Eclipse AirHeat AH series Guide

Eclipse AirHeat
Burner
AH Serie
135 Design Guide
6/16/2010
Version 2

2
Copyright
Copyright 1999 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.
Disclaimer Notice
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 specified herein, confirmation
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.
Liability & Warranty
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
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 manual, any
adjustment, or assembly procedures not recommended or
authorized in these instructions shall void the warranty.
Document Conventions
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.
This is the safety alert symbol. It is used to alert you to potential personal
injury hazards. Obey all safety messages that followthis symbol to avoid
possible injury or death.
Indicates ahazardous situation which, ifnot avoided, will result in death
or serious injury.
Indicates ahazardous situation which, ifnot avoided, could result in
death or serious injury.
Indicates ahazardous situation which, ifnot avoided, could result in
minor or moderate injury.
Is used to address practices not related to personal injury.
Indicates an important part oftext. Read thoroughly.
NOTE
NOTICE
CAUTION
WARNING

3
Eclipse AirHeat Burner, V2, Design Guide 135, 6/16/2010
Table of Contents
1 Introduction............................................................................................................................ 4
Product Description .............................................................................................................. 4
Audience .............................................................................................................................. 4
Purpose................................................................................................................................ 4
Related Documents.............................................................................................................. 4
2 Safety...................................................................................................................................... 5
Safety Warnings................................................................................................................... 5
Capabilities........................................................................................................................... 5
Operator Training ................................................................................................................. 5
Replacement Parts...............................................................................................................5
3 System Design....................................................................................................................... 6
Design .................................................................................................................................. 6
Step 1: Burner Option Selection........................................................................................... 6
Step 2: Blower Option Selection........................................................................................... 7
Step 3: Control Methodology................................................................................................ 8
Step 4: Ignition System ........................................................................................................ 9
Step 5: Flame Monitoring Control System............................................................................ 9
Step 6: Main Gas Shut-Off Valve Train ................................................................................ 10
Appendix ................................................................................................................................... i
Conversion Factors ..............................................................................................................i
Key to Schematics................................................................................................................ ii

4Eclipse AirHeat Burner, V2, Design Guide 135, 6/16/2010
Introduction
Product Description
Eclipse AirHeat Burners are line type burners ideal for
generating large volumes of clean, hot air. Applications
include ovens, dryers, fume incinerators, and similar
industrial equipment. Burners are constructed of
aluminum burner bodies and diverging stainless steel air
wings. The burner bodies supply fuel to the center of the
air wings. The air and fuel mixture inside the burner is
controlled to optimize emissions and efficiency.
AirHeat Burners are assembled from straight sections
allowing for customized inputs. An integral combustion air
blower can be ordered mounted on the back of the
burner’s steel or stainless steel housing case. By
supplying the correct air volume and pressure to the
burner, the blower allows stable operation over a wide
range of duct velocities without installing a profile plate
around the burner.
Brackets are available for slot firing or duct mounting and
flanges are available for continuous flange mounting.
Right hand or left hand gas piping can be supplied with
BSP or NPT connections. A reduced port fuel control
valve can be supplied with a variety of control motor and
linkage options. Ignition can be by direct spark or by spark
ignited pilot. Flame rod flame supervision can be from
either or both ends. Several air flow switches are also
available factory mounted on the burner.
Figure 1.1. AirHeat Burner
Audience
This manual has been written for personnel already
familiar with all aspects of a gas burner and it’s add-on
components, also referred to as the burner package.
These aspects are:
• Design / Selection
• Use
• Maintenance
• Safety
The audience is expected to be qualified and have
experience with this type of equipment and its working
environment.
Purpose
The purpose of this manual is to make sure that the design
of a safe, effective and trouble-free system is carried out.
AirHeat Documents
Design Guide No. 135
• This document
Datasheet Series No. 135
• Available for individual AirHeat models
• Required to complete installation
Installation Guide No. 135
• Used with Datasheet to complete installationn
Related Documents
• EFE 825 (Combustion Engineering Guide)
• Eclipse Bulletins and Information Guides: 710, 720,
732, 742, 760, 818, 832, 852, 854, 856, 610, 620,
630, 826, 820, 930, I-354
Burner with blower
Burner less blower
with inlet gas piping
and fuel control valve
and continuous
mounting flanges
Burner less blower
with inlet gas piping
and fuel control valve
and spark ignited pilot.
1

5
Eclipse AirHeat Burner, V2, Design Guide 135, 6/16/2010
Safety
Important notices for safe operation of the burner system
will be found in this section. To avoid personal injury,
damage to property or the facility, the following warnings
must be observed. Read this entire manual before
attempting to start the system. If any part of the
information in this manual is not understood, contact
Eclipse before continuing.
Safety Warnings
ŶThe burners covered by this guide are designed to
mix gas with air and burn the resulting mixture. All
gas burning devices are capable of producing fires
and explosions if improperly applied, installed,
adjusted, controlled or maintained.
ŶDo not bypass any safety feature; fire or explosion
could result.
ŶNever try to light a burner if it shows signs of
damage or malfunction.
ŶThe burner and duct sections are likely to have
HOT surfaces. Always wear protective clothing
when approaching the burner.
ŶThis manual provides information in the use of the
burner for its specific design purpose. Do not
deviate from any instructions or application limits
described herein without written advice from
Eclipse.
Capabilities
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.
Operator Training
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.
Replacement Parts
Order replacement parts from Eclipse only. Any customer
supplied valves or switches should carry UL, FM, CSA,
CGA and/or CE approvals where applicable.
DANGER
WARNING
NOTICE
2

6Eclipse AirHeat Burner, V2, Design Guide 135, 6/16/2010
System Design
Design
When selecting an AirHeat burner, choices are available
to define a burner that will be safe and reliable for the
system in which it will be installed. The design process is
divided into the following steps:
1. Burner Option Selection:
• Burner Model / Size Selection
• Burner Style
• Air Supply
• Fuel Type
• Manifold Type
• Mounting Flange
• Burner Configuration
• Gas Pipe Connection
• Control Valve
• Ignition Type
• Flame Supervision
• Control Motor
• Air Flow Switch
2. Blower Option Selection:
• Power Supply Frequency
• Blower Motor Type
• Blower Inlet
• Motor Orientation
• Remote Blower Sizing
3. Control Methodology:
• Burner Control
4. Ignition System:
• Ignition Transformer
• Trial for Ignition
• Ignition Gas Piping
5. Flame Monitoring System:
• Flame Sensor
• Flame Monitoring Control
6. Main Gas Shut-Off Valve Train Selection:
• Component Selection
• Valve Train Size
Step 1: Burner Option Selection
This section describes how to select burner options to suit
an application. Use the AirHeat Price List 135 and
Datasheet, 135 when following this selection process.
ŶConsult EFE-825, Eclipse Combustion
Engineering Guide, or contact Eclipse Combustion
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.
•Process Air Temperature - Upstream process air
temperature will determine the housing material
required.
•Combustion Chamber Pressure - Consider the
effects that large or varying chamber pressures
have on burner performance.
•Altitude - Data supplied is based on burner
operation at 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
performance. The combustion air supply
temperature should not exceed 250° F.
•Fuel Type - Variation in calorific value and density
will affect burner performance.
Burner Style
AirHeat burners are available in straight sections only.
The standard housing material is steel, but for upstream
process temperature above 500°F (260°C), the stainless
steel housing option should be chosen.
Air Supply
AirHeat burners can be ordered with or without a
combustion air blower directly mounted to the burner. For
remote blower applications, see "Remote Blower Sizing".
CAUTION
3

7
Eclipse AirHeat Burner, V2, Design Guide 135, 6/16/2010
Fuel Type
If using an alternative fuel supply, contact Eclipse with an
accurate breakdown of the fuel components.
Manifold Type
AirHeat burners are available with aluminum burner
manifolds only.
Mounting Flange
Select the mounting hardware best suited to your
application. Hardware is available for Duct Mounting, Slot
Firing and Continuous Flange Mounting.
Burner Configuration
Left hand or right hand piping is available. Configuration is
based on viewing the burner from the air inlet.
Gas Pipe Connection
The piping, burner gas inlet, and fuel modulating valve (if
selected) are threaded using the customer selected pipe
thread option.
Control Valve
AirHeat Burners can be supplied with the following control
options:
•Reduced Port Packaged - The control valve is
sized based on burner input and fuel type. (See
pages 3 & 4 of Datasheet 135)
•Reduced Port Separate - Order when fuel control
valve cannot be mounted directly to the burner due
to system considerations.
•Less Control Valve - If not supplied by Eclipse,
customer must supply a suitable fuel control valve
capable of suppling fuel in accordance with the
burners operating range.
Ignition Type
Ignition can be by direct spark or spark ignited pilot.
Flame Supervision
Flame supervision is by flame rod or UV scanner.
Depending on configuration selected, flame sensor can
be mounted at either or both ends of the burner (see
Datasheet 135).
Control Motor
Select a control motor. Standard control motor options
include various models which Eclipse will mount to the
burner. Burners can be ordered with control motor bracket
and mounting hardware only. Customer supplied control
motors must conform to the these specifications:
• 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 fit an
application
- there is a need to indicate a high and/or low fire
butterfly valve position
Air Flow Switch
The air flow 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.
ŶEclipse 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.
Step 2: Blower Option Selection
NOTE: Standard blower options are listed in Price List
135, additional blower options are available through
Eclipse, price and leadtime may vary.
Power Supply Frequency
Blowers are available with 60Hz motors. Motors have
NEMA frames.
Blower Motor Type
Motor types include various options: voltages, single or
three phase.
Blower Inlet
When selecting an inlet, consider the following:
• amount and size of particles in the air
• cleanliness requirements of the process
Table 3.1 Fuel Type
Fuel Symbol
Gross
Heating
Value
Specific
Gravity
Stoichiometric
Air/Gas Ratio
Į(ft3air/ft3gas)
Natural
Gas CH490%+ 1000 BTU/ft3
(40.1 MJ/m3)0.60 1290 BTU/ft3
Propane C3H82525 BTU/ft3
(101.2 MJ/m3)
1.55 2028 BTU/ft3
Butane C4H10 3330 BTU/ft3
(133.7 MJ/m3)
2.09 2303 BTU/ft3
BTU/ft3@ standard conditions (MJ/m3@ normal conditions)
WARNING

8Eclipse AirHeat Burner, V2, Design Guide 135, 6/16/2010
Motor Orientation
All AirHeat burners are assembled with a right-hand
blower motor orientation.
Remote Blower Sizing
For remote blower applications, the blower should be
sized to supply sufficient flow and pressure to the burner
to ensure proper burner performance.
Example:
Fire an AirHeat0200 burner on natural gas at 800,000
BTU/hr/ lineal ft. resulting in maximum input of 1,600,000
BTU/hr at an air pressure drop of 1" w.c. In the chart,
locate 800,000 Btu/hr/LF and read up to the 1" w.c. 'P
curve and then left to determine the excess air
percentage. In this case, 44% excess air.
1. Determine Air Factor (1+ excess air %) = 1.44
2. Determine Fuel Flow (Input/Gros Heating Value*)
= (1,600,000/1000) = 1,600 scfh
3. Determine Air Flow (Air Factor x Stoichiometric Air
Requirement* x Fuel Flow) = 1.44 x 10 x 1,600
= 23,040 scfh air flow
* See Fuel Type Table
Step 3: Control Methodology
Input is normally controled by a motorized butterfly valve
in the gas line to the burner.
• A control signal is sent from a process temperature
controller (sold separately) to the control motor.
(Refer to Bulletin 818C or contact Eclipse
Combustion for further information on temperature
controllers.)
• The control motor modulates the gas butterfly valve
(BV) which controls the fuel flow to the burner.
• Air pressure and flow in the burner body remain
fixed throught the operating range.
• Modulation of fuel flow only, provides turndowns of
40:1.
ŶDo not use other control methods without prior
approval from Eclipse.
Control and Operational Zone
10
100
1000
10000
0200 400 600 800 1000
Input x1000 BTU/hr/lineal ft.
% Excess Air
Input (kW/lineal meter)
200 400 600 800 1000
0.6"w.c.
1.5mbar
0.8" w.c.
2.0 mbar
1.2" w.c.
3.0 mbar
0.6" w.c.
1.5 mbar
Typical Fixed
Air Control
1" w.c. (2.5 mbar)
0
Combustion
Air
Blower
Heat
Gas Flow
BV Valve
Control
Motor
Gas Flow
Control
Signal
Gas Flow
Process
Set Point Process
Controller
Control
Motor
Gas
BV
erutarepmeT
Mechanical
Linkage
WARNING

9
Eclipse AirHeat Burner, V2, Design Guide 135, 6/16/2010
Step 4: Ignition System
Ignition Transformer
For the ignition system, use a transformer with:
• secondary voltage 6000 to 8000 VAC
• minimum secondary current 0.02 amp continuous
• full wave output
DO NOT USE the following:
• twin outlet transformer
• distributor type transformer
Trial For Ignition
It is recommended that low fire start be used. However,
under certain circumstances AirHeat burners 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 gas flow conditions at start-up.
The possibility exists where the low fire 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 spark ignited pilot.
Ignition Gas Piping
AirHeat burners are capable of ignition with either direct
spark or spark ignited pilot.
Direct Spark Ignition
Spark Ignited Pilot
When ordered, the pilot is packaged with the burner and
includes an adjustable flow gas cock and pressure
regulator.
ŶIt is not possible to use a continuous or
intermittent pilot. The pilot fuel flow should be
interrupted after the trial ignition period has
expired.
Step 5: Flame Monitoring Control System
The flame monitoring control system consists of two main
components:
• flame sensor
• flame monitoring control
Flame Sensor
Two types can be used on AirHeat Burners:
• flame rod
• UV scanner
The UV scanner must be compatible to the flame
monitoring control that is used. Refer to the manual of
your selected control for proper selection of the scanner.
Flame Monitoring Control
The flame monitoring control processes the signal from
the flame sensor and controls the start-up and shut-down
sequences.
Eclipse recommends the following flame monitoring
controls:
• Trilogy series T400 (Instruction Manual 830)
• Veri-Flame series 5600 (Instruction Manual 818)
• Bi-Flame series 6500 (Instruction Manual 826)
• Multi-Flame series 6000 (Instruction Manual 820)
If other controls are considered, contact Eclipse to
determine how burner performance may be affected.
Flame monitoring controls that have lower sensitivity
flame detecting circuits may limit burner turndown and
change the requirements for ignition.
Flame monitoring controls that stop the spark as soon as
a signal is detected may prevent establishment of flame,
particularly when using UV scanners. The flame
monitoring control must maintain the spark for a fixed time
interval that is long enough for ignition.
Main Gas
shut-off
valve train
NC
Main Gas
Shut-Off
Valve Train
Pilot
CAUTION

10 Eclipse AirHeat Burner, V2, Design Guide 135, 6/16/2010
Step 6: Main Gas Shut-Off Valve Train
Component Selection
Eclipse can help in the design of a main gas shutoff valve
train that satisfies 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 burner inlet (Tap B) must be
10" w.c. The valve train should be sized sufficiently to
provide the specified pressure.

i
Conversion Factors
Metric to English
Metric to Metric
English to Metric
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 9/5) + 32
kilogram (kg) pound (lb) 2.205
kilowatt (kW) BTU/hr 3415
meter (m) foot (ft) 3.281
millibar (mbar) inches water column ("w.c.) 0.402
millibar (mbar) pounds/sq in (psi) 14.5 x 10-3
millimeter (mm) inch (in) 3.94 x 10-2
MJ/Nm³ BTU/ft³ (standard) 26.86
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
From To Multiply By
cubic foot (ft³) cubic meter (m³) 2.832 x 10-2
cubic foot/hour (cfh) cubic meter/hour (m³/h) 2.832 x 10-2
degrees Fahrenheit (°F) degrees Celsius (°C) (°F - 32) x 5/9
pound (lb) kilogram (kg) 0.454
BTU/hr kilowatt (kW) 0.293 x 10-3
foot (ft) meter (m) 0.3048
inches water column ("w.c.) millibar (mbar) 2.489
pounds/sq in (psi) millibar (mbar) 68.95
inch (in) millimeter (mm) 25.4
BTU/ft³ (standard) MJ/Nm³ 37.2 x 10-3
Appendix

ii Eclipse AirHeat Burner, V2, Design Guide 135, 6/16/2010
Appendix
Symbol Appearance Name Remarks
Bulletin/
Info Guide
AirHeat Burner
Main Gas Shut-Off Valve Train Eclipse strongly endorses NFPA
as a minimum. 756
Gas Cock
Gas cocks are used to manually
shut-off the gas supply on both
sides of the main gas shut-off
valve train.
710
Solenoid Shut-Off Valve
(Normally Closed)
Solenoid valves are used to
automatically shut off the gas
supply on a bypass gas system or
on small capacity burners.
760
Pressure Regulator
The pressure regulator reduces
gas pressure to a stable, usable
pressure.
684
Automatic Gas Control Valve
An automatic gas control valve
adjusts gas flow to the burner
based on control system
requirements.
720
Main gas
shut-off
valve train
NC

iii
Eclipse AirHeat Burner, V2, Design Guide 135, 6/16/2010
Notes

Offered By:
Power Equipment Company
2011 Williamsburg Road
Richmond, Virginia 23231
Phone [phone]
Fax [phone]
www.peconet.com