Bulletin 7200

SMARTFIRE™

Intelligent Combustion Control System

Precise electronic control of air and fuel flow tothe burner to maximize efficiency and minimize 

emissions simultaneously 

• Maintain emissions or fuel efficiency over theentire operating range of the burner, not just at one burner set point 

• Automatically compensates for changesin combustion or process conditions with full cross-limited ratio control, maximizing burner performance and ensuring a highly repeatable heat source 

• Plug ‘n Play, turnkey system for easy installation and set-up 

• Integrates easily with all burnermanagement systems, reducing 

engineering costs in retrofit applications 

• Advanced diagnostics and troubleshootingprovide real-time information about combustion 

and process system performance 

• Optional remote monitoring gateway reduces 

process downtime by providing immediate off-site technical support over a standard phone line 

• Rugged industrial design includes NEMA 4X enclosures, high torque actuators, and all-digital field 

device communications, ensuring reliable operation in harsh environments 

• Redundant system safety checks built into intelligent components, significantly reducing the 

risks associated with combustion system commissioning and maintenance neglect 

• FM and CSA approved

• Meets requirements for European Electromagnetic Compatibility (EMC) and Low VoltageDirectives

Manufactured under U.S. patent #6,247,919 

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

 

Bulletin 7202

SMARTFIRE™ Intelligent Combustion Control System

4/03 

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

The SMARTFIRE™ Intelligent Combustion ControlSystem is a turnkey, mass flow air/fuel ratio controlsystem for industrial burners. The System is com-prised of five components that integrate easily with aconventional burner management system and pipetrain: an Interface Panel; Air Valve Actuator andFuel Valve Actuator; and Air Flow Controller and FuelFlow Controller.

The Interface Panel includes a Burner Brain, 24VDC Power Supply, and User Display. The BurnerBrain contains all of the factory-installed, combustionintelligence (such as burner-specific air/fuel ratio andflow data), enabling the SMARTFIRE™ System to beeasily commissioned after field installation. TheUser Display panel allows the Operator to monitorand adjust the performance of the combustionsystem. The Valve Actuators are factory-calibratedassemblies that include rugged, high-quality plan-etary gearheads and stepper motors for highlyrepeatable and precise control of Maxon’s butterflyvalves. The Air and Fuel Flow Controllers eachconsist of a precision-calibrated thermal mass flowsensor, control electronics, and flow body withintegrated flow conditioners for a highly repeatablemeasurement.

Other SMARTFIRE™ System functions includefuel totalizing, air/fuel flow and valve position analogoutputs for DCS interfacing, (optional) remotemonitoring, and many redundant system safetyfunctions. The SMARTFIRE™ System specifica-tions are as follows:

Burners and Fuels

The SMARTFIRE™ System can be used with themajority of Maxon’s natural gas fired burners, espe-cially those designed for low-emission applications(e.g., KINEDIZER ® , CYCLOMAX ® , CROSSFIRE ® ,OXYTHERM ® ). For application of SMARTFIRE™ tonon-Maxon burners or use with other fuels, contactMaxon.

Principle of Operation

As shown in the block diagram below, the fiveSMARTFIRE™ components each communicate over apeer-to-peer digital network. Control functions areperformed in the field devices and the Burner Brain,providing higher accuracy and reliable operation inelectrically noisy industrial environments that oftenaffect the performance of systems with analog (4-20mA or low voltage) control signals. The distributedintelligence also allows redundant system safetychecks which prevent tampering and unsafe conditionsthat can occur during combustion system commission-ing and after long-term operation.

The SMARTFIRE™ System permits the burner tobe started in response to the commands from theUser’s burner management system. Once the se-quence is completed, the System maintains thefactory-installed air/fuel ratio for the desired heatoutput set by the User’s process controller. TheSystem’s cross-limited mass flow control of air andfuel automatically compensates for changes thataffect combustion performance such as air and fueltemperature and pressure and chamber pressure. Theprocess controller and burner management system arenot included as part of the SMARTFIRE™ System.These functions can be obtained using one of severalMaxon combustion command panel products.

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ValveActuator(Air)

ControlValve

FlowController

(Air)

FlowBody

FlowController(Fuel)

FlowBody

ValveActuator(Fuel)

ControlValve

BurnerBrain

UserInterface

PowerSupply

Burner Management

and Flame Safeguard

Process

ControlSMARTFIRE

TM

 Interface Panel

Firing Rate

Status

Peer-to-Peer Communication

Gateway (Option)

Commands

Status