Hauck PBGII User manual

PBG PACKAGED GAS BURNER
TABLE OF CONTENTS
Subject Page
A.
General Information…………………………………………………………. 2
B.
Receiving and Inspection…………………………………………………… 2
C.
Capacities……………………………………………………………………..
3
D.
Dimensions……………………………………………………………………
5
E.
Installation……………………………………………………………………. 5
F.
Electrical Power Supply…………………………………………………….. 6
G.
Gas Supply…………………………………………………………………… 7
H.
Initial Setup……………………………………………………………………
8
I.
Ignition…………………………………………………………………………
10
J.
Operation…………………………………………………………………….. 10
K.
Flame Monitoring……………………………………………………………. 11
L.
Maintenance…………………………………………………………………. 11
M.
Recommended Spare Parts………………………………………………...
14
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.
HAUCK MANUFACTURING CO.,
P.O. Box 90 Lebanon, PA 17042-0090 717-272-3051
2/12 www.hauckburner.com Fax: [phone] PBG-9
INSTRUCTIONS
These instructions are intend
ed 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 precl
ude
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.

Page 2
PBG-9
A. GENERAL INFORMATION
The Hauck PBG Packaged Gas Burners are designed for applications where it is desirable to
have all of the necessary components for a high turndown combustion system contained in one
compact and easy-to-use assembly. Configured versions of the burner system are available
with selections for fuel type, air control, fuel control, power supply and flame supervision and/or
burner control. The basic burner and air pressure switch includes the burner assembly with
spark igniter and flame rod, and the straight combustor alloy tile. Auxiliary tube selections are
available to provide longer burner lengths or provide a 90° bend to the flame. Selections for the
air control method include manual, 4-20mA controlled actuator, or VFD. Flame supervision and
burner control is accommodated by the KromSchroder BCU 370. A pre-configured temperature
control panel, PBG-BCS, is also available that incorporates the BCU and customer settings to
provide optimized burner control. Modifications can be made to these standard configurations
to meet other customer specifications to provide a premier custom engineered product.
For further information on any components supplied with the package, see specific product
literature available from Hauck.
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.
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 shut-off 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
PBG-9
C. BURNER CAPACITY TABLES
Notes:
1. Capacities based on integral blower with 230/3/60 power supply. Amp Draw is based on use with
VFD. Without VFD, the amp draw is equivalent to high fire requirements.
2. Air and gas flows based on 60°F, 0°C.
3. Flame lengths are based on the straight combustor tube firing into a chamber without forced air flow.
4. For operation at altitude, consult Hauck for re-rated capacity.
5. For chambers operating above 1 inch w.c. of back pressure or vacuum, consult Hauck for re-rated
capacity.
6. Minimum gas flow on the fuel-only control manifold is dependent on valve port adjustment and supply
pressure. 2 psig minimum supply pressure is suggested.
7. Additional gas pressure required for additional upstream components, such as optional manifolds.
Table 1. PBGII 300 – 1000 Burner Capacities
PBG-300 PBG-500 PBG-750 PBG-1000
Blower Horsepower
(hp) 1/3
1/3
1/3
1/3
Ratio Regulator Gas Manifold
Minimum Supply Pressure
(in w.c.) 14
14
21
14
BURNER SPECIFICATIONS - HIGH FIRE
Body Pressure
(in. w.c.) 6.5
5.2
5.9
5.9
Blower Amp Draw
(A) 0.6
0.7
1.1
1.1
Air Flow
(scfh) 3250
5400
8000
11050
Natural Gas Flow
(scfh) 300
500
750
1000
Flame Length
(in) 12
14
24
32
Maximum Excess Air
(%) 3200
3600
5300
3600
BURNER SPECIFICATIONS - LOW FIRE
Body Pressure
(in w.c.) 0.1
0.1
0.1
0.3
Blower Amp Draw
(A) 0.2
0.2
0.2
0.2
Air Flow
(scfh) 400
750
1040
1580
Min. Gas Flow (NFPA)
(scfh) 10
15
15
30
Min. Gas Flow (Ratio Reg.)
(scfh) 16
16
32
32
Flame Length
(in) Tile
Tile
Tile
Tile
Metric Capacities
PBG-300 PBG-500 PBG-750 PBG-1000
Blower Horsepower
(kW) 0.25
0.25
0.25
0.25
Ratio Regulator Gas Manifold
Minimum Supply Pressure
(mbar) 35
35
52
35
BURNER SPECIFICATIONS - HIGH FIRE
Body Pressure
(mbar) 16.2
12.9
14.7
14.7
Blower Amp Draw
(A) 0.6
0.7
1.1
1.1
Air Flow
(Nm3/hr) 87
145
214
296
Natural Gas Flow
(Nm3/hr) 8
13
20
27
Flame Length
(cm) 30
36
61
81
Maximum Excess Air
(%) 3200
3600
5300
3600
BURNER SPECIFICATIONS - LOW FIRE
Body Pressure
(mbar) 0.25
0.25
0.25
0.75
Blower Amp Draw
(A) 0.2
0.2
0.2
0.2
Air Flow
(Nm3/hr) 10.7
20
27.9
42.3
Min. Gas Flow (NFPA)
(Nm3/hr)
0.3
0.4
0.4
0.8
Min. Gas Flow (Ratio Reg.)
(Nm3/hr)
0.4
0.4
0.4
0.8
Flame Length
(in) Tile
Tile
Tile
Tile

Page 4
PBG-9
C. BURNER CAPACITY TABLES (Continued)
Notes:
1. Capacities based on integral blower with 230/3/60 power supply. Amp Draw is based on use with
VFD. Without VFD, the amp draw is equivalent to high fire requirements.
2. Air and gas flows based on 60°F, 0°C.
3. Flame lengths are based on the straight combustor tube firing into a chamber without forced air
flow.
4. For operation at altitude, consult Hauck for re-rated capacity.
5. For chambers operating above 1 inch w.c. of back pressure or vacuum, consult Hauck for re-
rated capacity.
6. Minimum gas flow on the fuel-only control manifold is dependent on valve port adjustment and
supply pressure. 2 psig minimum supply pressure is suggested.
7. Additional gas pressure required for additional upstream components, such as optional manifolds.
Table 2. PBGII 2000 – 5000 Burner Capacities
PBG-2000 PBG-3000 PBG-5000
Blower Horsepower
(hp) 2
2
2
Ratio Regulator Gas Manifold
Minimum Supply Pressure
(in w.c.) 14
14
28
BURNER SPECIFICATIONS - HIGH FIRE
Body Pressure
(in. w.c.) 5.5
5.5
5.5
Blower Amp Draw
(A) 4.3
4.8
5.5
Air Flow
(scfh) 22250
33000
55000
Natural Gas Flow
(scfh) 2000
3000
5000
Flame Length
(in) 60
66
72
Maximum Excess Air
(%) 1000
4000
2500
BURNER SPECIFICATIONS - LOW FIRE
Body Pressure
(in w.c.) 0.3
0.3
0.3
Blower Amp Draw
(A) 2.3
2.4
2.6
Air Flow
(scfh) 4875
5500
13750
Min. Gas Flow (NFPA)
(scfh) N/A
N/A
N/A
Min. Gas Flow (Ratio Reg.)
(scfh) 60
70
90
Flame Length
(in) Tile
Tile
Tile
Metric Capacities
PBG-2000 PBG-3000 PBG-5000
Blower Horsepower
(kW) 1.50
1.50
1.50
Ratio Regulator Gas Manifold
Minimum Supply Pressure
(mbar) 14
35
52
BURNER SPECIFICATIONS - HIGH FIRE
Body Pressure
(mbar) 13.7
13.7
13.7
Blower Amp Draw
(A) 4.3
4.8
5.5
Air Flow
(Nm3/hr) 596
884
1473
Natural Gas Flow
(Nm3/hr) 54
80
134
Flame Length
(cm) 152
168
183
Maximum Excess Air
(%) 1000
4000
2500
BURNER SPECIFICATIONS - LOW FIRE
Body Pressure
(mbar) 0.75
0.75
0.75
Blower Amp Draw
(A) 2.3
2.4
2.6
Air Flow
(Nm3/hr) 131
147
368
Min. Gas Flow (NFPA)
(Nm3/hr)
N/A
N/A
N/A
Min. Gas Flow (Ratio Reg.)
(Nm3/hr)
2
2
2
Flame Length
(in) Tile
Tile
Tile

Page 5
PBG-9
D. DIMENSIONS
See appropriate section PBG-3 through PBG-3.6 Dimension sheet for detailed dimensional
information.
E. INSTALLATION
1. The Hauck PBG burner can fire in any position. Burner and blower orientations may be
adjusted to fit application constraints. Therefore, it can be installed to fire through side-walls,
roofs or the bottoms of ovens, dryers, or furnaces. Note that Kromschroder Valvario
components may not be installed with the solenoid actuator facing down. Note that
KromSchroder GIK must be installed with the spring tower side facing down.
2. The PBG burners will bolt to the oven or furnace wall. Prepare the oven wall appropriately
to support the weight of the burner and any other associated components. Install the burner
combustor tube so that it is properly insulated in the furnace wall. For walls thicker than the
standard length of the combustor alloy tile or in cross-flow applications the use of a straight
or 90° auxiliary firing tube may be required.
3. For air heating installations where the burner will fire into a chamber under negative
pressure, spacers may be installed between the burner mounting bracket and the
oven/furnace wall to draw secondary air past the firing tube.
4. On installations where there is a positive pressure within the combustion chamber, the
opening in the oven or furnace wall should be at least 1 inch (25mm) larger than the burner
combustor tube/tile. Pack the space around the alloy tile with ceramic fiber suitable for the
temperatures involved. Ceramic fiber packing should not extend past wall thickness.
Installation of the high temperature gasket between the burner mounting plate/flange and
the oven or furnace wall is recommended for all positive pressure ovens or furnaces.
5. On installations using the auxiliary firing tube, the area between the burner alloy tile and
firing tube should be packed with ceramic fiber. Ceramic fiber packing should not extend
past the wall thickness or the end of the alloy tile (See Figure 1).
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 6
PBG-9
Figure 1. Typical Installation Package Burner Unit
6. If the burner will be located outdoors, protection should be provided to prevent rain and/or
snow from being drawn into the blower. Properly select all accessory items for outdoor
operation. A rain hood or other suitable protection is recommended for burners installed in
areas of direct rain or snow exposure.
7. If the Hauck PBG burner is to be operated within an enclosed area, verify that an adequate
fresh air supply is available to supply combustion air to the burner.
F. ELECTRICAL POWER SUPPLY
Local and national codes and/or standards should be adhered to. Voltage, phase and frequency
must be compatible with the motor and electrical accessory nameplate ratings. All wiring to the
burner blower, air control motor, and control accessories must be completed before the burner
is ignited.
Any burner unit to be used with a 50 Hz power supply should also select a VFD. The VFD
converts any incoming power supply to a 230 V, 3 phase supply. The VFD is directly connected
to the blower, which uses a 230 V, 3 phase motor. Using the standard burner with a 50 Hz
power supply will de-rate the burner capacity and require different burner settings.
NOTE
If the PBG burner will be subjected to backpressure from the chamber
or furnace into which it is firing, a larger blower motor may be required
to achieve the desired heat input; consult Hauck.
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Page 7
PBG-9
G. GAS SUPPLY
The Hauck PBG Burners are designed to operate with a regulated gas supply pressure to the
inlet of the manifold of 20 to 55 in.w.c. (50 to 140 mbar) for natural gas at a nominal HHV of
1034 Btu/ft3 (LHV of 10.21 kWh/Nm3) or propane at a nominal HHV of 2499 Btu/ft3 (LHV of 25.3
kWh/Nm3). Failure to provide adequate gas pressure will result in compromised burner
performance, e.g. a reduction in capacity or unreliable ignition.
For multiple burner installations, consult Hauck for the design of a common pre-piped gas
manifold. If supplied via third party, confirm that the gas supply pressures to the individual
burners are within the 20 to 55 in.w.c. (50 to 140 mbar) range. For accurate burner control, the
combustion air and gas should be controlled by the components packaged with the burners and
not with central or common air and gas components.
NOTE
Pressure testing of the manifold and combustion equipment is required by the
customer after installation. Failure to do so may result in unsafe conditions and may
violate local or national codes.
SPECIAL NOTE
Hauck recommends the use of gas manifolds conforming to National Fire Protection
Association (NFPA) standards. NFPA 86 standards for gas manifolds vary for burner
capacity as well as single burner versus multiple burner installations. The Hauck PBG with
NFPA manifold contains all features required for burner capacity as well as single and
multiple burner installations.

Page 8
PBG-9
H. INITIAL SET-UP
The PBG is factory adjusted to conform to capacity and ignition limits. Although the burner
should require no adjustment upon initial set-up, several adjustments can be made in situations
where the burner needs to be tuned to the application.
1. Combustion Air
If using a combustion air valve and actuator, the valve travels 90from closed to the
fully open position. The valve is designed for use with a directly coupled IC40
actuator, which is controlled by a 4-20 mA input signal. The air valve must be at the
ignition position to light the burner, which for most applications will be about 20°
open. For applications that require special control motor settings, the IC40 can be
reprogrammed in a variety of different ways using Opticord adapter, (P/N 74960437)
a laptop computer, and a free software package.
A third-party actuator may be used, and Hauck supplies a universal connection kit.
Operationally, the actuator must control the valve in the same manner, and be able
to provide the same ignition point.
If the air is controlled by VFD, the motor will operation between 60Hz at high fire and
15Hz at low fire. In certain applications, such as those operating under pressure, it
may be necessary to increase the low fire frequency to satisfy the air pressure
switch. Applications that have a 50 Hz supply voltage, should select the VFD option
for the ability to fire at the rated high-fire capacity. Applications with a 50 Hz supply
voltage that do not use a VFD will have a de-rated burner capacity and require
different burner settings.
A manual air valve handle may be used to control the air flow to the burner. In a
fuel-only control application, the manual handle has the ability to be fixed, and may
be the desired method of air control.
WARNING
Adjustment of this equipment by unqualified personnel can
result in fire, explosion, severe personal injury, or even death.
NOTE
The use of a third-party actuator without a BCS may require additional
electronic components to be installed and wired by the customer.

Page 9
PBG-9
2. Gas Ratio Regulator
The gas ratio regulator proportions gas flow through the burner relative to the burner
air pressure. Adjusting the bias of the regulator can increase or decrease the ratio of
gas to the burner air. The bias adjustment is located below the valve body on the
VAG regulator, or under the cap on the GIK regulator stem. For the VAG, the bias is
indicated on the adjustment wheel. For the GIK, clockwise adjustment of the bias
screw will increase gas flow, while counter-clockwise adjustment will decrease gas
flow. The GIK regulator features a fixed bypass through the regulator. For
processes that require a lower low-fire than the regulator function provides, simply
un-bias the regulator; low-fire gas flow will then be regulated using the fixed bypass.
Figure 2. Bias Adjustment Locations
Y8458 Sht. 10
(NOT TO SCALE)
NOTE
For operation with fuel type other than natural gas, replace the orifice
plate between union halves with orifice supplied for intended fuel.

Page 10
PBG-9
3. Fuel-Only Control
The Linear Flow Control Valve, LFC, is used for the fuel-only control manifold. The
valve is directly coupled to an IC40 actuator, which is controlled by a 4-20 mA input
signal. The LFC flow characteristic can be adjusted by biasing the valve piston.
Additionally, this manifold has an adjustable high fire limiting valve and a orifice
meter to measure fuel flow.
I. IGNITION
Each PBG comes equipped with a spark igniter. Since PBG burners are preset, no
adjustment to the igniter should be necessary upon initial light-off. However, if ignition problems
occur or a new igniter is installed, follow the procedure in Figure 3 to replace and adjust the
igniter. Spark ignition requires the burner to be properly grounded to the oven/furnace.
Figure 3. Spark Igniter & Flamerod Installation
J. OPERATION
Sequential operation of the PBGburner will depend on the control method used on the burner
and various component selections.
NOTE
Maintain electrical power supply to the blower motor until the chamber
or furnace temperature is below 200°F (93°C). If the blower is shut off
with a hot chamber, hot air may exhaust through the burner and
damage internal components.
Y8458 Sht. 9
(NOT TO SCALE)