burner arrangement, 4 Back up bar (inside)
as viewed from back (or casting side) of 5 Gasket, inside
assembly. For example: 6 Back up bar (outside)
7 Burner body gasket (between joints)
9 6" mixing plate
13 M10 - 1.5 finished hex nut
3. Specify quantity of each replacement 16 #10 -24 x 2-1/4" indented hex head machine screw
item required from table at right. 17 Washer
19 M10 - 1.5 hex nut finished
9/03
Notes
COMBUSTIFUME® Line Burners Page 5700-S-1
a safety control system) shut the fuel supply off with a
These mounting instructions for COMBUSTIFUME®
Burners are in addition to the general AIRFLO® Line loss of electrical power. Manual reset valves require
Burner installation instructions published on operator attendance each time the system is started
Maxon catalog pages 5000-S-1 through 5000-S-10. up (or restarted after a shut-down). Motorized shut-
Specific instructions are also offered for other off valves permit automatic start/restart when used
Maxon component items: with appropriate control system.
– Shut-Off Valves (pages 6000-S-1 through S-14) Test connections are essential for burner adjust-
– Flow Control Valves (pages 7000-S-1 through S-4) ment. At a minimum, they should be provided down-
– Mixing Tubes (pages 3200-S-1 through S-6) stream of any mixing tube and at each burner inlet.
Read complete instructions before proceeding, Test connections should never be installed in elbows
and familiarize yourself with all the system’s equip- or pipe tees. Test connections must be plugged
ment components. Verify that your equipment has except when readings are being taken.
shutdown periods of more than a few hours. Maxon 4. Tighten the bolts again to the full value starting at
Control Valves, such as the Series “CV” and position 1 and working to position 6.
MICRO-RATIO® Valves, are not intended for tight
shut-off.
required pressure, including pipe train losses and any
positive chamber pressure. Follow the instructions
attached to the regulator during installation.
to meet pilot flow and pressure needs), a solenoid
Bolt Size Bolt Material Torque Value Units
valve and shut-off cock. An adjustable gas orifice at
M10 Plated steel 186 in lbs
the pilot inlet simplifies adjustment.
M10 Stainless steel 248 in lbs
Appropriate pilots should be provided which are
compatible with the type of burner and control system M10 High Alloy 45 ft lbs
being used.

mCORPORATION
Page 5700-S-2 COMBUSTIFUME® Line Burners
INCINO-PAK® Burner Sections
INCINO-PAK® Burner sections are special configu- INCINO-PAK® Burner sections mount through the
rations of 12" and 36" back inlet feed sections de- duct/chamber wall and extend the AIRFLO® Burner
signed to provide “outside-the-duct” access to the body and mixing plates out into the air stream. They
pilot, ignitor and flame safeguard components. must still be profiled in the duct, since velocity must
These sections are used in end-fired incinerators or be maintained just like all Maxon AIRFLO® Burners.
preheaters, or when burner is fired at an elbow in the The externally mounted burner body housing
ductwork. As such, the mounting and installation of remains on the outside of the duct/chamber.
INCINO-PAK® Burner sections differs slightly from the A typical INCINO-PAK® Burner system piping
other Maxon AIRFLO® Burners. layout is illustrated in the drawing below:
Maxon assumes no responsibility for the use or misuse of the piping layout shown. Specific piping and
wiring diagrams should always be submitted to the appropriate agencies for approval on each
application.
mCORPORATION

INCINO-PAK® Burner Mounting CAUTION: Prior to attempting burner separa-
tion, completely remove the spark ignitor from
the INCINO-PAK® Burner assembly. Replace
ignitor only after INCINO-PAK® section is securely
mounted.
Remove remaining (3) flange bolts from burner
inlet flange. (Instruction packet is attached to this
flange joint at time of manufacture.) Once the (4) body
inlet flange bolts are removed, the burner element can
be separated from the gas inlet tube sub-assembly by
pulling gas inlet body out of burner element.
NOTICE: The gas scanner
tube and spark ignitor tube
must align themselves with
the large holes in the burner
body casting face.
A typical method of through-wall mounting of
INCINO-PAK® Burner is shown above. The This alignment and the
INCINO-PAK® Burner’s back housing is normally inlet flange joint integrity
mounted and secured onto a separate “wall plug” that must be maintained when
is large enough to allow the burner element to be burner is re-assembled.
inserted through the duct/chamber wall opening and Place large body flange
center itself in the profile plate. The burner element’s gasket (shipped loose) onto
weight must be independently supported. gas inlet tube to seal body
The “wall plug” is secured into the opening of the inlet flange and combustion
duct/chamber wall, positioning the burner element in chamber wall joint prior to
the air stream, and providing a maintenance/inspec- mounting burner element
tion access port for the burner and combustion and/or gas inlet burner body
chamber. into position on your combus-
The INCINO-PAK® Burner section can be used tion chamber.
alone (with appropriate end plates, etc.) or as an inlet Provide a liberal coating of
feed section in a larger COMBUSTIFUME® Burner the high-temperature “Never-
assembly. Seez” gasket paste (shipped
You must separate the INCINO-PAK® Burner loose) on both metal flange
body housing and gas scanner tube sub- surfaces. Insert the 2"
assembly from the COMBUSTIFUME® Burner diameter inlet flange gasket
element, then re-assemble it after mounting in (shipped loose) between
your duct/chamber. these surfaces prior to re-
assembling burner element
and inlet tube sub-assembly.
NOTE: Wooden alignment
dowels inserted through the
large holes of the burner
element face casting will help
to remount and align the gas
scanner tube and spark
ignitor tube when re-assem-
bling the burner assembly.

m
CORPORATION

If Maxon instructions conflict with any codes or Typical Electric Control Motor
regulations, contact Maxon Corporation before with Series “CV” Control Valve
For initial burner start-up of raw Check for proper blower motor rotation and
gas burner system: are working. Allow air handling equipment to run
1. Close all burner fuel valves or cocks. Make for adequate purge of your manifolds and com-
preliminary adjustments to fuel gas regulators. bustion chamber plenums. With main gas shut
Remove pilot and main gas regulators’ adjusting off, manually advance MICRO-RATIO® Control
screw covers. Turn adjusting screw down Valve’s operating crank to “high fire” position so
(clockwise) to approximately mid-position. Close that air only flows through burner and combustion
pilot gas adjustable orifice screw by turning in chamber.
Then back out the adjustable orifice (counter- CAUTION: Do not by-pass control panel timers
clockwise) approximately 2-3 turns. typically controlling sequential operations.
2. Check all electric circuitry. Verify that all 6. To light and adjust gas pilot: Pilot gas regula-
control devices and interlocks are operable and tor should initially be set at approximately mid-
functioning within their respective settings/ point of its adjustment range. With pilot gas
ranges. Be sure all air and gas manifolds are solenoid valve closed, open main fuel gas and
tight and that test ports are plugged if not being pilot gas cock. Energize spark ignitor and open
used. pilot gas solenoid. Observe pilot ignition through
3. Check that all duct and chamber dampers a sight port and/or by viewing micro-amp signal
are properly positioned and locked into metered from flame safeguard relay circuit.
operating positions. Refine pilot setting for a hard blue flame (and/or
Initial start-up adjustment should only be accom- strongest flame safeguard signal) by adjusting gas
plished during a “manual” burner control mode. flow through pilot orifice and/or pilot regulator.
7. Prepare to ignite main burner by adjusting
4. Disconnect the automatic control motor’s main gas regulator to approximately midpoint
linkage from your MICRO-RATIO® Control of its adjustment range. Linkage arrangement for
Valve’s operating crank arm (or from your the use of Series “CV” Gas Control Valve is
Maxon Control Valve) by loosening the control illustrated above for a typical control motor.
motor’s connecting rod from the valve’s toggle Arrange accordingly.
mCORPORATION


8. With control valve at “minimum”, ignite main C. Once your flame is established and refined at
burner by opening main fuel shut-off valve. this position, and without advancing the
Adjust main gas regulator to give the desired screw carrier quadrant higher, screw all
outlet pressure. Refine pilot adjustment if it has remaining screws down to at least the same
been affected. Adjust burner “minimum” by level as your first adjusted screw.
turning in on the minimum stop screw of the gas NOTE: A preliminary setting can be estab-
control valve until stable flame appears in the lished with all the remaining adjusting
narrow zipper channel at the base of burner screws. Generally, each succeeding screw
mixing plates. needs to be screwed in approximately one
A good minimum fire should provide uniform full turn deeper than its preceding screw. A
flame across the entire burner face, contained smooth “stair-step” gradient pre-set at this
within the zipper flame channel at the base of point from low to high will simplify the re-
burner mixing plates. Any thin spots or gaps maining adjustment steps.
indicate uneven air velocity over the burner D. Without advancing the SYNCHRO Valve
which must be corrected or a higher minimum quadrant, screw down on second screw (one
fire established by continuing to turn in on the or two turns). Then slowly advance the
minimum stop screw. SYNCHRO Valve quadrant to the #1 posi-
NOTE: If your Maxon COMBUSTIFUME® tion. Refine flame appearance at this new
Burner was furnished with an adjustable gradi- position.
ent type Series “Q” or SYNCHRO Control Valve E. Turn all higher-numbered screws in at least
instead of a Series “CV” Valve, proceed to step as far as the one last adjusted, then turn next
8A for specific instructions and differences in one in as necessary to achieve desired flame
adjustment procedures. while rotating valve mechanism to that
position on indicator strip.
Adj. Screws F. Repeat for each remaining screw.
(under cover) NOTE: To avoid possible damage to cam
strips, always turn all higher-numbered
Handle for
screws in as far as the one last adjusted.
Manual
Operation
G. Refine adjustment as needed, always turning
Position valve so that position indicator matches
Indicator screw being adjusted. For more fuel, turn
Pointer screw in (clockwise); for less fuel, turn screw
out (counter-clockwise). If screws must be
Locking Screw
turned in flush with carrier casting, increase
for manual
operation fuel pressure and re-adjust by starting at
minimum over again.
H. Cycle system off and on, and through all
A. From step #5, the automatic control motor firing rates until satisfied with performance.
linkage has already been disconnected from I. Reconnect control motor linkage and check
your adjustable gradient type control valve that operator does not “bind” and that all
and the valve is at its “minimum” position. interlocks are performing properly.
B. Open fuel supply and begin adjustment of 9. Adjust burner “high fire” by slowly rotating
appropriate adjustable gradient valve by fuel control valve crank arm towards its
turning in minimum (or lowest numbered) maximum. Observe flame characteristics
screw until desired flame is achieved. (Main carefully. Flame should remain a bright blue
fuel regulator may need adjusted at this color with a length beyond the mixing plates as
point.) indicated in capacity/specification data. If flame
becomes too long and yellow, gas pressure is
too high and/or air velocity is too low.

m
CORPORATION

NOTE: Dust and/or chemicals entrained into crank ➃ to the previously-determined maximum
passing air stream may affect physical color of firing rate position. Tighten toggle clamp bolt ➂,
flame. In this case, adjust burner for stable flame thus fixing clamp to motor crank.
shape and geometry. Cycle control motor back to minimum, watch-
To measure gas pressure, connect water ing carefully that it does not bind before reaching
column (manometer) to the test connection in minimum.
burner’s end plate. To determine air velocity, If it is stopped or if minimum is not reached,
use a velometer at the profile opening. Correct loosen toggle clamp screw ➀ and move toggle
velocities by increasing or decreasing profile clamp along the connecting linkage so both
opening size. motor and valve can assume their minimum
If flame is too short, gas pressure may be too positions. Then retighten toggle clamp screw ➀.
low and should be increased or velocities are Refine adjustment by cycling several times
too high and may need to be decreased. Note between low and high control motor position
that air velocities should be measured only when while re-adjusting toggle clamp bolt ➂ as
the fan is handling air at the desired control necessary until control motor travels through its
temperature. full cycle while moving control valve crank arm
The desired maximum capacity may be from its minimum only up to the desired maxi-
achieved with less than full control valve open- mum previously determined.
ing. Mark with a pencil or scribe the point on 11. Relight burner and cycle control system from
valve crank arm where the desired maximum is low to high fire several times to observe
obtained, then return crank arm to low position performance. Refine adjustments of pilot and
and shut system off. main burner minimum if necessary.
10. Referring to illustration on page 5700-S-4,
reconnect control motor linkage (with control
motor in low or minimum position) by loosening
toggle clamp screw ➀ and moving toggle clamp
➁ along the connecting linkage to a point where
toggle clamp bolt ➂ can be placed at the 12. Check carefully that all interlocks and limits
outermost position of control motor crank slot. are in full operating condition and before
Then tighten toggle clamp screw ➀, thus fixing system is placed into full service, instruct
clamp to linkage. operator personnel on proper start-up,
Allowing toggle clamp bolt ➂ to slide in the operation and shut-down of system, estab-
crank arm slot, cycle control motor towards its lishing written instructions for reference.
maximum position and move fuel control valve
Raw Gas Firing Start-Up Instructions for INCINO-PAK® Burner Sections

INCINO-PAK® Burner
sections are started up in the
same manner as other
COMBUSTIFUME® Burners,
except the designed manifolding
for the raw gas brings all the
components to the “outside” of
the duct.
INCINO-PAK® Burners as
described earlier for raw gas
m CORPORATION


COMBUSTIFUME® Line Burners may also be Gas supply piping must be large enough to
installed in oxygen-starved air streams. In those maintain the required fuel pressures cataloged for the
applications, a full or partial premixed air/gas mixture particular burner size used with burner operating at
must be supplied to your COMBUSTIFUME® Burner full-rated capacity.
to support proper combustion. With “partial-premixed” Natural gas pressure generally required (as
COMBUSTIFUME® Burner systems, a Series “HG” measured at the mixer gas inlet) is 1 PSIG higher
Mixing Tube with MICRO-RATIO® Control Valve is than air pressure for “HG” Mixing Tubes.
often used to premix gas and air prior to its introduc- Anything more than minimal distance or piping
tion to the COMBUSTIFUME® Line Burner assembly. turns may necessitate “oversizing” piping runs to keep
A typical “HG” Mixing Tube system piping pressure drops within acceptable ranges.
layout is illustrated below. Inlet pipe leading to any burner should be at least
four pipe diameters in length. If multiple burners are
For initial burner start-up of partial-

premixed burner system:
Start-up steps #1 through #5 are the same for
partial-premix and raw gas burner systems. See page
5700-S-4 for first five start-up steps, then continue
with step #6 below.
misuse of the piping layout shown. Specific
pressure only at each burner with a water
Combustion air blower provides the air (oxygen) column manometer. Any reading below 0.25" wc
supply to your combustion system and is essential to differential (natural gas) requires re-adjustment
the mixing of fuel gas. It should be located in the as described below.
coolest, cleanest position that you can find near the Setting minimum mixture pressure with a
burner itself. It must not be exposed to direct radiant MICRO-RATIO® Control Valve and Series
heat or positioned where it might draw in the inert “HG” Mixing Tube system:
gases or hot air rising from a furnace or oven. If If minimum mixture pressure must be in-
problems exist, consider filters, relocation and/or creased, open the MICRO-RATIO® air valve
ducting of an outside fresh air supply. slowly (by turning toward higher-numbered
Minimize combustion air pressure drop between positions) until the required differential air
blower and mixing tube. Keep a minimum straight run (mixture) pressure is reached, then mark air
of four pipe diameters into the mixer air inlet. Down- valve dial at the position opposite pointer. This
stream piping from mixer to burner should be kept as point will become the minimum air setting for
short as possible. your MICRO-RATIO® Valve mixing tube system
Electrical service must match the voltage, phase (see sketch on page 5700-S-8).

mCORPORATION

Having marked and/or recorded the MICRO-
RATIO® Control Valve’s air valve settings for
both minimum and maximum firing positions,
you may adjust the linkage and travel of the gas
valve’s stroke (see sketch below).

“minimum”.
maximum-end adjustment point. (Note: It doesn’t
matter which is maximum or minimum, as long
as you identify and keep the same reference
points for the next adjustment steps.)
Now rotate MICRO-RATIO® Valve to “maxi-
tube system.
mum” position. The air valve maximum setting
was previously determined. Loosen binding
screw “B” and adjust pointer and linkage to
correct just half the distance required to make
the air valve pointer indicate the maximum air
valve setting.
m
CORPORATION


Re-tighten binding screw “B” and return the NOTE: At this point, it is more important to get
MICRO-RATIO® Valve to the “minimum” air any kind of a flame as soon as possible. The
setting. flame geometry can be adjusted and refined as
This time, loosen set screw “A” and again needed later.
correct for just half the distance required to Continue turning in slowly until flame be-
make the air valve pointer indicate the minimum comes noticeably rich (usually purple or green
air valve setting. with a slight yellow tip). Then slowly back the
Re-tighten set screw “A” and again return the screw out until the flame becomes bright blue.
MICRO-RATIO® Valve to its maximum position. A good minimum fire should provide uniform
Similarly, correct one half the distance with flame across the entire burner face, contained
binding screw “B” for the maximum setting, etc. within the zipper flame channel at the base of
Continue this adjustment procedure until the burner mixing plates. Any thin spots or gaps
gas and air valves reach their minimum and indicate uneven air velocity over the burner
maximum positions simultaneously. Normally, which must be corrected or a higher minimum
this is accomplished within seven adjustments. fire established by continuing to turn in on the
7. Remove cover plate from screw carrier cam minimum stop screw.
assembly and turn all adjusting screws counter- 10. Once your flame is established and refined at
clockwise until flush with outer surface of casting this position, and without advancing the screw
(new equipment is shipped this way). carrier quadrant higher, screw all remaining
8. Open main and pilot gas cocks and light first screws down to at least the same level as your
burner pilot following instructions appropriate for first adjusted screw.
that burner and pilot type. If multiple pilots are NOTE: A preliminary setting can be established
used, open individual cocks and adjust each in with all the remaining adjusting screws. Gener-
turn. ally, each succeeding screw needs to be
To light and adjust gas pilot: Check to screwed in approximately one full turn more
insure pilot combustion air supply is flowing to (clockwise) than its preceding screw. A smooth
any pressure pilot mixer. Pilot gas regulator “stair-step” gradient pre-set at this point from low
should initially be set at approximately midpoint to high will simplify the remaining adjustment
of its adjustment range. With pilot gas solenoid steps.
closed, open main fuel gas and pilot gas cock.
return MICRO-RATIO® Control Valve to
minimum position and shut off fuel (if flame
safeguard has not already done so). Turn in
slightly on adjusting screw at point where
Refine pilot setting for a hard blue flame
ignition was lost, then return valve to minimum
(and/or strongest micro-amp signal) by adjusting
position, re-establish pilot, open fuel valve and
gas flow through pilot orifice and/or pilot
verify ignition.
regulator.
Shut off pilot gas cock to extinguish pilot fire. 11. Without advancing the valve quadrant, screw
Re-open and confirm easy re-ignition several down clockwise on second screw (one or two
times. The flame safeguard relays should now turns). Then slowly advance the screw carrier
power the main fuel shut-off valves. quadrant to the #1 position. Adjust flame
9. Light main burners at minimum as follows: appearance at this new position.
First, turn MICRO-RATIO® Valve to its NOTE: If firing chamber is of refractory construc-
minimum setting (which may be at position 1 or tion, allow your burner system to operate at this
2 after completing step 6), then open fuel shut- low setting for the necessary dry/cure-out time
off valve and turn corresponding screw in period recommended by the chamber or refrac-
(clockwise) until flame ignites at all burner tory manufacturer. Then continue adjustments of
nozzles. (This may take several turns of the valve.
screw.)

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CORPORATION

12. Again, without moving valve, bring the third and CAUTION: After completing previously listed
all remaining adjusting screws down to the same steps, check all interlocking safety components
level as the second screw. and circuitry to prove that they are properly
NOTE: If approximate pre-set gradient was installed, correctly set, and fully operational. If
made earlier, the remaining screws will already in doubt, shut the system down, close main and
be at or below appropriate levels. pilot cocks, and contact responsible individual
progression slope from your first screw to the 14. Reconnect linkage to control motor, plug all
“maximum” position. test connections, replace equipment cover caps
As each is adjusted, you must turn the and tighten linkage screws.
to prevent possible damage to flexible cam through light-off at minimum, interrupting pilot,
strips inside the screw carrier cam assembly. and allowing temperature control system to
Turning a screw in “clockwise” gives more cycle burner from minimum to maximum and
gas at that setting; turning it out gives less. return.
NOTE: To adjust the flame at any position, you Re-check all safety system interlocks for
must move the valve quadrant to the number proper setting and operation.
you desire to adjust. This aligns the adjusting WARNING: Test every UV installation for
screw directly on top of the fuel valve plunger. A dangerous spark excitation from ignitors and
resulting adjustment of the screw is directly other possible sources of direct or reflected UV
applied to the fuel valve plunger and its intercon- radiation. Use only gas-tight scanner
nected valve body linkage. connections.
recommended), shut off pilots and cycle burner operation and shut-down of system. Establish
mCORPORATION

COMBUSTIFUME® Line Burners Page 5700-A/P-1
Assembly Numbers
COMBUSTIFUME® Line Burners Ductile iron bodies Ductile iron bodies
Material Specifications > w/#310 SS mixing plates w/ Hastelloy X mixing plates
Configured Item Number > CF4D24 CF4D48 CF4D96 CF4D120 CF5D24 CF5D48 CF5D96 CF5D120
Old Style 4CF 4CF4 4CF5 --- 5CF 5CF4 5CF5 ---
Designations >
Current CF4D24 CF4D48 CF4D96 CF4D120 CF5D24 CF5D48 CF5D96 CF5D120
1047387 1047394 1047401 1047408 1047415 1047422 1047429 1047436
6" straight (-6)
(15) (15) (15) (15) (15) (15) (15) (15)
1047388 1047395 1047402 1047409 1047416 1047423 1047430 1047437
12" straight (-12)
Burner (18) (18) (18) (18) (18) (18) (18) (18)
Sections 1047389 1047396 1047403 1047410 1047417 1047424 1047431 1047438
12" x 6" tee (-T)
(30) (30) (56) (30) (30) (30) (30) (30)
1047390 1047397 1047404 1047411 1047418 1047425 1047432 1047439
12" x 12"cross (-X)
(37) (37) (37) (37) (37) (37) (37) (37)
1047391 1047398 1047405 1047412 1047419 1047426 1047433 1047440
Back Inlet Feed 12" back inlet straight (12B) (31) (31) (31) (31) (31) (31) (31) (31)
Sections
1047392 1047399 1047406 1047413 1047420 1047427 1047434 1047441
(each requires 12" x 12" back inlet cross (-BX)
(42) (42) (42) (42) (42) (42) (42) (42)
inlet flange from
Page 5700-A/P-2) 36" back inlet "H" section (-BH) 1047393 1047400 1047407 1047414 1047421 1047428 1047435 1047442
(95) (95) (95) (95) (95) (95) (95) (95)
COMBUSTIFUME® Line Burners Aluminum bronze bodies

Material Specifications > w/Hastelloy X mixing plates
Configured Item Number > CF5B24 CF5B48 CF5B96 CF5B120
Old Style 6CF4 --- --- ---
Designations >
Current CF5B24 CF5B48 CF5B96 CF5B120
1047443 1047447 1047451 1047455
6" straight (-6)
(18) (18) (18) (18)
Burner 1047444 1047448 1047452 1047456
12" straight (-12)
Sections (20) (20) (20) (20)
1047445 1047449 1047453 1047457
12" x 6" tee (-T)
(35) (35) (35) (35)
Back Inlet Feed
Sections
1047446 1047450 1047454 1047458
(each requires inlet 12" back inlet straight (12B)
(36) (36) (36) (36)
flange from Page
5700-A/P-2)
NOTE: To order line burner arrangements, order the appropriate configured item number. To order loose

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CORPORATION
Page 5700-A/P-2 COMBUSTIFUME® Line Burners
Assembly Numbers
Inlet Flange Options
Description All CF4 CF5D CF5B
1.5" 1.5" Inlet Flange (12B) 1.5D BIF 1.5B BIF
For 12" (-B)

2" 2" Inlet Flange (12B) 2D BIF 2B BIF
back inlet 2.5" 2.5" Inlet Flange (12B) 2.5D BIF 2.5B BIF
sections
3" 3" Inlet Flange (12B) 3D BIF 3B BIF
A.N.S. Inlet 4" 4" Inlet Flange (12B) 4D BIF ---

Flange Options 1.5" 1.5" Inlet Flange (36B) 1.5D BIF ---
(for inlet feed
sections on Page For 36" (-BH) 2" 2" Inlet Flange (36B) 2D BIF ---
5700-A/P-1) back inlet 2.5" 2.5" Inlet Flange (36B) 2.5D BIF ---
sections
3" 3" Inlet Flange (36B) 3D BIF ---
4" 4" Inlet Flange (36B) 4D BIF ---
For 12"x12" (-BX) 3" 3" Inlet Flange (cross) 3D XIF ---
back inlet cross
sections 4" 4" Inlet Flange (cross) 4D XIF ---
Segment Choice Detail –Configured Inlet Flanges for Back Inlet & Cross Sections
Configured Item Segment Choice
FLANGE DI Ductile iron

1.5D BIF MATERIAL GI Gray iron
2D BIF
2.5D BIF GAS ANSI_THRD ANSI threaded
3D BIF CONNECTION ISO_THRD ISO threaded
4D BIF
1.5B BIF 1000 1000°F approach air temperature (max)
2B BIF
2.5B BIF 1050* 1050°F approach air temperature (max)
3B BIF MAX APPROACH
450 450°F approach air temperature (max)
3D XIF AIR TEMP (F)
4D XIF 600 600°F approach air temperature (max)
NOTE: All choices are not available in some cases.
mCORPORATION

Assembly Numbers
Ductile iron bodies Ductile iron bodies Aluminum bronze
COMBUSTIFUME® Line Burners Material Specifications> w/#310 SS mixing w/Hastelloy X bodies w/Hastelloy
plates mixing plates X mixing plates
Configured Item Number> CF4D24 - 120 CF5D24 - 120 CF5B24 - 120
PLAIN END PLATE SET: 2-PC
End Plate Sets (A) 1047743 (4) 1047750 (4) 1047757 (4)
Plain end plate set - 2 piece
DIR SPRK SET W/18075 SI
Direct spark set includes #18075 spark ignitor &
1047744 (4) 1047751 (4) ---
provision to mount a flame rod (order #18117
Direct Spark End flame rod, if used, separately)
Plate & End Inlet
Flange Sets (A) 2" INLET DS SET W/18075 SI
2" inlet direct spark set includes #18075 spark
1047745 (4) 1047752 (4) ----
ignitor & provision for mounting a flame rod (order
#18117 flame rod, if used, separately)
BUILT-IN PILT SET (DIRECT MNT)
Built-in pilot set, for direct mounted flame rod/UV
scanner & spark ignitor, includes #18075 spark 1047746 (6) 1047753 (6) 1047758 (6)
ignitor (order #18291 flame rod, if used,
separately)
BUILT-IN PILT SET (EXT MOUNT)
Built-in pilot set, for externally mounting flame
rod/UV scanner & spark electrode (order flame rod 1047747 (6) 1047754 (6) 1047759 (6)
and/or electrode and external mounting assembly
Pilot End Plate separately)
Sets (A) AIRFLO-PAK PILT SET (DIR MNT)
AIRFLO-PAK pilot set, for direct mounted flame
rod/UV scanner & spark ignitor, includes #18075 1047748 (8) 1047755 (8) 1047755 (8) [1]
spark ignitor (order #18291 flame rod, if used, and
pilot mixer separately)
AIRFLO-PAK PILT SET (EXT MNT)
AIRFLO-PAK pilot set, for externally mounting
flame rod/UV scanner & spark electrode (order 1047749 (8) 1047756 (8) 1047756 (8) [1]
flame rod and/or spark electrode, pilot mixer and
external mounting assembly separately)
ATMOSPHERIC PILOT MIXER
20103 (1) 20103 (1) [1]
Pilot Mixers for Atmospheric pilot mixer
AIRFLO-PAK pilots PRESSURE PILT MIXER W/ADJ ORIF
(A) Pressure pilot mixer 11680 (2) 11680 (2) [1]
includes #38579 adjustable orifice
EXT MTG PLT: INT SI & EXT UV
40907 (3)
External Mounting For internal spark ignitor & external UV scanner
Plate Assemblies EXT MTG PLT: EXT SPK ELEC & UV
(A) For external spark electrode & external UV 36544 (3)
scanner (order shrouded electrode separately)
[1] Uses ductile iron castings instead of aluminum-bronze castings. Lowers the maximum approach temperature to 1000°F.

mCORPORATION
Assembly Numbers
COMBUSTIFUME® Line Burners Material Specifications> w/#310 SS mixing w/Hastelloy X bodies w/Hastelloy
plates mixing plates X mixing plates
Configured Item Number> CF4D24 - 120 CF5D24 - 120 CF5B24 - 120
DIRECT MOUNTED SPARK IGN: 14MM
18075 (0.5)
Direct mounted spark ignitor 14mm
EXT MTD SHROUDED ELEC: L=12"
36539
12" External mounted shrouded electrode
EXT MTD SHROUDED ELEC: L=18"
36540
Spark Ignitor EXT MTD SHROUDED ELEC: L=24"
36541
Sub-Assemblies 24" External mounted shrouded electrode
(A) EXT MTD SHROUDED ELEC: L=36"
36542
QUARTZ IGNITOR W/DI END FLG
CF4DQIGN CF5DQIGN ---
Quar tz ignitor w/ DI flange (See Page 5700-A/P-6)
QUARTZ IGNITOR W/AL-BZ END FLG
Quar tz ignitor w/ AI BRZ flange CF5BQIGN
(See Page 5700-A/P-6)
FR-DIRECT MOUNTED (L=7.125")
Direct mounted flame rod sub-assembly 18117
(length=7.125")
FR-DRCT MNTD (L=7.125") W/RBR CVR
(length=7.125") with rubber cover
FR-DIRECT MOUNTED (L=12")
Flame Rod (length=12")
Sub-Assemblies
(A) FR-DRCT MNTD (L=12") W/RBR CVR
(length=12") with rubber cover
Externally mounted flame rod sub-assembly 18410
(length=24")
Externally mounted flame rod sub-assembly 1050319
with cover (length=24")
UNIVERSAL SUPPORT BRKT: (CS)
Universal suppor t bracket, plated carbon steel, 23577
good up to 800°F (order in pairs)
UNIVERSAL SUPPORT BRKT: #304SS
Universal suppor t bracket,#304SS, good up to 39940
1600°F (order in pairs)
DIVISION PLATE
1048448
Division plate (A)
Optional
PROFILE PLATE BRACKET
Accessory & 24003
Profile plate bracket (A)
Replacement Items
Electrode cover for flame rod or spark ignitor,
18722
good for up to 450°F (R)
BODY FLANGE KITS
1049627 or 1049626 or 1049625
Body flange kits (fastener kits for joining two
(depends on temperature)
burner bodies)
2" END INLET FLANGE
End inlet flange kit (See Page 5700-A/P-5 for CF4D 2EIF CF5D 2EIF CF5B 2EIF
segment choices)
mCORPORATION

Assembly Numbers
Configured End Inlet Flange Kits - Segment Choices
Configured
Item Segment Choices Descriptions Segment Values
Number
2" NPT W/ .75"-10 THRD
For quar tz ignitors
2" ISO W/ .75"-10 THRD
2" NPT W/ 18075 (14MM) IGNITOR
Local internal ignitor
2" ISO W/ 18075 (14MM) IGNITOR
2" NPT W/ .62 DRILL-THRU
CF4D 2EIF For feed-through shrouded ignitors
CF5D 2EIF 2" ISO W/ .62 DRILL-THRU Specify quantities
CF5B 2EIF
600F BODY FLANGE KIT (STL) 600°F body flange fastener kit
800F BODY FLANGE KIT (SS) 800°F body flange fastener kit
High temperature body flange kit for
CF4D and CF5D
High temperature body flange
fastener kit for CF5B

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CORPORATION
Assembly Numbers
Segment Choice Detail – Quartz Ignitors
Configured Segment Choices
Item Number (DEFAULT is shaded)
12 12" long
18 18" long
20 20" long
24 24" long
LENGTH
30 30" long
36 36" long
42 42" long
CF4DQIGN 48 48" long

CF5DQIGN CS Carbon steel
MATERIAL
SS Stainless steel
MAX APPROACH AIR TEMP (F)
FLANGE KIT
YES Choice selected
12 12" long
18 18" long
24 24" long
LENGTH 30 30" long
36 36" long
42 42" long
48 48" long
CF5BQIGN MATERIAL SS Stainless steel
MAX APPROACH AIR TEMP (F) 450 450°F approach air temperature (max)
FLANGE KIT
YES Choice selected
mCORPORATION

Assembly Numbers
Configured Spare Parts Kits
Description Aluminum bronze bodies Ductile iron bodies
COMBUSTIFUME® Burners CFB RSP CFD RSP
Segment Choice Detail - Configured Spare Parts Kits for COMBUSTIFUME® Burners
Segment Choices
DIRECT MTD SPARK IGNITOR NONE No segment choices available
7.125" LONG (FOR DIR MTD) 7.125" flame rod for direct mounting
MOUNTED FLAME ROD 12" LONG (FOR DIR MTD) 12" flame rod for direct mounting
24" LONG (FOR EXTL MTD) 24" flame rod for external mounting
7.125" LONG (FOR DIR MTD) 7.125" flame rod for direct mounting
MTD FLAME ROD W/RUBBER COVER 12" LONG (FOR DIR MTD) 12" flame rod for direct mounting
24" LONG (FOR EXTL MTD) 24" flame rod for external mounting
INERNAL SPARK FEED-THRU NONE No segment choices available
FEED-THRU INSULATOR PACKING NONE No segment choices available
CERAMIC IGNITOR
CERAMIC IGNITOR W/RUBBER CVR
QUARTZ IGNITOR
QUARTZ IGNITOR W/CS TUBE
Continued on following page

mCORPORATION
Assembly Numbers
Segment Choice Detail - Configured Spare Parts Kits for COMBUSTIFUME® Burners (continued)
Segment Choices
QUARTZ IGNITOR W/SS TUBE
RUBBER COVER NONE No segment choices available
Adjustable orifice available only with ductile iron body
ADJUSTABLE ORIFICE Not Available NONE
assemblies
GASKET SEALANT NONE No segment choices available
Segment Choice Detail -Configured Spare Parts Kits for COMBUSTIFUME® Burners (continued)
Segment Choices
Segment Name Aluminum Secondary Segment Choices Segment Choice Description
Ductile Iron
Bronze
BODY FLANGE CHOICES
GASKET/FASTENER KITS
CROSS BACK INLET CHOICES
SEAL PLATE CHOICES
mCORPORATION

Assembly Numbers
Optional Accessory and Replacement Items - Spark Ignitors
COMBUSTIFUME® Line Burner
with #310 SS mixing with Hastelloy X bodies w/Hastelloy X
Material Specifications >
plates mixing plates mixing plates
Configured Item Number > CF4D24 - 120 CF5D24 - 120 CF5B24 - 120
12" 24715
18" 21063
Ceramic ignitor
24" 21064
36" 35553
12" 36539
Ceramic ignitor 18" 36540
with rubber cover 24" 36541
36" 36542
12" 44665
18" 44666
20" 45716
24" 44667
Quartz ignitor
30" 44668
36" 44669
42" 44935
Spark Ignitors 48" 44670
(R) 12" 44658
18" 44659
20" 45715
with carbon steel tube 30" 44661
36" 44662
42" 44933
48" 44663
12" 44652
18" 44653
20" not available
with stainless steel tube 30" 44655
36" 44656
42" 44934
48" 44657

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CORPORATION
Assembly Numbers
Optional Accessory and Replacement Items - Flame Rods
Ductile iron Ductile iron bodies Aluminum bronze
bodies with #310 with Hastelloy X bodies w/Hastelloy X
SS mixing plates mixing plates mixing plates
7.125" long (for direct
18117
Mounted Flame mounted)
Rod 12" long (for direct mounted) 18291
24" long (for external mounted) 18410
Flame Rods
7.125" long (for direct
Mounted Flame mounted) 1037597
Rod with Rubber
12" long (for direct mounted) 1050318
Cover
24" long (for external mounted) 1050319
Optional Accessory and Replacement Items - Gasket/Fastener Kits

Ductile iron Ductile iron bodies Aluminum bronze
bodies with #310 with Hastelloy X bodies w/Hastelloy X
SS mixing plates mixing plates mixing plates
Body Flange 600°F (max) Gasket Kit 1049627
Gasket/ Choices 800°F (max) Gasket Kit 1049874
Fastener Kits 1050°F (max) Gasket Kit 1049875
Cross Back Inlet 600°F (max) Gasket Kit 1049896
Plated (600°F max) 1068683
End Plate Spare Stainless Steel (800°F max) 1068685
Fastener Kits A-286 High Temp
1068681
(1050°F max)
Seal Plate
Seal Plate Gasket Only 1047669
Choices
mCORPORATION

Assembly Numbers
Raw Gas INCINO-PAK® Burner Sections Segment choices are as follows for
(includes spark electrode & adjustable pilot gas orifice) configured products:
Ductile iron bodies Ductile iron bodies
Description with #310 stainless with Hastelloy X • Connection type
steel mixing plates mixing plates • Back inlet type
Series 600 CF • Section type
• Extension (location A)
Series 800 CF CF4D IP CF5D IP
• Extension (location B)
Series 1100 CF • Extension (location C)
NOTE: Each open end of these burner sections must be closed • Extension (location D)
off with an end plate from options listed onpage 5700-A/P-3. • Max. Approach Air Temp. (°F)
Segment Choice Detail – INCINO-PAK® Burner Sections

Segment Choice
(DEFAULT is shaded)
ANSI_THRD ANSI threaded
CONNECTION TYPE Type of threaded connection
ISO_THRD ISO threaded
BACK INLET TYPE Type of back inlet 600 23.8" (600 mm) wall to body centerline
12B 12" B straight back inlet
SECTION TYPE Type of burner section
36H 36" H back inlet
EXTENSION (LOCATION A) Additional section 12 12" straight section
EXTENSION (LOCATION B) Additional section 12 12" straight section
EXTENSION (LOCATION C) Additional section 12 12" straight section
EXTENSION (LOCATION D) Additional section 12 12" straight section
MAX. APPROACH AIR Maximum approach air 450 450°F approach air temperature (max)
TEMP (°F) temperature 600 600°F approach air temperature (max)

m CORPORATION
Assembly Numbers
Configured Spare Parts Kit for CF INCINO-PAK® Burners
Description Ductile Iron Bodies
600 CF INCINO-PAK 600 IP RSP

Item Numbers (If ordered individually)
Segment Description Segment Choice
600 800 1100
SPARK IGNITOR Specify quantity 36934 36935 36936
ADJUSTABLE ORIFICE Specify quantity 15726
MOUNTING GASKET
(10" diameter)
BODY GASKET (5.75" diameter) Specify quantity 1047672
INLET FLANGE GASKET Specify quantity 1047675
GASKET SEALANT (1/4 lb.) Specify quantity 39565
LV HIGH TEMPERATURE
FASTENER KIT*
CF HIGH TEMPERATURE
FASTENER KIT
*Intended for LV INCINO-PAK® Burners (refer to Catalog Section 5400)
mCORPORATION

Bulletin 5750
Circular INCINO-PAK® Burners
Circular INCINO-PAK® Burner shown with wall mounting plug
• Circular INCINO-PAK® Burners have been specifically designed for the thermal incineration in
cylindrical combustion chambers of combustible gaseous effluents from a wide variety of industrial
processes.
• These special cone-type COMBUSTIFUME® Burners provide outside-the-duct access to the

raw gas pilot, ignitor, and flame safeguard components. The vital parts are easily retractable and
protected from the heat from the combustion chamber. Easy installation, operation, and maintenance
are assured.
• Considerable savings in primary energy are realized since the raw gas Circular INCINO-PAK®
Burners do not require any external combustion air source. All the oxygen for combustion comes
from the oxygen content normally in most effluent air streams.
• Two popular sizes are offered: 4,000,000 or 8,000,000 maximum Btu/hr capacities. Both sizes
provide 20:1 turndown capabilities on natural gas.
• Application of a Maxon Circular INCINO-PAK® Burner greatly simplifies the construction

of your cylindrical incinerator chamber, since both burner sizes are available as “standard” with a
through-the-wall mounting, or complete with an insulated “wall mounting plug” that further simplifies
burner installation.
Page 5752

The time-tested Maxon AIRFLO® Burner prin-
ciples are also designed into the Circular INCINO-
PAK® Burner. A customer-installed profile plate
surrounds the burner and creates a pressure drop
which directs the passing effluent air stream through
the burner’s cone and extension ring at a high
velocity where it is mixed with a controlled volume of
fuel gas. With the intensive mixing and turbulent
condition created within the burner’s mixing cone, a
rapid temperature rise from the combustion reaction is
produced to help ensure complete incineration of the
effluents.
The burner is a nozzle-mixing type which does
not need external combustion air; only the fuel gas
flow needs to be controlled.
The burner can be ignited by means of the
integrated raw gas pilot, or by direct-spark ignition of Cross sectional view
the main burner. Direct-spark ignition must incor-
porate a “low fire start” inter-lock.
A special feature is the central gas inlet on
which a spark ignitor, a pilot and sight tube for the If necessary, the extension ring can be replaced,
UV-scanner are mounted. These vital parts are e.g. if the burner has to operate under severe working
easily retractable and protected from the heat ema- conditions.
nating from the combustion chamber. Neither the A complete Circular INCINO-PAK® Burner
pilot nor ignitor/sight tube need any compressed/ system normally includes a gas train, an adjustable
cooling air. gradient-type gas control valve and a combustion
The mixing cone is two-part: the primary cone control panel. Your Maxon representative can help
of a special stainless steel, which can withstand very you choose from the broad range available.
high temperatures. It not only guarantees resistance
to high-reaching temperatures but also ensures Circular INCINO-PAK® Burner
accurate supply of oxygen-bearing effluent to the applications
burner. This burner is typically used for direct gas-fired
Radial and tangential drillings in this primary incineration of combustible gaseous effluents in
cone create the right swirl required to mix oxygen- applications such as:
bearing effluent and gas correctly inside the mixing Coil coating lines Paint baking ovens
cone resulting in an excellent flame stability and a Fiberglass curing Printing processes
large turndown. Lithographing ovens Textile dryers
The special connection between the primary Metal coating lines Wire enameling
cone and extension ring allows for expansion in all
directions. The construction is such that no mounting
or support brackets are required, thus avoiding
deformation.
7/92
Circular INCINO-PAK® Burners Page 5753

Determine air stream flammability limits Profiling for higher temperature
and/or minimum oxygen content levels. applications
Since oxygen content within the effluent is critical When calculating profile dimensions for Circular
to the flammability range of any raw gas type burner, INCINO-PAK® Burner systems in applications with
it also directly affects the maximum capacity (Btu/hr) higher inlet air temperatures, greater temperature
of a Circular INCINO-PAK® Burner. rises, and/or variable air stream volumes, the effluent
The chart (below) graphically relates the incoming with elevated temperatures and densities must be
air stream temperatures (°F) and the measured considered.
percentage of oxygen remaining in this effluent.
Any combination of temperature and oxygen
level falling above the raw gas firing diagonal line Burner Design Parameters
should support combustion with a raw gas Circu-
lar INCINO-PAK® Burner system.
Temperature limits:
CAUTION: Combinations of incoming tempera-
Maximum Inlet 1200°F (649°C)
tures and measured percent of oxygen falling
below the diagonal line are not acceptable Temperatures Outlet 1700°F (927°C)
applications for the raw gas Circular INCINO-
PAK® Burner. Alternate choices may be selected
from Maxon catalog sections 4200 and/or 5700. Burner net free areas:
4M size 110 square inches
8M size 170 square inches
Calculating Circular INCINO-PAK®

Burner capacity requirements in
effluent air streams:
Sample calculations for designing a raw gas
Circular INCINO-PAK® Burner system for a thermal
fuel incinerator (with 16+% oxygen level) are provided
on the following page.
To calculate heat requirements, you must know:

SCFM of effluent air stream
°F inlet air temperature
°F outlet air temperature
7/92
Page 5754 Circular INCINO-PAK® Burners

General Selection Procedure CFH gas

Evolvement of “K” = x 1000
1. Determine available oxygen level in air stream SCFM air
to be heated.
For a raw gas application, we will use 16+%
oxygen level. Enter chart at 700°F inlet temperature line (from step
2. Determine the SCFM of air through the incinera- 3); follow across to intersect the 1500°F discharge
tor. Include any variations in this flow. temperature sloped line, then drop straight down to
For our calculations, we will use a constant read the “K” multiplier factor of 1150.
volume air fan of 5000 SCFM. Therefore, the maximum heat input required:
3. Determine inlet temperature of effluent to
Circular INCINO-PAK® Burner. Btu/hr = 5000 SCFM x 1150 = 5,750,000
We will use inlet temperature of 700°F.
4. Determine outlet or discharge temperatures Calculating Circular INCINO-PAK® Burner
from the incinerator. profile opening:
For our example, we will design for 1500°F.
5. Calculate maximum total heat required. 6. “Net” profile opening calculations:
Btu/hr = SCFM x “K” ACFH

Net Area (in2) =
(from step 2) (from chart below) 1655 x “K” x inches wc drop
Multiply SCFM of air by multiplier (K), which specific gravity
combines hypothetical available heat and a 1.08
composite air heating factor to give the value in Btu
required being “gross heating value” of fuel. Since ACFH = SCFM x 460 + inlet temp. x 60 min/hr
multiplier (K) varies with inlet and discharge air
temperature, the various factors are graphically 460 + ambient temp.
shown below:
“K” = 0.78 orifice coefficient for Circular
For 1300°F, 1500°F and 1700°F
INCINO-PAK® Burner profile opening
discharge temperatures
Inches wc drop = desired pressure drop
(see optimum range on page 5755)
Specific gravity = 1.0 x 460 + ambient temp.

460 + inlet temp.
7. “Gross” opening calculations:
Gross opening =
net area + (425.6 in2 – burner net free area)
(from (approx. area (from chart
step 6) of extension pg. 5753)
sleeve blockage)
Radius = Gross opening

3.14
Diameter = 2 x radius

Required natural
gas inlet Capacities (Btu/hr) Series “G” Circular INCINO-PAK® Burners
pressures (in
inches wc) for Performance Data
capacities shown 4M 8M
18" wc 6,000,000 12,000,000
Operations in gray
12.5" wc 5,000,000 10,000,000
shaded areas require
8" wc 4,000,000 8,000,000 special consideration
4.5" wc 3,000,000 6,000,000
3.2" wc 2,500,000 5,000,000
2" wc 2,000,000 4,000,000
1.125" wc 1,500,000 3,000,000
0.5" wc 1,000,000 2,000,000

Optimum
Design
Area
0.125" wc 500,000 1,000,000

450,000 900,000
0.08" wc 400,000 800,000
350,000 700,000
300,000 600,000
0.03" wc 250,000 500,000
200,000 400,000
150,000 300,000 Operations in gray

shaded areas require
special consideration
0.005" wc 100,000 200,000
50,000 100,000
Duct static pressure drop
through profile plate 0.2 0.3 0.4 0.5 0.7 0.9 1.0 1.2 1.5 2.0 2.5 3.0 4.0
(inches wc)
Approximate air stream
1500 1750 2000 2500 3000 3500 4500 5500
velocities (SFPM)
7/92

Series “G” Circular INCINO-PAK® Burner with wall mounting plug
Series “G” Circular INCINO-PAK® Burner for through-wall mounting
Spark Ignitor

– Spark ignitor assembly
– Extension ring
To order parts for an existing Circular INCINO-PAK®
Burner assembly, list:
1. Name(s) or part(s) from above illustration
3. Burner nameplate information:
• size and series number of burner
• designation
• if available, serial number of Maxon fuel shut-off
valve in-line to burner (This serial number is on
Maxon valve’s nameplate.)
7/94
Notes
Circular INCINO-PAK® Burners Page 5750-S-1
General Fuel shut-off valves (when properly connected to a
safety control system) shut the fuel supply off with a
These mounting instructions for Circular INCINO-
PAK® Burners are in addition to the specific instruc- loss of electrical power. Manual reset valves require
tions offered for other Maxon component items: operator attendance each time the system is started
– Shut-Off Valves (pages 6100-S-1 through S-10) up (or restarted after a shut-down). Motorized shut-
– Flow Control Valves (pages 7000-S-1 through S-4) off valves permit automatic start/restart when used
Clean fuel lines are essential to prevent blockage with appropriate control system.
of pipe train components or burner gas ports. All dirt, Test connections are essential for burner adjust-
scale and pipe dope should be blown out of any gas ment. At a minimum, they should be provided at each
line before actually connecting to the burner system. burner inlet. Test connections should never be
Main gas shut-off cock should be upstream of installed in elbows or pipe tees. Test connections
both main gas regulator and pilot line take-off. Use it must be plugged except when readings are being
to shut off fuel to both pilot and main burner during taken.
shutdown periods of more than a few hours. Circular INCINO-PAK® Burners are special configu-
rations of back inlet feed sections designed to provide
Maxon Control Valves, such as the Series “Q” “outside-the-duct” access to the pilot, ignitor and
and MICRO-RATIO® Valves, are not intended for flame safeguard components.
tight shut-off. These burners are used in end-fired incinerators or
Main gas regulator is essential to maintain a preheaters. As such, the mounting and installation of
uniform system supply pressure. A separate regulator Circular INCINO-PAK® Burners differs slightly from
should be provided in the branch leading to each other types of Maxon AIRFLO® Burners.
burner system if more than one is served by a com- Circular INCINO-PAK® Burners mount through the
mon main. Size regulator for full system capacity at duct/chamber wall and extend their burner mixing
required pressure, including pipe train losses and any cones out into the air stream. They must still be
positive chamber pressure. Follow the instructions profiled in the chamber, since a pressure drop must
attached to the regulator during installation. be maintained within certain limits just like all Maxon
Pilot take-off should be upstream of main gas AIRFLO® Burners.
regulator but downstream of main gas cock. It should The externally mounted burner body housing
normally include its own pilot gas regulator (selected remains on the outside of the duct/chamber.
to meet pilot flow and pressure needs), a solenoid A typical Circular INCINO-PAK® Burner system
valve, and shut-off cock. The adjustable gas orifice piping layout is illustrated in the drawing below:
cock at the pilot inlet simplifies adjustment.
Maxon assumes no responsibility for the use or misuse of the piping layout shown. Specific
piping and wiring diagrams should always be submitted to the appropriate agencies for
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CORPORATION
Page 5750-S-2 Circular INCINO-PAK® Burners
Circular INCINO-PAK® Burner mounting
Customer fabricated profile plate required.

To assure proper operating design pressure drop
for optimum performance of your Maxon Circular
INCINO-PAK® Burner, it is necessary to reduce the
duct area at the location of the burner assembly. This
is done by “silhouetting” the burner element with an
opening in a plate at right angles to the direction of
the air stream movement.
The profile opening should be shaped to frame
your burner as symmetrically as possible, and sized
to maintain the desired operating pressure drop
through the spaced opening surrounding the burner
element.
All Maxon Circular INCINO-PAK® Burner assem-
blies must have a specific design operating pressure
drop across and through the burner element. Consult
Maxon catalog specification for the pressure drop
required to obtain the burner capacity for your specific
application. Install profile plates to attain this pressure
drop.
For best mixing downstream, the profile plate
should extend a minimum of 6" from the walls of
the duct around the entire burner assembly.
The burner cone should protrude about 2 inches
through the profile plate.
A differential pressure switch (or manometer) can
The Circular INCINO-PAK® Burner is used only be mounted across the profile plate to make sure the
for the heating of air in motion. It should be mounted burner only operates when pressure drop is high
so as to direct its flame parallel to and in the same enough. Provide sufficient test connections for
direction as the movement of the air which is to be measuring process differential pressure.
heated. Observation sight windows (ports) located in
Do not mount the Circular INCINO-PAK® Burner so duct to permit visual inspection of pilot and main
that the flow of air is across the face of the cone, nor burner flame(s) help on initial start-up, as well as with
should it be mounted too near to a turn in the duct routine maintenance/inspections.
which will cause the air to be directed at an angle The Circular INCINO-PAK® is a raw gas burner.
over the burner. There is no flammable air-gas mixture in the feeder
Flow of air at operating temperature must be line. However, the burner depends completely on the
uniform and pressure drops not less than the effluent air stream to supply the oxygen for combus-
values specified for the application. tion. A correct pressure drop is therefore very impor-
tant. The nominal process air pressure drop is 0.5 to
2.0" wc and should be checked prior to start-up, as
well as the burner installation and its profile plate, the
electrical wiring, and the leak testing of the pipe train.
mCORPORATION


tion systems, with control/safety circuitry and
Series “Q” Valve with connecting base and linkage position-
ing a typical electric control operator
For initial burner start-up of raw
gas burner system: Set minimum differential pressure with
1. Close all burner fuel valves or cocks. Make minimum stop screw located on the side of the
preliminary adjustments to fuel gas regulators. screw carrier quadrant of Series “Q” Control
Remove pilot and main gas regulators’ adjusting Valve (see sketch below).
screw covers. Turn adjusting screw down
(clockwise) to approximately mid-position. Close
pilot gas adjustable orifice screw by turning in
Then back out the adjustable orifice (counter-
clockwise) approximately 2-3 turns.
ranges. Be sure all air and gas manifolds are
tight and that test ports are plugged if not being This minimum stop screw creates a mechani-
used. cal block which prohibits the screw carrier
3. Check that all duct and chamber dampers quadrant and its direct-connected air butterfly
are properly positioned and locked into valve from closing completely. Thus a “mini-
operating positions. mum” volume of fuel is allowed in through the
control valve to the burner(s). This becomes the
Initial start-up adjustment should only be accom- minimum gas pressure.
plished during a “manual” burner control mode. Screwing in (clockwise) on the minimum stop
4. Disconnect the automatic control motor’s screw through its lock nut will open up the
linkage from your Maxon Control Valve’s butterfly and increase the minimum differential
operating crank arm by loosening the control pressure setting.

m
CORPORATION

Once your manometer readings confirm the Turning in the adjusting screws ⑤ (clockwise)
minimum differential readings, lock the minimum gives a contour to flexible steel cam strips ➅ .
stop screw in that position so the valve cannot These cam strips bear on a plunger and cap
be moved back below this minimum firing assembly ➆ that determines opening of the gas
position. Regardless of what numerical value the butterfly valve. Cam strips serve to provide a
indicator strip shows, this becomes the minimum continuous gradient.
firing position for your specific system in this Turning adjusting screw in until it is flush with
application. quadrant and opens gas butterfly fully. Do not
5. Start all system-related fans and blowers. attempt to force screw further.
Check for proper blower motor rotation and 8. With control valve at “minimum”, ignite main
impeller direction. Verify that all control inter- burner by opening main fuel shut-off valve.
All Maxon Flow Control Valves are designed for
throttling service only and are not intended for
combustion chamber plenums.
tight shut-off.
NOTE: If your Maxon Circular INCINO-PAK®
Burner was furnished with an adjustable gradi-
6. To light and adjust gas pilot: Pilot gas regula- ent type SYNCHRO Control Valve instead of a
tor should initially be set at approximately mid- Series “Q” Valve, proceed to step 8A for specific
point of its adjustment range. With pilot gas instructions and differences in adjustment
solenoid valve closed, open main fuel gas and procedures.
pilot gas cock. Energize spark ignitor and open
pilot gas solenoid. Observe pilot ignition through Adj. Screws
a sight port and/or by viewing micro-amp signal (under cover)
Handle for
Refine pilot setting for a hard blue flame (and/or
Manual
strongest flame safeguard signal) by adjusting gas Operation
flow through pilot orifice and/or pilot regulator. Position
7. Prepare to ignite main burner by adjusting Indicator
main gas regulator to approximately midpoint Pointer
of its adjustment range.
The quadrant (shown in sketch on page 5750- Locking Screw
S-3) is rotated either manuall or by a control for manual
operation
operator to change firing rate as indicated by a
position indicator strip. The minimum stop screw
limits rotation and establishes a minimum flow. A. From step #4, the automatic control motor
linkage has already been disconnected from
your adjustable gradient type control valve
and the valve is at its “minimum” position.
B. Open fuel supply and begin adjustment of
appropriate adjustable gradient valve by
turning in minimum (or lowest numbered)
screw until desired flame is achieved.
C. Once your flame is established and refined at
this position, and without advancing the
screw carrier quadrant higher, screw all
Removing a cover strip reveals a numbered remaining screws down to at least the same
series of adjusting screws ➄ which bear on a set level as your first adjusted screw.
of cam strips ➅ beneath the quadrant (see sketch
above).
mCORPORATION


NOTE: A preliminary setting can be estab- To measure gas pressure, connect water
lished with all the remaining adjusting column (manometer) to the test connection in
screws. Generally, each succeeding screw burner’s back plate. To determine pressure
needs to be screwed in approximately one drop, use a manometer or differential pressure
full turn deeper than its preceding screw. A switch (see page 5750-S-2) at the profile
smooth “stair-step” gradient pre-set at this opening. Correct pressure drop by increasing or
point from low to high will simplify the re- decreasing profile opening size.
maining adjustment steps. If flame is too short, gas pressure may be too
D. Without advancing the SYNCHRO Valve low and should be increased or pressure drops
quadrant, screw down on second screw (one are too high and may need to be decreased.
or two turns). Then slowly advance the Note that pressure drops should be measured
SYNCHRO Valve quadrant to the #1 posi- only when the fan is handling air at the desired
tion. Refine flame appearance at this new control temperature.
position. 10. Referring to photograph on page 5750-S-3,
E. Turn all higher-numbered screws in at least reconnect control motor linkage (with control
as far as the one last adjusted, then turn next motor in low or minimum position).
one in as necessary to achieve desired flame Tighten toggle clamp bolt and secure clamp
while rotating valve mechanism to that to motor crank.
position on indicator strip. Cycle control motor back to minimum, watch-
F. Repeat for each remaining screw. ing carefully that it does not bind before reaching
NOTE: To avoid possible damage to cam minimum.
strips, always turn all higher-numbered If it is stopped or if minimum is not reached,
screws in as far as the one last adjusted. loosen toggle clamp screw and move toggle
G. Refine adjustment as needed, always turning clamp along the connecting linkage so both
valve so that position indicator matches motor and valve can assume their minimum
screw being adjusted. For more fuel, turn positions. Then retighten toggle clamp screw.
screw in (clockwise); for less fuel, turn screw Refine adjustment by cycling several times
out (counter-clockwise). If screws must be between low and high control motor position
turned in flush with carrier casting, increase while re-adjusting toggle clamp bolt as neces-
fuel pressure and re-adjust by starting at sary until control motor travels through its full
minimum over again. cycle while moving control valve crank arm from
H. Cycle system off and on, and through all its minimum only up to the desired maximum
firing rates until satisfied with performance. previously determined.
I. Reconnect control motor linkage and check 11. Relight burner and cycle control system from
that operator does not “bind” and that all low to high fire several times to observe
interlocks are performing properly. performance. Refine adjustments of pilot and
9. Adjust burner “high fire” by slowly rotating main burner minimum if necessary.
fuel control valve crank arm towards its
maximum. Observe flame characteristics
carefully. If flame becomes too long and yellow,
gas pressure is too high and/or air velocity is too
low.
12. Check carefully that all interlocks and limits
NOTE: Dust and/or chemicals entrained into
are in full operating condition and before
passing air stream may affect physical color of
system is placed into full service, instruct
flame. In this case, adjust burner for stable flame
operator personnel on proper start-up,
shape and geometry.
operation and shut-down of system, estab-
lishing written instructions for reference.

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CORPORATION

Raw Gas Firing Start-Up Instructions for Circular INCINO-PAK® Burner Sections
Circular INCINO-PAK®
Burner sections are started up
in the same manner as other
raw gas AIRFLO® Burners,
except the designed manifolding
for the raw gas brings all the
components to the “outside” of
the duct.
as described earlier for raw gas
m CORPORATION

Circular INCINO-PAK® Burners Page 5750-A/P-1
Assembly Numbers
Series “G” Circular INCINO-PAK® Burners Replacement Items
Series "G" Standard Burner assembly Spark Ignitor assembly includes
41057
INCINO-PAK® through-wall complete with #41058 ignitor, #18722 electrode cover,
(2)
Burner Size assembly wall plug spark wire & ceramic spacers
39425 39629 15726

4M Pilot adjustable orifice cock
(110) (225) (1)
39557 39630 21639

8M Observation glass
(110) (225) (0.5)
Spark ignitor assembly includes
46900
#41058 ignitor, #18722 electrode cover,
(1)
spark wire & quar tz tube

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CORPORATION
Bulletin 5800
LO-NOX™ Line Burners
24 lineal feet assembly of LN4-12-G LO-NOX™ Burner including end plates and pilot assembly
• Provides direct-fired, in-the-duct, process air heating with greatly reduced generation of NOx
• Burns clean and odor-free with most low pressure gaseous fuels
• Direct-firing optimizes heat transfer efficiencies. All available heat from the gaseous fuel is
released directly into the passing air stream.
• Modular burner design permits shaping the burner element and total heat release to match your
specific application’s requirements. Basic building block concept provides infinite number of possible
burner configurations to meet your needs.
• Long service life and lower maintenance cost result from rust-resistant iron burner bodies and
the controlled expansion of stainless steel mixing plate’s design
• High turndown ratio promotes application flexibility for all fresh or recirculated air stream
heating

Page 5802

LO-NOX™ Line Burners are designed for heating
process air-in-motion and consist of a rust-resistant
iron body (which serves as the air/fuel manifold), drilled
to discharge the fuel/air mixture between diverging
stainless steel or Hastelloy-X mixing plates.
mixing plates. Carefully controlled mixing plate aeration
patterns give progressive mixing, superior cross-
ignition and flame retention across the entire burner
assembly length. The LO-NOX™ Line Burner burns
clean and odor-free with extremely low levels of NOx
production.
Accurate air/fuel ratio and air velocities with
resulting duct static pressure drop are the key to
successful operation. They are established by the
use of a customer-installed profile plate within the duct.
A minimum profile plate width of 6" is required LO-NOX™ Line Burners are part of a complete
surrounding all LO-NOX™ Line Burner assemblies. burner system designed and proven to give low
Optimum burner performance and maximum formation of oxides of nitrogen.
service life demands that air stream velocities be A complete LO-NOX™ Burner system normally
uniform across the entire burner assembly. includes a gas train, proportioning/mixing equipment,
Normal capacities vary widely with applications. combustion air supply, and a combustion control panel.
Fuel used and design velocities affect turndown. Your Maxon representative can help you choose from
Modular design permits shape and total heat release to the broad range available.
match your application needs. LO-NOX™ Line Burners are offered in three
Performance data varies depending upon different types. Each type is optimized for a specific
temperature of air upstream and downstream of burner type of application. All require a full air/gas premixture
assembly, the percent of oxygen (by volume) in the and are intended for use in heating process air in
passing air stream, and the allowable duct static motion with maximum inlet air temperatures up to
pressure drop (which relates to velocity of air across 800°F (427°C):
the burner). • LN-3 LO-NOX™ Line Burners have iron bodies and
#321 stainless steel mixing plates and require an
Combustion Air Requirements air/gas premixture system and/or outlet
Combustion air blower should be sized for an air/fuel temperatures up to 1000°F (538°C).
ratio of 14:1. • LN-4 LO-NOX™ Line Burners have iron bodies and
CAUTION: A variation in excess of ±25°F #310 stainless steel mixing plates as above for
combustion air temperature can affect NOx level applications with outlet temperatures up to 1500°F
production and/or cross ignition of a LO-NOX™ (816°C).
Burner. Locate air inlet of combustion air blower in • LN-5 LO-NOX™ Line Burners compliment their iron
area where incoming air temperature is relatively bodies with Hastelloy-X mixing plates for use in
constant. applications with up to 1700°F (927°C) outlet
temperature requirements.
9/03
LO-NOX™ Line Burners Page 5803

Total heat release and LO-NOX™ Burner footage Burner duct area displacement
are normally selected from the tables given in the For purposes of calculating operating air velocities
Series “HG” Mixing Tube section of the Maxon and resulting static pressure drops across the burner
catalog (Section 3200). assembly and profile plate, use the following equiva-
Nominal burner capacity lent displacements:
Each 6" straight section: 0.35 ft2
Maximum: 550,000 Btu/hr per lineal foot Each 12" straight section: 0.7 ft2
(requires 12" wc mixture pressure) Each 12" x 6" tee section: 0.75 ft2
Minimum: 140,000 Btu/hr per lineal foot Each 12" x 12" cross section: 0.85 ft2
(requires 0.8" wc mixture pressure)
For example:
A LO-NOX™ Line Burner assembly is made up of:
(2) 12" straight sections @ 0.7 ft2 displ. area
(1) 12" back inlet straight @ 0.7 ft2 displ. area
(2) 12" x 6" tee sections @ 0.75 ft2 displ. area
Total duct area displaced by this burner assembly:
(3 x 0.7 ft2) + (2 x 0.75 ft2) = 3.6 ft2
Volume (CFM)
Velocity (FPM) = Net Free
Area (ft2)
The net free area of the duct, and consequently the

profile opening surrounding the burner element can
be determined by inserting the air volume and/or the
desired operating velocity into this formula. The
burner displaces area in the duct and must be added
to the air handling area to determine the appropriate
profile dimensions.
Air stream velocity and resulting static pressure
drop affect performance and are achieved by means
of a silhouette profile plate within the duct.
A minimum profile plate width of 6" is required
surrounding all LO-NOX™ Line Burner
assemblies.
Air velocity over burner

Based on information given in catalog section Minimum - 700 SFPM
3200, and within the constraints of duct size and air Optimum -1500 SFPM
volume flows, a LO-NOX™ Line Burner assembly is Maximum -3000 SFPM
designed utilizing the available sections shown on the
following pages. NOTE: Burner is not sensitive to velocity variations
When ordering a burner assembly made up from within the desired range, but NOx levels may increase
the module components, be sure to provide an by 33% if fired at 600,000 Btu/hr, ft and at 3000
assembly sketch of the complete burner (as viewed SFPM velocity.
from the back, or upstream, side) including locations
of all accessories and/or individual component
sections.
3/92
Page 5804 LO-NOX™ Line Burners

Manifolding and Ductwork Considerations • Use flexible connectors if assembly includes more
than 2 inlet feed sections.
Manifolding and ductwork considerations are
• Keep main header at least 36" back from burner
extremely important in the design of LO-NOX™
element to lessen chance of “shadow effect” on the
systems. LO-NOX™ Burner systems can be
air flow across the burner.
susceptible to noise generation. In order to minimize
the possibility of noise, we suggest the following: Do not exceed the footage feed limitations shown
– Adjust burner with a “fuel-lean” air/fuel ratio in the table below.
– Burner element should be supported independently
from the manifolding Inlet feed capacity limitations
– No flat transitions or turns should be made in
Burner Inlet Flanges LO-NOX™ Burner
ductwork downstream of burner
– All sheet metal ductwork should be rigidly fastened 2" end inlet flange
1 ft.
and have adequate stiffeners attached 2" back inlet flange
Burner inlet feed piping must be adequate to 2.5" back inlet flange 1.5 ft.
provide a well-distributed flow of air/gas throughout 3" back inlet flange
the burner assembly. 4" back inlet flange 2 ft.
• Be generous with inlet sections. Use enough to 3" back inlet cross flange
achieve a uniform mixture pressure within the 4" back inlet cross flange 4 ft.
burner.
• Use more 12" -B sections, and fewer crosses
(which are most likely to generate noise problems). Inlet flanges bolt directly to burner body casting
• Keep manifolding symmetrical, with an extension and accept threaded NPT piping. Chart above shows
beyond last “take-off” of at least 2 pipe diameters in maximum lineal feet of LO-NOX™ Line Burner that
length. may be fed by a given inlet flange.
LO-NOX™ Line Burner Designation
Example: 12" x 12" BK INLET SECTION LN 5 – BX – D – 120

Section Description
LN = LO-NOX™ Line Burner
5 = Hastelloy-X
Section Code
Body Material
G = gray iron body
T = 12" x 6" tee section
D = ductile iron body
LO-NOX™ Line Burners with Series “HG” Mixing Tubes
Fresh and recirculated air streams may be heated Table 1: Design Parameters
with LO-NOX™ Burners supplied with a full premixture Maximum Combustion air Differential mixture
of air and natural, propane, or butane gas. capacity required pressure (inches w.c.)
A complete burner system to handle these heat release through "HG" Mixing as measured between
applications would include a LO-NOX™ Line Burner Btu/hr per lineal Tube (SCFM per burner inlet and
foot of LO-NOX lineal foot of duct/chamber static
assembly, Series “HG” Mixing Tube, MICRO-RATIO® ™ Burner LO-NOX™ Burner) [1] pressure
Control Valve and a combustion air blower. Your
200,000 40 1.7
Maxon representative can help you select from the
300,000 60 3.5
broad range of options available.
400,000 80 6.5
General Selection Procedure: 500,000 100 10
1. Calculate gross heat requirement. 550,000 110 12
2. Determine burner footage and inlet feed [1] This air volume is for a 12:1 air/gas ratio.
requirements.
3. Enter Table 1 under column with your capacity
needs for parameters of your application. Table 2: Series "HG" Mixing Tube Selection
4. Select “HG” Mixing Tube size from Table 2 based "HG" Mixing SCFM combustion air volume required at
Tube Size maximum through "HG" Mixing Tube
upon the volume of air required.
2" 0 to 190
Example: 3" 90 to 260
– Required heat release of 7,000,000 Btu/hr 4" 175 to 500
From Table 1 6" 400 to 1167
8" 880 to 2500
A. Gross heat required: 7,000,000 Btu/hr
7,000,000 Btu Table 3: Gas Orifice Drillings for Series "HG" Mixing Tubes
B. = 14 ft. NOTE: Drillings below based on 2 PSIG inlet gas pressure
500,000 Btu/ft (measured at "HG" Mixing Tube gas inlet)
For fully premixed systems
C. 14 ft. x 100 SCFM/ft = 1400 SCFM primary air with Size of "HG"
Combustion air Gas orifice drillings for
Mixing Tube
differential mixture pressure = 14" wc pressure LO-NOX™ Burners (number of gas
measured at air for for for orifices in
From Table 2 inlet of "HG" Natural Propane Butane parentheses)
Mixing Tube Gas Gas Gas
D. Since single 8" “HG” Mixing Tube is rated for a
maximum of 2500 SCFM, this requires (1) 8" “HG” 8 osi 11/64" 9/64" #29
Mixing Tube with gas orifices from Table 3. 12 osi 7/32" #16 #18 2" HG
(4)
E. Select MICRO-RATIO® Control Valve 16 osi 15/64" #11 #14
– For 1400 SCFM air = (84,000 SCFH) 8 osi 3/16" #23 #27
– For 7000 SCFH natural gas 12 osi 13/64" #18 #22 3" HG
(6)
(See Maxon catalog bulletin 7000) 16 osi 7/32" #15 #18
NOTE: Select gas control valve carefully to achieve 8 osi A #1 2 #15
maximum operating flexibility within its adjusting 12 osi F #3 #8 4" HG
capability. Keep control valve size small so pressure (8)
16 osi J #1 3/8"
drop through fully open valve at maximum flow
8 osi F #4 #8
capacity is within range of controllability. 6" HG
12 osi K #1 7/32"
F. If available inlet gas pressure is above 10 PSIG, (12)
16 osi N D A
consider double stage regulation to minimize
8 osi S 9/32" 17/64"
droop.
12 osi 13/32" U 11/32" 8" HG
(12)
16 osi 15/32" U 11/32"
9/03

Typical End Views
Straight Tee and


NOTE: 12B and XB back inlet

sections must be ordered with
12" x 12"
one of the back inlet flange
12" back inlet section back inlet cross sets shown below.
Back Inlet Flanges

Flange Sets for 12" Inlet flanges bolt directly to Flange Sets for 12" x 12"
either standard NPT or standard
ISO threaded piping of indi-
cated size.
NOTE: Refer to page 5804
2" 2-1/2" 3" 4"
for specific inlet feed capacity
LFB LFB LFB LFB
limitations. 3" 4"
A (size) B A (size)
2 0.88 3
2.5 4
1.25
3
4 3.5
9/03

Plain end 2" inlet

plate set set
Plain end plate

closure includes
1/8" NPT test
connection
Pilot set
UV scanner can be
flame rod.
Alternate
flame rod
position
Flame rod ( if used) must be ordered separately

with all end plate and pilot sets.
2" inlet pilot set
UV scanner can be
flame rod.
Alternate
flame rod
NOTE: See catalog page position

Pilot Assemblies
AIRFLO-PAK pilot arrangements

Direct mounted version includes 14mm spark ignitor.
Order electrode separately for externally mounted
version. Order flame rod (if used) separately.
Optional air/gas pilot mixers for all LO-NOX™ pilot assemblies
Atmospheric type
with fixed orifice
Atmospheric type
with adjustable orifice Pressure type with adjustable orifice
External Mounting Plate Assemblies as used with AIRFLO-PAK pilot assemblies

External mounting plate assembly for internal spark External mounting plate assembly for external spark
ignitor & internal flame rod electrode & external UV scanner
NOTE: Order
18" long spark
electrode sub-
assembly
separately
External mounting plate assembly for external flame

rod & external spark ignitor
External mounting plate assembly for external NOTE:
UV scanner & internal spark ignitor Order 18"
long spark
electrode
and 24"
flame rod
sub-
assemblies
separately
9/03

External mounting plate details

A plate is included with all assemblies shown on
page 5809.
Mounting plate with two

(2) feed-through insula-
tors for internal mounting
of spark ignitor and flame
assemblies shown on
page 5809.
Positioning mounting plate in relation to

LO-NOX™ Burner pilot location
Through-wall opening required

Provides support for Provides isolation of burner
profile within closed burner feed(s) where desirable.
loop. On some applica-
tions, it may be necessary
to restrict air flow between
adjacent burner rows to Optional electrode cover
achieve design operating Protects porcelain insulator and
velocities. This is done by electrical connection from dirt
installing customer-fabricated profile plates on profile and moisture. May be used for
mounting bracket(s). See sketch 1 below for use on ambient temperatures up to
square openings (formed by adjacent cross-sections 450°F (232°C).
of burner). Sketch 2 applies to rectangular opening.
1 14mm
Spark Ignitor
18"
Spark Electrode

For those burners using flame rods, most
applications are covered by one of three sizes
(specific number depends on nominal length “N” of
rod extension). These may need cut to dimension “L”
specified in tables on pages 9908 and 9908A before
use in your particular application.
N
7-1/8"
Universal support bracket
Normally used in pairs as shown below. Mount to 12"
24"
Two versions available: zinc plated carbon steel for
maximum inlet temperature up to 750°F (399°C) or
#304SS for maximum inlet temperature up to 1600°F
(871°C).
9/03
Maintenance & Component Identification/Spare Parts
Item
Part Description
Number 1. Identify specific LO-NOX™ Burner series/type
1 Burner body from burner assembly information plate pictured
2 Back up bar (straight)
below.
3 Gasket, body (straight)
2. Provide sketch of burner arrangement, as
4 Back up bar (inside)
5 Gasket, inside
viewed from back (or casting side) of assembly.
6 Back up bar (outside) For example:
7 Flame protection rail (outside)
7a Flame protection rail (inside)
9 6" mixing plate
13 M10 - 1.5 finished hex nut 3. Specify quantity of each replacement item
required from table at left.
16 #10 -24 x 2-1/4" indented hex head machine screw
17 Washer LO-NOX™ Line Burner Information Plate
LO-NOX™ Line Burners Page 5800-S-1
These mounting instructions for LO-NOX™ Line a safety control system) shut the fuel supply off with a
loss of electrical power. Manual reset valves require
Burners are in addition to the general AIRFLO® Line
operator attendance each time the system is started
Burner installation instructions published on
Maxon catalog pages 5000-S-1 through 5000-S-10. up (or restarted after a shut-down). Motorized shut-
Specific instructions are also offered for other off valves permit automatic start/restart when used
– Shut-Off Valves (pages 6000-S-1 through S-14) Test connections are essential for burner adjust-
– Flow Control Valves (pages 7000-S-1 through S-4) ment. At a minimum, they should be provided down-
– Mixing Tubes (pages 3200-S-1 through S-6) stream of any mixing tube and at each burner inlet.
Read complete instructions before proceeding, Test connections should never be installed in elbows
and familiarize yourself with all the system’s equip- or pipe tees. Test connections must be plugged
ment components. Verify that your equipment has except when readings are being taken.
Clean fuel lines are essential to prevent blockage Bolt Torque Tightening
of pipe train components or burner gas ports. All dirt, 1. Apply Never-Seez (anti-seize and lubricating
scale and pipe dope should be blown out of any new compound) to the threads of the bolts to improve
gas line before actually connecting to the burner the pre-loading of the gasket.
system. 2. Tighten the bolts to 1/2 the specified value (see
Main gas shut-off cock should be upstream of table below), starting at position 1 and working to
both main gas regulator and pilot line take-off. Use it position 6.
to shut off fuel to both pilot and main burner during 3. Tighten the bolts to the full torque value, starting at
shutdown periods of more than a few hours. MICRO- position 1 and working to position 6.
RATIO® Control Valves are not intended for tight 4. Tighten the bolts again to the full value starting at
shut-off. position 1 and working to position 6.
installation.
normally include its own pilot gas regulator (selected
to meet pilot flow and pressure needs), a solenoid Torque Values
valve and shut-off cock. An adjustable gas orifice at Bolt Size Bolt Material Torque Value Units
the pilot inlet simplifies adjustment. M10 Plated steel 186 in lbs
Appropriate pilots should be provided which are M10 Stainless steel 248 in lbs
compatible with the type of burner and control system M10 High alloy 45 ft lbs
being used.

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CORPORATION
Page 5800-S-2 LO-NOX™ Line Burners
1. Always design air/gas manifold piping for uniform Sketch below shows four inlets being fed from one
distribution to multiple-feed or multiple-burner end-fed header. Note that full premixture manifold
systems. Select manifold piping sizes by start- size is continued past all burner take-offs, and outlet
ing at the burner/nozzle end and working extended and capped one pipe diameter length
backward to the premixer discharge. beyond last take-off. Always keep premixer device a
greater in cross-sectional area than the total cross- take-off.
sectional area(s) of any and all pipes being fed.
air/gas mixture line between the premixing device
and its burner(s).
General Pipe Data

Inside Outside
Diameter Diameter
(inches) (inches)
1/8 0.269 0.405 0.057
1/4 0.364 0.54 0.104
3/8 0.493 0.675 0.191
1/2 0.622 0.84 0.304
3/4 0.824 1.05 0.533
1 1.049 1.315 0.864
1-1/4 1.38 1.66 1.496
1-1/2 1.61 1.9 2.036
2 2.067 2.375 3.356
2-1/2 2.469 2.875 4.788
3 3.068 3.5 7.393
3-1/2 3.548 4 9.887
4 4.026 4.5 12.73
5 5.047 5.563 20.006
6 6.065 6.625 28.89
8 7.981 8.625 50.027
10 10.02 10.75 78.854
12 12 12.75 113.097
mCORPORATION

A fully premixed air/gas mixture must be supplied Natural gas pressure generally required (as
to your LO-NOX™ Burner to support proper combus- measured at the mixer gas inlet) is 1 PSIG higher
tion. With “fully-premixed” LO-NOX™ Burner systems, than air pressure for “HG” Mixing Tubes.
a Series “HG” Mixing Tube with MICRO-RATIO® Anything more than minimal distance or piping
Control Valve is often used to premix gas and air prior turns may necessitate “oversizing” piping runs to keep
to its introduction to the LO-NOX™ Line Burner pressure drops within acceptable ranges.
assembly. Inlet pipe leading to any burner should be at least
A typical “HG” Mixing Tube system piping four pipe diameters in length. If multiple burners are
layout is illustrated below. fed from a single gas train, care should be taken to
For initial burner start-up of LO-NOX™

premixed gas burner system:

Maxon assumes no responsibility for the use or tion systems, with control/safety circuitry and
misuse of the piping layout shown. Specific with knowledge of the overall installation.
piping and wiring diagrams should always be Instructions provided by the company and/or
submitted to the appropriate agencies for individuals responsible for the manufacture
approval on each application. and/or overall installation of complete system
Combustion air blower provides the air (oxygen) incorporating Maxon burners take precedence
supply to your combustion system and is essential to over these provided by Maxon. If Maxon in-
the mixing of fuel gas. It should be located in the structions conflict with any codes or regula-
coolest, cleanest position that you can find near the tions, contact Maxon Corporation before
burner itself. It must not be exposed to direct radiant attempting start-up.
heat or positioned where it might draw in the inert
gases or hot air rising from a furnace or oven. If 1. Close all burner fuel valves or cocks. Make
problems exist, consider filters, relocation and/or preliminary adjustments to fuel gas regulators.
ducting of an outside fresh air supply. Remove pilot and main gas regulators’ adjusting
Minimize combustion air pressure drop between screw covers. Turn adjusting screw down
blower and mixing tube. Keep a minimum straight run (clockwise) to approximately mid-position. Close
of four pipe diameters into the mixer air inlet. Down- pilot gas adjustable orifice screw by turning in
stream piping from mixer to burner should be kept as clockwise until it stops. (Do not over-tighten.)
short as possible. Then back out the adjustable orifice (counter-
Electrical service must match the voltage, phase clockwise) approximately 2-3 turns.
and cycle of all electrical system components and be 2. Check all electric circuitry. Verify that all
compatible with burner nameplate ratings. Insure that control devices and interlocks are operable and
all normal control safeguards are satisfied. Combus- functioning within their respective settings/
tion air blower should continue to run after shutdown ranges. Be sure all air and gas manifolds are
to allow burner to cool. tight and that test ports are plugged if not being
Gas supply piping must be large enough to used.
maintain the required fuel pressures cataloged for the 3. Check that all duct and chamber dampers
particular burner size used with burner operating at are properly positioned and locked into
full-rated capacity. operating positions.

mCORPORATION
linkage from your MICRO-RATIO® Control
Valve’s operating crank arm (or from your
Maxon Control Valve) by loosening the control
impeller direction. Verify that all control inter-
shut off, manually advance MICRO-RATIO®
Control Valve’s operating crank to “high fire”
position so that air only flows through burner and
combustion chamber.
pressure only at each burner with a water Having marked and/or recorded the MICRO-
column manometer. Any reading below 0.10" wc RATIO® Control Valve’s air valve settings for
differential (natural gas) requires re-adjustment both minimum and maximum firing positions,
as described below. you may adjust the linkage and travel of the gas
Setting minimum mixture pressure with a valve’s stroke (see sketch below).
MICRO-RATIO® Control Valve and Series Loosen Allen set screw “A” and binding screw
“HG” Mixing Tube system: “B” in toggle “C”. Move the toggle in universal
If minimum mixture pressure must be in- cam assembly slot towards the center of rotation
creased, open the MICRO-RATIO® air valve so that gas valve can rotate from its minimum to
slowly (by turning toward higher-numbered maximum position, while the air valve swings
positions) until the required differential air between the established (and marked) minimum
(mixture) pressure is reached, then mark air and maximum settings.
your MICRO-RATIO® Valve mixing tube system.
tube system.
mCORPORATION

Place air valve on pre-determined “minimum” Refine pilot setting for a hard blue flame
position and rotate gas valve to its “minimum” (and/or strongest micro-amp signal) by adjusting
setting position. Tighten down set screw “A” and gas flow through pilot orifice and/or pilot
binding screw “B” with both valves set at regulator.
“minimum”. Shut off pilot gas cock to extinguish pilot fire.
Establish set screw “A” as minimum-end Re-open and confirm easy re-ignition several
adjustment point and binding screw “B” as times. The flame safeguard relays should now
maximum-end adjustment point. (Note: It doesn’t power the main fuel shut-off valves.
matter which is maximum or minimum, as long 9. Light main burners at minimum as follows:
as you identify and keep the same reference First, turn MICRO-RATIO® Valve to its
points for the next adjustment steps.) minimum setting (which may be at position 1 or
Now rotate MICRO-RATIO® Valve to “maxi- 2 after completing step 6), then open fuel shut-
mum” position. The air valve maximum setting off valve and turn corresponding screw in
was previously determined. Loosen binding (clockwise) until flame ignites across burner
screw “B” and adjust pointer and linkage to face. (This may take several turns of the screw.)
correct just half the distance required to make NOTE: At this point, it is more important to get
the air valve pointer indicate the maximum air any kind of a flame as soon as possible. The
valve setting. flame geometry can be adjusted and refined as
Re-tighten binding screw “B” and return the needed later.
MICRO-RATIO® Valve to the “minimum” air A good minimum fire should provide uniform
setting. flame across the entire burner face, contained
This time, loosen set screw “A” and again within the zipper flame channel at the base of
correct for just half the distance required to burner mixing plates. Any thin spots or gaps
make the air valve pointer indicate the minimum indicate uneven air velocity over the burner
air valve setting. which must be corrected or a higher minimum
Re-tighten set screw “A” and again return the fire established by continuing to turn in on the
MICRO-RATIO® Valve to its maximum position. minimum stop screw.
Similarly, correct one half the distance with 10. Once your flame is established and refined at
binding screw “B” for the maximum setting, etc. this position, and without advancing the screw
Continue this adjustment procedure until the carrier quadrant higher, screw all remaining
gas and air valves reach their minimum and screws down to at least the same level as your
maximum positions simultaneously. Normally, first adjusted screw.
this is accomplished within seven adjustments. Once the gas is applied to the burner, you
7. Remove cover plate from screw carrier cam may find that a LOUD howling is set-up by the
assembly and turn all adjusting screws counter- duct system. This howling means that the burner
clockwise until flush with outer surface of casting is firing too rich. Back out on the gas screws and
(new equipment is shipped this way). the noise will stop. The burner is then adjusted
8. Open main and pilot gas cocks and light first so that the flame is lean. You will know you have
burner pilot following instructions appropriate for adjusted the burner too lean if the flame fails to
that burner and pilot type. If multiple pilots are cross ignite across the face.
used, open individual cocks and adjust each in NOTE: A preliminary setting can be established
turn. with all the remaining adjusting screws. Gener-
To light and adjust gas pilot: Check to ally, each succeeding screw needs to be
insure pilot combustion air supply is flowing to screwed in approximately one full turn more
any pressure pilot mixer. Pilot gas regulator (clockwise) than its preceding screw. A smooth
should initially be set at approximately midpoint “stair-step” gradient pre-set at this point from low
of its adjustment range. With pilot gas solenoid to high will simplify the remaining adjustment
closed, open main fuel gas and pilot gas cock. steps.
m
CORPORATION
CAUTION: If flame is extinguished, immediately NOTE: Dust and/or chemicals entrained into
return MICRO-RATIO® Control Valve to passing air stream may affect physical color of
minimum position and shut off fuel (if flame flame. In this case, adjust burner for stable flame
safeguard has not already done so). Turn in shape and geometry.
slightly on adjusting screw at point where To measure mixture pressure, connect
ignition was lost, then return valve to minimum water column (manometer) to the test connec-
position, re-establish pilot, open fuel valve and tion in burner’s end plate. To determine air
verify ignition. velocity, use a velometer at the profile opening.
Correct velocities by increasing or decreasing
11. Without advancing the valve quadrant, screw profile opening size.
down clockwise on #2 screw (one or two turns). If flame is too short, gas pressure may be too
Then slowly advance the screw carrier quadrant low and should be increased, or velocities are
to the #2 position. Adjust flame appearance at too high and may need to be decreased.
this new position #2. NOTE: Air velocities should be measured only
NOTE: If firing chamber is of refractory construc- when the fan is handling air at the desired
tion, allow your burner system to operate at this control temperature.
low setting for the necessary dry/cure-out time 13. Cycle burner from minimum to maximum and
period recommended by the chamber or refrac- refine adjustment, if necessary.
tory manufacturer. Then continue adjustments of For operation with interrupted pilot (as
valve. recommended), shut off pilots and cycle burner
12. Again, without moving valve, bring #3 and all from minimum to maximum and back several
remaining adjusting screws down to the same times to verify the flame is maintained.
level as #2 screw.
NOTE: If approximate pre-set gradient was CAUTION: After completing previously listed
made earlier, the remaining screws will already steps, check all interlocking safety components
be at or below appropriate levels. and circuitry to prove that they are properly
Progressively work your way up through each installed, correctly set, and fully operational. If
adjusting screw position, developing a smooth in doubt, shut the system down, close main and
progression slope from your first screw to the pilot cocks, and contact responsible individual
“maximum” position. before proceeding further.
As each is adjusted, you must turn the 14. Reconnect linkage to control motor, plug all
remaining unadjusted screws in at least that far test connections, replace equipment cover caps
to prevent possible damage to flexible cam and tighten linkage screws.
strips inside the screw carrier cam assembly. 15. Check out overall system operation by cycling
Turning a screw in “clockwise” gives more through light-off at minimum, interrupting pilot,
gas at that setting; turning it out gives less. and allowing temperature control system to
NOTE: To adjust the flame at any position, you cycle burner from minimum to maximum and
must move the valve quadrant to the number return.
you desire to adjust. This aligns the adjusting Re-check all safety system interlocks for
screw directly on top of the fuel valve plunger. A proper setting and operation.
applied to the fuel valve plunger and its intercon- WARNING: Test every UV installation for
nected valve body linkage. dangerous spark excitation from ignitors and
Observe flame characteristics carefully. other possible sources of direct or reflected UV
Flame should remain a bright blue color with a radiation. Use only gas-tight scanner
length beyond the mixing plates as indicated in connections.
capacity/specification data. If flame becomes 16. Before system is placed into full service,
long and yellow, gas pressure is too high and/or instruct operator personnel on proper start-up,
air velocity is too low. operation and shut-down of system. Establish
mCORPORATION

LO-NOX™ Line Burners Page 5800-A/P-1
Assembly Numbers
LN3 LN4 LN5

LO-NOX™ Line Burner Material Iron bodies [1] with #321 Iron bodies [1] with #310 Iron bodies [1] with
Specifications> stainless steel mixing stainless steel mixing Hastelloy X mixing
plates plates plates
Configured Item Number> LN3 LN4 LN5
Item Description Designation Designation Designation
6" straight (-6) LN3-6-G-120 1049724 (15) LN4-6-G-120 1049725 (15) LN5-6-G-120 1049726 (15)
Burner 12" straight (-12) LN3-12-G-120 1049739 (22) LN4-12-G-120 1049740 (22) LN5-12-G-120 1049741 (22)
Sections 12" x 6" tee (-T) LN3-T-G-120 1049842 (30) LN4-T-G-120 1049843 (30) LN5-T-G-120 1049844 (30)
12" x 12" cross (-X) [1] LN3-X-D-120 1049775 (35) LN4-X-G-120 1049776 (35) LN5-X-D-120 1049777 (35)
Back Inlet 12" back inlet straight
Feed Sections LN3-12B-G-120 1049754 (31) LN4-12B-G-120 1049755 (31) LN5-12B-G-120 1049756 (31)
(-12B)
(each requires
an inlet flange
from options 12" x 12" back inlet
LN3-BX-D-120 1049833 (42) LN4-BX-D-120 1049834 (42) LN5-BX-D-120 1049835 (42)
listed below) cross (-BX) [1]
2" NPT 04122 (3) / 21380*

For "12B" 2-1/2"
back inlet 18694 (4) / 21444*
NPT
A.N.S. Inlet sections
Flange Options (cast iron) 3" NPT 00295 (5) / 21384*
for back inlet
feed sections 4" NPT 15348 (7) / 25949 *
above For 12" x 12" 3" NPT 18806 (6) / 24493*
back inlet
cross sections
(ductile iron) 4" NPT 18807 (7) / 22006*
Plain end plate set LN3-AL3-G 1050142 (4) LN4-D 1050148 (4) LN5-D 1050153 (4)
End Plate &
End Inlet 2" NPT inlet set LN3-AL3-G 1050143 (4) --- --- --- ---
Flange Sets 2" NPT inlet set w/ SQ
LN3-AL3-G 1052134 --- --- --- ---
Pipe Plug
DS set includes #18075
spark ignitor & provision
for mounting flame rod LN3-AL3-G 1050144 (5) LN4-D 1050149 (5) --- ---
(order #18117 flame rod,
Direct Sparked if used, separately)
End Plate &
End Inlet 2" inlet DS set includes
Flange Sets #18075 spark ignitor &
provision for mounting
LN3-AL3-G 1050145 (5) LN4-D 1050150 (5) LN5-D 1050154 (5)
flame rod (order #18117
flame rod, if used,
separately)
[1] 12" x 12" cross and 12" x 12" back inlet cross sections include ductile iron body castings; all others are gray iron
* ISO threaded.

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CORPORATION
Page 5800-A/P-2 LO-NOX™ Line Burners
Assembly Numbers
LO-NOX™ Line Burner LN3 LN4 LN5
Material Specifications > Gray iron Gray iron Gray iron
bodies [1] with bodies [1] with bodies [1] with
#321 stainless #310 stainless Hastelloy X
Item Description steel mixing steel mixing mixing plates
plates plates
AIRFLO-PAK pilot set FR/SI for direct end-mounted
flame rod/UV scanner & spark ignitor (includes #18075
1050146 (8) 1050151 (8) 1050155 (8)
AIRFLO-PAK Pilot Sets spark ignitor; order flame rod, if used, and pilot mixer
(each requires a pilot separately)
mixer from options listed AIRFLO-PAK pilot set FR/SI for externally mounted
below) flame rod/UV scanner & spark electode (order flame rod
1050147 (8) 1050152 (8) 1050156 (8)
and/or spark electrode, pilot mixer, and external mounting
assembly separately)
Atmospheric pilot mixer 16948 (1) 20103
Pilot Mixer Options for
Atmospheric pilot mixer includes shut-off cock, tubing,
AIRFLO-PAK pilot 12326 (2) --- ---
and #39294 adjustable orifice
assemblies above
Pressure pilot mixer includes #38579 adjustable orifice 17082 (2) 11680
For internal spark ignitor & external UV scanner 19561 (3)
For internal spark ignitor & internal flame rod 19225 (3)
External Mounting For external spark electrode & external UV scanner
Plate Assemblies 36593 (3) 36544 (3)
(order spark electrode separately)
For external spark electrode & external flame rod (order
36594 (3) ---
spark electrode & flame rod separately)
14mm spark ignitor (for direct mounted assemblies) (R) 18075 (0.5)
L = 12" --- 36539 (2.5)
Spark Ignitor/Electrode
L = 18" 36538 (4) 36540 (4)
Sub-Assemblies Externally mounted electrodes (A)
L = 24" --- 36541 (6)
L = 36" --- 36542 (8)
Flame Rod Flame rod L = 7.125" (for direct mounted assemblies) 18117 (0.5) ---
Sub-Assemblies Flame rod L = 24" (for externally mounted assemblies) 36537 (1.3) ---
Plated 1068679
End Plate Spare
Stainless steel 1068678
Fastener Kit
A-286 high temp 1068686
Universal support Plated carbon steel,
23577 (0.2)
bracket good up to 800°F
(order in pairs) (A) #304SS, good up to 1600°F 39940 (0.2)
Division plate (A) 18891 (0.5)
Profile plate bracket (A) 20223 (0.5)
Optional Accessory L = 12" --- 24715 (2)
and L = 18" 17426 (1) 21063 (3)
Replacement Spark electrode (R)
Items L = 24" --- 21064 (4)
L = 36" --- 35553 (5)
Flame rod L = 24" (R) 18410 (1)
Rubber cover for flame rod/spark ignitor (A/R) 18722 (0.2)
Adjustable orifice 3/8" (for pressure pilot mixer) (R) 38579 (0.5)
Adjustable orifice (for atmospheric pilot mixer) (R) 39294 (0.5)
[1] 12" x 12" cross and 12" x 12" back inlet cross sections include ductile iron body castings
mCORPORATION
INDUSTRIAL COMBUSTION EQ
COMBUSTION UIPMENT AND VAL
EQUIPMENT VES
ALVES
LO-NOX™ Line Burners Page 5800-A/P-3
Assembly Numbers
Configured Spare Parts Kits

Description Configured Part Number
LN3 LO-NOX Lineburners LN3 RSP
LN4 & LN5 LO-NOX Lineburners LN4 RSP
Segment Choice Detail - Configured Spare Parts Kits for LN3 LO-NOX
DIRECT MTG SPARK IGNITOR Direct mounted spark ignitor
DIRECT MTG FLAME ROD -7.125" Direct mounted flame rod (length = 7.125")
EXTERNAL MTD FLAME ROD - 24" External mounted flame rod (length - 24")
SPARK ELECTRODE - 18" Spark electrode (length = 18")
BACK INLET FLANGE GSKT - STR Back inlet flange gasket - straight
BACK INLET FLANGE GSKT - H Back inlet flange gasket - H
LN3 RSP

m
CORPORATION
Page 5800-A/P-4 LO-NOX™ Line Burners
Assembly Numbers
Segment Choice Detail - Configured Spare Parts Kits for LN4 & LN5 LO-NOX™ Burners
Configured Item
Segment Name Segment Choices Segment Description
Number
DIRECT MTG SPARK IGNITOR Specify quantity Direct mounted spark ignitor
DIRECT MTG FLAME ROD -7.125" Specify quantity Direct mounted flame rod (length = 7.125")
EXTERNAL MTD FLAME ROD - 24" Specify quantity External mounted flame rod (length - 24")
FEED-THRU INSULATOR PACKING Specify quantity Feed-thru insulator packing
12" SHROUDED ELECTRODE
CERAMIC IGNITOR Ceramic ignitor
CERAMIC IGNITOR W/RUBBER CVR Ceramic ignitor with rubber cover
LN4 RSP RUBBER COVER Specify quantity Rubber cover for flame rod or spark electrode
ADJUSTABLE ORIFICE (PRESS) Specify quantity Adjustable orifice (pressure)
BODY FLANGE GASKET Specify quantity Body flange gasket
BACK INLET FLANGE GSKT - STR Specify quantity Back inlet flange gasket - straight
BACK INLET FLANGE GSKT - H Specify quantity Back inlet flange gasket - H
BACK INLET FLANGE GSKT -CROSS Specify quantity Back inlet flange gasket - cross
GASKET SEALANT Specify quantity Gasket sealant
STR FLANGE KIT 600F (MAX) Specify quantity Straight flange kit 600° F (maximum)
STR FLANGE KIT 800F (MAX) Specify quantity Straight flange kit 800° F (maximum)
STR BI FLANGE KIT 800F (MAX) Specify quantity Straight back inlet flange kit 800° F (maximum)
36H BI FLANGE KIT 800F (MAX) Specify quantity 36H back inlet flange kit 800° F (maximum)
CRSS BI FLANGE KIT 800F (MAX) Specify quantity Cross back inlet flange kit 800° F (maximum)
ADJUSTABLE ORIFICE (ATMOS) Specify quantity Adjustable orifice (atmosphere)
mCORPORATION
INDUSTRIAL COMBUSTION EQ
COMBUSTION UIPMENT AND VAL
EQUIPMENT VES
ALVES
Bulletin 5900
Maxon “HC” AIRFLO® Gas Burners
• High heat release per unit of burner length
• Process pressure drops across the burner as low as 0.2" w.c. (0.5 mbar)
• Operates on low O2 levels in process streams such as turbine exhaust gases
• Short flame length allows use of short combustion chambers
• Extremely clean and odor-free combustion with low NOx and CO production levels
Page 5902
Maxon “HC” AIRFLO® Gas Burners

Maxon Series “HC” AIRFLO® Line Burners are Principle of Operation
designed for fresh and recirculating air heating Part of the air stream to be heated is forced through
applications. It is possible to operate Series “HC” the burner mixing plates and is used as combustion
AIRFLO® Burners in a process air stream with 12% or air. Carefully controlled aeration patterns give pro-
less O2 content, provided adequate inlet temperature. gressive mixing, superior cross-ignition, flame reten-
The design ensures that requirements of space, tion and clean combustion.
capacity and low pressure drops of any application
are met. Applications
• Turbine exhaust reheat applications, with after-
burners where low pressure drops are required.
Start-up burners for fluidized bed combustion.
• Processes where recirculating air has to be re-
heated and where oxygen levels may be down to
12%, but also depending on other parameters.
• Fresh air heating.
End Plate
Mixing
Plate
Pilot
End Plate Burner
Size
Gas
Inlet
7/97
“HC” AIRFLO® Gas Burners Page 5903
Specifications
“HC” AIRFLO® Gas Burners English Units Metric Units
Maximum capacity for TEG 5.5 MBtu/hr/ft 1600 kW/ft
Maximum capacity for fresh air 6.1 MBtu/hr/ft 1800 kW/ft
Minimum capacity for TEG and fresh air heating 0.68 MBtu/hr/ft 200 kW/ft
Fuels Natural gas - hydrogen gas or mixture of both
Natural gas pressure for maximum capacity 14.5 psig 1 bar
TEG 0.2" - 0.6" w.c. 0.5 - 1.5 mbar
Process air pressure differential over burner
Fresh air 0.2" w.c. 0.5 mbar
TEG max. 6.6 ft. 2m at max. capacity
Flame length with natural gas fuel Fresh air 6.6 feet @ 3.4 MBtu/hr/ft
25 m at 1 MW and over
max. and over
Flame width with natural gas fuel 3.28 ft. Approx. 1 m at max capacity
Maximum burner length for end feed fuel inlet 6 ft. 1.83 meters
Burner width 16.53" 420 mm
Burner displacement 1.237 ft2/foot length 1150 cm2/unit
Upstream of
1112°F 600°C
burner
Temperature limits
Downstream
1742°F 950°C
of burner
CO < 100mg/nm3 @ 3% O2
Fresh air CO < 84 ppm @ 3% O2 dr y
dr y
Emissions NOx < 102 ppm @ 3% O2 NOx < 200mg/nm3 @ 3%
Fresh air
dr y O2 dr y
TEG ① Less than TA luft air quality standards
➀ NOx and CO emissions are affected by the O2 level of the turbine exhaust gas (TEG). Check with technical staff at Maxon
Cor poration or Maxon International.
7/97
Page 5904 “HC” AIRFLO® Gas Burners
Specifications
Net free area cm2 required per 1000 actual m3/h air flow
Inlet temperature °C
Press.
drop 15 50 100 150 200 250 300 350 400 450 500 550 600 650
mbar
0.5 394.32 372.34 346.49 325.37 307.69 292.61 279.55 268.10 257.95 248.87 240.69 233.26 226.48 220.26
0.55 375.97 355.02 330.36 310.23 293.37 279.00 266.55 255.63 245.95 237.29 229.49 222.41 215.94 210.01
0.6 359.96 339.90 316.30 297.02 280.88 267.12 255.20 244.74 235.48 227.19 219.72 212.94 206.75 201.07
0.65 345.84 326.57 303.89 285.37 269.86 256.64 245.19 235.14 226.24 218.27 211.10 204.58 198.64 193.18
0.7 333.26 314.69 292.84 274.99 260.05 247.30 236.27 226.59 218.01 210.33 203.42 197.14 191.41 186.16
0.75 321.96 304.02 282.91 265.66 251.23 238.92 228.26 218.90 210.62 203.20 196.52 190.46 184.92 179.84
0.8 311.74 294.36 273.92 257.23 243.25 231.33 221.01 211.95 203.93 196.75 190.28 184.41 179.05 174.13
0.85 302.43 285.57 265.75 249.55 235.99 224.42 214.41 205.62 197.84 190.88 184.60 178.90 173.71 168.93
0.9 293.91 277.53 258.26 242.51 229.34 218.10 208.37 199.83 192.27 185.50 179.40 173.86 168.81 164.18
0.95 286.07 270.13 251.37 236.05 223.22 212.28 202.81 194.50 187.14 180.55 174.61 169.23 164.31 159.80
1 278.83 263.29 245.01 230.07 217.57 206.91 197.68 189.58 182.40 175.98 170.19 164.94 160.15 155.75
1.05 272.11 256.94 239.10 224.52 212.33 201.92 192.91 185.01 178.00 171.74 166.09 160.97 156.29 152.00
1.1 265.85 251.03 233.60 219.36 207.44 197.28 188.48 180.75 173.91 167.79 162.27 157.27 152.70 148.50
1.15 260.01 245.52 228.47 214.54 202.88 192.94 184.33 176.78 170.09 164.10 158.71 153.81 149.34 145.24
1.2 254.53 240.35 223.66 210.02 198.61 188.88 180.45 173.06 166.51 160.65 155.36 150.57 146.19 142.18
1.25 249.39 235.49 219.14 205.78 194.60 185.06 176.81 169.56 163.14 157.40 152.22 147.53 143.24 139.31
1.3 244.55 230.92 214.88 201.78 190.82 181.47 173.37 166.27 159.97 154.34 149.27 144.66 140.46 136.60
1.35 239.98 226.60 210.87 198.01 187.25 178.08 170.13 163.16 156.98 151.46 146.48 141.96 137.83 134.05
1.4 235.65 222.52 207.07 194.44 183.88 174.87 167.07 160.22 154.16 148.73 143.84 139.40 135.35 131.63
1.45 231.55 218.65 203.47 191.06 180.68 171.83 164.16 157.44 146.14 141.34 141.34 136.98 133.00 129.34
1.5 227.66 214.97 200.05 187.85 177.65 168.94 161.40 154.79 143.69 138.96 138.96 134.67 130.76 127.17
"K" factor = 0.78
With Profile
s s s
HC
Flow AIRFLO
Specifications
Net free area cm2 required per 1000 actual m3/h air flow
Inlet temperature °C
Press.
drop 15 50 100 150 200 250 300 350 400 450 500 550 600 650
mbar
0.5 307.57 290.43 270.26 253.79 240.00 228.24 218.05 209.12 201.20 194.12 187.74 181.94 176.66 171.81
0.55 293.26 276.91 257.68 241.98 228.83 217.62 207.91 199.39 191.84 185.09 179.00 173.48 168.44 163.81
0.6 280.77 265.12 246.71 231.67 219.09 208.35 199.05 190.90 183.67 177.21 171.38 166.09 161.27 156.84
0.65 269.76 254.72 237.04 222.59 210.49 200.18 191.24 183.41 176.47 170.25 164.66 159.58 154.94 150.68
0.7 259.94 245.46 228.41 214.49 202.84 192.90 184.29 176.74 170.05 164.06 158.67 153.77 149.30 145.20
0.75 251.13 237.13 220.67 207.22 195.96 186.36 178.04 170.75 164.28 158.50 153.29 148.56 144.24 140.28
0.8 243.15 229.60 213.66 200.64 189.74 180.44 172.39 165.32 159.06 153.47 148.42 143.84 139.66 135.82
0.85 235.89 222.75 207.28 194.65 184.07 175.05 167.24 160.39 154.31 148.88 143.99 139.55 135.49 131.77
0.9 229.25 216.47 201.44 189.16 178.88 170.12 162.53 155.87 149.97 144.69 139.93 135.61 131.67 128.06
0.95 223.13 210.70 196.07 184.12 174.11 165.58 158.19 151.71 145.97 140.83 136.20 132.00 128.16 124.64
1 217.48 205.36 191.10 179.45 169.70 161.39 154.19 147.87 142.27 137.26 132.75 128.65 124.92 121.49
1.05 212.24 200.41 186.50 175.13 165.61 157.50 150.47 144.31 138.84 133.96 129.55 125.55 121.91 118.56
1.1 207.36 195.81 182.21 171.10 161.81 153.88 147.01 140.99 135.65 130.88 126.57 122.67 119.10 115.83
1.15 202.81 191.50 178.21 167.34 158.25 150.50 143.78 137.89 132.67 128.00 123.79 119.97 116.48 113.29
1.2 198.54 187.47 174.45 163.82 154.92 147.33 140.75 134.99 129.88 125.30 121.18 117.44 114.03 110.90
1.25 194.52 183.68 170.93 160.51 151.79 144.35 137.91 132.26 127.25 122.70 118.74 115.07 111.73 108.66
1.3 190.75 180.12 167.61 157.39 148.84 141.55 135.23 129.69 124.78 120.39 116.43 112.84 109.56 106.55
1.35 187.18 176.75 164.48 154.45 146.06 138.90 132.70 127.27 122.45 118.14 114.25 110.73 107.51 104.56
1.4 183.81 173.56 161.51 151.67 143.43 136.40 130.31 124.97 120.24 116.01 112.19 108.73 105.57 102.67
1.45 180.61 170.54 158.70 149.03 140.93 134.03 128.05 122.80 118.15 113.99 110.24 106.84 103.74 100.89
1.5 177.58 167.68 156.04 146.52 138.56 131.77 125.89 120.74 116.16 112.08 108.39 105.05 101.99 99.19
"K" Factor = 1
Without Profile
s s s
HC
Flow AIRFLO
7/97
Dimensions
A
B
C
D
To Be
Specified 2" NPT Mixing Plate
L Male Support Bracket
To Be
Specified
L
Burner A B C D
(length)
Type
inches mm inches mm inches mm inches mm inches mm
HC-1 14.09 358
HC-1.5 20.0 510
HC-2 24.5 622
HC-2.5 32.0 815
HC-3 38.0 967
HC-3.5 16.53 420 8.188 208 3.34 85 1.67 42.5 44.0 1120
HC-4 50.0 1272
HC-4.5 56.10 1425
HC-5 62.0 1577
HC-5.5 68.0 1729
HC-6 74.0 1882
Dimensions
“HC” AIRFLO® Burner Plug-Mounted
Mounting Support
Process Flow
Gas Inlet 2" NPT Male

Pressure Diff.
Switch Connection
Mounting Plug
Mixing Plate Support Bracket

GAS
MAXO
N
Pilot Gas Inlet Process Flow

3/8" NPT Female
Cooling Air Inlet
3/8" NPT Female Burner Support Bracket - Length to be Specified
Flame Detector Port
Mounting Support
“HC” AIRFLO® Burner – Horizontal Process Flow Options

C D
= =
Differential
B
Pressure Taps 1/4" .
MAXON
GAS
GF
GAS
MAXON
E
M .
L .
A K
To Be Burner To Be J
Specified Specified H
To Be Size
Specified
P N
Internal
Duct
Dimensions A B C D E F G H J K L M N P
inches 11.8 3.34 1.96 16x.433 22.0 20.94 5x4.19 12.20 11.10 3x3.7 3.34 0.177 9.84 9.84
mm 300 85 50 16x11 560 532 5x106.5 810 282 3x94 85 45 250 250
NOTE: Dimensions “N” and “P” are minimums. Radiation from flame should be considered when sizing
burner length relative to duct size. If dimensions less than 18" are required, a flame shield is
recommended for the duct walls.
7/97
Dimensions
“HC” AIRFLO® – Pilot Burner (Gas)
038009 Adjustable Orifice
UV Scanner Cooling Air

Inlet 3/8" NPT Female
UV Scanner Sight Tube Pilot Gas Inlet
3/8" NPT Female
MAXON
GAS
L
GAS
MAXON
038557
1" NPT Adjustable Orifice
Spark Wall Mounting Set* d = 2.283"
Female
Ignitor (optional) (58mm) Pressure Test
Connection
Length (L)
Assembly Numbers
inches mm
300561 17.72 450
300563 23.62 600
300565 29.63 750
300567 35.43 900
300574 to be specified
NOTE: capacity 50K - 150 KBtu/hr
nat. gas inlet pressure differential at orifice = 4.0" wc (10 mbar)
“HC” AIRFLO® – Spark Ignitor

L
M14 x 1.25
310005 310243 Insulator 310441 Insulator
Ignitor Cap Wrench Size L = 0.905" (23mm) L = 0.748" (19mm)
0.826" (21mm)
0.511" (13mm)
Insulator
(enlarged)
Length (L)
Assembly Numbers
inches mm
300562 15.75 400
300564 21.65 550
300566 27.56 700
300568 33.46 850
300575 to be specified
“HC” AIRFLO® Gas Burners Page 5900-S-1
These mounting instructions for “HC” AIRFLO® burner. Also, the burner should not be mounted too
Burners are in addition to the general AIRFLO® Line near a turn in the duct which may cause air to be
Burner installation instructions published on Maxon directed at an angle over the burner.
catalog pages 5000-S-1 to 10. Velocity and flow of air at operating temperature
Specific instructions are also offered for other must be uniform and not less than the values speci-
Maxon component items: fied for the application and the air should not have a
– Shut-off Valves (pages 6100-S-1 through S-14) swirl.
– Flow Control Valves (pages 7000-S-1 through S-4) Install adjustable profile plates to attain this velocity
The “HC” AIRFLO® Line Burner is used only for the if required.
heating of air in motion. It should be mounted so as to Install a differential pressure switch, or any flow
direct the air perpendicular to the burner axes. It can proving method, across the profile plate to make sure
fire in any direction. the burner can only operate when air velocity is high
Do not mount the “HC” AIRFLO® assembly so that enough.
the movement of air is across the face of the line
Flame Detector Connection Differential

Scanner Cooling Air Inlet Pressure Switch + -
Profile Plate or other Flow
Pilot Gas Inlet
Duct Proving Method Duct
Differential Pressure
Switch Connection
MAXON
GAS
GAS
MAXON
Direction of
air movement
Gasket
Gas Inlet
Burner Support Observation
Bracket Profile Plate
Mounting Plug "HC" Port
Mounting Manhole (if applicable)
AIRFLO®
Burner Support

mCORPORATION
Page 5900-S-2 “HC” AIRFLO® Gas Burners
A manhole is recommended for inspection or the other end should be able to move fully. Only the
maintenance. Sufficient observation ports should be weight of the burner should be supported by the
installed to overview both pilot and main burner burner support. Ample duct length and space around
flames. the burner shall be designed to prevent duct over-
Ample space shall be reserved to remove mainte- heating. Space between two burner rows should not
nance/replacement parts from the burner for regular be less than 1000 mm.
inspection. The Maxon “HC” AIRFLO® Burner is a Gas piping and valves should be sufficiently large
single piece burner and requires space for complete enough to flow the maximum capacity at rated
burner removal if necessary. pressures.
The burner inlet side is fixed to the duct wall and
Burner Support Detail

Mixing Plate
End Plate
Duct
Mounting
Support
Weight of Burner
Movement of Burner
Duct
Burner Support Bracket length

can be adapted to duct dimensions
Burner Body
Mounting
Support
Direction of Air Movement
mCORPORATION

“HC” AIRFLO® Gas Burners Page 5900-S-3
Read complete instructions before proceeding, and 1. Bleed air from the gas pipe train.
familiarize yourself with all the system’s equipment 2. Check process air flow and check whether
components. Verify that your equipment has been system has been purged.
installed in accordance with the original 3. Light the pilot as follows:
manufacturer’s current instructions. – Set the pilot regulator to get a reliable ignition
of the pilot (slightly above combustion chamber
pressure).
– A pilot should have a steady blue color and be
about 2.4–4.0 inches (60-100 mm) in height.
tion systems, with control/safety circuitry and
– The capacity of the pilot is 68K Btu/hr (51K –
154K Btu/hr).
4. Adjustment of the Maxon gas control valve:
individual responsible for the manufacture and/
(see catalog section 7000)
or overall installation of a complete system
– Disconnect the control motor.
– Place the handle of the gas control valve in the
low fire position. The valve is now closed. Then
structions confict with any codes or regula-
open the main gas shut-off valve.
tions, contact Maxon Corporation or Maxon
– Increase the low fire position on the gas control
International before attempting start-up.
valve slowly until the flame covers the entire
The “HC” AIRFLO® Burner is a raw gas burner. There burner surface between the mixing plates.
is no flammable air-gas mixture in the feeder line and, – Open the gas control valve completely. Set the
therefore, a flashback cannot occur. However, the main gas regulator to obtain the rated differen-
burner depends completely on the process air to tial gas pressure. Flame length will vary
supply the oxygen for combustion. A correct air depending on the actual pressure drop.
velocity and well distributed air flow is therefore very – Connect the control motor in such a manner
important. The minimum process air pressure is the that it travels between the minimum and
design pressure drop and should not be less than maximum position of the gas control valve, as
0.2" wc (0.5 mbar). It should be checked prior to start- set.
up as well as checking the burner installation and its 5. Operate the control valve several times by
profile plates, the electrical wiring and the leak testing adjusting the temperature controller higher and
of the pipe train. lower. Make sure that the adjustment is satisfac-
tory and reproducible.
Check all other safety devices such as pressure
switches, high temperature limits, etc. and adjust
these devices to their correct value.

m
CORPORATION
Page 5900-S-4 “HC” AIRFLO® Gas Burners
Notes
m
CORPORATION

“HC” AIRFLO® Gas Burners Page 5900-A/P-1
Assembly Numbers
Burner Type Assembly Number
HC-1 300955
HC-1.5 300956
HC-2 300957
HC-2.5 300958
HC-3 300959
HC-3.5 300960
HC-4 300961
HC-4.5 300962
HC-5 300963
HC-5.5 300964
HC-6 300965

m
CORPORATION
Bulletin 6100
Maxon Shut-Off and Vent Valves

General Purpose
2.5" Series 808 2" Series 5000-CP 2.5" Series STO-ACP

position "TO" position “L” position “R”
with stainless steel body
• Electrically actuated valves shut off gas or oil lines reliably.

• Normally open versions available for vent or process purge lines with Maxon's long-
lasting metal-to-metal seating.
• Application flexibility provided with 3/8" through 6" diameter line sizes, Cv flow
factors up to 1230, and line pressures up to 600 PSIG.
• All Maxon top assembly enclosures meet approval sanctions:
– NEMA 1, 3, 3S, 4, and 12; CSA 2, 4, and 5; Available with NEMA 4X trim (optional)
Page 6102
Normally open or normally closed valves
4" Series 5000-SCP 1.5" Series STO-M

position “L” position “L”
• Sanctioned service valve approvals: 4" Series 7000

position “L”
– FM (Factory Mutual) sanctioned
– UL (Underwriters Laboratories) sanctioned
– CGA (Canadian Gas Association) sanctioned
– IRI (Industrial Risk Insurers) approvable for block/bleed/vent systems
– Contact your Maxon sales representative for international sanctions information
• Handles flowing fluid temperatures:
– Rising stem bodies from -20°F (-28°C) to +140°F (+60°C)
– Swinging gate bodies from -20°F (-28°C) to +550°F (+288°C)
– Any ambient temperature from -20°F (-28°C) to +140°F (+60°C)
• Valve body connections designed to ANSI (American National Standards Institute)
standards. ISO (International Standards Organization) standards also available.
• Various application requirements met with manual reset or automatic reset
motorized operators.
• Minimize line pressure drops with straight-through flow swinging gate or rising stem
(guillotine action) valve bodies
Page 6103
Maxon Valves – large or small, gas or oil, open or closed
1" Series 23300 1" Series 8730 1" Series 760

position "L" position "TO" position “L”
• Minimal field maintenance required.

• Positive visual indication of valve body position is provided by large two-color
open-shut indicator.
• Bodies built for heavy duty industrial service of one-piece cast iron, cast steel or
cast stainless steel.
• Installation piping convenience obtained from field rotatable top assemblies.
• Special operating features available in Special Service Packaged versions.
• Micro-lapped seating wears in, not out.
Page 6104
Accessory Options
1" Series 25300

position “L”
with socket welded nipples & flanges
1.25" Series 808

position “R”,
with wheel & chain assembly
• Positive indication of valve body position provided through:

– Auxiliary SPDT and DPDT signal switches mounted inside valve top enclosure.
– Proof-of-open and/or Proof-of-closed position switches.
• Built-in over travel valve body design meets requirements of insurance standards.
• External junction box requirement eliminated with built-in valve wiring
compartment and electrical terminal block.
• Manual reset valves may be mounted in overhead lines with use of wheel and
chain option.
• Companion flange sets available to simplify installation.
1/99
Maxon Valves Page 6105
Design Features and Operating Concepts

Valves with electro-mechanical actuators
for quick opening or closing action
Normally closed shut-off valves are used in Normally open vent valves are most often used
burner system fuel supply lines on industrial boilers, as the bleed valve in a block-and-bleed pipe train,
furnaces, ovens, kilns, and other heating processes. sometimes required by insurance authorities. They
All valves are designed to shut-off fuel automatically are designed to open a vent line automatically and
and instantly with any interruption in the electric instantly upon any interruption in the electric power
power supplied through your safety circuit. supply through your safety control circuit.
These valves are also used for the manual or These normally open valves are also used in
motorized opening or closing of pipe lines carrying protective atmosphere systems and other gaseous
gases and liquids commonly used in industrial proc- and fluid service requiring quick opening or by-pass
esses. Normally closed valves cannot be opened until purging action.
the interlocking safety control circuit is proven and
resulting electrical power is supplied to the shut-off Like the normally closed versions, both automatic
valve. and manual reset actuators are available for remote
access locations, or when operating personnel's
Motorized automatic valve actuators are used physical presence is preferred.
where remote access or unmanned applications are
needed. All Maxon valves feature one-piece cast iron or
cast steel bodies with micro-lapped seats and discs.
NOTE: Valve motors are protected against thermal Straight through flow path minimizes pressure drop
overload. Normal duty cycles of 1 cycle per minute or through full open swinging gate or rising stem (guillo-
less should allow motor thermal overload to suffi- tine action) bodies.
ciently cool between cycles. If the normal valve duty
cycle is exceeded, the motor must be allowed to cool
before the thermal protection will automatically reset.
Manual reset actuators require operating person-

nel to be physically present to actuate the valve from
its at rest position.
1/99
Page 6106 Maxon Valves
Valve Body Design Details

To provide seals in your process service lines, Maxon uses
two different styles of valve bodies:
Valve Body
Assembly Rising stem (guillotine action) bodies are frequently used
in normally closed and normally open gas valves. The micro-
lapped, spring loaded guillotine disc gets a pressure assist from
the flowing gases to seal against the downstream micro-lapped
metal seat ring. The carefully machined seal surfaces and
extremely close tolerances of the valve body operating mecha-
nism promote positive closing action. Frequent cycling action
constantly shears accumulated dirt or residue from the disc and
seat to insure instantaneous and reliable sealing.
The location of the port in the disc is the basic difference

between normally open and normally closed valve bodies. Both
Seat valves function by the top assembly mechanism driving the stem
and disc down into the valve body, opening (or closing) the flow
path. Both valves trip to their rest position when their top
assembly's compression spring is released to pull the stem and
connected disc up out of the body.
Normally-Closed
Disc
Normally-Open
Disc
Swinging gate bodies are frequently used in normally closed

oil valves and for some non-combustible gas applications. This
Valve Body design provides the same seal capabilities, but in a slightly
Assembly different operating mode. The hard faced micro-lapped seat nut
is threaded into the one-piece valve body. The free-floating, hard
faced, spring loaded circular disc swings across the seat. Line
pressure also assists in sealing the disc to the downstream seat.
Here again, frequent use and cycling actually helps to keep

your valve clean. Since the free-floating disc is swinging across
Disc the circular seat nut on the arc created by the disc carrier, the
Carrier disc rotates slightly on every cycle. This provides a fresh, clean
surface area for sealing off the flow lines.
Disc
Seat Maxon valve bodies have special service trim options

available to meet your particular fluid service requirements.
Contact your Maxon representative for details.
Valve Body Capacities/Specifications

Table 1: Normally closed valve bodies Table 2: Normally open valve bodies
Body End Pipe Size Cv Body Body End Pipe Size Cv Body
Material Connections (in inches) Factor Type [1] Material Connections (in inches) Factor Type [1]
.375 & .5 3.4 SG .75 20 RS

1 20 RS
9.6 SG
.75 1.5 53 RS
20 RS Threaded
12 SG 2 86 RS
1
20 RS Gray 2.5 304 RS
17 SG Iron 3 423 RS
Threaded 1.25
45 RS 2 86 RS
1.5 53 RS 2.5 304 RS
2 86 RS Flanged
3 423 RS
127 RS
Gray 2.5 4 490 RS
Iron 304 RS
1 20 RS
173 RS
3 Threaded 1.5 53 RS
423 RS
Cast 2 86 RS
2 86 RS
Steel 2.5 304 RS
127 RS
2.5
304 RS Flanged 3 423 RS
3 423 RS 4 490 RS
Flanged
490 RS Each complete valve assembly must include one of
4
719 RS these valve bodies, regardless of ultimate series
869 RS designation.
6
1172 RS Flows through the valve body and resulting pres-
.5 3.4 SG sure drops may be estimated by inserting your
.75 9.6 SG
specific conditions into the following formula and
using Cv flow factors given for each valve body.
12 SG
1
20 RS
Threaded
17 SG
1.25 Gases: Q = (1360) x (Cv) x (P1+P2) (P1–P2)
Cast 45 SG x
Steel 1.5 53 RS G Tf 2
or
Stainless 2 86 RS
Steel 2.5 304 RS
Liquids: V = (Cv) x (P1–P2)
3 423 RS
490 RS Gf
Flanged 4
719 RS
869 RS Where:
6
1172 RS G = Gas specific gravity (air = 1.0)
[1] RS = Rising Stem valve body
Gf = Specific gravity @ flowing temperature °F
SG = Swinging Gate valve body
P1 = Inlet pressure PSIA (14.7 psi + psi gauge)
See catalog pages 6117-6119 for construction details. P2 = Outlet pressure PSIA (14.7 psi + psi gauge)
NOTE: Typically, pressure drop for gas flows should not Q = Cubic feet per hour @ 14.7 PSIA and 60°F
exceed 10% of inlet pressure; however, for 2" and smaller
valves, the drop should not exceed 5 PSIG, and for 2.5" and Tf = Flowing temperature absolute (460° + °F)
larger valves, must not exceed 2.5 PSIG. V = Flow in U.S. gallons/minute of water
Select valve size on basis of the lower of these parameters
to avoid critical flow conditions.
2/00
Valve Body Capacities

with Natural Gas at 5 inches w.c. Inlet Pressure
Approximate pressure drops
for various valve sizes and flows
Cv may be determined by using this
1172
Cv graph.
50000 869 Typically, pressure drop for
Cv
C 719
6" H fuel flows should not exceed
S Cv 10% of inlet pressure.
6" R 490 v
C Select valve size on basis of
C 423
4" H the lower of these parameters
Cv to avoid critical flow conditions.
P RS 304
4" C P RS
3" C S
.5 " CP R 173
Cv
2
Cv
127
S
3" R v
5000 86 C
RS
2.5"
v
S 53 C
2" R 45 Cv
RS
1.5" RS
"
1.25 v
20 C
&1 " RS
.75 "
500
0.2 0.3 0.4 0.5


with Natural Gas at 1 PSIG Inlet Pressure
Approximate pressure
drops for various valve
sizes and flows may be
determined by using this 500000
graph.
Typically, pressure drop
v
for fuel flows should not 2C
117 v
exceed 10% of inlet C
pressure. 869 Cv
719
Select valve size on
basis of the lower of these Cv
490 Cv
parameters to avoid critical HC 423 v
flow conditions. 6" S C
R 304
50000 6" HC
4"
S Cv
PR 173 v
C C
4" 127
RS
" CP S Cv
3 R 86
" CP
2.5 Cv
53 v
RS 45
C
3" S
5000 "R
2.5
RS Cv
2" S 20
"R
1.5
S
2 5"R
1. RS
& 1"
"
.75
500
0.5 5
1/99

with Natural Gas at 5 PSIG Inlet Pressure
v
7 2C Approximate pressure drops
11 v for various valve sizes and flows
9C
500000
86 9 Cv may be determined by using this
71 v graph.
0C Typically, pressure drop for
493 Cv
42 v fuel flows should not exceed
4C 10% of inlet pressure; however,
30
for 2" and smaller valves, the
" HC 3C
v drop should not exceed 5 PSIG,
6 S 17 Cv and for 2-1/2" and larger size
R
6" HC 12
7
valves, must not exceed 2.5
4" RS Cv PSIG.
50000
CPP RSRS 86 Select valve size on basis of
"
43" C P Cv the lower of these parameters
"C 53 Cv
2.5 45
to avoid critical flow conditions.
RS
3" RS
" Cv
2.5 S 20
R
2"
" RS
1.5 RS
5"
5000
1.2 RS
1"
"&
.75
500
0.5 5 50

with #2 Oil
To select a valve for
YOUR application, use
either Cv factor calcula-
tions, or this graph
showing approximate
pressure drop at various
flows of #2 oil.
Typically, pressure
drop for fuel flows
should not exceed 10%
of inlet pressure.
For preheated #5 or #6 oil, multiply Oil Grade #5 #6

the required flow rate in GPH by the
factor given in the table at right, then °F @ Inlet 125 160 120 140 180 210 220
select a valve based upon that Factor 1.43 1.11 2.86 2.00 1.25 1.11 1.05
equivalent flow of #2 oil and the
allowable drop. For example: To size for 5 PSIG drop with a 3500 GPH flow of #6 oil
preheated to 140°F, the multiplier is 2. Equivalent flow of #2 oil is
then 3500 x 2, or 7000 GPH. Chart shows that a 5 PSIG drop will
require use of a valve body having a Cv factor of at least 45.
1/99
Selection Data
Normally closed, swinging gate valves
Series Designation Features:

Body Material> Gray Iron Cast Steel • Normally closed
Top Assembly Sanctioned Special Service Sanctioned Special Service
Function Service [1] (Non-sanctioned) [2] Service [1] (Non-sanctioned) [2] • Electrically actuated
790-S
Manual Reset 730 790 730-S; 760 • Swinging gate body
33790; 23300
4730-S 4790-S; 8790-S
Automatic Reset 4730; 8730 4790; 8790
4760; 8760 33479; 25300 • For shut-off service
[1] Sanctioned valves are sold for fuel oils and may carry one or more sanctions (UL, FM, • For liquid and non-
CGA). They are IRI approvable for liquified petroleum gases, #1 and #2 fuel oils, kerosene, JP-
4 and preheated #4, #5 and #6 oils with maximum viscosity of 5000 SSU. combustible gas service
[2] Non-sanctioned valves do not carry blanket approval/listings, and the pressure limits
shown apply only for selected special service applications. An analysis of your fluid will
determine the actual rating, trim, and specifics for your application.
Temperature Limits
All of these valves can handle fluid temperatures from -20°F (-28°C) to
+250°F (+121°C). The Series 33000 valves are designed to handle higher
fluid temperatures up to +450°F (+232°C) and even up to +550°F (+288°C)
with addition (at extra charge) of special stem seals.
Ambient temperature limits vary. Any valve on this page using DC
voltage and all Series 8700 valves can handle ambient temperatures from
-20°F (-28°C) to +125°F (+52°C). The other valves on this page handle
ambient temperatures from -20°F (-28°C) to +140°F (+60°C).
Operation
All of these electro-mechanical valves require a constant supply of
electrical energy to their holding solenoids inside the top assembly actua-
tors. Once the solenoid is energized, the manual reset valve may be
opened manually, or the automatic reset valve will automatically open. Any
interruption of the electrical power to either of these valves causes an 1" Series 760
immediate trip of the valve to its normally closed position.
Available Sizes and Pressure Ratings

Maximum Inlet Pressure (PSIG)
Pipe Size Body CV
(inches) Flow Factor Gray Iron Bodies Cast Steel Bodies
Fuel Oils Special Service Fuel Oils Special Service
.375 [1] --- ---
3.4
.5 [1]
.75 [1] 9.6 300 300
600 600
1 12
1.25 17
1.25 HC 45 --- --- 300 300
1.5 123 --- --- 150 150
2 218 --- --- 100 100
[1] Available in 8730, 8760 & 8790
Shaded areas indicate 300# raised face flanged bodies.
Selection Data
Normally closed, rising stem valves
Body Material> Gray Iron Cast Steel • Normally closed
Manual Reset 808; 808-CP 818; 818-CP 808-S; 808-S-CP 818-S; 818-S-CP
• Rising stem body
Automatic 5000; 5000-CP 5100; 5100-CP 5000-S; 5000-S-CP 5100-S; 5100-S-CP
Reset 7000 7100 7000-S 7100-S
• For shut-off service
[1] Sanctioned valves may carry one or more sanctions (UL, FM, CGA) for air, natural and liquified
petroleum gases. They are normally approvable for clean fuel gases. Additionally, series with internal trim -2
are sanctioned for #1 and #2 fuel oils (except Series 7000 (-S) are not listed FM approved for #2 fuel oil).
'SG' valves are preferable for liquid service (see page 6112).
[2] Non-sanctioned valves do not carry blanket sanctions, and the pressure limits shown apply only for
selected special service applications. An analysis of your fluid will determine the actual rating, trim and
specifics for your application.
Temperature Limits
All these valves can handle fluid temperatures from -20°F (-28°C) to +140°F (+60°C).
Oil viscosity not to exceed 5000 SSU. Ambient temperature limits vary. Any valve on
this page using DC voltage and all Series 7000 valves can handle ambient temperatures
from -20°F (-28°C) to +125°F (+52°C). The other valves on this page handle ambient
temperatures from -20°F (-28°C) to +140°F (+60°C).
Operation
All of these electro-mechanical valves require a constant supply of electrical energy to
their holding device inside the top assembly actuators. (In Series 808 and 5000 valves,
the device is a solenoid and Series 7000 valves use an electro-magnetic clutch.) Once
that device is energized, the manual reset valve may be manually opened, or the auto-
matic reset valve will automatically open. Any interruption of the electrical power to either
of these valves causes an immediate trip of the valve to its normally closed position.
4" Series 7000
Maximum Inlet Pressure (psi) [3]
Pipe Size Body CV
(inches) Flow Factor Gray Iron Bodies Cast Steel Bodies
Clean Gases Special Service Clean Gases Special Service
.75 125 30 --- ---
20
1 125 30 125 30
1.25 45 100 30 --- ---
1.5 53 70 20 70 20
70 15 70 15
2 86
70 15 70 15
40 10 --- ---
2.5 127
40 10 --- ---
50 15 50 15
2.5 CP 304
50 15 50 15
3 173 30 5 --- ---
40 10 40 10
3 CP 423
40 10 40 10
4 CP 490 40 10 40 10
4 HC [4] 719 60 10 60 [5] 10
6 869 30 5 30 5
6 HC [4] 1172 50 10 50 [5] 10
[3] Maximum operating pressure differential (MOPD) in psi must not exceed maximum inlet pressure shown.
[4] Series 7000 valves
[5] Contact your Maxon representative for pressure ratings for 5-3 trim
NOTE: Shaded areas indicate flanged valve bodies. All others are threaded.
2/00
Selection Data
Normally open, rising stem valves

Body Material> Gray Iron Cast Steel • Normally open
Manual Reset STO-M STO-M STO-MS STO-MS
• Rising stem body
Automatic STO-A STO-A STO-AS STO-AS
Reset STO-A-CP STO-A-CP STO-AS-CP STO-AS-CP • For vent and by-pass
[1] Sanctioned valves may carr y one or more sanctions (UL, FM, CGA) for air, natural
or liquified petroleum gases. They are normally approvable for clean fuel gases.
service
Additionally, series with internal trim -2 are sanctioned for #1 and #2 fuel oils.
[2] Non-sanctioned valves do not carr y blanket sanctions, and the pressure limits
shown apply only for selected special ser vice applications. An analysis of your fluid will
determine the actual rating, trim and specifics for your application.
Temperature Limits
All these valves can handle fluid temperatures from -20°F (-28°C) to
+140°F (+60°C). Oil viscosity not to exceed 5000 SSU.
Ambient temperature limits vary. Any valve on this page using DC
voltage can handle ambient temperatures from -20°F (-28°C) to +125°F
(+52°C). The other valves on this page can handle ambient temperatures
from -20°F (-28°C) to +140°F (+60°C).
Operation
electrical energy to their holding solenoids inside the top assembly
actuators. Once the solenoid is energized, the manual reset valve may be
manually closed, or the automatic reset valve will automatically close.
Any interruption of the electrical power to either of these valves causes
2.5" Series STO-ACP
an immediate trip of the valve to its normally open position.

Pipe Size Body CV
Gray Iron Bodies Cast Steel Bodies
(inches) Flow Factor
.75 125 30 --- ---
20
1 125 30 125 [4] 30
1.5 53 70 20 70 20
70 15 70 [4] 15
2 86
70 15 70 15
50 15 50 15
2.5 CP 304
50 15 50 15
40 10 40 10
3 CP 423
40 10 40 [4] 10
4 CP 490 40 10 40 10
[3] Maximum operating pressure differential (MOPD) in psi must not exceed maximum inlet pressures shown.
[4] Contact your Maxon representative for pressure ratings for 5-3 trim.
Rising Stem Body/Trim Specifications

All Maxon Rising Stem Gate Valves carry a two- WARNING: Do not attempt field repair of Maxon valve
part trim identification (for example, Trim 1-1).
body or electro-mechanical actuator. Any field
The first digit (a 1, 2, 3, 4 or 5 before the
alterations void all warranties.
hyphen) identifies valve body and bonnet
material as shown in Table 1 below.
The second digit (a 1, 2 or 3 after the hyphen)
identifies the specific internals used, as
described in Tables 2, 3 and 4, and identified in
the sketches at right.
Internal trim -1 is normally suitable for clean
fuel gases (for example, natural gas, propane,
butane, clean atmosphere gases).
Internal trim -2 may be required for clean
gases that require Viton seals or such gases as
coke oven, refinery, town or off-gas.
Internal trim -3 is designed for more corrosive
environments such as digester gas, sour natural
gas and landfill gas. Contact Maxon with specific
fuel analysis for prices and/or availability.
Normally closed and normally open threaded
and flanged body versions are identical in
material specifications.
The drawing at right carries item numbers
matching those in Table 2. This information is
furnished for identification only, not for ordering
parts.
Table 1: Body (Item 1) and Bonnet (Item 2) Specifications

Body Description Body 1– Body 2– Body 3– Body 4– Body 5 –
Material Cast Iron, G3000, CL 30 Cast Steel Cast Iron, G3000, CL 30 Cast Steel Stainless Steel
Specifications ASTM A159 / UL 429 ASTM A216-WCB / UL 429 ASTM A159 / UL 429 ASTM A216-WCB / UL 429 A351-CF8M
Special Coating --- --- Electroless Nickel-Coated Electroless Nickel-Coated ---
Table 2: Internal Trim Specifications

Item Trim: –1
Description
No. .75" – 2" 2.5", 3" 2.5" – 4" CP 6"
3 Seat #440-F Stainless Steel #416 Stainless Steel #440-F Stainless Steel #303 Stainless Steel
4 Disc 80-55-06 Ductile Iron 80-55-06 Ductile Iron 80-55-06 Ductile Iron 80-55-06 Ductile Iron
Low-Carbon Steel Low-Carbon Steel
5 Follow Ring Leadaloy (nickel plated) Ductile Iron (nickel plated)
(nickel plated) (nickel plated)
6 Seat O-Ring Buna N Buna N Buna N Buna N
7 Gasket Buna N Buna N Buna N Steel
8 Wavy-Spring Washer #302 Stainless Steel #302 Stainless Steel #302 Stainless Steel #302 Stainless Steel [1]
9 Stem Steel (chrome plated) Steel (chrome plated) Steel (chrome plated) Steel (chrome plated)
High Carbon Steel High Carbon Steel
10 Stem/Disc Pins --- Shear-Proof Steel
(hardened) (hardened)
11 Stem O-Rings Buna N Buna N Buna N Buna N
12 Striker Plate #17-7 Stainless Steel #17-7 Stainless Steel #17-7 Stainless Steel Carbon Steel (6" 808 only)
13 Bumper Buna N Buna N Viton Buna N
--- Clevis [2] --- --- --- Ductile Iron
[1] Compression Spring [2] For 6" 808 and 4" & 6" 7000 valves only; not shown in illustration above
1/99

Table 3: Internal Trim Specifications for Trim -2
Item Trim: -2
Description
No. .75" – 2" 2.5", 3" 2.5" – 4" CP 6"
3 Seat #303 SS (hard faced) #303 SS (hard faced) #303 SS (hard faced) #303 SS (hard faced)
80-55-06 Ductile Iron 80-55-06 Ductile Iron 80-55-06 Ductile Iron 80-55-06 Ductile Iron
4 Disc
(chrome plated) (chrome plated) (chrome plated) (chrome plated)
303 SS 303 SS 303 SS 303 SS (chrome
5 Follow Ring
(chrome plated) (chrome plated) (chrome plated) plated)
6 Seat O-ring Viton Viton Viton Viton
7 Bonnet O-ring Viton Viton Viton Steel
Wavy-Spring
8 #302 Stainless Steel #302 Stainless Steel #302 Stainless Steel #302 Stainless Steel
Washer
10 Stem/Disc Pins #420 Stainless Steel #420 Stainless Steel --- Shear-Proof Steel
11 Stem O-rings Viton Viton Viton Viton
12 Striker Plate #17-7 Stainless Steel #17-7 Stainless Steel #17-7 Stainless Steel Carbon Steel
13 Bumper Viton Viton Viton Viton

Item Trim: -3
Description
No. .75" – 2" 2.5", 3" 2.5" – 4" CP 6"
3 Seat PEEK PEEK PEEK PEEK
4 Disc A351-CF8M A351-CF8M A351-CF8M A351-CF8M
5 Follow Ring PEEK PEEK PEEK PEEK
7 Bonnet O-ring Viton Viton Viton Viton
Wavy-Spring
Washer
9 Stem Car penter Custom 450 Car penter Custom 450 Car penter Custom 450 Car penter Custom 450
10 Stem/Disc Pins --- --- --- ---
12 Striker Plate #17-7 Stainless Steel #17-7 Stainless Steel #17-7 Stainless Steel #17-7 Stainless Steel
Swinging Gate Body/Trim Specifications

Trim identification of Maxon Swinging Gate Shut- Non-sanctioned services or unusual applications
Off Valves is two-part. The first digit before the may require upgrading of internal trim. Contact Maxon
hyphen is a number (1, 2, 3 or 4) identifying body with specific fuel analysis for price and availability.
material as shown in Table 1 below. The second digit The drawings shown on the following page carry
after the hyphen identifies a trim utilizing the materials item numbers matching those in Table 2. This infor-
indicated in Table 2 below. mation is furnished for identification only, not for
Standard sanctioned valves incorporating a cast ordering parts.
iron body will normally be identified by trim 1-B or
WARNING: Do not attempt field repair of Maxon valve
1-D. Sanctioned valves with steel body will normally
body or electro-mechanical top actuator. Any field
be trim 2-D. alterations void all warranties.
Table 1: Body (Item 1) Specifications

Body Description Body 1- Body 2- Body 3- Body 4-
Material Cast Iron, G3000, CL 30 Cast Steel Cast Iron, G3000, CL 30 Cast Steel
ASTM Spec A159 A216-WCB A159 A216-WCB
Special Coating --- --- Electroless Nickel-Coated Electroless Nickel-Coated
Table 2: Internal Trim Material Specifications

Item Part for .375" & .75" valves For 1" & 1.25" valves For 1.5" & 2" valves
No. Description Trim: -D Trim: -N Trim: -B Trim: -D Trim: -N Trim: -B Trim: -D
Cast Iron with Cast Iron with
Hex Nut or Renewable Hard-Faced Hard-Faced Hard-Faced
2 Hard-Faced Steel Hard-Faced Steel #420 Stainless
Steel Steel
#420 Stainless
Steel
Seat Steel Seat Ring Steel Seat Ring
Zinc-Plated Zinc-Plated Zinc-Plated #416 Stainless #416 Stainless
3 Stem Bushing Zinc-Plated Steel Zinc-Plated Steel
Steel Steel Steel Steel Steel
#416 Stainless #416 Stainless #416 Stainless #416 Stainless #416 Stainless #416 Stainless #416 Stainless
4 Stem Steel Steel Steel Steel Steel Steel Steel
5 Stem Spring Steel Steel Steel Steel Steel Steel Steel
Steel w/Nedox Steel w/Nedox
6 Disc Carrier Steel
coating
Steel Steel
coating
Steel Steel
Hard-Faced Hard-Faced Hard-Faced

7 Disc Hard-Faced Steel Hard-Faced Steel Nodular Iron
Steel Steel
Nodular Iron
Steel
8 Stem O-Rings Hydrin Hydrin Viton Viton Viton Viton Viton
9 Disc Spring Steel Steel Steel Steel Steel Steel Steel
10 Inner Stem Thrust Ring Teflon Teflon Teflon Teflon Teflon Grafoil Teflon
11 Back-up O-Rings Teflon Teflon Teflon Teflon Teflon --- ---
12 Body Gaskets Soft Iron Soft Iron Soft Iron Soft Iron Soft Iron Soft Iron Soft Iron
13 Stem Bushing Gasket Soft Iron Soft Iron Soft Iron Soft Iron Soft Iron Soft Iron Soft Iron
14 Body O-Ring Viton Viton Viton Viton Viton --- ---
15 Stem Packing Ring Grafoil Grafoil --- --- --- --- ---
16 Packing Nut Zinc-Plated Steel Zinc-Plated Steel --- --- --- --- ---
Steel (same as Steel (same as

17 Outlet Flange --- --- --- --- ---
body material) body material)
1/99

Typical construction of Typical construction of
.375" through .75" screwed body valves 1" through 2" screwed body valves
Typical construction of
1.5" through 2" flanged body valves
General Maintenance and Spare Parts
All safety devices should be tested at least To determine suggested spare parts, identify
monthly* and more often if deemed advisable. series designation and serial number from the valve’s
Periodic testing for tightness of manual or motor- nameplate. Refer to the illustration and legend below
ized shut-off valve closure is equally essential. to identify suggested spare parts.
*per NFPA 86-Appendix B-4 (1995)
To order, specify:
These Maxon valves are designed for long trouble-
1. Quantity
free service. Only items shown as suggested spare
2. Assembly part number (if available)
parts are considered field replaceable.
3. Description
WARNING: Do not attempt field repair of valve 4. Electrical specification
body, top assembly or motor drive unit. Any 5. Full nameplate information (from existing valve)
Nameplate
Manual Reset Automatic Reset (typical)
Note: Drawings are illustrative only. Actual valves may vary slightly. (shown for listed
valves; others
similar)
Nameplate
designation does
not reflect external
1 accessory items or
motor limit switch
1
2
3
2 3
Normally closed valve designation
Series 808
Series 5000 3" 5000-S CP D 2
VCS Used *
DC Solenoid (if used)
CP Body (if used)
TO CLUTCH
Steel Body (if used)
2 1
Valve Series
12 11 10 9 8 7 6 5 4 3 2 1
4 Valve Size (NPT)

#1 BLACK TO
TERMINAL #1
COM
NO
NC
*Signal Switch legend:
#3 BLACK TO
BLACK TO MOTOR
0 No Switch 2 VCS-2 Switch
TERMINAL #3
1 VCS-1 Switch 2H VCS-2 (Herm. Sealed)

2
1H VCS-1 (Herm. Sealed)
Series 808-CP
Series 7000 Normally open valve designation
Legend: 4 3" STO-AS CP D 2
1 – Nameplate
2 – Solenoid VOS Used *
3 – VOS motor limit/signal SHUT
DC Solenoid (if used)
switch for normally closed
CP Body (if applicable)
valve; VCS for normally
open valve Steel Body (if used)
4 – Printed Circuit Board Valve Series
(PCB) Valve Size (NPT)
Series 8700 0 No Switch 2 VOS-2 Switch
1 VOS-1 Switch 2H VOS-2 (Herm. Sealed)
1H VOS-1 (Herm. Sealed)
1/99
Electrical Data
for normally closed valves
General Diagrams show valve in its normally closed (at rest)
All Maxon shut-off valves are electrically actuated position. The indicated internal wiring is present only
from a power source, normally through the flame when the appropriate auxiliary switches are specified.
safeguard and/or safety control circuits. Automatic reset valves always include a VOS-1 SPDT
Standard valve assemblies include an internal valve open motor limit switch.
holding solenoid or printed circuit board for 115 volt Good practice normally dictates that auxiliary
60 hertz AC power. (Other electrical current options switches in valves used for safety shut-off functions
are available upon request.) should be used for signal duty only, not to operate
Series 808, 730, 760, 5000, 4730, and 4760 valves additional safety devices.
have the internal solenoid. Series 8700 and 7000 Signal switch designations:
valves incorporate the printed circuit board.
VCS (Valve Closed Switch) is actuated at the end
The solenoid (or the printed circuit board) is
of the closing stroke. VCS-1 is SPDT; VCS-2 is
energized whenever the valve is powered. The motor
DPDT.
operator on automatic reset versions is powered only
VOS (Valve Open Switch) is actuated at the end of
during the opening stroke.
the opening stroke. VOS-1 is SPDT; VOS-2 is DPDT.
Switch wiring diagrams (reproduced on the next
Switch amp ratings are shown on the schematic
page) are part of each valve assembly, summarizing
wiring diagrams on page 6122. DO NOT EXCEED
electrical data and wiring for a valve equipped with
rated amperage or total load shown.
terminal block and a full complement of optional
signal switches.
Volt Ampere (VA) Ratings: Manual Reset

Valve AC Operation DC Operation
Size Series Opening Holding Opening Holding
.75" – 3" 808, 818 (-S)
1" – 1.25" 730, 760, 790 (-S)
22 22
1.5" – 2" 23300 14 14
1" – 1.25" 33790 (-S)
2.5" – 4" 808-CP, 818-CP (-S)
34 34
6" 808, 818 (-S) 16 16
Volt Ampere (VA) Ratings: Automatic Reset

Valve AC Operation (115 VAC, 60 Hz) DC Operation (24 VDC)
Size Series Opening Holding Opening Holding
.75" – 3" 5000, 5100 (-S) 220 [1] 22 212 14
1" – 1.25" 4730, 4760, 4790 (-S) 220 [1] 22 212 14
1.5" – 2" 25300 220 [1] 22 212 14
1" – 1.25" 33479 220 [1] 22 212 14
2.5" – 4" 5000-CP, 5100-CP (-S) 232 [2] 34 214 16
4" – 6" 7000, 7100 (-S) 376 8 428 [3] 8 [3]
.375" – .75" 8730, 8760, 8790 (-S) 143 5 --- ---
[1] 220 VA shown is for 60 her tz; if 50 her tz power, VA rating is 342
[2] 232 VA shown is for 60 her tz; if 50 her tz power, VA rating is 354
[3] Based on 120 VDC
NOTE: The VA rating shown in the DC column is based on an AC motor, DC solenoid.
Electrical Data
Manual Reset Series:

.75" – 3" Series 808, 818 (-S);
1" – 1.25" Series 730, 760, 790 (-S);
1" – 1.25" Series 33790 (-S);
2.5" – 4" Series 808-CP, 818-CP (-S);
6" Series 808, 818 (-S)
Automatic Reset Series:

.75" – 3" Series 5000, 5100 (-S);
1" – 1.25" Series 4730, 4760, 4790 (-S);
1" – 1.25" Series 33479;
2.5" – 4" Series 5000-CP, 5100-CP (-S)
4"– 6" Series 7000, 7100 (-S)
.375" through .75"

Series 8730, 8760,
and 8790 (-S)
11/02
Electrical Data
for normally open valves
General Signal switch designations:
All Maxon normally open vent valves are electri- VCS (Valve Closed Switch) is actuated at the end
cally actuated from a power source, normally through of the closing stroke. VCS-1 is SPDT; VCS-2 is
the flame safeguard and/or safety control circuits. DPDT.
Standard valve assemblies include an internal VOS (Valve Open Switch) is actuated at the end of
holding solenoid for 115 volt 60 hertz AC power. opening stroke. VOS-1 is SPDT; VOS-2 is DPDT.
(Other electrical current options are available upon Switch amp ratings are shown on the schematic
request.) wiring diagrams below and on the next page. DO
The solenoid is energized whenever the valve is NOT EXCEED rated amperage or total load shown.
powered. The motor operator on automatic reset
version is powered only during the closing stroke. Volt Ampere (VA) Ratings
Switch wiring diagrams (reproduced below and on Valve AC Operation DC Operation
next page) are part of each valve assembly, summa- Size Series Closing Holding Closing Holding
rizing electrical data and wiring for a valve equipped
.75" – 3" STO-M 22 22 14 14
with terminal block and a full complement of optional
2.5" – 4" STO-M CP 34 34 14 14
signal switches.
.75" – 3" STO-A 220 [1] 22 212 14
Diagrams show valve in its normally open (at rest)
position. The indicated internal wiring is present only 2.5" – 4" STO-A CP 232 [2] 34 214 16
when the appropriate auxiliary switches are specified. [1] 220 VA is for 60 her tz; if 50 her tz, then VA is 342
[2] 232 VA is for 60 her tz; if 50 her tz, then VA is 354
Automatic reset valves always include a VCS-1 SPDT
valve closed motor limit switch.
Good practice normally dictates that auxiliary The VA rating shown in the DC column is based on
switches in valves used for safety shut-off functions an AC motor, DC solenoid.
should be used for signal duty only, not to operate
additional safety devices.
.75" – 2" Series STO-M and STO-A (-S)

2.5" – 4" Series STO-M-CP and STO-A-CP (-S)
SWITCH CONTACT POSITIONS P/N 26379M
SHOWN WITH VALVE OPEN VALVE WIRING DIAGRAM
MOTORIZED VALVE ONLY
VCS-1 VCS-2 VOS-1 VOS-2
SOLENOID
INTERNAL
WARNING! WIRING
VALVE MTR
MUST BE
WIRED AS
SHOWN H(+) N(-) 1 2 3 4 5 6 7 8 9 10 11 12
OPTIONAL SPDT SPDT SPDT SPDT FIELD

D.C. POWER HERMETICALLY SEALED HERMETICALLY SEALED
SUPPLY WIRING
ALL NI VALVES INCLUDE DPDT DPDT
HERMETICALLY SEALED GENERAL PURPOSE GENERAL PURPOSE
SWITCHES, SUITABLE FOR L1-H L2-N
HAZARDOUS LOCATIONS AC-POWER
CLASS I, DIV. 2, ABCD
CLASS II, DIV. 2, FG SEE NAME PLATE FOR VOLTAGE AND HZ
CLASS III, DIV. 2
SWITCH RATINGS VALVE VCS-1 VCS-2 VOS-1 VOS-2
Total connected load not to exceed 1700 VA
GENERAL PURPOSE HAZARDOUS LOCATION MODE 1-3 1-3 4-5 4-6 7-8 7-9 7-8 7-9 10-11 10-12
SPDT DPDT SPDT FULLY OPEN
125 VAC - 15 AMP 125 VAC - 10 AMP 28 VDC - 5 AMP
250 VAC - 15 AMP 250 VAC - 10 AMP 125 VAC - 1 AMP INTERMEDIATE
125 VDC - 0.5 AMP 125 VDC - 0.3 AMP
FULLY SHUT
250 VDC - 0.25 AMP 250 VDC - 0.15 AMP

808, 5000, STO-A, STO-M
.75" through 1.5" valves with rising stem bodies

7.34 Available
5.5 1.87 3.49 Top Assembly
2.0
Positions
B
K
(2) 3/4" NPT
Conduit D
Connection
G
A Pipe Size
(2) 1/4" NPTF
“R” “L”
J H Test Connection
2.3 C
5000 & STO-A
11.5
7.13 3.5 4.5
5.44 1.87 2.0
“AW” “TO”
R B
9.17
(2) 3/4" NPT
Conduit Connection D
G
NOTE: 2.75" needed
for terminal block
A Pipe Size cover removal.
(2) 1/4" NPTF
J H Test Connection
C
2.33
808 & STO-M
Pipe Valve
A B C D G H J K R
Size Series
808 & STO-M 11.58
.75"
5000 & STO-A ---
2.00 12.25 3.81 1.90 .78 1.94 .81 8.11
808 (-S) & STO-M (-S) 11.58
1"
5000 (-S) & STO-A (-S) ---
808 12.14
1.25" 2.44 12.81 .22 1.56 8.67
5000 ---
4.00 2.00 2.12
808 (-S) & STO-M (-S) 12.61
1.5" 2.69 13.31 .38 1.68 9.14
5000 (-S) & STO-A (-S) ---
10/02

808, 5000, STO-A, STO-M
2" through 3" valves with rising stem bodies
5000 & STO-A Available

2.38 7.51
Top Assembly
7.61 2.9 1.97 Positions
3.5
B
K (2) 3/4" NPT
Conduit
Connection D
G
A Pipe Size
(2) 1/4" NPT “R” “L”
J H
Test Connection
C
J S
L
G
M N A
P
Equally spaced H
T
13.12
8.55
7.61 2.73 “AW” “TO”
2.38 1.97 5.63
R B
K
D NOTE: 2.75" needed

G
A Pipe Size
for terminal block
cover removal.
J H
C
808 & STO-M
Pipe Valve
A B C D G H J K L M N P R S T
Size Series
808 (-S) & STO-M (-S)
2" 4.38 2.19 --- --- --- --- --- ---
5000 (-S) & STO-A (-S)
3.25 14.75 .44 2.25 1.88 10.6 14.38
808 (-S) & STO-M (-S)
2" F --- --- 3.01 2.38 .75 4 3.50 7.0
5000 (-S) & STO-A (-S)
808 14.25
2.5" 3.50 5.0 2.5 2.12 2.25 --- --- --- --- --- ---
5000 14.62 10.46
.63
2.5" F 808 & 5000 --- --- --- 2.5 2.0 3.5 2.75 .75 4 --- 3.75 7.5
3" 808 & 5000 2.94 14.86 5.19 2.59 2.12 2.56 10.71 --- --- --- --- --- ---

808-CP, 5000-CP, STO-MCP, STO-ACP
2.5" CP through 4" CP and 6" valves with rising stem bodies
Series 808 (-CP) & STO-M (-CP) Available
15.12
10.94 5.7 Top Assembly
8.87 2.83 4.2 Positions
R
B
A
A A
6.09 7.25 D
G
Pipe Size
A
3.0 (2) 1/4" NPTF
0.88 J H Test Connection
View A-A C
(2) 3/4" NPT 11.68
Conduit
S
Connection “R” “L”
L
Pipe Size
M N (dia.) A
P (no. of holes) (2) 1/4" NPTF
Equally spaced H Test Connection
T
8.87 2.83 4.2 7.51
B “AW” “TO”
A A
6.07 7.25 D
G
A (2) 1/4" NPTF

3.0 Test Connection NOTE: 2.75" needed
0.88 View A-A H for terminal block
11.68 C
(2) 3/4" NPT J cover removal.
Conduit
Connection Series 5000 (-CP) & STO-A (-CP)
Pipe Valve
A B C D G H J L M N P R S T
Size Series
808 (-SCP) 14.56
2.5" CP 4.31 5.0 2.5 .50 2.25 --- --- --- --- --- ---
5000 (-SCP), STO-A (-SCP) ---
14.56 2.12
2.5" F 808 (-SCP) 14.56
4.5 --- --- --- 2.2 3.5 2.75 .75 4 3.75 7.5
CP 5000 (-SCP), STO-A (-SCP) ---
808 (-SCP) 17.97
3"
5000-CP, STO-ACP 5.12 5.5 2.75 .62 2.12 2.56 --- --- --- --- --- --- ---
CP
5000 (-SCP), STO-A (-SCP) 17.97
3" F 808 (-SCP) 15.29 17.97
5.22 2.24 2.6 3.75 3.0 4 4.0 8.0
CP 5000 (-SCP), STO-A (-SCP) ---
--- --- --- .75
4" F 808 (-SCP) 17.97
5.55 2.25 2.56 4.5 3.75 8 4.5 9.0
CP 5000 (-SCP), STO-A (-SCP) ---
6" 808 7.5 20.75 --- --- --- 3.38 --- 5.5 4.75 .88 8 23.43 5.25 10.5
10/02

4" & 6" 7000 Valves
8.63 3.87 E 4.56
(2) 3/4" NPT

Conduit
B
Connection
G
P
Pipe Size
R S (dia.) A (2) 1/4" NPTF

8 holes Test Connection
equally spaced
3.25
H
Available Top Assembly Positions
“R” “L” “TO” “AW”
Valve Size Valve Series A B E G H P R S

4" 7000 (-S) & 7100 (-S) 7.31 23.88 4.19 4.5 9 4.5 3.75 0.75
6" 7000 (-S) & 7100 (-S) 8.38 25 5.81 5.25 10.5 5.5 4.75 0.88

8700, 23300, 25300
.375" through 2" valves with swinging gate bodies

Series 8730, 8760, 8790 & 8790-S (.375", .5" & .75")
6.22 2.72 6.42 3.93
11.06
Note: Series 8700 valves are
3/4" Conduit
Connection
available in top assembly positions
"R" and "TO" only.
Pipe Size
1.19
2.30 (for .375")
3.18 1.69 (for .5" & .75") 2.93
Series 23300 & 25300 (1.5" & 2") Available Top Assembly Positions
13.14 for Series 23300 & 25300
8.79
2.9
C D
E F
N
K
P
“L” “R”
Pipe Size
A
S (dia. of holes)
R
T (no. of holes) G
J H
7.59 2.9
C D
E 8.75
K “TO” “AW”
P
NOTE: 2.75" needed
Pipe Size for terminal block
A cover removal.
R S (dia. of holes)
T (no. of holes) G
J H
Valve Size Valve Series A C D E F G H J K N P R S T

1.5" 23300 & 25300 3.06 2.44 11.44 18.00 18.00 3.06 2.25 0.88 4
7.62 2.38 3.5 5.62 2.72
2" 23300 & 25300 3.25 2.69 11.94 18.37 18.37 3.25 2.5 0.75 8
10/02

4700, 700, 33479, 33790
1" & 1.25" valves with swinging gate bodies

1" & 1.25" Series 700, 4700 1" & 1.25" Series 33790, 33479
13.14
8.82
2.77 3/4"
C D Conduit E 5.7
Conn.
16.08 16.28
Pipe Size
1.44 1.44
G
H
7.63 2.77
C D E 7.56
3/4" Conduit
Connection
16.28
B
Pipe Size
1.44
2.94
G
H
NOTE: 2.75" needed Available Top Assembly Positions

for terminal block
cover removal.
"L" "R" "TO" "AW"
Valve Size Valve Series B C D E G H

730, 760, 790 & 790-S
13.53
1" 4730, 4760, 4790 & 4790-S 4.12
33790 & 33479 ---
7.62 2.38 3.5 1.94
730, 760, 790 & 790-S
13.53
1.25" 4730, 4760, 4790 & 4790-S 4.19
33790 & 33479 ---
Auxiliary Signal Switches

All Maxon valves may be equipped with internally- Auxiliary signal switches indicate when valve is open
mounted signal switch(es) to provide a “proof-of- or closed and are normally connected electrically into
open” or “proof-of-closure” valve position indication. your control panel lights or warning device circuit(s).
For normally-closed valves:

VCS (Valve Closed Switch) is actuated when valve on front of switch bracket. VOS-1 is an SPDT switch.
is fully shut. It is the upper, inverted snap-switch On automatic reset valves, its normally closed contact
mounted on rear of switch bracket. VCS-1 is an SPDT serves as a motor limit switch and is not available for
(single-pole, double-throw) switch. VCS-2 is a DPDT external circuitry. On manual reset valves, normally
(double-pole, double-throw) switch. All contacts are closed contact is available for external circuitry, but is
available for external circuitry. not wired to optional terminal block. VOS-2 is DPDT,
VOS (Valve Open Switch) is actuated when valve used in lieu of VOS-1 for additional contacts.
reaches full-open. It is the lower snap-switch mounted
VOS actuator
VOS
(VOS-2 shown) VCS
(VCS-2 shown)
VOS wands
VCS wand
VOS actuator VCS actuator
VCS actuator
Valve Open Valve Shut
Photos above of normally-closed valve

(typical for Series 730, 760, 790, 808, 818, 5000, 5100, 4730, 4760, 4790)
1/99

For normally-open valves:
VOS (Valve Open Switch) is actuated when valve mounted on front of switch bracket. VCS-1 is an
is fully open. It is the upper, inverted snap-switch SPDT switch. On automatic reset valves, its normally
mounted on rear of switch bracket. VOS-1 is an SPDT closed contact serves as a motor limit switch and is
(single-pole, double-throw) switch. VOS-2 is a DPDT not available for external circuitry. On manual reset
(double-pole, double-throw) switch. All contacts are valves, normally closed contact is available for
available for external circuitry. external circuitry, but is not wired to optional terminal
VCS (Valve Closed Switch) is actuated when valve block. VCS-2 is DPDT, used in lieu of VCS-1 for
reaches fully-closed. It is the lower snap-switch additional contacts.
VCS actuator
VOS
(VOS-2 shown)
VCS VOS wand

(VCS-2 shown)
VOS actuator
VCS wand
VCS actuator
Valve Shut Valve Open

Photos above of normally-open valve
(typical for Series STO-MCP (-S), STO-ACP (-S)
All Maxon proof-of-open and

proof-of-closure signal Fig. 3 Fig. 4
switches work in a similar
manner; but due to different
styles and types of top assem-
bly housings, the switches
appear in slightly different
positions in the various types of
valves. Illustrated below are
representative top housings for
4" – 6" Series 7000 (Fig. 3) and
.375" – .75" Series 8700 (Fig.
4) valves. Switch locations are
noted on sketches.
Maxon Valve Accessories Page 6131
Tandem Arrangements
(for simultaneous opening of main and blocking valves)
General Wiring Schematic

Wherever insurance underwriters or other regula-
tory groups require the use of a double-valve or Flame
Safeguard
"block-and-bleed" system, but manual operation is Contact Main Valve
preferred to the use of automatic reset valves, opera- (Normally Closed)
tion can be simplified by adding a tandem arrange-

ment to a pair of Maxon manual reset shut-off valves. Blocking Valve
A linkage overtravel spring in the tandem arrange- (Normally Closed)
ment latches the blocking valve just before the main VCS in
valve is latched, assuring latching of both valves. Main Valve
Vent Valve
If it is necessary to locate a tandem valve above (Normally Open)
arms reach, an overhead wheel and chain assembly VOS in
may be added which includes a loop of chain acces- Main Valve
sible to operating personnel. VOS in For Illustration Only

Blocking Valve (not a wiring diagram)
To order Main Fuel

Panel Light
Valves are to be specified in the usual manner and
Main valve and blocking valve wired in parallel.
must be in top assembly position TO or AW. VCS Switch on main valve powers vent valve.
VOS and VCS switches must be included on the VOS Switches on main and blocking valves
wired in series to signal light.
main valve and a VOS switch on the blocking valve to
permit electrical connection as shown in the wiring
schematic illustrated at right.
If overhead wheel and chain assembly is also
required, specify loop length to reach appropriate Table 1: Allowable Valve Spacing for Tandem Arrgt.
operating position. Extra chain (in one foot incre- Valve Size Minimum C-C Maximum C-C
ments) may be specified. .75" – 1.5" 18" 24"
Center line distance between valves must be within
2" – 3" 20" 27"
the ranges indicated in Table 1 and shown in sketch
below and must be specified at the time of order. 4" & 6" 27" 33"
Tandem Arrangement with

Overhead Wheel & Chain Tandem Arrangement
Blocking
Blocking
Valve
Valve
Tension
Tension
Spring
Spring
Specify
Flow loop length Flow
Piping by others if overhead Piping by others
wheel &
chain option See Table 1
above
1/99
Overhead Wheel & Chain Assembly

Overhead wheel and chain assembly allows
operation of a manual reset valve in an otherwise
inaccessible overhead location. A wheel is mounted
onto the handle of the valve. The attached chain is
weighted on one end and has a paddle handgrip on
the other.
Once the valve is electrically energized, pulling
down on the paddle will open normally closed ver-
sions or close normally open versions.
Maxon valve's free-handle design permits valve to
trip to its rest position on any power interruption.
Wheel and chain assembly includes a length of
chain to position the paddle handgrip slightly below
pipe centerline. A standard length of 7 feet of chain is
included with CP and larger valve sizes and 5 feet is
included with all other valves. Extra chain (in one foot
increments) may be specified to fit your specific
location.
Approximate envelope dimensions (nominal, in inches)

Swinging gate valves Rising stem valves
12.19
12.19 Maximum
6.94
Maximum 7.25
2.31 dia.
5.25 4.06
Maximum
NOTE: Overhead wheel & chain can only be mounted

on swinging gate valves with the top assembly
position TO.
Electro-Mechanical Valves Page 6100-S-1
1. Read complete instructions before proceeding B. Teflon tape acts as a lubricant and greatly
and do not discard packing materials until any/all reduces the pipe wrench turning force re-
loose items are located. Also, make sure that the quired to seal the threads.
installation of the Maxon valves will be in compli-
Take care not to overtighten threads as
ance with all applicable governmental, insurance
this can damage the valve.
and/or agency requirements or codes, such as
NFPA-70, National Electric Code, CSA C22.1, C. Good piping practice dictates that piping be
Canadian Electric Code, etc. independently supported, so that valve bodies
2. General considerations: are not placed in a bind. In addition, large
A. Prior to shipment, each valve is operated valves may require support.
electrically and cycled at rated and 1-1/2 D. Clean pipe lines of foreign materials before
rated pressure while being leak tested. Every installing valve into line.
Maxon valve is operationally tested and
For new installations, a gas filter or strainer shall be
meets the requirements of ANSI B16.104
installed in the fuel gas piping to protect the
Class VI Seat Leakage when it leaves our
downstream safety shut-off valves.
plant. per NFPA 86-4-2.4.3 (1999)
B. Inspect your valve for any shipping damage. NFPA 86C-4-2.4.3 (1999)
Contact Maxon Corporation with the valve’s NFPA 86D-4-2.4-3 (1999)
serial number (printed on the valve's name-
plate) for replacement and/or repair parts.
C. Read the nameplate on your valve. This If normal inlet pressure to the fuel pressure regula-
gives the maximum pressure, temperature tor immediately upstream from the valve exceeds
limitation, voltage requirements and service the valve’s pressure rating, a relief valve shall be
conditions of your specific valve. DO NOT provided and it shall be vented to a safe location.
per NFPA 86-5-7.1.7 (1999)
exceed nameplate ratings. NFPA 86C-5-7.1.7 (1999)
D. Select mounting location carefully. Your NFPA 86D-5-7.1.7 (1999)
Maxon valve is designed to operate for many
years if installed in a location that is cool, E. Mount valve so that open/shut window
clean and dry. indicator [1] will be visible to your operating
3. Pipe the valve in the direction of the flow arrow personnel. The open/shut window indicator
[3] on the valve body. The Maxon valve body can should never face downward. With Maxon
shut off flow in one direction only. electro-mechanical top assemblies, the motor
A. Remove all thread and flange protectors access side plate [2] should always be
before installing valve in your service line. vertical to the ground. Valves are usually
installed in horizontal piping; however, other
1
2 1
2
5 2
5
1 5
4 4
4

mCORPORATION
Page 6100-S-2 Electro-Mechanical Valves

orientations are acceptable, subject to the B. Maintain integrity of Maxon top assembly
above limitations. The top assemblies of all enclosure by using dust and water-tight
Maxon valves are field rotatable to allow electrical connectors. Use cable-sealing grips
installations involving conflicts with these and strain-relief loops for any cord or cable.
mounting restrictions. Use internal sealing materials on all conduit
F. Main system shut-off should always use a connections. Moisture can have a harmful
manual leak-tight upstream fuel cock. effect on valve internals if permitted to enter
G. Time lag between valve action and fluid flow through wiring connectors. Make sure that all
(or flame response) is reduced if valve is access cover plates are in place and securely
located near the burner (or outlet). fastened. All cover screws should be tight-
4. Wire the valve in accordance with all applicable ened using an alternate cross corner tighten-
codes and standards. Supply voltages must agree ing pattern to the values shown below.
with valve’s nameplate voltage within -15%/+10%
AC or DC for proper operation. For electrical Cover Torque (in-lbs)
wiring schematics, refer to appropriate Maxon #10-24 Operator Cover 25
catalog literature and/or the wiring schematic .25"-20 All other access covers 50
diagram affixed inside your valve’s access cover .25"-20 Extended Access Cover Plate 96
plate or in the terminal block cover housing.
A. The Maxon valve must be electrically While all covers are torqued at time of produc-
interlocked with your safety-limit devices in tion testing, torque should be rechecked
accordance with all applicable codes, stan- periodically to ensure adequate sealing
dards, and the authority having jurisdiction protection.
over the safety requirements for your overall 5. Pre-operational exercising:
system installation. Normally, Maxon valves Prior to initial fluid flow start-up and with upstream
are electrically wired in series with all of your manual cock still closed, operate the valve
safety-limit devices. Therefore, any one electrically for 10-15 cycles. This not only pro-
device can cause the valve to react. Each vides an electrical check, but also wipes valve
valve was production tested when manufac- body disc and seat free of accumulated foreign
tured. If it now appears inoperative, make matter.
sure it is being powered properly from and
through your control circuit.
m CORPORATION

Top Assembly Rotation

1
2 1
2
5 2
5
1 5
4 4
4
3
Series 25300
with socket welded
Series 5000-CP Series 808 nipples & flanges
Maxon valves can and should be ordered in a con- Auxiliary Switch Arrangement
figuration compatible with planned piping, but if open/
shut indicator window is not visible and/or valve orienta-
tion is not proper, the top assembly can be rotated in
90° increments around the valve body centerline axis
by the following procedure:
1. Shut off all electrical power and close off up-
stream manual cock.
2. Remove wiring access cover plate [2] and
disconnect power lead wires. (Tag carefully for later
re-assembly.)
3. Remove conduit and electrical leads.
4. Note physical position of any signal switch
actuator wands on auxiliary signal switches (see Wiring Diagram
switch arrangement sketch).
5. Unscrew the two body bolts [4] screwed up from A– Number Coded Wires H– Mounting Screws
the bottom to 1/4 inch. DO NOT completely re- B– Rubber Grommet I – Spring Retainer Extension
move. These bolts secure the valve body [3] to the C– Mounting Screws J– Switch Wand
D– Normal (de-energized) K– Actual (energized)
valve’s top assembly housing [5]. Position Switch Position Switch
6. Gently lift the top assembly [5] (not more than E– Insulating Barrier L– Switch Wand
1/4" in height); just enough to break the seal F– Bracket Mounting Pad M– Switch Mounting Bracket
between the valve body assembly and the rubber G– Drive Pin & Locating Hole N– Gasket
gasket adhering to the bottom of the top housing.
WARNING: LIFTING TOO FAR MAY DISLODGE
SOME SMALL PARTS INSIDE THE TOP
HOUSING, REQUIRING COMPLEX RE-
ASSEMBLY AND RETESTING BY TRAINED
FACTORY PERSONNEL.

m CORPORATION

Top Assembly Rotation (cont'd.)
7. Remove the two body bolts [4] screwed up 11. Reconnect conduit and electrical leads, then
from the bottom (were partially unscrewed in check that signal switch wands are properly
step 5). positioned and that open/shut indicator moves
8. Carefully rotate top assembly to the desired freely. Failure to correct any such misalign-
position in a plane parallel to the top of the valve ment can result in extensive damage to the
body casting. Rotate the top housing about 30° internal mechanism of your valve.
beyond this position, and then rotate it back. 12. Energize valve and cycle several times from
Reposition the top housing back down onto the closed to full open position. Also electrically trip
valve body casting. This should align the open/ the valve in a partially opened position to prove
shut indicator with its window and provide proper valve operates properly.
alignment of the internal mechanism. 13. Replace and secure side cover access plate
9. Realign holes in valve body casting with the and place valve in service.
corresponding tapped holes in the bottom of the
top assembly housing. Be sure the gasket is still Cover Torque
in place between the body and top housing. #10-24 Operator Cover 25 in/lbs
10. Reinsert the body bolts up from the bottom .25"-20 All other access covers 50 in/lbs
through the body and carefully engage threads of
.25"-20 Extended Access Cover Plate 96 in/lbs
the top assembly. Tighten securely.
.31" Body Bolts 15 ft/lbs
.38" Body Bolts 40 tl/lbs
Alternate Top Assembly Positions
“R” “L” “AW” “TO”
Four top assembly positions are available for body and the arrow on the valve body casting points
most Maxon valves. When looking at the open/shut in direction of fluid flow: to the right (position "R"), to
window indicator of an electro-mechanical valve the left (position "L"), towards you (position "TO") or
assembly, the motor (for motorized version), or the away from you (position "AW"). With smaller size
operating handle (for manual version), will be on the swinging gate valve bodies, only position "R" and
right side of the top assembly. The valve body is on position "TO" may be used.
the bottom. From this view, the unidirectional valve
m CORPORATION

Operating Instructions
Refer to appropriate catalog bulletin and specifi- Electro-mechanical manual reset valves require
cation page for operating sequence applying to your two positive actions to open: a half rotation of
specific valve. Never operate valve until all essen- handle to latch internal mechanism, and a reversed
tial allied equipment is operative and any neces- half rotation of handle to open valve. This refers to
sary purges completed. Failure of electro-mechani- normally closed valves. With normally open valves,
cally operated valve to operate normally indicates that the procedure is the same, but the valve body position
it is not powered. Check this first! Then check (i.e., open or closed) is opposite to the normally
internal holding solenoid and/or motor operator. closed version.
Main system shut-off should always be accom- Remotely located manual reset valves may be
plished with an upstream leak-tight manual fuel equipped with wheel-and-chain assembly. Instructions
cock. to operate the valve are on hand grip. Locate counter-
All Maxon valves react within a fraction of a weight overhead at pipe level and hand grip can be
second when de-energized (can drop out if electrical brought down to convenient operating personnel
power is interrupted for less than 1/2 cycle [8 ms]). height.
Normally closed motorized valves begin open-
All electro-mechanical manual reset valves may
ing cycle immediately upon being powered; motor
be operated manually when solenoid is electrically
runs only until full open position is reached. Normally
energized, but electrical tripping is recommended
open valves begin to close immediately, and motor
for normal shut-downs.
runs until fully closed position is reached.
Operator should be aware of and observe characteristic opening/closing action of the valve. Should operation
ever become sluggish, remove valve from service and contact Maxon for recommendations.
Address inquiries to: Maxon Corporation, P.O. Box 2068, Muncie, IN 47307
Phone (765) 284-3304
FAX (765) 286-8394
www.maxoncorp.com
Always include valve serial number and nameplate information to insure positive identification.

m
CORPORATION
Maxon valves are endurance tested far in excess of
the most stringent requirements of the various ap- Insurance authorities agree . . .
proval agencies. They are designed for long life even . . . that the safety of any industrial fuel burning
if frequently cycled, and to be as maintenance-free installation is dependent upon well-trained
and trouble-free as possible. operators who are able to follow instructions and
Every Maxon valve is operationally tested and to react properly in cases of emergency. Their
meets the requirements of ANSI B16.104 Class VI knowledge of, and training on, the specific
Seat Leakage when it leaves our plant. installation are both vital to safe operation.
Top assembly components require no field Safety controls may get out of order without the
lubrication and should never be oiled. operator becoming aware of it unless shutdowns
Auxiliary switches, motors and solenoids, may be result. Production-minded operators have been
replaced in the field. known to bypass faulty controls without reporting
the trouble.
WARNING: Do not attempt field repair of valve Continued safe operation of any installation is
body, top assembly or motor drive unit. Any then assured only if the plant management
alterations void all warranties. carefully develops an exact schedule for regular
Valve leak test, performed with valve in line as periodic inspection of all safety controls, insisting
prescribed by jurisdictional authorities, is strongly that it then be rigidly adhered to.
encouraged and should be done on a regularly A main gas shut-off cock should be located
scheduled basis. In rare instances where valve shows upstream from all other fuel train piping compo-
leakage, perform Pre-Operational Exercising (see nents and used to shut off all flow of fuel for
below) and retest. If leakage does not stop, remove servicing and other shutdowns.
valve from service. All safety devices should be tested at least
Pre-operational exercising: Prior to initial fluid monthly* and more often if deemed advisable.
flow start-up and with upstream manual cock still Periodic testing for tightness of manual or motor-
closed, operate the valve electrically for 10-15 cycles. ized shut-off valve closure is equally essential.
This not only provides an electrical check, but also
wipes valve body disc and seat free of accumulated
foreign matter.
Maxon valves are designed to be used with
clean fluids. If foreign material is present in the
fuel line, it will be necessary to inspect the
valve to make certain it is operating properly. If
abnormal opening or closing is observed, the
valve should be removed from service. Contact
your Maxon representative for instructions.
Address inquiries to: Maxon Corporation, P.O. Box 2068, Muncie, IN 47307
Phone (765) 284-3304
FAX (765) 286-8394
www.maxoncorp.com
m CORPORATION


Field Installation Instructions
NOTE: Instructions below are written for normally Fig. 1
.75" – 3"
closed valves. For normally open versions (STO- non-CP
M, STO-A, Fig. 1 & 2), reverse switch nomencla-
ture. (VOS becomes VCS and vice versa.) Remove
side cover plate.
General: Shut off fuel supply upstream of valve, then Switches mount
de-energize valve electrically. on bracket. (See
– Remove top or side cover to provide access, being "A" below)
careful not to damage gasket.
– Compare with illustrations at right to identify YOUR
valve type. Fig. 2
To replace existing switches: 2.5" – 4" -CP
– Note wand position and mounting hole location 6" 808
carefully, then remove 2 screws and lift existing switch.
– Install replacement switch in same mounting holes on Remove
side cover plate.
bracket and verify correct wand position. Switches mount
– Replace existing wiring one connection at a time, on bracket. (See
following original route and placement. "B" below)
To add switches to existing valve:
– Check illustrations at right. If your valve uses a switch
mounting bracket as in Fig. 1 & 2, mount switches to Fig. 3 TO CLUTCH
bracket using the mounting holes appropriate for valve 4" – 6" 7000 2 1
type and size. 12 11 10 9 8 7 6 5 4 3 2 1
Remove 2-piece top cover.

– Position bracket so VCS wand just touches top of
Switches mount on support #1 BLACK TO
TERMINAL #1
COM
NO
NC
actuator, then move downward slightly, depressing stand. #3 BLACK TO

TERMINAL #3
BLACK TO MOTOR
wand until switch clicks, then tighten mounting screws

to hold this position.
– Pin bracket by drilling 1/8" dia. holes 1/4" deep into
bracket mounting pad through drive pin holes, then tap Fig. 4
drive pin in until flush. .375" – .75" 8700 SHUT
– Route wires to wiring compartment as shown, then

Remove top cover.
complete wiring connections and clean out metal Switches mount on actuator
drilling chips from previous procedure. frame
– Cycle valve, checking switch actuation points carefully.
(VCS actuates at top of stem stroke, VOS at bottom.)
Simultaneously the valve body must be tested for
switch continuity and seat leakage. Bend VOS switch Wand Position Mounting Brackets
wands slightly if necessary to insure valve is opening For 1", 1.25" C.I. 3",4",6"(-2)
VOS switch wand 3",4",6"(-2)
fully. should be actuated
& 2", 3" non-CP 2-1/2"(-2)
– Replace gasket and cover, then return valve to from above.
2-1/2"(-1)
VCS switch mounts
service. on back of bracket
VCS Switch
on back
Oil SOV &
2"-6" Gas
Cover Torque (ft-lbs) 1-1/2"
#10-24 Operator Cover 25

1-1/4"
3/4", 1"
VOS switch
B VOS switch
on front
.25"-20 All other access covers 50

VCS switch wand
should be actuated
A Drive
on front
from below. Pins

.25"-20 Extended Access Cover Plate 96 Bracket
Mounting
Holes
Bracket
Mounting
Slots

m
CORPORATION
Electrical Data
Normally Closed Valves
.75" – 3" Series 808, 818 (-S);
1" – 1.25" Series 730, 760, 790 (-S);
1" – 1.25" Series 33790 (-S):
2.5" – 4" Series 808-CP (-S); 818-CP (-S);
6" Series 808, 818 (-S)

.75" – 3" Series 5000, 5100 (-S);
1" – 1.25" Series 4730, 4760, 4790 (-S);
1" – 1.25" Series 33479;
2.5" – 4" Series 5000-CP(-S); 5100-CP(-S)
4" – 6"
Series 7000, 7100 (-S)
.375" – .75"
Series 8730, 8760,
and 8790 (-S)
m CORPORATION

Electrical Data
Normally Open Valves
.75" – 2" Series STO-M and STO-A (-S)

2.5" – 4" Series STO-MCP and STO-ACP (-S)
SWITCH CONTACT POSITIONS P/N 26379M

SHOWN WITH VALVE OPEN VALVE WIRING DIAGRAM
MOTORIZED VALVE ONLY
VCS-1 VCS-2 VOS-1 VOS-2
SOLENOID
INTERNAL
WARNING! WIRING
VALVE MTR
MUST BE
WIRED AS
SHOWN H(+) N(-) 1 2 3 4 5 6 7 8 9 10 11 12
OPTIONAL SPDT SPDT SPDT SPDT FIELD

D.C. POWER HERMETICALLY SEALED HERMETICALLY SEALED
SUPPLY WIRING
ALL NI VALVES INCLUDE DPDT DPDT
HERMETICALLY SEALED GENERAL PURPOSE GENERAL PURPOSE
SWITCHES, SUITABLE FOR L1-H L2-N
HAZARDOUS LOCATIONS AC-POWER
CLASS I, DIV. 2, ABCD
CLASS II, DIV. 2, FG SEE NAME PLATE FOR VOLTAGE AND HZ
CLASS III, DIV. 2
SWITCH RATINGS VALVE VCS-1 VCS-2 VOS-1 VOS-2
Total connected load not to exceed 1700 VA
GENERAL PURPOSE HAZARDOUS LOCATION MODE 1-3 1-3 4-5 4-6 7-8 7-9 7-8 7-9 10-11 10-12
SPDT DPDT SPDT FULLY OPEN
125 VAC - 15 AMP 125 VAC - 10 AMP 28 VDC - 5 AMP
250 VAC - 15 AMP 250 VAC - 10 AMP 125 VAC - 1 AMP INTERMEDIATE
125 VDC - 0.5 AMP 125 VDC - 0.3 AMP
FULLY SHUT
250 VDC - 0.25 AMP 250 VDC - 0.15 AMP

m
CORPORATION
Tandem Arrangements
Review and comply with all general valve installa- 8. Rotate the operating handle of the main valve
tion instructions provided separately. (See sketch fully to latching position for your particular valve,
below.) then hold handle firmly in this position while
1. Mount both valves in fuel line with center to center performing the next few steps.
spacing as originally specified, and blocking valve 9. Rotate blocking valve wheel fully counter-clock-
(without handle) downstream of main valve (with wise until it strikes a stop (it will slide within the
handle). loop of chain).
2. Check valve alignment to be certain that operat- 10. Still holding main valve wheel in place, move
ing wheels lie in the same plane. blocking valve wheel approximately 1/4 to 1/2
3. Remove tape from the wheel of the main valve inch back in the clockwise direction. Insert the
and unwind the attached chain. Do not remove #10-24 X 1/2" screw (furnished) through the chain
the screw holding chain to wheel; it has been link that lines up with the tapped hole on bottom
factory positioned to assure correct alignment. Do of blocking valve wheel, then fasten securely.
not remove tension spring attached to one end of 11. Verify that the valves are wired in parallel as
chain or the wooden block insert which preloads shown in wiring schematic on page 6121.
the spring.
4. Take free end of chain and loop it around the To add wheel & chain assembly to
wheels of both main and blocking valve as shown existing tandem valves:
in sketch below. Depending on the specific valve 1. Verify that both valves are in the same top
series and arrangement, tension spring may be assembly position (TO or AW). Rotate if neces-
located either above or below the wheel center- sary. (See top assembly rotation instructions on
line. pages 6100-S-3 and 6100-S-4.)
5. Draw free end of chain and tension spring to- 2. Bend handle of main valve outward about 25°.
gether so that as much slack as possible is 3. Cut off handle of blocking valve at outer wheel
eliminated, then insert the open eye of the spring face.
"S" hook through the link in the chain that will 4. Remove hardware holding main valve wheel in
most nearly maintain this position. place and mount new wheel and spacer to the
6. Crimp the "S" hook shut around the chain link, existing wheel with new hardware provided.
then cut and discard excess chain. 5. Cut chain loop to the desired length and secure to
7. Remove spring preload wood block insert from both wheels.
the tension spring, and verify that the chain is
drawn tight.
Blocking
Valve
Tension
Spring
Flow
Piping by others
m CORPORATION


the other.
location.

12.19
Maximum
6.94 12.19
Maximum 7.25
2.31 dia.
5.25 4.06
Maximum

position TO.

mCORPORATION
CAUTION: Valve leak testing should be under- Suggested leak test procedure for
taken only by trained and experienced personnel. double-blocking shut-off valves (without
Instructions provided by the company and/or vent line)
individuals responsible for the manufacture and/or
overall installation of complete system incorporat- (a) Shut down combustion system per manufacturer’s
ing Maxon valves take precedence over these recommended procedure.
provided by Maxon. If Maxon instructions conflict (b) Close manual valves A and B.
with any codes or regulations, contact Maxon (c) Visually inspect to verify that shut-off valves #1
Corporation before attempting this procedure. and #2 are closed.
(d) Remove the 1/4” pipe plug from downstream side
Valve leak test should be performed on a of shut-off valve #1. Install leak test apparatus.
quarterly basis to assure continued safe and Safely vent any trapped gas pressure.
reliable operation. Each valve should be checked (e) Open manual shut-off valve A, then close leak
with available line pressure. Absolute zero leakage test apparatus. Insert tube into a container of
may not be obtained in the field. Any valve that water just below the surface.
exceeds the allowable leakage, as set forth by your (f) Open test apparatus and test valve for leakage.
local codes or insurance requirements (15 bubbles As a guideline, valve should be tested for 2
per minute), should be removed from service and minutes per inch of pipe diameter. Large diameter
your Maxon representative should be contacted. pipes or long piping runs between shut-off valves
may need additional testing time.
Every Maxon valve is operationally tested and (g) If valve testing indicates leakage exceeding 15
meets the requirements of ANSI B16.104 Class bubbles per minute, perform pre-operational
VI seat leakage when it leaves our plant. exercising as outlined on Page 6100-S-2 and
retest the valve. If valve continues to exceed
allowable leakage limit, remove from service and
Example of a gas piping diagram for leak test contact Maxon.
Shut-off Shut-off
Manual Gas Pressure Valve Valve
Valve Regulator #1 #2
A LGP HGP Manual
Switch Switch Valve
B
Strainer
To Combustion
System
Drip
Leg
Example of a wiring diagram for leak test

From Flame
Safeguard Neutral NOTES:
Hot
Push button must be tamper resistant.
Momentary Leak
Test Push Button LS-SV – Closes when Shut-off Valve #1
is fully open.
Shut-off
Valve #1
The “From Flame Safeguard” line is
energized only when all conditions for
LS-SV Shut-off safe operation have been satisfied.
Valve #2
mCORPORATION

Suggested leak test procedure for double-blocking shut-off valves (without vent line) - continued
(h) Secure test apparatus on valve #1. retest the valve. If valve continues to exceed
(i) Remove the 1/4” pipe plug from downstream side allowable leakage limit, remove from service and
of shut-off valve #2. Install leak test apparatus. contact Maxon.
(j) With an auxiliary power supply connected to valve (l) Secure test apparatus on valve #2.
#1, open test apparatus and test valve for leak- (m) Upon completion of valve leak testing, test all
age. As a guideline, valve should be tested for 2 other safety interlocks per manufacturer’s instruc-
minutes per inch of pipe diameter. Large diameter tions and verify they are operational.
pipes or long piping runs between shut-off valves (n) Restore combustion system to operational
may need additional testing time. condition. Be sure to remove all auxiliary power
(k) If valve testing indicates leakage exceeding 15 supplies and jumpers that may have been used
bubbles per minute, perform pre-operational during testing.
exercising as outlined on Page 6100-S-2 and
Suggested leak test procedure for double-blocking shut-off valves with vent line
Example of a gas piping diagram for leak test with vent line Vent
Valve
If vent valve is
present, use auxil- Shut-off
Manual Gas Pressure Valve
iary power supply to Valve Regulator #1 Shut-off Valve #2
power vent valve to A LGP Manual
HGP
closed position Switch Switch Valve
during this test B
Strainer
procedure. Follow
test instructions
above. Once test is To Combustion
System
complete, be sure Drip
vent valve is re- Leg
stored to normal
operation.
Example of a wiring diagram for leak test with vent line

From Flame
NOTES: Hot Safeguard
Neutral
Push button must be tamper
resistant. Shut-off Valve #2 Shut-off Valve #1
Momentary Leak Momentary Leak
Test Push Button Test Push Button
LS-VV – Closes when Vent
Valve is fully closed Vent
Valve
LS-SV – Closes when Shut-
off Valve #1 is fully open.
The “From Flame Safe-

guard” line is energized only LS-VV
Shut-off
when sall conditions for Valve #1
safe operation have been
satisfied.
LS-SV Shut-off
Valve #2

m CORPORATION
Notes
m
CORPORATION

Maxon Valves Page 6100-A/P-1
Assembly Numbers
Series 808 Shut-off Valves
Normally closed, rising stem, electrically actuated, manual reset, trip close
Sanctioned Valves Non-sanctioned Valves
(for clean fuel gases and light oils) [1] Valve Size (for special services)
MOPD Ship Wt.* MOPD
&
(psi) Designation (lbs) Designation (psi)
Assembly Number Cv Factor Assembly Number
Series Series
125 .75 808 808 .75" 21 818 .75 818 30

Cv = 20
125 1 808
808 1" 23
818
1 818 30
808-S Cv = 20 818-S
100 1.25 808 808 1.25" 23 818 1.25 818 30

Cv = 45
70 1.5 808
808 1.5" 23
818
1.5 818 20
808-S Cv = 53 818-S
808 818
2" 34
70 2 808 808-S 818-S 2 818 15
Cv = 86
808 35 818
808 2.5" 36 818
40 2.5 808 2.5 818 10
808 Cv = 127 46 ---
808-CP 44 818-CP
50 2.5CP 808 808-CP
2.5" CP 818-CP 2.5CP 818 15
Cv = 304 63
808-SCP 818-SCP
30 3 808 808 3" 38 818 3 818 5

Cv = 173
808-CP 818-CP
40 3CP 808 808-CP
3" CP 75 818-CP 3CP 818 10
Cv = 423
808-SCP 818-SCP
40 4CP 808
808-CP 4" CP 89
818-CP
4CP 818 10
808-SCP Cv = 490 818-SCP
30 6 808
808 6" 143
818
6 818 5
808-S Cv = 869 818-S
[1] Light oil suitability restricted to trims 1-2 and 2-2 only
Shaded areas are flanged body valves (valves with -S designation are raised face)
*Approximate. Actual weight will vary based on options selected.
Segment choices are as follows for configured 808 valves:

• Fuel • VOS switch
• Body trim • VCS switch
• Body connection • Terminal block
• Minimum fuel/ambient temperature • Time delay
• Maximum fuel temperature • Top assembly position
• Maximum ambient temperature • Handle sideplate
• Solenoid voltage • Tagging
• Enclosure rating

mCORPORATION
Page 6100-A/P-2 Maxon Valves
Assembly Numbers
Series 5000 & 7000 Shut-off Valves
Normally closed, rising stem, electrically actuated, automatic reset, trip close
(for clean fuel gases) Valve Size (for special services)
MOPD Ship Wt.* MOPD
&
Series Series
125 .75 5000 5000 .75" 23 5100 .75 5100 30

Cv = 20
125 1 5000
5000 1" 24
5100
1 5100 30
5000-S Cv = 20 5100-S
100 1.25 5000 5000 1.25" 25 5100 1.25 5100 30

Cv = 45
70 1.5 5000
5000 1.5" 27
5100
1.5 5100 20
5000-S Cv = 53 5100-S
5000 5100
2" 36
70 2 5000 5000-S 5100-S 2 5100 15
Cv = 86
5000 54 5100
5000 2.5" 39 5100
40 2.5 5000 2.5 5100 10
5000 Cv = 127 60 ---
5000-CP 44 5100-CP
50 2.5CP 5000 5000-CP
2.5" CP 5100-CP 2.5CP 5100 15
Cv = 304 68
5000-SCP 5100-SCP
30 3 5000 5000 3" 40 5100 3 5100 5

Cv = 173
5000-CP 49 5100-CP
40 3CP 5000 5000-CP
3" CP 5100-CP 3CP 5100 10
Cv = 423 69
5000-SCP 5100-SCP
40 4CP 5000
5000-CP 4" CP 88
5100-CP
4CP 5100 10
5000-SCP Cv = 490 5100-SCP
60 4 7000
7000 4" 145
7100
4 7100 10
7000-S Cv = 719 7100-S
50 6 7000
7000 6" 175
7100
6 7100 10
7000-S Cv = 1172 7100-S
Shaded areas are flanged body valves (valves with -S designations are raised face)
Segment choices are as follows for Segment choices are as follows for
configured 5000 valves: configured 7000 valves:
• Fuel • Solenoid voltage • Fuel • Clutch voltage
• Body trim • Enclosure rating • Body trim • Enclosure rating
• Body connection • VOS switch • Body connection • VOS switch
• Minimum fuel/ambient temp. • VCS switch • Minimum fuel/ambient temp. • VCS switch
• Maximum fuel temp. • Terminal block • Maximum fuel temp. • Terminal block
• Maximum ambient temp. • Time delay • Maximum ambient temp. • Top assembly position
• Motor voltage • Top assembly position • Motor voltage • Tagging
• Motor timing • Tagging • Motor timing
mCORPORATION

Assembly Numbers
Series STO-M Valves
Normally open, rising stem, electrically actuated, manual reset, trip open
(for clean fuel gases and light oils) [1] Valve Size (for special services)
MOPD Ship Wt.* MOPD
&
Series Series
125 .75 STOM STO-M .75" 21 STO-MU .75 STOMU 30

Cv = 20
125 1 STOM
STO-M 1" 23
STO-MU
1 STOMU 30
STO-MS Cv = 20 STO-MSU
70 1.5 STOM
STO-M 1.5" 23
STO-MU
1.5 STOMU 20
STO-MS Cv = 53 STO-MSU
STO-M STO-MU
2" 34
70 2 STOM STO-MS STO-MSU 2 STOMU 15
Cv = 86
STO-M 35 STO-MU
[1] Light oil suitability restricted to trims 1-2 and 2-2 only.
Segment choices are as follows for configured STO-M valves:

• Fuel
• Body trim
• Body connection
• Minimum fuel/ambient temperature
• Maximum fuel temperature
• Maximum ambient temperature
• Solenoid voltage
• VCS switch
• VOS switch
• Terminal block
• Time delay
• Top assembly position
• Handle sideplate
• Tagging

m CORPORATION
Assembly Numbers
Series STO-A Valves
Normally open, rising stem, electrically actuated, automatic reset, trip open
(for clean fuel gases) Valve Size (for special services)
MOPD Ship Wt.* MOPD
&
Series Series
125 .75 STOA STO-A .75" 23 STO-AU .75 STOAU 30

Cv = 20
125 1 STOA
STO-A 1" 24
STO-AU
1 STOAU 30
STO-AS Cv = 20 STO-ASU
70 1.5 STOA
STO-A 1.5" 27
STO-AU
1.5 STOAU 20
STO-AS Cv = 53 ATO-ASU
STO-A STO-AU
2" 39
70 2 STOA STO-AS STO-ASU 2 STOAU 15
Cv = 86
STO-A 54 STO-AU
STO-A-CP 46 STO-A-UCP
50 2.5CP STOA STO-A-CP
2.5" CP 66 STO-A-UCP 2.5CP STOAU 15
Cv = 304
STO-A-SCP 46 STO-A-SUCP
STO-A-CP 49 STO-A-UCP
40 3CP STOA STO-A-CP
3" CP STO-A-UCP 3DP STOAU 10
Cv = 423 69
STO-A-SCP STO-A-SUCP
40 4CP STOA
STO-A-CP 4"CP 88
STO-A-UCP
4CP STOAU 10
STO-A-SCP Cv = 490 STO-A-SUCP
These assemblies include General Purpose 115/60 AC motor and solenoid with General Purpose VCS-1 motor limit switch
Segment choices are as follows for configured STO-A valves:

• Fuel
• Body trim
• Body connection
• Motor voltage
• Motor timing
• VOS switch
• VCS switch
• Terminal block
• Time delay
• Tagging
mCORPORATION

Assembly Numbers
Series 700 / 23000 / 33000 Valves
Normally closed, swinging gate, electrically actuated, manual reset, trip close
(for clean fuel oils and heavy oils) Valve Size (for special services)
MOPD Ship Wt.* MOPD
&
Series Series
300 730 790 300
1 700 1" 37 1 790
760 790-S
600 Cv = 12 600
--- --- 41 33790 1 33790
300 730 790 300
1.25 700 1.25" 1.25 790
760 40 790-S
600 Cv = 17 600
--- --- 33790 1.25 33790
300 1.25 700 730-S 1.25" 40 790-S 1.25 790 300

Cv = 45
--- ---- --- 1.5" 70 23300 1.5 23300 150

Cv = 123
--- --- --- 2" 80 23300 2 23300 100

Cv = 218
These assemblies include General Purpose 115/60 AC solenoids.
Shaded areas are 300# raised flanged body valves
Segment choices are as Segment choices are as Segment choices are as

follows for configured follows for configured follows for configured
700 valves: 23300 valves: 33790 valves:
• Fuel • Fuel • Fuel
• Body trim • Body trim • Body trim
• Body connection • Body connection • Body connection
• Minimum fuel/ambient temp. • Minimum fuel/ambient temp. • Minimum fuel/ambient temp.
• Maximum fuel temperature • Maximum fuel temperature • Maximum fuel temperature
• Maximum ambient temperature • Maximum ambient temperature • Maximum ambient temperature
• Solenoid voltage • Solenoid voltage • Solenoid voltage
• Enclosure rating • Enclosure rating • Enclosure rating
• VOS switch • VOS switch • VOS switch
• VCS switch • VCS switch • VCS switch
• Terminal block • Terminal block • Terminal block
• Time delay • Top assembly position • Top assembly position
• Top assembly position • Handle sideplate • Handle sideplate
• Handle sideplate • Tagging • Tagging
• Tagging

mCORPORATION
Assembly Numbers
Series 4700 / 8700 / 25300 / 33479
Normally closed, swinging gate, electrically actuated, automatic reset, trip close
(for clean fuel oils and heavy oils) Valve Size (for special services)
MOPD Ship Wt.* MOPD
&
Series Series
300 .375 8700 8730 .375" 30 8790 .375 8790 300

Cv = 3.4
300 8730 .5" 8790 300
.5 8700 30 .5 8790
600 8760 Cv = 3.4 8790-S 600
300 8730 .75" 8790 300
.75 8700 30 .75 8790
6 00 8760 Cv = 9.6 8790-S 600
300 4730 4790 300
1" 1 4790
1 4700 42 4790-S
600 4760 Cv = 12 600
33479 1 33479
300 4730 4790 300
1.25" 1.25 4790
1.25 4700 42 4790-S
600 4760 Cv = 17 60
33479 1.25 33479
300 1.25 4700 4730-S 1.25" 42 4790-S 1.25 4790 ---

Cv = 45
--- --- --- 1.5" 74 25300 1.5 25300 150

Cv - 123
--- --- --- 2" 90 25300 2 25300 100

Cv = 218
Shaded areas are 300# raised flanged body valves.
Segment choices are Segment choices are Segment choices are Segment choices are
as follows for as follows for as follows for as follows for
configured 4700 configured 8700 configured 25300 configured 33479
valves: valves: valves: valves:
• Fuel • Fuel • Fuel • Fuel
• Body trim • Body trim • Body trim • Body trim
• Body connection • Body connection • Body connection • Body connection
• Min. fuel/ambient temp. • Min. fuel/ambient temp. • Min. fuel/ambient temp. • Min. fuel/ambient temp.
• Maximum fuel temp. • Maximum fuel temp. • Maximum fuel temp. • Maximum fuel temp.
• Maximum ambient temp. • Maximum ambient temp. • Maximum ambient temp. • Maximum ambient temp.
• Motor voltage • Motor voltage • Motor voltage • Motor voltage
• Motor timing • Motor timing • Motor timing • Motor timing
• Solenoid voltage • Clutch voltage • Solenoid voltage • Solenoid voltage
• Enclosure rating • Enclosure rating • Enclosure rating • Enclosure rating
• VOS switch • VOS switch • VOS switch • VOS switch
• VCS switch • VCS switch • VCS switch • VCS switch
• Terminal block • Terminal block • Terminal block • Terminal block
• Time delay • Time delay • Top assembly position • Top assembly position
• Top assembly position • Top assembly position • Tagging • Tagging
• Tagging • Tagging
mCORPORATION

Assembly Numbers – Spare Parts

Signal Switches
General Purpose .75" through 3" RS and 1" through 2" SG Valves
Valve Size
Old Switch Assembly Number 1" through 2" SG
.75" & 1" RS 1.25" RS 1.5" RS
2" through 3" RS
VCS1 (NC) VOS1 (NO) 18428 18428 57335 57347 57250
VCS2 (NC) VOS2 (NO) 18429 18429 57336 57348 57251
VCS1, VOS1 SW ASY 17541 W/19599 57325 57337 57349 57252
VCS2, VOS1 SW ASY 17542 W/19599 57326 57338 57350 57253
VCS1, VOS2 SW ASY 17541 W/25467 57327 57339 57351 57254
VCS2, VOS2 SW ASY 17542 W/25467 57328 57340 57352 57255

Valve Size
Old Switch Assembly Number 1" through 2" SG
.75" & 1" RS 1.25" RS 1.5" RS
2" through 3" RS
VCS1 (NC) VOS1 (NO) 18428 18428 57335 57347 57250
VCS2 (NC) VOS2 (NO) 18429 18429 57336 57348 57251
VOS1, VCS1 SW ASY 17541 W/19599 57325 57337 57349 57252
VOS2, VCS1 SW ASY 17542 W/19599 57326 57338 57350 57253
VOS1, VCS2 SW ASY 17541 W/25467 57327 57339 57351 57254
VOS2, VCS2 SW ASY 17542 W/25467 57328 57340 57352 57255
General Purpose 2.5", 3" 4" CP and 6" 808

Valve Size
Old Switch Assembly Number
2.5" 3", 4" & 6"
VCS1 (NC) VOS1 (NO) 23433 23433 57369
VCS2 (NC) VOS2 (NO) 23434 23434 57370
VCS1, VOS1 SW ASY 24470 W/23436 57323 57371
VCS2, VOS1 SW ASY 24470 W/23437 57324 57372
VCS1, VOS2 SW ASY 26301 W/23436 57329 57373
VCS2, VOS2 SW ASY 26301 W/23437 57330 57374 Key:
VOS = Valve Open Switch
Normally Open Valves VCS = Valve Closed Switch
Valve Size
2.5" 3", 4" & 6"
VCS1 (NC) VOS1 (NO) 23433 23433 57369
VCS2 (NC) VOS2 (NO) 23434 23434 57370
VOS1, VCS1 SW ASY 24470 W/23436 57323 57371
VOS2, VCS1 SW ASY 24470 W/23437 57324 57372
VOS1, VCS2 SW ASY 26301 W/23436 57329 57373
VOS2, VCS2 SW ASY 26301 W/23437 57330 57374

mCORPORATION
Solenoids
Maxon Valve Size & Series
1" & 1.25"
730 (-S); 760; 790 (-S)
4730 (-S); 4760; 4790 (-S) 2.5", 3", & 4"
.75", 1", 1.25", & 1.5" 808 (-S) CP; 818 (-S) CP
Electrical 2", 2.5", & 3"
808 (-S); 818 (-S) 5000 (-S) CP; 5100 (-S) CP
Specification 808 (-S); 818 (-S)
5000 (-S); 5100 (-S) STO-M (-S) CP; STO-A (-S) CP
5000 (-S); 5100 (-S)
STO-M (-S); STO-A (-S)
STO-M (-S); STO-A (-S)
1" & 1.25" 6"
33790 (-S); 33479 (-S) 808 (-S); 818 (-S)
23v 60 Hz 21025 22049 35885
46v 60 Hz 35886 35887 35888
50 Hz 37741 37747 37753
100v
60 Hz 35894 35895 35896
50 Hz 37742 37748 37754
115v
60 Hz 17555 22055 23243
50 Hz 37744 37750 37755
208v
60 Hz 35897 35898 35899
50 Hz 37745 37751 37756
230v
60 Hz 21026 22056 23244
50 Hz 37746 37752 37758
345v
60 Hz 35889 35890 ---
460v 60 Hz 21027 22052 ---
24v DC 39543 39545 39549 [1]
48v DC --- 39546 39550 [2]
120v DC 39544 39547 39551 [3]
240v DC --- 39548 39552 [4]
[1] None available (24v DC) for 6" 808, 818 (-S)
[2] For 6" 808, 818 (-S), use 39553 for 48v DC
[3] For 6" 808, 818 (-S), use 39555 for 120v DC and with TD-II unit
[4] None available (240v DC) for 6" 808, 818 (-S)
Key: v = Volts
Hz = Hertz
DC = DC
m CORPORATION

Assembly Numbers
Motor Operators and Internal Top Assembly Components

.75", 1", 1.25", 1.5", 2", 2.5",
3", & 4"
Motor Operator Electrical 5000 (-S); 5100 (-S) .75", 1", 1.25", 1.5", 2",
Specifications .75", 1", 1.5", & 2"
4730 (-S); 4760; 4790 (-S) 2.5", 3", & 4"
STO-A (-S)
5000 (-S) CP STO-A (-S) CP
5100 (-S) CP
33479 (-S); 25300
2.5 second 115v 50/60 Hz 41635 [5] 41635 ---
timing 230v 50/60 Hz 41647 [5] 41647 ---
115v 50/60 Hz 41637 41637 41637
Listed
6 second 230v 50/60 Hz 41649 41649 41649
timing 24v DC 36648 36648 ---
Unlisted
48v DC 36650 36650 ---

Motor Operator 4" & 6" .375", .5", & .75"
Electrical Specifications 7000 (-S) 8730; 8760
7100 (-S) 8790 (-S)
115v 50/60 Hz 32093 ---
12 second timing
230v 50/60 Hz 32094 ---
115v 60 Hz --- 27152
6 second timing
230v 50 Hz --- 27323
115v 60 Hz 32014 [1] / 32015 [2] 32766
Replacement Top Assembly
230v 50 Hz 36387 [1] / 36390 [2] 36400
115v 60 Hz 27134
Replacement Wiring Circuit Board 25354 [3]
230v 50 Hz 27547
Replacement Clutch Assembly 90v DC 25367 [3] 43121
Internally Wired Time Delay Feature
115/60 --- 32594 [4]
1.5 - 4 second delay
[1] For 4" Series 7000 valve [2] For 6" Series 7000 [3] For 115v 50/60 Hz or 230v 50/60 Hz
[4] This TD unit is FM (Factor y Mutual), UL (Underwriters Laborator y, and CGA (Canadian Gas Association) sanctioned
[5] 2.5 second option is not available for CP valves
Key: v = Volts
Hz = Hertz
DC = Direct Current

m
CORPORATION

Companion Flange Set Options
Pipe Line Size
Flange Description
2" 2.5" 3" 4" 6"
125#, flat faced, threaded, iron 39882 20338 20341 20206 ---
150#, flat faced, threaded, steel 39883 20339 20342 20208 20209
150#, flat faced, slip-on welding, steel 39884 20340 20343 20210 20211
Approximate weight in pounds 20 22 24 35 46
Flange sets include (2) flanges and gaskets with necessar y nuts and bolts to mount set to flanged body valve assemblies.
Wheel & Chain Accessory Options
Extra chain for Wheel & Chain Assemblies (in 1 foot increments) – 00035
Standard length on CP and larger valves is 7 feet; all other valves is 5 feet
mCORPORATION

Product: Electro-mechanical Valves Page: 6000-15 Date: 6/00
Valve Testing Intervals

Maxon Corporation practices a policy of conserva- The first and most conventional is the Double
tive safety practices in the industrial gas market. In Block and Bleed system. This system involves the
accordance with NFPA safety codes, it is our policy use of a Double Block Safety Shut-off Valve system
that users of Maxon Safety Shut-off Valves should with a Maxon STO vent valve positioned between the
inspect and test their Safety Shut-off Valve equip- 2 Safety Shut-off Valves. All three valves should
ment on a quarterly basis. While this is practical in include a Proof-of-Position switch which is inter-
many applications, some industrial sites may see a locked into the flame safeguard system.
need for increased safety in this area or decreased The second approach would be the installation of
time intervals for testing. In these cases, Maxon feels a three valve system involving three Safety Shut-off
that the use of the three valve safety system allows Valves in series. Again, as with the above, all three
for an increased time interval of up to one year for valves should include a Proof-of-Closure switch
these customers. This three valve system can be set- which has been interlocked into the flame safeguard
up in several ways. system.
Double Block & Bleed

Pipe Train
Triple Block
Pipe Train
Top Assembly Replacement for 4", 6" Series 7000 (S), 7100 (-S) valves et al.
To remove old top assembly:

1. Shut off upstream gas cock.
2. Shut off all electric power to valve.
3. Remove terminal access plate. (Make certain
valve is in shut position.)
4. Remove incoming lead wires from terminal
➨ block.
5. Tag leads for re-assembly.
6. Remove conduit and leads.
➨
Step 5 Step 6
➨ 7. Remove top cover. (Two of twelve screws are

sealed. Break seal and remove screws.)
8. Lift cover straight up to avoid damage to mecha-
nism.
9. Remove lock spacer, shock pad washer, and
shock pad. (Prevent spring retainer from turning
while removing lock spacer by inserting pin or
Allen wrench into 1/4" diameter hole. Pin will ➨
stop possible spring retainer rotation when lock
spacer is unthreaded.)
Step 7 Step 9
➨ 10. Remove four hex head mounting screws (3/8" –

16 N.C.), which hold top assembly to upper
flange of valve bonnet.
11. Lift top assembly of valve bonnet. (Spring will
stay in place and hold valve closed.) ➨
Step 10 Step 11
Top Assembly Replacement (continued)

To install new top assembly:
1. Match same size top assembly and valve body
then re-assemble by reversing procedure.
2. For optional installation of 6" top assembly on 4"
valve body, see supplemental instructions.
➨ a. Slide new top assembly onto valve body.
b. Re-install and tighten hex head mounting
screw (3/8" – 16 N.C.) into lower portion of
top assembly and snug with wrench.
➨
c. Replace shock pad and shock pad washer,
Step 2a and lock spacer onto valve stem and tighten. Step 2b
(6" valves will have one roll pin for limit
switches; 4" valve will have two roll pins for
limit switch.)
3. Always operating valve electrically several times
after re-assembly and check carefully for correct
operation.
4. Replace top cover and terminal access plate.
(50"-lbs. torque required on each screw or bolt
to insure tight seal.)
Mismatching Sizes
Top assemblies for 6" valves deliver more thrust
and travel than their 4" counterparts. However, they
can be mounted on a 4" valve body and modified for
correct operation.
Conversely, a 4" top assembly could be mounted
on a 6" valve body but would not deliver adequate
thrust or travel. No modifications are available. This
arrangement should not be attempted.
1. Proceed to install 6" top assembly on 4" body
➨ same as 4" to 4", but stop prior to remounting
top cover.
2. Install 5/32" x 2-1/4" roll pin as shown in photo-
graph. This pin will actuate motor limit switch
(not shown) 3/4" early and compensate for ➨
shorter travel required for 4" valve body.
3. Complete remainder of installation same as for
4" top assembly.
4. Always operate valve electrically several times
Step 1 and check carefully for correct operation before Step 2
returning to service.
Product: Electro-mechanical CP Valves Page: 6100-19 Date: 1/99
DC Solenoid Replacement Procedure (Electro-mechanical CP Valves)
Figure #1
3 8 9
7
1 – Spring pin
1 2 – Mounting screws
3 – Mainbase
4 – Solenoid linkage
11 5 – Solenoid bracket
6 – Solenoid plunger
4 7 – Roller bearing
8 – Catch finger pedestal
10 9 – Spring retainer
10 – Bumper
11 – Catch finger lever arm
12 – Solenoid power leads
12 2 5
1. Shut off all electrical power and close off upstream manual cock.
2. Remove side cover access plate and disconnect solenoid power leads (12).
3. Knock out spring pin (1) in top of cast boss of the mainbase with a 3/16" punch.
4. Unscrew mounting screws (2) and remove the solenoid linkage assembly (4)
5. Place the new solenoid linkage (4) in the middle of the cast boss in the top of the mainbase. Make sure that
the catch finger lever arm (11) is to the right of the solenoid linkage (4). See Figure #1 for correct
orientation.
6. Start the spring pin (1) through the front side of the boss, through the solenoid linkage (4) and then through
the back side of the boss. Once started through the back side, drive the spring pin in until it is even with the
front side of boss.
7. Align holes in mainbase and solenoid bracket (5). Applying Loctite to the screws is recommended (Loctite
not included). Start threading mounting screws (2) to mainbase. Locate the solenoid in the upmost position
(away from valve body) before screws are tightened securely.
8. Reconnect the electrical leads.
9. Verify correct operation of the solenoid and catch finger linkage. To do this, first energize the valve. After
the solenoid plunger pulls in, place a large screwdriver behind the solenoid linkage (4) (see Figure #2).
While maintaining pressure to the solenoid linkage (4) with the screwdriver, shut-off the power to the valve
when the center of the roller bearing is horizontally in line with the center of the spring retainer pin (see
Figure #3).
CAUTION: Keep fingers clear of the mainbase internals.
Solenoid Plunger
Figure #2
Solenoid
Linkage
Screwdriver
Tab Stop
on
Solenoid
Bracket
Solenoid Linkage Pin
At this point, slowly release screwdriver pressure until the valve trips to the closed position and note the position
of the solenoid linkage. Verify that there is a visible gap between the end of the solenoid linkage pin and the tab
stops on the solenoid bracket.
Center of Spring
Catch Finger
Roller Bearing Retainer Pin
Pedestal
Figure #3
Center of
roller bearing is
horizontally in line
with center of
spring pin in
spring retainer
Tab Stop
on
Solenoid
Bracket
Solenoid
Linkage Pin
Note: If there is no visible gap, the solenoid may need to be adjusted. Loosen the mounting screws attaching
the solenoid bracket to the mainbase. Move the solenoid as far horizontally and vertically, in the direction of the
observation glass, as allowed. Tightly secure the two solenoid bracket screws and perform step 9 again.
10. Replace and secure side cover access plate and place valve in service.
Top Assembly Rotation (Electro-mechanical CP Valves)

Maxon valves can and should be ordered in a configuration compatible with planned piping, but if open/shut
indicator window is not visible and/or valve orientation is not proper, the top assembly can be rotated in 90°
increments around the valve body centerline axis by the following procedure:
1. Shut off all electrical power and close off upstream manual cock.
2. Remove side cover access plate and disconnect power lead wires. (Tag carefully for later re-assembly.)
4. Note physical position of any signal switch actuator wands on auxiliary signal switches.
5. Unscrew the two body bolts screwed up from the bottom to 1/4 inch. DO NOT completely remove. These
bolts secure the valve body to the valve’s top assembly housing.
6. Gently lift the top assembly (not more than 1/4" in height); just enough to break the seal between the valve
body assembly and the rubber gasket adhering to the bottom of the top housing.
WARNING: LIFTING TOO FAR MAY DISLODGE SOME SMALL PARTS INSIDE THE TOP HOUSING,
REQUIRING COMPLEX RE-ASSEMBLY AND RETESTING BY TRAINED FACTORY PERSONNEL.
7. Remove the two body bolts screwed up from the bottom (were partially unscrewed in step 5).
8. Carefully rotate top assembly to the desired position in a plane parallel to the top of the valve body casting.
Rotate the top housing about 30° beyond this position, and then rotate it back. Reposition the top housing
back down onto the valve body casting. This should align the open/shut indicator with its window and
provide proper alignment of the internal mechanism.
9. Realign holes in valve body casting with the corresponding tapped holes in the bottom of the top assembly
housing. Be sure the gasket is still in place between the body and top housing.
Figure #1 8 9
3 7
1 – Spring pin
1 2 – Mounting screws
3 – Mainbase
11 4 – Solenoid linkage
5 – Solenoid bracket
4 6 – Solenoid plunger
7 – Roller bearing
10 8 – Catch finger pedestal
9 – Spring retainer
10 – Bumper
11 – Catch finger lever arm
12 – Solenoid power leads
6
12 2 5
10. CHECK that roller arm assembly is aligned in the center of the catch finger pedestal, insuring that the roller
tracks up the center of the pedestal track.
11. Tighten body bolts securely and recheck the alignment of the roller arm to the center of the catch finger
assembly.
12. Reconnect the electrical leads.
13. Verify correct operation of the solenoid and catch finger linkage. To do this, first energize the valve. After
the solenoid plunger pulls in, place a large screwdriver behind the solenoid linkage (4) (see Figure #2).
While maintaining pressure to the solenoid linkage (4) with the screwdriver, shut-off the power to the valve
when the center of the roller bearing is horizontally in line with the center of the spring retainer pin (see
Figure #3).
CAUTION: Keep fingers clear of the mainbase internals.
Solenoid Plunger
˚Figure #2
Solenoid
Linkage
Screwdriver
Tab Stop
on
Solenoid
Bracket
Solenoid Linkage Pin
At this point, slowly release screwdriver pressure until the valve trips to the closed position and note the position
of the solenoid linkage. Verify that there is a visible gap between the end of the solenoid linkage pin and the tab
stops on the solenoid bracket.
Center of Spring
Catch Finger
Retainer Pin
˚Figure #3 Roller Bearing Pedestal
Center of
roller bearing is
horizontally in line
with center of
spring pin in
spring retainer
Tab Stop
on
Solenoid
Bracket
Solenoid
Linkage Pin
Note: If there is no visible gap, the solenoid may need to be adjusted. Loosen the mounting screws attaching
the solenoid bracket to the mainbase. Move the solenoid as far horizontally and vertically, in the direction of the
observation glass, as allowed. Tightly secure the two solenoid bracket screws and perform step 13 again.
14. Replace and secure side cover access plate and place valve in service.
Product Data Sheet Product: Maxon Valves
Page: 6000-9 Date: 6/00

Do Not Reproduce
Allowable seat leakage standards

Approval agencies have different standards for LP-Gas
allowable seat leakage. Below is a listing of the – Valves for handling liquid propane are tested with
standards each of our agencies employs. liquefied petroleum.
– Up to 1-1/2" port diameter (or rectangular diagonal)
NOTE: Test conditions are 60°F at 30 in. Hg baromet-
.008 Ft3/hr
ric pressure. Leakage allowances listed are for any
or 650 ml/hr
pressure up to 150% rated pressure. Bubbles per
or 10.8 ml/min
minute values are for a 1/4" OD x 0.032" wall tube
or 72.2 bubbles/min
submerged in water to a depth of 1/8" x 1/4", perpen-
dicular to the water surface. For any apparatus, – Larger than 1" port diameter (or rectangular
however, volume flow is the most accurate means. diagonal)
.235 ml/hr/inch of port diameter
FM 7400 3.9 ml/min/inch of port diameter
(test fluid is at the discretion of the agency)
– Gas shut-off valves: CGA 3.9:
(all sizes) 1 Ft3/hr – Gas valves are tested for seat leakage with air or
or 28,320 ml/hr nitrogen.
or 472 ml/min – Valves for handling liquid propane are tested
or 3147 bubbles/min with liquefied petroleum.
– Oil shut-off valves:
– Up to 1-1/2" port diameter (or rectangular
(all sizes) 12.6 cc per hour
diagonal)
.023 Ft3/hr
UL 429: Safety Shut-off Valve or 651 ml/hr
– Gas valves are tested for seat leakage with air or or 10.8 ml/min
nitrogen. or 72.4 bubbles/min
– Valves for handling liquids are tested with
liquefied petroleum. – Larger than 1-1/2" port diameter (or rectangular
diagonal)
– Up to 1" port diameter 150 ml/hr
(or rectangular diagonal): or 2.5 ml/min/inch of port
.008 Ft3/hr circumference (or perimeter)
or 235 ml/hr
or 3.9 ml/hr CGA 6.5:
or 26.1 bubbles/min – Gas valves are tested for seat leakage with air or
nitrogen.
– Larger than 1" port diameter – Valves for handling liquids are tested with
(or rectangular diagonal): liquefied petroleum.
235 ml/hr/inch of port diameter
3.9 ml/min/inch of port diameter – Up to 1" port diameter (or rectangular
diagonal)
.008 Ft3/hr
UL 842: General Purpose (Vent)
or 235 ml/hr
– Gas valves are tested for seat leakage with air or
or 3.9 ml/min
nitrogen.
or 26.1 bubbles/min
Natural or Manufactured Gas
0.191 Ft3/hr – Larger than 1" port diameter (or rectangular
or 5400 ml/hr diagonal)
or 90 ml/min 235 ml/min/inch of port diameter
or 600 bubbles/min 3.9 ml/min/inch of port diameter
Product Data Sheet Product: Maxon Valves
Page: 6000-9 Date: 6/00

Do Not Reproduce
Class VI Seat Leakage Allowable

(in accordance with ANSI B16.104-1976)
Nominal Allowable Leakage

Port Diameter ml/min bubbles/min
1" 0.15 1
1-1/2" 0.30 2
2" 0.45 3
2-1/2" 0.60 4
3" 0.90 6
4" 1.70 11
6" 4.00 27
8" 6.75 45
NOTE: For the ANSI requirements, the test pressure is

50 PSIG or the maximum rated differential pressure,
whichever is lower, and testing is done with air or
nitrogen.
Bulletin 6200
Maxon Shut-Off and Vent Valves

Hazardous Locations
2" Series 808NI 2-1/2" Series STO-ANI-CP 3"-F Series 5000NI-S

position “L” position “L” with flanged body
position “L”
• Electrically actuated valves shut off gas or oil lines in less than one second.
• Normally open versions available for vent or process purge lines with Maxon's long-
lasting metal-to-metal seating.
• Application flexibility provided with 3/4" through 6" diameter line sizes, Cv flow
factors up to 765, and line pressures up to 600 PSIG.
• All Maxon top assembly enclosures meet approval sanctions:
– NEMA 1, 3, 3S, 4, and 12; Available with NEMA 4X trim (optional)
“NI” valves are FM approved for hazardous locations:
Class I, Division 2, Groups A, B, C, and D: T5 (AC)
Class II, Division 2, Groups F and G: T5 (AC)
Class III, Division 2: T5 (AC)
“NI” Valves are built in accordance with the Non-Incendive Component Criteria as outlined
by NEC/NFPA 70-1996 Articles 500-2(a)(6)
Page 6202
Normally Open or Normally Closed valves
1-1/4" Series 4760NI 1" Series STO-MNI

position “L”, position “R”
socket welded nipples and flanges
• Sanctioned service valve approvals:

– FM (Factory Mutual) sanctioned
– IRI (Industrial Risk Insurers) approvable for block/bleed/vent systems
– Contact your Maxon sales representative for international sanctions information
• Handles flowing fluid temperatures:
– Rising stem bodies from -20°F (-28°C) to +140°F (+60°C)
– Swinging gate bodies from -20°F (-28°C) to +250°F (+121°C)
– Any ambient temperature from -20°F (-28°C) to +140°F (+60°C)
• Valve bodies designed to ANSI (American National Standards Institute) standards.
ISO (International Standards Organization) standards also available.
• Various application requirements met with manual reset or automatic reset
motorized operators.
• Minimize line pressure drops with straight-through flow swinging gate or rising stem
(guillotine action) valve bodies.
Page 6203
Maxon Valves – large or small, gas or oil, open or closed
2-1/2" Series 5000NI-CP 3"-F Series 808NI-S

position“R” with flanged body
position “L”
• Minimal field maintenance required.

• Positive visual indication of valve body position is provided by large two-color
open-shut indicator.
• Bodies built for heavy duty industrial service of one-piece cast iron or cast steel.
• Installation piping convenience obtained from field rotatable top assemblies.
• Special operating features available in Special Service Packaged versions.
• Micro-lapped seating wears in, not out.
Page 6204
Accessory Options
2" Series 808NI 1-1/4" Series 5000NI

position “L” with ISO threads
with wheel & chain assembly position “TO”
• Positive indication of valve body position provided through:

– Auxiliary SPDT signal switches mounted inside valve top enclosure.
– Proof-of-open and/or Proof-of-closed position switches.
• Built-in over travel valve body design meets requirements of insurance standards.
• External junction box requirement eliminated with built-in valve wiring compart-
ment and electrical terminal block.
• Manual reset valves may be mounted in overhead lines with use of wheel and
chain option.
• Companion flange sets available to simplify installation.
4/97
Hazardous Location Valves Page 6205

Valves with electro-mechanical actuators
for quick opening or closing action
Normally closed shut-off valves are used in Normally open vent valves are most often used
burner system fuel supply lines on industrial boilers, as the bleed valve in a block-and-bleed pipe train,
furnaces, ovens, kilns, and other heating processes. sometimes required by insurance authorities. They
All valves are designed to shut-off fuel automatically are designed to open a vent line automatically and
and instantly with an interruption in the electric power instantly upon an interruption in the electric power
supplied through your safety circuit. supply through your safety control circuit.
These valves are also used for the manual or These normally open valves are also used in
motorized opening or closing of pipe lines carrying protective atmosphere systems and other gaseous
gases and liquids commonly used in industrial proc- and fluid service requiring quick opening or by-pass
esses. Normally closed valves cannot be opened until purging action.
the interlocking safety control circuit is proven and
resulting electrical power is supplied to the shut-off Like the normally closed versions, both automatic
valve. and manual reset actuators are available for remote
access locations, or when operating personnel's
Motorized automatic valve actuators are used physical presence is preferred.
where remote access or unmanned applications are
needed. All Maxon valves feature one-piece cast iron or
cast steel bodies with micro-lapped seats and discs.
NOTE: Valve motors and solenoids are protected Straight-through flow path minimizes pressure drop
against thermal overload. If the valve duty cycle is through full open swinging gate or rising stem (guillo-
exceeded, the motor and/or solenoid must be allowed tine action) bodies.
to cool before the internal thermal protection will
automatically reset.
Manual reset actuators require operating person-

nel to be physically present to actuate the valve from
its at rest position.
4/97
Page 6206 Hazardous Location Valves
Valve Body Design Details

Rising Stem To provide fuel shut-off in your process service lines, Maxon
Valve Body uses two different styles of valve bodies:
Assembly
Rising stem (guillotine action) bodies are frequently used
in normally closed and normally open gas valves. The micro-
lapped, spring loaded guillotine disc gets a pressure assist from
the flowing gases to seal against the downstream micro-lapped
metal seat ring. The carefully machined seal surfaces and
extremely close tolerances of the valve body operating mecha-
nism promote positive closing action. Frequent cycling action
constantly shears accumulated dirt or residue from the disc and
seat to insure instantaneous and reliable sealing.
The location of the port in the disc is the basic difference

Seat between normally open and normally closed valve bodies. Both
valves function by the top assembly mechanism driving the stem
and disc down into the valve body, opening (or closing) the flow
path. Both valves trip to their rest position when their top
assembly's compression spring is released to pull the stem and
connected disc up out of the body.
Normally Closed
Disc
Normally Open Disc
Swinging Gate Swinging gate bodies are frequently used as normally

Valve Body closed oil valves and for some special service gas applications.
Assembly This design provides the same seal capabilities, but in a slightly
different operating mode. The hard faced micro-lapped seat nut
is threaded into the one-piece valve body. The free-floating, hard
faced, spring loaded circular disc swings across the seat. Line
pressure also assists in sealing the disc to the downstream seat.
Here again, frequent use and cycles actually helps to keep

your valve clean. Since the free-floating disc is swinging across
the circular seat nut on the arc created by the disc carrier, the
Disc disc rotates slightly on every cycle. This provides a fresh, clean
Carrier surface area for sealing off the flow lines.
Disc Maxon valve bodies have special service trim options

available to meet your particular fluid service requirements.
Seat

Table 1: Normally closed valve bodies Table 2: Normally open valve bodies
Body End Pipe Size Cv Body Body End Pipe Size Cv Body
Material Connections in inches Factor Type [1] Material Connections in inches Factor Type [1]
.75 20 RS .75 20 RS
12 SG 1 20 RS
1
20 RS 1.5 53 RS
Threaded
17 SG 2 86 RS
1.25
45 RS Gray 2.5 304 RS
Threaded 1.5 53 RS Iron 3 423 RS
2 86 RS 2 86 RS
127 RS 2.5 304 RS
Gray 2.5 Flanged
304 RS 3 423 RS
Iron
173 RS 4 490 RS
3
423 RS 1 20 RS
2 86 RS Threaded 1.5 53 RS
127 RS Cast 2 86 RS
2.5
304 RS Steel 2.5 304 RS
Flanged
3 423 RS Flanged 3 423 RS
4 490 RS 4 490 RS
6 869 RS
12 SG
Each complete valve assembly must include one of
1 these valve bodies, regardless of ultimate series
20 RS
designation.
17 SG Flows through the valve body and resulting pres-
Threaded 1.25 45 SG sure drops may be estimated by inserting your
45 RS specific conditions into the following formula and
Cast using Cv flow factors given for each valve body.
1.5 53 RS
Steel
2 86 RS
2.5 304 RS
Gases: Q = (1360) x (Cv) x (P1+P2) (P1–P2)
3 423 RS x
Flanged
4 490 RS G Tf 2
6 869 RS
[1] RS = Rising stem body; SG = Swinging gate body
Liquids: V = (Cv) x (P1–P2)
See catalog pages 6215-6217 for construction details Gf
NOTE: Typically, pressure drop for gas flows should not

exceed 10% of inlet pressure; however, for 2" and smaller
Where:
valves, the drop should not exceed 5 PSIG, and for 2-1/2" G = Gas specific gravity (air = 1.0)
and larger valves, must not exceed 2.5 PSIG. Gf = Specific gravity @ flowing temperature °F
Select valve size on basis of the lower of these parameters
to avoid critical flow conditions. P1 = Inlet pressure PSIA (14.7 psi + psi gauge)
P2 = Outlet pressure PSIA (14.7 psi + psi gauge)
Q = Cubic feet per hour @ 14.7 PSIA and 60°F
Tf = Flowing temperature absolute (460° + °F)
V = Flow in U.S. gallons/minute of water
2/00

with Natural Gas at 5 inches w.c.
100,000 Approximate pressure drops
for various valve sizes and flows
may be determined by using this
graph.
Typically, pressure drop for
50,000
fuel flows should not exceed
719
10% of inlet pressure.
Select valve size on basis of
490
SCFH Natural Gas with .65 Specific Gravity at 70°F
these parameters to avoid

6 " RS 423 critical flow conditions.
S
PR 304
4" C S
PR
3" C
RS
10,000
. 5 " CP 173
2
127
S
3" R
5,000 86
RS
2.5"
S 53
2" R 45
RS
1.5"
" RS
1.25 20
1,000
1" RS
.75"&
500
100
0.1 0.2 0.3 0.4 0.5
Pressure Drop in in-wc

based on 5 Inch wc inlet pressure

with Natural Gas at 1 PSIG
Approximate pressure 5
drops for various valve 76 1
sizes and flows may be 100000 55
determined by using this 2
43
graph.
Typically, pressure drop 4
RS 30
for fuel flows should not 50000 6"
exceed 10% of inlet
P RS
pressure. C S 3
Select valve size on 4" P R 17
C
basis of these parameters 3" RS
7
SCFH Natural Gas with .65 Specific Gravity at 70˚F
12
to avoid critical flow P
"C
conditions.
2.5
86
RS
10000
3"
RS 53
2 .5" 45
RS
2"
5000
" RS 20
1.5
" RS
1 .25
" RS
" &1
.75
1000
500
100
0.1 0.5 1 5 10

based on 1 PSIG inlet pressure
2/00

with Natural Gas at 5 PSIG
1000000 Approximate pressure
drops for various valve sizes
and flows may be determined
5 by using this graph.
500000 76
1 Typically, pressure drop for
55 fuel flows should not exceed
2
43 10% of inlet pressure; how-
4
30 ever, for 2" and smaller valves,
the drop should not exceed 5
3 PSIG, and for 2-1/2" and larger
SCFH Natural Gas with .65 Specific Gravity at 70˚F
17
RS size valves, must not exceed
100000
7
6" RS 12 2.5 PSIG.
CP S 86
Select valve size on basis of
50000 4" P R RS the lower of these parameters
C
3" CP 53 to avoid critical flow conditions.
"
2.5 RS 45
3" RS
"
2.5
20
RS
10000 2"
S
. 5 "R
1 S
5000
5 "R
1.2
RS
1"
"&
.75
1000
500
100
0.1 0.5 1 5 10 5 0 100

based on 5 PSIG inlet pressure

with #2 Oil
To select a valve for 10000
YOUR application, use
either Cv factor calcula-
tions, or this graph 5000
showing approximate
pressure drop at various
flows of #2 oil.
Typically, pressure
drop for fuel flows
G
should not exceed 10% 5" S
of inlet pressure. 1.2
G
1" S
U.S. Gallons/Hour at 60˚F
1000
500
100
50
10
0.1 0.5 1 5 10
Pressure Drop in psi

factor given in the table at right, then °F @ Inlet 125 160 120 140 180 210 220
allowable drop. For example: To size for 5 PSIG drop with a 3500 GPH flow of #6 oil
preheated to 140°F, the multiplier is 2. Equivalent flow of #2 oil is
then 3500 x 2, or 7000 GPH. Chart shows that a 5 PSIG drop will
2/00
Selection Data
Normally closed, swinging gate valves

Body Material> Gray Iron Cast Steel
• Normally closed
Top Assembly Function Sanctioned Service [1] Sanctioned Service [1]
Manual Reset 730NI 760NI • Electrically actuated
Automatic Reset 4730NI 4760NI • Swinging gate body
[1] Sanctioned series are sold for fuel oils and carr y FM sanctions. They are IRI
approvable for #1 and #2 fuel oils, kerosene, JP-4 and preheated #4, #5 and #6 • For shut-off service
oils with maximum viscosity of 5000 SSU. Other gases and liquids may be
sanctioned. Contact Maxon with your fuel analysis.
Temperature Limits
All of these valves can handle fluid temperatures from -20°F (-28°C) to
+250°F (+121°C).
Ambient temperature limits vary. The valves on this page handle
Operation
All electro-mechanical valves require a constant supply of electrical
energy to their holding solenoids inside the top assembly actuators. Once
the solenoid is energized, the 730NI and 760NI valves may be opened
manually, or the 4730NI and 4760NI valves will automatically open. Any
interruption of the electrical power to either of these valves causes an
1.25" Series 4760NI
immediate trip of the valve to its normally closed position.

Maximum Inlet Pressure (PSIG) [1]
Pipe Size Body Cv
Fuel Oils Special Service [1] Fuel Oils Special Service [1]
1 12
300 265 600 265
1.25 17
1.25 HC 45 --- --- 300 265
[2] In accordance with NACE Standard MR0175-96, special ser vice valves should be reviewed thoroughly before application
is completed.
Selection Data
Normally closed, rising stem valves
Series Designation
Features:
Body Material > Gray Iron Cast Steel • Normally closed
Top Assembly Function Sanctioned Service [1] Sanctioned Service [1] • Electrically actuated
808NI 808NI-S • Rising stem body
Manual Reset
808NI-CP 808NI-SCP
5000NI 5000NI-S • For shut-off service
Automatic Reset
5000NI-CP 5000NI-SCP
[1] Sanctioned series carr y FM sanctions for air, natural or liquified petroleum gases. They
are normally approvable for clean fuel gases. Additionally, series with internal trim -2 are
sanctioned for #1 and #2 fuel oils. Other gases and liquids may be sanctioned. Contact
Maxon with your fuel analysis.
Temperature Limits
All these valves can handle fluid temperatures from -20°F (-28°C) to +140°F
(+60°C). Oil viscosity not to exceed 5000 SSU. Ambient temperature limits
vary. The valves on this page handle ambient temperatures from -20°F (-28°C)
to +140°F (+60°C).
Operation
All of these electro-mechanical valves require a constant supply of electrical
energy to their solenoid inside the top assembly actuators. Once that device is
energized, the Series 808NI (-CP) valves may be manually opened, or the Series
5000NI (-CP) valves will automatically open. Any interruption of the electrical
power to either of these valves causes an immediate trip of the valve to its
normally closed position.
3" Series 808NI
Pipe Size Body Cv
Clean Gases Special Service [2] Clean Gases Special Service [2]
.75 125 65 --- ---
20
1 125 65 125 65
1.25 45 100 65 --- ---
1.5 53 70 65 70 65
70 65 70 65
2 86
70 65 70 65
40 40 --- ---
2.5 127
40 40 --- ---
50 50 50 50
2.5 CP 304
50 50 50 50
3 173 30 30 --- ---
40 40 40 40
3 CP 423
40 40 40 40
4 CP 490 40 40 40 40
6 869 30 30 30 30
[2] In accordance with NACE Standard MR0175-96, special ser vice valves should be reviewed thoroughly before application
is completed.
2/00
Selection Data
Normally open, rising stem valves

Body Material > Gray Iron Cast Steel • Normally open
Top Assembly Function Sanctioned Service [1] Sanctioned Service [1] • Electrically actuated
STO-MNI STO-MNI-S
Manual Reset • Rising stem body
STO-MNI-CP STO-MNI-SCP
STO-ANI STO-ANI-S • For vent and by-pass
Automatic Reset
STO-ANI-CP STO-ANI-SCP service
[1] Sanctioned series carry FM sanctions for air, natural or liquified petroleum
gases. They are normally approvable for clean fuel gases. Additionally, series with
internal trim -2 are sanctioned for #1 and #2 fuel oils. Other gases and liquids may
be sanctioned. Contact Maxon with your fuel analysis.
Temperature Limits
All these valves can handle fluid temperatures from -20°F (-28°C) to
+140°F (+60°C). Oil viscosity not to exceed 5000 SSU.
Ambient temperature limits vary. The valves on this page can handle
Operation
electrical energy to their holding solenoids inside the top assembly
actuators. Once the solenoid is energized, the STO-MNI (-CP) valves may
be manually closed, or the STO-ANI (-CP) valves will automatically close.
Any interruption of the electrical power to either of these valves causes 1" Series STO-ANI
an immediate trip of the valve to its normally open position.

Pipe Size Body Cv
Clean Gases Special Service [2] Clean Gases Special Service [2]
.75 125 65 --- ---
20
1 125 65 125 65
1.5 53 70 65 70 65
70 65 70 65
2 86
70 65 70 65
50 50 50 50
2.5 CP 304
50 50 50 50
40 40 40 40
3 CP 423
40 40 40 40
4 CP 490 40 40 40 40
[1] Maximum operating pressure differential (MOPD) in psi must not exceed maximum inlet pressures shown.
[2] In accordance with NACE Standard MR0175-96, special service valves should be reviewed thoroughly before application
is completed.

All Maxon Rising Stem Gate Valves carry a two- WARNING: Do not attempt field repair of Maxon valve
part trim identification (for example, Trim 1-1). body or electro-mechanical actuator. Any field
The first digit (a 1, 2, 3 or 4 before the hyphen) alterations void all warranties.
identifies valve body and bonnet material as
shown in Table 1 below. Typical stem/disc
The second digit (a 1 or 2 after the hyphen) connection used with
identifies the specific internals used, as smaller sized valves
described in Table 2 and identified in the 11
sketches at right. 13 13
7
fuel gases (for example, natural gas, propane,
10
butane, clean atmosphere gases). 7
Internal trim -2 may be required for clean 12
9 12
gases that require Viton seals or such gases as 4
6 5
coke oven, refinery, town or off-gas, or #1 and
#2 fuel oils. Contact Maxon with specific fuel
analysis for prices and/or availability. 8
Normally closed and normally open threaded FLOW

material specifications. Typical
The drawing at right carries item numbers threaded body
CP design
matching those in Table 2. This information is is shown
1
3
furnished for identification only, not for ordering 4
parts.
Table 1: Body (Item 1) and Bonnet (Item 2) Specifications

Specifications ASTM A159 ASTM A216-WCB ASTM A159 ASTM A216-WCB
Electroless Nickel- Electroless Nickel-
Special Coating --- ---
Coated Coated

Item Trim: -1
Description
No. 3/4" Ð 2" 2-1/2", 3" 2-1/2" Ð 4" CP 6"
#440-F Stainless #440-F Stainless
3 Seat #416 Stainless Steel #303 Stainless Steel
Steel Steel
4 Disc 80-55-06 Ductile Iron 80-55-06 Ductile Iron 80-55-06 Ductile Iron 80-55-06 Ductile Iron
Leadaloy Ductile Iron Low Carbon Steel Low-Carbon Steel
5 Follow Ring
(nickel plated) (nickel plated) (nickel plated) (nickel plated)
6 Seat O-ring Buna N Buna N Buna N Buna N
7 Bonnet O-ring Buna N Buna N Buna N Steel
8 Wavy-Spring Washer #302 Stainless Steel #302 Stainless Steel #302 Stainless Steel #302 Stainless Steel
High Carbon Steel High Carbon Steel
10 Stem/Disc Pins --- Shear-Proof Steel
(hardened) (hardened)
11 Stem O-rings Buna N Buna N Buna N Buna N
13 Bumper Buna N Buna N Viton Buna N
4/97

Item
Description
No. .75" Ð 2" 2.5", 3" 2.5" Ð 4" CP 6"
3 Seat #303 SS (hard faced) #303 SS (hard faced) #303 SS (hard faced) #303 SS (hard faced)
80-55-06 Ductile Iron 80-55-06 Ductile Iron 80-55-06 Ductile Iron 80-55-06 Ductile Iron
4 Disc
(chrome plated) (chrome plated) (chrome plated) (chrome plated)
303 SS 303 SS 303 SS
5 Follow Ring 303 SS (chrome plated)
(chrome plated) (chrome plated) (chrome plated)
7 Bonnet O-ring Viton Viton Viton Steel
Wavy-Spring
Washer
10 Stem/Disc Pins #420 Stainless Steel #420 Stainless Steel --- Shear-Proof Steel
Typical stem/disc
connection used with
smaller sized valves
11
13 13
7
10
7
12
9 12
4
6 5
FLOW
Typical
threaded body
CP design
1
is shown 3
4

Trim identification of Maxon Swinging Gate Shut- Non-sanctioned services or unusual applications
Off Valves is two-part. The first digit before the hyphen may require upgrading of internal trim. Contact Maxon
is a number (1, 2, 3 or 4) identifying body material as with specific fuel analysis for price and availability.
shown in Table 1 below. The second digit after the The drawings shown carry item numbers matching
hyphen identifies a trim utilizing the materials indicated those in Table 2. This information is furnished for
in Table 2 below. identification only, not for ordering parts.
Standard sanctioned valves incorporating a cast iron
WARNING: Do not attempt field repair of Maxon valve
body will normally be identified by trim 1-B or 1-D.
body or electro-mechanical top actuator. Any field
Sanctioned valves with steel body will normally be
trim 2-D.
Table 1: Body (Item 1) Specifications
ASTM Spec ASTM A159 ASTM A216-WCB ASTM A159 ASTM A216-WCB

For 1" & 1-1/4" Valves
Item No. Part Description
Trim: -B Trim: -D
2 Hex Nut or Renewable Seat Cast Iron with #420 Stainless Steel Seat Ring Hard-Faced Steel
3 Stem Bushing Zinc-Plated Steel Zinc-Plated Steel
4 Stem #416 Stainless Steel #416 Stainless Steel
5 Stem Spring #302 Stainless Steel #302 Stainless Steel
6 Disc Carrier Steel Steel
7 Disc Nodular Iron Hard-Faced Steel
8 Stem O-rings Viton Viton
9 Disc Spring #302 Stainless Steel #302 Stainless Steel
10 Inner Stem Thrust Ring Teflon Teflon
11 Back-up O-rings Teflon Teflon
12 Body Gaskets Soft Iron Soft Iron
13 Stem Bushing Gasket Soft Iron Soft Iron
14 Body O-ring Viton Viton
10
8
11 5
Typical construction
4
of 1"and 1.25"
3
screwed body valves 13
Flow
14
2
1
12 7 6 9
4/97
General Maintenance and Spare Parts
All safety devices should be tested at least To determine suggested spare parts, identify
monthly* and more often if deemed advisable. series designation and serial number from the
Periodic testing for tightness of manual or motor- valve’s nameplate. Refer to the illustration and
ized shut-off valve closure is equally essential. legend below to identify suggested spare parts.
To order, specify:
These Maxon valves are designed for long trouble-
1. Quantity
free service. Only items shown as suggested spare
2. Assembly part number (if available)
parts are considered field replaceable.
3. Description
WARNING: Do not attempt field repair of valve 4. Electrical specification
body, top assembly or motor drive unit. Any 5. Full nameplate information (from existing valve)
Normally closed valve designation Manual Reset Automatic Reset

3" 5000NI-SCP 2 4X Note: Drawings are illustrative only. Actual valves may vary slightly.
NEMA 4X 3
VCS Used * 2 1 2
CP Body (if used)
Steel Body (if used)
Valve Series 1
Valve Size (NPT) 3
0 No Switch 2 VCS-2 Switch
1 VCS-1 Switch
4 4
Normally open valve designation Series 808NI Series 5000NI
3" STO-ANI-SCP 2 4X
NEMA 4X 2 Legend:
VOS Used * 1 – Nameplate
CP Body (if applicable) 2 – Solenoid
Steel Body (if used) 1 3 – VCS signal switch for
Valve Series normally closed valve;
VOS for normally open
Valve Size (NPT)
valve
4 – VOS motor limit/signal
0 No Switch 2 VOS-2 Switch
1 VOS-1 Switch switch for normally closed
Series 808NI-CP valve; VCS for normally
open valve
Nameplate
(typical)
(shown for listed
valves; others
similar)
Nameplate
designation does
not reflect external
accessory items or
motor limit switch
Electrical Data
General
All Maxon shut-off valves are electrically actuated Good practice normally dictates that auxiliary
from a power source, normally through the flame switches in valves used for safety shut-off functions
safeguard and/or safety control circuits. should be used for signal duty only, not to operate
Standard valve assemblies include an internal additional safety devices.
holding solenoid for 115 volt 50/60 hertz AC power.
(230 volt 50/60 hertz available upon request.) Signal switch designations:
The solenoid is energized whenever the valve is VCS (Valve Closed Switch) is actuated at the end
powered. The motor operator on automatic reset of the closing stroke. VCS-1 is SPDT; VCS-2 is 2
versions is powered only during the opening stroke. SPDT switches mounted side by side.
Switch wiring diagram (reproduced below) is part VOS (Valve Open Switch) is actuated at the end of
of each valve assembly, summarizing electrical data the opening stroke. VOS-1 is SPDT; VOS-2 is 2
and a full complement of optional signal switches. SPDT switches mounted side by side.
Diagram shows valve in its normally closed (at rest) Switch amp ratings are shown on the schematic
position. The indicated internal wiring is present only wiring diagram below.
when the appropriate auxiliary switches are specified. DO NOT EXCEED rated amperage or total load
Automatic reset valves always include a VOS-1 SPDT shown.
valve open motor limit switch.
Volt Ampere (VA) Ratings: Manual Reset Volt Ampere (VA) Ratings: Automatic Reset
AC Operation AC Operation
Valve Valve
50Hz/60Hz 50Hz/60Hz
Size Series Opening Holding Size Series Opening Holding
.75" - 3" 808NI (-S) .75" - 3" 5000NI (-S)
24/15 24/15 344/213 24/15
1" - 1.25" 730NI (-S), 760NI 1" - 1.25" 4730NI (-S), 4760NI
2.5" - 6" 808NI-(S)CP 34/26 34/26 2.5" - 4" 5000NI-(S)CP 354/224 34/26
NOTE: Total VA of solenoid (manual reset valves) or solenoid and motor (motorized valves) must not exceed the limits shown.

.75" – 3" Series 808NI (-S)
1" – 1.25" Series 730NI, 760NI
2.5" – 4" Series 808NI-(S)CP
6" Series 808NI (-S)

.75" – 3" Series 5000NI (-S)
1" – 1.25" Series 4730NI, 4760NI (-S)
2.5" – 4" Series 5000NI-(S)CP
4/97
Electrical Data
for normally open valves
General Automatic reset valves always include a VCS-1 SPDT
All Maxon normally open vent valves are electri- valve closed motor limit switch.
cally actuated from a power source, normally through Good practice normally dictates that auxiliary
the flame safeguard and/or safety control circuits. switches in valves used for safety shut-off functions
Standard valve assemblies include an internal should be used for signal duty only, not to operate
holding solenoid for 115 volt 50/60 hertz AC power. additional safety devices.
(230 volt 50/60 hertz available upon request.) Signal switch designations:
The solenoid is energized whenever the valve is VCS (Valve Closed Switch) is actuated at the end
powered. The motor operator on automatic reset of the closing stroke. VCS-1 is SPDT; VCS-2 is 2
version is powered only during the closing stroke. SPDT switches mounted side by side.
Switch wiring diagrams (reproduced below and on VOS (Valve Open Switch) is actuated at the end of
next page) are part of each valve assembly, summa- opening stroke. VOS-1 is SPDT; VOS-2 is 2 SPDT
rizing electrical data and a full complement of optional switches mounted side by side.
signal switches. Switch amp ratings are shown on the schematic
Diagrams show valve in its normally open (at rest) wiring diagrams below and on the next page.
position. The indicated internal wiring is present only
DO NOT EXCEED rated amperage or total load
when the appropriate auxiliary switches are specified.
shown.
Volt Ampere (VA) Ratings: Manual Reset Volt Ampere (VA) Ratings: Automatic Reset
AC Operation AC Operation
Valve Valve
50Hz/60Hz 50Hz/60Hz
Size Series Opening Holding Size Series Opening Holding
.75" - 3" STO-MNI (-S) 24/15 24/15 .75" -3" STO-ANI (-S) 344/213 24/15
2.5" - 4" STO-MNI-(S)CP 34/26 34/26 2.5" - 4" STO-ANI-(S)CP 354/224 34/26
NOTE: Total VA of solenoid (manual reset valves) or solenoid and motor (automatic reset valves) must not exceed the limits shown.
Manual Reset Series

.75" – 3" Series STO-MNI (-S)
2.5" – 4" Series STO-MNI-(S)CP
Automatic Reset Series

.75" – 3" Series STO-ANI (-S)
2.5" – 4" Series STO-ANI-(S)CP

.75" through 1.5" valves with rising stem bodies
5.48 Available Top Assembly
1.81
5.5 2.0 7.34 Positions
B
K
(2) 3/4" NPT
Conduit Connection D “L” “R”
G
A Pipe Size
2.27 Maxon Maxon
J H
C (2) 1/4" NPTF
5000NI, STO-ANI Test Connection
11.5
11.5 “TO” “AW”
7.19
5.5 1.81
5.48 4.88
11.58
(2) 3/4"
B K NPT NOTE: 2.75" needed
Conduit for terminal block
Connection D
cover removal.
G
A Pipe Size
J H
2.27 (2) 1/4" NPTF
C
Test Connection
808NI, STO-MNI
Pipe Valve
A B C D G H J K R
Size Series
808NI & STO-MNI 11.58
.75"
5000NI & STO-ANI ---
2.00 12.25 3.81 1.90 .78 1.94 .81 8.11
808NI (-S) & STO-MNI (-S) 11.58
1"
5000NI (-S) & STO-ANI (-S) ---
808NI 12.14
1.25" 2.44 12.81 .22 1.56 8.67
5000NI ---
4.00 2.00 2.12
808NI (-S) & STO-MNI (-S) 12.61
1.5" 2.69 13.31 .38 1.68 9.14
5000NI (-S) & STO-ANI (-S) ---
10/02

2" through 3" valves with rising stem bodies
808NI & STO-MNI Available Top Assembly
13.12
8.56 5.38 Positions
7.62 2.9 1.97
2.38 5.62
(2)
R 3/4"
B K NPT
Conduit
Connection D
G
A Pipe Size
“L” “R”
J H (2) 1/4" NPTF
C
J S Test Connection
L
G Pipe Size
Maxon Maxon
N A
M
P
Equally H
T
Spaced
5.38
2.38
7.59 2.84
1.97 7.52 “TO” “AW”
B K (2)
3/4" NPT
NOTE: 2.75" needed
Conduit D
Connection G for terminal block
cover removal.
A Pipe Size
J H (2) 1/4" NPTF

C Test Connection
5000NI & STO-ANI
Pipe Valve
A B C D G H J K L M N P R S T
Size Series
808NI (-S) & STO-MNI (-S)
2" 4.38 2.19 --- --- --- --- --- ---
5000NI (-S) & STO-ANI (-S)
3.25 14.75 .44 2.25 1.88 10.6 14.38
808NI (-S) & STO-MNI (-S)
2" F --- --- 3.01 2.38 .75 4 3.50 7.0
5000NI (-S) & STO-ANI (-S)
808NI 14.25
2.5" 3.50 5.0 2.5 2.12 2.25 --- --- --- --- --- ---
5000NI
14.62 10.46
808NI
2.5" F --- --- --- .63 2.5 2.0 3.5 2.75 .75 4 3.75 7.5
5000NI ---
808NI
3" 2.94 14.86 5.19 2.59 2.12 2.56 10.71 --- --- --- --- --- ---
5000NI

2.5" CP through 4" CP and 6" valves with rising stem bodies
Series 808NI-CP, STO-MNI-CP Series 5000NI-CP, STO-ANI-CP
15.13
10.94 8.88 2.83 6.14 7.52
8.88 2.83
6.14 6.29
B
R
B A A
7.25 D
A A 5.32
D G
5.32 7.25
G
A
A Pipe Size 3.0
3.0 J H (2) 1/4" NPTF
J H (2) 1/4" NPTF 0.88
View A-A C Test Connection
0.88 C Test Connection
View AA
MDM DATABASE INFO - DO NOT MODIFY!
11.68
(2) 3/4" NPT 11.68
Conduit Connection J S
L
Pipe Size
N (dia.) A
M
P (no. of holes)
(2) 1/4" NPTF
Available Top Assembly Positions
equally spaced H
T Test Connection
2.5" CP through 4" CP Valves

Maxon Maxon
L
M
Pipe Size “L” “R” “TO” “AW”

A
N (dia.) (2) 1/4" NPTF

P (no. of holes) H
Test Connection NOTE: 2.75" needed
equally spaced
for terminal block
T cover removal.
6" 808NI Valves
Pipe Valve
A B C D G H J L M N P R S T
Size Series
808NI, 808NI (-S) 14.56
2.5" CP 5000NI, STO-ANI 4.31 5.0 2.5 .50 2.25 --- --- --- --- --- ---
---
5000NI (-S), STO-ANI (-S)
14.56 2.12
808NI, 808NI (-S) 14.56
2.5" F
5000NI, STO-ANI 4.5 --- --- --- 2.2 3.5 2.75 .75 4 3.75 7.5
CP ---
5000NI (-S), STO-ANI (-S)
808NI, 808NI (-S) 17.97
3"
5000NI, STO-ANI 5.12 5.5 2.75 .62 2.12 2.56 --- --- --- --- --- --- ---
CP
5000NI (-S), STO-ANI (-S) 17.97
808NI, 808NI (-S) 17.97
3" F 15.29
5000NI, STO-ANI 5.22 2.24 2.6 3.75 3.0 4 4.0 8.0
CP ---
5000NI (-S), STO-ANI (-S) --- --- --- .75
4" F 808NI (-S) 17.97
5.55 2.25 2.56 4.5 3.75 8 4.5 9.0
CP 5000NI (-S), STO-ANI (-S) ---
6" 808NI 7.5 20.75 --- --- --- 3.38 --- 5.5 4.75 .88 8 23.43 5.25 10.5
10/02

1" and 1.25" valves with swinging gate bodies
Series 730NI, 760NI Available Top Assembly

13.14 Positions
5.4 5.7
8.82
7.62 2.77 1.97
2.38
1.31
16.08
16.28
12.21
(2) 3/4" “R” “TO”
NPT
Conduit
Connection
1.44
.041
4.54 Pipe
2.94 Size
Series 4730NI, 4760NI

5.4
7.59 2.77
1.97 7.54
2.38
1.31
16.28
12.21
(2) 3/4"
NPT Conduit
Connection
1.44
0.41
4.54 Pipe
2.94 Size
NOTE: 2.75" needed

for terminal block
cover removal.

All Maxon NI Valves may be equipped with inter- when valve is open or closed and are normally con-
nally-mounted hermetically-sealed signal switch(es) to nected electrically into your control panel lights or
provide a proof-of-open or proof-of-closure valve warning device circuit(s).
position indication. Auxiliary signal switches indicate
For normally closed valves:

VCS hermetically-sealed (Valve Closed Switch) is snap-switch mounted on front of switch bracket. VOS-
actuated when valve is fully shut. It is the upper, 1 is an SPDT switch. On automatic reset valves, its
inverted snap-switch mounted on rear on switch normally closed contact serves as a motor limit switch
bracket. VCS-1 is an SPDT (single-pole, double- and is not available for external circuitry. On manual
throw) switch. VCS-2 is (2) SPDT switches mounted reset valves, normally closed contact is available for
side by side. All contacts are available for external external circuitry. VOS-2 is (2) SPDT switches
circuitry. mounted side by side, used in lieu of VOS-1 for
VOS hermetically-sealed (Valve Open Switch) is additional contacts.
actuated when valve reaches full-open. It is the lower
Photos above of normally closed valve

(typical for Series 808NI (-S), 5000NI (-S), 730NI (-S), 760NI, 4730NI (-S), 4760NI)
4/97

For normally open valves:
VOS hermetically-sealed (Valve Open Switch) is lower snap-switch mounted on front of switch bracket.
actuated when valve is fully open. It is the upper, VCS-1 is an SPDT switch. On automatic reset valves,
inverted snap-switch mounted on rear of switch its normally closed contact serves a motor limit switch
bracket. VOS-1 is an SPDT (single-pole, double- and is not available for external circuitry. On manual
throw) switch. VOS-2 is (2) SPDT switches mounted reset valves, normally closed contact is available for
side by side. All contacts are available for external external circuitry. VCS-2 is (2) SPDT switches
circuitry. mounted side by side, used in lieu of VCS-1 for
VCS hermetically-sealed (Valve Closed Switch) is additional contacts.
actuated when valve reaches fully closed. It is the
Photos above of normally open valve

(typical for Series STO-MNI-(-S)CP, STO-ANI-(S)CP)
Tandem Arrangements
General Wiring Schematic

Wherever insurance underwriters or other regula-
Flame
tory groups require the use of a double-valve or Safeguard
"block-and-bleed" system, but manual operation is Contact Main Valve
(Normally Closed)
preferred to the use of automatic reset valves, opera-
tion can be simplified by adding a tandem arrange-
ment to a pair of Maxon manual reset shut-off valves. Blocking Valve
(Normally Closed)
A linkage overtravel spring in the tandem arrange-
ment latches the blocking valve just before the main VCS in
valve is latched, assuring latching of both valves. Main Valve
Vent Valve
If it is necessary to locate a tandem valve above (Normally Open)
arms reach, an overhead wheel and chain assembly VOS in

Main Valve
may be added which includes a loop of chain acces-
sible to operating personnel. VOS in For Illustration Only
Blocking Valve (not a wiring diagram)
To order Main Fuel

Panel Light
Valves are to be specified in the usual manner and Main valve and blocking valve wired in parallel.
must be in top assembly position TO or AW. VCS Switch on main valve powers vent valve.
VOS Switches on main and blocking valves
VOS and VCS switches must be included on the wired in series to signal light.
main valve and a VOS switch on the blocking valve to
permit electrical connection as shown in the wiring
schematic illustrated below.
If overhead wheel and chain assembly is also Table 1: Allowable Valve Spacing for Tandem Arrgt.
required, specify loop length to reach appropriate
Valve Size Minimum C-C Maximum C-C
operating position. Extra chain (in one foot incre-
ments) may be specified. .75" - 1.5" 18" 24"
Center line distance between valves must be within 2" - 3" 20" 27"
the ranges indicated in Table 1 and shown in sketch 4" & 6" 27" 33"
below and must be specified at the time of order.
Tandem Arrangement with

Overhead Wheel & Chain Tandem Arrangement
Blocking Blocking
Valve Valve
Tension
Tension
Spring
Spring
Specify
Flow loop length Flow
Piping by others if overhead Piping by others
wheel &
chain option See Table 1
above
4/97

the other.
location.
12.19
12.19 Maximum
6.94
Maximum 7.25
2.31 dia.
5.25 4.06
Maximum

position TO.
NEMA 4X Hardware Kit

General Information
Maxon “NI” Valves are available with hardware When these kits are factory installed, the
modifications which make it NEMA 4X compliant. nameplate will indicate NEMA 4X in the designation
On automatic valves, these kits may be installed in block as shown on Page 6218.
the field. However, due to the linkage set-up of
manual valves, this kit is only available as a factory
Cover Torque (in-lbs)
installed accessory.
These kits consist of new corrosion resistant #10-24 Operator Cover 25
stainless steel external fasteners for all covers. .25"-20 All other access covers 50
When ordering the factory installed NEMA 4X .25"-20 Extended Access Cover Plate 96
kit for manual valves, the kit will include a new
handle made of corrosion resistant stainless steel.
* * *
* *
* *
Extended
Access Cover
Plate * Operator
Cover
*
808NI, STO-MNI, 730NI 5000NI, STO-ANI, 4730NI
* Asterisks indicate fasteners included in kit (for appropriate valve series)
4/97
Notes
Hazardous Location Valves Page 6200-S-1
1. Read complete instructions before proceeding B. Teflon tape acts as a lubricant and greatly
and do not discard packing materials until any/all reduces the pipe wrench turning force re-
loose items are located. Also, make sure that the quired to seal the threads.
NFPA-70, National Electric Code, CSA C22.1, C. Good piping practice dictates that piping be
Canadian Electric Code, etc. independently supported, so that valve bodies
2. General considerations: are not placed in a bind. In addition, large
A. Prior to shipment, each valve is operated valves may require support.
electrically and cycled at rated and 1-1/2 D. Clean pipe lines of foreign materials before
rated pressure while being leak tested. Every installing valve into line.
Maxon valve is operationally tested and
meets the requirements of ANSI B16.104
Class VI Seat Leakage.
B. Inspect your valve for any shipping damage. per NFPA 86-4-2.4.3 (1999)
Contact Maxon Corporation with the valve’s NFPA 86C-4-2.4.3 (1999)
serial number (printed on the valve's name- NFPA 86D-4-2.4-3 (1999)
C. Read the nameplate on your valve. This If normal inlet pressure to the fuel pressure regula-
gives the maximum pressure, temperature tor immediately upstream from the valve exceeds
limitation, voltage requirements and service the valve’s pressure rating, a relief valve shall be
conditions of your specific valve. DO NOT provided and it shall be vented to a safe location.
exceed nameplate ratings. per NFPA 86-5-7.1.7 (1999)
NFPA 86C-5-7.1.7 (1999)
D. Select mounting location carefully. Your NFPA 86D-5-7.1.7 (1999)
years if installed in a location that is cool, E. Mount valve so that open/shut window
clean and dry. indicator [1] will be visible to your operating
3. Pipe the valve in the direction of the flow arrow personnel. The open/shut window indicator
[3] on the valve body. The Maxon valve body can should never face downward. With Maxon
shut off flow in one direction only. electro-mechanical top assemblies, the motor
A. Remove all thread and flange protectors access side plate [2] should always be
before installing valve in your service line. vertical to the ground. Valves are usually
installed in horizontal piping; however, other
1 1 1
2
2 2
5
5 5
4 4
4
3
3

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CORPORATION
Page 6200-S-2 Hazardous Location Valves

orientations are acceptable, subject to the B. Maintain integrity of Maxon top assembly
above limitations. The top assemblies of all enclosure by using dust and water-tight
Maxon valves are field rotatable to allow electrical connectors. Use cable-sealing grips
installations involving conflicts with these and strain-relief loops for any cord or cable.
mounting restrictions. Use internal sealing materials on all conduit
F. Main system shut-off should always use a connections. Moisture can have a harmful
manual leak-tight upstream fuel cock. effect on valve internals if permitted to enter
G. Time lag between valve action and fluid flow through wiring connectors. Make sure that all
(or flame response) is reduced if valve is access cover plates are in place and securely
located near the burner (or outlet). fastened. All cover screws should be tight-
4. Wire the valve in accordance with all applicable ened using an alternate cross corner tighten-
codes and standards. Supply voltages must agree ing pattern to the values shown below.
with valve’s nameplate voltage within -15%/+10%
AC for proper operation. For electrical wiring Cover Torque (in-lbs)
schematics, refer to appropriate Maxon catalog #10-24 Operator Cover 25
literature and/or the wiring schematic diagram .25"-20 All other access covers 50
affixed inside your valve’s access cover plate or in .25"-20 Extended Access Cover Plate 96
the terminal block cover housing.
A. The Maxon valve must be electrically While all covers are torqued at time of produc-
interlocked with your safety-limit devices in tion testing, torque should be rechecked
accordance with all applicable codes, stan- periodically to ensure adequate sealing
dards, and the authority having jurisdiction protection.
over the safety requirements for your overall 5. Pre-operational exercising:
system installation. Normally, Maxon valves Prior to initial fluid flow start-up and with upstream
are electrically wired in series with all of your manual cock still closed, operate the valve
safety-limit devices. Therefore, any one electrically for 10-15 cycles. This not only pro-
device can cause the valve to react. Each vides an electrical check, but also wipes valve
valve was production tested when manufac- body disc and seat free of accumulated foreign
tured. If it now appears inoperative, make matter.
sure it is being powered properly from and
through your control circuit.
m CORPORATION


1
2 1 1
2
5 2
5
5
4 4
4
3
3
Series 4760NI
with socket welded
Series 808NI-CP Series 5000NI nipples & flanges
Maxon valves can and should be ordered in a con- Auxiliary Switch Arrangement
figuration compatible with planned piping, but if open/
shut indicator window is not visible and/or valve orienta-
tion is not proper, the top assembly can be rotated in
90° increments around the valve body centerline axis
by the following procedure:
1. Shut off all electrical power and close off up-
stream manual cock.
disconnect power lead wires. (Tag carefully for later
re-assembly.)
actuator wands on auxiliary signal switches (see Wiring Diagram
5. Unscrew the two body bolts [4] screwed up from A– Number Coded Wires H– Mounting Screws
the bottom to 1/4 inch. DO NOT completely re- B– Rubber Grommet I – Spring Retainer Extension
move. These bolts secure the valve body [3] to the C– Mounting Screws J– Switch Wand
valve’s top assembly housing [5]. Position Switch Position Switch
6. Gently lift the top assembly [5] (not more than E– Insulating Barrier L– Switch Wand
1/4" in height); just enough to break the seal F– Bracket Mounting Pad M– Switch Mounting Bracket
between the valve body assembly and the rubber G– Drive Pin & Locating Hole N– Gasket
FACTORY PERSONNEL.

m CORPORATION

7. Remove the two body bolts [4] screwed up Cover Torque (in-lbs)
from the bottom (were partially unscrewed in
#10-24 Operator Cover 25
step 5).
8. Carefully rotate top assembly to the desired .25"-20 All other access covers 50
position in a plane parallel to the top of the valve .25"-20 Extended Access Cover Plate 96
body casting. Rotate the top housing about 30° 11. Reconnect conduit, electrical leads, and all
beyond this position, and then rotate it back. pneumatic lines, then check that signal switch
Reposition the top housing back down onto the wands are properly positioned and that open/shut
valve body casting. This should align the open/ indicator moves freely. Failure to correct any
shut indicator with its window and provide proper such misalignment can result in extensive
alignment of the internal mechanism. damage to the internal mechanism of your
9. Realign holes in valve body casting with the valve.
corresponding tapped holes in the bottom of the 12. Energize valve and cycle several times from
top assembly housing. Be sure the gasket is still closed to full open position. Also electrically trip
in place between the body and top housing. the valve in a partially opened position to prove
10. Reinsert the body bolts up from the bottom valve operates properly.
through the body and carefully engage threads of 13. Replace and secure side cover access plate
the top assembly. Tighten securely. and place valve in service.
Maxon Maxon
“L” “R” “TO” “AW”

Four top assembly positions are available for body and the arrow on the valve body casting points
most Maxon valves. When looking at the open/shut in direction of fluid flow: to the right (position "R"), to
window indicator of an electro-mechanical valve the left (position "L"), towards you (position "TO") or
assembly, the motor (for motorized version), or the away from you (position "AW"). With smaller size
operating handle (for manual version), will be on the swinging gate valve bodies, only position "R" and
right side of the top assembly. The valve body is on position "TO" may be used.
the bottom. From this view, the unidirectional valve
m CORPORATION

Refer to appropriate catalog bulletin and specifi- Electro-mechanical manual reset valves require
cation page for operating sequence applying to your two positive actions to open: a half rotation of
specific valve. Never operate valve until all essen- handle to latch internal mechanism, and a reversed
tial allied equipment is operative and any neces- half rotation of handle to open valve. This refers to
sary purges completed. Failure of electro-mechani- normally closed valves. With normally open valves,
cally operated valve to operate normally indicates that the procedure is the same, but the valve body position
it is not powered. Check this first! Then check (i.e., open or closed) is opposite to the normally
internal holding solenoid and/or motor operator. closed version.
Main system shut-off should always be accom- Remotely located manual reset valves may be
plished with an upstream leak-tight manual fuel equipped with wheel-and-chain assembly. Instructions
cock. to operate the valve are on hand grip. Locate counter-
All Maxon valves react within a fraction of a weight overhead at pipe level and hand grip can be
second when de-energized. One cycle drop in electri- brought down to convenient operating personnel
cally supplied power can cause this reaction. height.
All electro-mechanical manual reset valves may Normally closed motorized valves begin open-
be operated manually when solenoid is electrically ing cycle immediately upon being powered; motor
energized, but electrical tripping is recommended for runs only until full open position is reached. Normally
normal shut-downs. open valves begin to close immediately, and motor
Address inquiries to: Maxon Corporation, Muncie, IN 47302, Phone (765) 284-3304
FAX (765) 286-8394

m
CORPORATION
the trouble.
Installation Instructions) and retest. If leakage does servicing and other shutdowns.
not stop, remove valve from service. All safety devices should be tested at least
monthly* and more often if deemed advisable.
Maxon valves are designed to be used with Periodic testing for tightness of manual or motor-
clean fluids. If foreign material is present in the ized shut-off valve closure is equally essential.
fuel line, it will be necessary to inspect the *per NFPA 86-Appendix B-4 (1995)
FAX (765) 286-8394
mCORPORATION


Hermetically Sealed
.75" – 3" NI
closed valves. For normally open versions (STO-
non-CP
MNI, STO-ANI, Fig. 1 & 2), reverse switch nomen-
clature. (VOS becomes VCS and vice versa.)
General: Shut off fuel supply upstream of valve, then Remove
de-energize valve electrically. side cover plate.
– Remove top or side cover to provide access, being Switches mount
careful not to damage gasket. on bracket. (See
"A" below)
valve type.
To replace existing switches:
– Note wand position and mounting hole location
– Install replacement switch in same mounting holes on
bracket and verify correct wand position. Fig. 2
– Replace existing wiring one connection at a time, 2.5" – 4" NI-CP
following original route and placement. 6" 808NI
– Check illustrations at right. If your valve uses a switch Remove
mounting bracket as in Fig. 1 & 2, mount switches to side cover plate.
bracket using the mounting holes appropriate for valve Switches mount
type and size. on bracket. (See
"B" below)
actuator, then move downward slightly, depressing
bracket mounting pad through drive pin holes, then tap
drive pin in until flush.
– Route wires to wiring compartment as shown,
then complete wiring connections and clean
out metal drilling chips from previous proce- Wand Position Mounting Brackets
For 1", 1.25" C.I. 3",4",6"(-2)
dure.
VOS switch wand & 2", 3" non-CP 3",4",6"(-2)
– Cycle valve, checking switch actuation points should be actuated 2-1/2"(-2)
2-1/2"(-1)
carefully. (VCS actuates at top of stem stroke, from above. VCS switch mounts VCS Switch
VOS at bottom.) Simultaneously the valve on back of bracket on back
Oil SOV &
body must be tested for switch continuity and 2"-6" Gas
1-1/2"
seat leakage. Bend VOS switch wands slightly
if necessary to insure valve is opening fully.
1-1/4"
3/4", 1"
VOS switch
B
– Replace gasket and cover, then return valve VCS switch wand
should be actuated
A on front VOS switch
on front
to service. Drive
Pins
from below. Bracket
Mounting
Holes
Bracket
Mounting
Slots

m CORPORATION
Electrical Data
Electro-Mechanical Valves

.75" – 3" Series 808NI, 818NI (-S);
1" – 1.25" Series 730NI, 760NI (-S);
2.5" – 4" Series 808NI-(S)CP;
6" Series 808NI (-S)

.75" – 3" Series 5000NI (-S);
1" – 1.25" Series 4730NI, 4760NI (-S);
2.5" – 4" Series 5000NI-(S)CP
.75" – 2" Series STO-MNI &

STO-ANI (-S)
2.5" – 4" Series STO-MNI-CP

& STO-ANI-(S)CP
m CORPORATION

Tandem Arrangements
Review and comply with all general valve installa- 8. Rotate the operating handle of the main valve
tion instructions provided separately. (See sketch fully to latching position for your particular valve,
below.) then hold handle firmly in this position while
1. Mount both valves in fuel line with center to center performing the next few steps.
spacing as originally specified, and blocking valve 9. Rotate blocking valve wheel fully counter-clock-
(without handle) downstream of main valve (with wise until it strikes a stop (it will slide within the
handle). loop of chain).
2. Check valve alignment to be certain that operat- 10. Still holding main valve wheel in place, move
ing wheels lie in the same plane. blocking valve wheel approximately 1/4 to 1/2
3. Remove tape from the wheel of the main valve inch back in the clockwise direction. Insert the
and unwind the attached chain. Do not remove #10-24 X 1/2" screw (furnished) through the chain
the screw holding chain to wheel; it has been link that lines up with the tapped hole on bottom
factory positioned to assure correct alignment. Do of blocking valve wheel, then fasten securely.
not remove tension spring attached to one end of 11. Verify that the valves are wired in parallel as
chain or the wooden block insert which preloads shown in wiring schematic on page 6219.
the spring.
4. Take free end of chain and loop it around the To add wheel & chain assembly to
wheels of both main and blocking valve as shown existing tandem valves:
in sketch below. Depending on the specific valve 1. Verify that both valves are in the same top
series and arrangement, tension spring may be assembly position (TO or AW). Rotate if neces-
located either above or below the wheel center- sary. (See top assembly rotation instructions on
line. pages 6200-S-3 and 6200-S-4.)
5. Draw free end of chain and tension spring to- 2. Bend handle of main valve outward about 25º.
gether so that as much slack as possible is 3. Cut off handle of blocking valve at outer wheel
eliminated, then insert the open eye of the spring face.
"S" hook through the link in the chain that will 4. Remove hardware holding main valve wheel in
most nearly maintain this position. place and mount new wheel and spacer to the
6. Crimp the "S" hook shut around the chain link, existing wheel with new hardware provided.
then cut and discard excess chain. 5. Cut chain loop to the desired length and secure to
7. Remove spring preload wood block insert from both wheels.
the tension spring, and verify that the chain is
drawn tight.
Blocking
Valve
Tension
Spring
Flow
Piping by others

m
CORPORATION

the other.
location.
12.19
Maximum
6.94 12.19
7.25
Maximum
2.31 dia. 5.25 4.06

Maximum

position TO.
m CORPORATION

CAUTION: Valve leak testing should be under- Suggested leak test procedure for
taken only by trained and experienced personnel. double-blocking shut-off valves (without
Instructions provided by the company and/or vent line)
individuals responsible for the manufacture and/or
overall installation of complete system incorporat- (a) Shut down combustion system per manufacturer’s
ing Maxon valves take precedence over these recommended procedure.
provided by Maxon. If Maxon instructions conflict (b) Close manual valves A and B.
with any codes or regulations, contact Maxon (c) Visually inspect to verify that shut-off valves #1
Corporation before attempting this procedure. and #2 are closed.
(d) Remove the 1/4” pipe plug from downstream side
Valve leak test should be performed on a of shut-off valve #1. Install leak test apparatus.
quarterly basis to assure continued safe and Safely vent any trapped gas pressure.
reliable operation. Each valve should be checked (e) Open manual shut-off valve A, then close leak
with available line pressure. Absolute zero leakage test apparatus. Insert tube into a container of
may not be obtained in the field. Any valve that water just below the surface.
exceeds the allowable leakage, as set forth by your (f) Open test apparatus and test valve for leakage.
local codes or insurance requirements (15 bubbles As a guideline, valve should be tested for 2
per minute), should be removed from service and minutes per inch of pipe diameter. Large diameter
your Maxon representative should be contacted. pipes or long piping runs between shut-off valves
may need additional testing time.
Every Maxon valve is operationally tested and (g) If valve testing indicates leakage exceeding 15
meets the requirements of ANSI B16.104 Class bubbles per minute, perform pre-operational
VI seat leakage when it leaves our plant. exercising as outlined on Page 6200-S-2 and
retest the valve. If valve continues to exceed
allowable leakage limit, remove from service and
Example of a gas piping diagram for leak test contact Maxon.
Shut-off Shut-off
Manual Gas Pressure Valve Valve
Valve Regulator #1 #2
A LGP HGP Manual
Switch Switch Valve
B
Strainer
To Combustion
System
Drip
Leg

From Flame NOTES:
Hot Safeguard Neutral
Push button must be tamper resistant.
Momentary Leak LS-SV – Closes when Shut-off Valve #1

Test Push Button
is fully open.
Shut-off
Valve #1 The “From Flame Safeguard” line is
energized only when all conditions for
safe operation have been satisfied.
LS-SV Shut-off
Valve #2

m CORPORATION
(h) Secure test apparatus on valve #1. retest the valve. If valve continues to exceed
(i) Remove the 1/4” pipe plug from downstream side allowable leakage limit, remove from service and
of shut-off valve #2. Install leak test apparatus. contact Maxon.
exercising as outlined on Page 6200-S-2 and
Example of a gas piping diagram for leak test with vent line
Vent
Valve
If vent valve is
present, use auxil- Shut-off
iary power supply to Manual Gas Pressure Valve
Valve Regulator #1
power vent valve to Shut-off Valve #2
A Manual
closed position LGP HGP
Switch Switch Valve
during this test B
procedure. Follow Strainer
test instructions
above. Once test is To Combustion
complete, be sure System
vent valve is re- Drip
Leg
stored to normal
operation.
Example of a wiring diagram for leak test with vent line

From Flame
NOTES: Hot Safeguard
Neutral
Push button must be tamper
resistant. Shut-off Valve #2 Shut-off Valve #1
LS-VV – Closes when Vent
Valve is fully closed Vent
Valve
LS-SV – Closes when Shut-
off Valve #1 is fully open.
The “From Flame Safe-

guard” line is energized only LS-VV
Shut-off
when all conditions for Valve #1
safe operation have been
satisfied.
LS-SV Shut-off
Valve #2
m CORPORATION

Hazardous Location Valves Page 6200-A/P-1
Assembly Numbers
Series 808NI Shut-Off Valves
Sanctioned Valves Ship
Valve Size & MOPD
Series Valve Body Sub-assembly [1] Weight
Cv Factor Assembly Number (psi)
Designation Trim ANSI ISO (lbs.)
1-1 29662 31730
.75"
.75 808NI 808NI 1-2 29667 31735 125 21
Cv = 20
3-2 29678 ---
1-1 29663 31731
808NI 1-2 29668 31736
1" 3-2 29679 ---
1 808NI 125 23
Cv = 20 2-1 29672 31740
808NI-S 2-2 29675 31743
4-2 30038 ---
1-1 29664 31732
1.25"
1.25 808NI 808NI 1-2 29669 31737 100 23
Cv = 45
3-2 29680 ---
1-1 29665 31733
808NI 1-2 29670 31738
1.5" 3-2 29681 ---
1.5 808NI 70 23
Cv = 53 2-1 29673 31741
808NI-S 2-2 29676 31744
4-2 30039 ---
1-1 29666 31734
808NI 1-2 29671 31739
3-2 29682 ---
34
2-1 29674 31742
2"
2 808NI 808NI-S 2-2 29677 31745 70
Cv = 86
4-2 30040 ---
1-1 38987 38988
808NI 1-2 38989 38990
35
3-2 38991 ---
2.5"
2.5 808NI 808NI 1-1 18010 21116 40 36
Cv = 127
3"
3 808NI 808NI 1-1 18011 21117 30 38
Cv = 173
[1] Valve body sub-assemblies in bold are standard bodies in this valve assembly
These assemblies include Non-Incendive 115-50/60 VAC solenoids.

Other gases and liquids may be sanctioned. Contact Maxon with your fuel analysis.
Shaded areas are flanged body valves (valves with -S designation are steel body valves)
• Fuel • Enclosure rating

• Body trim • VOS switch
• Body connection • VCS switch
• Minumum fuel/ambient temperature • Terminal block
• Maximum fuel temperature • Time delay
• Maximum ambient temperature • Top assembly position
• Solenoid voltage • Handle sideplate
• Tagging

mCORPORATION
Page 6200-A/P-2 Hazardous Location Valves
Assembly Numbers
Series 808NI Shut-off Valves
Valve Size & Cv MOPD
Factor Assembly Number (psi)
Designation (lbs.)
Trim ANSI ISO
1-1 35968 35986
808NI-CP 1-2 35971 35989 44
3-2 35974 ---
2.5" 1-1 38999 39000
CP 2.5CP 808NI 808NI-CP 1-2 39003 39004 50
Cv = 304 3-2 39007 ---
63
2-1 41162 41170
808NI-SCP 2-2 41163 41171
4-2 41178 ---
1-1 35969 35987
808NI-CP 1-2 35972 35990 48
3-2 35975 ---
3" 1-1 39001 39002
CP 3CP 808NI 808NI-CP 1-2 39005 39006 40
Cv = 432 3-2 39009 ---
75
2-1 41186 41194
808NI-SCP 2-2 41187 41195
4-2 41202 ---
1-1 35970 35988
808NI-CP 1-2 35973 35991
4" 3-2 35976 ---
CP 4CP 808NI 40 89
Cv = 551 2-1 41210 41218
808NI-SCP 2-2 41211 41219
4-2 41226 ---
1-1 29403 29405
808NI 1-2 29406 29408
6" 3-2 30032 ---
6 808NI 30 143
Cv = 765 2-1 41270 41272
808NI-S 2-2 41271 41273
4-2 41274 ---
These assemblies include Non-Incendive 115-50/60 VAC solenoids.

Shaded areas are flanged body valves (valves with -S designation are steel body valves).

• Fuel • Enclosure rating
• Body trim • VOS switch
• Body connection • VCS switch
• Minumum fuel/ambient temperature • Terminal block
• Maximum fuel temperature • Time delay
• Maximum ambient temperature • Top assembly position
• Solenoid voltage • Handle sideplate
• Tagging
mCORPORATION

Assembly Numbers
Series 5000NI Shut-Off Valves
Designation (lbs.)
Trim ANSI ISO
1-1 29662
.75" 31730
.75 5000NI 5000NI 1-2 29667 125 23
Cv = 20 31735
3-2 29678
1-1 29663 31731
5000NI 1-2 29668 31736
1" 3-2 29679 ---
1 5000NI 125 24
Cv = 20 2-1 29672 31740
5000NI-S 2-2 29675 31743
4-2 30038 ---
1-1 29664 31732
1.25"
1.25 5000NI 5000NI 1-2 29669 31737 100 25
Cv = 45
3-2 29680 ---
1-1 29665 31733
5000NI 1-2 29670 31738
1.5" 3-2 29681 ---
1.5 5000NI 70 27
Cv - 53 2-1 29673 31741
5000NI-S 2-2 29676 31744
4-2 30039 ---
1-1 29666 31734
5000NI 1-2 29671 31739
3-2 29682 ---
36
2-1 29674 31742
2"
2 5000NI 5000NI-S 2-2 29677 31745 70
Cv = 86
4-2 30040 ---
1-1 38987 38988
5000NI 1-2 38989 38990 54
3-2 38991 ---
2.5"
2.5 5000NI 5000NI 1-1 18010 21116 40 39
Cv = 127
3"
3 5000NI 5000NI 1-1 18011 21117 30 40
Cv = 173
These assemblies include Non-Incendive 115-50/60 VAC solenoids and motors.


• Fuel • Motor voltage • Terminal block
• Body trim • Motor timing • Time delay
• Body connection • Solenoid voltage • Top assembly position
• Minumum fuel/ambient temperature • Enclosure rating • Tagging
• Maximum fuel temperature • VOS switch
• Maximum ambient temperature • VCS switch

m CORPORATION
Assembly Numbers
Series 5000NI Shut-off Valves
Sanctioned Valves
Ship
Designation (lbs.)
Trim ANSI ISO
1-1 35968 35986
5000NI-CP 1-2 35971 35989 44
3-2 35974 ---
1-1 38999 39000
2.5" CP
2.5CP 5000NI 5000NI-CP 1-2 39003 39004 50
Cv = 304
3-2 39007 ---
68
2-1 41162 41170
5000NI-SCP 2-2 41163 41171
4-2 41178 ---
1-1 35969 35987
5000NI-CP 1-2 35972 35990 49
3-2 35975 ---
1-1 39001 39002
3" CP
3CP 5000NI 5000NI-CP 1-2 39005 39006 40
Cv = 432
3-2 39009 ---
68
2-1 41186 41194
5000NI-SCP 2-2 41187 41195
4-2 41202 ---
1-1 35970 35988
5000NI 1-2 35973 35991
4" C P 3-2 35976 ---
4CP 5000NI 40 27
Cv = 551 2-1 41210 41218
5000NI-SCP 2-2 41211 41219
4-2 41226 ---
These assemblies include Non-Incendive 115-50/60 VAC solenoids and motors.

Shaded areas are flanged body valves (valves with -S designation are steel body valves).

• Fuel • Solenoid voltage
• Body trim • Enclosure rating
• Body connection • VOS switch
• Minumum fuel/ambient temperature • VCS switch
• Maximum fuel temperature • Terminal block
• Maximum ambient temperature • Time delay
• Motor voltage • Top assembly position
• Motor timing • Tagging
mCORPORATION

Assembly Numbers
Series STO-MNI Vent Valves
Normally open, rising stem, electrically actuated, manual reset, trip open
Sanctioned Valves
Ship
Valve Size MOPD
& Cv Factor Assembly Number (psi)
Designation (lbs.)
Trim ANSI ISO
1-1 29704 31754
.75"
.75 STOMNI STO-MNI 1-2 29708 31758 125 21
Cv = 20
3-2 30044 ---
1-1 29705 31755
STO-MNI 1-2 29709 31759
1" 3-2 30045 ---
1 STOMNI 125 23
Cv = 20 2-1 29712 31762
STO-MNI-S 2-2 29715 31765
4-2 30048 30048
1-1 29706 31756
STO-MNI 1-2 29710 31760
1.5" 3-2 30046 ---
1.5 STOMNI 70 23
Cv = 53 2-1 29713 31763
STO-MNI-S 2-2 29716 31766
4-2 30049 ---
1-1 29707 31757
STO-MNI 1-2 29711 31761
3-2 30047 ---
34
2-1 29714 31764
2"
2 STOMNI STO-MNI-S 2-2 29717 31767 70
Cv = 86
4-2 30050 ---
1-1 38993 38994
STO-MNI 1-2 38995 38996 35
3-2 38997 ---
1-1 36005 36023
STO-MNI-CP 1-2 36008 36026 44
3-2 36011 ---
1-1 39011 39012
2.5" CP
2.5CP STOMNI STO-MNI-CP 1-2 39015 39016 50
Cv = 304
3-2 39019 ---
63
2-1 41164 41172
STO-MNI-SCP 2-2 41165 41173
4-2 41179 ---
1-1 36006 36024
STO-MNI-CP 1-2 36009 36027 48
3-2 36012 ---
1-1 39013 39014
3" CP
3CP STOMNI STO-MNI-CP 1-2 39017 39018 40
Cv = 432
3-2 39021 ---
75
2-1 41188 41196
STO-MNI-SCP 2-2 41189 41197
4-2 41203 ---
1-1 36007 36025
STO-MNI-CP 1-2 36010 36028
4" CP 3-2 36013 ---
4CP STOMNI 40 89
Cv = 551 2-1 41212 41220
STO-MNI-SCP 2-2 41213 41221
4-2 41227 ---
These assemblies include Non-Incendive 115-50/60 VAC solenoids. Other gases and liquids may be sanctioned. Contact Maxon with your fuel analysis.
m
Segment choices are listed on page 6200-A/P-7
CORPORATION
Assembly Numbers
Series STO-ANI Vent Valves
Normally open, rising stem, electrically actuated, automatic reset, trip open
Sanctioned Valves
Ship
Assembly Series Valve Body Sub-assembly [1] Weight
Factor (psi)
Number Designation (lbs.)
Trim ANSI ISO
1-1 29704 31754
.75"
.75 STOANI STO-ANI 1-2 29708 31758 125 21
Cv = 20
3-2 30044 ---
1-1 29705 31755
STO-ANI 1-2 29709 31759
1" 3-2 30045 ---
1 STOANI 125 23
Cv = 20 2-1 29712 31762
STO-ANI-S 2-2 29715 31765
4-2 30048 ---
1-1 29706 31756
STO-ANI 1-2 29710 31760
1.5" 3-2 30046 ---
1.5 STOANI 70 23
Cv = 53 2-1 29713 31763
STO-ANI-S 2-2 29716 31766
4-2 30049 ---
1-1 29707 31757
STO-ANI 1-2 29711 31761
3-2 30047 ---
34
2-1 29714 31764
2"
2 STOANI STO-ANI-S 2-2 29717 31767 70
Cv = 86
4-2 30050 ---
1-1 38993 38994
STO-ANI 1-2 38995 38996 35
3-2 38997 ---
1-1 36005 36023
STO-ANI-CP 1-2 36008 36026 44
3-2 36011 ---
1-1 39011 39012
2.5" CP
2.5CP STOANI STO-ANI-CP 1-2 39015 39016 50
Cv = 304
3-2 39019 ---
63
2-1 41164 41172
STO-ANI-SCP 2-2 41165 41173
4-2 41179 ---
1-1 36006 36024
STO-ANI-CP 1-2 36009 36027 48
3-2 36012 ---
1-1 39013 39014
3" CP
3CP STOANI STO-ANI-CP 1-2 39017 39018 40
Cv = 432
3-2 39021 ---
75
2-1 41188 41196
STO-ANI-SCP 2-2 41189 41197
4-2 41203 ---
1-1 36007 36025
STO-ANI-CP 1-2 36010 36028
4" CP 3-2 36013 ---
4CP STOANI 40 89
Cv = 551 2-1 41212 41220
STO-ANI-SCP 2-2 41213 41221
4-2 41227 ---
These assemblies include Non-Incendive 115-50/60 VAC solenoids. Other gases and liquids may be sanctioned. Contact Maxon with your fuel analysis.
m
Segment choices are listed on page 6200-A/P-7
CORPORATION
Assembly Numbers
Series STO-MNI and STO-ANI Valves
For Series STO-MNI Valves: For Series STO-ANI Valves:
configured products: configured products:
• Fuel • Fuel
• Body trim • Body trim
• Body connection • Body connection
• Minimum fuel/ambient temperature • Minimum fuel/ambient temperature
• Maximum fuel temperature • Maximum fuel temperature
• Maximum ambient temperature • Maximum ambient temperature
• Solenoid voltage • Motor voltage
• Enclosure rating • Motor timing
• VCS switch • Solenoid voltage
• VOS switch • Enclosure rating
• Terminal block • VOS switch
• Time delay • VCS switch
• Top assembly position • Terminal block
• Handle sideplate • Time delay
• Tagging • Top assembly position
• Tagging

m
CORPORATION
Assembly Numbers
Series 730NI/760NI Valves
for oil and liquid service
Normally closed, swinging gate, electrically actuated, manual reset, trip close
Series Valve Body Sub-assembly Weight
Designation Trim ANSI ISO (lbs.)
1" 730NI 1-B 27244 27259 300

1 700NI 37
Cv = 12 760NI 2-D 27245 27261 600
1.25" 730NI 1-B 27246 27260 300
40
Cv = 17 760NI 2-D 27247 27262 600
1.25 700NI
1.25" HC
730NI-S 2-D 29054 35581 600 40
Cv = 45
Series 4730NI/4760NI Valves

Normally closed, swinging gate, electrically actuated, automatic reset, trip close
Valve Size & MOPD
Assembly Series Valve Body Sub-assembly Weight
Cv Factor (psi)
Number Designation Trim ANSI ISO (lbs.)
1" 4730NI 1-B 27244 27259 300
1 4700NI 42
Cv = 12 4760NI 2-D 27245 27261 600
1.25" 4730NI 1-B 27246 27260 300
42
Cv = 17 4760NI 2-D 27247 27262 600
1.25 4700NI
1.25" HC
4730NI-S 2-D 29054 35581 600 42
Cv = 45
Valve body sub-assemblies in bold are standard bodies in this valve assembly.
These assemblies include Non-Incendive 115-50/60 VAC solenoids. Other gases and liquids may be sanctioned. Contact Maxon with your
fuel analysis. Valves with -S designations are steel body valves.
For 700 Valves: For 4700 Valves:

Segment choices are a follows for configured Segment choices are a follows for configured
products: products:
• Fuel • Fuel
• Solenoid rating • Motor voltage
• Enclosure rating • Motor timing
• VOS switch • Solenoid rating
• VCS switch • Enclosure rating
• Terminal block • VOS switch
• Time delay • VCS switch
• Top assembly position • Terminal block
• Handle sideplate • Time delay
• Tagging • Top assembly position
• Tagging
mCORPORATION

Assembly Numbers
Spare Parts
Signal Switches
Hermetically Sealed 3/4" through 3" RS and 1" through 2" SG Valves
Valve Size
3/4" & 1" 1-1/4" 1-1/2" 2" through 3"
VCS1 (NC) VOS1 (NO) 43268 43268 57341 57353 57256
VCS2 (NC) VOS2 (NO) 43269 43269 57342 57354 57257
VCS1, VOS1 SW ASY 43271 W/43273 57331 57343 57355 57258
VCS2, VOS1 SW ASY 43271 W/43270 57332 57344 57356 57259
VCS1, VOS2 SW ASY 43272 W/43273 57333 57345 57357 57260
VCS2, VOS2 SW ASY 43272 W/43270 57334 57346 57358 57261
Hermetically Sealed 2-1/2", 3" and 4" CP

Valve Size
2-1/2" 3" and 4"
VCS1 (NC) VOS1 (NO) 43267 43267 57379
VCS2 (NC) VOS2 (NO) 43260 43260 57380
VCS1, VOS1 SW ASY 43266 W/43262 57375 57381
VCS2, VOS1 SW ASY 43266 W/43261 57376 57382
VCS1, VOS2 SW ASY 43263 W/43262 57377 57383
VCS2, VOS2 SW ASY 43263 W/43261 57378 57384
Solenoids
2.5", 3", & 4"
Maxon Valve Size 1" & 1.25"
.75", 1", 1.25", 808NI (-S)CP; 5000NI (-S)CP;
and Series > 730NI (-S); 760NI; 4730NI (-S); 4760NI
& 1.5" STO-ANI (-S)CP
808NI (-S); 5000NI (-S); 2", 2.5", & 3"
Electrical STO-MNI (-S); STO-ANI (-S) 6"
808NI (-S); 5000NI (-S);
Specification 808NI (-S)
STO-MNI (-S); STO-ANI (-S)
115v 50/60 Hz 47120 47121 47122
230v 50/60 Hz 47123 47124 47125
24 VDC 1040851 1040580 1040581*
* Not available with 6" 808NI.
Key: VOS = Valve Open Switch

VCS = Valve Closed Switch
v = Volts
Hz = Hertz

m CORPORATION
Assembly Numbers
Spare Parts
Motor Operators and Internal Top Assembly Components

Maxon Valve Size and Series > .75", 1", 1.25", 1.5",
.75", 1",
2", 2.5", 3", & 4" 2.5", 3", & 4"
1.5", & 2"
5000NI (-S); 4730NI (-S); 4760NI; STO-ANI (-S)CP
Motor Operator Electrical Specifications STO-ANI (-S)
5000NI (-S)CP
115v 50/60 Hz 47822 [1] 47822 ---
2-1/2 second timing
230v 50/60 Hz 47823 [1] 47823 ---
115v 50/60 Hz 47824 --- 47824
6 second timing
230v 50/60 Hz 47825 --- 47825
115v 50/60 Hz 47826 --- ---
14 second timing
230v 50/60 Hz 47827 --- ---
[1] 2-1/2 second timing option is not available for CP valves
Companion Flange Set Options

Pipe Line Size
Flange Description
2" 2.5" 3" 4" 6"
125#, flat faced, threaded, iron 39882 20338 20341 20206 ---
150#, flat faced, threaded, steel 39883 20339 20342 20208 20209
150#, flat faced, slip-on welding, steel 39884 20340 20343 20210 20211
Approximate weight in pounds 20 22 24 35 46
Flange sets include (2) flanges and gaskets with necessary nuts and bolts to mount set to flanged body valve assemblies.
NEMA 4X Hardware Kits – Manual Valves Wheel & Chain Accessory Option
Must be returned to factory Extra chain (in one foot increments) – 00035
Standard chain length on CP and larger valves is 7
NEMA 4X Hardware Kits – Automatic Valves feet; all other valves is 5 feet
.75", 1", 1.25", & 2", 2.5", & 3"
1.5" 5000NI
Maxon Valve Series 5000NI STO-ANI
& Size 1" & 1.25"
.75", 1", & 1.5"
4730NI (-S)
STO-ANI
4760NI
NEMA 4X Kit
47695 47696
Assembly Number
NEMA 4X rating pertains only to valve top assembly.
If additional protection is required, contact Maxon.
m CORPORATION

Bulletin 6300
Maxon ACTIONAIR® Valves
1-1/4" Series 3320
1-1/2" Series 2010

4" Series 1220
• Air actuated valves shut off gas or oil lines in less than one second
• FM (Factory Mutual) approved for General Purpose and Hazardous Duty locations
• CGA (Canadian Gas Association) certified for General Purpose and Hazardous Duty locations
– Series 1000 and Series 2000 valves only
• Powerful spring-loaded air operators permit much higher differential pressure ratings
than are possible with listed electro-mechanical operators
• Gain application flexibility with 1/2" through 6" diameter line sizes, Cv factors up to 1230, and line
pressures up to 700 PSIG
• Internal trim options provided for special service lines
• Handle flowing fluid temperatures from -40°F (-40°C) to +550°F (+288°C) with ambient temperatures
from -40°F (-40°C) to +140°F (+60°C)
• Bodies designed to ASME/ANSI standards (ISO standards also available)
Page 6302
Maxon Valves with Air Actuators

For quick opening or closing action

Normally-closed shut-off valves use 65 - 100 PSIG instrument air to open in
approximately four seconds, release of control air through 3-way solenoid valve
gives closure in less than one second.
Normally-open vent valves use 70 - 100 PSIG instrument air to close in

approximately four seconds after introduction of control air and will open in less
than one second upon release of control air.
ACTIONAIR® valve enclosures meet NEMA 1, 2, 3, 3R, 4 & 12; and CSA 2, 4
& 5.
All ACTIONAIR® Valves meet: Hazardous Duty ACTIONAIR® Valves meet:
Class I, Div. 2, Groups A, B, C, & D Class I, Div. 1, Groups C & D
Class II, Div. 2, Groups E, F, & G Class II, Div. 1, Groups E, F, & G
Class III, Div. 2, ID #T3B Class III, Div. 2, ID #T3B
ACTIONAIR® valve electrical components and accessories comply with UL

(Underwriters Laboratories) and CSA (Canadian Standards Association)
standards.
Rotatable top assembly for field piping convenience and lubrication-free body
design means minimal field maintenance.
Cast iron or cast steel bodies feature metal-to-metal seating that wears in,
not out. Straight-through flow path minimizes pressure drop through full open
swinging gate or rising-stem guillotine action bodies.
1-1/2" Series 1210
Large two-color open/shut indicator provides positive visual indication of
valve's body position.
Series Designations and Available Sizes

Series 1000 – 3/4" to 6" rising stem bodies with normally-closed actuators are CGA (Canadian Gas Associa-
tion) certified and have FM (Factory Mutual) approval for use with air, natural gas, LP gases,
#1 and #2 fuel oils.
Series 2000 – 3/4" to 4" rising stem bodies with normally-open actuators are CGA (Canadian Gas Associa-
tion) certified and have FM (Factory Mutual) approval listings for use with air, natural gas, LP
gases, #1 and #2 fuel oils.
Series 3000 – 1/2" to 1-1/4" swinging gate bodies with normally-closed actuators have FM (Factory Mutual)
approval for use with #1, #2,# 4, and preheated #5 and #6 fuel oils.
All ACTIONAIR® valves have special service trim options available.
7/93
ACTIONAIR® Valves Page 6303

Table 1: Normally-closed valve bodies Table 2: Normally-open valve bodies
Body End Pipe Size Body Body End Pipe Size Cv Body
Cv Factor
Material Connections in Inches Type [1] Material Connections in Inches Factor Type [1]
1/2 3.4 SG 3/4 20 RS
9.6 SG 1 20 RS
3/4
20 RS 1-1/2 53 RS
Threaded
12 SG 2 86 RS
1
20 RS Gray 2-1/2 304 RS
Threaded 17 SG Iron 3 432 RS
1-1/4
45 RS 2 86 RS
1-1/2 53 RS 2-1/2 304 RS
Gray Flanged
2 86 RS 3 432 RS
Iron
2-1/2 304 RS 4 551 RS
3 432 RS 1 20 RS
2 86 RS Threaded 1-1/2 53 RS
2-1/2 304 RS Cast 2 86 RS
3 432 RS Steel 2-1/2 304 RS
Flanged
551 RS Flanged 3 432 RS
4
903 RS 4 551 RS
6 1230 RS [1] RS = Rising stem body
1/2 3.4 SG
3/4 9.6 SG Each complete valve assembly must include one of
12 SG these valve bodies, regardless of ultimate series
1
20 RS designation.
Threaded
17 SG Flows through the valve body and resulting pres-
1-1/4 sure drops may be estimated by inserting your
45 SG
1-1/2 53 RS
specific conditions into following formula and using Cv
Cast flow factors given for each valve body.
2 86 RS
Steel
1-1/2 123 SG
2 218 SG
2-1/2 304 RS Gases: Q = (1360) x Cv x (P1+P2) (P1–P2)
x
Flanged 3 432 RS G Tf 2
551 RS
4
903 RS
6 1230 RS Liquids: V = Cv x (P1–P2)
[1] RS = Rising stem body; SG = Swinging gate body Gf
See catalog page 6313 for construction details
Where:
G = Gas specific gravity (air = 1.0)
Gf = Specific gravity @ flowing temperature °F
P1 = Inlet pressure PSIA (14.7 psi + psi gauge)
P2 = Outlet pressure PSIA (14.7 psi + psi gauge)
Q = Cubic feet per hour @ 14.7 PSIA and 60°F
Tf = Flowing temperature absolute (460° + °F)
V = Flow in U.S. gallons/minute
10/92
Page 6304 ACTIONAIR® Valves

with Natural Gas at 1 PSIG inlet pressures
determined by using this
graph.
for fuel flows should not
exceed 10% of inlet
pressure; however, for 2"
and smaller valves, the
drop should not exceed 5
PSIG, and for 2-1/2" and
larger size valves, must
not exceed 2.5 PSIG.
basis of the lower of these
parameters to avoid critical
flow conditions.

with Natural Gas at 5 PSIG inlet pressure
determined by using this
graph.
for fuel flows should not
exceed 10% of inlet
pressure; however for 2"
and smaller valves, the
drop should not exceed 5
PSIG, and for 2-1/2" and
larger size valves, must
not exceed 2.5 PSIG.
basis of the lower of these
parameters to avoid critical
flow conditions.
7/93

with #2 Oil
To select a valve
for YOUR applica-
tion, use either Cv
factor calculations, or
this graph showing
approximate pres-
sure drop at various
flows of #2 oil.
Typically, pressure
drop for fuel flows
should not exceed
10% of inlet pres-
sure.

factor given in the table at right, then ºF @ Inlet 125 160 122 140 180 210 220
allowable drop. For example: To size for 5 psi drop with a 3500 GPH flow of #6 oil
preheated to 140°F, the multiplier is "2". Equivalent flow of #2 oil is
then 3500 x 2, or 7000 GPH. Chart shows that a 5 psi drop will
Selection Data
• For gas service

Series 1000 • Normally closed
• Rising stem body design
1-1/2" Series 1220
Available sizes and pressure ratings

Pipe Size
Body Cv Gray Iron Bodies Cast Steel Bodies
(inches)
3/4 19 200 125 --- ---
1 20 200 125 255 125
1-1/4 45 200 100 --- ---
1-1/2 53 200 70 255 70
2 86 200 70 255 70
2-1/2 304 175 60 175 60
3 432 135 45 135 45
4 551 135 45 135 45
4-HC 903 120 40 120 40
6-HC 1230 100 35 100 35
NOTE: Ambient and fluid temperature limits are -40°F (-40°C) to +140°F (+60°C).
Series Designation
General Purpose (GP) Hazardous Duty (HD)
Body Material
Gray Iron Cast Steel Gray Iron Cast Steel
Special Special Special Special
Actuator Sanctioned * Sanctioned * Sanctioned * Sanctioned *
Service (Non- Service (Non- Service (Non- Service (Non-
Function Service Service Service Service
sanctioned) sanctioned) sanctioned) sanctioned)
Automatic 1010 1110 1210 1310 1010-HD 1110-HD 1210-HD 1310-HD
Manual 1020 1120 1220 1320 1020-HD 1120-HD 1220-HD 1320-HD
Power-to-Close --- 1130 --- 1330 --- 1130-HD --- 1330-HD
*Sanctioned ser vice fuels include: air, natural gas, manufactured gas, liquified petroleum gases, #1 and #2 fuel oils.
NOTE: All standard actuators require 115v 50/60 AC electrical signal to operate the air control
solenoid, which opens the valve assembly. Contact your Maxon representative for optional
electrical voltages.
8/94
Selection Data
• For gas service

Series 2000 • Normally open
• Rising stem body design
1-1/2" Series 2010

Pipe Size
(inches)
3/4 19 200 125 --- ---
1 20 200 125 255 125
1-1/2 53 200 70 255 70
2 86 200 70 255 70
2-1/2 304 1 75 60 175 60
3 432 135 45 135 45
4 551 135 45 135 45
NOTE: Ambient and fluid temperature limits are -40°F (-40°C) to +140°F (+60°C).
Series Designation
Body Material
Manual 2020 2120 2220 2320 2020-HD 2120-HD 2220-HD 2320-HD
*Sanctioned ser vice fuels include: air, natural gas, manufactured gas, liquified petroleum gases, #1 and #2 fuel oils.
solenoid, which closes the valve assembly. Contact your Maxon representative for optional
Selection Data
• For oil service

Series 3000 • Normally closed
• Swinging gate body design
1-1/4" Series 3320

Maximum Inlet Pressure (PSIG) [1]
Pipe Size
(inches)
Clean Oils Special Service Clean Oils Special Service
1/2 3.4
3/4 9.6 500 150
700 500
1 12
1-1/4 17
400 135
1-1/4 HC 45 550 185
1-1/2 123 350 110 400 135
2 218 225 75 225 75
[1] Note: Maximum Operating Pressure ratings indicated are for fluid temperatures in range of -40°F to +150°F with minimum cylinder air
pressures of 95 PSIG. Fluid temperatures above 150°F (to a maximum of 450°F) or air cylinder pressures below 95 PSIG will lower the
Maximum Operating Pressure rating. Contact your Maxon representative with specific application details.
NOTE: Minimum ambient and fluid temperature limit is -40°F (-40°C). Maximum ambient temperature limit is +140°F (+60°C). Maximum fluid
temperature limit for standard body is +150°F (+66°C) at the pressure listed in the table above. Fluids up to 450°F can be used with a
reduction in the maximum inlet pressure (see Product Information Sheet 6300-1 & 2), and with special high temperature body can go up to
+550°F (+288°C).
Series Designation
Body Material
Manual 3020 3120 3220 3320 3020-HD 3120-HD 3220-HD 3320-HD
*Sanctioned ser vice fuels include: light oil (i.e. #1, 2 & 4) and preheated heavy oils (i.e. #5 & 6) with maximum viscosity of 5000 SSU
solenoid, which opens the valve assembly. Contact your Maxon representative for optional
8/94
Notes

All Maxon Rising Stem Gate Valves carry a two- WARNING: Do not attempt field repair of ACTIONAIR®
part trim identification (for example, Trim 1-1). valve body or pneumatic actuator. Any field altera-
The first digit (a 1, 2, 3 or 4 before the hyphen) tions void all warranties.
identifies valve body and bonnet material as
shown in Table 1 below.
The second digit (a 1 or 2 after the hyphen)
identifies the specific internals used, as de-
scribed in Table 2 and identified in the sketches
at right.
fuel gases and oils (for example, natural gas,
propane, butane, clean atmosphere gases, #1
and #2 fuel oil).
Internal trim -2 may be required for such
gases as coke oven, refinery, town or off-gas.
Contact Maxon with specific fuel analysis for
prices and/or availability.
Normally closed and normally open threaded
material specifications.
The drawing at right carries item numbers
matching those in Table 2. This information is
furnished for identification only, not for ordering
parts.
Table 1: Body (item 1) and Bonnet (item 2) Specifications


Item Trim: -1 Trim: -2
Description
No. 3/4" - 2" 2-1/2" - 3" 4", 6" (HC) CP (2-1/2" - 4") 3/4" -2" 4", 6" (HC) CP (2-1/2" - 4")
#440-F #416 #303 #440-F #303 SS #303 SS #303 SS
3 Seat
Stainless Steel Stainless Steel Stainless Steel Stainless Steel (Hard Faced) (Hard Faced) (Hard Faced)
80-55-06 80-55-06 80-55-06
80-55-06 80-55-06 80-55-06 80-55-06
4 Disc Ductile Iron Ductile Iron Ductile Iron
Ductile Iron Ductile Iron Ductile Iron Ductile Iron
(chrome plated) (chrome plated) (chrome plated)
Leadaloy Ductile Iron Low-Carbon Steel Low-Carbon Steel Leadaloy Low-Carbon Steel Low-Carbon Steel
5 Follow Ring
(nickel plated) (nickel plated) (nickel plated) (nickel plated) (nickel plated) (nickel plated) (nickel plated)
6 Seat O-Ring Buna N Buna N Buna N Buna N Viton Viton Viton
7 Gasket O-Ring Buna N Buna N Buna N Buna N Viton Viton Viton
Wavy-Spring #302 #302 #302 #302 #302 #302 #302
8
Washer Stainless Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel
Steel Steel Steel Steel Steel Steel Steel
9 Stem
(chrome plated) (chrome plated) (chrome plated) (chrome plated) (chrome plated) (chrome plated) (chrome plated)
#1070 Carbon #1070 Carbon #420
10 Stem/Disc Pins --- --- --- ---
Steel (hardened) Steel (hardened) Stainless Steel
11 Stem O-Rings Buna N Buna N Buna N Buna N Viton Viton Viton
#17-7 #17-7 #17-7 #17-7 #17-7 #17-7 #17-7
12 Striker Plate
Stainless Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel
13 Bumper Viton Viton Viton Viton Viton Viton Viton
7/95
Page 6311A ACTIONAIR® Valves

Trim identification of Maxon Swinging Gate Shut- Non-listed services or unusual applications may
Off Valves is two-part. The first digit before the require upgrading of internal trim. Contact Maxon with
hyphen is a number (1, 2, 3 or 4) identifying body specific fuel analysis for price and availability.
material as shown in Table 1 below. The second digit The drawings shown carry item numbers matching
after the hyphen identifies a trim utilizing the materials those in Table 2. This information is furnished for
indicated in Table 2 below. identification only, not for ordering parts.
Standard sanctioned valves incorporating a cast
iron body will normally be identified by trim 1-B or 1- WARNING: Do not attempt field repair of ACTIONAIR®
D. Non-sanctioned valves with steel body will nor- valve body or pneumatic top actuator. Any field
mally be trim 2-D. alterations void all warranties.
Table 1: Body (item 1) Specifications


Item Part For 1/2" & 3/4" valves For 1" & 1-1/4" valves For 1-1/2" & 2" valves
No. Description Trim: -D Trim: -B Trim: -D Trim: -B Trim: -D
Hex Nut or Hard-Faced Cast Iron with #420 Hard-Faced Cast Iron with #420 Hard-Faced
2
Renewable Seat Steel Stainless Steel Seat Ring Steel Stainless Steel Seat Ring Steel
Zinc-Plated Zinc-Plated Zinc-Plated #416 Stainless #416 Stainless
3 Stem Bushing
#416 Stainless #416 Stainless #416 Stainless #416 Stainless #416 Stainless
4 Stem
5 Stem Spring
6 Disc Carrier Steel Steel Steel Steel Steel
Hard-Faced Hard-Faced Hard-Faced
7 Disc Nodular Iron Nodular Iron
Steel Steel Steel
8 Stem O-Rings Hydrin Viton Viton Viton Viton
9 Disc Spring
Inner Stem Thrust
10 Teflon Teflon Teflon Grafoil Teflon
Ring
11 Back-Up O-Rings Teflon Teflon Teflon --- ---
12 Body Gaskets Soft Iron Soft Iron Soft Iron Soft Iron Soft Iron
13 Stem Bushing Gasket Soft Iron Soft Iron Soft Iron Soft Iron Soft Iron
14 Body O-Ring Viton Viton Viton --- ---
15 Stem Packing Ring Grafoil --- --- --- ---
Zinc-Plated
16 Packing Nut --- --- --- ---
Steel
Steel (same as Steel (same as
17 Outlet Flange --- --- ---
body material) body material)

Typical construction of Typical construction of
1/2" through 3/4" screwed body valves 1" through 2" screwed body valves
Typical construction of
1-1/2" through 2" flanged body valves
7/96
Page 6312A ACTIONAIR® Valves
ACTIONAIR® Valve Nameplate Designations

Example:
3/4" ACTIONAIR 1 0 1 1 – HD – D – 2E – TD
Pipe Size “TD” Trip Delay Unit

“HT” High Temperature
Body
Body Function Switch Identification

1 = Normally-closed (gas) 0 = None
2 = Normally-open (gas) 1 = VCS-1 & VOS-1
3 = Normally-closed (oil) (general purpose)
1H = VCS-1 & VOS-1
(hermetically sealed)
1E = VCS-1 & VOS-1
Body Type (hazardous duty)
0 = Iron body (listed) 2 = VCS-2 & VOS-2
1 = Iron body (unlisted) (general purpose)
2 = Steel body (listed) 2H = VCS-2 & VOS-2
3 = Steel body (unlisted) (hermetically sealed)
2E = VCS-2 & VOS-2
(hazardous duty)
Operator Type
1 = Automatic solenoid valve
2 = Manual solenoid valve Solenoid Valve Voltage
3 = Power-to-XXX solenoid valve A = AC voltage
D = DC voltage
NOTE: Nameplate shows
specific voltage
Operator Cylinder Designation
There are five designations (#1 – #5) Operator Classification
which are automatically selected with GP = general purpose
actuator HD = hazardous duty
For quotation or order entry, specify:

1. Quantity 5. End connection:
2. Pipe size or fluid flow rate: – Threaded ends
– Specific fluid service – Socket-welded nipples
– Maximum line pressure – Flanged ends
– Fluid temperature 6. Operator type
– Viscosity (if oil service) 7. Operator classification
3. Body function 8. Solenoid valve voltage
4. Body type 9. Accessory options:
– Signal switch sets
– High temperature body
– Trip delay unit
10. Top assembly position:
– “R”, “L”, “TO” or “AW”
Electrical Data
General For normally closed versions
ACTIONAIR® Valves are air operated and the air (Series 1000 & 3000)
supply is controlled by a 115V 50/60 AC solenoid VCS (Valve Closed Switch) is actuated at the end of
valve wired directly into the control system. the closing stroke. VCS-1 is SPDT; VCS-2 is DPDT.
Switch wiring diagrams (reproduced below) are VOS (Valve Open Switch) is actuated at the end of
part of each valve assembly, summarizing electrical opening stroke. VOS-1 is SPDT; VOS-2 is DPDT.
data and wiring for a valve equipped with terminal Switch amp ratings are shown on the schematic
block and a full complement of optional switches. wiring diagrams below. DO NOT EXCEED rated
Good practice normally dictates that auxiliary amperage or total load shown.
switches in valves used for safety shut-off functions Diagrams show valve in its normally closed (at rest)
should be used for signal duty only, not to operate position with a full complement of switches. The
additional safety devices. indicated internal wiring is present only when the
appropriate auxiliary switches are specified.
Normally closed
Series 1000 & 3000
ACTIONAIR® Valves
(internal wiring schematic)
Power-to-Close
Series 1000 & 3000
ACTIONAIR® Valves
WARNING: ACTIONAIR®
Valves equipped with
Power-to-Close actuator
assembly require electrical
power and compressed air
to be opened. The valve
will remain in the opened
position for a minimum of
15 minutes on loss of
power. The valve will return
to its normally closed
position with a loss of
cylinder air or continuous
power to the overriding
solenoid valve.
8/94
Electrical Data (continued)

For normally open versions (Series 2000)
VCS (Valve Closed Switch) is actuated at the end Switch amp ratings are shown on the schematic
of the closing stroke. VCS-1 is SPDT; VCS-2 is wiring diagrams below. DO NOT EXCEED rated
DPDT. amperage or total load shown.
VOS (Valve Open Switch) is actuated at the end of Diagram shows valve in its normally open (at rest)
opening stroke. VOS-1 is SPDT; VOS-2 is DPDT. position with a full complement of switches. The
indicated internal wiring is present only when the
appropriate auxiliary switches are specified.
Normally open
Series 2000
ACTIONAIR® Valve
Power-to-Open
Series 2000
ACTIONAIR® Valve
Power-to-Open actuator
to be closed. The valve will
remain in the closed
to its normally open
solenoid valve.
Approximate envelope dimensions for Series 1000 & 2000

(Nominal, in inches)
Valve
Figure A B G H J K L M N
Size
3/4"
2 25.4 1.9 3.81 0.81
1"
1-1/4" I 2.43 26.5 --- --- --- ---
2 4 1.56
1-1/2" 2.69 27.2
2.19 4.38 1.88
2" 3.25 28.3
II 3.5 7 2 3/4 4 3 2.38
I 4.31 2.5 5 --- --- --- ---
2-1/2" 35.9 2.25
II 4.5 3.75 7.5 3/4 4 3.5 2.75
I 5.12 2.75 5.5 --- --- --- ---
3" 37.5 2.56
5.25 4 8 4 3.75 3
4" 5.43 37.7 2.27 3/4
II 4.5 9 4.5 3.75
4 HC 7.31 46.5 3.25 8
6" 8.38 51 5.25 10.5 3.62 7/8 5.5 4.75
Fig. II - Iron bodied flanged valves are flat-faced ANSI Class #125.
Steel bodied flanged valves are flat-faced ANSI Class #150.
Special "raised face" ANSI Class #150 steel bodied valves are
available. Contact Maxon representative for cost and availability.
9/90
Approximate envelope dimensions for Series 3000

(Nominal, in inches)
Valve
Figure A B E G H J K L M N P
Size
1/2"
1.19 29.1 6.8 4.34 3.19
3/4"
2.91 --- --- --- --- ---
1" I
1.44 29.5 7.2 4.78 3.25
1-1/4"
6.84 4.36
1-1/2" 1.88 32.4 7/8 4 3.06 2.25 3.7
9.4 7.02 11.4 2.72
II
2" 2.12 33.6 7.27 11.9 3/4 8 3.25 2.5 4.5
Fig. II - Steel bodied flanged valves are raised face ANSI Class #300

ACTIONAIR® Valves Page 6300-S-1
1. Read complete instructions before proceeding E. Mount valve so
and do not discard packing materials until any/all that open/shut
loose items are located. Also, make sure that the window indicator
installation of the Maxon valves will be in compli- [1] will be visible
ance with all applicable governmental, insurance to your operating
and/or agency requirements or codes, such as personnel.
NFPA-70, National Electric Code, CSA C22.1, F. Main system
Canadian Electric Code, etc. shut-off should
2. General considerations: always use a
A. Prior to shipment, each valve is operated manual leak-tight
electrically and cycled at rated and 1-1/2 upstream fuel
rated pressure while being leak tested. Every cock.
Maxon valve is operationally tested and G. Time lag between
meets the requirements of ANSI B16.104 valve action and
Class VI Seat Leakage. fluid flow (or flame
B. Inspect your valve for any shipping damage. response) is
Contact Maxon Corporation with the valve’s reduced if valve is
serial number (printed on the valve's name- located near the
plate) for replacement and/or repair parts. burner (or outlet).
C. Read the nameplate on your valve. This 4. Wire the valve in
gives the maximum pressure, temperature accordance with all
limitation, voltage requirements and service applicable codes and standards. Supply voltages
conditions of your specific valve. DO NOT must agree with valve’s nameplate voltage within
exceed nameplate ratings. -15%/+10% AC for proper operation. For electri-
D. Select mounting location carefully. Your cal wiring schematics, refer to appropriate Maxon
Maxon valve is designed to operate for many catalog literature and/or the wiring schematic
years if installed in a location that is cool, diagram affixed inside your valve’s access cover
clean and dry. plate.
3. Pipe the valve in the direction of the flow arrow A. The Maxon valve must be electrically
[3] on the valve body. The Maxon valve body can interlocked with your safety-limit devices in
shut off flow in one direction only. accordance with all applicable codes, stan-
A. Remove all thread and flange protectors dards, and the authority having jurisdiction
before installing valve in your service line. over the safety requirements for your overall
B. Teflon tape acts as a lubricant and greatly system installation. Normally, Maxon valves
reduces the pipe wrench turning force re- are electrically wired in series with all of your
quired to seal the threads. safety-limit devices. Therefore, any one
device can cause the valve to react. Each
valve was production tested when manufac-
tured. If it now appears inoperative, make
C. Good piping practice dictates that piping be sure it is being powered properly from and
independently supported, so that valve bodies through your control circuit.
are not placed in a bind. In addition, large B. Maintain integrity of Maxon top assembly
valves may require support. enclosure by using dust and water-tight
D. Clean pipe lines of foreign materials before electrical connectors. Use cable-sealing grips
installing valve into line. and strain-relief loops for any cord or cable.
Use internal sealing materials on all conduit
connections. Moisture can have a harmful
effect on valve internals if permitted to enter
per NFPA 86-4-2.4.3 (1995)

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Page 6300-S-2 ACTIONAIR® Valves

through wiring connectors. Make sure that all 6. Air actuated valves require clean, dry air at
access cover plates are in place and securely designated pressures. Outlets and vents, where
fastened. All cover screws should be tight- present, should be protected from accidental
ened using an alternate cross corner tighten- blockage.
ing pattern to the values shown below. NOTE: Although Maxon ACTIONAIR® Valves do
not require lubrication, they do contain Buna N
Cover Torque (in-lbs) bellows diaphragms in the air actuator sub-
.25"-20 access covers 50 assembly. Quality of the compressed air supply
must not contain any lubricant that is not compat-
ible to Buna N elastomers. Although many
While all covers are torqued at time of pro- synthetic oils and additives have been publicized
duction testing, torque should be rechecked for advanced lubricating characteristics in pneu-
periodically to ensure adequate sealing matic systems, strict attention should be exer-
protection. cised to avoid their use, even in small amounts.
5. Pre-operational exercising: 7. Air-operated ACTIONAIR® Valves equipped with
Prior to initial fluid flow start-up and with upstream the Power-to-Close or Power-to-Open actuator
manual cock still closed, operate the valve assembly require electrical power and com-
electrically for 10-15 cycles. This not only pro- pressed air to be actuated. The valve will remain
vides an electrical check, but also wipes valve in the actuated position for a minimum of 15
body disc and seat free of accumulated foreign minutes on loss of power. The valve will return to
matter. its normal position with a loss of cylinder air or
continuous power to the overriding solenoid valve.
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Maxon valves can and should be ordered in a

configuration compatible with planned piping, but if
open/shut indicator window is not visible and/or valve
orientation is not proper, the top assembly can be
rotated in 90° increments around the valve body
centerline axis by the following procedure:
1. Shut off all electrical and pneumatic power
and close off upstream manual cock.
disconnect power lead wires. (Tag carefully for
later re-assembly.)
3. Remove conduit, electrical leads, and any air
line connections.
actuator wands on auxiliary signal switches (see
5. Unscrew the two body bolts [4] screwed up from
the bottom to 1/4 inch. DO NOT completely
remove. These bolts secure the valve body [3] to
the valve’s top assembly housing [5].
6. Gently lift the top assembly [5] (not more than
1/4" in height); just enough to break the seal
between the valve body assembly and the rubber
This step may require loosening the stem
coupling [6] to permit components freedom of
movement. Auxiliary Switch Arrangement
FACTORY PERSONNEL.
7. Remove the two body bolts [4] screwed up from
the bottom (were partially unscrewed in step 5).
8. Carefully rotate top assembly to the desired
position in a plane parallel to the top of the valve
body casting. Rotate the top housing about 30°
beyond this position, and then rotate it back.
Reposition the top housing back down onto the Wiring Diagram
valve body casting. This should align the open/
shut indicator with its window and provide proper A– Number Coded Wires H– Mounting Screws
alignment of the internal mechanism. B– Rubber Grommet I – Spring Retainer Extension
C– Mounting Screws J– Switch Wand
9. Realign holes in valve body casting with the
corresponding tapped holes in the bottom of the Position Switch Position Switch
top assembly housing. Be sure the gasket is still E– Insulating Barrier L– Switch Wand
in place between the body and top housing. F– Bracket Mounting Pad M– Switch Mounting Bracket
G– Drive Pin & Locating Hole N– Gasket
Retighten the stem couplings.

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10. Reinsert the body bolts up from the bottom 11. Reconnect conduit, electrical leads, and all
through the body and carefully engage threads of pneumatic lines, then check that signal switch
the top assembly. Tighten securely. wands are properly positioned and that open/shut
indicator moves freely. Failure to correct any
Cover Torque (in-lbs) such misalignment can result in extensive
.25"-20 access covers 50 damage to the internal mechanism of your
valve.
12. Energize valve and cycle several times from
closed to full open position. Also electrically trip
the valve in a partially opened position to prove
valve operates properly.
13. Replace and secure side cover access plate
and place valve in service.
Maxon Maxon
“L” “R” “TO” “AW”

Four top assembly positions are available for view, the unidirectional valve body and the arrow on
most Maxon valves. When looking at the open/shut the valve body casting points in direction of fluid flow:
window indicator of a valve assembly, the motor (for to the right (position "R"), to the left (position "L"),
motorized version), or the operating handle (for towards you (position "TO") or away from you (posi-
manual version), will be on the left side of the top tion "AW"). With smaller size swinging gate valve
assembly. The valve body is on the bottom. From this bodies, only position "R" and position "TO" may be
used.
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Refer to appropriate catalog bulletin and specifi- All manual reset valves may be operated manu-
cation page for operating sequence applying to your ally when solenoid is electrically energized, but
specific valve. Never operate valve until all essen- electrical tripping is recommended for normal shut-
tial allied equipment is operative and any neces- downs.
sary purges completed. Failure of pneumatically Manual reset valves require two positive actions
operated valve to operate normally indicates that it is to open: a half rotation of handle to latch internal
not powered. Check this first! Then check air control mechanism, and a reversed half rotation of handle to
solenoid and/or cylinder air supply. open valve. This refers to normally closed valves.
Main system shut-off should always be accom- With normally open valves, the procedure is the
plished with an upstream leak-tight manual fuel same, but the valve body position (i.e., open or
cock. closed) is opposite to the normally closed version.
All Maxon valves react within a fraction of a Normally closed motorized valves begin open-
second when de-energized. One cycle drop in electri- ing cycle immediately upon being powered; motor
cally supplied power can cause this reaction. runs only until full open position is reached. Normally
open valves begin to close immediately, and motor
FAX (765) 286-8394

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the trouble.
Installation Instructions) and retest. If leakage does servicing and other shutdowns.
not stop, remove valve from service. All safety devices should be tested at least
Maxon valves are designed to be used with Periodic testing for tightness of manual or motor-
clean fluids. If foreign material is present in the ized shut-off valve closure is equally essential.
fuel line, it will be necessary to inspect the *per NFPA 86-Appendix B-4 (1995)
FAX (765) 286-8394
mCORPORATION


.75" – 3" NI
closed valves. For normally open versions (STO-
non-CP
MNI, STO-ANI, Fig. 1 & 2), reverse switch nomen-
clature. (VOS becomes VCS and vice versa.)
General: Shut off fuel supply upstream of valve, then Remove
de-energize valve electrically. side cover plate.
– Remove top or side cover to provide access, being Switches mount
careful not to damage gasket. on bracket. (See
"A" below)
valve type.
To replace existing switches:
– Note wand position and mounting hole location
– Install replacement switch in same mounting holes on
bracket and verify correct wand position. Fig. 2
– Replace existing wiring one connection at a time, 2.5" – 4" NI-CP
following original route and placement. 6" 808NI
– Check illustrations at right. If your valve uses a switch Remove
mounting bracket as in Fig. 1 & 2, mount switches to side cover plate.
bracket using the mounting holes appropriate for valve Switches mount
type and size. on bracket. (See
"B" below)
actuator, then move downward slightly, depressing
bracket mounting pad through drive pin holes, then tap
drive pin in until flush.
– Route wires to wiring compartment as shown,
then complete wiring connections and clean
out metal drilling chips from previous proce- Wand Position Mounting Brackets
For 1", 1.25" C.I. 3",4",6"(-2)
dure.
VOS switch wand & 2", 3" non-CP 3",4",6"(-2)
– Cycle valve, checking switch actuation points should be actuated 2-1/2"(-2)
2-1/2"(-1)
carefully. (VCS actuates at top of stem stroke, from above. VCS switch mounts VCS Switch
VOS at bottom.) Simultaneously the valve on back of bracket on back
Oil SOV &
body must be tested for switch continuity and 2"-6" Gas
1-1/2"
seat leakage. Bend VOS switch wands slightly
if necessary to insure valve is opening fully.
1-1/4"
3/4", 1"
VOS switch
B
– Replace gasket and cover, then return valve VCS switch wand
should be actuated
A on front VOS switch
on front
to service. Drive
Pins
from below. Bracket
Mounting
Holes
Bracket
Mounting
Slots

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Electrical Data
ACTIONAIR® Valves

Normally closed
Series 1000 & 3000
ACTIONAIR® Valves
Power-to-Close
Series 1000 & 3000
ACTIONAIR® Valves
Power-to-Close actuator
to be opened. The valve will
remain in the opened
to its normally closed
solenoid valve.
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Electrical Data
ACTIONAIR® Valves

Normally open
Series 2000
ACTIONAIR® Valves
Power-to-Open
Series 2000
ACTIONAIR® Valves
Power-to-Open actuator
to be closed. The valve will
remain in the closed
to its normally open
solenoid valve.

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Notes
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ACTIONAIR® Valves Page 6300-A/P-1
Assembly Numbers
.75" Series 1000: Normally closed, rising stem, threaded body
Series Designation
Size .75" C v
= 19 Iron Steel
Assembly Number
Automatic 1011 --- .75 1010GP

Manual 1021 --- .75 1020GP
Automatic HS 1011-HS --- .75 1010HS
Listed
Manual HS 1021-HS --- .75 1020HS
Automatic HD 1011-HD --- .75 1010HD
Manual HD 1021-HD --- .75 1020HD
Automatic 1111 --- .75 1110GP
Manual 1121 --- .75 1120GP
Manual HS 1121-HS --- .75 1120HS
Unlisted Power-to-Close 1131 --- .75 1130GP
Power-to-Close HS 1131-HS --- .75 1130HS
Manual HD 1121-HD --- .75 1120HD
Power-to-Close HD 1131-HD --- .75 1130HD
Spare Parts
VOS-1/VCS-1 (GP) 38433
VO2-2/VCS-2 (GP) 38434
Switch VOS-1/VCS-2 (HS) 38435
Sets VOS-2/VCS-2 (HS) 38436
VOS-1/VCS-1 (HD) 37468
VOS-2/VCS-2 (HD) 37485
KEY: GP = General Pur pose; HD = Hazardous Duty; HS = Hermetically Sealed
Descriptions of segment choices are listed on pages 6300-A/P-20 & 6300-A/P-21
Segment choices are as follows for configured Segment choices are as follows for "Power-to-
ACTIONAIR® Valves: Close" configured ACTIONAIR® Valves:
• Fuel • Fuel
• Solenoid voltage • Primary solenoid voltage
• Cylinder pressure • Secondary solenoid voltage
• Solenoid valve body and tubing material • Cylinder pressure
• Enclosure rating • Enclosure rating
• VOS & VCS switch • VOS & VCS switch
• Time delay • Top assembly position
• Top assembly position • Tagging
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Page 6300-A/P-2 ACTIONAIR® Valves
Assembly Numbers
1" Series 1000: Normally closed, rising stem, threaded body
Series Designation
Size 1" Cv = 20 Iron Steel
Assembly Number
Automatic 1011 1211 1 1010GP

Manual 1021 1221 1 1020GP
Automatic HS 1011-HS 1111-HS 1 1010HS
Listed
Manual HS 1021-HS 1221-HS 1 1020HS
Automatic HD 1011-HD 1211-HD 1 1010HD
Manual HD 1021-HD 1221-HD 1 1020HD
Automatic 1111 1311 1 1110GP
Manual 1121 1321 1 1120GP
Unlisted Power-to-Close 1131 1331 1 1130GP
Power-to-Close HS 1131-HS 1331-HS 1 1130HS
Power-to-Close HD 1131-HD 1331-HD 1 1130HD
Spare Parts
VOS-1/VCS-1 (GP) 38433
VO2-2/VCS-2 (GP) 38434
VOS-1/VCS-1 (HD) 37468
VOS-2/VCS-2 (HD) 37485

• Fuel • Fuel
• Tagging
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Assembly Numbers
1.25" Series 1000: Normally closed, rising stem, threaded body
Series Designation
Size 1.25" Cv = 44 Iron Steel
Assembly Number
Automatic 1011 --- 1.25 1010GP

Manual 1021 --- 1.25 1020GP
Automatic HS 1011-HS --- 1.25 1010HS
Listed
Manual HS 1021-HS --- 1.25 1020HS
Automatic HD 1011-HD --- 1.25 1010HD
Manual HD 1021-HD --- 1.25 1020HD
Automatic 1111 --- 1.25 1110GP
Manual 1121 --- 1.25 1120GP
Automatic HS 1111-HS --- 1.25 1110HS
Manual HS 1121-HS --- 1.25 1120HS
Unlisted Power-to-Close 1131 --- 1.25 1130GP
Power-to-Close HS 1131-HS --- 1.25 1130HS
Automatic HD 1111-HD --- 1.251110HD
Manual HD 1121-HD --- 1.25 1120HD
Power-to-Close HD 1131-HD --- 1.25 1130HD
Spare Parts
VOS-1/VCS-1 (GP) 38433
VO2-2/VCS-2 (GP) 38434
VOS-1/VCS-1 (HD) 38791
VOS-2/VCS-2 (HD) 38829
• Fuel • Fuel
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Assembly Numbers
1.5" Series 1000: Normally closed, rising stem, threaded body
Series Designation
Assembly Number
Automatic 1011 1211 1.5 1010GP

Manual 1021 1221 1.5 1020GP
Automatic HS 1011-HS 1111-HS 1.5 1010HS
Listed
Manual HS 1021-HS 1221-HS 1.5 1020HS
Automatic HD 1011-HD 1211-HD 1.5 1010HD
Manual HD 1021-HD 1221-HD 1.5 1020HD
Automatic 1111 1311 1.5 1110GP
Manual 1121 1321 1.5 1120GP
Manual HS 1121-HS 1321-HS 1.5 1120HS
Unlisted Power-to-Close 1131 1331 1.5 1130GP
Power-to-Close HS 1131-HS 1331-HS 1.5 1130HS
Manual HD 1121-HD 1321-HD 1.5 1120HD
Power-to-Close HD 1131-HD 1331-HD 1.5 1130HD
Spare Parts
VOS-1/VCS-1 (GP) 38433
VO2-2/VCS-2 (GP) 38434
VOS-1/VCS-1 (HD) 38833
VOS-2/VCS-2 (HD) 38853
• Fuel • Fuel
• Tagging
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Assembly Numbers
2" Series 1000: Normally closed, rising stem
Series Designation
Assembly Number
Automatic 1011 1211 2 1010GP

Manual 1021 1221 2 1020GP
Listed
Automatic 1111 1311 2 1110GP
Manual 1121 1321 2 1120GP
Spare Parts
VOS-1/VCS-1 (GP) 38433
VO2-2/VCS-2 (GP) 38434
VOS-1/VCS-1 (HD) 38903
VOS-2/VCS-2 (HD) 38907
• Fuel • Fuel
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• Tagging
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Assembly Numbers
2.5" Series 1000: Normally closed, rising stem
Series Designation
Assembly Number
Automatic 1011 1211 2.5 1010GP

Manual 1021 1221 2.5 1020GP
Listed
Manual HS 1021-HS 1221-HS 2.5 1020HS
Manual HD 1021-HD 1221-HD 2.5 1020HD
Automatic 1111 1311 2.5 1110GP
Manual 1121 1321 2.5 1120GP
Manual HS 1121-HS 1321-HS 2.5 1120HS
Manual HD 1121-HD 1321-HD 2.5 1120HD
Spare Parts
VOS-1/VCS-1 (GP) 37803
VO2-2/VCS-2 (GP) 37804
VOS-1/VCS-1 (HD) 38772
VOS-2/VCS-2 (HD) 38776
• Fuel • Fuel
• Tagging
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Assembly Numbers
3" Series 1000: Normally closed, rising stem
Series Designation
Assembly
Automatic 1011 1211 3 1010GP

Manual 1021 1221 3 1020GP
Listed
Automatic 1111 1311 3 1110GP
Manual 1121 1321 3 1120GP
Spare Parts
VOS-1/VCS-1 (GP) 37803
VO2-2/VCS-2 (GP) 37804
VOS-1/VCS-1 (HD) 38772
VOS-2/VCS-2 (HD) 38776
• Fuel • Fuel
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Assembly Numbers
4" Series 1000: Normally closed, rising stem, flanged body
Series Designation
Assembly Number
Automatic 1011 1211 4 1010GP

Manual 1021 1221 4 1020GP
Listed
Automatic 1111 1311 4 1110GP
Manual 1121 1321 4 1120GP
Spare Parts
VOS-1/VCS-1 (GP) 37803
VO2-2/VCS-2 (GP) 37804
VOS-1/VCS-1 (HD) 38772
VOS-2/VCS-2 (HD) 38776

configured ACTIONAIR® Valves: "Power-to-Close" configured ACTIONAIR®
• Fuel Valves:
• Body trim • Fuel
• Body connection • Body trim
• Minimum fuel/ambient temperature • Body connection
• Maximum fuel temperature • Minimum fuel/ambient temperature
• Maximum ambient temperature • Maximum fuel temperature
• Solenoid voltage • Maximum ambient temperature
• Cylinder pressure • Primary solenoid voltage
• Solenoid valve body and tubing material • Secondary solenoid voltage
• Enclosure rating • Cylinder pressure
• VOS & VCS switch • Enclosure rating
• Time delay • VOS & VCS switch
• Top assembly position • Top assembly position
• Tagging • Tagging
m CORPORATION

Assembly Numbers
4" HC Series 1000: Normally closed, rising stem, flanged body
Series Designation
Size 4"HC Cv = 903
Iron Steel
Assembly Number
Automatic 1011 1211 4HC 1010GP

Manual 1021 1221 4HC 1020GP
Automatic HS 1011-HS 1111-HS 4HC 1010HS
Listed
Manual HS 1021-HS 1221-HS 4HC 1020HS
Automatic HD 1011-HD 1211-HD 4HC 1010HD
Manual HD 1021-HD 1221-HD 4HC 1020HD
Automatic 1111 1311 4HC 1110GP
Manual 1121 1321 4HC 1120GP
Automatic HS 1111-HS 1311-HS 4HC 1110HS
Manual HS 1121-HS 1321-HS 4HC 1120HS
Unlisted Power-to-Close 1131 1331 4HC 1130GP
Power-to-Close HS 1131-HS 1331-HS 4HC 1130HS
Automatic HD 1111-HD 1311-HD 4HC 1110HD
Manual HD 1121-HD 1321-HD 4HC 1120HD
Power-to-Close HD 1131-HD 1331-HD 4HC 1130HD
Spare Parts
VOS-1/VCS-1 (GP) 37803
VO2-2/VCS-2 (GP) 37804
VOS-1/VCS-1 (HD) 38780
VOS-2/VCS-2 (HD) 38784
• Fuel • Fuel
m
• Tagging
CORPORATION
Assembly Numbers
6" HC Series 1000: Normally closed, rising stem, flanged body
Series Designation
Size 6"HC Cv = 1230
Iron Steel
Assembly Number
Automatic 1011 1211 6 1010GP

Manual 1021 1221 6 1020GP
Listed
Automatic 1111 1311 6 1110GP
Manual 1121 1321 6 1120GP
Spare Parts
VOS-1/VCS-1 (GP) 37803
VO2-2/VCS-2 (GP) 37804
VOS-1/VCS-1 (HD) 38788
VOS-2/VCS-2 (HD) 38792

• Fuel • Fuel
• Tagging
mCORPORATION

Assembly Numbers
.75" Series 2000: Normally open, rising stem, threaded body
Series Designation
Size .75" C v
= 19
Iron Steel
Assembly Number
Automatic 2011 --- .75 2010GP

Manual 2021 --- .75 2020GP
Listed
Manual HS 2021-HS --- .75 2020HS
Manual HD 2021-HD --- .75 2020HD
Automatic 2111 --- .75 2110GP
Manual 2121 --- .75 2120GP
Unlisted
Manual HS 2121-HS --- .75 2120HS
Manual HD 2121-HD --- .75 2120HD
Spare Parts
VOS-1/VCS-1 (GP) 38433
VO2-2/VCS-2 (GP) 38434
VOS-1/VCS-1 (HD) 37527
VOS-2/VCS-2 (HD) 38783
KEY: GP = General Purpose; HD = Hazardous Duty; HS = Hermetically Sealed
Segment choices are as follows for configured

ACTIONAIR® Valves:
• Fuel
• Body trim
• Body connection
• Cylinder pressure
• Solenoid valve body and tubing material
• VOS & VCS switch
• Time delay
• Tagging

m
CORPORATION
Assembly Numbers
1" Series 2000: Normally open, rising stem, threaded body
Series Designation
Size 1" C v
= 20 Iron Steel
Assembly Numbers
Automatic 2011 2211 1 2010GP

Manual 2021 2221 1 2020GP
Listed
Automatic 2111 2311 1 2110GP
Manual 2121 2321 1 2120GP
Unlisted
Spare Parts
VOS-1/VCS-1 (GP) 38433
VO2-2/VCS-2 (GP) 38434
VOS-1/VCS-1 (HD) 37527
VOS-2/VCS-2 (HD) 38783

ACTIONAIR® Valves:
• Fuel
• Body trim
• Body connection
• Time delay
• Tagging
mCORPORATION

Assembly Numbers
1.5" Series 2000: Normally open, rising stem, threaded body
Series Designation
Size 1.5" C v
= 53
Iron Steel
Assembly Number
Automatic 2011 2211 1.5 2010GP

Manual 2021 2221 1.5 2020GP
Listed
Manual HS 2021-HS 2221-HS 1.5 2020HS
Manual HD 2021-HD 2221-HD 1.5 2020HD
Automatic 2111 2311 1.5 2110GP
Manual 2121 2321 1.5 2120GP
Unlisted
Manual HS 2121-HS 2321-HS 1.5 2120HS
Manual HD 2121-HD 2321-HD 1.5 2120HD
Spare Parts
VOS-1/VCS-1 (GP) 38433
VO2-2/VCS-2 (GP) 38434
VOS-1/VCS-1 (HD) 38851
VOS-2/VCS-2 (HD) 38865

ACTIONAIR® Valves:
• Fuel
• Body trim
• Body connection
• Time delay
• Tagging

m
CORPORATION
Assembly Numbers
2" Series 2000: Normally open, rising stem
Series Designation
Size 2" C v
= 86
Iron Steel
Assembly Number
Automatic 2011 2211 2 2010GP

Manual 2021 2221 2 2020GP
Listed
Automatic 2111 2311 2 2110GP
Manual 2121 2321 2 2120GP
Unlisted
Spare Parts
VOS-1/VCS-1 (GP) 38433
VO2-2/VCS-2 (GP) 38434
VOS-1/VCS-1 (HD) 38905
VOS-2/VCS-2 (HD) 38909

ACTIONAIR® Valves:
• Fuel
• Body trim
• Body connection
• Time delay
• Tagging
mCORPORATION

Assembly Numbers
.375" Series 3000: Normally closed, swinging gate, threaded body
Series Designation
Size .375" Cv = 3.4
Iron
Assembly Number
Automatic 3011 .375 3010GP

Manual 3021 .375 3020GP
Automatic HS 3011-HS .375 3010HS
Listed
Manual HS 3021-HS .375 3020HS
Automatic HD 3011-HD .375 3010HD
Manual HD 3021-HD .375 3020HD
Automatic 3111 .375 3110GP
Manual 3121 .375 3120GP
Automatic HS 3111-HS .375 3110HS
Manual HS 3121-HS .375 3120HS
Unlisted Power-to-Close 3131 .375 3130GP
Power-to-Close HS 3131-HS .375 3130HS
Automatic HD 3111-HD .375 3110HD
Manual HD 3121-HD .375 3120HD
Power-to-Close HD 3131-HD .375 3130HD
Spare Parts
VOS-1/VCS-1 (GP) 38433
VO2-2/VCS-2 (GP) 38434
VOS-1/VCS-1 (HD) 38833
VOS-2/VCS-2 (HD) 38853
• Fuel • Fuel
m
• Tagging
CORPORATION
Assembly Numbers
Series Designation
Size .5" C v
= 3.4
Iron Steel
Assembly Number
Automatic 3011 3212 .5 3010GP

Manual 3021 3222 .5 3020GP
Automatic HS 3011-HS 3212-HS .5 3010HS
Listed
Manual HS 3021-HS 3222-HS .5 3020HS
Automatic HD 3011-HD 3212-HD .5 3010HD
Manual HD 3021-HD 3222-HD .5 3020HD
Automatic 3111 3312 .5 3110GP
Manual 3121 3322 .5 3120GP
Manual HS 3121-HS 3322-HS .5 3120HS
Unlisted Power-to-Close 3131 3332 .5 3130GP
Power-to-Close HS 3131-HS 3332-HS .5 3130HS
Manual HD 3121-HD 3322-HD .5 3120HD
Power-to-Close HD 3131-HD 3332-HD .5 3130HD
Spare Parts
VOS-1/VCS-1 (GP) 38433
VO2-2/VCS-2 (GP) 38434
VOS-1/VCS-1 (HD) 38833
VOS-2/VCS-2 (HD) 38853

• Fuel • Fuel
• Tagging
mCORPORATION

Assembly Numbers
Series Designation
Size .75" Cv = 9.6
Iron Steel
Assembly Number
Automatic 3011 3212 .75 3010GP

Manual 3021 3222 .75 3020GP
Listed
Manual HS 3021-HS 3222-HS .75 3020HS
Manual HD 3021-HD 3222-HD .75 3020HD
Automatic 3111 3312 .75 3110GP
Manual 3121 3322 .75 3120GP
Manual HS 3121-HS 3322-HS .75 3120HS
Unlisted Power-to-Close 3131 3332 .75 3130GP
Power-to-Close HS 3131-HS 3332-HS .75 3130HS
Manual HD 3121-HD 3322-HD .75 3120HD
Power-to-Close HD 3131-HD 3332-HD .75 3130HD
Spare Parts
VOS-1/VCS-1 (GP) 38433
VO2-2/VCS-2 (GP) 38434
VOS-1/VCS-1 (HD) 38833
VOS-2/VCS-2 (HD) 38853

• Fuel • Fuel
• Tagging

m
CORPORATION
Assembly Numbers
1" Series 3000: Normally closed, swinging gate, threaded body
Series Designation
Assembly Number
Automatic 3011 3212 1 3010GP

Manual 3021 3222 1 3020GP
Listed
Automatic 3111 3312 1 3110GP
Manual 3121 3322 1 3120GP
Spare Parts
VOS-1/VCS-1 (GP) 38433
VO2-2/VCS-2 (GP) 38434
VOS-1/VCS-1 (HD) 38903
VOS-2/VCS-2 (HD) 38907

• Fuel • Fuel
• Tagging
mCORPORATION

Assembly Numbers
1.25" Series 3000: Normally closed, swinging gate, threaded body
Series Designation
Size 1.25" Cv = 17 (45 for HC)
Iron Steel
Assembly Number
Automatic 3011 3212 1.25 3010GP

Manual 3021 3222 1.25 3020GP
Listed
Manual HS 3021-HS 3222-HS 1.25 3020HS
Manual HD 3021-HD 3222-HD 1.25 3020HD
Automatic 3111 3312 1.25 3110GP
Manual 3121 3322 1.25 3120GP
Manual HS 3121-HS 3322-HS 1.25 3120HS
Manual HD 3121-HD 3322-HD 1.25 3120HD
Spare Parts
VOS-1/VCS-1 (GP) 38433
VO2-2/VCS-2 (GP) 38434
VOS-1/VCS-1 (HD) 38903
VOS-2/VCS-2 (HD) 38907

• Fuel • Fuel
• Tagging

m
CORPORATION
Assembly Numbers
Segment Choice Detail - Series 1000 & 2000 ACTIONAIR Valves
Segment Choice
(DEFAULT is shaded)
AIR Air
AMM Ammonia
BUT Butane Gas
COKEC Coke Oven Gas (clean)
COKED Coke Oven Gas (dir ty)
DEL Delco Combusted
DIG Digester Gas
ENDO Endothermic AGA 302
EXO Exothermic
HYDC Hydrogen Gas (clean)
FUEL Type of fuel
HYDD Hydrogen Gas (diaphragm cell)
MFGD Manufactured Gas
NAT Natural Gas
NIT Nitrogen Gas
OXYH Oxygen High Pressure
OXYL Oxygen Low Pressure
PROP Propane Gas
REF Refinery Gas
SOUR Sour Natural Gas
TOWN Town Gas
11 1-1 Trim
12 1-2 Trim
21 2-1 Trim
BODY TRIM Type of valve body internal trim
22 2-2 Trim
32 3-2 Trim
42 4-2 Trim
ANSI_FFFLG ANSI Flat-Face Flanged
ANSI_RFFLG ANSI Raised-Face Flanged
DIN_FFFLG DIN Flat-Face Flanged
BODY CONNECTION Type of connection DIN_RFFLG DIN Raised-Face Flanged
IS0_THRD ISO Threaded
NIP Nippled
NIP_150 Nippled w/150# flanges
NIP_300 Nippled w/300# flanges
Minimum fuel and ambient NEG20 -20F temperature limit
MIN. FUEL/AMBIENT TEMPERATURE
temperature limit NEG40 -40F temperature limit
Choice of maximum fuel 125 125F/50C temperature limit
MAXIMUM FUEL TEMPERATURE
temperatures 140 140F/60C temperature limit
MAXIMUM AMBIENT TEMPERATURE Maximum ambient temperature 140 140F/60C temperature limit
m CORPORATION

Assembly Numbers
Segment Choice Detail - Series 1000 & 2000 ACTIONAIR Valves (continued)
Segment Choice
(DEFAULT is shaded)
115V50 115V 50Hz
115V60 115V 60Hz
Choice of primary solenoid valve 120VDC 120VDC
PRIM SOLENOID VALVE VOLTAGE
voltage 230V50 230V 50Hz
230V60 230V 60Hz
24VDC 24VDC
115V50 115V 50Hz
SEC SOLENOID VALVE VOLTAGE Power-to-Close valves only
115V60 115V 60Hz
65 65 PSI
Choice of cylinder pressure (in pounds 75 75 PSI
CYLINDER PRESSURE
per square inch) 85 85 PSI
95 95 PSI
Choice not available on Power-to- SS Stainless Steel materials
SOL VLV BODY & TUBING MAT'L
Close valves STD Standard materials
ENCLOSURE RATING Rating of top enclosure 4 NEMA 4 rated
NONE No switch ordered
VOS & VCS SWITCH Type of switches available VCS1_VOS1 VCS-1/VOS-1 switch
VCS2_VOS2 VCS-2/VOS-2 switch
Choice not available for Power-to-
TIME DELAY NO Choice not selected
Close valves
AW Away
L Left
TOP ASSEMBLY POSITION Valve body top assembly position
R Right
TO Toward
ALW Aluminum (wire-on)
NONE No tagging
TAGGING Types of tagging available
SSP Stainless Steel (permanent)
SSW Stainless Steel (wire-on)
Maximum operating pressure
MOPD RATING Calculated ---
differential rating
PRIM SOLENOID VALVE CURRENT Current of primary solenoid valve Calculated ---
SEC SOLENOID VALVE CURRENT Power-to-Close valves only Calculated ---
Not applicable to Power-to-Close
TIME DELAY CURRENT Calculated ---
valves
AGENCY SANCTIONS Calculated ---
valves

m CORPORATION
Assembly Numbers
Segment Choice Detail - Series 3000 ACTIONAIR Valves
Segment Choice
(DEFAULT is shaded)
AMM Ammonia
BUTL Butane (liquid)
JP4 JP4
KERO Kerosene
NO1OIL No. 1 Fuel Oil
NO2OIL No. 2 Fuel Oil
FUEL Type of fuel NO4OIL No. 4 Fuel Oil
OXYH Oxygen HighPressure
OXYL Oxygen Low Pressure
PNO4OIL (Preheated) No. 4 Fuel Oil
STEAM Steam
1B 1-B Trim
1D 1-D Trim
BODY TRIM Type of valve body internal trim 2D 2-D Trim
3D 3-D Trim
4D 4-D Trim
IS0_THRD ISO Threaded
NIP Nippled
BODY CONNECTION Type of connection
NIP_150 Nippled w/150# Flanges
Minimum fuel and ambient NEG20 -20F temperature limit
MIN. FUEL/AMBIENT TEMPERATURE
temperature limit NEG40 -40F temperature limit
150 150F/65C temperature limit
Choice of maximum fuel 250 250F/120C temperature limit
MAXIMUM FUEL TEMPERATURE
temperatures 450 450F/230C temperature limit
550 550F/290C temperature limit
MAXIMUM AMBIENT TEMPERATURE Maximum ambient temperature 140 140F/60C temperature limit
115V50 115V 50Hz
115V60 115V 60Hz
Choice of primary solenoid valve 120VDC 120VDC
PRIM SOLENOID VALVE VOLTAGE
voltage 230V50 230V 50Hz
230V60 230V 60Hz
24VDC 24VDC
115V50 115V 50Hz
SEC SOLENOID VALVE VOLTAGE Power-to-Close valves only
115V60 115V 60Hz
65 65 PSI
Choice of cylinder pressure (in 75 75 PSI
CYLINDER PRESSURE
pounds per square inch) 85 85 PSI
95 95 PSI
m CORPORATION

Assembly Numbers
Segment Choice Detail - Series 3000 ACTIONAIR Valves (continued)
Segment Choice
(DEFAULT is shaded)
Choice not available on Power-to- SS Stainless Steel materials
SOL VLV BODY & TUBING MAT'L
Close valves STD Standard materials
ENCLOSURE RATING Rating of top enclosure 4 NEMA 4 rated
NONE No switch ordered
VOS & VCS SWITCH Type of switches available VCS1_VOS1 VCS-1/VOS-1 switch
VCS2_VOS2 VCS-2/VOS-2 switch
Choice not available for Power-to-
TIME DELAY NO Choice not selected
Close valves
AW Away
L Left
TOP ASSEMBLY POSITION Valve body top assembly position
R Right
TO Toward
NONE No tagging
TAGGING Types of tagging available
SSP Stainless Steel (permanent)
SSW Stainless Steel (wire-on)
Maximum operating pressure
MOPD RATING Calculated ---
differential rating
PRIM SOLENOID VALVE CURRENT Current of primary solenoid valve Calculated ---
SEC SOLENOID VALVE CURRENT Power-to-Close valves only Calculated ---
TIME DELAY CURRENT Calculated ---
valves
AGENCY SANCTIONS FM Factory Mutual
valves

m CORPORATION
Assembly Numbers
Spare Items
Air Cylinder Assemblies

Rising Stem (gas) Series 1000 Series 2000 1130
Size Style SOV (auto) SOV (manual) STO (auto) STO (manual) PTC (auto)
.75 GP, HS, HD
38915
1 GP, HS, HD
1.25 GP, HS, HD 37947 --- 38914
1.5 GP, HS, HD
38915
2 GP, HS, HD
2.5 GP, HS, HD
3 GP, HS, HD 38309 38310
4 GP, HS, HD ---
4HC GP, HS, HD 38312 38313
6 GP, HS, HD 38314 38315
Swinging Gate - iron bodied (oil) Series 3000 3130

.375 GP, HS, HD
.5 GP, HS, HD
.75 GP, HS, HD 37947 --- 38914
1 GP, HS, HD
1.25 GP, HS, HD
Swinging Gate - steel bodied (oil) Series 3000 3130

.375 GP, HS, HD ---
.5 GP, HS, HD
.75 GP, HS, HD
38316 --- 38317
1 GP, HS, HD
1.25 GP, HS, HD
mCORPORATION

Assembly Numbers
Spare Items
Quick Exhaust Valve Assemblies
Rising Stem (gas) Series 1000 Series 2000 1130
GP, HS 38418 38417
.75
HD 38440 38428
38417
GP, HS 38418 38417
1
HD 38440 38428
GP, HS 38418 --- ---
1.25 38418 38416
HD 38440 --- ---
GP, HS 38418 38417
1.5
HD 38440 38428
38417
GP, HS 38418 38417
2
HD 38440 38428
GP, HS 37945 38443 37547
2.5
HD 39590 39585 39588
GP, HS 37945 38443 37547
3
HD 39590 39585 39588
GP, HS 37945 38443 37547
4 ---
HD 39590 39585 39588
GP, HS 37946 38445 37341
4HC
HD 39491 39587 39592
GP, HS 37946 38445 37341
6
HD 39591 39587 39592
Swinging Gate - iron bodied (oil) Series 3000 3130
GP, HS 38418
.375
HD 38440
GP, HS 38418
.5
HD 38440
GP, HS 38418
.75 38418 --- 38416
HD 38440
GP, HS 38418
1
HD 38440
GP, HS 38418
1.25
HD 38440
Swinging Gate - steel bodied (oil) Series 3000 3130

GP, HS
.375 --- --- --- --- ---
HD
GP, HS 37945 41571 37547
.5 --- ---
HD 39590 39585 39588
GP, HS 37945 41571 37547
.75 --- ---
HD 39590 39585 39588
GP, HS 37945 41571 37547
1 --- ---
HD 39590 39585 39588
GP, HS 37945 41571 37547
1.25 --- ---
HD 39590 39585 39588

m CORPORATION
Assembly Numbers
Spare Items
Solenoid Tube Assemblies

Rising Stem (gas)
Series 1000 Series 2000 1130 PTC (auto)
Size Style SOV (auto) SOV (manual) STO (auto) STO (manual) CS SS
CS SS CS SS CS SS CS SS sol to cyl sol to sol sol to cyl sol to sol
GP, HS 37567 41517 37566 41516 38446 41531 37550 41530 37553
.75
HD 37563 41513 37565 41515 37577 41527 37549 41529 37489
GP, HS 37567 41517 37566 41516 38446 41531 37550 41530 37553
1
HD 37563 41513 37565 41515 37577 41527 37549 41529 37489
GP, HS 37567 41517 37566 41516 37553
1.25 --- --- --- --- 37551
HD 37563 41513 37565 41515 37489
GP, HS 37567 41517 37566 41516 38446 41531 37550 41530 37553
1.5
HD 37563 41513 37565 41515 37577 41527 37549 41529 37489
GP, HS 37567 41517 37566 41516 38446 41531 37550 41530 37553
2
HD 37563 41513 37565 41515 37577 41527 37549 41529 37489
---
GP, HS 37571 41521 37570 41520 37557
2.5
HD 37564 41514 37562 41512 37490
GP, HS 37571 41521 37570 41520 37557
3
HD 37564 41514 37562 41512 37490
GP, HS 37571 41521 37570 41520 37557
4 --- 37552
HD 37564 41514 37562 41512 37490
GP, HS 37573 41523 37572 41522 37559
4HC
HD 37567 41517 37566 41516 37553
GP, HS 37575 41525 37574 41524 37561
6
HD 37569 41519 37568 41518 37555
Swinging Gate - iron bodied (oil)
Series 3000 3130 PTC (auto)
CS SS CS SS CS SS CS SS sol to cyl sol to sol sol to cyl sol to sol
GP, HS 37567 41517 37566 41516 37553
.375
HD 37563 41513 37565 41515 37489
GP, HS 37567 41517 37566 41516 37553
.5
HD 37563 41513 37565 41515 37489
GP, HS 37567 41517 37566 41516 37553
.75 --- 37551 ---
HD 37563 41513 37565 41515 37489
GP, HS 37567 41517 37566 41516 37553
1
HD 37563 41513 37565 41515 37489
GP, HS 37567 41517 37566 41516 37553
1.25
HD 37563 41513 37565 41515 37489
Swinging Gate - steel bodied (oil)
Series 3000 3130 PTC (auto)
CS SS CS SS CS SS CS SS sol to cyl sol to sol sol to cyl sol to cyl
GP, HS
.375 --- --- --- --- --- --- --- --- --- ---
HD
GP, HS 37571 41521 37570 41520 37557
.5
HD 37564 41514 37562 41512 37490
GP, HS 37571 41521 37570 41520 37557
.75 ---
HD 37564 41514 37562 41512 37490
--- 37552
GP, HS 37571 41521 37570 41520 37557
1
HD 37564 41514 37562 41512 37490
GP, HS 37571 41521 37570 41520 37557
1.25
HD 37564 41514 37562 41512 37490
m
CORPORATION

Assembly Numbers
Spare Items
Solenoid Valve Assemblies - SOV (auto)

Rising Stem (gas) Series 1010, 1110, 1210 & 1310
CS SS
Size Style
115v50 115v60 230v50 230v60 24vDC 120vDC 115v50 115v60 230v50 230v60 24vDC 120vDC
GP, HS 38821 38823 57130 39301 57145 57150 57163 57158
.75
HD 38647 38649 57128 39340 57143 57148 57161 57156
GP, HS 38821 38823 57130 39301 57145 57150 57163 57158
1
HD 38647 38649 57128 39340 57143 57148 57161 57156
GP, HS 38821 38823 57130 39301 57145 57150 57163 57158
1.25
HD 38647 38649 57128 39340 57143 57148 57161 57156
GP, HS 38821 38823 57130 39301 57145 57150 57163 57158
1.5
HD 38647 38649 57128 39340 57143 57148 57161 57156
GP, HS 38821 38823 57130 39301 57145 57150 57163 57158
2
HD 38647 38649 57128 39340 57143 57148 57161 57156
GP, HS 38821 38823 57130 39301 57145 57150 57163 57158
2.5
HD 38647 38649 57128 39340 57143 57148 57161 57156
GP, HS 38821 38823 57130 39301 57145 57150 57163 57158
3
HD 38647 38649 57128 39340 57143 57148 57161 57156
GP, HS 38821 38823 57130 39301 57145 57150 57163 57158
4
HD 38647 38649 57128 39340 57143 57148 57161 57156
GP, HS 38821 38823 57130 39301 57145 57150 57163 57158
4HC
HD 38647 38649 57128 39340 57143 57148 57161 57156
GP, HS 38821 38823 57130 39301 57145 57150 57163 57158
6
HD 38647 38649 57128 39340 57143 57148 57161 57156
Swinging Gate - iron bodied (oil) Series 3010 & Series 3110
CS SS
Size Style
GP, HS 38821 38823 57130 39301 57145 57150 57163 57158
.375
HD 38647 38649 57128 39340 57143 57148 57161 57156
GP, HS 38821 38823 57130 39301 57145 57150 57163 57158
.5
HD 38647 38649 57128 39340 57143 57148 57161 57156
GP, HS 38821 38823 57130 39301 57145 57150 57163 57158
.75
HD 38647 38649 57128 39340 57143 57148 57161 57156
GP, HS 38821 38823 57130 39301 57145 57150 57163 57158
1
HD 38647 38649 57128 39340 57143 57148 57161 57156
GP, HS 38821 38823 57130 39301 57145 57150 57163 57158
1.25
HD 38647 38649 57128 39340 57143 57148 57161 57156
Swinging Gate - steel bodied (oil) Series 3210 & Series 3310
CS SS
Size Style
GP, HS
.375 --- --- --- --- --- --- --- --- --- --- --- ---
HD
GP, HS 38821 38823 57130 39301 57145 57150 57163 57158
.5
HD 38647 38649 57128 39340 57143 57148 57161 57156
GP, HS 38821 38823 57130 39301 57145 57150 57163 57158
.75
HD 38647 38649 57128 39340 57143 57148 57161 57156
GP, HS 38821 38823 57130 39301 57145 57150 57163 57158
1
HD 38647 38649 57128 39340 57143 57148 57161 57156
GP, HS 38821 38823 57130 39301 57145 57150 57163 57158
1.25
HD 38647 38649 57128 39340 57143 57148 57161 57156

mCORPORATION
Assembly Numbers
Spare Items
Solenoid Valve Assemblies - SOV (manual)

CS SS
Size Style
115v50 115v60 230v50 230v60 120vDC 115v50 115v60 230v50 230v60 120vDC
GP, HS 38817 38819 39303 57169 57175 57181
.75
HD 37943 37582 39334 57167 57173 57179
GP, HS 38817 38819 39303 57169 57175 57181
1
HD 37943 37582 39334 57167 57173 57179
GP, HS 38817 38819 39303 57169 57175 57181
1.25
HD 37943 37582 39334 57167 57173 57179
GP, HS 38817 38819 39303 57169 57175 57181
1.5
HD 37943 37582 39334 57167 57173 57179
GP, HS 38817 38819 39303 57169 57175 57181
2
HD 37943 37582 39334 57167 57173 57179
GP, HS 38817 38819 39303 57169 57175 57181
2.5
HD 37943 37582 39334 57167 57173 57179
GP, HS 38817 38819 39303 57169 57175 57181
3
HD 37943 37582 39334 57167 57173 57179
GP, HS 38817 38819 39303 57169 57175 57181
4
HD 37943 37582 39334 57167 57173 57179
GP, HS 38817 38819 39303 57169 57175 57181
4HC
HD 37943 37582 39334 57167 57173 57179
GP, HS 38817 38819 39303 57169 57175 57181
6
HD 37943 37582 39334 57167 57173 57179
Swinging Gate - iron bodied (oil) Series 3020 & Series 3120
CS SS
Size Style
115v50 115v60 230v50 230v60 120vDC 115v50 115v60 230v50 230v60 120vDC
GP, HS 38817 38819 39303 57169 57175 57181
.375
HD 37943 37582 39334 57167 57173 57179
GP, HS 38817 38819 39303 57169 57175 57181
.5
HD 37943 37582 39334 57167 57173 57179
GP, HS 38817 38819 39303 57169 57175 57181
.75
HD 37943 37582 39334 57167 57173 57179
GP, HS 38817 38819 39303 57169 57175 57181
1
HD 37943 37582 39334 57167 57173 57179
GP, HS 38817 38819 39303 57169 57175 57181
1.25
HD 37943 37582 39334 57167 57173 57179
Swinging Gate - steel bodied (oil) Series 3220 & Series 3320
CS SS
Size Style
115v50 115v60 230v50 230v60 120vDC 115v50 115v60 230v50 230v60 120vDC
GP, HS
.375 --- --- --- --- --- ---
HD
GP, HS 38817 38819 39303 57169 57175 57181
.5
HD 37943 37582 39334 57167 57173 57179
GP, HS 38817 38819 39303 57169 57175 57181
.75
HD 37943 37582 39334 57167 57173 57179
GP, HS 38817 38819 39303 57169 57175 57181
1
HD 37943 37582 39334 57167 57173 57179
GP, HS 38817 38819 39303 57169 57175 57181
1.25
HD 37943 37582 39334 57167 57173 57179
mCORPORATION

Assembly Numbers
Spare Items
Solenoid Valve Assemblies - STO (auto)

CS SS
Size Style
GP, HS 38822 38824 57131 39302 57146 57151 57164 57159
.75
HD 38648 38650 57129 39341 57144 57149 57162 57157
GP, HS 38822 38824 57131 39302 57146 57151 57164 57159
1
HD 38648 38650 57129 39341 57144 57149 57162 57157
GP, HS 38822 38824 57131 39302 57146 57151 57164 57159
1.25
HD 38648 38650 57129 39341 57144 57149 57162 57157
GP, HS 38822 38824 57131 39302 57146 57151 57164 57159
1.5
HD 38648 38650 57129 39341 57144 57149 57162 57157
GP, HS 38822 38824 57131 39302 57146 57151 57164 57159
2
HD 38648 38650 57129 39341 57144 57149 57162 57157
GP, HS 38822 38824 57131 39302 57146 57151 57164 57159
2.5
HD 38648 38650 57129 39341 57144 57149 57162 57157
GP, HS 38822 38824 57131 39302 57146 57151 57164 57159
3
HD 38648 38650 57129 39341 57144 57149 57162 57157
GP, HS 38822 38824 57131 39302 57146 57151 57164 57159
4
HD 38648 38650 57129 39341 57144 57149 57162 57157
GP, HS 38822 38824 57131 39302 57146 57151 57164 57159
4HC
HD 38648 38650 57129 39341 57144 57149 57162 57157
GP, HS 38822 38824 57131 39302 57146 57151 57164 57159
6
HD 38648 38650 57129 39341 57144 57149 57162 57157
Solenoid Valve Assemblies - STO (manual)

CS SS
Size Style
115v50 115v60 230v50 230v60 120vDC 115v50 115v60 230v50 230v60 120vDC
GP, HS 38818 38820 39304 57170 57176 57182
.75
HD 37581 38398 39335 57166 57172 57178
GP, HS 38818 38820 39304 57170 57176 57182
1
HD 37581 38398 39335 57166 57172 57178
GP, HS 38818 38820 39304 57170 57176 57182
1.25
HD 37581 38398 39335 57166 57172 57178
GP, HS 38818 38820 39304 57170 57176 57182
1.5
HD 37581 38398 39335 57166 57172 57178
GP, HS 38818 38820 39304 57170 57176 57182
2
HD 37581 38398 39335 57166 57172 57178
GP, HS 38818 38820 39304 57170 57176 57182
2.5
HD 37581 38398 39335 57166 57172 57178
GP, HS 38818 38820 39304 57170 57176 57182
3
HD 37581 38398 39335 57166 57172 57178
GP, HS 38818 38820 39304 57170 57176 57182
4
HD 37581 38398 39335 57166 57172 57178
GP, HS 38818 38820 39304 57170 57176 57182
4HC
HD 37581 38398 39335 57166 57172 57178
GP, HS 38818 38820 39304 57170 57176 57182
6
HD 37581 38398 39335 57166 57172 57178

mCORPORATION
Assembly Numbers
Spare Items
Solenoid Valve Assemblies Solenoid Valve Assemblies

PTC - primary (auto) PTC - secondary (auto)
Rising Stem (gas) Series 1130 & Series 1330 Rising Stem (gas) Series 1130 & Series 1330
CS CS
Size Style Size Style
115v50 115v60 230v50 230v60 115v50 115v60 230v50 230v60
GP, HS 38815 57126 GP, HS 38813
.75 .75
HD 38657 57125 HD 38655
GP, HS 38815 57126 GP, HS 38813
1 1
HD 38657 57125 HD 38655
GP, HS 38815 57126 GP, HS 38813
1.25 1.25
HD 38657 57125 HD 38655
GP, HS 38815 57126 GP, HS 38813
1.5 1.5
HD 38657 57125 HD 38655
GP, HS 38815 57126 GP, HS 38813
2 2
HD 38657 57125 HD 38655
---
GP, HS 38815 57126 GP, HS 38813
2.5 2.5
HD 37583 57124 HD 37587
GP, HS 38815 57126 GP, HS 38813
3 3
HD 37583 57124 HD 37587
GP, HS 38815 57126 GP, HS 38813
4 4
HD 37583 57124 HD 37587
GP, HS 38815 57126 GP, HS 38813
4HC 4HC
HD 37583 57124 HD 37587
GP, HS 38815 57126 GP, HS 38813
6 6
HD 37583 57124 HD 37587
Swinging Gate - iron bodied (oil) Series 3130 Swinging Gate - iron bodied (oil) Series 3130
CS CS
115v50 115v60 230v50 230v60 115v50 115v60 230v50 230v60
GP, HS 38815 57126 GP, HS 38813
.375 .375
HD 38657 57125 HD 38655
GP, HS 38815 57126 GP, HS 38813
.5 .5
HD 38657 57125 HD 38655
GP, HS 38815 57126 GP, HS 38813
.75 .75 ---
HD 38657 57125 HD 38655
GP, HS 38815 57126 GP, HS 38813
1 1
HD 38657 57125 HD 38655
GP, HS 38815 57126 GP, HS 38813
1.25 1.25
HD 38657 57125 HD 38655
Swinging Gate - steel bodied (oil) Series 3330 Swinging Gate - steel bodied (oil) Series 3330
CS CS
115v50 115v60 230v50 230v60 115v50 115v60 230v50 230v60
GP, HS GP, HS
.375 --- --- .375 ---
HD HD
GP, HS 38815 57126 GP, HS 38813
.5 .5
HD 37583 57124 HD 37587
GP, HS 38815 57126 GP, HS 38813
.75 .75 ---
HD 37583 57124 HD 37587
GP, HS 38815 57126 GP, HS 38813
1 1
HD 37583 57124 HD 37587
GP, HS 38815 57126 GP, HS 38813
1.25 1.25
HD 37583 57124 HD 37587
mCORPORATION

Bulletin 6400
Maxon Series 8000 Air Actuated Valves
• Pneumatically actuated valves with powerful closing spring for reliable operation
• Compact design with integral solenoid, quick exhaust, switches and cylinder that protects components,
simplifies piping and minimizes space requirements
• Factory Mutual (FM) and CSA (6.5 C/I & 3.9) approved safety shut-off and vent valves
• Hazardous Location approved: Intrinsically Safe for Class I, Div. 1; Non-Incendive for Class I, Div. 2
• Top mounted 360-degree open-shut visual position indication
• Cast iron, carbon steel, low temperature carbon steel and stainless steel body assemblies with internal
trim options to handle general purpose or corrosive gases; oxygen compatibility available
• Ambient temperature ranges of -40°F (-40°C) to 140°F (60°C); Gas temperature range of -40°F (-40°C) to
212°F (100°C)
• Application flexibility provided with 3/4" through 4" line sizes (6" size pending) & line pressures up to 255
psig
• Actuator assemblies are field-replaceable and available in 120VAC 50/60 Hz, 240VAC 50/60 Hz, and
24VDC, rated for NEMA 4, NEMA 4X and IP65
• Unique bonnet design eliminates packing adjustments, reducing maintenance and minimizing drag on
closing
• Series 8000 Valves meet Fluid Control Institute (FCI) 70-2-1998 control valve standard for Class VI seat
leakage
Page 6402
Features & Benefits

combine a unique space-saving design with a
maintenance-free bonnet seal and a replaceable
actuator for easy installation and smooth,
trouble-free operation.
The valve's quick exhaust and powerful
closing spring provide valve closure in less
than one second and reliable, long-life operation.
Series 8000 Valve's compact design
simplifies piping design and minimizes space
requirements.
The field-replaceable actuator provides
easier maintenance and reduced downtime. The
actuator can also be rotated around the valve
body in 90° increments to fit your specific
application requirements.
A unique bonnet design eliminates packing
adjustments for reduced maintenance and
minimized drag on closing.
The top-mounted open-shut indicator is
visible from all angles for easy proof of valve
position.
2" Series 8000 Valve

Page 6403
Switch Assemblies
• Provides positive valve position - open or
closed
• Complies with "proof of closure" requirements
• Easily integrates with an analog control
system, DCS or PLC
VOS2/VCS2 Switch Assemblies (shown at right)

with Terminal Blocks and Leads Mounted
• Factory-mounted to terminal strip to shorten Standard Switch Assem- IP67 Switch Assembly
installation time bly for General Purpose for Non-Incendive Class
• Easy replacement (2 screws) and Intrinsically Safe I Div. 2 Areas
• Locating pins guarantee accurate Class I Div.1 Areas
mounting position
• No adjustment required
Body and Trim Selections Normally-closed shut-off valves use

instrument air to open quickly. Removal of
Cast iron, carbon steel and stainless steel body electrical signal allows release of control
assemblies feature metal-to-metal seating that air through solenoid and quick exhaust
meets FCI 70-2-1998 control valve standard for valve allowing the powerful closing spring
Class VI seat leakage. Industrial-strength PEEK in the Series 8000 Valve to close the
seats and followers are available for corrosive fluids valve in less than one second. Optional
that contain traces of H2S and CO2. Stainless steel speed control set kit available for slower
body assemblies are constructed per NACE opening adjustment.
Standard MR0175. Contact Series 8011, 8012 & 8013
Maxon with your specific require 40-100 psig instrument air
application details. Series 8111, 8112 & 8113
require 65-100 psig instrument air
Valve bodies are available in
your choice of threaded,
Normally-open vent valves use instru-
flanged and socket-
ment air to close quickly. Removal of
welded connections.
electrical signal allows release of control
Bodies are currently
air through solenoid and quick exhaust
available in 3/4"
valve allowing the Series 8000 Valve to
through 4" line
open in less than one second. Optional
sizes (6" size under
speed control set kit available for slower
development) with
closing adjustment.
line pressures up to
Series 8021, 8022 & 8023
255 psig. require 45-100 psig instrument air
Series 8121, 8122 & 8123
require 70-100 psig instrument air
Page 6404

Safety shut-off and vent valve approved per FM Class 7400 and CSA 6.5 standards
• FM Approved for Hazardous Locations • CSA Approved for Hazardous Locations
Non-incendive Protection Method Non-incendive Protection Method

(max ambient temp 140°F/60°C) (max ambient temp 140°F/60°C)
Class I, Div. 2 Group A,B,C,D; Temp. Code T4 Class I, Div. 2 Group A,B,C,D; Temp. Code T4
Class I, Zone 2, Group IIC; Temp. Code T4 Class II, Div. 2 Group F,G; Temp. Code T4
Class II, Div. 2 Group F,G; Temp. Code T4 Class III, Div. 2; Temp. Code T4
Class III, Div. 2; Temp. Code T4
Intrinsically Safe Protection Method Intrinsically Safe Protection Method

(max ambient temp 122°F/50°C) (max ambient temp 122°F/50°C)
Class I, Div. 1 Group A,B,C,D; Temp. Code T5 Class I, Div. 1 Group A,B,C,D; Temp. Code T5
Class II, Div. 1 Group E,F,G; Temp. Code T5 Class II, Div. 1 Group E,F,G; Temp. Code T5
Class III, Div. 1; Temp. Code T5 Class III, Div. 1; Temp. Code T5
FM approved for fluid temperatures -40°F (-40°C) to 140°F (60°C)
CSA approved for fluid temperatures -40°F (-40°C) to 212°F (100°C)
Series Designations and Available Sizes
Normally-Closed Shut-off Valves Normally-Open Vent Valves

Series 8011 Series 8111 Series 8021 Series 8121
General Purpose General Purpose General Purpose General Purpose

Class I, II, Div.2 Class I, II, Div.2 Class I, II, Div.2 Class I, II, Div.2

Class I, Div. 1 Class I, Div. 1 Class I, Div. 1 Class I, Div. 1
Standard MOPD ratings High pressure MOPD ratings Standard MOPD ratings High pressure MOPD ratings
CP body only All bodies CP body only All bodies
2.5" through 4" sizes .75" through 4" sizes 2.5" through 4" .75" through 4" sizes
7/03
Series 8000 Air Actuated Valves Page 6405
Valve Model Number Description

Every Maxon Series 8000 Valve can be accurately number. The first five choices determine the valve’s
identified by the model number shown on the valve configured item number. Valve body and actuator
nameplate. The example below shows a typical Series options are identified by the next eight characters in
8000 Valve model number, along with the available the model number.
choices for each item represented in the model
Configured Item Number Valve Body Actuator
Classification
Internal Trim
Body Seals
Connection
Secondary
& Bumper
Enclosure
Language
Pressure
Capacity
Package
Position
Material
Primary
Voltage
Normal
Switch
Option
Rating
Rating
Valve
Body
Body
Flow
Area
Size
300 C 81 1 1 A A 1 1 B 1 A 1
Valve Size Body Connection Primary Voltage

075 –.75” A – ANSI Threaded A – 120VAC 50Hz
100 – 1” B – ANSI Flanged B – 120VAC 60Hz
125 – 1.25” C – ISO Threaded D – 240VAC 50Hz
150 – 1.5” D – DIN Flanged E – 240VAC 60Hz
200 – 2” E – Socket Welded Nipple G – 24VDC
250 – 2.5” F – Socket Welded Nipple X – Special
300 – 3” w/ANSI Class 150 Flanges * - Valve Body Only
400 – 4” G – Socket Welded Nipple
600 – 6” (future availability) w/ANSI Class 300 Flanges Switch Option
X – Special 0 – None
Flow Capacity * - Actuator Only 1 – VOS1/VCS1
S – Standard 2 – VOS2/VCS2
C – CP Body Construction Body Seals & Bumper X – Special
A – Buna N * - Valve Body Only
Pressure Rating B – Viton
80 – Pneumatic Standard Pressure C – Ethylene Propylene Enclosure Rating
81 – Pneumatic High Pressure (see note 2) A – NEMA 4, IP65
X – Special B – NEMA 4X, IP65
Normal Position * - Actuator Only X – Special
1 – Normally-Closed Shut-Off Valve * - Valve Body Only
(also actuator only) Body Material
2 – Normally-Open Vent Valve 1 – Cast Iron Secondary Language
(also actuator only) 2 – Carbon Steel 1 – French
5 – Stainless Steel * - Valve Body Only
Area Classification 6 – Low Temp Carbon Steel
1 – General Purpose X – Special
2 – Non-incendive, Class I Div. 2 * - Actuator Only
3 – Intrinsically Safe, Class I Div. 1
(see note 1) Internal Trim Package
Note 1: 122°F (50°C) maximum
4 – Valve Body Only 1 – Trim Package 1
ambient temperature limit
X - Special 2 – Trim Package 2 Note 2: -0°F (-17°C) minimum
3 – Trim Package 3 ambient temperature limit
4 – Trim Package 2, Oxy Clean
5 – Trim Package 3, Oxy Clean
X – Special
* - Actuator Only
7/03
Page 6406 Series 8000 Air Actuated Valves
Valve Body Assembly Options & Specifications

Series 8000 Normally-Closed Shut-Off Valves
Actuator Body
Nominal Flow Body Trim Package Cv MOPD Rating
Pressure Connections
Pipe Size Capacity Material Options Rating (psig)
Class Available
.75" Std. High Press. A, C 1, Cast Iron 1, 2, 3 19 200
A, C 1, Cast Iron 200
1" Std. High Press. 2,6 Carbon Steel 1, 2, 3 20
A, C, E, F, G 255
5, Stainless Steel
1.25" Std. High Press. A, C ona
1, Cast Ire 1, 2 45 200
A, C
Ar
1,gCnast Iron 200
si
1.5" Std. High Press. D2e,6 Carbon Steel 1, 2, 3 53
m
A, C, E, F, G 255
timu 5, Stainless Steel
B,pC, D
A, O 1, Cast Iron 200
A, C, E, F, G 255
5, Stainless Steel
Std. High Press. 1, Cast Iron 1 127 150
A, B, C, D
1, Cast Iron
Std. 2,6 Carbon Steel 50
B, D
2.5" 5, Stainless Steel
CP 1, 2, 3 304
A, B, C, D 1, Cast Iron
High Press. 2,6 Carbon Steel 175
B, D
5, Stainless Steel
Std. High Press. A, C 1, Cast Iron 1 173 150
B, D
3" 5, Stainless Steel
CP 1, 2, 3 423
B, D
5, Stainless Steel
1, Cast Iron
5, Stainless Steel
4" CP B, D 1, 2, 3 490
1, Cast Iron
5, Stainless Steel
Body Connections: Body Material: Trim Package Options and Typical Material:
A – ANSI Threaded 1 – Cast Iron 1 – 400 Series Stainless Steel Seat, Hardened Cast Iron
B – ANSI Flanged 2 – Carbon Steel Disc, Nickel Plated Carbon Steel Follower Ring
C – ISO Threaded 5 – Stainless Steel 2 – Hard Faced 300 Series Stainless Steel Seat, Chrome
D – DIN Flanged 6 – Low Temp Plated Cast Iron Disc, Chrome Plated Follower Ring
E – Socket Welded Nipple Carbon Steel 3 – PEEK Seat, 300 Series Stainless Steel Disc, PEEK
F – Socket Welded Nipple Follower Ring
w/150 lb. ANSI Flange Body Seals and Bumper:
G – Socket Welded Nipple All configurations allow for Buna-N and Viton elastomers
w/300 lb. ANSI Flange as standard. Kalrez and Ethylene Propylene are available
for special services. Consult Maxon for proper application.
Valve Body Assembly Options & Specifications

Series 8000 Normally-Open Vent Valves
Actuator Body
Nominal Flow Body Trim Package Cv MOPD Rating
Pressure Connections
Pipe Size Capacity Material Options Rating (psig)
Class Available
.75" Std. High Press. A, C 1, Cast Iron 1, 2, 3 19 200
A, C, E, F, G 255
5, Stainless Steel
1.5" Std. High Press. 2,6 Carbon Steel 1, 2, 3 53
A, C, E, F, G 255
5, Stainless Steel
A, B, C, D 1, Cast Iron 200
A, C, E, F, G 255
5, Stainless Steel
B, D
5, Stainless Steel
2.5" CP 1, 2, 3 304
B, D
5, Stainless Steel
B, D
5, Stainless Steel
3" CP 1, 2, 3 423
B, D
5, Stainless Steel
1, Cast Iron
5, Stainless Steel
4" CP B, D 1, 2, 3 490
1, Cast Iron
5, Stainless Steel
Body Connections: Body Material: Trim Package Options and Typical Material:
A – ANSI Threaded 1 – Cast Iron 1 – 400 Series Stainless Steel Seat, Hardened Cast
B – ANSI Flanged 2 – Carbon Steel Iron Disc, Nickel Plated Carbon Steel Follower
C – ISO Threaded 5 – Stainless Steel Ring
D – DIN Flanged 6 – Low Temp 2 – Hard Faced 300 Series Stainless Steel Seat,
E – Socket Welded Nipple Carbon Steel Chrome Plated Cast Iron Disc, Chrome Plated
F – Socket Welded Nipple Follower Ring
w/150 lb. ANSI Flange 3 – PEEK Seat, 300 Series Stainless Steel Disc,
G – Socket Welded Nipple PEEK Follower Ring
w/300 lb. ANSI Flange
Body Seals and Bumper:
All configurations allow for Buna-N and Viton
elastomers as standard. Kalrez and Ethylene Propy-
lene are available for special services. Consult Maxon
for proper application.
7/03
Valve Body Assembly Specifications

11 15 13
14
Typical stem/disc
connection used with
3 smaller sized valves Body Seals and Bumper Material
6 Item No. Description Material
Standard material options
2 1 Seat O-Ring
are Buna-N and Viton.
4
12 2 Body O-Ring Kalrez and Ethylene
5 Propylene are available
16 for special service.
3 Stem O-Ring
10 Consult Maxon for proper

4 Bumper
material selection.
FLOW
9 1
8 7
Body and Bonnet Materials (See Note 1 below)

Material Code
1 2 5 6
5 Body Low Temp Carbon
Cast Iron Carbon Steel Stainless Steel
Steel
6 Bonnet ASTM A159 Gr. 3000 ASTM A216 Gr. WCB ASTM A351 Gr. CF8M
ASTM A352 Gr.LCB
Trim Package Materials

Internal Trim Package
1 2 3
Hardened 400 Series Hard Faced 300 Series
7 Seat PEEK
Stainless Steel Stainless Steel
8 Disc Hardened Ductile Iron Chrome Plated Ductile Iron 300 Series Stainless Steel
Nickel Plated
9 Follower Ring Chrome Plated Stainless Steel PEEK
Carbon Steel or Ductile Iron
10 Wavy Spring 300 Series - Stainless Steel
11 Stem 17-4 PH - Stainless Steel
12 Striker Plate 17-7 PH - Stainless Steel 300 Series - Stainless Steel
13 Spring Retainer Blackened Carbon Steel
14 Compression Spring 17-7 PH - Stainless Steel
15 Jam Nut Zinc Plated Carbon Steel
16 Spring Pin (when req'd.) Carbon Steel 400 Series Stainless Steel 18-8 Stainless Steel
Valve Body Assembly — Gas Compatibility

Suggested Material Options Agency Approvals
Gas MOPD
Gas Body Seals Body & Trim
Code Rating FM CSA CE
& Bumper Bonnet Package
Air AIR A, B, C 1, 2, 5, 6 1, 2, 3 Std. X X
Ammonia AMM C 1, 2, 5, 6 1, 2, 3 Std. X X
Butane Gas BUT A, B 1, 2, 5, 6 1, 2, 3 Std. X X
Coke Oven Gas COKE B 5 3 Std. X X
Delco Combusted Gas DEL C 1, 2, 5, 6 1, 2, 3 Std. X X
Digester Gas (see note 1) DIG Analysis Required 5 3 Std. X X
Endothermic AGA 302 Gas ENDO A, B 1, 2, 5, 6 1, 2, 3 Std. X X
Exothermic Gas EXO A, B 1, 2, 5, 6 1, 2, 3 Std. X X
See
Hydrogen Gas HYD A, B, C 2, 5, 6 2, 3 X X
note 2
Manufactured Gas
MFGD Analysis Required 5 3 Std. X X
(see note 1)
Natural Gas NAT A, B 1, 2, 5, 6 1, 2, 3 Std. X X
Nitrogen NIT A, B, C 1, 2, 5, 6 1, 2, 3 Std. X X
Oxygen
200 psig
(up to 200 psig, <200 ft/sec) OXYH B, C 2, 5, 6 4, 5 X X
max.
(see note 3)
Oxygen
30 psig
(up to 30 psig, <200 ft/sec) OXYL B, C 1, 2, 5, 6 4, 5 X X
max.
(see note 3)
Oxygen
(up to 255 psig, <175 ft/sec) OXYX B, C 2, 5, 6 4, 5 Std. X X
(see note 3)
Propane Gas PROP A, B 1, 2, 5, 6 1, 2, 3 Std. X X
Refiner y Gas (see note 1) REF Analysis Required 5 3 Std. X X
Sour Natural Gas
SOUR Analysis Required 5 3 Std. X X
(see note 1)
Town Gas (see note 1) TOWN Analysis Required 5 3 Std. X X
Land Fill Gas LAND Analysis Required 5 3 Std. X X
NOTES:
1. Other body and trim packages may be acceptable pending fuel analysis. For pricing inquiry, Viton body seals and
bumper material will be standard option. Contact Maxon for details.
2. Valve maximum operating pressure (MOPD) to be reduced by 25% from standard ratings.
3. 0°F (-17°C) minimum ambient temperature limit
Body Seals & Bumper: Body & Bonnet: Trim Package:

A - Buna N 1 - Cast Iron 1 - Trim Package 1
B - Viton 2 - Carbon Steel 2 - Trim Package 2
C - Ethylene Propylene 5 - Stainless Steel 3 - Trim Package 3
(see note 3) 6 - Low Temp Carbon Steel 4 - Trim Package 2, Oxy Clean
5 - Trim Package 3, Oxy Clean
7/03
Valve Actuator Assembly Specifications

29 22 16 28 27 15 13 34
25 26
3
21 23
19
30
20 20
17 18 35
12
7 24
36
8 14 View without Top Plate
9 48A 46A
5 5
31 48 46 45 47 47A
10 32
7 34 49
29 6
11
36
12 36B
4 29 6 42
1
36A
43
2 12
Typical Actuator Assembly 44
1 38
40 41 39 37
4
General Purpose Switch Assembly
Typical Cylinder Assembly Mounting
w/Terminal Block & Leads Mounted
Item No. Description Item No. Description

1 Base Plate 27 O-Ring
2 Bonnet Gasket 28 Indicator Cover
3 Drive Pin 29 M6-1.0 x 20 Cap Screw
4 Filter Vent 30 3/4" Pipe Plug
5 Cylinder Assembly 31 .125 Inlet Pipe Plug
6 M6 Lock Washer 32 Info Plate
7 M5-0.8 x 40 Hex Screw 33 Actuator Bolts (Not Shown)
8 O-Ring 34 Switch Assembly
9 O-Ring 35 Liquid Tight Connector
10 Solenoid Adapter Inlet 36 Solenoid w/Quick Exhaust Assembly
11 Housing 36A Solenoid Coil
12 Housing Gasket 36B Solenoid Cap
13 M6-1.0 x 60 Soc HD Cap Screw 37 Switch & Terminal Bracket
14 O-Ring 38 DIN Rail
15 Top Plate 39 End Stop
16 Indicator 40 Terminal Block
17 Washer 41 End Cover
18 M5-0.8 x 10 Ground Screw 42 Marker Strips
19 Top Housing 43 M4-0.7 x 6 Slotted Screw
20 M4-0.7 x 6 Slotted Screw 44 Switch Bracket
21 Terminal Block Cover Gasket 45 Switch Insulator
22 Info Label 46 V7 Switch
23 Terminal Block Cover 46A IP67 Switch
24 M5-0.8 x 12 Cap Screw 47 #4-40 x .75 Slotted Screw
25 Top Housing Gasket 47A #2-56 x .437 Slotted Screw
26 #8-18 x .38 Self-Threading Screw 48 #4-40 Hex Nut
48A #2-56 Hex Nut
49 Wire
Electrical Data
General
Series 8000 Valves are pneumatically operated and VCS (Valve Closed Switch) is actuated at the end of
a solenoid valve controls the air supply. The solenoid the closing stroke.
valve is directly wired into the control system. VOS (Valve Open Switch) is actuated at the end of
Switch wiring diagrams (reproduced below) are the opening stroke.
part of each valve assembly, summarizing electrical
data and wiring for a valve equipped with terminal block Switch amperage ratings are shown on the sche-
and a full complement of optional switches. matic wiring diagrams below. DO NOT EXCEED rated
Good practice normally dictates that auxiliary amperage or total load shown. Diagrams show valve
switches in valves should be used for signal duty only, with a full complement of switches. The indicated
not to operate additional safety devices. internal wiring is present only when the appropriate
Valve position switches are offered in SPDT auxiliary switches are specified.
(Single Pole/Double Throw). Standard packages
include one open switch and one closed switch,
(VOS1/VCS1) and additional auxiliary switches
designated by VOS2/VCS2.
Figure 1: Normally-Closed Shut-Off Valve

See Nameplate
VALVE SWITCH WIRING DIAGRAM
for Voltage and Hz.
'
SCHEMA DE RACCORDEMENT DE LA SOUPAPE
Voir plaque signaletique
pour'tension d'alimentation et VOS-1 VCS-1 VOS-2 VCS-2
frequence (Hz)
WARNING Internal Wiring

' '
VALVE MUST Cablage Interne
BE WIRED
AS SHOWN
1 2 3 4 5 6 7 8 9 10 11 12 13 14
AVERTISSEMENT ' '
Field Wiring
Cett soupape
' doit etre ' Cablage
' ' Externe
raccordee tel qu'indique ici
Valve Mode VOS-1 VCS-1 VOS-2 VCS-2
Position de la Valve 3-4 3-5 6-7 6-8 9-10 9-11 12-13 12-14
Standard
Standard
Fully Shut
IP67 '
Fermee Completement
'
24VDC 0.5 Amps 24VDC 2.0 Amps

Intermediate
120VAC 11 Amps 120VAC 2.0 Amps Entrouverte
240VAC 11 Amps 240VAC 2.0 Amps
Fully Open
Ouverte Completement
'
Figure 2: Normally-Open Vent Valve

See Nameplate VALVE SWITCH WIRING DIAGRAM
for Voltage and Hz. SCHEMA DE RACCORDEMENT DE LA SOUPAPE
'
Voir plaque signaletique
pour' tension d'alimentation et VCS-1 VOS-1 VCS-2 VOS-2
frequence (Hz)
WARNING Internal Wiring

VALVE MUST Câblage Interne
BE WIRED
AS SHOWN
AVERTISSEMENT 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Cett soupape doit être Field Wiring
raccordeé tel qu'indiqué ici Câblage Externe
Valve Mode VCS-1 VOS-1 VCS-2 VOS-2
Standard
Standard Fully Shut
IP67
Fermee'
Completement
'

Intermediate
Fully Open
'
7/03
Electrical Data
General Purpose — Series 8011, 8111, 8021 & 8121
Solenoid valve power ratings
Amperage (amps) Power
Voltage
In-Rush Holding In-Rush Holding
24VDC .20 .20 4.8 Watts 4.8 Watts
120VAC 50Hz .09 .07 11 VA 8.5 VA
120VAC 60Hz .08 .05 9.4 VA 6.9 VA
240VAC 50Hz .05 .04 11 VA 8.5 VA
240VAC 60Hz .04 .03 9.4 VA 6.9 VA
Standard switch amperage ratings

as shown on the valve switch wiring diagram
Voltage Maximum Amperage (amps)
24VDC 0.5
120VAC 50/60Hz 11
240VAC 50/60Hz 11
Class I, Div. 2 Hazardous Location — Series 8012, 8112, 8022 & 8122
Solenoid valve power ratings
Amperage (amps) Power
Voltage
In-Rush Holding In-Rush Holding
24VDC .20 .20 4.8 Watts 4.8 Watts
120VAC 50Hz .09 .07 11 VA 8.5 VA
120VAC 60Hz .08 .05 9.4 VA 6.9 VA
240VAC 50Hz .05 . 04 11 VA 8.5 VA
240VAC 60Hz .04 .03 9.4 VA 6.9 VA
IP67 switch amperage ratings

as shown on the valve switch wiring diagram
Voltage Maximum Amperage (amps)
24VDC 2.0
120VAC 50/60Hz 2.0
240VAC 50/60Hz 2.0
Electrical Data
Class I Div. 1 - Series 8013, 8113, 8023 & 8123
The Series 8000 Valve achieves Class I Div.1 include the barriers/isolators that are depicted below in
hazardous location certification through the Intrinsically the NON-HAZARDOUS LOCATION; however, they can
Safe protection method. Below is a representation of be provided as an additional accessory. Consult
the Control Drawing. Maxon standard offering does not Maxon Corporation for details.
7/03
Dimensions & Weights

Series 8100: .75” to 3”
Normally-Closed Shut-Off Valve Body Connection A & C
Series 8111 - General Purpose Visual Indication 3.5 2.8
Series 8112 - Class I, II, III, Div. 2 of Valve Position 2.5
2.5
Series 8113 - Class I, II, III, Div. 1 2X 3/4"
Conduit
Conn.
Normally-Open Vent Valve 1/8" N.P.T. Air

10.7
Inlet Conn.
Series 8121 - General Purpose
J
Series 8122 - Class I, II, III, Div. 2 4.0
Series 8123 - Class I, II, III, Div. 1 M 2X 1/4" N.P.T.

Air Exhaust Test Conn.
"Do Not Block"
Pipe Size
H
2.6 K
L
Body Connection B & D Body Connection E Body Connection F & G

2X 1/4" N.P.T. 2X 1/4" N.P.T.
N Test Conn.
N 2X 1/4" N.P.T. Test Conn. dia.
dia. Test Conn. P
Pipe Size dia.
P
dia. Pipe Size
H H
H
K K
R Dia. of Holes K L R Dia. of Holes L
S No. of Holes L S No. of Holes
(equally spaced) (equally spaced)
Approximate Dimensions (in inches) Approximate Weight (in pounds)

Valve Flow Body Body/Bonnet
Size Capacity Connection Material Body Actuator
H J K L M N P R S Total Weight
Assembly Assembly
.75" S A, C Cast Iron N/A 8 20
A, C Cast Iron 1.9 3.8 N/A 8 20
A, C N/A 9 21
2.0 14 7
1" S E Carbon Steel & 6.9 13.8 N/A 11 23
F Stainless Steel 4.3 3.1 0.62 15 27
7.3 14.5 4
G 4.9 3.5 0.75 17 29
1.25" S A, C Cast Iron 2.4 N/A 9 21
A, C Cast Iron 2.0 4.0 N/A 11 23
A, C N/A 11 23
15 8
1.5" S E Carbon Steel & 2.7 6.8 13.6 N/A 14 26
F Stainless Steel 5.0 3.9 0.62 21 33
7.2 14.4 4 12
G 6.1 4.5 0.88 26 38
A, C 2.2 4.4 N/A 16 28
B Cast Iron 6.0 4.8 0.75 26 38
3.5 7.0 4
D 6.5 4.9 0.71 26 38
2" S A, C 3.3 2.2 4.4 N/A 18 30
E Carbon Steel & 6.9 13.8 N/A 23 35
F Stainless Steel 16 9 6.0 4.8 0.75 4 33 45
7.3 14.5
G 6.5 5.0 0.75 8 37 49
A,C 2.9 2.5 5.0 N/A 19 31
2.5" S B Cast Iron 7.0 5.5 0.75 30 42
3.1 3.8 7.5 4
D 7.3 5.7 0.71 30 42
3" S A, C Cast Iron 3.0 2.6 5.2 N/A 20 32
Flow Capacity: Body Connection:

S - Standard A - ANSI Threaded D - DIN Flanged
C - CP Body Construction B - ANSI Flanged E - Socket Welded Nipple
C - ISO Threaded F - Socket Welded Nipple w/ 150 lb. ANSI Flange
G - Socket Welded Nipple w/ 300 lb. ANSI Flange

Series 8000: 2.5”CP, 3”CP, 4”CP
Series 8011 - General Purpose Visual Indication 3.5 2.8 2.5

of Valve Position
Series 8012 - Class I, II, III, Div. 2 2.5
2X 3/4"
Series 8013 - Class I, II, III, Div. 1 Conduit
Conn.
1/8" N.P.T. Air

Normally-Open Vent Valve Inlet Conn. 13.5
Series 8021 - General Purpose 5.3

J
Series 8022 - Class I, II, III, Div. 2

Series 8023 - Class I, II, III, Div. 1 Air Exhaust
"Do Not Block"
M 2X 1/4" N.P.T.
Test Conn.
2.6 Pipe Size
2.6 K
L

2X 1/4" N.P.T. 2X 1/4" N.P.T.
2X 1/4" N.P.T. Test Conn. Test Conn.
Test Conn. N
dia. P
N
dia. P Pipe Size dia.
H dia. Pipe Size H
H
K
L K
R Dia. of Holes K L
S No. of Holes R Dia. of Holes
L S No. of Holes
(equally spaced)
(equally spaced)

Assembly Assembly
A, C 4.3 2.5 5.0 N/A 19 32
B Cast Iron 7.0 5.5 0.75 31 44
2.5" C D 11 7.3 5.7 0.71 31 44
4.5 3.8 7.5 4
B Carbon Steel & 7.0 5.5 0.75 34 47
D Stainless Steel 7.3 5.7 0.71 34 47
A, C 5.1 2.8 5.5 N/A 24 37
B Cast Iron 7.5 6.0 0.75 4 46 59
20 13
3" C D 7.9 6.3 0.71 8 46 59
5.2 4.0 8.0
B Carbon Steel & 7.5 6.0 0.75 4 47 60
D Stainless Steel 12 7.9 6.3 0.71 8 47 60
B 9.0 7.5 0.75 64 77
Cast Iron
D 8.7 7.1 0.71 64 77
4" C 5.5 4.5 9.0 8
B Carbon Steel & 9.0 7.5 0.75 64 77

S - Standard A - ANSI Threaded
C - CP Body Construction B - ANSI Flanged
C - ISO Threaded
D - DIN Flanged
E - Socket Welded Nipple
F - Socket Welded Nipple w/ 150 lb. ANSI Flange
7/03

Series 8100: 2.5"CP, 3”CP, 4”CP
Series 8111 - General Purpose Visual Indication

of Valve Position 4.5 3.3 3.0
3.0
2X 3/4"
Series 8113 - Class I, II, III, Div. 1 Conduit
Conn.
1/8" N.P.T. Air
Inlet Conn.
Normally-Open Vent Valve 15.0
Series 8121 - General Purpose J

6.4
Series 8123 - Class I, II, III, Div. 1 Air Exhaust 2X 1/4" N.P.T.
M Test Conn.
"Do Not Block"
Pipe Size
H
3.6 K
L

2X 1/4" N.P.T.
2X 1/4" N.P.T. 2X 1/4" N.P.T. Test Conn.
Test Conn. Test Conn. N
N dia.
P
dia. P dia.
dia. Pipe Size
Pipe Size
H H
R Dia. of Holes K K
K L R Dia. of Holes L
S No. of Holes L S No. of Holes
(equally spaced) (equally spaced)

Assembly Assembly
A, C 4.3 2.5 5.0 N/A 19 41
B Cast Iron 7.0 5.5 0.75 31 53
2.5" C D 21 7.3 5.7 0.71 31 53
4.5 3.8 7.5 4
B Carbon Steel & 7.0 5.5 0.75 36 58
A, C 5.1 2.8 5.5 N/A 27 49
B Cast Iron 7.5 6.0 0.75 4 48 70
13 22
3" C D 7.9 6.3 0.71 8 48 70
5.2 4.0 8.0
B Carbon Steel & 7.5 6.0 0.75 4 49 71
D Stainless Steel 22 7.9 6.3 0.71 8 49 71
B 9.0 7.5 0.75 66 88
Cast Iron
D 8.7 7.1 0.71 66 88
4" C 5.5 4.5 9.0 8
B Carbon Steel & 9.0 7.5 0.75 67 89

S - Standard A - ANSI Threaded
C - CP Body Construction B - ANSI Flanged
C - ISO Threaded
D - DIN Flanged
E - Socket Welded Nipple
F - Socket Welded Nipple w/ 150 lb. ANSI Flange
Accessories
Speed Control Set Kits
Manually adjustable valve restricts flow to the
actuator inlet and so reduces opening speed of the
normally closed shut-off valve or reduces the closing
speed of normally open vent valves.
- Available in carbon steel and stainless steel
construction
- 90° mating elbow provided for easy assembly
- Tamper-proof set screw prevents accidental Kit No. 1067124 Kit No. 1067125
misadjustment Carbon Steel Stainless Steel
construction construction
Intrinsic Safety Interfaces

Approved units interposed between the hazardous - Suitable for use in Class 1 Div. 2 areas
and safe area circuits limit parameters such as - DIN rail mounted
voltage, current or power. - Compliments intrinsically safe Series 8000
Valves
Zener Diode Safety Barriers Isolator

- Circuit must be isolated from earth in hazardous - Circuit may be earthed at one point in hazardous
area area
Barrier - Solenoid Isolator - Solenoid

P/N 1067656 P/N 1067660
Barrier - Switches Isolator - Switches

(2 barriers required (1 isolator required for
for VOS1/VCS1) VOS1/VCS1)
P/N 1067655 P/N 1067659
7/03
Notes
Series 8000 Air Actuated Valves Page 6400-S-1
B. Inspect your valve for any shipping damage.
The Installation, Operating and Maintenance
Contact Maxon Corporation with the valve’s
Instructions contain important information that
serial number (printed on the valve's name-
must be read and followed by anyone operating
or servicing this product. Do not operate or
C. Read the nameplate [10] on your valve. This
service this equipment unless the instructions
gives the maximum pressure, temperature
have been read. IMPROPER INSTALLATION OR
limitation, voltage requirements and service
USE OF THIS PRODUCT COULD RESULT IN
conditions of your specific valve. DO NOT
BODILY INJURY OR DEATH.
exceed nameplate ratings.
D. Select mounting location carefully. Your
1. Read complete instructions before proceeding
and do not discard packing materials until any/all
years if installed in a location that is cool,
loose items are located. Also, make sure that the
clean and dry.
3. Pipe the valve in the direction of the flow arrow [1]
on the valve body. The Maxon valve body can
shut off flow in one direction only.
NFPA-70, National Electric Code, CSA C22.1,
A. Remove all thread and flange protectors
Canadian Electric Code, etc.
before installing valve in your service line.
2. General considerations:
B. Teflon tape acts as a lubricant and greatly
A. Prior to shipment, each valve is operated
reduces the pipe wrench turning force required
electrically and cycled at rated and 1-1/2
to seal the threads.
rated pressure while being leak tested. Every
Maxon valve is operationally tested and Take care not to overtighten threads as this
meets the requirements of FCI 70-2 Class VI can damage the valve.
Seat Leakage.
C. Good piping practice dictates that piping be
independently supported so that valve bodies
are not placed in a bind. In addition, large
2 valves may require support.
9 D. Clean pipe lines of foreign materials before
4
installing valve into line.
3 installed in the fuel gas piping to protect the down-
stream safety shut-off valves.
5 per NFPA 86-4-2.4.3 (1999)
NFPA 86C-4-2.4.3 (1999)
NFPA 86D-4-2.4-3 (1999)
10
If normal inlet pressure to the fuel
8
pressure regulator immediately
upstream from the valve exceeds the
valve’s pressure rating, a relief valve
shall be provided and it shall be
vented to a safe location.
6
per NFPA 86-5-7.1.7 (1999)
NFPA 86C-5-7.1.7 (1999)
NFPA 86D-5-7.1.7 (1999)
7
1

mCORPORATION
Page 6400-S-2 Series 8000 Air Actuated Valves

E. Mount valve so that open/shut indicator [2] over the safety requirements for your overall
will be visible to your operating personnel. The system installation. Normally, Maxon valves
open/shut indicator should never face are electrically wired in series with all of your
downward. Valves are usually installed in safety-limit devices. Therefore, any one device
horizontal piping; however, other orientations can cause the valve to react. Each valve was
are acceptable, subject to the above limitation. production tested when manufactured. If it now
The top assemblies of all Maxon valves are appears inoperative, make sure it is being
field rotatable to allow installations involving powered properly from and through your control
conflicts with these mounting restrictions. circuit.
F. Main system shut-off should always use a C. Maintain integrity of Maxon top assembly
manual leak-tight upstream fuel cock. enclosure by using dust and watertight electri-
G. Time lag between valve action and fluid flow cal connectors. There are (2) 3/4” NPT conduit
(or flame response) is reduced if valve is thread connections per valve. Use cable-
located near the burner (or outlet). sealing grips and strain-relief loops for any
H. In some instances, it may be desired to cord or cable. Use internal sealing materials on
utilize a slow opening feature for either applica- all conduit connections. If conduit is not used,
tion or code-related reasons. If a slow opening suitable liquid-tight connections must be used
feature is required for normally closed shut-off in order to maintain NEMA 4 or 4X enclosure
valves, use Maxon’s optional speed control rating. Moisture can have a harmful effect on
set kit. valve internals if permitted to enter through
4. Wire the valve in accordance with all applicable wiring connectors. Make sure that all access
codes and standards. Supply voltages must agree cover plates are in place and securely fas-
with valve’s nameplate voltage within -15%/+10% tened. All cover screws should be tightened
for proper operation. For electrical wiring schemat- using an alternate cross corner tightening
ics, refer to pages 6400-S-7 & 6400-S-8 and/or the pattern to the values shown in Table 1 below.
wiring schematic diagram affixed inside your While all covers are torqued at time of produc-
valve’s access cover plate or in the terminal block tion testing, torque should be rechecked
cover housing. periodically to ensure adequate sealing
A. Electrical Specifications protection.
Actuator assemblies available in 120VAC 50
or 60Hz, 240VAC 50 or 60Hz, and 24VDC. Table 1 - Torque Specifications
(Note: 24VDC is the only option available for Item
Cover Torque
the 8013, 8113, 8023, and 8123 Intrinsically Number
Safe series valves.) 3 M5 x 0.8 Terminal Block Screws 45 in-lbs.
i. Ground is achieved with a grounding screw 9 M6 x 1.0 Top Access Plate Screws 50 in-lbs.
which is located in the top assembly 6 M8 x 1.25 Actuator/Body Bolts 25 ft-lbs.
ii. Customer connections are provided via 6 M10 x 1.50 Actuator/Body Bolts 40 ft-lbs.
terminal blocks also located in the top
assembly
5. Pre-operational exercising:
iii. Main power wiring (120VAC or 240VAC)
Prior to initial fluid flow start-up and with upstream
must be segregated from lower voltage
manual cock still closed, operate the valve
24VDC signal wiring, when both are re-
electrically for 10-15 cycles. This not only provides
quired.
an electrical check, but also wipes valve body disc
B. The Maxon valve must be electrically
and seat free of accumulated foreign matter.
interlocked with your safety-limit devices in
accordance with all applicable codes, stan-
dards, and the authority having jurisdiction
m CORPORATION

6. Series 8000 Valves require clean, dry gas piped to the inlet of the actuator at the designated pressures de-
picted on the valve nameplate. Typically compressed air is the actuating medium, however, certain applications
require the use of other gases to the actuator inlet.
A. Compressed Air
i. The vent, located on the underside of the base plate, should be protected from accidental blockage.
ii. Although Maxon Series 8000 Valves do not require lubrication, they do contain Buna-N seals in the
actuator sub-assembly. Quality of the compressed air supply must not contain any lubricant that is not
compatible with Buna-N elastomers. Although many synthetic oils and additives have been publicized for
advanced lubricating characteristics in pneumatic systems, strict attention should be exercised to avoid
their use, even in minute amounts.
B. Natural Gas and other fuel gases can be used to actuate the Series 8000 Valve when the appropriate
considerations are taken into account.
i. Apply only the Intrinsically Safe Series 8000 Valve for the application. The general purpose and non-
incendive options are not suitable for fuel gas activation.
ii. The activating fuel gas must be clean and free of moisture. The Series 8000 actuator contains Buna-N
elastomers and brass components that will come in contact with the activating gas. The quality of the
gas must not contain any contaminates or constituents that are not compatible with Buna-N or brass. If
needed, contact Maxon Corporation for appropriate application assistance.
iii. The exhaust gas must be vented to the atmosphere in a safe manner by piping from the filtered vent,
located on the underside of the actuator’s base plate. A female 1/8” NPT connection in the base plate
allows for proper piping.
7. Environmental Specifications
A. Actuators are rated for NEMA 4, IP65 or NEMA 4, 4X, IP65
B. Ambient temperature range of -40°F (-40°C) to 140°F (60°C) for the 8011, 8111, 8021, and 8121 General
Purpose and 8012, 8112, 8022, and 8122 Non-Incendive series valves.
C. Ambient temperature range of -40°F (-40°C) to 122°F (50°C) for 8013, 8113, 8023, and 8123 Intrinsically
Safe series valves.
D. All valves for oxygen service or using Ethylene Propylene body seals are limited to a minimum ambient
temperature of 0°F (-17°C).
8. Product Approvals
Area Classification Applicable Standards
A. General Purpose FM 7400, CSA 6.5-2000,
CSA 22.2 No. 1010.1
B. Non-Incendive, Division 2 Areas as follows: FM 7400/3600/3611/3810,

Class I, Division 2, Groups ABCD, T4 CSA 22.2 No. 213;
Class II, Division 2, Groups FG, T4 CSA 6.5-2000
Class III, Division 2, T4
C. Intrinsically Safe, Division 1 Areas as follows: FM 7400/3600/3610/3810

Class I, Division 1, Groups ABCD, T5 CSA 22.2 No. 157,
Class II, Division 1, Groups EFG, T5 CSA 6.5-2000
Class III, Division 1, T5
Solenoid Entity Parameters: Vmax=28V Imax=115mA Pi=1.6W Ci=0 Li=0

Switch Entity Parameters: Vmax=30V Imax=500mA Pi=2W Ci=0 Li=0

mCORPORATION
Actuator Assembly Rotation/Replacement

Maxon Series 8000 Valves should be ordered in a 3. Remove conduit and electrical leads.
configuration compatible with planned piping. If valve 4. Remove all pneumatic lines.
orientation is not proper, the actuator assembly can be 5. Unscrew the actuator/body bolts [6] screwed up
rotated in 90° increments around the valve body from the bottom. These bolts secure the valve
centerline axis using the procedure below. This actuator [8] to the valve body [7].
procedure should also be followed for field replacement 6. Gently lift the actuator [8] off valve body assem-
of the actuator. bly enough to break the seal between body
1. Shut off all electrical power and close off assembly and the rubber gasket adhering to the
upstream manual cock. bottom of the actuator base plate.
2. Remove terminal block access cover plate [5]
and disconnect power lead wires. (Tag carefully for
later re-assembly.)
Switch
Access Switch Access Cover [4]
Cover
Screws [9]
Terminal Block Cover [5]

and Screws [3]
Open/Shut Indicator [2]
See Note 1 below.
Actuator Assembly [8]
Valve Body [7]
Actuator/Body
Bolts [6]
Note 1: Open/Shut indication is 360°.

Flow Arrow on If required, the observation window
Valve Body [1] may be cleaned with a damp cloth.
m CORPORATION

Actuator Assembly Rotation/Replacement (cont'd.)
7. Carefully rotate/replace actuator assembly to 10. Reconnect conduit, electrical leads, and all
the desired position. Reposition the actuator back pneumatic lines, then check that signal switch
down onto the valve body casting. wands are properly positioned. Failure to correct
8. Realign holes in valve body casting with the any such misalignment can result in extensive
corresponding tapped holes in the bottom of the damage to the internal mechanism of your
actuator base plate. Be sure the gasket is still in valve.
place between the body and actuator base plate. 11. Energize valve and cycle several times from
9. Reinsert the body bolts up from the bottom closed to full open position. Also electrically trip
through the body and carefully engage threads of the valve in a partially opened position to prove
the actuator assembly. Tighten securely referring valve operates properly.
to Table 1 on page 6400-S-2 for appropriate torque 12. Replace and secure cover plates and place valve
specifications. in service.
Alternate Actuator Assembly Positions
"L" "R" "TO" "AW"
Four actuator assembly positions are available for view, the unidirectional valve body and the arrow on
Maxon Series 8000 Valves. When looking at the the valve body casting points in direction of fluid flow:
terminal block access cover plate on the actuator, the to the right (position "R"), to the left (position "L"),
valve body is positioned on the bottom. From this towards you (position "TO") or away from you (position
"AW").

m
CORPORATION
Field Installation of Valve Position Switch
WARNING:
NOTE: Instructions below are written for nor-
Substitution of components may affect suitability
mally- closed shut-off valves. For normally-open
for Hazardous Locations. Reference tables below
vent valves, reverse switch nomenclature. (VOS
for the appropriate switch
becomes VCS and vice versa.)
assembly.
General: Shut off fuel supply upstream of valve, then

de-energize valve electrically.
– Remove top cover and terminal block cover to Figure 1:
provide access, being careful not to damage gasket. Typical Switch
Sub-Assembly
See page 6400-S-7 for instructions on adding or
replacing switches.
Complete Switch Assembly w/Terminal Blocks & Leads Mounted

Assembly Numbers
Nominal
Flow Ref. Model
Valve General Purpose & Class I, Div. 1 IP67 - Class 1, Div. 2
Capacity Number
Size
VOS1/VCS1 VOS2/VCS2 VOS1/VCS1 VOS2/VCS2
.75" S 075 S 1053969 1053970 1053971 1053973
1" S 100 S 1053969 1053970 1053971 1053973
1.25" S 125 S 1053976 1053978 1053979 1053980
1.5" S 150 S 1053981 1053982 1053983 1053985
2" S 200 S 1053986 1053987 1053988 1053989
2.5" S 250 S 1053986 1053987 1053988 1053989
2.5" C 250 C 1053990 1053991 1053992 1053993
3" S 300 S 1053986 1053987 1053988 1053989
3" C 300 C 1053994 1053995 1053996 1053997
4" C 400 C 1053994 1053995 1053996 1053997
Individual Mounted Switch Assembly Brackets w/Leads - VOS1/VCS1

Assembly Numbers
Nominal Valve Size Flow Capacity Ref. Model Number
General Purpose & Class I, Div. 1 IP 67 Class I, Div. 2
.75" S 075 S 1063528 1063534
1" S 100 S 1063528 1063534
1.25" S 125 S 1063529 1063535
1.5" S 150 S 1063530 1063536
2" S 200 S 1063531 1063537
2.5" S 250 S 1063531 1063537
2.5" C 250 C 1063532 1063538
3" S 300 S 1063531 1063537
3" C 300 C 1063533 1063539
4" C 400 C 1063533 1063539
mCORPORATION

Field Installation of Valve Position Switch (continued)
Replacement Switches: Add Switches:

– Carefully remove field wiring from the terminal block. – Carefully remove field wiring from the terminal block.
Insure field wires are clearly marked to correct Insure field wires are clearly marked to correct
terminal. terminal.
– Unwire the solenoid valve lead wires from terminals – Unwire the solenoid valve lead wires from terminals
labeled #1 and #2. labeled #1 and #2.
– Remove screws that secure the switch sub-assem- – Remove screws that secure the switch sub-assem-
bly to the actuator housing. The switch sub-assembly to the actuator housing. The switch sub-assem-
bly should be easily removable from actuator bly should be easily removable from actuator
assembly (see Figure 1: Typical Switch Sub- assembly (see Figure 1: Typical Switch Sub-
Assembly). Assembly).
– Note wand position and mounting hole location. – Reference Figures 2, 3, 4, or 5 to ensure correct
Carefully remove the 2 screws and lift existing switch location. Valve size is depicted in the model
switch. Reference Figures 2, 3, 4 or 5 (below) to number by the first 4 digits. For example, a 3” CP
ensure correct switch location. valve should have Model No. 300C.
– Install replacement switch in same mounting – Install switch and insulators, when provided, to
holes on bracket and verify correct wand position. correct hole. Insure proper alignment. VCS switch
– Replace existing wiring one connection at a time, should have activation wand pointed upward and
following original route and placement. VOS activation wand should be pointed down-
– Reassemble switch sub-assembly in actuator ward.
housing. Dowel pins are provided to insure proper – Wire new switches to terminals provided.
placement of switch sub-assembly. – Reassemble switch sub-assembly in actuator
– Wire the solenoid valve leads to terminals labeled #1 housing. Dowel pins are provided to insure proper
and #2. placement of switch sub-assembly.
– Cycle valve, checking switch actuation points – Wire the solenoid valve leads to terminals labeled #1
carefully. VCS switch actuates at top of stem stroke and #2.
and VOS at bottom for normally-closed shut-off – Cycle valve, checking switch actuation points
valves; vice-versa for normally-open vent valves. carefully. VCS switch actuates at top of stem stroke
– Replace covers, and then return valve to service. and VOS at bottom for normally-closed shut-off
valves; vice-versa for normally-open vent valves.
– Replace covers, and then return valve to service.
2.5"CP, 3"CP,
2.5"CP, 3"CP, 4"CP, 4" & 6" VCS
4"CP, 4" & 6" VCS
.75", 1", 1.25", 1.5"

2", 2.5" & 3" VCS
.75", 1", 1.25", 1.5"
2", 2.5" & 3" VCS
.75" & 1" VOS
2.5"CP VOS
.75" & 1" VOS 2.5"CP VOS 1.25" VOS
1.5" VOS
3"CP, 4"CP,
2", 2.5" & 3" VOS 4" & 6" VOS
1.25" VOS
3"CP, 4"CP,
4" & 6" VOS
1.5" VOS
2", 2.5" & 3" VOS
Figure 2: Figure 3: Figure 4: Figure 5:

IP67 Switch Bracket IP67 Switch Bracket General Purpose General Purpose
Switch Bracket Switch Assembly

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CORPORATION
Electrical Data
Normally-Closed Shut-Off Valves
General Purpose See Nameplate

VALVE SWITCH WIRING DIAGRAM
for Voltage and Hz.
Normally-Closed Valves Voir plaque signaletique
'
SCHEMA DE RACCORDEMENT DE LA SOUPAPE
pour'tension d'alimentation et VOS-1 VCS-1 VOS-2 VCS-2
Series 8011 & Series 8111 frequence (Hz)
Switches: Standard
Internal Wiring
Solenoid Valve: Standard WARNING
VALVE MUST
BE WIRED
' '
Cablage Interne
24 VDC, 4.8W AS SHOWN
120VAC, 50/60 Hz, 11/9.4 VA Peak, AVERTISSEMENT ' '

1 2 3 4 5 6 7 8 9 10 11 12 13 14
Field Wiring
Cett soupape doit etre '
8.5/6.9 VA Holding
'
raccordee tel qu'indique ici Cablage
' ' Externe
Valve Mode VOS-1 VCS-1 VOS-2 VCS-2

240VAC, 50/60 Hz, 11/9.4 VA Peak, Position de la Valve 3-4 3-5 6-7 6-8 9-10 9-11 12-13 12-14
Standard
8.5/6.9 VA Holding Standard IP67
Fully Shut
Fermee'
Completement
'

Intermediate
Class I, Div. 2 240VAC 11 Amps 240VAC 2.0 Amps
Fully Open
'
Hazardous Location
Normally-Closed Valves
Series 8012 & Series 8112
Switches: IP67
Solenoid Valve: Standard
24 VDC, 4.8W
120VAC, 50/60 Hz, 11/9.4 VA Peak, 8.5/6.9 VA Holding
Class I, Div. 1 Intrinsically Safe

Hazardous Location
Normally-Closed Valves
Switches: Standard
Solenoid Valve: Intrinsically Safe
m CORPORATION

Electrical Data
Normally-Open Vent Valves
General Purpose See Nameplate VALVE SWITCH WIRING DIAGRAM

for Voltage and Hz. SCHEMA DE RACCORDEMENT DE LA SOUPAPE
Normally-Open Vent Valves Voir plaque signaletique
'
pour' tension d'alimentation et VCS-1 VOS-1 VCS-2 VOS-2

Series 8021 & Series 8121 frequence (Hz)
Switches: Standard
Solenoid Valve: Standard WARNING
VALVE MUST
Internal Wiring
Câblage Interne
24 VDC, 4.8W BE WIRED
AS SHOWN
120VAC, 50/60 Hz, 11/9.4 VA Peak, AVERTISSEMENT 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Field Wiring
8.5/6.9 VA Holding Cett soupape doit être
raccordeé tel qu'indiqué ici Câblage Externe
240VAC, 50/60 Hz, 11/9.4 VA Peak, Valve Mode VCS-1 VOS-1 VCS-2 VOS-2
8.5/6.9 VA Holding Standard
Standard Fully Shut
IP67
Fermee'
Completement
'

Intermediate
Class I, Div. 2 240VAC 11 Amps 240VAC 2.0 Amps
Entrouverte
Fully Open
'
Hazardous Location
Switches: IP67
Solenoid Valve: Standard
24 VDC, 4.8W
Class I, Div. 1 Intrinsically Safe

Hazardous Location
Switches: Standard
Solenoid Valve: Intrinsically Safe

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CORPORATION
Refer to appropriate catalog bulletin and Main system shut-off should always be
specification page for operating sequence applying to accomplished with an upstream leak-tight manual
your specific valve. Never operate valve until all fuel cock.
essential allied equipment is operative and any Normally-closed shut-off valves begin opening cycle
necessary purges completed. Failure of valve to immediately upon being powered.
operate normally indicates that it is not powered or Normally-open vent valves begin to close
supply air pressure is not adequate. Check this first! immediately upon being powered.
Maxon Series 8000 Valves are endurance tested far
in excess of the most stringent requirements of the Insurance authorities agree . . .
various approval agencies. They are designed for long . . . that the safety of any industrial fuel burning
life even if frequently cycled, and to be as mainte- installation is dependent upon well-trained opera-
nance-free and trouble-free as possible. tors who are able to follow instructions and to react
Every Maxon valve is operationally tested and properly in cases of emergency. Their knowledge
meets the requirements of FCI 70-2 Class VI Seat of, and training on, the specific installation are both
Leakage when it leaves our plant. vital to safe operation.
Actuator assembly components require no field Safety controls may get out of order without the
Auxiliary switches or complete actuator may be result. Production-minded operators have been
the trouble.
body or actuator. Any alterations void all then assured only if the plant management
warranties. carefully develops an exact schedule for regular
Page 6400-S-2) and retest. If leakage does not stop, servicing and other shutdowns.
remove valve from service. All safety devices should be tested at least
Maxon valves are designed to be used with clean Periodic testing for tightness of manual or motor-
fluids. If foreign material is present in the fuel ized shut-off valve closure is equally essential.
line, it will be necessary to inspect the valve to *per NFPA 86-Appendix B-4 (1995)
make certain it is operating properly. If abnormal
opening or closing is observed, the valve should
be removed from service. Contact your Maxon
representative for instructions.
Operator should be aware of and observe characteristic opening/closing action of the valve. Should operation ever
become sluggish, remove valve from service and contact Maxon for recommendations.
Address inquiries to: Maxon Corporation, Muncie, IN 47302
Phone (765) 284-3304; Fax (765) 286-8394
www.maxoncorp.com
Always include valve serial number and nameplate information

for positive identification.
m CORPORATION

CAUTION: Valve leak testing should be undertaken Suggested leak test procedure for double-
only by trained and experienced personnel. Instruc- blocking shut-off valves (without vent line)
tions provided by the company and/or individuals (a) Shut down combustion system per manufacturer’s
responsible for the manufacture and/or overall recommended procedure.
installation of complete system incorporating Maxon (b) Close manual valves A and B.
valves take precedence over these provided by (c) Visually inspect to verify that shut-off valves #1
Maxon. If Maxon instructions conflict with any and #2 are closed.
codes or regulations, contact Maxon Corporation (d) Remove the 1/4” pipe plug from downstream side
before attempting this procedure. of shut-off valve #1. Install leak test apparatus.
Valve leak test should be performed on a Safely vent any trapped gas pressure.
quarterly basis to assure continued safe and (e) Open manual shut-off valve A, then close leak
reliable operation. Each valve should be checked test apparatus. Insert tube into a container of
with available line pressure. Absolute zero leakage water just below the surface.
may not be obtained in the field. Any valve that (f) Open test apparatus and test valve for leakage.
exceeds the allowable leakage, as set forth by your As a guideline, valve should be tested for 2
local codes or insurance requirements (15 bubbles per minutes per inch of pipe diameter. Large diameter
minute), should be removed from service and your pipes or long piping runs between shut-off valves
Maxon representative should be contacted. may need additional testing time.
(g) If valve testing indicates leakage exceeding 15
Every Maxon valve is operationally tested and bubbles per minute, perform pre-operational
meets the requirements of FCI 70-2 Class VI seat exercising as outlined on Page 6400-S-2 and retest
leakage when it leaves our plant. the valve. If valve continues to exceed allowable
leakage limit, remove from service and contact
Maxon.
Example of a gas piping diagram for leak test without vent line
Shut-off Shut-off
Gas Pressure Valve Valve
Regulator #1 #2
Manual
Valve HGP
A Switch
LPG Manual
Switch Valve
B
Strainer
To Combustion
System
Drip
Leg

From Flame NOTES:
Hot Safeguard Momentary Leak Neutral Push button must be
Test Push Button tamper resistant.
Shut-off
Valve #1 LS-SV - Closes when
shut-off Valve #1 is fully
open.
The "From Flame Safeguard"

LS-SV Shut-off line is energized only when all
Valve #2 conditions for safe operation
have been satisfied.

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CORPORATION
(h) Secure test apparatus on valve #1. the valve. If valve continues to exceed allowable
(i) Remove the 1/4” pipe plug from downstream side leakage limit, remove from service and contact
of shut-off valve #2. Install leak test apparatus. Maxon.
exercising as outlined on Page 6400-S-2 and retest
If vent valve is present, use auxiliary power supply to power vent valve to closed position during this test proce-
dure. Follow test instructions above. Once test is complete, be sure vent valve is restored to normal operation.
Example of a gas piping diagram for leak test with vent line
Vent Valve
Gas Pressure Shut-off

Regulator Valve Shut-off
Manual #1 Valve
Valve #2 HGP
A LPG Switch
Switch Manual
Valve
B
Strainer
To Combustion
System
Drip
Leg
From Flame NOTES:

Shut-off Valve #2 Shut-off Valve #1
Hot Safeguard Neutral Push button must be
tamper resistant.
Vent LS-VV - Closed when Vent
Valve Valve is fully closed.
LS-SV - Closes when

shut-off Valve#1 is fully
LS-VV Shut-off open.
Valve #1
The "From Flame Safeguard"
line is energized only when all
LS-SV Shut-off conditions for safe operation
Valve #2 have been satisfied.
m CORPORATION

Series 8000 Air Actuated Valves Page 6400-A/P-1
Assembly Numbers
To determine the Configured Item Number:
Select one choice each from the following five categories
Configured Item Number Example:

Valve Flow Pressure Normal Area
Size Capacity Rating Position Classification To order a 3” CP body, high pressure
rating, normally-closed shut-off valve for
general purpose use, make the following
selections:
Valve Size:
075 –.75” Valve Size ........................................ 300
100 – 1” Flow Capacity ..................................... C
125 – 1.25” Pressure Rating ................................. 81
150 – 1.5” Normal Position ................................... 1
200 – 2” Area Classification .............................. 1
250 – 2.5”
300 – 3” The Configured Item Number for this
400 – 4” valve is:
600 – 6” 300 C 8111.
(future availability)
Flow Capacity:
S – Standard Segment choices for Series 8000
C – CP Body Construction Air Actuated Valves are shown on
the following pages
Pressure Rating:
80 – Pneumatic Standard Pressure
81 – Pneumatic High Pressure
Normal Position:
1 – Normally-Closed Shut-Off Valve (also actuator only)
2 – Normally-Open Vent Valve (also actuator only)
Area Classification:
1 – General Purpose
2 – Non-incendive, Class I Div. 2
3 – Intrinsically Safe, Class I Div. 1
4 – Valve Body Only
Configured Item Numbers are designated as follows:
Valve Size space Flow Capacity space Pressure Rating, Normal Position, Area Classification

m CORPORATION
Page 6400-A/P-2 Series 8000 Air Actuated Valves
Assembly Numbers
Segment Choice Detail - NOTE: Some choices may not be available with all sizes and types of valves.
Segment Choices
(DEFAULT is shaded)
MODEL NUMBER 1 Calculated ---
MODEL NUMBER 2 Calculated ---
SIZE Determined by Calculated ---
FLOW CAPACITY Configured Item Number Calculated ---
PRESSURE RATING selection (see page 6400-A/P-1) Calculated ---
NORMAL POSITION Calculated ---
AREA CLASSIFICATION Calculated ---
* (*) Actuator only
A (A) ANSI threaded
B (B) ANSI flanged
C (C) ISO threaded
BODY CONNECTION Type of body connection D (D) DIN flanged

E (E) Socket welded nipple
(F) Socket welded nipple
F
w/ANSI Class 150 flanges
(G) Socket welded nipple
G
w/ANSI Class 300 flanges
* (*) Actuator only
BODY SEALS, BUMPER Material specification for valve A (A) Buna N
MATERIAL body seals and bumper B (B) Viton
C (C) Ethylene Propylene
* (*) Actuator only
1 (1) Cast iron
BODY MATERIAL Type of valve body material 2 (2) Carbon steel
5 (5) Stainless steel
6 (6) Low Temp Carbon Steel
* (*) Actuator only
1 (1) Trim package 1
Materials used for valve body 2 (2) Trim package 2
INTERNAL TRIM PACKAGE
internal components 3 (3) Trim package 3
4 (4) Trim package 2, oxy clean
5 (5) Trim package 3, oxy clean
* (*) Valve body only
A (A) 120VAC 50Hz
B (B) 120VAC 60Hz
PRIMARY VOLTAGE Electrical voltage - actuator
D (D) 240VAC 50Hz
E (E) 240VAC 60Hz
G (G) 24VDC
0 (0) None
SWITCHES Switch options desired, if any
1 (1) VOS1 / VCS1
2 (2) VOS2 / VCS2
m CORPORATION

Series 8000 Air Actuated Valves Page 6400-A/P-3
Assembly Numbers
Segment Choice Detail - NOTE: Some choices may not be available with all sizes and types of valves.
Segment Choices
(DEFAULT is shaded)
ENCLOSURE RATING Rating of actuator enclosure A (A) NEMA 4, IP65
B (B) NEMA 4X, IP65
Second language for valve * (*) Valve body only
SECONDARY LANGUAGE
labeling 1 (1) French
AIR Air
AMM Ammonia
BUT Butane Gas
COKE Coke Oven Gas
DEL Delco Combusted
DIG Digester Gas
ENDO Endothermic AGA 302
EXO Exothermic
HYD Hydrogen Gas
LAND Landfill Gas
FUEL Type of fuel to be used
MFGD Manufactured Gas
NAT Natural Gas
NIT Nitrogen Gas
OXYH Oxygen (up to 200 psig, <200 fps
OXYL Oxygen (up to 30 psig, <200 fps
OXYX Oxygen (up to 255 psig, <175 fps)
PROP Propane Gas
REF Refinery Gas
SOUR Sour Natural Gas
TOWN Town Gas
AW Away
L Left
TOP ASSEMBLY POSITION Actuator position
R Right
TO Toward
NONE No tagging
TAGGING Type of tagging
SSP Stainless steel (permanent)
SSW Stainless steel (wire-on)
MIN. CYLINDER INLET
No choices available Calculated ---
PRESSURE
MOPD No choices available Calculated ---
MIN/MAX AMBIENT
TEMPERATURE
SOLENOID CURRENT/POWER
RATING
AGENCY SANCTIONS No choices available Calculated ---

m CORPORATION
Page 6400-A/P-4 Series 8000 Air Actuated Valves
Assembly Numbers
Spare Parts
Complete Switch Assembly w/Terminal Blocks & Leads Mounted

Assembly Numbers
Nominal
Flow Ref. Model
Valve General Purpose & Class I, Div. 1 IP67 - Class 1, Div. 2
Capacity Number
Size
VOS1/VCS1 VOS2/VCS2 VOS1/VCS1 VOS2/VCS2
.75" S 075 S 1053969 1053970 1053971 1053973
1" S 100 S 1053969 1053970 1053971 1053973
1.25" S 125 S 1053976 1053978 1053979 1053980
1.5" S 150 S 1053981 1053982 1053983 1053985
2" S 200 S 1053986 1053987 1053988 1053989
2.5" S 250 S 1053986 1053987 1053988 1053989
2.5" C 250 C 1053990 1053991 1053992 1053993
3" S 300 S 1053986 1053987 1053988 1053989
3" C 300 C 1053994 1053995 1053996 1053997
4" C 400 C 1053994 1053995 1053996 1053997
Individual Mounted Switch Assembly Brackets w/Leads - VOS1/VCS1

Assembly Numbers
Nominal Valve Size Flow Capacity Ref. Model Number
General Purpose & Class I, Div. 1 IP 67 Class I, Div. 2
.75" S 075 S 1063528 1063534
1" S 100 S 1063528 1063534
1.25" S 125 S 1063529 1063535
1.5" S 150 S 1063530 1063536
2" S 200 S 1063531 1063537
2.5" S 250 S 1063531 1063537
2.5" C 250 C 1063532 1063538
3" S 300 S 1063531 1063537
3" C 300 C 1063533 1063539
4" C 400 C 1063533 1063539
Solenoid Coil w/Quick Exhaust Assembly Accessories

Assembly Assembly
Description Ref. Number Description
Number Number
General Purpose and Class I, Div. 2, Carbon steel speed control set kit 1067124
1056273 3000-196AA
120VAC 50/60 Hz
Stainless steel speed control set kit 1067125
General Purpose and Class I, Div. 2,
1056274 3000-196AB
240VAC 50/60 Hz Solenoid barrier for intrinsically safe 1067656
General Purpose and Class I, Div. 2, Switch barrier for intrinsically safe 1067655
1056272 3000-196DB
24VDC
Solenoid isolator for intrinsically safe 1067660
Intrinsically Safe for Class I, Div. 1,
1055029 ---
24VDC Switch isolator for intrinsically safe 1067659
m CORPORATION

Bulletin 6500
Maxon “Modular” Special Service Valves

Whatever your valve needs, you can’t afford less than Maxon quality.
Special Service Valves are ruggedly designed The “Modular” Valve design provides application
and built for a long service life in today’s industrial flexibility and the capability to “create” the valve that
processing environments. best meets your specifications. Building block concept
Maxon Valves are built to order – individually allows you to select the appropriate valve body for
assembled and tested to very stringent quality control flow capacity conditions and/or code specification,
standards that support Maxon’s dedication to total then choose and add the manual or automatic operat-
customer satisfaction. ing mechanism required for your application.
Body Types
Threaded Bodies Flanged Bodies (single-or double-seated)
Single-seated Double-seated
Standard “FL” Extended outlet “XL” Elbow Outlet “EL” Single Inlet –
Double Outlet
Operating Mechanisms
Lever Wheel Fusible Link
for fast manual for slower for “automatic”
operation manual opening or closing
operation of manually
“cocked” valve
upon exposure to
ambient tempera-
tures exceeding
link rating.
Rack & Pinion Spring Return Air

for greater for “dead man” for unattended
leverage in fast control with operation using a
manual operation automatic return controlled air supply.
to either open or Variations include
closed position double-acting air
when handle is cylinders and
released air/spring
combinations to open
or close.
Page 6502
Maxon “Modular” Special Service Valves

Principle of Operation This trim is frequently selected for natural gas, propane
To provide “bubble-tight” seals in your process or butane service.
service lines, Maxon uses swinging gate bodies for A special electro-less nickel coating may provide
special service gas applications. The hard-faced micro- additional corrosion/erosion protection to the valve
lapped seat nut is threaded into the one-piece cast body itself.
valve body. The free-floating, hard-faced, spring-loaded Contact Maxon with your specific application needs
circular disc swings across the seat. Line pressure for recommendations.
also assists in sealing the disc to the downstream
Double Stem Packing Arrangements
seat.
Frequent use and cycles actually helps to keep your Maxon “Modular” Special Service valves incorporate
a double stem packing for superior reliability. Long
valve clean. The valve wears in, not out. Since the
packing life and minimal wear can be expected be-
free-floating disc is swinging across the circular seat
cause the valve stem rotates in operation rather than
nut on the arc created by the disc carrier, the disc
sliding through the packing.
rotates slightly on every cycle. This provides a fresh,
clean surface area for sealing off your flow lines. The initial stem seal is provided by an “inside”
All Maxon valve bodies have special service trim packing ring with additional protection furnished by the
“outside” packing set.
options available to meet your particular fluid service
Packing arrangements are shown below.
requirements.
Fig.1 Fig.2
Lever Actuated
Threaded Valve Assembly
Disc
Carrier
Disc
Figure 1 shows the threaded outside packing nut
Seat arrangement furnished on 1/2" through 1-1/4" threaded
valves (Type SL) and 1", 1-1/4" flanged valves (Type
XL, EL).
Bodies and Trims Figure 2 shows the bolted outside packing gland
All feature metal-to-metal seating, with a swinging arrangement furnished with all 1-1/2" through 8" flanged
gate design that minimizes leakage potential by body valves.
requiring only slight rotation of stem through double
Stem Packing Options
stem packing/seals.
Stem packing is offered in the three versions
Flanged and threaded, single and double seated
shown in the photograph below.
versions are available in 1/2" through 8" pipe sizes.
– Standard trim consists of a carbon-based composi-
Ratings to 1000 PSI or 1000°F.
tion (Grafoil) inner ring and chevron formed set of
Valve Body Trim Selection Teflon outer packing. It is suitable for temperatures
“Modular” Special Service Valve bodies are offered up to 450°F (232°C).
in two basic trims: Trim 3 and Trim 5. – Trim “G” uses the Grafoil composition ring forms for
Our “standard”, Trim 3, includes Stellited Steel seat both inside and outside packings and is suitable for
and disc and is suitable for a broad range of pressures temperatures up to 1000°F (538°C).
and temperature conditions, including steam and some – Trim “T” uses the
corrosive services. formed Teflon rings for
A lower cost alternative where high temperatures both inside and
and corrosion are not a problem is Trim 5, which outside packings and
includes Stellited Steel seat and Nodular Iron disc. is restricted to tem-
peratures below 450°F
(232°C).
7/92
“Modular” Special Service Valves Page 6503
Valve Body Ratings/Materials

All “Modular” Special Service Valves incorporate a The primary service rating chart below shows the
metal-to-metal seated swinging gate valve body. relationships of pressure and temperature. As the
Addition of various operating mechanisms gives a temperature increases, the maximum pressure
lever, wheel, air operated valve assembly, etc. The decreases and vice versa.
type of operating mechanism selected will determine Therefore, a 600# body might handle 1480 PSIG at
the maximum operating pressure differential ambient temperatures of -20°F to +100°F (WOG
(MOPD) rating of the valve assembly. This MOPD rating), but only 105 PSIG if temperature climbed up
rating is the maximum pressure that this particular to 1000°F. The maximum pressure and tempera-
body/operating mechanism combination can reliably ture combination is the WSP rating (for example –
open (or close) against within the limits imposed by for a 600# valve body: 600 PSIG at 840°F).
the operating mechanism.
Valve body casting ratings Maximum non-shock service pressure rating (PSIG)
All valve body assembly ratings may be specified Primary service pressure rating (PSIG)
Service
with at least four different ratings:
Temp. °F 150 250 300 600
• WOG rating: Generally accepted to be the maxi- -20 285 500 740 1480
mum water, oil or gas pressure rating at ambient 100 285 500 740 1480
temperatures (-20°F or -29°C to +100°F or +38°C)
that a valve body can accept. 150 270 480 705 1415
200 260 460 675 1350
• WSP rating: Defined as the maximum working 250 245 415 665 1330
steam pressure rating that the valve body can
accept. This WSP rating must always be a psi rating 300 230 375 655 1315
at a given temperature. It is typically lower than 350 215 335 645 1295
WOG ratings. 400 200 290 635 1270
• ANS rating: Primarily a mechanical piping code for 450 185 250 615 1235
wall thickness, metallurgy, bolt circle dimensions 500 170 --- 600 1200
and flange thickness, etc. This rating is used to 550 155 --- 575 1100
insure pipe line fixture compatibility. A 300# ANS
valve should mate with any ANS 300# companion 600 140 --- 550 1095
flange, etc. 650 125 -- 535 1075
700 110 --- 520 1065
• Primary non-shock service pressure ratings:
This is another way of presenting the WOG and 750 95 --- 505 1010
WSP ratings. The primary service rating is the 800 80 --- 410 825
maximum pressure and temperature combination 850 65 --- 270 535
that a valve body can withstand. (This is also the
WSP rating definition.) 900 50 --- 170 345
950 35 --- 105 205
1000 20 --- 50 105
7/00
Page 6504 “Modular” Special Service Valves
Valve Body Ratings/Materials

“Modular” Special Service Valve bodies are offered Regardless of the ultimate designation, each
in five distinct types/ratings: SL-25, SLD-30, SL-60, contains a valve body in a primary service rating of
FL-15 and FL-30. The table below summarizes the 150, 250, 300 or 600 psi. Suitable water/steam/oil
ratings for each in its standard trim. The lower half of working pressure is a function of service temperature
the table lists construction materials of major valve as outlined in the table below. Some operating
body components. mechanism options may require lower pressure limits
as outlined in their specific catalog literature.
Valve Body Ratings and Materials

Designation SL-25-5 SLD-30-5 SL-60-3 FL-15-3 FL-30-3
WSP psi rating 250 300 600 150 300

@ temperature 450°F 812°F 840°F [1] 535°F [1] 840°F [1]
WOG psi rating 500 600 1480 285 720

@ temperature (°F) -20 to +100 -20 to +100 -20 to +100 -20 to +100 -20 to +100
Body Cast Iron Ductile Iron Cast Steel Cast Steel Cast Steel
Seat Stainless Stainless Stellited Steel Stellited Steel Stellited Steel
Material Disc Nodular Iron Nodular Iron Stellited Steel Stellited Steel Stellited Steel
Stem Stainless Stainless Stainless Stainless Stainless
Stem Bushing Plated Steel Plated Steel Plated Steel Plated Steel Plated Steel
[1] This temperature exceeds limits of standard stem packing. Use trim "G" for temperatures exceeding 450°F.
Valve Body Quality Assurance (per Maxon Material Specification Sheet #MP-1042)
Whether you are a long-time customer that origi- bodies is not a standard option). All flanged valves
nally knew us as Okadee, or a first-time contact, you going into service in a refinery, utility, chemical
will find Maxon’s reputation for quality products is plant, or boiler blow-off service must be subjected to
well-deserved. During manufacture, ALL Maxon hydrostatic shell testing. Hydrostatic shell testing
“Modular” Special Service Valve bodies are tested should always be requested for valves handling a
as follows: hazardous fluid unless such testing cannot be given
because of service restrictions, such as oxygen
• Seat tests: All seats are tested for tightness at air service valves.
pressures of 25 PSIG and 300 PSIG. In addition, a
Hydrostatic test should be requested for all
lower seat pressure test, such as 5 PSIG, may be
valves (threaded or flanged) going into greater
requested if the valve is to be used at low differen-
than 200 PSIG service (at net extra charge).
tial pressure. The lower seat pressure test is not a
Regardless of maximum operating pressure, the
standard option.
following hydrostatic test pressures are used:
• Shell tests: All valves are tested for porosity and
joint tightness while immersed under water while WOG rating Hydrostatic test
Type of Valve
being subjected to 300 PSIG internal air pressure. (PSIG) pressure (PSIG)
Our intent is to test all valves at a minimum of one FL-15 285 430
and one-half times the maximum pressure that the SL-25 500 750
valve will be subjected to in actual service. SLD-30 600 900
• Hydrostatic shell tests (must be specified on SL-30
740 1110
order ): Hydrostatic shell testing is standard on all FL-30
XL and EL valve bodies (testing on other valve SL-60 1480 2200
Capacities/Specifications
Valve body sizing/selection That Cv factor may be used to determine gas and
Maxon “Modular” Special Service Valves are noted liquid flow rates or pressure drop for your conditions,
for their full-open flow port design with extremely low using the appropriate formula from those given below:
pressure drops. Always select valve size based Liquids: V = Cv (P1 - P2)
upon volume flow capacities at their acceptable
pressure drop conditions. Gf
Approximate pressure drop as a function of
water flow is shown in the chart below. The Cv factor
(shown in parentheses after valve size) is, by defini- W = (500) Cv (P1 - P2) Gf
tion, the number of U.S. gallons per minute of water
which will pass through that valve with exactly one (1)
psi pressure drop. Gases: Q = (1360) Cv (P1 - P2) (P1 + P2)
G Tf 2
Water W = (4.56) Cv (P1 - P2) P2 Gf
Steam: W = (63.4) Cv (P1 - P2) w2
V
&8 Sat. Steam: W = (3) Cv (P1 - P2) P2
6"
3)
" (87 Where:
4
1) G = Gas specific gravity (air = 1.0)
" (49 1)
3 4 Gf = Specific gravity @ flowing temperature °F
/2 " (3
2-1 8) P1 = Inlet pressure PSIA (14.7 psi + psi gauge)
(21 P2 = Outlet pressure PSIA (14.7 psi + psi gauge)
2"
3) Q = Cubic feet per hour @ 14.7 PSIA and 60°F
" (12
/2 ) Tf = Flowing temperature absolute (460° + °F)
1-1 " (85
1 / 4 V = Flow in U.S. gallons/minute
1- )
(55 W = Flow in pounds per hour
1"
1) w2 = Density of steam (pounds/cubic foot)
/4 " (3
3
9)
/2 " (1 For example: If your application calls for a flow of 60
1
gpm of #2 oil at 100°F, 150 psi inlet pressure and with
an allowable drop of 5 psi, we can calculate . . .
1 V = gpm 60 = Cv 5
.865
Gf = .865 60 = Cv 5.78
P1 - P2 = 5 PSIG 60 = Cv (2.4)
required Cv = 25
Looking at chart at left, we see that a 3/4" valve (with

a Cv of 31) is the smallest that would meet our needs.
7/00
Nomenclature
Maxon “Modular” Special Service Valves are
identified by a six-part designation system that
provides the following information:
• Part 1 – Valve and pipe size
• Part 2 – Valve seating (single or double) and
operator type
• Part 3 – Body type
• Part 4 – ANS body class
• Part 5 – Seating and stem packing materials
• Part 6 – Accessory items
Each “Modular” Special Service Valve bears a
nameplate similar to the one reproduced at right. The
information stamped there at manufacture allows
permanent identification of the valve.
Body Type A.N.S. Class Seating material Stem packing

Seating
(W.S.P.)
Type of Operator SL Threaded Stellited steel STANDARD
3
Single Double 15 150# seat and disc * Composition inside
Threaded Teflon outside
SLD 25 250# Stellited steel
Basic valve body (ductile iron)
0 00 5 seat & nodular COMPOSITION
assembly
FL Flanged 30 300# iron disc G Composition inside
1 2 Lever Flanged Composition outside
60 600#
XL
(extra long outlet) TEFLON
3 4 Rack & pinion T Teflon inside
Flanged
EL Teflon outside
Left hand gear (elbow outlet)
5 6
mechanism SPECIAL
X
Right hand gear PACKING
7 8
mechanism
Spring closing
9 10
(lever operated)
11 12
Spring closing 2" Fig 19 – FL – 30 – 3 T – AM Accessories
Factory Mounted
(rack & pinion oper.) A
Accessory
Spring closing Valve and
13 14 fusible link M Special Machining
(lever operator) Pipe Size
Spring closing
15 16 fusible link
(rack & pinion oper.)
Spring opening The example above in simplified nomenclature describes a 2" single-seated,
17 18 fusible link flanged, 300# ANS valve with stellited steel seat and disc, Teflon inner and outer
(lever operator) stem packings, complete with ATO/SC (single acting air cylinder/spring closing
19 20
Cylinder to open mechanism) and with both special machining and factory-mounted accessories.
Spring to close The actual order for such a valve would also include assembly numbers
Cylinder to close shown in appropriate catalog section and might look like this:
21 22
Spring to open
1 2" Fig 19-FL-30-3T-AM valve consisting of
Double-acting air
23 24 1 2"-0-FL-30-3 valve body assembly
cylinder
1 with inside Teflon packing
25 26 Cross lever 1 with electroless nickel body
1 with 3 x 7 ATO/SC mechanism (one spring)
1 with SPDT Limit Switch & Bracket sub-assembly
1 with Air Control Set (120/60)
1 and with Speed Control Set
Stem Packing Selection

Assembly numbers for both inside and outside The materials supplied under each assembly
packing in each of the three valve alternatives are number may consist of a single formed element or
shown in the table below. multiple formed elements, depending on specific
valve and trim.
Stem Packing Options

Valve Standard G packing T packing
Type Size Series Inside Outside Inside Outside Inside Outside
.5 – .75 SL-25 74538 70552 74538 74545 70558 70552
Threaded 1 – 1.25 SL-25, 30, 60 74537 70551 74537 74544 70557 70551
Body 1.5 – 2 SLD-30; SL-30, 60 74535 70549 74535 74542 70555 70549
2.5 – 3 SL-30,60 74536 70550 74536 74543 70556 70550
1 – 1.25 XL-30 74537 70551 74537 74544 70557 70551
1.5 FL-30; XL, EL-30
2 FL-15, 30; XL, EL-30 74535 70549 74535 74542 70555 70549
FL-15
2.5
Flanged FL-30; XL, EL-30
Body 3 FL-15, 30 74536 70550 74536 74543 70556 70550
FL-15
4
FL-30 74539 70553 74539 74547 70559 70553
6 FL-30 74540 70554 74540 74546 70560 70554
8V FL-15 74539 70553 74539 74547 70559 70553
Valve Body Alternatives

Alternate piping arrangements (shown on Special provisions for oxygen service include:
Product Information Sheet 6500-7) are offered with – Degreasing of all valve body and internals
threaded steel bodied valves (up to 2") and include: – Special handling and packaging
– Addition of grounding strap. The grounding strap is
Figure I: Indicates a threaded, steel body with
required for oxygen service but is available as an
Schedule #80 pipe nipples socket-welded in place.
option for any flanged valve.
Other pipe nipples may be available as options.
A plugged 1/4" bleed port is provided in the body
Contact Maxon for more information.
of all double-seated flanged valves and may be
Figure II: Indicates Schedule #80 pipe nipples provided (at net extra charge) in threaded double-
socket-welded into steel body and outboard ends seated valves.
have welding couplings in place. Contact Maxon for Electro-less nickel coating of valve bodies is
other options and availability. available (at net extra cost) to provide an additional
coating of corrosion resistance to the durable cast
Figure IV: Indicates Schedule #80 pipe nipples
iron and steel valve bodies. This option will extend
socket-welded into steel body and slip-on, raised face
normal delivery times.
flanges welded in place. Available with 150#, 300# or
Special flush-out cleaning ports may be
600# flanges.
provided in valve bodies (at net extra cost).
7/00

Flanged Valve Body Sub-assemblies
Type FL-15, FL-30 Valve Bodies
NOTE: All flanged

"Modular" Special
Service valves are
raised face flanges
Type XL-30 Valve Bodies Type EL-30 Valve Bodies
See XL-30 illustration at left to identify

G, H, J and K dimensions
Pipe Designations F G H J
Sketch
size A B C D E dia. dia. bolt dia. bolt quantity K L
Single Double No.
(inches) flange circle holes of holes
seated seated
1 0-XL-30-3 --- 9.25 7.72 2.25 4.75 3.06 4.88 3.5
0.75
1.25 0-XL-30-3 --- 3 9.38 7.91 2.44 4.94 3.53 5.25 3.88 ---
0-XL-30-3 00-XL-30-3 11.44
7.59 4 45°
1.5 0-EL-30-3 00-EL-30-3 4 9.53 2.88 6.25 3.68 6.12 4.5 0.88 4.5
0-FL-30-3 00-FL-30-3 1 7.48 6.56

---
0-XL-30-3 00-XL-30-3 3 11.88
7.91 6.5 5 8 22.5°
0-EL-30-3 00-EL-30-3 4 10.44 4.75
2 3.25 6.62 4.5 0.75
0-FL-15-3 00-FL-15-3 6.92 6.38 6 4.75 4 45°
1
0-FL-30-3 00-FL-30-3 8.5 6.87 6.5 5 ---
0-XL-30-3 00-XL-30-3 3 12.44 8 22.5°

8.47 7.5 5.88 0.88
0-EL-30-3 00-EL-30-3 4 11.44 5.75
2.5 3.75 7.75 5.5
0-FL-15-3 00-FL-15-3 7.45 6.56 7 5 0.75 4 45°
0-FL-30-3 00-FL-30-3 9.44 7.38 5.88 0.88 8 22.5°

1 7.5
0-FL-15-3 00-FL-15-3 7.9 7 6 6 0.75 4 45°
3 4.12 8.12
0-FL-30-3 00-FL-30-3 11.07 8.38 6.06 8.25 6.62 0.88 ---
0-FL-15-3 00-FL-15-3 8.83 7.31 9 7.69 9 7.5 0.75 8 22.5°
4 5
0-FL-30-3 00-FL-30-3 11.8 9.44 8.5 7.88 10 7.88
2
6 0-FL-30-3 00-FL-30-3 15.78 13.44 7.5 11 10.62 12.5 10.62 0.88 12 15°
8V 0-FL-15-3 00-FL-15-3 11.4 9.3 6 9.5 10 13.5 11.75 8 22.5°

Threaded Valve Body Sub-assemblies
Single-seated version
Fig. 0-SL-25
Fig. 0-SLD-30
Fig. 0-SL-30
Fig. 0-SL-60
Double-seated version
Fig. 00-SL-25
Fig. 00-SLD-30
Fig. 00-SL-30
Fig. 00-SL-60
Designation (seating) Dimension (threaded body)

Pipe Size
(Single) (Double) A B C D E F
0-SL-25 --- 3.2 5.44 2.22
0-SL-60 --- 3.31 5.53 3.88 2.38
.5" --- 00-SL-25 2.22
3.53 5.73
--- 00-SL-60 2.75 2.19
1.75 1.19
0-SL-25 --- 3.2 5.44 2.22
0-SL-60 --- 3.31 5.53 3.88 2.38
.75" --- 00-SL-25 2.22
3.53 5.73
--- 00-SL-60 2.75 2.19
0-SL-25 --- 4.12 6.47 3.19 1.56
0-SL-30, 60 --- 4.02 6.38 2.81 1.5
1" 2.25 4.75
--- 00-SL-25
4.47 6.75 2.75 1.44
--- 00-SL-30, 60
0-SL-25 --- 4.19 6.53 3.38
1.69
0-SL-30, 60 --- 4.12 6.44 3.19
1.25" 2.44 4.94
--- 00-SL-25 3.56 1.81
4.57 6.88
--- 00-SL-30, 60 3.19 1.69
0-SLD-30 ---
4.36 7.28
0-SL-30, 60 ---
1.5" 2.88 6.25 3.69 1.88
--- 00-SLD-30
4.53 7.44
--- 00-SL-30, 60
0-SLD-30 --- 4.42
7.34 4.25
0-SL-30, 60 --- 4.36
2" --- 00-SLD-30
3.25 6.62 2.12
4.62 7.53 4.47
--- 00-SL-30, 60
0-SL-30, 60 --- 5.73 8.91 5.06
2.5" 3.75 7.75 2.62
--- 00-SL-30, 60 5.84 9.03 5.38
0-SL-30, 60 --- 5.98 9.12 5.75
3" 4.12 8.12 2.88
--- 00-SL-30, 60 6.98 9.25 6.06
Pipe threads on this page conform to NPT (B2.1)
7/00
Operating Mechanism Selection for Manual Operation

Where straight manual operation of “Modular” Table 1: Manual operation selection guide
Special Service Valves is desired, your choice of Size .5 .75 1 1.25 1.5 2 2.5 3 4 6 8V
operating mechanism may be lever, rack & pinion or
--- --- --- --- --- 15 15 15 15 --- 15
wheel, depending on valve size, series and applica-
Series 25 25 25 25 --- --- --- --- --- --- ---
tion pressure.
Designation --- --- 30 30 30 30 30 30 30 30 ---
A selection guide is provided in Table 1 at right to
help you make your choice. 60 60 60 60 60 60 --- 60 --- --- ---
To use the table, locate your desired valve size on 25 L L L L L L L L L R R
top line, then move down through the column indi- 50 L L L L L L L L L R R
cated for your series designation to the first horizontal 100 L L L L L L L L R R R
row matching or exceeding your desired maximum 150 L L L L L L R R R W W
operating pressure differential. If you find the letter “L” 200 L L L L L L R R R W W
in that block, select a lever operating mechanism (“R”
250 L L L L L R R R W W W
indicates rack & pinion, “W” indicates wheel), unless Line
pressure 300 L L L L L R R R W W W
you prefer the slower operation of a wheel. (PSIG)
Table 1 is based on a maximum required pull of 70 350 L L L L L R R W W W W
pounds at end of the lever or on a wheel rim. 400 L L L W R R R W W W W
Torque requirements per 100 psi operating 450 L L W W R R W W W W W
differential pressure are shown in Table 2 below. 500 L L W W R R W W W W W
See catalog pages covering specific operating 550 L L W W R W W W W W W
mechanisms for additional guidelines for application. 600 L L W W W W W W W W W
Table 2: Torque requirements per 100 psi differential line pressure

Lever operating Wheel operating
Valve Rack & pinion
Torque/100 psi differential mechanisms mechanism
Series pressure (inch-pounds) Length Pull force Length Pull force Number of Pull force
Size
Designation (inches) (pounds) (inches) (pounds) turns (pounds)
.5, .75 -25, -60 60 6 10 --- ---
1 -25, -60 150 17 --- --- 4.5
9 4.5
1.25 -25, -30, -60 180 20 5
1.5 -30, -60 300 19 7 4
5.5
2 -15, -30, -60 500 16 32 20 12
9
-15 50 20
2.5 885 7.25
-30, -60 49 15 10
3 -15, -30, -60 1320 74 25 21 13
18 8
-15 42
4 2660 148 30
-30 30 33 7.5
6 -30 8077 --- --- --- --- 9.5 20
8V -15 6460 18 360 30 70 8.25 60
NOTE: Decision for recommendation of greater

CAUTION: Data given in Table 2 above is speci-
mechanical advantaged operating mechanism is
fied per 100 psi differential pressure. For example:
based upon assumption that a person can only exert
a 4"-FL-15-3 valve could use a rack & pinion
up to 70 pound force. Thus, any operating mechanism
operator up to 100 PSIG, but above approximately
requiring over 70 pounds should not be considered a
150 PSIG, the pull force required becomes too
good choice for “manual” operation.
great for one person to pull and a wheel operating
mechanism is the better choice.
Lever Operating Mechanisms

Lever operating mechanisms provide for fast Figure 1 & Figure 2 Figure 25 & Figure 26
manual operation on “modular” special service valves. Lever operating mechanism Cross-lever operating
for 1/2" – 4" valves mechanism for 1/2" – 4"
Four basic configurations are available: valves in overhead service lines
Figure 1 – Lever operated single-seated valves
Figure 2 – Lever operated double-seated valves
Figure 25 – Cross-lever operated single-seated
valves in overhead lines
Figure 26 – Cross-lever operated double-seated
valves in overhead lines
NOTE: Lever operating mechanisms are not a
practical option for 6" and 8" modular valves. See
rack & pinion or wheel operations for these sizes. Above: Cross-lever
operating mechanism on
Selection of any lever operating mechanism 1-1/4" Figure
25-SL-60-3 valve
must begin with the choice of your valve body
from pages 6503-6505 of this section, meeting your Left: Lever operating
specific flow, pressure and temperature requirements. mechanism on 1-1/2"
Once valve size, series and body type have been Figure 1-FL-15-3 valve
determined, verify suitability of this type operating
mechanism to your valve selection from Table 1
below. Lever operating mechanisms are recom-
mended only for those applications indicated by For manual operation of valves at higher pres-
the letter “L” in the table below. sures, see rack & pinion or wheel operating mecha-
nism selection charts.
Accessory items which may be used with lever
Manual operation selection guide operating mechanisms include:
Size .5 .75 1 1.25 1.5 2 2.5 3 4 6 8V • Optional limit switches to prove position electri-
--- --- --- --- --- 15 15 15 15 --- 15 cally. Assembly includes bracket and two switches,
25 25 25 25 --- --- --- --- --- --- --- one actuated at each end of valve stroke. Offered
Series
Designation --- --- 30 30 30 30 30 30 30 30 ---
with SPDT or DPDT contacts in both moisture-proof
and hazardous duty versions.
60 60 60 60 60 60 --- 60 --- --- ---
• Optional locking mechanism to safeguard against
25 L L L L L L L L L R R
unwanted operation. Specify whether locking is
50 L L L L L L L L L R R desired in open or closed position (padlock not
100 L L L L L L L L R R R included).
150 L L L L L L R R R W W
200 L L L L L L R R R W W To order, specify:
Line
250 L L L L L R R R W W W 1. Valve body (size, series, single/double-seating,
pressure 300 L L L L L R R R W W W trim)
(PSIG) 2. Type of operator desired (lever, cross-lever)
350 L L L L L R R W W W W
400 L L L W R R R W W W W 3. Accessory items desired
450 L L W W R R W W W W W 4. Quantity of each
500 L L W W R R W W W W W
5. Fluid service (analysis, pressure, ambient and
operating temperatures)
550 L L W W R W W W W W W
600 L L W W W W W W W W W
7/00

Cross-lever operating mechanisms are shown in Table 2: Limit switch assemblies and mounting brackets
Table 1. Cross-lever assemblies include a 10' loop of Series Size Moisture-proof Hazardous duty
chain. For additional reach, specify the assembly designation (inches) SPDT DPDT SPDT DPDT
number and length of extra chain needed (twice the SL-25 .5 – 1.25 73988 73990 73989 73991
extra reach). 1.5 - 2 74127 74129 74128 74130
SL-25, SLD-30
For example: a 2" FL-15 valve located 20' above the
floor would require a #74390 cross-lever operating mecha- 1, 1.25 73988 73990 73989 73991
SL-30
nism with 24 extra feet of #74963 chain. 1.5 - 3 74127 74129 74128 74130
Here is how we arrived at that: desired height of chain .5 - 1.25 73988 73990 73989 73991
loop above floor = 5'. Approximate reach of standard chain SL-60
1.5 - 3
below pipe centerline = 3'. Required additional reach = 15'
SL-15 2-4 74127 74129 74128 74130
– 3" = 12'. Additional chain required = 2' x 12' = 24'.
1.5 - 3
Optional limit switch assemblies are shown in FL-30
Table 2. Assemblies include bracket and two 4 73992 73994 73993 73995
switches, one actuated at each end of valve stroke. XL 1, 1.25 73988 73990 73989 73991
Choose with SPDT or DPDT contacts in either
moisture-proof or hazardous duty versions. Optional lever locking device set (available only
for valves equipped with a limit switch assembly from
Table 1: Cross-lever operating mechanisms above) prevent unauthorized operation of valve.
Padlock not included. See Table 3.
Valve Chain
Type Size Series (per foot)
Table 3: Lever locking device sets
.5, .75 SL-25, 60
Valve type Size Assembly Number
1, 1.25 SL-25, 30, 60 73962
SL, SLD .5 - 1.25 74124
1.5, 2 SLD-30, SL-30, 60
1.5 - 2 74125
2.5, 3 SL-30, 60 SL, SLD
2.5 74126
1.5 FL-30
3 74125 [1]
2 FL-15, 30 1.5, 2
FL-15 73963 74124
FL 2.5 2.5 (FL-15)
FL-30 FL
2.5 (FL-30) 74126
3 FL-15, 30 3 - 8V 74125
4 FL-15, 30 1, 1.25 74124
1, 1.25 XL-30 XL
73962 1.5 - 2.5
XL, EL 1.5, 2 XL, EL-30 74125
EL 1.5 - 2.5
2.5 XL, EL-30 73963 [1] For single-seated version; use #74126 for double-seated.

for limit switch assemblies on
lever operated mechanisms
Size Series A B C
.5, .75 All 5.19 6
1 All 9.5 6.06
9.5
1.25 All 6.25
1.5 All 6.62
8.81 16.62
2 All 7
FL-15 7.5
2.5 11.31 18.62
Others 8.5
3 All 12.06 18.75
11.31
FL-15 9.38 18.62 4" FL-30 flanged valves All other valves
4
FL-30 11.75 11.16 18.75

Threaded Valve Bodies Flanged Valve Bodies

Designation Dimension Valve Designation Dimension
Valve
size Single Double C Single Double C
A B D E Type Size A B D E
seated seated rad. seated seated rad.
.5" & 1-SL-25 2-SL-25 1.5" 1-FL-30-3 2-FL-30-3 42° 6.19 2.88
22° 37° 6 5 1.75
.75" 1-SL-60 2-SL-60
1-FL-15-3 2-FL-15-3 6
1-SL-25 --- 45° 2" 25° 50° 16.6 3.25
5.72 1-FL-30-3 2-FL-30-3 6.5
1-SL-30, 60 --- 39°
1" 2.25 1-FL-15-3 2-FL-15-3 6.19
--- 2-SL-25 2.5" 53° 3.75
38° 6
--- 2-SL-30, 60 FL 1-FL-30-3 2-FL-30-3
23° 9.5 7
1-SL-25 --- 45° 1-FL-15-3 2-FL-15-3
5.7 3" 27° 55° 18.6 4.12
1-SL-30, 60 --- 42° 1-FL-30-3 2-FL-30-3 8
1.25" 2.44
--- 2-SL-25 45°
6.12 1-FL-15-3 2-FL-15-3 57° 6.94
--- 2-SL-30, 60 42° 4" 5
1-FL-30-3 2-FL-30-3 30° 61° 18.75 8.88
1-SLD-30 ---
6.53 1" 1-XL-30-3 --- 6.97 2.25
1-SL-30, 60 ---
1.5" 42° 2.88 45° 9.5
--- 2-SLD-30 1.25" 1-XL-30-3 --- 23° 7.16 2.44
6.69
--- 2-SL-30, 60 1-XL-30-3 ---
0° 16.62 1.5" 42° 6.84 2.88
1-SLD-30 --- --- 2-XL-30-3
44° 6.59
1-SL-30, 60 --- XL 16.6
2" 3.25 1-XL-30-3 --- 0° 44° 7.16
--- 2-SLD-30 2" 3.25
50° 6.78 --- 2-XL-30-3 50° 7.03
--- 2-SL-30, 60
--- 1-XL-30-3 --- 47°
1-SL-30, 60 47° 2.5" 27° 18.6 7.72 3.75
--- --- 2-XL-30-3 50°
2.5" 8.2 3.75
--- 1.5" 1-EL-30-3 2-EL-30-3 42° 6.84 2.88
2-SL-30, 60
---
27° 50° 18.62 1-EL-30-3 --- 0° 44° 16.6 7.16
--- 2" 3.25
1-SL-30, 60 8.37 EL --- 2-EL-30-3 50° 7.03
---
3" 4.12 1-EL-30-3 --- 47°
--- 2.5" 27° 18.6 7.72 3.75
2-SL-30, 60 54° 8.5
--- --- 2-EL-30-3 50°
NOTE: For dimensions related to valve body details, see pages 6508 and 6509.
7/00

Cross-lever Operating Mechanisms
Threaded Body Valves Flanged Body Valves

Valve
size Single Double Single Double
A A1 B C D Type Size A A1 B C D
seated seated seated seated
25-SL-25 1.5" 25-FL-30-3 26-FL-30-3 6.75 18.12 6.88
--- 5.44
.5" & 25-SL-60
4.69 6.81 25-FL-15-3 26-FL-15-3 6.62
.75" 26-SL-25 2" 7.12 19.94
--- 5.81 25-FL-30-3 26-FL-30-3 7.12
26-SL-60
25-SL-25 10.56 6.31 25-FL-15-3 26-FL-15-3 7.62 20.88 6.75
--- FL 2.5" 37 18.5
25-SL-30, 60 10 6.06 25-FL-30-3 26-FL-30-3 7.94 21.06 7.88
1" 4.5
26-SL-25 10.56 25-FL-15-3 26-FL-15-3 7.5
--- 6.69 3" 8.31 21.69
26-SL-30, 60 9.88 25-FL-30-3 26-FL-30-3 8.88
25-SL-25 10.75
--- 6.31 4" 25-FL-15-3 26-FL-15-3 9.19 22.81 7.88
25-SL-30, 60 10.47
1.25" 19 9.5 4.69 1" 25-XL-30-3 --- 4.5 10.19 7.44
26-SL-25 10.75
--- 6.69 1.25" 25-XL-30-3 --- 4.69 10.62 7.75
26-SL-30, 60 10.5
25-SLD-25 1.5" 25-XL-30-3 26-XL-30-3 19 9.5 6.75 12.12 6.75
--- 6.62
25-SL-30, 60 XL 25-XL-30-3 --- 12.69 6.38
1.5" 6.75 10.12 2" 7.12
26-SLD-25 6.88 --- 26-XL-30-3 13.06 7.25
---
26-SL-30, 60 6.75
25-XL-30-3 --- 20.12 6.81
25-SLD-25 2.5" 37 18.5 7.94
--- 12.69 6.88 --- 26-XL-30-3 20.60 7.88
25-SL-30, 60
2" 7.12 1.5" 25-EL-30-3 26-EL-30-3 6.75 12.12 6.75
26-SLD-25
--- 13.06 7
26-SL-30, 60 25-EL-30-3 --- 19 9.5 12.69 6.38
2" 7.12
25-SL-30, 60 --- 20.12 8.25 EL --- 26-EL-30-3 13.06 7.25
2.5" 7.94
--- 26-SL-30, 60 20.62 8.38 25-EL-30-3 --- 20.12 6.81
2.5" 37 18.5 7.94
37 18.5 --- 26-EL-30-3 20.62 7.88
25-SL-30, 60 --- 21 8.5
3" 8.31
--- 26-SL-30, 60 21.56 8.88
Modular Special Service Valves Page 6515
Rack & Pinion Operating Mechanisms

Rack & pinion operating mechanisms provide
for fast manual operation on Modular Special Service
Valves in applications with higher line pressures.
The rack & pinion mechanism provides a greater
mechanical advantage than lever operating
mechanisms.
NOTE: Excessive pull on valve arm, as through
impact or use of a cheater bar, can cause threaded For use with 1-1/2"
valves to turn in the line and may result in leakage through 8"V flanged
and/or mechanical damage. Therefore, the rack & body valves
pinion operating mechanism is not a practical
option for a threaded valve body assembly.
Selection of any rack & pinion operating Rack & pinion operating mechanism on
mechanism must begin with the choice of your 1-1/2" Figure 3-FL-15-3 valve
valve body from pages 6503-6505 of this section,
meeting your specific flow, pressure and temperature
requirements. Once valve size, series and body type Rack & pinion operating mechanisms are
have been determined, verify suitability of this type recommended only for those applications indi-
operating mechanism to your valve selection from cated by the letter R in Table 1.
Table 1 below. For manual operation of valves at higher pres-
sures, see wheel operating mechanism selection
Table 1: Manual operation selection guide charts.
Size .5 .75 1 1.25 1.5 2 2.5 3 4 6 8V Two basic configurations are available:
--- --- --- --- --- 15 15 15 15 --- 15 Figure 3 – Rack & pinion single-seated flanged
Series 25 25 25 25 --- --- --- --- --- --- --- valves
Designation --- --- 30 30 30 30 30 30 30 30 --- Figure 4 – Rack & pinion double-seated flanged
60 60 60 60 60 60 --- 60 --- --- --- valves.
25 L L L L L L L L L R R To order, specify:
50 L L L L L L L L L R R 1. Valve (size, series, single/double seating, trim)
100 L L L L L L L L R R R
2. Type of operator desired (rack & pinion)
3. Quantity and assembly number of each
4. Fluid service (analysis, pressure, ambient and
operating temperatures)
Line 250 L L L L L R R R W W W
Rack & pinion operating mechanisms are shown
pressure 300 L L L L L R R R W W W
(PSIG) in Table 2 below. Enter the table under your desired
350 L L L L L R R W W W W
valve size. Drop down to the line opposite the appro-
400 L L L W R R R W W W W
priate valve series to identify the required assembly
450 L L W W R R W W W W W number.
Table 2: Rack & pinion operating mechanism assembly numbers

Nominal valve size
Valve series
1.5" 2" 2.5" 3" 4" 6" 8"V
FL-15 --- 71886 71892 --- 71899
71886 71892
FL-30 74446 71892 71899 71900 ---
XL-30
71887 71887 71893 --- --- --- ---
EL-30
7/00
Page 6516 Modular Special Service Valves

Rack & pinion operating mechanisms (with flanged valve bodies)
Valve Designation Dimension
Type Size Single seated Double seated A B C rad. D E

1.5" 3-FL-30-3 4-FL-30-3 86° 6.44
5
3-FL-15-3 4-FL-15-3
2" 54° 95° 20 6.81
3-FL-30-3 4-FL-30-3 5.4
3-FL-15-3 4-FL-15-3 103° 5 7.31
2.5"
3-FL-30-3 4-FL-30-3 125° 5.7 8.19
FL 3-FL-15-3 4-FL-15-3 5.4
3" 47° 133° 25 8.56
3-FL-30-3 4-FL-30-3 6.75
3-FL-15-3 4-FL-15-3 145° 5.94 9.44
4"
3-FL-30-3 4-FL-30-3 110° 7.94 11
6" 3-FL-30-3 4-FL-30-3 60° 103° 30 9.9 13
8"V 3-FL-15-3 4-FL-15-3 110° 7.8 11.5
1.5" 3-XL-30-3 4-XL-30-3 86° 5 6.44
54° 20
XL 2" 3-XL-30-3 4-XL-30-3 103° 5.4 6.81
2.5" 3-XL-30-3 4-XL-30-3 47° 135° 25 5.7 8.19
1.5" 3-EL-30-3 4-EL-30-3 86° 5 6.44
54° 20
EL 2" 3-EL-30-3 4-EL-30-3 103° 5.4 6.81
2.5" 3-EL-30-3 4-EL-30-3 47° 135° 25 5.7 8.19
Wheel Operating Mechanisms

Wheel operating mechanisms allow slow-acting
manual operation of “Modular” Special Service
Valves, even in high-pressure applications. Clockwise
rotation of a handwheel closes valve; counter-clock-
For use with
wise rotation opens valve.
1" through 8"V
Four basic configurations are available:
Maxon “Modular”
Figure 5 – “Standard” left-hand wheel operating
Valves
mechanism for single-seated valve
bodies (left-hand: with valve stem to left
side of valve as you face the handwheel)
Figure 6 – “Standard” left-hand wheel operating
mechanism as above, but for use with
double-seated valve bodies
Figure 7 – Optional “right-hand” wheel operating
mechanism for single-seated valve
bodies (right-hand: with valve stem to Wheel operating mechanisms are recom-
right side of valve as you face the mended only for those applications indicated by
handwheel) the letter “W” in Table 1 or where slow manual
Figure 8 – Optional “right-hand” wheel operating operation might be required. For fast-acting manual
mechanism as above, but for use with operation of valves at lower pressures, see lever or
double-seated valve bodies rack & pinion operating mechanism selection charts.
Selection of any wheel operating mechanism
must begin with the choice of your valve body from Accessory items which may be used with wheel
pages 6503-6505 of this section, meeting your operating mechanisms include:
specific flow, pressure and temperature requirements. • Optional chain wheel assembly permits manual
Once valve size, series and body type have been operation of overhead-mounted valves. Wheel and
determined, verify suitability of this type operating chain assemblies are available as a standard left
mechanism to your valve selection from table below. hand or right hand assembly. To order a wheel
and chain assembly, choose the wheel and
Table 1: Manual operation selection guide chain option first; do not choose the wheel
Siz e .5 .75 1 1.25 1.5 2 2.5 3 4 6 8V orientation first.
--- --- --- --- --- 15 15 15 15 --- 15 Standard assemblies include a special sprocket
Series 25 25 25 25 --- --- --- --- --- --- --- wheel and closed 20-foot loop of chain. Additional
Designation --- --- 30 30 30 30 30 30 30 30 --- lengths of chain are available by changing the
60 60 60 60 60 60 --- 60 --- --- --- default length of 20-foot to the desired value.
25 L L L L L L L L L R R
50 L L L L L L L L L R R To order, specify:
100 L L L L L L L L R R R 1. Valve body (size, series, single/double seating,
150 L L L L L L R R R W W trim)
200 L L L L L L R R R W W 2. Type of operator desired (standard wheel, right-
Line 250 L L L L L R R R W W W hand wheel)
pressure 300 L L L L L R R R W W W 3. Accessory items desired
(PSIG) 350 L L L L L R R W W W W 4. Quantity and assembly number of each
400 L L L W R R R W W W W 5. Fluid service (analysis, pressure, ambient and
450 L L W W R R W W W W W operating temperatures)
7/00

Wheel Operating Mechanisms
Threaded Body Valves Flanged Body Valves

Pipe
size Single Double Single Double
A B C D E Type Size A B C D E
seated seated seated seated
SL-25 --- 4.31 1.5" FL-30 FL-30 7
5
FL-15 FL-15
1" SL-30, 60 --- 4.25 4.19 2" 5.31 7
FL-30 FL-30 7.38 5.5
--- SL-25
4.75 FL-15 FL-15 5
--- SL-30, 60 2.5"
6 3.5 5. 5 FL-30 FL-30 8.5 5.75 10
SL-25 --- 4.38
FL-15 FL-15 5.44
SL-30, 60 --- 4.31 FL 3" 8.88
FL-30 FL-30 6.81 5.75 8.25
1.25" 4.44
--- SL-25 4.81 FL-15 --- 5.75
9.75
--- SL-30, 60 4.69 4" --- FL-15 6
FL-15 FL-15 13 7.81 12.88 9.88 ---
SLD-30 SLD-30
1.5" 7 6" FL-30 FL-30 18.56 9.81 18 12.19 ---
SL-30, 60 SL-30, 60
5 8"V FL-15 FL-15 14 7.69 12.88 9.88 ---
SLD-30
--- 5.31 7
SL-30, 60 1" XL-30 --- 4.25 5.56
2" 7.38 6 3.5 5.5
SLD-30 1.25" XL-30 --- 4.44 5.75
--- 5.25
SL-30, 60 XL 1.5" XL-30 XL-30 7 5
10 5.31 7
SL-30, 60 --- 6.19 2" XL-30 XL-30 7.38 5.5
2.5" 8.5
--- SL-30, 60 6.31 2.5" XL-30 XL-30 8.5 5.75 5.75 8.25
10
5.75 8.25 1.5" EL-30 EL-30 7 5
SL-30, 60 --- 6.44 5.31 7
3" 8.88 EL 2" EL-30 EL-30 7.38 5.5
--- SL-30, 60 6.5 2.5" EL-30 EL-30 8.5 5.75 5.75 8.25
NOTE: Wheel turns clockwise to close valve,

counter-clockwise to open. The clearance for
right-hand mechanism (E) is greater than for
left-hand mechanism (D) because of valve
body bulge.
Modular Special Service Valves Page 6519
Spring Return Operating Mechanisms

Spring return operating mechanisms provide For use with
dead man control of Modular Special Service Valves. .5" through 8"V
Valve is operated manually, against a powerful return
Maxon
spring. When handle is released, spring returns valve
to original position. “Modular” Valves
Four basic configurations are available:
Figure 9 – Type SC spring closing, lever oper-
ated mechanism for single-seated
valve body assemblies. Shown: SC spring closing operating
Figure 10 – Type SC spring closing, lever oper- mechanism on 2" Fig-9-SL-30-3 valve
ated mechanism for double-seated
valve bodies. Typical applications include chemical transfer
Figure 11 – Type SC spring closing, rack & lines, fluid transfer and/or sampling lines, furnace or
pinion operated mechanism for single- oven viewing ports, vehicular dumps/drains, water
seated valve body assemblies. deluge devices or any other application requiring
Figure 12 – Type SC spring closing, rack & manual supervision while valve is functioning.
pinion operated mechanism for
NOTE: Excessive pull on valve lever handle, as
double-seated valve bodies.
through impact or use of a cheater bar, can cause
Selection of a spring return operating mecha-
threaded valves to turn in the line and may result in
nism should begin with a choice of valve body
leakage and/or mechanical damage.
from pages 6503 – 6505 of this catalog section
meeting your specific flow and pressure requirements. To order, specify:
Once valve size, series and body type have been 1. Valve (size, series, single/double seating, trim)
determined, verify suitability of application in tables 2. Type of operator desired (SC)
below, locating the appropriate operating mechanism 3. Quantity and assembly number of each
and assembly number while noting applicable maxi- 4. Fluid service (analysis, pressure, ambient and
mum operating pressure differential (MOPD). operating temperatures)
Table 1: SC spring closing operating Table 2: SC spring closing operating

mechanisms for use with threaded body valves mechanisms for use with flanged body valves
Valve Valve MOPD
MOPD
(psi) Type Size Series (psi)
Type Size Series
SL-25 250 1.5" FL-30 100
.5" & .75" FL-15
SL-60 350 2" 90
FL-30
SL-25 FL-15 65
2.5"
1" SL-30 175 FL-30 70
SL-60 3" FL-15, 30 45
FL
SL-25 FL-15 20
1.25" 145 4"
SL, SLD SL-30, 60 FL-30 80
SLD-30 6" FL-30 40
1.5" 120
SL-30, 60
FL-15 10
SLD-30 8"V
2" 90 FL-15 35
SL-30, 60
1" XL-30 175
2.5" SL-30, 60 80 1.25" XL-30 145
3" SL-30, 60 50 XL, EL 1.5" XL, EL-30 120
2" XL, EL-30 90
2.5" XL, EL-30 80
7/00
Page 6520 Modular Special Service Valves

Spring Return Operating Mechanisms
SC Spring-Closing Operating Mechanisms

For .5" – 1.25" Threaded Body Valves For 1.5", 2" Valves
For Threaded Body For Flanged Body
For 2.5" – 4" Valves For 8"V Flanged Body Valves

(except Rack & Pinion versions)
For 4" – 8"V Flanged Body Valves Valve Dimensions

(Rack & Pinion versions only) Type Size Series A D
.5", .75" SL-25, 60 9.5 6
1", 1.25" SL-25, 30, 60 10 9.5
SL, SLD 1.5", 2" SLD-30; SL-30, 60 11 16.62
2.5" SL-30, 60 19
18.62
3" SL-30, 60 18.5
1.5" FL-30
10.5
2" FL-15, 30 16.62
FL-15
2.5"
FL-30
18.5
3" FL-15, 30 18.62
FL
FL-15
4"
FL-30 [1]
25 20
6" FL-30 [1]
FL-15 18.5 30.75
8"V
FL-15 [1] 25 20
NOTE: For dimensions related to valve body 1", 1.25" XL-30 10 9.5
details, see pages 6508 and 6509. XL, EL 1.5", 2" XL, EL-30 11 16.62
2.5" SL, EL-30 19 18.62
[1] Rack & pinion versions
Spring Return Fusible Link Operating Mechanisms

Fusible link operating mechanisms provide
automatic spring-opening or spring-closing through
operation of a UL/FM listed temperature-sensitive link. For
If tripped by excessive temperature, fusible link .5" – 8"V
must be replaced. Otherwise valve may be opened Valves
or closed manually without damage to the tempera-
ture-sensitive link.
Four basic SCF (spring-closing fusible link)
configurations are available:
Figure 13 – Type SCF spring-closing, fusible link,
lever operating mechanism for single- Shown: SCF spring-closing fusible link operating mechanism on 2"
seated valve body assemblies. Fig 13-SL-30-3 valve
Figure 14 – Type SCF spring-closing, fusible link,
lever operated mechanism for double- Fusible link options include your choice of two
seated valve bodies. alternate temperature ratings for standard link (165°F
Figure 15 – Type SCF spring-closing, fusible link, link is included in mechanism). Optional fusible links
rack & pinion operated mechanism for are also available with 212° and 286° temperature
single-seated valve body assemblies. ratings.
Figure 16 – Type SCF spring-closing, fusible link, CAUTION: All fusible link valves should be
rack & pinion operated mechanism for inspected regularly for dust, corrosion, grease
double-seated valve bodies. or paint build-up which might affect perfor-
The SCF spring-closing fusible link operating mance. A spare link should be kept on hand,
mechanisms listed above allow valve to be manually and in some circumstances, periodic replace-
opened and latched or held open by the fusible link ment may be desirable.
(commonly used for emergency shut-off of fuel,
solvent, paint or hazardous chemical lines). CAUTION: Excessive pull on valve arm, as
The SOF spring-opening fusible link operating through impact or use of a cheater bar, can cause
mechanisms listed below allow valve to be manually threaded valves to turn in the line and may result
closed and latched or held closed by the fusible link in leakage and/or mechanical damage.
(commonly used for emergency opening of dip tank
discharges, chemical diversion lines, water deluge To order, specify:
systems, etc.). 1. Valve (size, series, single/double seating, trim)
Two basic SOF (spring-opening fusible link) 2. Type of operator desired (SCF, SOF)
configurations are available: 3. Accessory items desired (alternate links)
Figure 17 – Type SOF spring-opening, lever 4. Quantity and assembly number of each
operating mechanism for single-seated 5. Fluid service (analysis, pressure, ambient and
valve body assemblies. operating temperatures)
Figure 18 – Type SOF spring-opening, lever
operated mechanism for double-seated
valve bodies.
Selection of any spring return operating mecha-
nism should begin with a choice of valve body from
pages 6503-6505 of this catalog section, meeting
your specific flow and pressure requirements. Once
valve size, series and body type have been deter-
mined, verify suitability of application in tables on the
following page, locating the appropriate operating
mechanism while noting applicable maximum operat-
ing pressure differential (MOPD).
7/00
Spring Return Fusible Link Operating Mechanisms

SCF spring-closing fusible link operating SOF spring-opening fusible link operating
mechanisms are shown in Table 1. Locate your mechanisms are shown in Table 2. Selection is
selected valve body type in the first column, then accomplished as outlined for SCF mechanisms.
move right to the desired valve size and series. On
that same line, you will find the maximum operating Table 2: SOF spring opening fusible link
pressure differential (MOPD) for the applicable operating mechanisms
operating mechanism.
Valve MOPD
Table 1: SCF spring closing fusible link operating Type Size Series (psi)
mechanisms SL-25 250
1"
Valve MOPD SL-30, 60 300
Type Size Series (psi) 1.25" SL-25, 30, 60 250
SL, SLD SLD-30
SL-25 250 2.5" 80
.5", .75" SL-30, 60
SL-60 60 0
SLD-30
SL-25 250 3" 50
SL-30, 60
1" SL-30 300 1.5" FL-30 250
SL-60 35 0
2" FL-15, 30 150
SL-25 250
1.25" FL-15 65
SL, SLD SL-30, 60 290 2.5"
FL FL-30 70
SLD-30
1.5" 240 3" FL-15, 30 45
SL-30, 60
4" FL-15 20
SLD-30
2" 180 8"V FL-15 10 [1]
SL-30, 60
2.5" SL-30, 60 160 1" XL-30 300
3" SL-30, 60 100 1.25" XL-30 250
1.5" FL-30 200 XL, EL 1.5" XL, EL-30 325
FL-15 150 2" XL, EL-30 200
2"
FL-30 180 2.5" XL, EL-30 80
FL-15 130 [1] Denotes rack & pinion arrangement (throw direction is
2.5" opposite of standard lever arrangement)
FL-30 140
FL 3" FL-15, 30 90
FL-15 40
4"
FL-30 160 [1]
6" FL-30 80 [1]
FL-15 20
8"V
FL-15 70 [1]
1" XL-30 300
1.25" XL-30 290
XL, EL 1.5" XL, EL-30 240
2" XL, EL-30 180
2.5" XL, EL-30 160
[1] Denotes rack & pinion arrangement (throw direction is
opposite of standard lever arrangement)

SCF Spring-Closing Fusible Link Operating Mechanisms
For .5" – 1.25" Threaded Body Valves For 1.5", 2" Valves
For 2.5" – 4" Valves For 8"V Flanged Body Valves

For Threaded Body For Flanged Body (except Rack & Pinion versions)
Valve Dimension
Type Size Series A D E F [1]
For 4" – 8"V Flanged Body Valves
.5", .75" SL-25, 60 9.5 6 3.19 4.5
1", 1.25" SL-25, 30, 60 10 9.5 6 9
(only Rack & Pinion versions)
SLD-30
SL, SLD 1.5", 2" 11 16.62
SL-30, 60
2.5" SL-30, 60 19 18.62
3" SL-30, 60 18.5 18.62
1.5" FL-30
10.5 8.62 11.38
2" FL-15, 30 16.62
FL-15
2.5"
FL-30
18.5 18.62
3" FL-15, 30
FL
FL-15 24.62
4"
FL-30 [2] 25 20 9.62 15.12
FL-15 18.5 30.75 10.25 15
8"V FL-15
25 20 9.62 15.12
FL-30 [2]
1", 1.25" XL-30 10 9.5 6 9 NOTE: For dimensions related to valve body
XL, EL 1.5", 2" XL, EL-30 11 16.62 details, see pages 6508 and 6509.
8.62 11.38
2.5" XL, EL-30 19 18.62
[1] Clearance to disengage handle.
[2] Rack & pinion version
7/00

SOF Spring-Opening Fusible Link Operating Mechanisms
For 1" – 2" Valves For 8"V Flanged Body Valves

Valve Dimension
Type Size Series A D E F [1]
For 2.5" – 4" Valves
1", 1.25" SL-25, 30, 60 10.5 9.5 6.38 9
SL, SLD
For Threaded Body For Flanged Body 2.5", 3 SL-30, 60 18.5 18.62
1.5" FL-30 12
2" FL-15, 30 10.5 16.62
FL-15 8.62 11.38
2.5"
FL FL-30
18.62
3" FL-15, 30 18.5
4" FL-15 24.62
8"V FL-15 30.75 8.38 13.12
1", 1.25" XL-30 10.5 9.5 6.38 9
1.5" XL, EL-30 11.5
XL, EL 16.62
2" XL, EL-30 12 8.62 11.38
2.5" XL, EL-30 18.5 18.62
[1] Clearance to disengage handle
Air Operating Mechanisms

Air operating mechanisms permit automatic,
unattended operation of Modular Special Service For .5" to 8"V
Valves and at higher maximum operating pres- Valve Bodies
sures than would be possible with manual actua-
tors. A broad range of air operating mechanisms are
offered including air cylinders from 1-1/8" diameter x
3" long through 5" diameter x 12" long, and up to as
many as four powerful return springs for quick positive 2" Figure 19-FL-15-3 ATO/SC valve
action upon loss of control air supply. assembly with optional limit switch, bracket
and air control set
Three types of air operating mechanisms
are offered:
• ATO/SC air-to-open/spring closing operating Figure 24 – ATO/ATC air-to-close/air-to-open
mechanism, commonly used on shut-off applica- operating mechanism for double-seated
tions, allow control air to open the valve. Loss of valves
control air supply or electrical power to the control Selection of any air operating mechanism
solenoid valve allows powerful spring closing should begin with the choice of a valve body from
mechanism to close valve body. page 6503-6505 of your catalog, meeting your
Two basic configurations are available: specific flow and pressure requirements. Once valve
Figure 19 – ATO/SC air-to-open/spring close size, series and body type have been determined,
operating mechanism for single-seated refer to the appropriate Specification table to choose
valves your operator.
Figure 20 – ATO/SC air-to-open/spring close
operating mechanism for double-seated WARNING: Maximum operating pressure
valves differential (MOPD) should never exceed the
pressure/temperature limits shown on page
• ATC/SO air-to-close/spring opening operating 6503 for your particular valve body.
mechanism, commonly used on vent or by-pass The following pages include tables listing the air
line applications, allow control air to close the operating mechanisms available, specific valve sizes
valve. Loss of control air supply or electrical power and series which they fit, maximum allowable operat-
to the control solenoid valve allows built-in return ing pressure and required air supply pressure.
spring(s) to open valve body.
Two basic configurations are available: NOTE: Maximum air supply pressure must not
Figure 21 – ATC/SO air-to-close/spring opening exceed 125 psi or 20 psi above the minimum
operating mechanism for single-seated cylinder air pressure shown in specification
valves tables.
Figure 22 – ATC/SO air-to-close/spring opening Accessory items which may be used with air
operating mechanism for double-seated operating mechanisms are shown on page 6526.
valves
To order, specify:
• ATO/ATC air-to-open/air-to-close operating 1. Valve body (size, series, single/double seating,
mechanism, commonly used in process flow trim)
diversion applications, permit both opening and 2. Type of operator desired (ATC/SO, ATO/SC,
closing of valve body by control air. Loss of control ATO/ATC)
air supply or power to the control solenoid will not 3. Accessory items desired
change the valve body position. 4. Quantity and assembly number of each
Two basic configurations are available: 5. Fluid service (analysis, pressure, ambient and
Figure 23 – ATO/ATC air-to-close/air-to-open operating temperatures)
operating mechanism for single-seated
valves
7/00
Specifications
ATO/SC Air-to-Open/Spring Closing Operating Mechanisms
ATO/SC operating mechanisms are shown in Accessories

table on page 6527. To select, locate your desired Optional air control set includes a four way, two
valve size at the left of the table and move right to the position 120/60 AC general purpose air solenoid and
section indicating your particular valve series. In most hoses for control of air supply to cylinder of operating
cases, you will find several selection lines available. mechanism. If not ordered with valve, customer must
Choose the lowest maximum operating differen- supply.
tial pressure (MOPD) line that exceeds your Optional speed control set (1/4", manually
requirements and verify that the required minimum adjusted) restricts intake or exhaust air flow from
cylinder air pressure is available. control valve and so reduces operating speed of air
Additional data provided on the same line include actuator mechanism.
the number of return springs and the air cylinder size Optional limit switch and bracket assemblies
which will be supplied. are also available. Each contains two switches of the
type shown; one indicating full open position; the
other full closed.
Be sure to see general notes and ordering

procedures on page 6525.
Speed Control Air Control Air to Upper

Cylinder Connection
Set Set
Air to Lower ▲
▲
Controlled Cylinder Exhaust

▲
Flow Connection Air In

(ATO/ATC only)
Specifications
ATO/SC air-to-open/spring closing operating mechanisms
Valve Maximum operating pressure Minimum air cylinder Cylinder size
Quantity of springs
Size Series differential (PSIG) pressure (PSIG) dia. x length (in inches)
.5" & .75" SL-60 300 75 1 1-1/8 x 3
110 75 1-1/8 x 3
SL-30
1" 70 1 2x4
SL-60 295
35 3-14 x 4
90 75 1-1/8 x 3
SL-30
1.25" 70 1 2x4
SL-60 245
35 3-14 x 4
SL-30, SL-60 290 50
290 50 3-1/4 x 7
1
1.5" 65
FL-30 410
40
4x7
720 65 2
SL-30 175 50
SL-60 245 65
3-1/4 x 7
175 50 1
65
FL-15 245
40
4x7
2" 490 70 2
175 50
3-1/4 x 7
65 1
245
FL-30 40
490 70 2 4x7
660 90 3
SL-30 140 65 1 3-1/4 x 7
SL-60 275 70 2 4x7
100 50
3-1/4 x 7
65 1
FL-15 140
2.5" 40
4x7
275 70 2
65 3-1/4 x 7
140 1
FL-30 40
4x7
275 70 2
SL-30 95 65 1 3-1/4 x 7
SL-60 190 70 2 4x7
3" 65 3-1/4 x 7
FL-15 95 1
FL-30 40
4x7
190 70 2
65 3-1/4 x 7
45 1
FL-15 40
4x7
90 70
4"
135 65 2 4 x 12
FL-30 100 40
5 x 12
200 70 4
55 65 4 x 12
2
8"V FL-15 40 40
5 x 12
80 70 4
7/00

ATO/SC Air-to-Open/Spring Closing Operating Mechanisms
For .5" through 1.25" SL-30, -60 valves with 1-1/8" dia. x 3" lg cylinder only
Valve A B C
D F
Size Series (cylinder size) (cylinder size & number of return springs) radius
15.19 1.97
.5" & .75" SL-60 --- --- --- 7.12 5
(2" X 3") (2" X 3")
2.38 7.75
SL-30 20.38 20.38
1" & 1.25" (2" X 4" --- --- 10.75 6.12
SL-60 (2" X 4") (3-1/4" X 4")
W/1)
SL-30 26.56 26.69
1.5" & 2" --- --- 6.7
SL-60 (3-1/4" X 7") (4" X 7")
SL-30 27.19 27.31
2.5" & 3" 8.5
SL-60 (3-1/4" X 7") (4" X 7")
1.5"
FL-30
26.56 26.69 1.88
2" 6.5
(3-1/4" X 7") (4" X 7") (3-1/4" X 7" 11.62 6.5
3
FL-15 W/1) 3.06
2.5" (4" X 7"
(4" X 7" W/2)
W/1)
2.5"
FL-30
27.19 27.31
3" 8
(3-1/4" X 7") (4" X 7")
FL-15
4"
4" FL-30 5.25 2.32

34.75 33.62 5
(4" X 12" (5" X 12" 16 6.88 8.88
8"V FL-15 (4" X 12") (5" X 12) (5" X 12" W/4)
W/2) W/2)
NOTE: For dimensions related to valve body details, see catalog pages 6508 and 6509
Specifications
ATC/SO Air-to-Close/Spring Opening Operating Mechanisms
ATC/SO operating mechanisms are shown in Accessories

the table below. To select, locate your desired valve Optional air control sets are available. If not
size at the left of the table and move right to the ordered with valve, customer must supply. Operation
section indicating your particular valve series. In most is described on page 6526.
cases, you will find several selection lines available. Optional speed control set (1/4" ) is described on
Choose the lowest maximum operating differential page 6526.
pressure (MOPD) line that exceeds your requirements Optional quick exhaust valve kit (3/8" ) speeds
and verify that the required minimum cylinder air operation of single acting air operated valves.
pressure is available. Optional limit switch and bracket assemblies
Additional data provided on the same line includes are available. Each contains two switches of the type
the number of return springs and the air cylinder size shown; one indicating full open position; the other full
which will be supplied. closed.
Be sure to see general notes and ordering
procedures on page 6525.
ATC/SO air-to-close/spring opening operating mechanisms

Valve Maximum operating Minimum air cylinder Cylinder size
Number of springs
Size Series pressure differential (PSIG) pressure (PSIG) dia. x length (in inches)
1" SL-30, 60 375 45

3-1/4" X 4"
1.25" SL-30, 60 300 40
1.5" FL-30 425

65
2" FL-15, 30 250
1
FL-15 70
2.5" 150 3-1/4" X 7"
FL-30
65
3" FL-15, 30 100
FL-15 50 70
4"
FL-30 220
110 4 4" X 12"
8"V FL-15 90
7/00

ATC/SO Air-to-Close/Spring Opening Operating Mechanisms
Valve A B C
D E
Size Series (cylinder size) (with number of return springs) radius
SL-30 20.38 2.38

1" & 1.25" 9.12 7.75 6.12
SL-60 (3-1/4" X 4") (W/1)
1.5"
FL-30
26.06
2" 10.5 6.5
(3-1/4" X 7")
FL-15
2.5" 1.88
6.5
2.5" (W/1) 7
FL-30
26.69 8
3" 11.62
(3-1/4" X 7")
FL-15 7
4"
4" FL-30 35.25 4.81
16 6.88 8.8
8"V FL-15 (4" X 12") (W/4)
Specifications
ATO/ATC Air-to-Open/Air-to-Close Operating Mechanisms
ATO/ATC operating mechanisms are shown in Accessories

the table below. To select, locate your desired valve Optional air control sets are available. Operation
size at the left of the table and move right to a section is described on page 6526. If not ordered with valve,
applying to your particular valve series. customer must supply.
Three columns of selection data are offered. Optional speed control set (1/4" ) is described on
Choose the one applying to your available air supply page 6526.
pressure (30, 60 or 90 PSIG) then identify the lowest Optional limit switch and bracket assemblies
maximum operating pressure differential (MOPD) are available. Each contains two switches of the type
which meets your requirements. shown: one indicating full open position; the other full
CAUTION: If air pressure to air control set is closed.
lost, valve remains in position held at that time;
but if only electrical supply to air control set Be sure to see general notes and ordering
solenoid is lost valve returns to its initial at rest instructions on page 6525.
position.
ATO/ATC operating mechanisms

Maximum operating pressure differential (PSIG)
Valve Cylinder size
at indicated cylinder air pressure
dia. x length (in inches)
Size Series 30 PSIG 60 PSIG 90 PSIG
.5" & .75" SL-60 300 790 1200 2" X 3"
SL-30 75 195 240 1-1/8" X 3"
1"
SL-60 500 1150 1200 3-1/4" X 4"
SL-30 60 150 260 1-1/8" X 3"
1.25"
SL-60 41 5 975 1200 3-1/4" X 4"
SL-30
1.5" 10 0 270 440
SL-60
2" X 7"
SL-30
2" 60 160 265
SL-60
FL-15 10 0 240 275 3-1/4" X 7"
2.5"
FL-30 195 435 680
FL-15
3" 130 295 460 4" X 7"
FL-30
FL-15 65 145 225
4" 100 225 350 4" X 12"
FL-30
165 365 565 5" X 12"
45 95 150 4" X 12"
8"V FL-15
70 155 240 5" X 12"
7/00

ATO/ATC Air-to-Open/Air-to-Close Operating Mechanisms
For 1" & 1.25" SL-30, -60 Valves For all others
with 1-1/8" x 4" cylinder only
Valve A B C
D F
Size Series (cylinder size) (cylinder size) radius
14.44 1.25
.5" & .75" SL-60 --- --- 7.12 5
(2" x 3") (2" x 3")
7.75
SL-30 17.38 1.88
1" & 1.25" --- --- 9 6.12
SL-60 (3-1/4" x 4") (3-1/4" x 4")
SL-30 22.56 1.25
1.5" & 2" --- --- 6.7
SL-60 (2" x 7") (2" x 7")
22.56 1.88
FL-15 --- --- 6.2
2.5" (3-1/4" x 7") (3-1/4" x 7")
FL-30 --- --- 10.12 6.5
7
FL-15 25.31 --- 2.25 ---
3"
FL-30 (4" x 7") --- (4" x 7") --- 8
FL-15 --- --- 7

4"
FL-30 32.75 33.62 2.25 2.75 8.9
15.12 6.9
8"V FL-15 (4" x 12) (5" x 12) (4" x 12") (5" x 12") 8.7
Threaded Body Assemblies - Valve Bodies
Body Parts (threaded valves)

Item Description Item Description
1 – Hex nut (Trim -3) 7 – Information plate
– Hex nut (Trim -5) 8 – Escutchen pin
– Hex nut (Trim -5) SL-30- only 9 – Hex nut
2 – Body gasket set [1] 10 – Stud (gland)
3 – Disc (single seat) Trim -3 11 – Gland
– Disc (single seat) Trim -5 12 – Outer stem packing [1]
3d – Disc (double seat) Trim -3 13 – Stem bushing: current (square)
– Disc (double seat) Trim-5 – Stem bushing: old style (hex)
4 – Disc spring 14 – Stem bushing gasket [1]
5 – Disc carrier (single) 15 – Inner stem packing [1]
5d – Disc carrier (double) 16 – Stem
6 – Body SL-25 (single seat) 17 – Packing nut
– Body SLD-30 (single seat)
– Body SL-60 (single seat) [1] Component listed normally will be furnished as a
6d – Body SL-25 (double seat) part of the valve body maintenance kit
– Body SLD-30 (double seat)
– Body SL-60 (double seat)
7/00
Threaded Body Assemblies - Operating Mechanisms
Parts for wheel operating mechanisms Parts for rack & pinion operating
mechanisms
Item Description
20 – Sector (left hand) Item Description
– Sector (right hand) 36 – Sector
21 – Shaft bearing 37 – Socket head cap screw
22 – Worm gear (left hand) 38 – Information plate
– Worm gear (right hand) 39 – Escutcheon pin
23 – Badge plate 40 – Pinion lever
24 – Drive shaft 41 – Pinion lever handle
25 – Worm shaft (left hand) 42 – Hex nut
– Worm shaft (right hand) 43 – Hex head cap screw
26 – Cotter pin 44 – Lockwasher
27 – Shaft washer 45 – Hex head cap screw
28 – Gear case 46 – Pinion lever adapter plate
29 – Hex head cap screw 47 – Eccentric fulcrum
30 – Lockwasher 48 – Flat steel washer
31 – Handwheel caution plate
32 – Hex nut
33 – Handwheel
34 – Spacer
Parts for lever operating mechanisms
Item Description
18 – Stem nut
19 – Lockwasher
35 – Handle
Flanged Body Assemblies – Valve Bodies
Body parts (flanged valves)

1 – Hex nut to body stud 10 – Disc seat
2 – Outlet (straight) 11 – Badge plate
– Outlet - XL 15 – Hex nut (2)
– Outlet - EL 16 – Packing gland
3 – Body stud 17 – Gland stud
4 – Body gasket set [1] 18 – Outer packaing set [1]
5 – Renewable seat 19 – Stem bushing (current: square)
6 – Disc (single seat) – Stem bushing (old style: hex)
6d – Disc (double seat) 20 – Stem bushing gasket [1]
7 – Disc spring (single seat) 21 – Inner packing [1]
7d – Disc spring (double seat) 22 – Stem
8 – Disc carrier (single seat) – Stem (XL & EL only)
8d – Disc carrier (double seat) 25 – Packing nut
9 – Body (single seat)
9d – Body (double seat) [1] Component listed normally will be furnished as a
part of the valve body maintenance kit
7/00
Flanged Body Assemblies – Operating Mechanisms
"XL" & "EL"

valves only
All others
Flanged Body Assemblies – Operating Mechanisms
Parts for wheel operating mechanisms Parts for lever operating mechanisms
23 – Hex, jam nut (XL & EL only) 12 – Handle (FL)
24 – Lockwasher (XL & EL only) – Handle (EL & XL)
26 – Socket jam screw (FL only) 13 – Handle cap screw
27 – Taper screw (FL only) 14 – Hex nut
28 – Sector FL (right hand) 23 – Hex, jam nut (XL & EL only)
– Sector XL & EL (right hand) 24 – Lockwasher (XL & EL only)
– Sector FL (left hand)
– Sector XL & EL (left hand)
29 – Worm gear FL (right hand)
– Worm gear XL & EL (right hand) Parts for rack & pinion operating
– Worm gear FL (left hand) mechanisms
– Worm gear XL & EL (left hand)
30 – Thrust washer Item Description
31 – Bearing 57 – Socket jam screw
32 – Body stud 58 – Taper screw (FL only)
33 – Gear pad spacer 59 – Sector (FL only)
34 – Pin – Sector (EL & XL only)
35 – Drive screw 60 – Flat steel washer
36 – Badge plate 61 – Information plate
37 – Cotter pin 62 – Pinion lever
38 – Shaft washer 63 – Hex nut
39 – Gear case 64 – Pinion lever handle
40 – Lockwasher 65 – Hex head cap screw
41 – Hex nut (heavy) 66 – Hex nut (heavy)
42 – Square head set screw 67 – Lockwasher
43 – Plug 68 – Adapter stud
44 – Spacer 69 – Hex nut (jam)
45 – Shaft bearing 70 – Lockwasher
46 – Bearing 71 – Pinion lever adapter plate
47 – Adjusting screw 72 – Eccentric fulcrum
48 – Worm shaft (left hand) 73 – Cotter pin
– Worm shaft (right hand) 74 – Hex head cap screw
49 – Hand wheel 75 – Socket head cap screw
50 – Hand wheel caution plate
51 – Hex nut
52 – Spring
53 – Washer
54 – Bushing (Oilite)
55 – Hex head cap screw
7/00
Notes
“Modular” Special Service Valves Page 6500-S-1
Installation/Operating/Maintenance Instructions
General Data: Operation:
Maxon “Modular” Special Service Valves Do not exert excessive force at the end of travel
feature metal-to-metal seating. Because seating on manually-operated valves. Shut-off is obtained
faces of discs and seats are ultra-lapped to near- as soon as the disc laps the seat. Since discs are full-
perfect flatness, parts are field-replaceable. floating and move parallel to the seats (without
Valves discs are full-floating and move parallel wedging), strain on the operating mechanism and
to the seats. They do not wedge but wipe seat faces stem packing can be minimized by backing off slightly
clean due to the combined action of line pressure and from either full-open or closed position.
disc spring. Discs also rotate a few degrees with each “Modular” Special Service Valves require no
operation, thus promoting uniform wear. lubrication to provide tight shut-off. The stem
packing gland is properly adjusted at assembly. If
Single-seated valves seal in the indicated
stem leakage develops, tighten gland or stud as
direction only. Double-seated valves may be
necessary, or remove from line and replace packing.
installed with flow in either direction.
The operating mechanisms of Rack & Pinion or
All valves are non-lubricated and provide a full- geared valves may be lubricated. An eccentric
open, non-restricted port. Each is leak-tested and screw permits adjustment of tooth engagement on
cycled at 150% of its maximum rated pressure before some Rack & Pinion Valves.
shipment.
To insure long valve life and dependable service, Maintenance:
read and follow the installation and operating proce- If the simple installation and operating instructions
dures outlined below. outlined above have been observed, Maxon “Modular”
Special Service Valves will give long and satisfactory
All valves except those intended for oxygen service without further attention. We recommend,
service are sprayed internally with a rust however, that you run periodic checks observing
preventative oil after final factory tests. This operation and noting any departure from normal feel
should be flushed out with a good solvent or conditions.
before installation. Seats and discs may be relapped in the field if
scratches are only minor. Worn or deeply scratched
Installation: parts should be replaced with new.
All valves are shipped with end protectors to If adjustment or repairs are necessary, your
prevent entrance of foreign material in valve or valve can be returned to our factory in Muncie,
damage to flange faces or threads. Do not remove Indiana for reconditioning on a “time and material”
protectors until ready to install. basis, or parts can be supplied for your installation per
Piping and upstream systems should be blown the procedures outlined on the back of this sheet.
or flushed clear of abrasive materials which could
cause damage to valve seats and discs. See component identification drawings and
accompanying tables for identification. Always
If optional manual bleed has been furnished
specify quantity, assembly number, valve size,
with double-seated valves, note carefully the fluid
serial number, and all available nameplate
temperature limitation of 450°F imposed by the Teflon
information when ordering repair parts.
seat within bleed valve.
Do not orientate valve with body bulge down- Various valve operating mechanisms such as
ward or line debris may accumulate there to prevent wheels, cylinders, solenoids, springs and fusible
full-opening. links may require additional maintenance as
indicated in applicable catalog pages.
WARNING: Do not tighten or loosen hex nut of Fusible link valves should be inspected regularly
threaded valves. Use two wrenches: one to for dust, corrosion, grease or paint build-up which might
hold hex nut, the other to turn pipe. Failure to affect link accuracy or performance. A spare link should
do so may affect valve operation and/or cause be kept on hand, and in some circumstances, periodic
leakage. replacement may be desirable.
Air Cylinders should be inspected regularly for
O-ring seal deterioration and care taken to maintain a
“dry” air supply.

mCORPORATION
Page 6500-S-2 “Modular” Special Service Valves
To disassemble: seat permanently. (Double-seated bodies 1-1/2"
Refer to appropriate component identification diagram and smaller must have stem and disc carrier
on pages 6533 to 6537, then: placed on a ledge or track, which assures align-
1. Remove Rack & Pinion or gear assembly secured ment with the discs, to prevent locking.)
to body by cap screws (and stud nut for some 7. Flanged valves only: reinstall outlet to body,
flanged valves). pulling stud nuts down gradually and evenly
2. Remove handle or stem nut and sectors (fitted according to the following sequence correspond-
over a tapered square on stem end). ing to the number of studs present (1-3-2-4,
3. Open valve fully so that discs are contained in the 1-4-3-6-2-5, or 1-5-3-7-2-6-8-4).
body bulge. 8. Replace any additional operating mechanism re-
4. Flanged valves only: remove stud nuts and lift off moved in steps 1 and 2 of disassembly procedure.
outlet. 9. Cycle valve repeatedly to check for proper operation.
5. Threaded valves: remove hex nut seat by un- Be sure to pressure test for leakage before
screwing from body. Discard used metal ring valve is placed back in service.
gaskets. Flanged valves: remove stem-side seat,
tapping outside of the body (not seat) if necessary
to break it loose. Seat Alignment:
6. For double-seated valves: remove back disc and
WRONG – Insufficient
hex nut seat. Threaded valves: will require an
gaskets. Disc must climb seat
open-end wrench of proper size and handle
in closing and will not wipe
extension to provide necessary leverage. Flanged seat properly. Add gaskets to
valves: may require a special spanner wrench. align seat surface with disc
7. Close valve and remove disc(s). track.
8. Remove gland assembly, stem bushing, stem and
carrier in order listed.
RIGHT – Seating surface in
To reassemble: alignment with disc track.
1. Clean body and all parts thoroughly, inside and out. Select gaskets to give best
2. Make certain that all machined surfaces where possible alignment.
gaskets are applied are clean and smooth. During
assembly, use only new gaskets of a compound
such as “TITE SEAL, LIGHTWEIGHT GASKET
AND JOINT SEALING” or equivalent. WRONG – Too many
3. Install back disc and hex nut seat of double-seated gaskets. Disc must climb disc
valves. track to open, causing hard
4. Install carrier, stem, stem bushing and gland operation. Remove gaskets to
assembly. If composition packing is used, tighten align seat surface with disc
to 40 ft-lbs then loosen and retighten to 10 ft-lbs. If track.
Teflon packing is used, tighten firmly.
5. Replace disc and disc spring and move valve to
OPEN position so disc(s) is/are contained in body Inlet Torque (threaded body):
bulge. Once gaskets have been chosen to give proper
seat alignment, threaded body seat should be torqued
WARNING: Valve must be in OPEN position when
into place with approximate force (ft-lbs) shown in
installing seat, or both seat and disc may be damaged.
table below. Over-tightening can damage threads.
6. Make test installation of hex nut seat (threaded Under-tightening can cause leakage. (Additional data
bodies) or seat (flanged bodies) using a test upon request.)
combination of various metal ring gasket thick-
Seat Type
nesses supplied. Seats must be as nearly in line
Valve Size Iron Steel Stellited
with the disc track and body as is possible. See
w/S.S. seat ring w/S.S. seat ring steel
accompanying illustration for proper alignment.
1/2" & 3/4" --- --- 175
Select the combination of gasket sizes which gives
1" 125 200 375
best alignment and smooth operation, then apply
1-1/4" 145 225 400
gasket compound to each gasket and assemble
1-1/2" --- --- 425
m
2" --- --- 525
CORPORATION
“Modular” Special Service Valves Page 6500-A/P-1
Assembly Numbers
Valve Body Selection
Threaded Valve Body Sub-assemblies Flanged Valve Body Sub-assemblies

Valve Configured Product Numbers Valve body size Configured Product Numbers
Body (raised face flange) Single seated valve Double seated valve
Single seated valves Double seated valves
Size
(NPT) Trim #3 Trim #5 Trim #3 Trim #5 1" 1 0XL30 ---
.5 0SL25 --- .5 00SL25 --- 1-1/4" 1.25 0XL30 ---
.5"
.5 0SL60 --- .5 00SL60 --- 1.5 0XL30 1.5 00XL30
.75 0SL25 --- .75 00SL25 ---
1-1/2" 1.5 0EL30 1.5 00EL30
.75"
.75 0SL60 --- .75 00SL60 ---
1.5 0FL30 1.5 00FL30
1 0SL25 1 0SL25 1 00SL25 1 00SL25
2 0XL30 2 00XL30
1" --- 1 0SL30 --- 1 00SL30
2 0EL30 ---
1 0SL60 --- 1 00SL60 --- 2"
2 0FL15 2 00FL15
1.25 0SL25 1.25 0SL25 1.25 00SL25 1.25 00SL25
2 0FL30 2 00FL30
1.25" --- 1.25 0SL30 --- 1.25 00SL30
2.5 0XL30 2.5 00XL30
1.25 0SL60 --- 1.25 00SL60 ---
1.5 0SLD30 1.5 0SLD30 1.5 00SLD30 1.5 00SLD30 2.5 0EL30 2.5 00EL30
2-1/2"
--- 1.5 0SL30 --- 1.5 00SL30 2.5 0FL15 ---
1.5"
1.5 0SL60 --- 1.5 00SL60 --- 2.5 0FL30 2.5 00FL30
2 0SLD30 2 0SLD30 2 00SLD30 2 00SLD30 3 0FL15 3 00FL15

3"
2" --- 2 0SL30 --- 2 00SL30 3 0FL30 3 00FL30
2 0SL60 --- 2 00SL60 --- 4 0FL15 4 00FL15
4"
--- 2.5 0SL30 --- 2.5 00SL30 4 0FL30 4 00FL30
2.5"
2.5 0SL60 --- 2.5 00SL60 --- 6" 6 0FL30 6 00FL60
--- 3 0SL30 --- 3 00SL30
3" 8"V 8V 0FL15 ---
3 0SL60 --- 3 00SL60 ---

mCORPORATION
Page 6500-A/P-2 “Modular” Special Service Valves
Assembly Numbers
Valve Body Selection
Configurator Segment Choice Detail - Valve Bodies

Segment Choices
(DEFAULT is shaded)
Valve Body Trim TRIM3 Stellited steel seat and disc

(default varies according to size) TRIM5 Stellited steel seat and nodular iron disc
STD Grafoil inner, Teflon outer 450F (Std)
Stem Packing Trim TRIMG Grafoil packing 1000F (TrimG)

TRIMT Teflon packing 450F (TrimT)
Socket Weld Nipples NONE No socket weld nipples

(available for .5" to 2" SL only) Segment choices vary according to size
Flanges NONE No flanges
Couplings NONE No couplings desired
Optional Grounding Strap YES Need oxy serv ground strap
(Flanged bodies only) NONE Grounding strap not needed
Operating Mechanism Choice of up to 12 operating mechanisms - See table below
Operating Temp Deg. F Enter value from -20°F to 1000°F
Operating Pressure PSI Enter value from 0 to 5000
WOG Rating (PSI) 500 Only choice available
YES Oxygen being used
Oxygen Service (SPL Degrease)
NO Some other fluid besides oxygen
NO No tag desired
SS Wire-On Tag
YES 31616 Tag Desired
Assembly Numbers Operating Mechanism Segment Choices

Configured Product
Operating Mechanisms Type of Mechanism
Number
Air to Close, Spring to Open ATCSO
Select an operating mechanism from the Air to Open, Air to Close ATOATC
table at right Air to Open, Spring to Close ATOSC
Cross Lever CLVR
Lever LVR
Right Hand Wheel RHWHL
Rack & Pinion RP
Spring Close Fusible Link SCFL
Spring Open Fusible Link SOFL
Spring Closing SPRINGRET
Standard Left Hand Wheel WHL
Right or Left Hand Wheel & Chain WHLCHN
m CORPORATION

Assembly Numbers
Lever Operating Mechanism Segment Choice Detail

Segment Choices
Operating Mechanism Segment Name Segment Choice Description
(DEFAULT is shaded)
DPDTHD Double pole, double throw, hazardous duty
Limit Switch Type DPDTMP Double pole, double throw, moisture-proof

(switches not available
NONE No limit switches wanted
on some XL & EL
LVR versions) SPDTHD Single pole, double throw, hazardous duty
SPDTMP Single pole, double throw, moisture-proof
NONE Locking device not wanted

Locking Device
YES Want optional lock device
Cross Lever Operating Mechanism Segment Choices

Segment Choice
(DEFAULT is shaded)
Limit Switch Type DPDTMP Double pole, double throw, moisture-proof

(switches not available
NONE No limit switches wanted
on some XL & EL
versions) SPDTHD Single pole, double throw, hazardous duty
CLVR SPDTMP Single pole, double throw, moisture-proof
NONE Locking device not wanted

Locking Device
YES Want optional lock device
20 Default chain length (10 ft. closed loop = 20 ft.)

Chain Length (Ft)
Specify value Specify chain length if over 20 feet is required
Rack & Pinion Operating Mechanism - not configured
To order, specify the following:

1. Valve (size, series, single/double seating, trim)
2. Type of operator desired (rack & pinion)
3. Quantity and assembly number (from table below)
4. Fluid service (analysis, pressure, ambient and operating temperatures)
Rack & Pinion Operating Mechanism Assembly Numbers

Nominal Valve Size
Valve Series
1.5" 2" 2.5" 3" 4" 6" 8"V
FL-15 --- 71886 71892 --- 71899
71886 71892
FL-30 74446 71892 71899 71900 ---
XL-30
71887 71887 71893 --- --- --- ---
EL-30

mCORPORATION
Assembly Numbers
Wheel & Chain Operating Mechanism Segment Choice Detail

Segment Choices
(DEFAULT is shaded)
RH Right hand wheel
Position of Wheel
STD Standard left hand wheel
WHLCHN
20 Default value
Chain Length (Ft)
Specify value Specify length of chain if over 20 ft. is required
Right Hand Wheel (RHWHL) and Standard Left Hand Wheel (WHL) - not configured
To order, specify the following:

1. Valve body (size, series, single/double seating, trim)
2. Type of operator desired (standard wheel, right hand wheel)
3. Accessory items desired
4. Quantity and assembly number of each (see tables below)
5. Fluid service (analysis, pressure, ambient and operating temperatures)
Standard Left Hand Wheel (WHL) Operating Mechanism Assembly Numbers

Nominal Valve Size
Valve Series
1", 1.25" 1.5" 2" 2.5" 3" 4" 6" 8"V
SL-25 --- --- --- --- --- --- ---
71882
SL-30, 60 71894 71894 --- --- ---
71888 71888
SLD-30 --- --- --- --- --- ---
FL-15 --- --- 71884 71897 --- 71891
71884 71897
FL-30 --- 71884 71897 71891 72654 ---
EL-30 --- --- --- --- ---
71888 71888 71894
XL-30 71882 --- --- --- ---
Right Hand Wheel (RHWHL) Operating Mechanism Assembly Numbers

Nominal Valve Size
Valve Series
1", 1.25" 1.5" 2" 2.5" 3" 4"
SL-25 --- --- --- --- ---
71883
SL-30, 60 71895 71895 ---
71889 71889
SLD-30 --- --- --- ---
FL-15 --- --- 71890 71898
71890 71898
FL-30 --- 71890 71898 ---
EL-30 --- --- ---
71889 71889 71895
XL-30 71883 --- ---
mCORPORATION

Assembly Numbers
Spring Return Operating Mechanism Segment Choice Detail

Segment Choices
(DEFAULT is shaded)
SS Stainless extension spring
SPRINGRET Extension Spring Material
STD Standard extension spring
Spring Closing Fusible Link Operating Mechanism Segment Choice Detail

Segment Choices
(DEFAULT is shaded)
LINK165 Standard 165°F link
Link Temperature Ratings LINK212 Optional 212°F link
SCFL LINK286 Optional 286°F link

Extension Spring Material*
*The stainless steel extension spring is standard on .5 & .75 SL versions and 4" & 6" FL30 versions
Spring Opening Fusible Link Operating Mechanism Segment Choice Detail

Segment Choices
(DEFAULT is shaded)
LINK165 Standard 165°F link
Link Temperature Ratings LINK212 Optional 212°F link
SOFL LINK286 Optional 286°F link

Extension Spring Material

m CORPORATION
Assembly Numbers
Air-to-Open, Spring-to-Close Operating Mechanism Segment Choice Detail

Segment Choices
Operating Mechanism Segment Name Segment Choice Detail
(DEFAULT is shaded)
Cylinder Segment choices vary according to valve size
Optional NONE No speed control set

Speed Control Set YES Speed control set
Optional NONE No air control set

Air Control Set YES Air control set
ATO/SC
DPDTMP Double pole, double throw, moisture-proof
Limit Switch Type NONE No limit switches wanted

SPDTHD Single pole, double throw, hazardous duty
Air-to-Close, Spring-to-Open Operating Mechanisms Segment Choice Detail

Segment Choices
(DEFAULT is shaded)


Air Control Set YES Air control set
Optional NONE No exhaust valve

Quick Exhaust Valve
ATC/SO YES Exhaust valve

mCORPORATION

Assembly Numbers
Air-to-Open, Air-to-Close Operating Mechanism Segment Choice Detail

Segment Choices
(DEFAULT is shaded)
Assembly Choice 72981 Lower MOPD choice

(4 FL30, 8V only) 72982 Higher MOPD choice


Air Control Set*
ATO/ATC YES Air control set

SPDTMP Double pole, double throw, moisture-proof
*If not ordered with valve, customer must supply

mCORPORATION
Assembly Numbers
For Threaded Body Valves
Body parts (threaded valves)

Item Description .5" .75" 1" 1.25" 1.5" 2" 2.5" 3"
Hex nut (Trim -3) 70765 70766 20242 20543 71627 70466 71644 71636
1 Hex nut (Trim -5) --- --- 20246 20540 71626 70464 74344 71638
Hex nut (Trim -5) SL-30-5 only --- --- 20242 20543 71627 70466 71641 71636
2 Body gasket set [2] [2]
Disc (single seat) Trim -3 70732 20254 20250 71031 70510 70144 70130
3
Disc (single seat) Trim -5 --- 20252 20248 71045 70139 71316 71177
Disc (double seat) Trim -3 70732 71393 71366 70587 70506 71492 71337
3d
Disc (double seat) Trim -5 --- 71391 71368 71524 70441 71491 71448
4 Disc spring 70783 20326 71416 20050 20056
5 Disc carrier (single) 70772 20287 20251 71517 70431 71485 70131
5d Disc carrier (double) 70782 71395 71365 71523 70446 71489 71444
Body SL-25 (single seat) 73587 73588 70792 71399 ---
6 Body SLD-30 (single seat) --- 71326 70370 --- ---
Body SL-60 (single seat) 71345 71346 71411 71398 71325 71323 71315 71401
Body SL-25 (double seat) 73589 71389 71363 ---
6d Body SLD-30 (double seat) --- 71342 70590 --- ---
Body SL-60 (double seat) 70222 70305 71362 71343 70396 71359 71417
7 Information plate 71053 70009
8 Escutchen pin 40159
9 Hex nut --- 40035
10 Stud (gland) --- 70030 70031
11 Gland 70788 70999 70140 70129
12 Outer stem packing [2] [2]
Stem bushing: current (square) 74307 74308 74309 70147 [1]
13
Stem bushing: old style (hex) 70769 70773 70141 70147
14 Stem bushing gasket [2] [2]
15 Inner stem packing [2] [2]
16 Stem 70771 70790 70430 71330
17 Packing nut 74303 ---
[1] Hex, not square
[2] Component listed normally will be furnished as a par t of the valve body maintenance kits listed on page 6500-A/P-9.
mCORPORATION

Assembly Numbers
For Threaded Body Valves
Parts for wheel operating mechanisms Parts for lever operating mechanisms
Item Description 1" & 1.25" 1.5" & 2" 2.5" & 3" .5" & 1" & 1.5" & 2.5" &
Item Description
Sector (left hand) 71371 71711 71402 .75" 1.25" 2" 3"
20 18 Stem nut 40028 40040 40046 40058
Sector (right hand) 71372 71712 71403
19 Lockwasher 40097 40100 40102 40103
21 Shaft bearing 71373 71720
35 Handle 70770 70793 70385 70358
Worm gear (left hand) 71369 70252
22
Worm gear (right hand) 71370 70253 Parts for rack & pinion operating mechanisms
23 Badge plate 70304 71885 Item Description 1.5" & 2" 2.5" & 3
24 Drive screw 40420 36 Sector 70447 71387
Worm shaft (left hand) 71376 70428 71404 37 Socket head cap screw 40378 40384
25 38 Information plate 71536 71530
Worm shaft (right hand) 71386 70425 70426
39 Escutcheon pin 40159
26 Cotter pin 40124 40135
40 Pinion lever 73535 73534
27 Shaft washer 71374 70301
41 Pinion lever handle 73537 73538
28 Gear case 71375 70722
42 Hex nut 40019
29 Hex head cap screw 40292 40325
43 Hex head cap screw 40269
30 Lockwasher 40097 40101 44 Lockwasher 40101
31 Handwheel caution plate 71182 45 Hex head cap screw 40325
32 Hex nut 40028 40035 46 Pinion lever adapter plate 70450 71413
33 Handwheel 71364 70247 47 Eccentric fulcrum 74447 71414
34 Spacer --- 71405 48 Flat steel washer 40081 40084
Valve body maintenance kits for threaded body valves

Valve size .5" & .75" 1" 1.25" 1.5" 2" 2.5" 3"
Kit assembly number 74502 74503 74504 74505 74506 74507 74508
Valve body maintenance kits include standard stem packing (inside and outside), stem bushing gasket, and body gasket set. Normally
recommended when any internal par t is replaced in a threaded body assembly.

m CORPORATION
Assembly Numbers
For Flanged Body Valves
Valve body maintenance kits for flanged body valves

Size 1.5" 2" 2.5" 3" 4" 6" & 8"V 8"V 6"
Valve FL-15 FL-15
Series FL-30 FL-15 FL-30 FL-15 FL-30 0-FL-15 00-FL-15 FL-30
FL-30 FL-30
Kit assembly number 74509 74510 74511 74512 74513 74514 74515 74516 74518 74517
Valve body maintenance kits include standard stem packing (inside and outside), stem bushing gasket and body gasket set. Normally
recommended when any internal par t is replaced in a flanged body valve assembly.
mCORPORATION

Assembly Numbers
For Flanged Body Valves
Body parts for flanged body valves

Series FL-15 Item Series FL-30, XL- and EL-30
Part Description
2" 2.5" 3" 4" 6" 8"V No. 1" 1.25" 1.5" 2" 2.5" 3" 4" 6"
40041 40053 1 Hex nut to body stud 40041 40048 40053 40059 40053
70135 70133 71253 70027 71057 Outlet (straight) --- 71514 70422 71483 71435 71451 70226
--- 2 Outlet - XL 71128 70996 71537 71534 71531 ---
--- Outlet - EL --- 71538 71535 71532
70039 70040 70041 3 Body stud 70040 71035 70034 70035 70036 70037 70038 70037
[1] 4 Body gasket set [1] [1]
70137 70174 70132 71252 70024 5 Renewable seat 71131 70994 70562 70137 70174 70132 70349 70413
70510 70144 70130 71251 70414 6 Disc (single seat) 20254 20248 71031 70510 70144 70130 71383 70414
70506 71492 71447 71466 70410 6d Disc (double seat) --- 70587 70506 71492 71447 71456 70414
20050 20056 70023 7 Disc spring (single seat) 20326 71416 20050 20056 70023
20050 20056 7d Disc spring (double seat) --- 71416 20050 20056 70023
70212 70143 70131 71250 70022 8 Disc carrier (single seat) 20287 20251 71517 70212 71485 70131 71504 70383
70446 71818 71444 71464 70438 8d Disc carrier (double seat) --- 71523 70446 71489 71444 71455 70377
70172 70177 70176 71254 70059 71058 9 Body (single seat) 71132 71025 70366 70376 71482 71434 71499 70220
70374 71493 71500 71463 71505 71575 9d Body (double seat) --- 71520 70375 71488 71441 71453 70218
70577 71494 71502 70350 71794 71576 10 Disc seat --- 71527 70578 71495 71450 70350 71794
70009 11 Badge plate 71053 70009
40033 40033 --- 15 Hex nut (2) --- 40033 40033 ---
70140 70129 70025 16 Packing gland 70999 70140 70129 70025
70030 70031 17 Gland stud --- 70030 70031 70032 70033
[1] 18 Outer packing set [1] [1]
74309 70147 70145 Stem bushing (current: square) 74308 74309 70147 70145 70347
19
70141 70147 70145 Stem bushing (old style: hex) 70773 --- 70141 70147 70145 70347
[1] 20 Stem bushing gasket [1] [1]
[1] 21 Inner packing [1] [1]
70150 70128 70058 Stem --- 71516 70150 71484 70128 70058 70416
22
--- Stem (XL & EL only) 70790 71651 71803 ---
--- 25 Packing nut 74304 ---
[1] Component listed normally will be furnished as a par t of the valve body maintenance kit shown on page 6500-S-10.

m
CORPORATION
Assembly Numbers
Parts for lever operating mechanisms (flanged body valves)
Part Description
2" 2.5" 3" 4" No. 1" 1.25" 1.5" 2" 2.5" 3" 4"
70138 70107 Handle (FL) --- 70138 70107 70108 70019
12
--- Handle (EL & XL) 70743 70793 70385 71358 ---
40300 40307 13 Handle cap screw --- 40300 40307 40650
40028 40031 14 Hex nut --- 40028 40031 ---
--- 23 Hex, jam nut (XL & EL only) 40040 40046 40058 ---
--- 24 Lockwasher (XL & EL only) 40100 40102 40103 ---
Parts for rack & pinion operating mechanisms (flanged body valves)
Part Description
2" 2.5" 3" 4" 6" 8"V No. 1.5" 2" 2.5" 3" 4" 6"
40412 40413 57 Socket jam screw 40412 40413 40414
71140 71091 58 Taper screw (FL only) 71140 71091 70453 ---
70409 71481 71460 71899 Sector (FL only) 70409 71481 71460 70382
59
--- Sector (EL & XL only) 70447 71387 ---
40081 40084 --- 60 Flat steel washer 40081 40084 ---
71536 61 Information plate 71536
73535 73534 73536 62 Pinion lever 73535 73534 73536
40019 63 Hex nut 40019
73537 73538 73539 64 Pinion lever handle 73537 73538 73539
40269 65 Hex head cap screw 40269
--- 40048 66 Hex nut (heavy) --- 40048
40101 40102 67 Lockwasher 40101 40102
--- 70415 68 Adapter stud --- 70415
--- 40058 69 Hex nut (jam) --- 40058
--- 40103 70 Lockwasher --- 40103
70450 71413 70379 71 Pinion lever adapter plate 70450 71413 70379
70451 71414 70380 72 Eccentric fulcrum 7447
70451 71414 70380
--- 40135 73 Cotter pin --- 40135
40325 --- 74 Hex head cap screw 40325 ---
40664 40384 75 Socket head cap screw 40378 40664 40384
m CORPORATION

Assembly Numbers
Parts for wheel operating mechanisms (flanged body valves)
Part description
2" 2.5" 3" 4" 6" 8"V No. 1" 1.25" 1.5" 2" 2.5" 3" 4" 6" [1] 6" [2]
--- 23 Hex, jam nut (XL & EL only) 40040 40046 40058 ---
--- 24 Lockwasher (XL & EL only) 40100 40102 40103 ---
40412 40413 26 Socket jam screw (FL only) --- 40412 40413 70714 40414
71140 71091 27 Taper screw (FL only) --- 71140 71091 70453
70368 71478 --- Sector FL (right hand) --- 70368 71478 ---
--- Sector XL & EL (right hand) 71372 71712 71403 ---
28
70367 71477 71479 71477 Sector FL (left hand) --- 70367 71477 71479 71671
--- Sector XL & EL (left hand) 71371 71711 71402 ---
70253 --- Worm gear FL (right hand) --- 70253 ---
--- Worm gear XL & EL (right hand) 71370 70253 ---
29
70252 70436 Worm gear FL (left hand) --- 70252 70436
--- Worm gear XL & EL (left hand) 71369 70252 ---
--- 30 Thrust washer --- 71687
31 Bearing --- 71830
--- 70035 32 Body stud --- 70035
--- 33 Gear pad spacer --- [3]
--- 34 Pin --- 33418
40420 35 Drive screw 40420 40426 40420
71885 71533 36 Badge plate 70304 71885 71533
40135 37 Cotter pin 40129 40135 40136
70301 38 Shaft washer 71374 70301 40085
70722 71400 39 Gear case 71375 70722 71400 71675
40101 40102 40 Lockwasher 40097 40101 40102
--- 40048 41 Hex nut (heavy) --- 40048
--- 42 Square head set screw --- 40532
--- 43 Plug --- 71678
--- 71405 --- 44 Spacer --- 71405 --- 71673
71720 70256 45 Shaft bearing 71373 71720 70256 71688
--- 46 Bearing --- 71831
--- 47 Adjusting screw --- 71676
70428 71404 70435 Worm shaft (left hand) 71376 70428 71404 70435 --- 71674
48
70425 70426 --- Worm shaft (right hand) 71386 70425 70426
70247 70418
49 Hand wheel 71364 71363 70247 70418 70246
71182 50 Hand wheel caution plate 71182
40035 51 Hex nut 40028 40035
--- 52 Spring --- 70251
--- 53 Washer --- 40085
--- 70257 54 Bushing (Oilite) --- 70257 ---
40325 --- 55 Hex head cap screw 40242 40492 40325 ---
[1] Valves built prior to Jan. 1, 1983 unless designated HRW (High Ratio Wheel)
[2] Valves built after Jan. 1, 1983 or designated HRW (High Ratio Wheel)
[3] Combination of #74345 (.060"), #74346 (.125") and #74347 (.188") as determined at assembly.

m CORPORATION
Notes
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CORPORATION

Product: Air-to-Open Relay Valves Page: 6500-3 Date: 7/92
Maxon Air-to-Open Relay Valve
• 3/8" bronze body

• 600 psi WOG rating
• Operated by 50-150 psi air
Maxon Air-to-Open Relay Valves open and close a fluid line in

response to varying instrument control air. Simple design without
timing element or nozzles makes the unit virtually trouble-free.
Product: Air-to-Open Relay Valve Page: 6500-4 Date: 7/92
Operation
Mounted in a line to control fluid flow, Maxon’s Air- Lower piston cavity vents to outlet. Venting to
to-Open Relay Valve is normally closed. Introduction atmosphere is available at extra cost. Simple con-
of 50 to 150 psi instrument or compressed air struction gives virtually trouble-free operation.
through 1/4" operating inlet overcomes spring Typical applications include air trap condensate
pressure and opens valve allowing flow. Loss or drain and compressor cooling water flow control.
interruption of control air pressure causes valve
closure.
Dimensions & Component Identification
Parts Index
Item No. Assembly No. Description Materials
1 70102 Body Bronze
2 70104 Valve Stainless steel
3 70103 Valve spring Stainless steel
4 70108 Valve cap Steel
5 70198 Cylinder Bronze
6 70106 Piston Brass
7 70105 Piston cap Composition
To order, specify: #70101 3/8" Relay Valve
Bulletin 7000
Flow Control Valves

MICRO-RATIO® Valve assemblies are used
for air, gas and oil proportioning control. The multiple
screw cam assembly provides mechanical adjustment
capabilities to the air/fuel ratio at each valve position
throughout the entire capacity range of your burner
system.
Throttling range is fully adjustable and designed to
operate over the extremely wide turndown capabilities
of Maxon’s modern burner systems.
Stand-by fuel requirements are simplified by
using tandem-linked “air-gas-oil” valves to provide
single point control for multiple fuel or multiple zone
systems (see photo below).
Oil
Air Gas
M- 4" x 1-1/2" -P MICRO-RATIO® Valve
SYNCHRO Valves (below) may be used

independently for individual adjustable gradient fuel
flow control, or in tandem with other fuel control
valves for more sophisticated multi-zone control
Gas applications. Totally enclosed cam option is available
for greater protection against hostile environments.
Smaller sizes of SYNCHRO Valves use
characterized “V” ports in a poppet disc for greatest
refinement of control. Larger sizes feature a butterfly-
type disc for maximum capacity with minimum
pressure drop for gas or air flows.
Air
Poppet-type Gas/Oil Butterfly-type Gas
SYNCHRO Valve SYNCHRO Valve
M- 10" x 4" -M x 3/4" -O -200 MICRO-RATIO® triplex

valve arrangement with optional companion flange set
MICRO-RATIO® Valves covered by U.S. Patents

2,286,173; 2,035,904; and 3,706,438.
1" -O -400 with totally 2-1/2" -M SYNCHRO Valve
enclosed cam with standard cam assembly
Page 7002
Flow Control Valves

Series “Q” Gas Control Valves provide the high
capacity and low pressure drop benefits of a butterfly
valve construction, plus an adjustable gradient feature
for accurate fuel flow control.
They are used independently for throttling of fuel
gases and with PREMIX® Blower Mixers and
AIRFLO® Mixers for stand-by fuel systems, where
they allow change-over to alternate fuels without re-
adjustment.
Series “Q” Valves are UL (Underwriters
Laboratories) listed for use with air, natural gas and
liquefied petroleum gases.
3" Series “Q” Valve
Series “CV” Control Valves incorporate a full-

flow, fixed gradient butterfly valve design for high
capacities at low pressure drops, using minimum
operating torque.
2" Series “CV” Valve with
This economical assembly includes a minimum optional connecting base
stop screw and can be supplied with connecting base and linkage assembly
and linkage assembly to mount your electric control
operator.
Versions available with UL (Underwriters
Laboratories) listing for air, natural gas and liquefied
petroleum gas service.
Series “BV” Balancing Valves are used to

balance gas or air flows in multiple-burner systems
fed by a common manifold. They feature a full-flow
butterfly design with provision for locking in any 2-1/2" Series
position. “BV” Valve
Air Control Valves permit throttling control of air to

burners. They feature a fixed gradient butterfly valve
design with an adjustable minimum stop, friction
brake screw and provision for manual or automatic
operation. Air control valves are offered in 1-1/2"
through 18" pipe sizes.
A complete system using Maxon Flow Control M-6" Manual Air

Valves will typically include burner, gas and/or oil pipe Control Valve with
trains, mixing equipment, pressure blower and a optional Low Fire
control panel. Your Maxon representative can help Start Switch
11/90
Flow Control Valves Page 7003

MICRO-RATIO® Valves
Principle of Operation Nomenclature

®
MICRO-RATIO Valve assemblies typically consist MICRO-RATIO® Valve assemblies are designated
of a fixed-gradient air butterfly valve mechanically by listing the individual valves, starting with the air
linked to one or more adjustable gradient SYNCHRO valve, then each of the fuel valves to be included, as
Fuel Control Valve(s). well as their relative position in the assembly.
Examples:
“Duplex” MICRO-RATIO ® Valve assembly
M- 6" x 2" -P
(air) x (gas)
“Quadriplex” MICRO-RATIO ® Valve assembly

M- 10" x 4" -M x 1/2" -O -200 x 2" -P
(air) x (gas) x (oil) x (gas)
Cut-away view of
3/4" -O -200
Cut-away view of M- 3" x 1-1/4" -P MICRO-RATIO ® Valve SYNCHRO Oil Valve
with standard cam
assembly
The tandem linkage gives accurate proportioning of
the air/fuel(s) ratios required for your specific burner
system/application.
The multiple screw adjustment feature of the
SYNCHRO Valve provides a mechanical means of
adjusting the air/fuel(s) ratios at each of twelve valve
positions throughout the capacity range of each valve.
Maximum application flexibility is provided from
over 500 possible valve combinations.
Air-gas-oil valves in tandem-linked combination
are ideal for multi-zone or stand-by fuel system
control.
Totally enclosed cam assemblies are available
to protect the valve’s internal adjusting mechanism Cut-away view of
against moisture and/or hostile environments. 2-1/2" -P
Air-gas-oil SYNCHRO Valves may be used SYNCHRO Gas
Valve with standard
independently for single control or throttling of
cam assembly
multiple flow paths or fuels.
5/03
Page 7004 Flow Control Valves

SYNCHRO and MICRO-RATIO® Valves
General All valve combinations will be assembled in “right

hand” flow direction unless specified as “left hand”
All Maxon Flow Control Valves are designed for assembly. When looking directly at the air valve
throttling service only and are not intended for indicator dial, a “right hand” arrangement is indicated
tight shut-off. by flow coming from the right side of the fuel valve
Flow direction is not a factor with butterfly-type quadrant and flowing to the left side. A “left hand”
valve bodies; however, with poppet-type SYNCHRO assembly is opposite, with flow from left to right.
Valves, fluid flow through the valve must only be in For instructions for reversing valve body flow
the direction indicated by the arrowhead cast into direction in the field, see page 7016.
each valve body. Torque requirements listed in tables below are
important and are to be used in selecting your
automatic control operators. Torque figures (inch-
SYNCHRO Valve Specifications
Maximum ambient temperature: 125°F (52°C) pounds) are additive for your complete MICRO-
Cv Maximum RATIO® Valve assembly.
SYNCHRO Valve Torque Maximum
Flow Inlet
Required [2] Fluid
Type Size
Factor Pressure
(inch-pounds) Temperature
Example: For M- 6" x 2" -P MICRO-RATIO® Valve:
[1] (PSIG)
M- 6" requires 60 in-lbs
1-1/2"-M
80 2" -P requires 90 in-lbs
3"-S
M- 6" x 2" -P assembly requires 150 in-lbs
2"-M
135
120
4"-S
200°F The automatic control motor you select must be
Standard 2-1/2"-M 200 (93°C) capable of developing at least 150 in-lbs of torque in
Butterfly 3"-M 380 5
Type
4"-M 600
order to throttle this particular MICRO-RATIO® Valve
6"-M 1550 combination if valve is applied at maximum inlet
8"-M 2750 pressures shown.
180
10"-M 4300 450°F
12"-M 6200 (232°C)
1-1/2" -M -SHP Air Control Valve Specifications
80 15
Special 3" -S -SHP Maximum ambient temperature: 125°F (52°C)
High 2" -M -SHP Maximum fluid temperature: 200°F (93°C)
Pressure 135 12 200°F High temperature version available to 800°F
4" -S -SHP 180
(SHP) (93°C)
Butterfly 2-1/2" -M -SHP 200 11 Torque
Butterfly Type Cv Flow Maximum Inlet
Type 3" -M -SHP 380 9 Required [2]
Air Valve Size Factor [1] Pressure (PSIG)
4" -M -SHP 600 6 (inch-pounds)
1/2" -P 4.6 M- 1-/2" 80
3/4" -P 6.5 20 M- 2" 135
1" -P 8 5
Gas M- 2-1/2" 200
200°F
Poppet 1-1/4" -P 11.8 90
15 (93°C) M- 3" 380
Type 1-1/2" -P 17.7
2" -P 40 M- 4" 600 30
5
2-1/2" -P 50 M- 6" 1550 60
5
3/8" -O -8 0.05 M- 8" 3750
125 @ 100
1/2" -O -20 0.14 10 PSIG M- 10" 4300
Oil 1/2" -O -50 0.35 M- 12" 6200
350°F
Poppet 1/2" -O -100 0.7 300 or
(177°C) M- 14" 8430
Type 3/4" -O -200 1.41
220 @
200
1" -O -400 2.82 M- 16" 11020
250 PSIG
1" -O -750 5.3 M- 18" 13950
[1] Cv factors based on flow through a wide-open valve. [1] Cv factors based on flow through a wide-open valve.
[2] Torque required is shown for maximum rated pressure unless noted [2] Torque required is shown for maximum rated pressure. At
otherwise. At lower pressures, less torque may be required.
[3] High temperature version is available up to 450°F. lower pressures, less torque may be required.
Performance Data
(M-) Style Control Valves – Air Service
Air Valves are normally
sized to match the combustion
air pipe sizing. Pressure drops
of 1" wc to 2.5" wc are typical.
If supply pressures are higher
than required, smaller valves
can be used, or travel limited to
restrict maximum flow rate.
Note: The capacities and

pressure drops indicated in
this chart are based on flow
through a wide-open valve. If
valve is less than fully open,
higher drops and lower flows
will result.
[1] S.T.P. = Standard

Temperature and Pressure
defined at: (60°F and 14.7
PSIA and 15.6°C and 760mm
Hg)
11/90
Performance Data
SYNCHRO Gas Valves – Natural Gas Service
through a wide-open valve. If
valve is less than fully open,
higher drops and lower flows
will result.

defined at: (60°F and 14.7 PSIA
and 15.6°C and 760mm Hg)
Gas Valves are normally Gas Inlet Pressure Suggested Pressure Drop
sized based on inlet pressure 3" wc - 5" wc 0.5" wc - 1.5" wc
and allowable pressure drop. 4 osi - 8 osi 1" wc - 2" wc
See guidelines at right. 8 osi - 16 osi 2" wc - 5" wc
2 psi - 3 psi 6" wc - 10" wc
Performance Data
SYNCHRO Gas Valves – Propane Gas Service
Note: The capacities
and pressure drops
indicated in this chart
are based on flow
through a wide-open
valve. If valve is less
than fully open, higher
drops and lower flows
will result.

Temperature and
Pressure defined at: (60°F
and 14.7 PSIA and 15.6°C
and 760mm Hg)
Gas Valves are normally sized Gas Inlet Pressure Suggested Pressure Drop
based on inlet pressure and 3" wc - 5" wc 0.5" wc - 1.5" wc
allowable pressure drop. See 4 osi - 8 osi 1" wc - 2" wc
guidelines at right. 8 osi - 16 osi 2" wc - 5" wc
2 psi - 3 psi 6" wc - 10" wc
11/90
Performance Data
SYNCHRO Oil Valves – #2 Fuel Oil Service
Oil Valves are normally sized for
approximately 5 psi pressure drop. For #2 oil
service, see chart at left.
For preheated #5 or #6 oil, multiply the
required flow rate in gph by the factor given in
the table shown below the chart, then select a
valve based upon that equivalent flow of #2 oil
and its allowable pressure drop.
Note: The capacities and pressure drops

indicated in this chart are based on flow
through a wide-open valve. If valve is less
than fully open, higher drops and lower flows
will result.
Oil Grade #5 #6
Temperature (°F) at
125 160 122 140 180 210 220
Inlet
Factor 1.43 1.11 2.86 2 1.25 1.11 1.05
For example: To size for 5 psi drop with a 50 gph

flow of #6 preheated to 140°F, the multiplier is “2”.
Equivalent flow of #2 oil is then 50 x 2, or 100 gph.
Chart shows that a 5 psi drop will require use of a
1/2" -O -100 SYNCHRO Oil Valve.

(M-) Style Manual Air Control Butterfly-type Valves
M- 1-1/2" through M- 4" Valves M- 6" through M- 18" Valves
Size A C D E F [2] G H [1] J K

M- 1-1/2" 1.75 1.75 1.75
3.62 1.81
M- 2" 1.94 3.56 1.94 1.94
M- 2-1/2" 2.38 3.88 2.38 1.94 2.38
--- 9
M- 3" 2.62 4.0 4.06 2.62 2 .0 0.75 2.62
M- 4" 3.19 4.25 4.56 3.19 2.12 3.19
M- 6" 6.06 4.25 6.06 4.44 2.12 4.44
M- 8" 7.5 4.5 7.56 5.88 1.12 10.12 2.25 5.88
M- 10" 7.75 6.5 8.38 6.5 3.62 12.38 3.25 1.25 8
M- 12" 8.75 5.31 9.5 8 4.62 13.38 9.5
2.69
M- 14" 9.75 5.38 10.5 8.69 5.75 14.5 10.5
1.5
M- 16" 10.62 8.12 9.69 6.62 15.38 4.06 11.75
11.38
M- 18" 11.62 8.5 10.75 7.62 16.38 4.25 12.5
[1] M- 10" and larger are wafer-type. Companion flanges not included.
[2] Centerline offset (on M- 8" and larger sizes only)
5/03

SYNCHRO Oil Valves
SYNCHRO Gas Poppet Valves
SYNCHRO Oil Valves SYNCHRO Gas Poppet Valves

C H Size A C H
Size
350°F 450°F 350°F 450°F 1/2" -P
3/8" -O -8 3/4" -P 1.81 4.25 2.12
1/2" -O -20 1" -P
1/2" -O 50 1-1/4" -P
2.31 5.62 2.81
1/2" -O -100 4 4.5 2 2.25 1-1/2" -P
3/4" -O -200 2" -P 7.25 3.62
3.75
1" -O -400 2-1/2" -P 7.5 3.75
1" -O 750


(-M) Style SYNCHRO Butterfly-type Gas Valves (1-1/2" through 6") – cast iron bodies
Size A B C D E G H J K L
1-1/2" -M 3.62 1.94 1.94 1.82 0.75 1.94
3" -S 7.0 2.56 2.56 3.5 2.25 2.56
2" -M 3.56 6.5 3.62 1.91 1.94 8.31 1.82 0.75 1.94 6.75
4" -S 8.25 3.19 3.19 4.12 2.75 3.19 Pipe threads on this page conform to NPT
2-1/2" -M 3.88 2.38 2.38 1.94 2.38
3" -M 4.06 4.0 2.62 2.62 2.0 2.56
7.5 9.31 0.75 7.75
4" -M 4.56 4.25 3.19 3.19 2.12 3.19
6"-M 5.94 9.56 4.25 6.06 4.44 11.31 2.12 4.44 9.81
5/03

(-M) Style SYNCHRO Butterfly-type Gas Valves (8" through 12") – cast iron bodies


(-M) Style SYNCHRO Butterfly-type Gas Valves (1-1/2" through 4" sizes, steel bodies)
1-1/2" through 3" -M Valves
Size A B C D&E G H K L Bolt Holes

1-1/2" -M 3.62 7.31 3.38 2.25 9.06 1.69 2.5 7.56
Pipe threads on this page
2" -M 3.56 7.38 3.62 3 1.81 3 7.62 conform to NPT
9.12 4
2-1/2" -M 4.06 7.88 3.88 3.5 1.94 3.5 8.12 (ANSI Standard B2.1)
3" -M 4.31 8.12 4 3.75 9.88 2 3.75 8.38
4" -M 5.06 9 4.25 4.56 10.75 2.12 4.5 9.25 8
5/03

MICRO-RATIO® Valve arrangements (right hand arrangement shown)
For dimensions not

shown on this page,
see pages 7009
through 7013.
SYNCHRO Gas Valves

Air Control Valves
Butterfly-type Poppet-type
Size A C D E F H J K Size A B C Size C
M- 1-1/2" 1.75 1.75 1.75 1-1/2" -M 3.62 1/2" -P
3.62 1.81
M- 2" 1.94 3.56 1.94 1.94 3" -S 7.0 3/4" -P 4.25
M- 2-1/2" 2.38 3.88 2.38 1.94 2.38 2" -M 3.56 6.5 3.62 1" -P
---
M- 3" 2.62 4.0 4.06 2.62 2.0 0.75 2.62 4" -S 8.25 1-1/4" -P
5.62
M- 4" 3.19 4.25 4.56 3.19 2.12 3.19 2-1/2" -M 3.88 1-1/2" -P
M- 6" 6.06 4.25 6.06 4.44 2.12 4.44 3" -M 4.06 4.0 2" -P 7.25
7.5
M- 8" 7.5 4.5 7.56 5.88 1.12 2.25 5.88 4" -M 4.56 4.25 2-1/2" -P 7.5
M- 10" 7.75 6.5 8.38 6.5 3.62 3.25 1.25 8 6" -M 5.94 9.5 4.25
M- 12" 8.75 5.31 9.5 8 4.62 9.5 8" -M 7.38 10.69 4.5
2.69
M-14" 9.75 5.38 10.5 8.69 5.75 10.5 10" -M 7.75 13.75 6.5
1.5
M- 16" 10.62 8.12 9.69 6.62 4.06 11.75 12" -M 8.75 14.75 7.5
11.38
M- 18" 11.62 8.5 10.75 7.62 4.25 12.5

MICRO-RATIO® and SYNCHRO Flow Control Valves
(-M) SYNCHRO Gas Valve (-O) SYNCHRO Oil Valve (-P) SYNCHRO Gas Valve
Butterfly-type with totally Poppet-type with standard Poppet-type with standard
enclosed cam assembly cam assembly cam assembly
Legend
Item Description
1 Adjusting Screws
Duplex MICRO-RATIO® Valve 2 Cam Springs
3 Plunger/Cap Assembly
(M-) air valve with (-M) type gas valve 4 Plunger Bushing
and standard cam assembly 5 Set Collar
6 Operating Crank
7 Upper Spring Retainer
8 Gas Valve Spring
9 Spring Return Shaft
10 Shaft Retainer
11 Lower Spring Retainer
12 Packing Collar
13 O-rings
14 Operating Shaft
15 Valve Disc
16 Valve Body
17 Valve Disc Spring
18 Valve Disc Guide
19 Valve Stem
20 Spring Support Plug
21 Stud Bolt
22 Bushing
23 Locking Screw
Suggested Spare Parts
– Cam Springs SYNCHRO Valve Nameplate
– Plunger/Cap Assembly
– Adjusting Screws
Order spare parts for Flow Control Valves by identifying required
items from drawings above, and referencing information on SYNCHRO
Valve nameplate (shown at right)
10/94

Maxon MICRO-RATIO® Valves
Field Rotation of SYNCHRO Valves in Valve Lubrication Suggestions

MICRO-RATIO® Valve Assemblies Some lubrication of moving parts may be
Flow direction through (-P) and (-O) poppet-type required. All moving parts, O-rings and cam strips are
SYNCHRO Valves must be in the direction indicated lubricated at time of manufacturing. A periodic
on valve body casting. If reversal of the SYNCHRO inspection should be performed to insure all parts
Valve body is required for piping convenience, follow continue to move freely and function properly. A
these steps: periodic re-application of lubricant will extend the
service life of your Maxon MICRO-RATIO® Valve.
1. Loosen neck set screws (one on each side) [1].
2. Remove bracket cap screws [2] and save. The following lubricants are suggested:
3. Remove valve body [3] while supporting air butterfly Manufacturer Lubricant
[5] and adjusting screw carrier assembly [4].
Keystone Div., #84-EP-2, NLGI #2
4. Rotate valve body [3] 180°, then reposition and Philadelphia, PA Lithium base grease
install bracket cap screws [2] loosely.
Standard Oil Co. Stanolith grease #42
5. Check carefully that screw carrier assembly [4] is
(of Indiana)
lowered into position, then tighten neck set screws
[1] into neck indentation. Shell Oil Co. Alvania grease #1
6. Tighten bracket cap screws [2]. Stewart Warner Corp. Alemite lubricant #32

Series “Q” Adjustable Gradient Gas Control Valves
The Series “Q” butterfly gas valve is equipped with CB & L assemblies are available for the most
the Maxon multiple-screw adjusting cam for adjusting commonly-used electric and air operators.
the flow from maximum to minimum. The numbers on Maxon CB & L assemblies are designed to
an external indicator strip correspond to a series of position control operators, not to support them.
adjusting screws which may be set initially to give the User must provide auxiliary support in the form of wall
desired contour to the cam. brackets, floor stands, turnbuckle hangers, etc. to
A Series “Q” Valve may be used for most gas support the weight and size of your operator.
throttling applications and provides flexibility of Optional tandem linkage assembly is available to
adjustment. connect two Series “Q” Valves together for control by a
Series “Q” Valves can be easily adapted for single automatic control operator.
automatic operation with either electric or pneumatic Connecting linkage is available to mount a Series
control operators. “Q” Valve in a stand-by fuel arrangement with
Maxon has designed a broad range of Connecting PREMIX® Blower Mixers or Series “66” AIRFLO®
Base and Linkage (CB & L) assemblies to properly Mixers as shown on page 7018.
position and align those operators for control of Maxon
Flow Control Valves.
Series “Q” Valve with connecting base and linkage Series “Q” Valve with connecting base and linkage
positioning a typical electric control operator positioning a typical pneumatic control operator
11/90

General Series "Q" Gas Control Valve Specifications

Maximum ambient temperature: 125°F (52°C)
All Maxon Flow Control Valves are designed for Maximum fluid temperature: 150°F (66°C)
throttling service only and are not intended for Series "Q"
Cv Flow Maximum Inlet
Torque
Butterfly-type Required [2]
tight shut-off. Valve Size
Factor [1] Pressure (PSIG)
(inch-pounds)
All Series “Q” Gas Control Valves are UL (Under- 1" -Q 18
25 120
writers Laboratory) listed for air, natural gas and 1-1/4" -Q 42
liquefied petroleum gas service. 1-1/2" -Q 80 20 100
Torque requirements listed in table at right are to 2" -Q 138
10 48
be used in selecting your automatic control operator. 2-1/2" -Q 180
3" -Q 265 5 24
Nomenclature [1] Cv factors based on flow through a wide-open valve.
Series “Q” Valves are designated first by the pipe [2] Torque required is shown for maximum rated pressure. At
size (inlet and outlet), followed by the letter “Q” to lower pressures, less torque is required.
indicate the valve series.
Example: 2" -Series “Q” Control Valve
Special application of Series “Q” Valve for stand-by service on PREMIX®

Blower Mixers and Series “66” AIRFLO® Mixers
Propane is frequently used as a stand-by fuel for
natural gas. When propane is carburetted with air at a
central mixing point and delivered in the regular natural
gas lines at a Btu value and specific gravity permitting
performance characteristics closely matching the
primary fuel, it may be burned in most industrial gas
equipment without any change in adjustment.
However, LPG can also often be used in the raw,
uncarburetted state. For example, the Maxon Series
“Q” Gas Control Valve may be linked to the ratio valve
of a Maxon PREMIX® Blower Mixer or Series “66”
AIRFLO® Mixer to provide for pre-adjustment of the
fuel-air ratio for both the primary fuel and a stand-by
fuel.
Performance Data
Series “Q” Control Valves – Natural Gas Service
and pressure drops
are based on flow
through a wide-open
will result.

Temperature and
and 760mm Hg)
Gas Valves are normally sized Gas Inlet Pressure Suggested Pressure Drop
based on inlet pressure and 3" wc - 5" wc 0.5" wc - 1.5" wc
allowable pressure drop. See
4 osi - 8 osi 1" wc - 2" wc
guidelines at right.
8 osi - 16 osi 2" wc - 5" wc
2 psi - 3 psi 6" wc - 10" wc
11/90
Performance Data
Series “Q” Control Valves – Propane Gas Service
and pressure drops
are based on flow
through a wide-open
will result.

Temperature and
and 760mm Hg)
Gas Inlet Pressure Suggested Pressure Drop Gas Valves are normally sized
3" wc - 5" wc 0.5" wc - 1.5" wc based on inlet pressure and
4 osi - 8 osi 1" wc - 2" wc
allowable pressure drop. See
guidelines at left.
8 osi - 16 osi 2" wc - 5" wc
2 psi - 3 psi 6" wc - 10" wc

Series “Q” Gas Control Valves
NOTE: 1" through 2"
Series “Q” Valves have
threaded bodies.
2-1/2" and 3" Series “Q”
Valves are flanged body
as illustrated in dimen-
sional data below.
2" Series “Q” Valve
Size (inches) A B C D E G
1"
1.81 7.19 3.5 2
1-1/4"
5 2.5
1-1/2"
2.25 7.44 3.75 2.62
2"
2-1/2" 3.88 1.94
3.12 8.19 4.5 3.62
3" 4.25 2.12
6/92
Suggested Spare Parts Series “Q” Valve Nameplate

– Cam springs
– Plunger/cap assembly
– Adjusting screws
Order spare parts for Series “Q” Valves by
identifying required items from drawing above and
referencing information on valve nameplate (shown at
right).

Series “CV” Control Valves and Series “BV” Balancing Valves
General Series "CV" Control Valve Specifications

Maximum ambient temperature: 125°F (52°C)
All Maxon Flow Control Valves are designed for Maximum fluid temperature: 150°F (66°C)
throttling service only and are not intended for Butterfly-type Cv Flow Maximum
Torque Required [2]
tight shut-off. Series "CV" Factor Inlet Pressure
(inch-pounds)
Valve Size [1] (PSIG)
Series “CV” Valves are offered in four different 1/2" -CV
versions: 5
3/4" -U -CV [3]
1. Standard assemblies without connecting base and
3/4" -CV
linkage (CB & L) assembly (order CB & L 11
separately) 1" -U -CV [3]
25
2. UL (Underwriters Laboratory) listed assemblies 1" -CV
18
without CB & L (CB & L ordered separately) 1-1/4" -U -CV [3] 25
3. Standard assemblies with CB & L to accept electric 1-1/4" -CV 42
control operators, such as: 1-1/2" -CV 80
A. Penn/Johnson #M-80 or #M-81 2" -CV 138
B. Honeywell #M644, #M744, #M941, #M944 or 20
2-1/2" -CV 180
#M7044
3" -CV 265 15
C. Barber-Colman #EA50
[1] Cv factors based on flow through a wide-open valves.
4. UL (Underwriters Laboratory) listed assemblies with [2] Torque required is shown for maximum rated pressure. At lower
CB & L as in #3 above. pressures, less torque may be required.
[3] "U" designates undersized por ts.
Designations
Both of these valve types are designated first by the
nominal pipe size (inlet and outlet) followed by the Series "BV" Balancing Valve Specifications
letters indicating the valve series. Maximum ambient temperature: 125°F (52°C)
Example: Maximum fluid temperature: 150°F (66°C)
1" - Series “BV” Balancing Valve Butterfly-type Series
Cv Flow Factor [1]
Maximum Inlet
1-1/4" -U Series “CV” Control Valve "BV" Valve Size Pressure (PSIG)
1/2" -BV 5
UL (Underwriters Laboratory) listed series “CV”
Valve assemblies are available in all sizes for air, 3/4" -BV 11
natural gas and liquefied petroleum gas service. 1" -BV 18 25
1-1/4" -BV 42
1-1/2" -BV 80
2" -BV 138
20
2-1/2" -BV 180
3" -BV 265 15
[1] Cv factors based on flow through a wide-open valve.
11/90
Performance Data
Series “BV” and “CV” Gas Control Valves – Natural Gas Service
this chart are based on
flow through a wide-open
valve. If valve is less than
fully open, higher drops
and lower flows will result.

Hg)
Gas Inlet Pressure Suggested Pressure Drop Gas Valves are normally
3" wc - 5" wc 0.5" wc - 1.5" wc sized based on inlet
pressure and allowable
4 osi - 8 osi 1" wc - 2" wc
pressure drop. See
8 osi - 16 osi 2" wc - 5" wc
guidelines at left.
2 psi - 3 psi 6" wc - 10" wc
Performance Data
Series “BV” and “CV” Gas Control Valves – Propane Gas Service
through a wide-open valve.
If valve is less than fully
open, higher drops and
lower flows will result.

Hg)
Gas Valves are normally Gas Inlet Pressure Suggested Pressure Drop
sized based on inlet 3" wc - 5" wc 0.5" wc - 1.5" wc
pressure and allowable
4 osi - 8 osi 1" wc - 2" wc
pressure drop. See
8 osi - 16 osi 2" wc - 5" wc
guidelines at left.
2 psi - 3 psi 6" wc - 10" wc
11/90
Performance Data
Series “BV” and “CV” Gas Control Valves – Air Service
through a wide-open valve.
If valve is less than fully
open, higher drops and
lower flows will result.

Hg)
Air Valves are normally sized to match the combustion air pipe sizing.
Pressure drops of 1" wc to 2.5" wc are typical. If supply pressures are higher
than required, smaller valves can be used, or travel limited to restrict maximum
flow rate.

Series “CV” Control Valves
A
Size B C D E G
B-C [1] M-H [2]
1/2" 1.78
0.78
3/4" 3.25 1.89 1.62
4.19 4.62 3.06
1" 1.98 1
1-1/4" 3.38 1.94 1.19 1.69
1-1/2"
3.94 4.38 3.31 3.62 2.38 1.62 1.81
2"
2-1/2" 4.62 2.69 1.94 2.31
3.19 3.62 4.06
3" 5 3.06 2.31 2.5
[1] Barber-Colman
[2] Honeywell
7/94

Series “BV” Balancing Valves
Size A B C D E
1/2"
0.75
3/4" 1.25 3.25 1.25
2.25
1" 1
1-1/4" 1.38 3.38 1.19 1.44
1-1/2" 1.81 1.31 1.56
2.5 3.62
2" 1.88 1.62 1.88
2-1/2" 4.62 1.94 2.19
2.75 3.25
3" 5 2.31 2.56

Series “BV” Balancing Valves and Series “CV” Flow Control Valves
Series “BV” Balancing Valve
Series “CV” Control Valves
Series “CV” Control Valve Nameplate
Order spare parts for Series “CV” and “BV” Flow

Control Valves by identifying required items from the
drawings above and referencing information on valve
nameplate (shown above).
Typical internal construction
(Series “CV” Valve shown)
7/96
Accessories
Adjustable Stop Connecting Base & Linkage Assemblies
for air control Maxon has designed a broad range of Connecting
valves Base & Linkage Assemblies (CB & L) to properly
Optional Adjustable position and align the popular operators for control of
Stop shown at right Maxon flow control valves.
sets a minimum to Proper position and alignment are essential for
prevent full closure of smooth and trouble-free operation of flow control
the air valve. valves.
Position Switches for electrical indication of

valve position
Standard Low Fire Start (LFS) Switch opens the
circuit when valve leaves minimum position. Weather-
proof and Hazardous Location/Weatherproof versions
differ only in the physical switch size and rating. High
and low fire position switch includes (2) SPDT
switches. One switch may be field-set to activate at
“high” position, while other is set to activate at “low” fire
position.
Air operator shown on Series “Q” Control Valve and

MICRO-RATIO ® Valve
Flow Control Valves Page 7000-S-1
– Support weight of piping independently. Do not lessens the chance of internal flow turbulence being
place any Maxon Flow Control Valve in a piping set-up in the piping manifolds and control valve.
bind. Provide pipe hangers and/or special support – Check fluid flow direction through “-P” and “-O”
for related manifolds. poppet-type valves. It must flow only in direction
– Maxon connecting base and linkage assemblies matching the arrow cast into valve body. If neces-
are designed to locate and/or position the sary, valve body may be rotated per instructions
control operator for its interaction with the Flow given on page 7016.
Control Valve assembly. They are not intended to – Install flow control valves carefully and maintain
support the weight of the control motor. Special adequate dimensional clearance to allow full
provisions will be required to support the weight of stroke and travel of the valve’s control linkage.
the control operators. Internal drive mechanisms within a control motor
– Use of pipe heavier than schedule #40 can may be damaged if linkage is restricted as to cause
cause interference with butterfly-type Flow Control binding in high or low flow position.
Valves and restrict the valve from full opening.
CAUTION: All Flow Control Valves are designed
– Flow Control Valves provide the means to
for throttling service only and are not intended
adjust fluid and/or gas flows. They should be
for tight shut-off.
installed with at least four pipe diameter lengths of
straight pipe before and after the valve. This – Main system shut-off should always use a
manual “leak-tight” upstream fuel cock.
Mounting Instructions for motor operator on Series “CV” Flow Control Valves
For those Series “CV” Valve assemblies furnished with
connecting base and linkage, the accompanying diagrams Honeywell
illustrate mounting procedures relative to each specific type #M644, M744,
operator. M941 or M944
First, mount your control motor to connecting base in (7616BR Crank)
accordance with diagrams at right.
Mount with four short bolts
Secondly, determine if your electric operator travels
and nuts at indicated holes. Crank & Linkage Side
through 90° or 180° rotations. Then arrange connecting
linkage and motor crank arm as shown below for your
specific operator.
Barber-Colman
EA50
Mount with three short bolts

and nuts at indicated holes.
Crank & Linkage Side
Penn/Johnson
M80, M81
(MD3-600 Crank)
Mount with two short bolts
and nuts and long bolt
90° Control Motor 160° – 180° Control Motor screwed into operator base
through slotted hole. Crank & Linkage Side

m
CORPORATION
Page 7000-S-2 Flow Control Valves
Adjusting Instructions
Notice: Only generalized instructions can be provided 3. Check that any air handling dampers are
here. Detailed adjusting instructions are provided with properly positioned and locked into operating
each individual Maxon burner and/or mixer system. positions.
General Instructions linkage from your control valve’s operating crank
arm by loosening the control motor’s connecting
rod from the burner’s toggle linkage.
Initial adjustment should only be
To prevent damage in transit, some connecting accomplished during a “manual” control
base and linkage components may be packed mode.
separately and shipped loose with your new Maxon 5. Start all system-related fans and blowers.
Flow Control Valve. Check for proper motor rotation and impeller
The Flow Control Valve is normally only a part of direction. Verify that all control interlocks are
your complete combustion system. Additional pipe working. Allow air handling equipment to run for
train accessories and control components may be adequate purge of your manifolds.
required for a complete system installation.
and familiarize yourself with all the system’s
equipment components. Verify that your equipment 6. With MICRO-RATIO® Valve combinations of
has been installed in accordance with the original air and fuel valves, the minimum differential
manufacturer’s current instructions. pressure setting is initially established with
the air valve only.
CAUTION: Initial adjustment and light-off of
A. By disconnecting the linkage between the air
burner systems should be undertaken only by
butterfly valve and interconnected fuel
trained and experienced personnel familiar with
valve(s), the minimum and maximum limits of
travel on the air valve may be determined.
For example, a combustion system may
need the air valve to be 15° open for the
“minimum” setting and the “maximum”
requirements are satisfied with the air valve
open to 60°. By marking these points on the
air valve’s indicating strip, you are ready to
reconnect the SYNCHRO Fuel Valve’s
B. The next step involves adjusting the
connecting linkage between the air valve
and the fuel valve(s) so that each fuel valve
For initial adjustment and/or burner start-up: travels its full quadrant range (i.e. from
1. Close all burner fuel valves and cocks. Make minimum to maximum), while the air valve
preliminary adjustments to fuel gas regulators. swings from its pre-determined minimum and
2. Check all electric circuitry. Verify that all maximum positions.
control devices and interlocks are operable and C. With Series “CV” Valves and Series “Q”
functioning within their respective settings/ adjustable-gradient Flow Control Valves,
ranges. Be sure all air and fuel manifolds are the minimum flow position is set by their
tight and that test ports are plugged if not being minimum stop screw. This adjustable stop is
used. located on the side of the screw carrier of
Series “Q” Valves and at the base of crank
arm of Series “CV” Valves. Screwing “in” on
the minimum stop screw produces a physical
stop on the quadrant’s travel that prohibits
valve from being completely closed off.
m CORPORATION

D. SYNCHRO gas and oil valves have 10. To light and adjust burner on gas:
multiple adjusting screws and, when used With gas pilot established and flame supervision
alone (without an inter-connected air valve as system operational, opening the main fuel Shut-
in the MICRO-RATIO® Valve assemblies), the Off Valve(s) will allow fuel flow to the Flow
minimum adjusting screws are not screwed Control Valve.
in, thus not permitting flows at the specific 11. To adjust SYNCHRO Fuel Control Valve(s):
minimum flow positions. With SYNCHRO
E. Series “BV” Balancing Valves have fixed Valve at minimum
Adj. Screws
setting control points. The butterfly-type body position, open (under cover)
may be locked in any particular flow position upstream fuel Handle for
by simply screwing “in” on the locking Allen cock. Using the Manual
Operation
screw on the side of the wheel handle. Allen wrench Position
Indicator
provided, turn
CAUTION: Verify all safety interlocks are Pointer
minimum adjusting Locking Screw
operational before opening any main and/or
screw “down” for manual
individual burner valves. operation
(clockwise) to
7. Open main and pilot gas cocks, then attempt permit fuel flow to
spark ignition to light pilot while slowly turning your burner.
pilot gas regulator clockwise and/or adjustable NOTE: At this point, it is more important to get any
orifice screw counter-clockwise to increase fuel kind of flame as soon as possible. The flame
flow. Repeat procedure as necessary until pilot geometry can be adjusted and refined as needed
ignites, as air might have to bled out of fuel later.
supply lines before reliable pilot flame is 12. Once your flame is established and refined at
established. Pilot gas regulator should normally this position, and without advancing the screw
be set for as low a pressure as possible. carrier quadrant higher, screw all remaining
8. After ignition, adjust pilot flame with pilot gas screws down to at least the same level as your
adjustable orifice for good stable flame shape. A first adjusted screw.
“rule of thumb” is that any pilot over a tennis ball NOTE: A preliminary setting can be established with
size is probably too large. This assumes you all the remaining adjusting screws. Generally each
have visual access to the pilot flame. If this is not succeeding screw needs to be screwed in
possible, then adjust pilot to give a strong and approximately one full turn deeper than its preceding
stable flame signal through your flame safety screw. A smooth “stair-step” gradient pre-set at this
circuit. This signal strength can be read with a point from low to high will simplify the remaining
micro-amp meter. The signal strength (or range) adjustment steps.
will be determined by the specific type of flame
safeguard instrument you have with your burner
return Flow Control Valve to minimum position
system.
and shut off fuel (if flame safeguard has not
already done so). Turn in slightly on adjusting
screw at point where ignition was lost, then
return Flow Control Valve to minimum position,
ignition within a second or two. The flame
re-establish pilots, open fuel valve and verify
safeguard relays should now power your main
ignition.
fuel Shut-Off Valve(s).
13. Without advancing the Flow Control Valve
quadrant, screw down on #2 screw (one or two
turns). Then slowly advance the Flow Control
Valve quadrant to the #2 position. Adjust flame
appearance at this new position #2.
proceeding further.

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CORPORATION
NOTE: If firing chamber is of refractory construction, 15. Refine adjustment as needed, always turning
allow your burner system to operate at this low setting valve so that position indicator matches screw
for the necessary dry/cure-out time period being adjusted.
recommended by the chamber or refractory For more fuel, turn screw in (clockwise). For
manufacturer. Then continue adjustments of Flow less fuel, turn screw out (counter-clockwise).
Control Valve. If screws must be turned in flush with carrier
Again, without moving valve, bring #3 and all casting, increase fuel pressure and re-adjust.
remaining adjusting screws down to the same 16. Repeat procedure for any other fuels.
level as #2 screw. (If approximate pre-set 17. Cycle burner from minimum to maximum and
gradient was made earlier, the remaining screws refine adjustment, if necessary. Always set
will already be at or below appropriate levels.) Flow Control Valve to the numbered position you
14. Progressively work your way up through each wish to adjust.
adjusting screw position, developing a smooth For operation with interrupted pilot (as
progression slope from your first screw to the recommended), shut off pilots and cycle burner
maximum position. from minimum to maximum and back several
NOTE: To adjust the flame at any position, you must times to verify the flame is maintained.
move the Flow Control Valve to the number you 18. Reconnect linkage to control motor, plug all
desire to adjust. This aligns the adjusting screw test connections, replace equipment cover caps
directly on top of the fuel valve plunger. A resulting and tighten linkage screws.
adjustment of the screw is directly applied to the fuel 19. Check out overall system operation by cycling
valve plunger and its interconnected valve body through light-off at minimum, interrupting pilot,
linkage. and allow temperature control system to cycle
CAUTION: Oil flames are highly radiant. Use eye
20. Recheck all safety system interlocks for proper
protection and avoid prolonged viewing. Prepare
to shut off oil quickly if there is a noticeable
drop in oil pressure or if ignition does not WARNING: Test every UV installation for
occur. dangerous spark excitation from ignitors and
NOTE: To avoid possible damage to cam strips,
always turn all higher-numbered screws in as far as
connections.
the last one adjusted.
instruct operator personnel on proper start-up,
operation and shut-down of system. Establish
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– Support weight of piping independently. Do not lessens the chance of internal flow turbulence being
place any Maxon Flow Control Valve in a piping set-up in the piping manifolds and control valve.
bind. Provide pipe hangers and/or special support – Check fluid flow direction through “-P” and “-O”
for related manifolds. poppet-type valves. It must flow only in direction
– Maxon connecting base and linkage assemblies matching the arrow cast into valve body. If neces-
are designed to locate and/or position the sary, valve body may be rotated per instructions
control operator for its interaction with the Flow given on page 7016.
Control Valve assembly. They are not intended to – Install flow control valves carefully and maintain
support the weight of the control motor. Special adequate dimensional clearance to allow full
provisions will be required to support the weight of stroke and travel of the valve’s control linkage.
the control operators. Internal drive mechanisms within a control motor
– Use of pipe heavier than schedule #40 can may be damaged if linkage is restricted as to cause
cause interference with butterfly-type Flow Control binding in high or low flow position.
Valves and restrict the valve from full opening.
CAUTION: All Flow Control Valves are designed
– Flow Control Valves provide the means to
adjust fluid and/or gas flows. They should be
for tight shut-off.
installed with at least four pipe diameter lengths of
straight pipe before and after the valve. This – Main system shut-off should always use a
manual “leak-tight” upstream fuel cock.
Mounting Instructions for motor operator on Series “CV” Flow Control Valves
For those Series “CV” Valve assemblies furnished with
connecting base and linkage, the accompanying diagrams Honeywell
illustrate mounting procedures relative to each specific type #M644, M744,
operator. M941 or M944
First, mount your control motor to connecting base in (7616BR Crank)
accordance with diagrams at right.
Mount with four short bolts
Secondly, determine if your electric operator travels
through 90° or 180° rotations. Then arrange connecting
linkage and motor crank arm as shown below for your
specific operator.
Barber-Colman
EA50
Mount with three short bolts

Penn/Johnson
M80, M81
(MD3-600 Crank)
Mount with two short bolts
and nuts and long bolt
90° Control Motor 160° – 180° Control Motor screwed into operator base
through slotted hole.

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Notice: Only generalized instructions can be provided 3. Check that any air handling dampers are
here. Detailed adjusting instructions are provided with properly positioned and locked into operating
each individual Maxon burner and/or mixer system. positions.
General Instructions linkage from your control valve’s operating crank
To prevent damage in transit, some connecting accomplished during a “manual” control
base and linkage components may be packed mode.
separately and shipped loose with your new Maxon 5. Start all system-related fans and blowers.
Flow Control Valve. Check for proper motor rotation and impeller
The Flow Control Valve is normally only a part of direction. Verify that all control interlocks are
your complete combustion system. Additional pipe working. Allow air handling equipment to run for
train accessories and control components may be adequate purge of your manifolds.
required for a complete system installation.
and familiarize yourself with all the system’s
equipment components. Verify that your equipment 6. With MICRO-RATIO® Valve combinations of
has been installed in accordance with the original air and fuel valves, the minimum differential
manufacturer’s current instructions. pressure setting is initially established with
the air valve only.
A. By disconnecting the linkage between the air
butterfly valve and interconnected fuel
valve(s), the minimum and maximum limits of
travel on the air valve may be determined.
For example, a combustion system may
need the air valve to be 15° open for the
air valve’s indicating strip, you are ready to
reconnect the SYNCHRO Fuel Valve’s
For initial adjustment and/or burner start-up: travels its full quadrant range (i.e. from
1. Close all burner fuel valves and cocks. Make minimum to maximum), while the air valve
preliminary adjustments to fuel gas regulators. swings from its pre-determined minimum and
2. Check all electric circuitry. Verify that all maximum positions.
control devices and interlocks are operable and C. With Series “CV” Valves and Series “Q”
functioning within their respective settings/ adjustable-gradient Flow Control Valves,
ranges. Be sure all air and fuel manifolds are the minimum flow position is set by their
tight and that test ports are plugged if not being minimum stop screw. This adjustable stop is
used. located on the side of the screw carrier of
Series “Q” Valves and at the base of crank
arm of Series “CV” Valves. Screwing “in” on
the minimum stop screw produces a physical
stop on the quadrant’s travel that prohibits
valve from being completely closed off.
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Flow Control Valves Page 7000-S-3A
“Push-to-Close” SYNCHRO Valve
D. “Push-to-Close” SYNCHRO gas and oil CAUTION: After completing these steps, re-
valves have multiple adjusting screws and, check all interlocking safety components and
when used alone (without an inter-connected circuitry to prove that they are properly
air valve as in the MICRO-RATIO® Valve installed, correctly set, and fully operational. If
assemblies), the minimum adjusting screws in doubt, shut the system down, close pilot
are screwed “in”, thus reducing flows at the cock and contact responsible individual before
minimum flow positions. proceeding further.
WARNING: The “Push-to-Close” SYNCHRO
Valve is adjusted differently than a standard 10. To light and adjust burner on gas:
Maxon SYNCHRO Valve. Before installing or With gas pilot established and flame supervision
operating, read and comply with all instructions system operational, opening the main fuel Shut-
and warnings shipped by Maxon Corporation in Off Valve(s) will allow fuel flow to the “Push-to-
envelope with your Maxon Flow Control device. If Close” SYNCHRO Control Valve.
you are unclear about the method of adjustment NOTICE: If fuel valve has been shipped directly
or if these instructions were misplaced or not from the factory, the adjusting screws will normally
received, immediately contact Maxon be in their inner position (valve port fully closed).
Corporation in Muncie, Indiana, U.S.A. for a set Turn adjusting screws “counter-clockwise” to open
before attempting to use the valve. valve port and/or increase flow. This is opposite
CAUTION: Verify all safety interlocks are to standard Maxon SYNCHRO Control Valve.
operational before opening any main and/or 11. To adjust “Push-to-Close” SYNCHRO Fuel
individual burner valves. Control Valve(s):
7. Open main and pilot gas cocks, then attempt With SYNCHRO Adj. Screws
spark ignition to light pilot while slowly turning Valve at minimum (under cover)
pilot gas regulator clockwise and/or adjustable position, open Handle for
Manual
orifice screw counter-clockwise to increase fuel upstream fuel Operation
Position
flow. Repeat procedure as necessary until pilot cock. Using the Indicator
ignites, as air might have to be bled out of fuel Allen wrench Pointer
supply lines before reliable pilot flame is provided, turn Locking Screw
for manual
established. Pilot gas regulator should normally minimum operation
be set for as low a pressure as possible. adjusting screw

8. After ignition, adjust pilot flame with pilot gas “out” (counter-
adjustable orifice for good stable flame shape. clockwise) to permit fuel flow to your burner.
This assumes you have visual access to the pilot NOTE: At this point, it is more important to get a
flame. If this is not possible, then adjust pilot to stable flame as soon as possible. The flame geometry
give a strong and stable flame signal through can be adjusted and refined as needed later.
your flame safety circuit. This signal strength 12. Once your flame is established and refined at
can be read with a micro-amp meter. The signal this position, and without advancing the screw
strength (or range) will be determined by the carrier quadrant higher, screw all remaining
specific type of flame safeguard instrument you screws “out” to at least the same level as your
have with your burner system. first adjusted screw.
9. Re-check pilot ignition by closing pilot gas cock NOTE: A preliminary setting can be established with
or otherwise causing pilot outage. Re-light and all the remaining adjusting screws. Generally each
refine pilot gas adjustment as necessary to get succeeding screw needs to be screwed “out”
ignition within a second or two. The flame (counter-clockwise) approximately one full turn farther
safeguard relays should now power your main than its preceding screw. A smooth “stair-step”
fuel Shut-Off Valve(s). gradient pre-set at this point from low to high will
simplify the remaining adjustment steps.

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CORPORATION
Page 7000-S-4A Flow Control Valves
“Push-to-Close” SYNCHRO Valves
CAUTION: If flame is extinguished, immediately NOTE: To avoid possible damage to cam strips,
shut off fuel (if flame safeguard has not already always turn all higher-numbered screws “out” as far
done so) and return Flow Control Valve to as the last one adjusted.
minimum position . Re-adjust screw slightly at 15. Refine adjustment as needed, always turning
point where ignition was lost, then return Flow valve so that position indicator matches screw
Control Valve to minimum position, re-establish being adjusted.
pilots, open fuel valve and verify ignition. For more fuel, turn screw “out” (counter-
clockwise). For less fuel, turn screw “in”
13. Without advancing the Flow Control Valve (clockwise).
quadrant, screw “out” on #2 screw (one or two 16. Repeat procedure for any other fuels.
turns). Then slowly advance the Flow Control 17. Cycle burner from minimum to maximum and
Valve quadrant to the #2 position. Adjust flame refine adjustment, if necessary. Always set
appearance at this new position #2. Flow Control Valve to the numbered position you
NOTE: If firing chamber is of refractory construction, wish to adjust.
allow your burner system to operate at this low setting For operation with interrupted pilot (as
for the necessary dry/cure-out time period recommended), shut off pilots and cycle burner
recommended by the chamber or refractory from minimum to maximum and back several
manufacturer. Then continue adjustments of “Push-to- times to verify the flame is maintained.
Close” Flow Control Valve. 18. Reconnect linkage to control motor, plug all
Again, without moving valve, bring #3 and all test connections, replace equipment cover caps
remaining adjusting screws “out” to the same and tighten linkage screws.
level as #2 screw. (If approximate pre-set 19. Check out overall system operation by cycling
gradient was made earlier, the remaining screws through light-off at minimum, interrupting pilot,
will already be at or above appropriate levels.) and allow temperature control system to cycle
14. Progressively work your way up through each burner from minimum to maximum and return.
adjusting screw position, developing a smooth 20. Recheck all safety system interlocks for proper
progression slope from your first screw to the setting and operation.
maximum position.
NOTE: To adjust the flame at any position, you must WARNING: Test every UV installation for
move the “Push-to-Close” Flow Control Valve to the dangerous spark excitation from ignitors and
number you desire to adjust. This aligns the adjusting other possible sources of direct or reflected UV
screw directly on the fuel valve plunger. A resulting radiation. Use only gas-tight scanner
adjustment of the screw is directly applied to the fuel connections.
valve plunger and its interconnected valve body 21. Before system is placed into full service,
linkage. instruct operator personnel on proper start-up,
CAUTION: Oil flames are highly radiant. Use operation and shut-down of system. Establish
eye protection and avoid prolonged viewing. written instructions for their future reference,
Prepare to shut off oil quickly if there is a emphasizing the difference between these
noticeable drop in oil pressure or if ignition “Push-to-Close” valves and the standard Maxon
does not occur. SYNCHRO Valve.
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Flow Control Valves Page 7000-A/P-1
Assembly Numbers
SYNCHRO Valves
-P Style Gas Poppet Type Valves

Size Configured Item Number
1/2" -P .5P SYNCHRO
3/4" -P .75P SYNCHRO
1" -P 1P SYNCHRO
1-1/4" -P 1.25P SYNCHRO
1-1/2" -P 1.5P SYNCHRO
2" -P 2P SYNCHRO
2-1/2" -P 2.5P SYNCHRO
Segment Choice Detail - -P Style Poppet Type Valves

Segment Choice
(DEFAULT is shaded)
O2ANSI ANSI oxygen service
O2ISO ISO oxygen service [1]
BODY TYPE Type of valve body
STDANSI Standard ANSI poppet valve body
STDISO Standard ISO poppet valve body [1]
PTC Push-to-close (1.25P SYNCHRO and larger only)
CAM TYPE Type of cam STD Standard cam
TE Totally enclosed cam
SS Stainless steel trim
VALVE STYLE (TRIM) Valve internal trim material
STD Standard trim
ISO ISO flange
FLANGE TYPE For 2P and 2.5P sizes only
STD NPT flange
BAR_COL_HT Barber-Colman electric EA70 High Torque CB&L
BARB_COL Barber-Colman electric EA51-58, MC, MP, MF CB&L
FOX_JOR Foxboro-Jordan electric SM-1510 CB&L
HW_ACTION Honeywell electric Actionator (Discontinued)
Type of connecting base and
CONNECTING BASE & HW_AIR Honeywell air 01-11/861P 03-8/863T CB&L
linkage assembly (CB&L), if
LINKAGE HW_HERC Honeywell Herculine motor
desired
HW_MOD Honeywell electric Modutrol CB&L
HW_01986M Honeywell air actuated 01-9/861M CB&L
LEEDS_NOR Leeds & Nor thrup electric CB&L
NONE No CB&L
PENN_JOHN Penn/Johnson electric M80, M81 CB&L
TAYLOR Taylor air 40VF6 CB&L
AUX Auxiliary position switch
GPLF General purpose lo position switch
GPLFHF General purpose, hi & lo position switches
Type of position switch
SWITCHES HDLF Hazardous duty lo position switch
required
WLF Weatherproof lo position switch
WLFHF Weatherproof, lo & hi position switches
[1] Not available for .5P, 2P and 2.5P sizes

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Page 7000-A/P-2 Flow Control Valves
Assembly Numbers
SYNCHRO Valves
-M Style Gas Butterfly Valves -S Style Gas Butterfly Valves

Type Size Configured Item Number Type Size Configured Item Number
1-1/2" -M 1.5M SYNCHRO
3" -S 3S SYNCHRO
2" -M 2M SYNCHRO -S Style
2-1/2" -M 2.5M SYNCHRO 4" -S 4S SYNCHRO
3" -M 3M SYNCHRO
-M Style 4" -M 4M SYNCHRO
6" -M 6M SYNCHRO
8" -M 8M SYNCHRO
10" -M 10M SYNCHRO [1]
12" -M 12M SYNCHRO [1]
[1] These selections are not available for the Top Valve in a Two
Fuel or the Gas Valve in an MM MRV.
Segment Choice Detail - -M and -S Style Valves

Segment Choice
(DEFAULT is shaded)
Valve internal trim material SS Stainless steel trim
VALVE STYLE (TRIM)
(for 1-1/2" through 4" sizes) STD Standard trim material
PTC Push-to-close cam
CAM STYLE Cam style desired STD Standard cam
ISO ISO threaded flange (not available for 8" size)
Flange choices for 1-1/2"
SOC Socket welded flanges (for 4", 6" & 8" sizes only)
through 8" valves
STD NPT threaded flange
FLANGE TYPE
Flange choices available for NONE No flange
10M SYNCHRO & 12M 125 125# cast iron flange
SYNCHRO only 150 150# cast steel socket welded flange
Spring choices (for 1-1/2" SHP SHP (high pressure) version
SPRING TYPE
through 4" valves) STD Standard -M valve spring
BAR_COL_HT Barber-Colman electric EA70 high torque CB&L
FOX_P25 Foxboro air P-25 CB&L
Type of connecting base and HW_AIR Honeywell air 01-11/861P 03-8/863T CB&L
CONNECTING BASE
& LINKAGE HW_HERC Honeywell Herculine motor
desired
HW_01986M Honeywell air 01-9/861M CB&L
NONE No CB&L
AUX Auxiliar y position switch
GPLF General pur pose lo position switch
GPLFHF General pur pose, hi & lo position switches
required
WLF Weather proof lo position switch
WLFHF Weather proof, lo & hi position switches
VALVE GASKET Gasket material for 4" STD Standard neoprene gasket
MATERIAL through 8" valves SURSEAL Fiber with nitrile binder
mCORPORATION

Assembly Numbers
SYNCHRO Valves
-O Style Oil Valves

3/8" - O - 8 .375O8 SYNCHRO
1/2" - O - 20 .5O20 SYNCHRO
1/2" - O - 50 .5O50 SYNCHRO
1/2" - O - 100 .5O100 SYNCHRO
3/4' - O - 200 .75O200 SYNCHRO
1" - O - 400 1O400 SYNCHRO
1" - O - 750 1O750 SYNCHRO
Segment Choice Detail - -O Style Oil Valves

Segment Choice
(DEFAULT is shaded)
SS Stainless steel trim material
TRIM CHOICE Valve internal trim material
STD Standard trim material
CAM STYLE Type of cam STD Standard cam
ISO ISO 350 degree (for 3/4" & 1" valves only)
STD Standard 350 degree
VALVE BODY TYPE Type of valve body 450 450 degree steel ANSI
450ISO 450 degree steel ISO (for 3/4" & 1" valves only)
450SOC 450 degree steel socket weld
CONNECTING BASE &
LINKAGE HW_HERC Honeywell Herculine motor
desired
NONE No CB&L
AUX Auxiliary position switch
GPLF General purpose lo position switch
GPLFHF General purpose, hi & lo position switches
required
WLF Weatherproof lo position switch
WLFHF Weatherproof, lo & hi position switches

mCORPORATION
Assembly Numbers
SYNCHRO Valves
M Style Air Control Valves

M- 1-1/2" M1.5 AIRVLV
M- 2" M2 AIRVLV
M- 2-1/2" M2.5 AIRVLV
M- 3" M3 AIRVLV
M- 4" M4 AIRVLV
M- 6" M6 AIRVLV
M- 8" M8 AIRVLV
M- 10" M10 AIRVLV
M- 12" M12 AIRVLV
M- 14" M14 AIRVLV
M- 16" M16 AIRVLV
M- 18" M18 AIRVLV
Segment Choice Detail - M Style Air Control Valves (sizes 1.5" through 8")
Segment Choice
(DEFAULT is shaded)
200 Standard 200 degree valve
TEMPERATURE
Temperature rating desired 450 450 degree valve
RATING
800 800 degree valve (3" through 8" sizes only)
ISO ISO threaded flange (1.5" through 3" only)
FLANGE TYPE Type of flange required SOC Socket welded flange (4", 6" & 8" sizes only)
STD NPT threaded flange
CONNECTING BASE &
linkage assembly (CB&L), if HW_HERC Honeywell Herculine motor
LINKAGE
desired HW_MOD Honeywell electric Modutrol CB&L
NONE No CB&L
Type of position switch NONE No switches
SWITCHES
required OM Omron lo position switch
WLF weather proof lo position switch
ADJUSTABLE STOP Optional adjustable stop NO No adjustable stop
OPTION feature YES Adjustable stop wanted
GASKET MATERIAL STD Standard neoprene gasket
Type of gasket material
CHOICE SURSEAL Fiber with nitrile binder
mCORPORATION

Assembly Numbers
SYNCHRO Valves
Segment Choice Detail - M Style Air Control Valves (sizes 10" through 18")
Segment Choice
(DEFAULT is shaded)
TEMPERATURE 200 Standard 200 degree valve
Temperature rating desired
RATING 800 Special 800 degree valve
NONE No flange
FLANGE TYPE Type of flange required 125 125# cast iron
150 150# cast steel socket welded
CONNECTING BASE &
LINKAGE
desired HW_MOD Honeywell electric Modutrol CB&L
NONE No CB&L
Type of position switch NONE No switches
SWITCHES
required OM Omron lo position switch
WLF weather proof lo position switch
STD Standard cam
CAM STYLE Type of cam required
ADJUSTABLE STOP Optional adjustable stop NO No #23226 adjustable stop
OPTION feature YES Adjustable stop wanted (#23226)

mCORPORATION
Assembly Numbers
Duplex MICRO-RATIO® Valves NOTE: When ordering any duplex or triplex MICRO-
MICRO-RATIO® Valve Configured Item Number RATIO® Valve assembly, choose the same cam style
MXP MP MRV and air valve temperature rating at all levels. Any
MXM MM MRV MICRO-RATIO® Valve which uses Series “A” Valves
MXS MS MRV must use the standard cam style.
MXO MO MRV
MXA MA MRV
Duplex MICRO-RATIO® Valve Combinations

Configured Item Segment Choices
AIR VALVE SIZE See page 7000-A/P-4 [1]
GAS VALVE SIZE See page 7000-A/P-1, 7000-A/P-2 & 7000-A/P-3
L LEFT
FLOW DIRECTION
R RIGHT
ALW Aluminum wire-on
MP MRV TAGGING NONE No label
& SSW Stainless steel wire-on
MO MRV PTC Push-to-close cam
CAM STYLE STD Standard cam
200 200 degree valve
AIR VALVE TEMPERATURE RATING 450 450 degree valve w/special trim
800 800 degree high temperature version
GAS VALVE SIZE See page 7000-A/P-1 & 7000-A/P-2
TAGGING NONE No label
MM MRV SSW Stainless steel wire-on
& PTC Push-to-close cam
MS MRV CAM STYLE STD Standard cam
200 200 degree valve
AIR VALVE TEMPERATURE RATING 450 450 degree valve w/special trim
800 800 degree high temperature version
GAS VALVE SIZE See page 7100-A/P-1
MA MRV
SSW Stainless steel wire-on
[1] CB&L's not available for air valves in MICRO-RATIO Valve assemblies
mCORPORATION

Assembly Numbers
Triplex MICRO-RATIO® Valves NOTE: When ordering any duplex or triplex MICRO-
RATIO® Valve assembly, choose the same cam style
MICRO-RATIO® Valve Configured Item Number
and air valve temperature rating at all levels. Any
Triplex MICRO-RATIO Assembly TRIPLEX MRV MICRO-RATIO® Valve which uses Series “A” Valves
must use the standard cam style.
Triplex MICRO-RATIO® Valve Combinations

AA
See page 7100-A/P-2 through 4 for segment
AO
descriptions
AP
MA
DUPLEX TO ADD SYNCHRO TO
MM
MO See page 7000-A/P-6 for segment descriptions
MP
MS
TRIPLEX MRV
See pages 7000-A/P-1 through 3 or page 7100-A/P-1 for segment choices and
THIRD VALVE (ADDED TO DUPLEX)
descriptions
Two Fuel SYNCHRO Valves

SYNCHRO Valve Configured Item Number
Two Fuel SYNCHRO Valve Assembly TWO FUEL
Two Fuel SYNCHRO Valve Combinations

FIRST (BOTTOM) FUEL VALVE See pages 7000-A/P-1 to 3 or page 7100-A/P-1 for segment choices
SECOND (TOP) FUEL VALVE See pages 7000-A/P-1 to 3 or page 7100-A/P-1 for segment choices
TWO FUEL

mCORPORATION
Assembly Numbers
Series Q Gas Control Valves
Series Q Gas Control Valves

Configured Product Numbers
Size &
Designation Non - UL Stand - by Stand - by
UL Version
Version Non - UL Version UL Version
1" 1Q 1 QUL 1 QSB 1 QSBUL
1-1/4" 1.25 Q 1.25 QUL 1.25 QSB 1.25 QSBUL
1-1/2" 1.5 Q 1.5 QUL 1.5 QSB 1.5 QSBUL
2-1/2" 2.5 Q 2.5 QUL 2.5 QSB 2.5 QSBUL
Segment Choice Detail - Series Q Gas Control Valves

Segment Choice
(DEFAULT is shaded)
ANSI_THRD ANSI threads
ISO_THRD ISO threads [1]
CS Carbon steel
SHAFT MATERIAL Material used for shaft
SS stainless steel
HW_ACTION Honeywell Actionator electric (Discontinued)
HW_HERC Honeywell Herculine motor
Type of connecting base and HW_AIR Honeywell Air 01-11/861P 863T
OPERATING LINKAGE
[2] HW_MOD Honeywell Modutrol electric CB&L
desired
HW_01986M Honeywell 01986M air actuated CB&L
NONE No CB&L
POSITION SWITCH [2] OMWPHLPS Omron weather proof hi & lo position switch
required
OMWPLPS Omron weather proof lo position switch
Maximum operating
MOPD RATING Default is maximum pressure and varies according to valve size
pressure differential (psi)
EXTRA FOOT Extra foot bracket for tandem NONE No extra foot bracket needed
BRACKET mounting YES Extra foot bracket provided
[1] ISO threads are not available on UL versions
[2] These selections are not available on UL versions
Tandem Linkage Assembly

Tandem Linkage Configured Product Number
Assembly TAN Q
Segment Choice Detail - Tandem Linkage Assembly

Segment Choice
(DEFAULT is shaded)
TOP VALVE First Q Valve See table above for segment choices and descriptions
CONNECTING AUTO Automatic CB&L
Linkage to connect Q Valves
LINKAGE MAN Manual CB&L
BOTTOM VALVE Second Q Valve See table above for segment choices and descriptions
mCORPORATION

Assembly Numbers
Series CV Control Valves
Series CV Control Valves

Series "CV" Valve Assemblies
Standard Version UL Version
Stock Configured Size & Stock Configured
Assembly Product Designation Assembly Product
Number Number Number* Number
18809 .5 CV 1/2" -CV 32779 .5 CVUL
18810 .75 CV 3/4" -CV 32780 .75 CVUL
23880 .75U CV 3/4" -U -CV 32781 .75U CVUL
18206 1 CV 1" -CV 32782 1 CVUL
23881 1U CV 1" -U -CV 32783 1U CVUL
18207 1.25 CV 1-1/4" -CV 32784 1.25 CVUL
23882 1.25U CV 1-1/4" -U -CV 32785 1.25U CVUL
18208 1.5 CV 1-1/2" -CV 32786 1.5 CVUL
18209 2 CV 2" -CV 32787 2 CVUL
18210 2.5 CV 2-1/2" -CV 32788 2.5 CVUL
18211 3 CV 3" -CV 32789 3 CVUL
*Includes CB&L assembly
Segment Choice Detail - Series CV Control Valves

Segment Choice
(DEFAULT is shaded)
ISO_THRD ISO threads [1]
CS Carbon steel
SS Stainless steel
BELIMO_ACT Belimo CV Actuator Assembly
HW_ACTION Honeywell Actionator electric (Discontinued)
Type of connecting base and HW_AIR Honeywell air 01-11/861P 863T CB&L
CONNECTING BASE &
LINKAGE [2]
desired HW_MOD Honeywell Modutrol electric CB&L
NONE No CB&L
BELIMO_LFS Belimo Low Fire Star t Switch
POSITION SWITCH Type of position switch NONE No position switch
[2] required OMWPHLPS Omron weatherproof hi & low position switch
OMWPLPS Omron weatherproof low position switch
Maximum operating
[1] ISO threads are not available on UL versions.
[2] These selections are not available on UL versions.

mCORPORATION
Assembly Numbers
Series BV Balancing Valves
Series BV Balancing Valves

Size and Stock Configured
Designation Assembly Number Product Number
1/2" -BV 19118 .5 BV
3/4" -BV 19119 .75 BV
1" -BV 19120 1 BV
1-1/4" -BV 19121 1.25 BV
1-1/2" -BV 19122 1.5 BV
2" -BV 19123 2 BV
2-1/2" -BV 19124 2.5 BV
3" -BV 19125 3 BV
Segment Choice Detail - Series BV Balancing Valves

Segment Choice
(DEFAULT is shaded)
ISO_THRD ISO threads
CS Carbon steel
SS Stainless steel
Maximum operating
mCORPORATION

Assembly Numbers

Manufacturer SYNCHRO & MICRO-RATIO® Valves M Style Series Series
Air
Standard Totally-enclosed Q CV
Name Description Control
Cam Cam Valves Valves
Valves
42776
Barber-Colman electric EA51-58, MC, MP, MF 15166 25657 32820 17377
Barber-Colman 18194*
Barber-Colman electric EA70 high torque 30091 29696 32821 --- ---
Foxboro air P-25 24429 25641 32810 24383 24422
Foxboro
Foxboro air P-50 24430 25642 32814 24384 ---
Foxboro-Jordan Foxboro-Jordan electric SM-1510 34456 34469 --- --- ---
Honeywell air 01-11/861P 03-8/863T 17280 25654 32811 17376 19320
Honeywell air 01-9/861M 13116 25790 32813 17711 ---
42776
Honeywell Honeywell electric Modutrol 16241 25656 32819 17372
18194*
Honeywell electric Actionator (Discontinued) 14526 25777 32818 17378 19852
Honeywell Herculine motor 1066872 1066901 1066902 1066900 1066903
Johnson Controls Johnson Controls air --- --- --- 17867 19916
Leeds & Northrup Leeds & Nor thrup electric 14127 29687 32817 --- ---
42776
Penn/Johnson Penn/Johnson electric M80, M81 16241 25656 32819 17372
18194*
Taylor Taylor air 40VF6 12883 27348 32815 17708 19850
Beck Beck electric 11-150 09041 --- --- --- ---
Belimo Belimo LM24SR.1MX --- --- --- --- 1060202
* Use top number for 1-1/4" and smaller valves; bottom number for 1-1/2" and larger
Auxiliary Signal Switch Assemblies - SYNCHRO, MICRO-RATIO® & M Style Air Valves
SYNCHRO & MICRO-RATIO® Valves
Switch Description M Style Air Control Valve
with standard cam with totally-enclosed cam
Auxiliar y position switch 14309 --- ---
General pur pose lo position switch 14316 --- 33089
General pur pose, hi & lo position switches 18189 --- ---
Hazardous duty lo position switch 35945 53508 ---
Weather proof lo position switch 35614 53507 35612
Weather proof, lo & hi position switches 39508 --- ---
Omron lo position switch --- --- 46656

m
CORPORATION
Assembly Numbers
Auxiliary Signal Switch Assemblies - Series Q & Series CV Control Valves

Valve Series & Size Switch Description
Omron weatherproof Omron weatherproof Belimo low fire
Series Size
hi & lo position switch lo position switch start switch
Series Q Valves All sizes 1038975 1038974 ---
.5 1036009 1036373 1060210
.75 1036009 1036373 1060210
1 1036009 1036373 1060210
1.25 1036009 1036373 1060210
Series CV Valves
1.5 1036009 1036373 1060210
2 1036009 1036373 1060210
2.5 1036009 1036373 1060210
3 1059410 1059409 1060210
mCORPORATION

Bulletin 7100
Series “A” Flow Control Valves
Cut-away of 3" positive push/pull SYNCHRO Valve
• Valve bodies are designed to meet ANSI specifications (DIN flange option for future availability)
• High pressure rating
• Cast iron, carbon steel and brass bodies
• Positive push/pull actuator
• SYNCHRO Valves may be used independently for individual adjustable gradient fuel flow
control, or in tandem with other fuel control valves for more sophisticated multi-zone control
or multi-fuel applications.
• Low torque
CORPORATION 201 East 18th Street, P.O. Box 2068, Muncie, Indiana, 47307-0068. Phone: (765) 284-3304. FAX: (765) 286-8394
Page 7102
Series “A” Flow Control Valves

Principle of Operation Nomenclature
®
MICRO-RATIO Valve assemblies typically consist MICRO-RATIO® Valve assemblies are designated
of an air butterfly valve mechanically linked to one or by listing the individual valves, starting with the air
more adjustable gradient SYNCHRO Fuel Control valve, then each of the fuel valves to be included, as
Valves(s). well as their relative position in the assembly (bottom
to top).
Examples:
“Duplex” MICRO-RATIO® Valve assembly
A-4” X 1-1/2 ”-A
(air) X (gas)
“Quadriplex” MICRO-RATIO® Valve assembly

M- 10” X 4”-A X 1/2” -O -200 X 2”-A
(air) X (gas) X (oil) X (gas)
View of a A-3” x 1-1/2” -A MICRO-RATIO® Valve
The tandem linkage gives accurate proportioning of

air/fuel(s) ratios required for your specific burner
system/application.
The multiple screw adjustment feature of the
SYNCHRO Valve provides a mechanical means of
adjusting the air/fuel(s) ratios at each of twelve valve View of Triplex M-6" x 1-1/2"-A x 1/2"-P
positions throughout the capacity range of each valve.
This provides accurate fuel/air control.
Air-gas-oil valves in tandem-linked combination Design Features
are ideal for multi-zone or stand-by fuel system Series “A” Flow Control Valves are available in
control. manual handle and positive push/pull SYNCHRO
Air-gas-oil SYNCHRO Valves may be used versions.
independently for single control or throttling of Valve bodies are available in cast iron, steel and
multiple burners. brass versions. All versions have a stainless steel
shaft and disc. Brass versions are compatible for
oxygen service.
The positive push/pull actuator is tested to over
250,000 cycles.
6/02
CORPORATION 201 East 18th Street, P.O. Box 2068, Muncie, Indiana, 47307-0068. Phone: (765) 284-3304. FAX: (765) 286-8394
Series “A” Flow Control Valves Page 7103

General
All Maxon Flow Control Valves are designed for Flow direction is not a factor with butterfly-type
throttling service only and are not intended for valve bodies. However, with poppet-type SYNCHRO
tight shut-off. Valves, fluid flow through the valve must only be in the
direction indicated by the arrowhead cast into each
valve body.
Series “A” Manual Control Valves

Maximum Maximum Maximum Fluid
Minimum Torque
Maximum Cv Inlet Body Temperature (°F)
Size Controllable Required
Rating Pressure Pressure
Cv Rating (in-lbs) Iron & Steel Brass
(psig) (psig)
1" 27 .50 100 100 10 250 400
1.25" 70 .60 100 100 20 250 400
1.5" 105 .70 100 100 30 250 400
2" 190 1.30 100 100 65 250 400
2.5" 260 2.40 90 100 100 250 400
3" 360 3.00 60 100 125 250 400
4" 750 5.00 30 100 140 250 N/A
Cv factors based on flow through a wide-open valve.
Torque required is shown for maximum rated pressure. At lower pressures, less torque may be required.
Series “A” SYNCHRO Control Valves

Maximum Maximum Maximum Fluid
Minimum Torque
Maximum Cv Inlet Body Temperature (°F)
Size Controllable Required
Rating Pressure Pressure
Cv Rating (in-lbs) Iron & Steel Brass
(psig) (psig)
1" 27 .50 100 100 55 250 400
1.25" 70 .60 100 100 60 250 400
1.5" 105 .70 100 100 70 250 400
2" 190 1.30 55 100 75 250 400
2.5" 260 2.40 30 100 75 250 400
3" 360 3.00 16 100 75 250 400
4" 750 5.00 8 100 75 250 N/A
Cv factors based on flow through a wide-open valve.
Torque required is shown for maximum rated pressure and smooth linear cam strip settings. For applications that require
non-linear cam strip settings, double the torque required.
Torque Requirements listed in tables above are Example #1: Linear Cam Strip Setting
important and are to be used in selecting your auto- A-4" x 1-1/2"-A MICRO-RATIO® Valve
matic control operators. Torque figures (inch-pounds) A-4" manual requires 140 in-lbs.
1-1/2"-A SYNCHRO requires 70 in-lbs.
are additive for your complete MICRO-RATIO® Valve
Total torque required: 210 in-lbs.
assembly.
Example #2: Non-Linear Cam Strip Setting
When pneumatic actuators are applied, oversize to A-4" x 1-1/2"-A MICRO-RATIO® Valve
achieve accurate control. A-4" manual requires 140 in-lbs.
1-1/2"-A SYNCHRO requires 140 in-lbs.
Total torque required: 280 in-lbs.
8/03
Page 7104 Series “A” Flow Control Valves

Valve Body
B dia.
A dia.
C dia.
D
E
Cast Iron Bodies Carbon Steel Bodies

Size A B C D E Size A B C D E
1" 3.12 0.63 4.25 0.66 1.31 1" 3.12 0.63 4.25 0.66 1.31
1.25" 3.50 0.63 5.00 0.66 1.31 1.25" 3.50 0.63 5.00 0.66 1.31
1.5" 3.88 0.63 5.00 0.66 1.31 1.5" 3.88 0.63 5.00 0.66 1.31
2" 4.75 0.75 6.00 0.84 1.69 2" 4.75 0.75 6.00 0.84 1.69
2.5" 5.50 0.75 7.50 0.91 1.81 2.5" 5.50 0.75 7.50 0.91 1.81
3" 6.00 0.75 7.50 0.91 1.81 3" 6.00 0.75 7.50 0.91 1.81
4" 7.50 0.75 9.00 1.03 2.06 4" 7.50 0.75 9.00 1.03 2.06
Brass Bodies
Size A B C D E
1" 3.12 0.63 4.25 0.66 1.31
1.25" 3.50 0.63 5.00 0.66 1.31
1.5" 3.88 0.63 5.00 0.66 1.31
2" 4.75 0.75 6.00 0.84 1.69
2.5" 5.50 0.75 7.50 0.91 1.81
3" 6.00 0.75 7.50 0.91 1.81

Flange High Position Switch Low Position Switch &

Set Adapter Foot Accessories 6.498 rad.
Accessory 1/2" NPSM
Conduit
Inlet
4.35
5.44 1/2" NPT
Conduit 0.68
.71 Inlet
E
E 3.17 2.83
Low Position Switch Top View
A
C 3.0
D
1.0
2.0 3.0
Adapter B
1.0 Foot
Mounting
2.0

Size A B C D E F Thrd. Welded Thrd. Welded
Size A B E F
C C D D
1" 5.08 2.91 1.41 2.82 5.67 4.00
1" 5.08 2.91 1.41 1.41 2.82 2.82 5.67 4.00
1.25" 5.51 3.16 1.53 3.06 6.17 4.25
1.25" 5.51 3.16 1.53 1.53 3.06 3.06 6.17 4.25
1.5" 5.51 3.16 1.60 3.20 6.17 4.25
1.5" 5.51 3.16 1.60 1.60 3.20 3.20 6.17 4.25
2" 5.51 3.41 1.91 3.81 6.17 4.50
2" 5.51 3.41 1.91 1.91 3.81 3.81 6.17 4.50
2.5" 6.08 4.14 2.09 4.18 6.67 5.25
2.5" 6.08 4.14 2.09 2.09 4.18 4.18 6.67 5.25
3" 6.08 4.14 2.16 4.32 6.67 5.25
3" 6.08 4.14 2.16 2.16 4.32 4.32 6.67 5.25
4" 6.63 5.28 2.41 4.81 7.29 6.38
4" 6.63 5.28 2.41 2.41 4.81 4.81 7.29 6.38
Brass Bodies Valve Weight - Manual Valves (in lbs.)

Thrd. Solder Thrd. Solder Body Material
Size A B E F Valve Size
C C D D
Cast Iron Carbon Steel Brass
1" 5.08 2.91 1.41 1.78 2.82 3.81 5.67 4.00 1" 8.1 8.5 9.3
1.25" 5.51 3.16 1.53 1.84 3.06 3.81 6.17 4.25 1.25" 9.6 10.2 11.2
1.5" 5.51 3.16 1.60 1.92 3.20 3.97 6.17 4.25 1.5" 9.4 10.0 10.9
2" 5.51 3.41 1.91 2.51 3.81 5.13 6.17 4.50 2" 13.2 14.1 15.6
2.5" 6.08 4.14 2.06 2.79 4.11 5.48 6.67 5.25 2.5" 20.2 21.7 24.1
3" 6.08 4.14 2.16 2.85 4.32 5.70 6.67 5.25 3" 19.0 20.4 22.7
4" 27.6 29.8 ---
Note: All weights are approximate and do not include
accessories
6/03

Series “A” SYNCHRO Control Valves
1/2"
NPT
Conduit
Inlet 6.24
Position Switch Manual Knob &

Foot Adapter Accessories
2.36
Low 3.65
Flange Set Accessory Position
Switch
1/2" NPT
Conduit Inlet 2.98
1.11
1.11 10.69
1/2" NPT 9.00

Conduit Inlet
High 1.57
Position
Switch 4.68
F B
A
D
E
3.0
1.0
2.0 3.0
C
1.0
Adapter Foot Mounting 2.0

Size A B C D E F Thrd. Welded Thrd. Welded
Size A B C F
D D E E
1" 5.06 8.44 2.91 1.41 2.82 4.00
1" 5.06 8.44 2.91 1.41 1.41 2.82 2.82 4.00
1.25" 5.56 8.94 3.16 1.53 3.06 4.25
1.25" 5.56 8.94 3.16 1.53 1.53 3.06 3.06 4.25
1.5" 5.56 8.94 3.16 1.60 3.20 4.25
1.5" 5.56 8.94 3.16 1.60 1.60 3.20 3.20 4.25
2" 5.56 8.94 3.41 1.91 3.81 4.50
2" 5.56 8.94 3.41 1.91 1.91 3.81 3.81 4.50
2.5" 6.06 9.44 4.14 2.09 4.18 5.25
2.5" 6.06 9.44 4.14 2.09 2.09 4.18 4.18 5.25
3" 6.06 9.44 4.14 2.16 4.32 5.25
3" 6.06 9.44 4.14 2.16 2.16 4.32 4.32 5.25
4" 6.69 10.06 5.28 2.41 4.81 6.38
4" 6.69 10.06 5.28 2.41 2.41 4.81 4.81 6.38
Brass Bodies Valve Weight - SYNCHRO Valves (in lbs.)

Thrd. Solder Thrd. Solder Body Material
Size A B C F Valve Size
D D E E
Cast Iron Carbon Steel Brass
1" 5.06 8.44 2.91 1.41 1.78 2.82 3.81 4.00
1" 17.6 18.0 18.8
1.25" 5.56 8.94 3.16 1.53 1.84 3.06 3.81 4.25
1.25" 19.1 19.7 20.7
1.5" 5.56 8.94 3.16 1.60 1.92 3.20 3.97 4.25
1.5" 18.9 19.5 20.4
2" 5.56 8.94 3.41 1.91 2.51 3.81 5.13 4.50
2" 22.7 23.6 25.1
2.5" 6.06 9.44 4.14 2.06 2.79 4.11 5.48 5.25
2.5" 29.7 31.2 33.6
3" 6.06 9.44 4.14 2.16 2.85 4.32 5.70 5.25
3" 28.5 29.9 32.2
Pipe threads on this page conform to NPT (ANSI Standard B2.1) 4" 37.1 39.3 ---
Note: All weights are approximate and do not include
accessories

®
MICRO-RATIO Valve Arrangements (right hand arrangement shown)
2.0
“O” Type
4.88 Outlet Inlet
Oil Valve
2.38 Spacer
“P” Type
4.88 Outlet Inlet
Gas Valve
For dimensions not shown
on this page, see pages
5.50 Spacer 7009 through 7014.
“-A” Type NOTE: Spacer

Gas Valve supplied separately
A or with connecting
linkage assembly
C
B
3"-A
“M-” Type
Air Valve
M-12"
10.27 D
SYNCHRO Gas Valves - Butterfly Type "M-" Air Valves - Dimension D

C Size D
Size A B C
Brass
M- 1-1/2" thru M-6" ---
1" 5.06 4.00 2.82 2.82
M-8" 1.12
1.25" 5.56 4.25 3.06 3.06
M-10" 3.62
1.5" 5.56 4.25 3.20 3.20
M-12" 4.62
2" 5.56 4.50 3.81 3.81
M-14" 5.75
2.5" 6.06 5.25 4.18 4.11
M-16" 6.62
3" 6.06 5.25 4.32 4.32
M-18" 7.62
4" 6.69 6.38 4.81 ---
Note: Dimension "D" is dependent upon the size of air valve
selected.
6/02
Accessories
Position switches Connecting Base
for electrical indication of valve position and Linkage
Standard Low Fire Start (LFS) switch opens the Assemblies
circuit when valve leaves minimum position. Hi/Lo fire Maxon has designed a
position switch set includes (2) SPDT switches. One broad range of Connecting
switch may be field-set to activate at high position, Base and Linkage assem-
while the other is set to activate at low position. blies (CB & L) to properly
position and align the
popular operators for
SYNCHRO Valves
control of Maxon flow
control valves.
Proper position and
alignment are essential for
smooth and trouble-free
operation of flow control
valves.
Other Accessories
Poppet to A- SYNCHRO Spacer Kit
Manual Handle Valves
Universal Adapter Bracket Kit

5 6
7
9
3
2
4
1
10
Legend
Item Description
1 Manual Valve Adapter
2 Cap Screws
3 Indicator Plate
4 Manual Shaft Bushing
5 Manual Handle
6 Manual Sleeve
7 Set Screw
8 Brake Spring
9 Brake
10 Valve Body Sub-Assembly
6/02
Series “A” SYNCHRO Flow Control Valves
22
24
10 23 22
32
A A
27
26
25
29
Legend 28
Item Description
1 Housing
2 Operating Rack
3 Operating Rack Bearings
16 17 18 17
4 Compression Spring 10 19 20 19
21
5 Spring Retainer
6 Base 13 9
Section A-A
7 Locking Screw
15 30
8 Base Bolts 31
3
9 Lube Fitting
10 Screw Carrier
11 Cam Screws
12 Retainer Screws
13 Cam Strips
14 Yoke
14
12
15 Dust Cover 8 5 4 3 2
6
Screw Carrier Bolt 7
16 11
17 Washer
18 Bearing
19 Washer
20 Bearing
21 Set Screw
22 Indicator Strip
23 Plate Screw
24 Cam Screw Cover Plate
25 Identification Plate
26 Drive Screw
27 Valve Body Sub-Assembly
28 Ground Straps (Brass Only)
29 Drive Screw (Brass Only)
30 Spur Gear
31 Cap Screws
32 Cover Plate

Series “A” SYNCHRO Flow Control Valves
Valve Lubrication Suggestions

Some lubrication of moving parts may be
required. All moving parts, O-rings and cam strips are
lubricated at time of manufacturing. A periodic
inspection should be performed to insure all parts
continue to move freely and function properly. A
periodic re-application of lubricant will extend the
service life of your Maxon MICRO-RATIO® Valve.
The following lubricants are suggested:
Manufacturer Lubricant
Keystone Div., #84-EP-2, NLGL #2

Philadelphia, PA Lithium base grease
Standard Oil Co. Stanolith grease #42

(of Indiana)
Shell Oil Co. Alvania grease #1
Stewart Warner Corp. Alemite lubricant #32
6/02
Notes
Series “A” Flow Control Valves Page 7100-S-1
• Support weight of piping independently. Do not • Install flow control valves carefully and maintain
place any Maxon Flow Control Valve in a piping adequate dimensional clearance to allow full
bind. Provide pipe hangers and/or special support stroke and travel of the valve’s control linkage.
for related manifolds. Internal drive mechanisms within a control motor
• Maxon connecting base and linkage assemblies may be damaged if linkage is restricted as to cause
are designed to locate and/or position the binding in high or low flow positions.
control operator for its interaction with the Flow
CAUTION: All flow control valves are designed
Control Valve assembly. They are not intended to
support the weight of the control motor. Special
for tight shut-off.
provisions will be required to support the weight of
the control operators. • Main system shut-off should always use a
• Use of pipe heavier than Schedule #40 can cause manual “leak-tight” upstream fuel cock.
interference with butterfly-type Flow Control Valves
and restrict the valve from full opening.
• Flow Control Valves provide the means to adjust
fluid and/or gas flows. They should be installed
with at least four pipe diameter lengths of straight
pipe before and after the valve. This lessens the
chance of internal flow turbulence being set-up in
the piping manifolds and control valve.
Screw Carrier Rotation Instructions

To rotate screw carrier in 90° increments:
– Remove four base bolts.
– Rotate screw carrier on its shaft to desired position.
– Reinstall base bolts.
Spur Gear
Base Bolts
Housing
Bolt

mCORPORATION
Page 7100-S-2 Series “A” Flow Control Valves
Series “A” Push/Pull SYNCHRO Valves
General Instructions The Push/Pull SYNCHRO relies on direct

Important: Do not discard packing materials connections from the adjusting screw through to
until all loose items are accounted for. the valve shaft. Carefully follow these adjusting
instructions to prevent permanent damage to the
To prevent damage in transit, some connecting cam strips or linkages, which could cause the
base and linkage components may be packed sepa- valve to not operate properly or result in an
rately and shipped loose with your new Maxon flow unsafe condition.
control valve.
The flow control valve is normally only a part of
your complete combustion system. Additional pipe The following tools are needed to adjust the Maxon
train accessories and control components may be Push/Pull SYNCHRO screw carrier:
required for a complete system installation. Read • Flat tipped screw driver
complete instructions before proceeding, and familiar- • 5mm hex wrench (screw carrier position lock)
ize yourself with all the system’s equipment compo- • 5/32” hex (‘T’ handle recommended) wrench
nents. Verify that your equipment has been installed (adjusting screws)
in accordance with the original manufacturer’s current 1. Remove any connecting linkages as needed to allow
instructions. access to the screw carrier.
2. Lock the screw carrier in a convenient position (use
5mm hex wrench).
3. Swing out of the way or remove the adjusting
screws cover plate (flat tipped screw driver).
4. Unlike the ‘M’ style screw carrier, which is adjusted
by setting the MAX and MIN screw positions and
then blending the remaining screw positions, the
Push/Pull screw carrier cannot be adjusted in this
manner due to its different design.
complete systems incorporating Maxon burners As a general rule of thumb, there should not be
more that 1/8” difference between screw heights.
This is approximately 3 turns between 2 adjacent
screws.
For ease of operation, longer cam strip life and
reduced torque, it is best to adjust the cam strips to
a smooth ramp from MIN to MAX.
Adjusting the Series “A” Push/Pull Try to spread adjustments out over several
screws to avoid distortion of the cam strips. This
SYNCHRO Control Valve:
may take more time to achieve a good ramp, but it
The Series “A” Push/Pull SYNCHRO has multiple
will eliminate the possibility of damage to the cam
adjusting screws that are pre-set by Maxon to an
strips or adjusting screws.
approximate ramp to assist the customer in beginning
A smooth ramp will also lengthen the life of the
their adjustments.
cam strips, other components of the screw carrier
CAUTION: Pre-set condition will allow flow to and the control motor.
occur.
mCORPORATION

Series “A” Flow Control Valves Page 7100-S-3
For initial adjustment and/or burner start-up: CAUTION: Verify all safety interlocks are opera-
1. Close all burner fuel valves and cocks. Make tional before opening any main and/or individual
preliminary adjustments to fuel gas regulators. burner valves.
spark ignition to light pilot while slowly turning
pilot gas regulator clockwise and/or adjustable
ranges. Be sure all air and fuel manifolds are
orifice screw counter-clockwise to increase fuel
tight and that test ports are plugged if not being
flow. Repeat procedure as necessary until pilot
used.
ignites, as air might have to bled out of fuel
3. Check that any air handling dampers are
supply lines before reliable pilot flame is
established. Pilot gas regulator should normally
positions.
be set for as low a pressure as possible.
8. After ignition, adjust pilot flame with pilot gas
linkage from the control valve’s operating crank
adjustable orifice for good stable flame shape. A
“rule of thumb” is that any pilot over a tennis ball
size is probably too large. If visual access to the
pilot flame is not available, adjust pilot to give a
accomplished during a “manual” control
strong and stable flame signal through the
mode.
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 used with the
burner system.
adequate purge of your manifolds.
CAUTION: Do not by-pass control panel timers or otherwise causing pilot outage. Re-light and
typically controlling sequential operations. refine pilot gas adjustment as necessary to get
ignition within a second or two. The flame
6. With MICRO-RATIO® Valve combinations of
safeguard relays should now power the main fuel
air and fuel valves, the minimum differential
Shut-Off Valve(s).
pressure setting is initially established with
the air valve only. CAUTION: After completing steps above, re-
A. By disconnecting the linkage between the air check all interlocking safety components and
butterfly valve and interconnected fuel circuitry to prove that they are properly
valve(s), the minimum and maximum limits of installed, correctly set, and fully operational. If
travel on the air valve may be determined. in doubt, shut the system down, close pilot
For example, a combustion system may cock and contact responsible individual before
need the air valve to be 15° open for the proceeding further.
10. To light and adjust burner on gas:
With gas pilot established and flame supervision
system operational, opening the main fuel Shut-
air valve’s indicating strip, the SYNCHRO Fuel
Off Valve(s) will allow fuel flow to the Flow
Valve’s linkage is ready to be reconnected to
Control Valve.
the air valve.
11. To adjust SYNCHRO flow control valves:
With SYNCHRO valve in minimum position, open
upstream fuel cock. Using a 5/32" hex wrench,
turn minimum adjusting screw (first adjusting
travels its full quadrant range (i.e. from
screw) clockwise to permit fuel flow to the burner.
minimum to maximum), while the air valve
swings from its pre-determined minimum and
maximum positions.

mCORPORATION
Page 7100-S-4 Series “A” Flow Control Valves
CAUTION: Pre-set of adjusting screw gradiant CAUTION: Oil flames are highly radiant. Use eye
may permit fuel flow at minimum position. protection and avoid prolonged viewing. Prepare
Flame safeguard interlocking safety to shut off oil quickly if there is a noticeable
components and circuitry must be operating drop in oil pressure or if ignition does not
properly. occur.
NOTE: At this point, it is more important to get any
14. Refine adjustment as needed, always turning
kind of flame as soon as possible. The flame
geometry can be adjusted and refined as needed later. valve so that position indicator matches screw
being adjusted.
12. Once flame is established and refined at this For more fuel, turn screw in (clockwise). For
position, and without advancing the screw carrier less fuel, turn screw out (counter-clockwise).
quadrant higher, place the 5/32" hex wrench on If screws must be turned in flush with carrier
the next screw and rotate to position #1 (second casting, increase fuel pressure and re-adjust.
adjusting screw). Observe and refine flame 15. Repeat procedure for any other fuels.
characteristics per the appropriate burner 16. Cycle burner from minimum to maximum and
adjustment procedures. refine adjustment, if necessary. Always set
Flow Control Valve to the desired numbered
position to be adjusted.
CAUTION: If flame is extinguished, immediately For operation with interrupted pilot (as
return Flow Control Valve to minimum position recommended), shut off pilots and cycle burner
and shut off fuel (if flame safeguard has not from minimum to maximum and back several
already done so). Turn in slightly on adjusting times to verify the flame is maintained.
screw at point where ignition was lost, then 17. Reconnect linkage to control motor, plug all
return Flow Control Valve to minimum position, test connections, replace equipment cover caps
re-establish pilots, open fuel valve and verify and tighten linkage screws.
ignition. 18. Check out overall system operation by cycling
NOTE: If firing chamber is of refractory construction, through light-off at minimum, interrupting pilot,
allow the burner system to operate at this low setting and allow temperature control system to cycle
for the necessary dry/cure-out time period burner from minimum to maximum and return.
recommended by the chamber or refractory 19. Recheck all safety system interlocks for
manufacturer. Then continue adjustments of Flow
Control Valve.
13. Progressively work up through each adjusting dangerous spark excitation from ignitors and
screw position, developing a smooth progression other possible sources of direct or reflected UV
slope from the first screw to the maximum radiation. Use only gas-tight scanner
position while adjusting and refining flame connections.
geometry as required.
NOTE: To adjust the flame at any position, move the
instruct operator personnel on proper start-up,
Flow Control Valve to the desired number to be
operation and shut-down of system. Establish
adjusted. This aligns the adjusting screw directly on
written instructions for future reference.
top of the fuel valve yoke shaft and its interconnected
valve body linkage.
m
CORPORATION

Series “A” Flow Control Valves Page 7100-A/P-1
Assembly Numbers
Series “A” Valves
Series "A" Flow Control Valves

1" 1A CTLVLV
1.25" 1.25A CTLVLV
1.5" 1.5A CTLVLV
2" 2A CTLVLV
2.5" 2.5A CTLVLV
3" 3A CTLVLV
4" 4A CTLVLV
Segment Choice Detail - Series "A" Control Valves

Segment Choices
(DEFAULT is shaded)
BR Brass version (suitable for oxygen service)
VALVE TYPE (MATERIAL) Valve body material CI Cast iron version
STL Carbon steel version
MAN Manual handle version
MANUAL OR SYNCHRO Valve operating mode
SYN SYNCHRO (automatic) version
BRANSITHRD Brass ANSI Threaded Flanges
BRSLDR Brass Soldered Flanges
CIANSITHRD Cast Iron ANSI Threaded Flanges
FLANGE SET Flanges desired
CSANSITHRD Carbon Steel ANSI Threaded Flanges
CSWLDG Carbon Steel Welding Flanges
NONE None Selected
Connecting Base & Linkage
CB&L'S HW_ACTION Honeywell electric Actionator M-640A, 940A CB&L
assembly desired
HW_AIR Honeywell air 01-11/861P, 03-8/863T CB&L
NONE No CB&L
AUX Auxiliary position switch set
HD Hazardous duty switch set
HILO Weatherproof hi-lo position switch set
SWITCHES Type of switch set desired Weatherproof high-position switch set
HIPOS
(manual version only)
LOPOS Weatherproof low position switch set
NONE No switches
MANUAL CONTROL NONE No manual control knob
Optional knob kit desired
KNOB KIT YES Manual control knob wanted
NONE No foot plate adapter kit
FOOT ADAPTER KIT Optional adapter kit desired
YES Foot plate adapter kit wanted

mCORPORATION
Page 7100-A/P-2 Series “A” Flow Control Valves
Assembly Numbers
MICRO-RATIO® Valve Combinations NOTE: When ordering any duplex or triplex MICRO-
MICRO-RATIO® Valve Configured Item Number
and air valve temperature rating at all levels. Any
MXA MA MRV MICRO-RATIO® Valve which uses Series “A” Valves
AXA AA MRV must use the standard cam style.
AXP AP MRV
AXO AO MRV

Segment Choices
Configured Item Number Segment Name Segment Choice Description
(DEFAULT is shaded)
1.5 M-1.5" Air Control Valve
10 M-10" Air Control Valve

AIR VALVE CHOICE
2.5 M-2.5" Air Control Valve

1 1"-A Gas Valve
MA MRV 1.25 1.25"-A Gas Valve

1.5 1.5"-A Gas Valve
GAS VALVE CHOICE 2 2"-A Gas Valve
2.5 2.5"-A Gas Valve
3 3"-A Gas Valve
4 4"-A Gas Valve
GPLF General purpose low position switch
NONE No switch
AIR VALVE SWITCH CHOICE
OM Omron low position switch
WLF Weather-proof low position switch
mCORPORATION

Assembly Numbers
Segment Choices
(DEFAULT is shaded)
1 A-1" Manual Handle Air Valve
1.25 A-1.25" Manual Handle Air Valve
AIR VALVE CHOICE 2 A-2" Manual Handle Air Valve
1 1"-A Gas SYNCHRO Valve
AA MRV 1.25 1.25"-A Gas SYNCHRO Valve
1.5 1.5"-A Gas SYNCHRO Valve
GAS VALVE CHOICE 2 2"-A Gas SYNCHRO Valve
2.5 2.5"-A Gas SYNCHRO Valve
1 A-1" Air Valve
1.25 A-1.25" Air Valve
AIR VALVE SELECTION 2 A-2" Air Valve
3 A-3" Air Valve
4 A-4" Air Valve
.5 .5"-P Gas Valve
.75 .75"-P Gas Valve
AP MRV 1 1"-P Gas Valve
GAS VALVE SELECTION 1.25 1.25"-P Gas Valve
1.5 1.5"-P Gas Valve
2 2"-P Gas Valve
2.5 2.5"-P Gas Valve
NOTE: When ordering any duplex or triplex MICRO-RATIO® Valve assembly,

choose the same cam style and air valve temperature rating at all levels.
Any MICRO-RATIO® Valve which uses Series “A” Valves must use the
standard cam style.

m CORPORATION
Assembly Numbers
Segment Choices
(DEFAULT is shaded)
1 A-1" Air Control Valve
1.25 A-1.25" Air Control Valve
AIR VALVE SELECTION 2 A-2" Air Control Valve
.375 3/8"-O-8 Oil SYNCHRO Valve
AO MRV .520 1/2"-O-20 Oil SYNCHRO Valve
OIL VALVE SELECTION .550 1/2"-O-50 Oil SYNCHRO Valve
1400 1"-O-400 Oil SYNCHRO Valve
1750 1"-O-750 Oil SYNCHRO Valve
NOTE: When ordering any duplex or triplex MICRO-RATIO® Valve assembly,

choose the same cam style and air valve temperature rating at all levels.
Any MICRO-RATIO® Valve which uses Series “A” Valves must use the
standard cam style.
mCORPORATION

Assembly Numbers
Triplex MICRO-RATIO® Valves NOTE: When ordering any duplex or triplex MICRO-
MICRO-RATIO® Valve Configured Item Number and air valve temperature rating at all levels.
®
Triplex MICRO-RATIO Assembly TRIPLEX MRV Any MICRO-RATIO® Valve which uses Series “A”
Valves must use the standard cam style.
Triplex MICRO-RATIO® Valve Combinations

AA
See page 7100-A/P-3 & 4 for segment
AO
descriptions
AP
MA
DUPLEX TO ADD SYNCHRO TO
MM
MO See page 7000-A/P-6 for segment descriptions
MP
MS
TRIPLEX MRV
See pages 7000-A/P-1 through 3 or page 7100-
THIRD VALVE (ADDED TO DUPLEX) .375
A/P-1 for segment choices and descriptions
Two Fuel SYNCHRO Valves

SYNCHRO Valve Configured Item Number
Two Fuel SYNCHRO Valve Assembly TWO FUEL
Two Fuel SYNCHRO Valve Combinations

See pages 7000-A/P-1 to 3 or page 7100-A/P-1
FIRST (BOTTOM) FUEL VALVE .5P
for segment choices
See pages 7000-A/P-1 to 3 or page 7100-A/P-1
SECOND (TOP) FUEL VALVE .5P
for segment choices
TWO FUEL TAGGING NONE No label

mCORPORATION
Assembly Numbers
Flange Kits
Valve Size 1" 1.25" 1.5" 2" 2.5" 3" 4"
Cast iron ANSI threaded 44300 44301 43993 44302 44303 44304 46596
Carbon steel ANSI threaded 46969 46970 46971 46972 46973 46974 46975
Carbon steel welded 46810 46811 46812 46813 46814 46815 46816
Brass ANSI threaded 44310 44311 44312 42629 44314 44315 ---
Brass soldered 44305 44306 44307 42593 44308 44309 ---

Manufacturer Series "A" Control Valves
Name Description SYNCHRO version Manual handle version
Barber-Colman electric EA51-58, MC, MP, MF 48053 48054
Barber-Colman
Barber-Colman electric EA70 high torque 47450 47797
Foxboro air P-25 47795 47796
Foxboro
Foxboro air P-50 47791 47792
Foxboro-Jordan Foxboro-Jordan electric SM-1510 47750 47798
Honeywell air 01-11/861P 03-8/863T 47451 47448
Honeywell air 01-9/861M 47793 47794
Honeywell
Honeywell electric Modutrol 47365 47725
Honeywell electric Actionator 47449 47799
Penn/Johnson Penn/Johnson electric M80, M81 47365 47725
Beck Beck electric 11-150 47979 ---
Auxiliary Signal Switch Assemblies

Series "A" Control Valves
Switch Description
SYNCHRO version Manual handle version
Auxiliary position switch 47843 ---
Hazardous duty switch set 47845 ---
Weatherproof hi-lo position switch set 45885 ---
Weatherproof low position switch set 45884 47366
Spare Parts and Accessories

Spare Parts & Accessories Part Number
Manual Control Knob Kit 46934
Foot Adapter Kit 44044
m CORPORATION

Product Data Sheet Product: Series “A” Flow Control Valves
(for Maxon Personnel only) Page: 7100-1 Date: 6/02
Do Not Reproduce
Series “A” SYNCHRO Valve - Technical Data Sheet Instructions:
(Data sheet is located in Phoenix\Template\Engineering Worksheets\Valve Sizing\A-VALVE sizing sheet 1060228.xls)
See following page for detailed explanation of the data sheet shown below.
Do Not Reproduce
Series “A” SYNCHRO Valve Technical Data Sheet Instructions:

1. All required inputs are highlighted in yellow blocks.
2. All calculated or pulled data values are in highlighted green blocks.
3. If “other” is selected from the Gas pull-down menu, inputs are highlighted under the “Other Gas” heading in light
red.
4. Label Technical Data Sheet by “Customer Name” and “Proposal or Job #”.
5. Select type of Gas from the pull-down menu.

5.1 Gas from pull-down menu inputs Gg, Z, k & R values @ 80 deg. F
5.2 If gas is available from the pull-down menu, but the temperature changes the values of Gg, Z, k & R
significantly, choose “Other” from the gas pull-down menu and input values of Gg, Z, k & R under the
“Other Gas” heading.
5.3 If gas is not available from pull down menu, choose “Other” and input values for Gg, Z, k & R under the
“Other Gas” heading.
6. Input “Gas Temperature”, “Maximum Flow” and “Turndown Required” in their respective units.
7. Select “Gage Pressure Units” from the pull-down menu in inches of H2O or PSI.
8. Input “Valve Inlet Pressure at Maximum Flow (P1)” in previously selected units.
8.1 This is the static pressure measured 2 nominal pipe diameters upstream of the control valve.
8.2 Piping losses must be considered between the regulator and the control valve.
For example:
At maximum flow conditions, the customer has 8 in. of H2O outlet of the regulator and will achieve an
additional 1.5 inches of H2O drop up to the control valve (due to piping and SOVs). The value to input will
be 6.5 of H2O.
9. Input “Valve Outlet Pressure at Maximum Flow (P2)” in previously selected units.
9.1 This is the static pressure measured 6 nominal pipe diameters downstream of the control valve.
9.2 This value is typically the gas pressure required at the burner at maximum flow. However, if significant
piping losses are to occur between the control valve and burner, the losses must be accounted for in this
input.
10. Input “Upstream Pressure Drops to Regulated Source Plus Droop”.

10.1 This input is required to determine if the turndown required is achievable.
10.2 Using the example in 8.2 above, the value for this input would be 1.5 in. of H2O.
11. The Application Summary section tabulates the flow, inlet and outlet pressure and a preliminary Cv required at
maximum and minimum conditions. The values assume equal valve size and line size.
12. Select customer’s line size from the pull-down menu.

Do Not Reproduce
Series “A” SYNCHRO Valve Technical Data Sheet Instructions:

13. Select valve size from the pull-down menu that will operate per the following guidelines:
13.1 Valve is to operate between 80% and 90% of capacity.
13.2 Valve outlet velocity to not exceed 33% sonic velocity due to noise considerations.
13.3 Valve selected must have a minimum catalog Cv rating lower than the application Cv at minimum
conditions.
13.4 Valve application cannot have a higher MOPD than catalog value.
14. “Suggestions” box will help you to accurately size the valve per the above requirements:
14.1 When the Application Required Cv is greater than Valve Catalog Cv at Maximum:
- Choose a larger valve or increase inlet pressure.
14.2 When the Application Cv is less than 60% of the Valve Catalog Cv at Maximum:
- Choose a smaller valve or decrease inlet pressure.
14.3 When the Application Cv is greater than 90% but less than 100% of the Valve Catalog Cv:
- Increase inlet pressure to decrease capacity to < 90%
14.4 When the Application Cv is greater than 60% but less than 80% of the Valve Catalog Cv:
- Lower inlet pressure to increase capacity to > 80%
14.5 When Minimum Catalog Cv is greater than Minimum Condition Application Cv:
- Turndown not achievable. Modify parameters.
14.6 When fluid velocity at outlet is greater than 33% sonic velocity:
- Caution: Velocity should be < 33% sonic to minimize noise.
Page: 7100-4 Date: 6/02

Do Not Reproduce
Using the Series “A” SYNCHRO Technical Data Sheet for Valve Sizing:
Example:
Customer’s Application Details

Fluid .................................................................... Natural Gas
Fluid Temperature ................................................ 60°F
Max Flow at High Fire .......................................... 20,000 SCFH
Turndown Required .............................................. 20:1
Valve Inlet Pressure ............................................ 15 in. of H2O
Valve Outlet Pressure (Burner Pressure) ............. 5 in of H2O
Upstream Pressure Drop to
Regulated Source and Droop ............................... 8 in. of H2O
Line Size ............................................................. 3 inches
Option #1: Valve can be smaller than pipe size
2” Series “A” SYNCHRO Flow Control Valve

NOTE: Customer must use 2” x 3” reducer
1. Maximum condition: 2” will operate at 87.4% capacity

2. Outlet velocity equal to or less than 33% sonic: 19.7% sonic
3. Minimum conditions: Catalog Cv minimum (1.30) equal to or less than application Cv (5.56)
Option #2: Valve to be same size as pipe line
3” Series “A” SYNCHRO Flow Control Valve

NOTE: Inlet pressure to valve must be decreased to 6.5 in of H2O
1. Maximum condition: 3” will operate at 80.4% capacity

2. Outlet velocity equal to or less than 33% sonic: 7.9% sonic
3. Minimum conditions: Catalog Cv minimum (3.00) equal or less than application Cv (4.75)
Bulletin 7200
SMARTFIRE™
Intelligent Combustion Control System
• Precise electronic control of air and fuel flow to

the burner to maximize efficiency and minimize
emissions simultaneously
• Maintain emissions or fuel efficiency over the
entire operating range of the burner, not just
at one burner set point
• Automatically compensates for changes
in combustion or process conditions with
full cross-limited ratio control, maximizing
burner performance and ensuring a highly
repeatable heat source
• Plug ‘n Play, turnkey system for easy
installation and set-up
• Integrates easily with all burner
management systems, reducing
engineering costs in retrofit applications
• Advanced diagnostics and troubleshooting
provide real-time information about combustion
and process system performance
• Optional remote monitoring gateway reduces
process downtime by providing immediate off-site
technical support over a standard phone line
• Rugged industrial design includes NEMA 4X enclosures, high torque actuators, and all-digital field
device communications, ensuring reliable operation in harsh environments
• Redundant system safety checks built into intelligent components, significantly reducing the
risks associated with combustion system commissioning and maintenance neglect
• FM and CSA approved
• Meets requirements for European Electromagnetic Compatibility (EMC) and Low Voltage
Directives
Manufactured under U.S. patent #6,247,919
Bulletin 7202
SMARTFIRE™ Intelligent Combustion Control System

Design and Application Details Burners and Fuels
The SMARTFIRE™ Intelligent Combustion Control The SMARTFIRE™ System can be used with the
System is a turnkey, mass flow air/fuel ratio control majority of Maxon’s natural gas fired burners, espe-
system for industrial burners. The System is com- cially those designed for low-emission applications
prised of five components that integrate easily with a (e.g., KINEDIZER®, CYCLOMAX®, CROSSFIRE®,
conventional burner management system and pipe OXYTHERM®). For application of SMARTFIRE™ to
train: an Interface Panel; Air Valve Actuator and non-Maxon burners or use with other fuels, contact
Fuel Valve Actuator; and Air Flow Controller and Fuel Maxon.
Flow Controller.
The Interface Panel includes a Burner Brain, 24 Principle of Operation
VDC Power Supply, and User Display. The Burner
As shown in the block diagram below, the five
Brain contains all of the factory-installed, combustion
SMARTFIRE™ components each communicate over a
intelligence (such as burner-specific air/fuel ratio and
peer-to-peer digital network. Control functions are
flow data), enabling the SMARTFIRE™ System to be
performed in the field devices and the Burner Brain,
easily commissioned after field installation. The
providing higher accuracy and reliable operation in
User Display panel allows the Operator to monitor
electrically noisy industrial environments that often
and adjust the performance of the combustion
affect the performance of systems with analog (4-
system. The Valve Actuators are factory-calibrated
20mA or low voltage) control signals. The distributed
assemblies that include rugged, high-quality plan-
intelligence also allows redundant system safety
etary gearheads and stepper motors for highly
checks which prevent tampering and unsafe conditions
repeatable and precise control of Maxon’s butterfly
that can occur during combustion system commission-
valves. The Air and Fuel Flow Controllers each
ing and after long-term operation.
consist of a precision-calibrated thermal mass flow
sensor, control electronics, and flow body with Firing Rate
integrated flow conditioners for a highly repeatable Process
Control Status
measurement. Commands
TM
SMARTFIRE Interface Panel

Other SMARTFIRE™ System functions include Burner Management Burner User Power
Status Brain Interface Supply
fuel totalizing, air/fuel flow and valve position analog and Flame Safeguard
outputs for DCS interfacing, (optional) remote

monitoring, and many redundant system safety Gateway (Option)
functions. The SMARTFIRE™ System specifica- Peer-to-Peer Communication
tions are as follows:

Valve Flow Flow Valve
Valve Position 0.1 angular degree resolution Actuator Controller Controller Actuator
Control (Air) (Air) (Fuel) (Fuel)
Flow Control ± 1% of flow reading over a turndown of 20:1 Control Flow Flow Control
Valve Body Body Valve
Air/Fuel Ratio ± 2% with turndown of 20:1
Control
Power Supply 100-120 VAC @ 2.5 Amps max, 50-60 Hz The SMARTFIRE™ System permits the burner to
Input 200-240 VAC @ 1.5 Amps max, 50-60 Hz
be started in response to the commands from the
Approvals FM & CSA (CE approval pending) User’s burner management system. Once the se-
Ambient -20°F to 122°F (-29°C to 50°C) quence is completed, the System maintains the
Temperature
factory-installed air/fuel ratio for the desired heat
Output: 350 Ohms max user load resistance output set by the User’s process controller. The
4-20 mA I/O Input: 20 mA max current, 250 Ohm input System’s cross-limited mass flow control of air and
resistance
fuel automatically compensates for changes that
Input Coil: 120 VAC @ 7.5 mA affect combustion performance such as air and fuel
Control 240 VAC @ 3.8 mA
Relays temperature and pressure and chamber pressure. The
Output Contacts: 250 VAC @ 10 Amps, 30
VDC @ 10 Amps process controller and burner management system are
not included as part of the SMARTFIRE™ System.
These functions can be obtained using one of several
Maxon combustion command panel products.
4/03
SMARTFIRE™ Intelligent Combustion Control Page 7203
Electrical Specifications
Valve Position Control 0.1 angular degree resolution
Flow Control ± 1% of flow reading over a turndown of 20:1
Air/Fuel Ratio Control ± 2% with turndown of 20:1
100-120 VAC @ 2.5 Amps max, 50-60 Hz
Power Supply Input
200-240 VAC @ 1.5 Amps max, 50-60 Hz
Approvals FM & CSA (CE approval pending)
Ambient Temperature -20°F to 122°F (-29°C to 50°C)
Output: 350 Ohms max user load resistance
4-20 mA I/O
Input: 20 mA max current, 250 Ohm input resistance
Input Coil: 120 VAC @ 7.5 mA
Control Relays 240 VAC @ 3.8 mA
Output Contacts: 250 VAC @ 10 Amps, 30 VDC @ 10 Amps
Dimensions (inches)
Interface Panel
12.88
0.25
Mounting Holes
4-Places
0.31
24 VDC
Power
Supply
User Display
Size: 3.25 x 5.75
Size: 5.5 x 4.125
14.75
Burner Brain Size: 4.375 x 10.0
Panel Depth: 4.25 Panel Weight

9 pounds
5/03
Page 7204 SMARTFIRE™ Intelligent Combustion Control
Dimensions (inches)
6.25
Flow Controllers / Flow Bodies Flow Controller

Depth: 3.25
4.0
Flow Controller Weight:
3 pounds plus Flow Body
Probe Length:
10.75 for Air

6.75 for Gas
Flow Body OD:

(see table)
Flow Body Length:

(see table)
Low Range High Range

Air Flow Body Dimensions (Inches) Max
Min Flow Max Flow Min Flow Max Flow High Range
No. of Weight Flanges 1000's 1000's 1000's 1000's Pressure
Size O.D. Length Drop ("wc)
Pcs. (lbs.) Type Weight scfh scfh scfh scfh
8 8.63 34 1 50 Rolled Angle* 12 2.8 50 3.8 75 4.7
12 12.75 50 1 68 Rolled Angle* 16 6.2 111 8.3 167 4.7
16 16.0 64 2 110 Rolled Angle* 20 9.8 176 13.2 263 4.7
20 20.0 80 2 220 Rolled Angle* 25 15.3 276 20.7 414 4.7
24 24.0 96 2 250 Rolled Angle* 28 22.2 399 29.9 599 4.7
28 28.0 96 2 275 Rolled Angle* 31 30.3 546 40.9 818 4.7
*Chicago Metal Rolled Products (773) 523-5757
Low Range High Range

Gas Flow Body Dimensions (Inches) Max
Min Flow Max Flow Min Flow Max Flow High Range
Size O.D. Length Drop ("wc)
2 2.38 8 1 13 ANSI* 15 0.2 2.7 0.3 5.4 4.2
3 3.5 12 1 28 ANSI* 20 0.5 8.1 0.4 11.3 3.6
4 4.5 16 1 45 ANSI* 28 0.6 11.3 0.6 22.5 4.5
6 6.63 24 1 70 ANSI* 32 1.3 22.5 1.1 45.0 3.6
6HC 6.63 24 1 70 ANSI* 32 3.8 67.5 2.3 90.0 14.3
*150 lb. rating
Oxygen (or Air) Stainless Steel Flow Body Dimensions Low Range High Range
Max
(Inches) Min Flow Max Flow Min Flow Max Flow High Range
Size O.D. Length D rop ("wc)
2 2.38 8 1 13 ANSI* 15 0.2 2.7 0.3 5.4 8.3
3 3.5 12 1 28 ANSI* 20 0.5 8.1 0.4 8.1 7.1
4 4.5 16 1 45 ANSI* 28 0.6 11.3 0.6 11.3 9.0
6 6.63 24 1 70 ANSI* 32 1.3 22.5 1.1 22.5 7.1
*150 lb. rating
Valve Body Specifications

2
6
4 8
9
7
12
1
8
10
11
3
7 8
Valve Body Material Specifications - 1" thru 4"

Item Valve Body Assembly
Description
No.
GP Flat Faced GP Raised Faced Oxy Flat Faced
Gray Iron Carbon Steel Brass
1 Valve Body
ASTM A157 GR, G3000 ASTM A216 GR, WCB ASTM B62 UNS No. C83600
2 Valve Stem 303 Stainless Steel - ASTM A157 GR, G3000
3 Butterfly Disc 304 Stainless Steel - ASTM A240 Type 304 UNS No. S30400
4 Top Bushing
5 Bottom Bushing Bronze - ASTM B271, B505 and B584 UNS No. C93200
6 Top Shim Bushing
7 O-Ring
8 O-Ring Buna-N Viton
9 O-Ring
10 Screw 18-8 Stainless Steel
11 Washer 304 Stainless Steel
12 Retaining Ring 316 Stainless Steel
4/03
2
6
5
7 11
4
10
1
12
Valve Body Material Specifications - 6" thru 16"

Valve Size
6" & 8" 10" - 16"
1 Valve Body Gray Iron - ASTM A157 GR, G3000
2 Valve Stem 316 Stainless Steel - ASTM A276
304 Stainless Steel - ASTM A167 Carbon Steel - ASTM A108
3 Butterfly Disc
UNS No. S30400 UNS No. G10180
4 Top & Bottom Bushing Bronze - ASTM B271, B505 and B584
5 Shim Bushing UNS No. C93200
6 O-Ring
Buna-N
7 O-Ring
8 Screw 304 Stainless Steel Zinc Plated Carbon Steel
9 Hex Nut 316 Stainless Steel Zinc Plated Carbon Steel
10 Retaining Ring
Carbon Steel - SAE 1060-1090 UNS No. G10600-G10900
11 Retaining Ring
12 Pipe Plug Alloy Steel - ASTM A322 UNS G40370

3A
8A 6A
7A 10A
4A 9A
5A
2A
1A
11A
4A
SMARTFIRE Valve Body Assembly Material Specifications

Item No. Description SMARTFIRE Component Material Specifications
1A Valve Body Sub-assembly Assembly per pages 7205 & 7206
2A Locating Spring Pin Zinc Plated Carbon Steel
3A Adapter Bracket ASTM B179 T6 Aluminum
4A † Socket Head Cap Screw Zinc Plated Carbon Steel
5A Coupling ASTM A582 Type 303 Stainless Steel
6A Locking Collar 18-8 Type 303 Stainless Steel
7A Spring Pin Zinc Plated Carbon Steel
8A Dowel Pin 303 Stainless Steel
9A Hard Stop Screw 18-8 Stainless Steel
10A Hard Stop Nut Stainless Steel
11A † Cover Plate Aluminum
† - These items used only on sizes 1" thru 4"
4/03

1" SMARTFIRE™ Valve Actuator 1.25" SMARTFIRE™ Valve Actuator
4.0 4.4
4.0 4.4
2.0 2.0
.5" NPT .5" NPT
Threads Threads
10.2 10.2
12.2
12.7
.62 dia.
.62 dia. 4 holes
4 holes
3.0 45˚ 45˚
4.2 dia. 3.5
3.5 dia.
bolt circle
A
3.1 dia.
2.5 bolt circle A
2.9
2.7 1.4 5.0 dia.
1.1 dia. 3.2 dia.
1" 1" M8 - 1.25 tap

.62 deep
2 holes 1 1 M8 - 1.25 tap
1.31 .62 deep
2 holes
1.31
Flange Dimension "A" Flange Dimension "A"

Iron Threaded 2.87 Iron Threaded 3.05
Threaded 3.15 Threaded 3.12
Steel Steel
Socket Welded 2.84 Socket Welded 3.05
Brass Brass
Solder Cup 3.51 Solder Cup 3.63
Dimensions (inches)
1.5" SMARTFIRE™ Valve Actuator 2" SMARTFIRE™ Valve Actuator
4.0
4.0 4.4
2.0
2.0 4.4
.5" NPT
.5" NPT
Threads Threads
10.2 10.2
12.7 12.7
.62 dia. .75 dia.

4 holes 4 holes
3.5 5.0 dia. 3.5 45˚ 6.0 dia.

45˚
4.8 dia.
bolt circle
A 3.9 dia.
bolt circle A
3.2 2.8 3.0
3.4
1.7 dia. 2.2 dia.
1" 1" M8 - 1.25 tap M8 - 1.25 tap

.62 deep .62 deep
2 holes
1 1
2 holes
1.31
1.69 1"

Steel Steel
Brass Brass
4/03

2.5" SMARTFIRE™ Valve Actuator 3" SMARTFIRE™ Valve Actuator
4.0 4.0
4.4
2.0 4.4 2.0
.5" NPT .5" NPT
Threads Threads
10.2 10.2
13.2 13.2
.75 dia.
7.5 dia. 4 holes
.75 dia.
4 holes
7.5 dia.
4.0 45˚ 4.0 45˚
2.6 dia.
3.3 dia.
6.0 dia.
A A
bolt circle
4.2 3.8 5.5 dia. 4.2 3.8
bolt circle
M8 - 1.25 tap
M8 - 1.25 tap
1 1 .62 deep
1 1 .62 deep
2 holes
2 holes
1.81 1.81

Steel Steel
Brass Brass

4" SMARTFIRE™ Valve Actuator 6" SMARTFIRE™ Valve Actuator
4.0
4.4
4.0 2.0
4.4 .5" NPT
2.0
.5" NPT Threads
Threads
10.2 10.2
13.8
15.1
1/2-13 UNC
8.9 dia. 6 holes
9.0 dia. 4.3 dia.
6.1 dia. 7.75" dia.

4.6 bolt circle
5.9
22.5˚ 7.5 dia.
bolt circle
.75 dia.
A 4.9 8 holes
5.3
60˚
5.9
M8 - 1.25 tap
.62 deep 6.1
1 1
2 holes 1.5
4.3 1.0 .438 deep
2.06 1.0 4 holes
1.0
3.0
1.0
3.0
Flange Dimension "A"

Iron Threaded 4.13
Threaded 4.06
Steel
Socket Welded 4.06
4/03

4.0 4.4
2.0 4.0 4.4
.5" NPT 2.0
Threads .5" NPT
Threads
10.2 10.2
16.2
10.25 dia. 16.0 dia.
1/2-13 UNC 18.4
bolt circle
6 holes 14.2 dia.
13.0 dia. bolt circle
8.0 dia.
7.0 10.0 dia.

11.8
dia. 9.2
1.1 1.0 dia.
12 holes
3.6
60˚
7.4
7.6
7.6
1.5 1.0
.438 deep 1.0
4.4 4 holes
8.4
1.0 2.5
3.0 6.5 1.0
1.0 .438 deep 1.0
4 holes
3.0 1.0
3.0
1.0
3.0
Note: Flanges are shipped loose.


4.0 4.4
4.0 4.4
2.0
2.0 .5" NPT
.5" NPT Threads
Threads
10.2 10.2
21.0 dia.
17.0 dia.
bolt circle 18.8 dia.
19.4 bolt circle
19.0 dia. 20.6
1.0 dia.
12 holes 17.4
dia.
10.2 16.0 dia. 13.2
11.4

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Catalog MAXON

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Bulletin 1100

Maxon Burner Nozzles

PREMIX® Blower Mixers

Provides positive flame retention and stable clean burning, while

with refractory tunnel block for sealed-port firing

Series “HG” Mixing Tubes

Series “LG” Mixing Tubes

Improve higher temperature operating efficiency and atmosphere

Maxon Burner Nozzles

Design and Application Details

Example: SPA – 2-1/2" – 27

SP = PILOTPAK™ Nozzle Main gas

Design and Application Details

“SN” Sealed Nozzle

All Sealed Nozzle sizes include provision for Flame

WARNING: Optional pilot port cover kit must be

If the optional flame rod is specified, standard

Optional electrode cover (shown in Sketch 2)

Optional cooling tee shown in Sketch 3 allows Typical

With Cover: Sketch 2

With Cooling Tee: Sketch 3

Tuyere Block dimensions (in inches)

Flame Rods for PILOTPAK™ Nozzles 10mm Spark Ignitor

Nozzle Support Nozzle Spacing

Dimensions (in inches)

“HD” and “BP” STICKTITE™ Nozzles “HV” STICKTITE™ Nozzles

Nozzle dimensions (in inches)

Pipe threads on this page conform to NPT (ANSI Standard B2.1)

Dimensions (in inches)

Nozzle dimensions (in inches)

Pipe threads on this page conform to NPT (ANSI Standard B2.1)

Dimensions (in inches)

NOTE: Optional pilot port cover must be used to seal

Optional cooling tee sets

10mm Spark Ignitor

STICKTITE™ and PILOTPAK™ Nozzles are Table 1: Clearances

For Furnaces For Solution Heating

INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES

General Start-up Instructions 4. Orientate nozzle for best performance. When

INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES

Burner Mounting In either case, size the opening in your refractory

General Start-up Instructions

INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES

Installation and Maintenance Instructions

INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES

INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES

To order a combination of the following, order a STICKTITE configured product.

STICKTITE® STICKTITE® Nozzle Type

Nozzle Segment BP DSHD HD HV

Miscellaneous Replacement and/or Spare Parts

STICKTITE® PILOTPAK™ Nozzle Types [1] Nozzle Support Bracket

INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES

Series SN Sealed Nozzles

INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES

Premix-type Line Burners

Type “VF” LINOFLAME® Burners

Premix-type Line Burners

Manufactured under U.S. Patents RE 24,405 and 3,588,301

Air/gas premixing equipment used to provide thorough blending

VENTITE™ Inspirator Mixers