BBC BETA BURNERS

TABLE OF CONTENTS Subject Page

A. General Information…………………………………………………………….. 2 B. Receiving And Inspection………………………………………………………. 2 C. Burner Capacity Tables………………………………………………………… 3 D. Pre Installation Recommendations…………………………………………… 4 E. Installation………………………………………………………………….……. 5 F. Initial Burner Set-Up……………………………………………………………. 10 G. Burner Operation………………………………………………………………... 11 H. Maintenance……………………………………………………………………... 12

Appendix: Dimensions BBC 1104 – 3104 X6677……………… 15 Dimensions BBG_106 - _118 Y6871……………… 16 Dimensions BBC_106 - _118 Y4115……………… 17 Dimensions BBG_124 Y6872...……………. 18 Dimensions BBC 1124 Y5527……………… 19 Tile Dimensions BBC/BBG X6869……………… 20 Attachment: IPG-9

INSTRUCTIONS

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

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.

BBC-9

NOTE These instructions are intended for BBC burners firing gas or light oil. For heavy oil BBC applications using compressed air atomization, see BBC-9.1

HAUCK MANUFACTURING CO., P.O. Box 90 Lebanon, PA 17042-0090 717-272-3051 10/06 www.hauckburner.com Fax: 717-273-9882

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A. GENERAL INFORMATION Beta burners are baffle type burners designed for low-pressure air operation in furnace environments with temperatures up to 2100°F with the stainless steel baffle and up to 2700°F with the refractory baffle. Preheated air versions are available. The BBC and BBG burners fire any clean industrial fuel gas or No. 2 fuel oil, as appropriate for the model selected. (For heavy oil fuel see instruction sheet BBC-9.1). Capacities range from 2.5 million to 90 million Btu/Hr. Higher capacity models are available upon request. The Beta Burner flame shapes are well-defined throughout the burner’s operating range. Two tile options are available. The diverging tile produces a slow mixing, long, wide flame. The converging tile produces a shorter, narrower more well-defined flame. Turndown is approximately 8:1 on gas and 5:1 on oil. If operating with excess air, thermal turndown is greater. B. RECEIVING AND INSPECTION 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. Please review all drawings and instruction materials to become familiar with burner components, piping schematics, installation and operating procedures and safety precautions.

WARNING This equipment is potentially dangerous with the possibility of serious personal injury and property damage. Hauck Manufacturing Company recommends the use of flame supervisory equipment and fuel safety shutoff valves. Furthermore, Hauck urges rigid adherence to National Fire Protection Association (NFPA) standards and insurance underwriter’s requirements. Operation and regular preventative maintenance of this equipment should be performed only by properly trained and qualified personnel. Annual review and upgrading of safety equipment is recommended.

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 all motors, bearings, refractory material and control panels, if applicable, to protect them from rain or excessive moisture.

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C. BURNER CAPACITY TABLES Model Designations: 11XX = 1100 Series – Stainless Steel Baffle, 21XX = 2100 Series – Refractory Baffle, 31XX = 3100 Series – Refractory Baffle With Insulating Inserts BBC Models – Natural Gas Fired

Burner Model

Number

Atomizing Air Flow @ 4 OSI

(SCFH)

Main Air Flow @ 8 OSI (SCFH)

Total Burner Air Flow (SCFH)

Nominal Natural Gas Flow Rate

(SCFH)

Nominal Capacity Btu/hr

BBC_104 1,200 23,200 24,440 2,440 2,440,000 BBC_106 5,500 49,000 54,500 5,450 5,450,000 BBC_108 5,500 88,000 93,500 9,350 9,350,000 BBC_110 5,500 136,000 141,500 14,150 14,200,000 BBC_112 8,800 198,000 206,800 20,680 20,700,000 BBC_114 15,500 270,000 285,500 28,550 28,600,000 BBC_118 15,500 444,000 459,500 45,950 45,950,000 BBC_124 15,500 870,000 885,500 88,550 88,550,000

BBC Models – No. 2 Fuel Oil Fired

Burner Model

Number

Atomizing Air Flow

(SCFH)

Main Air Flow @ 8 OSI (SCFH)

Total Burner Air Flow (SCFH)

Nominal No. 2 Oil Flow Rate

(GPH)

Nominal Capacity Btu/hr

BBC_104 2,400 23,200 25,600 18.6 2,560,000 BBC_106 11,000 49,000 60,000 43.5 6,000,000 BBC_108 11,000 88,000 99,000 71.8 9,900,000 BBC_110 11,000 136,000 147,000 106.5 14,700,000 BBC_112 17,500 198,000 215,500 155.4 21,600,000 BBC_114 31,000 270,000 301,000 217.5 30,100,000 BBC_118 31,000 444,000 475,000 344.0 47,500,000 BBC_124 37,000 870,000 905,000 656.0 90,500,000

BBG Models – Natural Gas Fired Burner Model

Number Main Air Flow

@ 8 OSI (SCFH) Total Burner Air

Flow (SCFH) Nominal Natural Gas

Flow Rate (SCFH) Nominal

Capacity Btu/hr BBG_104 22,000 22,000 2,200 2,200,000 BBG_106 49,000 49,000 4,900 4,900,000 BBG_108 88,000 88,000 8,800 8,800,000 BBG_110 136,000 136,000 13,600 13,600,000 BBG_112 198,000 198,000 19,800 19,800,000 BBG_114 270,000 270,000 27,000 27,000,000 BBG_118 444,000 444,000 44,400 44,400,000 BBG_124 870,000 870,000 87,000 87,000,000

Notes: 1. Fuel flow rates based on natural gas at 1000 Btu/ft3 (S.G. = 0.60) and No. 2 fuel oil at a higher heating value of 138,000

Btu/gal. (S.G. = 0.87). 2. Fuel flow rates listed at Stoichiometric operation. 3. Nominal fuel turndown ratio is approximately 8:1 on natural gas and 5:1 on No. 2 oil; a greater thermal turndown ratio can be

achieved with excess air operation. 4. Air flows listed are for air at 100°F and sea level. 5. Main and atomizing air pressures listed are static pressures measured at their respective air pressure taps. 6. Oil pressure required for the high fire flow rates listed is 5 psig at the burner oil inlet. 7. Natural gas pressure required at the burner varies with furnace conditions. Typically, 4 OSI or less is required. 8. Atomizing air pressure required on oil firing for BBC_104 is 16 OSI and for BBC_124 is 20 OSI. All other sizes require a

minimum of 14 OSI atomizing air pressure for oil firing. (Atomizing air pressures above minimum rating {up to 20 osi} enhance performance.)

9. Higher capacities than listed are available. Consult factory for specific details.

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D. PRE INSTALLATION RECOMMENDATIONS The following guidelines and recommendations are made to assist personnel in avoiding potentially hazardous situations. 1. It is essential for those involved in installation and operation of burner equipment to become

familiar with all instruction materials, including burner components, piping schematics and installation, start-up and operating procedures.

2. Proper weather protection of equipment before installation will help ensure optimum system

performance. 3. Hauck Beta Burners must be mounted on properly braced, rigid furnace structures capable

of supporting burner weight. 4. All piping must be properly supported and aligned to avoid stresses at the burner

connections. Use flexible pipe nipples in the fuel & air lines to alleviate stress. 5. Initial adjustment and burner start-up should be performed only by trained and experienced

personnel who are familiar with combustion systems, control and safety circuitry, and overall system installation and operation.

6. Manual ignition or torch lighting is not recommended. 7. Do not attempt to bypass established control and flame safety procedures under normal

operating conditions. 8. Avoid exposure to products of combustion and be sure of proper ventilation at all times;

improper ventilation of combustion products can quickly lead to a hazardous environment. 9. Always be sure burner internals have cooled sufficiently before attempting to disassemble

any components. 10. Before any attempt is made to start burner equipment, check bolted joints for tightness of

fasteners and conduct a gas leak test in accordance with accepted practices.

WARNING Adjustment of this equipment, and its components, by unqualified personnel, can result in fire, explosion, severe personal injury, or even death.

Burner Model Approximate Burner Weight –Pounds Approximate Tile Weight – Pounds BBC/BBG-_104 BBC/BBG-_106 350 140 BBC/BBG-_108 350 140 BBC/BBG-_110 370 210 BBC/BBG-_112 425 300 BBC/BBG-_114 580 510 BBC/BBG-_118 1200 540 BBC/BBG-_124 3345 1200

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E. INSTALLATION Burner Mounting

1. The furnace shell plate must be provided with studs to match the mounting plate as shown on dimension drawing X6677, Y4115 or Y5527 SEE APPENDIX.

2. For installation in an existing soft wall furnace refer to drawing W7324 (below): remove the ceramic fiber blanket or board where the burner tile will be installed, 1" (25mm) larger than the outside diameter of the tile. Wrap tile with one layer of 1" (25mm) fiber rated for a higher temperature than the furnace. Secure fiber wrap with tape or twine to compress the ceramic fiber wrap to retain the fiber during installation. Pack additional fiber to fill any remaining openings completely. It is important to make sure the fiber is well packed around the burners silicon carbide firing tube. Fiber must be repacked after the initial firing of the burners. 3. For installation in an existing hard refractory wall refer to drawing W7324 (below): make the holes in the hard refractory where the burner tile will be installed, 1" (25mm) larger than the outside diameter of the tile. Wrap tile with one layer of 1" (25mm) fiber rated for a higher temperature than the furnace. Secure fiber wrap with tape or twine to compress the ceramic fiber wrap to retain the fiber during installation. Pack additional fiber to fill any remaining openings completely. It is important to make sure the fiber is well packed around the burners silicon carbide firing tube. Fiber must be repacked after the initial firing of the burner.

W7324 (NOT TO SCALE)

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4. If the burner has not been supplied with a self-supporting tile, a burner port will be needed. Refer to drawing X4195 or X5565 (below) for recommended burner port layout. If the self-supporting tile is being used, proceed to step #7.

5. Form the burner port to dimensions per drawing X4195 or X5565, using wood or metal mandrels centered on mounting plate studs. Mandrel dimensions include sufficient draft or taper for easy removal.

X5565 BBC/BBG_124 (NOT TO SCALE)

X4195 (NOT TO SCALE)

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6. Use only good quality plastic or castable refractory with a temperature rating of 2400°F, or

400°F above the maximum furnace design temperature, whichever is higher.

7. Hauck recommends refractory brick or high temperature alloy anchors to secure the burner refractory mass to the furnace shell. Use suggestions per drawing X4195 or X5565 as to spacing of anchors and provision for expansion joints, or follow the refractory manufacturer’s recommendations.

8. After the refractory has set properly, remove the burner port mandrel.

9. If the self-supporting tile is used, mount it to the furnace shell plate using 1" studs

positioned as shown on the dimensional drawings in the appendix. Place the burner tile mounting plate gasket over the studs, and then the burner tile assembly. Secure with lock washers and hex nuts.

10. Mount the burner to the furnace shell plate (or to the self-supporting tile mounting plate) as

follows: a. Position the main air inlet in the desired direction. b. Place the mounting plate gasket provided over the burner

mounting studs. c. Cover the outside surfaces of the burner tile with a 1/8" thick layer of high-

temperature cement or bonding mortar. d. Gently position the burner on its mounting studs and insert the body into the

burner tile or port. Check to make sure the main air inlet is positioned in the desired direction.

e. Position lock washers and mounting nuts on studs and tighten. f. Wipe off any excess cement which has been forced into the combustion chamber

at the joint between the burner body and the burner tile or port. If this cannot be done from inside the furnace, it will be necessary to remove the burner backplate assembly to permit access to clean off the inside surface of the tile (See Maintenance Section).

g. Cast refractory around the tile as needed or in a ceramic fiber wall, stuff the joint between the tile and fiber lining with extra fiber to compensate for eventual fiber shrinkage.

Air & Fuel Connections

11. Install the main air line at the burner body connection.

12. If necessary, the atomizing (primary) air connection and/or gas connection may be rotated in 45 degree increments as follows:

a. Remove the hex nuts and washers holding the atomizing (primary) air/gas body to the main air body.

b. Rotate the atomizing (primary) air/gas body to the desired position(s). c. Make sure the gaskets between the atomizing (primary) air/gas body and the

main air body are properly seated. d. Replace washers, hex nuts and securely tighten.

13. BBC AND BBG MODELS: Install and connect the gas line. 14. BBC MODELS ONLY: Install and connect the atomizing (primary) air line.

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15. BBC MODELS ONLY: Install the oil valve on burner oil inlet connection.

16. BBC MODELS ONLY: Connect the oil supply line to the inlet of the oil valve.

17. Install the pilot tip in the center port of one of the two sets of accessory ports on the burner body. Consult appendix drawings Y4115 or Y5527 and instructions that accompany the pilot for additional information.

16. If the observation port, pilot, and UV scanner must be relocated during installation due to interferences with piping, etc., the alternate ports can be utilized as follows (see drawing Y7205):

a. Remove the pipe plugs (or caps) from the alternate port connections. b. Remove the ceramic fiber insulation from the ports. c. Insert screwdriver or rod into each port and gently tamp on the plug of high

temperature cement to dislodge the plug. Use caution not to chip away refractory from the opening in the refractory ring.

d. Insert the ceramic fiber insulation into the original parts. Failure to insert ceramic fiber insulation into the unused ports may result in damage to the outer metal burner housing.

e. Secure the pipe plugs (or caps) in the original port connections.

IMPORTANT All burner models are provided with two sets of connections for observation port, pilot and scanner mounting. If the main air connection is at 6 or 12 o’clock, the accessory ports at either 3 or 9 o’clock can be used. However, both the pilot and scanner MUST be in adjacent ports on the SAME side of the burner. If the main air connection is at 3 or 9 o’clock, use the pilot and scanner connection ports located 180° from the main air connection. Neither the pilot nor the flame scanner should be located below the horizontal centerline of the burner, where they could be adversely affected by dirt and debris. Scanner connection should be supplied with 1 psi of purge air.

IMPORTANT All piping must be properly supported and aligned to avoid stresses on the burner and associated equipment. Hauck recommends that unions and flexible connections be used on all air and fuel lines. The unions will allow the burner to be more easily serviced when required, and the flexible connections will help isolate the burner from piping movement due to expansion, contraction and vibration.

NOTE The BBC/BBG_124 scanner connections are positioned at 45° and 225° clockwise from the air connection center line. Use above guidelines to choose scanner port.

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f. Install a thin coat of high temperature cement over the original ports from the inside of the burner (Hauck recommends Resco Adamant or equivalent) to contain the ceramic fiber insulation.

17. If an ultraviolet flame detection scanner is used, install it in the correct accessory port adjacent to the pilot connection. Provide a 1 psi air source for the scanner air purge by connecting the atomizing (primary) air line to the 3/8" NPT bushing on the scanner adapter using 3/8" OD tubing and a suitable isolating valve. 18. Complete the mounting of pilot components and connection of air, gas and mixture lines.

19. Inspect all bolted joints on the burner. Be sure all fasteners are tight.

20. Before the burner is placed in service, a gas leak test should be conducted in accordance

with standard, accepted practices. One method is to apply a soap and water solution to ALL threaded and flanged joints in the gas body and the gasket around the burner backplate (including the bolts) and any other area where the possibility of a gas leak exists. Pressure should be present for this test.

CAUTION In order to ensure an adequate seal, it is important that the burner backplate bolts be sufficiently tight. Before any attempt is made to start the burner, check to ensure that the bolts are sufficiently tight and conduct a gas leak test. Failure to check and ensure that a satisfactory seal exists by conducting a leak test could result in the formation of a hazardous gas leakage condition. Whenever burner internals are removed for cleaning or replacement, be sure to tighten the backplate bolts and conduct a gas leak test.

CY7205

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F. INITIAL BURNER SETUP For pilot operation with burner sizes _106 through _118, see sheet IPG-9. For pilot operation with the _124 model burner, see appendix.

CAUTION Initial adjustment and burner start-up should be undertaken only by trained and experienced personnel familiar with combustion systems, control and safety circuitry and overall installation procedures.

NOTE • Beta Burner Model _104 uses a Hauck #1 pilot IPG5411A. • Beta Burner Models _106 through _118 use a Hauck #3 pilot IPG5413A. • The _124 model uses a forced air premix pilot system.

CAUTION Ensure that all safety equipment and limits are working properly before proceeding.

CAUTION Failure to achieve ignition of pilot or main flame within a safe period (10 sec.) could result in a build-up of a combustible gas mixture which could lead to an explosion. In the event that the pilot or main flame does not light within the above time period, shut off fuel valves and re-purge the chamber before attempting further adjustment.

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G. BURNER OPERATION

a. Atomizing (primary) air pressure should be 14 osi (16 osi for BBC_104 and 20 osi for BBC_124) for No. 2 oil, and 4 osi for gas-fired BBC models. No atomizing (primary) air is needed for gas-fired BBG models. All models will operate with up to 20 osi atomizing air pressure.

b. Main air pressure ranges from approximately 0.1 osi (minimum rating) to 8 osi (maximum rating) static pressure at the burner inlet.

c. Oil pressure required for the high fire rates listed is 5 psig at the burner oil connection.

d. Nominal natural gas pressure required at the burner is 4 osi (7" wc). Actual pressure required may vary.

e. Ignite the burner by proceeding as follows: (1) BE SURE all fuel shutoff valves are closed and all control valves are in

the LOW FIRE position. (2) Start the combustion air blower. (3) Ensure that the pilot gas cock is closed. (4) Turn the pilot air cock to the full open position. (5) Energize the ignition transformer. (6) Open the pilot gas cock. (7) Once the pilot flame has been established, (confirm using observation

port), discontinue the spark. (8) Slowly open the main fuel shutoff valve(s). (9) Allow the burner to remain on low fire for a few seconds before

repositioning the firing rate control valve. (10) Close the pilot gas cock, while leaving the pilot air cock open. (11) Modulate the burner up and down to be sure the system responds

properly and the fuel/air ration does not exceed the limits of the burner. (12) Lock all linkage adjustments and return all control system functions to

normal, if changed during initial adjustment. To shut down the burner:

1. Return the burner to the low fire position. 2. Close all fuel shutoff valves. 3. Allow the furnace to cool to 800°F or less before shutting off the combustion air blower.

Daily Operation

1. The specific operation of the burner will depend on the individual system components comprising the combustion system. Refer to the instruction sheets and system piping schematics which accompany the individual items.

2. The burner should always be ignited under low fire conditions.

IMPORTANT The burner tile should be subjected to rapid heat increases at initial start-up. Allow low fire drying for at least 6 – 8 hours before exposing the system to normal firing operation. Thereafter, if the tile is exposed to excessive moisture or extended periods of dampness, allow at least 30 minutes of low fire drying before beginning normal operation.

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3. If the burner ignition tile is exposed to excessive moisture or extended periods of dampness, allow at least 30 minutes of low fire drying before beginning normal operation. Failure to do so will cause any moisture present to expand rapidly, causing damage to the refractory.

H. MAINTENANCE Hauck Beta Burners have been carefully engineered to provide dependable performance while requiring low maintenance. As with any product, it is very important to follow operating instructions and all procedures carefully to obtain optimum performance. Please refer to the applicable Beta Burner Parts List to become familiar with the various burner components and assemblies.

1. Burner components which should be checked periodically and cleaned, if necessary, include: a. Oil valve (separated purchase item – BBC models only b. Oil atomizer (BBC models only)

(1) Disconnect oil line from burner. (2) Remove bolts from atomizer backplate. (3) Completely remove backplate/oil tube/atomizer from burner. (4) Measure the distance from the inside of the backplate to the rear of the oil

nozzle. (5) Inspect parts and disassemble to clean, if needed. (6) Reassemble after cleaning, making sure that above dimension (step #4) is

maintained. (7) Reinsert the assembly into burner body, making sure that the gasket is

properly seated. (8) Replace bolts and securely tighten. (9) Reconnect oil line to oil valve.

c. Atomizer assembly (BBC models only) (1) Disconnect oil and atomizing (primary) air lines from burner. (2) Remove rear set of hex bolts from gas body backplate. (3) Remove atomizer assembly from burner. (4) Inspect and clean, if needed. (5) Inspect gas tube, looking into rear of gas body, and clean if any oil or residue

exists. (6) Reinsert atomizer assembly into burner body, making sure that the gasket is

properly seated and the primary air inlet is properly repositioned. (7) Replace hex bolts and securely tighten. (8) Reconnect oil and atomizing (primary) air lines.

d. Gas body assembly (All Models) (1) Disconnect fuel and atomizing (primary) air lines (if used). (2) Remove front set of hex bolts from air body backplate. (3) Remove gas body assembly from burner.

CAUTION Be sure burner internals have cooled sufficiently before attempting to disassemble any components. Use care when separating gasket surfaces to avoid damage to the gaskets.

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(4) Inspect internal parts. Clean the interior walls of gas body assembly and gas tube assembly of any oil or residue.

(5) Check condition of internal baffle and clean main air openings in baffle, if needed.

(6) Clean the atomizer assembly, if necessary. (7) Reinsert gas body assembly, making sure that the gasket is properly seated

and inlets are properly repositioned. (8) Replace hex bolts and securely tighten. (9) Reconnect fuel and atomizing (primary) air lines.

2. Replacement of Internal Baffle In certain situations, it may become necessary or desirable to replace the internal baffle of the burner. The baffle on Beta Burner 1100 series models is made of high temperature stainless steel, while the baffles on 2100 and 3100 series burners are made of high temperature refractory. In order to replace the internal baffle, use the following procedure:

a. Disconnect fuel and atomizing (primary) air lines (if used). b. Loosen the backplate bolts. c. Remove burner internals after breaking the seal between the internal baffle and

the main tile. Be careful not to damage the internal body liners (BBC-3100 models).

d. For 1100 series models (stainless steel baffle): (1) Remove (3) ¼" hex head cap screws and baffle from gas tube. (2) Place new baffle on gas tube. (3) Replace hex screws and tighten.

e. For 2100 and 3100 series models (refractory baffle): (1) Remove the backplate flange bolts. (2) Remove the backplate with the gas tube attached. (3) Replace the Fiberfrax gasket on the gas tube end. (4) Remove the refractory baffle from the burner. (5) Coat the outside of the new baffle with liquid Fiberfrax. (6) Install in the burner.

f. For all models: (1) Coat the outer rear edge of the plate forming a seal between the burner shell

and the refractory baffle. (2) Reinstall the burner backplate with the fiber gasket in place on the gas tube

end. (3) Tighten the flange bolts (torque to 30 ft-lbs). (4) Reinstall all piping and check for gas leaks before restarting burner.

CAUTION Failure to check and ensure that a satisfactory seal exists by conducting a gas leak test could result in a hazardous condition.

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3. Replacement of Self-Supporting Refractory Tile Refractory tiles should be checked for coke/residue build-up or damage. If this cannot be done from inside the furnace, it will be necessary to gain access to the tile by removing the burner backplate assembly as described in step 2. Should it ever become necessary to replace the burner refractory tile, use the following procedure:

a. Disconnect all fuel and air piping from burner. b. Remove flame scanning equipment and pilot from accessory ports. c. Support the burner weight before loosening mounting nuts. d. Loosen the (4) 1" burner mounting nuts from the burner mounting studs and

remove the burner assembly from the furnace. e. Loosen and remove the (8) 1" tile mounting nuts from the mounting plate studs. f. Remove the existing burner tile from the furnace wall and clean the tile port

opening. g. Inspect the refractory in the area surrounding the tile and repair any damage. h. Replace the burner tile mounting gasket, if necessary. i. Mount the new burner refractory tile. j. Replace tile mounting nuts and tighten. k. Scrape off any excess mortar from the face of the burner. l. Repeat steps 8 through 18 in the installation section (G.) of these instructions.

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APPENDIX A

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APPENDIX B

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APPENDIX C

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APPENDIX D

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APPENDIX E

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APPENDIX F

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APPENDIX G BBC/BBG-_124 Burner Pilot System The BBC/BBG-_124 can employ a Hauck forced air premix pilot. The pilot uses a Hauck Retain-A-Flame tip. Nominal capacity is 250,000 Btu/hr. Minimum air pressure differential required: 14"wc Minimum gas pressure differential required: 3"wc Spark gap: 1/8" Operation: Before connecting the pilot assembly, the fuel line should be purged to remove any dirt. Pipe the pilot gas supply line to the inlet of the pilot shutoff valve, check for leaks. Size the pilot gas supply line to avoid excessive pressure drops. For supply lines up to 25', use ½" pipe. Constant gas pressures ranging from 12-18 psig must be available at the inlet of the Hauck gas pilot manifold. Note: the gas pressure must not exceed 20 psig, and pressure lower than 12 psig can result in a weak, unreliable pilot. The spark wire gap is factory set at 1/8" This gap can be changed by carefully removing the pilot internals. Bend the spark wire to adjust, reinsert and check the gap. The thickness of a nickel can be used as a gauge for adjusting the spark gap. Complete the initial adjustment as follows: 1. Make sure the spark igniter is connected to the ignition transformer. 2. Place the pilot butterfly valve at the ½ open position 5. 3. Remove the protective hex cover from the Hauck Adjustable Gas Limiting Valve (LVG) and

rotate the adjustment screw 3 to 4 turns from the fully closed position. This initial recommended setting may be changed during the final adjustment of the pilot.

4. Remove the protective cover from the pilot gas regulator and rotate the adjustment screw until the scale on the regulator indicates that it is one-half open. This is only a preliminary setting and may be changed to provide optimal pilot performance.

5. Adjust the LVG (and if necessary the air valve) until a good strong pilot is obtained. 6. The pilot flame can be observed through one of the observation ports on the side of the

burner.

CAUTION Avoid contact with the ignition wire as a painful shock can result.

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HAUCK MANUFACTURING CO., P.O. Box 90 Lebanon, PA 17042-0090 717-272-3051 www.hauckburner.com Fax: 717-273-9882

IPG IGNITION GAS PILOTS BACK-LOADED GAS

TABLE OF CONTENTS Subject Page A. General Information ……………………………………………………….…..….……. 2 B. Receiving and Inspection ………………………………………….…….…...…….….. 2 C. Capacities ………….……………………………………………………………………. 3 D. Dimensions …………….………………………………………………………………... 4 E. Installation ……………………………………………………………………………….. 8 F. Ignition……………………………………………………………………………………. 8 G. Operation…………………………………………………………………………………. 11 H. Shutoff Valve Leak Testing…………………………………………………………….. 11 I. Maintenance……………………………………………………………………………… 13 HAUCK MANUFACTURING CO., P.O. Box 90 Lebanon, PA 17042-0090 717-272-3051

10/07 www.hauckburner.com Fax: 717-273-9882 IPG-9

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

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.

INSTRUCTIONS

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IPG-9

A. GENERAL INFORMATION The Hauck Series IPG Blast Type Back-Loaded Gas Pilot provides a means of lighting the flame of Hauck burners and many other industrial gas or oil burners. IPG pilots are engineered for exceptional flame stability and long life, even under the most severe and adverse operating conditions. IPG pilots are designed for electric spark ignition. The standard IPG Back-Loaded Pilots are suitable for firing into neutral, negative or positive pressure applications. The back-loaded feature offers the capability to compensate the pilot air/fuel ratio for variations in furnace or burner pressure. B. RECEIVING AND INSPECTION 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.

WARNING This equipment is potentially dangerous with the possibility of serious personal injury and property damage. Hauck Manufacturing Company recommends the use of flame supervisory equipment and fuel safety shutoff valves. Furthermore, Hauck urges rigid adherence to National Fire Protection Association (NFPA) standards and insurance underwriter’s requirements. Operation and regular preventative maintenance of this equipment should be performed only by properly trained and qualified personnel. Annual review and upgrading of safety equipment is recommended.

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 all motors and bearings, if applicable, to protect them from rain or excessive moisture.

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IPG-9

C. CAPACITIES

NOTES: 1. Capacities based on natural gas with HHV of 1034 Btu/ft3, a stoichometric air/gas ratio of

9.74:1 with a 6"wc mixture pressure and the pilot firing into burner.

2. Ambient combustion air is required at a constant air pressure to the inlet of the mixing tee in the 14 - 55"wc range; capacities listed based on static air pressure of 27.7"wc.

3. Ambient gas should be supplied to the inlet of the gas regulator at a nominal

14"wc; maximum gas supply pressure is 27.7"wc.

Table 1. IPG Capacities

NOTES: 1. Capacities based on natural gas with LHV of 36.74 MJ/nm3, a stoichometric air/gas ratio of

9.74:1with a 1.5 kPa mixture pressure and the pilot firing into burner.

2. Ambient combustion air is required at a constant air pressure to the inlet of the mixing tee in the 3.5 - 14.7 kPa range; capacities listed based on static air pressure of 6.9 kPa.

3. Ambient gas should be supplied to the inlet of the gas regulator at a nominal 3.5 kPa

maximum gas supply pressure is 6.9 kPa.

Table 2. IPG Metric Capacities

PILOT SIZE

SPECIFICATIONS 1 2 3

Port Area (in2) 0.069 0.122 0.254

Input @ Stoichiometric Air/Fuel (Btu/hr) 21,800 40,800 80,500

Air Flow @ 27.7"wc (scfh) 205 385 760

PILOT SIZE

SPECIFICATIONS 1 2 3

Port Area (nm2) 44.5 78.7 164

Input @ Stoichiometric Air/Fuel (kW) 5.8 10.8 21.3

Air Flow @ 6.9 kPa (nm3/hr) 5.5 10.3 20.4

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IPG-9

D. DIMENSIONS

Figure 1. Dimensions Back-Loaded Gas

Y813

1 (N

OT

TO S

CAL

E)

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D. DIMENSIONS (Continued)

Figure 2. Metric Dimensions Back-Loaded Gas

Y813

1 M

ETR

IC

(NO

T TO

SC

ALE)

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IPG-9

D. DIMENSIONS (Continued)

Figure 3. Dimensions Back-Loaded Gas Less Solenoid Valves

Y237

5 (N

OT

TO S

CAL

E)

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IPG-9

D. DIMENSIONS (Continued)

Figure 4. Metric Dimensions Back-Loaded Gas Less Solenoid Valves

Y237

5 M

ETR

IC

(NO

T TO

SC

ALE)

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IPG-9

WARNING Adjustment of this equipment by unqualified personnel can result in fire, explosion, severe personal injury, or even death.

E. INSTALLATION 1. Ensure that all components of the factory assembled pilot are present and properly

connected. The pilot unit consists of a low pressure gas regulator, air ball valve, gas ball valve, gas mixer, pilot nozzle assembly, union (threaded pilots only), and flexible pipe nipple.

2. Install the pilot assembly in the air and gas lines. The gas pressure regulator is used as a zero governor and is suitable for any mounting position without restriction. a. Connect the air piping to the inlet side of the air ball valve. Low pressure air should be

supplied at a constant pressure ranging from 14 - 55"wc (3.5 - 13.7 kPa) at the inlet of the ball valve.

b. Connect the gas piping to the inlet side of the gas ball valve. Low pressure gas should be supplied at approximately 14"wc (3.5 kPa) at the inlet of the regulator. The regulator is designed to operate from 13.8 - 27.7"wc (3.4 - 6.9 kPa); maximum allowable inlet pressure is 1 psig (6.9 kPa).

c. Ensure that the air and gas ball valves are fully closed. F. IGNITION

1. Be sure the spark plug is set as shown in Figure 5. Ideally, initial pilot set-up should be done

with the pilot outside of the burner. 2. Connect a 5000/6000 volt standard coil type ignition transformer to the spark plug on the

spark igniter using a high voltage ignition wire. Ensure that the spark plug’s wire electrode is centered in the pilot nozzle.

NOTE To reduce pressure losses, use adequate sized pipe and minimize elbows in the air and gas lines to the pilot assembly. It is recommended that the air and gas supply be equal to or greater than their respective pilot air and gas connection sizes. If the pilot is installed at the end of a long run of pipe or will be operated in a dirty environment, it is recommended that a sediment trap be installed in the pilot air line.

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IPG-9

F. IGNITION Continued)

Figure 5. Spark Gap Setting and Electrode Positioning 3. Ensure that the gas ball valve is closed. 4. Start the blower or air supply. 5. Open the air ball valve to the full open position.

NOTE Ensure pilots are properly grounded to prevent equipment damage or personal injury. Exercise care to avoid over-tightening the spark plug holding nut as this may crack the ceramic insulator of the plug. Avoid, where possible, the use of long ignition wires. Long ignition wire can cause rapid spark plug wear or erosion. Suggested methods to avoid this problem are explained in Application Sheet GJ57.

CAUTION Ignition of the pilot results in a high voltage spark in excess of 5000 volts and an open flame. Remain clear of ignition wire, spark plug and pilot nozzle while firing the pilot.

S4241 (NOT TO SCALE)

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IPG-9

6. Energize the ignition transformer and verify that an adequate spark is produced. 7. Open the gas ball valve fully. This ball valve should be open fully at all times when

the pilot is burning. 8. Adjust the pilot until the proper flame is achieved. The best flame is a sharp, high velocity,

blast type, blue flame. The tangential holes around the nozzle should have small sharp flames coming out of them and the edges of the nozzle should begin to glow red. However, if this flame is achieved when the nozzle is outside of the burner port, the pilot can burn rich (i.e., excess fuel) when properly seated in the burner. Therefore, when adjusting the pilot outside of the burner port, a slightly lean (i.e., excess air) flame is recommended. When the pilot nozzle is inserted into the burner, the flame will burn ‘on ratio’ (i.e., stoichiometric air/fuel ratio) and have the characteristics desired.

Air/Fuel ratio adjustment is accomplished as follows:

a. Loosen the lock nut on the mixer. b. Rotate the mixture adjusting screw clockwise for a leaner flame or counterclockwise for a richer flame. c. Tighten the lock nut.

Figure 6. Pilot Mixer Adjustment

9. To extinguish the pilot: a. Close gas ball valve first. b. Close air ball valve last (if desired).

NOTE When lighting grouped pilots, as soon as one pilot in a group (supplied by one large mixer) is ignited, light the others in the group at once before starting a new group or igniting the main burners.

S4243 (NOT TO SCALE)

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IPG-9

10. Insert a slip-fit pilot into the burner and tighten the setscrew on the burner to lock the pilot

nozzle in place (if applicable). 11. Insert a threaded pilot as follows:

a. Disconnect the union between the pilot nozzle and flex nipple. b. Thread the pilot into the port and wrench tighten until snug. c. Reconnect the union.

G. OPERATION When properly adjusted, the pilot should produce a sharp, high velocity, blast type, blue flame. If adjustment is necessary, refer to the Ignition section. H. SHUTOFF VALVE LEAK TESTING Both safety shutoff valves in the gas pilot manifold should be leak tested on a yearly basis at minimum. Refer to the gas pilot piping diagram for leak testing shown in Figure 7.

Figure 7. Gas Pilot Piping Diagram for Leak Testing

NOTE The pilot nozzle tip should be located slightly behind the main burner nozzle discharge area so that it will not obstruct or be affected by the air/fuel discharge of the main burner.

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H. SHUTOFF VALVE LEAK TESTING (Continued) 1. Shutoff the burner (s) and furnace. 2. Close the manual shutoff valve downstream of Safety Shutoff Valve No. 2. 3. Open the equipment isolation valve downstream of Safety Shutoff Valve NO. 2 4. Bleed off trapped gas by opening both Leak Test Valves No. 1 and No. 2. 5. Close Leak test Valve No. 2. 6. Connect 3/16" (4.8mm) ID tubing to Leak Test Valve No. 1 and immerse the open end of

the tubing in a container of water. Hold the tubing vertically 1/8 to 1/4" (3 to 6mm) below the surface. If bubbles appear, record the leakage rate in bubbles/min and refer to the IMPORTANT note at the end of this section.

7. Close Leak Test Valve No. 1 and apply auxiliary power to open Safety Shutoff Valve No. 1. 8. Wait several minutes so that any leakage through Safety Shutoff Valve No. 2 will have time

to fill the pipe between Safety Shutoff Valve No. 2 and the manual shutoff valve. 9. Connect the tubing to Leak Test Valve No. 2 and immerse the open end in water as before.

Open Test Valve No. 2. If bubbles appear, record the leakage rate in bubbles/min and refer to the IMPORTANT note at the end of this section.

10. When no leaks are detected, open the shutoff valve at the outlet of the PGM and return to normal operation.

IMPORTANT The fact that bubbles are present during the leak test does not necessarily mean that a safety shutoff valve is not functioning properly in the closed position. Refer to the National Fire Protection Association’s publication NFPA 86 for acceptable leakage rates for a given pipe size per UL, ANSI, CSA, FM or EN standards. If the acceptable bubbles/min leakage rate is exceeded, the safety shutoff valve is leaking and the manufacturer’s instructions should be referenced for corrective action.

WARNING Do not attempt to operate the combustion system until all leaks are repaired.

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IPG-9

I. MAINTENANCE All components of the pilot assembly are engineered to provide relatively maintenance free operation. It is sometimes necessary, however, to clear the mixer jet of any debris as this causes mixer capacity to diminish. The mixer jet is easily cleaned by removing the air piping downstream of the air ball valve and running a wire into the mixing tee opening through the jet. The gas inlet of the mixer can also be cleaned by the same method. Fully removing the adjustment screw also provides access to clean the mixer. The pilot nozzle may become plugged with debris or carbon buildup. To clean the nozzle, remove the pilot assembly from the burner. Disconnect the nozzle from the pilot assembly and remove the spark plug assembly. Check carefully to ensure the ceramic insulator is not broken. Clean the small tangential holes that surround the main hole and blow the nozzle out with air when complete. Reassemble the pilot assembly, test fire, and reinsert the pilot into the burner (see Figure 8). Periodically remove and inspect the spark plug. If the ceramic insulator is cracked or broken, replace it. Clean the unit of any carbon buildup. When replacing the plug, avoid over-tightening the nut holding the plug to avoid cracking the plug’s ceramic insulator. Before use, ensure the plug’s wire electrode is centered in the pilot nozzle (see Figure 5 for setting spark plug).

Figure 8. Cleaning Pilot Nozzle and Piloting Holes

Gas Pilot Body Gas Pilot Shell

Clean Pilot NozzleOrifices With Thin

Wire & Air.

Pilot Air/Gas Mix Inlet

Main Pilot Orifice.Clean As Necessary

If any dirt or buildup accumulates on GasPilot Shell, clean with wire brush. Keepholes around Gas Pilot Shell Clear.

(NOT TO SCALE)

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HAUCK MANUFACTURING CO., P.O. Box 90 Lebanon, PA 17042-0090 717-272-3051 www.hauckburner.com Fax: 717-273-9882