Elster Eclipse Linnox Tee ULE User manual

Eclipse Linnox Burners
Models Straight ULE and Tee ULE
Version 1
Operating Instructions Edition 6.15

2
Copyright
Copyright 2011 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

Table of Contents
3Linnox, V1, Operating Instructions, Edition 6.15
1 Introduction............................................................................................................................ 4
Product Description .............................................................................................................. 4
Audience .............................................................................................................................. 4
Purpose................................................................................................................................ 4
Linnox Straight ULE and Tee ULE Documents .................................................................... 4
Related Documents.............................................................................................................. 4
2 Safety...................................................................................................................................... 6
Introduction .......................................................................................................................... 6
Safety Warnings................................................................................................................... 6
Capabilities........................................................................................................................... 6
Operator Training ................................................................................................................. 6
Replacement Parts...............................................................................................................6
3 Installation.............................................................................................................................. 7
Introduction .......................................................................................................................... 6
Handling ............................................................................................................................... 6
Storage................................................................................................................................. 6
Position of Components ....................................................................................................... 6
Approval of Components...................................................................................................... 6
Checklist Before Installation ................................................................................................. 7
General Installation Conditions ............................................................................................ 7
Burner Mounting................................................................................................................... 7
Flame Sensor Installation..................................................................................................... 7
Gas Piping............................................................................................................................ 7
Air Piping .............................................................................................................................. 10
Electrical Supply................................................................................................................... 10
Profile Plates ........................................................................................................................ 10
Burner Support..................................................................................................................... 10
Checklist After Installation....................................................................................................10
4 Adjustment, Start and Stop .................................................................................................. 12
Introduction .......................................................................................................................... 12
Checklist Before Burner Start-Up ......................................................................................... 12
Adjustment Procedure.......................................................................................................... 13
Start Procedure .................................................................................................................... 14
Stop Procedure .................................................................................................................... 17
5 Maintenance and Troubleshooting ...................................................................................... 18
Introduction .......................................................................................................................... 18
Maintenance......................................................................................................................... 18
Troubleshooting.................................................................................................................... 20
Appendix ................................................................................................................................... i
Notes.......................................................................................................................................... ii

4Linnox, V1, Operating Instructions, Edition 6.15

5Linnox, V1, Operating Instructions, Edition 6.15

Introduction
4Linnox, V1, Operating Instructions, Edition 6.15
Product Description
The Linnox is a line model burner designed for
applications where a maximum linear heat distribution is
required.
The Linnox burner is a pre-mix type burner, designed for
direct-air heating applications where the lowest
achievable NOxand CO levels are required.
Linnox combustion is based on high excess air, pre-mix
combustion to keep the flame temperatures low. At the
same time, the burner geometry establishes an internal
recirculating flame pattern. These two factors result in
ultra low NOxand CO emissions across the turndown
range while maintaining extremely stable combustion.
This burner can be easily configured for many different
capacities by choosing from a wide range of burner
modules each 300 mm in length.
The Linnox is designed to provide:
• Reliable operation
• Simple adjustments
• Efficient ratio controlled combustion
• Burner modules varying from 90 to 2700 kBtu/h
(26 to 791 kW per 300 mm).
Purpose
The purpose of this manual is to ensure a safe, effective
and trouble-free installation.
Figure 1.1 Linnox Straight ULE Burner
Figure 1.2 Linnox Tee ULE Burner
Audience
This manual has been written for personnel already
familiar with all aspects of pre-mix burners.
These aspects include:
• Installation
• Use
• Maintenance
• Safety
The audience is expected to be qualified and have
experience with this type of equipment and its working
environment.
Linnox Straight ULE and Tee ULE
Documents
Design Guide 159
• Used with Datasheets to design the burner system
Datasheet Series 159
• Required to complete design and selection
Installation Guide 159
• This document
Worksheet 159
• Required to provide application information to
Eclipse Engineering
Spare Parts List Series 159
• Recommended replacement part information
Related Documents
• EFE 825 (Combustion Engineering Guide)
• Eclipse Bulletins and Information Guides: 610, 710,
720, 730, 742, 744, 760, 930
1

Safety
5
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

Installation
6Linnox, V1, Operating Instructions, Edition 6.15
Introduction
This section provides guidance for correct installation of
Eclipse Linnox burners.
NOTE: Information in Datasheet Series 159 may be
necessary to complete some of the installation
procedures.
■Only qualified, competent personnel with
combustion system experience are allowed to
install, adjust and maintain the burner.
■All installation work must be carried out in
compliance with jurisdictional codes.
Handling
• Inspect the burner and its components ensuring that
all components are clean and free of damage.
• Use the appropriate support equipment when lifting
the burner and its components.
• Protect the burner and its components from the
weather, damage, dirt and moisture.
Storage
• Make sure the burner and its components are clean
and free of damage.
• Store the burner and its components in a cool,
clean, dry room.
• After you have made sure 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 three factors: burner design, system design and
chosen control method. All three factors are considered in
“System Design” chapter of the Linnox Design Guide 159.
Use the information in that chapter 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 electrical wiring must comply with all applicable local
codes and/or standards such as:
• NFPA Standard 70
• IEC60364
• CSA C22
• BS7671
Piping
All gas piping must comply with all applicable local codes
and/or standards such as:
• NFPA Standard 54
• ANSI Z223
• EN 746-2
The gas piping must meet jurisdictional codes.
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
WARNING
3

7Linnox, V1, Operating Instructions, Edition 6.15
The FM Standards are available from:
1151 Boston-Providence Turnpike
PO Box 9102
Norwood, MA 02062
www.fmglobal.com/approvals
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
Air Supply
To admit fresh combustion air from outdoors, provide an
opening in the room of at least one square inch per 4,000
Btu/h (6 cm2per 1 kW). If there are corrosive fumes or
materials in the air, supply the burner with clean air from
an uncontaminated area, and always provide a sufficient
air filtering system.
Exhaust
Do not allow exhaust fumes to accumulate in the work
area. Provide some positive means for exhausting fumes
from the furnace and the building.
Access
Make sure to install the burners in such a way that you can
gain easy access for inspection and maintenance.
Environment
Make sure the burner operating 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
• Adequate oxygen concentration for combustion on
the process gases
• Humidity, altitude and temperature of the air
• Presence of damaging corrosive gases in the air
• Prevent direct exposure to water
General Installation Conditions
Perform the following audits before installing the burner:
• Remove all dirt, dust, and other particles from inside
the burner air/gas piping, and avoid further soiling
during piping and accessory installation.
• Check that there are no obstructions in the burner
duct or in the supply piping connections.
Electrical
Install the high-voltage ignition transformer (as applicable)
as close to the burner as possible.
Burner Mounting
Make sure the chamber wall is strong enough to support
the weight of the burner. If necessary, reinforce the
mounting area.
Mount burner to process duct using customer supplied
bolts, nuts, and lockwashers.
The burner mounting plate is provided with:
• a peep sight for pilot flame observation
• a pressure tap for measuring process pressure
• a pipe nipple to mount the UV scanner and the UV
scanner cooling air connection
• or without an insulation box (refer to assembly
drawing)
Flame Sensor Installation
Install the UV scanner onto the 3/4” NPT pipe nipple
extending from the outside of the burner mounting plate.
The UV scanner must be connected to the flame safety for
that burner. Cooling air piping must be supplied to the tee
connection located between the UV scanner and the
mounting plate.
■The burner flame shields can reach a temperature
of 1650°F (900°C) at 480°F (250°C) process
temperature upstream from the burner.
Measurements should be taken to prevent
excessive thermal load on the process ducting.
Gas Piping
Care should be taken to ensure that the incoming gas pipe
is adequately sized for the necessary gas flow and burner
pressure (See Datasheets 159-1 and 159-2 for gas
pressure requirements).
Gas piping not supplied with the burner must be
supported independently of the burner.
CAUTION

8Linnox, V1, Operating Instructions, Edition 6.15
Figure 3.1. 8:1 Ratio Regulators Impulse Line Piping
Figure 3.2. 10:1 Ratio Regulators Impulse Line Piping

9Linnox, V1, Operating Instructions, Edition 6.15
■Gas inlet pressures must stay within the specified
range. Pressure above the specificed range can
damage the ratio regulator.
■Pressure below the specified gas inlet pressure
range can impair the ability of the ratio regulator to
control the gas flow.
Air Piping
Combustion air piping between the blower and the burner
air connection point must be supported independently of
the burner.
Electrical Supply
The burner must be controlled via a sequence
programmer, approved according to jurisdictional codes.
■Wiring to the burner must be in accordance with
jurisdictional wiring standards. It is vital that the
live and neutral wires are connected correctly as
reversal could present a hazard. Also the
grounding must be checked to ensure a good
connection. (Wiring diagrams are provided only
for a burner system that incorporates an Eclipse
furnished control panel.)
■GAS PIPEWORK MUST NOT BE USED FOR
GROUNDING PURPOSES.
■If burner control signals are supplied via a flame
safeguard control panel provided by others,
Eclipse Combustion shall not accept any
responsibility for incorrect interfacing.
Profile Plates
Profile plates need to be installed to obtain the proper
process air axial velocity as specified in Datasheets
159-1 and 159-2. See Figure 3.4 for suggested profile
plate locations. Profile plates must be supported
independently from the burner.
Burner Support
Burners with rows over four feet long must be supported,
but not constrained, on the manifold at the end opposite
the pilot in order to prevent excessive stress caused by
thermal expansion. Reference Figure 3.3 for manifold
support location.
Figure 3.3.
WARNING NOTICE

10Linnox, V1, Operating Instructions, Edition 6.15
Checklist After Installation
To verify proper system installation, perform the following
audits:
1. Make sure there are no leaks in the gas piping or the
air piping.
2. Make sure all the components of the flame monitoring
system and the control system are properly installed.
This includes making sure that all the switches are
installed in the correct locations and that all the wiring,
pressure lines, and impulse lines are properly
connected.
3. Make sure all interlocks and safety components are
installed and working properly.
4. Make sure the required air and gas pressures are
available. Verify that the blower wheel rotation is
correct. If it is incorrect, have a qualified electrician
rewire the blower to reverse its rotation.
5. Make sure all components of the spark ignition system
are installed and functioning properly.
6. Make sure the burner control system operates under
interrupted pilot timing; i.e. the controller should shut
the pilot off after the trial for ignition period.
Figure 3.4. Suggested profile plate locations
Profile Plate
Profile Plate
Side View
Front View
1/2”
gap

12Linnox, V1, Operating Instructions, Edition 6.15
Adjustment, Start
and Stop
Introduction
In this chapter you will find instructions on how to adjust,
start and stop a Linnox burner.
■The burners covered by this guide are designed to
burn a mixture of gas and air. All gas burning
devices are capable of producing fires and
explosions if improperly applied, installed,
adjusted, controlled or maintained.
■Do not bypass any safety feature. This can cause
fires and explosions.
■Obey the safety precautions in the “Safety”
chapter of this document, and read this chapter
thoroughly before starting your system.
■Never try to light a burner if it shows signs of
damage or malfunction.
NOTE: Adjustment requires two guides: Installation Guide
159 and Datasheet 159. This chapter refers to the
component information explained in Design Guide 159.
Checklist Before Burner Start-up
Preliminary Installation Checks
• Verify that the process control setpoints are correct.
• Check that the main control panel switch is ON.
• Verify that the process air and combustion air
blowers are operating correctly.
• Confirm that the burner, the system interlocks, the
customer interlocks, and the safeties are in working
order.
• Open the main manual gas supply valve.
• Verify that the main gas inlet pressure is correct.
Preparation
1. Ensure all installation work has been completed in
compliance with jurisdictional codes.
2. Ensure all gas supply pipework has been purged of air
in compliance with jurisdictional codes.
3. Ensure all required utilities are available.
4. Ensure all pre-checks have been completed in
compliance with jurisdictional codes.
5. Ensure a digital or “U”-tube manometer for pressure
measurement is available.
6. Set the low gas pressure switch to 20% below the
lowest pressure given in the "Main Gas Inlet Pressure"
range specified in DataSheet 159.
7. Set the high gas pressure switch to 20% above the
highest pressure given in the "Main Gas Inlet Pressure"
range specified in DataSheet 159.
8. Verify the location of the pilot tube with respect to the
end shield prior to installing the burner. Reference
Figure 4.1 for proper pilot location.
DANGER
4

13Linnox, V1, Operating Instructions, Edition 6.15
Figure 4.1. Pilot Location - All dimensions shown in inches (mm)
NOTE: Eclipse authorized personnel should perform the
initial start of all Eclipse burners.
Adjustment Procedure
Become familiar with burner methods before attempting to
make adjustments.
Follow these steps to adjust the Linnox system for the first
time:
Step 1: Dry Run
1. Ensure that the process air blower is running.
2. Close all the manual and automatic gas valves.
3. Initiate the electrical supply to start the operating
sequence. The combustion air blower will start running.
If the sequence is operating correctly, the system will
run through to the point of ignition, the safety shut-off
valves will open and, in absence of a flame, the system
will proceed to a lockout condition.
■If simulated limits or simulated flame failure do not
shut down the fuel system within the required
response time, immediately correct the problem
before proceeding.
Step 2: Combustion Air Check
NOTE: On multiple burner systems with a central
combustion air blower, one should remember that the
combustion air pressure will change depending on the
total air demand. If one burner is adjusted, it is advised to
set the combustion air of all other burners to at least 50%
of the maximum capacity if the burners are not in
operation. This will prevent flame failures or inability to
reach the high-fire capacity when the installation is
switched to normal operation.
NOTE: Start all process air blowers that affect chamber
pressure.
0.39
(10.0)
Pilot
Location
Duct Spacing
Duct Spacing
7.9 (200)
11.8 (300)
15.8 (400)
19.7 (500)
23.6 (600)
27.6 (700)
31.5 (800)
35.4 (900)
39.4 (1000)
Pilot Location
7.4 (188)
3.5 (88)
7.4 (188)
3.5 (88)
7.4 (188)
3.5 (88)
7.4 (188)
3.5 (88)
7.4 (188)
DANGER

14Linnox, V1, Operating Instructions, Edition 6.15
Low-Fire and High-Fire Air Adjustment
Procedure:
1. Start the combustion air blower.
2. Drive control motor to low-fire position (activate the
manual switch or lock first).
3. Measure air differential pressure (Tap A to Tap D).
4. Adjust low-fire air if necessary.
NOTE: The slot at the end of the BV (air damper) shaft
indicates the position of the BV. The BV is closed when
the shaft slot is perpendicular to the direction of air flow
through the BV. For adjustment of the BV, adjust the lever
mechanism.
5. Verify ignition position
a.Drive the combustion air control valve to ignition
position, 30% open.
b.Adjust air pressure if necessary.
6. Verify high-fire air
a.Drive combustion air control valve to high fire, fully
open.
b.Adjust high fire air if necessary.
7. Return the combustion air control valve to low-fire
position.
8. Close the pressure taps
Start Procedure
Step 3: StartUp Procedure
NOTE: The maximum gas pressure allowed at the inlet of
the adjustable port pilot gas cock is 1/2 psig. Do not
exceed this pressure.
1. Check the pre-setting of the adjustment valves.
2. Switch the combustion air control valve to “automatic”.
3. Open all gas manual isolating ball valves.
4. Initiate the burner management system to start the
operating sequence. The combustion air control valve
will be driven to the start position after which the ignition
will take place.
The pilot flame should be approximately 1 - 2 inches
(25 - 51 mm) long and be contained within the flame
shields in a mixed blue and yellow color. If the flame is too
weak or too big, adjust the pilot flame to the pressures
indicated in Datasheets 159-1 and 159-2. Adjustment of
the adjustable port pilot gas cock is outlined in Figure 4.2.
Pilot flame appearance also depends on the start position
of the combustion air control valve and process air
conditions.
Figure 4.2. Adjustable Port Pilot Gas Cock
After the trial for ignition period determined by local
regulations, the safety shut-off valves will open, and the
main flame will ignite. A clear blue line flame will appear
at the burner base. The appearance will vary for the
different capacity ratings of the burner elements.
If the burner does not light the first time, it will be
necessary to reset the sequence and follow the start
procedure again.
5. If the burner did not ignite after several attempts:
a.Verify that the air has been purged from the main and
pilot gas piping.
b.If the pilot flame does not appear, adjust the gas and
air pressures to the values listed in the datasheet.
c.If the flame appears at ignition, but the main burner
does not light, turn the bias adjusting screw of the gas
ratio regulator one turn clockwise to increase gas flow
and try to ignite the burner again.
d.Repeat steps b and c several times until the burner
ignites. If the burner does not ignite, follow the
guidelines in Section 7 of this document,
“Maintenance and Troubleshooting”.
Top Screw
Handle
(Shown in
Open Position)
Adjusting Screw
(Clockwise for less pilot gas,
Counterclockwise for more pilot gas)

15Linnox, V1, Operating Instructions, Edition 6.15
Low-Fire Settings
6. Set the system control to stay at low fire during and
after the ignition sequence, or set the control motor to
manual.
Ensure the combustion air control valve stops at low fire.
7. Adjust ratio regulator bias adjustment for lowest gas
flow that maintains a stable flame signal:
- clockwise for more fuel
- counterclockwise for less fuel
Ensure that the lowest flame signals are stable.
At low fire the gas differential pressure across the mixer
will be too low, for a reliable reading.
Eventually, the static gas pressure at the mixer can be
used as a pre-setting for the burner.
NOTE: A visual check of the flame is important to ensure
the correct burner adjustment.
NOTE: If the recirculating process air is cold, < 212°F
(100°C), the burner elements will not glow or will partially
glow.
NOTE: If the recirculating process air is hot, > 390°F
(200°C), the burner elements will glow.
NOTE: The visual appearance of the low-fire flame should
be clear blue with some of the burner elements glowing.
Figure 4.3. Low Fire Flame Appearance
Lambda 1.8
Lambda 1.8 Lambda 1.4 Lambda 1.1
Lambda 1.4 Lambda 1.1

16Linnox, V1, Operating Instructions, Edition 6.15
When operating at high fire, if the flame becomes too rich,
carefully close the manual gas adjustment valve until the
flame starts blowing off. Open the valve again to pull the
flame back in. The flame should look like the center image
in Figure 4.3. The flame shields may be slightly red and
the flame may extend beyond these shields.
High-Fire Settings
8. Set the burner to high fire:
a. Check the differential air pressure against the values
given in Datasheets 159-1 and 159-2.
b. Adjust the corresponding gas pressure with the
adjustment butterfly valve.
Fasten the lock screw, by tightening gently, at the
adjustment butterfly valve after finishing adjustment.
NOTE: A visual check of the flame is important to ensure
the correct burner adjustment. The flame will be sharp
blue-white with a slightly orange glowing tip. The length of
this tip depends on the burner capacity rating.
NOTE: If the flame tip is dominantly orange, the burner
may be set too gas rich. Refer to the “Troubleshooting”
section of this document.
NOTE: The burner flame shields are allowed to glow red
hot depending on the burner capacity rating and the
process temperatures.
9. If the setting of adjustment valve has been changed,
repeat Steps 6 and 7 to check and readjust the low-fire
setting.
Figure 4.4. High Fire Flame Appearance
A flame that is too lean (Lambda > 1.4) will produce too
much CO and have a fluctuating flame signal. A rich flame
(Lambda < 1.4) will create too much NOx and burner parts
will overheat
■Adjusting the burner too gas rich will shorten the
lifetime of the burner elements and flame shields.
Therefore, have a qualified Eclipse engineer adjust
and regularly check the burner settings.
Step 4: Operation Inspections
1. Simulate a flame-out condition by closing the manual
inlet ball valve. Run the ignition cycle again.
2. Have a qualified technician check high gas pressure
switch for correct operation.
3. Have a qualified technician check the combustion air
pressure switch for correct operation.
4. Measure and record the gas and air differential
pressure and flame signal at low and high fire for future
reference.
■If simulated limits or simulated flame failures do
not shut down the fuel system within the required
response time, immediately correct the problem
before proceeding.
Lambda 1.8 Lambda 1.4 Lambda 1.1
CAUTION
DANGER

17Linnox, V1, Operating Instructions, Edition 6.15
■Do not turn the combustion air blower off until the
chamber temperature is below 250°F (120°C). This
will prevent hot gases from flowing back through
the burner, which would cause damage to the
burner.
Stop Procedure
1. Shut off the load, or the control system demand switch
to initiate shutdown.
2. Shut off main and pilot manual gas supply valves.
3. Drive combustion air valve to high-fire position.
4. Leave the combustion air at high fire until the
combustion chamber is cooled to under 250°F (120°C);
once cooled, shut off the combustion air fan. Higher
shutdown temperatures may be allowed depending on
the system design. Consult Eclipse for more
information.
5. Shut down all manual valves as required.
All initial settings shall be documented in a proper manner
and kept as the initial commissioning data for future
reference.
CAUTION

Maintenance and
Troubleshooting
18Linnox, V1, Operating Instructions, Edition 6.15
Introduction
This section is divided into two parts. The first part
describes the maintenance procedures. The second part
identifies problems that may occur and gives advice on
how to solve these problems.
Maintenance
Preventative maintenance is the key to a reliable, safe
and efficient system. The following are suggested
guidelines for periodic maintenance. Burners in severe
environments or operational conditions should be
checked more frequently.
NOTE: The monthly and yearly lists are an average
interval. If your environment is dirty, the intervals may be
shorter. Check with the local authorities that have
jurisdiction over recommended maintenance schedules.
■Turn off power to burner and controls before
proceeding with burner inspection.
■Turn off the main gas supply.
One Month after Startup
1. Check and compare burner adjustments with the
original recorded settings. Correct the settings if they
are outside the specified tolerance range.
2. Check and clean or replace the gas filter if necessary.
3. Check all gas piping and connections for leakage.
Leaks must be repaired immediately.
4. Check tightness of all bolted/screwed joints.
5. Check burner and mixer unit for leakage, damage or
deterioration. Those parts in contact with the process
environment, must be inspected thoroughly.
6. Check the flame shields, burner elements and all joints
for wear and damage.
7. Check if the burner module fastening nuts are tight.
8. Check the burner surroundings for signs of excessive
corrosion or deformation due to thermal overload or
moisture. Repair or replace insulation or thermal
protection shields if necessary.
Every Three Months
1. Visually check all components for damage.
2. Check manual shut-off valve for correct operation.
3. Visually check all cables and connectors for damage
and tightness.
4. Visually check the condition of the blower inlet filter;
replace if necessary.
Every Six Months
1. Check burner and mixer unit for leakage, damage or
deterioration. Those parts in contact with the process
environment must be inspected thoroughly.
2. Check the flame shields, burner elements and all joints
for wear and damage.
3. Check if the burner element fastening nuts are tight.
4. Check and clean or replace the igniter.
5. Check the flame quality, verifying both visually and via
the air-fuel ratio that the flame is neither too lean or too
rich.
It is important that the flame at low fire is stable and
doesn’t blow off, which happens when the mixture is too
lean (has too much excess air).
If the mixture is too rich (not enough excess air), the parts
in the burner modules will begin to glow immediately and
possibly overheat. Simultaneously, the NOx emissions
will increase. An incorrectly tuned flame will also result in
a low flame signal and could create a flame failure.
CAUTION
5

19Linnox, V1, Operating Instructions, Edition 6.15
Yearly Checklist
1. Check and compare burner adjustments with the
original recorded settings. Correct the settings if they
are outside the specified tolerance range.
2. Check for correct operation.
3. Check and clean or replace the gas filter if necessary.
4. Leak test shut-off valves.
5. Check all gas piping and connections for leakage.
Leaks must be repaired immediately.
6. Check tightness of all bolted/screwed joints.
7. Check the interlocks by simulating fault conditions.
Resolve all flame safety problems before restarting the
burner.
8. Check the direct burner surroundings for signs of
excessive corrosion or deformation due to thermal
overload or moisture. Repair or replace insulation or
thermal protection shields if necessary.
As per Supplier’s Instructions
1. Replace the UV scanner within the time frame as
specified by the supplier.
Depending on the Circumstances
1. Check and clean or replace the combustion air filter if
necessary.
2. Clean the burner. Flame shields and burner modules
must not be covered with dust or dirt.
Troubleshooting
Troubleshooting of electrical circuits should be done by qualified plant electricians, technicians or engineers experienced
in all facets of this type of combustion equipment.
Problem Possible Cause Solution
Cannot initiate startup
sequence.
Air pressure switch has not made contact. Check air pressure switch adjustment.
Check air filter. Check for correct rotation of
the blower wheel.
External interlock failure. Check all external interlocks.
High gas pressure switch has activated. Check pressure switch settings.
Low gas pressure switch has activated. Check pressure switch settings.
Malfunction of the flame safeguard. Have a qualified electrician troubleshoot
and correct the problem.
No power to the flame safeguard.
Burner sequence starts but
locks out before ignition.
Combustion air fault: Blower failure. Check blower and remedy the fault.
Combustion air fault: Blocked blower inlet
or filter.
Clean inlet. Clean or replace filter.
Combustion air fault: Pressure switch
failure.
Check operation of the pressure switch and
replace it if necessary.
Combustion air fault: 3-way solenoid valve
failure.
Check solenoid valve. Replace coil if
necessary.