Eclipse TA Series User manual

Installation Guide 114
4/7/06
ThermAir
Burners
TA Series
version 1

Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 4/7/06
2
Copyright
DisClaimer NotiCe
liability aND
WarraNty
Copyright 1998 by Eclipse Combustion, Inc. All rights reserved
worldwide.This publication is protected by federal regulation
and shall not be copied, distributed, transmitted, transcribed or
translated into any human or computer language, in any form or
by any means, to any third parties, without the express written
consent of Eclipse Combustion, Inc., Rockford, Illinois, U.S.A.
We reserve the right to change the construction and/or
configuration of our products at any time without being obliged
to adjust earlier supplies accordingly.
The material in this manual is believed adequate for the
intended use of the product. If the product, or its individual
modules or procedures, are used for purposes other than those
specified herein, confirmation of their validity and suitability
must be obtained. Eclipse Combustion, Inc. warrants that the
material itself does not infringe any United States patents. No
further warranty is expressed or implied.
We have made every effort to make this manual as accurate
and complete as possible. Should you find errors or
omissions, please bring them to our attention so that we may
correct them. In this way we hope to improve our product
documentation for the benefit of our customers. Please send
your corrections and comments to our Documentation
Manager.
It must be understood that Eclipse Combustion’s liability for
its products, whether due to breach of warranty, negligence,
strict liability, or otherwise, is limited to the furnishing of such
replacement parts and Eclipse Combustion will not be liable for
any other injury, loss, damage or expenses, whether direct or
consequential, including but not limited to loss of use, income
of or damage to material arising in connection with the sale,
installation, use of, inability to use or the repair or replacement
of Eclipse Combustion’s products.
Any operation expressly prohibited in this Guide, any
adjustment, or assembly procedures not recommended or
authorized in these instructions shall void the warranty.

Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 4/7/06 3
About this manual
auDieNCe This manual has been written for people who are already
familiar with all aspects of a nozzle-mix burner and its add-on
components, also referred to as “the burner system.”
These aspects are:
• installation
• use
• maintenance.
The audience is expected to have had experience with this kind
of equipment.
Installation Guide No. 114
• This document
ThermAir Data Sheets, Series 114
• Available for individual TA models
• Required to complete design & selection
Design Guide No. 114
Used with Data Sheet to design burner system
ThermAir Price List No. 114
Used to order burners
• EFE 825 (Combustion Engineering Guide)
• Eclipse Bulletins and Info Guides: 710, 732, 742, 760, 818,
832, 852, 854, 856, 610, 620, 630, 826, 820, 930, I-354.
Purpose
The purpose of this manual is to ensure the installation of a
safe, effective, and trouble-free combustion system is carried
out.
thermair
DoCumeNts
relateD DoCumeNts

Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 4/7/06
4
There are several special symbols in this document.You must
know their meaning and importance.
The explanation of these symbols follows below. Please read it
thoroughly.
Danger:
Indicates hazards or unsafe practices which
WILL result in severe personal injury or even
death.
Only qualified and well trained personnel are
allowed to carry out these instructions or
procedures.
Act with great care and follow the instructions.
Warning:
Indicates hazards or unsafe practices which
could result in severe personal injury or damage.
Act with great care and follow the instructions.
Caution:
Indicates hazards or unsafe practices which could result in
damage to the machine or minor personal injury.
Act carefully.
Note:
Indicates an important part of the text. Read thoroughly.
If you need help, you can contact your local Eclipse
representative. A complete listing of Eclipse representatives
world wide can be found at www.eclipsenet.com.
You can also contact Eclipse at:
1665 Elmwood Rd.
Rockford, IL 61103
815-877-3031
DoCumeNt
CoNveNtioNs
hoW to get help

Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 4/7/06 5
Table of contents
1
About this manual ........................... 3
Audience ..................................... 3
ThermAirDocuments .......................... 3
RelatedDocuments............................. 3
DocumentConventions ......................... 4
HowtoGetHelp .............................. 4
Table of Contents ............................ 5
Introduction ................................. 7
ProductDescription ............................ 7
Safety ...................................... 9
Capabilities ...................................10
OperatorTraining ..............................10
ReplacementParts .............................10
Installation ..................................11
HandlingandStorage ...........................11
Approvals of Components . . . . . . . . . . . . . . . . . . . . . . . 11
ElectricalWiring................................12
Wheretogetstandards..........................12
Pre-installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . 13
Burner ......................................13
GasPiping ....................................14
Installing the flame sensor . . . . . . . . . . . . . . . . . . . . . . . . 15
Check List After Installation . . . . . . . . . . . . . . . . . . . . . . 15
Prepareforadjustment..........................16
Adjustment, Start & Stop .....................17
Introduction...................................17
System 1
Burner adjustment with a ratio regulator . . . . . . . . . . . . 17
Step 1 Reset the system . . . . . . . . . . . . . . . . . . . . . . 17
Step 2 Verify Air flow. . . . . . . . . . . . . . . . . . . . . . . . . 18
Step 3a Ignite the burner (Option 1). . . . . . . . . . . . . 18
Step 3b Ignite the burner (Option 2) . . . . . . . . . . . . 19
Step 4 Set high fire gas . . . . . . . . . . . . . . . . . . . . . . . 20
Step 5 Set low fire gas. . . . . . . . . . . . . . . . . . . . . . . . 21
Step 6 Verify gas settings . . . . . . . . . . . . . . . . . . . . . . 21
2
3
4

Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 4/7/06
6
Maintenance & Troubleshooting ...............25
Maintenance ..................................25
MonthlyChecklist..............................25
YearlyChecklist................................26
Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . 27
Appendix ...................................30
ConversionFactors ............................30
Key to System Schematics . . . . . . . . . . . . . . . . . . . . . . . 31
Parts Drawing................................32
PartsList .....................................33
PartsListcontinued ............................34
5
Adjustment, Start & Stop (Cont.)...............21
System 2
Burner adjustment without a ratio regulator . . . . . . . . . 21
Step 1 Reset the system . . . . . . . . . . . . . . . . . . . . . . 22
Step 2 Verify the system . . . . . . . . . . . . . . . . . . . . . . 22
Step 3a Ignite the burner (Option 1). . . . . . . . . . . . . 22
Step 3b Ignite the burner (Option 2) . . . . . . . . . . . . 23
Step 4 Set high fire gas . . . . . . . . . . . . . . . . . . . . . . . 24
Step 5 Set low fire gas. . . . . . . . . . . . . . . . . . . . . . . . 24
Step 6 Verify gas settings . . . . . . . . . . . . . . . . . . . . . . 24
4

Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 4/7/06 7
Introduction 1
The ThermAir burner (TA Series) is a nozzle-mix burner with
a packaged combustion air blower that is designed to fire with
fixed combustion air over a wide gas turndown range. An
integral gas orifice is provided to ease burner setup. The burner
is designed to facilitate:
• fixed air operation
• direct spark ignition
• simple gas control
• multiple fuel capability
The burner is suitable for direct and indirect air heating for a
wide range of applications on industrial furnaces and ovens.
Figure 1.1 ThermAir Burner
proDuCt
DesCriptioN

Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 4/7/06
8
Blank page.

Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 4/7/06 9
Safety 2
This section is provided as a guide for the safe operation of the
ThermAir burner system. All involved personnel should read
this section carefully before operating this system.
  Danger:
The ThermAir burners, described herein, are
designed to mix fuel with air and burn the
resulting mixture. All fuel burning devices are
capable of producing fires and explosions if
improperly applied, installed, adjusted, controlled,
or maintained.
Do not bypass any safety feature; fire or explosion
could result.
Never try to light a burner if it shows signs of
damage or malfunction.
  Warning:
The burner might have HOT surfaces. Always wear protective
clothing when approaching the burner.
  Note:
This manual provides information in the use of these burners
for their specific design purpose. Do not deviate from any
instructions or application limits described herein without
written advice from Eclipse Combustion.
Read the entire manual before attempting to start this
system. If you do not understand any part of the information
contained in this manual, contact your local Eclipse
representative or Eclipse Combustion before continuing.
iNtroDuCtioN
safety

Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 4/7/06
10
Only qualified personnel, with good mechanical aptitude and
experience on combustion equipment, should adjust, maintain,
or troubleshoot any mechanical or electrical part of this system.
The best safety precaution is an alert and trained operator.
Train new operators thoroughly and have them demonstrate an
adequate understanding of the equipment and its operation. A
regular retraining schedule should be administered to ensure
operators maintain a high degree of proficiency.
Order replacement parts from Eclipse Combustion only. All
Eclipse Combustion approved, customer supplied valves or
switches should carry UL, FM, CSA, CGA, and/or CE approval,
where applicable.
Capabilities
operator traiNiNg
replaCemeNt parts

Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 4/7/06 11
Installation 3
iNtroDuCtioN
haNDliNg aND storage
approvals of
CompoNeNts
Limit Controls and Safety
Equipment
In this section you will find important notices about safe
operation of the burner:
Handling:
1. Make sure that the components are clean and free of dam-
age.
2. Protect the components from weather, damage, dirt and
moisture.
• Transport in original shipping container
•Do not drop
3. Protect the components from excessive temperatures and
humidity.
4. Use appropriate support equipment, i.e. harnesses, straps,
chains etc. when lifting burner components.
Storage:
1. Make sure that the area is clean.
2. Store the components in a cool, clean, dry room.
3. After you have made sure everything is present and in good
condition, keep the components in the original package as
long as possible.
All limit controls and safety equipment must comply with the
current following standards:
• NFPA Standard 86
• NFPA Standard 86C
• UL
• FM
• CGA
• EN 746-2
• all applicable local codes and/or standards.

Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 4/7/06
12
All electrical wiring must comply with one of these standards:
• NFPA Standard 70
• ANSI-C11981
• EN 746-2
• the electrical wiring must be acceptable to the local
authority having jurisdiction
All gas piping must comply with one of these standards:
• NFPA Standard 70
• ANSI Z223
• EN 746-2
• the gas piping must be acceptable to the local authority
having jurisdiction
The NFPA Standards are available from:
National Fire Protection Agency
Batterymarch Park
Quincy, MA 02269
The ANSI Standards are available from:
American National Standard Institute
1430 Broadway
New York, NY 10018
The UL Standards are available from:
333 Pfingsten Road
Northbrook, IL 60062
The FM Standards are available from:
1151 Boston-Providence Turnpike
P.O. Box 9102
Norwood, MA 02062
Information on the EN standards, and where to get the
standards is available from:
Comité Européen de Normalisation
Strassartstraat 36
B-1050 Brussels
Phone: [phone]
Fax: [phone]
Comité Européen de Normalisation Electronique
Strassartstraat 36
B-1050 Brussels
Phone: [phone]
Fax: [phone]
Electrical wiring
Gas Piping
Where to get standards

Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 4/7/06 13
Air Supply
Provide an opening in the burner room of at least one square
inch per 4000 BTU/hr (6 cm2 per 1 kW) to supply the burner
intake with fresh, outdoor, combustion air.
If there are corrosive fumes or materials in the surrounding air,
find an uncontaminated source to supply air to the burner.
Exhaust
Do not allow exhaust gases to accumulate in the work area.
Provide a means for exhausting these gases from the building.
Access
Install the burner so it may be easily accessed for inspection and
maintenance.
Environment
Be sure the burner operating environment matches the original
operating specifications. Check the following items:
• voltage, frequency, and stability of electrical power
• fuel type and fuel supply pressure
• adequate fresh, clean, combustion air
• humidity, altitude, and temperature of the supply air
• presence of damaging corrosive gases in the air
• prevent direct exposure to water.
Chamber Opening
Provide an opening in the chamber wall at least ½” (12mm)
larger in diameter than the outside diameter of the combustor.
Provide an accessible pressure tap on the chamber wall to
measure the pressure inside the firing chamber. The pressure
tap should be located near the burner.
Mounting Pattern
Attach four mounting bolts to the chamber wall. Position these
bolts to match the clearance holes (C) on the burner mounting
flange. Refer to the appropriate ThermAir data sheet.
pre-iNstallatioN
CheCklist
burNer
“C”
Minimum 1/4" (6mm)
space per side
Combustor
Chamber wall

Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 4/7/06
14
Chamber Wall
Make sure the chamber wall is strong enough to support
the weight of the burner . If necessary, reinforce the
mounting area.
Burner Mounting
Mount burner to chamber wall using four (4) customer supplied
nuts and lock washers.
1. Make sure that you install the burner mounting gasket, item
 , between the burner mounting flange and the chamber
wall.
2. Make sure that the gasket does not leak.
Insulate the Firing Tube
To insure that radiated heat doesn’t reach the exterior of
the chamber, insulate the combustion tube over the length
contained within the chamber wall, filling any clearance
completely. If the firing tube extends beyond the chamber wall
thickness, do not insulate the exposed end of the tube.
iNstallatioN
(CoNtiNueD)
Burner Piping
The burner is factory assembled and shipped as ordered.
Note:
If it is necessary to redirect piping, be sure the:
• ratio regulator spring column is pointing up.
• arrow on the ratio regulator points in the direction of
gas flow .
• integral fuel orifice and o-rings are re-installed.
• same straight runs of pipe remains between the ratio
regulator and the burner .
Supply Piping
Inlet pressure to the ratio regulator (if supplied) should be at
least 15”w.c. (37.5 mbar). It should not exceed the maximum
pressure rating of the ratio regulator.
• Locate the valve train close to the burner. The gas must
reach the burner during the fixed trial for ignition.
• Sufficiently size shut off valves in the valve train.
• Make sure piping is large enough.
• Minimize piping elbows.
Pipe Connections
• 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.
gas pipiNg
4
2
Chamber
insulation
1
Bracket
Pipe
Union

Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 4/7/06 15
Piping Support
Use brackets or hangers to support the gas piping. If you have
questions, consult your local gas company.
Control Motor
Install a control motor to modulate the gas control valve if not
previously installed on the burner.
There are two different types of flame sensors:
U.V. scanner:
Each ThermAir burner is capable of U.V. flame monitoring.
The burner will not come equipped with a U.V. scanner. A ½”
NPT connection is provided on each ThermAir burner for the
connection of a U.V. scanner.
For detailed information on how to install and connect an
Eclipse U.V. scanner, refer to:
– straight U.V. scanner; Bulletin / Info Guide 854
– 90° U.V. scanner; Bulletin / Info Guide 852
– self-check U.V. scanner; Bulletin / Info Guide 856.
Flame rod:
If the flame rod option was selected when the burner was
ordered, the burner will be delivered with the flame rod already
installed on the burner.
  Note:
Only specific burner sizes are capable of using a flame rod.
These models are TA015, 025, 040, 075, and 100.
For detailed information on how to install and connect a flame
rod, refer to:
– Bulletin / Info Guide 832.
Installing the flame sensor
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 system 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.
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.
5.Be sure all valves are installed in the proper location and
correctly oriented relative to the flow direction.
CheCk list after
iNstallatioN

Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 4/7/06
16
prepare for aDjustmeNt After installation of the burner system components is complete,
the following steps should be followed in order to prepare for
adjustment:
1. Set the air flow switch so that it drops out at 20% below the
maximum pressure of the combustion air blower.
2. Set the low gas pressure switch at 20% below the gas
pressure measured at the inlet to the main gas valve train.
3. Set the high gas pressure switch at 20% above the gas
pressure measured at the inlet to the main gas valve train.
4. Close all manual valves feeding the burner.
5. Try to ignite the burner before the purge and other
timers have finished their cycles. Make sure that the flame
monitoring system indicates a flame failure.
6. Trip out the pressure switches and other limit interlocks.
Make sure that the main gas valve train closes.
Danger:
If simulated limits or simulated flame failures do
not shut down the fuel system within the required
failure response time, immediately correct the
problem before proceeding.

Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 4/7/06 17
Adjustment, Start &
Stop 4
In this chapter you will find instructions on how to start and
stop a burner. The chapter begins with general instructions
that are useful for adjustment.
Adjustment
There are two separate system adjustment procedures:
• System 1
Adjust a ThermAir burner with a ratio-regulator
iNtroDuCtioN
  Danger:
The ThermAir burners, described herein, are
designed to mix fuel with air and burn the
resulting mixture. All fuel burning devices are
capable of producing fires and explosions if
improperly applied, installed, adjusted, controlled,
or maintained.
Do not bypass any safety feature; fire or explosion
could result.
Never try to light a burner if it shows signs of
damage or malfunction.
• System 2
Adjust a ThermAir burner without a ratio-regulator
system 1
burNer aDjustmeNt
With a Ratio-Regulator
If you are adjusting a ThermAir burner equipped with a ratio-
regulator for the first time, you must follow these steps:
1. Reset the system
2. Verify air flow
3. Ignite the burner
4. Set high fire gas
5. Set low fire gas
6. Verify gas settings
7. Stop Procedure
1. Close these valves
-the automatic gas valves
-the manual gas cocks
2. Start the combustion air blower
Step 1: Reset the system

Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 4/7/06
18
Step 2: Verify air flow
Main Gas
Valve Train
Tap "A"
Tap "C"
TA 015, 025, 040, 075, 100, 200
1. Make sure that the pressure tap located on the chamber is
open.
2. Connect the manometer to the chamber pressure tap.
3. Measure the chamber air pressure.
4. Determine actual air flow from the burner specific Data
Sheet (ref.:Air flow vs. Chamber Pressure Chart) for the
burner being setup.
5. Remove the manometer.
6. Close the pressure tap.
1. Make sure that pressure taps A and C are open.
2. Connect the manometer to taps A and C.
3. Measure the air differential pressure.
4. Determine actual air flow from the burner specific Data
Sheet (ref.:Air flow vs.Air Orifice ∆P Chart) for the burner
being setup.
5. Remove the manometer.
6. Close the pressure taps
TA 300, 400, 500
  Note:
A pressure tap is open when the screw inside the tap is
unscrewed approximately half a turn.
  Note:
Chamber pressure will directly influence air flow from the
blower. Air flows should be rechecked once the process reaches
its operating temperature and pressure. An oxygen analyzer
may be used to confirm air flow rates once the system is
operating.
There are two separate ignition procedures which depend upon
whether or not bypass start gas is installed on the burner. Each
procedure is unique and both are outlined below.
  Warning:
This procedure assumes that a flame monitoring
control system is installed and is serviceable. It
also assumes that normal low fire start is being
used.
If low fire gas is too low to be used for ignition
consider increasing low fire or providing bypass
start gas. Refer to the section 3b on page 19.
Step 3a: Ignite the burner
(Option 1: Burner not
equipped with bypass
start gas)
Chamber
Pressure
Tap
Chamber
Wall
TA 015 thru TA 200
TA 300 thru TA 500

Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 4/7/06 19
1. Drive the gas control valve to low fire.
2. Make sure the combustion air blower is running.
3. Verify that the adjusting screw on the ratio-regulator is six
full (360°) turns down from the top.
4. Open all manual gas valves feeding the burner.
5. Initiate the ignition sequence through the flame monitoring
control system.
6. Verify that the burner has ignited.
If the burner does not ignite:
a) Try to ignite again to purge the air out of the gas piping.
b) If the burner does not ignite after one or two additional
ignition attempts, see the Trouble shooting Guide
contained in the Maintenance & Troubleshooting section
of this guide.
  Warning:
This procedure assumes that a flame monitoring
control system is installed and is serviceable. It
also assumes that a normal, low fire start is being
used.
1. Drive the gas control valve to low fire.
2. Make sure the combustion air blower is running.
3. Verify that the adjusting screw on the ratio-regulator is six
full (360°) turns down from the top.
4. Open the flow adjusting valve in the bypass gas line.
5. Open the manual gas valve in the bypass gas line.
6. Initiate the ignition sequence through the flame monitoring
control system.
7. Verify that the burner has ignited.
If the burner does not ignite:
a) Try to ignite again to purge the air out of the gas piping.
b) If the burner does not ignite after one or two additional
ignition attempts, see the Trouble shooting Guide
contained in the Maintenance & Troubleshooting section
of this guide.
Step 3b: Ignite the burner
(Option 2: Burner equipped
with bypass start gas)
Main Gas
Valve Train
NC
  Note:
All ThermAir burners are limited to ignition at inputs below
40% of maximum unless the control circuit on page 15 of
Design Guide 114 is followed.

Eclipse ThermAir T/A Series v1.10, Installation Guide No. 114, 4/7/06
20
If the burner has ignited:
a) Adjust the bypass flow adjusting valve such that the
burner is able to maintain a stable flame and an adequate
flame signal.
b) Open all remaining manual gas valves feeding the burner.
1. If the burner has and is ignited, drive the main gas control
valve to high fire (full open).
2. Verify air flow with the burner firing, repeat Step 2 “Verify air
flow”.
3. Make sure that pressure taps B and D are open.
4. Connect the manometer to taps B and D.
5. Measure the gas differential pressure.
6. Use the gas curve from the appropriate ThermAir Data
Sheet for the gas being used to find the differential gas
pressure needed at high fire.
  Note:
Select the appropriate gas orifice differential pressure based
upon the desired amount of excess air in the burner.
7. Readjust the control valve linkage to achieve the desired high
fire gas flow.
  Note:
The ThermAir gas orifice is sized to limit high fire gas flow
to approximately 15% excess air with a packaged burner
assembly purchased with a ratio-regulator and gas control
valve.
8. Once the chamber conditions stabilize, (i.e. pressure and
temperature), repeat items 2 through 7.
9. Check the gas pressure at the inlet to the ratio regulator.
This should be at least 15”w.c. (37.5 mbar) It should not
exceed the maximum pressure rating of the ratio regulator.
  Warning:
Insufficient gas inlet pressure may cause the ratio
regulator to remain fully open if there is a loss
of air flow to the burner. This can cause excess
fuel operation and the possible accumulation of
unburned fuel in the chamber.
In extreme cases, this may cause explosions or
fires.
Step 4: Set high fire gas
Tap "D"
Tap "B"