Eclipse RatioAir RA Series User manual

RatioAir
Burners
Design Guide
No.115 2/14/05
Version 1
RA Series

Eclipse RatioAir v1 - Design Guide No. 115, 2/14/05
C OPYRIGHT
D ISCLAIMER N OTICE
L IABILITY AND
W ARRANTY
2
Cop yright 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
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 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 e pressed 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 wa y 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 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.

Eclipse RatioAir v1 - Design Guide No. 115, 2/14/05
About this manual
A UDIENCE
3
This manual has been written for people who are alr eady 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 had experience with
this ind of equipment.
Design Guide No. 115
 This document
RatioAir Data Sheets, Series 115
 Available for individual RA models
 Required to complete design & selection
Installation Guide No. 115
Used with Data Sheet to complete installation
RatioAir Price List No. 115
Used to order burners
 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.
R ATIO A IR
D OCUMENTS
R ELATED D OCUMENTS

Eclipse RatioAir v1 - Design Guide No. 115, 2/14/05
4
There are several special symbols in this document. You must
now their meaning and importance.
The explanation of these symbols follows below. Please read it
thoroughly.
Danger:
Indicates hazards or unsafe practices which WILL
r esult in se vere personal injury or even death.
Only qualified and well trained personnel are
allowed to carry out these instructions or
procedures.
Act with gr eat care and follow the instructions.
Warning:
Indicates hazards or unsafe pratices which could
result in se vere personal injury or damage.
Act with gr eat care and follow the instructions.
Caution:
Indicates hazards or unsaf e 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
repr esentative. You can also contact Eclipse Combustion at any
of the addresses listed on the back of this document.
D OCUMENT
C ONVENTIONS
H OW TO G ET H ELP

Eclipse RatioAir v1 - Design Guide No. 115, 2/14/05
Table of C ontents
1
5
About this man ual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
RatioAir Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Document Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
How to Get Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
perator Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
System Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Step 1: Burner ption Selection . . . . . . . . . . . . . . . . . . . . 10
Step 2: Blower ption Selection . . . . . . . . . . . . . . . . . . . . 12
Step 3: Control Methodology . . . . . . . . . . . . . . . . . . . . . .13
Step 4: Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Step 5: Flame Monitoring Control System . . . . . . . . . . . . 16
Step 6: Main Gas Shut- ff Valve Train . . . . . . . . . . . . . . . . 17
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Key to System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . 20
2
3

Eclipse RatioAir v1 - Design Guide No. 115, 2/14/05
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Introduction
P RODUCT D ESCRIPTION
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 ov er a wide gas turndown range
at a controlled ratio. Available with three different outlet tube
velocity characteristics (standard, medium and high velocity ,
RatioAir Burners are capable of flame speeds of 250 ft/s for
the medium velocity and 500 ft/s for 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.
The RatioAir Burner

Eclipse RatioAir v1 - Design Guide No. 115, 2/14/05
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I NTRODUCTION
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 a pplied, installed, adjusted,
controlled, or maintained.
Do not bypass any safety feature; fire or
explosion could result.
ev er try to light a burner if it shows signs of
damage or malfunction.
Warning:
The burner might ha ve HOT surfaces. Alway s
w ear protectiv e clothing when ap proaching the
burner.
Note:
This manual pr ovides information in the use of these burners
for their specif ic 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 befor e
continuing.
S AFETY
Safety
2

Eclipse RatioAir v1 - Design Guide No. 115, 2/14/05
Only qualified personnel, with good mechanical aptitude and
experience on 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 r eplacement parts fr om Eclipse Combustion only. All
Eclipse Combustion approved, customer supplied valves or
switches should car ry L, FM, CSA, CGA, and/or CE approval,
where applicable.
C APABILITIES
O PERATOR T RAINING
R EPLACEMENT P ARTS
8

Eclipse RatioAir v1 - Design Guide No. 115, 2/14/05
9
System Design
D ESIGN
Design structure
The design process is divided into the following steps:
1. Burner Option Selection including:
 Burner Model / Size Selection
 Fuel Type
 Air Supply
 Combustor Type
 Combustor Length
 Control Motor
 Burner Configuration
 Gas Pipe Connection
 Flame Supervision
 Air Flow Switch
2. Blo wer Option Selection including:
 Po wer Supply Frequency
 Pressure & Flow
 Blower Motor Type
 Blower Inlet
 Motor Orientation
3. Control Methodology including:
 Burner Control
4. Ignition System including:
 Ignition Transformer
 Trial For Ignition
 Ignition Gas Piping
5. Flame Monitoring Control System including:
 Flame Sensor
 Flame Monitoring Control
6. Main Gas Shut-Off Valve Train including:
 Component Selection
 Valve Train Size
3

Eclipse RatioAir v1 - Design Guide No. 115, 2/14/05
10
Step 1 describes how to select burner options to suit an
application. Use the RatioAir Price List 115 and Data Sheets,
Series 115 when following this selection process.
Caution:
Consult 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.
 Pow er Supply Fr equency. Burner capacity will vary
with power supply frequency (60Hz power).
 Combustion Chamber Pressure . Consider the
ef fects that large or varying chamber pressures have on
burner performance.
 Altitude. The maximum burner capacity is reduced by
appr oximately 3% each 1000 feet (300 meters) above
sea lev el.
 Combustion Air Supply. Combustion air should be
fresh (20.9% O
2
) and clean (without corr osives).
 Combustion Air Temperature. Changes in air suppl y
temperature can affect the burner capacity. The
combustion air supply temperature should not exceed
250° F.
 Fuel Type. Variation in calorific value and density will
af fect burner perf ormance.
Fuel Type
Fuel Symbol Gross Heating Value Specific Gravity
Natural gas CH490%+ 1000 BTU/ft30.60
1.52
1.95
(40 MJ/m3)
(103 MJ/m3)
(130 MJ/m3)
Propane C3H82570 BTU/ft3
Butane C4H10 3250 BTU/ft3
BTU/ft3@ standard conditions (MJ/m3@ normal conditions)
If using and alternative fuel supply, contact Eclipse Combustion
with an accurate breakdown of the fuel components.
Air Supply
When a standard RatioAir Version .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
refractor y block & holder. For ver tical do wn-firing
applications with block and holder, consult factor y.
Step 1: Burner Option
Selection