Page 1
Design Guide 115
11/12/2008
Eclipse RatioAir
Burners
RA Series
Version 1
Page 2
Co p y r i g h t
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.
Di s C l a i m e r No t i C e
li ab il it y a N D
Wa r r a N t y
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 specied herein, conrmation 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.
We have made every effort to make this manual as accurate
and complete as possible. Should you nd 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 benet of our customers. Please send your corrections and
comments to our Marketing Communications Manager.
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 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 Guide, any
adjustment, or assembly procedures not recommended or
authorized in these instructions shall void the warranty.
2
Eclipse RatioAir v1 Design Guide No. 115, 11/12/2008
Page 3
About This Manual
au D i e N C e
ra t i o ai r Do C u m e N t s
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.
Design Guide No. 115
This document•
Datasheet, Series 115
Available for individual RA models•
Required to complete design and selection•
Installation Guide No. 115
Used with Datasheet to complete installation•
Price List No. 115
Used to order burners•
Eclipse RatioAir v1 Design Guide No. 115, 11/12/2008
Related Documents
EFE 825 (Combustion Engineering Guide)•
Eclipse Bulletins and Info Guides: 710, 732, 742, 760, 818, •
832, 852, 854, 856, 610, 820, 930
Purpose
The purpose of this manual is to ensure that the design of a safe,
effective, and trouble-free combustion system is carried out.
3
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Do C u m e N t
Co N v e N t i o N s
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:
Indicates hazards or unsafe practices which WILL
result in severe personal injury or even death.
Only qualied and well trained personnel are allowed
to carry out these instructions or procedures.
Act with great care and follow the instructions.
Warning:
Indicates hazards or unsafe practices which could
result in severe personal injury or damage.
Act with great care and follow the instructions.
Caution:
Indicates hazards or unsafe practices which could result
in damage to the machine or minor personal injury, act
carefully.
ho W to ge t he l p
Note:
Indicates an important part of the text. Read thoroughly.
If you need help, contact your local Eclipse representative.
You can also contact Eclipse at:
1665 Elmwood Rd.
Rockford, Illinois 61103 U.S.A.
Phone: 815-877-3031
Fax: 815-877-3336
http://www.eclipsenet.com
4
Eclipse RatioAir v1 Design Guide No. 115, 11/12/2008
Page 5
Table of Contents
Introduction .................................................................... 6
1
Product Description ......................................................... 6
Safety .............................................................................. 7
2
Introduction ...................................................................... 7
Safety ..............................................................................7
Capabilities ......................................................................7
Operator Training.............................................................7
Replacement Parts ..........................................................7
System Design ............................................................... 8
3
Design .............................................................................8
Step 1: Burner Option Selection ......................................9
Step 2: Blower Option Selection ...................................... 11
Step 3: Control Methodology ...........................................11
Step 4: Ignition System.................................................... 12
Step 5: Flame Monitoring Control System ....................... 13
Step 6: Main Gas Shut-Off Valve Train ............................ 14
Appendix ........................................................................ 15
Conversion Factors .........................................................15
Key to System Schematics .............................................. 16
Eclipse RatioAir v1 Design Guide No. 115, 11/12/2008
5
Page 6
Introduction
1
pr o D u C t De s C r i p t i o N
The RatioAir is a nozzle-mix type burner designed for direct and
indirect air heating of a wide range of applications including:
Industrial Ovens and Furnaces•
Glass Lehrs•
Indirect Fired Air Heaters•
RTO Incinerators•
After Burners•
Galvanizing Kettles•
Waterbath Vaporizers•
The burner package includes a combustion air blower and an air/
gas ratio regulator to re over a wide gas turndown range with
controlled ratio. Available with three different outlet tube
velocity characteristics (standard, medium and high velocity),
RatioAir Burners are capable of outlet speeds of 250 ft/s with the
medium velocity and 500 ft/s with the high velocity.
The burner is designed for:
Efcient Ratio Controlled Combustion•
Reliable Burner Operation•
Simple Burner Adjustment•
Direct Spark Ignition•
Multiple Fuel Capability•
A wide variety of options and congurations are available due to
the modular design of the burner.
The RatioAir Burner
6
Eclipse RatioAir v1 Design Guide No. 115, 11/12/2008
Page 7
Safety
2
iN t r o D u C t i o N
sa f e t y
This section is provided as a guide for the safe operation of RatioAir burner system. All involved personnel should read this section
carefully before operating this system.
Danger:
The RatioAir burners, described herein, are designed
to mix fuel with air and burn the resulting mixture. All
fuel burning devices are capable of producing res
and explosions if improperly applied, installed,
adjusted, controlled, or maintained. Do not bypass
any safety feature; re or explosion could result.
Never try to light a burner if it shows signs of damage
or malfunction.
Warning:
The burner might have HOT surfaces. Always wear
protective clothing when approaching the burner.
Note:
This manual provides information in the use of these
burners for their specic design purpose. Do not
deviate from any instructions or application limits
described herein without written advice from Eclipse. Read
the entire manual before attempting to start this system. If
you do not understand any part of the information
contained in this manual, contact Eclipse before
continuing.
Ca p a b i l i t i e s
op e r a t o r tr a i N i N g
re p l a C e m e N t pa r t s
Eclipse RatioAir v1 Design Guide No. 115, 11/12/2008
Only qualied personnel, with good mechanical aptitude and
experience with combustion equipment, should adjust, maintain, or
troubleshoot any mechanical or electrical part of this system.
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 prociency.
Order replacement parts from Eclipse only. All Eclipse approved,
customer supplied valves or switches should carry UL, FM, CSA,
CGA, and/or CE approval, where applicable.
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Page 8
System Design
3
De s i g N
Design Structure
The design process is divided into the following steps:
Burner Option Selection Including:1.
Burner Model / Size Selection•
Fuel Type•
Air Supply•
Combustor Type•
Combustor Length•
Control Motor•
Burner Conguration•
Gas Pipe Connection•
Flame Supervision•
Air Flow Switch•
Blower Option Selection Including:2.
Power Supply Frequency•
Pressure and Flow•
Blower Motor Type•
Blower Inlet•
Motor Orientation•
Control Methodology Including:3.
Burner Control•
Ignition System Including:4.
Ignition Transformer•
Trial for Ignition•
Ignition Gas Piping•
Flame Monitoring Control System Including:5.
Flame Sensor•
Flame Monitoring Control•
Main Gas Shut-Off Valve Train Including:6.
Component Selection•
Valve Train Size•
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Eclipse RatioAir v1 Design Guide No. 115, 11/12/2008
Page 9
Step 1: Burner Option
Selection
Step 1 describes how to select burner options to suit an
application. Use the RatioAir Price List 115 and Datasheets,
Series 115 when following this selection process.
Caution:
Consult EFE-825 Eclipse Engineering Guide, or contact
Eclipse if you have special conditions or questions.
Burner Model / Size Selection
Consider the following when selecting the burner size:
Heat Input: • Calculate the required heat input to achieve
the required heat balance.
Power Supply Frequency: • Burner capacity will vary with
power supply frequency (60Hz power).
Combustion Chamber Pressure: • Consider the effects
that large or varying chamber pressures have on burner
performance.
Altitude:• The maximum burner capacity is reduced by
approximately 3% each 1000 feet (300 meters) above sea
level.
Combustion Air Supply:• Combustion air should be fresh
(20.9% O2) and clean (without corrosives).
Combustion Air Temperature: • Changes in air supply
temperature can affect the burner capacity. The
combustion air supply temperature should not exceed
250°F.
Fuel Type: • Variation in caloric value and density will
affect burner performance.
Fuel Type
Fuel Symbol Gross Heating Value Specic Gravity
Natural Gas CH490%+ 1000 BTU/ft3 (40 MJ/m3) 0.60
Propane C3H
Butane C4H
BTU/ft3 @ standard conditions (MJ/m3 @ normal conditions)
2570 BTU/ft3 (103 MJ/m3) 1.52
8
3250 BTU/ft3 (130 MJ/m3) 1.95
10
If using and alternative fuel supply, contact Eclipse with an accurate
breakdown of the fuel components.
Air Supply
When a standard RatioAir Version 1.0 burner is ordered, a
combustion air blower is supplied and mounted directly to the burner
body.
Combustor Type
Select a combustor type based on the application. Low temperature
applications use an alloy combustion tube. High temperature
applications use a silicon carbide (SiC) tube or a refractory block &
holder. For vertical down-ring applications with block and holder,
consult factory.
Eclipse RatioAir v1 Design Guide No. 115, 11/12/2008
9
Page 10
Step 1: Burner Option
Selection (Continued)
Conguration Selections:
Upright Left Hand Piping
Upright Right Hand Piping
Control Motor
Select a control motor. Standard control motor options include
various models which Eclipse will mount to the burner. RatioAirs
can be ordered with control motor bracket and mounting hardware
only. Customer supplied control motors must conform to the these
specications:
rotation not to exceed 2 rpm•
minimum torque of 25 in-lb (2,8 Nm)•
90° stroke•
continuous modulating or high/low modulating control•
reversible direction of rotation•
certain applications may require control motors with a limit •
switch or switches if:
-
the burner capacity is to be limited to t an application
- the chamber is to be red with positive or negative
pressure
- the chamber pressure is outside the range -1" w.c.
to +1" w.c. (-2,5 to 2,5 mbar)
- there is a need to indicate a high and/or low re air
buttery valve (BV) position
Burner Conguration
Select conguration.
Inverted Left Hand Piping
Inverted Right Hand Piping
Gas Pipe Connection
Select the gas pipe connection including the pipe thread type and
the turndown required.
The piping, burner gas inlet, and ratio regulator are threaded using
the customer selected pipe thread option.
The high turndown option includes a ratio regulator with an
adjustment for lower inputs.
Flame Supervision
Determine if a ame rod or an ultraviolet (UV) scanner will be
required. Flame rods are available on model RA0025, RA0040,
RA0075 and RA0100 burners with alloy or SiC tubes. A amerod
can also be used on RA0200 burners but with upright left hand
piping or inverted right hand piping congurations only. All other
options and models require UV scanners. If a UV scanner is
required, it must be ordered separately.
Warning:
A UV scanner could possibly detect another burner’s
ame if it is in the line of sight, and falsely indicate
ame presence.
Air Flow Switch
The air ow switch provides a signal to the monitoring system
when there is not enough air pressure from the blower. If a switch
is selected, it will be factory mounted.
Warning:
Eclipse supports the NFPA regulation requiring, as
a minimum standard for main gas shut-off systems,
the use of an air pressure switch in conjunction with
other system components.
10
Eclipse RatioAir v1 Design Guide No. 115, 11/12/2008
Page 11
Step 2: Blower Option
Air Inlet
Filter
Air
Flow
Switch
Right
Hand
Blowe
r
Motor
Gas Flow
Ratio
Regulator
Loading Line
Control
Motor
Air Butterfly Valve (BV)
Heat
Gas
Air
Stoichiometric
R
a
t
i
o
c
o
n
t
r
o
l
o
p
e
r
a
t
i
o
n
Excess air
Selection
Step 3: Control
Methodology
Note:
Standard blower options are listed in Price List 115,
additional blower options are available through Eclipse.
Price and leadtime may vary.
Power Supply Frequency
Select the 50Hz or 60Hz option. The 50Hz blower motors have
IEC frames and are CE marked. The 60Hz motors have NEMA
frames.
Pressure & Flow
RatioAirs include a combustion air blower.
Blower Motor Type
Motor types include various options: voltages, single or three
phase, TEFC or automotive duty enclosures.
Blower Inlet
When selecting an inlet, consider the following:
amount and size of particles in the air•
sound requirements•
space limitations•
cleanliness requirements of the process•
Motor Orientation
All RatioAirs are assembled with a right-hand blower motor
orientation.
All standard RatioAirs are designed for:
air:gas ratio controlled combustion•
10% to 15% excess air at high re•
higher excess air at low re•
Burner Control
RatioAirs come with a ratio regulator that maintains the air:gas
ratio.
Air/Gas Flow
Eclipse RatioAir v1 Design Guide No. 115, 11/12/2008
A control signal is sent from a process temperature controller •
(sold separately) to the control motor. (Refer to Bulletin 818C
or contact Eclipse for further information on temperature
controllers.)
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Page 12
Step 3: Control
Control
Signal
Gas Flow
Process
Set Point
Process
Controller
Control
Motor
Air
BV
Ratio
Regulator
Temperature
Pressure
Impulse
Methodology
(Continued)
The control motor modulates the air buttery valve (BV) which •
controls the combustion air ow.
Air pressure in the burner body sends an impulse down the •
loading line to the ratio regulator.
The ratio regulator controls the gas ow in proportion to the air •
ow.
Warning:
Do not use other control methods, such as, a xed-air
control, and do not alter the ratio regulator or burner
piping without prior approval from Eclipse.
Step 4: Ignition System
Ignition Transformer
For the ignition system, use a transformer with:
secondary voltage 6,000 to 8,000 VAC•
minimum secondary current 0.02 amps continuous•
full wave output•
DO NOT USE the following:
twin outlet transformer•
distributor type transformer•
Trial for Ignition
It is recommended that low re start be used. However, under
certain circumstances RatioAirs are capable of direct spark ignition
at higher gas inputs.
Most local safety codes and insurance requirements limit the
maximum trial for ignition time (the time it takes for a burner to
ignite). These requirements vary from one location to another;
check your local codes and comply to the strictest codes
applicable.
The time it takes for a burner to ignite depends on the following:
the distance between the gas shut-off valve and the burner•
the air:gas ratio•
the gas ow conditions at start-up•
The possibility exists where the low re is too low to ignite the
burner within the maximum trial for ignition time. The following
options must be considered under these conditions:
start at higher gas input levels•
resize and/or relocate the gas controls•
use bypass start gas•
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Eclipse RatioAir v1 Design Guide No. 115, 11/12/2008
Page 13
Step 4: Ignition System
Main gas
shut-off
valve train
Main gas
shut-off
valve train
NC
Optional fuel orifice meter recommended.
NC
(Continued)
Ignition Gas Piping
RatioAirs are capable of ignition with either low re or bypass start
gas.
Low Fire Start:
Bypass Start Gas (Optional):
Step 5: Flame Monitoring
Control System
Flame Rod
UV Scanner
Eclipse RatioAir v1 Design Guide No. 115, 11/12/2008
An optional fuel orice meter connected in the start gas piping can
simplify start-up and adjustment. To start the burner at the lowest
possible gas input, select a fuel orice meter for 5" to 10" w.c.
pressure drop when the gas ow is at the burner’s rated low re.
The ame monitoring control system consists of two main
components:
Flame Sensor•
Flame Monitoring Control•
Flame Sensor
Two types can be used on a RatioAir Burner:
Flame Rod•
UV scanner•
Flame rods are available on model RA0025, RA0040, RA0075
and RA0100 burners with alloy or SiC tubes. A ame rod can also
be used on RA0200 burners but with upright left hand piping or
inverted right hand piping congurations only. Further information
can be found in:
Info Guide 832•
A UV scanner can be used on all RatioAir Burner sizes. Further
information can be found in:
Info Guide 852; 90° UV scanner•
Info Guide 854; straight UV scanner•
Instruction Manual 855; solid state UV/IR scanner•
Info Guide 856; self-check UV scanner•
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Step 5: Flame Monitoring
Control System
(Continued)
Step 6: Main Gas Shut-Off
Valve Train
Flame Monitoring Control
The ame monitoring control is the equipment that processes the
signal from the ame rod or the UV scanner.
For ame monitoring control you may select several options:
ame monitoring control for each burner: if one burner goes •
down, only that burner will be shut off
multiple burner ame monitoring control: if one burner goes •
down, all burners will be shut off
There are three recommended ame monitoring controls:
Bi-ame series; see Instruction Manual 826•
Multi-ame series 6000; see Instruction Manual 820•
Veri-ame; see Instruction Manual 818•
Other manufacturer’s ame monitoring systems can be used with
the burner if spark is maintained for a xed time interval and is not
interrupted when a ame signal is detected during trial for ignition.
Component Selection
Eclipse can help in the design of a main gas shut-off valve train
that satises the customer and complies with all local safety
standards and codes set by the authorities within that jurisdiction.
Contact Eclipse for further information.
Note:
Eclipse supports NFPA regulations (two gas shut-off
valves as a minimum standard for main gas shut-off
systems).
Valve Train Size
Fuel pressure supplied to the ratio regulator inlet must be within
the range specied in the RatioAir datasheet. The valve train
should be sized sufciently to provide the specied pressure.
Warning:
Do not operate RatioAir burners with gas inlet
pressure less than the minimum listed on the RatioAir
datasheet. Lower gas inlet pressure may cause the
ratio regulator to remain fully open at lower inputs
as the burner transitions from low to high re. This
could result in the possible accumulation of unburned
fuel in the burner which, in extreme situations, could
cause a re or an explosion.
14
Eclipse RatioAir v1 Design Guide No. 115, 11/12/2008
Page 15
Appendix
Co n v e r s i o n
Fa C t o r s
Metric to English
From To Multiply By
cubic meter (m³) cubic foot (ft³) 35.31
cubic meter/hr (m³/h) cubic foot/hr (cfh) 35.31
degrees Celsius (°C) degrees Fahrenheit (°F) (°C 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
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
-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
degrees Fahrenheit (°F) degrees Celsius (°C) (°F - 32) ÷ 18
foot (ft) meter (m) 0.3048
inch (in) millimeter (mm) 25.4
inches water column ("w.c.) millibar (mbar) 2.49
pound (lb) kilogram (kg) 0.454
pounds/sq in (psi) millibar (mbar) 68.95
BTU/ft³ (standard) MJ/m³ (normal) 40.14
Eclipse RatioAir v1 Design Guide No. 115, 11/12/2008
-3
-2
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Page 16
Ke y to sy s t e m Dr a w i n g s
NC
Symbol Appearance Name Remarks
RatioAir
Main gas
shut-off
valve train
Main Gas Shut-
Off Valve Train
Eclipse strongly endorses NFPA
as a minimum.
Gas cocks are used to manually
Gas Cock
shut off the gas supply on both
sides of the main gas shut-off
valve train.
Solenoid valves are used to
Solenoid Valve
(normally closed)
automatically shut off the gas
supply on a bypass gas system or
on small capacity burners.
Fuel Orice Meter
Fuel orice meters are used to
measure gas ow.
Bulletin /
Info Guide
756
710
760
910
Adjustable
Limiting Orice
Pressure
Regulator
Ratio Regulator
Pressure Taps
Adjustable limiting orices are
used for ne adjustment of gas
ow.
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 ow in ratio with
the air ow. 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 burner body.
684
742
16
Impulse Line
Eclipse RatioAir v1 Design Guide No. 115, 11/12/2008
Page 17
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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