Hauck BBG**04 Series User manual

BBG BETA BURNER GAS SERIES
TABLE OF CONTENTS
Subject Page
A. General Information ……………………………………………………….…..….……. 2
B. Receiving and Inspection ………………………………………….…….…...…….….. 2
C. Capacities ………….……………………………………………………………………. 3
D. Dimensions …………….………………………………………………………………... 4
E. Installation ……………………………………………………………………………….. 4
F. Ignition…………………………………………………………………………………….. 10
G. Initial Set-Up……………………………………………………………………………… 12
H. Operation…………………………………………………………………………………. 14
I. Maintenance……………………………………………………………………………… 14
J. Recommended Spare Parts……………………………………………………………. 17
Attachments: IPG-9
ZMI Ionization Pilot
INSTRUCTIONS
WARNING
These instructions are intended for use only by experienced, qualified
combustion start-up personnel. Adjustment of this equipment and its
components by unqualified personnel can result in fire, explosion, severe
personal injury, or even death.
These instructions are intended to serve as guidelines covering the installation, operation, and maintenance of Hauck equipment. While
every attempt has been made to ensure completeness, unforeseen or unspecified applications, details, and variations may preclude
covering every possible contingency. WARNING: TO PREVENT THE POSSIBILITY OF SERIOUS BODILY INJURY, DO NOT USE OR
OPERATE ANY EQUIPMENT OR COMPONENT WITH ANY PARTS REMOVED OR ANY PARTS NOT APPROVED BY THE
MANUFACTURER. Should further information be required or desired or should particular problems arise which are not covered
sufficiently for the purchaser's purpose, contact Hauck Mfg. Co.
BBG-9
HAUCK MANUFACTURING CO., 100 North Harris Street Cleona, PA 17042 717-272-3051
1/14 www.hauckburner.com Fax: [phone]

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BBG-9
A. GENERAL INFORMATION
The BBG burners are baffle type gas burners designed for low pressure air operation in a wide
range of applications. Available with an alloy tile for ambient combustion air and application
temperatures up to 1800°F (980°C), or a refractory tile for application temperatures up to
2800°F (1540°C). With a refractory tile, the 1000 and 2000 series can operate with air preheat
temperatures up to 300°F (150°C), and the 3000 series can operate with air preheat
temperatures up to 900°F (480°C).
The BBG burners fire any clean industrial fuel gas. Capacities range from 3.1 million to 123
million Btu/hr (820 to 32,530 kW). Higher capacity models are available upon request. Two
refractory tile options are available: the diverging tile which produces a slow mixing, long, wide
flame, and the converging tile which produces a shorter, narrower, more well-defined flame.
Direct spark ignition is available on the BBG_ 204 through _212 burners, while gas pilot ignition
is available on all BBG burners. On ratio turndown is approximately 10:1 on natural gas. 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.
WARNING
This equipment is potentially dangerous with the possibility of serious personal injury
and property damage. Hauck Manufacturing Company recommends the use of flame
supervisory equipment and fuel safety shutoff valves. Furthermore, Hauck urges rigid
adherence to National Fire Protection Association (NFPA) standards and insurance
underwriter’s requirements. Operation and regular preventative maintenance of this
equipment should be performed only by properly trained and qualified personnel.
Annual review and upgrading of safety equipment is recommended.
IMPORTANT
If the installation is delayed and the equipment is stored outside,
provide adequate protection as dictated by climate and period of
exposure. Special care should be given to all motors, bearings,
refractory material and electronic devices, if applicable, to protect
them from rain or excessive moisture.
WARNING
Use care when handling as the equipment may be heavy, have sharp edges
or dust/fibers from refractory or gasket material. Always wear personal
protective gear and use appropriate equipment during handling and
installation.

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BBG-9
C. BURNER CAPACITIES
SPECIFICATIONS BURNER MODEL
xx04 xx06 xx08 xx10
Capacity (MMBTU/hr) 3.1 6.1 12.0 19.1
(kW) 820 1,610 3,170 5,050
 Air Capacity (scfh) 32,000 63,500 124,500 198,000
 (nm3/hr) 857 1,701 3,335 5,304
 Air Inlet Pressure (in.w.c.) 27.7 27.7 27.7 27.7
 (mbar) 68.9 68.9 68.9 68.9
 Gas Inlet Pressure (in.w.c.) 1.5 11.6 12.0 3.7
 (mbar) 3.7 28.9 29.9 9.2
 Flame Length (ft) 5.8 8.0 10.0 12.0
 (m) 1.8 2.4 3.0 3.7
 Flame Diameter (ft) 1.5 2.0 3.0 4.0
 (m) 0.5 0.6 0.9 1.2
SPECIFICATIONS BURNER MODEL
xx12 xx14 xx18 xx24
Capacity (MMBTU/hr) 25.6 38.3 64.7 123.0
(kW) 6,770 10,130 17,110 32,530
 Air Capacity (scfh) 265,000 397,000 670,000 1,275,000
 (nm3/hr) 7,099 10,635 17,948 34,155
 Air Inlet Pressure (in.w.c.) 27.7 27.7 27.7 27.7
 (mbar) 68.9 68.9 68.9 68.9
 Gas Inlet Pressure (in.w.c.) 5.8 1.5 11.8 2.9
 (mbar) 14.4 3.7 29.4 7.1
 Flame Length (ft) 14.0 15.0 17.0 25.0
 (m) 4.3 4.6 5.2 7.6
 Flame Diameter (ft) 4.0 4.5 5.0 5.0
 (m) 1.2 1.4 1.5 1.5
NOTES:
1. Capacities based on Natural Gas with HHV of 1034 Btu/ft3, (Standard), and LHV of 10.21 kWh/nm3(Metric)
0.59 S.G., and a stoichiometric ratio of 9.74:1 with burner firing into chamber under no pressure at 10% excess
air.
2. Air and fuel flows based on STP operating conditions at sea level and industry standard air and gas piping
practices.
3. Gas inlet pressure given for reference only and should not be used for measuring fuel flow to the burner.
4. Flame lengths measured from end of the combustion tile.
5. Burner is suitable for use on gaseous fuels other than Natural Gas and with combustion air other than ambient
temperature, consult Hauck.
Table 1. Burner Capacities

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BBG-9
D. DIMENSIONS
See appropriate Dimension sheet for detailed dimensional information.
E. INSTALLATION
Hauck BBG burners must be mounted on properly braced, rigid furnace structures capable of
supporting the burner and tile weight (see Table 2).
Burner Model
Approx.
Burner
Net Weight
Approx.
Refractory Tile
Net Weight
Approx.
Alloy Tile
Net Weight
BBG_ _04 100 lb (45 kg) 95 lb (43 kg) 45 lb (20 kg)
BBG_ _06 350 lb (159 kg) 140 lb (63 kg) 95 lb (43 kg)
BBG_ _08 350 lb (159 kg) 140 lb (63 kg) 95 lb (43 kg)
BBG_ _10 370 lb (168 kg) 210 lb (95 kg) 110 lb (50 kg)
BBG_ _12 425 lb (193 kg) 300 lb (136 kg) 130 lb (59 kg)
BBG_ 114 580 lb (263 kg) 510 lb (231 kg) 150 lb (68 kg)
BBG_ 118 1,200 lb (544 kg) 540 lb (245 kg) 195 lb (88 kg)
BBG_ 124 3,350 lb (1,520 kg) 1,200 lb (544 kg) 275 lb (125 kg)
Table 2. Burner and Tile Weights
Burner Mounting (see Figure 1 for Refractory Tile, Figure 2 for Alloy Tile)
1. Furnish an opening in the furnace shell 1" (25mm) larger than the outside diameter of the
burner tile.
2. Weld the appropriate size studs of appropriate length to the furnace shell to accept the tile
mounting flange.
3. Place the tile mounting gasket on the furnace studs.
4. 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 and retain the fiber
during installation.
5. Install the burner tile on the furnace shell and secure with appropriate lock washers and
nuts.
6. Place the tile cushion gasket into the recess in the burner tile.
7. Place the burner mounting gasket over the studs on the burner tile flange.
8. Install the BBG burner on the burner tile flange and secure with appropriate lock washers
and nuts.
NOTE
If the burner utilizes an ultraviolet (UV) scanner for flame
supervision, the burner should be positioned so that the UV
scanner is located above the horizontal centerline of the burner to
prevent moisture and airborne debris from setting into the UV
scanner port and blocking the lens.
WARNING
Use care when handling as the equipment may be heavy, have sharp edges
or dust/fibers from refractory or gasket material. Always wear personal
protective gear and use appropriate equipment during handling and
installation. Be sure your installation conforms to appropriate safety guidelines
for your application such as NFPA 86 or EN746.

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BBG-9
9. From inside the furnace, pack ceramic fiber blanket rated for a higher temperature than the
furnace into the annular opening between the burner tile and the furnace wall insulation or
refractory. It is important that the fiber is well packed to ensure that the furnace shell, tile
flange, burner flange, and associated gaskets are not damaged. Fiber must be repacked
after initial firing of the burner. (Refer to Figures 1or 2 for illustration)
10. For installations where the furnace wall is thicker than the burner tile, a port flare must be
provided at D° (see Figures 3 or 4 details). For recommended port design and features, use
Figures 3 and 4 as a reference. Use high quality refractory materials with a sufficient
temperature rating for the intended application.
Burner Mounting with customer supplied port (see Figure 3 or 4)
1. Furnish an opening in the furnace shell 1" (25mm) larger than the outside diameter of the
burner.
2. Weld the appropriate size studs of appropriate length to the furnace shell to accept the
burner mounting flange.
3. Place the burner mounting gasket on the furnace studs.
4. Place the tile cushion gasket into the recess in the burner tile.
5. Install the BBG burner on furnace wall to ensure correct fit-up.
6. Remove the burner prior to forming the burner port.
7. Form the burner port to dimensions per Figure 3 or Figure 4 using wood or metal mandrels
centered on mounting plate studs. Mandrel dimensions must include sufficient draft or taper
for easy removal.
8. For installations where the furnace wall is thicker than the burner port length, a port flare
must be provided at D°. If required, a maximum straight extension of 6" (152mm) may be
provided at the ‘tile’ discharge as shown in Figure 4. Use high quality refractory materials
with a sufficient temperature rating for the intended application.
9. 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.
10. Install the burner assembly into the fully cured refractory port with the appropriate lock
washers and nuts.
NOTE
If the BBG burner was not supplied with a self-supporting
refractory or alloy tile, then a field poured refractory port must be
installed. Installation requirements are available for field poured
refractory ports for BBG burners (reference Drawing X4195,
including removable, reusable metal mandrels; consult Hauck.
WARNING
Refractory can be heavy and laden with dust or fibers, use care in lifting and
always wear appropriate personal protective gear such as a respirator or dust
mask around refractory or gasket material.

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BBG-9
Figure 1. Burner Installation With Refractory Tile
Figure 2. Burner Installation With Alloy Tile
W7324
(NOT TO SCALE)
W7783
(NOT TO SCALE)

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BBG-9
Figure 3. Customer Supplied Refractory Port
Figure 4. Custom Installation For Thick Wall or Angle
X4195
(NOT TO SCALE)
X8427
(NOT TO SCALE)

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BBG-9
Air and Fuel Connections
1. Install the air piping to the burner body using a flexible connection. Avoid elbows and abrupt
directional changes in the piping where possible as turbulence can affect flow measurement
accuracy, and reduce pressure at the burner.
2. If necessary, the gas connection on direct spark ignited BBG_ 204 through _ 212 burners
can be rotated as follows:
a. Remove the screws and lock washers holding the gas inlet to the burner body.
b. Rotate the gas inlet until it is in the desired location.
c. Make sure the gasket between the gas inlet and the burner body is properly seated.
a. d. Replace the washers, hex nuts and securely tighten.
3. Install the gas line to the gas inlet using a flexible connection. Avoid elbows and abrupt
directional changes in the piping where possible as turbulence can affect flow measurement
accuracy, and reduce pressure at the burner.
4. For BBG burners using gas pilot ignition: Consult the appropriate dimensional sheet and
instructions that accompany the pilot for additional information (IPG-9 or ZMI Literature).
a. BBG_104 through _118 IPG Gas Pilot
Install the pilot tip in the connection located above the burner center line on the burner
body. Connect pilot air and gas to the appropriate connections on the gas pilot.
b. BBG_104 through _BBG112 ZMI Gas Pilot
Install the ZMI Pilot in the connection located on the burner gas inlet tee.
c. BBG_124 Forced Air Premix Pilot
Install the air/fuel premix outlet of the pilot manifold assembly to the pilot assembly.
Connect pilot air and gas to the appropriate connections on the pilot manifold.
NOTE
All piping must be properly supported and aligned to avoid stresses on the burner
and associated equipment. Hauck recommends that flexible connections be used on
all air and fuel lines to isolate the burner from piping movement due to expansion,
contraction, and vibration.
NOTE
Size the pilot gas supply line to avoid excessive pressure drops. For
supply lines up to 25 ft (7.6m) use 1/2" (DN 15) pipe; from 25 to 100
ft (7.6 – 30m) use 3/4" (DN 20) pipe. Prior to connecting to the pilot
gas manifold, the gas line should be purged to remove debris.
NOTE
All burner models are provided with two sets of connections for observation port, pilot
and UV scanner mounting. Neither the pilot nor the UV scanner should be located below
the horizontal centerline of the burner, where they could be adversely affected by dirt
and debris.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 IPG pilot and UV 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 IPG pilot and UV scanner connection ports located 180° from the main
air connection. Scanner connection should be supplied with 1 psi of purge air.
NOTE
The BBG_124 UV scanner connections are positioned at 45°
and 225° clockwise from the main air connection center line.
Use guidelines in previous note to choose UV scanner port.

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BBG-9
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.
5. If an ultraviolet flame detection scanner is used, install it in the correct accessory port
adjacent to the optional IPG pilot connection. Provide a clean, ambient air source for the UV
scanner air purge by connecting the main air line to the 1/8 NPT (DN 6) air connection on
the UV scanner adapter using 3/8" (1mm) OD tubing or larger and a suitable isolating valve.
6. If the observation port, IPG 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 5):
a. Remove the pipe plugs (or caps) from the alternate port connections.
b. Remove the ceramic fiber insulation from the ports.
c. Insert a 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 unused 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 unused port connections.
f. Install a thin coat of high temperature cement (Hauck recommends Resco Adamant or
equivalent) over the original ports from the inside of the burner to contain the ceramic
fiber insulation.
Figure 5. Port Sealing Arrangement
7. Verify that all piping connections are tight. Close all unused port openings on the burner
body.
8. Inspect all bolted joints on the burner to ensure that all fasteners are tight and gaskets are
properly seated.
Y7205
(NOT TO SCALE)

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BBG-9
WARNING
When using a standard coil ignition transformer,
provisions must be made to eliminate the ignition
spark falsely satisfying the “flame on” UV scanner.
Hauck designed flame supervisory panels accomplish
this by “timing out” the spark transformer after a short
(10 seconds for most applications) trial for ignition.
WARNING
Adjustment of this equipment by unqualified personnel
can result in fire, explosion, severe personal injury, or
even death.
F. IGNITION
BBG burners are available with an IPG of ZMI gas pilot igniter or an air-cooled spark igniter. If
using a Hauck IPG spark Ignited gas pilot or ZMI pilot see attached instructions for
detailed operating instructions. Otherwise, see pilot vendor literature. For either igniter, a
5000/6000 volt standard coil type ignition transformer or a half-wave "spark blind" solid state
type transformer can be utilized. Both transformers yield satisfactory results, however, the
standard coil type transformer provides reliable ignition over a wider range of air/fuel ratios than
the half-wave type.
For IPG Gas Pilot Ignited Burners (BBG_ 104 through _118):
1. Ensure that the gas pilot igniter is threaded tightly into the pilot port.
2. Connect the high voltage ignition wire from the transformer to the spark plug on the gas pilot
igniter. A snap-on ignition type connector is recommended.
3. See attached IPG literature for detailed operating instructions.
For ZMI Gas Pilot Ignited Burners (BBG_304-E through _312-E):
1. Ensure that the ZMI gas pilot is threaded tightly into the pilot port.
2. See Dimensional Drawings for the proper insertion depth of the ZMI pilot and tighten the
bushing to fix the position.
3. Connect the high voltage ignition wire from the transformer to the spark plug on the ZMI. A
snap-on ignition type connector is recommended.
4. See attached ZMI literature for detailed operating instructions.
For Forced Air Premix Pilot (BBG_124 only), the pilot is integral through the burner. Refer to
Figure 6 for pilot and manifold details.
1. The maximum gas supply pressure at the inlet to the pilot gas regulator is 5 psig (345 mbar).
The regulated pilot gas supply to the gas limiting valve must be a nominal 20"wc (50 mbar).
2. The pilot gas regulator should be back-loaded from the chamber into which the burner is
firing to ensure optimum pilot performance.
NOTE
Do not attempt manual ignition or torch lighting.
NOTE
Beta Burner Model _104 uses a Hauck #1 pilot IPG5411A.
Beta Burner Models _106 through _118 use a Hauck #3 pilot IPG5413A.
Beta Burner Model _124 uses a Hauck forced air premix pilot, 58155.