INSTRUCTIONS
RTG RADIANT TUBE GAS BURNERS
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.
TABLE OF CONTENTS
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
Subject
General Information ……………………………………………………….…..….…….
Receiving and Inspection ………………………………………….…….…...…….…..
Capacities ………….…………………………………………………………………….
Dimensions …………….………………………………………………………………...
Installation ………….……………………………………………………………….……
Ignition …..…………………………………………..………………….…..….…….…..
Initial Set-up ………………………………….…………………..……….…….……….
Operation………………………………………………………………………………….
Maintenance …………………………………………………………………..…………
Recommended Spare Parts List ………………………………………………………
Page
2
2
3
5
6
9
10
11
12
12
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
1/07
www.hauckburner.com
Fax: 717-273-9882
RTG-9
Page 2
RTG-9
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.
A. GENERAL INFORMATION
The Hauck RTG Series Radiant Tube Burners provide improved flame stability and uniform heat
distribution in all types of radiant tube applications. Flame length and air/gas premix controls
permit adjusting the flame shape to match tube configuration precisely. The RTG Series
Burners fire any clean industrial gas and will accommodate preheated air up to 700°F (371°C).
Hauck Application Sheet GJ60 provides guidelines for installation and operation of RTG burners
on hot air applications.
RTG burners typically operate with automatic control systems. The burners are capable of
proportional control over their entire capacity range. If the maximum firing rate does not allow a
high turndown, low-high-off control may be more appropriate. Since the RTG burner can be set
up for varying flame lengths and premix, the air requirements and heat inputs will vary with the
application. Refer to Section C, Capacity Tables, for typical performance data.
RTG burners can be spark ignited or will accommodate a premix gas pilot. The burners are
designed to accommodate UV flame supervision, monitoring main flame with a single scanner.
(A scanner adapter is required for preheated air operation). An air cooled flame rod is also
available.
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.
Page 3
RTG-9
C. BURNER CAPACITIES
SPECIFICATIONS
8 OSI
16 OSI
MODEL NUMBER
MODEL NUMBER
102
L
O Max. Input @ 10% Excess Air (Btu/hr) 367,100
N
G Max. Air Flow
(scfh)
3,800
F
L Min. Input @ Max. Air Flow
A
M
E Max. Excess Air
(Btu/hr)
(%)
(Btu/hr)
(%)
106
102
673,100 1,172,000 540,800
104
106
961,600 1,635,000
6,980
12,140
5,600
9,960
16,940
49,740
49,740
64,630
49,740
49,740
64,630
710
1,390
1,890
1,100
2,030
2,680
S
H Max. Input @ 10% Excess Air (Btu/hr) 540,800
O
R
Max. Air Flow
(scfh)
5,600
T
F Min. Input @ Max. Air Flow
L
A
M Max. Excess Air
E
104
901,600 1,521,000 739,300 1,310,000 2,134,000
9,340
15,760
7,660
13,580
22,110
89,440
149,100
200,800
89,440
149,100
200,800
560
560
730
810
870
1,070
NOTES:
3
1. Capacities based on natural gas with HHV of 1034 Btu/ft , 0.59 S.G., and a stoichiometric air/gas ratio
9.74:1 with burner firing into radiant tube.
2. Air and gas flows based on 60°F @ sea level; capacities for preheated air will differ from those shown.
3. Total air pressures measured 6 pipe diameters from burner air inlet.
4. All data based on industry standard air and gas piping practices.
5. Flame detection available via flame rod or UV scanner.
Table 1. Burner Capacities
Page 4
RTG-9
C. BURNER CAPACITIES (Continued)
SPECIFICATIONS
MODEL NUMBER
MODEL NUMBER
104
106
102
104
106
97.1
178
310
143
254
432
102
187
325
150
267
454
(kW)
13.2
13.2
17.1
13.2
13.2
17.1
(%)
710
1,390
1,890
1,100
2,030
2,680
143
238
402
196
346
564
150
250
422
205
364
592
(kW)
23.7
39.4
53.1
23.7
39.4
53.1
(%)
560
560
730
810
870
1,070
S
H Max. Input @ 10% Excess Air (kW)
O
R
3
Max. Air Flow
(nm /hr)
T
F Min. Input @ Max. Air Flow
L
A
M Max. Excess Air
E
6900 Pa
102
L
O Max. Input @ 10% Excess Air (kW)
N
3
G Max. Air Flow
(nm /hr)
F
L Min. Input @ Max. Air Flow
A
M
E Max. Excess Air
3450 Pa
NOTES:
3
1. Capacities based on natural gas with LHV of 36.74 MJ/nm , 0.59 S.G., and a stoichiometric air/gas
ratio 9.74:1 with burner firing into radiant tube.
2. Air and gas flows based on 0°C @ sea level; capacities for preheated air will differ from those shown.
3. Total air pressures measured 6 pipe diameters from burner air inlet.
4. All data based on industry standard air and gas piping practices.
5. Flame detection available via flame rod or UV scanner.
Table 2. Metric Burner Capacities
Page 5
RTG-9
Figure 1. Dimensions
(NOT TO SCALE)
Y6090
D. DIMENSIONS
Page 6
RTG-9
Figure 2. Metric Dimensions
(NOT TO SCALE)
Y6090 METRIC
D. DIMENSIONS (Continued)
Page 7
RTG-9
E. INSTALLATION
1. Typical mounting arrangements for the RTG burners are shown in Figure 3. The arrangement
used will depend on the relationship between the backplate and the diameter of the tube.
W197D
Figure 3. Three Typical Flange Mounting Arrangements
2. The RTG burners must be properly centered in either the tube or an auxiliary air sleeve to
ensure that the ignition nozzle to tube or sleeve gap is properly maintained. There are three
adjusting screws (21) on the ignition nozzle (see Figure 4). These screws MUST be adjusted
to EQUAL lengths so that the OD formed by the heads of the screws allows the burner to
slide snugly into and against the ID of the tube or auxiliary air sleeve. To adjust the screws,
loosen the locking nuts (22). After all screws have been properly adjusted, tighten the locking
nuts.
3. When the actual tube ID exceeds the maximum recommended, an auxiliary air sleeve must
be inserted into the tube. Substitutions should not be made since the area between the
ignition nozzle and the tube meters the flow of burner combustion air. If the tube ID exceeds
the maximum "I" dimension, the auxiliary sleeve must be specified on the order. Be sure the
actual installation corresponds to the original specification.
4. Prepare the end of the tube to accept the mounting bolts of the RTG burner backplate. The
arrangement used will depend on the relationship between the backplate and the diameter of
the tube.
5. Make sure that the burner gas and air inlets are properly aligned to meet the piping requirements. The gas inlet may be located in any position that will not obstruct the flame length
control screw or the observation ports. To rotate the gas inlet (refer to Figure 4):
A. Loosen the spark igniter holding screw (31) and remove the spark igniter assembly (25)
or (26).
B. Loosen the body setscrew (23).
C. Rotate the gas inlet assembly to the desired position.
D. Tighten the body setscrew (23).
E. Loosen the ignition nozzle setscrew (17).
F. Rotate the nozzle assembly (20) until the locating collar realigns itself with the spark
igniter hole in the air body.
G. Hand tighten the ignition nozzle setscrew (17).
H. Replace the spark igniter (25) or (26). Adjust the nozzle collar until the igniter slips
easily into place.
I. Ensure that the spark igniter tip is located 1/8" from the air/gas nozzle tip. (The igniter
pipe will "bottom out" on the burner ignition cup).
J. Tighten the setscrews (17 and 18).
Page 8
RTG-9
Y3243
(NOT TO SCALE)
Figure 4. Components
6. Inset the RTG burner into the end of the tube and securely bolt it into place.
7. Connect the fuel and air supply line to the appropriate connections on the burner and air
cooled spark igniter.
8. When UV flame scanning is used with an RTG burner in adverse conditions, i.e, preheated,
dirty, hot ambient, or high moisture air, Hauck recommends the use of a UV scanner adapter
assembly (34) which consists of 1/2 NPT (DN15) stainless steel pipe and heat block. To
install the assembly, accomplish the following:
A. Remove pipe plug for optional UV scanner connection.
B. Install UV scanner adapter assembly (34) into the vacant port. Ensure that heat block is
located between the UV scanner and the pipe nipple.
C. Connect a clean, unheated air source to the 1/8 NPT (DN3) purge connection located
on the heat block of approximately 100 scfh (2.7nm3/hr).
D. Install the UV scanner (33) on to the UV scanner adapter assembly (34).
Page 9
RTG-9
WARNING
Adjustment of this equipment by unqualified personnel
can result in fire, explosion, severe personal injury, or
even death.
F. IGNITION
Ignition of the RTG burner can be accomplished by a direct spark igniter or a premix gas pilot. A
5000/6000 volt standard coil type ignition transformer or a half-wave "spark blind" solid state
type transformer can be utilized. Both transformers yield satisfactory results, however, the
standard coil type transformer provides reliable ignition over a wider range of air/fuel ratios than
the half-wave type.
1. The RTG burner typically incorporates an air cooled or non-air cooled spark igniter. The
igniter spark gap should be set at 1/8" (3mm) for reliable spark ignition. The air cooled
spark igniter contains an orifice plate sized to allow proper cooling with an ambient air
supply of approximately 100 scfh (2.7nm3/hr) at pressure of 10-100 "wc (2.5 – 25 kPa);
27.7 "wc (6.9 kPa). Installation of the spark igniter and adjustment of the spark gap is
shown in Figure 5.
Y7267
(NOT TO SCALE)
Figure 5. Air Cooled Spark Igniter Installation
Page 10
RTG-9
2. For RTG burners utilizing a premix pilot spark igniter, accomplish the following:
A. Loosen the spark igniter holding screw (31).
B. Insert the pilot into the burner and allow the pilot nozzle to "bottom out" on the burner
ignition cup (20).
C. Secure the spark igniter holding screw (31).
D. Connect air/gas mixer to the inlet on the pilot.
E. Connect ignition wire from ignition transformer to the spark plug on the spark igniter.
G. INITIAL SET-UP
RTG burners typically operate with automatic control systems. The burners are capable of
proportional control over their entire capacity range. In a typical system, ignition will be
preceded by a series of steps
NOTE
For safety reasons, it is recommended that the burner be
ignited under low fire conditions.
WARNING
If standard coil ignition transformer is used, provisions
must be made to eliminate the ignition spark falsely
satisfying the “flame on” UV sensor. Hauck designed
flame supervisory panels accomplish this by “timing
out” the spark transformer after a short (10 seconds
for most applications) trial for ignition.
1. Once installed, the burner is ready for initial set-up. The specific operation of the burner will
depend on the individual system components in the entire combustion system. Refer to the
instruction sheets that accompany the individual components.
2. Combustion air pressure should be set at the combustion air control valve. Typical settings
will be specific to the application. Hauck recommends that the combustion air settings
remain at minimum until the burner has been ignited (refer to the burner capacities in Section
C for burner air flows at low fire conditions).
3. The flame length control screw (27) should be set at the midpoint of the adjustment. Loosen
the lock nut (28) and adjust the screw (27) until the slot in the screw head is at the
appropriate position. (Readjustment of this screw may be necessary for final burner set-up).
4. Premix adjustment of the burner should be initially set at 3 turns open. Loosen the premix nut
setscrew (24) and turn the premix nut (1) clockwise until it cannot be turned. Do not over turn
premix nut, or the premix roll pin can break. Next, turn the premix nut counter-clockwise
three turns then lock the setscrew. (Readjustment of this screw may be necessary for final
burner set-up).
5. Adjust the limiting orifice valve, or Hauck LVG, in the gas line to the required opening.
(Readjustment of the limiting orifice may be necessary for final burner set-up).
Page 11
RTG-9
6. Refer to Section F for spark igniter set-up. Note: If utilizing premix pilot spark igniter, refer to
Hauck IPG-9 for detailed operating instructions.
7. Once the spark igniter is set and the initial gas and air adjustments are made, the burner can
be ignited. BE SURE THAT THE BURNER IS BEING IGNITED UNDER LOW FIRE
CONDITIONS (MINIMUM GAS AND AIR FLOWS). Ignite the burner, or burners. When all
burners are ignited, increase the combustion air to the high fire position (refer to burner
capacities in Section C for burner air flows at high fire conditions).
8. Once the high fire combustion air is set, adjust the limiting gas orifice (step 5) to achieve
the desired gas flow at high fire.
9. Verify air/gas ratio using orifice meters in the air and gas lines.
10. Flame length can be set to match the tube. Adjust the flame length control screw (26) to
achieve the desired flame length. For most "U" tube applications, flame lengths that come
slightly beyond the firing leg of the tube are acceptable. If a helical stripe appears on the
tube, shorten the flame length until the stripe disappears.
11. Premix can be adjusted to improve flame stability and shape the flame. In some cases, the
premix adjustment will assist in removing "hot spots" on the tube. Counter-clockwise rotation
of the premix nut (1) will increase the amount of air in the premix, while clockwise rotation
will decrease the amount of air in the premix. Typical adjustment range of premix is 2 to 4
turns from fully closed, i.e., turn premix nut (1) clockwise until it can no longer be turned
(closed position), then turn counter-clockwise 2 to 4 turns.
12. Tighten the premix nut setscrew (24) and the flame length control screw lock nut (28).
13. Drive the burner to the low fire position and verify that the settings are consistent. Repeat
steps 8 through 11 as necessary until high and low fire settings remain consistent and the
desired flame characteristics are achieved.
14. To shut down the burner system:
A. Return the burner to low fire position.
B. Close all fuel shutoff valves.
C. To prevent damage to the burner and other components, allow the furnace to cool to
below 800°F before shutting off the combustion air.
H. OPERATION
Once properly installed, ignited and fired, the burner is ready for operation. The operation of the
burner will depend on the specific items in the combustion control system and the application of
the burners. Refer to the instruction sheet that accompanies each item. The burner should be
ignited at low fire conditions. When the burner is operating, the spark igniter or pilot can be shut
off since the burner is designed to maintain ignition of the air/gas mixture. In any case, igniter
cooling air should remain on to assure optimum igniter service life.
Page 12
RTG-9
NOTE
If a loud, roaring noise occurs, it could be resonance. To eliminate
resonance, first adjust the premix nut on the burner. If premix does
not eliminate resonance, gradually restrict the exhaust outlet leg of
the tube until the resonance is eliminated. This can be done with a
stainless steel plate. DO NOT ATTEMPT TO RESTRICT THE
TUBE WHILE THE BURNER IS FIRING. Shut down the burner,
place the restriction on the tube then resume firing the burner.
NEVER COMPLETELY RESTRICT THE END OF THE TUBE.
When minimum noise is reached, the steel plate can be welded to
the tube.
I. MAINTENANCE
The RTG burner design and use of clean fuel gas, makes the system virtually maintenance free.
For long life and optimum operation, however, it is recommended that the burner be periodically
removed for cleaning.
Periodically check the air/gas ratio to ensure the burner is operating at peak efficiency. Flue gas
analysis can be performed with any commercially available flue gas analyzer.
J. RECOMMENDED SPARE PARTS LIST
Item
1
2
3
4
5
Qty.
1
1
1
1
1
Part Number
See Parts List
See Parts List
See Parts List
20579
See Parts List
Description
Air Cooled Spark Igniter Assembly (If Applicable)
Non-Air Cooled Spark Igniter Assembly (If Applicable)
Gas Pilot Assembly (If Applicable)
UV Scanner (If Applicable)
Flame Rod Assembly ( If Applicable)
Table 3. Recommended Spare Parts