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
6
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
7
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

Eclipse RatioAir v1 - Design Guide No. 115, 2/14/05
11
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 specifications:
 rotation not to exceed rpm.
 minimum tor que of 5 in-lb. ( ,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.
- the chamber is to be fired with positive or negative
pressure.
- the chamber pressure is outside the range -1 w.c.
to +1 w.c. (- ,5 to ,5 mbar)
- there is a need to indicate a high and/or low fire air
butterfly valve (BV) position.
Burner Configuration
Select configuration.
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 flame rod or an ultra violet (U.V.) scanner will be
required. Flame rods are a vailable on model RA00 5, RA0040,
RA0075 and RA0100 burners with alloy or SiC tubes. All
other options and models require UV scanners. If a U.V.
scanner is required, it must be ordered separately.
Warning:
A U.V. scanner could possibl detect another burner s flame
if it is in the line of sight, and falsel indicate flame presence.
Inverted
right hand piping
Upright
left hand piping Upright
right hand piping
Configuration selections:
Inverted
left hand piping

Eclipse RatioAir v1 - Design Guide No. 115, 2/14/05
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.
Warning:
Eclipse Combustion supports the NFPA
regulation requiring, as a minimum standard for
main gas shut-off s stems, the use of an air
p ressure switch in conjunction with other s stem
components.
Note:
Standard blower options are listed in Price List 115,
additional blower options are available through Eclipse
Combustion. 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
NE A frames.
Pressure & Flow
RatioAirs include a combustion air blowe r.
Blower Motor Type
otor types include various options: voltages, single or three
phase, TEFC or automotive duty enclosures.
Blow er 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.
Step 1: Burner Option
Selection (continued)
12
Step 2: Blow er Option
Selection
Air Inlet
Filter Air
Flow
Switch
Right Hand
Blower Moto
r

Eclipse RatioAir v1 - Design Guide No. 115, 2/14/05
All standard RatioAirs are designed for:
 air:gas ratio controlled combustion.
 10% to 15% excess air at high fire.
 higher excess air at low fire
Burner Control
RatioAirs come with a ratio regulator that maintains the air:gas
ratio.
 A control signal is sent from a process temperature
controller (sold separately) to the control motor. (Refer to
Bulletin 818C or contact Eclipse Com ustion for further
information on temperature controllers.)
Control
Signal
Gas Flow
Process
Set Point Process
Controller
Control
Motor
Air
BV
Ratio
Regulator
Temperature
Pressure
Impulse
 The control motor modulates the air butterfly valve (BV)
which controls the combustion air flow.
 Air pressur e in the burner body sends an impulse down the
loading line to the ratio regulator.
 The ratio regulator controls the gas flow in proportion to the
air flow.
Warning:
Do not use other control methods, such as, a fixed-air
control, and do not alter the ratio regulator or
burner piping without prior appr oval from Eclipse
Combustion.
13
Step 3: Control
ethodology
Air/Gas Flow
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
Gas Flow
Ratio
Regulator
Loading Line
Control
Motor
Air Butterfly Valve (BV)
Heat

Eclipse RatioAir v1 - Design Guide No. 115, 2/14/05
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 NO USE the following:
 twin outlet transformer
 distributor type transformer.
Trial For Ignition
It is recommended that low fire start be used. How ever,
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 take s 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 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 bypass start gas.
14
Step 4: Ignition System

Eclipse RatioAir v1 - Design Guide No. 115, 2/14/05
Ignition Gas Piping
RatioAirs are capable of ignition with either low fire or bypass
start gas.
Low Fire Start:
Main gas
shut-off
valve train
Bypass Start Gas (optional):
Main gas
shut-off
valve train
NC
Optional fuel orifice meter recommended.
NC
An optional fuel orifice 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 orifice meter for 5
to 10 w.c. pressure drop when the gas flow is at the burners
rated low fire.
15
Step 4: Ignition System
(continued)

Eclipse RatioAir v1 - Design Guide No. 115, 2/14/05
The flame 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
 U .V. scanner
Flame rods are a vailable only for the RA0100 Burner model
with alloy or SiC tube. Further information can be found in
 Info Guide 832
A U.V. scanner can be used on all RatioAir Burner sizes.
Further information can be found in
 Info Guide 852; 90º U.V. scanner
 Info Guide 854; straight U.V. scanner
 Instruction Manual 855; Solid State UV/IR scanner
 Info Guide 856; self-check U .V. scanner.
Flame Monitoring Control
The flame monitoring control is the equipment that processes
the signal from the flame rod or the U.V. scanner.
For flame monitoring control you may select several options
 flame monitoring control for each burner if one burner
goes down, only that burner will be shut off
 multiple burner flame monitoring control if one burner goes
down, all burners will be shut off
There are three recommended flame monitoring controls
 Bi-flame series; see Instruction Manual 826
 Multi-flame series 6000; see Instruction Manual 820
 Veri-flame; see Instruction Manual 818
Other manufacturers flame monitoring systems can be used
with the burner if spark is maintained for a fixed time interval
and is not interrupted when a flame signal is detected during
trial for ignition.
16
Flame Rod
U.V. Scanner
Step 5: Flame Monitoring
Control System

Eclipse RatioAir v1 - Design Guide No. 115, 2/14/05
Component Selection
Eclipse Combustion can help in the design of a main gas shut-
off valve train that satisfies the customer and complies with all
local safety standards and codes set by the authorities within
that jurisdiction. Contact Eclipse Combustion for further
information.
Note:
Eclipse Combustion 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 specified in the RatioAir data sheet. The valve train
should be sized sufficiently to provide the specified pressure.
Warning:
Do not operate RatioAir burners with gas inlet
pressure less than the minimum listed on the
RatioAir Data Sheet. Lower gas inlet pressures
may cause the ratio regulator to remain ully
open at lower inputs as the burner transitions
rom lo w to high ire. This could result in the
possible accumulation o unburned uel in the
burner which, in extreme situations, could cause
a ire or an explosion.
17
Step 6: Main Gas Shut-Off
Valve Train

Eclipse RatioAir v1 - Design Guide No. 115, 2/14/05
18
Appendix
C ONVERSION
F ACTORS
Metric to English.
F rom To Multiply By
cubic meter (m
3
) cubic foot (ft
3
) 35.31
cubic meter/hour (m
3
/h) cubic foot/hour (cfh) 35.31
degrees Celsuis (ºC) degrees Fahrenheit (ºF) (ºC x 1.8) + 32
kilogra (kg) pound (lb) 2.205
kilowatt (kW) BTU/hr 3414
eter ( ) foot (ft) 3.28
illibar ( bar)
inches water colu n (w .c.) 0.401
illibar ( bar) pounds/sq in (psi) 14.5 x 10
-3
millimeter (mm) inch (in) 3.94 x 10
-2
MJ/m
3
(normal) BTU/ft
3
(standard) 2.491 x 10
-2
Metric to Metric.
kiloPascals (kPa) millibar (mbar) 10
meter (m) millimeter (mm) 1000
millibar (mbar) kiloPascals (kPa) 0.1
millimeter (mm) meter (m) 0.001
English to Metric.
F rom To Mulitply By
BTU/hr kilowatt (kW) 0.293 x 10
-3
cubic foot (ft
3
) cubic meter (m
3
) 2.832 x 10
-2
degrees Fahrenheit (ºF) degrees Celsius (ºC) (ºF  32) ÷ 1.8
foot (ft) meter (m) 0.3048
inches (in) millimeter (mm) 25.4
inches ater column ( c) millibar (mbar) 2.49
pound (lb) kilogram (kg) 0.454
pounds/sq in (psi) millibar (mbar) 68.95
BTU/ft
3
(standard) MJ/m
3
(normal) 40.14

Eclipse RatioAir v1 - Design Guide No. 115, 2/14/05
19
RatioAir
Main Gas Shutoff
Valve Train
Gas Cock
Solenoid Valve
(normally closed)
Fuel Orifice Meter
Adjusta le Limiting
Orifice
Pressure Regulator
Eclipse Com ustion, Inc.
strongly endorses NFPA as a
minimum
Gas cocks are used to
manually shut off the gas
supply on oth sides of the
main gas shut-off valve train.
Solenoid valves are used to
automatically shut off the gas
supply on a ypass gas system
or on small capacity urners.
Fuel orifice meters are used to
measure gas flow.
Adjusta le limiting orifices are
used for fine adjustment of gas
flow.
NC
K EY TO S YSTEM
S CHEMATICS
These are the symbols used in the schematics.
756
710
760
910
684
742
Symbol Appearance Name Remarks Bulletin/
Info Guide
A ratio regulator is used to control
the air/gas ratio. The ratio
regulator is a sealed unit that
adjusts the gas flow in ratio with
the air flow. To do this, it measures
the air pressur e with a pressure
sensing line, the impulse line. This
impulse line is connected between
the top of the ratio regulator and
the burner body.
A pressur e regulator reduces
gas pressure to a stable, usable
pressure.
Ratio Regulator

Eclipse RatioAir v1 - Design Guide No. 115, 2/14/05
Pressure Ta ps
Impulse Line
K EY TO S YSTEM
S CHEMATICS ( CONTINUED )
20
Symbol Appearance Name Remarks Bulletin/
Info Guide