Installation Guide 111

9/26/2016

Eclipse Winnox
Burners
WX Series
Version 3

32-00057-01
Copyright expenses, whether direct or consequential, including but
not limited to loss of use, income, or damage to material
Copyright 2007 by Honeywell Interanational Inc. All rights
arising in connection with the sale, installation, use of,
reserved worldwide. This publication is protected by
inability to use, or the repair or replacement of Honeywell
federal regulation and shall not be copied, distributed,
Eclipse’s products.
transmitted, transcribed or translated into any human or
computer language, in any form or by any means, to any Any operation expressly prohibited in this manual, any
third parties, without the express written consent of adjustment, or assembly procedures not recommended or
Honeywell Eclipse. authorized in these instructions shall void the warranty.
Disclaimer Notice Document Conventions
In accordance with the manufacturer’s policy of continual There are several special symbols in this document. You
product improvement, the product presented in this must know their meaning and importance.
brochure is subject to change without notice or obligation.
The explanation of these symbols follows below. Please
The material in this manual is believed adequate for the read it thoroughly.
intended use of the product. If the product is used for
purposes other than those specified herein, confirmation How To Get Help
of validity and suitability must be obtained. Honeywell If you need help, contact your local Honeywell Eclipse
Eclipse warrants that the product itself does not infringe representative. You can also contact Honeywell Eclipse
upon any United States patents. No further warranty is at:
expressed or implied.
1665 Elmwood Rd.
Liability & Warranty Rockford, Illinois 61103 U.S.A.
Phone: 815-877-3031
We have made every effort to make this manual as
Fax: 815-877-3336
accurate and complete as possible. Should you find errors
or omissions, please bring them to our attention so that we Please have the information on the product label available
may correct them. In this way we hope to improve our when contacting the factory so we may better serve you.
product documentation for the benefit of our customers.
Please send your corrections and comments to our
Technical Documentation Specialist.
www.eclipsenet.com
It must be understood that Honeywell Eclipse’s liability for Product Name
its product, whether due to breach of warranty, Item #
negligence, strict liability, or otherwise is limited to the S/N
furnishing of replacement parts and Honeywell Eclipse will DD MMM YYYY
not be liable for any other injury, loss, damage or

This is the safety alert symbol. It is used to alert you to potential personal
injurt hazards. Obey all safety messages that follow this symbol to avoid
possible injury or death.

Indicates a hazardous situation which, if not avoided, will result in death

or serious injury.

Indicates a hazardous situation which, if not avoided, could result in

WARNING death or serious injury.

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CAUTION minor or moderate injury.

NOTICE Is used to address practices not related to personal injury.

NOTE Indicates an important part of text. Read thoroughly.

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Table of Contents
Introduction .................................................................................................. 4
Product Description ................................................................................. 4
Audience.................................................................................................. 4
Winnox Documents ................................................................................. 4

Safety ............................................................................................................ 5
Safety Warnings ...................................................................................... 5
Capabilities .............................................................................................. 5
Operator Training .................................................................................... 5
Replacement Parts .................................................................................. 5

Installation .................................................................................................... 6
Introduction.............................................................................................. 6
Handling & Storage ................................................................................. 6
Approvals of Components ....................................................................... 6
Checklist Before Installation .................................................................... 7
Installing the Flame Sensor ..................................................................... 7
Burner Mounting ...................................................................................... 7
Gas Piping ............................................................................................... 9
Checklist After Installation ....................................................................... 10
Remote Blower Air Pre-Mix Line Installation (WX0850 only) .................. 10

Adjustment, Start & Stop ............................................................................ 11

Step 1: Reset the system ........................................................................ 11
Step 2: Set low fire air ............................................................................. 12
Step 3: Ignite the burner .......................................................................... 13
Step 4: Set low fire gas............................................................................ 14
Step 5: Set high fire gas .......................................................................... 15
Step 6: Verify Settings ............................................................................. 15

Maintenance & Troubleshooting ................................................................ 17

Monthly Checklist .................................................................................... 17
Yearly Checklist....................................................................................... 17
Recommended Spare Parts .................................................................... 18
Troubleshooting....................................................................................... 18

Appendix....................................................................................................... i

System Schematics ..................................................................................... ii

Notes ............................................................................................................. iv

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Introduction 1
Product Description Audience

The Winnox is a nozzle-mix type, low-emissions burner This manual has been written for people who are already
designed for direct and indirect air heating, and oven familiar with all aspects of a nozzle-mix burner and its add-
applications up to 1800°F (980°C). on components, also referred to as “the burner system”.

The burner package includes a combustion air blower and These aspects are:
ratio regulator to fire over a wide gas turndown range at a • Design / Selection
controlled ratio. • Use
• Maintenance
The burner is designed for:
The audience is expected to have previous experience
• low NOX and CO emissions
with this type of equipment.
• efficient ratio controlled combustion
• reliable burner operation Winnox Documents
• simple burner adjustment Installation Guide No. 111
• direct spark ignition • This document
• multiple fuel capability Datasheet, Series 111
• Available for individual WX models
The wide variety of options and configurations are • Required to complete design and selection
available due to the modular design of the burner.
Design Guide No. 111
• Used with Datasheet to design burner system
Spare Parts List, Series 111
• Recommended replacement part information
Related Documents
• EFE 825 (Combustion Engineering Guide)
• Eclipse Bulletins and Info Guides: 710, 732, 756,
760, 930

Figure 1.1 Winnox Burner

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Safety 2
Important notices which help provide safe burner
operation will be found in this section. To avoid personal
injury and damage to the property or facility, the following NOTICE
warnings must be observed. All involved personnel should
read this entire manual carefully before attempting to start ■ This manual provides information regarding the
or operate this system. If any part of the information in this use of these burners for their specific design
manual is not understood, contact Eclipse before purpose. Do not deviate from any instructions or
continuing. application limits described herein without written
approval from Eclipse.
Safety Warnings
Capabilities
DANGER Only qualified personnel, with sufficient mechanical
aptitude and experience with combustion equipment,
■ The burners, described herein, are designed to mix should adjust, maintain or troubleshoot any mechanical or
fuel with air and burn the resulting mixture. All fuel electrical part of this system. Contact Eclipse for any
burning devices are capable of producing fires and needed commissioning assistance.
explosions if improperly applied, installed,
adjusted, controlled or maintained. Operator Training
The best safety precaution is an alert and trained
■ Do not bypass any safety feature; fire or explosion
operator. Train new operators thoroughly and have them
could result.
demonstrate an adequate understanding of the
■ Never try to light a burner if it shows signs of equipment and its operation. A regular retraining schedule
damage or malfunction. should be administered to ensure operators maintain a
high degree of proficiency. Contact Eclipse for any needed
site-specific training.
WARNING Replacement Parts
Order replacement parts from Eclipse only. All Eclipse
■ The burner and duct sections are likely to have
approved valves or switches should carry UL, FM, CSA,
HOT surfaces. Always wear the appropriate
CGA and/or CE approval where applicable.
protective equipment when approaching the
burner.
■ Eclipse products are designed to minimize the use
of materials that contain crystalline silica.
Examples of these chemicals are: respirable
crystalline silica from bricks, cement or other
masonry products and respirable refractory
ceramic fibers from insulating blankets, boards, or
gaskets. Despite these efforts, dust created by
sanding, sawing, grinding, cutting and other
construction activities could release crystalline
silica. Crystalline silica is known to cause cancer,
and health risks from the exposure to these
chemicals vary depending on the frequency and
length of exposure to these chemicals. To reduce
the risk, limit exposure to these chemicals, work in
a well-ventilated area and wear approved personal
protective safety equipment for these chemicals.

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Installation 3
Introduction Gas Piping
In this chapter you will find information and instructions All the gas piping must comply with all applicable local
needed to install the burner and system components. codes and/or standards such as:
Handling & Storage • NFPA Standard 54
Handling • ANSI Z223
• Make sure that the area is clean. • EN 746-2
• Protect the components from the weather, damage, Where to Get the Standards:
dirt and moisture.
The NFPA Standards are available from:
• Protect the components from excessive
National Fire Protection Agency
temperatures and humidity.
Batterymarch Park
• Take care not to drop or damage components. Quincy, MA 02269
Storage www.nfpa.org
• Make sure that the components are clean and free The ANSI Standards are available from:
of damage. American National Standard Institute
• Store the components in a cool, clean, dry room. 1430 Broadway
• After you have made sure that everything is present New York, NY 10018
and in good condition, keep the components in the www.ansi.org
original package as long as possible.
The UL Standards are available from:
333 Pfingsten Road
Approval of Components Northbrook, IL 60062
Limit Controls & Safety Equipment www.ul.com
All limit controls and safety equipment must comply with The FM Standards are available from:
all applicable local codes and/or standards and must be 1151 Boston-Providence Turnpike
listed for combustion safety by an independent testing PO Box 9102
agency. Typical application examples include: Norwood, MA 02062
www.fmglobal.com/approvals
• American: NFPA 86 with listing marks from UL, FM,
CSA Information on the EN standards and where to get
• European: EN 746-2 with CE mark from TuV, them is available from:
Gastec, Advantica Comité Européen de Normalisation
Stassartstraat 36
Electrical Wiring B-1050 Brussels
All the electrical wiring must comply with all applicable Phone: +32-25196811
local codes and/or standards such as: Fax: +32-25196819
www.cen.eu
• NFPA Standard 70
• IEC60364 Comité Européen de Normalisation Electronique
Stassartstraat 36
• CSA C22 B-1050 Brussels
• BS7671 Phone: +32-25196871
Fax: +32-25196919
www.cenelec.org

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Checklist Before Installation Installing the Spark Plug
Intake Install the spark plug into the opening in the rear cover.
To admit fresh combustion air from outdoors, provide an NOTE: Do not apply any grease to the threads of the
opening in the room of at least one square inch per 4,000 spark plug or bad grounding of the spark plug may occur,
BTU/hr (1.17 kW). If there are corrosive fumes or resulting in a weak spark.
materials in the air, then supply the burner with clean air
from an uncontaminated area, or provide a sufficient air
filtering system. NOTICE
Exhaust ■ If flame monitoring controls other than those
Do not allow exhaust fumes to accumulate in the work recommended in the Design Guide are used
area. Provide some positive means for exhausting from contact Eclipse to determine how the burner
the furnace and the building. performance may be affected, adjustments may
vary from Eclipse published values. Consult with
Access the engineer who specified the alternate control
Make sure that you install the burner in such a way that for limitations.
you can gain easy access for inspection and
maintenance.
Burner Mounting
Chamber Opening
Environment
Provide an opening in the chamber wall at least 1/2"
Make sure the local environment matches the original (12 mm) larger in diameter than the outside diameter of
operating specifications. Check the following items: the combustor (1/4" - 6 mm per side). The combustor
• Voltage, frequency and stability of the electrical diameter can be found in the Winnox datasheet, series
power 111.
• Type and supply pressure of the fuel Provide an accessible pressure tap on the chamber wall
• Availability of enough fresh, clean combustion air to measure the pressure inside the firing chamber. The
pressure tap should be located near the burner.
• Humidity, altitude and temperature of air
• Presence of damaging corrosive gases in the air Minimum 1/4" (6mm)
• Prevent direct exposure to water space per side

Installing the Flame Sensor

Slots
1. Install the flame sensor into the 1/2" NPT opening in the
rear cover.
2. Make sure that you connect the flame sensor of a
burner to the electrical circuit of that burner. Combustor
Chamber Wall
DANGER Figure 3.1. Chamber Opening
■ Connecting the flame sensor of a burner to the Mounting Pattern
electrical circuit of the wrong burner can result in
Attach eight mounting bolts to the chamber wall. Position
a fire or explosion.
these bolts to match the clearance holes (C) on the burner
There are two different types of flame sensors; UV mounting flange. Refer to Winnox datasheet, series 111.
scanner and flame rod.
UV Scanner “C”
The UV scanner must be compatible to the flame
monitoring control that is used. Refer to the manual of
your selected control for proper selection of the scanner.
Flame Rod
NOTE: Only specific burner sizes with alloy or silicon
carbide combustors can use a flame rod (see specific
burner datasheets).
Figure 3.2. Mounting Pattern
For detailed information on how to install and connect a
flamerod, refer to Info Guide 832.

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Tube Shrouding Considerations 1
Applications in which there is process air flow 3
perpendicular to and across the Winnox combustor
greater than 1000 ft/min (5 m/s) may cause flame

Combustor
instability and/or high production of CO emissions. In

Slots
these applications a shroud may be required to shield the
combustor. Contact Eclipse for more information.
Chamber Wall Fiber Insulation
Make sure the chamber wall  is strong enough to
Chamber
support the weight of the burner . If necessary, reinforce 2
Insulation
the mounting area. See Figure 3.3.
NOTE: The slots in the combustor must not be covered Figure 3.4. Alloy Combustion Tube
with insulation. If necessary, taper the chamber insulation
at a minimum of 45° to provide clearance for the Refractory Plug
combustor slots. Slot dimensions can be found in the When using the refractory plug the customer must provide
Winnox datasheet, series 111. a refractory combustion tube. The customer is responsible
for supplying all refractory materials for combustion tube
field installation as follows:
1
1. Install the chosen refractory realizing it is essential that:
3 45° Minimum • The combustion tube dimensions are held as given
in the Winnox Datasheet series 111. See Figure 3.5.
Combustor

• The inside diameter of the combustion tube is

Slots

concentric with the refractory plug.

2. Support refractory combustion tube according to the
refractory supplier’s recommendations. The alloy
anchors should be coated with bitumastic whenever
Chamber they are used.
2 Insulation 3. Fiber insulation must be installed between the
refractory plug and customer supplied refractory
Figure 3.3. Chamber Wall
combustion tube.
Burner Mounting
4. After the burner and refractory have been installed, a
Mount the burner to the chamber wall using eight (8) proper curing schedule should be followed according
customer supplied nuts and lock washers. to refractory supplier’s recommendations.
Alloy Combustion Tube
1. Be sure gasket  is installed between burner  and
chamber wall . See Figure 3.4.
2. Pack fiber insulation around the tube to a depth not Fiber
beyond the combustor slot position, as shown in Insulation
Figure 3.4.

Customer Supplied
CAUTION Refractory
Combustion Tube
■ Placing insulation over combustor slots will
Refractory
impede burner performance and decrease
Plug
combustor life.
90°

Figure 3.5. Refractory Plug

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Gas Piping
Burner Piping CAUTION
The burner is factory assembled and shipped as ordered. ■ Do not alter the bypass regulator. The NFPA
NOTE: If it is necessary to redirect piping, remove the requires that the bypass regulator  be
outer four bolts only . Rotate the rear cover and appropriately vented and protected.
replace bolts. When reassembling, be sure that:
■ For applications in which the Winnox is operating
• ratio regulator spring column  is pointing down indoors, a vent limiting device is installed in the
• the bypass regulator spring column is pointing up bypass regulator.
• arrow on the ratio regulator points in the direction of
gas flow ■ For applications in which the Winnox is operating
• integral fuel orifice and o-rings  are reinstalled outdoors, an insect/rain protector is installed in
the bypass regulator.
• the same straight run of pipe  remains between
the ratio regulator and the burner. Supply Piping
Inlet pressure to the ratio regulator must stay within
CAUTION specified limits. Refer to the appropriate Winnox
datasheet, series 111.
■ Do not attempt to redirect piping by removing the
• Locate the valve train close to the burner. The gas
inner circle bolts . Internal burner parts will be
must reach the burner during the fixed trial for
damaged. ignition period.
• Sufficiently size the shut off valve in the valve train.
• Make sure piping is large enough to accommodate
flow required to meet burner input.
• Minimize piping elbows.
 • Install fuel flow measurement device  upstream
from the burner inlet.
• If necessary to maintain inlet pressures to the
burner (see datasheet for your burner), install a gas
pressure regulator  upstream of the burner inlet
and downstream of the valve train and fuel
measurement device .




Main gas
 shut-off
valve train

 Figure 3.7. Supply Piping

 Pipe Connections
Figure 3.6. Burner Piping Installation of a pipe union in the gas line is recommended
to simplify burner removal.
Use of flexible pipe is optional.
NOTE: Flexible pipe causes higher pressure drops than
standard pipe. Consider this when sizing your gas lines.

32-00057—01 9
 Checklist After Installation
To verify the system was properly installed, perform the
following checks:
1. Be sure there are no leaks in the gas lines.
2. Be sure all the components contained in the flame
monitoring and control systems are properly installed.
This includes verifying that:
• all the switches are installed in the correct locations.
• all wiring, pressure, and impulse lines are properly
connected.
Bracket
3. Be sure all components of the spark ignition system
are installed and functioning properly.
4. Be sure the blower rotates in the proper direction. If the
rotation is incorrect, have a qualified electrician rewire
the blower to rotate in the proper direction.
Pipe 5. Be sure all valves are installed in the proper location
Union and correctly oriented relative to the flow direction.

Figure 3.8. Pipe Connections Remote Blower Air Pre-Mix Line Installation
Piping Support (WX0850 only)
Use brackets or hangers to support the gas piping. If you When using a remote blower instead of the packaged
have questions, consult your local gas company. blower on the WX0850, the low fire air pre-mix line must
Control Motor be installed to the combustion air line. 1/4" diameter
braided hose is recommended, located as shown in figure
Install a control motor to modulate the air butterfly valve if 3.10.
not factory installed on the burner.
NOTE: Be sure the control motor shaft and air butterfly NOTE: A 24" length of 1/4" diameter braided hose is
valve shaft are aligned properly. included with the burner.

Motor Remote
BV Shaft Blower
Shaft Pre-Mix
Air Line Combustion
Set Air Modulation Remote
Valve Blower
Screws
Control
Motor Fuel
Inlet

Figure 3.10.

Coupling

Figure 3.9. Control Motor

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Adjustment, Start & 4
Stop
In this chapter, you will find instructions on how to adjust,
start, and stop the burner system. Become familiar with
burner control methods before attempting to make
DANGER
adjustments.
■ If simulated limits or simulated flame failure do not
shut down the fuel system within the required
DANGER failure response time, immediately correct the
problem before proceeding. Refer to the
“Troubleshooting” chart in section 5.
■ The Winnox burners are designed to mix fuel with
6. If the burner is firing into a duct or chamber with a
air and burn the resulting mixture. All fuel burning
circulating fan, start the fan to produce full process air
devices are capable of producing fires and
flow past the burner.
explosions if improperly applied, installed,
adjusted, controlled, or maintained. 7. Adjust main gas inlet pressure to the ratio regulator
within the range specified in the appropriate
■ Do not bypass any safety feature; fire or explosion datasheet.
could result.

■ Never try to light a burner if it shows signs of WARNING

damage or malfunction.
Step 1: Reset the System ■ Gas inlet pressures must stay within the specified
1. Set the low gas pressure switch to 20% below the range. Pressure above the specified range can
“Fuel Inlet Pressure” range as specified in the damage the ratio regulator.
appropriate datasheet.
■ Pressure below the specified range can impair the
2. Set the high gas pressure switch to 20% above the
ability of the ratio regulator to control the gas flow.
“Main Gas Inlet Pressure” range as specified in the
appropriate datasheet.
■ Operating the system outside the specified range
3. Close all the burner gas valves ̶ manual and can cause excess fuel consumption and the
automatic. possible accumulation of unburned fuel in the
chamber.
4. Try to ignite the burner; be sure the flame monitoring
system indicates a flame failure.
■ In extreme cases, this accumulation of unburned
5. Activate the pressure switches and other limit fuel may cause fires or explosions.
interlocks. Be sure the switches fail as intended in the
8. Verify the actuator opens the air butterfly valve
event of a power failure.
towards the back of the burner as shown in Figure 4.1.
If it doesn’t, refer to the actuator’s literature for
instructions on how to reverse the direction.

32-00057—01 11
 4. Set low fire air.
a. Loosen the set screw  on the burner side of
coupling.
There is a slot in the end of the butterfly valve shaft
that is parallel to the air damper. This slot is used for

Back
visual indication of the butterfly valve position. The
butterfly valve is closed when the shaft slot is
perpendicular to the direction of air flow through the
butterfly valve.
b. Rotate the air butterfly valve shaft to a fully closed
position. (Holes in the butterfly valve will supply low
fire air.)
Closed c. When firing into a positive chamber pressure, rotate
Open in this
the air butterfly valve from the closed position in the
direction only direction of actuator travel to obtain a minimum
0.3" w.c. (0,8 mbar) air differential pressure.
Open

d. Hold the butterfly valve shaft firmly in place and

tighten set screw .
Figure 4.1. Air Butterfly Valve Open Direction High fire air adjustment is not required if the burner is firing
into a neutral pressure chamber and a 90° travel control
Step 2: Set Low Fire Air motor is used. It may be necessary to limit control motor
1. Start combustion air blower. stroke to less than 90° if firing into a large negative
chamber. Contact Eclipse for further information.
2. Drive control motor to low fire position.
3. Measure the air differential pressure between Tap C

and the combustion chamber.

NOTE: The pressure tap is in the open position when the

screw inside the tap is unscrewed approximately 1/2 turn.
Do not remove the screw. Be sure to tighten the pressure
tap screw clockwise to the closed position after pressure

measurements have been taken.

Figure 4.3. Air Butterfly Valve Adjustment

5. Verify high fire air:
a. Drive control motor to high fire, full open.
b. Compare the high fire air differential pressure
between Tap C and the combustion chamber to the
approximate datasheet chart “Air Δp vs. Input”. If
high fire air is insufficient, refer to section 5,
“Troubleshooting & Maintenance”, in this document.
To Chamber 6. Return the control motor to the low fire position.
Tap C 7. Close the pressure taps.

Figure 4.2. Air Differential Pressure

32-00057—01 12
 8. If burner does not ignite.
a. Shut off gas.
b. When chamber temperature is below 250°F
(121°C), shut off combustion air blower.
c. Restart combustion air blower, drive through purge
cycle and ignite the burner.
d. Measure low fire gas pressure to the burner gas
BV shaft shown inlet . Verify pressure at  is within the range
in closed position
specified on the datasheet for your burner. range
specified on the datasheet for your burner.
Figure 4.4. Air Butterfly Valve Shaft
10.After ignition, verify low fire flame:
Step 3: Ignite the Burner a. Shut off gas.
Low Fire Start b. When chamber temperature is below 250°F
(121°C), shut off combustion air blower.
WARNING c. Restart combustion air blower and ignite burner.
d. Measure low fire gas pressure to the burner gas
inlet .Verify pressure at  is within the range
■ These procedures are written with the assumption specified on the datasheet for your burner.
the burner has a flame monitoring control system
e. Verify repeatability of ignition and low fire flame
installed and operating. A proper purge cycle must
signal.
be part of the system and purge timing should not
be bypassed. NOTE: If the flame signal is too low, use the bypass
regulator  and/or the adjustable limiting orifice  to
increase the pressure at Tap E and provide better flame
signal. However, this can have a negative impact on
emissions and/or nozzle life.
11. Close all pressure taps.
 Main gas Pilot Start Option
shut-off
valve train
Tap E    WARNING

Figure 4.5. Low Fire Start ■ These procedures are written with the assumption
the burner has a flame monitoring control system
1. Drive control motor to low fire.
installed and operating. A proper purge cycle must
2. Be sure combustion air blower is running. be part of the system and purge timing should not
be bypassed.
3. Open main gas manual shut off valves.
4. With pressure taps open, connect the manometer
between Tap E and the chamber.
 Main gas
5. Set system control to stay at low fire during and after shut-off
ignition sequence. valve train

6. Attempt to ignite burner. Tap E   

Pilot gas
shut-off
7. During trial for ignition, adjust bypass pressure valve train
regulator  and adjustable limiting orifice  to achieve
the appropriate Δp between Tap E and the chamber as
Figure 4.6. Low Fire Start with Pilot Start Option
listed in the appropriate datasheet.
NOTE: If viewing the flame, it should be blue with flashes 1. Drive control motor to low fire.
of yellow. The flame should be completely within the 2. Be sure combustion air blower is running.
combustion tube. When firing propane or butane, a proper
low fire flame may have sustained flashes of yellow. 3. Open pilot gas manual shut off valve.

32-00057—01 13
NOTE: Be sure main gas manual shut off valves are
closed.
4. With pressure taps open, connect a manometer
between Tap E and the chamber.
5. Set system control to stay at low fire during and after
ignition sequence.
6. Attempt to ignite burner.
1 Bias
7. During trial for ignition, adjust bypass pressure CCW for adjusting
regulator  and adjustable limiting orifice  to achieve more gas
the appropriate Δp between Tap E and the chamber as
screw
listed in the appropriate datasheet.

NOTE: If viewing the flame, it should be blue with flashes

of yellow. The flame should be completely within the
combustion tube. When firing propane or butane, a proper
low fire flame may have sustained flashes of yellow.
8. If burner does not ignite:
Figure 4.7. Ratio Regulator Adjustment
a. Attempt to ignite the burner again to purge air from
the gas piping. NOTE: To adjust manual butterfly valve:
b. If burner still does not ignite, adjust bypass pressure
a. Loosen set screw
regulator  a half turn clockwise to increase gas
flow. b. Turn dial

c. Repeat until burner ignites. If necessary, refer to c. Tighten set screw

Chapter 5, “Maintenance & Troubleshooting” in this
manual. Outer Dial

10.After ignition, verify bypass flame:

a. Shut off gas. When chamber temperature is below
250°F (121°C), shut off combustion air blower.
Full Open
b. Restart combustion air blower, drive through purge
cycle, and ignite burner.
c. Measure low fire gas pressure to the burner gas inlet
. Verify pressure at  is within the range specified
Set Screw
on the datasheet for your burner.
d. Verify repeatability of ignition and low fire flame p en
signal.
75 %O
11. Close all pressure taps.

Step 4: Set Low Fire Gas

WARNING Figure 4.8. Manual Butterfly Valve Adjustment

3. Open all manual gas shut off valves.
■ This procedure is written with the assumption the
burner has a flame monitoring control system 4. Set system control to stay at low fire during and after
installed and operating. A proper purge cycle must ignition sequence.
be part of the system and purge timing should not
5. With taps open, connect manometer between Tap B
be bypassed.
and the combustion chamber.
1. Set manual gas butterfly valve to 75% open. See
6. Ignite the burner.
Figure 4.8.

32-00057—01 14
NOTE: If viewing the flame, it should be blue with flashes Example: (500,000 Btu/h input) x (1 cuft Natural Gas/1000
of yellow. The flame should be completely within the Btu) = 500 cuft/h or scfh of Natural Gas.
combustion tube. When firing propane or butane, a proper
6. Measure existing gas ∆P “w.c. (mbar) across
low fire flame may have sustained flashes of yellow.
customer supplied in-line fuel orifice meter, and using
7. Verify low fire flame. the manufacturer’s conversion flow chart for the fuel
orifice meter, calculate* the existing gas flow scfh
a. Drive control motor from low fire and back. Verify
low fire and stable flame signal are repeat-ed. (Nm3/h) through orifice.
b. Turn the burner off and repeat the ignition (* = making the manufacturer’s prescribed corrections for
sequence. Verify low fire and stable flame signal are Fuel Type, Temperature, and Elevation.)
repeated.
8. Close all pressure taps.
Step 5: Set High Fire Gas 7. If the required gas flow scfh (Nm3/h) from step 5 does
not correspond with the existing gas flow scfh
(Nm3/h) from step 6, adjust existing gas flow using
manual butterfly valve (refer to step 1 for adjustment
procedure) to match required gas flow for the desired
high fire burner input.
8. If required gas flow cannot be achieved, refer to
Chapter 5, “Maintenance and Troubleshooting”.
Step 6: Verify Settings

To 
Chamber
Tap C

Figure 4.9. High Fire Gas Adjustment Chamber

Tap C
1. Set manual gas butterfly valve to 75% open. See
Figure 4.8.
NOTE: To adjust manual butterfly valve:
a. Loosen set screw
Figure 4.10. Verify Pressure Settings
b. Turn dial
1. With burner lit, drive control motor to high fire.
c. Tighten set screw
2. Wait for the chamber to reach normal operating
2. With burner lit, drive control motor to high fire position.
conditions (e.g. chamber temperature, process flows,
3. Measure air loading line pressure from Tap C to the etc.).
chamber.
3. Measure high fire fuel using fuel flow measurement
4. Refer to the “Air ∆P vs. Input” graph on page 2 of the device. Compare this to the rated high fire on
appropriate Eclipse Data Sheet. Find your measured datasheet.
high fire air ∆P “w.c. (mbar) on vertical axis at left and
4. Measure high fire air differential pressure between
plot the intersection point it makes with performance
Tap C and the chamber. Compare this pressure to the
curve in center of chart. Follow chart straight down
“Air Δp vs. Input” chart on the datasheet.
from this intersection point to confirm the desired high
fire burner input Btu/h (kW) charted on horizontal axis 5. Drive the control motor to low fire and verify low fire
across the bottom. flame signal and flame appearance (if viewing).

5. Calculate the required gas flow scfh (Nm3/h) for the 6. Cycle burner from high to low several times to check
desired high fire burner input Btu/h (kW). repeatability of settings.

32-00057—01 15
7. Readjust burner if the settings do not repeat as
expected. If necessary, refer to Chapter 5,
“Maintenance & Troubleshooting”.
8. Use the Systems Schematics on Appendix page ii to
record all setup data as an aid for future
troubleshooting and setup operations.

CAUTION

■ Do not turn the combustion air blower off until the

chamber temperature is below 250°F (121°C). This
will prevent hot gases from back flowing into the
burner and blower causing damage to the burner.
9. Stop the burner.

32-00057—01 16
Maintenance & 5
Troubleshooting
This section is divided into two parts. The first part Yearly Checklist
describes the maintenance procedures, and the second
1. Test (leak test) safety shut-off valves for tightness of
part helps you to identify problems that may occur and
closure.
gives recommendations on how to solve these problems.
2. Test pressure switch settings by checking switch
Preventative maintenance is the key to a reliable, safe
movements against pressure settings and compare
and efficient system. The following are suggested
these with the actual impulse pressure.
guidelines for periodic maintenance. Burners in severe
environments or operational conditions should be 3. Visually check ignition cable and connectors.
checked more frequently.
4. Inspect impulse piping for leaks.
NOTE: The monthly and yearly lists are an average
5. Be sure the following components are not damaged or
interval. If your environment is dirty, then the intervals may distorted:
be shorter. Check with local authorities having jurisdiction
on their recommended maintenance schedules. • the burner nozzle
• the igniter
CAUTION • the flame sensors
• the combustion tube or block
■ Turn off the power to the burner and controls
before proceeding with burner inspection.
Monthly Checklist
1. Inspect flame-sensing devices for good condition and
cleanliness.
2. Check for proper air/gas pressures. Refer to the
Winnox datasheet, series 111.

3. Test all alarms for proper signals. 
4. Check and clean igniter electrodes.
5. Check the air control valve for smooth, trouble free Figure 5.1 Component Inspection
operation and adjustment.
The nozzle can be inspected without removing the burner
6. Check for the proper operation of ventilating from the chamber wall or entering the chamber. See
equipment. Figure 5.1 and Figure 5.2. Perform the following:
7. Test interlock sequence of all safety equipment and a. Shut the burner off and manually close the main gas
manually make each interlock fail, noting that related shut off cocks.
equipment closes or stops as specified by the b. Allow the chamber temperature to cool down to
manufacturer. Test flame safeguard by manually 250°F (121°C).
shutting off gas to burner. c. Disconnect the gas piping at a union or the gas inlet
flange  provided on the burner.
8. Test all manual fuel valves for operation.
d. Remove the four bolts .
9. Clean and/or replace the combustion air blower filter.
10.Inspect and clean the combustion air blower rotor.

32-00057—01 17
 
CAUTION
■ Do not attempt to remove the rear cover by  
removing the inner circle bolts . Internal burner
parts will be damaged.
e. Remove bolts .
f. Remove the rear cover / nozzle assembly  from the 
burner housing . 
g. To reassemble, follow this sequence in the reverse
order. Figure 5.2 Nozzle Inspection
NOTE: The combustor can be inspected only by removing
Recommended Spare Parts
the burner from the chamber wall or entering the chamber.
To make sure that the downtime of the system is as short
as possible in case of a failure, you should keep a stock of
spare parts. Please refer to the Eclipse Product
Information Center (EPIC) for a full listing of spare parts:
http://www.eclipsenet.com/products
Troubleshooting
Problem Possible Cause Solution
Start-up sequence runs but No ignition. There is no power to the ignition Restore the power to the ignition
burner does not light. transformer. transformer.
No ignition. Open circuit between the Repair or replace the wiring to the igniter.
ignition transformer and the igniter.
No ignition. The igniter needs cleaning. Clean the igniter.
No ignition. The igniter is not correctly Clean the threads on the igniter and the
grounded to the burner. burner. NOTE: Do not apply grease to the
threads on the igniter.
No ignition. Igniter insulator is broken. Inspect the igniter. Replace if broken.
Igniter is grounding out.
Igniter grounds out, igniter is bent. Inspect ignitor by removing nozzle and rear
cover. Check if gaps exist, readjust if
needed.
Not enough gas. The gas pressure into the Check the start-up setting. Measure the
ratio regulator is too low. gas pressures and adjust where necessary.
Not enough gas. The impulse line to the Repair any leaks.
ratio regulator is leaking.
Not enough gas. The adjustable orifice Adjust bypass or low fire gas.
valve is not open far enough.
Not enough gas. Start gas solenoid valve Check the solenoid valve coil for proper
does not open. operation. Replace it if necessary.
Not enough gas. Gas valve does not open. Check the wiring to the automatic gas shut-
off valve. Check the output from the flame
safeguard. Open manual gas cock.
Not enough gas. Ratio regulator is Adjust the ratio regulator to the proper
incorrectly set. setting.
No flame signal. Broken flamerod and/or Inspect and clean sensor. Replace if
dirty UV scanner lens. necessary.
Too much gas. Gas butterfly valve too far Check for proper setting.
open.

32-00057—01 18
Troubleshooting
Problem Possible Cause Solution
The low fire flame is weak or Not enough gas flowing to the burner. Adjust the ratio regulator or bypass fuel
unstable. adjustable orifice valve to increase the gas
flow.
Not enough air. Check for proper blower rotation. Check air
filter for blockage. Compensate for
chamber by opening the low fire air butterfly
valve position.
The burner goes out when it Not enough gas pressure into the ratio Check the start-up settings. Measure the
cycles to high fire. regulator. gas pressures and adjust them where
necessary. Check for valve train pressure
loss.
Loading line to the ratio regulator is leaking. Repair the leak in the loading line.
Not enough gas flowing to the burner. Adjust the ratio regulator to increase the
gas flow.
Fuel bypass line is not set correctly Set fuel bypass pressure per datasheet.
Additional minor adjustments to the fuel
bypass ALO valve may be required to
achieve a stable flame through the
transition between low and high fire.
The burner is erratic and Internal damage to the burner. Some parts Contact Eclipse for further information.
does not respond to inside the burner are loose, dirty or burned
adjustment. out.
The burner is unstable or The air/gas ratio is out of adjustment. Measure all the gas pressures and air
produces soot, smoke, or pressures. Compare these pressures to the
excessive carbon monoxide. documented initial start-up settings and
adjust them where necessary.
The burner cannot achieve Air filter is blocked. Clean or replace the air filter.
full capacity. Gas pressure going into the ratio regulator Adjust the gas pressure.
is too low.
Cannot initiate a start Air pressure switch has not made contact. Check air pressure switch adjustment.
sequence. Check air filter. Check blower rotation.
Check outlet pressure from blower.
High or low gas pressure switch has Check incoming gas pressure. Adjust gas
activated. pressure if necessary. Check pressure
switch setting and operation.
Malfunction of the flame safeguard system Have a qualified electrician troubleshoot
(e.g. shorted-out flame sensor or electrical and correct the problem.
noise in the sensor line).
No power to the control unit. Have a qualified electrician troubleshoot
and correct the problem.
Main power is off. Be sure the main power to the system is
switched to the “On” position.

32-00057—01 19
Appendix
Conversion Factors
Metric to English
From To Multiply By
actual cubic meter/h (am³/h) actual cubic foot/h (acfh) 35.31
normal cubic meter/h (Nm³/h) standard cubic foot /h (scfh) 38.04
degrees Celsius (°C) degrees Fahrenheit (°F) (°C x 9/5) + 32
kilogram (kg) pound (lb) 2.205
kilowatt (kW) Btu/h 3415
meter (m) foot (ft) 3.281
millibar (mbar) inches water column ("w.c.) 0.402
millibar (mbar) pounds/sq in (psi) 14.5 x 10-3
millimeter (mm) inch (in) 3.94 x 10-2
MJ/Nm³ Btu/ft³ (standard) 26.86

Metric to Metric

From To Multiply By
kiloPascals (kPa) millibar (mbar) 10
meter (m) millimeter (mm) 1000
millibar (mbar) kiloPascals (kPa) 0.1
millimeter (mm) meter (m) 0.001

English to Metric

From To Multiply By
actual cubic foot/h (acfh) actual cubic meter/h (am³/h) 2.832 x 10-2
standard cubic foot /h (scfh) normal cubic meter/h (Nm³/h) 2.629 x 10-2
degrees Fahrenheit (°F) degrees Celsius (°C) (°F - 32) x 5/9
pound (lb) kilogram (kg) 0.454
Btu/h kilowatt (kW) 0.293 x 10-3
foot (ft) meter (m) 0.3048
inches water column ("w.c.) millibar (mbar) 2.489
pounds/sq in (psi) millibar (mbar) 68.95
inch (in) millimeter (mm) 25.4
Btu/ft³ (standard) MJ/Nm³ 37.2 x 10-3

32-00057—01 20
System Schematics
Bulletin/
Symbol Appearance Name Remarks
Info Guide

Gas cocks are used to manually shut off the

Gas Cock 710
gas supply.

A ratio regulator is used to control the air/gas

ratio. The ratio regulator is a sealed unit that
adjusts the gas pressure in ratio with the air
pressure. To do this, it measures the air
Ratio Regulator
pressure with a pressure sensing line, the
impulse line. This impulse line is connected
between the top of the ratio regulator and the
burner body.

Main Gas
Shut-Off Main Gas Shut-Off Valve Eclipse strongly endorses NFPA as a
790/791
Valve Train minimum.
Train

Pilot Gas Eclipse strongly endorses NFPA as a

Shut-Off Pilot Gas Valve Train 790/791
Valve Train minimum.

Shut-off valves are used to automatically shut

Automatic Shut-Off
off the gas supply on a gas system or a 760
Valve
burner.

Orifice Meter Orifice meters are used to measure flow. 930

The combustion air blower provides the

Combustion Air Blower 610
combustion air to the burner(s).

32-00057—01 21
 Bulletin/
Symbol Appearance Name Remarks
Info Guide

Hermetic Booster Booster is used to increase gas pressure. 620

Automatic butterfly valves are typically used

Automatic Butterfly Valve 720
to set the output of the system.

Manual butterfly valves are used to balance

Manual Butterfly Valve 720
the air or gas flow at each burner.

Adjustable Limiting Adjustable limiting orifices are used for fine

728/730
Orifice adjustment of gas flow.

A switch activated by rise or fall in pressure.

A manual reset version requires pushing a
Pressure Switch 840
button to transfer the contacts when the
pressure set point is satisfied.

Pressure Gauge A device to indicate pressure. 940

A check valve permits flow only in one

Check Valve direction and is used to prevent back flow of 780
gas.

A strainer traps sediment to prevent blockage

Strainer
of sensitive components downstream.

Flexible connectors isolate components from

Flexible Connector
vibration, mechanical, and thermal stresses.

Heat exchangers transfer heat from one

Heat Exchanger 500
medium to another.

Pressure Taps Pressure taps measure static pressure.

32-00057—01 22
Notes

32-00057—01 23
Automation and Control Solutions
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® U.S. Registered Trademark
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32-00057—01 M.S. 09-16
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