Eclipse ThermJet TJ0015 Guide

Models TJ0015 – TJ2000
Version 2
Eclipse ThermJet
Burners
3/5/07
Design Guide 205

Eclipse ThermJet Design Guide No. 205, 3/5/07
Copyright
DisClaimer NotiCe
liability aND
WarraNty
Copyright 2007 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.
In accordance with the manufacture’s policy of continual prod-
uct 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 intend-
ed use of the product. If the product is used for purposes other
than those specied herein, conrmation of validity and suit-
ability must be obtained. Eclipse warrants that the product itself
does not infringe upon 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 nd errors or omissions,
please bring them to our attention so that we may correct
them. In this way we hope to improve our product documenta-
tion for the benet of our customers. Please send your cor-
rections 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 Guide, any adjust-
ment, or assembly procedures not recommended or authorized
in these instructions shall void the warranty.

3
Eclipse ThermJet Design Guide No. 205, 3/5/07
auDieNCe
relateD DoCumeNts
About this manual
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:
Design/selection
Use
Maintenance.
The audience is expected to have had experience with this
kind of equipment.
Design Guide No. 205
This document
Data Sheet No. 205-1 through 205-13
Available for individual TJ models
Required to complete design calculations in this guide
Installation Guide No. 205
Used with Data Sheet to complete installation
Price List No. 205
Used to order burners
EFE 825 (Combustion Engineering Guide)
Eclipse bulletins and Info Guides:
610, 710, 720, 730, 742, 744, 760, 930
Purpose
The purpose of this manual is to make sure that the design of a
safe, effective and trouble-free combustion system is carried out.
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thermJet DoCumeNts

Eclipse ThermJet Design Guide No. 205, 3/5/07
DoCumeNt
CoNveNtioNs
hoW to get help
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 qualied and well trained personnel are
allowed to carry out these instructions or proce-
dures.
Act with great care and follow the instructions.
Warning:
Indicates hazards or unsafe practices 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 care-
fully.
Note:
Indicates an important part of the text. Read thoroughly.
If you need help, contact your local Eclipse representative.You
can also contact Eclipse at:
1665 Elmwood Rd.
Rockford, Illinois 61103 U.S.A.
Phone: [phone]
Fax: [phone]
http://www.eclipsenet.com

5
Eclipse ThermJet Design Guide No. 205, 3/5/07
Table of contents
1
2
3
Introduction
Product Description.......................................................................... 6
Figure 1.1 The ThermJet Burner ..................................................... 6
Safety
Introduction ........................................................................................ 7
Safety..................................................................................................... 7
Capabilities ......................................................................................... 8
Operator Training............................................................................... 8
Replacement Parts............................................................................. 8
System Design
Design................................................................................................... 9
Step 1: Burner model selection....................................................... 9
Step 2: Control Methodology.......................................................... 10
Figure 3.1: Modulating gas & air:
On-ratio control or excess air @ low re............................ 12
Figure 3.2: Modulating gas with xed-air control ...................... 13
Figure 3.4: High/Low gas with xed-air control ........................ 15
Step 3: Ignition System..................................................................... 16
Figure 3.5: Bypass start gas circuit schematics ........................... 17
Step 5: Combustion Air System: Blower
and air pressure switch ............................................................. 19
Table 3.1: Required calculation information................................ 20
Table 3.2: Fuel gas heating values................................................... 20
Example blower calculation............................................................. 21
Step 6: Main gas shut-off valve train.............................................. 22
Step 7: Process Temperature Control System............................ 22
Appendix
Conversion Factors ........................................................................... 23
Key to System Schematics ............................................................... 24

Eclipse ThermJet Design Guide No. 205, 3/5/07
Introduction
proDuCt
DesCriptioN
1
The ThermJet is a nozzle-mix burner that is designed to re an
intense stream of hot gases through a combustor using ambient
combustion air.
The high velocity of the gases improves temperature uniformity,
product quality and system efciency.
The ThermJet burner comes in two types:
High Velocity (HV)
Medium Velocity (MV)
The gas velocity can be as high as 500 ft/s for the High Velocity
burner, and 250 ft/s for the Medium Velocity burner.
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Figure 1.1 The ThermJet Burner

7
Eclipse ThermJet Design Guide No. 205, 3/5/07
Important notices about safe burner operation will be found in
this section. Read this entire manual before attempting to start
the system. If any part of the information in this manual is not
understood, then contact your local Eclipse representative or
Eclipse, Inc. before continuing.
Danger:
The burners covered in this manual are designed
to mix fuel with air and burn the resulting mix-
ture. All fuel burning devices are capable of
producing res and explosions when improperly
applied, installed, adjusted, controlled or main-
tained.
Do not bypass any safety feature. Fires and ex-
plosions can be caused.
Never try to light the burner if the burner shows
signs of damage or malfunctioning.
Warning:
The burner is likely to have HOT surfaces. Al-
ways wear protective clothing when approaching
the burner.
Note:
This manual gives information for the use of these burners
for their specic design purpose. Do not deviate from any in-
structions or application limits in this manual without written
advice from Eclipse, Inc.
Safety 2
iNtroDuCtioN
safety

Eclipse ThermJet Design Guide No. 205, 3/5/07
Warning:
Eclipse products are designed to minimize the
use of materials that contain crystalline silica.
Examples of these chemicals are: respirable
crystalline silica from bricks, cement or other
masonry products and respirable refractory
ceramic bers from insulating blankets, boards,
or gaskets. Despite these efforts, dust created by
sanding, sawing, grinding, cutting, and other con-
struction activities could release crystalline silica.
Crystalline silica is known to cause cancer, and
health risks from the exposure to these chemi-
cals vary depending on the frequency and length
of exposure to these chemicals. To reduce this
risk, limit exposure to these chemicals, work in a
well-ventilated area and wear approved personal
protective safety equipment for these chemicals.
Adjustment, maintenance and troubleshooting of the mechanical
and the electrical parts of this system should be done by quali-
ed personnel with good mechanical aptitude and experience
with combustion equipment.
The best safety precaution is an alert and competent opera-
tor. Thoroughly instruct new operators so they demonstrate
an adequate understanding of the equipment and its operation.
Regular retraining must be scheduled to maintain a high degree
of prociency.
Order replacement parts from Eclipse only. Any customer-sup-
plied valves or switches should carry UL, FM, CSA,CGA and/or
CE approval where applicable.
Capabilities
operator traiNiNg
replaCemeNt parts
safety (CoNtiNueD)


Eclipse ThermJet Design Guide No. 205, 3/5/07
System Design 3
DesigN
Step 1: Burner model selection
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 model selection:
The burner size and quantity
The ame velocity
The fuel type and pressure
The combustor type
2. Control methodology
3. Ignition system
4. Flame monitoring system
5. Combustion air system: blower and air pressure switch
6. Main gas shut-off valve train selection
7. Process temperature control system
Burner size and quantity
Select the size and number of burners based on the heat bal-
ance. For heat balance calculations, refer to the Combustion
Engineering Guide (EFE 825).
Performance data, dimensions and specications are given for
each ThermJet model in Data Sheets 205-1 through 205-13
Flame velocity
Each burner size comes in two versions, High or Medium
Velocity. Select the version needed based on requirements for
temperature uniformity, circulation, chamber size, air pressure
and overall operating costs.
Flame velocity information is available in Data Sheets 205-1
through 205-13
a.
b.
c.
d.

10 Eclipse ThermJet Design Guide No. 205, 3/5/07
Fuel type & fuel pressure
The usable fuel types are:
Natural gas
Propane
Butane
For other fuels less than 800 Btu/ft (330 MJ/m
3
) contact Eclipse
Combustion with an accurate breakdown of the fuel contents.
The gas pressure must be at the minimum level shown.
The required gas pressure at the burner can be found in Therm-
Jet Data Sheets 205-1 through 205-13
Combustor
The combustor that you choose depends on the temperature
and the construction of the furnace.
The furnace temperature limits of the combustors can be found
in ThermJet Data Sheets 205-1 through 205-13
The control methodology is the basis for the rest of the design
process. Once it is known what the system will look like, the
components that are in it can be selected. The control method-
ology chosen depends on the type of process to be controlled.
Note:
The stated operational characteristics only apply if the de-
scribed control circuits are followed. Use of different control
methods will result in unknown operational performance
characteristics. Use the control circuits contained within this
section or contact Eclipse Combustion for written, approved
alternatives.
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Step 2: Control Methodology

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Eclipse ThermJet Design Guide No. 205, 3/5/07
Control Methods
There are two main methods to control the input of a Therm-
Jet system. Each of these methods also has two variants.These
methods may be applied to single burner as well as multiple
burner systems.
The methods and variants are:
1. Modulating control
Modulating gas & air, on-ratio control or excess air @ low
re on page 12.
Modulating gas with xed-air control on page 13.
2. High/low control
High/low air & gas control (pulse ring) on page 14.
High/low gas with xed-air control (Can also be used for
pulse ring) on page 15.
Note:
Use of a ratio regulator in a xed-air system is optional. How-
ever, eliminating the ratio regulator will adversely affect the
ignition reliability at inputs greater than 40% of maximum.
Use of a ratio regulator in a xed-air system also provides
automatic gas modulation if system air ow changes over
time (such as a clogged air lter).
In the pages that follow you will nd schematics of these control
methods. The symbols in the schematics are explained in the
“Key to System Schematics” (see Appendix).
Automatic gas shut-off by burner or shut-off by zone
The automatic gas shut-off valve can be installed in two opera-
tional modes:
Automatic gas shut-off by burner
If the ame monitoring system detects a failure, the gas shut-
off valves close the gas supply to the burner that caused the
failure.
Automatic gas shut-off by zone
If the ame monitoring system detects a failure, the gas
shut-off valves close the gas supply to all the burners in the
zone that caused the failure.
Note:
All ThermJet control schematics on the following pages reect
a single gas automatic shut-off valve.
NC
This may be changed to conform to local safety and/or insur-
ance requirements (Refer to page 9 ofThermJet Installation
Guide No. 205).
a.
b.
a.
b.
1.
2.
Step 2: Control Methodology
(continued)

1 Eclipse ThermJet Design Guide No. 205, 3/5/07
Modulating gas & air
On-ratio control or excess air @ low re
A burner system with modulating control gives an input that
is in proportion with the demands of the process. ANY input
between high and low re is possible.
Air
The control valve 1 is in the air line. It can modulate air
ow to any position between low and high re air.
Gas
The ratio regulator 2 allows the on-ratio amount of gas to
go to the burner. Low re gas is limited by the ratio regula-
tor 2. High re gas is limited by the manual buttery valve
3.
Note:
The ratio regulator can be biased to give excess air at low re
Note:
Do not use an adjustable limiting orice (ALO) as the high
re gas limiting valve 3. ALO’s require too much pressure
drop for use in a proportional system.
1.
2.
Step 2: Control Methodology
(continued)
Multiple burners
Automatic shut-off at the burner
Multiple burners
Automatic shut-off by zone
Single burner
Figure 3.1 Modulating gas & air.
On-ratio control or excess air @ low fire
NC
NC
NC
P
to other Zones to other Burners
Main gas
shut-off
valve train to other Burners
Automatic
shut-off at
the burner
➊
➋
➌
Main gas
shut-off
valve train
P
to other Zones to other Burners
Automatic
shut-off by
zone
to other Burners
➌
➋
to other Zones
➊
➊
➋
➌
Main gas
shut-off
valve train
P
Optional IF flame monitoring system controls the main gas shut-off
valve train AND ignition above 40% of maximum is NOT required.

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Eclipse ThermJet Design Guide No. 205, 3/5/07
Modulating gas with xed-air control
A burner system with modulating control gives an input that
is in proportion with the demands of the process. ANY input
between high and low re is possible.
Air
The amount of air to the burner is xed.
Gas
The control valve 1 is in the gas line. It can modulate to any
position between low and high re.
Note:
Use of a ratio regulator 2in a xed-air system is optional
on a single burner system only. However, eliminating the
ratio regulator will adversely affect the ignition reliability at
inputs greater than 40% of maximum.
1.
2.
Step 2: Control Methodology
(continued)
Multiple burners
Automatic shut-off at the burner
Multiple burners
Automatic shut-off by zone
Single burner
Figure 3.2: Modulating gas with fixed-air control
Optional IF flame monitoring system controls the main gas shut-off
valve train AND ignition above 40% of maximum is NOT required.
NC
Automatic
shut-off by
zone
NC
Automatic
shut-off at
the burner
P
to other Zones
to other Burners
Main gas
shut-off
valve train
to other Burners
➊
➋
to other Zones
P
to other Zones
to other Zones
Main gas
shut-off
valve train to other Burners
to other Burners
➊
➋
P
NC
➊
Main gas
shut-off
valve train
➋
(optional)

1 Eclipse ThermJet Design Guide No. 205, 3/5/07
High/low air & gas control (pulse ring)
A burner system with high/low control gives a high or low re
input to the process. No input between high and low re is
possible.
1. Air
Low re:
A control input closes the solenoid valve 4. As a result
the CRS valve 5quickly moves to low re.
High re:
A control input opens the solenoid valve 4. As a result
the CRS valve 5 quickly moves to high re.
2. Gas
Low re:
A control input closes the solenoid valve 1.
Low re gas passes through the buttery valve 3.
High re:
A control input opens the solenoid valve 1.
a.
b.
a.
b.
NC
Automatic
shut-off by
zone
NC
Automatic
shut-off at
the burner
P
to other Zones
to other Zones
to other Burners
Main gas
shut-off
valve train
to other Burners
➊➋
➍
➌
➎
to other Zones
to other Zones
Main gas
shut-off
valve train
to other Burners
to other Burners
➊➋
➍
➌
➎
P
P
Main gas
shut-off
valve train
➊
➋
➌
➍
➎
If fast high/low control is not necessary, the CRS valve can be
replaced with a two-position automatic butterfly valve.
Multiple burners
Automatic shut-off by zone
Single burner
Multiple burners
Automatic shut-off at the burner
Figure 3.3: High/Low air & gas control (pulse ring)
Step 2: Control Methodology
(continued)

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Eclipse ThermJet Design Guide No. 205, 3/5/07
High/low gas with xed-air control
(Can also be used for pulse ring.)
A burner system with high/low control gives a high or a low
input to the process. NO input between high and low re is
possible.
Air
The amount of air to the burner is xed.
Gas
Low re:
A control input closes the solenoid valve 1.
Low re gas passes through the buttery valve 3.
High re:
A control input opens the solenoid valve 1.
High re gas passes through the open solenoid valve 1.
Note:
Use of a ratio regulator 2in a xed-air system is optional
on a single burner system only. However, eliminating the
ratio regulator will adversely affect the ignition reliability at
inputs greater than 40% of maximum.
1.
2.
a.
b.
Step 2: Control Methodology
(continued)
Multiple burners
Automatic shut-off by zone
Single burner
Multiple burners
Automatic shut-off at the burner
Figure 3.: High/Low gas with fixed-air control
(Can also be used for pulse firing.)
NC
Automatic
shut-off by
zone
NC
Automatic
shut-off at
the burner
to other Burners
to other Burners
to other Zones
to other Zones
Main gas
shut-off
valve train
➊
➋
➌
P
P
P
to other Zones
to other Zones
Main gas
shut-off
valve train
➊
➋
➌
to other Burners
to other Burners
Main gas
shut-off
valve train
➊
➋
➌
(optional)

1 Eclipse ThermJet Design Guide No. 205, 3/5/07
Step 3: Ignition System For the ignition system use:
6,000 VAC transformer
Full-wave spark transformer
One transformer per burner
DO NOT USE:
10,000 VAC transformer
Twin outlet transformer
Distributor type transformer
Half-wave transformer
It is recommended that low re start be used, however,Therm-
Jet burners are capable of direct spark ignition anywhere within
the operating range.
Note:
You must follow the control circuits described in the previous
section,“Control Methodology,” to obtain reliable ignition.
Local safety and insurance require limits on the maximum trial
for ignition time. These time limits vary from country to country.
The time it takes for a burner to ignite depends on:
The distance between the gas shut-off valve and the burner
The air/gas ratio
The gas flow at start conditions
It is possible to have the low re too low to ignite within the
trial for ignition period. Under these circumstances you must
consider the following options:
Start at higher input levels.
Resize and/or relocate the gas controls.
Use bypass start gas. (See the circuit schematics on the next page.)
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Eclipse ThermJet Design Guide No. 205, 3/5/07
Bypass start gas (optional)
A bypass start gas circuit provides gas ow around zone gas
conrol valves during the trial for ignition period.This should only
be used if excess air (proportional or xed air control) is being
used on low re; it should NOT be used with on-ratio low re
systems. During the trial for ignition period, the solenoid valve
in the bypass line plus the automatic gas shut-off valve (either at
each burner or each zone) are opened. If a ame is established,
the bypass solenoid valve closes at the end of the trial for igni-
tion period. If a ame is not established, then the bypass sole-
noid valve and the automatic gas shut-off valve close.
Figure 3.5: Bypass start gas circuit schematics
Main gas
shut-off
valve train
NC
Bypass option
Main gas
shut-off
valve train
Bypass option
NC
NC
Bypass option
Main gas
shut-off
valve train
Step 3: Ignition System
(Continued)
Modulating gas with xed air control
High/low air & gas control
High/Low gas with xed air control

1 Eclipse ThermJet Design Guide No. 205, 3/5/07
U.V. scanner
A ame monitoring system consists of two main parts:
A flame sensor
Flame monitoring control
Flame sensor
There are two types that you can use for a ThermJet burner:
U.V. scanner
Flame rod
A U.V. scanner can be used with all combustor types.
You can nd information in:
Info Guide 852 for 90º U.V. scanners
Info Guide 854 for straight U.V. scanners
Info Guide 856 for self-check U.V. scanners.
Note:
Flame rod option is not available for the TJ300 and larger
The standard flame rod is used with natural gas and pre-
heated air up to 300ºF.
The high-grade flame rod is used with propane, butane, and
preheated air up to 700ºF.
You can nd more information in Info Guide 832.
Flame Monitoring Control
The ame monitoring control is the equipment that processes
the signal from the ame rod or the U.V. scanner. For ame
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 ame monitoring controls:
Bi-flame series; see instruction manual 826
Multi-flame series 6000; see Instruction Manual 820
Veri-flame; see Instruction Manual 818
Other manufacturers’ ame monitoring systems can be used
with the burner if spark is maintained for a xed time interval
and is not interrupted when a ame signal is detected during
trial for ignition.
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Step 4: Flame monitoring
system

1
Eclipse ThermJet Design Guide No. 205, 3/5/07
Effects of atmospheric conditions
The blower data is based on the International Standard Atmo-
sphere (ISA) at Mean Sea Level (MSL), which means that it is
valid for:
Sea level
29.92" Hg (1,013 mbar)
70ºF (21ºC)
The makeup of the air is different. above sea level or in a hot
area.The density of the air decreases, and as a result, the outlet
pressure and the ow of the blower decrease. An accurate de-
scription of these effects is in the Eclipse Combustion Engineer-
ing Guide (EFE 825).The Guide contains tables to calculate the
effect of pressure, altitude and temperature on air.
Blower
The rating of the blower must match the system requirements.
You can nd all the blower data in: Bulletin/Info Guide 610
Follow these steps:
Calculate the outlet pressure.
When calculating the outlet pressure of the blower, the total of
these pressures must be calculated.
The static air pressure required at the burner
The total pressure drop in the piping
The total of the pressure drops across the valves
The pressure in the chamber (suction or pressurized)
Recommend a minimum safety margin of 10%
•
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1.
•
•
•
•
•
Step 5: Combustion Air Sys-
tem: Blower and
air pressure switch
Series SMJ turbo blower

0 Eclipse ThermJet Design Guide No. 205, 3/5/07
2. Calculate the required ow
The blower output is the air ow delivered under standard at-
mospheric conditions. It must be enough to feed all the burners
in the system at high re.
Combustion air blowers are normally rated in terms of standard
cubic feet per hour (scfh) of air.An example calculation follows
the information tables below:
Table 3.1: Required calculation information
DesCriptioN uNit of
measure
formula
symbol
Number of burners - -
Type of fuel - -
Gross heating value of fuel Btu/ft3q
Desired excess air percentage
(typical excess air percentage
@ high re is 15%)
percent %
Air/gas ratio (fuel specic, see
table below) -a
Air ow scfh Vair
Gas ow scfh Vgas
Table 3.2: Fuel gas heating values
fuel gas
stoiChiometriC*
air/gas ratio
a(ft3
air/ft3 gas)
gross heat-
iNg value
q(btu/ft3)
Natural gas
(Birmingham,AL) 9.41 1,002
Propane 23.82 2,572
Butane 30.47 3,225
Step 5: Combustion Air
System: Blower and
air pressure switch
(continued)