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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

BURNER

MS-25 – 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 Eclipse, Inc.

MS-9

Eclipse, Inc.,

1665 Elmwood Road, Rockford, IL 61103-1299 Ph: 717-272-3051

4/18

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

Subject

Page

General Information……………………………………………………………………

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

Burner Capacities……………………………………………………………………...

Dimensions……………………………………………………………………………..

Component Identification……………………………………………………………..

Combustion Flighting………………………………………………………………….

Burner Mounting……………………………………………………………………….

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

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

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

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

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

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

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

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

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

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

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

Primary Air……………………………………………………………………………...

Burner Setup……………………………………………………………………………

Operation……………………………………………………………………………….

Adjustments…………………………………………………………………………….

W. Maintenance……………………………………………………………………………

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

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

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

GJ75 MegaStar Application Sheet

Содержание Hauck MEGASTAR MS-150

Страница 1: ...VED 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 Eclipse Inc MS 9 Eclipse Inc 1665 Elmwood Road Rockford IL 61103 1299 Ph 717 272 3051 4 18 www eclipsenet com Fax 717 273 9882 Subject Page A General Information 2 B Receiving Inspection 2 C Burner Capacities 3 D Dimens...

Страница 2: ...ION Upon 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 gi...

Страница 3: ... 75 100 125 150 Capacity MMBTU hr 31 53 82 100 135 153 MW 8 5 14 3 22 3 27 2 36 5 41 5 Main Air Flow scfh 365 000 643 300 1 030 000 1 270 000 1 720 000 1 960 000 nm3 hr 9 800 17 200 27 600 34 000 46 100 52 500 Main Air Pressure in w c 12 0 14 3 12 0 16 2 13 7 144 0 mbar 29 9 35 6 29 9 40 3 34 1 358 3 Primary Air Flow scfh 46 500 46 500 46 500 46 500 46 500 46 500 nm3 hr 1 200 1 200 1 200 1 200 1 2...

Страница 4: ... 8 46 0 37 3 45 5 Primary Air Flow scfh e 46 500 46 500 46 500 46 500 46 500 nm3 hr n d 1 200 1 200 1 200 1 200 1 200 Primary Air Pressure in w c i 62 62 62 62 62 mbar n 154 154 154 154 154 Propane Flow Rate gal g 550 880 1 070 1 400 1 590 lph 2 080 3 330 4 050 5 300 6 020 Flame Length 30 Spin ft 10 14 15 13 15 m 3 1 4 3 4 6 4 0 4 6 Flame Diameter 30 Spin ft 4 5 5 6 6 m 1 2 1 5 1 5 1 8 1 8 NOTES 1...

Страница 5: ...c t t 12 0 16 2 13 2 14 4 mbar 29 9 40 3 32 8 35 8 Compressed Air Flow scfh A A 3 600 3 600 5 400 5 400 nm3 hr v a v a 100 100 100 100 Compressed Air Pressure psig i i 60 60 60 60 bar l l 4 4 4 4 Oil Flow Rate gal a a 560 710 920 1 060 lph b b 2 120 2 690 3 480 4 010 Flame Length 30 Spin ft l l 9 9 10 10 m e e 2 7 2 7 3 1 3 1 Flame Diameter 30 Spin ft 5 5 5 5 m 1 5 1 5 1 5 1 5 NOTES 1 Air Flows Li...

Страница 6: ...nge 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 ...

Страница 7: ...Page 7 MS 9 E COMPONENT IDENTIFICATION Figure 1 MegaStarTM Burner Components Y8978 NOT TO SCALE ...

Страница 8: ...e 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 Eclipse for recommended burner mounting options If applicable choose a...

Страница 9: ...valves mounted on it In addition 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 burn...

Страница 10: ... for best operation and compliance with NFPA 54 see Figure 2 2 A manual equipment isolation valve sediment trap and gas strainer must be installed upstream of the gas control regulator to ensure compliance to NFPA requirements The manual NOTE Eclipse recommends the use of gas manifolds that meet NFPA guidelines NFPA requires two fuel safety shutoff valves wired in series and a shutoff valve downst...

Страница 11: ...hould be sized to minimize pressure losses See Figure 3 for pipe pressure losses 6 The OMG gas orifice meter is an integral 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 25 50 75 100 125 150...

Страница 12: ...Page 12 MS 9 Figure 3 Simplified Gas and Air Flow Chart Atmospheric Conditions GL86 ...

Страница 13: ... 3 000 4 000 5 000 0 20 000 40 000 60 000 80 000 100 000 120 000 140 000 160 000 180 000 0 2 4 6 8 10 12 14 Orifice Pressure Drop mbar Natural Gas Flow Rate m3 h Natural Gas Flow Rate SCFH Orifice Pressure Drop in w c MegaStar Orifice Meters Natural Gas SG 0 6 MS125 MS150 MS75 MS100 MS50 MS25 ...

Страница 14: ...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 achieved...

Страница 15: ...ering 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 pe...

Страница 16: ...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...

Страница 17: ...uction 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 desire...

Страница 18: ...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 ...

Страница 19: ... switch to the oil manifold heat tracing kit is energized the self regulating heat tracing should 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...

Страница 20: ...ment is removed 4 When the oil temperature drops below the set point 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 ...

Страница 21: ...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...

Страница 22: ...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...

Страница 23: ...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...

Страница 24: ...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 ...

Страница 25: ...w 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 the horizontal indicator bar follo...

Страница 26: ...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...

Страница 27: ...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 Eclipse 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 equipment including the baghouse an...

Страница 28: ...aks 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 Eclipse for recommendations CAUTION Eclipse 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 T...

Страница 29: ...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...

Страница 30: ...d 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 Eclipse 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 vaporizin...

Страница 31: ...Page 31 MS 9 Figure 14 Vapor Pressures of Propane Butane and Butane Propane Mixtures ...

Страница 32: ... 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...

Страница 33: ...Page 33 MS 9 Figure 16 Burner Front End Figure 17 LP Insert W9048 NOT TO SCALE W9048 NOT TO SCALE ...

Страница 34: ... 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 Comp...

Страница 35: ...t at multiple control points using the BCS7000 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 requir...

Страница 36: ...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 ...

Страница 37: ...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...

Страница 38: ...emble 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 ...

Страница 39: ... On Motor Shaft X RECOMMENDED SPARE PARTS ITEM QTY PART NO DESCRIPTION 1A 1 HK16847 Control Motor Fuel Medium Torque 2 1 16281 UV Scanner 3 2 KS84447812 Air Pressure Switch Combustion Air Purge Air 1 20 wc 25 508mm wc LP Low Pressure Oil Only 4 1 KS84447832 Air Pressure Switch Primary Air 12 60 wc 405 1520mm wc 5 1 HK61020 Air Pressure Switch Compressed Air 30 psig 207 kPa Table 14 Recommended Spa...

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