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1 Table of Contents Click to go to section Section I Product Bulletin Section II Safety Statement Safety and Hazard Recognition Hazard Recognition Basic Safety Guidelines Hazardous Work Permit Flammable Gas Mixtures Can Explode Combustion Products May Kill Electric Shock Can Kill Pressurized Fluids Can Rupture Pipes & Hoses Moving Parts Can Pinch Adjustments Can Cause Flammable Mixture Emergency Shutdown Section V Installation Handling and Storage Furnace Wall Preparation Section VI Operation Overview Normal Operation Post Commissioning Adjustment and Procedure Section VII Maintenance and Troubleshooting Spare Parts List Routine Maintenance Troubleshooting Guide Section III Specifications Capacitites Dimensions & Weights Configuration Options & Specials Section IV System Design Burner Selection

2 Section One Product Bulletin 01

3 Combustion North American Combustion Burners 4441 North American Tempest High Velocity Gas Burner Jet action burner offering superior recirculation Slotted tile produces exceptional temperature uniformity Extraordinary performance across various furnace applications in a spectcrum of industries

4 The North American Tempest High Velocity Gas Burner is one of the world s most widely used and respected burners The Tempest has gained acclaim for its high velocity jet action and superior recirculation promoting capabilities. These two features bring both the quality benefit of close temperature uniformity and the productivity benefit of safe higher heating rates up to 3000 F (1650 C). Additionally, a variety of tile material and outlet shape choices provide flexibility in installation with a flame fitting to the shape of the combustion chamber. TYPES OF APPLICATIONS Periodic kilns in the ceramics and refractory industries Tunnel kilns in the ceramics and refractory industries Forge furnaces Heat treat furnaces Galvanizing baths Scrap preheaters Carbon baking furnaces Cupolas Pipe coaters Portable refractory dry out Preheat equipment Variety of other applications 4441 Tempest. Shown with alumina/mullite tile "A" for fiber wall furnace installation. PERFORMANCE BENEFITS Low NOx emissions High excess air and excess fuel Direct spark ignition Integral air and gas meters Sturdy cast construction Wide operating limits Range of ignition and flame supervision capabilities Compatible with StepFire or other pulse fired control system Tempest. Shown with alumina/mullite slotted tile for narrow lane firing and better temperature uniformity.

5 North American Tempest High Velocity Gas Burner Performance Data Combustion Air: "w.c. ( kpa) air pressure, max 350 F (177 C). Fuel: Natural gas with propane gas versions available in the -1 thru -4-B sizes. Gas pressure varies per size with 19"w.c. (4.7 kpa) is maximum required at design capacity, for 27.7"w.c. (6.9 KPA) combustion air pressure, stoich ratio. Control: Excellent performance with all control systems; StepFire, on-ratio and thermal turndown. A limiting orifice valve must be installed in gas supply line within 1 ft. (30 cm) of burner. A ratio regulator should be within 4 ft. (122 cm) of burner. Relight: Tempest burners require spark for re-ignition. They will not relight from a hot tile or furnace. Flame Supervision: Flame rod or UV detector Consult National Safety Standards and insurance underwriters for specific flame supervision requirements. Flame supervisory components must be ordered separately. See Section 7.1 for correct flame rod part number. Ignition: Direct spark (no pilot) with 6000 V transformer. A halfwave transformer prevents UV sensing of the spark during trial for ignition. Lighting not recommended above 27.7"w.c. (6.9 kpa) main air pressure. Excess air required for ignition. Imperial 4441 Natural Gas Performance Data Piping: For cross-connected systems, maximum gas pressure at the burner can be adversely impacted by excessive pressure drop in the gas line between the ratio regulator and the burner. The design, selection, and installation of these systems must take into account the gas pressure required at the burner to achieve the desired heat release (i.e. gas flow). For more detailed information on cross-connected control systems, see section 4.1. Capacities of the burners have not changed. Imperial units of static pressure are now given in inches of water column. (Performance for 27.7"w.c main air pressure operating at stoichiometric ratio unless stated otherwise) Burner Size A -4-B A -8-B -8-C Air Flow, not burning (scfh) Air Flow, (scfh) Air Orifice, UA-DA, ("w.c.) Gas Orifice, UG-DG ("w.c.) Gas Pressure UG ("w.c.) Gas Pressure UG ("w.c.), 30% XSF Max. % XSA, (ignition and flame signal limit) Max. % XSF, (ignition and flame signal limit) Flame Length (in.) Flame Diameter (in.) Metric 4441 Natural Gas Performance Data (Performance for 6.9 kpa main air pressure operating at stoichiometric ratio unless stated otherwise) Burner Size A -4-B A -8-B -8-C Air Flow, not burning (Nm3/h) Air Flow, burning (Nm3/h) Air Orifice, UA-DA, (mbar) Gas Orifice, UG-DG (mbar) Gas Pressure UG (mbar) Gas Pressure UG (mbar), 30% XSF Max. % XSA, (ignition and flame signal limit) Max. % XSF, (ignition and flame signal limit) Flame Length (mm) Flame Diameter (mm)

6 North American Tempest High Velocity Gas Burner Performance Data Imperial 4441 Propane Gas Performance Data (Performance for 27.7"w.c main air pressure operating at stoichiometric ratio unless stated otherwise) Burner Size A -4-B Air Flow, not burning (scfh) Air Flow, (scfh) Air Orifice, UA-DA, ("w.c.) Gas Orifice, UG-DG ("w.c.) Gas Pressure UG ("w.c.) Gas Pressure UG ("w.c.), 30% XSF Max. % XSA, (ignition and flame signal limit) Max. % XSF, (ignition and flame signal limit) Flame Length (in.) Flame Diameter (in.) Metric 4441 Propane Gas Performance Data (Performance for 6.9 kpa main air pressure operating at stoichiometric ratio unless stated otherwise) Burner Size A -4-B Air Flow, not burning (Nm3/h) Air Flow, burning (Nm3/h) Air Orifice, UA-DA, (mbar) Gas Orifice, UG-DG (mbar) Gas Pressure UG (mbar) Gas Pressure UG (mbar), 30% XSF Max. % XSA, (ignition and flame signal limit) Max. % XSF, (ignition and flame signal limit) Flame Length (mm) Flame Diameter (mm) CONTACT US: Fives North American Combustion, Inc East 71st Street - Cleveland, OH USA Tel: Fax: fna.sales@fivesgroup.com Copyright Fives - All rights reserved /17

7 Section Two Safety Statement 02

8 2.1 Safety and Hazard Recognition Introduction to Safety and Hazard Recognition WARNING Situations potentially dangerous to personnel and property may exist with the operation and maintenance of any combustion equipment. The presence of fuels, oxidants, hot and cold combustion products, hot surfaces, electrical power in control and ignition circuits, etc., are inherent with any combustion application. North American urges compliance with National Safety Standards and Insurance Underwriters recommendations, and care in operation. The owner or operator of the combustion equipment manufactured by the Fives North American Combustion, Inc. is hereby warned that failure to observe the included safety information may result in serious injury to personnel and/or damage to property. The Fives North American Combustion, Inc. neither states as fact, nor in any way implies that the included safety information is an all inclusive list, the observance of which will prevent all damage to property or injury to personnel. Every effort has been taken to ensure that complete and correct instructions have been included in this manual. Who Must Read This Manual The Installation, Operation and Maintenance Instructions for the North American combustion system must be read and understood by all individuals who will use or service the combustion system. Do not attempt to operate or service this equipment without first reading and understanding this manual. Do not allow untrained persons to operate or service combustion and control equipment. What Is Covered In This Manual This manual provides descriptive and detailed information needed to install, operate, and maintain North American combustion systems. What Is Not Covered In This Manual This manual dœs not cover pre-existing hazards that may be present at your site such as hot surfaces, open flames, striking objects, asphyxiation, falls, electrocution, etc. The precautions and procedures in this manual are provided to complement existing safety, health and environmental regulations for your site.

9 2.2 Safety and Hazard Recognition NOTICE If you should encounter a technical problem that is not directly covered in this manual or not otherwise clearly set forth, immediately contact your Fives North American Combustion, Inc. factory representative for clarification. Do not modify this equipment or manual without prior written consent from Fives. Fives makes no representation, warranty, or guarantee as to the information provided herein, or the results which can be achieved through the use of the information in this manual. No warranties by North American shall be implied or otherwise created, including but not limited to warranty of merchantability and warranty of fitness for a particular purpose. Copyright Fives - All rights reserved

10 2.3 Safety and Hazard Recognition SAFETY I. Hazard Recognition Fives has provided a combustion system to be used for this heating process. By taking proper precautions and following recommended procedures, the Combustion System can be operated with limited risk. However, all individuals who use or service this system must recognize that hazards do exist. These hazards include but are not limited to: Flammable fuel mixtures can explode Combustion products can kill Electric shock can kill Pressurized fuels can rupture pipes and hoses Moving parts can pinch Adjustments can cause flammable mixtures Precautions and procedures to avoid these hazards are described herein. Failure to follow the precautions and procedures may result in harm to both personnel and property. Protect yourself and others by heeding these warnings. II. Basic Safety Guidelines The following safety guidelines apply to the combustion system at all times: It is imperative that all National, State, and Local Codes and Regulations pertaining to the installation of this equipment be adhered to. Installation should be done by qualified personnel. Failure to do so may result in personal injury and/or property damage. Insurance carrier should review and approve the combustion system design and the associated operating procedures. No open flames, smoking, or sources of ignition are permitted near the combustion system to guard against fires caused by fuel leaks. A Hazardous Work Permit (or equivalent) is required before servicing the equipment because of the need for coordination of actions of operations and maintenance personnel, and because of the potential hazards to personnel and equipment. Lock out the pressure supply source of fuels and de-pressurize all piping, tubing and pressurized vessels before maintenance or repair to avoid the hazards of a release of pressure, such as striking objects or fire. Follow established Lock Out / Tag Out procedures. Use special caution when working in confined spaces to prevent asphyxiation. Follow established Confined Space Entry procedures. De-energize and Lock Out electrical circuits before attempting any repair or maintenance of electrical equipment to prevent electrical shock. Follow established Lock Out / Tag Out procedures. Check all safety devices periodically to ensure continued reliability. NFPA 86 (EN746-2 in Europe) requires safety devices to be tested at least annually. NFPA 86 requires Safety Shutoff Valves to be replaced before they exceed their maximum rated cycles. If the number of cycles are estimated, replace Safety Shutoff Valves before they reach 90 percent of the lifetime open-closed cycles. Never operate the system without all safety devices intact and operating properly. Never operate the system if the fuel is leaking. Make no substitutions for the prescribed procedure or material when repairing the system.

11 2.4 Safety and Hazard Recognition Equipment must only be used for the purpose for which it was designed. Any unauthorized use or application must be avoided in order to prevent accidents. Always operate and maintain this equipment in accordance with the manufacturers' and plant operating instructions. At the first indication of any trouble or malfunction, investigate and shut down the equipment if necessary to determine the cause or for safety reasons. Do not operate until trouble has been corrected. III. Hazardous Work Permit The purpose of a Hazardous Work Permit is to ensure that work known to be hazardous or work that could cause a hazardous condition is properly planned and controlled, so that it can be accomplished with reduced risk. Servicing the Combustion System involves situations that are not normally encountered in standard operations. Proper procedures, planning, and a pre-job discussion between worker and supervisor are necessary to reduce risk to personnel. Hazards must be anticipated. During a pre-job discussion, the worker and the supervisor must recognize hazards and plan means to avoid them. The following types of work on the combustion system should be covered by the Hazardous Work Permit or equivalent: Pressure testing Any work or entry into areas where oxygen deficiency might reasonably be encountered. All electrical repair work and troubleshooting. Any work on equipment or piping where pressure may still exist or be trapped. Any site specific job that the plant supervision has designated to require a Hazardous Work Permit. Leak test equipment with approved medium only. Leak test pressure must not exceed the specified system operating pressure. Incorrect medium or excessive pressure may damage the equipment or components. Make no substitutions for the prescribed procedure or material when repairing the equipment. IV. Flammable Gas Mixtures Can Explode Explosion and improper combustion are major hazards of any combustion system for process furnaces. To minimize your exposure to this hazard be sure to: Follow the recommended procedures for operating and servicing the fuel systems. Keep all personnel away from furnace areas during startup. The greatest potential danger of an explosion exits during a cold light-off when fuel can accumulate in the furnace, and when the furnace temperature is below the auto-ignition temperature of fuel being used. When the furnace temperature is above 1400F, there is less danger of an explosion because fuel and air oxidize upon mixing. WARNING Check all safety devices periodically to ensure correct operation. Never operate the system without all safety devices intact and operating properly. Never operate the system if the fuel is leaking. In case of a fuel leak, stop the combustion system immediately. Before attempting to repair any leak that involves more than the in-situ tightening of fittings, flanges, unions etc. or one where there is any risk of fracture of fuel-carrying components, ALWAYS: Disconnect and Lock Out all power sources Close and Lock Out manual fuel equipment isolation valves Bleed pressurized fluids from piping systems Install isolation blanks in the fuel supply lines Purge fuel lines with clean, dry, oil-free air Do not use nitrogen in confined spaces Pressure test the repair before returning the system to service

12 2.5 Safety and Hazard Recognition V. Combustion Products May Kill Any maintenance that is done inside furnaces may be dangerous due to the possible accumulation of fuel and/or combustion products, including carbon monoxide, carbon dioxide, hydrogen, and nitrogen oxides. Mixtures of fuel and air in a confined area may explode when brought in contact with a flame or other source of ignition. Carbon monoxide is a toxic, colorless, odorless, and tasteless gas. Even at low concentrations, it can rapidly cause harmful effects, including death, without warning. Carbon dioxide can cause rapid asphyxiation and death in confined, poorly ventilated areas. Hydrogen is a flammable gas and an asphyxiant. A mixture of hydrogen with oxygen or air in a confined area may explode if ignited by spark or flame. Nitrogen oxides are highly toxic gases and may accelerate combustion. Before any work is performed inside the furnace, ALWAYS: Disconnect and Lock Out all power sources. Close and Lock Out manual fuel equipment isolation valves Bleed pressurized fluids from piping systems Install isolation blanks in fuel supply lines Purge fuel lines with clean, dry, oil-free air Do not use nitrogen in confined spaces Follow your site confined space entry procedures VI. Electric Shock Can Kill Follow all NFPA 70E Standard for Electrical Safety in the Workplace requirements when working on electrical equipment (EN 50110:2013 in Europe). Electricity is present at many different points throughout the system. Improper use of electrical devices or attempting to service equipment without first disconnecting the electric power source can lead to electrical shock or electrocution. WARNING Unqualified personnel must not attempt to service or repair electrical equipment. Do not attempt to troubleshoot or service electrical equipment when it is energized. Some wires remain energized even if all switches are turned off. De-energize and Lock Out all electrical sources before opening enclosures. Close panel door before operating. Do not bypass or disconnect safety interlocks. Manual fuel valves should be closed when servicing the electrical system. Any time service is being performed, Lock Out/Tag Out procedures should be observed and/or to prevent someone from starting the system, close and Lock Out the manual fuel valve(s) and electrical disconnect(s). Electrical hazards also exist within a junction box. More than one disconnect may be required to safely de-energize a system.

13 2.6 Safety and Hazard Recognition VII. Pressurized Fluids Can Rupture Pipes and Hoses Compression of any fluid introduces hazards. Similar to a spring, compressed fluids represents stored energy. Should a break occur, piping or hoses may become a lethal whip. Should a rupture occur, failing equipment may be fragmented and the fragments propelled with great force. For these reasons, wear protective equipment, such as safety glasses and protective gloves when tending to this equipment. All vessels, piping, and equipment that may contain pressurized fluids must be designed, installed, and tested to strict codes and standards before use to prevent a rupture. Pressure relief devices should be installed wherever higher than design pressures could be experienced because of negligence, accident or component failure. WARNING Piping contains pressurized fluids. Make sure piping, tubing and pressure vessels are depressurized before repairs are attempted. VIII. Moving Parts Can Pinch Pinching hazards exist on the fuel train due to the manual and automatic operation of the actuators. Wear protective equipment, such as safety glasses and protective gloves when tending to this equipment. Keep hands, body, and loose clothing away from moving parts. IX. Adjustment Can Cause Flammable Mixture Safety devices have been installed in this system to verify the system performs in the design manner. Operating these devices with settings other than those designed and set by Fives for this process may expose personnel and equipment to serious hazards. Access to devices and settings must be limited to qualified technicians who are trained in combustion systems. Do not tamper with the controls and safety devices or attempt to alter their program or settings. Tampering with a controller may make the process unsafe. Operating with a controller other than the one which was designed and installed by North American may expose personnel to serious hazards. The controllers must not be changed without prior written consent from North American. XI. Emergency Shutdown Familiarize yourself with all normal and emergency shutdown procedures before starting and operating this equipment. Control panels must be equipped with a large, red MASTER STOP button on the door of the control panel. Pressing this button causes the automatic fuel valves to close, stopping the flow of fuel. The fuel system must also be equipped with manual valves. Close these valves to ensure stopping the flow of fuel.

14 Section Three Specifications 03

15 3.1 Capacities All Data:...is based on firing with ambient combustion air. UA-DA:...Published data is reasonably accurate between 6.9 and 34.6"w.c. (1.7 and 8.6 kpa) main air pressure (UA) if piped with >5 diameters of straight pipe into burner. Square rooting the UA-DA pressure drops using the published 27.7"w.c. (6.9 kpa) data is reasonably accurate between "w.c. ( kpa) air pressure. Below 6.9"w.c. (1.7 kpa) the UA-DA data is suspect and should not be used for accurate air metering. Square rooting will over-estimate air flow below 6.9"w.c. (1.7 kpa) and underestimate above 34.6"w.c. (8.6 kpa). UG-DG:...UG-DG information can be used to approximate fuel gas flow. External gas orifices or O 2 analysis should be used for precise determination of fuel metering and air/fuel ratio. Max % XSAir, fs Max % XSAir, UV Max % XSAir, flame rod Max % XSFuel, fs fs - indicates the maximum flame supervisory XSAir or XSFuel using either a UV detector or the specified flame rod listed on the 4441 parts list. Max % XSAir, ignition Max % XSFuel, ignition ignition - indicates the maximum XSAir or XSFuel at which the integral igniter will light the burner. DG:...Tile pressures are average values and are subject to considerable variation (±10%) NOTE: The capacity of the burners has not changed but static pressure has been transitioned to measuring static pressure in imperial units by inches of water column. Previous versions of the bulletin measured static air pressure in ounces per square inch. Conversion: 1 osi = 1.73 w.c. Natural Gas, Imperial Main Air Pressure, (UA pressure tap), "w.c Air Flow, not burning (scfh) 1600 Air Flow, (scfh) Air Orifice, UA-DA, ( w.c.) Gas Orifice, UG-DG ( w.c.) Tile Pressure, DG ( w.c.) Max. % XSAir, fs, ignition Max. % XSFuel, fs Max. % XSFuel, ignition Flame Length (in.) Flame Diameter (in.) Air Flow, not burning (scfh) 2700 Air Flow, (scfh) Air Orifice, UA-DA, ( w.c.) Gas Orifice, UG-DG ( w.c.) Tile Pressure, DG ( w.c.) Max. % XSAir, fs, ignition Max. % XSFuel, fs Max. % XSFuel, ignition Flame Length (in.) Flame Diameter (in.)

16 3.2 Capacities Natural Gas, Imperial Main Air Pressure, (UA pressure tap), "w.c Air Flow, not burning (scfh) 4000 Air Flow, (scfh) Air Orifice, UA-DA, ( w.c.) Gas Orifice, UG-DG ( w.c.) Tile Pressure, DG ( w.c.) Max. % XSAir, fs, ignition Max. % XSFuel, fs Max. % XSFuel, ignition Flame Length (in.) Flame Diameter (in.) A Air Flow, not burning (scfh) 6100 Air Flow, (scfh) Air Orifice, UA-DA, ( w.c.) Gas Orifice, UG-DG ( w.c.) Tile Pressure, DG ( w.c.) Max. % XSAir, fs, ignition Max. % XSFuel, fs Max. % XSFuel, ignition Flame Length (in.) Flame Diameter (in.) B Air Flow, not burning (scfh) 8200 Air Flow, (scfh) Air Orifice,UA-DA, ( w.c.) Gas Orifice, UG-DG ( w.c.) Tile Pressure, DG ( w.c.) Max. % XSAir, fs, ignition Max. % XSFuel, fs Max. % XSFuel, ignition Flame Length (in.) Flame Diameter (in.)

17 3.3 Capacities Natural Gas, Imperial Main Air Pressure, (UA pressure tap), "w.c Air Flow, not burning (scfh) Air Flow, (scfh) Air Orifice, UA-DA, ( w.c.) Gas Orifice, UG-DG ( w.c.) Tile Pressure, DG ( w.c.) Max. % XSAir, fs, ignition Max. % XSFuel, fs Max. % XSFuel, ignition Flame Length (in.) Flame Diameter (in.) Air Flow, not burning (scfh) Air Flow, (scfh) Air Orifice, UA-DA, ( w.c.) Gas Orifice, UG-DG ( w.c.) Tile Pressure, DG ( w.c.) Max. % XSAir, fs, ignition Max. % XSFuel, fs Max. % XSFuel, ignition Flame Length (in.) Flame Diameter (in.) Air Flow, not burning (scfh) Air Flow, (scfh) Air Orifice, UA-DA, ( w.c.) Gas Orifice, UG-DG ( w.c.) Tile Pressure, DG ( w.c.) Max. % XSAir, fs, ignition Max. % XSFuel, fs Max. % XSFuel, ignition Flame Length (in.) Flame Diameter (in.)

18 3.4 Capacities Natural Gas, Imperial Main Air Pressure, (UA pressure tap), "w.c A Air flow, not burning, scfh Air flow, stoich., scfh Air Orifice ΔP, (UA-DA), w.c Gas Orifice ΔP, (UG-DG), w.c., stoich Tile Pressure, wc Max. % XSA, fs, ignition Max. % XSFuel, fs Flame Length, in Flame Diameter, in B Air flow, not burning, scfh Air flow, stoich., scfh Air Orifice ΔP, (UA-DA), w.c Gas Orifice ΔP, (UG-DG), w.c., stoich Tile Pressure, wc Max. % XSA, fs, ignition Max. % XSFuel, fs Flame Length, in Flame Diameter, in C Air flow, not burning, scfh Air flow, stoich., scfh Air Orifice ΔP, (UA-DA), w.c Gas Orifice ΔP, (UG-DG), w.c., stoich Tile Pressure, wc Max. % XSA, fs, ignition Max. % XSFuel, fs Flame Length, in Flame Diameter, in

19 3.5 Capacities Propane, Imperial Main Air Pressure, (UA pressure tap), "w.c Air Flow, not burning (scfh) 1700 Air Flow, (scfh) Air Orifice, UA-DA, ( w.c.) Gas Orifice, UG-DG ( w.c.) Tile Pressure, DG ( w.c.) Max. % XSAir, fs, ignition Max. % XSFuel, fs Max. % XSFuel, ignition Flame Length (in.) Flame Diameter (in.) Air Flow, not burning (scfh) 2700 Air Flow, (scfh) Air Orifice, UA-DA, ( w.c.) Gas Orifice, UG-DG ( w.c.) Tile Pressure, DG ( w.c.) Max. % XSAir, fs, ignition Max. % XSFuel, fs Max. % XSFuel, ignition Flame Length (in.) Flame Diameter (in.) Air Flow, not burning (scfh) 3850 Air Flow, (scfh) Air Orifice, UA-DA, ( w.c.) Gas Orifice, UG-DG ( w.c.) Tile Pressure, DG ( w.c.) Max. % XSAir, fs, ignition Max. % XSFuel, fs Max. % XSFuel, ignition Flame Length (in.) Flame Diameter (in.)

20 3.6 Capacities Propane, Imperial Main Air Pressure, (UA pressure tap), "w.c A Air Flow, not burning (scfh) Air Flow, (scfh) Air Orifice, UA-DA, ( w.c.) Gas Orifice, UG-DG ( w.c.) Tile Pressure, DG ( w.c.) Max. % XSAir, fs, ignition Max. % XSFuel, fs Max. % XSFuel, ignition Flame Length (in.) Flame Diameter (in.) B Air Flow, not burning (scfh) 8600 Air Flow, (scfh) Air Orifice, UA-DA, ( w.c.) Gas Orifice, UG-DG ( w.c.) Tile Pressure, DG ( w.c.) Max. % XSAir, fs, ignition Max. % XSFuel, fs Max. % XSFuel, ignition Flame Length (in.) Flame Diameter (in.) Natural Gas, Metric Main Air Pressure, (UA pressure tap), kpa Capacity, Nm3/h main air (not burning) 43 Capacity, Nm3/h burner (burning stoich) Air Orifice ΔP, (UA-DA) mbar Gas Orifice ΔP, (UG-DG) mbar Tile Pressure, (DG) mbar Max. % XSAir, fs, ignition Max. % XSFuel, fs Max. % XSFuel, ignition Flame Length, mm Flame Diameter, mm

21 3.7 Capacities Natural Gas, Metric Main Air Pressure, (UA pressure tap), kpa Capacity, Nm3/h main air (not burning) 72 Capacity, Nm3/h burner (burning stoich) Air Orifice ΔP, (UA-DA) mbar Gas Orifice ΔP, (UG-DG) mbar Tile Pressure, (DG) mbar Max. % XSAir, fs, ignition Max. % XSFuel, fs Max. % XSFuel, ignition Flame Length, mm Flame Diameter, mm Capacity, Nm3/h main air (not burning) 107 Capacity, Nm3/h burner (burning stoich) Air Orifice ΔP, (UA-DA) mbar Gas Orifice ΔP, (UG-DG) mbar Tile Pressure, (DG) mbar Max. % XSAir, fs, ignition Max. % XSFuel, fs Max. % XSFuel, ignition Flame Length, mm Flame Diameter, mm A Capacity, Nm3/h main air (not burning) 163 Capacity, Nm3/h burner (burning stoich) Air Orifice ΔP, (UA-DA) mbar Gas Orifice ΔP, (UG-DG) mbar Tile Pressure, (DG) mbar Max. % XSAir, fs, ignition Max. % XSFuel, fs Max. % XSFuel, ignition Flame Length, mm Flame Diameter, mm

22 3.8 Capacities Natural Gas, Metric Main Air Pressure, (UA pressure tap), kpa B Capacity, Nm3/h main air (not burning) 219 Capacity, Nm3/h burner (burning stoich) Air Orifice ΔP, (UA-DA) mbar Gas Orifice ΔP, (UG-DG) mbar Tile Pressure, (DG) mbar Max. % XSAir, fs, ignition Max. % XSFuel, fs Max. % XSFuel, ignition Flame Length, mm Flame Diameter, mm Capacity, Nm3/h main air (not burning) 294 Capacity, Nm3/h burner (burning stoich) Air Orifice ΔP, (UA-DA) mbar Gas Orifice ΔP, (UG-DG) mbar Tile Pressure, (DG) mbar Max. % XSAir, fs, ignition Max. % XSFuel, fs Max. % XSFuel, ignition Flame Length, mm Flame Diameter, mm Capacity, Nm3/h main air (not burning) 529 Capacity, Nm3/h burner (burning stoich) Air Orifice ΔP, (UA-DA) mbar Gas Orifice ΔP, (UG-DG) mbar Tile Pressure, (DG) mbar Max. % XSAir, fs, ignition Max. % XSFuel, fs Max. % XSFuel, ignition Flame Length, mm Flame Diameter, mm

23 3.9 Capacities Natural Gas, Metric Main Air Pressure, (UA pressure tap), kpa Capacity, Nm3/h main air (not burning) 676 Capacity, Nm3/h burner (burning stoich) Air Orifice ΔP, (UA-DA) mbar Gas Orifice ΔP, (UG-DG) mbar Tile Pressure, (DG) mbar Max. % XSAir, fs, ignition Max. % XSFuel, fs Max. % XSFuel, ignition Flame Length, mm Flame Diameter, mm A Air flow, not burning, Nm3/h 962 Air flow, stoich., Nm3/h Air Orifice ΔP, (UA-DA), mbar Gas Orifice ΔP, (UG-DG), mbar Tile Pressure, mbar Max. % XSA, fs, ignition Max. % XSFuel, fs Flame Length, mm Flame Diameter, mm B Air flow, not burning, Nm3/h 1337 Air flow, stoich., Nm3/h Air Orifice ΔP, (UA-DA), mbar Gas Orifice ΔP, (UG-DG), mbar Tile Pressure, mbar Max. % XSA, fs, ignition Max. % XSFuel, fs Flame Length, mm Flame Diameter, mm

24 3.10 Capacities Natural Gas, Metric Main Air Pressure, (UA pressure tap), kpa C * Air flow, not burning, Nm3/h 1684 Air flow, stoich., Nm3/h Air Orifice ΔP, (UA-DA), mbar Gas Orifice ΔP, (UG-DG), mbar Tile Pressure, mbar Max. % XSA, fs, ignition Max. % XSFuel, fs Flame Length, mm Flame Diameter, mm Propane, Metric Main Air Pressure, (UA pressure tap), kpa Capacity, Nm3/h main air (not burning) 45 Capacity, Nm3/h burner (burning stoich) Air Orifice ΔP, (UA-DA) mbar Gas Orifice ΔP, (UG-DG) mbar Tile Pressure, (DG) mbar Max. % XSAir, fs, ignition Max. % XSFuel, fs Max. % XSFuel, ignition Flame Length, mm Flame Diameter, mm Capacity, Nm3/h main air (not burning) 72 Capacity, Nm3/h burner (burning stoich) Air Orifice ΔP, (UA-DA) mbar Gas Orifice ΔP, (UG-DG) mbar Tile Pressure, (DG) mbar Max. % XSAir, fs, ignition Max. % XSFuel, fs Max. % XSFuel, ignition Flame Length, mm Flame Diameter, mm

25 3.11 Capacities Propane, Metric Main Air Pressure, (UA pressure tap), kpa Capacity, Nm3/h main air (not burning) 72 Capacity, Nm3/h burner (burning stoich) Air Orifice ΔP, (UA-DA) mbar Gas Orifice ΔP, (UG-DG) mbar Tile Pressure, (DG) mbar Max. % XSAir, fs, ignition Max. % XSFuel, fs Max. % XSFuel, ignition Flame Length, mm Flame Diameter, mm Capacity, Nm3/h main air (not burning) 103 Capacity, Nm3/h burner (burning stoich) Air Orifice ΔP, (UA-DA) mbar Gas Orifice ΔP, (UG-DG) mbar Tile Pressure, (DG) mbar Max. % XSAir, fs, ignition Max. % XSFuel, fs Max. % XSFuel, ignition Flame Length, mm Flame Diameter, mm A Capacity, Nm3/h main air (not burning) 166 Capacity, Nm3/h burner (burning stoich) Air Orifice ΔP, (UA-DA) mbar Gas Orifice ΔP, (UG-DG) mbar Tile Pressure, (DG) mbar Max. % XSAir, fs, ignition Max. % XSFuel, fs Max. % XSFuel, ignition Flame Length, mm Flame Diameter, mm

26 3.12 Capacities Propane, Metric Main Air Pressure, (UA pressure tap), kpa B Capacity, Nm3/h main air (not burning) 230 Capacity, Nm3/h burner (burning stoich) Air Orifice ΔP, (UA-DA) mbar Gas Orifice ΔP, (UG-DG) mbar Tile Pressure, (DG) mbar Max. % XSAir, fs, ignition Max. % XSFuel, fs Max. % XSFuel, ignition Flame Length, mm Flame Diameter, mm

27 3.13 Dimensions and Weight DIMENSIONS, inches through -6 ¾" NPT for flame supervision "R" TILE - Flanged Mounting optional ¼" ("J" tile only) "J" TILE Includes metal jacket through -6 (-7 pipe dimensions below) "A" TILE Flanged Mounting only 5 8" dia. slot E G IGN FS UG UA OBS DG DA mounting ears ("R" tile only) D D 1 sq. K H max. OD Fives North American F Cleveland, OH USA B NPT Gas Inlet A NPT Air Inlet 5 8" 9 C 5 8" 9" (Parts for -7 only) B NPT Gas Inlet ¾" NPT for flame supervision CI "R" TILE - Flanged Mtg. optional Mtg. Ears ("R" tile only) Gas Inlet Elbow R " 153 8" "J" Tile Includes metal jacket G FS OBS Air Orifice Plate " dia. slot E sq. F IGN UG Fives North American DG Cleveland, OH USA A NPT Air Inlet A NPT Air Inlet UA Air Flange (2) Air Inlet R Flange Gasket (2) DA** C 9" K D sq. D 1 sq. Imperial Burner designation DIMENSIONS IN INCHES A B C D D1 E F G Round Tile K Slotted Tile A Tile (max. OD) H Weight, lb R J A ¼ ¾ ½ ¾ 4 ½ ¼ ¾ ½ ¾ 4 ½ ½ ½ ¾ ½ ¾ 4 ½ A ½ ¾ 4 ½ 1 ¾ B ½ ¾ 4 ½ ½ 1 ¼ ½ 12 ½ ¾ ½ ¼ ½ 12 ½ ¾ ½ ½ 12 ½ ¾ ½ 7 ½

28 3.14 Dimensions and Weight DIMENSIONS, metric through -6 ¾" NPT for flame supervision "R" TILE - Flanged Mounting optional 6 ("J" tile only) "J" TILE Includes metal jacket through -6 (-7 pipe dimensions below) "A" TILE Flanged Mounting only 16 dia. slot E G IGN FS UG UA OBS DG DA mounting ears ("R" tile only) D D 1 sq. K H max. OD Fives North American F Cleveland, OH USA B BSPT Gas Inlet A BSPT Air Inlet 16 C (Parts for -7) B BSPT Gas Inlet ¾" NPT for flame supervision CI "R" TILE - Flanged Mtg. optional Mtg. Ears ("R" tile only) Gas Inlet Elbow R "J" Tile Includes metal jacket G FS OBS Air Orifice Plate " dia. slot E sq. F IGN UG Fives North American DG Cleveland, OH USA A BSPT Air Inlet A BSPT Air Inlet UA Air Flange (2) Air Inlet R Flange Gasket (2) DA** C 299 K D sq. D 1 sq. Burner designation DIMENSIONS IN MM A B C D D1 E F G Round Tile K Slotted Tile A Tile (max. OD) H Weight, KG R J A A B

29 3.15 Dimensions and Weight DIMENSIONS, inches (metric) 6 NPT (BSPT) Main Air. conn. ¼ NPT pressure tap connection (310) (538) (195) 97 8 (251) 18 (457) OD Flange 2 ½ NPT (BSPT) Gas conn. 14 (356) OD ¾ NPT Observation Port 16 (406) BC 12 x 3 8 (9.5) ¼ NPT Flame Safety Connection 4 (102) ½ (13) 9 (229) A/E, B/E, C/E with Igniter only "A" dimension A 3¾" (95) B 4¼" (108) C 47 8" (124) 1 5 /8 1 /4 NPT Gas pressure taps CL Burner 3 1 /2 (89) 3 /8 NPT Pilot premix connection Pilot Assembly A/G B/G, C/G with Pilot assembly DIMENSIONS SHOWN ARE SUBJECT TO CHANGE. PLEASE OBTAIN CERTIFIED PRINTS FROM FIVES NORTH AMERICAN COMBUSTION, INC. IF SPACE LIMITATIONS OR OTHER CONSIDERATIONS MAKE EXACT DIMENSION(S) CRITICAL.

30 3.16 Configuration Option TILE and MOUNTING OPTIONS Tile materials and shapes to suit your specific needs. Tile Materials/Mountings A Tile Alumina/Mullite tile for fiber wall and most applications up to 3000 F (1649 C). Available with flanged mounting only. R Tile Traditional square refractory block for applications to 3000 F (1649 C). Note: Recommended only for installation in solid wall construction furnaces/kilns. Available with either flanged or eared mounting. Exit Shapes R Round for high penetration and maximum drive. S Slotted for narrow lane firing and better temperature uniformity (available with A tile only). Installation For tile installation, see Section 5 for more information. J Tile Traditional square refractory block with metal jacket for applications to 1800 F (982 C). Note: Recommended for installation of a square refractory block tile in soft wall. Aardvark Alloy Tile The Aardvark s threaded snout can be screwed directly into a fitting. Good for applications up to 2000 F (1093 C). Consult North American for Aardvark tile option. ORDERING INFORMATION ( thru -7 size only) H Air/Gas connections Blank = NPT M = BSPT Air pipe size -1 = 1¼" -2 = 1¼" -3 = 1½" -4-A = 2" -4-B = 2" -5 = 2½" -6 = 3" -7 = 4" -8-A = 6" -8-B = 6" -8-C = 6" 4441 Capacities scfh (Nm 3 /h) 27.7" w.c. (6.9 kpa) air 1250 (33) 2200 (59) 3300 (88) 5250 (140) 6900 (184) 9500 (254) (401) (588) See 3.17 Tile Exit Shape Fuel Blank = Natural Gas fuel only P = Propane fuel only (-1 thru -4-B only) Mountings E = Eared (with "R" tile only) F = Flanged (optional with "R" tile and standard with all others) Tile Exit Size H = High Velocity Tile (standard) Tile Material R = Square block refractory A = Alumina/Mullite J = Square block refractory with 309 SST tile jacket R = Round S = Slotted Slot orientation - horizontal with respect to burner air connection at 4:30, unless otherwise specified on order. Slot orientation is field adjustable, by loosening body mounting bolts and rotating exit accordingly. Examples: AASH/F = -4-A Capacity 4441 Burner with an Alumina/Mullite slotted high velocity tile, with flanged mounting RRH/E = -2 Capacity 4441 Burner with a square refractory high velocity tile, with eared mounting. M ARH/F = -7 Capacity 4441 Burner with an Alumina/Mullite round high velocity tile, with flanged mounting, BPST air/gas connections.

31 3.17 Configuration Option ORDERING INFORMATION ( sizes only) Air/Gas connections Blank = NPT M = BSPT / A million Btu/h HHV (937 kw LHV) B million Btu/h HHV (1230 kw LHV) C million Btu/h HHV (1611 kw LHV) E - with spark igniter G - with pilot assembly

32 Section Four System Design 04

33 4.1 Burner Selection RECOMMENDED PIPING for 4441 and 4442 TEMPEST GAS BURNERS Imperial Gas/Air Ratio Regulator (shown w/ bypass, required within 4' of burner) Limiting Orifice Valve required within 1' of burner H Table 1. Recommended component selection for 4441/4442 Tempest burners with StepFire TM Control. Air Side Fuel Side Burner Size A B C D E F G H I -1 1¼" 1¼" 1¼" 1¼" ¾" ¾" ¾" ¾" ¾" -2 1¼" 1¼" 1¼" 1¼" ¾" ¾" ¾" ¾" ¾" -3 1½" 1½" 1½" 1½" ¾" ¾" ¾" ¾" ¾" -4-A 2" 2" 2" 2" 1" 1" 1" 1" 1" -4-B 2" 2" 2" 2" 1" 1" 1" 1" 1" -5 2½" 2½" 2½" 2½" 1¼" 1¼" 1¼" 1¼" 1¼" -6 3" 3" 3" 3" 1½" 1½" 1½" 1½" 1½" -7 4" 4" 4" 4" 2" 2" 2" 2" 2" Legend for Table 1 AIR A 8697/8695 Metering Orifice (optional) B 1122 Manual Air Valve C 1196 StepFire Air Valve D 8770/8773 Flexible Connection or 2947 Blower Sleeve FUEL E 8697 Metering Orifice F BP Regulator (with bypass) G Threaded Pipe Union H 1807 Limiting Orifice Valve J 8773 Flexible Pipe

34 4.2 Burner Selection INSTRUCTIONS 1. System has been sized for standard conditions. For any unusual conditions including elevation, high ambients, preheated air, etc., the individual components must be selected based on the maximum actual flow rates that will be encountered during operation. 2. System has been sized based on 27.7"w.c. (6.9 kpa) air pressure at the burner at high fire and 1"wc air pressure at the burner at low fire. To ensure tight shutoff of the BP regulator at low fire, allow for a 2" bias on the regulator spring. Thus the maximum gas pressure available from the 7216 regulator at high fire is 25.7"wc (with 27.7"w.c. impulse). 3. To increase the air impulse available to the 7216 (if necessary), a metering orifice or other fixed resistance component can be installed downstream between the 1196 and the air impulse line to the regulator. 4. For the components selected in Table 1, and under the conditions specified above, the , -2, -3, -5, and -6 will operate with up to 30% XSF. For the A and -4-B, 1"w.c. of additional air impulse pressure is required to reach 30% XSF capability. In order to achieve higher XSF on any size, additional air pressure is required to impulse the 7216 regulator.

35 Section Five Installation 05

36 5.1 Handling and Storage Site Equipment Installation Checklist Use this guide to establish the site readiness. To save time and undue expense, ensure that all of the items have been successfully completed prior to scheduling a start-up technician. Burner Burner Mounting Burner Tile Installed Burner Tile Dried Ignition Transformers Installed Ignition Transformers Wired Ignition Cables Installed Flame Rod or UV Detector Installed Flame Rod or UV Detector Wired Fuel Train Loose Flow Components Installed with Proper Direction and Orientation Fuel Supply Lines Installed Fuel Supply Line Cleaned Fuel Supply Line Pressure Tested Fuel Train Frame anchored to floor or support structure Fuel Train Mounted/Piped Equipment Leak Tested Burner Fuel Feed Piping Installed Burner Fuel Feed Piping Cleaned Burner Fuel Feed Piping Pressure Tested All Vent Piping Installed All Vent Piping Leak Tested All Impulse Lines Installed All Impulse Lines Leak Tested All Supervisory Components Wired All Component Wiring has been rung out All Flow and Pressure Transmitters have been calibrated Limiting Orifice Gas Valve Installed within 1" of Burner Gas Connection Air System Blower is Mounted and Secured to Foundation per Recommendations Loose Flow Components Installed with Proper Direction and Orientation Burner Air Feed Piping Installed Burner Air Feed Piping Cleaned Burner Air Feed Piping Pressure Tested All Impulse Lines Installed All Impulse Lines Leak Tested Flow Control Valve Wiring has been rung out All Flow and Pressure Transmitters have been calibrated

37 5.2 Handling and Storage Combustion Control and Flame Supervision System Control Panel Installed All Field Wiring Installed All Field Wiring Tested All Field Components Tested Control Panel Power Fuses Tested All Motor Directions Checked Other Process equipment is ready for start-up Power Fuses Tested

38 5.3 Furnace Wall Prep TEMPEST GAS BURNER TILE INSTALLATION INSTRUCTIONS inches (mm) Ceramic Tile in Fiber Wall Installation Instructions (see Figure 1) 1. Cut circle opening in furnace shell. Allow ¼ " clearance all the way around tile.the hole size in the shell for through -4-B is 5½ " (140) and for through -7 is 8" (203). 2. Cut a straight hole in fiber wall for the burner tile. The hole should be approximately ½ (13) smaller than the tile OD to allow the fiber to be tight up against the tile. 3. Wrap the tile in cling wrap and then insert tile into the fiber wall. The cling wrap will assist in pushing the tile into a smaller fiber hole. 4. Bolt burner to furnace shell. We recommend using a flanged burner with a gasket at this joint for applications with pressurized chambers. A burner mounting gasket is available from North American. 5. Periodically check for fiber shrinkage in vicinity of the burner tile. Repack any voids with bulk fiber insulation to maintain a thermal seal between the furnace interior and the shell. Ceramic Tile in Monolithic/Brick Wall Installation Instructions (see Figure 2) 1. Cut circle opening in furnace shell. Allow ¼ " clearance all the way around tile.the hole size in the shell for through -4-B is 5½ " (140) and for through -7 is 8" (203). 2. Make hole in furnace wall to insert the tile. We recommend a minimum gap of 1½ " (38) between the tile and the brick/monolithic wall. Fill this gap with compressed ceramic fiber. The hole in the wall can be either square or round. If pushing the tile through the fiber, wrap the tile in cling wrap to assist the tile through the fiber. 3. Bolt burner to furnace shell. We recommend using a flanged burner with a gasket at this joint for applications with pressurized chambers. A burner mounting gasket is available from North American. 4. Pack fiber tightly around the tile. Fill all voids to provide a tight thermal seal from the furnace interior to the shell. 5. Periodically check for fiber shrinkage in vicinity of the burner tile. Repack any voids with bulk fiber insulation to maintain a thermal seal between the furnace interior and the shell. Ceramic Fiber Monolithic/Brick Material Ceramic Fiber Figure 1: Cross section through a fiber-lined furnace wall with a ceramic tile. Figure 2: Cross section through a hard wall with a ceramic tile.

39 5.4 Furnace Wall Prep Square Block Refractory in Fiber Wall Installation Instructions (see Figure 3) Please consider using a ceramic tile for a fiber wall (See Figure 1) 1. Cut square opening in furnace shell. Allow ¼ (6) clearance all the way around the tile and jacket. 2. Cut a hole for the burner tile and jacket in fiber wall. The hole should be approximately ½ (13) smaller than the jacket to allow the fiber to be tight up against the jacket. 3. Insert tile with metal jacket into the fiber wall. We suggest a metal jacket around the tile to support the refractory. Do not use a metal jacket for application higher than 1800 F (982 C). For temperatures above 1800 F (982 C), please see Figure 4 for the recommended tile installation. 4. Bolt burner to furnace shell. We recommend using a flanged burner with a gasket at this joint for applications with pressurized chambers. A burner mounting gasket is available from North American. Square Block Refractory Tile in Brick or Monolithic Wall Installation Instructions (see Figure 4) 1. Cut square opening in furnace shell. Allow ¼ (6) clearance all the way around the tile. The hole size in the shell for through -4-B is 8" (203) square hole and for through -7 is 10½ " (267) square hole. 2. Make a hole in the wall. We recommend a minimum gap of 9" (229) between the tile and the monolithich/brick wall for the castable/rammed material. 3. Bolt burner to furnace shell. We recommend using a flanged burner with a gasket at this joint for applications with pressurized chambers. A burner mounting gasket is available from North American. 4. Use a castable or rammed material to support and secure tile. Provide a shelf support angle to support castable or rammed material. 5. Use densely packed ceramic fiber around castable or rammed material to act as an expansion joint. 6. Waterproofing may be required to prevent surrounding refractory from absorbing water from castable refractory. Using a plastic sheet to waterproof is recommended. Ceramic Fiber See Supplement DF-M1 for a more detailed explanation of this installation. Monolithic/Brick Material Ceramic Fiber Castable/Rammed Material Figure 3: Cross section through a fiber wall with square block refractory tile. Includes metal jacket for tile support. Figure 4: Cross section through a hard wall with square block refractory tile. WARNING: Situations dangerous to personnel and property may exist with the operation and maintenance of any combustion equipment. The presence of fuels, oxidants, hot and cold combustion products, hot surfaces, electrical power in control and ignition circuits, etc., is inherent with any combustion application. Parts of this product may exceed 160F in operation and present a contact hazard. Fives North American Combustion, Inc. urges compliance with National Safety Standards and Insurance Underwriters recommendations, and care in operation.