Eclipse
Eclipse
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lt Eclipse ThermThief lnstallation Guide 3 l0-3/96
#. About this manual
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l Auoreruce This manual has been written for those persons who are already
familiar with all the aspects of a nozzle-mix burner and its add-on
components, also referred to as "the burner system".
These aspects are:
. design/selection
. installation
. use
. maintenance.
The audience is expected to have previous experience with this
kind of equipment.
Scope Contents
This manual contains essential information that you need to deal
with all the above mentioned aspects of the burner system.
Purpose
The purpose of this manual is to make sure that you carry out
design, installation, use and maintenance in a safe, effective and
trouble-free way.
luponrANT NortcEs . Read this manual carefully. Make sure that you understand the
structure and contents of this manual.
a Obey all the safety ¡nstructions.
a Do not deviate from any instructions or appli'cation limits in
this manual without written advice from Eclipse Combustion,
lnc.
lf you do not understand any part of the information in this
manual, then do not continue. Contact your Eclipse
representative or Eclipse Combustion, lnc.
X Danger:
lndicates hazards or unsafe practices whichWlLL
result in severe personal injury or even death.
Only Qualified and WellTrained Personnel are
allowed to carry out these instructions or
procedures.
Act with great care and follow the instructions.
Warning:
w lndicates hazards or unsafe practices which could
result in severe personal injury or damage.
Act with great care and follow the instructions.
Caution:
lndicotes hozords or unsofe proctices which could result in
domoge to the mochine or minor personol injury.
Act corefully.
Note:
d lndicotes on importont port of the text
Reod the text thoroughly.
i How To GET HELP lf you need help, you can contact your local Eclipse
representative.
I You can also contact Eclipse Combustion at these addresses:
r
USA: Europe:
Eclipse Combustion, lnc. Eclipse Combustion B.V.
1665 Elmwood Road P.O. box 37
Rockford 2800 AA Gouda
lllinois 61103 USA The Netherlands
L
Table oF EontenEs
Table of contents .
lntroduction . t-t
ProductDescription .l-l
2 Safety 2-t
lntroduction .2'l
Safety . 2-l
Capabilities. . 2-l
OperatorTraining. . 2-2
Replacement Parts . 2-2
t-
.J lnstallation . s't
lntroduction . 5-l
Handling and Storage ' 5-l
Position of Components. . 5'l
Approval of Components .l . . 5-2
Limit controls and safety equipment . 5-2
Electrical wiring . 5-2
Gas piping. . 5-2
Where to get the standards . 5-2
Checklist Before lnstallation . 5-A
Prepare the Burner . 5-4
Step l: Adjust the nozzle . 5-4
Step 2: lnstall the U.V. scanner (if required) . 5-7
lnstallation . 5-8
Step l: lnstallthe Burner. . 5-B
Step 2: lnstall theValves . 5-9
Step 3: lnstall the Flame safeguard system . 5-9
ChecklistAfter lnstallation'. 5-l O
t-
Adjustment, Start & Stop 6-l
lntroduction .6-t
Adjustment procedure . 6-t
Step l: Resetthe system . E-l
Step 2: Set high fire air. . E-z
Step 3: Set low fire air . E-a
Step 4: Verify the air settings . E-g
r Step 5: lgnite the burners . 5-3
Step 6: Set high fire gas . 6-5
I
Step 7: Verify the gas settings . E-E
Step 8: Adjust low fire
¡
. 6-6
Start procedure .
I
6-7
Stop Procedure. . 5-7
Orifice curves . 6-8
Static air pressures 6-t S
I Maintenance&Trouble-shooting.. .7-t
lntroduction . T-t
Maintenance . 7-t
Monthly Checklist . T-t
Yearly Checklist . T-z
Trouble-shooting . . 7-g
lllustrated Parts List . . A-t
fl
lntroduction
SOTFB I 7'TFB
Flame guidance
An alloy air tube maintains the proper air velocity past the nozzle,
regardless of the heater tube diameter. The flame heats the
heater tube uniformly without hot spots that might reduce the
life of the tube or overheat the process fluid.
Heat exchanger
The ThermThief can be used with or without an exhaust leg
recuperator. An exhaust leg recuperator is a heat exchanger that
transfers heat from the exhaust air to the combustion air.
Preheating the combustion air can increase the fuel efficiency by
as much as 20%.The ThermThief can handle combustion air
temperatures up to 800"F.
The recommended recuperator for the ThermThief is the Eclipse
Bayonet Ultra (refer to Bulletin 3 l8).
lNrnooucrtoN ln this section you will find important notices about safe
operation of a burner system.
Danger:
Sarerv W
The burners covered in this manual are designed
to mix fuelwith air and burn the resulting mixture.
All fuel burning devices are capable of producing
fires and explosions when improperly applied,
instal led, adjusted, controlled, or maintained.
(, Warning:
The burner is likely to have HOT surfaces. Always
wear protective clothing when approaching the
burner.
Note:
d This monuol gives informotion for the use of these burners
for
their specific design purpo.se. Do not deviote
from ony
instructions or opplicotion limi:a in this monual without written
odvice from Eclipse Combustion.
Note:
d Reod ¿his entire monuol before you ottemptto stort the system.
lf you do not understond ony port of the informotion in this
monuol, then contact.your locol Eclrpse representotive or
Eclipse Combustion before you continue.
Rep¡-acEMENT Panrs Order replacement parts from Eclipse only. Any customer-
supplied valves or switches should carry UL, FM, CSA. and/or
CGA approval where applicable.
r
L_-
lnstallation
lNrnooucrtoN ln this section you will find the information and instructions that
you need to install the burner and the recommended accessories.
*l
f Note:
Most of the illustrotions in this chopter ore bosed on o 30TFB,
but ore typicol for oll ThermThief burners.
Where necessory, customized i//ustrotions are used to describe
specific detoils.
Storage ,
l. Make sure that the components are clean and free of damage.
2. Store the components in a cool, clean, dry room.
3. After you have made sure that everything is present and in
' good condition, keep the components in the original package
as long as possible.
AppnovaL oF
CoupoNENTs
Limit controls and safety All limit controls and safety equipment must comply with the
equipment current standards that follow:
. NFPA Standard 86
. NFPA Standard 86C
.UL
.FM
. CGA
. EN 746-2
. all applicable local codes and/or standards.
Electrical wiring All the electrical wiring must comply with one of these standards:
. NFPA Standard 70
. ANSI-CII98I
. EN 746-2
. the electrical wiring must be acceptable to the local authority
having jurisdiction.
Gas piping AI the Gas piping must comply with one of these standards:
a NFPA Standard 54
a ANS| 2223
o EN 746-2
a the gas piping must be acceptable to the local authority having
jurisdiction.
Where to get the standards The NFPA Standards are available from:
National Fire Protection Agency
Batterymarch Park
Quincy,l1A02269
The ANSI Standards are available from:
American National Standard lnstitute
1430 Broadway
NewYork, NY 10018
The UL Standards are available from:
333 Pfingsten Road
Northbrook,lL 60062
The FM Standards are available from:
I I 5 I Boston-Providence Turnpike
PO.Box 9102
Norwood, MA 02062
Exhaust
Do not allow exhaust gases to accumulate in the worlk area.
Provide some positive means for exhausting them from the
furnace and the building.
Access
Máke sure that you install the system in such a way that you can
get easy access to the burner for inspection and maintenance.
Environment
Make sure that the local environment matches the original
operat¡ng specifications (see Chapter 3 "Specifications").
Check the following items:
. voltage, frequency and'stability of the electrical power
. type and supply pressure of the fuel
. availability of enough fresh, clean combustion air
. humidity, altitude and temperature of air
. presence of damaging corrosive gases in the air.
Find dimension A
€-ir< t?
r' Dimension A is different for each fuel type, tube diameter and
burner size.
7t3 . For the 30TFB and 75 TFB;use Table 5. L
. For the 200 TFB; use Table 5.2.
Natural gas %
3/
/a \, .W' 5/
/a
,Á 1/
Propane % /a /2
,Á 3/
Butane % % /a
Propane /a %
3/
Butane Y^ /s
3. Pull the rear cover @ far enough away from the housing @ to
get access to the lock nut @.
SOTFB I 75TFB
W!|:*i:li;
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":-
th.
"
,.1 I
%il,.f
I l. The end of the ignition rod O should line up with the
grounding lug @ on the nozzle @.
12. The ignition rod is adjustable at the threaded end of the
ignitor.
o
t4. Assemble the burner
Note;
d Foilure to olign ignitor with the ignition lug moy result in rough
ignition.
Note:
d Moke sure thot the O-rings show no srgns of domoge.
Coution:
ü
lf you use preheoted oir,then you must protect the LJ.V.
sconner from high temperotures.lnstoll the tJ.V. scanner with
Note:
d When using the U.V. sconner,it is necessory to use mounting
odoptor part#109750 to ensure thotthe IJ.V.sconner willnot
detect the ignition spork
Flome sensor:
90' U.V. sconner 3. lnstall the U.V. scanner, and if necessary the heat block seal, in
opening O.
)k
will leak if the center peepsight is not installed.
Danger:
X
Connecting the flame sensor of a burner to the
electrical circuit of the wrong burner can cause
fires and explosions.
The burner will bolt to the tube flange.Align the air and gas ro
accommodate accepted piping practices.
Pipe connections
. lnstall a pipe union in the line to each burner.This simplifies
removal of the burner.
. The use of flexible pipe nipples in the air and gas lines to the
burner is optional. Flexible nipples can absorb stresses due to
heat expansion.
. Flexible pipe nipples may cause higher pressure drops than
equivalent standard pipes. Consider that when you size the
air lines.
i
I 5-B Eclipse ThermThief lnstallation Guide 3 l0-3/96
I
I
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t>-
-
lnstallation
StepZ lnstall theValves (Refer to the Appendix for function descriptions of the valves.)
Valve orientation
lnstall all the valves in such a way that the arrow (if present) on
the valve body points in the direction of flow.
C Nore;
lf there is no orrow on the volve
body, then there is no
mondotory direaion of flow through the volve.
Gas cocks
Make sure that the handle of a gas cock is at a right angle to the
valve body when the valve is in the closed position.This is an
important position indicator. lf you do not do that, somebody
may th¡nk that the gas cock is in the closed position, while it is
actually in the open position.
Step 3. lnstallthe Flame Refer to the System Schematic in chapter 4 for the control
safeguard system methodology you are using. There you wíll find the recommended
components, which are explained in further detail in the
Appendix. Use the appropriate flame safeguard if you chose this
option.
I
i¡
I Cuecrllsr Arren To make sure that the system is installed correctly, do the steps
Danger:
.r If simulated limits or simulated flame failures do
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i
Danger:
)k
Do not bypass any safety feature.You can cause
fires and explosions.
Obey the safety precautions in Chapter 2 "Safety,'
Ao¡usrMENT lf you adjust the system for the firsr time, then you must follow
PROCEDURE these steps:
§fcB f: Reset the system t. Close the automatic gas valves and the gas cocks.
Coution:
Moke sure thot the blower rototes in the correct direction. lf
incorrect,then hove o quolified electricion rewire the blower to
reyerse its rotot¡on.
§*cp §" Set high fire air t. Make sure that the system is at high fire.
Note:
d A pressure top is open when the screw inside the tap is
unscrewed opproximotely holf o turn.
_-'
r
Adjustment procedure
Step §; Set low fire air The following steps apply to an ambient air system
with orifice plates installed:
l. Set the system to low fire.
2. choose one burner in the zone. connect the manometer to
tap A and tap B of the burner (across the air orifice).
3. Adjust the automatic zone air control valve until the low-fire
air-pressure differential is 0.2" w.c.This is your initial sert¡ng
only. Further adjustment may be required.
3. Adjust the automatic zone air control valve until the low-fire
static air-pressure is:
5.' Repeat steps 2. and 3. for the other zones (if any).
Step 4: Yerify the air settings Make sure that all the settings are stiil the same after you cycre
the system several times between high fire and low fire.
X Danger:
Do not touch the ignition plug or the ignition wire
when the ignition is on.You will get a shock.
7. While viewing down the peepsight, open the manual gas cock
at burner. Burner should ignite.
8. lf burner does not light within 20 seconds, close gas cock.
Add 180" rotation down on ratio regulator.
9. Repeat step 7.
3. Set the manual gas butterfly valve at each burner to 50% open.
4. Set the adjusting screw on the ratio regulator 7 full rotat¡ons
of 360' down from the top (initial serting).
5. Open the zone manual gas cock.
6. Open the manual gas cock at each burner.
7. Initiate the ignition sequence through the flame safety.
8. Check that all the burners in rhe zone have ignited.
Note:
d lnitiolly it moy be necessory to repeot step 7. two or three
t¡mes to purge oll the air out of the gos pipework.
9- lf all the burners have ignited,then drive the zone air butterfly
valve to high flre. Make sure that the burners stay ignited.
Step 5: Set high fire gas t. Use the gas curves in "Orifice curves" on page 6-8 to find the
-5 gas pressure-differential that you need at high fire.This is now
your target value for high fire.
2. Verify settings when the furnace is at operating temperature.
4. Measure the high fire gas-pressure drop for the first burner.
t 5. Adjust the manual gas butterfly valve at the burner unt¡l the
gas flow is at the target value.
f
6. Repeat 4. and 5. for the other burners in the zone (if any).
t
$
Step 7: Yerify the gas t. Make sure that all the settings are still the same after you
settings cycle the system several times between high fire and low fire.
Danger:
)k
!f a burner does not light, and the system does not
shut down automatically, then you must close the
main gas cock. An uncontrolled flow of gas can
cause fires and explosions.
a all the manual shut-off valves in the gas line upsti'eam of the
burner gas cock.
6
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Propane lnPut' x!000 Btu/hr
(7s TFB)
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Butane
(7s TFB)
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5 I
Fisure 6.3 Orifice curves for the 200TFB (Continued)
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30 I -350 2.0-2.5 3.0-4.0 4.0-5.0
35 r-400 2.5-3.0 4.0-5.0 5.0-6.0
40 I -s00 3.0-s.0 5.0-7.0 6.0- t0
50 I -600 5.0-7.0 7.0- t0
60 I -750 7.0- t0
fl
5 MaintenanEg &
Trouble-shooting
IrurRooucrroN lntroduction
This section is divided into two parts:
. The first part describes the maintenance procedures.
. The second part helps you to identify problems that may
occur, and gives advice on how to solve these problems.
Coution:
The monthly list ond the yeorly /ist ore on overoge intervol.lf
your environment is dirty,then the intervols should be shorter.
Monthly Checklist l. lnspect U.V. scanners for good condition, and cleanliness.
2. Check for proper inlet airlgas ratios.
3. Test all the alarm systems, or both, for proper signals.
4.. Check ignition rod.
I
Yearly Checklist t. Test interlock sequence of all safety equipment. Manually
make each interlock fail, noting that related equipment closes
or stops as specified by the manufacturer.
Test flame safeguard by manually shutting off gas to burner.
TnoueLE-sHoortNG
Toble 7,I Trouble-shooting
it;.,a1llrttl:!;a ;;:;1;;;t;¡;:s§ ,;*::r.*i}:;*§Cü ,*i,:lv.;::*
Burner does not light. Not enough gas: Repeat the start attempt several
(See also next page). . Air in the gas line. times.
No ignition: Restore the power to the ignition
. There is no power to the transformer.
ignition transformer.
No ignition: Repair or replace the wiring to the
. Open circuit between the ignition rod.
ignition transformer and the
ignition rod.
No ignition: Clean the ignition rod.
. The ignition rod needs cleaning.
No ignition: Clean the threads of the ignition
. The ignition rod is not correctly rod and the burner.
grounded to the burner. Do not use pipe sealant on ignition
plug threads.
No ignition: Check the ignition rod position.
. The ignition rod is grounded to
the nozzle or the air shroud.
Not enough gas: Measure the gas pressure into the
. The gas pressure into the ratio ratio regulator and adjust gas
regulator is too low. pressure if necessary.
i
i
I
Trouble-shooting
Burner pulsates or produces noise. Acoustic feedback from tube. Slide a piece of steel plate over the
(The exact cause ofthis end of the tube until the rumbling
problem is unknown.) disappears.Weld the plate in place.
Readjust the burner controls if
necessary.
Input inconsistent with nozzle Check if input is consistent with
settings. nozzle settings and adjust if
necessary.
. Loading line pressure too low. Open the zone air control valves
to¡ncrease the air volume and
Pressure.
. Adjusting valve has closed. Open the valve to previous setting
and check the input and flue gas
settings to verifr proper
oPerations.
Blower is wired backwards. A blower wired to turn backwards
will produce approximately 60% of
its rated capacity. Check the
rotation of the blower impeller. lf
spinning backwards, have a
qualified electrician reverse the
electrical wiring.
cannot initiate start sequence Air pressure switch has not Check air pressure switch
made contact. adjustment.
§t T
a
Eclipse ThermThief lnstallation Guide 3 l0-3/96
A-2
I zoorra
*il#Iffiflml r§:
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§ffieffi#tr
Spark electrode assembly I 00640-x 1,2,4-6,
I 0, 32-34, 36
2 Tube, gas I 5998-x t- t0
3 PF.Locknut, l- ll%NPT 17014
4 Cover, rear 70 t3
5 4 Washer, lock, M8 15222
6 4 Screw, hex head, M8x22 I 5886
7 Peepsight % " I 0509
8 Peepsight % " I 0509
9 PF.Plug,Test,%" NPT t3445
t0 Seal, O'ring.Viton,YT 47 14778
il Plate, gas orifice l4 188-x
t2 Seal, O'ring.Viton,YT 47 t4777
l3 lnlet, gas 3973-x t,3
t4 PEPlug,TEST%"NPT 13445
t5 4 Washer, lock, M8 15222
t6 4 Screw, hex head, M8x22 I 5888
t7 4 Screw, hex head, M8x22 r 5888
t8 4 Washer,lock, M8 15222
t9 I PF.Plug,TEST%"NPT 13445
20 I Air inlet block 3996-x 1,2
2t I Plate, air orifice t4802
22 I Screw, hex cap, M8x l6 t52 t5
23 I Washer,lock, M8 15222
24 I PEPlug,TEST%"NPT 13445
25 I Housing 3994
26 I Screw, hex cap, M8x l6 t52 t5
27 I Nozzle 7012
28 I Air tube I 5999-x t- t0
FI FI
//
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--7
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' Eclipse ThermThief lnstallation Guide 3 l0-3/96
Main Oflice USA
Eclipse Combustlon, lnc.
1665 Elmwood Road
Rockford
lllinois 61103 USA
.:
,:C Phone: I r 5-877-3035
i^t Notice: For Design Guide
Fax: 8rs-877-3t20
Please Call or Fax Ermail: [email protected]
Eclipse Main Office. http://www.ecl i psenet.com/eci
Europe Office
Eclipse Combustion B.V
P.O. box 37
2800 AA Gouda
The Netherlands
Phone: 3t-t82-5r5988
Fax: 3r-r82-533269
As.ia Office
Eclipse Combustign China, Ltd.
Unit 1026 Block d
Focal lndustrial Centre
2l Man Lok Street
Hunghom,Kowloon
Hong Kong
Phone: 852-2333-8350
Fax: 8s2-23s6-00 I 4