Instructions 4832-2 Page 2
SEALING AROUND BURNER TILES
Tile life will be greatly improved if compression can be maintained all around the perimeter. It is most important to prevent fluing of hot gases between tile and adjacent refractory. In a sprung arch, use a tapered tile (and flexible air and gas connections). If this cannot be done, a matrix should be cast or rammed all around each tile (see Figure 4).
When tile is smaller than roof opening, gap can be filled by one of the following methods:
A. Fill areas up to 6" wide with castable refractory, which should be keyed into brick work for support.Wider areas should have anchors cast into them with overhead steel work supporting the mass. When pouring or ramming against existing refractory, wet the refractory surface so it will not absorb water from the new material.
B. To fill larger gaps (6" or more in width), it is suggested (a) that a monolithic roof be cast or rammed around the positioned burner tiles, or (b) that a suspended roof of fired shapes (such as made by Detrick) be installed in accord with manufacturer’s recommendations.
In all cases, cast refractory should overlap the angled step at the top of the burner tile (Figure 4).
Seal with lightweight castable
Castable
Tapered burner tile
Grooved burner tile
Cast, rammed, or suspended roof
Anchor tile
Figure 4
REPLACING TILES
Handle with care. Unmounted tiles are even more fragile than mounted ones.
Remove cast iron burner cover plate from furnace and clean thoroughly. Butter entire top surface of replacement tile with a 3⁄8 " to ½ " thick layer of air setting high temperature refractory cement. Tiles come notched for pilot and flame supervision. Line up with cover plate.
Gently press cover plate onto tile. Place washers and nuts on the four anchor bolts and tighten them evenly by hand. Then tighten evenly with a wrench (leaving 1⁄8 " or less cement between cover plate and tile at tile throat).
Loosen nuts ¼ turn. Remove excess mortar and form a smooth throat at junction between metal cover plate and refractory tile. Repeat last step after several hours if necessary: Mortar may ooze out of junction for some time after mounting is pressed on.
On some burner sizes, top of tile may intrude in cover plate pilot and flame supervision holes. If pilot and/or flame supervision are to be used, ream out tile through these holes to provide an unobstructed view.
IMPORTANT: After installing new tiles, bring furnace up to temperature slowly.
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