Eclipse BoostPak Installation Manual
630-2 Installation Guide
6/22/2010
Eclipse BoostPak
Packaged Gas Booster System
Model MS, MR and MH
Version 2
Copyright
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Eclipse, Inc.
other injury, loss, damage or expenses, whether direct or
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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.
Disclaimer Notice
In accordance with the manufacture’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.
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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
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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
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How To Get Help
If you need help, contact your local Eclipse representative.
Your Eclipse representative can be reached at:
2011 Williamsburg Road
Richmond, Virginia 23231 U.S.A.
Phone: 804-236-3800 Fax: 804-236-3882
http://www.peconet.com
Please have the information on the product label available
when contacting the factory so we may better serve you.
www.peconet.com
Product Name
Item #
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DD MMM YYYY
2
Table of Contents
1 Introduction............................................................................................................................ 4
Product Description .............................................................................................................. 4
Audience .............................................................................................................................. 4
Purpose................................................................................................................................ 4
Related Documents.............................................................................................................. 4
2 Safety...................................................................................................................................... 5
Safety Warnings ................................................................................................................... 5
Capabilities........................................................................................................................... 5
Operator Training ................................................................................................................. 5
Replacement Parts...............................................................................................................5
3 Installation.............................................................................................................................. 6
Introduction .......................................................................................................................... 6
Handling & Storage ..............................................................................................................6
Checklist Before Installation ................................................................................................. 6
Mechanical Installation .........................................................................................................6
Piping Installation ................................................................................................................. 6
Electrical Installation............................................................................................................. 7
Checklist After Installation ....................................................................................................8
4 Commissioning...................................................................................................................... 9
Introduction .......................................................................................................................... 9
Applying Power .................................................................................................................... 9
Motor Rotation Check........................................................................................................... 9
Applying Gas Supply ............................................................................................................ 9
Operational Tests ................................................................................................................. 9
Verifying Settings ................................................................................................................. 9
Commissioning Record for Models MS/MR/MH................................................................... 10
MH Models Temperature Control Settings ........................................................................... 11
MH Models Rotary Actuator Settings ................................................................................... 11
5 Operation................................................................................................................................ 12
Introduction .......................................................................................................................... 12
Heat Exchanger Loop Operation.......................................................................................... 12
Alarm Silence ....................................................................................................................... 12
Shutdown ............................................................................................................................. 12
6 Maintenance & Troubleshooting.......................................................................................... 13
Monthly Checklist ................................................................................................................. 13
Yearly Checklist.................................................................................................................... 13
Alarm Conditions.................................................................................................................. 13
BoostPak Models MS/MR/MH Wiring Diagram .................................................................... 15
Boost Motor Voltage.............................................................................................................17
Heat Exchanger Motor Voltage ............................................................................................ 17
Panel Layout and Enclosure ................................................................................................ 18
BoostPak Model MS/MR/MH Piping Schematics ................................................................. 19
Appendix ................................................................................................................................... i
Conversion Factors ..............................................................................................................i
Key to System Drawings ...................................................................................................... ii
Eclipse Packaged Gas BoostPak, V2, Installation Guide 630-2, 6/22/2010
3
Introduction
1
Product Description
The Eclipse BoostPak is designed for installations when
the gas pressure to a building is inadequate to operate the
appliances. It provides a reliable cost-effective packaged
solution for pumping low natural gas supply pressures up
to meet the requirements of high performance combustion
equipment. The discharge pressure is the total of the
booster added pressure plus the incoming gas pressure.
The BoostPak is a completely integrated skid mounted
package. It is factory assembled, wired, tested, and ready
for field power and gas connections. The system includes
but is not limited to a hermetically sealed centrifugal type
gas booster blower, check valve, gas pressure switch,
isolating valves, inlet and outlet piping and flange
connectors, pressure gauges, and control system all
mounted, assembled, wired, and tested. All essential
components for automatic operation are enclosed in an
industrial control panel designed to meet local and
national electrical codes.
Various standard options may be selected to configure a
complete model number. The options determine the
control modes, pressure boost, flow, and environmental
conditions.
Figure 1.1. Eclipse BoostPak
Audience
This manual has been written for personnel already
familiar with all aspects of a gas booster system and it’s
add-on components.
These aspects are:
• Installation
• Use
• Maintenance
• Safety
The audience is expected to be qualified and have
experience with this type of equipment and its working
environment.
Purpose
The purpose of this manual is to make sure that you carry
out the installation of a safe, effective and trouble-free
system.
BoostPak Documents
Installation Guide No. 630-2
• This document
Datasheet No. 630-2
• Available for BoostPak model MS
• Provides assembly drawing numbers
• Required to complete installation
Datasheet No. 630-3
• Available for BoostPak model MR
• Provides assembly drawing numbers
• Required to complete installation
Datasheet No. 630-4
• Available for BoostPak model MH
• Provides assembly drawing numbers
• Required to complete installation
Related Documents
• EFE 825 (Combustion Engineering Guide)
• Eclipse Bulletins and Information Guides: 620, 710,
780, 904 (MH only), 925 (MH only), 940
4
Eclipse Packaged Gas BoostPak, V2, Installation Guide 630-2, 6/22/2010
Safety
2
Important notices for safe operation of the BoostPak
system will be found in this section. To avoid personal
injury, damage to property or the facility, the following
warnings must be observed. Read this entire manual
before attempting to start the system. If any part of the
information in this manual is not understood, contact
Eclipse before continuing.
Safety Warnings
DANGER
Ŷ The BoostPak packaged gas booster systems,
covered by this guide are designed to increase gas
pressure to a gas utilization appliance. All fuel
handling devices are capable of producing fires
and explosions if improperly applied, installed,
adjusted, controlled or maintained.
Ŷ Do not bypass any safety feature; fire or explosion
could result.
Ŷ Never try to operate a BoostPak if it shows signs
of damage or malfunction.
Capabilities
Only qualified personnel, with good mechanical aptitude
and experience with combustion equipment, should
adjust, maintain or troubleshoot any mechanical or
electrical part of this system.
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.
Replacement Parts
Order replacement parts from Eclipse only. Any customer
supplied valves or switches should carry UL, FM, CSA,
CGA and/or CE approvals where applicable.
NOTICE
Ŷ This manual provides information in the use of the
BoostPak for its specific design purpose. Do not
deviate from any instructions or application limits
described herein without written advice from
Eclipse.
Eclipse Packaged Gas BoostPak, V2, Installation Guide 630-2, 6/22/2010
5
Installation
3
Introduction
In this chapter you will find information and instructions
needed to install the BoostPak and system components.
The system drawings are shipped with the BoostPak.
Refer to the data sheet for the drawing number and
contact Eclipse for a replacement.
WARNING
Ŷ All installation work must be carried out in
compliance with current legislated standards.
Handling & Storage
Handling
• Make sure the area is clean.
• Inspect the system, ensure that all components are
clean and free from damage.
• Use appropriate support and handling equipment
when lifting the BoostPak.
• Protect the components from weather, damage, dirt
and moisture.
• Protect the system and components from excessive
temperatures and humidity.
around the BoostPak in order to facilitate servicing and
field replacement of components. Avoid obstructing the
open access to the control panel.
NOTE:
from the front of the control panel door and the swing of
the door should not be obstructed from opening 120°. If
local codes are different than these requirements, those
codes should be adhered to during installation.
There should be no less than 36" of clearance
Environment
Be sure the operating environment matches the original
operating specifications. Check the following items:
• Voltage, frequency, and stability of electrical power
• Ambient temperature and humidity
• Area classification (non-hazardous or hazardous)
• Exposure to sunlight, water, ice, wind, and vibration
Mechanical Installation
Lift Points
Use lifting lugs on mounting base for all lifting. Do not use
piping or supports as lift points unless designated by
manufacturer labeling.
Mounting
Storage
• Make sure the components are clean and free of
damage.
• Store the components in a cool, clean, dry room.
• After making sure everything is present and in good
condition, keep the components in original
packages as long as possible.
Checklist Before Installation
Placement
The Eclipse BoostPak is completely factory piped, wired
with controls, tested and ready for field connections. The
system should be installed in an accessible ventilated
location on a level concrete floor or substantial mounting
pad. Place the BoostPak to avoid excessive numbers of
bends and fittings in the interconnecting piping.
Access
The BoostPak location must allow easy accessibility for
inspection and maintenance. Provide adequate space all
6
Bolt the unit base securely using the mounting holes
provided in the BoostPak base.
Piping Installation
Gas Piping
All gas piping must be done in accordance with the
national fuel gas code, local utility company and municipal
agency requirements. Protect and prevent contamination
of the piping during installation.
NOTE:
devices are properly oriented with respect to flow direction
and vertical (gravity) orientations.
NOTE:
unnecessary fittings, and excessive bends that may
cause additional flow restriction and pressure loss.
Elbows within 5 pipe diameters may reduce pressure and
capacity below operating requirements.
Eclipse Packaged Gas BoostPak, V2, Installation Guide 630-2, 6/22/2010
If it is necessary to redirect piping, make sure all
Avoid severe size reductions in pipe connections,
Piping Support
WARNING
Leak Testing
Use brackets or hangers to support the gas piping. If you
have questions, consult your local gas company.
Initial Fitting
• Remove any shipping materials and inspect for
foreign objects in the piping.
• Connect inlet gas piping from the utility supply to the
inlet flange as indicated by directional arrows and
system drawings.
• Connect the gas pipe requiring the boosted gas
pressure feeding your appliance to the discharge
gas pipe outlet flange, also indicated by label and
system drawing.
Vent Piping
The model MS, MR and MH BoostPaks do not require
vent piping. Vent piping may be required for components
added to the system. Check the individual product data
sheets for specific manufacturer’s recommendations.
Inlet Low Gas Manual Reset Pressure Switch
This switch may come already mounted and wired on the
BoostPak, or it may be supplied as a kit to be remotely
mounted. Install loose inlet gas low pressure switch kit in
location determined by the utility company. Normally it is
located downstream of the main regulator just inside the
building where the supply pipe enters.
Inlet High Gas Pressure Switch
If used, this optional switch may come already mounted
and wired on the BoostPak, or it may be supplied as a kit
to be remotely mounted. Install loose inlet gas high
pressure switch kit in location determined by the
specifying engineer. Normally it is located downstream of
the main regulator just inside the building where the
supply pipe enters.
Pressure Switch Settings
• Check and adjust the pressure switches as
required.
• The utility company dictates the setting of the low
inlet gas pressure switch typically at 3-4" w.c. to
prevent operation when there is insufficient gas
volume.
• The discharge gas pressure switch should be set 24" w.c. below the rated discharge pressure at the
maximum flow conditions for the site application.
• If installed, the optional inlet high gas pressure
switch should be set to 90% of the pressure where
the sum of the inlet plus the rated boost equals the
maximum rating of downstream equipment.
(Alternately it can be set to 20% above the minimum
requirement of the downstream equipment.)
The BoostPak is tested and leak tight at the factory,
however, shipping and installation may cause joints to
loosen. Check and test all piping for leaks.
Ŷ Test pressure must not exceed 5 PSIG and the
pressure gauges or any components with ratings
less than the test pressure should first be isolated.
Check the individual product datasheets for
specific ratings.
Electrical Installation
General
All electrical wiring must be done in accordance with the
national electrical code, local utility company and
municipal agency requirements. The schematics are
shipped with the BoostPak. Contact Eclipse for
replacement, drawing 10025020.
The BoostPak is pre-wired and therefore only the
electrical power supply and any externally supplied
control devices must be terminated. Depending on the
specific model configuration, the external devices can
include the appliance run interlock contact and the low
inlet gas pressure switch.
Review Name Plate
Before making any electrical connections, compare the
electrical supply circuit ratings at the installation site to
those on the nameplates of the BoostPak, control panel,
booster and (MH only) heat exchanger motor(s). The
supply for the BoostPak model MS/MR/MH varies based
on booster and motor option, and may be 120VAC,
208VAC, 230VAC or 460VAC nominal and must be
capable of supplying the booster and (MH only) heat
exchanger motor full load current and starting current.
Terminal Check
During shipment, the control panel terminals may have
loosened. Check the tightness of all connections in the
panel and at the pressure switches.
Supply Power Wiring
The incoming power to the control panel must be wired
into the terminals as designated in the schematic diagram.
Earth ground must be connected to terminal G.
Wiring for Continuous Operation
This control mode allows an operator to turn a local
control panel switch on when pressure boost is needed
and turn the switch off when the boost is not needed. For
this mode, a jumper is installed between terminals 1321
and 2161.
Eclipse Packaged Gas BoostPak, V2, Installation Guide 630-2, 6/22/2010
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