Hauck Eco-StarII 100B Instructions Manual Download | Manualshive

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TABLE OF CONTENTS

WARNING

These instructions are intended for use only by experienced, qualified combustion start-
up personnel. Adjustment of this equipment by unqualified personnel can result in fire,
explosion, severe personal injury or even death.

To make changes to the burner or adjust firing inputs: 1. Shut the burner down; 2. Make
changes; 3. Restart the burner.

STAND CLEAR OF THE BURNER UNDER ANY

FIRING CONDITIONS.

INSTRUCTIONS

MEGASTAR

TM

BURNER

MS-50 – MS-150

These instructions are intended to serve as guidelines covering the installation, operation, and maintenance of Hauck equipment. While
every attempt has been made to ensure completeness, unforeseen or unspecified applications, details, and variations may preclude
covering every possible contingency.

WARNING: TO PREVENT THE POSSIBILITY OF SERIOUS BODILY INJURY, DO NOT USE OR

OPERATE ANY EQUIPMENT OR COMPONENT WITH ANY PARTS REMOVED OR ANY PARTS NOT APPROVED BY THE
MANUFACTURER.

Should further information be required or desired or should particular problems arise which are not covered

sufficiently for the purchaser's purpose, contact Hauck Mfg. Co.

MS-9

HAUCK MANUFACTURING CO.,

100 North Harris Street Cleona, PA 17042 717-272-3051

1/15

www.hauckburner.com Fax: 717-273-9882

Subject

Page

A. General

Information…………………………………………………………………… 2

B.

Receiving & Inspection………………………………………………………………..

2

C. Burner

Capacities……………………………………………………………………... 3

D. Dimensions…………………………………………………………………………….. 5
E. Component

Identification…………………………………………………………….. 6

F. Combustion

Flighting…………………………………………………………………. 7

G. Burner

Mounting……………………………………………………………………….

7

H.

Fuel Manifold Installation……………………………………………………………...

8

I.

Natural Gas Fuel Piping System……………………………………………………..

9

J.

Light Fuel Oil Piping System………………………………………………………….

13

K.

Heavy Fuel Oil Piping System……………………………………………………….. 15

L.

Oil Manifold Heat Tracing……………………………………………………………..

18

M.

Heavy Oil Insert Heater……………………………………………………………….

18

N.

Fuel Oil Nozzle………………………………………………………………………… 20

O.

Compressed Air/Oil Atomizer…………………………………………………………

21

P.

Liquid Propane (LP) Fuel Piping System……………………………………………

26

Q.

Liquid Propane (LP) Nozzle…………………………………………………………..

31

R.

Burner Pilot System……………………………………………………………………

33

S. Primary

Air……………………………………………………………………………... 34

T. Burner

Setup…………………………………………………………………………… 34

U. Operation………………………………………………………………………………. 35
V. Adjustments……………………………………………………………………………. 36
W. Maintenance…………………………………………………………………………… 37
X.

Recommended Spare Parts………………………………………………………….

38

Appendix: Field Installation Weld-In Type flights, Y7100………………………..

39

Required Reference: Appropriate Burner Data Sheet
GJ73 Dryer Drum Gas Analysis

GJ75 MegaStar Application Sheet

1
2
3
...
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Summary of Contents for Eco-StarII 100B

Page 1: ...BY THE MANUFACTURER Should further information be required or desired or should particular problems arise which are not covered sufficiently for the purchaser s purpose contact Hauck Mfg Co MS 9 HAUCK MANUFACTURING CO 100 North Harris Street Cleona PA 17042 717 272 3051 1 15 www hauckburner com Fax 717 273 9882 Subject Page A General Information 2 B Receiving Inspection 2 C Burner Capacities 3 D D...

Page 2: ...on receipt check each item on the bill of lading and or invoice to determine that all equipment has been received A careful examination of all parts should be made to ascertain if there has been any damage in shipment IMPORTANT If the installation is delayed and the equipment is stored outside provide adequate protection as dictated by climate and period of exposure Special care should be given to...

Page 3: ... 17 200 27 600 34 000 46 100 52 500 in w c 14 3 12 0 16 2 13 7 144 0 mbar 35 6 29 9 40 3 34 1 358 3 scfh 46 500 46 500 46 500 46 500 46 500 nm 3 hr 1 200 1 200 1 200 1 200 1 200 in w c 62 62 62 62 62 mbar 154 154 154 154 154 gal 370 580 710 950 1 080 lph 1 400 2 200 2 690 3 600 4 090 ft 10 12 12 10 12 m 3 1 3 7 3 7 3 1 3 7 ft 4 5 5 4 5 m 1 2 1 5 1 5 1 2 1 5 Main Air Flow Main Air Pressure Primary ...

Page 4: ...52 500 in w c 12 0 16 2 13 2 14 4 mbar 29 9 40 3 32 8 35 8 scfh 3 600 3 600 5 400 5 400 nm 3 hr 100 100 100 100 psig 60 60 60 60 bar 4 4 4 4 gal 560 710 920 1 060 lph 2 120 2 690 3 480 4 010 ft 9 9 10 10 m 2 7 2 7 3 1 3 1 ft 5 5 5 5 m 1 5 1 5 1 5 1 5 N o t A v a i l a b l e Compressed Air Pressure Main Air Pressure BURNER MODEL COMPRESSED AIR SPECIFICATIONS Capacity Main Air Flow Main Air Pressure...

Page 5: ...ge of 0 25 to 1 wc 6 to 2 5 mbar at the burner breech plate to exhaust the products of combustion 6 MegaStarTM Burner airflow can be accurately monitored using the body pressure tap on either side of the burner air plenum An accurate device capable of reading up to 15 wc 75 mbar will be required for this measurement 7 All burner fuel manifolds are supplied with fuel flow measuring devices Liquid f...

Page 6: ...Page 6 MS 9 E COMPONENT IDENTIFICATION Figure 1 MegaStarTM Burner Components Y8978 NOT TO SCALE ...

Page 7: ...ame pitch as the drum Install a structure to support the burner Refer to dimensional drawings in the Section D The support structure must be able to support the weight of the burner see Table 3 If the optional primary air turbo blower TBA is to be mounted on the same structure as the burner allow for the additional weight Consult Hauck for recommended burner mounting options If applicable choose a...

Page 8: ...on to modulating fuel valves the manifold includes the automatic oil gas and LP safety shutoff valves IMPORTANT Fuel manifolds must be mounted in a horizontal position Safety shutoff valves will not function properly if mounted vertically Liquid fuel manifolds should not be mounted above the burner centerline Oil and LP manifolds should be mounted as close to the burner as possible For heavy fuel ...

Page 9: ...st be installed upstream of the gas control regulator to ensure compliance to NFPA requirements The manual equipment isolation valve facilitates servicing of the gas control regulator sediment trap strainer and other components in the gas manifold 3 The gas company should purge the main gas line to remove scale and dirt before it is attached to the burner gas manifold NOTE Hauck recommends the use...

Page 10: ...ral part of the gas manifold located on the burner refer to Figure 2 Refer to individual burner gas orifice meters graph for gas flows through the gas orifice meter see Figure 4 Orifice meter sizes and part numbers are shown below in Table 6 MegaStar Model No 50 75 100 125 150 OMG Part No 19816 48242x001 47181x005 Pipe Size 4 DN 100 6 DN 150 8 DN 200 Orifice Size 3 25 82 5mm 4 8 122 mm 6 0 152 mm ...

Page 11: ...Page 11 MS 9 Figure 3 Simplified Gas and Air Flow Chart Atmospheric Conditions GL86 ...

Page 12: ...Page 12 MS 9 Figure 4 MegaStar Gas Orifice Meters Graph ...

Page 13: ...N50 75 1 DN25 1 DN25 1 DN32 1 DN25 1 DN32 1 DN32 1 DN32 1 DN40 2 DN50 100 1 DN25 1 DN25 1 DN32 1 DN32 1 DN32 1 DN32 1 DN32 1 DN40 2 DN50 125 1 DN25 1 DN32 1 DN40 1 DN32 1 DN32 1 DN40 1 DN40 2 DN50 2 DN50 150 1 DN25 1 DN32 1 DN40 1 DN32 1 DN32 1 DN40 1 DN40 2 DN50 2 DN50 Table 8 Minimum Pipe Size For Hauck Oil Supply Pumping Units 3 Adjust the bypass relief valve until required oil pressure is achi...

Page 14: ... valve is preset to travel from position 2 to 11 The low fire oil flow setting can be changed by loosening the coupling connecting the oil valve to the control motor adjusting the oil valve pointer and re tightening the coupling The high fire oil flow setting can be changed via the burner control system or if necessary by increasing or decreasing fuel oil pressure See the individual burner perform...

Page 15: ...rking with heated oil Figure 5 Typical Schematic of Burner Light Fuel Oil Piping K HEAVY FUEL OIL PIPING SYSTEM IMPORTANT For all heavy fuel oil applications i e any oil requiring heating for use oil piping must be heat traced electric or steam and insulated Self regulating heat tracing is recommended to maintain the desired temperature of a given fuel oil to achieve 90 SSU 1 8 x 10 5 m2 sec or le...

Page 16: ... on suction type oil heaters 3 Set the fuel oil heater temperature set point and the indicating low oil temperature switch located on the burner s oil manifold to the temperature determined from step 2 4 Adjust the bypass relief valve until the required oil pressure is achieved See individual burner performance sheets for approximate settings Final oil pressure will have to be adjusted to attain d...

Page 17: ...old The flow meter glass can be rotated to view the scale if required Figure 6 Typical Schematic of Burner Heavy Fuel Oil Piping X7872 NOT TO SCALE NOTE Fuel oil flow settings per the individual burner performance sheets are for initial set up only Final settings may have to be readjusted for required operation ...

Page 18: ...r switch to the oil manifold heat tracing kit is energized the self regulating heat tracing will automatically switch on and off based on heat demand M HEAVY OIL INSERT HEATER Heavy waste or recycled fuel oils require some means of viscosity control The Hauck heavy oil insert heater installed in the burner s oil tube see Figure 8 is a perfect solution to the viscosity control problem and reliable ...

Page 19: ...ment is removed 4 When the oil temperature drops below the setpoint on the oil temperature indicating controller the oil temperature indicating controller switch contact will close and the heater element will energize See ESII 9 2 Heavy Oil Insert Heater Kit Instructions for more specific detail on the operation and maintenance of the heavy oil insert heater V7867 NOT TO SCALE NOTE Adjusting the t...

Page 20: ...oil nozzle must be retracted into or extended out of the primary air tube see Figure 9 4 Remove the bolts securing the backplate to the burner and disconnect the pilot air pipe 5 Loosen the jam nut on the backplate of the burner oil insert assembly 6 Rotate the backplate to effect the required retraction or extension of the oil atomizer nozzle One full rotation of the backplate will move the atomi...

Page 21: ...om the compressor to the burner compressed air inlet For longer runs than those listed in the table increase the hose by one pipe size Before attaching lines purge the hose to remove any dirt that could clog and damage the oil atomizer MegaStarTM Model No Min Hose Size Max Hose Length 75 100 3 4 NPT DN20 70 ft 21m 125 150 1 NPT DN25 160 ft 49m Table 10 Flexible Air Hose Size Requirements 2 Compres...

Page 22: ...d air manifold must be 90 psig 620 kPa or greater The supply pressure is measured via the gauge on the inlet to the compressed air flow meter see Figure 10 The compressed air low supply pressure switch is preset at 60 psig 414 kPa Set point adjustment may be required depending on the burner and compressed air piping specifics 3 For the compressed air manifold with regulator to function properly th...

Page 23: ...ced electric or steam and insulated Self regulating heat tracing is recommended to maintain the desired temperature of a given fuel oil to achieve 90 SSU 1 8 x 10 5 m2 sec or less at the burner Electrical heat tracing with a nominal rating of 12W ft 39W m covered with a nominal 2 50mm fiberglass type insulation is sufficient for most applications Y7041 NOT TO SCALE ...

Page 24: ...o determine the compressed air flow rate refer to Figure 12 and proceed as follows 1 Read the inlet pressure on the pressure gauge of the compressed air flow meter 2 Select the appropriate inlet pressure psig vertical line or interpolated value closest to the gauge reading and follow the line upward until it intersects the brightly colored horizontal indicator bar 3 From the intersecting point on ...

Page 25: ...ientation of the air oil nozzle in the burner Determine if the air oil nozzle must be retracted into or extended out of the primary air tube see Figure 9 4 Loosen the two set screws on the backplate lock collar of the air oil insert assembly 5 Slide the insert assembly to effect the required retraction or extension of the air oil nozzle 6 Once the proper positioning of the air oil nozzle is comple...

Page 26: ...ammable and heavier than air It will accumulate near the ground in the area of a leak and will dissipate relatively slowly LP or Butane in its liquid state can cause freezing and severe injury Hauck does not recommend installation of a line reducing regulator in the LP supply line If the regulator diaphragm were to total system pressure would be applied to the burner and could result in damage to ...

Page 27: ...leaks are repaired NOTE The LP piping system shown in Figure 13 is designed for optimum performance at ambient air temperatures above 40o F 5 C For operation in ambient temperatures below 40o F consult Hauck for recommendations CAUTION Hauck strongly recommends that a bypass flow control valve and a backpressure regulator be installed in all LP systems and piped as shown in Figure 13 X7869 NOT TO ...

Page 28: ...er To adjust the back pressure regulator open the ball valve between of the back pressure regulator and the tank and adjust the regulator to an initial setting of 25 psig 172 kPa below the flow control valve setting f Adjust the back pressure regulator to the following initial settings 100 Commercial Propane 210 psig 14 50 bar 50 50 Propane Butane 145 psig 10 00 bar 100 Butane 70 psig 4 80 bar CAU...

Page 29: ...ed on propane butane or mixtures of both to assure optimum vaporization and combustion If using a butane or propane butane mixture be sure to specify the fuel when ordering and consult Hauck for specific nozzle hole sizes 10 The MegaStarTM utilizes a multi port LP nozzle assembly positioned around the primary air tube Atomizing air supplied from an auxiliary blower assists in mixing and vaporizing...

Page 30: ...Page 30 MS 9 Figure 14 Vapor Pressures of Propane Butane and Butane Propane Mixtures ...

Page 31: ... choke ring is present it must be removed to accept the LP nozzle 2 Remove the access door from the rear of the burner air housing Verify that a 2 NPT pipe plug is installed in the primary air tube see Figure 17 3 Loosen the lock nut and insert backplate from the LP insert 4 From the front end of the burner insert the nozzle and feed piping from the primary tube 5 When properly installed LP nozzle...

Page 32: ...Page 32 MS 9 Figure 16 Burner Front End Figure 17 LP Insert W9048 NOT TO SCALE W9048 NOT TO SCALE ...

Page 33: ...f the Hauck gas pilot manifold Pilot capacity should not exceed 150 000 Btu hr 44kW 3 The spark wire gap is factory set at 1 8 3mm This gap can be changed by carefully removing the pilot internals Bend the spark wire to adjust reinsert and check the gap For field adjustment a U S 5 coin with 0 08 2mm thickness can be used as a gauge for adjusting the spark gap Figure 18 Pilot Manifold Detail 4 Com...

Page 34: ... at multiple control points using the BCS6000 control panel Nominal Settings see Figure 19 1 All control motors have a travel of 90 2 The low fire starting frequency for the combustion air blower is 16Hz Always be sure that the combustion air blower is operating at 16Hz prior to pilot and main flame ignition During operation the blower frequency will need to modulate between 16 and 60Hz as require...

Page 35: ...Control Motor Settings U OPERATION 1 The MegaStarTM uses individual control motors directly coupled for each fuel control valve The optional remote rack mounted fuel manifold includes a separate control motor for the fuel control valves which is electronically linked to the air control Air control is performed with a VFD modulating the output frequency between 16 Hz and 60 Hz to achieve a precise ...

Page 36: ...t low fire V ADJUSTMENTS 1 In order to drive each control motor consult burner control panel instructions 2 The spin vane adjustment affects the flame shape and combustion intensity Spin set at 0 will produce a long narrow flame a spin setting of 50 will produce a short wide flame see individual burner capacity and performance data sheets For most applications the spin should be set in the mid ran...

Page 37: ...semble the oil nozzle reattach the nozzle to primary air tube and then attach the burner backplate to the burner body f Check to ensure that the atomizing oil nozzle is at the proper position inside the burner see Section N 3 Periodically check all safety equipment such as pressure switches solenoid valves and safety shutoff valves to ensure they are not clogged with dirt or in any way inoperative...

Page 38: ...X RECOMMENDED SPARE PARTS ITEM QTY PART NO DESCRIPTION 1 1 20627 Control Motor Air High Torque 1A 1 62960 Control Motor Fuel Medium Torque 2 1 20579 UV Scanner 3 2 84447812 Air Pressure Switch Combustion Air Purge Air 1 20 wc 25 508mm wc LP Low Pressure Oil Only 4 1 84447832 Air Pressure Switch Primary Air 12 60 wc 405 1520mm wc 5 1 61020 Air Pressure Switch Compressed Air 30 psig 207 kPa Table 14...

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Page 47: ...ith the manufacturer of the equipment In most instances good readings require that the manufacturers instructions be adhered to rigidly Conditions to perform a good analysis 1 Use a reliable gas analyzer 2 Sample pipe must be installed in the dryer drum to eliminate reading stray O2 overheated RAP or overheated AC 3 Sample should be taken with average tonnage moisture and firing rates 4 Allow at l...

Page 48: ...amount of combustibles are present Then reduce fuel by a small amount for a safety margin NOTE Typically some CO and combustibles will always be present Variables Affecting the Combustion Process 1 Poor atomization of fuel Atomizer contamination with particulate Air passages clogged 2 Poor oil Oil laden with particulate and unburnables 3 Switching fuels Light to heavy oils LP to butane 4 Flame sha...

Page 49: ...Page 3 GJ73FE BATCH PLANT TYPICAL SAMPLE TUBE INSTALLATION FOR DRYER DRUM GAS ANALYSIS W7406 NOT TO SCALE ...

Page 50: ...Page 4 GJ73FE DRUM MIX PLANT TYPICAL SAMPLE TUBE INSTALLATION FOR DRYER DRUM GAS ANALYSIS W7407 NOT TO SCALE ...

Page 51: ...t has material veil can result in elevated operating costs increased pollutant emissions and result in scrapped material Solutions to problems of combustion zone size and material veiling will be addressed in this application sheet To prevent veiling combustion zone flights are required Welded in flights are recommended for aggregate dryers The recommended combustion flights are designed to be low...

Page 52: ... recommended combustion flighting works well Combustion Zone Sizing The following example demonstrates how to calculate the necessary combustion zone length Hauck s e Solutions for Combustion Asphalt Heat Balance program is also available 1 Determine the maximum Btu hr from the burner capacity sheet necessary assume burner capacity of 100 000 000 Btu hr for this example 2 Take the Btu hr and divid...

Page 53: ... conditions or lower if pollution requirements necessitate very low CO and THC levels Ideal conditions mean that the burner chosen will run near its maximum firing capability Running the burner near its maximum capacity will allow for higher efficiency promote optimum mixing and result in lowest emissions Due to the variety of rotary drying applications the proper number to use for sizing the comb...

Page 54: ...gth Burner mounting is determined by the type of plant and the fuel used The Eco StarIITM or MegaStarTM comes standard with a nose that can be inserted into most drums to prevent overheating of the breech plate Insertion depth depends on the fuel and the configuration of the inside of the dryer If there are any inside projections such as an overhead discharge make sure the burner is inserted far e...

Page 55: ...Compressed Air Atomization Oil Low Pressure Atomization Gas Liquid Propane Nominal Firing Rate 25 XSA MMBtu hr Length Diameter Length Diameter Length Diameter Length Diameter ES 0 NA NA 14 2 75 13 2 5 12 3 35 25 45 NA NA 8 3 5 8 4 8 3 34 60 NA NA 8 4 7 5 4 5 8 3 5 33 ES 0 NA NA 14 3 15 3 12 3 62 50 45 NA NA 10 4 12 4 9 3 75 63 60 NA NA 7 5 5 7 6 7 6 60 ESII 75B 0 11 4 14 5 5 15 5 13 4 5 75 30 8 7 ...

Page 56: ... 28 7 50 27 50 61 82 102 122 143 163 8000 79 28 3 52 27 50 60 81 101 121 141 161 8500 77 27 8 53 26 49 59 79 98 118 138 157 9000 76 27 4 55 26 48 58 78 97 116 136 155 9500 75 27 57 25 47 57 77 96 115 134 153 10000 74 26 6 59 25 46 57 76 94 113 132 151 10500 73 26 2 60 25 46 56 74 93 112 130 149 11000 72 25 7 63 24 45 55 73 92 110 129 147 11500 70 25 3 64 24 44 54 71 89 107 125 143 12000 69 24 9 67...

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