Iti - ThermJet - USA (ECLIPSE) PDF
Iti - ThermJet - USA (ECLIPSE) PDF
Iti - ThermJet - USA (ECLIPSE) PDF
The material in this manual is believed adequate for the How To Get Help
intended use of the product. If the product is used for If you need help, contact your local Eclipse
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2
Table of Contents
1 Introduction............................................................................................................................ 4
Product Description .............................................................................................................. 4
Audience .............................................................................................................................. 4
Purpose ................................................................................................................................ 4
ThermJet Documents ........................................................................................................... 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 Model Selection............................................................................................ 6
Step 2: Control Methodology................................................................................................ 7
Step 3: Ignition System ........................................................................................................ 12
Step 4: Flame Monitoring Control System............................................................................ 14
Step 5: Combustion Air System (Blower and Air Pressure Switch)...................................... 14
Step 6: Main Gas Shut-Off Valve Train ................................................................................ 16
Step 7: Process Temperature Control System..................................................................... 16
Appendix ................................................................................................................................... i
System Schematics.................................................................................................................. ii
Notes.......................................................................................................................................... iv
5
System Design 3
Design Fuel Type
Designing a burner system is a straight-forward exercise Table 3.1 Fuel Type
of combining modules that add up to a reliable and safe
Gross Heating Specific WOBBE
system. Fuel Symbol
Value Gravity Index
The design process is divided into the following steps:
Natural 1000 Btu/ft3 1290
CH490%+ 0.60
1. Burner model selection: Gas (40.1 MJ/m3) Btu/ft3
■ If the burner is shut off during operation at 1. Automatic Gas Shut-Off by Burner
temperatures above 1000°F (538°C), provisions If the flame monitoring system detects a failure, the
must be made to provide an adequate amount of gas shut-off valves close the gas supply to the burner
flowing combustion air to keep the burner internal that caused the failure.
components cool.
2. Automatic Gas Shut-Off by Zone
The control methodology is the basis for the rest of the
design process. Once it is known what the system will look If the flame monitoring system detects a failure, the
like, the components that are in it can be selected. The gas shut-off valves close the gas supply to all the
control methodology chosen depends on the type of burners in the zone that caused the failure.
process to be controlled. NOTE: All ThermJet control schematics on the following
NOTE: The stated operational characteristics only apply if pages reflect a single gas automatic shut-off valve. This
the described control circuits are followed. Use of different may be changed to conform to local safety and/or
control methods will result in unknown operational insurance requirements. (Refer to the ThermJet
performance characteristics. Use the control circuits Installation Guide No. 205).
contained within this section or contact Eclipse for written,
approved alternatives.
There are two main methods to control the input of a
ThermJet 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:
a. Modulating gas & air, on-ratio control or excess air
@ low fire on page 8.
b. Modulating gas with fixed-air control on page 9.
2. High/low control:
a. High/low air & gas control (pulse firing) on page
10.
b. High/low gas with fixed-air control (Can also be
used for pulse firing) on page 11.
NOTE: Use of a ratio regulator in a fixed-air system is
optional. However, eliminating the ratio regulator will
adversely affect the ignition reliability at inputs greater
than 40% of maximum.
Use of a ratio regulator in a fixed-air system also provides
automatic gas modulation if system air flow changes over
time (such as a clogged air filter).
In the pages that follow you will find schematics of these
control methods. The symbols in the schematics are
explained in the “Key to System Schematics” (see
Appendix).
NC
Automatic
Main gas
shut-off shut-off at
the burner
valve train to other Burners
Single Burner P
Main gas NC
shut-off
valve train
Optional IF flame monitoring system controls the main gas shut-off
valve train AND ignition above 40% of maximum is NOT required.
Figure 3.1 Modulating Gas & Air (On-Ratio Control or Excess Air @ Low Fire)
to other
Multiple Burners
Automatic Shut-Off Zones to other Burners
P
at the Burner
to other NC
Zones Automatic
Main gas
shut-off shut-off at
valve train the burner
to other Burners
to other
Multiple Burners Zones to other Burners
Automatic Shut-Off P
by Zone
Automatic
shut-off by
to other zone
Main gas Zones
NC
shut-off
valve train
to other Burners
Single Burner P
(optional)
Main gas NC
shut-off
valve train
Optional IF flame monitoring system controls the main gas shut-off
valve train AND ignition above 40% of maximum is NOT required.
to other
Multiple Burners Zones to other Burners
P
Automatic Shut-Off at the Burner
to other
Zones NC
Automatic
shut-off by
zone
to other
Zones
Main gas NC
shut-off
valve train
to other Burners
Single Burner P
Main gas
shut-off
valve train
If fast high/low control is not necessary, the CRS valve can be
replaced with a two-position automatic butterfly valve.
The amount of air to the burner is fixed. NOTE: Use of a ratio regulator in a fixed-air system is
optional on a single burner system only. However,
2. Gas: eliminating the ratio regulator will adversely affect the
ignition reliability at inputs greater than 40% of maximum.
to other
Multiple Burners Zones to other Burners
P
Automatic Shut-Off at the Burner
to other
Zones
NC
Automatic
shut-off by
zone
to other
Zones
Main gas NC
shut-off
valve train to other Burners
Single Burner P
Main gas
shut-off
valve train (optional)
Figure 3.4 High/Low Gas with Fixed-Air Control
Main gas NC
shut-off
valve train
Bypass option
NC
Main gas
shut-off
valve train
Bypass option
Main gas NC
shut-off
valve train
Bypass option
Combustion air blowers are normally rated in terms of • Gas flow of 2,894 ft3/hr is required.
standard cubic feet per hour (SCFH) of air. An
example calculation follows the informations tables c. Calculate required stoichiometric air flow:
below:
Vair-stoichiometric = α (air/gas ratio) x Vgas
Table 3.2 Required Calculation Information
Unit of Formula = 9.41 x 2,894 ft3/hr = 27,235 ft3/hr
Description
Measure Symbol • Stiochiometric air flow of 27,235 SCFH required.
Number of burners - - d. Calculate final blower air flow requirement based
Type of fuel - - on the desired amount of excess air:
Gross heating value of fuel Btu/ft3 (MJ/m3) q
Desired excess air percentage Vair = (1 + excess air%) x Vair-stoichiometric
(Typical excess air percentage percent % = (1 + 0.15) x 27,235 ft3/hr = 31,320 ft3/hr
@ high fire is 15%)
Air/Gas ratio (Fuel specific, • For this example, final blower air flow requirement is
- 31,320 SCFH at 15% excess air.
see table below)
Air flow scfh (Nm3/hr) Vair NOTE: It is common practice to add an additional 10% to
Gas flow scfh (Nm3/hr) Vgas the final blower air flow requirement as a safety margin.
3. Find the blower model number and motor horsepower
(hp). With the output pressure and the specific flow,
Table 3.3 Fuel Gas Heating Values you can find the blower catalog number and the motor
Stoichiometric* Gross Heating hp in Bulletin 610.
Fuel Gas Air/Gas Ratio Value 4. Eclipse recommends that you select a totally enclosed
(ft3 /ft3 (Btu/ft3) fan cooled (TEFC) motor.
air gas) q
Natural Gas 5. Select the other parameters:
9.41 1,002 (40 MJ/m3)
(Birmingham, AL)
• inlet filter or inlet grille
Propane 23.82 2,564 (102,5 MJ/m3)
• Inlet size (frame size)
Butane 30.47 3,333(133,3 MJ/m3)
• voltage, number of phases, frequency
*Stoichiometric: No excess air. The precise amount of air • blower outlet location, and rotation direction
and gas are present for complete combustion. clockwise (CW) or counter-clockwise (CCW).
Example Blower Calculation NOTE: The use of an inlet air filter is strongly
recommended. The system will perform longer and the
A batch furnace requires a gross heat input of 2,900,000
settings will be more stable.
Btu/hr (based on 45% efficiency). The designer decides to
provide the required heat input with four burners operating NOTE: When selecting a 60 Hz Blower for use on 50 Hz,
on natural gas using 15% excess air. a pressure and capacity calculation is required. See
Eclipse Engineering Guide (EFE 825).
Calculation Example:
The total selection information you should now have:
a. Decide which ThermJet burner model is
appropriate: • blower model number
• motor hp
Q (total heat input) of 2,900,000 BTU/hr 725,000
= • motor enclosure (TEFC)
4 burners BTU/hr/burner
• voltage, number of phases, frequency
• Select 4 model TJ0075 ThermJet burners based on • outlet position and rotation direction (CW or CCW)
the required heat input of 725,000 Btu/hr for each
burner.
WARNING
■ Eclipse supports NFPA and EN regulations, which
require the use of an air pressure switch in
conjunction with other safety components, as a
minimum standard for main gas safety shut-off
systems.
Step 6: Main Gas Shut-Off Valve Train
Consult Eclipse
Eclipse can help you design and obtain a main gas shut-
off valve train that complies with the current safety
standards.
The shut-off valve train must comply with all the local
safety standards set by the authorities that have
jurisdiction.
For details, please contact your local Eclipse
representative or Eclipse.
NOTE: Eclipse supports NFPA regulations (two shut-off
valves) as a minimum standard for main gas safety shut-
off systems.
Step 7: Process Temperature Control
System
The process temperature control system is used to control
and monitor the temperature of the system. There is a
wide variety of control and measuring equipment
available.
For details, please contact your Eclipse representative or
the Eclipse family.
Metric to Metric
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
English to Metric
From To Multiply By
actual cubic foot/h (acfh) actual cubic meter/h (am³/h) 2.832 x 10-2
standard cubic foot /h (scfh) normal cubic meter/h (Nm³/h) 2.629 x 10-2
degrees Fahrenheit (°F) degrees Celsius (°C) (°F - 32) x 5/9
pound (lb) kilogram (kg) 0.454
Btu/h 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
i
System Schematics
Bulletin/
Symbol Appearance Name Remarks
Info Guide
Main Gas
Shut-Off Main Gas Shut-Off Valve Eclipse strongly endorses NFPA as a
790/791
Valve Train minimum.
Train
ii
Bulletin/
Symbol Appearance Name Remarks
Info Guide
iii
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