Page 1
Installation Guide
No. 111, 8/26/05
Winnox
Burners
WX Series
Version 1.00
Page 2
C
OPYRIGHT
Copyright 2005 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., Rockford, Illinois, U.S.A.
D
ISCLAIMER NOTICE
L
IABILITY AND
W
ARRANTY
We reserve the right to change the construction and/or
configuration of our products at any time without being
obliged to adjust earlier supplies accordingly.
The material in this manual is believed adequate for the
intended use of the product. If the product, or its individual
modules or procedures, are used for purposes other than
those specified herein, confirmation of their validity and
suitability must be obtained. Eclipse, Inc. warrants that the
material itself does not infringe any United States patents. No
further warranty is expressed or implied.
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 Documentation
Manager .
It must be understood that Eclipses liability for its products,
whether due to breach of warranty, negligence, strict liability,
or otherwise, is limited to the furnishing of such replacement
parts and Eclipse, Inc. 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 of or damage to
material arising in connection with the sale, installation, use of,
inability to use or the repair or replacement of Eclipses
products.
Any operation expressly prohibited in this Guide, any
adjustment, or assembly procedures not recommended or
authorized in these instructions shall void the warranty.
2
Eclipse Winnox WX Series v1, Installation Guide No. 111, 8/26/05
Page 3
About this manual
A
UDIENCE
P
URPOSE
W
INNOX
D
OCUMENTS
This manual has been written for people who are already
familiar with all aspects of a nozzle-mix burner and its add-on
components, also referred to as the burner system.
These aspects are:
installation
use
maintenance.
The audience is expected to have had experience with this
kind of equipment.
The purpose of this manual is to ensure that the design of a
safe, effective, and trouble-free combustion system is carried
out.
Installation Guide No. 111
This document
Winnox Data Sheets, Series 111
Available for individual WX models
Required to complete design, selection & installation
R
ELATED DOCUMENTS
Design Guide No. 111
Used with Data Sheet to design burner system
Winnox Price List No. 111
Used to order burners
EFE 825 (Combustion Engineering Guide)
Eclipse Bulletins and Info Guides: 684, 710, 732, 742, 756,
760, 930
Eclipse Winnox WX Series v1, Installation Guide No. 111, 8/26/05
3
Page 4
D
OCUMENT
C
ONVENTIONS
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.
Danger:
d
Indicates hazards or unsafe practices which WILL
result in sever e personal injury or even death.
Only qualified and well trained personnel are
allowed to carry out these instructions or
procedures.
Act with great care and follow the instructions.
Warning:
w
Indicates hazards or unsafe practices which could
result in severe personal injury or damage.
Act with great care and follow the instructions.
Caution:
c
Indicates hazards or unsafe pr actices which could result in
damage to the machine or minor personal injury, Act carefully.
H
OW TO GET HELP
Note:
n
Indicates an important part of the text. Read thoroughly.
If you need help, contact your local Eclipse Combustion
representative. You can also contact Eclipse Combustion at any
of the addresses listed on the back of this document.
4
Eclipse Winnox WX Series v1, Installation Guide No. 111, 8/26/05
Page 5
Table of Contents
1
2
3
4
About this manual
Table of Contents
Introduction
Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Safety
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety 7
Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Operator Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Handling and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Approvals of Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pre-installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Check List After Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Adjustment, Start & Stop
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Step 1: Reset the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Step 2: Set low fire air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Step 3: Ignite the Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Step 3: Optional, low fire start with piloting gas . . . . . . . . . 19
Step 4: Set low fire gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Step 5: Set high fire gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Step 6: Verify Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . . . . . . . . . . . . . . . . 15
5
Maintenance & Troubleshooting
Appendix
Eclipse Winnox WX Series v1, Installation Guide No. 111, 8/26/05
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
. . . . . . . . . . . . . . . . . . . 23
5
Page 6
Introduction
1
P
RODUCT
D
ESCRIPTION
The Winnox Version 1.00 is a nozzle-mix type, low-emissions
burner designed for direct air heating, indirect air heating, and
oven applications up to 1600 °F (875 °C).
The burner package includes a combustion air blower and an
air:gas ratio regulator to fire over a wide gas turndown range
at a controlled ratio.
The burner is designed for:
low NO
efficient ratio controlled combustion
reliable burner operation
simple burner adjustment
direct spark ignition
multiple fuel capability
A wide variety of options and configurations are available due
to the modular design of the burner.
Figure 1.1 The Winnox Burner
and CO emissions
x
6
Eclipse Winnox WX Series v1, Installation Guide No. 111, 8/26/05
Page 7
Safety
2
I
NTRODUCTION
S
AFETY
This section is provided as a guide for the safe operation of the
Winnox burner system. All involved personnel should read this
section carefully before operating this system.
Danger:
d
The Winnox 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.
Warning:
w
The burner might have HOT surfaces. Always
wear protective clothing when approaching the
burner.
Note:
n
This manual pro vides information in the use of these burners
for their specific design purpose. Do not de viate from any
instructions or application limits described herein without
written advice from Eclipse Combustion.
Read the entire this manual and all r elated documents before
attempting to start this system. If you do not understand any
part of the information contained in this manual, contact your
local Eclipse representative or Eclipse Combustion before
continuing.
Eclipse Winnox WX Series v1, Installation Guide No. 111, 8/26/05
7
Page 8
C
APABILITIES
Only qualified personnel, with good mechanical aptitude and
experience on combustion equipment, should adjust, maintain,
or troubleshoot any mechanical or electrical part of this
system.
O
PERAT OR
R
EPLACEMENT
T
RAINING
P
ARTS
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.
Order replacement parts from Eclipse Combustion only. All
Eclipse Combustion approved, customer supplied valves or
switches should carry UL, FM, CSA, CGA, and/or CE approval,
where applicable.
8
Eclipse Winnox WX Series v1, Installation Guide No. 111, 8/26/05
Page 9
Installation
3
I
NTRODUCTION
H
ANDLING AND
S
TORA GE
A
PPROVALS OF
C
OMPONENTS
In this chapter you will find information and instructions
needed to install the burner and system components.
Handling
Inspect the system, make sure the components are clean and
free of damage.
Use the appropriate support and handling equipment when
lifting the burner.
Protect all components on the system from weather, damage,
dirt and moisture.
Protect the system and its components from excessive
temperatures and humidity.
Storage
When storing the system for an extended period Eclipse
recommends placing it in a cool, clean, dry room.
K eep all the system components stored in their original
packaging as long as possible.
Limit controls and safety equipment
All limit controls and safety equipment must comply with all
applicable local codes and/or standards, which may include:
NFPA Standard 86
NFPA Standard 86C
UL
FM
CGA
EN 746-2
Electrical wiring
All electrical wiring must comply with all applicable local codes
and/or standards, which may include:
NFPA Standard 70
ANSI-C11981
EN 746-2
Eclipse Winnox WX Series v1, Installation Guide No. 111, 8/26/05
9
Page 10
Gas piping
All gas piping must comply with all applicable local codes and/
or standards, which may include:
NFPA Standard 54
CSAZ662-03, CAN/CSA B149.1
EN 746-2, EN969
Where to get the standards:
NFPA:
National Fire Protection Agency
1 Batterymarch Park
Quincy, MA 02169
www.nfpa.org
ANSI:
American National Standard Institute
25 West 43rd St., 4th Floor
New York, NY 10036
www.ansi.org
UL:
Underwriters Labs
333 Pfingsten Road
Northbrook, IL 60062
www.ul.com
FM:
Factory Mutual System
1151 Boston-Providence Turnpike
P.O. Box 9102
Norwood, MA 02062
www.fmglobal.com
CSA:
The CSA Standards are available from:
178 Rexdale Boulvard
Toronto, Ontario
Canada M9W 1R3
www.csa-international.org
Information on the EN standards, and where to get the
standards is available from:
Comité Européen de Normalisation
Strassartstraat 36
B-1050 Brussels
Comité Européen de Normalisation Electronique
Strassartstraat 36
B-1050 Brussels
10
Eclipse Winnox WX Series v1, Installation Guide No. 111, 8/26/05
Page 11
PRE-
INST ALLATION
C
HECKLIST
Air Supply
Provide an opening in the burner room of at least one square
inch per 3000 BTU/hr (5 cm
2
per 1 kW) to supply the burner
intake with fresh, outdoor, combustion air.
If there are corrosive fumes or materials in the surrounding air,
find an uncontaminated source to supply air to the burner.
Exhaust
Do not allow exhaust gases to accumulate in the work area.
Provide a means for exhausting these gases from the building.
Access
Install the burners so they may be easily accessed for
inspection and maintenance.
Environment
Be sure the burner operating environment matches the original
operating specifications. Check the following items:
voltage, fr equency, and stability of electrical power
fuel type and fuel supply pressure
adequate fresh, clean, combustion air
humidity, altitude, and temperature of the supply air
presence of damaging corrosive gases in the air
prevent direct exposure to water.
B
URNER
Chamber wall
“C”
Minimum 1/4" (6mm)
space per side
Slots
Combustor
Chamber Opening
Provide an opening in the chamber wall at least ½ (12mm)
larger in diameter than the outside diameter of the combustor
(1/4 - 6mm per side).
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.
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 the appropriate Winnox data sheet.
Eclipse Winnox WX Series v1, Installation Guide No. 111, 8/26/05
11
Page 12
I
NSTALLATION
(
CONTINUED
3
)
Combustor
45 Minimum
slots
Chamber Wall
Make sure the chamber wall 2 is strong enough to support
the weight of the burner 3. If necessary, reinforce the
mounting area.
Note:
n
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.
Chamber
2
insulation
Figure 3.1 Chamber wall
1
3
slots
Combustor
Fiber insulation
Chamber
2
insulation
Figure 3.2 Alloy combustion tube
Fiber
insulation
Customer Supplied
Refractory
Combustion Tube
90˚ Hold
Burner Mounting
Mount burner to chamber wall using eight (8) customer
supplied nuts and lock washers.
Alloy Combustion Tube
1.
Be sure gasket 1 is installed between burner 3 and
chamber wall 2.
2.
Pack fiber insulation around the tube to a depth not
beyond the combustor slot position, as illustrated.
Caution:
c
Placing insulation over combustor slots will impede burner
performance and decrease combustor life
3.
No gasket is supplied or required between burner and
combustor.
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 that it is essential
that:
the combustion tube dimensions are held as given on
Eclipse drawings.
the inside diameter of the combustion tube is
concentric with the refractory plug.
12
2.
Support refractory tube according to the refractory
suppliers recommendations. The alloy anchors should be
coated with bitumastic wherever they are used.
3.
After the burner and refractory have been installed, a
proper curing schedule should be followed according to
refractory suppliers recommendations.
Eclipse Winnox WX Series v1, Installation Guide No. 111, 8/26/05
Page 13
GAS
1
3
P
IPING
5
4
c
1
2
Burner Piping
The burner is factory assembled and shipped as ordered.
Note:
n
If it is necessary to redirect piping, remove
BOLTS ONLY
When reassembling, be sure that:
ratio regulator spring column 2 is pointing up.
arrow on the ratio regulator points in the direction of
gas flow.
integral fuel orifice and o-rings 3 are reinstalled.
same straight run of pipe 4 remains between the ratio
regulator and the burner .
Caution:
c
Do not attempt to redirect piping by removing the inner
circle bolts 5. Internal burner parts will be damaged.
1
. Rotate rear cover and replace bolts.
OUTER FOUR
2
1
Tap "E"
Figure 3.4 Optional start piping
valvetrain
NC
3
Main gas
shut-off
NC
Supply Piping
Inlet pressure to the ratio regulator must stay within
specified limits. Refer to the appropriate Winnox data sheet.
Locate the valve train close to the burner. The gas
must reach the burner during the fixed trial for
ignition.
Sufficiently size shut off valves in the valve train.
Make sure piping is large enough.
Minimize piping elbows.
Install fuel flow measurement device 1 upstream from
the burner inlet.
If necessary to maintain inlet pressures to the burner
(see Data Sheet for your burner), install a gas pressure
regulator 2 upstream of the burner inlet and
downstream of the valve train and fuel measurement
device 1.
Pilot Start Gas Piping (optional)
Install the piping as shown in the schematics in Chapter 3 of
the Winnox Design Guide No. 111 using the following
guidelines:
Locate the start gas solenoids 3 close to the burner.
The gas must reach the burner during the trial for
ignition period.
Minimize piping elbows.
Eclipse Winnox WX Series v1, Installation Guide No. 111, 8/26/05
13
Page 14
GAS P
IPING (CONTINUED
Bracket
Pipe
Union
)
Pipe Connections
Installation of a pipe union in the gas line is
recommended to simplify burner removal.
Use of flexible pipe is optional.
Note:
n
Flexible pipe causes higher pressure drops than standard
pipe. Consider this when sizing your gas lines.
Piping Support
Use brackets or hangers to support the gas piping. If you
have questions, consult your local gas company.
Figure 3.5 Pipe Connections
Motor
BV
Shaft
Shaft
Set
Screws
Figure 3.6 Control Motor
C
HECK
I
NSTALLATION
Control
Motor
Coupling
L
IST
A
FTER
Washers
Control Motor
Install a control motor to modulate the air butterfly valve if
not previously installed on the burner.
Note:
n
To verify the system was properly installed, perform
the following checks:
1.
2.
3.
4.
5.
Be sure the control motor shaft and air butterfly valve
shaft are aligned properly. If using an Eclipse Actuator
Mounting Parts Kit, the supplied washers may be used as
shims (stacked 0, 1, or 2 high) to ensure proper alignment.
Additionally, a flexible coupling can be used to handle
minor misalignment.
Be sure there are no leaks in the gas lines.
Be sure all the components contained in the flame
monitoring and control system 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.
Be sure all components of the spark ignition system are
installed and functioning properly.
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.
Be sure all valves are installed in the proper location and
correctly oriented relative to the flow direction.
14
Eclipse Winnox WX Series v1, Installation Guide No. 111, 8/26/05
Page 15
Adjustment, Start &
Stop
4
I
NTRODUCTION
A
DJUSTMENT
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..
Danger:
d
The Winnox 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.
Adjustment steps:
1.
Reset the system
2.
Set low fire air
3.
Ignite the burner
4
. Set low fire gas
5
. Set high fire gas
6.
Verify settings
Step 1: Reset the system
Reset procedure:
1.
Set the low gas pressure switch to 20% below the Main
gas inlet pressure range as specified in the appropriate
data sheet.
2
. Set the high gas pressure switch to 20% above the Main
gas inlet pressure range as specified in the appropriate
data sheet.
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.
Eclipse Winnox WX Series v1, Installation Guide No. 111, 8/26/05
15
Page 16
Step 1: Reset system
(continued)
back
5.
Activate the pressure switches and other limit interlocks.
Be sure the switches fail as intended in the event of a
power failure.
Danger
d
If simulated limits or simulated flame failures do
not shut down the fuel system within the
required failure response time, immediately
correct the problem before proceeding.
6.
If the burner is firing into a duct or chamber with a
circulating fan, start the fan to produce a full process air
flow past the burner.
7.
Adjust main gas inlet pressure to the ratio regulator
within the range specified in the appropriate data sheet.
Warning:
w
Gas inlet pressures must stay within the specified
range. Pressure above the specified range can
damage the ratio regulator.
Warning:
w
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.
Closed
Open in this
direction only
Open
Figure 4.1 Air BV open direction
8.
Verify that the actuator opens the air BV towards the
back of the burner as shown. If it doesnt, refer to the
actuators literature for instructions on how to reverse
the direction.
16
Eclipse Winnox WX Series v1, Installation Guide No. 111, 8/26/05
Page 17
Step 2: Set low fire air
To Chamber
Tap C
Figure 4.2 Air Differential Pressure
1
Low fire air adjustment procedure:
1.
Start combustion air blower.
2.
Drive control motor to low fire position.
3.
Measure air differential pressure between tap (C ) and
combustion chamber.
Note:
n
The pressure tap is in the open position when the screw inside
the tap is unscrewed approximately 1/2 turn. Do not remove
screw. Be sure to tighten pressure tap screw clockwise to the
closed position after pressure measurements have been taken.
4.
Set low fire air.
a.
Loosen the set screw 1 on burner side of coupling 2.
Note:
n
There is a slot in the end of the BV shaft that is parallel to
the air damper. This slot is used for visual indication of the BV
position. The BV is closed when the shaft slot is perpendicular
to the direction of air flow through the BV.
b.Rotate air BV shaft to fully closed position. (Holes
in BV damper will supply low fire air.)
Note
n
When firing into a positive chamber pressure, rotate the air
BV from closed position in the direction of actuator travel to
obtain a minimum 0.3 w.c. (0,8 mbar) air differential
pressure.
2
Figure 4.3 Air BV Adjustment
BV shaft shown
in closed position
Figure 4.4 Air BV Shaft
c.
Hold BV shaft firmly in place and tighten set screw 1 .
Note:
n
High fire air adjustment is not required if burner is firing into
a neutral pressure chamber and a 90° tr avel control motor is
used.
It may be necessary to limit control motor stroke to less than
90° if firing into a large positive or negative chamber.
Contact your Eclipse Combustion representative for further
information.
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
appropriate data sheet chart Air ∆P vs. Input. If
high fire air is insufficient, refer to Section 5,
Troubleshooting and Maintenance, in this document.
6.
Return the control motor to the low fire position.
7.
Close the pressure taps.
Eclipse Winnox WX Series v1, Installation Guide No. 111, 8/26/05
17
Page 18
Step 3: Ignite the Burner
Low fire start
Warning:
w
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
Tap "E"
Main gas
shut-off
valvetrain
4
2
3
Low fire start :
1.
Drive control motor to low fire.
2.
Be sure combustion air blower is running.
3.
Turn bias adjusting screw 1 on ratio regulator spring column three
complete (360°) turns counter -clockwise (up) from bottom.
3.
Open main gas manual shut off valves.
4.
With pressure taps open, connect manometer between tap E and the
chamber.
5.
Set system control to stay at low fir e during and after ignition sequence.
6
. Attempt to ignite burner.
7.
During trial for ignition, adjust bypass pressure regulator 2
limiting orifice 3 to achieve the appropriate ∆P between tap E and the
chamber as listed in the appropriate data sheet.
Note:
n
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 burner again to purge air from the gas piping.
b.If burner still does not ignite, turn bias adjusting screw 1 a half turn
clockwise to increase gas flow.
c.
Repeat until burner ignites. If necessary, refer to Chapter 5,
Maintenance and Troubleshooting in this manual, for help.
9.After ignition, verify low fire flame:
a.Shut off gas. When chamber temperature is below 250°F (121°C),
shut off combustion air blower .
b.Restart combustion air blower and ignite burner.
c.
Measure low fire gas pressure to the burner gas inlet 4.
at 4 is within the range specified on the Data Sheet for your burner .
d.
Verify repeatability of ignition and low fire flame signal.
10.
Close all pressure taps.
and adjustable
Verify pressure
18
Eclipse Winnox WX Series v1, Installation Guide No. 111, 8/26/05
Page 19
Step 3: Optional: Ignite the Burner L ow fire start with pilot start option:
Warning:
w
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
Main gas
Tap "E"
2
6
shut-off
valvetrain
NC
NC
5
Low fire start with piloting option:
4
1.
Drive control motor to low fire.
2.
Be sure combustion air blower is running.
3.
Turn bias adjusting screw 1 on ratio regulator spring column three
complete (360°) turns counter -clockwise (up) from bottom.
4.
Open manual shut off valve 3 in the piloting system.
Note:
n
Be sure main gas manual shut off valves are closed.
5.
With pressure taps open, connect manometer between tap E and the
chamber.
6.
Set system control to stay at low fire during and after ignition sequence.
7.Attempt to ignite burner by energizing spark and bypass gas solenoid
valves 4.
8.
During trial for ignition, adjust bypass pressure regulator 2
limiting orifice 5 to achieve the appropriate ∆P between tap E and the
chamber as listed in the appropriate data sheet.
Note:
n
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.
9.If burner does not ignite
a.Attempt to ignite burner again to purge air from the gas piping.
b.If burner still does not ignite, turn bias adjusting screw 1 a half turn
clockwise to increase gas flow.
c.
Repeat until burner ignites. If necessary, refer to Chapter 5,
Maintenance and Troubleshooting in this manual, for help.
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 and ignite burner .
c.
Measure low fire gas pressure to the burner gas inlet 6.
at 6 is within the range specified on the Data Sheet for your burner .
d.
Verify repeatability of ignition and low fire flame signal.
11.
Close all pressure taps.
:
3
and adjustable
Verify pressure
Eclipse Winnox WX Series v1, Installation Guide No. 111, 8/26/05
19
Page 20
Step 4: Set low fire gas
CW for
more gas
Figure 4.7 Ratio regulator
adjustment
Outer Dial
Bias
Adjusting
Screw
Set low fire gas procedure:
Warning:
w
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.
Verify bias adjusting screw 1 on ratio regulator spring
column is three full clockwise turns (360° x 6) up from
the bottom.
2.
Set manual gas BV to 75% open.
Note:
n
To adjust manual BV:
a.
Loosen set screw.
b.
Turn dial.
c.
Tighten set screw.
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 combustion chamber.
6.
Ignite the burner.
7.
T urn bias adjusting screw 1 slightly to achieve 0.1 w.c.
(0.3 mbar) ∆P between tap B and combustion chamber.
Repeat ignition sequence until burner lights.
Set Screw
75% Open
Figure 4.8 Manual BV adjustment
Full Open
Note:
n
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 pr oper lo w fire flame may
have sustained flashes of yello w .
8.
Verify low fire flame .
a.
Drive control motor from low f i re and back. Verify
low fire and stable flame signal are repeated.
b.
Turn the burner off and repeat the ignition sequence.
Verify low fire and stable flame signal are repeated.
9
. Close all pressure taps.
20
Eclipse Winnox WX Series v1, Installation Guide No. 111, 8/26/05
Page 21
Step 5: Set high fire gas Set high fire gas procedure
1.
Set manual gas BV to 75% open.
Note:
n
To adjust manual BV:
a.
Loosen set screw.
b.
Turn outer dial.
c.
Tighten set screw.
2.
With burner lit, drive control motor to high fire
Ta p
"B"
1
Ta p
"C"
Figure 4.9 High fire gas adjustment
2
To
Chamber
position.
3.
Measure air loading line pressure from Tap C to
chamber.
4.
Refer to Air ∆P vs. Input graph on appropriate Data
Sheet and determine the desired input for measured air
∆
P.
5.
Measure gas flow and input using customer supplied
measuring device.
6.
Adjust high fire gas flow using manual butterfly valve
(Refer to step 1 for adjustment procedure) to match
the desired input determined in step 4.
7.
Measure gas pressure at the burner inlet 2 and verify
the pressure is within the range specified on the Data
Sheet.
8
. If required gas flow cannot be achieved, refer to
Chapter 5, Maintenance and Troubleshooting for
guidance.
1
Eclipse Winnox WX Series v1, Installation Guide No. 111, 8/26/05
21
Page 22
Step 6: Verify Settings
Tap "C"
Chamber
Setting verification:
1.
With burner lit, drive control motor to high fire.
2.
Wait for the chamber to reach normal operating conditions
(e.g. chamber temperature, p rocess flows, etc.).
3.
Measure high fire fuel using fuel flow measurement
device. Compare this to rated high fire on Data Sheet.
4.
Measure high fire air differential pressure between tap
(C) and the chamber. Compare this pressure to the Air
∆
P vs. Input chart on the data sheet.
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 sev eral times to check
repeatability of settings.
7.
R
eadjust burner if the settings do not repeat as excepted. If
necessary, refer to Chapter 5, Maintenance & Troubleshooting.
8.
Use the system setup summary sheet on page 30 to record
all setup data as an aid for future troubleshooting and setup
operations.
Figure 4.10 Verify pressure settings
c
9.
Caution:
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.
Stop the burner.
22
Eclipse Winnox WX Series v1, Installation Guide No. 111, 8/26/05
Page 23
Maintenance &
Troubleshooting
5
I
NTRODUCTION
M
AINTENANCE
Monthly Checklist
This chapter is divided into two sections:
Maintenance procedures
Troubleshooting guide
Preventive maintenance is the key to a reliable, s afe and
efficient system. The core of any preventive maintenance system
is a list of periodic tasks.
n
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Note:
These are guidelines only. The customer should make the
final determination on maintenance intervals and tasks to
be performed while considering the working environment.
Inspect the flame sensing devices for good condition and
cleanliness.
Check for proper air/gas pressures (Refer to the Winnox
Data Sheets, Series 111).
Test all the system alarms for proper response signals.
Check and clean igniter electrodes.
Check the air control valve for smooth, trouble free
operation and adjustment.
Check for the proper operation of ventilating equipment.
Test the interlock sequence on all safety equipment.
Manually fo rce each interlock to intentionally fail while at
the same time noting if related equipment closes or stops
as specified by the manufacturer. Test the flame safeguard
by manually shutting off the gas to the burner.
Test the manual gas shut off cocks for proper operation.
Clean and/or replace the combustion air blower filter.
Inspect and clean the combustion air blower rotor.
Eclipse Winnox WX Series v1, Installation Guide No. 111, 8/26/05
2
3
Page 24
Yearly Checklist
1
1.
Leak test the safety shut-off valves for tightness of closure.
2.
Test the pressure switch settings by checking the switch
movements against pressure settings and comparing these
with the actual impulse pressure.
3.
Visually check igniter 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
c
5
1
Figure 5.2 Nozzle inspection
1
The nozzle can be inspected without removing the burner
from the chamber wall or entering the chamber. 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 1 provided on the burner.
d.
Remove the four bolts 2.
Caution:
c
Do not attempt to remove rearcover by removing the inner
circle bolts 5. Internal burner parts will be damaged.
e.
Remove the rear cov er 3 from the burner housing 4.
f.
To reassemble, follow this sequence in the reverse
order.
Note:
n
The combustor can be inspected only by removing the burner
from the chamber wall or entering the chamber.
2
4
Eclipse Winnox WX Series v1, Installation Guide No. 111, 8/26/05
Page 25
T
ROUBLESHOOTING
P
ROCEDURES
PROBLEM POSSIBLE CAUSE SOLUTION
Start-up sequence runs but
burner does not light.
No ignition:
There is no power to the
ignition transformer.
No ignition:
Open circuit between the
ignition transformer and the
igniter.
No ignition:
The igniter needs cleaning.
No ignition:
The igniter is not correctly
grounded to the burner.
Restore the power to the
ignition transformer.
Repair or replace the wiring to
the igniter.
Clean the igniter .
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.
Ignitor grounds out:
Ignitor is bent.
Not enough gas:
The gas pressure going into the
ratio regulator is too low.
Not enough gas:
The impulse line to the ratio
regulator is leaking.
Not enough gas:
The adjustable orifice valve is
not open far enough.
Not enough gas:
Start gas solenoid valve does
not open.
Inspect the igniter . Replace if
broken.
Inspect ignitor by removing
nozzle and rear cover. Check if
gaps exist, readjust if needed.
Check the start-up settings.
Measure the gas pressures and
adjust where necessary.
Repair any leaks.
Adjust bypass or low fire gas.
Check the solenoid valve coil
for proper operation. Replace it
if necessary .
Not enough gas:
Gas valve does not open.
Not enough gas:
Ratio regulator is incorrectly
set.
Eclipse Winnox WX Series v1, Installation Guide No. 111, 8/26/05
Check the wiring to the
automatic gas shut-off valve.
Check the output from the
flame safeguard.
Open manual gas cock.
Adjust the ratio regulator to the
proper setting.
2
5
Page 26
PROBLEM POSSIBLE CAUSE SOLUTION
Start-up sequence runs but
burner does not light.
(continued)
The low fire flame is weak or
unstable.
The burner goes out when it
cycles to high fire.
No flame signal:
Broken flamer od
Dirty UV scanner lens
Too much gas:
Gas BV too far open
Not enough gas flowing to
the burner.
Not enough air.
Not enough gas pressure
into the ratio regulator .
Inspect and clean sensor
Replace if necessary
Check for proper setting.
Adjust the ratio regulator or
bypass fuel adjustable orifice
valve to increase the gas flow.
Check for proper blower
rotation.
Check air filter for blockage.
Compensate for chamber by
opening the low fire air butterfly
valve position.
Check the start-up settings.
Measure the gas pressures and
adjust them where necessary.
Check for valve train pressure
loss.
The burner is erratic and does
not respond to adjustment.
The burner is unstable or
produces soot, smoke, or
excessive carbon monoxide.
The burner cannot achieve full
capacity.
Loading line to the ratio
regulator is leaking.
Internal damage to the burner:
Some parts inside the burner
are loose, dirty, or burned
out.
The air/gas ratio is out of
adjustment.
Air filter is blocked.
Gas pressure going into the
ratio regulator is too low.
Repair the leak in the loading
line.
Contact your Eclipse
representative or Eclipse
Combustion for further
information.
Measure all the gas pressures
and air pressures. Compare
these pressures to the
documented initial start-up
settings and adjust them where
necessary.
Clean or replace the air filter.
Adjust the gas pressure.
2
6
Eclipse Winnox WX Series v1, Installation Guide No. 111, 8/26/05
Page 27
PROBLEM POSSIBLE CAUSE SOLUTION
Cannot initiate a start
sequence.
Air pressure switch has not
made contact.
High gas pressure switch has
activated.
Low gas pressure switch has
activated.
Malfunction of the flame
safeguard system (e.g., shorted-
out flame sensor or electrical
noise in the sensor line).
No power to the control unit.
Check air pressure switch
adjustment.
Check air filter.
Check blower rotation.
Check outlet pressure from
blower.
Check incoming gas pressure.
Adjust gas pressure if necessary.
Check pressure switch setting
and operation.
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.
Eclipse Winnox WX Series v1, Installation Guide No. 111, 8/26/05
2
7
Page 28
Appendix
C
ONVERSION
F
ACT ORS
Metric to English.
From To Multiply By
3
cubic meter (m
cubic meter/hour (m
) cubic foot (ft3) 35.31
3
/h) cubic foot/hour (cfh) 35.31
degrees Celsius (ºC) degrees Fahrenheit (ºF) (ºC x 1.8) + 32
kilogram (kg) pound (lb) 2.205
kilowatt (kW) BTU/hr 3414
meter (m) foot (ft) 3.28
millibar (mbar)
inches water column (w.c.)
0.401
millibar (mbar) pounds/sq in (psi) 14.5 x 10
millimeter (mm) inch (in) 3.94 x 10
MJ/m3 (normal) BTU/ft3 (standard) 2.491 x 10
Metric to Metric.
kiloPascals (kPa) millibar (mbar) 10
meter (m) millimeter (mm) 1000
millibar (mbar) kiloPascals (kPa) 0.1
millimeter (mm) meter (m) 0.001
-3
-2
-2
English to Metric.
From To Multiply By
BTU/hr kilowatt (kW) 0.293 x 10
cubic foot (ft3) cubic meter (m3) 2.832 x 10
-3
-2
degrees Fahrenheit (ºF) degrees Celsius (ºC) (ºF 32) ÷ 1.8
foot (ft) meter (m) 0.3048
inches (in) millimeter (mm) 25.4
inches water column (wc) millibar (mbar) 2.49
pound (lb) kilogram (kg) 0.454
pounds/sq in (psi) millibar (mbar) 68.95
3
BTU/ft
2
8
(standard) MJ/m3 (normal) 40.14
Eclipse Winnox WX Series v1, Installation Guide No. 111, 8/26/05
Page 29
KEY TO S
S
CHEMATICS
YSTEM
These are the symbols used in the schematics.
Symbol Appearance Name Remarks Bulletin/
Info Guide
Winnox
NC
Main Gas Shutoff
V alv e Train
Gas Cock
Solenoid Valve
(normally closed)
Pressure Regulator
Ratio Regulator
Eclipse Combustion, Inc.
strongly endorses NFPA as a
minimum
Gas cocks are used to
manually shut off the gas
supply on both sides of the
main gas shut-off valve train.
Solenoid valves are used to
automatically shut off the gas
supply on a bypass gas system
or on small capacity burners.
A pressure regulator reduces
gas pressure to a stable, usable
pressure.
A ratio regulator is used to control
the air/gas ratio. The ratio
regulator is a sealed unit that
adjusts the gas flow in ratio with
the air flow . To do this, it measures
the air pressure with a pressure
sensing line, the impulse line. This
impulse line is connected between
the top of the ratio regulator and
the burner body.
756
710
760
684
742
Eclipse Winnox WX Series v1, Installation Guide No. 111, 8/26/05
2
9
Page 30
System Setup Summary
Parameter
Main gas pressure
Gas pressure into the
ratio regulator
Bypass fuel differential pressure:
Tap E - Chamber
HighFire Input:
Fuel Flow Measurement Device
Setting
Low Fire High Fire
Loading line pressure:
Tap C - Chamber
Flame signal strength
Figure A.1
Tap locations
Ta p
"E"
Ta p
"C"
Fuel Flow
Measurement
Device
30
Eclipse Winnox WX Series v1, Installation Guide No. 111, 8/26/05
Page 31
Offered By:
Burnerparts.com
2011 Williamsburg Road
Richmond, Virginia 23231
Phone (804) 236-3881
Fax (804) 236-3882
www.burnerparts.com
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