Eclipse Combustion Air Conditioner AH User Manual

Info 140  
11/4/03  
ECLIPSE AIR HEAT BURNERS  
Series “AH, DAH, TAH” & “CAH”  
U.S. Reissue Pat. No. 26,244 Canadian Pat. No. 743,782  
AH, Front View  
Data 140-1  
AH, Back View  
Data 140-1  
TAH  
Data 140-3  
CAH  
Data 140-4  
DAH, Blower Down  
Data 140-2  
WARNING  
The burners covered in this Guide are designed to  
mix fuel with air and burn the resulting mixture. All  
fuel burning devices are capable of producing explo-  
sions and fires when improperly applied, installed,  
adjusted, controlled, or maintained. This Guide will  
provide information for using these burners for their  
limited design purpose. Do not deviate from any in-  
structions or application limits in this Guide without  
written advice from the Eclipse Combustion Division  
in Rockford, Illinois. Read this entire Guide before at-  
tempting to light burners. If you do not understand  
any part of the information in this Guide, contact your  
local Eclipse representative or Eclipse Combustion  
before proceeding further.  
 
Specifications  
Input:  
1,000,000 Btu/hr. per lineal foot (962 kW/m).  
Fuels:  
Natural gas or 100% propane vapor. Call Eclipse for information on using other fu-  
els.  
Gas Turndown:  
Pilot Input:  
40:1  
Approximately 25,000 Btu/hr. (7.3 kW)  
Gas Inlet Pressure:  
800,000 Btu/hr/ft. (769 kW/m):  
Nat. Gas: 2.2" w.c.  
Propane: 0.9" w.c.  
5.5 mbar  
2.2 mbar  
1,000,000 Btu/hr/ft. (962 kW/m):  
Nat. Gas: 3.5" w.c.  
Propane: 1.3" w.c.  
8.7 mbar  
3.2 mbar  
Gas pressure shown is a differential measured between the gas inlet and a tap on  
the duct wall 10" to 20" (254 to 508 mm) downstream of the burner.  
Ambient Temp. Limits*:  
40°to +104° F  
40° to +40° C  
815° C  
Downstream Temp. Limits: 1500° F  
Flame Length**:  
800,000 Btu/hr. (769 kW/m):  
1,000,000 Btu/hr. (962 kW/m):  
28"  
46"  
0.71 m  
1.17 m  
Piloting:  
Integral spark-ignited pilot; ignition plug included.  
Flame Monitoring:  
Flame rod supplied. UV scanner adaptors are available. For UV scanners, Eclipse  
recommends a flame monitoring system that terminates the ignition spark and  
proves the pilot flame without spark prior to opening the main gas valves.  
CGA requires two flame rods on burners over 36" long (914 mm). Use a flame  
monitoring endplate (see Data 140-6) to mount a second flame rod on the end op-  
posite the gas inlet.  
Motor:  
Standard: 230/460/3/60 TEFC. Other motors can be supplied.  
Materials:  
Emissions:  
All portions of the burner exposed to flame are cast iron or #321 stainless steel.  
Emissions performance depends not only on the burner,  
but also other factors such as chamber temperature, chamber design, and heat load-  
ing. For estimates of emissions performance in your application, call Eclipse.  
Packaging Options:  
Models:  
Available with complete valve trains and control systems. AH burners and systems  
can be supplied mounted on duct sections as specified by the customer. Call Eclipse  
for information on custom packaged systems.  
Model Description  
Data Sheet  
AH  
DAH  
TAH  
CAH  
Line-shape, blower mounted on rear  
Data 140-1  
Data 140-2  
Data 140-3  
Data 140-4  
Line-shape, blower mounted on bottom  
“I”-shape, blower mounted on rear  
Cross-shape, blower mounted on rear  
Related Information:  
Blower and motor specifications  
Data 140-5  
* Based on blower motor limitations.  
** Based on parallel air flow. If mounted in a cross flow, then flame will be shorter.  
CAUTION: It is dangerous to use any fuel burning equipment unless it is equipped with suitable flame sensing de-  
vices and automatic fuel shut-off valves. Eclipse can supply such equipment or information on alternate sources.  
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Eclipse AirHeat v1.0 - Installation Guide No. 140, 11/4/03  
 
2.0 Control System Requirements  
Turndown Method  
Input is normally controlled by a motorized butterfly valve in the gas line to the  
burner.  
Regulator Loading Lines  
Connect the top diaphragm chambers of the main gas and pilot gas regulators to the  
duct approximately 10" downstream of the burner. This will allow the regulators to  
maintain a constant supply pressure to the burner regardless of varying pressures in  
the duct.  
Piloting  
Pilot gas flow is adjusted as shown in Figure 6.  
Ignition voltage should be 6000 VAC.  
Ignition  
Check Valve  
See Figure 3. At high fire, the gas pressure at the burner inlet is higher than the air pressure, and  
the check valve is closed. At low fire, gas pressure falls below the air pressure, and the check  
valve opens, permitting a small amount of air to mix with the gas. This premix at low fire stabilizes  
the flame and helps distribute the flame evenly down the length of the burner.  
w
Do not install any valve or controlling device in the gas line between the  
burner and the check valve tee, Figure 3. Because this section of the gas  
line carries a partial pemix at low fire, it is possible under unusual condi-  
tions for the flame to travel back through the pipe to the tee. Devices in-  
stalled in this section may be damaged and may melt, releasing gas to the  
atmosphere and causing fires or explosions.  
Warning  
Pressure Switch Connection See Figure 4 for typical connection of combustion air and circulating fan limit  
switches.  
Limit Controls &Safety Equipment Limit controls and safety equipment should comply with current NFPA Stan-  
dards* 86 and 86C, and all applicable local codes and/or standards.  
*Available from:  
National Fire Protection Association  
Batterymarch Park  
American National Standard Inst.  
1430 Broadway  
Quincy, MA 02269  
New York, New York 10018  
Figure 3–Check Valve Operation  
Figure 4—Pressure Switch Location  
Blower  
Pressure Switch  
WARNING!  
Do Not Install Any Valves Here!  
See Section 2.0  
P
Tube at  
Blower Inlet  
Burner Air Tap  
See Figure 7  
Lo  
Hi  
Tee  
Process Air  
Gas Inlet  
Manifold  
P
Check Valve Opens When  
Gas Inlet Pressure Is at Low Fire  
Tube Points  
Downstream  
Tube Points  
Upstream  
Hi  
Lo  
Circulating Air  
Pressure Switch  
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Eclipse AirHeat v1.0 - Installation Guide No. 140, 11/4/03  
 
Figure 5–Mounting & Duct Lengths  
Sealed  
In-Duct  
Slot-Fired  
Duct Press: +0.2" to –0.5" w.c.  
+0.5 to –1.2 mbar  
Duct Press: 0" to –0.5" w.c.  
0 to –1.2 mbar  
Min./Max. Velocity: 500 to 6000 fpm  
2.54 to 30.48 m/s  
Optimum Velocity:1000 to 4000 fpm  
5.08 to 20.32 m/s  
Min./Max. Velocity: 500 to 1200 fpm  
Min./Max. Velocity: 500 to 1200 fpm  
2.54 to 6.10 m/s  
2.54 to 6.10 m/s  
• Provide at least 3" (76 mm) clear-  
ance between burner and top, bot-  
tom and sides of the duct.  
• Profile plates are not required for  
good burner operation, but uni-  
form velocity must be maintained  
for full length of burner. If velocity  
is not uniform, profile plates can  
be used to correct this condition.  
Min./Max. Velocity: 500 to 1200 fpm  
Min./Max. Velocity: 500 to 1200 fpm  
2.54 to 6.10 m/s  
2.54 to 6.10 m/s  
Guidelines for All Mounting Arrangements  
• Center the burner in the duct.  
• Allow a minimum of 46" (1168 mm) from burner to nearest point  
of possible flame impingement at an input of 1,000,000 Btu/hr.  
(962 kW/m).  
Min./Max. Velocity: 500 to 6000 fpm  
2.54 to 30.48 m/s  
• On burners longer than 36" (914 mm), use a hanger or a pedes-  
tal to support the blower and motor.  
Optimum Velocity:1000 to 4000 fpm  
5.08 to 20.32 m/s  
Duct Lengths  
Minimum Distance Before Transition  
Rectangular Ducts: One Height or Width, Whichever is Greater  
Round Ducts: One Diameter  
7.5°  
Maximum  
Air Flow  
AH  
Burner  
Minimum Distance Before  
Possible Flame Impingement = 46"  
5
Eclipse AirHeat v1.0 - Installation Guide No. 140, 11/4/03  
 
3.0 Duct Design and Burner Mounting  
Duct Design  
See Figure 5 for typical mounting arrangements and duct designs.  
Support  
The mounting flange or brackets supplied with an AH burner are capable of sup-  
porting the weight of the burner and blower. The AH burner case itself is de-  
signed to support the weight of the blower, so the blower does not require inde-  
pendent support.  
Valve Train Support  
Gas Piping  
Support valve trains independently of the burner.  
Use flexible nipples to allow for thermal expansion of the burner.  
Gas flow through the check valve must be horizontal. See Figure 3.  
Check Valve Piping  
Gas Piping Standards  
Gas piping must comply with American National Standard entitled “National Fuel  
Gas Code”* (NFPA No. 54 or ANSI Z223.1), or must be acceptable to the author-  
ity having jurisdiction.  
Wiring Standards  
Electrical wiring must comply with the National Electric Code*, (NFPA Std. 70 or  
ANSI-CI 1981), or must be acceptable to the authority having jurisdiction.  
*Available from:  
National Fire Protection Association  
Batterymarch Park  
American National Standard Inst.  
1430 Broadway  
Quincy, MA 02269  
New York, New York 10018  
4.0 Start-Up And Adjustment  
Initial Settings  
Adjust the linkage of the gas control valve so that when heat is called for, the  
valve is 10° from fully open, and when cooling is required, the valve is approxi-  
mately 5° from fully closed.  
Close all manual gas cocks.  
With the pilot cock handle in the closed position, remove the top screw and turn  
the adjusting screw five turns out from fully closed. See Figure 6.  
Start Blower  
Start the combustion air blower on the burner. Check the rotation to make sure it  
is correct. If not, have a qualified electrician rewire the blower for proper rotation.  
Start Circulating Fan  
Start the duct circulating fan.  
Figure 6–Pilot Cock  
Figure 7–Pressure Measurement  
Handle  
(Shown in  
Open Position)  
Top Screw  
Air Pressure  
Taps (2)  
Gas  
Pressure  
Tap  
Duct Tap  
10" to 20"  
Downstream of Burner  
Adjusting Screw  
(Clockwise for less pilot gas,  
Counterclockwise for more pilot gas)  
6
Eclipse AirHeat v1.0 - Installation Guide No. 140, 11/4/03  
 
4.0 Start-Up And Adjustment (cont’d.)  
Set Air Pressure Drop  
Measure the air pressure drop across the burner as shown in Figure 7.  
Turn the disc on the blower air inlet until the air pressure drop is between 0.4"  
w.c. minimum and 1.0" w.c. maximum. For a given input, lower air pressure  
drops will produce a longer flame, and higher drops will produce a shorter flame.  
Large Burners Only: Some models, such as the 640, 680, and 720 TAH burn-  
ers, contain a butterfly valve in the check valve line as shown in Figure 8. On  
these models, after setting the air flow as described in the previous paragraph,  
measure the air pressure drop between the gas pressure tap and duct as shown  
in Figure 7. Gas flow must be off. Adjust the butterfly valve to produce an air  
pressure drop of 0.2" w.c.  
Figure 8–Butterfly  
in Check Valve Line  
Start Spark  
Energize the ignition spark. Do not touch  
the ignition rod, ignition wire, or trans-  
former while the spark is energized, or  
you will get a shock.  
Butterfly Valve On  
640, 680 & 720  
TAH Burners  
Check  
Valve  
Set Pilot Flow  
Open all pilot gas valves, including the  
handle of the pilot cock, Figure 6. The pilot  
should light.  
Turn the pilot adjusting screw to produce a  
bushy blue flame that provides a flame  
monitoring signal strong enough to reliably  
open the gas shut-off valves.  
Set Gas Flow  
Measure the gas differential pressure as  
shown in Figure 7.  
With the gas control valve at low fire, open  
all main gas valves. The burner should  
light with a stable, blue low fire flame that extends evenly down the burner  
length.  
Drive the control valve to high fire and adjust the gas adjusting valve to produce  
a pressure drop that corresponds to the desired high fire rate, as shown in Fig. 1.  
When setting high fire, be sure the flame does not impinge on anything down-  
stream of the burner. To shorten the flame length for a given gas input, increase  
the air pressure drop as described above.  
Check All Settings  
Return the burner to low fire and check to be sure that the burner remains lit with  
a stable flame that extends down the burner length. Cycle the burner between  
low and high fire several times, checking pressure drops and flame lengths.  
5.0 Routine Maintenance  
Motor Lubrication  
Oil the blower motor according to the manufacturer’s instructions as printed on  
the motor label.  
Ignition Plug/Flame Rod  
Ignition plugs and flame rods wear out over long periods of normal burner opera-  
tion. Eclipse recommends that the user keep at least one of each in stock at all  
times to prevent nuisance shutdowns.  
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Eclipse AirHeat v1.0 - Installation Guide No. 140, 11/4/03  
 
6.0 Trouble-Shooting  
Symptom  
Cause  
Check  
Remedy  
1. Burner does not  
start initially.  
a) Air pressure switches  
not making.  
a) Check pressures in  
duct at location of  
switch connections.  
b) Check electrical  
portion of switch.  
a) Change pressure  
connections where  
a more positive  
b) Faulty pressure  
switches.  
pressure is present.  
2. Burner kicks out  
shortly after start-up.  
a) Low gas pressure  
switch set too high.  
a) Check low pressure  
switch setting.  
a) Reset  
3. Pilot will not ignite on  
initial light-off.  
a) Raw gas fed into pilot  
causing carbon hair on  
spark plug.  
a) Check spark plug for  
carbon hair; also check  
gap on plug (should be  
3/64" - 3/32".  
a) Adjust pilot gas cock by  
first screwing needle  
closed, then with trans-  
former powered, open  
needle slowly 1/4 turn  
at a time.  
4. Flame failure when  
burner goes to high fire.  
a) Gas pressure to pilot  
regulator too high.  
a) Check pilot gas pressure  
to regulator (should be  
1 PSIG maximum).  
a) Relocate pilot gas line or  
use second pilot  
regulator.  
b) Bolts which fasten pilot  
casting to burner are not  
tight enough.  
c) Pilot regulator not react-  
ing fast enough to duct  
pressure changes.  
b) Check tightness of bolts.  
b) Tighten bolts.  
c) Clean impulse line of any  
dirt particles and relocate  
duct connection to trans-  
mit maximum duct  
pressure.  
c) Check impulse line for  
possible dirt clogging;  
also check impulse line  
duct connection to  
d) Check valve stuck open.  
determine if an effective  
pressure is being trans-  
mitted to regulator.  
d) Clean check valve.  
e) Too much pilot gas.  
e) Reduce pilot gas flow.  
a) See Remedy 4a.  
5. Flame failure when main  
burner returns from high  
to low fire.  
a) Gas pressure to pilot  
regulator.  
a) See Check 4a.  
b) Under-gassing pilot.  
b) Check pilot regulator  
inlet and outlet gas  
pressures; also check  
pilot flame.  
b) Open needle on pilot  
adjusting cock slowly  
1/4 turn at a time.  
c) See Check 4c.  
c) See Remedy 4c.  
6. Main flame too large at  
high fire.  
a) Gas pressure too high  
at burner inlet.  
a) Check gas pressures.  
a) Screw out on main gas  
pressure regulator.  
Adjust linkage on gas  
control valve to hold  
valve less than full open  
when at high fire.  
b) Combustion air pressure  
too low.  
b) Check air pressure  
differential.  
c) Check valve stuck open.  
b) Open air shutter on  
makeup air blower.  
c) Clean check valve.  
7. Main flame not  
a) Air pressure  
differential too high.  
b) Burner not firing rated  
input.  
a) Check air pressure  
differential between  
combustion air manifold  
and main duct.  
b) Check gas pressure  
differential.  
a) Close air shutter on  
makeup air blower.  
b) Screw in on main gas  
pressure regulator to  
provide more gas.  
c) Clean gas holes with #42  
MTD drill. Clean air  
holes with #27 MTD  
drill.  
extending beyond face  
of burner at high fire.  
c) Burner gas holes  
plugged.  
c) Check gas holes for dirt  
or lint.  
8. Main flame long and  
yellow.  
a) Velocity past burner  
lower than 500 FPM.  
b) Check valve stuck open.  
a) Check velocities and  
rotation of main  
a) Open shutter on  
makeup air blower.  
b) Clean check valve.  
circulating fan.  
Info 140 11/4/03  
 

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