In this technical rundown, Tony Cardwell, Senior Project Manager at Deutsche Beverage + Process, walks through burners used on direct-fire brewhouse systems—covering how they work, common issues, and best practices for troubleshooting and maintenance. You’ll learn what your burner is telling you, how main gas header pressure and manifold pressure impact performance, and what to check when a burner trips or fails to ignite. Tony also explains key components like orifices, ignition probes, ionization probes, relays, and control units, along with when simple resets are enough versus when it’s time to call a burner technician. This video is designed for brewers and operators running direct-fire systems who want to reduce downtime, avoid brew day delays, and extend the life of their burner equipment through proper routine maintenance.
Topics covered include:
- How Real burners function in direct-fire brewhouses
- Typical burner sizing and BTU ranges
- Gas pressure checks and why they matter
- Resetting burners after pressure fluctuations
- Ignition vs. ionization probes and how they work
- Cleaning and inspecting probes
- Orifices and proper gas mixture
- Recommended maintenance intervals
- When to troubleshoot in-house vs. call a tech
Replacement parts—including ignition probes, ionization probes, orifices, control components, and full burner assemblies—are available through the Deutsche Beverage + Process parts store. 🔧 If you’re in maintenance season or running a direct-fire system, this is a must-watch. 📞 Have questions or need support? Contact the Deutsche team—we’re here to help.
Hey, Tony Cardwell here with Deutsche Beverage + Process. Today we’re talking about Real burners—their function, what they mean to your brewhouse, and the necessary troubleshooting steps and proper maintenance procedures you may need to consider.
We’re going to go over this in depth, including orifices, main header pressure, manifold pressure, ignition, ionization probes, and more. These are the standard burners we use on any direct-fire system. I’ll also touch on the construction and models we use, along with routine maintenance you should consider when operating and selecting a direct-fire system from Deutsche Beverage + Process.
Our preferred burner supplier is Riello. These burners range from 120,000 to 750,000 BTUs, typically used on brewhouses from about 3.5 barrels up to 10–15 barrels. Like most burners, they are very hardy machines. When properly maintained and cared for, they can last a very long time. However, we do see issues arise when routine maintenance is neglected.
One of the first things to check if you’re having a burner issue is your main gas header pressure and your manifold pressure off the control valve. These pressures should match the recommended settings for your specific burner, which can be found in your Riello manual. The main header pressure refers to the gas pressure coming from your natural gas supply, while the manifold pressure is downstream of the main control valve in the burner gas train. If needed, have a qualified gas technician verify these settings to ensure proper firing.
If the issue seems electrical, the first step is often very simple: press the reset button on the front of the burner. When powered, this button will typically have a faint red glow. Pressing it resets the burner. We often see burners trip due to fluctuations in main gas pressure—especially when pressure is set right at the maximum allowable limit—causing the burner to fall out of process and require a reset.
If the issue persists and appears to be electrical, it’s important to understand the ignition and ionization probes. The ignition probe creates the spark that ignites the flame. A contactor generates a spark between the ignition probe and the burner’s front plate, lighting the gas as it flows through. The ionization probe then verifies that a flame is present by sensing changes in air chemistry. If the flame goes out, the ionization probe detects this and shuts down the system for safety.
If you suspect an electrical issue, check the back of the burner and make sure the probe connections are properly seated. If needed, the probes can be removed and cleaned. This isn’t something that needs to be done frequently, but an annual inspection is recommended to ensure clean probes, good spark contact, and accurate flame detection.
Another component to consider is the burner orifice. During installation, your Deutsche technician or project manager will have selected and installed the correct orifice. However, if you continue to experience issues related to gas mixture or repeated burner trips, it may be worth consulting Deutsche or a burner technician to verify the orifice selection. Orifices control the gas mixture entering the burner and play a critical role in proper combustion.
Some electrical components, such as 120-volt relays, can also fail over time. If this occurs, Deutsche can assist with troubleshooting and replacement recommendations.
As for maintenance frequency, it’s a good idea to perform a quick visual inspection every six months and a more detailed inspection annually, ideally with a burner technician. While these burners are extremely durable and simple in design, lack of maintenance will eventually lead to failure. Proper burner maintenance is critical for any direct-fire system.
Replacement parts—including ignition probes, ionization probes, orifices, control components, and complete burner assemblies—are available through Deutsche Beverage + Process. You can find these on our website using the link in our bio.
If something seems off with your burner, feel free to give us a call. We’re happy to recommend troubleshooting steps and help determine the best path forward.
How often should a brewery burner be inspected and maintained?
A brewery burner should be visually inspected every 3–6 months and professionally inspected once per year. Regular brewery burner maintenance helps ensure proper ignition, stable flame detection, and correct gas pressure while reducing the risk of unexpected shutdowns or brew day delays.
What should I check first if my brewery burner won’t ignite or trips offline?
If a brewery burner fails to ignite or trips, first verify that main gas header pressure and burner manifold pressure are set to the manufacturer’s specifications. Next, press the burner reset button, which often resolves issues caused by gas pressure fluctuations. These steps address the most common brewery burner troubleshooting scenarios.
What are ignition and ionization probes on a brewery burner, and why are they important?
A brewery burner uses an ignition probe to create the spark that lights the flame and an ionization probe to confirm that the flame is present. If the flame is lost, the ionization probe signals the system to shut down for safety. Clean, properly seated probes are critical for reliable brewery burner operation.
Can brewery burner orifices cause combustion or performance issues?
Yes. Brewery burner orifices regulate gas flow and ensure the correct gas-to-air mixture. An incorrect, damaged, or dirty orifice can cause unstable flames, inefficient combustion, or repeated burner trips. Orifices are selected during installation, but ongoing brewery burner issues may require inspection or replacement.
When should brewery burner parts be cleaned or replaced?
Brewery burner components such as ignition probes, ionization probes, relays, and control modules should be inspected during routine maintenance. Cleaning may resolve minor issues, but worn or failed components should be replaced with OEM-approved parts to maintain safe and consistent brewery burner performance.
