Eclipse Combustion RatioAir RA Series User manual

RatioAir
Burners
Installation Guide
No.115 4/7/06
Version 1
RA Series

Eclipse RatioAir v1 - Installation Guide No. 115, 4/7/06
2
Copyright 2004 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.
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 Eclipse’s 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 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.
Copyright
DisClaimer NotiCe
liability aND
WarraNty

Eclipse RatioAir v1 - Installation Guide No. 115, 4/7/06 3
About this manual
auDieNCe 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.
Installation Guide No. 115
• This document
RatioAir Data Sheets, Series 115
• Available for individual RA models
• Required to complete installation
Design Guide No. 115
Used with Data Sheet to design burner system
• 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 the installation and
adjustment of a safe, effective and trouble-free combustion
system.
ratioair
DoCumeNts
relateD DoCumeNts

Eclipse RatioAir v1 - Installation Guide No. 115, 4/7/06
4
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 qualified 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 pratices 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.
Note:
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:
1665 Elmwood Rd.
Rockford, Illinois 61103 USA
Phone: [phone]
Fax: [phone]
http://www.eclipsenet.com
DoCumeNt
CoNveNtioNs
hoW to get help

Eclipse RatioAir v1 - Installation Guide No. 115, 4/7/06
5
Table of Contents
1
About this manual ...........................3
Audience .....................................3
RatioAirDocuments............................3
RelatedDocuments.............................3
DocumentConventions .........................4
HowtoGetHelp ..............................4
Table of Contents ............................5
Introduction .................................6
ProductDescription ............................6
Safety ......................................7
Capabilities ...................................8
OperatorTraining ..............................8
ReplacementParts .............................8
Installation ..................................9
HandlingandStorage ...........................9
ApprovalsofComponents .......................9
Pre-installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . 11
Burner ......................................11
GasPiping ....................................13
Check List After Installation . . . . . . . . . . . . . . . . . . . . . . 15
Adjustment, Start & Stop .....................16
Step1: Resetthesystem ........................16
Step2: Setlowfireair..........................18
Step 3: Ignite the burner . . . . . . . . . . . . . . . . . . . . . . . . 19
Step 4: Set low fire gas (if required) . . . . . . . . . . . . . . . 24
Step5: Verifysettings ..........................26
Maintenance & Troubleshooting ...............27
Maintenance ..................................27
MonthlyChecklist..............................27
YearlyChecklist................................28
Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . 29
IllustratedPartsList ............................32
Appendix ...................................35
ConversionFactors ............................35
Key to System Schematics . . . . . . . . . . . . . . . . . . . . . . . 36
2
3
4
5

Eclipse RatioAir v1 - Installation Guide No. 115, 4/7/06
6
Introduction 1
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 fire 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:
• 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.
proDuCt DesCriptioN
The RatioAir Burner

Eclipse RatioAir v1 - Installation Guide No. 115, 4/7/06 7
iNtroDuCtioN This section is provided as a guide for the safe operation of the
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 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:
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 specific design purpose. Do not deviate from any
instructions or application limits described herein without
written advice from Eclipse Combustion.
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 your local Eclipse representative or
Eclipse Combustion before continuing.
safety
Safety 2

Eclipse RatioAir v1 - Installation Guide No. 115, 4/7/06
8
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.
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.
Capabilities
operator traiNiNg
replaCemeNt parts

Eclipse RatioAir v1 - Installation Guide No. 115, 4/7/06 9
iNtroDuCtioN
haNDliNg aND storage
approvals of
CompoNeNts
Installation 3
In this chapter you will find information and instructions needed
to install the burner and system components.
Handling
Inspect the system, being 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.
Keep 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 RatioAir v1 - Installation Guide No. 115, 4/7/06
10
Gas piping
All gas piping must comply with all applicable local codes and/or
standards, which may include:
• NFPA Standard 54
• ANSI Z223
• EN 746-2
Where to get the standards
The NFPA Standards are available from:
National Fire Protection Agency
Batterymarch Park
Quincy, MA 02269
The ANSI Standards are available from:
American National Standard Institute
1430 Broadway
New York, NY 10018
The UL Standards are available from:
333 Pfingsten Road
Northbrook, IL 60062
The FM Standards are available from:
1151 Boston-Providence Turnpike
P.O. Box 9102
Norwood, MA 02062
The CGA Standards are available from:
55 Scarsdale Road
Toronto, Ontario
Canada M3B 2R3
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

Eclipse RatioAir v1 - Installation Guide No. 115, 4/7/06 11
pre-iNstallatioN
CheCklist
burNer
Minimum 1/4" (6mm)
space per side
Combustor
Chamber wall
“C”
Air Supply
Provide an opening in the burner room of at least one square
inch per 4000 BTU/hr (6 cm2 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, frequency, 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.
Chamber Opening
Provide an opening in the chamber wall at least ½” (12mm)
larger in diameter than the outside diameter of the combustor,
or ½” (12mm) larger in height and width than the refractory
block.
(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 four mounting bolts to the chamber wall. Position
these bolts to match the clearance holes (C) on the burner
mounting flange. Refer to the appropriate RatioAir data sheet.

Eclipse RatioAir v1 - Installation Guide No. 115, 4/7/06
12
iNstallatioN
(CoNtiNueD)
4
2
Chamber
insulation
1
Chamber Wall
Make sure the chamber wall is strong enough to support
the weight of the burner . If necessary, reinforce the
mounting area.
Burner Mounting
Mount burner to chamber wall using four (4) customer supplied
nuts and lock washers.
Alloy Combustor
1. Make sure the gasket is installed between
the burner and the chamber wall .
2. Make sure that gasket does not leak.
3. Check the size of the clearance. If the gap
around the firing tube is larger than 1/2”, pack the
gap with ceramic fiber .
Silicon Carbide (SiC) Combustor only
1. Make sure the gasket is installed between the
burner flange and chamber wall.
2. Make sure that gasket is installed between SiC tube
and flange .
3. Make sure neither gasket nor leaks.
4. Check the size of the clearance. If the gap
around the firing tube is larger than 1/2”, pack the gap
with ceramic fiber .
1
2
1
3
4
1
2
5
6
5
1
4
3
Alloy
1
2
4
6
5
Silicon Carbide

Eclipse RatioAir v1 - Installation Guide No. 115, 4/7/06 13
Refractory Block
1. Be sure the gasket is installed between the burner 
and the block holder .
2. Be sure the gasket is installed between the block holder
and the chamber wall .
3. Support the weight of the refractory block with hard
brick work . Fill space around the block with soft
gasket material 3.
Burner Piping
The burner is factory assembled and shipped as ordered.
Note:
If it is necessary to redirect piping, be sure the:
• ratio regulator spring column is pointing up.
• arrow on the ratio regulator points in the direction of
gas flow .
• integral fuel orifice and o-rings are re-installed.
• same straight run of pipe remains between the ratio
regulator and the burner .
Supply Piping
Inlet pressure to the ratio regulator must stay within specified
limits. Refer to the appropriate RatioAir 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.
gas pipiNg
Refractory Block
Burner Piping
2
9
10
3
8
7
1
4

Eclipse RatioAir v1 - Installation Guide No. 115, 4/7/06
14
Control Motor
Pipe Connections
Bypass Start Gas Piping
Set
Screws
Motor
Shaft
Control
Motor
Coupling
Washers
BV
Shaft
Main gas
shut-off
valve train
NC
43
2
1
5
NC
Bracket
Pipe
Union
Bypass Start Gas Piping (optional)
nstall the piping as shown in the schematics using the following
guidelines.
• Locate the start gas solenoids 1 close to the burner. The gas
must reach the burner during the trial for ignition period.
• Minimize piping elbows.
• Install an adjustable limiting orifice (ALO) 2 for start gas
adjustment. Refer to Bulletin 728 and 730 for further
information.
• Include a straight run of pipe at least 8 inches long 3 before
(upstream from) the start gas orifice 5(optional) and at least 4
inches long 4after (downstream from) the start gas orifice.
Pipe Connections
• Installation of a pipe union in the gas line is recommended to
simplify burner removal.
• Use of flexible pipe is optional.
Note:
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.
Control Motor
Install a control motor to modulate the air butterfly valve if not
previously installed on the burner.
Note:
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.

Eclipse RatioAir v1 - Installation Guide No. 115, 4/7/06 15
CheCk list after
iNstallatioN
To verify the system was properly installed, perform the
following checks:
1. Be sure there are no leaks in the gas lines.
2. 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.
3. Be sure all components of the spark ignition system are
installed and functioning properly.
4. 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.
5. Be sure all valves are installed in the proper location and
correctly oriented relative to the flow direction.

Eclipse RatioAir v1 - Installation Guide No. 115, 4/7/06
16
iNtroDuCtioN
aDjustmeNt
Adjustment, Start &
Stop 4
Step 1: Reset the system
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:
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 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. Verify settings
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 RatioAir v1 - Installation Guide No. 115, 4/7/06 17
Step 1: Reset system
(continued)
Air BV
Open in this
direction only
Closed
Open
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:
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:
Gas inlet pressures must stay within the
specified range. Pressure above the specified
range can damage the ratio regulator.
Warning:
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.
8. Verify that the actuator opens the air BV towards the back
of the burner as shown. If it doesn’t, refer to the actuator’s
literature for instructions on how to reverse the direction.

Eclipse RatioAir v1 - Installation Guide No. 115, 4/7/06
18
Air BV Adjustment
Step2: Set low fire air
BV shaft shown in
closed position
Air BV Shaft
Air Differential Pressure
1
2
To
Chamber
Tap "C"
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:
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 on burner side of coupling .
Note:
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
When firing into a positive chamber pressure it may be
necessary to rotate the air BV from closed position in
the direction of actuator travel to increase air differential
pressure for reliable ignition.
c. Hold BV shaft firmly in place and tighten set screw 1.
Note:
High fire air adjustment is not required if burner is firing
into a neutral pressure chamber and a 90° travel 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. Air Flow.”
The air differential pressure may be up to 1” w.c.
lower than shown in the chart when the burner is not
firing. 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 RatioAir v1 - Installation Guide No. 115, 4/7/06 19
Step3: Ignite the burner
Ignition procedure:
Warning:
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.
Determine system layout and use the applicable ignition procedure.
Low fire start without high turndown option.
Procedure “A”, page 20
Bypass start gas without fuel orifice meter
Procedure “C”, page 22
Bypass start gas with fuel orifice meter
Procedure “D”, page 23
Low fire start with high turndown option.
Procedure “B”, page 21
Note:
The ratio regulator is factory set. Use Procedure
“A” only if burner does not ignite or requires
further adjustment.
Note:
The RatioAir burner with high turndown
option includes a ratio regulator with internal
bypass adjustment.
Main gas
shut-off
valve train
Main gas
shut-off
valve train
Ratio regulator
with bypass
adjusting screw
Main gas
shut-off
valve train
NC
NC
Main gas
shut-off
valve train
NC
NC

Eclipse RatioAir v1 - Installation Guide No. 115, 4/7/06
20
Ratio Regulator
Step3: Ignite the burner
Procedure A:
Low fire start without high
turndown option.
Bias
Adjusting
Screw
CW for
more gas
Main gas
shut-off
valve train
Low fire start without high turndown option:
1. Drive control motor to low fire.
2. Be sure combustion air blower is running.
3. Verify bias adjusting screw 1on ratio-regulator spring
column is six full clockwise turns (360° x 6) down from the
top (initial setting). Use five turns for Model RA0025 only.
4. Open main gas manual shut off valves.
5. Set system control to stay at low fire during and after
ignition sequence.
6. Attempt to ignite burner.
7. 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. Attempt to ignite burner.
d. Repeat steps b and cuntil burner ignites. If necessary,
refer to Chapter 5 for troubleshooting tips.
8. Flame signal strength:
Adjust gas flow with bias adjusting screw 1for lowest gas
flow that maintains a stable flame signal:
• clockwise, for more fuel
• counterclockwise, for less fuel.
9. 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. Verify repeatability of ignition and low fire flame signal.