Honeywell Hauck MEGASTAR MS-25 Instructions Manual

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These instructions are intended for use only by experienced, qualified combustion start-

up personnel. Adjustment of this equipment by unqualified personnel can result in fire,

explosion, severe personal injury or even death.

To make changes to the burner or adjust firing inputs: 1. Shut the burner down; 2. Make

changes; 3. Restart the burner. STAND CLEAR OF THE BURNER UNDER ANY

FIRING CONDITIONS.

Subject

General Information..............................................................................

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

Burner Capacities.................................................................................

Dimensions.........................................................................................

Component Identification.......................................................................

Combustion Flighting............................................................................

Burner Mounting..................................................................................

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

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

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

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

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

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

Fuel Oil Nozzle....................................................................................

Compressed Air/Oil Atomizer..................................................................

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

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

Burner Pilot System..............................................................................

Primary Air..........................................................................................

Burner Setup.......................................................................................

Operation...........................................................................................

Adjustments........................................................................................

Maintenance.......................................................................................

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

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

These instructions are intended to serve as guidelines covering the installation, operation, and maintenance of Hauck equipment. While

every attempt has been made to ensure completeness, unforeseen or unspecified applications, details, and variations may preclude

covering every possible contingency. WARNING: TO PREVENT THE POSSIBILITY OF SERIOUS BODILY INJURY, DO NOT USE OR

OPERATE ANY EQUIPMENT OR COMPONENT WITH ANY PARTS REMOVED OR ANY PARTS NOT APPROVED BY THE

MANUFACTURER. Should further information be required or desired or should particular problems arise which are not covered sufficiently

for the purchaser's purpose, contact Eclipse, Inc.

Eclipse, Inc., 1665 Elmwood Road, Rockford, IL 61103-1299

www.eclipsenet.com

4/18

MEGASTAR

MS-25 - MS-150

Required Reference: Appropriate Burner Data Sheet

GJ73 Dryer Drum Gas Analysis

GJ75 MegaStar Application Sheet

BURNER

WARNING

Ph: 717-272-3051

Fax: 717-273-9882

INSTRUCTIONS

Page

MS-9

Table of Contents

Summary of Contents for Honeywell Hauck MEGASTAR MS-25

Page 1: Table Of Contents
INSTRUCTIONS MEGASTAR BURNER MS-25 – MS-150 WARNING These instructions are intended for use only by experienced, qualified combustion start- up personnel. Adjustment of this equipment by unqualified personnel can result in fire, explosion, severe personal injury or even death. To make changes to the burner or adjust firing inputs: 1. Shut the burner down; 2. Make changes;...
Page 2: General Information
Natural gas firing does not require a primary air blower. NOTE The MegaStar is supplied with a Honeywell C7027A ultraviolet flame scanner. If an alternate flame scanner is required, consult Eclipse. 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.
Page 3 Page 3 MS-9 C. BURNER CAPACITIES Table 1. Burner Capacity Data For Natural Gas & Light Oil MEGASTAR BURNER MODEL GAS SPECIFICATIONS (MMBTU/hr) Capacity (MW) 14.7 24.2 29.3 39.6 45.2 (scfh) 365,000 636,600 1,050,000 1,270,000 1,720,000 1,960,000 Main Air Flow /hr) 9,800 17,100...
Page 4: Burner Capacities
Page 4 MS-9 C. BURNER CAPACITIES (Continued) Table 2. Burner Capacity Data For Liquid Propane MEGASTAR BURNER MODEL LIQUID PROPANE SPECIFICATIONS (MMBTU/hr) Capacity (MW) 13.5 21.7 26.4 34.6 39.3 (scfh) 594,160 980,000 1,200,000 1,590,000 1,810,000 Main Air Flow /hr) 15,900 26,300 32,100 42,600...
Page 5 Page 5 MS-9 Table 2. Burner Capacity Data For Compressed Air MEGASTAR BURNER MODEL COMPRESSED AIR SPECIFICATIONS (MMBTU/hr) Capacity (MW) 21.4 27.2 35.3 40.7 (scfh) 1,030,000 1,310,000 1,700,000 1,960,000 Main Air Flow /hr) 27,600 35,100 45,500 52,500 (in.w.c.) 12.0 16.2 13.2 14.4 Main Air Pressure...
Page 6: Dimensions
Page 6 MS-9 C. BURNER CAPACITIES (Continued) Table 1 & 2 Notes: 1. Burner capacity is based on 60Hz power and scfh (nm /hr) 60°F (0°C) air at sea level. Correction factors must be applied for variations in altitude, temperature, or frequency; consult Eclipse.
Page 7: Component Identification
Page 7 MS-9 E. COMPONENT IDENTIFICATION Figure 1. MegaStar Burner Components...
Page 8: Combustion Flighting
Page 8 MS-9 F. COMBUSTION FLIGHTING Flight design in the combustion zone is very important. Correct flighting can minimize pollutant emissions, and provide heat shielding to keep the drum surface temperature down. To obtain complete combustion, the combustion zone must be sized to provide enough combustion volume for the flame to burn, and it should also be clear of veiling material that can quench the flame, resulting in poor combustion efficiency.
Page 9: Fuel Manifold Installation
Page 9 MS-9 3. The standard nose burner is supplied with a split-mounting companion flange that can be bolted onto the dryer breech plate (see Table 4), and is an option for the long nose version. This allows positioning the burner at various insertion depths past the breech plate. Typical burner insertion depth is 18 to 24"...
Page 10: Natural Gas Fuel Piping System
Page 10 MS-9 I. NATURAL GAS FUEL PIPING SYSTEM NOTE Eclipse recommends the use of gas manifolds that meet NFPA guidelines. NFPA requires two fuel safety shutoff valves wired in series and a shutoff valve downstream of the second (blocking) safety shutoff valve, and high and low pressure switches that are interlocked with the burner's safety shutoff valves.
Page 11 Page 11 MS-9 equipment isolation valve facilitates servicing of the gas control regulator, 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.
Page 12 Page 12 MS-9 Figure 3. Simplified Gas and Air Flow Chart GL86 (@ Atmospheric Conditions)
Page 13 Page 13 MS-9 Figure 4. MegaStar™ Gas Orifice Meters Graph...
Page 14: Light Fuel Oil Piping System
Page 14 MS-9 J. LIGHT 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. NOTE Eclipse recommends the use of oil manifolds that meet NFPA guidelines.
Page 15 Page 15 MS-9 MegaStar™ Nominal Oil Pressure Nominal Oil Pressure Model No. w/Low Pressure Atomizer w/Compressed Air Atomizer 30 psig (4.14 bar) 75 psig (5.15 bar) 75 psig (5.15 bar) 90 psig (6.20 bar) 85 psig (5.85 bar) 100 psig (6.90 bar) 65 psig (4.50 bar) 90 psig (6.20 bar) 80 psig (5.50 bar)
Page 16: Heavy Fuel Oil Piping System
Page 16 MS-9 X7864 (NOT TO SCALE) Figure 5. Typical Schematic of Burner Light Fuel Oil Piping K. 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.
Page 17 Page 17 MS-9 NOTE Eclipse recommends 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. When preheated oil is used, a low/high oil temperature limit switch must be interlocked with the burner’s safety shutoff valves.
Page 18 Page 18 MS-9 NOTE Fuel oil flow settings per the individual burner performance sheets are for initial set-up only. Final settings may have to be readjusted for required operation. 8. Fuel oil flow rates can be checked with the in-line oil flow meter on the burner fuel oil manifold.
Page 19: Oil Manifold Heat Tracing
Page 19 MS-9 L. OIL MANIFOLD HEAT TRACING For heavy, waste, or recycled oil applications, the oil manifold piping must be heat traced and insulated to maintain the desired temperature, and hence, viscosity, of the fuel oil (see Figure 7). The heat tracing installed on the heavy oil manifold will aid in viscosity control and reliable main flame ignition of the burner.
Page 20 Page 20 MS-9 V7867 (NOT TO SCALE) Figure 8. Heavy Oil Insert Heater NOTE 120V/60Hz power for the heavy oil insert heater must be supplied separately by the customer and wired into the heater junction box. Operation of the heavy oil insert kit is as follows (see Figure 8): 1.
Page 21: Fuel Oil Nozzle
Page 21 MS-9 N. FUEL OIL NOZZLE The position of the fuel oil atomizer affects its ability to atomize the oil. The compressed air atomizer or low pressure atomizer should be positioned as shown in Figure 9. CAUTION Ensure that the correct atomizer W7868 is being used when firing oil.
Page 22: Compressed Air/Oil Atomizer
Page 22 MS-9 O. COMPRESSED AIR/OIL ATOMIZER The Hauck high pressure oil nozzle is designed to finely atomize No. 2 fuel oil and clean preheated No. 4, No. 5 and No. 6 fuel oil. Oil viscosity should be 90 SSU (1.8 x 10 /sec) or less.
Page 23 Page 23 MS-9 Compressed Oil Pressure Air Pressure MegaStar To Burner Compressed To Burner Model No. Oil Flow Nozzle Air Flow Nozzle (gpm) (lpm) (psig) (kPa) (scfm) /min) (psig) (kPa) 45.4 75/100 34.1 22.7 1.25 68.1 125/150 37.9 18.9 11.4 Table 11.
Page 24 Page 24 MS-9 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 /sec) or less at the burner.
Page 25 Page 25 MS-9 PIPE PLUG PRIMARY AIR TUBE BURNER HOUSING DETAIL A ACCESS DOOR W7084 (NOT TO SCALE) Figure 11. Primary Air Tube Pipe Plug Location COMPRESSED AIR FLOW METER The compressed air flow meter is offered with a standard multi-pressure flow scale. The multi-pressure flow scale has a vertically graduated scale, calibrated for air in standard cubic feet per minute (scfm) at 1.0 s.g.
Page 26 Page 26 MS-9 Figure 12. Compressed Air Flow Meter and Scale To change the compressed air/oil nozzle position. 1. Ensure that the burner is not firing, then close the manual oil valve and the manual compressed air ball valve at the burner. The burner must not be firing 2.
Page 27: Liquid Propane (Lp) Fuel Piping System
Page 27 MS-9 P. LIQUID PROPANE (LP) FUEL PIPING SYSTEM WARNING Adjustment of this equipment and its components by unqualified personnel can result in fire, explosion, severe personal injury, or even death. LP is highly flammable and heavier than air. It will accumulate near the ground in the area of a leak and will dissipate relatively slowly.
Page 28 Page 28 MS-9 X7869 (NOT TO SCALE) Figure 13. Typical Schematic of LP Piping NOTE The LP piping system shown in Figure 13 is designed for optimum performance at ambient air temperatures above 40 F (5°C). For operation in ambient temperatures below 40 F, consult Eclipse for recommendations.
Page 29 Page 29 MS-9 WARNING Frost or icing is an indication of an LP leak. It is possible for a leak to occur without such evidence. Although the LP supply is initially in a liquid state, as it is vaporized it becomes heavier than air and accumulates near the ground and dissipates relatively slowly, becoming highly flammable.
Page 30 Page 30 MS-9 g. The low/high LP pressure switch is factory set at a low set point of 165 psig (1140 kPa) and a high set point of 230 psig (15.9 bar). The low pressure switch setting should be approximately 15 psig (1.03 bar) below the back pressure regulator setting. h.
Page 31 Page 31 MS-9 Figure 14. Vapor Pressures of Propane, Butane and Butane-Propane Mixtures...
Page 32: Liquid Propane (Lp) Nozzle
Page 32 MS-9 Q. LIQUID PROPANE (LP) NOZZLE To install the liquid propane (LP) nozzle, it is necessary to work on both the front and rear of the burner. All necessary safety procedures should be followed to ensure that work can be performed on both ends of the burner.
Page 33 Page 33 MS-9 W9048 (NOT TO SCALE) Figure 16. Burner Front End W9048 (NOT TO SCALE) Figure 17. LP Insert...
Page 34: Burner Pilot System
Page 34 MS-9 R. BURNER PILOT SYSTEM The MegaStar™ incorporates a gas pilot with induced air (see Figure 18). The pilot is detected by the main burner UV scanner which is factory mounted and wired. The pilot is properly installed as delivered and should not need to be moved or adjusted.
Page 35: Primary Air
Page 35 MS-9 S. PRIMARY AIR Primary air is used for improved mixing at low fire on LP fuel, and for the optional low pressure atomization of oil fuel. Eclipse offers a TBA blower for primary air supply. The primary air blower is supplied with an outlet flange to mate to the air connection on the burner.
Page 36: Operation
Page 36 MS-9 5. Propane Metering Valve. Low fire is adjusted at the main LP fuel valve. Adjust while watching the LP fuel flow meter. If freezing occurs, open the low fire setting ¼ of a position at a time until the freezing stops. The valve travel varies for a given burner model (see individual burner capacity and performance data sheets).
Page 37: Adjustments
Page 37 MS-9 2. The combustion air must cycle to 60 Hz for purging the system before light off, the safety limits must be satisfied, and the purge air pressure switch must be made for the purge to begin. The plant exhaust fan must be running with its damper open sufficiently for the proper purge time.
Page 38: Maintenance
Page 38 MS-9 W. MAINTENANCE The Hauck MegaStar burner has minimal internal moving parts and is relatively maintenance free. However, there are a few items that should be periodically checked. 1. Check the fuel control valves for proper operation. 2. For burners fired on oil: Dirt can clog the atomizing air nozzle, as well as cause problems firing the burner.
Page 39: Recommended Spare Parts
Page 39 MS-9 8. Periodically check air/fuel ratio to ensure that the burner is operating at peak efficiency. Exhaust gas analysis can be performed with most commercially available gas analyzers. Y7871 (NOT TO SCALE) Figure 20. Proper Impeller Position On Motor Shaft X.
Page 40: Appendix: Field Installation Weld-In Type Flights, Y7100
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Honeywell Hauck MEGASTAR MS-25 Instructions Manual

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