Eclipse WX Series User manual

Eclipse Winnox
Burners
WX Series
Version 1
Design Guide 111
9/25/2008

Eclipse Winnox WX Series v1 Design Guide No. 111, 9/25/2008
2
Copyright 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 express written consent
of Eclipse, Inc.
We reserve the right to change the construction and/or
conguration 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 is used for purposes
other than those specied herein, conrmation 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.
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 documentation for
the benet 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 Guide, any
adjustment, or assembly procedures not recommended or
authorized in these instructions shall void the warranty.
Co p y r i g h t
Di s C l a i m e r No t i C e
li a b i l i t y a N D
Wa r r a N t y

3
Eclipse Winnox WX Series v1 Design Guide No. 111, 9/25/2008
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 previous experience with this
type of equipment.
Design Guide No. 111
This document•
Datasheet, Series 111
Available for individual WX models•
Required to complete design and selection•
Installation Guide No. 111
Used with Datasheet to complete installation•
Price List No. 111
Used to order burners•
Related Documents
EFE 825 (Combustion Engineering Guide)•
Eclipse Bulletins and Info Guides: 684, 710, 732, 742, 756,•
760, 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.
Wi N N o x Do C u m e N t s
au D i e N C e
About This Manual

Eclipse Winnox WX Series v1 Design Guide No. 111, 9/25/2008
4
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 procedures.
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
carefully.
Note:
Indicates an important part of the text. Read thoroughly.
If you need help, contact your local Eclipse representative.
Do C u m e N t
Co N v e N t i o N s
ho W toge t he l p

5
Eclipse Winnox WX Series v1 Design Guide No. 111, 9/25/2008
Table of Contents
Introduction.................................................................... 6
Product Description ......................................................... 6
Safety.............................................................................. 7
Introduction...................................................................... 7
Safety .............................................................................. 7
Capabilities...................................................................... 7
Operator Training............................................................. 7
Replacement Parts.......................................................... 7
System Design............................................................... 8
Design ............................................................................. 8
Step 1: Burner Option Selection...................................... 9
Step 2: Packaged Blower Option Selection..................... 11
Step 3: Control Methodology........................................... 12
Step 4: Ignition System.................................................... 13
Step 5: Flame Monitoring Control System....................... 14
Step 6: Main Gas Shut-Off Valve Train............................ 15
Step 7: Verify Chamber Design ....................................... 16
Appendix ........................................................................ 17
Conversion Factors ......................................................... 17
1
2
3

6Eclipse Winnox WX Series v1 Design Guide No. 111, 9/25/2008
Introduction
pr o D u C t De s C r i p t i o N The Winnox version 1 is a nozzle-mix type, low-emmisions burner
designed for direct air heating, indirect air heating, and oven
applications up to 1800°F (980°C).
The burner package includes a combustion air blower and an
air:gas ratio regulator to re over a wide gas turndown range at a
controlled ratio.
The burner is designed for:
low NO• Xand CO emmisions
efcient ratio controlled combustion•
reliable burner operation•
simple burner adjustment•
direct spark ignition•
multiple fuel capability•
The wide variety of options and congurations are available due to
the modular design of the burner.
Figure 1.1 The Winnox Burner
1

7
Eclipse Winnox WX Series v1 Design Guide No. 111, 9/25/2008
Safety
This section is provided as a guide for the safe operation of
Winnox burner system. All involved personnel should read this
section carefully before operating this system.
Danger:
The Winnox burners, described herein, are designed
to mix fuel with air and burn the resulting mixture. All
fuel burning devices are capable of producing res
and explosions if improperly applied, installed,
adjusted, controlled, or maintained. Do not bypass
any safety feature; re or explosion could result.
Never try to light a burner if it shows signs of damage
or malfunction.
Warning:
The burner might have HOT surfaces. Always wear
protective clothing when approaching the burner.
Note:
This manual provides information in the use of these
burners for their specic design purpose. Do not
deviate from any instructions or application limits
described herein without written advice from Eclipse. 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 Eclipse before
continuing.
Only qualied personnel, with good mechanical aptitude and
experience with 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 prociency.
Order replacement parts from Eclipse only. All Eclipse approved,
customer supplied valves or switches should carry UL, FM, CSA,
CGA, and/or CE approval, where applicable.
iN t r o D u C t i o N
sa f e t y
Ca p a b i l i t i e s
2
op e r a t o r tr a i N i N g
re p l a C e m e N t pa r t s

8Eclipse Winnox WX Series v1 Design Guide No. 111, 9/25/2008
System Design
Design Structure
The design process is divided into the following steps:
Burner Option Selection Including:1.
Burner Model / Size Selection•
Fuel Type•
Air Supply•
Combustor Type•
Control Motor•
Burner Conguration•
Gas Pipe Connection•
Flame Supervision•
Air Flow Switch•
Blower Option Selection Including:2.
Power Supply Frequency•
Pressure and Flow•
Blower Motor Type•
Blower Inlet•
Motor Orientation•
Control Methodology Including:3.
Burner Control•
Ignition System Including:4.
Ignition Transformer•
Trial for Ignition•
Flame Monitoring Control System Including:5.
Flame Sensor•
Flame Monitoring Control•
Main Gas Shut-Off Valve Train Including:6.
Component Selection•
Valve Train Size•
Verify Chamber Design7.
Firing Chamber Dimensions•
De s i g N
3

9
Eclipse Winnox WX Series v1 Design Guide No. 111, 9/25/2008
Step 1 describes how to select burner options to suit an
application. Use the Winnox Price List and Datasheets No. 111
when following this selection process.
Caution:
Consult EFE-825 Eclipse Engineering Guide, or contact
Eclipse 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. The burner air supply option
selected will affect available heat output from the burner.
Power Supply Frequency:• Burner capacity will vary with
power supply frequency (50Hz or 60 Hz power).
Combustion Chamber Pressure:• Consider the effects
that large or varying chamber pressures have on burner
performance.
Altitude:• The maximum burner capacity is reduced by
approximately 3% each 1000 feet (300 meters) above sea
level.
Combustion Air Supply:• Combustion air should be fresh
(20.9% O2) and clean (without particles or corrosives).
Combustion Air Temperature:• Changes in air supply
temperature can affect the burner capacity. The
combustion air supply temperature should not exceed
250°F.
Fuel Type:• Variation in caloric value and density will
affect burner performance. Nominal burner performance is
based on fuel properties in Table 3.1.
Table 3.1 Fuel Type
Fuel Symbol Gross Heating Value Specic Gravity
Natural Gas CH490%+ 1000 BTU/ft3(40.1 MJ/m3) 0.60
Propane C3H82525 BTU/ft3(101.2 MJ/m3) 1.55
Butane C4H10 3330 BTU/ft3(133.7 MJ/m3) 2.09
BTU/ft3 @ standard conditions (MJ/m3@ normal conditions)
If using and alternative fuel supply, contact Eclipse with an accurate
breakdown of the fuel components.
Air Supply
Select either a combustion air blower mounted directly to the burner
body, or a pipe connection type for remote blower operation. For
each selection, the burner will include an integral air buttery valve
(BV).
Step 1: Burner Option
Selection

Eclipse Winnox WX Series v1 Design Guide No. 111, 9/25/2008
10
Combustor Type
Select a combustor type based on the application:
Recommended Maximum Chamber Temperature °F (°C)
Model Standard
Alloy Tube
High Temp
Alloy Tube
Refractory
Plug
100, 200 1300° (704°) 1550° (843°) 1800° (982°)
300, 400 1300° (704°) 1550° (843°) 1800° (982°)
500, 600 1300° (704°) 1550° (843°) 1800° (982°)
1000 1100° (593°) 1400° (760°) Not Available
Tube and plug temperatures should be reduced 150°F when using
propane or butane.
Note:
When using a refractory plug, the customer must provide
their own refractory tube set up per Eclipse dimensions.
Control Motor
Select a control motor. Standard control motor options include
various models which Eclipse will mount to the burner. Winnox
burners can be ordered with control motor bracket and mounting
hardware only. Customer supplied control motors must conform to
these specications:
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 t an application
- the chamber is to be red with positive or negative
pressure
- the chamber pressure is outside the range -1" w.c.
to +1" w.c. (-2,5 to 2,5 mbar)
- there is a need to indicate a high and/or low re air
buttery valve (BV) position
Burner Conguration
Select conguration. See gure 3.2 on page 11 for illustrations.
Gas Pipe Connection
Select the gas pipe connection including the pipe thread type.The
piping, burner gas inlet, and fuel train components are threaded
using the customer selected pipe thread option.
Flame Supervision
Select a ame rod or an ultraviolet (UV) scanner. Both are
available on all Winnox burners. If a ame rod is selected, it will be
factory mounted in the burner. If a UV scanner is selected, it must
be ordered separately.
Warning:
A UV scanner can possibly detect another burner’s
ame if it is in the line of sight, and falsely indicate
ame presence. Use a ame rod in this situation. This
helps prevent accumulation of unburned fuel which,
in extreme situations, could cause a re or an
explosion.
Step 1: Burner Option
Selection (Continued)

11
Eclipse Winnox WX Series v1 Design Guide No. 111, 9/25/2008
Air Flow Switch
The air ow 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 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.
Packaged Blower Option Selections
Note:
Standard blower options are listed in Price List 111,
additional blower options are available through Eclipse.
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 NEMA
frames.
Pressure & Flow
Nominal and derated options are available.
Blower Motor Type
Motor types include various options: voltages, single or three
phase, TEFC or automotive duty enclosures.
Blower 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
Right-hand blower motor orientation is standard. If left-hand
blower motor orientation is required, contact factory.
Figure 3.2 Burner Conguration and Motor Orientation Choice
Step 2: Packaged Blower
Option Selection
Right Hand Blower Motor
Left Hand Piping Right Hand Piping

Eclipse Winnox WX Series v1 Design Guide No. 111, 9/25/2008
12
All standard Winnox burners are designed for:
air:gas ratio controlled combustion•
50% excess air at high re•
higher excess air at low re•
Burner Control
Winnox burners come with a ratio regulator that maintains the
air:gas ratio. An integral minimum fuel bypass line is used to
maintain and control a reliable low re input ow.
Figure 3.4 Basic Burner Components
A control signal is sent from a process temperature controller•
(sold separately) to the control motor. (Refer to Bulletin 818C
or contact Eclipse for further information on temperature
controllers.)
Figure 3.5 Basic Control Loop
The control motor modulates the integral air buttery valve •
(BV) which controls the combustion air ow.
Air pressure in the burner body sends an impulse down the•
loading line to the ratio regulator.
The ratio regulator controls the gas ow in proportion to the air •
ow.
Warning:
Do not use other control methods, such as, a xed-air
control, and do not alter the ratio regulator or burner
piping without prior approval from Eclipse.
Step 3: Control
Methodology
Integral Air BV
Minimum Fuel
By-Pass Line Control Motor
Ratio Regulator
Heat
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
Figure 3.3 Air:Gas Flow
Control
Signal
Gas Flow
Process
Set Point Process
Controller
Control
Motor
Integral air
BV
Ratio
Regulator
erutarepmeT
erusserP
Impulse

13
Eclipse Winnox WX Series v1 Design Guide No. 111, 9/25/2008
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 NOT USE the following:
twin outlet•
distributor type•
half wave output•
Trial for Ignition
It is required that low re start be used.
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 air:gas ratio•
the gas ow conditions at start-up•
Ignition Gas Piping
Winnox burners are capable of ignition with either low re or
bypass start gas.
Low Fire Start:
Pilot Start (Optional):
Piping for pilot start option needs to be sized to accomodate low
re gas ows as stated in datasheets.
Step 4: Ignition System
Main gas
shut-o
valvetrain
Main gas
shut-o
valvetrain
NC
NC

Eclipse Winnox WX Series v1 Design Guide No. 111, 9/25/2008
14
The ame monitoring control system consists of two main
components:
Flame Sensor•
Flame Monitoring Control•
Flame Sensor
Two types can be used on a Winnox Burner:
Flame rod•
UV scanner•
Flame rods are available for all Winnox burner sizes. Further
information can be found in:
Info Guide 832•
A UV scanner can be used on all Winnox burner sizes. Further
information can be found in:
Info Guide 852; 90° UV scanner•
Info Guide 854; straight UV scanner•
Info Guide 856; self-check UV scanner•
Flame Monitoring Control
The ame monitoring control processes the signal from the ame
rod, or UV scanner, and controls the start-up sequence and the
main gas shut-off valve sequence.
Eclipse recommends the use of ame monitoring control systems
which maintain a spark for the entire trail for ignition time when
using UV scanners.
Some of these ame monitoring models are:
Veri-ame; see Bulletin/Info Guide 610, 620, 630•
Bi-ame series; see Instruction Manual 826•
Multi-ame series 6000; see Instruction Manual 820•
DO NOT USE the following:
Flame monitoring relays which interrupt the trial for ignition•
when the ame is detected
Flame sensors which supply a weak signal•
Flame monitoring relays with low sensitivity•
Step 5: Flame Monitoring
Control System
Flame Rod
UV Scanner
Figure 3.6 Typical Sensors

15
Eclipse Winnox WX Series v1 Design Guide No. 111, 9/25/2008
Component Selection
Eclipse can help in the design of a main gas shut-off valve train
that satises 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).
Fuel Flow Measurement
Eclipse requires a fuel ow measurement device . Eclipse
recommendations can be found in the appropriate Winnox
datasheet, series 111.
Valve Train Size
Fuel pressure supplied to the ratio regulator inlet must be within
the range specied on the Winnox datasheet, series 111. The
valve train should be sized sufciently to provide the specied
pressure. A second main gas pressure regulator immediately
upstream from the burner gas inlet might be necessary to maintain
inlet pressure to the burner.
Low Fire Start:
Pilot Start (Option):
Pilot Start (Option Using Tee Fitting):
Step 6: Main Gas Shut-Off
Valve Train
Main gas
shut-o
valvetrain
Main gas
shut-o
valvetrain
NC
NC
Main gas
shut-o
valvetrain
Pilot gas
shut-o
valvetrain

Eclipse Winnox WX Series v1 Design Guide No. 111, 9/25/2008
16
Note:
For pilot congurations using the tee tting option to
connect the pilot fuel supply ahead of the 325 series
bypass regulator, back pressure to the bypass regulator
must be within an acceptable limit. The bypass regulators
used on all Winnox burners are designed to operate at
outlet pressures up to 2 psig with inlet pressures up to 10
psig. Back load pressures (outlet pressures) of 2 psig with
no inlet pressure will not affect components or the normal
operation of the regulator.
Warning:
Do not operate Winnox burners with gas inlet
pressure less than the minimum listed on the Winnox
datasheet. Lower gas inlet pressures may cause the
ratio regulator to remain fully open at lower inputs
as the burner transitions from low to high re. This
could result in the possible accumulation of unburned
fuel in the burner which, in extreme situations, could
cause a re or an explosion.
Firing Chamber Dimensions
The Winnox is a low emissions burner that might require a larger
ring chamber than a standard burner.
Chamber dimensions are a function of chamber temperature,
process air volume and burner input. Contact your Eclipse
representative to review your chamber design.
Step 6: Main Gas Shut-Off
Valve Train
(Continued)
Step 7: Verify Chamber
Design

17
Eclipse Winnox WX Series v1 Design Guide No. 111, 9/25/2008
Appendix
Co n v e r s i o n
Fa C t o r s 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 1.8) + 32
kilogram (kg) pound (lb) 2.205
kilowatt (kW) BTU/hr 3414
meter (m) foot (ft) 3.28
millibar (mbar) inches water column ("w.c.) 0.401
millibar (mbar) pounds/sq in (psi) 14.5 x 10-3
millimeter (mm) inch (in) 3.94 x 10-2
MJ/m³ (normal) BTU/ft³ (standard) 2.491 x 10-2
Metric to English
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
Metric to Metric
From To Multiply By
BTU/hr kilowatt (kW) 0.293 x 10-3
cubic foot (ft3) cubic meter (m3) 2.832 x 10-2
degrees Fahrenheit (°F) degrees Celsius (°C) (°F - 32) ÷ 18
foot (ft) meter (m) 0.3048
inch (in) millimeter (mm) 25.4
inches water column ("w.c.) millibar (mbar) 2.49
pound (lb) kilogram (kg) 0.454
pounds/sq in (psi) millibar (mbar) 68.95
BTU/ft³ (standard) MJ/m³ (normal) 40.14
English to Metric

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