Honeywell Eclipse Winnox WX Series User manual

32-00057-01
Eclipse Winnox
Burners
WX Series
Installation Guide 111
Version 3
9/26/2016

232-00057—01
Copyright
Copyright 2007 by Honeywell Interanational 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
Honeywell Eclipse.
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. Honeywell
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 Honeywell 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 Honeywell 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 Honeywell
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 Honeywell Eclipse
representative. You can also contact Honeywell Eclipse
at:
1665 Elmwood Rd.
Rockford, Illinois 61103 U.S.A.
Phone: [phone]
Fax: [phone]
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
Table of Contents
32-00057—01
Introduction .................................................................................................. 4
Product Description ................................................................................. 4
Audience.................................................................................................. 4
Winnox Documents ................................................................................. 4
Safety ............................................................................................................ 5
Safety Warnings ...................................................................................... 5
Capabilities .............................................................................................. 5
Operator Training .................................................................................... 5
Replacement Parts .................................................................................. 5
Installation .................................................................................................... 6
Introduction.............................................................................................. 6
Handling & Storage ................................................................................. 6
Approvals of Components ....................................................................... 6
Checklist Before Installation .................................................................... 7
Installing the Flame Sensor ..................................................................... 7
Burner Mounting ...................................................................................... 7
Gas Piping ............................................................................................... 9
Checklist After Installation ....................................................................... 10
Remote Blower Air Pre-Mix Line Installation (WX0850 only) .................. 10
Adjustment, Start & Stop ............................................................................ 11
Step 1: Reset the system ........................................................................ 11
Step 2: Set low fire air ............................................................................. 12
Step 3: Ignite the burner .......................................................................... 13
Step 4: Set low fire gas............................................................................ 14
Step 5: Set high fire gas .......................................................................... 15
Step 6: Verify Settings ............................................................................. 15
Maintenance & Troubleshooting ................................................................ 17
Monthly Checklist .................................................................................... 17
Yearly Checklist....................................................................................... 17
Recommended Spare Parts .................................................................... 18
Troubleshooting....................................................................................... 18
Appendix....................................................................................................... i
System Schematics ..................................................................................... ii
Notes ............................................................................................................. iv

4
Introduction
32-00057—01
Product Description
The Winnox is a nozzle-mix type, low-emissions burner
designed for direct and indirect air heating, and oven
applications up to 1800°F (980°C).
The burner package includes a combustion air blower and
ratio regulator to fire over a wide gas turndown range at a
controlled ratio.
The burner is designed for:
• low NOXand CO emissions
• efficient ratio controlled combustion
• reliable burner operation
• simple burner adjustment
• direct spark ignition
• multiple fuel capability
The wide variety of options and configurations are
available due to the modular design of the burner.
Figure 1.1 Winnox Burner
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:
• Design / Selection
• Use
• Maintenance
The audience is expected to have previous experience
with this type of equipment.
Winnox Documents
Installation Guide No. 111
• This document
Datasheet, Series 111
• Available for individual WX models
• Required to complete design and selection
Design Guide No. 111
• Used with Datasheet to design burner system
Spare Parts List, Series 111
• Recommended replacement part information
Related Documents
• EFE 825 (Combustion Engineering Guide)
• Eclipse Bulletins and Info Guides: 710, 732, 756,
760, 930
1

532-00057—01
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
Safety

632-00057—01
Introduction
In this chapter you will find information and instructions
needed to install the burner and system components.
Handling & Storage
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.
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
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
Installation 3

7
32-00057—01
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 (1.17 kW). If there are corrosive fumes or
materials in the air, then supply the burner with clean air
from an uncontaminated area, or provide a sufficient air
filtering system.
Exhaust
Do not allow exhaust fumes to accumulate in the work
area. Provide some positive means for exhausting from
the furnace and the building.
Access
Make sure that you install the burner in such a way that
you can gain easy access 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
• Prevent direct exposure to water
Installing the Flame Sensor
1. Install the flame sensor into the 1/2" NPT opening in the
rear cover.
2. Make sure that you connect the flame sensor of a
burner to the electrical circuit of that burner.
■Connecting the flame sensor of a burner to the
electrical circuit of the wrong burner can result in
a fire or explosion.
There are two different types of flame sensors; UV
scanner and flame rod.
UV Scanner
The UV scanner must be compatible to the flame
monitoring control that is used. Refer to the manual of
your selected control for proper selection of the scanner.
Flame Rod
NOTE: Only specific burner sizes with alloy or silicon
carbide combustors can use a flame rod (see specific
burner datasheets).
For detailed information on how to install and connect a
flamerod, refer to Info Guide 832.
Installing the Spark Plug
Install the spark plug into the opening in the rear cover.
NOTE: Do not apply any grease to the threads of the
spark plug or bad grounding of the spark plug may occur,
resulting in a weak spark.
■If flame monitoring controls other than those
recommended in the Design Guide are used
contact Eclipse to determine how the burner
performance may be affected, adjustments may
vary from Eclipse published values. Consult with
the engineer who specified the alternate control
for limitations.
Burner Mounting
Chamber Opening
Provide an opening in the chamber wall at least 1/2"
(12 mm) larger in diameter than the outside diameter of
the combustor (1/4" - 6 mm per side). The combustor
diameter can be found in the Winnox datasheet, series
111.
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.
Figure 3.1. Chamber Opening
Mounting Pattern
Attach eight mounting bolts to the chamber wall. Position
these bolts to match the clearance holes (C) on the burner
mounting flange. Refer to Winnox datasheet, series 111.
Figure 3.2. Mounting Pattern
DANGER
NOTICE
Minimum 1/4" (6mm)
space per side
Combustor
Slots
Chamber Wall
“C”

8
32-00057—01
Tube Shrouding Considerations
Applications in which there is process air flow
perpendicular to and across the Winnox combustor
greater than 1000 ft/min (5 m/s) may cause flame
instability and/or high production of CO emissions. In
these applications a shroud may be required to shield the
combustor. Contact Eclipse for more information.
Chamber Wall
Make sure the chamber wall is strong enough to
support the weight of the burner . If necessary, reinforce
the mounting area. See Figure 3.3.
NOTE: The slots in the combustor must not be covered
with insulation. If necessary, taper the chamber insulation
at a minimum of 45° to provide clearance for the
combustor slots. Slot dimensions can be found in the
Winnox datasheet, series 111.
Figure 3.3. Chamber Wall
Burner Mounting
Mount the burner to the chamber wall using eight (8)
customer supplied nuts and lock washers.
Alloy Combustion Tube
1. Be sure gasket is installed between burner and
chamber wall . See Figure 3.4.
2. Pack fiber insulation around the tube to a depth not
beyond the combustor slot position, as shown in
Figure 3.4.
■Placing insulation over combustor slots will
impede burner performance and decrease
combustor life.
Figure 3.4. Alloy Combustion Tube
Refractory Plug
When using the refractory plug the customer must provide
a refractory combustion tube. The customer is responsible
for supplying all refractory materials for combustion tube
field installation as follows:
1. Install the chosen refractory realizing it is essential that:
• The combustion tube dimensions are held as given
in the Winnox Datasheet series 111. See Figure 3.5.
• The inside diameter of the combustion tube is
concentric with the refractory plug.
2. Support refractory combustion tube according to the
refractory supplier’s recommendations. The alloy
anchors should be coated with bitumastic whenever
they are used.
3. Fiber insulation must be installed between the
refractory plug and customer supplied refractory
combustion tube.
4. After the burner and refractory have been installed, a
proper curing schedule should be followed according
to refractory supplier’s recommendations.
Figure 3.5. Refractory Plug
3
2
Chamber
Insulation
45° Minimum
Combustor
Slots
1
CAUTION
Fiber Insulation
Chamber
Insulation
1
3
2
Combustor
Slots
Fiber
Insulation
90°
Customer Supplied
Refractory
Combustion Tube
Refractory
Plug

9
32-00057—01
Gas Piping
Burner Piping
The burner is factory assembled and shipped as ordered.
NOTE: If it is necessary to redirect piping, remove the
outer four bolts only . Rotate the rear cover and
replace bolts. When reassembling, be sure that:
• ratio regulator spring column is pointing down
• the bypass 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 reinstalled
• the same straight run of pipe remains between
the ratio regulator and the burner.
■Do not attempt to redirect piping by removing the
inner circle bolts . Internal burner parts will be
damaged.
Figure 3.6. Burner Piping
■Do not alter the bypass regulator. The NFPA
requires that the bypass regulator be
appropriately vented and protected.
■For applications in which the Winnox is operating
indoors, a vent limiting device is installed in the
bypass regulator.
■For applications in which the Winnox is operating
outdoors, an insect/rain protector is installed in
the bypass regulator.
Supply Piping
Inlet pressure to the ratio regulator must stay within
specified limits. Refer to the appropriate Winnox
datasheet, series 111.
• Locate the valve train close to the burner. The gas
must reach the burner during the fixed trial for
ignition period.
• Sufficiently size the shut off valve in the valve train.
• Make sure piping is large enough to accommodate
flow required to meet burner input.
• Minimize piping elbows.
• Install fuel flow measurement device upstream
from the burner inlet.
• If necessary to maintain inlet pressures to the
burner (see datasheet for your burner), install a gas
pressure regulator upstream of the burner inlet
and downstream of the valve train and fuel
measurement device .
Figure 3.7. Supply Piping
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.
CAUTION






CAUTION


Main gas
shut-off
valve train

10
32-00057—01
Figure 3.8. Pipe Connections
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 air butterfly valve if
not factory installed on the burner.
NOTE: Be sure the control motor shaft and air butterfly
valve shaft are aligned properly.
Figure 3.9. Control Motor
Checklist After Installation
To verify the system was properly installed, perform the
following checks:
1. Be sure there are no leaks in the gas lines.
2. Be sure all the components contained in the flame
monitoring and control systems are properly installed.
This includes verifying that:
• all the switches are installed in the correct locations.
• all wiring, pressure, and impulse lines are properly
connected.
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.
Remote Blower Air Pre-Mix Line Installation
(WX0850 only)
When using a remote blower instead of the packaged
blower on the WX0850, the low fire air pre-mix line must
be installed to the combustion air line. 1/4" diameter
braided hose is recommended, located as shown in figure
3.10.
NOTE: A 24" length of 1/4" diameter braided hose is
included with the burner.
Figure 3.10.
Pipe
Union
Bracket
Set
Screws
Motor
Shaft
Control
Motor
Coupling
BV
Shaft
Remote
Blower
Pre-Mix
Air Line
Fuel
Inlet
Combustion
Air Modulation
Valve Remote
Blower

11
32-00057—01
In this chapter, you will find instructions on how to adjust,
start, and stop the burner system. Become familiar with
burner control methods before attempting to make
adjustments.
■The Winnox burners 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.
Step 1: Reset the System
1. Set the low gas pressure switch to 20% below the
“Fuel Inlet Pressure” range as specified in the
appropriate datasheet.
2. Set the high gas pressure switch to 20% above the
“Main Gas Inlet Pressure” range as specified in the
appropriate datasheet.
3. Close all the burner gas valves manual and
automatic.
4. Try to ignite the burner; be sure the flame monitoring
system indicates a flame failure.
5. Activate the pressure switches and other limit
interlocks. Be sure the switches fail as intended in the
event of a power failure.
■If simulated limits or simulated flame failure do not
shut down the fuel system within the required
failure response time, immediately correct the
problem before proceeding. Refer to the
“Troubleshooting” chart in section 5.
6. If the burner is firing into a duct or chamber with a
circulating fan, start the fan to produce full process air
flow past the burner.
7. Adjust main gas inlet pressure to the ratio regulator
within the range specified in the appropriate
datasheet.
■Gas inlet pressures must stay within the specified
range. Pressure above the specified range can
damage the ratio regulator.
■Pressure below the specified range can impair the
ability of the ratio regulator to control the gas flow.
■Operating the system outside the specified range
can cause excess fuel consumption and the
possible accumulation of unburned fuel in the
chamber.
■In extreme cases, this accumulation of unburned
fuel may cause fires or explosions.
8. Verify the actuator opens the air butterfly valve
towards the back of the burner as shown in Figure 4.1.
If it doesn’t, refer to the actuator’s literature for
instructions on how to reverse the direction.
DANGER
DANGER
WARNING
Adjustment, Start &
Stop
4

12
32-00057—01
Figure 4.1. Air Butterfly Valve Open Direction
Step 2: Set Low Fire Air
1. Start combustion air blower.
2. Drive control motor to low fire position.
3. Measure the air differential pressure between Tap C
and the combustion chamber.
NOTE: The pressure tap is in the open position when the
screw inside the tap is unscrewed approximately 1/2 turn.
Do not remove the screw. Be sure to tighten the pressure
tap screw clockwise to the closed position after pressure
measurements have been taken.
Figure 4.2. Air Differential Pressure
4. Set low fire air.
a. Loosen the set screw on the burner side of
coupling.
There is a slot in the end of the butterfly valve shaft
that is parallel to the air damper. This slot is used for
visual indication of the butterfly valve position. The
butterfly valve is closed when the shaft slot is
perpendicular to the direction of air flow through the
butterfly valve.
b. Rotate the air butterfly valve shaft to a fully closed
position. (Holes in the butterfly valve will supply low
fire air.)
c. When firing into a positive chamber pressure, rotate
the air butterfly valve from the closed position in the
direction of actuator travel to obtain a minimum
0.3" w.c. (0,8 mbar) air differential pressure.
d. Hold the butterfly valve shaft firmly in place and
tighten set screw .
High fire air adjustment is not required if the burner is firing
into a neutral pressure chamber and a 90° travel control
motor is used. It may be necessary to limit control motor
stroke to less than 90° if firing into a large negative
chamber. Contact Eclipse for further information.
Figure 4.3. Air Butterfly Valve Adjustment
5. Verify high fire air:
a. Drive control motor to high fire, full open.
b. Compare the high fire air differential pressure
between Tap C and the combustion chamber to the
approximate datasheet chart “Air Δp vs. Input”. If
high fire air is insufficient, refer to section 5,
“Troubleshooting & Maintenance”, in this document.
6. Return the control motor to the low fire position.
7. Close the pressure taps.
Open in this
direction only
Closed
Open
Back
Tap C
To Chamber



13
32-00057—01
Figure 4.4. Air Butterfly Valve Shaft
Step 3: Ignite the Burner
Low Fire Start
■These procedures are written with the assumption
the burner has a flame monitoring control system
installed and operating. A proper purge cycle must
be part of the system and purge timing should not
be bypassed.
Figure 4.5. Low Fire Start
1. Drive control motor to low fire.
2. Be sure combustion air blower is running.
3. Open main gas manual shut off valves.
4. With pressure taps open, connect the manometer
between Tap E and the chamber.
5. Set system control to stay at low fire during and after
ignition sequence.
6. Attempt to ignite burner.
7. During trial for ignition, adjust bypass pressure
regulator and adjustable limiting orifice to achieve
the appropriate Δp between Tap E and the chamber as
listed in the appropriate datasheet.
NOTE: If viewing the flame, it should be blue with flashes
of yellow. The flame should be completely within the
combustion tube. When firing propane or butane, a proper
low fire flame may have sustained flashes of yellow.
8. If burner does not ignite.
a. Shut off gas.
b. When chamber temperature is below 250°F
(121°C), shut off combustion air blower.
c. Restart combustion air blower, drive through purge
cycle and ignite the burner.
d. Measure low fire gas pressure to the burner gas
inlet . Verify pressure at is within the range
specified on the datasheet for your burner. range
specified on the datasheet for your burner.
10.After ignition, verify low fire flame:
a. Shut off gas.
b. When chamber temperature is below 250°F
(121°C), shut off combustion air blower.
c. Restart combustion air blower and ignite burner.
d. Measure low fire gas pressure to the burner gas
inlet .Verify pressure at is within the range
specified on the datasheet for your burner.
e. Verify repeatability of ignition and low fire flame
signal.
NOTE: If the flame signal is too low, use the bypass
regulator and/or the adjustable limiting orifice to
increase the pressure at Tap E and provide better flame
signal. However, this can have a negative impact on
emissions and/or nozzle life.
11. Close all pressure taps.
Pilot Start Option
■These procedures are written with the assumption
the burner has a flame monitoring control system
installed and operating. A proper purge cycle must
be part of the system and purge timing should not
be bypassed.
Figure 4.6. Low Fire Start with Pilot Start Option
1. Drive control motor to low fire.
2. Be sure combustion air blower is running.
3. Open pilot gas manual shut off valve.
BV shaft shown
in closed position
WARNING



Main gas
shut-off
valve train
Ta p E
WARNING



Pilot gas
shut-off
valve train
Main gas
shut-off
valve train
Ta p E

14
32-00057—01
NOTE: Be sure main gas manual shut off valves are
closed.
4. With pressure taps open, connect a manometer
between Tap E and the chamber.
5. Set system control to stay at low fire during and after
ignition sequence.
6. Attempt to ignite burner.
7. During trial for ignition, adjust bypass pressure
regulator and adjustable limiting orifice to achieve
the appropriate Δp between Tap E and the chamber as
listed in the appropriate datasheet.
NOTE: If viewing the flame, it should be blue with flashes
of yellow. The flame should be completely within the
combustion tube. When firing propane or butane, a proper
low fire flame may have sustained flashes of yellow.
8. If burner does not ignite:
a. Attempt to ignite the burner again to purge air from
the gas piping.
b. If burner still does not ignite, adjust bypass pressure
regulator a half turn clockwise to increase gas
flow.
c. Repeat until burner ignites. If necessary, refer to
Chapter 5, “Maintenance & Troubleshooting” in this
manual.
10.After ignition, verify bypass flame:
a. Shut off gas. When chamber temperature is below
250°F (121°C), shut off combustion air blower.
b. Restart combustion air blower, drive through purge
cycle, and ignite burner.
c. Measure low fire gas pressure to the burner gas inlet
. Verify pressure at is within the range specified
on the datasheet for your burner.
d. Verify repeatability of ignition and low fire flame
signal.
11. Close all pressure taps.
Step 4: Set Low Fire Gas
■This procedure is written with the assumption the
burner has a flame monitoring control system
installed and operating. A proper purge cycle must
be part of the system and purge timing should not
be bypassed.
1. Set manual gas butterfly valve to 75% open. See
Figure 4.8.
Figure 4.7. Ratio Regulator Adjustment
NOTE: To adjust manual butterfly valve:
a. Loosen set screw
b. Turn dial
c. Tighten set screw
Figure 4.8. Manual Butterfly Valve Adjustment
3. Open all manual gas shut off valves.
4. Set system control to stay at low fire during and after
ignition sequence.
5. With taps open, connect manometer between Tap B
and the combustion chamber.
6. Ignite the burner.
WARNING
1
Bias
adjusting
screw
CCW for
more gas
Set Screw
Outer Dial
Full Open
75% Open

15
32-00057—01
NOTE: If viewing the flame, it should be blue with flashes
of yellow. The flame should be completely within the
combustion tube. When firing propane or butane, a proper
low fire flame may have sustained flashes of yellow.
7. Verify low fire flame.
a. Drive control motor from low fire and back. Verify
low fire and stable flame signal are repeat-ed.
b. Turn the burner off and repeat the ignition
sequence. Verify low fire and stable flame signal are
repeated.
8. Close all pressure taps.
Step 5: Set High Fire Gas
Figure 4.9. High Fire Gas Adjustment
1. Set manual gas butterfly valve to 75% open. See
Figure 4.8.
NOTE: To adjust manual butterfly valve:
a. Loosen set screw
b. Turn dial
c. Tighten set screw
2. With burner lit, drive control motor to high fire position.
3. Measure air loading line pressure from Tap C to the
chamber.
4. Refer to the “Air ∆P vs. Input” graph on page 2 of the
appropriate Eclipse Data Sheet. Find your measured
high fire air ∆P “w.c. (mbar) on vertical axis at left and
plot the intersection point it makes with performance
curve in center of chart. Follow chart straight down
from this intersection point to confirm the desired high
fire burner input Btu/h (kW) charted on horizontal axis
across the bottom.
5. Calculate the required gas flow scfh (Nm3/h) for the
desired high fire burner input Btu/h (kW).
Example: (500,000 Btu/h input) x (1 cuft Natural Gas/1000
Btu) = 500 cuft/h or scfh of Natural Gas.
6. Measure existing gas ∆P “w.c. (mbar) across
customer supplied in-line fuel orifice meter, and using
the manufacturer’s conversion flow chart for the fuel
orifice meter, calculate* the existing gas flow scfh
(Nm3/h) through orifice.
(* = making the manufacturer’s prescribed corrections for
Fuel Type, Temperature, and Elevation.)
7. If the required gas flow scfh (Nm3/h) from step 5 does
not correspond with the existing gas flow scfh
(Nm3/h) from step 6, adjust existing gas flow using
manual butterfly valve (refer to step 1 for adjustment
procedure) to match required gas flow for the desired
high fire burner input.
8. If required gas flow cannot be achieved, refer to
Chapter 5, “Maintenance and Troubleshooting”.
Step 6: Verify Settings
Figure 4.10. Verify Pressure Settings
1. With burner lit, drive control motor to high fire.
2. Wait for the chamber to reach normal operating
conditions (e.g. chamber temperature, process flows,
etc.).
3. Measure high fire fuel using fuel flow measurement
device. Compare this to the rated high fire on
datasheet.
4. Measure high fire air differential pressure between
Tap C and the chamber. Compare this pressure to the
“Air Δp vs. Input”chart on the datasheet.
5. Drive the control motor to low fire and verify low fire
flame signal and flame appearance (if viewing).
6. Cycle burner from high to low several times to check
repeatability of settings.
To
Chamber

Tap C
Chamber
Tap C

16
32-00057—01
7. Readjust burner if the settings do not repeat as
expected. If necessary, refer to Chapter 5,
“Maintenance & Troubleshooting”.
8. Use the Systems Schematics on Appendix page ii to
record all setup data as an aid for future
troubleshooting and setup operations.
■Do not turn the combustion air blower off until the
chamber temperature is below 250°F (121°C). This
will prevent hot gases from back flowing into the
burner and blower causing damage to the burner.
9. Stop the burner.
CAUTION

17
32-00057—01
This section is divided into two parts. The first part
describes the maintenance procedures, and the second
part helps you to identify problems that may occur and
gives recommendations on how to solve these problems.
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, then the intervals may
be shorter. Check with local authorities having jurisdiction
on their recommended maintenance schedules.
■Turn off the power to the burner and controls
before proceeding with burner inspection.
Monthly Checklist
1. Inspect flame-sensing devices for good condition and
cleanliness.
2. Check for proper air/gas pressures. Refer to the
Winnox datasheet, series 111.
3. Test all alarms for proper signals.
4. Check and clean igniter electrodes.
5. Check the air control valve for smooth, trouble free
operation and adjustment.
6. Check for the proper operation of ventilating
equipment.
7. Test interlock sequence of all safety equipment and
manually make each interlock fail, noting that related
equipment closes or stops as specified by the
manufacturer. Test flame safeguard by manually
shutting off gas to burner.
8. Test all manual fuel valves for operation.
9. Clean and/or replace the combustion air blower filter.
10.Inspect and clean the combustion air blower rotor.
Yearly Checklist
1. Test (leak test) safety shut-off valves for tightness of
closure.
2. Test pressure switch settings by checking switch
movements against pressure settings and compare
these with the actual impulse pressure.
3. Visually check ignition cable and connectors.
4. Inspect impulse piping for leaks.
5. Be sure the following components are not damaged or
distorted:
• the burner nozzle
• the igniter
• the flame sensors
• the combustion tube or block
Figure 5.1 Component Inspection
The nozzle can be inspected without removing the burner
from the chamber wall or entering the chamber. See
Figure 5.1 and Figure 5.2. Perform the following:
a. Shut the burner off and manually close the main gas
shut off cocks.
b. Allow the chamber temperature to cool down to
250°F (121°C).
c. Disconnect the gas piping at a union or the gas inlet
flange provided on the burner.
d. Remove the four bolts .
CAUTION


Maintenance &
Troubleshooting
5

18
32-00057—01
■Do not attempt to remove the rear cover by
removing the inner circle bolts . Internal burner
parts will be damaged.
e. Remove bolts .
f. Remove the rear cover / nozzle assembly from the
burner housing .
g. To reassemble, follow this sequence in the reverse
order.
NOTE: The combustor can be inspected only by removing
the burner from the chamber wall or entering the chamber.
Figure 5.2 Nozzle Inspection
Recommended Spare Parts
To make sure that the downtime of the system is as short
as possible in case of a failure, you should keep a stock of
spare parts. Please refer to the Eclipse Product
Information Center (EPIC) for a full listing of spare parts:
http://www.eclipsenet.com/products
Troubleshooting
CAUTION





Problem Possible Cause Solution
Start-up sequence runs but
burner does not light.
No ignition. There is no power to the ignition
transformer.
Restore the power to the ignition
transformer.
No ignition. Open circuit between the
ignition transformer and the igniter.
Repair or replace the wiring to the igniter.
No ignition. The igniter needs cleaning. Clean the igniter.
No ignition. The igniter is not correctly
grounded to the burner.
Clean the threads on the igniter and the
burner. NOTE: Do not apply grease to the
threads on the igniter.
No ignition. Igniter insulator is broken.
Igniter is grounding out.
Inspect the igniter. Replace if broken.
Igniter grounds out, igniter is bent. Inspect ignitor by removing nozzle and rear
cover. Check if gaps exist, readjust if
needed.
Not enough gas. The gas pressure into the
ratio regulator is too low.
Check the start-up setting. Measure the
gas pressures and adjust where necessary.
Not enough gas. The impulse line to the
ratio regulator is leaking.
Repair any leaks.
Not enough gas. The adjustable orifice
valve is not open far enough.
Adjust bypass or low fire gas.
Not enough gas. Start gas solenoid valve
does not open.
Check the solenoid valve coil for proper
operation. Replace it if necessary.
Not enough gas. Gas valve does not open. Check the wiring to the automatic gas shut-
off valve. Check the output from the flame
safeguard. Open manual gas cock.
Not enough gas. Ratio regulator is
incorrectly set.
Adjust the ratio regulator to the proper
setting.
No flame signal. Broken flamerod and/or
dirty UV scanner lens.
Inspect and clean sensor. Replace if
necessary.
Too much gas. Gas butterfly valve too far
open.
Check for proper setting.

19
32-00057—01
Troubleshooting
Problem Possible Cause Solution
The low fire flame is weak or
unstable.
Not enough gas flowing to the burner. Adjust the ratio regulator or bypass fuel
adjustable orifice valve to increase the gas
flow.
Not enough air. Check for proper blower rotation. Check air
filter for blockage. Compensate for
chamber by opening the low fire air butterfly
valve position.
The burner goes out when it
cycles to high fire.
Not enough gas pressure into the ratio
regulator.
Check the start-up settings. Measure the
gas pressures and adjust them where
necessary. Check for valve train pressure
loss.
Loading line to the ratio regulator is leaking. Repair the leak in the loading line.
Not enough gas flowing to the burner. Adjust the ratio regulator to increase the
gas flow.
Fuel bypass line is not set correctly Set fuel bypass pressure per datasheet.
Additional minor adjustments to the fuel
bypass ALO valve may be required to
achieve a stable flame through the
transition between low and high fire.
The burner is erratic and
does not respond to
adjustment.
Internal damage to the burner. Some parts
inside the burner are loose, dirty or burned
out.
Contact Eclipse for further information.
The burner is unstable or
produces soot, smoke, or
excessive carbon monoxide.
The air/gas ratio is out of adjustment. Measure all the gas pressures and air
pressures. Compare these pressures to the
documented initial start-up settings and
adjust them where necessary.
The burner cannot achieve
full capacity.
Air filter is blocked. Clean or replace the air filter.
Gas pressure going into the ratio regulator
is too low.
Adjust the gas pressure.
Cannot initiate a 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 or low gas pressure switch has
activated.
Check incoming gas pressure. Adjust gas
pressure if necessary. Check pressure
switch setting and operation.
Malfunction of the flame safeguard system
(e.g. shorted-out flame sensor or electrical
noise in the sensor line).
Have a qualified electrician troubleshoot
and correct the problem.
No power to the control unit. Have a qualified electrician troubleshoot
and correct the problem.
Main power is off. Be sure the main power to the system is
switched to the “On” position.

Appendix
32-00057—01 20
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