BBC BETA BURNER burner...2 BBC-9 Page A. GENERAL INFORMATION Beta burners are baffle type burners...

BBC BETA BURNER

TABLE OF CONTENTS Subject Page

A. General Information…………………………………………………………….. 2 B. Receiving And Inspection………………………………………………………. 2 C. Burner Capacity Tables………………………………………………………… 3 D. Dimensions………………………………………………………………………. 5 E. Pre Installation Recommendations…………………………………………… 5 F. Installation………………………………………………………………….……. 6 G. Initial Burner Set-Up……………………………………………………………. 12 H. Burner Operation………………………………………………………………... 13 I. Maintenance……………………………………………………………………... 14

Appendix…………………………………………………………………………. 16 Attachment: IPG-9

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

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.

Cty TNHH THIẾT BỊ NHIỆT ĐÌNH HẢI ĐT: (08) 3863 7722

chi

Stamp

chi

Text Box

chi

Text Box

2

BBC-9 Page

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. 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.

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.

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.


3

BBC-9 Page

C. BURNER CAPACITY TABLES

NATURAL GAS OPERATION

Model Number

Specifications - HIGH FIRE _04 _06 _08 _10 _12 _14 _18 _24

Max Input @ 10% Excess Air (MMBtu/hr) 3.3 6.7 9.0 13.6 20.0 27.5 44.4 85.4

Max Excess Air (%) 320 320 400 500 560 600 700 600

Flame Length @ Max Input (ft) 7 8 9 13 14 15 18 25

LOW FIRE

Input @ 10% Excess Air (MMBtu/hr) 0.3 0.9 1.6 2.1 3.2 4.7 6.8 11.6

Max Excess Air (%) 150 210 350 260 250 80 270 100

LOW PRESSURE OIL OPERATION

Model Number



Max Excess Air (%) 270 690 400 1000 500 550 350 1000


LOW FIRE


Max Excess Air (%) 70 20 500 700 400 160 80 200

HIGH PRESSURE OIL OPERATION

Model Number



Max Excess Air (%) 70 160 120 400 400 600 350 750


LOW FIRE


Max Excess Air (%) 90 55 100 100 100 150 220 500

Notes: 1. All burners equipped with converging tile and refractory baffle plate. 2. Btu input based on HHV’s of natural gas with 1034 Btu/ft3, and 9.74:1 air/fuel ratio No. 2 oil with

138,000 Btu/gallon, and 1380:1 air/fuel ratio and No. 6 oil with 151,000 Btu/gallon, 1510:1 air/fuel ratio.

3. Flame lengths measured from the end of converging tile; for a diverging tile (available from size _ _06 to _ _18), add 18% to the converging tile flame length.

Table 1. BBC/BBG Capacities Cty TNHH THIẾT BỊ NHIỆT ĐÌNH HẢI ĐT: (08) 3863 7722

4

BBC-9 Page

C. BURNER CAPACITY TABLES (Continued)

NATURAL GAS OPERATION

Model Number


Max Input @ 10% Excess Air (MW) 0.9 1.8 2.4 3.6 5.4 7.3 11.7 22.6

Max Excess Air (%) 320 320 400 500 560 600 700 600

Flame Length @ Max Input (m) 2.0 2.4 2.7 4.0 4.3 4.6 5.5 7.6

LOW FIRE

Input @ 10% Excess Air (MW) 0.1 0.2 0.4 0.6 0.8 1.2 1.8 3.1

Max Excess Air (m) 150 210 350 260 250 80 270 100

LOW PRESSURE OIL OPERATION

Model Number



Max Excess Air (%) 270 690 400 1000 500 550 350 1000


LOW FIRE


Max Excess Air (%) 70 20 500 700 400 160 80 200

HIGH PRESSURE OIL OPERATION

Model Number



Max Excess Air (%) 70 160 120 400 400 600 350 750


LOW FIRE


Max Excess Air (%) 90 55 100 100 100 150 220 500

Notes:

1. All burners equipped with converging tile and refractory baffle plate. 2. Btu input based on LHV’s of natural gas with 36.74MJ/nm3, No. 2 oil with 37MJ/L, and No. 6 oil with 41.3 MJ/L 3. Flame lengths measured from the end of converging tile; for a diverging tile (available from size _ _06

to _ _18), add 18% to the converging tile flame length.

Table 2. BBC/BBG Metric Capacities Cty TNHH THIẾT BỊ NHIỆT ĐÌNH HẢI ĐT: (08) 3863 7722

5

BBC-9 Page

D. DIMENSIONS See appropriate Dimension sheet for detailed dimensional information. E. 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. Control regulators should be as close as possible to the burner. Hauck recommends total

distance of no more than 18 inches (460mm) from the burner. Regulators used for an oil system should be installed 6 inches (150mm) below burner centerline. Consult component literature for details.

3. For greatest efficiency, flow meters should be used. Orifice flow meters require 10 pipe

diameters of straight piping into the flow meter and 5 pipe diameters of straight piping downstream of the flow meter.

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

performance. 5. Hauck Beta Burners must be mounted on properly braced, rigid furnace structures capable

of supporting burner weight. Burners firing on oil must not be used in up-fired applications.

Burner Model

Approx. Burner

Net Weight

Approx. Refractory Tile

Net Weight BBC/BBG_ 104 100 lb (45 kg) 95 lb (43 kg) BBC/BBG_ 106 350 lb (159 kg) 140 lb (63 kg) BBC/BBG_ 108 350 lb (159 kg) 140 lb (63 kg) BBC/BBG_ 110 370 lb (168 kg) 210 lb (95 kg) BBC/BBG_ 112 425 lb (193 kg) 300 lb (136 kg) BBC/BBG_ 114 580 lb (263 kg) 510 lb (231 kg) BBC/BBG_ 118 1,200 lb (544 kg) 540 lb (245 kg) BBC/BBG_ 124 3,345 lb (1,520 kg) 1,200 lb (544 kg)

Table 3. Burner and Tile Weights

6. 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.

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


6

BBC-9 Page

7. 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.

8. Do not attempt manual ignition or torch lighting. 9. Do not attempt to bypass established control and flame safety procedures under normal

operating conditions. 10. 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. 11. Always be sure burner internals have cooled sufficiently before attempting to disassemble

any components. 12. 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. F. INSTALLATION

1. The furnace shell plate must be provided with studs to match the mounting plate as shown

on dimension drawings (See appropriate Dimensional sheets).

2. For horizontal tile installation in an existing hard or soft wall furnace refer to Figure 1.

Remove any hard material and any 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 burner tile. Fiber must be repacked after the initial firing of the burners. For angled or thick wall installations refer to step 3, otherwise proceed to step 8.

3. For optional installations in existing hard refractory walls refer to Figures 2 and 3. Both of

these mounting options can be accomplished with the burner supplied tile, as shown in Figure 3, or less the burner tile by ramming or casting the tile shape into the wall as shown in Figure 2. If the burner tile is installed (see Figure 3), follow the tile installation outlined in step 2 above, then proceed to step 4.

NOTE The burner can be supplied and mounted with the tile as shown in Figures 1 and 3 (required for soft wall installations) or the tile can be formed in a cast or rammed port block as shown in Figure 2.

NOTE Installation detail shown to emphasize burner tile/port geometry. Furnace wall shown as typical refractory construction; refractory and wall construction details and fabrication methods should be completed by qualified personnel. The burner tile and/or rammed refractory port must be protected from mechanical stress.


7

BBC-9 Page

F. INSTALLATION (Continued) If the wall is thicker than the tile, provide a port flare, D°, as shown in Figure 3. If the burner is supplied less tile, then the port opening must be formed as shown in Figure 2, by dimensions ‘A, B’, and ‘C. If the wall is thicker than the ‘tile’ or port length ‘C’, then provide a port flare, D°, as shown. If needed, a maximum straight extension of 6" (152mm) may be provided at the ‘tile’ discharge as shown in Figure 3. Proceed to step 4.

Figure 1. Burner Installation with Refractory Tile

W7324 (NOT TO SCALE)


8

BBC-9 Page

Figure 2. Burner Installation (less tile) in Hard Refractory Wall

Figure 3. Optional Tile Installation for Hard Refractory Thick or Angled Wall

X4195 (NOT TO SCALE)

X8427 (NOT TO SCALE)


9

BBC-9 Page

4. Form the burner port to dimensions per Figure 2 or Figure 3 using wood or metal mandrels

centered on mounting plate studs. Mandrel dimensions include sufficient draft or taper for easy removal.

5. 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. 6. Hauck recommends refractory brick anchors or high temperature alloy anchors to secure the

burner refractory mass to the furnace shell. Follow the refractory manufacturer’s recommendations, for anchoring and expansion joints to ensure there is no mechanical stress transmitted to the burner tile.

7. After the refractory has set properly, remove the burner port mandrel. 8. 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. Wrap the burner tile with ceramic fiber as required to tightly pack all voids. Place the burner tile mounting plate gasket over the studs, and then the burner tile assembly. Secure with lock washers and hex nuts.

9. 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, bonding mortar or tile cushion gasket. 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 10. Install the main air line at the burner body connection. 11. 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.

12. BBC AND BBG MODELS: Install and connect the gas line. 13. BBC MODELS ONLY: Install and connect the atomizing (primary) air line. Cty TNHH THIẾT BỊ NHIỆT ĐÌNH HẢI ĐT: (08) 3863 7722

10

BBC-9 Page

14. BBC MODELS ONLY: Install the oil valve on burner oil inlet connection. 15. BBC MODELS ONLY: Connect the oil supply line to the inlet of the oil valve. 16. Install the pilot tip in the center port of one of the two sets of accessory ports on the burner

body. Consult dimensional drawings and instructions that accompany the pilot for additional information.

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.

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.

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.


11

BBC-9 Page

17. 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 Figure 4):

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 ports. 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. 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.

Figure 4. Alternate Port Sealing Instructions

18. 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.

19. Complete the mounting of pilot components and connection of air, gas and mixture lines. 20. Inspect all bolted joints on the burner. Be sure all fasteners are tight. 21. Before the burner is placed in service, a gas leak test should be conducted in accordance

with standard, acceptance 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.

Y7205 (NOT TO SCALE)


12

BBC-9 Page

G. INITIAL BURNER SETUP For pilot operation with burner sizes _106 through _118, see attached sheet IPG-9. For pilot operation with the _124 model burner, see appendix (page 16). To determine flame lengths at different excess air values, use the following equation:

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.

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.


13

BBC-9 Page

H. BURNER OPERATION

a. 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. All models will operate with up to 20 osi primary air pressure.

b. Secondary air pressures range nominally from approximately 0.1 osi (minimum rating) to 8 osi 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. 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.

CAUTION All cast refractory burner components are porous and therefore subject to moisture absorption. Refractory components should not be stored or exposed to damp conditions potentially reducing their normal expected life. Care must be taken at initial startups and after extended idle times to assure refractory components have been sufficiently dried prior to normal firing conditions. It is highly recommended that low fire drying for at least 6-8 hours at 50 to 100% excess air occur at initial startups prior to exposing refractory components to normal firing operation. Thereafter, if the refractory components are exposed to excessive moisture, condensation, or high humidity for extended periods, allow at least 30 minutes of low fire drying before beginning normal operation. Failure to do so may cause any moisture present to expand rapidly resulting in refractory spalling and/or premature failure.


14

BBC-9 Page

I. 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) Verify nozzle location, 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. (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.

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.


15

BBC-9 Page

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) 1/4" 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.

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.

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


16

BBC-9 Page

APPENDIX 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 1/2" pipe. Constant gas pressure at a minimum of 5 psig (34.5 kPa) not to exceed 25 psig (172kPa) must be available at the inlet of the Hauck gas pilot manifold. 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.


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

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


chi

Stamp

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.


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


IPG-9

D. DIMENSIONS

Figure 1. Dimensions Back-Loaded Gas

Y81

31

(NO

T T

O S

CA

LE

)


IPG-9

D. DIMENSIONS (Continued)

Figure 2. Metric Dimensions Back-Loaded Gas

Y81

31 M

ET

RIC

(N

OT

TO

SC

AL

E)


IPG-9


Figure 3. Dimensions Back-Loaded Gas Less Solenoid Valves

Y23

75

(NO

T T

O S

CA

LE

)


IPG-9


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

Y23

75 M

ET

RIC

(N

OT

TO

SC

AL

E)


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.


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)


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)


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.

W8151 (NOT TO SCALE)


IPG-9

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.


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)

CTY TNHH THIẾT BỊ NHIỆT ĐÌNH HẢI-DHE VP: 189 Lý Thường Kiệt, P.6, Q.Tân Bình, TP HCM, VIỆT NAM ĐT: +84 (08) 3863 7722 # Fax: +84 (08) 3865 1859 Website: www.dinhhai.com - Email: [email protected]

User

Stamp

BBC BETA BURNER burner...2 BBC-9 Page A. GENERAL INFORMATION Beta burners are baffle type burners...

Documents

Transcript of BBC BETA BURNER burner...2 BBC-9 Page A. GENERAL INFORMATION Beta burners are baffle type burners...