Eclipse AH-MA Series Guide

No. 160, 8/1/05
Design Guide
AirHeat
Burners
Version 2
AH-MA Series

Eclipse AH-MA Air Heat Burner v2, Design Guide 160, 8/1/05
2
Copyright 2004 by Eclipse, In c. 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 e press
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 accordingl y.
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 e pressed or implied.
We have made every effort to make this man ual 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 will not be liable for any other injury, loss,
damage or e penses, 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 e pressly prohibited in this Guide, any
adjustment, or assembly procedures not recommended or
authorized in these instructions shall void the warranty.
C OPYRIGHT
D ISCLAIMER NOTICE
L IABILITY AND
WARRANTY

Eclipse AH-MA Air Heat Burner v2, Design Guide 160, 8/1/05
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This manual has been written for those persons who are already
familiar with all the aspects of an air heat burner and its add-on
components, also referr ed to as the burner system. These aspects
are:
 design/selection
 installation
 use
 maintenance
The audience is expected to have pr evious experience with this
ind of equipment.
Design Guide No. 160
 This publication.
Data Sheet No. 160
 Required to complete design calculations in this guide.
Installation Guide No. 160
 Used with Data Sheet to complete installation.
Price Sheet No. 160
 Used to order burners.
 EFE-825 (Combustion Engineering Guide)
 Eclipse Bulletins & Instruction Manuals: 818, 820, 826, 832, 852, 854, 856
A UDIENCE
A H - MA PUBLICATIONS
About this manual
R ELATED PUBLICATIONS

Eclipse AH-MA Air Heat Burner v2, Design Guide 160, 8/1/05
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 Read this manual carefull y. Mak e sure that you understand the
structure and contents of this manual.
 Ob ey all the safety instructions.
 Do not deviate from any instructions or application limits in this
man ual without written consent from Eclipse Combustion.
 If you do not understand any part of the information in this
man ual, do not continue. Contact your Eclipse sales office or
Eclipse Combustion.
here a re several special symbols in this document. You must know
their meaning and importance.
he explanation of these symbols follows. Please read it thoroughly.
Danger:
Indicates hazards or unsafe practices which WILL
result in seve re personal injury or even death.
Only qualified and well trained personnel ar e
allowed to carry out these instructions or
procedures.
Act with gr eat care and follow the instructions.
Warning:
Indicates hazards or unsafe practices which could
result in se vere personal injury or damag e.
Act with gr eat 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 the text thoroughly.
D OCUMENT
CONVENTIONS
I MPORTANT NOTICES

Eclipse AH-MA Air Heat Burner v2, Design Guide 160, 8/1/05
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About this manual ....................................................................... 3
Table of Contents ........................................................................ 5
Introduction .................................................................................... 6
Product Description ....................................................................... 6
Safety ................................................................................................... 7
Introduction....................................................................................... 7
Safety .................................................................................................... 7
Capabilities.......................................................................................... 8
Operator Training ............................................................................. 8
Replace ent Parts ........................................................................... 8
System Design ............................................................................... 9
Design .................................................................................................. 9
Burner Design ................................................................................... 10
Step 1a: Calculating Maxi u Input Required................... 10
Step 1b: Choosing Design Heat Input at High Fire ............ 10
Step 1c: Deter ining the Length of Burner Needed ........ 10
Step 1d: Calculating Mini u Input Required ................... 10
Step 1e: Layout of the Burner Sections................................. 11
Figure 3.1.1 Burner Sections .................................................... 12
Figure 3.1.2 End Plate Exa ples.............................................. 14
Step 1f: Sizing & Layout of Gas Manifold ............................... 15
Step 1g: Sizing Profile Plates ...................................................... 16
Syste Design ................................................................................... 19
Step 2: Control Methodology................................................... 20
Step 3: Ignition Syste ............................................................... 21
Step 4: Fla e Monitoring Syste ............................................ 22
Step 5: Gas V alv e Train................................................................. 23
Appendix .......................................................................................... 25
Conversion Factors ......................................................................... 25
Table of Contents
1
2
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Eclipse AH-MA Air Heat Burner v2, Design Guide 160, 8/1/05
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P RODUCT
DESCRIPTION
Eclipse AH-MA v2.10 Air Heat burners produce a uniform, odorless,
and smokeless flame ideal f or heating fresh air in mak e-up and process
air heating applications. The AH-MA design provides stable operation
o ver a ide range of velocities, inputs, and fuels.
AH-MA v2.10 burners are line type burners constructed of cast
iron or aluminum burner bodies and diverging stainless steel air
ings. The burner bodies supply fuel to the center of the air ings to
control the air and fuel mixture inside the burner and to optimize
emissions and efficiency. Completely corrosion resistant design
options are available using aluminum burner bodies or electroless
nickel plated cast iron burner bodies.
The AH-MA v2.10 Air Heat burner is assembled from straight
sections, tees, and crosses to produce nearly any configuration
required. Large burners can be built as a combination of staged,
individually controlled sections to increase turndo n.
Figure 1.1 AH-MA v2.10 Air Heat Burner
Introduction
Adjustable
Profile Plate
Adjustable
Profile Plate
Heated Air
Air Wing
Uniform
Air Flow
Uniform
Air Flow
Gas Feed Pipe
Burner Body
Flame
Length
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Eclipse AH-MA Air Heat Burner v2, Design Guide 160, 8/1/05
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I NTRODUCTION
S AFETY
Safety
In this section, you will find important notices about safe
operation of a burner system.
Danger:
The burners covered in this manual are designed
to mix fuel with air and burn the resulting
mixture. All fuel burn-ing devices are capable of
pr oducing fires and explosions when improperl y
applied, installed adjusted, controlled, or
maintained.
Do not bypass any safety feature.
You can cause fires and e xplosions.
ever try to light the burner if the burner shows
signs of damage or malfunctioning.
Warning:
The burner and duct sections are l i ke ly to have
HOT surfaces. Always w ear protective clothing
when approaching the burner.
Note:
This manual gives inf ormation f or the use of these burners
for their specific limited design purpose. Do not deviate from
any instructions limits in this manual without written advice
f r om Eclipse Combustion.
Note:
Read this entire manual before you attempt to start the
system. If you do not understand any part of the information
in this manual, then contact your Eclipse representative or
Eclipse Combustion before you continue.
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Eclipse AH-MA Air Heat Burner v2, Design Guide 160, 8/1/05
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Adjustment, maintenance and troubleshooting of the
mechanical and the electrical parts of this system should be
done by qualified personnel with good mechanical aptitude
and experience with combustion equipment.
The best safety precaution is an alert and competent operator.
Thor oughly instruct new operators so they demonstrate an
adequate understanding of the equipment and its operation. Regular
r etraining must be scheduled to maintain a high degree of
proficiency.
Order replacement parts fr om Eclipse only. Any customer
supplied al es or switches should carry UL, FM, CSA, CGA and/or
CE appro al where applicable.
O PERATOR TRAINING
R EPLACEMENT PARTS
C APABILITIES

Eclipse AH-MA Air Heat Burner v2, Design Guide 160, 8/1/05
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Design structure
Designing a burner system is a straight-forward exercise of
combining modules that add up to a reliable and safe system.
The design process is divided into the following steps:
1. Burner design
a. calculating the maximum input requirements
b. choosing design heat input at high fire
c. determining the length of burner needed
d. calculating the minimum input requirements
e. layout of the burner sections
f. sizing and layout of the gas manifold
g. sizing the profile plates
h. burner staging
2. Control methodology
3. gnition system
4. Flame monitoring system
5. Gas valve train selection
Note:
Information in Data Sheet No. 160 is necessary to complete
some of the procedures.
D ESIGN
System Design
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Eclipse AH-MA Air Heat Burner v2, Design Guide 160, 8/1/05
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Calculating the maximum input requirements
To calculate the total burner maximum input required, solve:
Max. Input (Btu/hr) = 1.3 x SCFM x
∆ T (max)
Caution:
This is an appro ximation based on the gr oss heating value of the
fuel. F or more accurate heat balance calculations, refer to the
Eclipse Combustion Engineering Guide (EFE-8 5).
Choosing design heat input at high fire
See Data Sheet No . 160 for the following:
1 ) Use the Operating Range chart to determine the ma imum and
minimum heat inputs per foot of burner based on the known air
pressur e drop.
2) Use the Flame Length chart to check flame length versus a vailable
distance downstr eam of the burner for uniform temperature
distribution.
Determining the length of burner needed
Burner length, feet = max. heat input, total burner (Btu/hr)
heat input per foot (Btu/hr/ft)
Note:
Round fractional lengths (in ft.) up to the next half-foot.
Calculating minimum input required
1) Minimum Input (Btu/hr) = 1.3 x SCFM x T (min)
2) Min. Heat Input per foot, Btu/hr/ft = min. heat input, total burner, Btu/hr.
burner length, feet
3) With the minimum heat input per foot, go to the Operating
Range chart in Data Sheet No. 160 and confirm that the burner
can operate at the input for the air pre ure drop the burner will
ee. If the minimum input required i too low, there are two
option to obtain thi operating condition:
a. U e a taged burner control ( ee burner taging and control
method in thi ection).
b . Modulate the air flo w to a lower pre ure drop, thu low ering
the minimum input capability of the burner.
Example : A make-up air heat burner will be used to heat
60,000 SCFM air from 0°F to 80°F maximum and, from 75°F to
80°F minimum. Air
∆ P across the burner is designed to be
0.7"w.c. at high fire. The fuel is natural gas.
1) Max. Input Required: Btu/hr = 1.3 X 60,000 X 80 = 6,240,000
Btu/hr.
Step 1: Burner design
D