Eclipse Immerso-Pak 100 IP Series Technical manual

Important Notices About Safe Burner Operation
General Precautions Store the burner inside. Exposure to the elements can damage the burner.
Adjustment, maintenance, and troubleshooting of the mechanical parts of this unit
should be done by people with good mechanical aptitude and experience with
combustion equipment.
Order replacement parts from Eclipse Combustion only. Any customer-supplied
valves or switches should carry UL, FM, CSA, and/or CGA approval where appli-
cable.
The best safety precaution is an alert and competent operator. Thoroughly instruct
new operators so they demonstrate an adequate understanding of the equipment
and its operation. Regular retraining must be scheduled to maintain a high degree
of proficiency. Eclipse Combustion or your local Eclipse representative can provide
training upon request.
The operator must have easy access to this Information Guide at all times.
1.0 Applications
Eclipse 100 Series Immerso-Pak burners are packaged nozzle-mixing burners de-
signed to fire long single- or multi-pass immersion tubes. Applications include large
industrial immersion heating equipment such as cleaning tanks, spray washers,
salt baths, quenching and tempering tanks, and large asphalt tanks.
WARNING The burners covered in this Guide are designed to mix fuel with air and burn
the resulting mixture. All fuel burning devices can cause explosions and
fires when improperly applied, installed, adjusted, controlled, or main-
tained. This Guide will provide information for using these burners for their
limited design purpose. Do not deviate from any instructions or application
limits in this Guide without written advice from the Eclipse Combustion Divi-
sion in Rockford, Illinois. Read this entire Guide before attempting to light
burners. If you do not understand any part of the information in this Guide,
contact your local Eclipse representative or Eclipse Combustion before pro-
ceeding further.
100 IP burner shown
with standard valve train
ECLIPSE INFORMATION GUIDE
IMMERSO–PAK PACKAGED BURNERS
Series 100 IP
Info 355
8/96
ECLIPSE COMBUSTION

2
2.0 Burner Operating Parameters & Requirements
Performance Data Note: Pressures listed below are for sizing purposes only and must NOT be
used for set-up. Use separate metering orifices for burner adjustment.
Gas Inlet Pressure
Burner Tube Flame Nat. Gas Propane
Size I.D. Max. Input Length 0.6 s.g. 1.5 s.g.
124 6" 1,000,000 Btu/hr. 22 ft. 7.0" w.c. 6.0" w.c.
English 132 8" 1,750,000 Btu/hr. 23 ft. 7.0" w.c. 6.0" w.c.
Units 140 10" 2,750,000 Btu/hr. 29 ft. 10.0" w.c. 7.5" w.c.
148 12" 4,000,000 Btu/hr. 35 ft. 12.0" w.c. 8.0" w.c.
124 152 mm 293 kW 6.7 m 17.4 mbar 15 mbar
Metric 132 203 mm 513 kW 7.0 m 17.4 mbar 15 mbar
Units 140 254 mm 806 kW 8.9 m 24.9 mbar 18.7 mbar
148 305 mm 1172 kW 10.7 m 29.9 mbar 19.9 mbar
Firing Chamber Limits Operates best with neutral pressure at exhaust end of immersion tube.
Ambient Temperature Limits -40°to +104°F (-40°to +40°C)
3.0 Immersion Tube Design
Bends and Elbows Immersion tubes may have standard, sweep or miter bends without affecting burner
operation. However, the first elbow must be a minimum of ten tube diameters from the
burner face. Figure 1 details the tube layout and a double mitered bend.
Tube Length The tube must be long enough to permit complete combustion before fluing to the
stack. If less than maximum rated input is required for the process, maximum tube
length can be reduced in direct proportion to the input reduction from catalog rating.
Draft Hood Do not seal the discharge of the immersion tube to a stack—use a draft breaking
hood, as detailed in Figure 2. Be sure that the manifold and stack are large enough for
the total flow of exhaust gases.
All draft hood and stack designs must conform to applicable codes.
4.0 Installation
Burner Inspection Make a thorough inspection of the burner when uncrating and before installing it. If any
parts appear broken, bent, or damaged, contact your Eclipse representative or the
Eclipse factory before installing the burner.
Companion Flange A companion flange must be welded to the immersion tube. This flange may be pur-
chased from Eclipse or supplied by others; see Figure 3.
Burner Mounting The main burner casting has an integral mounting flange. With the supplied gasket be-
tween them, bolt the burner mounting flange to the companion flange for an airtight
seal, as shown in Figure 3.
(Section 4.0 is continued on page 4)
If improperly adjusted or operated, burners can produce toxic concentra-
tions of gases, including carbon monoxide. Venting these gases into confined,
poorly ventilated areas is dangerous. To avoid this situation:
• Vent the appliance to the outdoors wherever feasible. Refer to the appliance
manufacturer’s instructions for flue and stack design guidelines.
• If outside venting is not possible, be certain that the building has enough vol-
ume and fresh air makeup to keep potentially harmful combustion products
within the safe levels defined by OSHA or other authorities having jurisdiction.
WARNING

3
Figure 1–Immersion Tube Design
Add 1.5' (457 mm)
equivalent length*
for each elbow and
3' (914 mm) for each “U”-bend.
Twice The Actual
Pipe O.D.
Twice The
Actual
Pipe O.D.
1.414 Times
The Actual
Pipe O.D.
Actual Outside Diameter
Angles Cut At
22.5° and 67.5°
Mitered bends may be used for any size immersion tube.
The double miter illustrated here is more efficient and has
less pressure drop than single miter configurations.
Dimensions apply to ACTUAL—not nominal—outside
diameter of the immersion tube.
Figure 2–Draft Breaking Hood
Dilution
Air
Roof
Draft
Hood
Stack*
Tube
Exhaust
Immersion Tank
* At least one pipe size larger than the tube exhaust.
See applicable codes for required size and height.
Rain Hat
1. Use a draft breaking hood as shown. This makes burner
operation less susceptible to atmospheric conditions and
lowers the temperature of flue gases as they pass through
the roof. Provide access between the hood and the tube in
case a damper plate must be installed to prevent rumbling.
2. When multiple exhausts are manifolded together into a
common stack, alway use draft hoods and size the stack
to handle the total exhaust flow from all the burners, plus
dilution air. This prevents cross-feeding of pressure be-
tween tubes which can cause pilot difficulties, burner insta-
bility, rumbling and popping.
Burner
Size % Efficiency
English Units Metric Units
Capacity,
1000’s Btu/hr. Tube
I.D.,
Inches
Tube
Length,
Feet*
Capacity,
Kw Tube
I.D.,
mm
Tube
Length,
m*Input Output Input Output
124 60 70
75
1000
1000
1000
600
700
750
6
6
6
18
37
48
293
293
293
176
205
220
152
152
152
5.5
11.3
14.6
132 60 70
75
1750
1750
1750
1050
1225
1315
8
8
8
23
45
55
513
513
513
308
359
385
203
203
203
7.0
13.7
16.8
140 60 70
75
2750
2750
2750
1650
1925
2060
10
10
10
30
59
73
806
806
806
484
564
604
254
254
254
9.0
17.7
22.2
148 60 70
75
4000
4000
4000
2400
2800
3000
12
12
12
40
69
80
1172
1172
1172
703
820
879
305
305
305
12.2
21.0
24.4
*Equivalent length based on straight length plus extra for elbows or “U”-bends as shown in the
illustration above. Tube lengths are for the listed efficiencies with the corresponding maximum in-
put. If desired, burner input, tube length, and net heat output may be reduced proportionally
while maintaining the same efficiency.

4
4.0 Installation (continued from page 2)
Leave Room For Adjustment Immerso-Pak burners can be purchased with three different valve train packages. All
three packaging options integrate an adjustable bias proportionator. Thus, allow a
minimum of 6" (152 mm) of space beneath the proportionator stem for bias adjust-
ment, as shown in Figure 3.
Gas Metering Orifice Each burner is test fired at Eclipse before shipment and supplied with a tag (Figure 6)
showing the differential gas pressure that corresponds to maximum rated input. This
provides only an approximate measurement of gas flow. For more precise measure-
ment, or if the burner will be operated at less than maximum input, install a gas meter-
ing orifice upstream of the burner.
When using a gas metering orifice, provide a straight run at least ten pipe diameters
upstream and at least five diameters downstream of the orifice. Failure to comply will
cause inaccurate meter readings.
Piping Suggestions Strictly follow the system designer’s recommendations on pipe sizing and layout. If you
insert piping elbows not planned for in the original design, you may introduce exces-
sive pressure losses which can prevent the system from performing properly.
Use flexible nipples on burner air and gas inlets. Solid piping may restrain the burner
from thermal expansion and damage the burner or its piping components.
Do not use the burner assembly to support the piping.
Gas piping must comply with American National Standard “National Fuel Gas Code”
(NFPA No. 54 or ANSI Z223.1)*, or must be acceptable to the authority having jurisdic-
tion.
General Wiring Suggestions See Figure 4 for wiring diagrams.
Electrical wiring must comply with the National Electric Code*, (NFPA Std. 70 or ANSI-
CI 1981), or must be acceptable to the authority having jurisdiction.
*Available from:
National Fire Protection Association American National Standard Institute
Batterymarch Park 1430 Broadway
Quincy, MA 02269 New York, NY 10018
Figure 3–Burner Mounting
Allow 6" (152 mm) Of Space
Beneath Proportionator Stem
For Bias Adjustment
Tank Wall
Immersion
Tube
Companion Flange
(By Customer)
Gasket
6"
(152 mm)
Maximum
Burner
Mounting Flange
Four
Mounting Holes
7/16" (11mm) Dia.
On “C” B.C.
1/4"
(6 mm)
“B”
Dia.
“A”
Dia.
Dimensions
ABC
Burner Inches mm Inches mm Inches mm
124 6-11/16 170 11-7/8 302 10-11/16 271
132 8-11/16 221 11-7/8 302 10-11/16 271
140 10-13/16 275 14-7/8 378 14 356
148 12-13/16 325 14-7/8 378 14 356
Companion Flange Dimensions

5
Figure 4–Wiring Diagrams
For Standard Valve Train
On/Off
7
S2
S1
V
2
115 V/1 Ph/60 Hz
Fused disconnect by customer.
L1 must always be hot, L2 must be ground.
DO NOT REVERSE!
3
4
5
Ignition Trans.
Pilot Solenoid
Main Gas Solenoid #1
Flame Rod
A
M
6000 VAC
To Igniter
Main Gas Solenoid #2
Air Flow
Switch
Black White
Black Stripe
Black
Red
Yellow
White
L2L1
Orange
Purple
Brown
Eclipse
5605-33
Blue
Green
Motor Starter
Interlock
(By Customer)
RBW
L1 L2
• EMA 418-1 drive motor starts burner
in low fire position, then starts to control
after main gas valve reaches fully open position.
• Connect “R” to “B” and motor drives to high fire.
• Disconnect “R” and “B” and motor returns to low fire.
LS-2 Switch
In MGV #2
NC
NO
C
1
Jumper
Temp.
Controller
EMA-1
Drive Motor
Common
115 VAC
Low High
Pilot Gas Valve
To Ignitor
Vent Valve
Auto. Shutoff Valve
T1 T2 T3 2 3 4 5 6 7 8 9 10 12 13 15 17 18
Use T1 & T2
For 1 Ph.
To Temp.
Controller
M
Comb.
Blower
Motor Gnd.
Flame
Rod
Gnd.
Flame
Rod
M
Use T1, T2 & T3
For 3 Ph.
L1
L2
C
NCNO
EMA-1
Drive
Motor
Gas Pressure Switches
Comb. Air Pressure Switch
Main Gas Valve
LS-2 Switch
In Gas Shutoff
Valve
Ignition Transformer (115/6000V)
For IRI Valve Trains

6
Figure 5–Components Identification
5.0 Start-Up & Adjustment
Refer to the above illustration for component identification and location.
Initial Start-up Instructions Close the manual main gas and pilot gas cocks.
Turn the burner on/off switch to “on.”
Open the manual main gas cock and then the pilot gas cock. Always open these two
valves in this sequence; reversing the sequence may blow out the pilot as the control
motor moves to the high fire position.
After the pilot gas cock is opened, the pilot should light, the automatic main gas valve
should open to establish a low fire flame, and the control motor should move the air
butterfly valve to the open—or high fire—position. Pilot gas flow is set at the Eclipse
factory during test firing and should be satisfactory for most applications. If pilot adjust-
ment is required, see the detailed instructions in Figure 7. Pilot gas flow should be the
minimum that will give reliable ignition and a steady flame signal.
Check Flue Gas Drive the burner to high fire. Using a flue gas analyzer, measure the flue gas compo-
nents in the exit end of the immersion tube. Adjust the gas butterfly to produce 2 to
4% O2, or 10 to 10.5% CO2for natural gas.
Adjust High Fire Gas Flow Using Tag Settings: Each burner is test fired at Eclipse before shipment and supplied
with a tag (Figure 6) showing the differential gas pressure that corresponds to maxi-
mum rated input. Attach a manometer as shown in Figure 6, and, if necessary, adjust
the air butterfly linkage until the gas differential pressure matches the pressure drop re-
corded on the tag. The differential pressure on the tag is for natural gas. For propane,
multiply this pressure by 0.4.
Using A Gas Metering Orifice: If a gas metering orifice was installed to provide more
accurate gas flow measurements, use a manometer to measure the pressure drop
across the orifice. If necessary, adjust the air butterfly linkage to produce the pressure
drop that corresponds to the desired high fire gas flow.
Ignition
Transformer
Flame Monitor
(Standard
Burner Only)
Wiring Box
IRI Only
Ignition Plug
#18193
Air Flow Switch
Control Motor
Blower Motor
Pilot
Solenoid Pilot
Regulator
Pilot
Adjusting Cock
Peepsight
Union
Flame Rod Port,
1/2" N.P.T.
Use Rod
#16946-1**
U.V. Scanner,
124 IP*
U.V. Scanner,
132 IP*
U.V. Scanner,
140, 148 & 156 IP*
* All U.V. scanner ports are 1/2"
N.P.T. Install the scanner in these
ports when it is substituted for a
flame rod.
** Cut the electrode length to 4-1/2"
(114mm) for the 124 & 132 IP, and
5" (127mm) for the 140, 148 & 156 IP
Gas Adjusting
Valve
Manual
Main
Gas Cock
Automatic Gas
Shut-Off Valve(s) Manual
Main
Gas Cock Proportionator

7
5.0 Start-Up & Adjustment (continued)
Check For Smoke If smoke is present in the exhaust, gradually close the gas butterfly valve until the
smoke disappears.
Adjust Low Fire Drive the burner to low fire. Check the tube outlet for smoke. If smoke is present,
adjust the adjustable bias proportionator as detailed in Figure 8. If smoke is still
present, then the air butterfly valve may need to be opened more. Readjust the
valve linkage to provide more air at low fire.
Recycle to Verify Firing Rates Cycle the burner several times to verify that the system is properly adjusted at all
firing rates.
Burner Shutdown Turn the main and pilot gas valves off.
Turn the burner on/off switch to “off.”
Figure 6–Supplied Burner Tag
Figure 7–Pilot Adjustment Figure 8–ABP Adjustment
Gasket
Cover Plate
Handle
(shown fully open)
Cap Adjusting
Screw
To Adjust Pilot Flame:
1) Remove the cap.
2) Turn the adjusting pin clockwise for less gas, and counterclock-
wise for more gas. Do not remove the pin from the valve.
3) Replace the cap after adjustment.
Differential
Pressure Drop
Pressure
Test Cock
Pressure
Test Cock
Pilot
Manual Cock
Reduced
Port Manual
Butterfly
Valve
Proportionator
Valve
Motorized
Gas Valve
Main Gas
Manual Cock
Gas
Inlet
Pilot Gas
Regulator
Pilot Gas
Solenoid
EFE 440 Rev. 12/76
ECLIPSE 100 SERIES IMMERSO-PAK®
Differential
Pressure Drop __________ "w.c. Flow – CFH _________ of .65 S.P. GR.
To Adjust Low Fire:
1) Remove the three screws that secure the
cover plate.
2) Remove the cover plate and the gasket.
3) With a screwdriver, adjust the internal ad-
justing screw clockwise for less gas, and
counterclockwise for more gas. Do not re-
move the screw from the stem.
4) Replace the gasket, cover plate and three
screws after adjustment.

8
6.0 Trouble-Shooting
CAUTION
1. On initial start-up, gas line may be filled with air. Repeat ignition trial sev-
eral times to purge.
2. No power to ignition transformer or pilot solenoid.
3. Open circuit between ignition transformer and spark plug.
4. Spark plug needs cleaning. See “Maintenance” section for instructions.
5. Spark plug improperly grounded. Do not use pipe dope on ignition plug
threads.
6. Pilot gas cock screw closed.
7. Insufficient gas pressure into or out of pilot regulator.
1. Pilot set too lean, becoming unstable as air increases.
2. Insufficient pressure into or out of main gas regulator.
3. Main gas adjusting valve not open enough.
1. Gas flow is rich. Main gas butterfly valve is open too far.
1. Gas flow is rich. Proportionator spring is screwed out too far.
2. Insuffiicient air flow due to dirty blower filter or impeller.
3. Air butterfly valve is closed too far.
4. Insufficient gas pressure into proportionator, causing it to track improperly
at all rates below high fire. Raise inlet gas pressure as listed in Section 2.
1. Burner not properly set. See Section 5.0.
2. If rumbling occurs, slide a piece of steel plate over the end of the tube until
the noise disappears. Then weld the plate in place.
PROBLEM CAUSE(S)
Trouble shooting of panels and electrical circuits should be done by
qualified plant electricians, technicians, or engineers experienced in
all facets of this type of combustion equipment.
Main flame fails to light
or goes out as burner
cycles to high fire.
Pilot fails to light.
Smoke on high fire.
Smoke on low fire.
Burner rumbles or bangs.

7.0 Maintenance
Maintenance Program A sound preventative maintenance program, carried out by qualified individuals, will
greatly increase equipment reliability and productivity. Frequency of maintenance
checks should reflect the duty cycle of the heating equipment and conditions such as
dirt and temperature. Any maintenance program should include at least the following
steps:
Check Pressure Settings Check the burner's high and low fire air and gas settings.
Check Filters Examine and, if necessary, clean or replace air and gas filter elements.
Check for Leaks Check all piping connections for leaks.
Check Flame Supervision Check the ability of the flame supervision system to function properly by simulating
system failures:
Simulate burner flameout by manually shutting off the gas.
Trip out pressure switches and other limit interlocks.
Try to light the burner before the purge and other timers have finished their cycles.
If simulated limit or flame failures do not shut down the fuel system within an accept-
ably short period of time, immediately take the equipment out of service and correct
the problem.
Leak test automatic and manual reset fuel valves per insurance procedures.
Check Bolts & Screws Check all bolts and screws for tightness.
Check for Overheating Check the area around the burner mounting flange for signs of overheating. Gasket re-
placement may be necessary.
Check for Water Leakage Check the interior of the burner and immersion tube for water accumulation. Small
amounts of water may collect due to condensation of combustion products. Large
amounts of water may be a sign of tube leakage.
Plug & Rod Replacement Ignition plugs and flame rods wear out over long periods of normal burner operation.
Eclipse recommends that the user keep at least one of each in stock at all times to
prevent nuisance shutdowns. See Figure 5 for plug and rod numbers.
The flame rod electrode lengths listed in Figure 5 extend the rod about 1/2" (13 mm)
into the flame. Be certain that the flame rod is not grounded.
The ignition plug specified has an adjustable electrode length. To install the plug,
loosen the electrode and thread the plug into the burner. Push the electrode toward
the burner centerline until it stops. Then pull the electrode back 3/32" (2 mm). Tighten
the electrode in this position.
ECLIPSE COMBUSTION
Litho In U.S.A.