Specifications RECEIVED
SEP 0 2 2011
- ` 31'igar d High School Outdoor Natural Gas K iln 0►�-�
CITY OF TIGARD
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(Similar finished kiln)
Approved 4:N [ 14---" Conditionally Appro ved ( j
See Le tter to: Fo llow [ ]
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a, OFFI COPY Permit Nu , , er . - � ;
Summary: The kiln is for educational enrichment of our students at Tigard High Schoo A e c r� `'i s-, • _ _ wr .
kilns, which cannot keep up with the current program demand serving over 500 students per year. o iciency, economic,
and safety reasons we need to permit the use of this natural gas kiln. The kiln is outdoors and covered with a prefabricated
certified steel canopy, which has a separate permit.
Safety advantage This kiln will fire 5 times our current volume allowing us to fire less often which will be
advantageous for the supervision of firings. This kiln is also 3x thicker than our current commercial kilns, which will
dramatically reduce heat loss thus lowering outside surface tem significantly. This will also be situated outside where
ventilation and clearance hazards associated with firing inside are avoided. The use of natural gas will also allow for safer
loading and un Overall this will be a significant step towards providing a safer learning environment for our students.
The kiln will also be locked within a gated fence to keep students away during and 18 hours after firing. This will be the 3 kiln
I have build and the 5th I have operated with experience of over 2,000 successful firings in t he 14 years I have practiced
ceramics.
Com mun i ty Support: . Students, their families, and the Tigard community have helped raise over $2500 by making
and selling 300 bowls in a recent "Empty Bowls" event. Our next step in serving the community is to begin the permit process.
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Tigard High School Outdoor Natural Gas Kiln
The Kiln: We are proposing the construction and use of a 48cu ft natural gas car kiln with 30cu ft of usable space. The
rationale for a kiln with this volume is both economic and related to our need based on our output. This very common and
popular kiln design comes from Nils Lou, a professor in ceramics and author of "The Art of Firing ". The kiln is compromised
mostly of IFB (Insulating fire brick) with a steel structural exoskeleton. This kiln will utilize two power burners with a
maximum BTU output of 300,000 ea. to reach a temperature of 2300 degrees Fahrenheit within n 8 -12 hours. Both burners
are equipped with BASO valve and electrical safety equipment for automatic shutoff in case of loss of power or loss of flame.
This kiln exists in many states and countries around the world because of its success. There are similar kilns locally at
Linfield College, McMinnville High School, David Douglas High, Western Oregon University, George Fox University, Mt. Hood
Community College, Portland State, and PCC. I can put you in contact with facilities directors at any of these locations if you
have any questions.
We want to work alongside the city in the permit process to enrich our community. If you have any further questions
for myself, manufacturers, or other qualified parties that I can put you in contact with; please don't hesitate to email or call my
cell phone at 503.434.0295.
Thank You,
Greg Johnson
Ceramics Art Teacher
Tigard - Tualatin School District
gjohnson @ttsd.k12..or.us
Materials: (see pages 8 -13 for specifications)
The kiln walls will be erected from insulated firebrick rated with an operation rating of 2300F. The IFB23 mineralogy is
(Ca0 • Al203 • 2 Si02). This gives IFB23 excellent strength at operating temperatures and resistance to corrosive alkali
environments. Walls will be double layered, staggered with an insulating width of 9 ", much thicker than the standard 5" used
in our existing commercial kilns.
The roof of this kiln will be constructed using 6" of the kaolin fiber with the trade name Superwool. Superwool is
manufactured from pure raw materials and processed to offer excellent performance in high- temperature applications.
Superwool offers an alternative to traditional solutions due to its high refractoriness and excellent non - wetting characteristics
with molten aluminum. Superwool is unaffected by incidental spills of oil or water. Thermal and physical properties are
restored after drying. Superwool has a temperature rating of 2370.
The floor will be compromised of 2 layers of high - density sr90 firebrick rated at 3000 °F (1649 °C) and one layer of
IFB23. These premium bricks are very dense and have excellent load bearing strength at temperatures above 3000 °F (1649 °C)
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Tigard High School Outdoor Natural Gas Kiln
and they provide excellent thermal shock resistance. The floor of the kiln will rest on one layer of cement blocking over a level
4" concrete slab.
The kiln chimney will stand approximately 11' high exiting through shed roof with 3 guy wiring for additional support
if needed. The 10" diameter chimney is lined with high heat rated refractory riser sleeves to reduce surface temp and will be
mortared in place with firebrick supports.
Burners: (see pg 14 for schematics and licensing)
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Power Burners are forced air burners that have several advantages over Venturi burners. Since air and gas
are independently controlled, then mixed, these burners are very efficient. The high volume, long flame
length helps produce quicker, more efficient firings. Power burners, with their forced air, do not depend
upon the chimney to provide draft. Chimneys need only be tall enough to remove the flue gases from the kiln
shed or building. Working on low pressure, Power Burners can be used with either propane or natural gas.
These burners are designed to deliver high output on low pressures (14 "WC or less). The Btu figures at right
are based on natural gas delivery @ 7 "WC with .65 specific gravity and propane delivery @ 11 "WC with
1.522 specific gravity. Orifices can be adjusted to deal with a wide range of low pressures.
3
Tigard High School Outdoor Natural Gas Kiln
A brass gas cock (1), provides 100% shutoff. Air is controlled by the variable speed control (2) and the
manual air shutter (4) and provided by the continuous duty blower (5). A sediment trap (3) prevents
sediment from passing through the gas train. The BASOT'' valve (12) is connected to the pilot burner (6)
which can be adjusted by the CSA /UL approved gas cock (10). The pilot energizes the thermocouple (7) and
ignites the main flame which is held constant by the flame retention nozzle (8). An CSA /UL approved ball
valve provides smooth gas flow adjustment (9). An optional electric solenoid valve (11) provides instant
shutoff in the event of power failure. Electrical connection is by a grounded 6' cord (13).
Additional Burner Equipment:
Electric Solenoid Valve. This valve provides instant shutoff in the event of power failure. Flame may lick up
the outside of the kiln or go back into the blower during a power outage if this valve is not present. Mounted
downstream of BASO; shuts down main burner but leaves pilot burning for automatic re- ignition upon re-
establishment of electricity. Mounted upstream of BASO; shuts down both main and pilot burners with loss
of current, calling for manual re- lighting.
Water Column Gauge. This gauge helps produce repeatable firings by providing a reference point based on
differential pressure or pressure drop depending on valve location in relation to flow control valve.
Ransome Piggyback Venturi Burner. This Venturi pilot burner is excellent for overnight warming and
windy areas. Power Burners may not be able to provide the very low settings needed for the start of bisque
firings. This optional pilot can provide several thousand Btu's of heat to completely dry out the load. Comes
with attaching clamp, large oval head, baffle plate, gas cock, supply line, and thermocouple fitting. 2,000 to
4,000 Btu output.
Adjustable Burner Stand. This burner stand securely holds the burner parallel to the floor and can be
rotated 360° or adjusted vertically. Two height ranges measured from the center of the main burner nozzle.
*Construction overview, materials specs, burner licenses, and detailed plans attached.
4
Tigard High School Outdoor Natural Gas Kiln
Plumbing:
After a consultation with a technician from NW Natural we were advised to use 1 black pipe plumbing
strapped to the kiln shed wall 1' from foundation. This meets 600,000 BTU requirements according to their
standards. Burners will be undercover from overhead structure. Here is a simple layout of plumbing to be
installed for this kiln:
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Tigard High School Outdoor Natural Gas Kiln
*Please note additional safety equipment installed in each burner configuration.
Site Plan:
This project is taking place outside in the large courtyard where there are no trees or combustible surfaces
nearby. The only current structure within a 10' range is our current kiln shed with a non - combustible wall surface.
The kiln itself will have clearance of 5' from this structure. This clearance of 5' will be on the northeast side, which
is on the right on the site plan diagram. This kiln will be situated facing South - Southwest on a 4" concrete slab.
Clearance from exit flu to the nearest window is over 10 feet, far surpassing the 4ft requirement.
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,` Features
"��� � �. _ - '1--
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F. 90 and 99 /o alumina firebrick
�; i " " Excellent low Si02 contents for use in Hydrogen
'`= a :' S . ; i ' : =` < i ,: . t atmospheres
<-- :,;. =3° " . x Excellent high temperature stability
Extremely recove high service units temperature
' . r i.,�,-- _w < ;3;a Applications Sulphur
sa.- ;; , v;
e ,.a
: y" : ; , %,, 3. =: ry
y p , „ , Incinerators
V : 0: • ° ', = b Secondary ammonia reformers
<' Description
°. The SR -90, SR -99, and SR -99 firebricks are premium high alu-
mina firebricks that are capable of handling very difficult appli-
y cations. These premium bricks are very dense and have
' excellent load beanng strength at temperatures above 3000°
g F
;, - ,; (1649 °C) and they provide excellent thermal shock resistance
< ” '; The extremely low silica content of both products make them
I ideal for hydrogen atmospheres.
8
Tigard High School Outdoor Natural Gas Kiln
y Q Sa z ` Daata8 "1 Cade
v f ui 114-1 r -`
1r . i - "M. 178' 151.8
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h. •iii 'rvis = ',� +•�� � .. ;1"�R • �; : � zn p i a:; �i/ ,
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z Physical Properties . SR -90 SR -99 SR -99 LS
e �
-;' Melting point, °F ( °C) 3480 (1915) 3660 (2016) 3660 (2016)
Density, ASTM C 134, pcf (kg /m 183 (2933) 193 (3093) 193 (3093)
1, lb/9" straight 10.6 (0.07) 11.3 (0.08) -
, ° - Modulus of rupture, psi (MPa), ASTM C 133
@ room temperature 3600 (24.83) 3800 (26.21) 4200 (28.97)
,`e A= @ 2000 °F (1093 °C) 4500 (31.03) 2900 (20.00) -
' 4 @ 2300 °F (1260 °C) 4200 (28.97) 1600 (11.03) 2000 (13.79)
@ 2600 °F (1427 °C) 2900 (20.00) 800 (5.52) 800 (5.52)
",!a ;,
.; @ 2800 °F (1538 °C) 2100 (14.48) 650 (4.48) -
Cold crushing strength, psi (Mpa), ASTM C 133 9000 (62.05) 8000 (55.16) 9000 (62.05)
0 Permanent linear shrinkage, %, after 24 hours, ASTM C 210
y _ = 5 hours @ 3200 °F (1760 °C) 1.5 - -
24 hours @ 3200 °F (1760 °C) - 0.3 -
`=g 72 hours @ 3200 °F (1760 °C) - - -0.6
-" ,u = Deformation under hot load, % @ 25 psi (0.17 Mpa), ASTM C 16
"u"'" 1/z hours @ 2800 °F (1538 °C) - -0.3 -
° °-° 1X hours @ 3000 °F (1649 °C) 0.1 - -
° %; 1'4 hours @ 3000 °F (1649 °C) 0.1 - -
;' �, 150 hours @ 3200 ° F (1760 °C) <0.25 - -
',,z
! Permeability, ft /hr•ft /psi 35 30 -
Abrasion loss, cm ASTM C 704 7.3 13.5 -
',., Porosit % ASTM C 20 18 17 20
Chemical Analysis,
4 . ` •- °' Alumina, Al203 88 99.4 99.5
`' Silica, Si02 12 0.4 0.1
Ferric oxide, Fe203 0.2 0.1 trace
Titanium oxide, 1102 trace trace trace
Calcium oxide, CaO 0.1 trace 0.2
Magnesium oxide, MgO trace trace trace
Alkalies, as Na20 and K20 0 1 0.1 0 2
Thermal Conductivity, BTU•in. /hr•ft'• °F (w /m•k), ASTM C 182
Mean temperature
@ 500 °F (260 °C) 24.6 (3.55) 38.9 (5 61) 38.9 (5.61)
@ 1000 °F (538 °C) 21.5 (3.10) 30.7 (4.42) 30.7 (4.42)
)_' :' @ 1500 °F (815 °C) 19.4 (2.80) 25.5 (3.68) 25.5 (3.68)
@ 2000 °F (1093 °C) 17.7 (2.55) 21.6 (3.11) 21.6 (3.11)
@ 2500 °F (1371 °C) 16 5 (2.38) 19.1 (2.75) 19.1 (2.75)
Standard Sizes"
9" x 4 x 2W' (22.5 cm x 11.25 cm x 6.25 cm) The values gven herein are typical average values obtained in accordance
9" x 4%" x 3" (22.5 cm x 11.25 cm x 7.5 cm) wAh accepted test methods and are subje to normal manufactunng vana-
bons The ar s as t service antl are s t c 9
Special sizes available upon request wdheut notice Therefore, the data contained herein should not be used far
specification purposes. check with your Thermal ceram,cs office to obtain
current information
Tigard High School Outdoor Natural Gas Kiln
y Datasheet °l
'ThennalY u,
r . :
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a� �;` t .Page j
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Features
( ;;: • Extremely low thermal conductivity
• Low densities
`• -; 1 '` 5 • Low heat storage
,''a • Good strength at room and high temperatures
, ' ' • Excellent resistance to alkali attack
9��j a �• ° y;..-:; Applications
• Backup insulation for carbon baking furnaces
:z, - ;. •' • Backup insulation in aluminum electrolytic cells
� *;y = ° :�- � : � • Electrical kilns for industrial and hobby use
• Backup insulation for blast furnace stove linings
_ . � : yN • Linings for carbonizing furnaces
'qt • Forge furnace linings
Description • Heat transfer linings
Thermal Ceramics was first to introduce insulating firebrick
(IFB) to the industry in the 1930's. The K -IFB are
manufactured with a unique slurry casting process which
creates a network of microporosity that produces low thermal
3 a -.
conductivity and good thermal shock characteristics. This
° process produces brick that are some of the most efficient
insulators available in the market. The high temperature firing
and resultant anorthite mineralogy (CaO • Al203 • 2 Si02) of
kz these low temperature K -IFB gives them excellent strength at
operating temperatures and resistance to corrosive alkali
environments.
The IFB range include the following products:
K -23 is a 2300 °F (1260 °C) rated "flagship" IFB
• Low density
• High hot strengths
• Good thermal stability
• Ultra low thermal conductivity
TC -23 is a 2300 °F (1260 °C) rated economical IFB
• Properties close to K -23
• Slightly lower appearance standard
IFB 23 Tile is 2300 °F (1260 °C) rated tile brick
• Large shape format
K -25 is a 2500 °F (1371 °C) rated IFB
-,'- • Low shrinkage at use limit
• Excellent insulation stability
10
Tigard High School Outdoor Natural Gas Kiln
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Via; � %' k \ , ;' , ,,;., :,- za - ,,u s: C od e ,
, � ;, °& -. , y ,- US 159 1
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f r a " __ * � $ `� d / /G � � ,�; x ; � d g "� W { r s .:r� :4'�' - = : ; > -, "� " ._ : 09, 2010' -.:
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Physical Properties K -23 TC -23 IFB 23 Tile K -25
'', Recommended Hot Face use limit, °F ( °C) 2300 (1260) 2300 (1260) 2300 (1260) 2500 (1371)
Density, ASTM C 134
' lb /9" straight (kg) 1.93 (0.86) 1.9 (0.86) 2 2 (1.0) 2.3 (1.05)
f„) >)n pcf (kg /m 31 - 35 (497 -560) 30 - 36 (480 - 576) 37 (593) 38 - 41 (593 -641)
rt Melting temperature, °F 2750 (1510) 2750 (1510) 2750 (1510) 2800 (1538)
Modulus of rupture, ASTM C 133
psi (MPa) 115 (0.79) 105 (0.72) 105 (0.72) 135 (0.93)
477 Cold crushing strength, ASTM C 133
s psi (MPa) 145 (1.0) 125 (0.86) 125 (0.86) 200 (1.38)
;1 '' Permanent linear change. %, per ASTM C 210
T ` °, @ 2250 °F (1232 °C) 0 to -0.1 -0.2 0 to -0.1 -
@ 2450 °F (1343 °C) - - - -0.3
°;•)^ Deformation under hot load, % @ 10 psi, ASTM C 16
.' 1' /a hr @ 2000 °F (1093 °C) 0 0.1 0 0
<, 1'/2 hr @ 2200 °F (1204 °C) 0.3 - - 0.1
Coefficeint of thermal expansion
-' -- in/,n °Fx10a 3 3 - 3.1
0. M' ; "`
' Chemical Analysis, %
Alum Al203 38 38 38.5 46
" Silica. Si02 45 45 47.5 37.5
` Ferric oxide, Fe203 0.3 0 3 0.4 0.3
- "-h.< Titanium oxide, TiO2 1.6 1.6 1.6 1.4
ie` - Calcium oxide, CaO 15 15 11 14
r°''' Magnesium oxide, Mg0 0.1 0.1 0.2 0.1
Alkalies, as, Na20 and K20 0.5 0.5 0.3 0.4
Thermal Conductivity, BTU•in. /hr•ftz• °F (W /m•K), ASTM C 201
g ` ' Mean temperature
'`'• ',, @ 500 °F (260 °C) 0.92 (0.13) 0.95 (0.13) 1.0 (0.14) 1.06 (0.15)
<,:;,.; @ 1000 °F (538 °C) 1.14 (0.16) 1.2 (0.17) 1.3 (0.18) 1.22 (0.18)
@ 1500 °F (815 °C) 1.39 (0.20) 1.5 (0.22) 1.6 (0.23) 1.38 (0.20)
@ 2000 °F (1093 °C) 1.64 (0.24) 1.7 (0.24) 1.8 (0.25) 1.54 (0.22)
Standard Sizes*
9" x 4W' x 2W' (229mm x 114mm x 63mm)
9" x 4%" x 3" (229mm x 114mm x 76mm)
IFB 23 Tile
` 9" x 9" x 3" to 24W x 9" x 3" (229mm x 229mm x 76mm to 622mm x 229mm x 76mm)
' Special sizes available upon request, including arch, wedge and key shapes
The values given herein are typical average values obtained in accordance
with accepted test methods and are subject to normal manufacturing varia-
tions They are supplied as a technical service and are subject to change 11
without notice Therefore, the data contained herein should not be used for
specification purposes Check with your Thermal Ceramics office to obtain
current information
Kiln .
4 4.,*- ”' Idgi,
Tigard High School Outdoor Natural Gas i
tiatorthoAC105'; ,:••=r,:4„:
rm dintseeurchannodlob:yiler lining
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:, - ' „ '',' - ''''',0%,..................,..," '''''liAt''7';;'/;21;',';''''"''''' 2!,*,',-//,/,;‘,')//e4,/,,,,,s,,,,r=',..Z; 11',' ,°,4';',:l'',;f2,,t,',7,;‘,;(4)`-'4,,,,;,;:r.4,?f,sN.1 keit:',:;11,' .:::' i 8 + 4 '13:5 a,' ,, '64:1 . , °:tk'1),:■:'''',3,1Vt
:7; : : ,, ', ' ', .,:,,,,, *4. ' ' ' ' ' . , . ' ' II l ra III n IM.... Ke 4 '''/, ' " '40 g -: 4:; '0 ' .1 '1 . ‘ a ;, • ''' •V'kK, '', ' : : '''' ', ; ,; , , P . 1, ', ' ' '; / M)A 3 : ' ' !' P'
'7;44 4.:4 ' .....' Pr'fr . lung ;,„„„;„ , , , ':5'.:, "%.''/V ,/,%%,/,'''',.. %,,, I • ' = ' ; ` ,. .;' , ' 4 ;' ,-- r. - ;;;.e5.T;;;;*: ::: :,a; ' , %;;;;;;„1-;;;;;; --,- . -:, pag9,..1,94„,-",,, , - ,
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F eatures
• Low biopersistence
• Thermal stability
,..,,I, ,.•,, ,;,.:
• Low heat storage .
,--,•m.Y' -- i,-;,, , ,, - , ' , -,1S.,,,',
..• G IF z e o mk d iuhnl r ee es at i en st dt a hr n ee c rs e mik t ae o ins t t e h a ola r c i t n kin g g p
erformance
,,,,,,?,,;,,:,ii,:s„'‘,-4,;,,%',,,,,,i'lll'lllq:,,,,:?,l'lllll ' ,:; ,,,,,i," .• E thermal
n t t p h a e ten a te l
Applications
4 .-,c,,J, ., • Furnace kiln, reformer t,4,?, ft' ; ....,;r ,, :0 F
',,, ; A.! 4v poratory ovens
:i:litrl,i,,p;,.';'';,'ll,;,,,;-,',,; ,, .• F F o u rn rn a a o c e e door lining and seals
4,..„, ....„ ,. , ' ;r7S '
and • •
casting mold wrap
Investment cas
offer excellent performance .
,. .: ve to traditional Superwool is manufactured from pure irnawhigh-temperature materials
'ig,i processed to offe a
t en al s
excellent non-wetting • • A s n tr n e e s a s li_n r g el f i u e r v n in a g ce blankets l
''';:':1'' lugtigoni cations. Superwool offers an alternative s due to its high refractorine
l'l applications.
and excellent so-
i ni linings
characteristics with molten alum'
chemical stability and resistance to
phosphoric a
; attack. . high g temperature abl estea magnd g as turbine insulation
pa
E packing
Superwool provides s ting
i Exceptions include hydrofluoric acid,
Etxnnelp acid proper-
• Cryogenic insulation
incidental alkalies (i.e. NaOH, Na0H, KOH). spills of oil or water. The
unaffected by • Acoustical service
' ns and is ••
ties are restored after drying.
Superwool is ideally
l ' ll 'll '
available in a wide range
suited of to individual and ava densities. The
l ;;,!: maximum continuous local he
use temperature Trmace ta pe i nds re o p n re t s h e e n ap t p iv li-
cation. Refer to
••;',• for advise.
Type
Alkaline Earth : 329211-92-g
12 Wool
;,.. CAS number:
'Cr;,' !:■'
y .
' ■
12
Tigard High School Outdoor Natural Gas Kiln
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a ;' '' Physical Properties
Superwool 607 Superwool Plus Superwool HT
Color white white white
' ',' -'' ( Classification Temperature Rating, °F ( °C) 2012 (1100) 2192 (1200) 2372 (1300)
; Density, pcf (kg /m 4, 6, 8, 10 4, 6, 8, 10 4, 6, 8, 10
(64, 96, 128, 160) (64, 96, 128, 160) (64, 96, 128, 160)
° A ' ° Tensile strength, psi (kPa)
'r k 4 pcf (64 kg /m 4 (30)
6 pcf (96 kg/m 7 (50)
m
8 pcf (128 kg / 11 (75) 11 (75)
10 pcf (160 kg /m') 14 (95)
•' Typical linear shrinkage, % 24 hours
@ 1000 °F (538 °C) 2 - -
@ 1800 °F (982 °C) 3 <1 -
s' " ? @ 2282 °F (1250 °C) - - <2
Chemical Analysis,
4 Silica, Si02 60 - 70 62 - 68 70 - 80
a „x Calcium Oxide, CaO 25 - 35 26 - 32 18 - 25
_, Magnesium Oxide, MgO 4 - 7 3 - 7 -
Other trace <1 <3
°- ''''"A°
Thermal Conductivity, Btu•in/hr•ft °F (w /m•k) (ASTM 201), measured at 8 pcf (128 kg /m
Mean temperature
@ 500 °F (260 °C) 0.42 (0.06) 0.39 (0.06) 0.35 (0.04)
@ 1000 °F (538 °C) 0.88 (0.13) 0.73 (0.11) 0.83 (0.12)
a, @ 1500 °F (816 °C) 1.53 (0.22) 1.28 (0.18) 1.66 (0.24)
@ 1832 °F (1000 °C) 2.00 (0.29) 1.73 (0.25)
@ 2000 °F (1093 °C) 2.77(0.4)
@ 2192 °F (1200 °C) 3.33 (0.48)
";.' " Availability
Thickness, in. (cm) Width, in. (cm) Length, in. (cm) Cartons /Pallet
Y (0.635) 24, 48 (61,122) 240 (610)
(1.27) 24, 48 (61,122) 600 (1524) 24" cartons on 19" x 19" x 25" pallet = 24 cartons /pallet
1 (2.54) 24, 48 (61,122) 300 (762)
1/ (3.81) 24, 48 (61,122) 180 (457) 48" cartons on 19" x 19" x 49" pallet = 12 cartons /pallet
2 (5.08) 24, 48 (61,122) 150 (381)
The values given herein are typical average values obtained in accordance with ac- This product may be covered by one or mare of the following patents or foreign equivalents
canted test methods and aresubject to normal manufactunng vanat,ons They are sup- US5332699, US571442t, US5611360, US5621te3, US5928975, US5955369, U55994247, ��
plied as a technical servtoa and are subject to change without nonce. Therefore, the US6f60546, EP0906250, GB2348640 A' Est of foreign patent numbers is evadable upon request
data contained herein should not be used for speciricetion purposes. Check with your to The Morgan Crucible Company pie Thermal Ceramics, Superwool, 607 and MAX are trade -
Thermal Ceramics office to obtain current Information
marks of The Morgan Crucible Company plc
„,
Tigard High School Outdoor Natural Gas Kiln
MB SERIES POWER BURNERS
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1. CONTINUOUS DUTY BLOWER 8, vitcyr BURNER CLAMP TS RASO SAFETY VALVE
2. SPARK ICNTTION LEAD 9. MIXING TUBE Pi GAS COCK
3. ,ZILQT AIR MI xER 10. AS Fklp I?. BLOWER SPEED - ONTRol.
A. VEN11.1R1 PILOT B U E R IL PILOT BURNER GAS SUPPLY If.LS1'ARKAWELCLMAAAN-1.2,Rak.R.
7. SPARK IGNITION ELECTRODE 17. PRESSURE GAUGE 19. 120 VOLT GM:.:NORD LINE
,B. THERMOCOUPLE 1;1. mor NEEDLE VALVE 20 FLOW CONTROL GATE VALVE
7. FLAME RETENSION NOZZLE i 4, ELECTRIC SOLENOID VALVE i 21. THERMOCDUPIS.I.EAU
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Tigard High School Outdoor Natural Gas Kiln
BURNER PLACEMENT
offset burner 1/2" to 1"
OPERATING INSTRUCTIONS
1. Make sure burner shutoff valve is open and the flow control valve is closed.
2. Open needle valve to pilot burner.
3. Hold down red BASOTM reset button and light the pilot burner while contin-
uing to hold down the reset button for 30-45 seconds. Release. If pilot does not
stay lit, see 'Troubleshooting" below.
4. Adjust blower to a low setting.
5. Slowly open flow control valve until main ignition occurs.
6. Increases in gas need to be accompanied lnr increases in air. It is easier to ad-
just the air, then, adjust the gas to match. Due to the circuitry involved in the
speed control, you may experience a lag in the air setting.
7. To turn off burners; Shut flow control valve, turn off blower, close gas cock.
Unplug after use.
TROUBLESHOOTING
PILOT WILL NOT LIGHT:
There probably is air in your gas lines if this is your first firing. Bleed off any excess air.
PILOT IGNITES, THEN GOES OUT WHEN RESET BUTTON IS RELEASED:
Bad thermocouple. These can be obtained from a hardware store in an emergency, but
will most likely not be of industrial quality. If you are having trouble with repeated
thermocouple failure, the burner is positioned incorrectly or you have too much kiln
backpressure. See placement diagram.
PILOT BLOWS OUT OR DANCES:
Kilns should be located away from windy areas. Incorrect port size and burner place-
ment can cause pilots to blow out or "dance ". See burner placement.
BURNER "PUFFS" AT LOW SETTINGS:
Too much air in the mix. Try using both the manual shutter and the speed controller to
adjust the air.
15
BURNER SHUTS DOWN SUDDENLY:
This is usually caused by a pilot flame that is not stable (dancing). The signal from the
+hormnrnnnlo is +r-Nn 1n.A, In lePPn +ho R ACC) valvo nnon Coo hr,rnor nlaromon+
Tigard High School Outdoor Natural Gas Kiln
KILN WILL NOT REACH TEMPERATURE:
Several things can cause this; Improper burner choice, poor kiln design, inadequate gas
supply (especially true of large demand natural gas kilns), burners not operated at full
BTU output, or LP tank freeze -up.
PROPANE TANK FREEZE -UP:
This happens when you try to remove too much gas from the tank in relation to its size.
Turning up the pressure will not help. If this is a recurring problem you need a larger
tank or several similar tanks hooked together.
REDUCTION TIPS
Power Burners offer more control than Venturi burners when it comes to the air/ gas ratio.
This can cause confusion if you are not used to forced air systems. Venturi burners pull the air
they need into themselves. They will not pull more than they need but, can be made to pull less
than they need. When you want to reduce with Venturis, you close down the primary air spin
plate and push the damper in some.
Since you have more control over the air with Power Burners, you can reduce as well as
spill excess air into the kiln. Excess air cools the flame and can be as wasteful as overreduction.
Also spilling excess air can reoxidize the ware by providing extra oxygen that would not other-
wise be present. The tightest small blue flame you can produce is most likely a cool, excess air
flame. To get a good air /gas ratio flame, look for the earliest signs of reduction such as a "swirly"
atmosphere, then clean up the flame by increasing the air or decreasing the gas. When the flame
first starts to clean up by becoming tighter and a little louder, your ratio is becoming correct.
To reduce with your Power Burners you can; increase the gas while leaving the air con-
stant or decrease the air and leave the gas constant. Increasing the gas will tend to keep the kiln
from stalling as much as if you decreased the air. If you want your reduction climb to go slowly,
you may want to decrease the air. You are going to be looking for normal reduction indicators:
Swirly atmosphere, short flames from top and middle spy holes. Long spy hole flames and flame
going up the chimney are signs of overreduction and a waste of gas. Your burner and it's settings
control reduction while the damper controls kiln pressure. You want to have positive pressure in
the kiln at the top and middle and neutral pressure at the bottom spy hole. Remember, any new
kiln or burner system takes some experimentation to understand the nuances.
SPARK IGNITION
1. Flip the toggle switch to the on position and depress the red BASOTM button,
follow remaining operating instructions. Turn off when firing is complete.
Any sparking device depends upon proper adjustment of the spark gap, the distance
from the electrode tip to the pilot burner. During shipment this gap can easily be misaligned.
You will get the best and hottest spark with a gap of 1 / 4" to 3/16". Make sure the electrode is
in the pilot flame. If it is not, it will continue to spark once the pilot flame is established. Too
small a gap will produce a cooler weak spark that may not ignite the gas. Too large a gap and
the sparking may be at irregular intervals. This gap is set before it leaves us, but can easily be
upset during shipping.
For spark ignition to work, your power cord must be plugged into a properly grounded 16
120 volt outlet.
Tigard High School Outdoor Natural Gas Kiln
STANDARDS & APPROVALS
AGA American Gas Association
ANS American National Standards
CGA Canadian Gas Association
CSA Canadian Standards Association
UL Underwriters Laboratory
Listed below is a component breakdown of the operating parts of the MB Series Power
Burners and their respective approvals. Virtually all burners are, themselves, not approved by the
above agencies because they become part of systems which are field approved by local agencies.
If you have problems with compliance to local codes, feel free to contact us or have inspectors
contact us. We use the finest approved parts available.
DAYTON SHADED POLE BLOWERS: MODEL 4C440, 4C442, & 4C443:
CSA & UL (under the motor component recognition program) File E47479 for thermal
protection, File E37403 for impedance protection and File E40077.
VARI -SPEED MOTOR SPEED CONTROL, MODEL: KBWC -13K; UL Approved
JOHNSON CONTROLS SERIES H15 BASOTM VALVE:
AGA, CSA, ANS tested Z21.20 Auto Ignition systems and Z21.21 Auto Valves.
JOHNSON CONTROLS SERIES H91 BASOTROL ELECTRIC SOLENOID VALVE:
AGA, CSA, ANS Z21.21 Auto Valves.
HONEYWELL PILOT BURNER MODEL Q314A: AGA, ANS Approved
JOHNSON CONTROLS PENN BASOTM THERMOCOUPLE MODEL: K16BT:
AGA, ANS Approved.
CAMSTAT PILOT REIGNITOR MODEL PR -120: UL Listed
JOMAR SHUTOFF/FLOW CONTROL FULL PORT BALL VALVE: MODEL 100:
UL,AGA,CSAApproved. 150WSP & 600 WOG
GIACOMINI GAS COCK VALVE; MODEL: R602 AGA, CSA, UL Approved.
CAROL GROUNDED 16/3 CORD SET: JACKET TYPE: SIT, UL, CSA Approved
WARRANTY
All burners and their components are warranted against defects in parts for one full year of
purchase date. Warranty covers normal use and safeguards. We will not warrant blowers without the
presence of electrical solenoid valves to prevent burnback in the event of power failure.
We will not be liable for any loss or damage that may arise in connection with the use or performance of any Item, including, without
limitation, any indirect or consequential damages. 17
Ward Burner Systems • PO Box 1086 • Dandridge, TN 37725
Ph: (865) 397 -2914 Fax: (865) 397 -1253
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Tigard High School Outdoor Natural Gas Kiln
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