Honeywell Hauck MEGASTAR MS-25 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-25 – 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 Eclipse, Inc.
MS-9
Eclipse, Inc., 1665 Elmwood Road, Rockford, IL 61103-1299 Ph: 717-272-3051
4/18 www.eclipsenet.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 Eclipse.
WARNING
This equipment is potentially dangerous with the possibility of serious personal injury and
property damage. Eclipse, Inc. recommends the use of flame supervisory equipment and
fuel safety shutoff valves. Furthermore, Eclipse 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
C. BURNER CAPACITIES
Table 1. Burner Capacity Data For Natural Gas & Light Oil
MEGASTAR
BURNER MODEL
GAS SPECIFICATIONS
25
50
75
100
125
150
Capacity
(MMBTU/hr)
31
54
89
108
146
166
(MW)
8.4
14.7
24.2
29.3
39.6
45.2
Main Air Flow
(scfh)
365,000
636,600
1,050,000
1,270,000
1,720,000
1,960,000
(nm3/hr)
9,800
17,100
28,100
34,000
46,100
52,500
Main Air Pressure
(in.w.c.)
12.0
14.3
12.6
15.3
13.8
14.5
(mbar)
29.9
35.6
31.3
38.1
34.3
36.1
Gas Flow Rate
(scfh)
30,000
52,300
86,200
104,300
141,300
161,000
(nm3/hr)
800
1,400
2,300
2,800
3,800
4,300
Capacity with FGR
(MMBTU/hr)
23.2
40.5
62
82
103
124
(MW)
6.3
11.0
16.8
22.2
27.9
33.6
Flame Length @ 30° Spin
(ft)
8
12
14
9
11
15
(m)
2.4
3.7
4.1
2.7
3.4
4.6
Flame Diameter @ 30° Spin
(ft)
3
4
7
5
8
7
(m)
0.9
1.2
2.0
1.5
2.4
2.1
MEGASTAR
BURNER MODEL
LIGHT OIL SPECIFICATIONS
25
50
75
100
125
150
Capacity
(MMBTU/hr)
31
53
82
100
135
153
(MW)
8.5
14.3
22.3
27.2
36.5
41.5
Main Air Flow
(scfh)
365,000
643,300
1,030,000
1,270,000
1,720,000
1,960,000
(nm3/hr)
9,800
17,200
27,600
34,000
46,100
52,500
Main Air Pressure
(in.w.c.)
12.0
14.3
12.0
16.2
13.7
144.0
(mbar)
29.9
35.6
29.9
40.3
34.1
358.3
Primary Air Flow
(scfh)
46,500
46,500
46,500
46,500
46,500
46,500
(nm3/hr)
1,200
1,200
1,200
1,200
1,200
1,200
Primary Air Pressure
(in.w.c.)
61
62
62
62
62
62
(mbar)
152
154
154
154
154
154
Oil Flow Rate
(gal)
220
370
580
710
950
1,080
(lph)
830
1,400
2,200
2,690
3,600
4,090
Flame Length @ 30° Spin
(ft)
8
10
12
12
10
12
(m)
2.4
3.1
3.7
3.7
3.1
3.7
Flame Diameter @ 30° Spin
(ft)
3
4
5
5
4
5
(m)
0.9
1.2
1.5
1.5
1.2
1.5
NOTES: 1. Fuel Flow rates based on Natural Gas at 1,043 BTU/scfh (HHV) / 36.74 MJ/nm3
(LHV) and No.2 Fuel Oil at 141,146 BTU/gal (HHV) / 36.99 MJ/liter (LHV)
2. Air Flows Listed are for ambient air at 60°F, 1.0 SG and Sea Level
3. Capacity Listed at 25% Excess Air for Natural Gas operation and 35% Excess Air for
No. 2 Fuel Oil

Page 4
MS-9
C. BURNER CAPACITIES (Continued)
Table 2. Burner Capacity Data For Liquid Propane
MEGASTAR
BURNER MODEL
LIQUID PROPANE SPECIFICATIONS
25
50
75
100
125
150
Capacity
(MMBTU/hr)
50
80
97
128
145
(MW)
13.5
21.7
26.4
34.6
39.3
Main Air Flow
(scfh)
594,160
980,000
1,200,000
1,590,000
1,810,000
(nm3/hr)
15,900
26,300
32,100
42,600
48,500
Main Air Pressure
(in.w.c.)
14.3
12.8
18.5
15.0
18.3
(mbar)
P
35.6
31.8
46.0
37.3
45.5
Primary Air Flow
(scfh)
e
46,500
46,500
46,500
46,500
46,500
(nm3/hr)
n
d
1,200
1,200
1,200
1,200
1,200
Primary Air Pressure
(in.w.c.)
i
62
62
62
62
62
(mbar)
n
154
154
154
154
154
Propane Flow Rate
(gal)
g
550
880
1,070
1,400
1,590
(lph)
2,080
3,330
4,050
5,300
6,020
Flame Length @ 30° Spin
(ft)
10
14
15
13
15
(m)
3.1
4.3
4.6
4.0
4.6
Flame Diameter @ 30° Spin
(ft)
4
5
5
6
6
(m)
1.2
1.5
1.5
1.8
1.8
NOTES 1. Fuel Flow rates based on Liquid Propane at 90,912 BTU/gallon (HHV) / 23.83 MJ/liter
(LHV) and No.2 Fuel Oil at 141,146 BTU/gal (HHV) / 36.99 MJ/liter (LHV)
2. Capacity Listed at 35% Excess Air for Liquid Propane

Page 5
MS-9
Table 2. Burner Capacity Data For Compressed Air
MEGASTAR
BURNER MODEL
COMPRESSED AIR SPECIFICATIONS
25
50
75
100
125
150
Capacity
(MMBTU/hr)
79
100
130
150
(MW)
21.4
27.2
35.3
40.7
Main Air Flow
(scfh)
N
N
1,030,000
1,310,000
1,700,000
1,960,000
(nm3/hr)
o
o
27,600
35,100
45,500
52,500
Main Air Pressure
(in.w.c.)
t
t
12.0
16.2
13.2
14.4
(mbar)
29.9
40.3
32.8
35.8
Compressed Air Flow
(scfh)
A
A
3,600
3,600
5,400
5,400
(nm3/hr)
v
a
v
a
100
100
100
100
Compressed Air Pressure
(psig)
i
i
60
60
60
60
(bar)
l
l
4
4
4
4
Oil Flow Rate
(gal)
a
a
560
710
920
1,060
(lph)
b
b
2,120
2,690
3,480
4,010
Flame Length @ 30° Spin
(ft)
l
l
9
9
10
10
(m)
e
e
2.7
2.7
3.1
3.1
Flame Diameter @ 30° Spin
(ft)
5
5
5
5
(m)
1.5
1.5
1.5
1.5
NOTES 1. Air Flows Listed are for ambient air at 60°F, 1.0 SG and Sea Level
3. Capacity Listed at 35% Excess Air for No. 2 Fuel Oil operation

Page 6
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
Eclipse. 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 nm3 air/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 7
MS-9
E. COMPONENT IDENTIFICATION
Figure 1. MegaStarTM Burner Components
Y8978 (NOT TO SCALE)

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.
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 Eclipse for details on flight design and
combustion zone requirements.
Flights are available from Eclipse to optimize performance of the MegaStar™ on a rotary dryer;
for detailed installation instructions of Eclipse weld-in type flights, see Y7100 in the Appendix. For
additional information on application issues for a 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 Eclipse 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 Eclipse for the remote
mounted fuel rack dimensional drawing HKY6967 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.
MegaStarTM Model No.
25 - 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 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" (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.
25 - 50
75-100
125-150
Companion Flange Part No.
HK407091
HK56548x001
HK56549x008
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.
Eclipse 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 10
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
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. Eclipse gas
manifolds have been designed to ensure compliance to NFPA
requirements.
Y7863
(NOT TO SCALE)

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.
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.
25 - 50
75-100
125-150
FPN Part No.
HK800598
HK800599
HK800600X014
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.
25
50
75-100
125-150
OMG Part No.
HK19814
HK19816
HK48242x001
HK47181x005
Pipe Size
3” (DN80)
4” (DN 100)
6" (DN 150)
8" (DN 200)
Orifice Size
2.40” (60.9mm)
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 12
MS-9
Figure 3. Simplified Gas and Air Flow Chart
(@ Atmospheric Conditions)
GL86

Page 13
MS-9
Figure 4. MegaStar™ Gas Orifice Meters Graph
0 5 10 15 20 25 30 35
0 1,000 2,000 3,000 4,000 5,000
0
20,000 40,000 60,000 80,000
100,000 120,000 140,000 160,000 180,000
0246810 12 14
Orifice Pressure Drop (mbar)
Natural Gas Flow Rate (m3/h)
Natural Gas Flow Rate (SCFH)
Orifice Pressure Drop (in.w.c.)
MegaStar Orifice Meters - Natural Gas (SG = 0.6)
MS125-MS150
MS75-MS100
MS50
MS25

Page 14
MS-9
J. LIGHT FUEL OIL PIPING SYSTEM
1. Eclipse 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)
25 - 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.
25 - 50
75-150
Flex Oil Hose Part No.
HK11078
HK20518
Size
1/2" (DN 15)
1" (DN 25)
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. Eclipse 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
personal injury, or even death.

Page 15
MS-9
MegaStar™
Model No.
Nominal Oil Pressure
w/Low Pressure Atomizer
Nominal Oil Pressure
w/Compressed Air Atomizer
25
30 psig (4.14 bar)
N/A
50
75 psig (5.15 bar)
N/A
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 16
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 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. Eclipse oil manifolds have been
designed to ensure compliance to NFPA requirements. Eclipse
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 an oil viscometer kit (HK16594 & HK300450) 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.

Page 18
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
X7872
(NOT TO SCALE)
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.

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. The oil manifold heat tracing should 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
The heat tracing cable should be 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 should 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 must
be supplied separately by the customer and wired into
the heat tracing power connection box.
X8046
(NOT TO SCALE)

Page 20
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 set point 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 set point 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.
V7867
(NOT TO SCALE)
NOTE
Adjusting the trip set point 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.