Eclipse PulsePak Installation Manual
791-2 Installation Guide
8/10/2010
Eclipse PulsePak
Valve Train Segments
NFPA and CE Models
Version 1
Gas
Valve
Train
2-1/2" - 3"
Air Valve Train
Copyright
Copyright 2010 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 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.
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
Marketing Communications Manager.
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.
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
This is the safety alert symbol. It is used to alert you to potential personal
injury 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.
WARNING
CAUTION
NOTICE
NOTE
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 m
Is used to address practices not related to personal injury.
Indicates an important part of text. Read thoroughly.
oderate injury.
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Table of Contents
1 Introduction............................................................................................................................ 4
Product Description .............................................................................................................. 4
Audience .............................................................................................................................. 5
Purpose................................................................................................................................ 5
Related Documents.............................................................................................................. 5
2 Safety...................................................................................................................................... 5
Safety Warnings ................................................................................................................... 5
Capabilities........................................................................................................................... 5
Operator Training ................................................................................................................. 5
Replacement Parts...............................................................................................................5
3 Installation.............................................................................................................................. 6
Introduction .......................................................................................................................... 6
Handling & Storage ..............................................................................................................6
Approval of Components...................................................................................................... 6
Checklist Before Installation ................................................................................................. 7
Installation ............................................................................................................................ 7
Checklist After Installation ....................................................................................................8
4 Adjustment, Start, and Stop ................................................................................................. 9
Before Applying Gas ............................................................................................................ 9
Tests .................................................................................................................................... 9
Leakage Rate Limits.............................................................................................................10
5 Maintenance & Troubleshooting.......................................................................................... 11
Introduction .......................................................................................................................... 11
Maintenance......................................................................................................................... 11
Monthly Checklist ................................................................................................................. 11
Yearly Checklist.................................................................................................................... 11
Troubleshooting Guide......................................................................................................... 11
Appendix ................................................................................................................................... i
Conversion Factors ..............................................................................................................i
Eclipse PulsePak Valve Train Segments, V1, Installation Guide 791-2, 8/10/2010
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Introduction
1
Product Description
The Pulsepak Valve Train Segments are sub-assemblies
used for pulse firing applications globally. Standardization
results in quicker throughput and a reduction of errors
from the beginning stages of quotations through the
stages of commissioning, operation and maintenance.
These segments include:
Gas:
• Two safety shut off valves with flow adjustment
NOTE:
shutoff valves is 1,000,000. It is recommended to
replace the valves at 90% of that cycle capacity. A
cycle counter can be found in the zone panel or
through the T400 Flame Safety Unit.
• Ratio regulator with low fire bypass
Maximum number of cycles for the safety
CAUTION
Ŷ Ratio regulator may be adjustable for gas rich
situation. Verify that the bias adjustment on the
ratio regulator is set for a safe setting.
• Permanent and ready means for leak testing
• Outlet manual isolation valve
• Visual position indicators
• Quick electrical disconnects
Air:
• Control valve with flow adjustment
NOTE:
valve is 1,000,000. It is recommended to replace the
valves at 90% of that cycle capacity. A cycle counter
can be found in the zone panel or through the T400
Flame Safety Unit.
• Low fire bypass with flow adjustment
• Quick electrical disconnect
Maximum number of cycles for the control
Where this document refers to NFPA 86, it is for the 2007
edition. For EN 746-2, it is for the 1997 edition with
foresight of the 2006 draft document.
Audience
This manual has been written for personnel already
familiar with all aspects of gas valves, safety devices and
piping components, also referred to as “the valve train”.
These aspects are:
• Design / Selection
• Use
• Maintenance
• Safety
The audience is expected to be qualified and have
experience of this type of equipment and its working
environment.
Purpose
The purpose of this manual is to make sure that the design
of a safe, effective and trouble-free combustion system is
carried out.
PulsePak Documents
Installation Guide No. 791-2
• This document
Datasheets No. 791-3 and 791-4
• Available for NFPA and CE models
• Required to complete design calculations in this
guide
Design Guide No. 862
• Used with datasheets to design your valve train
Related Documents
• EFE 825 (Combustion Engineering Guide)
• Eclipse Bulletins and Information Guides: 791, 862
To fully meet the requirements of local codes, these subassemblies will require additional components, such as a
drip leg, strainer, filter, dryer, regulator, high and low gas
pressure switches, air flow switch, and overpressure
protection depending on the end-use application.
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Eclipse PulsePak Valve Train Segments, V1, Installation Guide 791-2, 8/10/2010
Safety
2
Important notices for safe operation of the burner 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 valve trains covered in this manual may be
designed to deliver fuel gas to the burner. All fuel
burning devices are capable of producing fires and
explosions when improperly applied, installed,
adjusted, controlled or maintained.
Ŷ Do not bypass any safety feature; fire or explosion
could result.
Ŷ Never try to light a burner if it shows signs of
damage or malfunction.
NOTICE
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.
Ŷ This manual provides information for the use of
these valve trains for their specific design
purpose. Do not deviate from any instructions or
application limits in this manual without written
advice from Eclipse.
Eclipse PulsePak Valve Train Segments, V1, Installation Guide 791-2, 8/10/2010
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