Hauck NovaStar-75 User manual

NOVASTAR BURNER
NS75 – NS150
TABLE OF CONTENTS
Subject Page
A. General Information…………………………………………………………… 2
B. Receiving & Inspection………………………………………………………… 2
C. Burner Capacities……………………………………………………………… 3
D. Dimensions…………………………………………………………………….. 7
E. Component Identification……………………………………………………… 11
F. Combustion Flighting…………………………………………………………… 12
G Burner Mounting………………………………………………………………. 12
H. Fuel Gas Piping System……………………………………………………… 13
I. Burner Pilot System…………………………………………………………… 20
J. Burner Setup…………………………………………………………………… 21
K. Operation……………………………………………………………………….. 23
L. Adjustments……………………………………………………………………… 23
M. Maintenance…………………………………………………………………… 24
N. Recommended Spare Parts………………………………………………… 25
Appendix: Field Installation Weld-In Type Flights, Y7100……………… 26
GJ73 Dryer Drum Gas Analysis
APV-9
INSTRUCTIONS
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.
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
05/23www.hauckburner.com Fax: [phone] NS-9

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NS-9
A. GENERAL INFORMATION
The NovaStar Burner is Hauck’s premier product for ultra-low NOx emissions in the aggregate
drying industry. Reliable performance, quiet operation, and low operating costs are additional
benefits that result from the NovaStar’s patented lean premix technology. Because of the
combustion technology involved, the burner generates a short and compact flame, with no
adjustability required. The NovaStar is designed to burn clean gaseous fuels such as Natural
Gas or Gaseous Propane, with ultra-low emissions performance. The NovaStar is available with
a stand-alone gas manifold for a more versatile installation. The compact and sleek burner
design allows for simplified installation and low maintenance.
The NovaStar is coupled with Hauck’s BCS 6000 control panel. The BCS 6000 panel supervises
burner operation and provides control for burner air and fuel flows, material temperature, stack
temperature and dryer draft. The NovaStar’s air flow is provided by a single combustion air fan
that is controlled by an energy saving, variable frequency drive (VFD). The precise air/fuel ratio
required for optimal emissions is carefully maintained with mass-flow measuring and metering
technology in the BCS 6000 panel. The PLC based BCS 6000 uses a touchscreen display to
supply the operator with system status, fault annunciation, as well as an interface for burner
setup and tuning. The BCS 6000 panel guarantees that the burner is operating under ideal
conditions, with optimal emissions and efficient plant operation.
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. An immediate and 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 and
electronic devices, to protect them from rain or excessive moisture.

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NS-9
C. BURNER CAPACITIES
NovaStar-75 (Natural Gas)
Output Combustion
Air Flow Burner Air Pressure Natural Gas Flow Burner Gas Pressure Flame
VFD Burner Length Diameter
(Hz) (MMBTU/h) (SCFH) (in.w.c.) (SCFH) (in.w.c.) (ft) (ft)
LOW
FIRE 16 18 252,000 0.6 17,300 2.7 5 4
20 22 315,000 1.2 21,600 3.8 5 4
25 27 386,000 1.9 26,400 6.6 6 3
30 33 468,000 2.8 32,000 8.5 7 4
40 45 630,000 4.9 43,100 16.2 8 4
50 55 783,000 7.8 53,600 23.7 9 4
HIGH
FIRE 60 70 985,000 11.1 67,400 38.4 9 4
NovaStar-75 (Gaseous Propane)
Output Combustion
Air Flow Burner Air Pressure Propane Gas Flow Burner Gas Pressure Flame
VFD Burner Length Diameter
(Hz) (MMBTU/h) (SCFH) (in.w.c.) (SCFH) (in.w.c.) (ft) (ft)
LOW
FIRE 16 18 252,000 0.6 7,200 1.2 5 4
20 22 315,000 1.2 8,800 1.6 5 4
25 27 386,000 1.9 10,800 2.8 6 3
30 33 468,000 2.8 13,200 3.7 7 4
40 45 630,000 4.9 18,000 7.3 8 4
50 55 783,000 7.8 22,000 10.3 9 4
HIGH
FIRE 60 70 985,000 11.1 28,000 17.1 9 4
NOTES:
1. Capacities based on Natural Gas with a higher heating value of 1,042 BTU/ft3, 0.59
S.G., and a stoichiometric air to fuel ratio of 9.74:1 and Gaseous Propane with a
higher heating value of 2,500 BTU/ft3, 1.52 S.G., and a stoichiometric air to fuel ratio
of 23.8:1
2. Air and gas flows are based on 60°F @ sea level.
3. Burner air and gas pressures are measured upstream of the mixing assembly.
4. Capacities listed above are for 50% excess air. Capacities and excess air are
typically adjusted on site to achieve optimal emissions per application.
5. Burners are suitable for use on other clean industrial gaseous fuels, such as gaseous
propane, for more information please consult Hauck.
Table 1. Standard Capacities NS75

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NS-9
C. BURNER CAPACITIES
NovaStar-100 (Natural Gas)
Output Combustion
Air Flow Burner Air Pressure Natural Gas Flow Burner Gas Pressure Flame
VFD Burner Length Diameter
(Hz) (MMBTU/h) (SCFH) (in.w.c.) (SCFH) (in.w.c.) (ft) (ft)
LOW
FIRE 16 27 374,000 0.7 26,000 3.0 5 3
20 33 470,000 1.2 32,000 6.6 4 4
25 40 575,000 1.8 39,000 9.7 4 4
30 49 680,000 2.7 47,000 14.2 5 4
40 63 890,000 4.4 61,000 23.3 6 5
50 85 1,200,000 8.1 82,000 37.7 7 5
HIGH
FIRE 60 100 1,410,000 11.1 97,000 48.5 10 6
NovaStar-100 (Gaseous Propane)
Output Combustion
Air Flow Burner Air Pressure Propane Gas Flow Burner Gas Pressure Flame
VFD Burner Length Diameter
(Hz) (MMBTU/h) (SCFH) (in.w.c.) (SCFH) (in.w.c.) (ft) (ft)
LOW
FIRE 16 27 374,000 0.7 10,800 1.3 5 3
20 33 470,000 1.2 13,200 2.9 4 4
25 40 575,000 1.8 16,000 4.2 4 4
30 49 680,000 2.7 19,600 6.4 5 4
40 63 890,000 4.4 25,200 10.2 6 5
50 85 1,200,000 8.1 34,000 16.7 7 5
HIGH
FIRE 60 100 1,410,000 11.1 40,000 21.2 10 6
NOTES:
1. Capacities based on Natural Gas with a higher heating value of 1,042 BTU/ft3, 0.59
S.G., and a stoichiometric air to fuel ratio of 9.74:1 and Gaseous Propane with a
higher heating value of 2,500 BTU/ft3, 1.52 S.G., and a stoichiometric air to fuel ratio
of 23.8:1
2. Air and gas flows are based on 60°F @ sea level.
3. Burner air and gas pressures are measured upstream of the mixing assembly.
4. Capacities listed above are for 50% excess air. Capacities and excess air are
typically adjusted on site to achieve optimal emissions per application.
5. Burners are suitable for use on other clean industrial gaseous fuels, such as gaseous
propane, for more information please consult Hauck.
Table 2. Standard Capacities NS100

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NS-9
C. BURNER CAPACITIES (Continued)
NovaStar-125 (Natural Gas)
Output Combustion
Air Flow Burner Air Pressure Natural Gas Flow Burner Gas Pressure Flame
VFD Burner Length Diameter
(Hz) (MMBTU/h) (SCFH) (in.w.c.) (SCFH) (in.w.c.) (ft) (ft)
LOW
FIRE 16 34 475,000 0.6 33,000 3.1 4 3
20 42 605,000 1.0 41,000 7.6 5 3
25 53 750,000 1.5 51,000 11.7 5 3
30 64 910,000 2.1 62,000 17.3 6 4
40 87 1,220,000 3.8 84,000 31.9 7 4
50 111 1,560,000 5.5 107,000 49.1 8 5
HIGH
FIRE 60 129 1,820,000 8.0 125,000 74.1 10 5
NovaStar-125 (Gaseous Propane)
Output Combustion
Air Flow Burner Air Pressure Propane Gas Flow Burner Gas Pressure Flame
VFD Burner Length Diameter
(Hz) (MMBTU/h) (SCFH) (in.w.c.) (SCFH) (in.w.c.) (ft) (ft)
LOW
FIRE 16 34 475,000 0.6 13,600 1.4 4 3
20 42 605,000 1.0 16,800 3.3 5 3
25 53 750,000 1.5 21,200 5.2 5 3
30 64 910,000 2.1 25,600 7.6 6 4
40 87 1,220,000 3.8 34,800 14.1 7 4
50 111 1,560,000 5.5 44,400 21.8 8 5
HIGH
FIRE 60 129 1,820,000 8.0 51,600 32.5 10 5
NOTES:
1. Capacities based on Natural Gas with a higher heating value of 1,042 BTU/ft3, 0.59
S.G., and a stoichiometric air to fuel ratio of 9.74:1 and Gaseous Propane with a
higher heating value of 2,500 BTU/ft3, 1.52 S.G., and a stoichiometric air to fuel ratio
of 23.8:1
2. Air and gas flows are based on 60°F @ sea level.
3. Burner air and gas pressures are measured upstream of the mixing assembly.
4. Capacities listed above are for 50% excess air. Capacities and excess air are
typically adjusted on site to achieve optimal emissions per application.
5. Burners are suitable for use on other clean industrial gaseous fuels, such as gaseous
propane, for more information please consult Hauck.
Table 3. Standard Capacities NS125

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NS-9
C. BURNER CAPACITIES (Continued)
NovaStar-150 (Natural Gas)
Output Combustion
Air Flow Burner Air Pressure Natural Gas Flow Burner Gas Pressure Flame
VFD Burner Length Diameter
(Hz) (MMBTU/h) (SCFH) (in.w.c.) (SCFH) (in.w.c.) (ft) (ft)
LOW
FIRE 16 42 596,980 0.7 40,861 4.9 6 3
20 53 743,370 1.2 50,881 8.7 6 4
25 60 845,420 1.8 57,866 11.8 6 5
30 75 1,065,700 2.5 72,943 19.0 8 5
40 106 1,499,510 4.6 102,636 36.5 9 5
50 131 1,855,090 7.0 126,975 55.1 10 6
HIGH
FIRE 60 150 2,126,150 9.9 145,530 76.5 15 6
NovaStar-150 (Gaseous Propane)
Output Combustion
Air Flow Burner Air Pressure Propane Gas Flow Burner Gas Pressure Flame
VFD Burner Length Diameter
(Hz) (MMBTU/h) (SCFH) (in.w.c.) (SCFH) (in.w.c.) (ft) (ft)
LOW
FIRE 16 42 596,980 0.7 16,800 2.1 6 3
20 53 743,370 1.2 21,200 3.9 6 4
25 60 845,420 1.8 24,000 5.2 6 5
30 75 1,065,700 2.5 30,000 8.3 8 5
40 106 1,499,510 4.6 42,400 16.0 9 5
50 131 1,855,090 7.0 52,400 24.2 10 6
HIGH
FIRE 60 150 2,126,150 9.9 60,000 33.5 15 6
NOTES:
1. Capacities based on Natural Gas with a higher heating value of 1,042 BTU/ft3, 0.59
S.G., and a stoichiometric air to fuel ratio of 9.74:1 and Gaseous Propane with a
higher heating value of 2,500 BTU/ft3, 1.52 S.G., and a stoichiometric air to fuel ratio
of 23.8:1
2. Air and gas flows are based on 60°F @ sea level.
3. Burner air and gas pressures are measured upstream of the mixing assembly.
4. Capacities listed above are for 50% excess air. Capacities and excess air are
typically adjusted on site to achieve optimal emissions per application.
5. Burners are suitable for use on other clean industrial gaseous fuels, such as gaseous
propane, for more information please consult Hauck.
Table 4. Standard Capacities NS150

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NS-9
D. DIMENSIONS
Y8358 (NOT TO SCALE)
Figure 1. Dimensions NovaStar 75

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NS-9
D. DIMENSIONS (Continued)
Y8359 (NOT TO SCALE)
Figure 2. Dimensions NovaStar 100

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NS-9
D. DIMENSIONS (Continued)
Figure 3. Dimensions NovaStar 125
Y8360 (NOT TO SCALE)

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NS-9
D. DIMENSIONS (Continued)
Figure 4. Dimensions NovaStar 150
Y8361 (NOT TO SCALE)