Eclipse TFB030 User manual

TFB030-075
TFB200
Eclipse Tube Firing
Burners
Models TFB030, TFB075, TFB200
Version 2
11/14/2014
Installation Guide 310

2
Copyright
Copyright 2007 by Eclipse, 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, inc.
Disclaimer Notice
In accordance with the manufacturer’s policy of continual
product improvement, the product presented in this
brochure is subject to change without notice or obligation.
The material in this manual is believed adequate for the
intended use of the product. If the product is used for
purposes other than those specified herein, confirmation
of validity and suitability must be obtained. Eclipse
warrants that the product itself does not infringe upon any
United States patents. No further warranty is expressed or
implied.
Liability & Warranty
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
Technical Documentation Specialist.
It must be understood that Eclipse’s liability for its product,
whether due to breach of warranty, negligence, strict
liability, or otherwise is limited to the furnishing of
replacement parts and Eclipse 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, or damage to material arising in connection with
the sale, installation, use of, inability to use, or the repair
or replacement of Eclipse’s products.
Any operation expressly prohibited in this manual, any
adjustment, or assembly procedures not recommended or
authorized in these instructions shall void the warranty.
Document Conventions
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.
How To Get Help
If you need help, contact your local Eclipse
representative. You can also contact Eclipse at:
1665 Elmwood Rd.
Rockford, Illinois 61103 U.S.A.
Phone: [phone]
Fax: [phone]
http://www.eclipsenet.com
Please have the information on the product label available
when contacting the factory so we may better serve you.
Product Name
Item #
S/N
DD MMM YYYY
www.eclipsenet.com
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
death or serious injury.
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
Is used to address practices not related to personal injury.
Indicates an important part of text. Read thoroughly.
NOTE
NOTICE
CAUTION
WARNING

3
Eclipse TFB, V2, Installation Guide 310, 11/14/2014
Table of Contents
Introduction............................................................................................................................... 4
Product Description.............................................................................................................. 4
Audience .............................................................................................................................. 4
TFB Documents ...................................................................................................................4
Purpose................................................................................................................................ 4
Safety......................................................................................................................................... 5
Safety Warnings................................................................................................................... 5
Capabilities........................................................................................................................... 5
Operator Training................................................................................................................. 5
Replacement Parts...............................................................................................................5
Installation................................................................................................................................. 6
Handling............................................................................................................................... 6
Storage ................................................................................................................................ 6
Position of Components....................................................................................................... 6
Approval of Components ..................................................................................................... 6
Checklist Before Installation ................................................................................................ 7
Prepare the Burner ..............................................................................................................7
Burner Installation................................................................................................................ 9
Checklist After Installation ................................................................................................... 11
Prepare for Adjustment........................................................................................................ 11
Adjustment, Start & Stop ......................................................................................................... 12
Adjustment Procedure.......................................................................................................... 12
Step 1: Reset the System .............................................................................................. 12
Step 2: Set High Fire Air ................................................................................................ 12
Step 3: Set Low Fire Air................................................................................................. 13
Step 4: Verify the Air Settings........................................................................................ 13
Step 5: Ignite the Burners .............................................................................................. 13
Step 6: Set High Fire Gas.............................................................................................. 14
Step 7: Verify the Gas Settings...................................................................................... 15
Step 8: Adjust Low Fire.................................................................................................. 15
Start Procedure.................................................................................................................... 15
Stop Procedure .................................................................................................................... 15
Static Air Pressures.............................................................................................................. 15
Maintenance & Troubleshooting............................................................................................. 16
Maintenance ........................................................................................................................ 16
Monthly Checklist................................................................................................................. 16
Yearly Checklist ................................................................................................................... 16
Troubleshooting Procedures................................................................................................ 17
Appendix ................................................................................................................................... i
Conversion Factors..............................................................................................................i

4Eclipse TFB, V2, Installation Guide 310, 11/14/2014
Product Description
The TFB is a nozzle-mixing burner designed for tube firing
applications with multiple fuel capability. The burner
consists of a housing, rear cover, air and fuel inlet blocks,
spark rod, flame rod (if selected), UV scanner adapter (if
selected), gas tube, nozzle and air shroud.
Burner design provides:
• Adjustable air shroud to maintain correct air velocity
for different sized tube applications and fuels.
• Uniform tube temperatures for extending tube life.
Heat Exchanger
The TFB can be used with or without an exhaust leg
recuperator. An exhaust leg recuperator is a heat
exchanger that transfers heat from the exhaust air to the
combustion air. Preheating the combustion air can
increase the fuel efficiency by as much as 20%. The TFB
can handle combustion air temperatures up to 1000°F.
The recommended recuperators for the TFB are the
Eclipse Bayonet (Data 317) and the Bayonet-Ultra (Spec.
318).
Figure 1.1. TFB
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 previous experience
with this type of equipment.
TFB Documents
Installation Guide No. 310
• This document
Datasheet, Series No. 310-1 through 310-3
• Available for individual TFB models
• Required to complete installation
Design Guide No. 310
• Used with Datasheet to complete installation
Worksheet No. 310
• Required to provide application information to
Eclipse Engineering
Related Documents
• EFE 825 (Combustion Engineering Guide)
• Eclipse Bulletins and Info Guides: 610, 710, 720,
730, 742, 744, 760, 930, I-354
Purpose
The purpose of this manual is to ensure that you carry out
the installation of a safe, effective, and trouble free
combustion system.
TFB030-075
TFB200
1
Introduction

5
Safety
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
warnings must be observed. All involved personnel should
read this entire manual carefully before attempting to start
or operate this system. If any part of the information in this
manual is not understood, contact Eclipse before
continuing.
Safety Warnings
■The 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.
■The burner and duct sections are likely to have
HOT surfaces. Always wear the appropriate
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.
■This manual provides information regarding the
use of these burners for their specific design
purpose. Do not deviate from any instructions or
application limits described herein without written
approval from Eclipse.
Capabilities
Only qualified personnel, with sufficient mechanical
aptitude and experience with combustion equipment,
should adjust, maintain or troubleshoot any mechanical or
electrical part of this system. Contact Eclipse for any
needed commissioning assistance.
Operator Training
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. Contact Eclipse for any needed
site-specific training.
Replacement Parts
Order replacement parts from Eclipse only. All Eclipse
approved valves or switches should carry UL, FM, CSA,
CGA and/or CE approval where applicable.
DANGER
WARNING
NOTICE
2

Eclipse TFB, V2, Installation Guide 310, 11/14/2014
6
In this section you will find the information and instructions
that you need to install the burner and recommended
accessories.
NOTE: Most of the illustrations in this chapter are based
on a TFB030, but are typical for all TFB burners. Where
necessary, customized illustrations are used to describe
specific details.
Handling
• Make sure that the area is clean.
• Protect the components from the weather, damage,
dirt and moisture.
• Protect the components from excessive
temperatures and humidity.
• Take care not to drop or damage components.
Storage
• Make sure that the components are clean and free
of damage.
• Store the components in a cool, clean, dry room.
• After you have made sure that everything is present
and in good condition, keep the components in the
original package as long as possible.
Position of Components
The position and amount of components are determined
by the kind of control method chosen. All the control
methods can be found in Design Guide 310. Use the
schematics in the System Design section to build your
system.
Approval of Components
Limit Controls & Safety Equipment
All limit controls and safety equipment must comply with
all applicable local codes and/or standards and must be
listed for combustion safety by an independent testing
agency. Typical application examples include:
• American: NFPA 86 with listing marks from UL, FM,
CSA
• European: EN 746-2 with CE mark from TuV,
Gastec, Advantica
Electrical Wiring
All the electrical wiring must comply with all applicable
local codes and/or standards such as:
• NFPA Standard 70
• IEC60364
• CSA C22
• BS7671
Gas Piping
All the gas piping must comply with all applicable local
codes and/or standards such as:
• NFPA Standard 54
• ANSI Z223
• EN 746-2
Where to Get the Standards:
The NFPA Standards are available from:
National Fire Protection Agency
Batterymarch Park
Quincy, MA 02269
www.nfpa.org
The ANSI Standards are available from:
American National Standard Institute
1430 Broadway
New York, NY 10018
www.ansi.org
The UL Standards are available from:
333 Pfingsten Road
Northbrook, IL 60062
www.ul.com
The FM Standards are available from:
1151 Boston-Providence Turnpike
PO Box 9102
Norwood, MA 02062
www.fmglobal.com/approvals
Installation 3

7
Eclipse TFB, V2, Installation Guide 310, 11/14/2014
Information on the EN standards and where to get
them is available from:
Comité Européen de Normalisation
Stassartstraat 36
B-1050 Brussels
Phone: [phone]
Fax: [phone]
www.cen.eu
Comité Européen de Normalisation Electronique
Stassartstraat 36
B-1050 Brussels
Phone: [phone]
Fax: [phone]
www.cenelec.org
Checklist Before Installation
Intake
To admit fresh combustion air from outdoors, provide an
opening in the room of at least one square inch per 4,000
BTU/hr. If there are corrosive fumes or materials in the air,
then supply the burner with clean air from an
uncontaminated area.
Exhaust
Do not allow exhaust to accumulate in the work area.
Provide some positive means for exhausting them from
the furnace and the building.
Access
Make sure that you install the system in such a way that
the burners and components are easily accessible for
inspection and maintenance.
Environment
Make sure the local environment matches the original
operating specifications. Check the following items:
• Voltage, frequency and stability of the electrical
power
• Type and supply pressure of the fuel
• Availability of enough fresh, clean combustion air
• Humidity, altitude and temperature of air
• Presence of damaging corrosive gases in the air
Prepare the Burner
Burners are calibrated at the factory. However,
adjustments may be necessary for your particular
application. If re-calibration is required, follow the
instructions that follow:
Step 1: Adjust the Nozzle
Figure 3.1. Nozzle Adjustment
General Information
The distance between the end of the air tube and the end
of the nozzle, dimension A, is very important. If dimension
A is not correct, burners may not operate properly. Based
on the information provided in Table 3.1, Table 3.2, or
Table 3.3, verify that dimension A is correct for your
operating conditions. If adjustment is necessary, follow
the instructions on page 8, “Adjust the Nozzle”.
Find Dimension A
Dimension A is different for each fuel type, tube diameter
and burner size.
• For TFB030, use Table 3.1
• For TFB075, use Table 3.2
• For TFB200, use Table 3.3
Dimension A
Table 3.1 Dimension A Inches (mm) for TFB030
Fuel 50k-100k 101k-150k 151k-200k 201k-300k
Natural Gas 0.251 (6.4) 0.251 (6.4) 0.374 (9.5) 0.374 (9.5)
Propane 0.125 (3.2) 0.125 (3.2) 0.251 (6.4) 0.251 (6.4)
Butane 0.125 (3.2) 0.125 (3.2) 0.125 (3.2) 0.125 (3.2)

8Eclipse TFB, V2, Installation Guide 310, 11/14/2014
Adjust the Nozzle
NOTE: Place burner on a suitable working surface.
1. Remove the spark rod (3) or (3a) and flame rod (3) if
applicable.
2. Remove the four washers and bolts (1).
3. Pull the rear cover (2) far enough away from the
housing (4) to get access to the lock nut (5).
4. Loosen the lock nut (5).
5. Push the assembly back together.
6. Hold the rear cover (2) in position and screw the
nozzle in or out to adjust dimension A. See Figure 3.1.
7. Carefully pull the rear cover (2) and nozzle assembly
out of the housing (4).
Figure 3.2. Disassemble the Burner
Figure 3.3. Adjust the Nozzle
8. Turn the nozzle (6) over the shortest distance until the
opening (7) in the nozzle for the spark rod (3) aligns
with the appropriate opening in the rear cover (2).
9. Make sure that the nozzle (6) does not move and
tighten the lock nut (5).
10. Reinstall spark rod (3) or (3a) and flame rod (3) if
used.
Figure 3.4. Position the Spark Rod &
Flame Rod (if used)
Table 3.2 Dimension A Inches (mm) for TFB075
Fuel 301k-350k 351k-400k 401k-500k 501k-600k 601k-750k
Natural Gas 0.374 (9.5) 0.500 (12.7) 0.500 (12.7) 0.625 (15.9) 0.625 (15.9)
Propane 0.251 (6.4) 0.374 (9.5) 0.374 (9.5) 0.500 (12.7) 0.500 (12.7)
Butane 0.125 (3.2) 0.251 (6.4) 0.251 (6.4) 0.374 (9.5) 0.374 (9.5)
Table 3.3 Dimension A Inches (mm) for TFB200
Fuel 751k-800k 801k-900k 901k-1000k 1001k-
1100k
1101k-
1200k
1201k-
1300k
1301k-
1400k
Natural Gas 0.500 (12.7) 0.500 (12.7) 0.500 (12.7) 0.625 (15.9) 0.625 (15.9) 0.625 (15.9) 0.625 (15.9)
Propane 0.374 (9.5) 0.374 (9.5) 0.374 (9.5) 0.500 (12.7) 0.500 (12.7) 0.500 (12.7) 0.500 (12.7)
Butane 0.251 (6.4) 0.251 (6.4) 0.251 (6.4) 0.374 (9.5) 0.374 (9.5) 0.374 (9.5) 0.374 (9.5)
Fuel 1401k-
1500k
1501k-
1600k
1601k-
1700k
1701k-
1800k
1801k-
1900k
1901k-
2000k
Natural Gas 0.625 (15.9) 0.625 (15.9) 0.625 (15.9) 0.625 (15.9) 0.625 (15.9) 0.625 (15.9)
Propane 0.500 (12.7) 0.500 (12.7) 0.500 (12.7) 0.500 (12.7) 0.500 (12.7) 0.500 (12.7)
Butane 0.374 (9.5) 0.374 (9.5) 0.374 (9.5) 0.374 (9.5) 0.374 (9.5) 0.374 (9.5)
Spark rod location if
flame rod is used.


3a






5/8” (16 mm)


3a Spark rod location if
flame rod is used

9
Eclipse TFB, V2, Installation Guide 310, 11/14/2014
11. The disk end of the spark rod and flame rod should be
approximately 5/8" (16mm) past the face of the nozzle
(6).
12. The rods are adjustable at the threaded end of the
rod.
13. Tighten the compression nut on the rods after
positioning.
Figure 3.5. Assemble the Burner
14. Assemble the burner:
a. Install the rear cover (2) to the housing, (4) at the
relative position that you need to match the pipe
work.
b. Install the four washers and bolts (1).
15. Reconnect the piping.
Step 2: Install the UV Scanner (if required)
Figure 3.6. Position of the UV Scanner
■If combustion air is preheated, the UV scanner
must be protected from high temperatures. Install
the UV scanner with a heat block seal and supply
cooling air. See Bulletin 834.
1. Install the UV Scanner and, if necessary, the heat
block seal in the opening (2).
2. Make sure the UV scanner is connected to the
electrical circuit of that burner.
Flame monitoring controls that stop the spark as soon as
a signal is detected may prevent establishment of flame,
particularly when using UV scanners. The flame
monitoring control must maintain the spark for a fixed time
interval that is long enough for ignition
■Connecting the flame sensor of a burner to the
electrical circuit of the wrong burner can cause
fires and explosions.
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.
■Adjustments may vary from Eclipse published
values if the flame controls other than those
recommended in the Design Guide are used.
Consult with the engineer who specified the
alternate control for limitations.
Burner Installation
Figure 3.7. Install the Burner
Step 1: Install the Burner
Dimensions
For full information on the burner dimensions, refer to the
appropriate Datasheet: 310-1 (TFB030); 310-2 (TFB075);
310-3 (TFB200).
The burner will bolt to the tube flange. Align the air and
gas to accommodate accepted piping practices.



Flame Sensor;
UV Scanner

CAUTION
DANGER
NOTICE
Pipe
Union
10
Pipe
Ø
Integral Air
Orifice
Integral Gas
Orifice

10 Eclipse TFB, V2, Installation Guide 310, 11/14/2014
Straight Run of Pipe Before a Metering Orifice
NOTE: There must be a straight run of pipe at least 10
pipe diameters before the burner metering orifice. Failure
to provide this distance will result in inaccurate pressure
drop readings, and possibly poor burner performance.
Pipe Connections
• Install a pipe union in the line to each burner. This
simplifies removal of the burner.
• The use of flexible pipe nipples in the air and gas
lines to the burner is optional.
• Flexible pipe nipples may cause higher pressure
drops than equivalent standard pipes, an additional
consideration when sizing air lines.
Avoid Large Pressure Drops
NOTE: The pressure drop of the gas and the air in the
piping is a critical parameter. Ensure that the size of all the
piping is large enough to prevent excessive pressure
loses and that the number of elbows is kept to a minimum.
If using a recuperator, pressure drops increase with the air
temperature. For the effects of the temperature on the
pressure drop, refer to the Combustion Engineering Guide
(EFE 825).
Install the Recuperator
Figure 3.8. Install the Recuperator
In radiant tube applications, TFB burners can be used in
conjunction with an exhaust leg recuperator.
■Refer to the Moist PAK-D MSDS sheet for proper
PPE required when handling this product
• Insulate hot air piping and portion of recuperator
shown shaded in Figure 3.8 with “Moist PAK-D” by
Fiberfrax, Eclipse part #57325.
• DO NOT INSULATE THE BURNER.
• The use of flexible nipples in hot air piping is strongly
recommended to account for thermal expansion.
Step 2: Valve Installation
Valve Orientation
Install all the valves in such a way that the arrow (if
present) on the valve body points in the direction of flow.
Figure 3.9. Valve Orientation
Gas Cocks
Make sure that the handle of a gas cock is at a right angle
to the valve body when the valve is in the closed position.
This is an important position indicator. If you do not do this,
somebody may think that the gas cock is in the closed
position, while it is actually in the open position.
Gas Balancing Valves
A gas balancing valve is typically the same as a manual
butterfly valve. Refer to section below.
Manual Butterfly Valves
1. Install manual butterfly valves in accordance with
Bulletin/Info Guide 720.
2. Install manual butterfly valves in the gas line to the
burner (optional).
NOTE: It is recommended that there is a run of pipe with
a length of at least 10 pipe diameters between any flow
altering device and metering orifice on the burner.
Automatic Butterfly Valve
An automatic butterfly is driven by an actuator. Install the
control valve in accordance with Bulletin/Info Guide 720.
Ratio Regulator
• Connect an impulse line to the ratio regulator from
air supply line.
• Install the ratio regulator in accordance with Bulletin/
Info Guide 742.
Furnace
Wall
Exhaust
Ambient
Air
Gas Inlet
Hot
Air
TFB Burner
Recuperator
DANGER
Closed Open

11
Eclipse TFB, V2, Installation Guide 310, 11/14/2014
Figure 3.10. Valves
Step 3: Install the Flame Monitoring System
Refer to the System Schematic in Design Guide 310 for
the control methodology used. A detailed explanation of
components can be found in the appendix.
Checklist After Installation
To verify proper system installation, do the following:
1. Ensure that there are no leaks in the gas lines and the
air lines.
2. Ensure all the components of the flame monitoring
control system are properly installed. This includes
verifying that all switches are installed in correct
locations and all wiring, pressure and impulse lines
are properly connected.
3. Ensure components of spark ignition system are
installed and functioning properly.
4. Ensure that the blower rotates in the correct direction.
If incorrect, then have a qualified electrician rewire the
blower to reverse its rotation.
5. Ensure all valves are installed in proper location and
correctly oriented relative to the gas or air flow.
Prepare for Adjustment
After installation of the burner system components are
complete, the following steps should be followed in order
to prepare for adjustment:
1. Set the air pressure switch so that it drops out at 4"
w.c. (10 mbar) below the pressure rating of the blower.
2. Set the low gas pressure switch at 4" w.c. (10 mbar)
below the gas pressure measured at the inlet to the
main gas valve train.
3. Set the high gas pressure switch so that it comes on
at 4" w.c. (10 mbar) above the gas pressure
measured at the inlet to the main gas valve train.
4. Close all the burner gas cocks or pressure taps.
5. Try to light a burner before the purge and other timers
have finished their cycle. Make sure that the flame
monitoring system indicates a flame failure.
6. Trip out pressure switches and other limit interlocks.
Make sure that the main gas valve train closes.
■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.
Manual
Butterfly
Valve
Automatic
Butterfly
Valve Ratio Regulator
DANGER

Eclipse TFB, V2, Installation Guide 310, 11/14/2014
12
In this section you will find instructions on how to adjust a
system, and how to start and stop a system.
■Do not bypass any safety feature. You can cause
fires and explosions.
Adjustment Procedure
Step 1: Reset the System
Figure 4.1. Reset the System
1. Close the automatic gas valves and gas cocks.
2. Fully open the manual air butterfly valve at each
burner.
a. Drive the automatic zone air control valve to high
fire.
b. Adjust the automatic zone air control valve so that
it is fully open.
3. Start the blower.
■Make sure that the blower rotates in the correct
direction. If incorrect, have a qualified electrician
rewire the blower to reverse its rotation.
Step 2: Set High Fire Air
NOTE: The following steps apply to an ambient air
system with orifice plates installed.
1. Make sure that the system is at high fire.
2. Set high fire air.
Use the air curve of the datasheet for your particular
burner to find the air pressure differential that you need
at high fire. This is now your target value for high fire.
NOTE: A pressure tap is open when the screw inside
the tap is unscrewed approximately half a turn.
Figure 4.2. Set High Fire Air
a. Make sure that pressure tap A and pressure tap B
of the burner are open. (Open the internal screw
1/2 turn.)
b. Connect the manometer to tap A and tap B of the
burner (across the air orifice). Make sure that the
hose completely covers the side vents on pressure
tap.
c. Adjust the manual zone air butterfly valve until the
high fire air pressure differential is at the target
value. Make sure that the manual butterfly valves at
every burner are fully open.
d. Measure and note the air pressure differential for all
other burners in the zone.
e. If all the measured differential pressures are within
0.3" w.c. of each other, then proceed to the next
section. If the variation is greater than 0.3" w.c.,
then it will be necessary to adjust the manual air
butterfly valve at each burner to improve the
balance.
DANGER
NOTICE
Adjustment, Start &
Stop
4

13
Eclipse TFB, V2, Installation Guide 310, 11/14/2014
■Make sure that all the pressure taps are closed.
■Verify the required input levels. Firing at higher
levels will reduce tube life or even destroy tubes.
The following steps apply to a preheated air system
with recuperator, and with no orifice plates
installed:
1. Make sure the system is at high fire,
2. Set high fire.
Use ambient Static Pressure at the air inlet curve,
found in the data sheet, for your particular burner to find
the static air pressure that you need at high fire. This is
now your target value for high fire.
a. Make sure that pressure tap A of the first burner is
open.
b. Adjust the zone air manual butterfly valve until the
high fire air pressure is at the target value.
c. Measure and note the static air pressure for all
other burners in the zone.
d. If all the measured differential pressures are within
0.3" w.c. of each other, then proceed to the next
section. If the variation is greater than 0.3" w.c.,
then it will be necessary to adjust the manual air
butterfly valve at each burner to improve the
balance.
■Make sure that all the pressure taps are closed.
Step 3: Set Low Fire Air
The following steps apply to an ambient air system
with orifice plates installed:
1. Set the system to low fire.
2. Choose one burner in the zone. Connect the
manometer to tap A and tap B of the burner (across
the air orifice).
3. Adjust the automatic zone air control valve until the
low fire air pressure differential is 0.2" w.c. This is your
initial setting only. Further adjustment may be
required.
4. Repeat step 2 and 3 for the other zones (if any).
The following steps apply to a preheated air system
with recuperator, and with no orifice plates installed:
1. Set the system to low fire.
2. Choose one burner in the zone. Connect the
manometer to tap A.
3. Adjust the automatic zone air control valve until the
low fire static air pressure is:
• 0.05" w.c. for the TFB030
• 0.2" w.c. for the TFB075 and TFB200
4. This is your initial setting only. Further adjustment
may be required.
5. Repeat steps 2 and 3 for the other zones (if any).
Step 4: Verify the Air Settings
Make sure that all the settings are still the same after
cycling the system several times between high fire and
low fire.
Step 5: Ignite the Burners
Manual Ignition Steps:
Figure 4.3. Manual Gas Butterfly 50% Open
1. Drive the zone air automatic control valve to low fire.
2. Make sure the combustion blower is running.
3. Set the manual gas butterfly valve at each burner to
50% open.
Figure 4.4. Adjusting Set Screw
4. Set the adjusting screw (1) on the ratio regulator 6 full
rotations of 360° down from the top (initial setting).
CAUTION
CAUTION
Outer
Dial Set
Screw
50% Open
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14 Eclipse TFB, V2, Installation Guide 310, 11/14/2014
5. Open the zone manual gas cock.
6. Start ignition transformer.
■Do not touch the spark rod or the ignition wire
when the ignition is on. You will get a shock.
7. While viewing down the peepsight, open the gas cock
at burner. Burner should ignite.
8. If burner does not ignite within 15 seconds (verify with
local codes), close gas cock and purge with air.
Repeat steps 6 - 8 without any adjustment to ensure
all air is purged from the gas piping.
9. If burner still does not ignite adjust an additional turn
down on ratio regulator.
10. Repeat steps 6 - 9 if necessary.
11. Repeat steps 6 - 10 for all other burners in the zone.
Automatic Ignition Steps:
1. Drive the zone air automatic control valve to low fire.
2. Make sure the combustion air blower is running.
3. Set the manual gas butterfly valve at each burner to
50% open. See Figure 4.3.
4. Set the adjusting screw on the ratio regulator 6 full
rotations of 360° down from the top (initial setting).
5. Open the zone manual gas cock.
6. Open the manual gas cock at each burner.
7. Initiate the ignition sequence through the flame
monitoring system.
8. Check that all the burners in the zone have ignited.
• If a gas solenoid valve is fitted at each burner, then
repeat step 7 for all burners in the zone.
• If burners do not light, purge with air and adjust an
additional turn down on the ratio regulator. Repeat
step 7.
NOTE: Initially it may be necessary to repeat step 7
two or three times to purge all the air out of the gas
pipework.
9. If all the burners have ignited, then drive the zone air
butterfly valve to high fire. Make sure that the burners
stay ignited.
Step 6: Set High Fire Gas
1. Use the gas curves on the appropriate datasheet to
find the gas pressure differential needed at high fire.
This is the target value for high fire.
NOTE: A pressure tap is open when the screw inside
the tap is unscrewed approximately half a turn.
Figure 4.5. Set High Fire Gas
2. Make sure that pressure tap C and pressure tap D of
the burner are open (open the internal screw 1/2 turn).
3. Connect the manometer to tap C and tap D of the
burner (across the gas orifice).
4. Measure the high fire gas pressure drop for the first
burner.
5. Adjust the manual gas butterfly valve at the burner
until the gas flow is at the target value.
6. Repeat step 4 and step 5 for the other burners in the
zone (if any).
7. Check the gas pressure at the inlet to the zone ratio
regulator. This should be at least 5" w.c. higher than
the loading line pressure. It should not exceed the
maximum pressure rating of the ratio regulator.
8. Measure the oxygen level in the exhaust, using an
oxygen analyzer.
9. If the O2level is between 2.5% and 4%, the level is
correct. If not, adjust the manual gas butterfly valve
until you have the appropriate level.
10. Repeat steps 2 through step 9 for the other burners.
11. For each burner, connect the manometer across
pressure taps C and D and measure the pressure
drop.
• If all pressure drops are at or below the target value,
then the settings are correct.
• If necessary, adjust the manual zone air butterfly
valve to obtain the target value.
12. Verify settings when the furnace is at operating
temperature.
■Make sure that all the pressure taps are closed.
DANGER
CAUTION

15
Eclipse TFB, V2, Installation Guide 310, 11/14/2014
Step 7: Verify the Gas Settings
1. Make sure that all the settings are still the same after
you cycle the system several times between high fire
and low fire.
2. When all settings have been completed, mark the
position of the indicator on each butterfly valve to
indicate valve position. This will save time later.
■Make sure that you close all the pressure taps after
you remove the manometer. Gas that leaks from
the pressure taps can cause fires and explosions.
Step 8: Adjust Low Fire
1. Drive the system to low fire.
2. If a burner goes out, close gas cocks. Go to Step 5
“Ignite the Burners” on page 13, and follow
instructions.
3. Adjust the ratio regulator until the O2level is between
10% and 14%.
If the oxygen levels are between 10% and 14%, but
the temperature continues to rise above the
desired level:
4. Reduce low fire air flow by adjusting the zone air
control valve linkage. Recheck oxygen levels at low
and high fire.
5. If necessary, repeat step 3.
Start Procedure
■If a burner does not light, and the system does not
shut down automatically, then you must close the
main gas cock. An uncontrolled flow of gas can
cause fires and explosions.
■Do not touch the spark rod or the ignition wire
when the ignition is on. You will get a shock.
Manual Ignition
1. Make sure the gas cock at each burner is closed.
2. Start air blower.
3. Drive the automatic zone air control valve to low fire.
4. Start ignition transformers.
5. Open the gas cock at each burner checking to ensure
that the burner lights.
Automatic Ignition
1. Start the blower.
2. Open all the gas cocks.
3. Start the ignition sequence.
4. Verify that flame is present at each burner.
If a burner does not light and:
• The system does not shut down automatically:
Close the main gas cock manually. Do NOT operate
the system. Go to "Checklist After Installation" on
page 11. Repeat the start procedure.
• The system shuts down automatically:
See “Troubleshooting” on page 17.
Stop Procedure
1. Close the following valves:
• The manual gas cock at the main control valve
• The manual gas cock for each burner or zone
2. Let the burners cool down. Keep the blower on until
the chamber temperature is less than 1000°F (500°C)
and then stop the blower.
■Keeping the blower on after the burner is off
protects the burner and the other components
from hot gases that flow back through the burner.
Static Air Pressures
When a burner uses preheated combustion air, there are
no air orifices installed. In that case, the static air pressure
is used to set the initial air flow of a burner. From there on
the burner is further adjusted.
DANGER
DANGER
NOTICE

Eclipse TFB, V2, Installation Guide 310, 11/14/2014 16
This chapter is divided into two sections:
• Maintenance procedures
• Troubleshooting guide
Maintenance
Preventive maintenance is the key to a reliable, safe and
efficient system. The core of any preventive maintenance
system is a list of periodic tasks.
The following are suggestions for a monthly list and a
yearly list.
NOTE: The monthly list and yearly lists are an average
interval. If the environment is dirty, the intervals may be
shorter.
Monthly Checklist
1. Inspect flame sensing devices for good conditions,
and cleanliness.
2. Check for proper inlet air/gas ratios.
3. Test all the alarm systems for proper signals.
4. Check spark rod for damage or distortion.
5. Check valve motors and control valves for free,
smooth action and adjustment.
6. Measure and record the high fire oxygen levels in the
exhaust every month. If there is any change, find the
cause and correct it.
7. View down the peepsights on the burners and down
the exhaust legs of the tubes to check for unusual
flame or carbon build-up. If necessary, remove the
burner to investigate.
Yearly Checklist
1. Test interlock sequence of all safety equipment.
Manually make each interlock fail, noting that related
equipment closes or stops as specified by the
manufacturer.
2. Test (leak test) safety shut-off valves for tightness of
closure.
3. Test main fuel hand valves for operation.
4. Test pressure switch settings by checking switch
movements against pressure settings and comparing
with actual impulse pressure.
5. Visually check ignition cable and connectors.
6. Inspect impulse piping for leaks.
7. Remove and inspect all the burners. Clean off any
carbon build up.
8. Make sure that the following components are not
damaged or distorted.
• The burner nozzle
• The spark rods
• The flame tube
If applicable, remove and clean all the orifice plates.
Maintenance &
Troubleshooting
5

17 Eclipse TFB, V2, Installation Guide 310, 11/14/2014
Troubleshooting Procedures
Problem Possible Cause Solution
Start-up sequence runs but does not
light, no ignition
There is no power to the ignition
transformer.
Restore the power to the ignition
transformer.
Open circuit between the ignition
transformer and the spark rod.
Repair or replace the wiring to the
spark rod.
The spark rod needs cleaning. Clean the spark rod.
The spark rod is not correctly grounded
to the burner.
Clean the threads of the spark rod and
the burner. Do not use pipe sealant on
ignition plug threads.
The spark rod is grounded to the
nozzle or the air shroud.
Check the spark rod position.
The spark rod and flame rod wiring is
reversed.
Correct wiring.
Start-up sequence runs but does not
light, not enough gas
There is air in the gas line. Repeat the start attempt several times.
The gas pressure into the ratio
regulator is too low.
Measure the gas pressure into the ratio
regulator and adjust gas pressure if
necessary. (See “Adjustment, Start &
Stop” section)
The impulse line to the ratio regulator is
leaking.
Repair any leaks.
Start gas solenoid valve does not open
(if fitted).
Check wiring to the valve. Check
output from the flame safeguard.
Check solenoid valve coil for proper
operation. Replace if necessary.
Manual gas valve closed. Open the gas valve.
Manual gas cock not open. Open the manual gas cock.
Start-up sequence runs but does not
light, too much gas
Gas pressure out of ratio regulator is
too high.
Check adjustments. If necessary,
remove regulator and investigate.
Start-up sequence runs but does not
light, poor ignition
Incorrect type of flame safety, must
have ignition during all the trial for
ignition.
Change flame monitoring equipment.
Wrong type of ignition transformer. Use correct type.
Start-up sequence runs but does not
light
Improper air/gas settings. Check pressure and settings and
adjust as necessary.
Start-up sequence runs but does not
light, insufficient flame signal
Flame rod or UV scanner needs
cleaning.
Clean the flame rod or UV scanner
lens.
Flame rod is grounded to nozzle. Adjust position so ceramic insulation
contacts nozzle.
Flame rod and spark rod reversed. Reposition spark rod or flame rod.
Start-up sequence runs but does not
light, improper air/gas ratio
Air in the gas line. Repeat start-up several times.
Ratio regulator incorrectly set. Adjust to proper setting.
The low fire flame is weak or unstable Not enough gas. Readjust gas flow at ratio regulator.
Not enough air. Open automatic valve slightly.

18
Eclipse TFB, V2, Installation Guide 310, 11/14/2014
The burner does not light or goes off
when it cycles to high fire
Burner set too lean, becoming unstable
as air increases.
Adjust the settings to provide more
gas.
Insufficient pressure into ratio
regulator.
Adjust the pressure settings on the
main gas regulator or change spring.
Main gas adjustment valve not open
enough.
Adjust the main gas adjustment valve.
Marginal air pressure switch setting. Adjust the air pressure switch setting
Gas pressure switch set incorrectly. Adjust switch setting.
The burner is erratic and does not
respond to adjustment
Internal damage to the burner, some
parts inside the burner are loose, dirty
or burned out.
Contact Eclipse.
The burner is unstable and produces
soot, smoke or excessive carbon
monoxide
The air/gas ratio is out of adjustment. Reset the burner controls and clean
ignition rod and UV scanner.* See
“Adjustment, Start & Stop” section.
Bleed fitting (if used) is dirty. Clean fitting. Check and clean filters,
spark rod and UV scanner.* (If
necessary).
* After this step it is important that you clean the spark rod and UV scanner, and
make sure that there is no excessive soot on the nozzle. Clean where
necessary.
Burner pulsates or produces noise Acoustic feedback from tube. Slide a piece of steel plate over the end
of the tube until the rumbling
disappears. Weld the plate in place.
Readjust the burner controls if
necessary.
Input inconsistent with nozzle settings. Check if input is consistent with nozzle
settings and adjust if necessary.
Too much air. Check oxygen levels and adjust to 2%
to 4% O2(at high fire).
Burner could be improperly set to fire at
an input rate which exceeds its
maximum rated capacity.
Check the pressure drops to verify that
the inputs are at the correct levels.
Reduce the input on the air and gas as
required to achieve the specified
inputs.
Negative pressure in the building. In some cases, building exhaust
systems create a negative pressure
that “pulls” on the exhaust outlet of the
tube. By placing a washer or restriction
pate over the tube outlet, this suction
can be equalized by burner pressure.
Problem Possible Cause Solution

19 Eclipse TFB, V2, Installation Guide 310, 11/14/2014
Cannot achieve full capacity Combustion air inlet filter is blocked. Clean the filter.
Gas pressure too low into the ratio
regulator.
Adjust gas pressure.
Loading line pressure too low. Open the zone air control valve to
increase the air volume and pressure.
Recheck all burner settings.
Adjusting valve has closed. Open the valve to previous setting and
check the input and flue gas settings to
verify proper operations.
Blower is wired incorrectly. A blower wired to turn backwards will
produce approximately 60% of its rated
capacity. Check the rotation of the
blower impeller. If spinning backwards,
have a qualified electrician reverse the
electrical wiring.
Cannot initiate start sequence Air pressure switch has not made
contact.
Check air pressure switch adjustment.
Check air filter. Check blower rotation.
Check outlet pressure from blower.
High gas pressure switch has tripped. Check incoming gas pressure. Adjust
gas pressure if necessary. Check
pressure switch setting and operation.
Low gas pressure switch has tripped. Check incoming gas pressure. Adjust
gas pressure if necessary. Check
pressure switch setting and operation.
Malfunction of flame monitoring
system such as shorted out flame
sensor or electrical noise in the sensor
line.
Have a qualified electrician investigate
and rectify.
Purge cycle not completed. Check flame safeguard system, or
purge timer.
Main power is off. Make sure power is on to control
system.
No power to control unit. Have a qualified electrician investigate
and rectify.
Problem Possible Cause Solution

i
Conversion Factors
Metric to English
Metric to Metric
English to Metric
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
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
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
Appendix