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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, andasphalt kettles

CORPORATION 201 East 18th Street, P.O. Box 2068, Muncie, Indiana, 47307-0068. Phone: (765) 284-3304. Fax (765) 286-8394

202

Maxon Series “67” TUBE-O-FLAME® Gas Burners

Series “67” LB TUBE-O-FLAME® Burnershowing version less blower for thoseapplications requiring multiple burner zonesfrom common combustion air source

Typical TUBE-O-FLAME® Burner System Arrangement

11/90

Provide application flexibility with:

• Over 36 different styles

• Sizes for 6" through 14" diameter tubes

• Heat releases to 5,000,000 Btu/hr

• Optional 2-position (Hi/Lo) electric controlmotor

• Cost effective external blower (LB) version

CORPORATION 201 East 18th Street, P.O. Box 2068, Muncie, Indiana, 47307-0068. Phone: (765) 284-3304. Fax (765) 286-8394

Design and Application Details

2/96

Series “67” TUBE-O-FLAME ® Gas Burners

Maxon TUBE-O-FLAME® Burners are nozzle-mixing, gas-fired, refractory-less burners specificallydesigned for firing into an immersion tube. Typicalapplications have included various industrial solutionheating jobs such as dip tanks, spray washers,pickling or quench tanks, dye becks, salt baths,asphalt kettles, indirect air heaters and bakery ovens.

Standard Series “67” TUBE-O-FLAME ® Burnerpackage (shown at right) includes a combustion airblower with a non-sparking aluminum paddle-wheel-type impeller. A pilot and spark ignitor is included inthe cast iron burner body, as well as the ductile ironmixing disc, internally-connected air and gas controlvalves, gas nozzle and provisions for your flamesafeguard sensor.

Principle of operation (illustrated below)

The TUBE-O-FLAME® Burner is available in twobasic versions: 1) packaged with integral low horse-power combustion air blower, or 2) LB (less blower)for use with an external combustion blower source.Both versions incorporate a gas and air valve linkedtogether to control the gas-air ratio over the fullthrottling range of the burner. Gas flows out throughthe gas nozzle where it mixes with the swirled com-bustion air coming through the mixing disc. Thisresults in a long, swirling flame that spins down thefiring tube, scrubbing the internal tube walls andpromoting higher heat transfer efficiencies.

Model LB (less blower) Series “67” TUBE-O-FLAME ® Burners (shown below), like all TUBE-O-FLAME® Burner assemblies, are designed to deliverheat efficiently into your immersion tube.

Flanged burner body design on all Series “67”TUBE-O-FLAME® assemblies simplifies mounting andinstallation on your application. Most manufacturers’control motors require operating shaft in horizontalplane.

Minimal torque requirements permit use ofvirtually any electric or air operator. Maxon can supplyconnecting base and linkage assemblies for mountingmost temperature control operators.

Series “67” 8" LBTUBE-O-FLAME®

Burner with optionalMaxon hi/lo controlmotor set and burnermounting ring

Series “67”8" TUBE-O-FLAME®

Gas Burnerwith optionalhi/lo Maxoncontrol motor set



Any clean commercial fuel gas can be used, withadjustment provided by simply setting inlet gaspressure to the Series “67” TUBE-O-FLAME® Burner.

The burner can be mounted either straight, throughthe tank wall, or angled downward. If more than onepipe diameter of tube length is not solution-backed,overheating and deterioration of tube may occur.

NOTICE: Burner performance can be drasticallyaffected by tube configuration.

Tube design should consist of Schedule #40 pipeor lighter in the same size as burner. It is suggestedthat the first straight pass of tube consist of at least 10pipe diameters in length and not end in a single-mitreelbow turn. Burner capacity may be reduced if tubelayout has multiple single-mitre turns. Firing tubelength and resulting wetted tube surface area deter-mines combustion transfer efficiency.

Tube length and configuration

Many factors affect overall system efficiency. Tubelength is the most important. The graph above showsapproximate tube length required to attain a givenefficiency. Typical installations run in the 70% – 75%range. Space considerations (including tube displace-ment) may limit possible tube lengths and so reduceefficiency. Above 85% efficiency, there is a risk ofcondensation-caused tube damage.

Exhaust considerationsImmersion tubes are usually vented to the out-

doors, except for those in highly ventilated areas suchas a plating room with continuous high-volumeexhaust. An exhaust fan may be required if thebuilding is under negative pressure. Exhaust isnormally diluted to avoid the need for high-tempera-ture fans, but adequate make-up air must be avail-able.

This diluting can be done with an open tee installedin a vertical run (or in a horizontal run with the openend down), but such a system mixes slowly.

An adjustable hood (shown in sketch below) offersmuch better performance. In all cases, care must betaken that all products of combustion are exhaustedfrom the building.

An exhaust stack damper must be used, suit-able for 1000°F, and designed to prevent fullstack closure.



5/03

Series “67” TUBE-O-FLAME® Burners are offeredboth in a standard version (including a combustion airblower in your choice of the voltages listed below) andin an “LB” version to use with a separate combustionair supply.

“Packaged” TUBE-O-FLAME ® Burner internalcomponents include Rulon bearings which have amaximum temperature limit of +500°F (260°C) and aPlexiglass observation glass with a temperature limit of+175°F (80°C).

“LB” TUBE-O-FLAME ® Burners (less blower)versions do not have motor temperature limits. Theycan be equipped with a “high temperature kit” toreplace observation glass and flange gasket to raisemaximum combustion air temperature limit to +500°F(260°C).

Multiple burner arrangementA universal joint assembly permits cross-linking of

two Series “67” TUBE-O-FLAME® Burners for controlby a single operator. Additional universal joint assem-blies may be used to link as many as five burners to asingle control motor. Each assembly includes a 7/16" x22" aluminum rod and two (2) miniature universaljoints. Precise burner alignment is unnecessary, androd may be cut in field as required. No more than twoburners can be controlled to each side of “Primary”burner. Ten inch-pounds of torque is required for eachburner driven.

Distance between burner center lines should notexceed 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 eachburner, then install individual ignition systems.

To order this accessory, specify:1. Desired automatic burner2. Desired manual (secondary) burners3. Required universal joint assembliesNOTE: Multiple burner installations fed by a single pipetrain should incorporate a “balancing valve” and a“swing check valve” installed as close as possible toeach burner gas inlet for improved heating uniformityand more dependable light-off. Otherwise, gas manifoldmay act as a reservoir, preventing reliable light-offduring trial-for-ignition period of your control panelsequence.

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Typical Basic Burner System Arrangement

Temperature limitationsMotor manufacturers recommend maximum

ambient temperature of +140°F (+60°C). Temperaturelimits can vary with the type of motor and insulationused. Such special motors are available at net extracharge and with extended deliveries.

Control motor manufacturers normally establish amaximum ambient temperature for their operators at+125°F (52°C).



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 firingposition for pilot ignition and main flame light-off.

The built-in air and gas flow control valves aremechanically linked together. At Low, the air valve iscracked open but the gas valve is practically closed.

If some higher firing rate is selected for low fire onHigh-Low installations, both valves will be openedwider. The increased combustion air will necessitatemore gas for pilot ignition. If carried too far, thisincrease 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 thanpilot. Burners can be ordered with Maxon-supplied Hi/Lo Control Motor or with a Connecting Base &Linkage assembly to accept most operators.

With either Hi/Lo or modulating control, high-fire canbe set at any desired point within burner range.

Optional Low-Fire Start Switch includes camactuator on burner operating shaft to make contact ator near low fire position. Properly wired in series withpilot gas valve, switch can assure low-fire light-off. Ifused on multiple burner installation with universal jointarrangements, switch must mount on farthest leftburner.

Field installation of these switches on equipment notoriginally furnished with them may require minor drillingmodifications as outlined in Product Information Sheet2000-7/8, shipped with the 'loose' switch assembly.

Automatic control

Typical Low-Fire Startwiring

Automatic burner with Maxon hi/lo control motor(available for 120/60 or 240/60 AC)


Capacities and Specifications – 60 Hertz

10/95

[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%.

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Capacities and Specifications

60 Hz capacity and specification information forboth standard burners (including blower) and LBburners (requiring separate air supply) are given inthe table on page 2207. Measured sound levels andmotor information provided apply only to standardburners.

For operation on 50 Hz power, reduce capacitiesto 83% of those shown, pressures to 70%.

CAUTION: Burner performance can be drasti-cally affected by tube configuration.

Air pressure readings at test connection reflectthose that may be expected prior to light-off and mayvary as a result of tube and exhaust configurations.

Inlet air pressures and flows must not exceedthose given in the table. DO NOT OVERSIZE blowersfeeding LB Burners. If a blast gate or similar device isused to limit air pressure at an LB burner, air pressureat the burner will rise as firing rate is reduced until theblower's rated pressure is reached. This will result inincreased pilot and minimum capacities, as well asincreased excess air at lower firing rates.

Main gas train including regulator should be sizedto give no more than 2" wc pressure drop, less if firingpropane with 6" and 8" burner sizes.

Pilot piping and regulator should be sizedcarefully for the full pilot and minimum capacity shownand selected to insure 2-4" wc pressure is supplied topilot inlet connection after any piping losses (7-16" wcdepending on size, if optional adjustable orifice cockis used).

Self-piloting feature of burner allows pilot gas toby-pass internal gas control valve and issue frommain gas nozzle ports. We suggest use of continuouspilot arrangement. If interrupted pilot is used, adjustburner to prevent reaching full minimum position.Minimum capacity will be increased.

Low-fire start : Main flame light-off is possible athigher capacities, but larger pilots will be required andturndown will be sacrificed.

Dimensions (in inches)

Series “67” TUBE-O-FLAME ® Burner (automatic version)

4/95


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80-6 57.3 144.5

6 26.8 44.844.71 57.7

26.618.8 73.11 41

5.35.61 5.71 5.41 60.71

51-8 57.4 4/1-1 7 65.8 73.01 96.7

52-01

57.5

2/1-1

60.68 96.9 5.21 78.81

57.826.8

21.21 44.41

81

91

12

52.02 57.91

03-01

252.51 78.51 5.2 02 5.32 73.03

83-21

05-41 18.6 9 41 26.41 26.32 96.9 57.71 96.71 91 5 32 4.62 62 26.92

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Dimensions (in inches)

“LB”–67 TUBE-O-FLAME ® Burner (automatic version)

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BL-6 57.3 144.5

6 26.831

44.873.4

26.652.7 13.8 73.6 44.0 44.5

91.53

BL-8 57.4 4/1-1 7 65.8 73.01 96.7 21.5

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2/1-1

60.68 96.9 5.41 5.21

44.526.8

9 96.0178.8

65.057.7

26.5 4

BL-21 2 73.01 57.11 60.5 6

BL-41 18.6 2 9 41 9 26.41 96.9 26.9 21.11 57.11 52.01 91.8 8

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Accessory Dimensions (in inches)


Filter with silencer for “67” TUBE-O-FLAME ® Burner

11/95

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80-673.41 44.21

6113.91 44.01 19.22 61.32 88.92 65.33

51-8

52-01 83.41 65.41 44.12 23.8 26.32 68.52 7.23 62.63

03-0165.32 60.81 22 49.42 28.01 26.92 88.13 7.83 82.24

83-21

05-41 49.52 52.02 42 52.92 57.21 52.53 88.33 9.24 9.74


Accessory Dimensions (in inches)

TUBE-O-FLAME ® Burner Mounting Ring Flame Rod

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12/89

Component Identification

TUBE-O-FLAME ® Burner nameplateSuggested spare parts– 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:1. Name(s) of part(s) from above illustration2. Quantity of each required3. Series “67” TUBE-O-FLAME® Burner nameplate data:

• size and/or model number of burner• assembly number of burner• date of manufacture• if available, serial number of Maxon shut-off valve controlling fuel to

TUBE-O-FLAME® Burner (This serial number is on Maxon valve'snameplate)


Suggested Maintenance/Inspection Procedures

In normal operation, little more is required thanperiodic checking to see that control motor linkagehas not slipped from adjustment and that burnerremains tightly mounted to the firing tube.

Burner should be shielded from splashing andphysical abuse.

Inspect impeller for proper rotation, speed, and dirtbuild-up which might reduce air flow. If your systemincludes an air filter, schedule maintenance asrequired for your plant environment.Combustion air filters

Always keep air filters clean for optimum systemperformance.

Vacuum as needed to remove any dry accumula-tions. To remove oil and dirt, wash elements in hotwater and detergent as necessary.

Replaceable elements can be wrung gently andallowed to air dry before returning to service. Perma-nent elements should generally be blown dry afterrinsing, and if desired, a light coating of suitable oilapplied.

To avoid interruption to service, you may wish toorder a spare element “set”.

Flame rods and spark ignitors are critical tosafety and reliability of operation and start-ups. Besure flame rod is properly sized and installed to fityour specific burner model. (Refer to dimension “L” atright.)

Similarly, the spark ignitor must be the right length(dimension “L”) for reliable ignition.

Burner mounting position is limited only by thoserestrictions imposed by UV scanner or control motormanufacturers.

WARNING: Test every UV flame sensing instal-lation for dangerous spark excitation fromignitors, other burners and other possiblesources of direct or reflected UV radiation.

Flame rod

Spark ignitor

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If performance of a Series “67” TUBE-O-FLAME®

Burner has changed, review the following list.

Symptoms:“Tube or exhaust stack is sooty or smoky”“Burner produces rumbling or chugging noise”“Reduced capacity – not enough heat”

Corrective Actions:– Isolate burner fuel supply and confirm actual

capacity being consumed.– Check burner blower motor rotation.– Check control motor linkage to insure burner crank

is going to full “high-fire” position.– Check gas pressure regulator for proper function-

ing. Insure gas pressure and volume to burner inletmatches burner nameplate data.

– Check immersion tube for leaks, blockages, orinsulating layers of dirt inside or on outside of tube.

NOTICE: Burner performance can be drasticallyaffected by tube configuration and static condi-tions within tube created by exhaust fans anddampers in exhaust stack.

– Determine static condition of tube (draft or suc-tion).

Excessive suction can cause chugging andimplies hot combustion products are being drawn outof tube too fast, reducing thermal transfer efficiency.High tube suction also may affect differential gaspressure settings. Too high of a suction may lowerinlet gas pressures so that low gas pressureswitches cannot be adjusted.

Excessive back pressure can cause smoke andmay restrict firing capacity of burner.

Field Service Tips

– Determine differential air pressure at burnerbackplate air test port.1. Shut system down, close main and pilot cocks.2. Connect manometer between burner air test port

and to atmosphere.3. Restart exhaust fans and burner blower with fuel

gas cocks closed and burner at "high-fire" posi-tion. Record air test port reading.

4. Chart above shows normal “balanced tube” staticcondition readings.

5. If your reading exceeds the “normal” readings, youhave a “back pressure” in your tube.

6. If your readings are “lower” than the normalbalanced readings, you have an “exhaust suction”on the tube.

7. Adjust exhaust fan and/or stack damper to createburner air pressure test port readings as close aspossible to those shown for “normal” balancedconditions to maximize system's thermal transferefficiency.

11/04

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Notes


7/05

4" TUBE-O-FLAME ® Gas Burner

• Nozzle mixing burner for tube firing in small solutiontanks, washers and water heaters

• Cleanly burns natural gas

• Simple start-up and adjustment with direct sparkignition or pilot

• Easily interfaces with thermostatic controls (on/offand high/low) or modulating controls

• Readily accepts flame rods or UV scanners formaximum flexibility

• Rugged all-steel body construction with non-sparking blower design

4" TOF Required Tube Footage4" Pipe - 250 KBTU/hr6" Pipe - 400 KBTU/hr

0

5

10

15

20

25

30

40 50 60 70 80 90

Transfer Efficiency (%)

Wet

ted

Tube

Len

gth

(ft)

Sight Glass

UV Scanner Port1/2" NPT

13.725

Pos. 4

Pos. 3

Pos. 2

Pos. 1

6.0

18.29

4.5 8.56

Air Pressure SwitchConnection3/8" NPT

Test Port1/8" NPT

Flame Rod

Spark Ignitor

Interchangeable1/2" NPT Gas Inlets/Fuel Pressure Ports

0.4 dia. slot

7.42 dia.

45˚ 45˚

7.75(sq.)

Page 2218 Series “67” TUBE-O-FLAME ® Gas Burners

4" TUBE-O-FLAME ® Gas Burner

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The 4" TUBE-O-FLAME® Burner provides costeffective heating for small cabinet washers and diptanks. It will fire into a 4 inch tube or a 6 inch tube. Toachieve typical efficiencies (65 to 70%) in both tubesizes, a length of 15 to 16.5 is recommended. Thefollowing chart shows efficiency versus tube length forfiring into a 4 or 6 inch tube.

The burner should be run at an oxygen level no lessthan 3% for natural gas.

Tubes should be constructed from Schedule 40black iron pipe. For caustic tanks or condensing heattransfer (>80%), stainless steel tubes may be used.Tube passes should be limited to three or less withneglible pressure drop. Use of single miter returns mayreduce burner capacity.

High building negative pressures or altitudes willreduce the burner's maximum capacity.

�CORPORATIONMUNCIE, INDIANA, USAINDUSTRIAL COMBUSTION EQUIPMENT AND VALVES

Maxon practices a policy of continuous product improvement. It reserves the right to alter specifications without prior notice.

Gas supply piping must be large enough tomaintain the required fuel pressures cataloged for theparticular burner size used with burner operating atfull rated capacity.

Anything more than minimal distance or pipingturns may necessitate oversizing piping runs to keeppressure drops within acceptable ranges.

Inlet pipe leading to any burner should be at leastfour pipe diameters in length. If multiple burners arefed from a single gas train, care should be taken tominimize pressure drop and give maximum uniformity.

Clean fuel lines are essential to prevent blockageof pipe train components or burner gas ports.

Main Shut-Off Cock should be upstream of boththe main gas regulator and pilot line take-off. Use it toshut off fuel to both pilot and main burner during shut-down periods of more than a few hours.

The fuel throttling valve contained within a Maxonburner is not intended for tight shut-off.

Main gas regulator is essential to maintain auniform system supply pressure. If one pipe trainsupplies multiple burners, provide a separate regula-tor in the branch leading to each burner system.

Size the regulator for full system capacity at therequired pressure, carefully considering pipe trainlosses. Follow the instructions attached to the regula-tor during installation and be sure to remove anyshipping pin or block.

Pilot take-off should be upstream of the main gasregulator, but downstream of the main gas cock. Itshould normally include its own pilot gas regulator, asolenoid valve and shut-off cock. A pilot adjustableorifice at the pilot inlet simplifies adjustment.

Pilot piping must be large enough to provide forthe full flow and pressures shown in the catalog foryour particular burner size.

The 3/8" pilot connection of the Series “67” TUBE-O-FLAME® Burner is adequate for the pilot gas flowsshown, but care must be taken to assure that therequired gas pressure is available at pilot inlet. Toavoid excessive drop through solenoid and upstreamvalves and cocks, follow these guidelines:

Page 2200-S-1Series “67” TUBE-O-FLAME® Gas Burners

Installation Instructions

General InstructionsImportant: Do not discard packing material untilall loose items are accounted for.

To prevent damage in transit, the spark ignitor,mounting ring, flame rod and connecting linkagecomponents may be packed separately and shippedloose with your new Maxon TUBE-O-FLAME® Burner.

The burner itself is normally only a part of yourcomplete combustion system. Additional pipe trainaccessories and control components will be requiredfor a complete system installation. The sketch belowshows a typical gas train as might be used with aSeries “67” TUBE-O-FLAME® gas fired burner.

6/94

Piping Layout as sometimes required byinsurance and standards groups

Block and Bleed gas train arrangement illustratedwith Series “67” TUBE-O-FLAME® Burner

TUBE-O-FLAME® Burner provides the air supply(unless it is an LB version, which requires a separatecombustion air blower). It also serves as a fuel flowcontrol and fuel/air mixing device.

Burner should not be exposed to direct radiantheat or positioned where it might draw in inert gases.If such conditions exist, consider filters, relocation,and/or use of the LB version and external air supply.

Electrical service must match the voltage, phase,and cycle of all electrical system components and becompatible with burner nameplate ratings. Insure thatall normal control safeguards are satisfied. Combus-tion air blower should continue to run after shutdownto allow burner to cool.

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�CORPORATIONMUNCIE, INDIANA, USA INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES


Page 2200-S-2 Series “67” TUBE-O-FLAME® Gas Burners


Suggested supporting arrangementsFuel Shut-Off Valves (when properly connected toa control system) shut the fuel supply off when ahazardous operating condition is sensed. Manualreset valves require operator attendance each timethe system is started up (or restarted after a trip-out).Motorized shut-off valves permit automatic start orrestart 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 burneritself. Test connections must be plugged exceptwhen readings are being taken.

Exhaust stack dampers are necessary to theproper operation of an immersion tube burner system.They should be lockable, suitable for 1000ºF anddesigned to prevent full stack closure.

Horizontal mounting is preferred. Most manufac-turers’ control motors require operating shaft in ahorizontal plane.

Burner mounting requires four studs and a flatmounting surface perfectly centered on the firing tube.Burner can be mounted directly on tank wall usingfour welded studs, but the more common practiceutilizes an optional mounting ring (complete withstuds) welded to tank wall, end of tube, or othermounting surface. If the application calls for position-ing the burner in other than its normal upright position,be sure to align studs appropriately.

After placing burner in position over studs, add lockwashers and nuts, then draw up all four hand-tightonly. Check that burner is seated evenly around theflange, filling any gaps to prevent air leakage, thentighten all nuts firmly.

For proper performance of any burner, air inlet andmotor should be surrounded by clean, fresh, cool air.

Burner and pipe manifold support may berequired to support weight of the burner and con-nected pipe train components. Air control motors, inparticular, require additional support. Maxon connect-ing base and linkage assemblies are designed toposition the control motors to work with the burner,not to support their weight.

The Series “67” TUBE-O-FLAME® Burner mayrequire external auxiliary support provided by theuser. The support configuration may be similar to theleg support or knee bracket support illustrated.

Additional burner support may be required inconjunction with a stiffener plate when mountingTUBE-O-FLAME® Burner (weighing 100-350 pounds)onto tube or thin tank walls.

Exhaust ConsiderationsImmersion tubes are usually vented to the outdoors,

except for those in highly ventilated areas such as aplating room with continuous high volume exhaust. Anexhaust fan may be required if the building is undernegative pressure. Exhaust is normally diluted to avoidthe need for high temperature fans, but adequate make-up air must be available.

This diluting can be done with an open tee installedin a vertical run (or in a horizontal run with the openend down), but such a system mixes slowly.

An adjustable hood (shown in sketch below) offersmuch better performance. In all cases, care must betaken that all products of combustion are exhaustedfrom the building.

An exhaust stack damper must be used, suit-able for 1000°F, and designed to prevent fullstack closure.



Series “67” TUBE-O-FLAME® Gas Burners Page 2200-S-3


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Protective covers for burner should be added inthe field if exposure to dripping condensate, splashingflux, exhaust steam, etc. is unavoidable.

Sketches below illustrate some possible arrange-ments. Any cover used should be removable toprovide access to burner and should not interfere withcontrol linkage motion or observation port viewing.

Field conversion from a flame rod version to a UVscanner version and vice versa may require additionalparts in the burner. Contact Maxon for requirements.

Alternate fuels may require correction of supplypressures.

If TUBE-O-FLAME® Burner is equipped withMaxon Hi/Lo Control Motor, low-fire start wiring canbe accomplished as shown in the sketch below.

Maxon assumes no responsibility for the use ormisuse of the layouts shown. Specific pipingand wiring diagrams should always be submit-ted to the appropriate agencies for approval oneach application.

Multi-burner installations require special consid-erations if supplied by a common pipe train and/or airsupply. Air and Gas Balancing Valves should beused for improved heating uniformity; Gas Swing-Check Valves should be installed as close as pos-sible to each burner inlet for dependable lightoff (gasmanifold may otherwise act as a reservoir, preventinglightoff during trial-for-ignition period).

Control system's circuitry must not allow mainFuel Shut-Off Valve to be opened unless combustionair is on, and must de-energize valve upon loss ofcombustion air pressure, along with the other usualsystem interlocks. Motor starter is to be interlockedwith valve, whether or not a combustion air pressureswitch is used.

WARNING: Welding of burner flange to astiffener plate or firing tube may cause warpageof burner flange and require additional sealmaterial to prevent leakage.

Flame sensing can be accomplished by eitherflame rod or UV scanner. When UV scanner is used,it should be kept as close to burner as feasible. Donot use cooling air to scanner port: sighting isthrough gas cavity. Heat block, if used, may affectsignal strength with some brands of scanners.



Initial start-up adjustment should only beaccomplished during a “manual” burnercontrol mode.

5. Start all system-related fans and blowers.Check for proper motor rotation and impellerdirection. Verify that all control interlocks areworking. Allow air handling equipment to run foradequate purge of your manifolds and immersiontubes. With main gas shut off, manually advanceTUBE-O-FLAME® Burner's operating crank to“high fire” position so that air only flows throughburner and firing tube.

CAUTION: Do not by-pass control panel timerstypically controlling sequential operations.

Series “67”TUBE-O-FLAME®

Burners

6. Determine static condition of tube (draft orsuction) and verify differential air pressure atburner backplate air test port.

Measure your air pressure reading withmanometer connected between the burner's airpressure test port and atmosphere with the burnerat “high fire” position, fuel valves closed, and allair handling systems running.

Series “67” TUBE-O-FLAME® Gas Burners

Start-Up Instructions

Read complete instructions before proceeding,and familiarize yourself with all the system's equip-ment components. Verify that your equipment hasbeen installed in accordance with the original manu-facturer's current instructions.

CAUTION: Initial adjustment and light-offshould be undertaken only by trained andexperienced personnel familiar with combus-tion systems, with control/safety circuitry, andwith knowledge of the overall installation.Instructions provided by the company and/orindividuals responsible for the manufactureand/or overall installation of complete systemincorporating Maxon burners take precedenceover these provided by Maxon. If Maxoninstructions conflict with any codes or regula-tions, contact Maxon Corporation beforeattempting start-up.

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' adjustingscrew covers. Turn adjusting screw down (clock-wise) to approximately mid-position. Close pilotgas adjustable orifice screw by turning in clock-wise until it stops. (Do not over-tighten.) Thenback out the adjustable orifice (counter-clockwise)approximately 2-3 turns.

2. Check all electric circuitry. Verify that all controldevices and interlocks are operable and function-ing within their respective settings/ranges. Besure all air and gas manifolds are tight and thattest ports are plugged if not being used.

3. Check that the immersion tube stack damperis properly positioned and locked into operatingposition.

4. Disconnect the automatic control motor'slinkage from your TUBE-O-FLAME® Burner'soperating crank arm by loosening the controlmotor's connecting rod from the burner's togglelinkage.

00-S-4



Page 2200-S-5Series “67” TUBE-O-FLAME® Burners


11. Open main and pilot gas cocks, then attemptspark ignition to light pilot while slowly turningpilot gas regulator clockwise and/or adjustableorifice screw counter-clockwise to increase fuelflow. Repeat procedure as necessary until pilotignites, as air might have to be bled out of fuelsupply lines before reliable pilot flame is estab-lished. Pilot gas regulator should normally be setfor as low a pressure as possible, using fulleropening of pilot gas adjustable orifice (if used).

12. After ignition, adjust pilot flame for good stableflame shape. A rule of thumb is that any pilot overa tennis ball size is probably too large. Thisassumes you have visual access to the pilotflame. If this is not possible, then adjust pilot togive the strongest and most stable flame signalthrough your flame safety circuit. This signalstrength can be read with a micro-amp meter. Thesignal strength (or range) will be determined bythe specific type of flame safeguard instrumentyou have with your burner system.

13. Re-check pilot ignition by closing pilot gas cockor otherwise causing pilot outage. Re-light andrefine pilot gas adjustment as necessary to getignition within a second or two. The flame safe-guard relays should now power your main fuelShut-Off Valve(s).

CAUTION: After completing steps above, re-check all interlocking safety components andcircuitry to prove that they are properly in-stalled, correctly set, and fully operational. If indoubt, shut the system down, close pilot cockand contact responsible individual beforeproceeding further.

14. Establish main flame. With burner at low fireposition, back out main gas pressure regulatoradjusting screw (counter-clockwise) to get lowestoutlet pressure possible. Open all manual fuelshut-off valves (automatic fuel shut-off valveshould already be open) so gas flows to burnerinlet. There should be little, if any, change inflame appearance. Turn main regulator adjust-ing screw in (clockwise) to obtain outlet pressureof about 4"-6" wc higher than combustion cham-ber pressure (2"-4" wc for propane, considerablyhigher for some LB versions). Main flame shouldnow appear larger than pilot-only flame.

Record air test port reading. Chart below showsnormal balanced tube static condition readings.

If your reading exceeds these normal readings,you have a back pressure in your tube.

If your readings are lower than the normalbalanced readings, you have an exhaust suctionin your tube.

Excessive suction can cause chugging andimplies hot combustion products are being drawnout of the tube too fast, reducing thermal transferefficiency. High tube suction also may affectdifferential gas pressure settings. Too high of asuction may lower inlet gas pressures so that lowgas pressure switches cannot be adjusted.

Excessive back pressure can cause smokeand may restrict firing capacity of burner.

NOTE: The differential air pressure setting deter-mines the burner's capacity and performance capabili-ties.

7. Adjust exhaust fan and/or stack damper tocreate burner air pressure test port readings asclose as possible to those shown for normalbalanced conditions to maximize system's thermaltransfer efficiency.

NOTICE: Burner performance can be drasticallyaffected by tube configuration and staticconditions within tube created by exhaust fansand dampers in exhaust stack.

8. Determine the required differential gas pres-sure using this differential air pressure readingobtained from step 6. High fire pressures areprovided in Maxon product line catalog literatureand/or read data stamped into burner nameplate.

9. Verify that spark ignitor is properly positionedand lines up with the appropriate dimensionsrequired for your specific burner. (Refer to appro-priate Maxon catalog specification table.) Checkthat spark ignitor arcs at the end of your properlypositioned ignitor.

10. Return burner control valve/crank to low fireposition when purge of system is complete.

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17. Re-check differential gas pressure with unit atoperating temperature. Refine high fire setting ifnecessary, considering differential pressure,flame length, and appearance. Dust or contami-nants in the air stream may affect flame appear-ance.

18. Plug all test connections not in use to avoiddangerous fuel leakage. Replace equipmentcover caps and tighten linkage screws.

19. Check out overall system operation by cyclingthrough light-off at minimum, interrupting pilot,and allowing temperature control system to cycleburner from minimum to maximum and return.NOTE: Typical gas firing control sequence forMaxon burner is provided only as a guide. Instruc-tions provided by complete system manufacturerincorporating Maxon burners take precedence.

For gas firing Series “67”TUBE-O-FLAME® Burner

Light-off: Shut-down:1. Close cocks, shut-off valve(s) 1. Close main &2. Verify burner at low fire pilot gas cocks3. Start recirculating/exhaust fans 2. Keep combustion4. Start burner blower air blower running5. Purge at least 4 air changes after shut-down long6. Open pilot & main gas cocks enough to allow

burner to cool

Recheck all safety system interlocks for propersetting and operation.

WARNING: Test every UV installation for danger-ous spark excitation from ignitors and other pos-sible sources of direct or reflected UV radiation.Use only gas-tight scanner connections.

20. Before system is placed into full service,instruct operator personnel on proper start-upoperation with shut-down of system, establishingwritten instructions for their future reference.

Page 2200-S-6 Series “67” TUBE-O-FLAME® Gas Burners


15. Establish high fire setting by slowly movingburner crank toward high fire position whileobserving gas pressure at burner gas test con-nection. Refine main gas regulator adjustment asnecessary to provide correct differential gaspressure at high fire. If pressure cannot beadjusted low enough, a different regulator orregulator spring may be necessary, or a limitingorifice valve (such as Maxon's Series “BV”)should be added. Do not, however, exceed 4" wcpressure drop between regulator outlet andburner inlet.

CAUTION: If burner(s) go out, close shut-offvalve or shut main gas cock at once. Return tominimum setting, re-light pilots if necessary,then turn main gas on again. Check carefullythat every burner is lit before proceeding.

Cycle burner from minimum to maximumand refine adjustment, if necessary.

For operation with interrupted pilot (asrecommended), shut off pilots and cycle burnerfrom minimum to maximum and back severaltimes to verify the flame is maintained.

16. When burner performance is satisfactory andstable throughout the firing range, reconnectlinkage to control motor.

Control linkage travel must be such that burnercrank is moved throughout its complete travel, orcataloged capacities and turndowns will not beachieved.

If less than full-rated burner capacity is re-quired, linkage can be adjusted to limit maximumoutput. With interrupted pilot, it may be neces-sary to set control for somewhat higher thanminimum burner setting to permit hold-in of flamedetection system without pilot.

CAUTION: Internal drive mechanism within thecontrol motor may be damaged if linkage isadjusted so as to cause binding with burner inhigh or low fire position.

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