Little Monster and Bulldog Forge Burner Instructions
Never operate any gas forge in an enclosed area. Adequate cross ventilation is a must.
Never place the forge on or near any combustible materials including the surface its mounted to.
Keep your work area clear of combustibles and trip hazzards.
Everything on or near a forge will get hot. Never touch any part of a forge during or after use.
Always ensure that anyone coming into or anywhere near your work area is made aware.
Always inspect your forge, forge burners, plumbing, fuel lines and valves daily before starting work.
Plumbing your new burners
Your new burner/s comes equiped with a 1/4" shut off valve pre-installed. You will need to provide and install the proper fittings to provide propane to your burner. It is very important to use the proper fittings and ensure they are installed correctly and are free of leaks. If you are unsure of which fittings to use please seek the help of a licensed plumber in your area. The proper yellow thread sealant tape and thread sealant paste should be used on all pipe threads. Never attempt to connect a flare fitting such as that on a regulator hose to a pipe thread. They are not compatible with each other and no amount of sealant will stop the connection from leaking. Adaptors from pipe thread to flare are widely available and not very expensive.
You will need to take care when making your connections to the burner valve so that you do not knock anything out of alignment. Once you've made your connections, you will need to test them for leaks. Close the pre-installed shut off valve, and pressurize the plumbing you installed using compressed air. Soapy water sprayed on all connections will help indicate any small leaks by bubbling where the air is escaping. If any leaks are found repair the leak and test again. Repeat until you have no more leaks present . A pressure test gauge will also help locate slow leaks.
Installing your new burners
You will need to provide a collar which is secured to the forge shell. The collar should provide ateast 1" clearance around the burner tube. This collar should have a means by which to secure the burner into position. A common method is using 4 bolts that are long enough to extend through the collar, and when tightend, will securely hold the burner. Be careful not to over tighten and damage or crush the burner tube.
The burner should be positioned so that the very end of the flare is recessed approx one inch back into the wool. It should never extend into the forge chamber, nor should it be flush with the forge chamber insulation. It must be recessed into the insulation one inch. Doing so will do two things, first, it will extend the life of the flare by keeping it out of the extreme temps of the forge chamber. Secondly it will help the burner run more stable. When making the hole in the insulation that your burner will pass through, be sure not to over cut the outter most layer, it should be a snug fit. The inner most layer of insulation should be cut in a slight taper as if an extension of the flare. It does not need to be cut at an extreme angle. Care must be taken so that the inner most layer of insulation and any castable refractory applied to it will not impede or obstruct the flare.
Once you have your burners installed and secured into position, you will need to pack the collar around the burner tube tightly with ceramic fiber blanket. Be sure to leave no voids. After this is done, brush a little ceramic fiber rigidizer on to any exposed wool.
Lighting your burners.
After all the plumbing installed has been tested for leaks, and the burners have been installed correctly. Use the following to begin the process of lighting your burners. Be sure the forge is clear of ANY combustible materials including the surface it is placed upon. Always secure the forge so that it can not be knocked over or off of its stand. Ensure that everyone that can possibly come in contact with the forge is made aware that it is hot even a few hours after it has been turned off. Maintain a safe workspace at all times.
1) Ensure propane tank valve is closed.
2) Ensure regulator valve is closed. (Never attempt to run a forge without a regulator.)
3) Ensure Burner valve/s are closed.
4) Ensure any doors to the forge are open completely
5) Loosen the thumbscrew on the air choke of your burner/s and slide the air choke down so that it is 1/4th of the way open. Once in that postion, tighten the thumbscrew to hold this postion.
6) Open the Propane tank valve one and a half turns. (Ensure the regulator valve and burner valves are closed first)
7) Open the regulator valve one and a half turns)
8) Use a long enough ignitor so that NO part of your body is in front of, behind of, or within the forge chamber. The ignitor must be such that it can be pre lit and held near the burner flare within the forge chamber. Never place any part of your body within the forge chamber.
9) With the ignitor lit and in postion, slowly open the burner valve slightly. Once the burner is lit remove the ignitor from the forge, and open the Burner valve completely. Let the burner/s run for 5 minutes with the choke in this position to warm up. Once warmed up, loosen the thumbscrew on the air choke and slide open half way.
**If the burner flame should blow out, or does not light, immediately close the burner valve, wait 5 minutes then try again.
10) Once the burners are warmed up and the choke sleeve is positioned half way open, you will need to open the propane tank valve completely.
11) With the tank valve now open completely, you will now need to adjust the regulator to the desired pressure, while adjusting the position of the choke sleeve on the burner. You are looking for a neutral flame which has a light blue cone. Never close the choke sleeve completely while running. More pressure doesn't always mean more heat.
Shutting down the forge
To shut your forge down
1) Close the propane tank valve completely
2) Close the regulator completely
3) Close the burner valve completely
4) Using a pair of pliers (everything is hot on a forge) loosen the thumbscrew on the chile sleeve, and slide the choke sleeve up to a fully closed position. It is very important that you make a habit of doing so. The choke sleeves if left open will allow the burners to act as chimney stacks and will damage the burners.