INSTRUCTIONS PBG PACKAGED GAS BURNER 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. TABLE OF CONTENTS Subject Page A. General Information. 2 B. Receiving and Inspection 2 C. Capacities.. 3 D. Dimensions 5 E. Installation. 5 F. Electrical Power Supply.. 6 G. Gas Supply 7 H. Initial Setup 8 I. Ignition 10 J. Operation.. 10 K. Flame Monitoring. 11 L. Maintenance. 11 M. Recommended Spare Parts... 14 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. HAUCK MANUFACTURING CO., P.O. Box 90 Lebanon, PA 17042-0090 717-272-3051 2/12 www.hauckburner.com Fax: 717-273-9882
Page 2 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 shut-off 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. A. GENERAL INFORMATION The Hauck PBG Packaged Gas Burners are designed for applications where it is desirable to have all of the necessary components for a high turndown combustion system contained in one compact and easy-to-use assembly. Configured versions of the burner system are available with selections for fuel type, air control, fuel control, power supply and flame supervision and/or burner control. The basic burner and air pressure switch includes the burner assembly with spark igniter and flame rod, and the straight combustor alloy tile. Auxiliary tube selections are available to provide longer burner lengths or provide a 90 bend to the flame. Selections for the air control method include manual, 4-20mA controlled actuator, or VFD. Flame supervision and burner control is accommodated by the KromSchroder BCU 370. A pre-configured temperature control panel, PBG-BCS, is also available that incorporates the BCU and customer settings to provide optimized burner control. Modifications can be made to these standard configurations to meet other customer specifications to provide a premier custom engineered product. For further information on any components supplied with the package, see specific product literature available from Hauck. 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. 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.
C. BURNER CAPACITY TABLES Page 3 PBG-300 PBG-500 PBG-750 PBG-1000 Blower Horsepower (hp) 1/3 1/3 1/3 1/3 Ratio Regulator Gas Manifold Minimum Supply Pressure (in w.c.) 14 14 21 14 BURNER SPECIFICATIONS - HIGH FIRE Body Pressure (in. w.c.) 6.5 5.2 5.9 5.9 Blower Amp Draw (A) 0.6 0.7 1.1 1.1 Air Flow (scfh) 3250 5400 8000 11050 Natural Gas Flow (scfh) 300 500 750 1000 Flame Length (in) 12 14 24 32 Maximum Excess Air (%) 3200 3600 5300 3600 BURNER SPECIFICATIONS - LOW FIRE Body Pressure (in w.c.) 0.1 0.1 0.1 0.3 Blower Amp Draw (A) 0.2 0.2 0.2 0.2 Air Flow (scfh) 400 750 1040 1580 Min. Gas Flow (NFPA) (scfh) 10 15 15 30 Min. Gas Flow (Ratio Reg.) (scfh) 16 16 32 32 Flame Length (in) Tile Tile Tile Tile Metric Capacities PBG-300 PBG-500 PBG-750 PBG-1000 Blower Horsepower (kw) 0.25 0.25 0.25 0.25 Ratio Regulator Gas Manifold Minimum Supply Pressure (mbar) 35 35 52 35 BURNER SPECIFICATIONS - HIGH FIRE Body Pressure (mbar) 16.2 12.9 14.7 14.7 Blower Amp Draw (A) 0.6 0.7 1.1 1.1 Air Flow (Nm3/hr) 87 145 214 296 Natural Gas Flow (Nm3/hr) 8 13 20 27 Flame Length (cm) 30 36 61 81 Maximum Excess Air (%) 3200 3600 5300 3600 BURNER SPECIFICATIONS - LOW FIRE Body Pressure (mbar) 0.25 0.25 0.25 0.75 Blower Amp Draw (A) 0.2 0.2 0.2 0.2 Air Flow (Nm3/hr) 10.7 20 27.9 42.3 Min. Gas Flow (NFPA) (Nm3/hr) 0.3 0.4 0.4 0.8 Min. Gas Flow (Ratio Reg.) (Nm3/hr) 0.4 0.4 0.4 0.8 Flame Length (in) Tile Tile Tile Tile Notes: 1. Capacities based on integral blower with 230/3/60 power supply. Amp Draw is based on use with VFD. Without VFD, the amp draw is equivalent to high fire requirements. 2. Air and gas flows based on 60 F, 0 C. 3. Flame lengths are based on the straight combustor tube firing into a chamber without forced air flow. 4. For operation at altitude, consult Hauck for re-rated capacity. 5. For chambers operating above 1 inch w.c. of back pressure or vacuum, consult Hauck for re-rated capacity. 6. Minimum gas flow on the fuel-only control manifold is dependent on valve port adjustment and supply pressure. 2 psig minimum supply pressure is suggested. 7. Additional gas pressure required for additional upstream components, such as optional manifolds. Table 1. PBGII 300 1000 Burner Capacities
C. BURNER CAPACITY TABLES (Continued) Page 4 PBG-2000 PBG-3000 PBG-5000 Blower Horsepower (hp) 2 2 2 Ratio Regulator Gas Manifold Minimum Supply Pressure (in w.c.) 14 14 28 BURNER SPECIFICATIONS - HIGH FIRE Body Pressure (in. w.c.) 5.5 5.5 5.5 Blower Amp Draw (A) 4.3 4.8 5.5 Air Flow (scfh) 22250 33000 55000 Natural Gas Flow (scfh) 2000 3000 5000 Flame Length (in) 60 66 72 Maximum Excess Air (%) 1000 4000 2500 BURNER SPECIFICATIONS - LOW FIRE Body Pressure (in w.c.) 0.3 0.3 0.3 Blower Amp Draw (A) 2.3 2.4 2.6 Air Flow (scfh) 4875 5500 13750 Min. Gas Flow (NFPA) (scfh) N/A N/A N/A Min. Gas Flow (Ratio Reg.) (scfh) 60 70 90 Flame Length (in) Tile Tile Tile Metric Capacities PBG-2000 PBG-3000 PBG-5000 Blower Horsepower (kw) 1.50 1.50 1.50 Ratio Regulator Gas Manifold Minimum Supply Pressure (mbar) 14 35 52 BURNER SPECIFICATIONS - HIGH FIRE Body Pressure (mbar) 13.7 13.7 13.7 Blower Amp Draw (A) 4.3 4.8 5.5 Air Flow (Nm3/hr) 596 884 1473 Natural Gas Flow (Nm3/hr) 54 80 134 Flame Length (cm) 152 168 183 Maximum Excess Air (%) 1000 4000 2500 BURNER SPECIFICATIONS - LOW FIRE Body Pressure (mbar) 0.75 0.75 0.75 Blower Amp Draw (A) 2.3 2.4 2.6 Air Flow (Nm3/hr) 131 147 368 Min. Gas Flow (NFPA) (Nm3/hr) N/A N/A N/A Min. Gas Flow (Ratio Reg.) (Nm3/hr) 2 2 2 Flame Length (in) Tile Tile Tile Notes: 1. Capacities based on integral blower with 230/3/60 power supply. Amp Draw is based on use with VFD. Without VFD, the amp draw is equivalent to high fire requirements. 2. Air and gas flows based on 60 F, 0 C. 3. Flame lengths are based on the straight combustor tube firing into a chamber without forced air flow. 4. For operation at altitude, consult Hauck for re-rated capacity. 5. For chambers operating above 1 inch w.c. of back pressure or vacuum, consult Hauck for rerated capacity. 6. Minimum gas flow on the fuel-only control manifold is dependent on valve port adjustment and supply pressure. 2 psig minimum supply pressure is suggested. 7. Additional gas pressure required for additional upstream components, such as optional manifolds. Table 2. PBGII 2000 5000 Burner Capacities
Page 5 D. DIMENSIONS See appropriate section PBG-3 through PBG-3.6 Dimension sheet for detailed dimensional information. E. INSTALLATION 1. The Hauck PBG burner can fire in any position. Burner and blower orientations may be adjusted to fit application constraints. Therefore, it can be installed to fire through side-walls, roofs or the bottoms of ovens, dryers, or furnaces. Note that Kromschroder Valvario components may not be installed with the solenoid actuator facing down. Note that KromSchroder GIK must be installed with the spring tower side facing down. 2. The PBG burners will bolt to the oven or furnace wall. Prepare the oven wall appropriately to support the weight of the burner and any other associated components. Install the burner combustor tube so that it is properly insulated in the furnace wall. For walls thicker than the standard length of the combustor alloy tile or in cross-flow applications the use of a straight or 90 auxiliary firing tube may be required. 3. For air heating installations where the burner will fire into a chamber under negative pressure, spacers may be installed between the burner mounting bracket and the oven/furnace wall to draw secondary air past the firing tube. 4. On installations where there is a positive pressure within the combustion chamber, the opening in the oven or furnace wall should be at least 1 inch (25mm) larger than the burner combustor tube/tile. Pack the space around the alloy tile with ceramic fiber suitable for the temperatures involved. Ceramic fiber packing should not extend past wall thickness. Installation of the high temperature gasket between the burner mounting plate/flange and the oven or furnace wall is recommended for all positive pressure ovens or furnaces. 5. On installations using the auxiliary firing tube, the area between the burner alloy tile and firing tube should be packed with ceramic fiber. Ceramic fiber packing should not extend past the wall thickness or the end of the alloy tile (See Figure 1). NOTE All rotating components were balanced from factory at a level meeting ISO 1940-2. A variety of external causes such as handling, installation, or misalignment may cause imbalance prior to use. To ensure the intended long life of the equipment and components, and to meet warranty requirements, equipment and vibration levels should be checked by experienced personnel and trim balanced if no longer meeting ISO 1940-2 requirements. Under no circumstances should equipment with excessive vibration be operated at the risk of damaging that equipment or the personnel operating it.
Page 6 Y8458 Sht. 8 (NOT TO SCALE) Figure 1. Typical Installation Package Burner Unit 6. If the burner will be located outdoors, protection should be provided to prevent rain and/or snow from being drawn into the blower. Properly select all accessory items for outdoor operation. A rain hood or other suitable protection is recommended for burners installed in areas of direct rain or snow exposure. 7. If the Hauck PBG burner is to be operated within an enclosed area, verify that an adequate fresh air supply is available to supply combustion air to the burner. F. ELECTRICAL POWER SUPPLY Local and national codes and/or standards should be adhered to. Voltage, phase and frequency must be compatible with the motor and electrical accessory nameplate ratings. All wiring to the burner blower, air control motor, and control accessories must be completed before the burner is ignited. Any burner unit to be used with a 50 Hz power supply should also select a VFD. The VFD converts any incoming power supply to a 230 V, 3 phase supply. The VFD is directly connected to the blower, which uses a 230 V, 3 phase motor. Using the standard burner with a 50 Hz power supply will de-rate the burner capacity and require different burner settings. NOTE If the PBG burner will be subjected to backpressure from the chamber or furnace into which it is firing, a larger blower motor may be required to achieve the desired heat input; consult Hauck.
G. GAS SUPPLY Page 7 SPECIAL NOTE Hauck recommends the use of gas manifolds conforming to National Fire Protection Association (NFPA) standards. NFPA 86 standards for gas manifolds vary for burner capacity as well as single burner versus multiple burner installations. The Hauck PBG with NFPA manifold contains all features required for burner capacity as well as single and multiple burner installations. The Hauck PBG Burners are designed to operate with a regulated gas supply pressure to the inlet of the manifold of 20 to 55 in.w.c. (50 to 140 mbar) for natural gas at a nominal HHV of 1034 Btu/ft 3 (LHV of 10.21 kwh/nm 3 ) or propane at a nominal HHV of 2499 Btu/ft 3 (LHV of 25.3 kwh/nm 3 ). Failure to provide adequate gas pressure will result in compromised burner performance, e.g. a reduction in capacity or unreliable ignition. NOTE Pressure testing of the manifold and combustion equipment is required by the customer after installation. Failure to do so may result in unsafe conditions and may violate local or national codes. For multiple burner installations, consult Hauck for the design of a common pre-piped gas manifold. If supplied via third party, confirm that the gas supply pressures to the individual burners are within the 20 to 55 in.w.c. (50 to 140 mbar) range. For accurate burner control, the combustion air and gas should be controlled by the components packaged with the burners and not with central or common air and gas components.
H. INITIAL SET-UP Page 8 WARNING Adjustment of this equipment by unqualified personnel can result in fire, explosion, severe personal injury, or even death. The PBG is factory adjusted to conform to capacity and ignition limits. Although the burner should require no adjustment upon initial set-up, several adjustments can be made in situations where the burner needs to be tuned to the application. 1. Combustion Air If using a combustion air valve and actuator, the valve travels 90 from closed to the fully open position. The valve is designed for use with a directly coupled IC40 actuator, which is controlled by a 4-20 ma input signal. The air valve must be at the ignition position to light the burner, which for most applications will be about 20 open. For applications that require special control motor settings, the IC40 can be reprogrammed in a variety of different ways using Opticord adapter, (P/N 74960437) a laptop computer, and a free software package. A third-party actuator may be used, and Hauck supplies a universal connection kit. Operationally, the actuator must control the valve in the same manner, and be able to provide the same ignition point. NOTE The use of a third-party actuator without a BCS may require additional electronic components to be installed and wired by the customer. If the air is controlled by VFD, the motor will operation between 60Hz at high fire and 15Hz at low fire. In certain applications, such as those operating under pressure, it may be necessary to increase the low fire frequency to satisfy the air pressure switch. Applications that have a 50 Hz supply voltage, should select the VFD option for the ability to fire at the rated high-fire capacity. Applications with a 50 Hz supply voltage that do not use a VFD will have a de-rated burner capacity and require different burner settings. A manual air valve handle may be used to control the air flow to the burner. In a fuel-only control application, the manual handle has the ability to be fixed, and may be the desired method of air control.
2. Gas Ratio Regulator Page 9 The gas ratio regulator proportions gas flow through the burner relative to the burner air pressure. Adjusting the bias of the regulator can increase or decrease the ratio of gas to the burner air. The bias adjustment is located below the valve body on the VAG regulator, or under the cap on the GIK regulator stem. For the VAG, the bias is indicated on the adjustment wheel. For the GIK, clockwise adjustment of the bias screw will increase gas flow, while counter-clockwise adjustment will decrease gas flow. The GIK regulator features a fixed bypass through the regulator. For processes that require a lower low-fire than the regulator function provides, simply un-bias the regulator; low-fire gas flow will then be regulated using the fixed bypass. NOTE For operation with fuel type other than natural gas, replace the orifice plate between union halves with orifice supplied for intended fuel. Y8458 Sht. 10 (NOT TO SCALE) Figure 2. Bias Adjustment Locations
3. Fuel-Only Control Page 10 The Linear Flow Control Valve, LFC, is used for the fuel-only control manifold. The valve is directly coupled to an IC40 actuator, which is controlled by a 4-20 ma input signal. The LFC flow characteristic can be adjusted by biasing the valve piston. Additionally, this manifold has an adjustable high fire limiting valve and a orifice meter to measure fuel flow. I. IGNITION Each PBG comes equipped with a spark igniter. Since PBG burners are preset, no adjustment to the igniter should be necessary upon initial light-off. However, if ignition problems occur or a new igniter is installed, follow the procedure in Figure 3 to replace and adjust the igniter. Spark ignition requires the burner to be properly grounded to the oven/furnace. Figure 3. Spark Igniter & Flamerod Installation Y8458 Sht. 9 (NOT TO SCALE) J. OPERATION Sequential operation of the PBGburner will depend on the control method used on the burner and various component selections. NOTE Maintain electrical power supply to the blower motor until the chamber or furnace temperature is below 200 F (93 C). If the blower is shut off with a hot chamber, hot air may exhaust through the burner and damage internal components.
Page 11 K. FLAME MONITORING The PBG burner may be ordered with either a flame rod or an ultraviolet (UV) scanner. If UV scanners are used on an oven or furnace with multiple burners, care should be exercised so that the UV scanner from one burner does not sense the flame from another burner in the oven or furnace. WARNING If standard full wave coil ignition transformer is used along with the UV flame scanner, provisions must be made to eliminate the possibility of the ignition transformer falsely satisfying the UV scanner. Hauck designed flame supervisory panels eliminate this potential problem by timing out the spark igniter after the trial for ignition period. L. MAINTENANCE The Hauck PBG Packaged Burner has no moving parts requiring lubrication. However, preventative maintenance can eliminate costly down time. Periodic maintenance should include the following: 1. Check all pressure switches, clean or replace if necessary. For recommended pressure settings see table below. Switch Air Pressure (valve/actuator) Air Pressure (VFD) High Gas Pressure Low Gas Pressure Pressure Settings 4" w.c. (10 mbar) 0.2 w.c. (0.5 mbar) 2.5 psi (175 mbar) 20" w.c. (50 mbar) 2. Check bolts and screws for tightness, including those on the burner and safety shut-off valves. 3. Check operation of flame safety equipment. 4. In addition to leak testing the entire manifold, the safety shut-off manifold should be leak tested on at least a yearly basis. Refer to the National Fire Protection Association s publication NFPA 86 for details on leak testing components per UL, ANSI, CSA, FM or EN standards. 5. If an optional air filter is supplied, periodic cleaning is required to keep the burner operating at maximum efficiency. 6. To remove the spark igniter for cleaning or inspection, the spark igniter must be inserted with the proper orientation to ensure ignition (see Figure 3). The flame rod inserts the same way as the spark igniter (see Figure 1); however, no particular orientation is required.
L. MAINTENANCE (Continued) Page 12 BLOWER MOTOR REPLACEMENT WARNING Local and national codes and standards should be strictly adhered to. Exposure to energy sources including potential electrical, kinetic rotating mass and combustible fuels will be encountered during this procedure outlined below. Applicable Lock Out/Tag Procedures should be followed to prevent fire, explosion, property damage, severe personal injury, or even death. All maintenance, repair and wiring to the burner blower, air control motor, and control accessories must be completed by qualified personnel. A. BLOWER MOTOR REMOVAL 1. Power down equipment (burner and blower assembly), disconnect and isolate from electrical power supply. 2. Verify that the burner and blower assembly is off and can not be restarted and also that the impeller is not rotating. 3. Open the motor wiring terminal box (A) and remove the electrical power supply wires from the motor leads. Take note of wiring connection for new motor installation. Refer to Figure 4 for component identification. 4. Remove the eight sheet metal screws (B) that hold the blower face plate (C) onto the blower body (I), exposing the impeller (D). Care should be taken not to tear the face plate gasket (E). If undamaged, the gasket may be reused, set the gasket on a flat surface and protect from damage. 5. Loosen the two set screws (F) in the impeller hub. 6. Remove the impeller from the motor shaft (penetrating oil or lubricant may be required). Note that care must be taken not to damage the impeller during this process. Damaging or bending the impeller will cause an imbalance that will result in excessive vibration when the impeller is rotating which can damage motor bearings and other coupled equipment. 7. Secure and support the motor (G) and remove the four bolts (H) that fasten the blower housing to the motor face. Note removing these bolts will decouple the motor from the blower housing, the motor must be secured or supported to prevent the motor from falling and damaging equipment and/or personnel. 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.
Page 13 IMPORTANT When replacing the blower motor, it is important to note that the PBGII 300-1000 size burners are designed for and should be equipped with either: - Single Phase Motor = 1/3HP-T-3600RPM, 110-220V/1ph/60Hz, frame-56c, or - Three Phase Motor = 1/3HP-T-3600RPM, 230-460V/3ph/60Hz, frame-56c Replacement motor must meet these specifications to insure proper functionality of the system. WARNING Local and national codes and standards should be strictly adhered to. Voltage, phase and frequency must be compatible with the motor and electrical accessory nameplate ratings. All maintenance, repair and wiring to the burner blower, air control motor, and control accessories must be completed by qualified personnel. B. BLOWER MOTOR INSTALLATION 1. Secure and support new motor (G) mounting face against the blower housing (I), with the motor shaft inserted through the shaft opening into the blower housing. Refer to Figure 4 for component identification. 2. Insert and tighten the four 3/8-16 UNC bolts (H) that fasten the motor to the blower housing, tighten to 20 ft-lbs. 3. Insert the impeller (D) onto the motor shaft, the open side of the impeller faces away from the motor (penetrating oil or lubricant may be required). Note the motor shaft is keyed, and the key must be aligned with the corresponding key opening on the impeller hub. Note that care must be taken not to damage the impeller or the motor bearings during this process. Damaging the impeller or motor bearings will cause an imbalance that will result in excessive vibration when the impeller is rotating which can damage motor bearings and other coupled equipment. 4. Align the end of the motor shaft flush with the face of the impeller hub. Tighten the two ¼-20 set screws (F) on the impeller hub into the motor shaft, tighten to 55 in-lbs. 5. Spin the impeller by hand to confirm unimpaired rotation. The impeller and motor should spin freely with no contact with the blower housing or any fastener within. 6. Place the blower face plate gasket (E) onto the face plate (C), align the holes in the face plate and gasket with the corresponding holes in the blower housing face plate mounting flange. Insert and tighten the eight sheet metal screws (B). Care should be taken to keep the gasket properly aligned and flat for a proper seal. 7. Open the motor wiring terminal box (A); reconnect the electrical power supply wires to the appropriate motor leads. Close the motor wiring terminal box. 8. Verify the burner is off and reconnect the electrical power supply. 9. Momentarily energize the blower motor and verify proper rotational direction. Direction of rotation should correspond with the directional arrows (J) on the blower housing. 10. Verify blower and burner balance and vibration. Blower and burner assemblies are trim balanced to 0.26 in/sec. or less at motor speed (3600 rpm). Failure to trim balance and/or correct an imbalance will result in excessive vibration when the impeller is rotating which can damage motor bearings and other coupled equipment.
Page 14 11. Prior to restarting the burner system refer to the following sections: Section H Initial Setup, Section I Ignition, Section J Operation, Section L Maintenance. Figure 4. Blower Assembly M. RECOMMENDED SPARE PARTS ITEM DESCRIPTION QTY. PART NO. 1 Spark Igniter Assembly (If Applicable) 1 See Parts List 2 Flame Rod Assembly 1 See Parts List 3 UV Scanner (If Applicable) 1 84315205 4 Opticord Adapter 1 74960437 5 GFK (NFPA Manifold) 1 See Parts List 6 OMG (If Applicable) 1 See Parts List