Hauck long nose StarJet Operating instructions

TABLE OF CONTENTS

Subject Page

A. General Information ……………………………………………… 2

B. Receiving and Inspection ……………………………………….. 2

C. Burner Capacities ………………………………………………... 3

D. Dimensions ……………………………………………………… 5

E. Component Identification …………………………………….…. 10

F. Burner Mounting …………………………………………………. 11

G. Fuel Manifold Installation …………………………………….…. 12

H. Natural Gas Fuel Piping System ……………………………….. 13

I. Light Fuel Oil Piping System ……………………………………. 17

J. Heavy Fuel Oil Piping System ………………………………….. 20

K. Heavy Oil Insert Heater………………………………………….. 24

L. Fuel Oil Nozzle Adjustment …………………………………….. 26

M. Compressed Air/Oil System……………………………………... 27

N. Liquid Propane (LP) Fuel Piping System ……………………… 32

O. Burner Pilot System………………………………………………. 40

P. Operation………………………………………………………….. 41

Q. Flame Shape Adjustments ……………………………………… 45

R. Flame Holder Cone Adjustment ………………………………... 46

S. Maintenance ……………………………………………………… 47

T. Recommended Spare Parts ……………………………………. 48

Required Reference: Appropriate Burner Performance Table

GJ73 - Dryer Drum Gas Analysis

WARNING

These instructions are intended for use only by experienced, qualified

combustion start-up personnel. Adjustment of this equipment by unqualified

personnel can result in fire, explosion, severe personal injury or even death.

To make changes to the burner linkages or adjust firing inputs: 1. Shut the

burner down; 2. Make changes; 3. Restart the burner. STAND CLEAR OF THE

BURNER WHEN OPERATING UNDER ANY FIRING CONDITIONS.

INSTRUCTIONS

LNSJ-9

HAUCK LONG NOSE STARJET BURNER

LNSJ360 – LNSJ980

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

8/13 www.hauckburner.com Fax: 717-273-9882

Page 2

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A. GENERAL INFORMATION

The Hauck StarJet Burner combines reliable operation with a unique, adjustable flame shaping

feature, eliminating the weight and maintenance problems of ignition tiles. Matching burner flame

shape to dryer design is the real secret to overall dryer efficiency. Some dryers work best with a

long, narrow, hard driving flame, while other dryers with the same rated capacity require a short

bushy, turbulent flame. Frequently, problems such as overheating of the combustion chamber,

excessive exhaust gas temperatures, and poor heat transfer can be eliminated by shaping the

burner flame. The burners in the StarJet series have an extremely wide range of flame shape

adjustment.

Burner air consists of primary air (atomizing air) and secondary air. Both are supplied by the

Hauck Turbo Blower. The plant exhaust air provides the remaining air required for complete

combustion and exhaust gas removal.

The StarJet will burn all clean commercial grades of fuel oil, natural gas, landfill gas, and liquid

propane. The burner provides a 7 to 1 turndown from the maximum firing rate.

Flight design in the combustion zone is important. The combustion zone should be clear of veiling

material and large enough to accommodate complete combustion. Consult Hauck for

recommended combustion zone requirements.

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.

NOTE

StarJet burners firing liquid propane and heavier

fuel oils could have less than 7 to 1 turndown.

IMPORTANT

If 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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C. BURNER CAPACITIES

Refer to burner performance table.

Burner

Model Air Flow

(scfm) Pressure

(osig) TBA Blower

Model Motor

HP Fan Rating

(acfm @ 350°F) Max. Capacity

(MMBtu/hr)

SJ360 5,400 37 TBA - 36 - 75 75 43,000 75.6

SJ520 7,300 36 TBA - 36 - 100 100 55,000 96.8

SJ580 7,900 33 TBA - 36 - 100 100 68,000 120

SJ750 9,940 38 TBA - 36 - 125 125 85,000 150

SJ980 12,220 36 TBA - 36 - 150 150 128,000 200

Table 1. Long Nose StarJet Burner Capacities with High Pressure Direct Drive Blowers

Capacity Table Notes:

1. Oil capacities based on Higher Heating Value (HHV) of 138,000 Btu/gal and viscosity of oil delivered at

the burner of 90 SSU or lower.

2. Gas capacities based on HHV of 1,040 Btu/ft3 and 5 psig manifold inlet pressure with a 3 psig drop

across manifold.

3. Liquid propane capacities based on HHV of 91,044 Btu/gal and 50 psig above vapor pressure at

inlet of LP burner control valve (butane and 50/50 propane/butane mixture capacities available

upon request).

4. Burner capacities based on standard air density: sea level (29.92" Hg) at 70°F. Correction factors

must be applied for altitude/temperature variations; consult Hauck.

5. Only 40% of air for combustion is passed through the burner. The remaining 60% of air for

combustion plus a minimum of 20% excess air must be induced by the dryer exhaust system at

a negative 0.25" wc at the burner/breeching ring.

6. Horsepower rating is based on Hauck blower performance. Blowers of other manufacturers may be

used, however, higher horsepower motors may be required as a result of lower efficiencies.

7. "E", "F" & "G" Model burners can be accurately monitored for air flow by using the body pressure P1

test point with an accurate osig pressure gauge. Burners equipped with a blower inlet orifice can be

monitored for air flow using a draft gauge capable of reading negative 3" wc. Readings can be

related to scfm on corresponding burner charts.

8. Burners equipped with a gas orifice meter can be accurately checked for gas flow by measuring the

differential pressure across the orifice meter with a U-tube device capable of reading 0-20"wc.

Readings can be related to gas flow using corresponding Burner Performance Tables under gas

orifice P ("wc) and gas flow (scfh).

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C. BURNER CAPACITIES (METRIC)

Burner

Model Air Flow

(nm3/min)

Pressure

(kPa) TBA Blower

Model Motor

HP Fan Rating

(am3/min @ 177°C) Max. Capacity

(kW)

SJ360 145 15.9 TBA - 36 - 75 75 1,150 20,000

SJ520 196 15.5 TBA - 36 - 100 100 1,470 25,600

SJ580 212 14.2 TBA - 36 - 100 100 1,820 31,700

SJ750 266 16.4 TBA - 36 - 125 125 2,280 39,700

SJ980 327 15.5 TBA - 36 - 150 150 3,430 52,900

Table 2. Long Nose StarJet Burner Capacities with High Pressure Direct Drive Blowers

Metric Capacity Table Notes:

1. Oil capacities based on Lower Heating Value (LHV) of 36.17 MJ/ and viscosity of oil delivered at the

burner of 1.8 x10-5 m2/sec or lower.

2. Gas capacities based on LHV of 36.96 MJ/nm3 and 34.5 kPa manifold inlet pressure with a 20.7 kPa

drop across manifold.

3. Liquid propane capacities based on LHV of 23.83 MJ/ and 345 kPa above vapor pressure at

inlet of LP burner control valve (butane and 50/50 propane/butane mixture capacities available

upon request).

4. Burner capacities based on standard air density: sea level (760mm Hg) at 21°C. Correction factors

must be applied for altitude/temperature variations; consult Hauck.

5. Only 40% of air for combustion is passed through the burner. The remaining 60% of air for

combustion plus a minimum of 20% excess air must be induced by the dryer exhaust system at

a negative 6.3mm wc at the burner/breeching ring.

6. Horsepower rating is based on Hauck blower performance. Blowers of other manufacturers may be

used, however, higher horsepower motors may be required as a result of lower efficiencies.

7. "E", "F" & "G" Model burners can be accurately monitored for air flow by using the body pressure P1

test point with an accurate kPa pressure gauge. Burners equipped with a blower inlet orifice can be

monitored for air flow using a draft gauge capable of reading negative 76mm wc. Readings can be

related to nm3/hr on corresponding burner charts.

8. Burners equipped with a gas orifice meter can be accurately checked for gas flow by measuring the

differential pressure across the orifice meter with a U-tube device capable of reading 0-500mm wc.

Readings can be related to gas flow using corresponding Burner Performance Tables under gas

orifice P (mm wc) and gas flow (m3/hr).

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D. DIMENSIONS

Figure 1. Overall Length Dimensions LNSJ360 – LNSJ980

Y5373

(NOT TO SCALE)

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LNSJ -9

D. DIMENSIONS (Continued)

Figure 2. Dimensions LNSJ360 – LNSJ580

Y4060

(NOT TO SCALE)

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LNSJ -9

D. DIMENSIONS (Continued)

Figure 3. Metric Dimensions LNSJ360 – LNSJ580

Y4060 METRIC

(NOT TO SCALE)

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LNSJ -9

D. DIMENSIONS (Continued)

Figure 4. Dimensions LNSJ750 – LNSJ980

Y3351

(NOT TO SCALE)

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LNSJ -9

D. DIMENSIONS (Continued)

Figure 5. Metric Dimensions LNSJ750 – LNSJ980

Y3351 METRIC

(NOT TO SCALE)

NOTE:

1. ALL DIMENSIONS ARE IN MM.

Page 10

LNSJ -9

E. COMPONENT IDENTIFICATION

Figure 6. Hauck Long Nose StarJet Burner and Associated System Components

Y5374

(NOT TO SCALE)

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LNSJ -9

F. BURNER MOUNTING

Figure 7. Burner Mounting Tube Detail

1. The burner should be mounted on the drum centerline at the same pitch as the drum.

Install a structure to support and position the burner's skid. Burner repositioning may be

required for final burner adjustment.

2. Position the mini-skid on the support and securely bolt it in place.

3. Position the burner so that the distance from the inlet of the mounting tube to either the

bracket supporting the pilot, scanner and spin vane, or to the heatshield (whichever is

applicable) satisfies the “F” minimum dimension (see Figure 7).

4. Position the burner so that the end of the flame cone holder is flush with either the start of the

flared section or the open end of the burner mounting tube (whichever is applicable).

IMPORTANT

The pilot flame UV scanner must be aligned to view just

above the pilot as it passes through the flame holder

cone. The main flame UV scanner should be sighted just

over the edge of the flame holder cone, in line with the

flame.

X5375

(

NOT TO SCALE

)

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LNSJ -9

5. Shim under the burner skid, if necessary, to align the burner horizontal and vertical

centerlines with the horizontal and vertical centerlines of the dryer drum (or combustion

chamber). The assembled burner must be on the combustion chamber centerline and

at the same pitch as the combustion chamber (follow the dryer manufacturer’s

recommendation for burners used without combustion chambers).

G. FUEL MANIFOLD INSTALLATION

The Long Nose StarJet burner system is supplied with a separate fuel valve manifold. Depending

on fuel or fuels specified, the manifold(s) will be designated as POM - Prepiped Oil Manifold,

Prepiped Gas Manifold, or PLPM - Prepiped Liquid Propane (LP) Manifold. Refer to dimension

drawings supplied for component dimensions.

IMPORTANT

Valve manifolds must be mounted in a horizontal position. Valves will not

function properly mounted vertically. Liquid fuel manifolds should not be

mounted above the burner centerline. POM and PLPM manifold should be

mounted as close to the burner as possible.

For all heavy fuel oil applications, i.e., any oil requiring heating for use, oil

piping must be heat traced (electric or steam) and insulated. Self-

regulating heat tracing is recommended to maintain the desired temperature

of a given fuel oil to achieve 90 SSU (1.8x10-5 m2/sec) or less at the burner.

Electrical heat tracing with a nominal rating of 12 W/ft (39 W/m) covered with

a nominal 2" (50mm) fiberglass type insulation is sufficient for most

applications. Fuel oil temperature should not exceed 250°F(120°C). Oil

viscosity should be checked prior to burner operation.

Hauck recommends the use of solid pipe to connect fuel manifolds to the

burner fuel inlets. Schedule 40 iron pipe is recommended for gas and oil

systems. LP applications require the use of schedule 80 pipe and

fittings rated for 350 psig (2410 kPa). Flexible hoses should not be used in

LP applications to connect to the burner fuel inlet.

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LNSJ -9

H. NATURAL GAS FUEL PIPING SYSTEM

1. Install a controlling gas regulator in the main gas line within 25 ft (7.6m) of the burner. For

optimum control, supply 15-25 psig (103 – 172 kPa) to this regulator. This regulator should

be sized to provide the required gas flow at the inlet of the burner manifold; 2 - 5 psig

(14 - 35 kPa) is a nominal expected gas pressure. Exact gas pressures will be set at start-up.

2. A manual equipment isolation valve, sediment trap and gas strainer must be installed

upstream of the gas control regulator to ensure compliance to NFPA requirements. The

manual equipment isolation valve facilitates servicing of the gas control regulator, sediment

trap, strainer, and sediment trap, strainer, and other components in the gas manifold.

3. The gas company should purge the main gas line to remove scale and dirt before it is

attached to the burner gas manifold.

4. Connect the main gas line (see Figure 8).

WARNING

It is important to remove the high velocity oil sleeve

and install the low velocity gas sleeve in the 360 –

750 model burners when firing natural gas.

NOTE

Hauck recommends the use of gas manifolds

that meet NFPA guidelines. NFPA requires

two safety shutoff valves wired in series, a

shutoff valve downstream of the second

(blocking) shutoff valve, and high and low gas

pressure switches that are interlocked with

the burner’s safety shutoff valves. Hauck gas

manifolds have been designed to ensure

compliance to NFPA requirements.

IMPORTANT

Install a flexible fitting in the gas manifold to reduce flexing of the manifold resulting

from plant vibrations. Be sure to install the gas metering orifice section (see

Figure 9) provided with the gas valve metering kit to measure gas flow.

Excluding the gas metering orifice section will make initial setup and tuning

difficult.

Page 14

LNSJ -9

Figure 8. Typical Schematic of Burner Gas Manifold

Figure 9. Dimensions for Gas Metering Orifice

X4845

(NOT TO SCALE)

Y4220

(NOT TO SCALE)

Page 15

LNSJ -9

5. The piping from the gas regulator outlet to the burner gas manifold should be sized to

minimize pressure losses.

6. Check blower rotation. The impeller should rotate toward the blower discharge.

7. Inspect and operate the plant exhaust damper control. The exhaust damper should be

capable of maintaining a consistent negative pressure at the drum front bulkhead of

negative 0.2 to negative 0.5 "wc (negative 5 to negative 13mm wc) from low to high firing

rates for most applications.

8. Install a gas sampling probe in the dryer rear plate (see Application Sheet GJ73).

9. Set the low gas pressure switch to an initial setting of 0.5 psig (3.4 kPa).

10. Set the high gas pressure switch to an initial setting of 5 psig (34.5 kPa).

11. Complete the initial adjustment of the gas butterfly valve as follows: The valve is factory set

to travel 90 degrees from position 1 to position ‘Run’. This travel can be modified to increase

or decrease low fire by choosing a lower or higher starting point.

12. Open all manual shutoff valves in the gas line upstream of the gas pressure switch.

13. Start gas flow to the gas manifold.

14. Adjust the gas regulator until the pressure gauge upstream of the main gas automatic shutoff

valves indicates a pressure of 2 psig (13.8 k Pa).

15. High fire can be modified by increasing or decreasing gas pressure. After setting high fire

gas pressure, low fire must be rechecked. Refer to individual Burner Gas Orifice Meters

Graph for gas flows through the gas orifice meter (see Figure 10).

16. Burner flame adjustment spin vanes can be set at 0 to 60 degrees; 0 degrees narrows the

flame, 60 degrees widens the flame, and 30 degrees is a nominal starting point.

17. Burner air adjustments: (see Section P).

18. Recheck all linkages for tightness.

19. Install a U-tube manometer across the gas orifice meter taps.

20. Connect a gas analyzer to the gas sampling probe.

21. Exhaust gas readings should be taken with the burner firing at operating tonnage

(see Application Sheet GJ73).

WARNING

Adjustment of this equipment and its components by

unqualified personnel can result in fire, explosion, severe

personal injury, or even death.

Page 16

LNSJ -9

Figure 10. Gas Orifice Meters Graph

Q753

Page 17

LNSJ -9

I. LIGHT FUEL OIL PIPING SYSTEM

1. Light fuel oil supply manifold (see Figure 11 and 12): For recommended piping sizes,

see Table 3. For POM oil manifold installation instructions, see Section G.

Table 3. Minimum Pipe Size for Hauck Oil Supply Pumping Units

NOTE

Hauck requires the use of oil manifolds that meet

NFPA guidelines. NFPA requires two safety

shutoff valves piped in series in the burner’s main

oil line. A low/high oil pressure switch must be

interlocked with the burner’s safety shutoff valves.

WARNING

Adjustment of this equipment and its components by

unqualified personnel can result in fire, explosion,

severe personal injury, or even death.

Page 18

LNSJ -9

2. Before attaching fuel oil lines, purge the piping to remove scale and dirt that could clog and

damage oil equipment.

3. Open all shutoff valves upstream of the fuel oil metering valve(s).

4. Be sure that the metering valve(s) is in the low fire position.

5. Open the mini-ball valve to the pressure gauge.

6. Slowly adjust the bypass relief valve until the initial set-up fuel oil pressure is achieved (see

Table 4). Final pump pressure will have to be adjusted to attain desired burner output and

stack exhaust gas analysis.

Long Nose StarJet

Model No. Fuel Oil Pressure

w/36 osig (15.5 kPa) Blower

360 50 psig (345 kPa)

520 50 psig (345 kPa)

580 80 psig (550 kPa)

750 70 psig (485 kPa)

980 80 psig (550 kPa)

Table 4. Fuel Oil Pressures

7. Check rotation of the combustion blower. The impeller should rotate toward the blower

discharge.

8. Inspect and operate the plant exhaust damper control. The exhaust damper should be

capable of maintaining a consistent negative pressure at the drum front bulkhead of

negative 0.2 to negative 0.5 "wc (negative 5 to negative 13mm wc) from low to high firing

rates for most applications.

9. The low/high oil pressure switch is factory set at a low set point of 15 psig (103 kPa) and a

high set point of 80 psig (552 kPa). Set point adjustments may be required depending on the

burner and fuel oil piping specifics.

10. Inspect the complete fuel oil system for leaks. Repair as necessary.

11. The burner oil metering valve is factory set to travel 90 degrees from position 1 to 10.

12. The low fire oil valve is manually set and regulates low fire flow. This valve can easily be

changed to regulate low fire oil flow. Start this valve at position 9. The low fire valve can

easily be cleaned:

a. Mark the valve pointer position.

b. Turn the valve counterclockwise to the ’clean’ position.

c. Return the valve pointer to its original position.

Page 19

LNSJ -9

13. High fire oil flow can be adjusted by increasing or decreasing fuel oil pressure. After

changing fuel oil pressure, low fire flow should be rechecked. Low and high fire rates in

gal/min or liters/min can be checked and recorded with the in-line oil flow meter provided

with the prepiped oil manifold.

14. Burner flame spin vane adjustment can be set at 0 to 60 degrees. 0 degrees narrows the

flame, 60 degrees widens the flame, and 30 degrees is a nominal starting point.

15. Burner air adjustments: (see Section P).

16. Recheck all linkages for tightness.

17. Connect a gas analyzer to the gas sampling probe (see Application Sheet GJ73). Exhaust

gas readings should be taken at operating tonnage.

Figure 11. Typical Schematic of Burner Light Fuel Oil Piping

X6263

(NOT TO SCALE)

Page 20

LNSJ -9

Figure 12. POM Prepiped Oil Manifold Detail

J. HEAVY FUEL OIL PIPING SYSTEM

WARNING

Adjustment of this equipment and its components by

unqualified personnel can result in fire, explosion,

severe personal injury, or even death.

Heated fuel oil and piping is hot. Precautions must be

taken to prevent contact with heated oil and piping.

Proper insulation should be installed on hot oil pipes.

Protective gloves and clothing are recommended when

working with heated fuel oil.

NOTE

Oil manifold must be

mounted in a horizontal

position. Mount as close

to the burner as possible.

Mount manifold below

the burner’s center-line.

X6189

(NOT TO SCALE)

IMPORTANT

For all heavy fuel oil applications, i.e., any oil requiring heating for use,

oil piping must be heat traced (electric or steam) and insulated.

Self-regulating heat tracing is recommended to maintain the desired

temperature of a given fuel oil to achieve 90 SSU (1.8 x 10-5 m2/sec)

or less at the burner. Electrical heat tracing with a nominal rating of

12W/ft (39W/m) covered with a nominal 2" (50mm) fiberglass type

insulation is sufficient for most applications.

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Hauck long nose StarJet Operating instructions

Hauck long nose StarJet Operating instructions

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