Hauck MegaStar MS-50 User manual

TABLE OF CONTENTS
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; 3. Restart the burner. STAND CLEAR OF THE BURNER UNDER ANY
FIRING CONDITIONS.
INSTRUCTIONS
MEGASTARTM BURNER
MS-50 – MS-150
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.
MS-9
HAUCK MANUFACTURING CO., 100 North Harris Street Cleona, PA 17042 717-272-3051
1/15 www.hauckburner.com Fax: [phone]
Subject Page
A. General Information…………………………………………………………………… 2
B. Receiving & Inspection……………………………………………………………….. 2
C. Burner Capacities……………………………………………………………………... 3
D. Dimensions…………………………………………………………………………….. 5
E. Component Identification…………………………………………………………….. 6
F. Combustion Flighting…………………………………………………………………. 7
G. Burner Mounting………………………………………………………………………. 7
H. Fuel Manifold Installation……………………………………………………………... 8
I. Natural Gas Fuel Piping System…………………………………………………….. 9
J. Light Fuel Oil Piping System…………………………………………………………. 13
K. Heavy Fuel Oil Piping System……………………………………………………….. 15
L. Oil Manifold Heat Tracing…………………………………………………………….. 18
M. Heavy Oil Insert Heater………………………………………………………………. 18
N. Fuel Oil Nozzle………………………………………………………………………… 20
O. Compressed Air/Oil Atomizer………………………………………………………… 21
P. Liquid Propane (LP) Fuel Piping System…………………………………………… 26
Q. Liquid Propane (LP) Nozzle………………………………………………………….. 31
R. Burner Pilot System…………………………………………………………………… 33
S. Primary Air……………………………………………………………………………... 34
T. Burner Setup…………………………………………………………………………… 34
U. Operation………………………………………………………………………………. 35
V. Adjustments……………………………………………………………………………. 36
W. Maintenance…………………………………………………………………………… 37
X. Recommended Spare Parts…………………………………………………………. 38
Appendix: Field Installation Weld-In Type flights, Y7100……………………….. 39
Required Reference: Appropriate Burner Data Sheet
GJ73 Dryer Drum Gas Analysis
GJ75 MegaStar Application Sheet

Page 2
MS-9
A. GENERAL INFORMATION
The MegaStarTM Burner is the next generation of total air aggregate drying burners. It has the
same quiet operation and ecological benefits as its predecessors, with the improved efficiency,
emissions, and ease of operation. It is available with low pressure atomization for light fuel oils
or LP, and is a highly efficient natural gas or vaporous propane burner. It features our lowest
construction profile allowing for easier installation and easier access to working components on
the burner. Flame adjustability allows a tailored fit to any drum configuration. Air/fuel ratio for the
MegaStar burner can be maintained more precisely than ever before over the entire operating
range by an energy saving VFD for maximum efficiency.
The MegaStarTM can be supplied with fuel manifolds as an integral part of the burner, or with
optional remote rack mounted fuel manifolds. Natural gas firing does not require a primary air
blower.
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.
NOTE
The MegaStarTM is supplied with a Honeywell C7027A
ultraviolet flame scanner. If an alternate flame scanner is
required, consult Hauck.
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.

Page 3
MS-9
50 75 100 125 150
(MMBTU/hr)
54 89 108 146 166
(MW) 14.7 24.2 29.3 39.6 45.2
(scfh) 636,600 1,050,000 1,270,000 1,720,000 1,960,000
(nm
3
/hr) 17,100 28,100 34,000 46,100 52,500
(in.w.c.) 14.3 12.6 15.3 13.8 14.5
(mbar) 35.6 31.3 38.1 34.3 36.1
(scfh) 52,300 86,200 104,300 141,300 161,000
(nm
3
/hr) 1,400 2,300 2,800 3,800 4,300
(MMBTU/hr)
40.5 62 82 103 124
(MW) 11.0 16.8 22.2 27.9 33.6
(ft) 12 14 9 11 15
(m) 3.7 4.1 2.7 3.4 4.6
(ft) 4 7587
(m) 1.2 2.0 1.5 2.4 2.1
50 75 100 125 150
(MMBTU/hr)
53 82 100 135 153
(MW) 14.3 22.3 27.2 36.5 41.5
(scfh) 643,300 1,030,000 1,270,000 1,720,000 1,960,000
(nm
3
/hr) 17,200 27,600 34,000 46,100 52,500
(in.w.c.) 14.3 12.0 16.2 13.7 144.0
(mbar) 35.6 29.9 40.3 34.1 358.3
(scfh) 46,500 46,500 46,500 46,500 46,500
(nm
3
/hr) 1,200 1,200 1,200 1,200 1,200
(in.w.c.)62 62626262
(mbar) 154 154 154 154 154
(gal) 370 580 710 950 1,080
(lph) 1,400 2,200 2,690 3,600 4,090
(ft) 10 12 12 10 12
(m) 3.1 3.7 3.7 3.1 3.7
(ft) 4 5545
(m) 1.2 1.5 1.5 1.2 1.5
Main Air Flow
Main Air Pressure
Primary Air Flow
Primary Air Pressure
Oil Flow Rate
Flame Length @ 30°Spin
Flame Diameter @ 30°Spin
MEGASTAR BURNER MODEL
MEGASTAR BURNER MODEL
LIGHT OIL SPECIFICATIONS
Main Air Pressure
Main Air Flow
Capacity
GAS SPECIFICATIONS
Flame Diameter @ 30°Spin
Flame Length @ 30°Spin
Capacity with Flue Gas Recirc
Gas Flow Rate
Capacity
C. BURNER CAPACITIES
Table 1. Burner Capacity Data For Natural Gas & Light Oil

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MS-9
50 75 100 125 150
(MMBTU/hr)
80 97 128 145
(MW) 21.7 26.4 34.6 39.3
(scfh) 980,000 1,200,000 1,590,000 1,810,000
(nm
3
/hr) 26,300 32,100 42,600 48,500
(in.w.c.) 12.8 18.5 15.0 18.3
(mbar) 31.8 46.0 37.3 45.5
(scfh) 46,500 46,500 46,500 46,500
(nm
3
/hr) 1,200 1,200 1,200 1,200
(in.w.c.) 62626262
(mbar) 154 154 154 154
(gal) 880 1,070 1,400 1,590
(lph) 3,330 4,050 5,300 6,020
(ft) 14 15 13 15
(m) 4.3 4.6 4.0 4.6
(ft) 5566
(m) 1.5 1.5 1.8 1.8
50 75 100 125 150
(MMBTU/hr)
79 100 130 150
(MW) 21.4 27.2 35.3 40.7
(scfh) 1,030,000 1,310,000 1,700,000 1,960,000
(nm
3
/hr) 27,600 35,100 45,500 52,500
(in.w.c.) 12.0 16.2 13.2 14.4
(mbar) 29.9 40.3 32.8 35.8
(scfh) 3,600 3,600 5,400 5,400
(nm
3
/hr) 100 100 100 100
(psig) 60 60 60 60
(bar) 4444
(gal) 560 710 920 1,060
(lph) 2,120 2,690 3,480 4,010
(ft) 9 9 10 10
(m) 2.7 2.7 3.1 3.1
(ft) 5555
(m) 1.5 1.5 1.5 1.5
N
o
t
A
v
a
i
l
a
b
l
e
Compressed Air Pressure
Main Air Pressure
BURNER MODEL
COMPRESSED AIR SPECIFICATIONS
Capacity
Main Air Flow
Main Air Pressure
Compressed Air Flow
Oil Flow Rate
Flame Length @ 30°Spin
Flame Diameter @ 30°Spin
Primary Air Pressure
Flame Diameter @ 30°Spin
MEGASTAR BURNER MODEL
LIQUID PROPANE SPECIFICATIONS
Capacity
Main Air Flow
P
e
n
d
i
n
g
Propane Flow Rate
Flame Length @ 30°Spin
MEGASTAR
Primary Air Flow
C. BURNER CAPACITIES (Continued)
Table 2. Burner Capacity Data For Liquid Propane & Compressed Air

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MS-9
C. BURNER CAPACITIES (Continued)
Table 1 & 2 Notes:
1. Burner capacity is based on 60Hz power and scfh (nm3/hr) 60F (0°C) air at sea level.
Correction factors must be applied for variations in altitude, temperature, or frequency;
consult Hauck. An altitude correction table is available in Hauck Application Sheet GJ75.
2. Natural gas capacities based on higher heating value of 1,034 Btu per cubic foot (lower
heating value of 36.74 MJ/nm3), 2-4 psig (138 – 276 mbar) manifold pressure, 25% excess
air, and stoichiometric ratio of 9.74:1.
3. No. 2 fuel oil capacities based on higher heating value of 141,146 Btu per gallon (lower
heating value of 36.99 MJ/liter), 35% excess air, and stoichiometric ratio of 1371.1 cubic feet
air/gallon of No. 2 oil (9.7 nm3air/liter).
4. Liquid propane capacities based on higher heating value of 90,912 Btu per gallon (lower
heating value of 23.83 MJ/liter), 35% excess air, and stoichiometric ratio of 864 cubic feet
air/gallon of liquid propane (6.1 nm3air/liter).
5. The exhaust fan must be able to provide a slight negative pressure, suction in the range of
0.25 to 1” wc (.6 to 2.5 mbar), at the burner breech plate to exhaust the products of
combustion.
6. MegaStarTM Burner airflow can be accurately monitored using the body pressure tap on
either side of the burner air plenum. An accurate device capable of reading up to 15" wc (75
mbar) will be required for this measurement.
7. All burner fuel manifolds are supplied with fuel flow measuring devices. Liquid fuel
manifolds are equipped with an inline flow meter. Gaseous fuel manifolds are equipped with
a gas orifice meter that can be accurately checked for gas flow by measuring the differential
pressure across the orifice meter with a U-tube device (manometer) capable of reading in
the range of 0 to 20"wc (0 to 50 mbar).
8. Low pressure atomizing air, used for firing low pressure fuel oil or LP, is provided by a 36 osi
(155 mbar) Hauck high efficiency Turbo Blower. The low pressure air is used to not only
atomize liquid fuels, but also improve mixing speed in the combustion zone.
9. High pressure compressed air, used for firing heavy oils or any fuel oil at high elevations,
must be supplied by the customer at a nominal 60 psig (4140 mbar) to the burner nozzle for
optimum fuel oil atomization.
D. DIMENSIONS
See appropriate section of MS-3 for detailed dimensional information.

Page 6
MS-9
E. COMPONENT IDENTIFICATION
Figure 1. MegaStarTM Burner Components
Y8978 (NOT TO SCALE)

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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.
Combustion flights provide protection for the drum by shielding it from direct flame radiation.
Construction of the combustion flights should be such that no material is allowed to fall through
the flame. Combustion flights should also have a means of dissipating heat to prevent their
destruction by the flame. This is typically done by plowing material over the fights and keeping
the flights as low as possible to the drum. Consult Hauck for details on flight design and
combustion zone requirements.
Flights are available from Hauck to optimize performance of the MegaStar™ on a rotary dryer;
for detailed installation instructions of Hauck weld-in type flights, see Y7100 in the Appendix.
For additional information on application issues for an MegaStar™ on a rotary dryer, see Hauck
Application Sheet GJ75.
G. BURNER MOUNTING
1. The burner should be mounted on the drum centerline at the same pitch as the drum. Install
a structure to support the burner. Refer to dimensional drawings in the Section D. The
support structure must be able to support the weight of the burner (see Table 3). If the
optional primary air turbo blower (TBA) is to be mounted on the same structure as the
burner, allow for the additional weight. Consult Hauck for recommended burner mounting
options. If applicable, choose a suitable location for the optional remote mounted fuel rack
and primary air TBA blower. The fuel rack should be firmly attached to the base structure or
concrete pad. The fuel rack is supplied with mounting holes in the base angle iron. Consult
Hauck for the remote mounted fuel rack dimensional drawing Y6967 if applicable. Consult
TBA blower instruction sheet (TBA-9) for proper mounting instructions for the primary air
TBA blower.
2. The burner is supplied with lifting eyes to facilitate lifting the burner into place. Do not use
the lifting eye on the main blower motor for lifting the entire burner unit. The optional
TBA blower is also supplied with lifting eyes on the blower frame. Do not use the motor
lifting eye to lift the entire blower unit.
MegaStar
TM
Model No. 50 75 100 125 150
Approx. Net Weight* (lb)
[kg] 2,500 [1,130] 5,000 [2,270] 5,800 [2,630] 6,500 [2,950] 6,500 [2,950]
Table 3. MegaStar™ Approximate Burner Net Weights
IMPORTANT
For MegaStar™ burners with an extended burner nose length, the nose must be
supported to avoid undue strain on the burner housing. Consult dryer
manufacturer for extended burner nose support recommendations.

Page 8
MS-9
3. The burner can be ordered with a split-mounting companion flange that can be bolted onto
the dryer breech plate (see Table 4). This allows positioning the burner at various insertion
depths past the breech plate. Typical burner insertion depth is 18 to 24" (460 to 610mm).
Cut out a hole in the breech plate 2" (50mm) in diameter larger than the burner tube. Do not
weld the split-mounting flange to the burner body, as the breech will expand and contract
with changes in temperature. If the split-mounting flange is welded to the burner, heat and
stress will damage the burner. Tightly seal the burner to the breech. If using oil as a primary
fuel, the insertion depth may have to extend more than 24" (610mm) due to the amount of
radiant heat from an oil flame depending on the application.
MegaStarTM Model No. 50 75-100 125-150
Companion Flange Part No. 407091 56548x001 56549x008
Table 4. MegaStarTM Burner Recommended Split-Mounting Companion Flange
4. Bolt the burner to the support structure.
5. Wire the main fan motor and the optional TBA blower motor (if applicable) per instructions
on the motor.
6. Rotation of all blowers must be checked prior to burner startup. The rotation is marked with
an arrow on the blower housings. Do not operate the burner until all blowers are
checked for rotation and are rotating correctly.
H. FUEL MANIFOLD INSTALLATION
The MegaStarTM burner can be supplied with integral fuel manifolds on the burner or with
optional remote rack mounted fuel manifolds. The fuel manifold has all modulating fuel valves
mounted on it. In addition to modulating fuel valves, the manifold includes the automatic oil, gas
and LP safety shutoff valves.
IMPORTANT
Fuel manifolds must be mounted in a horizontal position. Safety shutoff valves will not function
properly if mounted vertically. Liquid fuel manifolds should not be mounted above the burner
centerline. Oil and LP manifolds should be mounted as close to the burner as possible. For heavy
fuel oil applications, i.e., any fuel 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. Electric
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. Fuel oil temperature should not exceed 250°F
(120°C). Oil viscosity should be checked prior to burner operation.
Hauck recommends the use of schedule 40 iron pipe and fittings rated for 150 psig (10.3 bar) for
natural gas and oil system interconnecting piping. LP applications require the use of schedule 80
pipe and fittings rated for 350 psig (24.1 bar).
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 9
MS-9
I. NATURAL GAS FUEL PIPING SYSTEM
Figure 2. Typical Schematic of Burner Gas Piping
1. Install a controlling gas regulator in the main gas line within 25 ft (7.6m) of the burner. This
regulator should be sized to provide the required gas flow at the inlet of the burner manifold.
Exact gas pressure must be set at the initial start-up depending on piping configuration,
burner size, and maximum capacity desired. Regular settings are designed for best
operation and compliance with NFPA 54 (see Figure 2).
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 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.
NOTE
Hauck 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. Hauck gas manifolds have been designed to ensure
compliance to NFPA requirements.
Y7863
(NOT TO SCALE)

Page 10
MS-9
4. Connect the main gas line (see Figure 2). A flexible pipe nipple should be used to
connect the gas line to the burner gas manifold (see Table 5 for sizes).
MegaStar™ Model No. 50 75-100 125-150
FPN Part No. 800598 800599 800600
Size 3” (DN 80) 4" (DN 100) 6" (DN 150)
Table 5. MegaStar™ Burner Recommended Flexible Pipe Nipples
5. The piping from the gas regulator outlet to the burner gas manifold should be sized to
minimize pressure losses. See Figure 3 for pipe pressure losses.
6. The OMG gas orifice meter is an integral part of the gas manifold located on the burner
(refer to Figure 2). Refer to individual burner gas orifice meters graph for gas flows through
the gas orifice meter (see Figure 4). Orifice meter sizes and part numbers are shown below
in Table 6.
MegaStar™ Model No. 50 75-100 125-150
OMG Part No. 19816 48242x001 47181x005
Pipe Size 4” (DN 100) 6" (DN 150) 8" (DN 200)
Orifice Size 3.25” (82.5mm) 4.8" (122 mm) 6.0" (152 mm)
Table 6. MegaStar™ Burner Natural Gas Orifice Meter Assemblies
IMPORTANT
Install a flexible fitting between the gas
manifold and the burner gas connection to
reduce vibration stress on the manifold.
IMPORTANT
Failure to use the gas orifice meter assembly to measure
gas flow will make initial setup and tuning difficult.

Page 11
MS-9
Figure 3. Simplified Gas and Air Flow Chart
(@ Atmospheric Conditions)
GL86

Page 12
MS-9
Figure 4. MegaStar™ Gas Orifice Meters Graph

Page 13
MS-9
J. LIGHT FUEL OIL PIPING SYSTEM
1. Hauck recommends using a flexible connection to connect the oil line to the oil manifold
on the burner. A flexible connection will reduce vibration stress on the oil manifold.
Refer to Table 7 for recommended flex connection.
Table 7. Recommended Flexible Oil Hose Size
2. For recommended piping sizes see Table 8. Before attaching fuel lines, purge the
piping to remove scale and dirt that could clog and damage oil equipment. Follow Figure 5
for the suggested piping layout.
Discharge Piping, Light Oil
Up to 100 SSU
(Up to 2.1 x 10-5 m2/sec)
Return Piping, Light Oil
Up to 100 SSU
(Up to 2.1 x 10-5 m2/sec)
Return Piping
Heavy Oil
MegaStar
Model No. Up to 25' (Up to
7.6m)
25'– 49'
(7.6-
14.9m)
50' – 100'
(15.2-
30.5m)
Up to 25'
(Up to
7.6m)
25' – 49'
(7.6-
14.9m)
50' – 100'
(15.2-
30.5m)
Up to 25'
(Up to
7.6m)
25'– 49'
(7.6-
14.9m)
50' – 100'
(15.2-
30.5m)
50 1"
(DN25) 1" (DN25) 1 ¼" (DN32) 1" (DN25) 1 ¼" (DN32) 1 ¼" (DN32) 1 ¼" (DN32) 1 ½" (DN40) 2" (DN50)
75 1"
(DN25) 1" (DN25) 1 ¼" (DN32) 1" (DN25) 1 ¼" (DN32) 1 ¼" (DN32) 1 ¼" (DN32) 1 ½" (DN40) 2" (DN50)
100 1"
(DN25) 1" (DN25) 1 ¼" (DN32) 1 ¼" (DN32) 1 ¼" (DN32) 1 ¼" (DN32) 1 ¼" (DN32) 1 ½" (DN40) 2" (DN50)
125 1"
(DN25) 1 ¼" (DN32) 1 ½" (DN40) 1 ¼" (DN32) 1 ¼" (DN32) 1 ½" (DN40) 1 ½" (DN40) 2" (DN50) 2" (DN50)
150 1"
(DN25) 1 ¼" (DN32) 1 ½" (DN40) 1 ¼" (DN32) 1 ¼" (DN32) 1 ½" (DN40) 1 ½" (DN40) 2" (DN50) 2" (DN50)
Table 8. Minimum Pipe Size For Hauck Oil Supply Pumping Units
3. Adjust the bypass relief valve until required oil pressure is achieved. See Table 9 for
approximate settings. Final oil pressure will have to be adjusted to attain desired burner
output and stack exhaust gas analysis.
MegaStar™ Model No. 50 75-150
Flex Oil Hose Part No. 11078 20518
Size 1/2" (DN 15) 1" (DN 25)
NOTE
Hauck 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. Hauck oil manifolds
have been designed to ensure compliance to NFPA
requirements.
WARNING
Adjustment of this equipment and its components by
unqualified personnel can result in fire, explosion,
severe
p
ersonal in
j
ur
y,
or even death.

Page 14
MS-9
MegaStar™
Model No. Nominal Oil Pressure w/Low Pressure Atomizer Nominal Oil Pressure w/Compressed Air Atomizer
50 75 psig (5.15 bar) 90 psig (6.20 bar)
75 75 psig (5.15 bar) 90 psig (6.20 bar)
100 85 psig (5.85 bar) 100 psig (6.90 bar)
125 65 psig (4.50 bar) 90 psig (6.20 bar)
150 80 psig (5.50 bar) 100 psig (6.90 bar)
Table 9. Nominal Light and Heavy Fuel Oil Pressure to Burner Manifold Inlet
4. The low/high oil pressure switch is factory set at a low set point of 15 psig (1.03 bar)
and a high set point of 80 psig (5.5 bar). Set point adjustments may be required
depending on the burner and fuel piping specifics.
5. Inspect the complete fuel oil system for oil leaks and repair as necessary. Do not
operate the burner until all fuel leaks are repaired.
6. The burner oil flow control (metering) valve is preset to travel from position 2 to 11.
The low fire oil flow setting can be changed by loosening the coupling connecting the oil
valve to the control motor, adjusting the oil valve pointer, and re-tightening the coupling. The
high fire oil flow setting can be changed via the burner control system, or if necessary, by
increasing or decreasing fuel oil pressure. See the individual burner performance sheets for
fuel oil flow data.
7. Fuel oil flow rates can be checked with the in-line oil flow meter on the burner fuel
oil manifold. The flow meter glass can be rotated to view the scale if required.
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.
CAUTION
Any adjustment to the fuel oil flow settings should be
made as a minor incremental change and verified that it
has not resulted in any detrimental effect to plant
operation prior to making another adjustment.

Page 15
MS-9
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 should be taken to
avoid contact with heated oil and piping. Proper insulation should
be installed on hot oil pipes. Protective gloves, clothing and a face
shield are recommended when working with heated oil.
Figure 5. Typical Schematic of Burner Light Fuel Oil Piping
K. HEAVY FUEL OIL PIPING SYSTEM
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.
X7864
(NOT TO SCALE)

Page 16
MS-9
NOTE
Hauck 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. Hauck oil manifolds have been
designed to ensure compliance to NFPA requirements. Hauck
recommends the use of a ‘Heavy Oil Kit’ whenever heavy fuel oil is
used. The components of the heavy oil kit are identified in Figure 6.
1. For recommended piping sizes see Table 8. Before attaching fuel lines, purge the piping
to remove scale and dirt that could clog and damage oil equipment. See Figure 6 for the
suggested piping layout.
2. Heavy fuel oil must be 90 SSU (1.8 x 10-5 m2/sec) or less for proper atomization and
burning. Use a Hauck viscometer kit (order separately - Part No. 36931) to determine
proper oil temperature to achieve this viscosity. Refer to the instructions that are supplied
with the kit for proper use. In general, the viscosity can be lower than 90 SSU (which
means higher oil temperature) if the fuel is not forming vapor (or steam) pockets in the oil
lines. Vapor pockets can cavitate the pumps used on suction type oil heaters.
3. Set the fuel oil heater temperature set point and the indicating low oil temperature switch
(located on the burner’s oil manifold) to the temperature determined from step 2.
4. Adjust the bypass relief valve until the required oil pressure is achieved. See individual
burner performance sheets for approximate settings. Final oil pressure will have to be
adjusted to attain desired burner output and stack exhaust gas analysis.
5. The low/high oil pressure switch is factory set at a low set point of 15 psig (1.03 bar) and a
high set point of 80 psig (5.5 bar). Set point adjustments may be required depending on
the burner and fuel piping specifics.
6. Inspect the complete fuel oil system for oil leaks and repair as necessary. Do not operate
the burner until all leaks are repaired.
7. The burner oil flow control (metering) valve is preset to travel from position 2 to 11. The low
fire oil flow setting can be changed by loosening the coupling connecting the oil valve to the
control motor, adjusting the oil valve pointer, and re-tightening the coupling. The high fire oil
flow setting can be changed via the burner control system, or if necessary, by increasing or
decreasing fuel oil pressure. See the individual burner performance sheets for fuel oil flow
data.
CAUTION
Any adjustment to the fuel oil flow settings should be
made as a minor incremental change and verified that it
has not resulted in any detrimental effect to plant
operation prior to making another adjustment.

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MS-9
8. Fuel oil flow rates can be checked with the in-line oil flow meter on the burner fuel oil
manifold. The flow meter glass can be rotated to view the scale if required.
Figure 6. Typical Schematic of Burner Heavy Fuel Oil Piping
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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.

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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 Hauck heat tracing kit installed on the heavy oil manifold will aid in viscosity control and
reliable main flame ignition of the burner. The oil manifold heat tracing kit consists of heat
tracing cable which is wrapped around all piping, and covered with fiberglass insulation and
jacketing.
Figure 7. Heavy Oil Manifold Heat Tracing Kit
The heat tracing cable is self-regulating with a nominal rating of 12 W/ft (39 W/m). When the
circuit breaker switch to the oil manifold heat tracing kit is energized, the self-regulating heat
tracing will automatically switch on and off based on heat demand.
M. HEAVY OIL INSERT HEATER
Heavy, waste, or recycled fuel oils require some means of viscosity control. The Hauck heavy
oil insert heater installed in the burner’s oil tube (see Figure 8) is a perfect solution to the
viscosity control problem and reliable main flame ignition of the burner at cold temperatures.
The heavy oil insert heating element, in conjunction with the oil temperature indicating
controller, will maintain an optimum oil temperature in the oil tube to ensure a reliable burner
main flame ignition after an extended shutdown of the burner.
NOTE
120V/60Hz power for the oil manifold heat tracing kit
must be supplied separately by the customer and wired
into the heat tracing power connection box.
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MS-9
Figure 8. Heavy Oil Insert Heater
Operation of the heavy oil insert kit is as follows (see Figure 8):
1. Adjust the low oil temperature controller to the desired temperature as determined in Section
K from testing of the heavy fuel oil viscosity.
2. Energize the insert heater circuit breaker switch.
3. When the oil temperature exceeds the setpoint on the oil temperature indicating controller,
the oil temperature indicating controller switch contact will open and power to the heater
element is removed.
4. When the oil temperature drops below the setpoint on the oil temperature indicating
controller, the oil temperature indicating controller switch contact will close and the heater
element will energize.
See ESII-9.2 Heavy Oil Insert Heater Kit Instructions for more specific detail on the operation
and maintenance of the heavy oil insert heater.
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NOTE
Adjusting the trip setpoint above the required temperature, as
determined by fuel oil viscosity testing, may result in coking of
the fuel oil in the oil insert assembly piping.
NOTE
120V/60Hz power for the heavy oil insert heater
must be supplied separately by the customer
and wired into the heater junction box.

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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.
To change the low pressure oil nozzle position:
1. Shut off the manual oil valve at the burner. The burner must not be firing and the atomizing
air fan must be shut off.
2. If heated heavy oil is being used, allow the oil in the pipe to cool to avoid burns. Drain
residual fuel into an appropriate container.
3. Note the present orientation of the oil nozzle in the burner. Determine if the oil nozzle must
be retracted into or extended out of the primary air tube (see Figure 9).
4. Remove the bolts securing the backplate to the burner, and disconnect the pilot air pipe.
5. Loosen the jam nut on the backplate of the burner oil insert assembly.
6. Rotate the backplate to effect the required retraction or extension of the oil atomizer nozzle.
One full rotation of the backplate will move the atomizer approximately 0.1" (2.5mm).
7. Once the proper positioning of the atomizer is completed:
a. Tighten the jam nut.
b. Attach the burner oil insert assembly to the oil manifold, using the union provided.
c. Open the manual oil valve and check for leaks using accepted practices.
CAUTION
Ensure that the correct atomizer
is being used when firing oil.
Figure 9. Oil Nozzle Position
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