Burner Selection Criteria
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1 UNI-RAD Radiant Tube Burners Page 4803 Burner Selection Criteria Combustion Air View Port/Optic Flame Sensor Mount Gas Inlet 3"- 4" Burner Selection The UNI-RAD Burner can be used with various radiant tube sizes, tube configurations, heat inputs, etc. The following information should be supplied to assist Maxon in matching the correctly sized UNI-RAD Burner to your specific application: 1. Radiant tube inside and outside diameters 2. Radiant tube configuration 3. Furnace or process temperature 4. Radiant tube length 5. Radiant tube material 6. Method of mounting (standard flange, packing gland, etc.) 7. Furnace wall thickness (see page 4800-S-1 for mounting instructions) 8. Requirement for heat recuperation (if used) Typical Burner Firing Rates Ignition Housing Size (inches) Natural Gas Flow (CFH) and Btu/hr Capacity x 1000 Btu/hr 4" " 70 5" 88 6" 26 7" 64 8" 02 Note: Burner firing rate is based on: Btu/CF Natural Gas " total "U" tube length within chamber 3. 2% excess oxygen and 0% combustibles Btu/sq.in. of tube surface area Electrical Ignition Connection Combustion Air CFM Combustion Air Housing Radiant Tube The table at left gives typical maximum capacities for the conditions shown. The UNI-RAD Burner has been used with firing rates ranging from 80,000 Btu/hr to 700,000 Btu/hr, depending upon tube length and diameter. Radiant Tube Life Competitive burner systems stress the fuel savings obtained by the use of combustion air preheated to 800 to 1000 from waste heat energy. The fact that preheated air produces much higher flame temperatures, and consequently decreases furnace alloy life is generally ignored. The UNI-RAD system overcomes this problem through the use of pulse firing and has consistently shown increases in the furnace alloy life while saving fuel. An extensive number of UNI-RAD Burner users have increased their radiant tube life by as much as 300%. UNI-RAD Burners have also successfully been applied to silicon carbide tubes. These tubes can handle higher operating temperatures than most alloy tubes, and allows for increased heat flux. Construction The UNI-RAD Burner is constructed of cast iron and carbon steel with internal components constructed of stainless steel. The air inlet tube length must be specified when ordering to provide for differences in the furnace wall thickness. 4/03
2 Page 4804 UNI-RAD Radiant Tube Burners Burner Selection Criteria Piping The gas and air piping for the UNI-RAD Burner is simple and direct. As shown in the piping schematic below, each UNI-RAD Burner uses one fuel gas line, one primary ignition air line, and one main combustion air line. Gas Metering A custom drilled gas spud orifice on each burner sets the desired capacity. Typical gas pressure requirements at the burner range from 8" 24" w.c. depending upon customer requirements. Air Metering Combustion air flow is metered with a Limiting Orifice Valve (LOV) located prior to the inlet of the recuperator. A minimum of supply air pressure of 10" w.c. at the inlet to the recuperator is usually required. Higher pressures may be necessary, depending upon burner capacity, or how the recuperator is sized. Primary ignition air is usually less than 7% of total air to the burner. The custom drilled air orifice in the ignition air pipe assembly sets the value. An LOV is sometimes used as a trim device to field optimize the burner ignition. The primary air is never throttled. It is kept on at all times. CAUTION: If main air ball valve is inadvertently closed, raw gas may be delivered to the tube, possibly creating an explosive condition. Conclusion The UNI-RAD Burner system has been successfully applied to a variety of furnaces. Its success is due not only to the quality of our equipment, but also to a careful evaluation of each application. We work with our customers to assure that every aspect of their combustion system is designed for optimum performance. Please contact your local Maxon representative for assistance. Typical Piping Schematic (Four Burners) MAX-SAVER Recuperator Zone Air Proof-of-Opening Switch Ball Valve Main Air LOV UNI-RAD Burner Main Air Main Air ** Note: Ig n i t i on Ai r M a i n A i r H e ade r I g n i t i on A i r M a i n G a s Air Control Valve M a i n G a s Ignition Air Main Gas Main Gas Maxon Series FG Combustion Air Blower Main Gas Control Solenoid Valve ** 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. From Zone Fuel Regulator & Safety Valve Train
3 UNI-RAD Radiant Tube Burners Page 4805 MAX-SAVER U-Shaped In-Situ Recuperator The Maxon UNI-RAD Burner System consists of two major components: UNI-RAD Direct Spark Ignited Burner MAX-SAVER In-Situ Recuperator When these features are combined, they provide the following advantages over existing systems: Fuel savings ranging from 25% to 50% over nonrecuperative systems Increased alloy life Improved furnace temperature uniformity Improved production quality Long recuperator life Typical Burner / Recuperator Layout Radiant Tube (by others) Y MAX-SAVER Recuperator UNI-RAD Burner Schedule 40 Piping Section Y-Y shown on page 4806 Y 4/03
4 Page 4806 UNI-RAD Radiant Tube Burners MAX-SAVER U-Shaped In-Situ Recuperator Section View Y-Y Exhaust Stack Eductor (by others) Cold Combustion Air Draw Band (by others) Optional Exhaust Cooling Air Bulkhead Plate (by others) Pre-heated Combustion Air Radiant Tube (by others) Draw Bands (by Maxon) 11.00" Dia. 9.50" Bolt Circle 7.00" O.Dia. 6.85" I.Dia. 0.75" Hole Custom draw band designs are available from Maxon by special request. 0.25" HRS Section A - A 31.3" Weld 304 SS Recuperator #58065 Weld " NPT REF: Drawing #SER_5287A 8.25"
5 UNI-RAD Radiant Tube Burners Page 4807 Dimensions (in inches) UNI-RAD Burners - used with metal tubes Removal Overall A B Sec. A D C 1/2" NPT E NPT F 1/2" NPT 3/4" NPT Gas Inlet 4 holes 3/4" dia. Sec. A Section A-A Tube Tube & Nozzle Assembly Nozzle Protrusion Housing Size* A B C D E NPT 4 UR 1-1/4" UR 1-1/4" UR /2" UR /2" UR /2" UR /2" UR " UR " UR " 8. 0 *Refers to size of burner housing; dimension "E" (NPT) and dimension "F" (inside diameter) F I.D. Tube Removal Overall Nozzle Protrusion Air Tube & Nozzle Assembly Gas Tube 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" 1" 36.5" 27.7" 10.9" 16.75" 19.25" 13.5" 38.5" 29.7" 12.9" 18.75" 2" 15.5" 40.5" 31.7" 14.9" 20.75" 23.25" 17.5" 42.5" 33.7" 16.9" 22.75" 25.25" Available by special request. 4/03
6 Page 4808 UNI-RAD Radiant Tube Burners Dimensions (in inches) UNI-RAD Burners - used with silicon carbide tubes Removal A Sec. A B Overall E NPT F D C 1/2" NPT 1/2" NPT 3/4" NPT Gas Inlet 4 holes 3/4" dia. Sec. A Section A-A Tube Tube & Nozzle Assembly Nozzle Protrusion Housing* Size A B C D E NPT 4.5C UR 1-1/4" C UR /2" 6. 0 *Refers to size of burner housing; dimension "E" (NPT) and dimension "F" (inside diameter) F I.D. Tube Removal Overall Nozzle Protrusion Air Tube & Nozzle Assembly Gas Tube 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" 1" 38.5" 27.7" 8.8" 16.75" 19.25" 13.5" 40.5" 29.7" 10.8" 18.75" 2" 15.5" 42.5" 31.7" 12.8" 20.75" 23.25" 17.5" 44.5" 33.7" 14.8" 22.75" 25.25" Available by special request.
7 UNI-RAD Radiant Tube Burners Page 4809 Dimensions (in inches) MAX-SAVER Recuperator - " *3.75" to 5.5" dia " NPT 1.66 dia. *Baffle diameters are normally selected to be 0.25" smaller than the I.D. of the firing tube 2.25 MaxSaver " Recuperator Pressure Drop vs. Flow at Various Preheat Temperatures 11/03
8 Page 4810 UNI-RAD Radiant Tube Burners Dimensions (in inches) MAX-SAVER Recuperator - " *From 3.5" to 7.5" dia " NPT 1.9 dia. *Baffle diameters are normally selected to be 0.25" smaller than the I.D. of the firing tube MaxSaver " Recuperator Pressure Drop vs. Flow at Various Preheat Temperatures
9 UNI-RAD Radiant Tube Burners Page 4811 MAX-SAVER Recuperator - 2" Dimensions (in inches) *5.5" to 10.0 dia " NPT 2.38 dia. *Baffle diameters are normally selected to be 0.25" smaller than the I.D. of the firing tube MaxSaver 2" Recuperator Pressure Drop vs. Flow at Various Preheat Temperatures /03
10 Page 4812 UNI-RAD Radiant Tube Burners UNI-RAD Burner Component Identification E D A F G H Z Y V X W B A C J I K L M N O P T U S AA CC DD R BB BB EE FF GG HH JJ Q KK Item Part Number Description A " HLW PIPE PLUG B " NPT OBSVTN GL C " MALL CR D " -27 SPUD HLDR E " CA-PLUG F " X.125" STL HEX BSHG G " X.75" X.75" MALL TEE H " - 27 BR SPUD - MAIN GAS I " BLK STL CLS NPL J " X.125" STL HEX BSHG K " X.5" STL HEX BSHG L M8 X 25 ISO4017 PLTD HEX M " FLG N UNI-RAD BRNT GSKT O M8- PLTD FIN HEX NU P M8-PLN ISO 7089 WSHR CLS Q UNI-RAD IGN AIR PIPE ASY R M9X10 CONE PT SET SCR S BRNR HSG Item Part Number T IGN ROD U " IDE INSL Description V UNI-RAD BRNR GSKT W IGN INSL RETN FLG X M8-PLN ISO 7089 WSHR CLS Y M8X16 ISO4017 SS HEX HD Z IGN TERM CAP AA " ID CRMC INSL BB GAS INLT HLDG CLR CC " ID INSL DD " ID INSL EE --- GAS INLT TB ASY FF CRMC CNTRG SPDR GG --- AIR TUBE & NOZZLE ASY HH BRNR CSTG GSKT JJ --- AIR INLT GSKT KK --- BRNR AIR INLT HSG For part numbers of shaded items, see next page
11 UNI-RAD Radiant Tube Burners Page 4813 UNI-RAD Burner Component Identification EE "A" Tube Nozzle GG JJ "B" KK Item "EE" Tube Item "JJ" - - Housing Size Gas Inlet Tube Assembly Dimension "A" Gas Inlet Tube Assembly Gasket JJ AIR INLT GSKT 4 UR C UR UR UR UR UR C UR UR EE GAS INLT TB ASY 4.0" " " " " " " UR UR UR Item "GG" Tube - Item "KK" - Burner Housing f or alloy tubes (pictured above) Housing Size Air Tube & Nozzle Assembly Dimension "B" Air Tube & Nozzle Assembly GG AIR TUBE & NOZZLE ASY 4.0" " " " " " " NOTE: Air tube and nozzle available only as an assembly, not separate items KK BRNR AIR INLT HSG 4 UR UR UR UR UR UR UR UR UR KK1 KK2 KK3 KK4 KK5 KK6 KK7 Item "KK" - Burner Housing f or silicon carbide tubes (pictured at left) Tube Size KK1 Housing KK2 Screw KK3 Washer KK4 Ring KK5 Gasket KK6 Plg Gland KK7 Nut 4.5"C "C Available by special request. 11/03
12 Page 4814 UNI-RAD Radiant Tube Burners Notes
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