W£8ST£R
COMBUSTION
A Selas Heat Technology Company
Webster Combustion Technology
619 Industrial Road, Winfield, KS 67156
Installation, Startup, Operation and Maintenance Manual
Cyclonetic J B Series
Forced Draft Burners
JB1-JB2-JB3
Gas - Oil - Gas/Oil
Manual Part No. 950063 - R1
www.webster-engineering.com
September, 2014
© 2014 All Rights Reserved
SAFETY PRECAUTIONS
Good safety practices must be used when working on burner equipment. The potential energy in the electrical supply,
fuel and related equipment must be handled with extreme care to prevent equipment failures, injuries and potential
death.
Throughout this manual, the following symbols are used to identify potential problems.
WARNING
This indicates a potential hazardous situation, which if not avoided, could result in personal injury or death.
CAUTION
This indicates a potentially hazardous situation, which if not avoided, could result in damage to the equipment.
The following general safety precautions apply to all equipment work.
WARNING
IF YOU SMELL GAS, OPEN WINDOW, EXTINGUISH ANY OPEN FLAMES, STAY AWAY FROM ELECTRICAL
SWITCHES, EVACUATE THE BUILDING AND IMMEDIATELY CALL THE GAS COMPANY.
IN ACCORDANCE WITH OSHA STANDARDS, ALL EQUIPMENT, MACHINES AND PROCESSES SHALL BE
LOCKED OUT PRIOR TO SERVICING.
IF THIS EQUIPMENT IS NOT INSTALLED, OPERATED AND MAINTAINED IN ACCORDANCE WITH THE MANUFACTURERS INSTRUCTIONS, THIS PRODUCT COULD EXPOSE YOU TO SUBSTANCES IN FUEL OR FROM
FUEL COMBUSTION WHICH CAN CAUSE DEATH OR SERIOUS ILLNESS AND WHICH ARE KNOWN TO THE
STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM.
IMPROPER SERVICING OF THIS EQUIPMENT MAY CREATE A POTENTIAL HAZARD TO EQUIPMENT AND
OPERATORS.
SERVICING MUST BE DONE BY A FULLY TRAINED AND QUALIFIED PERSONNEL.
BEFORE DISCONNECTING OR OPENING UP A FUEL LINE AND BEFORE CLEANING OR REPLACING
PARTS OF ANY KIND,
•
TURN OFF THE MAIN MANUAL FUEL SHUTOFF VALVES INCLUDING THE PILOT COCK, IF
APPLICABLE. IF A MULTIPLE FUEL BURNER, SHUT OFF ALL FUELS.
•
TURN OFF ALL ELECTRICAL DISCONNECTS TO THE BURNER AND ANY OTHER EQUIPMENT OR
SYSTEMS ELECTRICALLY INTERLOCKED WITH THE BURNER.
Date of Startup
Service Organization Information:
Company Name
Lead Technician
Address
Phone Number
JB Manual
Page Safety Precautions
TABLE OF CONTENTS
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
K.
L.
M.
N.
Safety Precautions ............................................................................................................................... 2
Introduction .......................................................................................................................................... 3
Burner Model Number ............................................................................................................. 5
JB1 Specifications ................................................................................................................... 6
JB2 Specifications ................................................................................................................... 8
JB3 Specifications ................................................................................................................... 10
Component ldentification ...................................................................................................................... 12
Installation ............................................................................................................................................ 17
Special lnstructions For Canadian lnstallations .....................................................................................18
Burner Mounting Criteria ...................................................................................................................... 19
Fuel Systems ........................................................................................................................................ 20
Initial Settings ....................................................................................................................................... 28
Ignition Systems ................................................................................................................................. 30
Start-up & Operating Adjustments ....................................................................................................... 32
Trouble Shooting .................................................................................................................................. 42
General Maintenance and Care ........................................................................................................... 45
Care of The Burner During Extended Shutdown .................................................................................. 48
Replacement Parts .............................................................................................................................. 48
Warranty Validation & Field Start-up Report ........................................................................................ 48
Start-Up Report ....................................................................................................................... 49
A. INTRODUCTION
This manual covers the Models JB1, JB2 and JB3 CYCLONETIC burners offered by Webster Engineering & Manufacturing Co., LLC. These burners can be used in a wide
variety of Cast Iron, Firebox, Firetube, Flextube and other
applications. They can fire gas, oil and combination gas
and oil with several different operating systems.
similar to the nameplates shown in Figure A-1. An
“X” in the model number refers to a low NOx burner,
where FGR or a NOx cone is used to reduce the NOx
in the combustion gases. If the burner is not a low NOx
burner, there is no “X” in the model.
Figure A-1 Nameplate
READ AND SAVE THESE INSTRUCTIONS FOR REFERENCE
WARNING
DO NOT ATTEMPT TO START, ADJUST OR MAINTAIN THIS BURNER WITHOUT PROPER TRAINING
OR EXPERIENCE. FAILURE TO USE KNOWLEDGEABLE TECHNICIANS CAN RESULT IN EQUIPMENT
DAMAGE, PERSONAL INJURY OR DEATH.
NOTE: This manual must be readily available to all operators and maintained in legible condition.
1. Nameplate Information
Each burner has a nameplate with important job details,
JB Manual
SERIAL NUMBER
U81375A-018-06
GAS INPUT RATING
OIL INPUT RATING
MBTU/HR
IN.WC
GPH
PSI
MAXIMUM
2940
2.8
21
300
MINIMUM
1680
1.0
12
100
FUEL
The startup and maintenance of the JB burner requires the
skills of an experienced and properly trained burner technician. Inexperienced individuals should not attempt to start
or adjust this burner.
Every attempt has been made to accurately reflect the
burner construction, however, product upgrades and special order requirements may result in differences between
the content of this manual and the actual equipment.
These special components will be described in the information provided with the burner and should be used as the
controlling document.
MODEL NUMBER
JB2C-15-RM7840L-UL-IRI
#2 FUEL OIL
NATURAL GAS
HP
VOLTS
AMPS
HERTZ
PHASE
CONTROL CIRCUIT
115
5.0
60
1
BURNER MOTOR
208
5.9
60
3
1.5
OIL PUMP MOTOR
208
4.3
60
3
1/2
The serial number represents the unique number for that
burner and is a critical number that will be needed for any
communications with Webster Engineering.
The input rates define the maximum and minimum inputs
for that burner, given in MBH for gas and GPH for oil. Air
atomized burners show both the oil pressure and air pressure. Pressure atomized burners only list the oil pres-
Page Introduction
sure. For gas firing, the gas manifold pressure is given in
“in wc” which is inches of water column.
The electrical ratings of the burner are given, with the voltage, current load, frequency and phase (this will either be
single or 3-phase). For motors, the motor HP is listed.
2. Ratings
e. Catalog cuts of the major components. These provide
details on the installation, adjustment and maintenance of
the components used on the burner.
5.
Service, Parts and other Information
Service and parts are available from your local Webster
Representative. For a list of Webster Representatives,
please visit the Webster web site at:
The ratings for each specific burner are given on the nameplate. The general burner ratings are given in Specification Sheets that follow this section. The maximum inputs
are given, based on the type of fuel. Other conditions, like
the supply gas pressure or the combination of fuels, emission requirements and control systems may prevent the
burner from reaching the lowest firing rate.
www.webster-engineering.com or call 620-221-7464.
3. Product Offering
The JB burner can fire natural gas, propane and digester
gas as well as all grades of light and heavy oil (#2, #4, #5
and #6 oils as defined by ASTM D396).
DO NOT USE GASOLINE, CRANKCASE OIL OR ANY
OIL CONTAINING GASOLINE.
This burner is also available as a low emission burner, and
will have model designation JBX. Several low NOx rates
are available for all gas and light oil burners, with the standard offering of 60 ppm and 30 ppm when firing natural
gas. Heavy oil is not allowed in combination with low NOx,
as the high sulfur content can recirculate from the vessel
through the burner when switched from heavy oil to gas.
Low sulfur heavy oil can be used with gas FGR, when the
sulfur is under ½% (the FGR is closed during oil firing).
The burner can also be equipped with a NOx cone for low
NOx on gas, which does not require FGR. (See Addendum 950064).
Figure A-2 lists the common variations and options available on this product. The minimum furnace conditions are
given in Section C.
4. Your Complete Manual
In addition to this manual, there are several other documents that should be considered as part of the complete
manual for the burner. All of these documents are needed
to support the installation and startup of the unit. These
additional items include:
a. The wiring diagram, which shows the limits and interconnection of the burner and vessel controls.
b. The gas and oil piping schematics, which show the
components and their relative positions in the piping train.
c. The unit material list which provides an overview of
the burner requirements and a complete bill of material,
including the part numbers and description for each item.
d. The flame safeguard manual provides the operating sequence for the burner management system. This will be a
critical document for troubleshooting any future problems.
JB Manual
Page Introduction
MODEL JB(X) BURNER MODEL CONFIGURATION
FIGURE A-2
JBX1G -05-RM7800L-M.25-M-A-UL/CSD-1
BURNER SERIES
JB
CODES AND
LISTINGS
JB SERIES
UL
FGR or NOx CONE
USED
X
NOT USED
BLANK
ULc
CSD-1
FM
IRI
HEAD SIZE (INCHES)
JB
JBX
1
7 1/8
7 1/2
2
9 1/8
9 1/2
3
11 1/8
11 1/2
NFPA-85
OIL SYSTEMS
Pressure Atomizing
FUELS
G
Gas
O
Oil
C
Gas / Oil
A
On - Off
L
Low Fire Start
H
Low - Hi - Low
MP
Modulation Simplex
MR
Modulation By-Pass
Air or Steam Atomization
BLOWER MOTOR
HORSEPOWER
MA
Air Atomization
MS
Steam Atomization
02
1/4
03
1/3
05
1/2
VGD
Siemens
07
3/4
VGG
Siemens
10
1
M
Maxon
15
1 1/2
20
2
Blank
All Others
(ASCO) - (std)
30
3
50
5
75
7 1/2
100
10
GAS TRAIN VENDOR
GAS TRAIN SIZE
FLAME SAFEGUARD
VENDOR DESIGNATION
RM7800L
Honeywell
M Mark
AutoFlame - mini mark
E110/EP170
Fireye
Nexus
Fireye
LMV51
Siemens
LMV52
Siemens
.15
1 1/2 inches
.20
2 inches
.25
2 1/2 inches
.30
3 inches
.40
4 inches
GAS SYSTEM
A
On-Off
L
Low Fire Start
H
Low-Hi-Low
M
Modulation
The above represents the common model designations.
Contact the factory for other options and special applications.
JB Manual
Page Identification
Model JB1 - Specification Data
(400 - 2500 MBH Input)
X
X
Air Flow Switch (also with oil systems using remote pump)
X
(2) Burner Mounted Control Panel,
Switch and Indicator Lights
X
X
Flame Safety Control
X
X
Ultra Violet Scanner
X
X
Motor Controller (single phase
voltage)
X
X
Duel Fuel Burners Only
Optional
Ignition
Proven Gas Pilot Ignition
Main Manual Shutoff Valve
X
Main Safety Shutoff Valve
X
Second Safety Shutoff Valve
X
Main Gas Regulator
X
Gas Checking Valve
X
High and Low Gas Pressure
Switches (st’d over 2500 MBH)
Opt.
Metering Valve (modulation only)
X
Oil Drawer Assembly with Diffuser
X
X
Pilot Solenoid Gas Valve
X
Oil Nozzle(s)
X
Pilot Gas Regulator & Manual Valve
X
Integral Oil Pump
X
Pilot Gas Ignition Transformer
X
Direct Spark Oil Ignition
X
Direct Spark Oil Ignition
Transformer
X
Oil Fuel
General
Fuel Selector Switch
Gas
No. 2 Oil
pressure
atomized
Motor, Fan and Air Inlet Control
AND IMPORTANT OPTIONS
STANDARD UL EQUIPMENT
AND IMPORTANT OPTIONS
Gas Fuel
Gas
(1) STANDARD UL EQUIPMENT
Fuel Burned
No. 2 Oil
pressure
atomized
Fuel Burned
Main Safety Shutoff Valve
X
Second Safety Shutoff Valve
X
Low Oil Pressure Switch
(STD when using remote oil pump)
Opt.
Inverted Housing
X
X
Oil Pressure Gauge
X
Alternate Control Cabinet
Positioning
X
X
Oil Metering Valve (modulating
systems)
X
Remote Control Panel
X
X
Future Gas Combustion Head-OPT
Fuel Metering CAM-NETIC II
X
X
Opt.
1. The configuration of each unit will vary with specific job requirements such as input rating, electrical specification and special agency approval
codes. The above chart shows those items standard to a basic burner plus a few options that may be added.
2. Indicator lights are “Power On”, “Call for Heat”, ”Fuel On” and ”Flame Fail” for hard wired panels. “Alarm”, “Low Water”, “Power”, “Call for
Heat”, “Ignition On”, and “Fuel On” for circuit board light panels.
Model JB1 - Sizing and Application Data (contact Webster for complete information)
Model
Number
Maximum
Furnace
Pressure
Burner Firing Capability
Range
Gas scfh
#2 Oil gph
Burner Motor HP
Gas Train
Gas Only
HP
(3) Oil or
Combination
Pipe Size
Oil Pump
Motor HP
(4) Inlet Pressure
On-Off, LFS
Modulation
JB1-02
1.25
400 / 1000
3.0 / 7.1
1/4
1/3
1”
6 / 14”
7 /14”
Integral
JB1-03
1.25
600 / 1500
4.0 / 10.7
1/3
1/2
1 1/4”
8 / 14”
9 / 14”
Integral
JB1-05
1.25
800 / 2100
6.0 / 14.8
1/2
1/2
1 1/2”
7 / 14”
8 / 14”
Integral
JB1-07
1.25
900 / 2500
7.0 / 17.8
3/4
3/4
1 1/2”
9 / 14”
11 / 14”
Integral
3. Larger motors may be required for single phase or 208 volts
4. Contact Webster for more complete details
The above maximum ratings are based on 0 furnace pressure, an altitude of 1000 feet, 90oF air temperature and 60 HZ electrical supply. Use
the following corrections for higher temperatures and altitude. Capacity decreases by 17% for 50 Hertz.
Capacity decreases by 4% for each 1000 feet above 1000 foot altitude.
Capacity decreases by 6% for each 1 inch of furnace pressure.
Capacity decreases by 2% for each 10oF increase in air temperature over 90oF.
Gas input ratings based on 1000 BTU/cu ft. and 0.64 specific gravity. Sizes and pressure will vary with gas.
Oil input ratings are based on 140,000 BTU/gal for ASTM #2 fuel oil.
Essential Ordering Information and Data:
Power Supply - Confirm 120-60-1 for control circuit and electrical supply for burner motor(s) (voltage, frequency and phase).
Describe Boiler or Heater to be Fired - Including the manufacturer, model number, furnace pressure and furnace size.
Firing Rate - Define firing rates in MBH for gas and GPH for oil.
Fuel to be Burned - Type of gas and/or oil, including the BTU value.
Approval Agency - UL, FM, IRI (GE GAP), CSD-1, NFPA, Mil spec and local codes, if applicable.
Flame Safety Control Preferred - Honeywell or Fireye controls.
Gas Train Components Preferred - ASCO/ITT, Honeywell or Landis
Control System - ON-OFF, Low Fire Start, Low-High-Low, Modulation, Posi-Control
Required Options - Mounting plate, limit controls, etc.
JB Manual
Page Specification
Model JB1 - Dimentional Data
(400 - 2500 MBH Input)
(Dimensions are +/- 1/4 inch)
9 1/2
24
5 5/16
4
26 5/8
8 1/4
10
15
18 3/8
15 11/16
Standard Arrangement
Elevation
11 7/16
21 7/8
Standard Arrangement
End View
4
36 15/16
36 15/16
4
14 3/8
18 3/8
7 1/4 O.D.
19 3/8
11 3/8
Standard Arrangement
Elevation
W/ Optional Back Mount Control Cabinet
Inverted Arrangement
Elevation
(Optional)
Fuels Burned and Control Systems
- Natural Gas, Propane, Digester or Mixed Gases
- Light #2 Oil, Mechanical Pressure
- On-Off, Low Fire Start, Low-High-Low, Modulating or Micro Modulation
- Control Circuit Requires 120 vac, 60 Hz, Single Phase Voltage Supply
Model JB1 burners are listed by Underwriters Laboratories, Inc. (UL / ULC). Also by the State of Massachusetts
Fire Marshal, City of New York Board of Standards and Appeals, State of Minnesota and can be packaged to meet
specific requirements of IRI, FM, GE GAP, NFPA, MIL spec. or other special insurance or local code requirements.
JB Manual
Page 7
Specification
Model JB2 - Specification Data
(6000 MBH Maximum Input)
No. 2 Oil
Main Manual Shutoff Valve
X
X
Main Safety Shutoff Valve
X
(2) Burner Mounted Control Panel,
Switch and Indicator Lights
X
X
X
Second Safety Shutoff Valve
X
Main Gas Regulator
X
Flame Safety Control
X
X
X
Gas Checking Valve
X
Ultra Violet Scanner
X
X
X
High and Low Gas Pressure Switches
X
Motor Controller (single phase voltage)
X
X
X
Metering Valve (modulating systems)
Motor Starter w/Overloads (3 PH volt)
X
X
X
Normally Open Vent Valve
X
Oil Drawer Assembly with Diffuser
X
X
X
Oil Nozzles
X
X
X
X
Integral Oil Pump (JB2-07 to JB2-20)
X
X
X
Remote Oil Pump (JB2-30 to JB2-50)
X
Opt.
X
Two Safety Shutoff Valves
X
X
X
Opt.
Duel Fuel Burners Only
Proven Gas Pilot Ignition
X
JB2-30 and JB2-50
X
Pilot Solenoid Gas Valve
Pilot Gas Regulator & Manual Valve
Pilot Gas Ignition Transformer
X
X
Direct Spark Oil Ignition
(3)
Direct Spark Oil Ignition
Transformer
Oil Fuel
General
Ignition
Air
Atomized
X
X
Fuel Selector Switch
Pressure
Atomized
X
X
Gas
Air
Atomized
X
Air Flow Switch
Gas Fuel
Pressure
Atomized
Motor, Fan and Air Inlet Control
AND IMPORTANT OPTIONS
X
Alternate Control Cabinet
Positioning
X
X
X
Low Air Atomizing Switch
X
Low Oil Pressure Switch (STD when
using remote oil pump)
X
X
X
Oil Pressure Gauge
X
X
X
Oil Metering Valve (modulating
system)
X
X
Opt.
Opt.
(3)
Inverted Housing
Options
STANDARD UL EQUIPMENT
AND IMPORTANT OPTIONS
Gas
(1) STANDARD UL EQUIPMENT
No. 2 Oil
Remote Control Panel
X
X
X
Future Gas Combustion Head
Fuel Metering CAM-NETIC II
X
X
X
Air Compressor
X
1. The configuration of each unit will vary with specific job requirements such as input rating, electrical specification and special agency approval codes.
The above chart shows those items standard to a basic burner plus a few options that may be added.
2. Indicator lights are “Power On”, “Call for Heat”, ”Fuel On” and ”Flame Fail” for hard wired panels. “Alarm”, “Low Water”, “Power”, “Call for Heat”, “Ignition
On”, and “Fuel On” for circuit board panels.
3. Maximum rate for direct spark is 20 GPH at low fire or 35 GPH at high fire. (standard on straight oil burners, pressure atomized)
Model JB2 - Sizing and Application Data (contact Webster for complete information)
Model
Number
Maximum
Furnace
Pressure
Burner Firing
Capability Range
Gas scfh
#2 Oil gph
Burner
Motor
HP
Gas Train
Oil Pump Motor HP
(3) Inlet Press (in wc)
Pipe Size
LFS, LHL
Modulation
Pressure
Atomizing
Air
Atomizing
Air
Compressor
Motor HP
JB2-07
2
900 / 2800
10 / 20
3/4
1 1/2”
10 / 14”
13”
Integral
N/A
N/A
JB2-10
2
900 / 3500
10 / 25
1
2”
8 / 14”
9 / 14”
Integral
Optional
2
JB2-15
2
900 / 3500
10 / 25
1 1/2
2”
8 / 14”
9 / 14”
Integral
Optional
2
JB2-20
2
1200 / 4200
12 / 30
2
2”
(4) 12 / 14”
(3) 13 / 14”
Integral
Optional
2
JB2-30
2.5
1200 / 5300
12 / 37.8
3
2 1/2”
N/A
13 / 14”
3/4
Optional
2
JB2-50
2.5
1200 / 6000
12 / 42.8
5
2 1/2”
N/A
2-5 psi
3/4
Optional
2
3. Lower pressures may apply to reduced inputs.
4. 11-14” with IRI and LFS or LHL. 12-14” with IRI and modulation.
The above maximum ratings are based on 0 furnace pressure, an altitude of 1000 feet, 90oF air temperature and 60 HZ electrical supply. Use the following corrections for higher temperatures and altitude. Capacity decreases by 17% for 50 Hertz.
Capacity decreases by 4% for each 1000 feet above 1000 foot altitude.
Capacity decreases by 6% for each 1 inch of furnace pressure.
Capacity decreases by 2% for each 10oF increase in air temperature over 90oF.
Gas input ratings based on 1000 BTU/cu ft. and 0.64 specific gravity. Sizes and pressure will vary with different gas properties.
Oil input ratings are based on 140,000 BTU/gal. for ASTM #2 fuel oil.
The vessel draft must be between -0.1 and +0.1 wc.
Essential Ordering Information and Data:
Power Supply - Confirm 120-60-1 for control circuit and electrical supply for burner motor(s) (voltage, frequency and phase).
Describe Boiler or Heater to be Fired - Including the manufacturer, model number, furnace pressure and furnace size.
Firing Rate - Define firing rates in MBH for gas and GPH for oil.
Fuel to be Burned - Type of gas and/or oil, including the BTU value.
Approval Agency - UL, FM, IRI (GE GAP), CSD-1, NFPA, Mil spec and local codes, if applicable.
Flame Safety Control Preferred - Honeywell or Fireye controls. Gas Train Components Preferred - ASCO/ITT, Honeywell or Landis
Control System - ON-OFF, Low Fire Start, Low High Low, Modulation, Posi-Control. Required Options - Mounting plate, limit controls, etc.
JB Manual
Page Specification
Model JB2 - Dimensional Data
(6000 MBH Maximum Input)
(Dimensions are +/- 1/4 inch)
6 1/2
24
28 5/8
5 5/16
4
9 1/2
10
15
19 1/16
19
17 3/4
Standard Arrangement
Elevation
30 11/16
Standard Arrangement
End View
4
39 1/4
4
39 1/4
14
18 1/2
19 1/2
9 1/8
O.D.
12 1/8
Standard Arrangement
Elevation
W/ Optional Back Mount Control Cabinet
Inverted Arrangement
Elevation
Fuels Burned and Control Systems
- Natural Gas, Propane, Digester or Mixed Gases
- Light #2 through Heavy #6 Fuel Oil
- Low Fire Start, Low-High-Low, Modulating or Micro Modulation
- Control Circuit Requires 120 vac, 60 Hz, Single Phase Voltage Supply
Model JB1 burners are listed by Underwriters Laboratories, Inc. (UL/ULC). Also by the State of Massachusetts Fire
Marshal, City of New York Board of Standards and Appeals, State of Minnesota and can be packaged to meet specific requirements of IRI, FM, GE GAP, NFPA, MIL spec. or other special insurance or local code requirements.
JB Manual
Page 9
Specification
Model JB3 - Specification Data
Pressure
Atomized
Air
Atomized
N0. 4 - 6 Oil
Air Atomized
X
Oil Drawer Assembly with Diffuser
X
X
X
X
Oil Nozzles
X
X
X
Pilot Gas Regulator & Manual Valve
X
X
X
Oil Heater with Integral Thermostat
Pilot Gas Ignition Transformer
X
X
X
Remote Oil Pump
X
Opt.
Opt.
Two Safety Shutoff Valves
X
X
X
Gas
STANDARD UL EQUIPMENT
AND IMPORTANT OPTIONS
Motor, Fan and Air Inlet Control
X
X
X
X
Main Manual Shutoff Valve
Air Flow Switch
X
X
X
X
Main Safety Shutoff Valve
X
Second Safety Shutoff Valve
X
Main Gas Regulator
X
Gas Checking Valve
X
High and Low Gas Pressure Switches
X
(2) Burner Mounted Control Panel,
X
X
X
X
X
Flame Safety Control
X
X
X
X
Ultra Violet Scanner
X
X
X
X
Motor Starter with Overloads
X
X
X
X
Metering Valve (modulating systems)
X
Fuel Selector Switch
Duel Fuel Burners Only
Normal Open Vent Valve (above
12,500 MBH)
X
Gas Fuel
Switch and Four Indicator Lights
Oil Fuel
Options
Gas
X
X
Air
Atomized
X
X
Pressure
Atomized
Proven Gas Pilot Ignition
Pilot Solenoid Gas Valve
EQUIPMENT
AND IMPORTANT OPTIONS
General
No. 2 Oil
No. 4 - 6 Oil
Air Atomized
No. 2 Oil
(1) STANDARD UL
Ignition
(12,600 MBH Maximum Input)
X
High Oil Temperature Switch
X
Low Air Atomizing Switch
X
Inverted Housing
X
X
X
X
Low Oil Pressure Switch
X
X
X
Alternate Control Cabinet Positioning
X
X
X
X
Oil Pressure Gauge
X
X
X
Remote Control Panel
X
X
X
X
Oil Metering Valve
X
X
X
Fuel Metering CAM-NETIC II
X
X
X
X
Future Gas Combustion Head
Opt.
Opt.
Opt.
Posi-Control
X
X
X
X
Air Compressor
X
X
1. The configuration of each unit will vary with specific job requirements such as input rating, electrical specification and special agency approval codes.
The above chart shows those items standard to a basic burner plus a few options that may be added.
2. Indicator lights are “Power On”, “Call for Heat”, ”Fuel On” and ”Flame Fail”.
Model JB3 - Sizing and Application Data (contact Webster for complete information)
Model
Number
Maximum
Furnace
Pressure
Burner Firing Capability Range
Gas scfh
#2 Oil
gph
JB3-30
3.5
1400 / 6300
10.2 / 45
10 / 42
3
2 1/2”
JB3-50
3.5
1400 / 8300
11 / 59.2
10 / 55.3
5
3”
JB3-75
3.5
1600 / 10500
12.3 / 75
11 / 70
7 1/2
3”
JB3-100
3.5
1800 / 12600
20.3 / 90
12 / 84
10
3”
#4-6
Oil gph
Burner
Motor
HP
Gas Train
Pipe
Size
Inlet
Press
#2 Oil Pump Motor HP
#4 - 6
Pump
Motor HP
Air
Compressor
Motor HP
Optional
Optional
2
Optional
Optional
2
1
Optional
Optional
2
1
Optional
Optional
2
Pressure
Atomizing
Air
Atomizing
12 / 27”
1
15 / 27”
1 1/2
23 / 27”
2-5 psi
The above maximum ratings are based on 0 furnace pressure, an altitude of 1000 feet, 90oF air temperature and 60 HZ electrical supply. Use the following corrections for higher temperatures and altitude. Capacity by 17% for 50 Hertz.
Capacity decreases by 4% for each 1000 feet above 1000 foot altitude.
Capacity decreases by 6% for each 1 inch of furnace pressure.
Capacity decreases by 2% for each 10oF increase in air temperature over 90oF.
Gas input ratings based on 1000 BTU/cu ft. and 0.64 specific gravity. Sizes and pressure will vary with gas.
Oil input ratings are based on 140,000 BTU/gal. for ASTM #2 fuel oil and 150,000 BTU/gal for ASTM #4-6 fuel oil.
The vessel draft must be between -0.1 and +0.1 wc.
Essential Ordering Information and Data:
Power Supply - Confirm 120-60-1 for control circuit and electrical supply for burner motor(s) (voltage, frequency and phase).
Describe Boiler or Heater to be Fired - Including the manufacturer, model number, furnace pressure and furnace size.
Firing Rate - Define firing rates in MBH for gas and GPH for oil.
Fuel to be Burned - Type of gas and/or oil, including the BTU value.
Approval Agency - UL, FM, IRI (GE GAP), CSD-1, NFPA, Mil spec and local codes, if applicable.
Flame Safety Control Preferred - Honeywell or Fireye controls.
Gas Train Components Preferred - ASCO/ITT, Honeywell or Landis
Control System - ON-OFF, Low Fire Start, Low High Low, Modulation, Posi-Control
Required Options - Mounting plate, operating controls, limit controls, etc.
JB Manual
Page 10
Specification
Model JB3 - Dimensional Data
(12,600 MBH Maximum Input)
(Dimensions are +/- 1/4 inch)
6 1/2
24
38 1/4
5 5/16
4
15 15/16
10
15
19 15/16
22 1/2
16
Standard Arrangement
Elevation
27
Standard Arrangement
End View
48
4
22 1/2
48
4
19 1/4
19 9/16
Standard Arrangement
Elevation
W/ Optional Back Mount Control Cabinet
11 1/4
O.D.
14 3/4
Fuels Burned and Control Systems
- Natural Gas, Propane, Digester or Mixed Gases
- Light #2 through Heavy #6 Fuel Oil
- Modulating Control System - Micro Modulation or Linkage
- Control Circuit Requires 120 vac, 60 Hz, Single Phase Voltage Supply
Inverted Arrangement
Elevation
Model JB3 burners are listed by Underwriters Laboratories, Inc. (UL/ULC). Also by the State of Massachusetts Fire
Marshal, City of New York Board of Standards and Appeals, State of Minnesota and can be packaged to meet specific requirements of IRI, FM, GE GAP, NFPA, MIL spec. or other special insurance or local code requirements.
JB Manual
Page 11
Specification
B. COMPONENT IDENTIFICATION
This secion shows the different common components used in the JB burner line and should be helpful to identify parts
described elsewhere in this manual.
Light & Switch Panel
Control Cabinet
Mod Motor
Control Transformer
Figure B-1
JB2 Burner
Oil Fuel
Sight Glass
Drawer Assembly
Blower Motor
Linkage
Gas Valve
Oil Pressure Switch
Louver Box
Oil Pressure Gauge
Oil Valve
Pilot Solenoid
Pilot Gas Regulator
Gas Actuator
Combustion
Head
Gas Valve
Manual Ball Valve
Figure B-2
JB1G Left Side View
Ignition
Transformer
Air Flow Switch
Pilot Gas Regulator
Gas Actuator
High Gas
Pressure Switch
JB Manual
Figure B-3
JB1G Right Side View
Page 12
Gas Pressure Gauge
Identification
Board to Light
Panel Cable
Combination Flame
SafeGuard Base
and Circuit Board
Switch / Light
Panel
Light Panel
Circuit Board
Flame SafeGuard
Base
Figure B-4
Control Panel
Circuit Board
Design
Field Wiring
Terminal Strips
Panel Wiring
Terminal Strip
Board to Light
Panel Cable
Electrical Panel Identification: The above pictures show the flame safeguard base mounted on a circuit board. Connections are wired via cable to
light / switch circuit board. Picture below shows the flame safeguard (base) mounted directly to the panel back plate.
Figure B-5
Control Panel
Hard Wired
Design
Control Relays
Transformer Fuses
Burner Motor
Starter
Control Transformer
Flame Safeguard
Switch / Light Panel
Terminal Strip
Air Chamber
Pressure
Gauge
Belt Guard
Electric Motor
Air Filter
Compressor
Figure B-6
Air Compressor
JB Manual
Page 13
Air Discharge
Connection
Identification
Air Inlet
Louver Box
Electrical Junction Box
Oil Cam
Low Atomizing
Air Press. Sw.
Drawer Assembly
Jack Shaft
Atomizing Air
Bleed Muffler
High Oil Temp.
Switch
Air Bleed Valve
Atomizing Air
Press. Gauge
Blower Motor
Oil Temp.
Gauge
Atomizing Line
to Nozzle
Supply Oil
Press. Gauge
Oil Metering
Valve
Trim Heater
Safety Relief
Valve
Trim Heater
Drawer Assm.
Pre-heat Oil
Lines
Oil Supply To
Nozzle
Thermostat Control
Switch & Cold Oil
Interlock Switch
N.O. Return
Oil Valve
Nozzle Oil
Press. Gauge
Safety Oil
Valves
Low Oil Press.
Switch
Figure B-7
JB Burner
#4 - 6 Fuel Oil
Choke Cone
JB1 & JB2 Only
Primary Gas Orifices
(Behind Retention Plate)
Diffuser Assembly
Oil Nozzle(s)
Gas Pilot
Secondary Gas Orifices
Retention Plate
Figure B-8
JB Combustion Head - Dual Fuel
JB Manual
Page 14
Identification
Mounting Flange
Gas Manifold
Orifice Plate
Secondary Gas Orifices
Nose Choke Cone
Primary Gas Orifice
Drawer Assembly
Retention plate Assembly
Ignition Electrode
Diffuser
Figure B-9
Standard Head Arrangement
Section View
Pilot Assembly
Gas Inlet
Gas Manifold (inner cylinder)
Retention Plate
Assembly
This connection between the retention plate assembly and the gas manifold inner cylinder must
be properly made for proper performance.
Oil Supply Line
Back Mounting
Plate w/View Port
Diffuser Mounting Bracket
Oil Nozzle(s)
Adapter
Oil Return Line
To Oil System
Return
Oil Nozzle(s)
Oil Supply Line
(lower pipe)
Diffuser
Pilot Gas
Supply Line
Gas Pilot
Pilot Gas Supply
Ignition Electrode
Figure B-10
JB3 Combination or Straight Oil Drawer Assembly
with Proven Gas Pilot
View Port
Oil Supply Line
Ignition Electrode
Gas Pilot
Pilot Gas Line
Pilot Gas Inlet
Oil Nozzle(s)
Adapter
Oil Nozzle(s)
Diffuser
Oil Supply Line
Sight Tube
Backplate
JB Manual
Figure B-11
JB1 & 2 Combination Drawer Assembly
with Proven Gas Pilot Ignition
Page 15
Identification
Oil Supply Line
View Port
Oil Ignition Electrodes
Diffuser
Oil Nozzle(s)
Oil Supply Line
Back Plate
Oil Nozzle(s)
Adapter
Sight Tube
Diffuser Clamp
Figure B-12
JB1 & 2 Straight #2 Oil Drawer Assembly
with Direct Spark Ignition
Gas Orifice Part Number and Description
Part No.
Description
090002
Sketch
Example
Vessel
FB
Gas orifice, 5/16” brass blank, no holes
090002-076
Gas orifice, 5/16” brass, (2) radial #48 holes, no axial hole (48 x 2)
B
090002-098
Gas orifice, 5/16” brass, (2) radial #40 holes, no axial hole (40 x 2)
B
FB
090054-xxx
Gas orifice, 5/16” brass, no radial holes, (1) axial hole (xxx = hole dia.)
E
FB, SF
090055-xxx
Gas orifice, 5/16” steel, no radial holes, (1) axial hole (xxx = hole dia.)
E
090069-xxx
Gas orifice, 5/16” brass, (4) #40 radial holes, (1) axial hole (xxx = hole dia.) (40 x 4 x __ )
A
090184-xxx
Gas orifice, 5/16” steel, (4) #40 radial holes, (1) axial hole (xxx = hole dia.) (40 x 4 x __ )
A
090185-000
Gas orifice, 5/16” steel blank, no radial or axial holes
090185-098
Gas orifice, 5/16” steel, (2) radial #40 holes, no axial hole (40 x 2)
B
090227-xxx
Gas orifice, 5/16” brass, (4) #48 radial holes, (1) axial hole (xxx = hole dia.) (48 x 4 x __ )
A
090284-xxx
Gas orifice, 1/4” steel, no radial holes, (1) axial hole (xxx = hole dia.)
E
090287
Orifice extention, 5/16” OD steel tube, 1.188” long
D
090288
Orifice extention, 5/16” OD steel tube, 2.75” long
D
090318
Orifice extention, 5/16” OD brass tube, 1.188” long
D
090319
Orifice extention, 5/16” OD brass tube, 2.75” long
D
OT (open tube)
FB, SF
SF
No orifice used (If no orifice part number given in BOM, asume OP)
Note: 1. Part numbers ending in “-xxx” use the drilled hole diameter as the last three digits, or
the “-xxx”. A number 40 drill would be “-098”.
2. Part numbers ending in “000” indicate no drilled hole.
3. Sketches show general appearance only, not number or type of holes.
4. Secondary orifices are closest to the burner center. primary orifices are on the outside.
4 Radial Holes
2 Radial Holes
FB = Firebox
SF = Scotch Firetube
1 Axial Hole
Orifice Example “E”
Orifice Example “A”
4 Radial Holes, Axial Hole -xxx
If the radial drill size is a # 40 drill, this
would be called a “40 by 4” orifice,
which is common in the JB burner line.
JB Manual
Orifice Example “B”
No Radial Holes, 1 Axial Hole
2 Radial Holes, No Axial Holes
If the radial drill size is a # 40 drill, this
would be called a “40 by 2” orifice,
which is common in the JB burner line.
Page 16
The threads run the full length
of the orifice. This orifice cannot
have radial holes.
Identification
C. INSTALLATION
Prior to installing the burner, the site conditions and utilities need to be evalulated. This section provides some
general questions that can help the review process. Inspect the burner for any undetected damage that may
have occurred during shipment or by job-site handling.
Special attention should be given to the control panel
and protruding parts such as linkages. Check linkages,
air louver stops, wiring connections and fasteners for
tightness.
Verify that all ship loose (or separately shipped) items
are on hand. This normally will be: gas train components,
mounting lugs and insulating rope. Also, front mounting
plate and remote oil pump set, if supplied. The burner
material list included with the instruction manual serves
as a good checklist for this purpose.
1. Is there adequate outside ventilation to supply the
needed air for safe combustion as required by your local
regulatory agency?
2. If a burner mounting plate is required, is it available
and does it meet specifications? (See Section E)
3. Is 120-60-1 voltage available for the control circuit
and is the correct voltage available for the blower motor
as well for the remote oil pump set and air compressor,
if used?
4. Will the burner properly fit the boiler or heater with
ample clearance on top, bottom and sides?
5. If a gas burner, will there be adequate gas pressure to
assure the specified firing rate?
6. If a straight oil burner with gas pilot, is gas available at
the burner location?
7. If an oil burner, what is the age and condition of the
oil tank(s) and will there be special piping arrangements
needed to deliver the oil to the burner?
Important Note: The JB series burners must be operated with a two-pipe system.
8. If an oil burner, what grade of fuel oil is in the tank(s) or
on order? If a retrofit installation, has the same oil grade
always been used? Does it meet the grade specified on
the burner’s UL rating plate?
regulator and/or sensing line.
15. Oil piping to be flushed (cleaned) prior to use.
16. Check pump suction pressure (max 10” Hg) or max
press (3 psig) if transfer pump is used or tank elevation is
higher than the pump.
17. Strainer before oil pump, sized for max pump suction
capacity.
18. If FGR is used, does it follow Webster guidelines. (see
addendum 950064)
19. If multiple vessels connect to a single stack, are they
sized and designed to maintain +/- 0.1” wc draft at the vessel outlet under all operating conditions.
20. Is stack designed to maintain +/- 0.1” wc at outlet during
all operating conditions.
WARNING
DO NOT USE TEFLON TAPE OR COMPOUNDS
CONTAINING TEFLON. THIS COULD DAMAGE THE
VALVES CREATING AN UNSAFE OPERATION
21. Is the burner mounting plate and burner head sealed
with rope gasket? (See Figure E-2)
22. Has the new gas and oil piping been purged to remove
debris?
23. Is there a drop leg in the gas supply to capture foreign
material? (See Figure C-1)
24. Is the piping between the gas train and burner done in
a manner that will minimize the pressure drop?
25. Has all of the piping been pressure checked for leaks?
26. Is the combustion chamber of proper size and is the
center-line height of the burner head adequate? (See
charts C-2 & C-3.)
CAUTION
The oil burner shall only burn that grade of oil shown
on the UL rating plate. DO NOT USE GASOLINE,
CRANKCASE OIL, OR ANY OIL CONTAINING GASOLINE OR TOXIC CONTAMINANTS.
9. Is there adequate flue provisions to assure SAFE and
proper venting of the burner?
10. All manuals should be reviewed and understood and
stored in a convenient place.
11. Teflon tape should not be used on any field piping.
12. Rope gaskets should be used between vessel and
mounting plate, and between mounting plate and burner.
13. Gas piping should be flushed (cleaned) prior to use.
14. Check minimum straight lengths for gas pressure
JB Manual
Page 17
Installation
Pilot
Shutoff
Valve
Pilot Gas
Pressure
Regulator
Pilot Solenoid
Valve
Normally
open vent
valve
Gas Supply
Low Gas
Pressure
Switch
Gas Pressure
Regulator
High Gas
Pressure
Switch
Manual Gas
Shutoff Valve
Burner
Shutoff
Valve
Shutoff
Valve
If applicable, Webster
supplied gas train
Leak Test
Valve
Figure C-1
Typical Gas Piping
Drip Leg
Chart C-2
Chart C-3
TYPICAL COMBUSTION CHAMBER SIZE
FOR SCOTCH MARINE FIRETUBE BOILERS
th
Leng
gth
Len
Width
ner
enter of Bur
t - Floor to C
ter
Diame
Heigh
FURNACE DIAMETER - INCHES
TYPICAL COMBUSTION CHAMBER SIZE
FOR FIREBOX BOILERS, WATERTUBE &
CAST IRON SECTIONAL TYPES
D. SPECIAL INSTRUCTIONS FOR CANADIAN INSTALLATIONS
1. The installation of a burner shall be in accordance with
the regulations of the provincial installation requirements,
or in their absence, the following shall govern:
Gas Burners--CGAB149.1 and CGAB149.2
Oil Burners--CSA Standard B139
Authorities having jurisdiction should be consulted before
installations are made.
2. All electrical wiring shall be done in accordance with
JB Manual
the Canadian Electrical Code, Part I.
3. The installer shall identify (label) the main electrical
power disconnect and the manual shut-off valve on the
gas and/or oil supply drop-line to the burner.
4. Oil and gas burning equipment shall be connected to
flues having sufficient draft at all times, to assure safe
and proper operation of the burner.
Page 18
Installation / Canadian Installations
E. BURNER MOUNTING CRITERIA
It is of vital importance that the burner be properly mounted to the boiler or appliance being fired. Improper mounting
can cause leakage of the hot gases back around the burner head resulting in warpage and deterioration. The following
illustrations show the proper way the burner must be installed to validate warranty conditions.
TYPICAL JB1, 2, 3 BURNER REFRACTORY FRONTPLATE
B - Bolt Circle
Use minimum
of four (4) 1/2”
studs with lugs.
Dimensions - Inches
Minimum 7 gauge
2” Minimum
A
2” Minimum
4”
A
MODEL
DIM. A
DIM. B
JB1
7 5/8
10 3/4
JB2
9 5/8
12 3/4
JB3
11 5/8
14 3/4
Note: For JB burners equipped
with a low NOx cone, refer to addendum number 950064
See Note 3
30o to 45o taper,
see note 4
A - Opening
Minimum of six (6) holes for
boiler mtg. studs, 1/2” or larger
Contact Webster for more detailed
refractory drawings
Refractory OD is sized to fit
vessel opening with 1/4” to
1/2” gap, Refractory must
extend 2” beyond tube
sheet for scotch boilers.
Minimum 14 Gauge
Figure E-1
Refractory Dimension
This surface must be
sealed against the vessel.
Check vessel mounting
requirements
Fill voids between front plate
and vessel with
ceramic blanket
4” deep or as
defined by vessel
manufacturer.
Tighten clamp bolts
uniformly - check after
firing for several hours
The burner must
be level
Refractory
Front Plate
Fiberglas rope
gasket must be
coiled to cover
the full mounting
flange surface
If gap is over 3/16”,
wrap burner nose
with high temperature ceramic insulating rope.
Attachment to vessel varies with manufacturer (follow vessel manufacturers
recommendation.
Pipe support required
Flange secured to floor
The gas piping from the burner to the
train should have as few elbows as possible to reduce presure drop.
Figure E-2
Burner Mounting Instruction
JB Manual
Page 19
Burner Mounting Criteria
F. FUEL SYSTEMS
The JB burner can be equipped with a wide range of fuel and operating systems to control the fuel, air, modulation
and pilots. This section describes how these systems operate. Burner start-up is expected to be done by service personnel who are qualified in the basics of mechanical know-how. The following illustrations and information is supplied
to identify the various fuel; air and ignition devices that have Adjustment Features. All adjustments can be done with
common place tools normally carried by burner and boiler service personnel.
NOTE
Refer to the bulletins included in the manufacturer’s data section of the burner instructions manual for items shown
below.
1. Pressure atomized oil systems
Safety Oil
Main Oil
Solenoid Valve Solenoid Valve
“A” - On - Off
1
Oil Nozzle
Gauge Port
Adjustment
Oil Pump
Check Valve
Return to Tank
(No Manual Valves
in this line)
1
Notes & Options
By Others
Check
Valve
Shutoff Valve
Suction
Supply Line
1 These Lines are Field
Strainer
Piped if a Remote
Pump is Used
By Others
Unless Specified on Order
Field Piped
“L” - Low Fire Start or “H” - Low - Hi - Low
N.O. Low Fire
Bypass Oil Valve
Low Fire Bypass Regulator
(Adjustment for Low Fire
Approx. 100 - 125 PSI)
2 or 3 1 (IN)
(out)
2
Low Oil
Press. Sw
IN
1
High Fire Cylinder
Louver Actuator
Return to Tank
(No Manual Valves
in this line)
IN
Gauge Port
Oil Nozzle
Adjustment
Oil Pump
Field Piped
Check Valve
1
By Others
Shutoff Valve
Check
Valve
Notes & Options
Strainer
Suction
Supply Line
Field Piped
JB Manual
.
Main Oil
Safety Oil
Solenoid
Valve Solenoid Valve
By Others
Unless Specified on Order
Page 20
1
These Lines are Field
Piped if a Remote Pump
is Used
2
Required Above 20 GPH
if a Remote Pump is Used
Fuel Systems
“MP” - Modulating Simplex Nozzle
2
Low Oil
Pressure Switch
Oil Metering
Valve
1
1
Oil Nozzle
Gauge Port
Adjustment
Oil Pump
Check
Valve
Return to Tank,
(No Manual
Valves in this
Line)
Main Oil
Safety Oil
Solenoid Valve Solenoid Valve
1
By Others
Shutoff
Valve
Suction
Supply Line
Field Piped
Notes & Options
Check
Valve
Strainer
By Others
(Unless Specified on Order)
1
These Lines are Field
Piped if a Remote Pump
is Used
2
Usage Requirement
Varies with Code
“MR” - Modulating Return Flow Nozzles
2
Back Pressure Low Oil Pressure
Reg. Valve Press. Sw. Gauge
1
Gauge Port
1
Shutoff
Valve
Suction
Supply Line
Check
Valve
Safety Oil
Main Oil
Solenoid Valve
Solenoid Valve
Inline
Check
Valve
Oil Nozzle
(Bypassing)
Oil Pump
Strainer
Notes & Options
By Others
(Unless Specified in Order)
Return to Tank
(No Manual
Valves in this Line
1
Check
Valve
Check
Valve
Oil Metering
Valve
Pressure
Gauge
1
2
These Lines are
Field Piped if a
Remote Pump is
Used
Required Above 20
GPH if a Remote
Pump is Used
Field Piped
JB Manual
Page 21
Fuel Systems
2. Air Atomized Oil Systems
Safety
Valve
Air Filter
Ball Valve
(man. set to adjust air
volume & high fire air
pressure)
Air pipe same size
Low
as discharge open- Atomizing
ing in air chamber Pressure
(field Piped)
Check Gauge
Valve
Compressor
Pressure
Gauge
Oil
Metering
Valve
Low Oil
Pressure
“MA” - Modulating #2 Oil
Air
Chamber
Safety
Oil
Valve
N.C.
Main Oil
Valve
Nozzle
Oil
Gauge
Ball
Valve
Flexible Metal Hoses or
Copper Tubing
Check
Valve
Relief
Valve
Gauge
Ball or
Gate
Valve
Compound
Gauge
Gauge
Strainer
Return
to Tank
Check
Valve
Gate
Valve
Oil
Suction
Field Piped
Oil Pump
Field Piped
Relief Valve
Air Filter
Ball Valve
(man. set to adjust
air volume & high
fire air pressure)
Valve
Oil
Metering
Valve
N.C. Main
Oil Valve
Ball
Valve
Safety
Oil Valve
N.O. Return
Oil Valve
1
Oil Supply for
Preheat Housing
Low Oil
High Oil
Temp. Sw. Temp. Sw.
Relief
Valve
Air
Gauge
Gauge
1
High Oil
Low Oil
Temp. Sw. Temp. Sw.
Drain
Oil Preheat Housing
Flexible Metal Hoses
or Copper Tubing
1/4” Ball
Valve
Oil Return from
Preheat Housing
1/4” Ball
Valve
Check
Valve
Plug
Ball or
Opening Gate Valve
Back
Ball or
Pressure
Gate Valve
Valve
3 valve bypass optional for
back pressure valve.
Note: For a single burner
with the pump set close to
the burner the back pressure
valve can be furnished piped
with the oil pump set.
Electric oil heater w/integral low
oil temp. switch
Nozzle
Oil
Gauge
Ball
Valve
Thermometer
1
“MA” - Modulating #4 - 6 Oil
Air pipe same as Low Air
discharge openPress Sw
ing in air chamber
Check
(field piped)
Compressor
Pressure
Gauge
1
Air
Chamber
Oil
Supply
Heating
System
Check
Valve
Relief
Compound
Valve Gauge Gauge
Ball or
Gate Valve
Strainer
Return
to Tank
Gate
Valve
Check
Valve
Oil
Suction
Oil Pump
Field Piped
“MA” or “MS” - Modulating House Air or Steam
Steam
Syphon
125 PSIG
Max.
Atomizing
Steam
Condensate
Return
JB Manual
Ball or Gate
Valve
300 lb.
Gauge
Pressure
Reducing
Valve
Steam
Strainer
Ball or Gate
Valve
Steam
Trap
Drip Leg
Field Piped
Page 22
Low Atomizing
Pressure Switch
Metering Lever
Ball Valve Linked
to Mod. Motor
N.C
Atomizing
Valve
Steam
Syphon
Gauge
Check
Valve
Steam
Syphon
NOTE: House air does not use steam Syphon or Steam Trap
Fuel Systems
3. Gas Systems
Illustrated Gas Trains by Capacity and Code: The following illustrations show the Webster configuration for UL,
FM and IRI as grouped by UL capacity ratings. Refer to the legend below for component part identification. These
illustrations are not to be used for field erection and/or system design purposes.
UL Capacity Range
BTU/Hr.
To 2,500,000
2,500,001
to
5,000,000
5,000,001
to 12,500,000
12,500,001
and Up
Operation Mode
Webster
Designation
Code
Illustration
UL / GE
GAP
FM
On-Off
A
X
X
722091
Low Fire Start
L
X
X
722001
Low Hi Low
H
X
X
722022
Modulating
M
X
X
722003
Low Fire Start
L
X
Low Fire Start
L
Low Hi Low
H
Low Hi Low
H
Modulating
M
Modulation
M
Modulating
M
Modulating
M
Modulating
M
Modulating
M
722002
X
X
722009
722023
X
X
722024
722004
X
X
722010
722005
X
X
722011
722082
X
722084
NOTE: Pressure Drops; Pressure drop through a given gas train will vary somewhat in relation to the individual items
used, the specific gravity of the gas to be burned and the overall length.
722091
Field Piped
Pilot Manual
Ball Valve
Pilot Gas
Pressure
Regulator
Pilot Solenoid
Valve
S
Gas Pilot
Ignitor
Vent To Outside
Atmosphere
Gas
Supply
Manual Ball
Valve
Gas Pressure
Regulator
Main Solenoid
Gas Valve
Main Diaphragm
Gas Valve
S
D
Manual
Test Valve
Manual Test
Valve
Manual Ball
Valve
Test
Connection
Field Piped
UL-FM On-Off Gas Piping Diagram - Up to 2,500 MBH Firing Rate 1/2 PSI Max
JB Manual
Page 23
Gas Burner
Manifold
722091
Fuel Systems
722001
Field Piped
Pilot Gas
Pressure
Regulator
Pilot Manual
Ball Valve
Pilot Solenoid
Valve
Gas Pilot
Ignitor
S
Vent To Outside
Atmosphere
Gas
Supply
Main Motorized
Gas Valve
26 Sec.
Main Solenoid
Gas Valve
Manual Ball
Valve
S
M
Gas Burner
Manifold
Field
Piped
Manual
Test Valve
Gas Pressure
Regulator
Test
Connection
Manual Ball
Valve
Manual Test Valve
UL-FM Low Fire Start Gas Piping Diagram - Up to 2,500 MBH Firing Rate
722022
Field Piped
Pilot Gas
Pressure
Regulator
Pilot Manual
Ball Valve
722001
Pilot Solenoid
Valve
Gas Pilot
Ignitor
S
Vent To Outside
Atmosphere
Gas
Supply
Main Motorized
Gas Valve
26 Sec.
Main Solenoid
Gas Valve
Manual Ball
Valve
S
Test
Connection
M
Gas Pressure
Regulator
Manual Ball
Valve
Manual Test
Valve
Field
Piped
Manual
Test Valve
Gas Burner
Manifold
UL-FM Low-Hi-Low Gas Piping Diagram - Up to 2,500 MBH Firing Rate
722003
Field Piped
Pilot Manual
Ball Valve
Pilot Gas
Pressure
Regulator
Pilot Solenoid
Valve
S
Vent To Outside
Atmosphere
Gas
Supply
722022
Manual Ball
Valve
Gas Pilot
Ignitor
Main Solenoid
Gas Valve
Main Motorized
Gas Valve
26 Sec.
S
M
Gas Pressure
Regulator
Manual
Ball Valve
Manual
Test Valve
Manual Test
Valve
Test
Connection
Gas Burner
Manifold
Fuel Flow
Control Valve
Field Piped
UL-FM Modulation Gas Piping Diagram - Up to 2,500 MBH Firing Rate
722002
Field Piped
Pilot Manual
Ball Valve
Pilot Gas
Pressure
Regulator
Gas
Supply
L
Gas Pressure
Regulator
Pilot Solenoid
Valve
S
Vent To Outside
Atmosphere
Manual Ball
Valve
Gas Pilot
Ignitor
Main Reset Low
Gas Pressure
Switch
S
Main Solenoid
Gas Valve
Field Piped
Manual Test Valve
Main Motorized
Gas Valve
26 Sec.
M
Manual
Test
Valve
Vent
Field-Piped
Page 24
Test
Connection
H
Main Reset High
Gas Pressure
Switch
UL Low Fire Start Gas Piping Diagram - 2,501 to 5,000 MBH Firing Rate
JB Manual
722003
Gas Burner
Manifold
Manual Ball
Valve
722002
Fuel Systems
722009
Field Piped
Pilot Manual
Ball Valve
Pilot Gas
Pressure
Regulator
S
Vent To Outside
Atmosphere
Gas
Supply
Manual Ball
Valve
Pilot Solenoid
Valve
Gas Pilot
Ignitor
Man Reset Low
Gas Pressure
Switch
M
L
Gas Pressure
Manual Test
Regulator
Valve
Vent
Main Motorized
Gas Valve
26 Sec.
Main Motorized
Gas Valve
14 Sec.
M
Field Piped
Man Reset High
Gas Pressure
Switch
Test
Connection
Field
Piped
H
Gas Burner
Manifold
Manual Ball
Valve
Manual
Test Valve
FM Low Fire Start Gas Piping Diagram - 2,501 to 5,000 MBH Firing Rate
722023
Field Piped
Pilot Manual
Ball Valve
Gas Pressure
Regulator
Gas
Supply
Pilot Gas
Pressure
Regulator
722009
Pilot Solenoid
Valve
S
Gas Pilot
Ignitor
Vent To Outside
Atmosphere
Manual Ball
Valve
Vent
Main Solenoid
Gas Valve
Main Motorized
Gas Valve
26 Sec.
S
M
L
Man Reset
Low Gas
Pressure
Switch
Manual Test
Valve
Field
Piped
Manual
Test Valve
H
Man Reset
High Gas
Pressure
Switch
Field
Piped
Test
Connection
Gas Burner
Manifold
Manual Ball
Valve
UL Low-Hi-Low Gas Piping Diagram - 2,501 to 5,000 MBH Firing Rate
722024
Field Piped
Pilot Manual
Ball Valve
Gas Pressure
Regulator
Gas
Supply
Pilot Gas
Pressure
Regulator
722023
Pilot Solenoid
Valve
S
Gas Pilot
Ignitor
Vent To Outside
Atmosphere
Manual Ball
Valve
Vent
Main Motorized
Gas Valve
14 sec.
Main Motorized
Gas Valve
26 Sec.
M
M
L
Man Reset
Low Gas
Pressure
Switch
Manual
Test Valve
H
Manual Test
Valve
Field
Piped
Man Reset
High Gas
Pressure
Switch
Field
Piped
Test
Connection
Gas Burner
Manifold
Manual Ball
Valve
FM Low-Hi-Low Gas Piping Diagram - 2,501 to 5,000 MBH Firing Rate
722004
Field Piped
Pilot Manual
Ball Valve
Pilot Gas
Pressure
Regulator
Gas
Supply
Pilot Solenoid
Valve
Gas Pilot
Ignitor
S
Vent To Outside
Atmosphere
Manual Ball
Valve
L
Man Reset Low
Gas Pressure
Switch
Main Motorized
Gas Valve
26 Sec.
S
Gas Pressure
Regulator
Main Solenoid
Gas Valve
M
Manual Test
Valve
Vent
H
Manual
Test Valve
Man Reset High
Gas Pressure
Switch
Test
Connection
Manual
Ball Valve
Field Piped
Fuel Flow
Control Valve
UL Modulation Gas Piping Diagram - 2,501 to 5,000 MBH Firing Rate
JB Manual
7722024
Page 25
Gas Burner
Manifold
722004
Fuel Systems
722010
Field Piped
Pilot Manual
Ball Valve
Pilot Gas
Pressure
Regulator
S
Vent To Outside
Atmosphere
Gas
Supply
Pilot Solenoid
Valve
Gas Pilot
Ignitor
Man Reset Low
Gas Pressure
Switch
Vent
Main Motorized
Gas Valve
26 Sec.
Main Mortorized
Gas Valve
14 Sec.
Manual Ball
Valve
M
L
M
Gas Pressure
Manual Test
Regulator
Valve
Man Reset
High Pressure
Switch
Test
Connection
H
Manual Ball Valve
Manual Test
Valve
Field Piped
Gas Burner
Manifold
Fuel Flow
Control Valve
FM Modulation Gas Piping Diagram - 2,501 to 5,000 MBH Firing Rate
722005
Field Piped
Pilot Manual
Ball Valve
Pilot Gas
Pressure
Regulator
Pilot Solenoid
Valve
Gas Pilot
Ignitor
S
Vent To Outside
Atmosphere
Gas
Supply
722010
Manual Ball
Valve
Main Motorized
Gas Valve
W/POC
26 Sec.
Man Reset Low
Gas Pressure
Switch
S
L
M
H
POC
Gas Pressure
Regulator Main Solenoid
Manual
Test Valve
Manual Test
Valve
Gas Valve
Vent
Man Reset High
Gas Pressure
Switch
Manual
Ball Valve
Test
Connection
Fuel Flow
Control Valve
Field Piped
UL Modulation Gas Piping Diagram - 5,001 to 12,500 MBH Firing Rate
722011
Field Piped
Pilot Manual
Ball Valve
Pilot Gas
Pressure
Regulator
Gas
Supply
722005
Pilot Solenoid
Valve
S
Vent To Outside
Atmosphere
Manual Ball
Valve
Man Reset Low
Gas Pressure
Switch
Main Motorized
Gas Valve
14 Sec.
Gas Pilot
Ignitor
Main Motorized
Gas Valve
W/ POC
26 Sec.
M
L
M
POC
Gas Pressure
Regulator
Manual Test
Valve
Vent
Man Reset
High Pressure
Switch
Test
Connection
H
Manual Test
Valve
Manual Ball Valve
Field Piped
Gas Burner
Manifold
Fuel Flow
Control Valve
FM Modulation Gas Piping Diagram - 5,001 to 12,500 MBH Firing Rate
722082
Field Piped
Pilot Manual
Ball Valve
Gas Pressure
Regulator
Gas
Supply
Manual Ball
Valve
Pilot Gas
Pressure
Regulator
Pilot Solenoid
Valve
Normally Open
Vent Valve
Gas Pilot
Ignitor
Vent
Main Motorized
Gas Valve
W/POC
14 sec.
Main Solenoid
Gas Valve
L
Man Reset Low Gas
Pressure Switch
S
S
Manual
Test Valve
M
POC
Vent
H
Manual Test
Valve
Man Reset High
Gas Pressure
Switch
Manual Ball
Valve
Fuel Flow
Control
Valve
Page 26
Test
Connection
Gas Burner
Manifold
Field Piped
UL Modulation Gas Piping Diagram - Over 12,500 MBH Firing Rate
JB Manual
722011
S
Vent To Outside
Atmosphere
Gas Burner
Manifold
722082
Fuel Systems
722084
Field Piped
Pilot Manual
Ball Valve
Gas Pressure
Regulator
Gas
Supply
Manual Ball
Valve
Pilot Gas
Pressure
Regulator
Pilot Solenoid
Valve
S
Vent To Outside
Atmosphere
Gas Pilot
Ignitor
Normally Open
Vent
Vent Valve
Main Motorized
Main Motorized
Gas Valve
Gas Valve
W/POC
W/POC - 14 sec.
14 sec.
M
L
S
POC
Man Reset Low Gas
Pressure Switch
M
POC
Manual
Test Valve
Vent
H
Manual Test
Valve
Man Reset High
Gas Pressure
Switch
Manual Ball
Valve
Fuel Flow
Control
Valve
Page 27
Gas Burner
Manifold
Field Piped
FM Modulation Gas Piping Diagram - Over 12,500 MBH Firing Rate
JB Manual
Test
Connection
722084
Fuel Systems
G. INITIAL SETTINGS
The burner will be set at the factory for normal initial settings. These are only rough settings that
must be adjusted at startup to match the furnace,
fuel pressure and environment of the specific application. These general settings are covered in
this chapter as a means of checking the burner
(linkage and settings can move in shipment) or
readjusting the burner if the settings are lost.
1. Oil nozzle position
The oil nozzle initial position is shown in Figure
G-2. The oil nozzle will be adjusted at start-up
and may be moved in or out from this initial setting. In some cases, the oil nozzle may be inside
the diffuser
B
Figure G-1
Oil Nozzle Position,
Gas Pilot
INNER FIRE CYLINDER
Chart G-2
PRESSURE ATOMIZED NOZZLE
Model
Diffuser
I.D.
Qty.
2
JB1
1 1/2”
1
JB2
JB3
1 3/4”
2
Spray
Angle
Dimension
Inches
30
3/8
45
1/4
30
7/8
45
3/4
30
3/4
45
5/8
60
1/2
AIR ATOMIZED NOZZLE
Diffuser
I.D.
Nozzle
Type
Spray
Angle
Dim.
A
Dim.
B
NA
NA
NA
NA
NA
2”
Single
Port
60o
1/4”
NA
Multi
Port
80o
NA
3/8
2 1/2”
3
60
5/8
2 1/2
2 7/8”
3
60
5/8
2 7/8
Flexible Strip
Return
Springs
Fire
Pos
it
Cam Set Screws
Jack
Shaft
Adjusting Screws
Low
ire
hF
Hig ition
s
Po
ion
Cam
Aluminum Strip
End Screws
Spring
End Screw
Adjusting Nut
Cam Follower
Retention
Plate
Roller Washers
Figure G-3
Fuel Cam Adjustment
JB Manual
Page 28
Roller
Cam Follower
Initial Settings
COMBUSTION AIR CONTROL
2. AIR PROVING SWITCH
Panel
The air proving switch has been adjusted at the factory
for an initial setting. If the switch trips during initial startup, turn the adjustment screw ccw two full turns to reduce the trip pressure setting.
Adjusting
Screw
Air Proving
Switch
AIR FLOW INTERLOCKING SWITCH
3. TYPICAL AIR AND FUEL ADJUSTMENT LOCATIONS
4. Fuel Cam Adjustments (if applicable)
The fuel cam needs to be checked for correct travel
and alignment. Positions can change during shipment
and installation and they must be reviewed prior to
startup. The fuel cams are mounted to the ends of the
jackshaft assembly. A cam follower link follows the profile
established by the adjusting screws and drives the fuel
valve. A thin metal band is used between the screw and
cam follower to provide a smooth profile. The adjusting
screws are backed by compressed nylon inserts, which
provide a resistance to turning.
The cam (Figure G-3) should be checked for the following
conditions:
a. At the low fire position, the roller should be between
the first two adjusting screws. If not, adjust the position
of the cam accordingly, making sure to maintain the same
low fire fuel valve position.
b. When the linkage is modulated from low to high fire,
the roller must stay in the center of the adjusting screws
within 1/8”. If needed, the two cam set screws can be
loosened and the cam moved to center it on the roller.
JB Manual
c. At high fire, the roller should be between the last two
adjusting screws.
d. The adjusting screws should form a smooth contour
with no jumps between the screws.
e. In preparation of startup, the retention plate can
be removed temporarily to make it easier to adjust the
screws.
THE RETENTION PLATE MUST BE REPLACED WHEN
SETUP IS COMPLETE.
If the unit is equipped with a parallel positioning system
(linkageless), the control valves can be positioned and
operated in a similar manner, but accomplished through
the controller. Refer to the instruction manual for details.
CAUTION
LINKAGE AND ACTUATOR MOUNTINGS CAN BE BENT
OR MOVED DURING SHIPMENT AND INSTALLATION.
THEY MUST BE CHECKED PRIOR TO OPERATION AND
ANY FAULTS CORRECTED. FAILURE TO CORRECT A
MISALIGNED CONTROL WILL RESULT IN PREMATURE
FAILURE.
Page 29
Initial Settings
H. IGNITION SYSTEMS
Electrode
Spark
Gap = 1/16”
Electrode Clamp
Pilot
Figure H-1
JB1 & JB2 Gas Pilot
Note: Required 2 1/2” - 3” wc
pressure for natural gas ans 1/2”
- 2” for LP, as measured at the
last solenoid in the pilot train.
Figure H-2 JB3 PILOT ASSEMBLY
Natural Gas Pressure;
4 - 6” wc
LP Gas Pressure;
1.5 - 2.5” wc
1. Gas Pilot Assembly
A crucial part of reliable burner operation is a dependable
pilot, which must be properly adjusted and kept clean. A gas
pilot is standard for all models except JB1 through JB2-20
straight oil pressure atomizing burners which have direct
spark ignition as standard. The following illustrations show
the typical configuration and nominal adjustment parameters of each pilot.
Figure H-1 showns the JB1 & JB2 gas pilot. Figure H-2
shows the JB3 gas pilot. Figure H-3 shows how the pilots
are positioned in the burner drawer.
Pilot gas pressure should be measured at the 1/8” port located on the downstream side of the last pilot solenoid valve.
2. Oil Nozzle Positiion, Direct Spark Oil.
Figures H-5 and H-6 show the position of direct spark ignition and nozzle positions. These are initial settings and will
be adjusted at start-up.
3. Air Damper Position
On a straight gas burner, the air damper should be open
about 1/4” at low fire and close to full open at high fire. In
JB Manual
some applications, the pilot requires an orifice in the pilot
gas supply line. With the exception of the JB3, this orifice is located external of the blower housing.
The pilot to diffuser dimension is the distance of the face
of the pilot to the outer diameter of the diffuser.
For an oil or combination burner, the air damper should
be open about 3/8” at low fire and close to full open at
high fire.
4. Gas Modualting Control Valve Position
The gas valve should be open about 10% at low fire and
stroked to abput 60% open at high fire.
5. Oil Modulatining Control Valve Position.
For pressure atomizing, the low fire position should be
adjusted to get the correct low fire presure, as stated
on the rating label. Typically, this would be 100 psi for
simplex systems and 65 psi for return flow nozzles. The
high fire position should be about 45o to 60o travel from
low fire.
For air atomizing, the low fire should be on about #2 position and the high fire should be about the #8 position.
Page 30
Ignition Systems
Figure H-3
7/8”
Figure H-4
(3 1/2”)
(2 1/2”)
FIGURE H-5 DIRECT SPARK PRESSURE ATOMIZING OIL IGNITION (See Table Below)
Diffuser
ID
FIGURE H-6
TRIPLE NOZZLE
DIRECT SPARK OIL IGNITION (See Table Below)
Note: These represent initial nozzle settings. The final position will be determined in the start-up process.
FIGURE H-7
DIMENSION TABLE FOR DIRECT SPARK OIL IGNITION (Pressure Atomizing)
BURNER DATA
Model
Diffuser I.D.
1
JB1
1 1/2”
JB2
1 3/4”
NOZZLE DATA
Qty.
Spray Angleo
1
30
1
45
1
30
1
45
2
30
2
45
2
ADJUSTMENT SETTINGS (Inches)
A
1/8
B
C
1/2
1/2
3/8
3/8
JB Manual
2 7/8
3
E
5/16
1/4
5/16
1/4
5/16
1/4
3/8
1/8
7/8
1/8
1 1/2
3/4
1/4
1.4
30
1/8
45
1 1/2
60
JB3
D
3/4
5/8
1/2
60
1/8
80
Page 31
1 1/2
5/8
7/16
Ignition Systems
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
I. STARTUP AND OPERATING ADJUSTMENTS
Pre-start Checkout
Linkage Adjustments
Fuel Cam Adjustments
FGR Adjustment
Burner Drawer Adjustments
Single Fuel Setups
Combination Gas and Pressure Atomized Oil
Combination Gas and Air Atomized #2 Oil
Combination Gas and Heavy Oil
Gas Setup
Pressure Atomized Oil Setup
Air Atomized #2 Oil Setup
Heavy Oil Setup
Operating Control Adjustments
Limit Tests
Pilot Test
Burner Shutdown
Restart After Extended Shutdown
This section covers the startup and operating adjustments
of the Webster Models JB and JBX burners.
WARNING
BURNER STARTUP, COMBUSTION ADJUSTMENTS
AND LIMIT CONTROLS ADJUSTMENTS SHOULD
ONLY BE PERFORMED BY TRAINED AND EXPERIENCED SERVICE TECHNICIANS. ATTEMPTING
TO PERFORM THESE FUNCTIONS WITHOUT THE
PROPER TRAINING AND EXPERIENCE CAN RESULT IN EQUIPMENT DAMAGE, PERSONAL INJURY
OR DEATH.
Before proceeding with the startup and adjustment, be
sure that the overall installation is complete. Review the
boiler operating and installation manual, as well as all control manuals to verify that all equipment is ready for operation. These manuals must be read and understood prior
to starting the equipment.
If you are not qualified to service this equipment, DO NOT
TAMPER WITH THE UNIT OR CONTROLS - CALL YOUR
SERVICEMAN.
At the conclusion of the startup, document valve and
linkage positions, pressures and settings for future reference.
READ AND SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE.
______All fuel lines are connected and tight.
______Pilot gas is connected.
______Burner is mounted to vessel and floor, with all bolts
secured.
______The linkage is correct (in low fire position) and
tight.
______The stack is connected and routed to the outside.
Draft controls are installed and operational, if needed.
______Gas vent lines are connected and routed to the
outside, if required per code.
______Do not start the unit unless all cleanout doors are
in place and secured.
______The vessel is completely installed, filled with water
and operating controls checked.
______Support equipment is in place and ready (feed
pumps, draft controls, steam/hot water systems, boiler
limits and controls and feedwater systems).
______A load must be available for the burner startup and
adjustment process. The burner must be operated at high
rates for extended periods of time and the load must be
capable of using this energy.
______A combustion analyzer with O2 and CO (for gas)
must be available to tune combustion. A smoke spot tester must be available for oil firing. If this is a low NOx
burner, a NOx analyzer must be available. All of these
analyzers must be recently calibrated and able to provide
accurate readings.
______Other test equipment, including manometers,
gauges and volt meter shall be available.
______Manometer or gauge on the gas manifold.
______Manometer or gauge before and after gas pressure regulator.
______Draft gauge or manometer (at stack outlet).
______Draft gauge or manometer for furnace pressure.
2. Linkage Adjustments
Adjusting the air damper and FGR control valve on a linkage system requires an understanding of linkage setups.
The rate of change for the fuel valve, air damper and FGR
valve must be matched by how the linkage is setup. If
the air damper or FGR valve opens too quickly, the flame
may become unstable or the NOx levels may not meet
the requirements. There are a few general guidelines that
should be followed in setting up the linkage of a burner,
a. The linkage must provide the correct stroke of the
valve, from low to high fire. Increasing the length of the
drive crank arm (B) or decreasing the length of the driven
crank arm (C) will increase the valve travel. To reduce
valve travel, decrease B or increase C (Figure I-1).
1. Pre-Start Check List
Before starting the burner, a complete review of the installation, wiring and piping of the burner, boiler and all supporting equipment must be complete and all of these items
must be ready for operation prior to starting. The following
is a general review:
______All wiring is connected. Test pulls on wire show
them to be tight.
JB Manual
Page 32
Startup and Operating Adjustments
Low
Fire
A
ible strip is required to move to a screw position where
it is initially not in contact with the screw. Also, the
movement from one screw to the next cannot be too
large (more then 1/8”). This will cause the strip to flex
and will lead to premature failure of the strip.
d. The adjusting screws have a limited range of adjustment. They can be turned in until they are flush with
the aluminum bar and adjusted out until the side washers of the roller contact the aluminum bar.
e. If any adjusting screw does not turn with some resistance, the cam must be replaced.
f. When the cam adjustment is complete, the retention
plate must be installed. The retention plate will help
insure that the fuel valve position will not get far from
its ideal position, even with interference or sticky valve
operation.
Drive Arm
B
Modulating
Range 90o
Jackshaft
D
High
Fire
Driven
Arm
Linkage Arm
Valve
(Air Damper,
FGR Valve...)
C
Dim
Smaller
Larger
Angle A
Slower LF driven
arm travel (D)
Faster LF driven
arm travel (D)
Length B
Reduce driven
arm travel (D)
Increase driven
arm travel (D)
Length C
Increase driven
arm travel (D)
Reduce driven
arm travel (D)
CAUTION
LARGE CHANGES FROM ONE ADJUSTING
SCREW TO ANOTHER WILL RESULT IN PREMATURE FAILURE OF THE CAM AND MAY PREVENT
THE BURNER FROM OPERATING PROPERLY.
Figure I-1
Linkage Adjustments
b. Decreasing the angle of the drive arm will slow the initial valve travel (and speed up the travel at high fire). This
would be done to get the air damper to match the fuel valve
action.
3. Fuel Cam Adjustments
The cam is used to adjust the intermediate fuel rate with
the low and high fire settings done by the linkage connections. The intermediate rates can be adjusted by turning the
adjusting screws in the clockwise direction to increase fuel
input and decrease the % O2 level in the flue gases. Turning the adjustment screws counterclockwise will decrease
fuel input and increase % O2 in the flue gases.
The following guidelines should be used for adjusting the
cam:
a. When adjusting the screws, the adjacent screws must
also be adjusted to provide a smooth contour from screw to
screw. When complete, the flexible strip between the adjusting screws and the roller must come in contact with each
screw, providing a smooth transition from low fire to high
fire.
b. The end screws (or nuts) can be adjusted to hold the strip
against the screws, but should not deform the strip.
c. There should be no upsets in the profile, where the flexJB Manual
WARNING
IF THE CAM ADJUSTING SCREWS DO NOT HAVE
RESISTANCE TO TURNING, THE CAM SHOULD
BE REPLACED, AS THE SCREWS MAY CHANGE
POSITION. FAILURE TO CHANGE A DEFECTIVE
CAM MAY RESULT IN INJURY OR DEATH.
g. If the contour has a sharp rise in the cam screw profile, trying to open the valve very quickly in the first few
screws, the linkage should be readjusted to cause the
air damper to open slower (make the jackshaft drive
arm more parallel to the linkage rod). Likewise, the opposite contour can be corrected by speeding up the air
damper drive (Figure I-1). The final cam screw profile
should be close to the profile of the cam with no abrupt
changes.
4. FGR Adjustments
Flue gas is recirculated back into the burner to reduce
the flame temperature, which reduces the NOx level.
High quantities of flue gas result in lower NOx levels,
but can also result in flame instability if there is too
much FGR. Natural gas fuel can handle larger quantities of flue gas than oil and can have much lower NOx
levels as a result. Generally, the NOx levels only apply
to gas firing and oil firing is not adjusted for NOx levels.
There may be exceptions to this, and the orders details
should be reviewed to identify any special combustion
requirements.
Dual fuel units may need additional adjustments and
compensation to handle the different FGR rates between natural gas and #2 fuel oil. Units that require
gas NOx levels above about 45 ppm can operate with
the same quantity of FGR on both fuels and no additional controls or adjustments are needed. Burners
Page 33
Startup and Operating Adjustments
equipped with Posi-Control can be adjusted for individual air
and FGR settings on both fuels and can easily handle these
variations, even with lower NOx levels. Linkage burners operating at 30 ppm NOx (natural gas) are equipped with a
potentiometer in the control panel that will allow the shut-off
valve to partially open and allows a small amount of FGR to
flow when firing oil. This keeps the oil inputs close to the gas
input (lower FGR rates increases the combustion air rate).
The oil combustion is generally better when FGR is used at
low rates resulting is a lower NOx level. Linkage levels with
NOx levels under 30 ppm will also use a multiple modulation
motor to provide separate gas and oil low fire and high fire
positions.
Linkage dual fuel units may also be equipped with the optional multiple set point (Landis) modulation motor in addition
to the above potentiometer. This motor allows for different
low and high fire settings on gas vs oil to obtain the correct
airflow for each fuel and optimize the turndown on gas.
On a dual fuel unit, the natural gas should be done first to
properly set the FGR inlet tube. Once gas is setup, oil can
be set.
For dual fuel linkage systems, the following guidelines
should be used:
• A 60 ppm system can be adjusted with the same FGR rate
on both fuels. The FGR control valve is set on gas and oil
follows that setting.
• A 30 ppm system uses the FGR limiting potentiometer
(located in the control panel) to obtain a partial flow of FGR
when firing oil. The FGR control valve is set when firing
gas. The FGR limiting potentiometer is adjusted to improve
combustion but not cause instability. The combustion needs
to be checked at several firing rates.
• Under 30 ppm, separate gas and oil operating points are
established in the modulating motor. Parallel positioning
(linkageless) systems allow all of the valves to be positioned
independently for each fuel. For this reason, the setup sequence can be more flexible.
end of the inner fire cylinder dimension.
• Loosen the two setscrews locking the pilot gas line
and gun tube to the backplate.
• Adjust the diffuser by moving the oil gun tube in and
out the amount determined above. When the best position is found, lock into place with the two setscrews on
the oil and pilot tubes.
b. To adjust the oil nozzle to diffuser position:
• Adjust the oil nozzle to obtain the best combustion.
• Watch for spray back on the diffuser when the oil nozzle is pulled too far back. The flame may appear good
but carbon will quickly develop on the diffuser.
• The drawer assembly must be removed to adjust the
oil nozzle to diffuser position.
The burner drawer must be removed for access to components, follow the following steps:
a. Disconnect the gas pilot line. Move the pilot line so
the drawer can be pulled out without interference.
b. If equipped with oil, disconnect the oil line(s), and
move the oil line out of the way to allow the drawer to
be pulled.
c. Loosen and remove the screws on the burner drawer.
d. Disconnect the ignition cable from the drawer assembly. It is attached with a snap-on fitting.
e. Pull the drawer out, holding the drawer centered in
the opening to prevent it from hanging up while being
pulled out.
f. Disconnect the scanner by screwing it off of the scanner tube. In some cases, the scanner simply pulls out,
with a spring tension. Secure the scanner so that it is
protected from shock.
g. Set the drawer down horizontally, do not set it on the
diffuser as it may flatten some fins or change positions.
To re-install the burner drawer, simply work the procedure in reverse.
5. Burner Drawer Adjustments
6. Single Fuel Setups
The burner drawer has several adjustments built into the design that allow the combustion to be tuned. While this can
simplify the combustion tuning process, care must be used
to retain the relative position of other components during this
sequence. If these adjustments are required, follow the sequence listed to perform the adjustments.
Single fuel burners can be adjusted following the procedures outlined in Section 10 for gas firing; Section 11 for
pressure atomized oil, Section 12 for Air atomized #2 oil
and Section 13 for heavy oil firing.
Before any adjustments are made, the position of each component must be marked. A felt tip pen or a combination of
masking tape and another type of pen can be used.
• Mark the distance of the oil gun tube from the backplate.
• Mark the distance of the gas pilot line to the backplate.
a. To adjust the diffuser to inner fire cylinder dimension:
• Measure the dimension from the backplate to the end of
the oil gun tube. This dimension, along with the initial position will determine the limit of the adjustment. For example,
if the diffuser is 1 inch behind the fire end of the inner fire
cylinder, then it can be adjusted in 3/4 inch or out 1/2 inch to
stay within the limits of 1/4 inch to 1 1/2 inch diffuser to fire
JB Manual
The procedures for each of the systems (linkage, cams,
FGR) must be completely understood and followed as
part of the setup process.
7. Combination Gas and Pressure Atomized Oil
Combination burners, firing both gas and oil, require
some compromises in the setup because they share
common controls for both fuels. In this case, linkage
units must have the gas input adjusted to match the oil
inputs because there is little flexibility in adjusting the oil
rates. Oil will be setup first and will set the air damper
positions to support the low and high fire oil inputs. Follow the procedure outlined in section 11 to complete the
oil setup. Then setup the gas input as defined in section
Page 34
Startup and Operating Adjustments
10, using the air damper positions defined by oil, and adjusting the gas input to match the air damper settings.
If the burner is equipped with an optional multiple set-point
modulating motor or parallel positioning, the low and high
fire rates, as well as lightoff rates, can be set independently
for each fuel. In this case, the gas is adjusted first, to set the
air damper locations for gas firing, as defined in Section 10.
Once gas is set, oil is setup as defined in Section 11, except
that the multipoint modulating damper motor is adjusted to
bring the low fire air setting to match the oil needs.
There are several different options available that can alter
the exact setup details, and these must be evaluated prior
to startup so that the procedures can be adjusted accordingly. The procedures given are for linkage systems. Parallel positioning (linkageless) systems allow for much more
flexibility in the fuel, air and FGR settings on each fuel, and
can be tuned to better match each fuels needs. The setup
details for linkageless controls will follow the same general
sequence, but differ in specifics for setting the valve positions.
8. Combination Gas and Air Atomized #2 Oil
Combination burners, firing both gas and oil, require some
compromises in the setup because they share common controls for both fuels. Air atomized #2 oil firing can have turndowns and air damper positions very similar to gas firing,
simplifying the setup. If the burner is equipped with FGR,
gas must be started first to set the FGR control valve positions to obtain the correct NOx performance. If there is
no FGR, either fuel can be started first, however the setup
cannot be finalized until both fuels have been reviewed to
determine the air damper positions. Follow the setup procedures defined in Section 10 for gas setup and Section 12 for
air atomized oil setup.
If the burner is equipped with an optional multiple set-point
modulating motor, the low and high fire rates, as well as lightoff rates, can be set independently for each fuel. In this
case, the gas is adjusted first, to set the air damper locations
for gas firing, as defined in Section 10. Once gas is set, oil
is setup as defined in Section 12, except that the multipoint
modulating damper motor is adjusted to bring the low fire air
setting to match the oil needs.
There are several different options available that can alter
the exact setup details, and these must be evaluated prior
to startup so that the procedures can be adjusted accordingly. The procedures given are for linkage systems. Parallel positioning (linkageless) systems allow for much more
flexibility in the fuel, air and FGR settings on each fuel, and
can be tuned to better match each fuels needs. The setup
details for linkageless controls will follow the same general
sequence, but differ in specifics for setting the valve positions.
9. Combination Gas and Heavy Oil
Combination burners, firing both gas and oil, require some
compromises in the setup because they share common controls for both fuels. Heavy oil burners cannot operate with
JB Manual
FGR and do not have this adjustment. If the burner does
not have a multiple setpoint modulating motor or linkageless control, oil must be set first, as the air damper
positions will be determined by this setup. With the multiple setpoint modulating motor, gas must be set first, as
it will dictate the damper positions. In either case, setup
cannot be finalized until both fuels have been reviewed
to determine the air damper positions. Follow the setup
procedures defined in Section 10 for gas setup and Section 13 for air atomized heavy oil setup.
There are several different options available that can alter the exact setup details, and these must be evaluated
prior to startup so that the procedures can be adjusted
accordingly. The procedures given are for linkage systems. Parallel positioning (linkageless) systems allow
for much more flexibility in the fuel, air and FGR settings
on each fuel, and can be tuned to better match each fuels needs. The setup details for linkageless controls will
follow the same general sequence, but differ in specifics
for setting the valve positions.
10. Gas Setup
a. Place the burner switch in the “OFF” position
b. Place the “Auto-Manual” switch in the manual position, for modulation or low fire hold, switch in low fire position for Lo-Hi-Lo operation. If this is a combination fuel
burner, make sure the fuel selector switch is on “GAS”.
c. Place the manual flame control potentiometer in the
MIN (low fire) position on modulating units.
d. Close the downstream manual shutoff valve (closest
to the burner head) on the gas train.
e. Turn the electrical power on for the burner, boiler and
related components.
f. Verify that the gas metering valve is nearly closed, the
vent valve (if equipped) is operating and the gas pilot
valve is not open (the solenoid will hum and feel warm).
g. If equipped with FGR, verify that the FGR control
valve is in the near closed position. A linkage system
should have the shutoff FGR valve in the closed position.
h. Turn the burner switch on. This will start the blower
motor and initiate the prepurge cycle.
i. When the prepurge sequence is complete and the
low fire start switch (if used) is made, the pilot valve will
open and the pilot flame should be visible through the
sight port.
j. When the pilot flame is established, the flame safeguard will energize the main gas valve (indicated with
the Fuel Valve Light). This operation of the main fuel
valves must be visually checked by observing the valve
stem operation.
k. After the timer has completed the trial for main flame,
the burner will go out on alarm (the closed manual gas
valve prevented the burner from lighting). At this time,
the gas valves must be visually checked to verify that
they have closed. This test sequence proves the proper
operation of the primary control.
l. Press the reset button and restart the burner. When
the pilot has started, open the manual gas valve to allow
Page 35
Startup and Operating Adjustments
the main flame to start.
m. If equipped with FGR, the shutoff FGR valve should
open on a linkage system, after the main flame has been
proven. The timing can be adjusted with the time delay inside the control panel, so that the FGR shutoff valve opens
5 to 10 seconds after the main flame is established. The
control valve of the linkageless system should move from
closed to a low flow position after light off timing has expired.
NOTE: If the burner is not operating as indicated, follow
the troubleshooting guide steps to determine the problem
and corrections required.
n. After a few seconds, the combustion analyzer should
have an accurate reading of the O2 in the stack. Figure
I-3 shows the typical range of O2 at different firing rates,
and the burner should be adjusted to be within this range.
Rough settings for low and mid fire combustion settings
are adequate at this time. Once the high fire is set, the
other settings can be fine tuned.
• Turning the cam screw in will add fuel, making it richer
and reducing the O2 level.
• Turning the cam screw out will reduce the fuel input,
increasing the O2 level.
If equipped with FGR, the NOx level should be close to the
desired NOx, as required by the specific order. The FGR
valve can be opened to decrease the NOx level, or closed
to increase the NOx level.
o. Operate the burner until the boiler is warmed up, and
near the operating pressure or temperature. Increase the
firing rate, using the manual potentiometer, or put low fire
hold switch in auto mode, while monitoring and adjusting
the O2 level. Adjust the gas pressure regulator as needed
to reach the high fire input.
p. If equipped with FGR, adjust the FGR valve as needed
to obtain the approximate NOx level.
q. Adjust the high fire input to match the maximum input
listed on the rating label. At high fire, the gas butterfly
valve should be at least 75 degrees open (more if available gas pressure is low), and the gas pressure regulator
adjusted to obtain the rating. The input should be
measured using the following equation:
Calculating Natural Gas Input
Gas MBH =
HHV x [(Patm + Pgas)/29.92] x [520/(Tgas +460)] x
[measured ft3/sec] x [3600 sec/hr]
Where:
MBH = 1000’s of BTU/M input
HHV = Higher heating value of gas, BTU/cubic feet
Patm = Atmospheric pressure in inches Hg
Pgas = Gas pressure before gas meter in inches Hg
(inches HG = PSIG x 2.04)
Tgas = Gas temperature at the flow meter, in
degrees F
Measured ft3 = volume of gas measured by meter
sec = Time for measured ft3 to flow through meter
Note: Some gas meters require a 6 inch wc correction
to Pgas. Consult your meter calibration data.
JB Manual
NOTE: The listed manifold pressure is only an approximate value and can vary with operating conditions and normal tolerances. The fuel flow rate must
be measured to obtain an accurate input value.
r. Adjust the air damper to obtain the correct O2 level.
s. If equipped with FGR, adjust the NOx level to be about
10% below any guaranteed NOx performance. A balance
of the FGR control valve and air damper are required to
obtain the final result, as each can impact the other.
t. Modulate the burner to low fire, adjusting the O2 level
as the burner modulates.
u. Adjust the low fire input, using the fuel cam and air
damper adjustments. The linkage may need to be readjusted to obtain the correct relationship between the fuel
valve and air damper. (Figure I-1)
v. Re-adjust the midfire points for the correct O2 level.
w. If equipped with FGR, adjust the NOx levels at low
and midfire rates to be about 10% under the guaranteed
levels.
x. Adjust the low gas pressure switch to be 10% below
the lowest expected gas pressure.
• With a gauge or manometer at the same location as the
low gas pressure switch, modulate the burner to determine the firing rate with the lowest gas pressure.
• At the lowest gas pressure, adjust the low gas pressure
setting up until the switch breaks and causes the burner
to shutdown.
• From the scale reading of the switch, adjust the setting to a pressure that is 10% lower than the shutdown
pressure. For example, if the switch opened at 10 inches
as indicated on the low gas pressure switch, the switch
should be adjusted to a reading of 9 inches.
• Remove the gauge or manometer and plug the opening.
• Cycle the burner on and off to determine if the limit
works properly.
• If the limit causes nuisance shutdowns because of
small pressure drops during startup, reduce the pressure
setting an additional 5%.
y. Adjust the high gas pressure switch to be 10% above
the highest expected gas pressure.
• With a gauge or manometer at the same location as the
high gas pressure switch, modulate the burner to determine the firing rate with the highest gas pressure.
• At the highest gas pressure, adjust the high gas pressure setting down until the switch opens and causes the
burner to shutdown.
• From the scale reading of the switch, adjust the setting to a pressure that is 10% higher than the shutdown
pressure. For example, if the switch opened at 10 inches
as indicated on the high gas pressure switch, the switch
should be adjusted to a reading of 11 inches.
• Remove the gauge or manometer and plug the opening.
• Cycle the burner on and off to determine if the limit
works properly.
• If the limit causes nuisance shutdowns because of small
pressure changes during startup, increase the pressure
setting an additional 5%.
Page 36
Startup and Operating Adjustments
Natural Gas
With FGR
Figure I-3
O2 levels
Oil
% Rate
Min
% O2
Max
% O2
Min
%O2
Max
%O2
Min
%O2
Max
%O2
30
5.0
7.0
5.0
7.0
3.5
7.5
40
4.0
7.0
4.0
7.0
3.0
7.0
50
3.0
5.0
3.0
5.0
3.0
5.0
100
3.0
5.0
3.0
5.0
3.0
5.0
z. The burner should be operating at low fire to adjust
the air proving switch. Turn the adjusting screw cw (in)
until the burner trips out (shutdown caused by the air flow
switch). Turn the adjustment screw ccw (out) 1 1/2 turns
from the point of shutdown. Check the operation at higher
rates.
11. Pressure Atomized Oil Setup
The pressure atomized oil system has a limited range of
adjustment for low and high fire, dictated by the operation
of the oil nozzle. The combustion air and FGR must be
adjusted to match these rates.
If the burner is equipped with FGR, and is a linkage system, the type of FGR control must be determined prior
to starting. If this is a dual fuel burner, the FGR rate is
determined by the NOx performance on gas. A 60 ppm
burner will operate with the same FGR rate on gas and oil.
A 30 ppm unit will use the limiting potentiometer to slightly
reduce the FGR rate on oil firing. For Oil only combustion,
the NOx level will be given on the burner detail sheet, and
should be used to set the FGR control valve.
a. Place the burner switch in the “OFF” position.
b. Place the “Auto-Manual” switch in the manual position
or low fire hold switch in the low fire position fo LO-HI-LO
operation. If this is a combination fuel burner, make sure
the fuel selector switch is on “OIL”.
c. Place the manual flame control potentiometer in the
min (low fire) position on modulation units.
d. Turn the electrical power for the burner, boiler and related components on.
e. Verify that the oil metering valve is nearly opened (the
valve will be closed at high fire).
f. Turn the burner switch on. This will start the blower motor and initiate the purge cycle.
g. When the prepurge sequence is complete and the low
fire start switch (if used) is made, the pilot valve will open
and the pilot flame should be visible through the burner
sight port.
h. When the pilot flame is established, the flame safeguard will energize the main oil valves (indicated with the
Fuel Valve Light), and the burner should ignite at low fire.
This operation of the main fuel valves must be visually
checked by observing the valve stem moving up with a
motorized valve or hearing the clicking noise from a solenoid valve.
NOTE: If the burner is not operating as indicated, follow
the troubleshooting steps to determine the problem and
corrective action.
i. The main flame may not light on the first attempt, beJB Manual
Natural Gas
No FGR
cause it must fill the oil lines before providing oil to the
nozzle. Press the reset button on the flame safeguard to
restart the burner.
WARNING
DO NOT ATTEMPT TO START THE BURNER WHEN EXCESS OIL
HAS ACCUMULATED, WHEN THE UNIT IS FULL OF VAPOR, OR
WHEN THE COMBUSTION CHAMBER IS HOT.
j. After a few seconds, the combustion analyzer should
have an accurate reading of the O2 in the stack. The O2
level should be between 4% and 7%, and the nozzle oil
pressure should be between 50 and 70 PSIG return line
pressure for the JB3. JB1 and JB2 burner low fire oil pressure should be 100 psig. Do not attempt to fine tune combustion until the high fire has been set.
If the burner is equipped with FGR, the FGR control valve
should be set for the approximate NOx level required.
1. Turning the cam screw in will add fuel, making it richer
and reducing the O2 level.
2. Turning the cam screw out will reduce the fuel input,
increasing the O2 level.
3. The air damper should be positioned for the correct
low fire settings.
k. Operate the burner until the boiler is warmed up, and
near the operating pressure or temperature.
l. Increase the firing rate, using the manual potentiometer or put the low fire hold switch in auto position, while
monitoring and adjusting the O2 level. Adjust the cam as
needed to reach the high fire input.
If the burner is equipped with FGR, adjust the FGR control
valve as required to maintain the NOx level.
m. At high fire (end of the modulating motor travel), adjust
the high fire input (open or close the fuel valve) to match
the maximum input and/or pressure listed on the rating
label. The fuel metering valve should be nearly closed
(or closed) at this point and the nozzle pressure should
be about 150 PSIG (return line) for JB3. For JB1 and JB2
250 to 300 psig.
n. If equipped with FGR, adjust the NOx level to be about
10% below any guaranteed NOx performance or if performance guarantee exists adjust the FGR to provide some
added turbulence but not high enough to impact flame stability. A balance of the FGR control valve and air damper
are required to obtain the final result, as each can impact
the other. If this is a 30 ppm system, the FGR limiting pot
should be adjusted to reduce the FGR rate for stable combustion, with the FGR control valve set when firing gas. If
this is a 60 ppm system, no adjustment is necessary.
o. Modulate the burner to low fire, adjusting the O2 level
as the burner modulates.
Page 37
Startup and Operating Adjustments
p. Adjust the low fire input, using the fuel cam or low fire
regulator on LO-HI-LO systems and air damper adjustments. If the burner is equipped with FGR, adjust the NOx
level according to the type of system (limiting potentiometer or matching gas).
q. Re-adjust the midfire points for the correct O2 levels.
The linkage may need to be readjusted to obtain the correct relationship between the fuel valve and air damper.
(Figure I-1)
r. If equipped with FGR, adjust the NOx levels at low and
midfire rates to be about 10% under the guaranteed levels
or as required for the gas firing.
s. The burner should be operating at low fire to adjust
the air proving switch. Turn the adjusting screw cw (in)
until the burner trips out (shutdown caused by the air flow
switch). Turn the adjustment screw ccw (out) 1 ½ turns
from the point of shutdown. Check the operation at higher
rates.
t. Adjust the oil pressure switch to trip and shutdown the
burner at a pressure that is 10% lower than the supply oil
pressure.
12. Air Atomized, #2 oil Setup
The air atomized oil system has the potential for a large
turndown range similar to gas and has the potential to be
adjusted to different low fire rates. See the burner nameplate for details on actual rates for this burner.
If the burner is equipped with FGR and is a linkage system, the type of FGR control must be determined prior
to starting. If this is a dual fuel burner, the FGR rate is
determined by the NOx performance on gas. A 60 ppm
burner will operate with the same FGR rate on gas and oil.
A 30 ppm unit will use the limiting potentiometer to slightly
reduce the FGR rate on oil firing. For Oil only combustion,
the NOx level will be given on the burner detail sheet, and
should be used to set the FGR control valve.
a. Place the burner switch in the “OFF” position.
b. Place the “Auto-Manual” switch in the manual position.
If this is a combination fuel burner, make sure the fuel selector switch is on “OIL”.
c. Place the manual flame control potentiometer in the
min (low fire) position.
d. Turn the electrical power for the burner, boiler and related components on.
e. Verify that the oil metering valve is at the nearly closed
position.
f. Turn the burner switch on. This will start the blower motor and initiate the purge cycle.
g. When the prepurge sequence is complete and the low
fire start switch is made, the pilot valve will open and the
pilot flame should be visible through the burner sight port.
h. When the pilot flame is established, the flame safeguard will energize the main oil valves (indicated with the
Fuel Valve Light), and the burner should ignite at low fire.
This operation of the main fuel valves must be visually
checked by observing the valve stem moving up with a
motorized valve or hearing the clicking noise from a solenoid valve.
NOTE: If the burner is not operating as indicated, follow
the troubleshooting steps to determine the problem and
JB Manual
corrective action.
WARNING
DO NOT ATTEMPT TO START THE BURNER WHEN EXCESS OIL HAS ACCUMULATED, WHEN THE UNIT IS FULL
OF VAPOR, OR WHEN THE COMBUSTION CHAMBER IS
HOT.
i. After a few seconds, the combustion analyzer should
have an accurate reading of the O2 in the stack. The O2
level should be between 4% and 7% (see Figure I-3 for
O2 rates), and the nozzle oil press should be between 5
and 15 PSIG (see Figure I-4). Do not attempt to fine tune
combustion until the high fire input has been set.
If the burner is equipped with FGR, the FGR control valve
or limiting potentiometer should be set for the approximate
NOx level required.
• Turning the cam screw in will add fuel, making it richer
and reducing the O2 level.
• Turning the cam screw out will reduce the fuel input,
increasing the O2 level.
• The air damper should be positioned for the correct low
fire settings.
• The atomizing air pressure can be adjusted using the air
bleed valve.
j. Operate the burner until the boiler is warmed up, and
near the operating pressure or temperature.
k. Increase the firing rate, using the manual potentiometer, while monitoring and adjusting the O2 level. Adjust the
cam, oil pressure and atomizing air pressure as needed to
reach the high fire input.
l. If the burner is equipped with FGR, adjust the FGR control valve or potentiometer as required to maintain the NOx
level.
m. At high fire (end of the modulating motor travel), adjust
the high fire input to match the maximum input listed on
the rating label. Using a flow meter, the fuel input may be
measured using the following equation,
Oil GPH =
[Gal end – Gal start] x [3600 sec/hr] /
[measured sec]
Where Gal end = meter gallons at end of test
Gal start = gallons at start of the test
Measured sec = measured time of test
GPH = Gallons of oil per hour
n. If equipped with FGR, adjust the NOx level to be about
10% below any guaranteed NOx performance or if no performance guarantee exists adjust the FGR to provide some
added turbulence but not high enough to impact flame stability. A balance of the FGR control valve and air damper
are required to obtain the final result, as each can impact
the other. If this is a 30 ppm system, the FGR limiting pot
should be adjusted to reduce the FGR rate for stable combustion, with the FGR control valve set when firing gas. If
this is a 60 ppm system, no adjustment is necessary.
o. Modulate the burner to low fire, adjusting the O2 level
as the burner modulates.
p. Adjust the low fire input, using the fuel cam and air
damper adjustments.
q. If the burner is equipped with FGR, adjust the NOx level
Page 38
Startup and Operating Adjustments
according to the type of system (limiting potentiometer or
matching gas).
r. Re-adjust the midfire points for the correct O2 levels.
The linkage may need to be readjusted to obtain the correct
relationship between the fuel valve and air damper. See
Figure I-1.
s. If equipped with FGR, adjust the NOx levels at low and
midfire rates to be about 10% under the guaranteed levels
or as required for the gas firing.
t. The burner should be operating at low fire to adjust the
air proving switch. Turn the adjusting screw cw (in) until the
burner trips out (shutdown caused by the air flow switch).
Turn the adjustment screw ccw (out) 1 ½ turns from the
point of shutdown. Check the operation at higher rates.
FIGURE I-4
Typical Atomizing Air Pressure
% Rate
Minimum
20
10 - 25
30
12 - 30
40
15 - 35
50
20 - 40
100
25 - 60
13. Heavy Oil Setup
CAUTION
WHEN WORKING WITH HEATED OIL, PROTECTIVE CLOTHING, INCLUDING GLOVES, SHOULD BE
WORN TO PROTECT FROM BURNS.
The air atomized heavy oil system requires the additional
adjustment of oil temperature in the burner setup. The temperature is adjusted to improve the viscosity for good atomization. Typically, this will be about 150oF for #4 oil, 180oF
for #5 oil and 200oF for # 6 oil.
a. Prior to startup, the oil system must be operating with the
oil temperature to the burner (before the trim heater) within
20oF of the final temperature.
b. Place the burner switch in the “OFF” position. If this is a
combination fuel burner, make sure the fuel selector switch
is on “OIL” and that the oil pump is running.
c. Place the “Auto-Manual” switch in the manual position.
d. Place the manual flame control potentiometer in the MIN
(low fire) position.
e. Turn the electrical power on for the burner, boiler and
related components.
f. The oil may take some time to get up to temperature. If
the oil is cool, the ball valve downstream of the N.O. oil return valve (Figure B-7) can be opened to make it easier for
the oil to circulate and reach operating temperature.
g. Verify that the oil metering valve is at the nearly closed
position.
h. Turn the burner switch to “ON”. This will start the blower
motor and initiate the prepurge cycle.
JB Manual
WARNING
DO NOT ATTEMPT TO START THE BURNER WHEN
EXCESS OIL HAS ACCUMULATED, WHEN THE
UNIT IS FULL OF VAPOR, OR WHEN THE COMBUSTION CHAMBER IS HOT.
i. When the prepurge sequence is complete and the low
fire start switch is made, the pilot valve will open and
the pilot flame should be visible through the burner sight
port.
j. When the pilot flame is established, the flame safeguard will energize the main oil valves (indicated with
the Fuel Valve Light), and the burner should ignite at low
fire. This operation of the main fuel valves must be visually checked by observing the valve stem moving up with
a motorized valve or hearing the clicking noise from a
solenoid valve.
k. After a few seconds, the combustion analyzer should
have an accurate reading of the O2 in the stack. The O2
level should be between 4% and 7% (See Figure I-3 for
O2 rates) and the nozzle oil press should be between 10
and 20 PSIG. Do not attempt to fine tune combustion
until the high fire input has been set.
• Turning the cam screw in will add fuel, making it richer
and reducing the O2 level.
• Turning the cam screw out will reduce the fuel input,
increasing the O2 level.
• The air damper should be positioned for the correct low
fire settings.
• The atomizing air pressure can be adjusted using the
air bleed valve (Figure I-4).
• The oil temperature can be adjusted to obtain the best
atomization.
l. Operate the burner until the boiler is warmed up and
near the operating pressure or temperature.
m. Increase the firing rate, using the manual potentiometer, while monitoring and adjusting the O2 level. Adjust
the cam, oil and atomizing air pressure and oil temperature as needed to reach the high fire input.
n. At high fire (end of the modulating motor travel), adjust the high fire input to match the maximum input listed
on the rating label. Using a flow meter, the fuel input may
be measured using the following equation,
Oil GPH = [Gal end – Gal start] x [3600 sec/hr]
/ [measured sec]
Where Gal end = meter gallons at end of test
Gal start = gallons at start of the test
Measured sec = measured time of test
GPH = Gallons per hour
o. Modulate the burner to low fire, adjusting the O2 level
as the burner modulates.
p. Readjust the low fire input, using the fuel cam and air
damper adjustments.
q. Re-adjust the midfire points for the correct O2 levels.
The linkage may need to be readjusted to obtain the correct relationship between the fuel valve and air damper.
(Figure I-1)
r. The burner should be operating at low fire to adjust
Page 39
Startup and Operating Adjustments
the air proving switch. Turn the adjusting screw cw(in) until
the burner trips out (shutdown caused by the air flow switch).
Turn the adjustment screw ccw (out) 1 ½ turns from the point
of shutdown. Check the operation at higher rates.
14. Operating Control Adjustments
The operating controls must be adjusted to properly cycle
the burner “ON and OFF” and provide modulation. The controls should not force the burner into rapid “ON-OFF” cycles,
as this will cause premature failure of the motor and operating equipment.
The operating control must be adjusted to provide the “ON”
pressure or temperature desired. It must allow the burner
to come on and start before the temperature or pressure
drops into the modulating range. The “OFF” pressure or
temperature must be sufficiently above the “ON” point to allow a reasonable run time.
The modulating control must be adjusted to start modulation
at some reasonable point below the “ON” temperature or
pressure and provide modulation to high fire at the lowest
temperature or pressure.
15. Limit Tests
Once the burner has been started and the operating pressures and temperatures have been set, the limit switches
need to be adjusted so that they will trip if the pressure or
temperature exceeds the operating value, but will not trip
with normal variations. The switch should be checked for
proper operation by allowing the temperature or pressure
to vary below (or above) the recommended level to insure
that they provide safe shutdown before the burner operation
is affected. In some high pressure or temperature switches, where the temperature or pressure cannot be set high
enough to trip the switch, the switch can be checked by lowering the set point to prove that the switch will provide a safe
shutdown.
The limit switches would include the air proving switch on
the burner. Limits for gas operation could include the high
and low gas pressure switches and for oil firing, the high
and low oil pressure switches, high and low oil temperature
switches and the atomizing air pressure switch. If in doubt
about which limits are on a burner, refer to the wiring diagram that will show each item.
Limit switches need to be checked at regular intervals to
ensure they are operating properly. See the maintenance
section for details.
16. Pilot Test
Once the burner as been set for the firing rates intended for
the burner, the pilot must be checked for proper operation
and safety.
The minimum pilot test is done to insure that a pilot which
can be seen by the scanner will light the main flame.
a. During a startup sequence, measure the time required
to light the main flame after the fuel valves have been energized. This will be used to monitor the test with reduced
pilot.
b. Lock the flame safeguard into the pilot position (refer to
JB Manual
the manual for the flame safeguard for this setting)
c. Adjust the gas pressure regulator to the pilot for a
minimum value while still holding the minimum signal
strength for the scanner.
d. Release the flame safeguard from the pilot position
and allow it to cycle though the main flame proving sequence.
e. This reduced pilot must reliably light the main flame.
Monitor the time from the main fuel valve opening and
do not allow the burner to continue if the time is more
than an additional two to three seconds from the initial
time measured above.
f. Run through two or three cycles.
g. If this is a combination fuel burner, repeat the test on
the other fuel.
h. Failures due to reduced scanner signal are also acceptable.
WARNING
THE MINIMUM PILOT TEST REQUIRES CLOSE SUPERVISION
OF THE COMBUSTION PROCESS. FAILURE TO CLOSELY
MONITOR THE MAIN FLAME TEST TIME COULD RESULT IN
DAMAGE, INJURY OR DEATH.
i. If the pilot does not light the main flame under these
test conditions, check and adjust the pilot as shown in
section “H”.
j. The infrared detector must be tested for hot refractory pickup. This test is performed to make sure that
the scanner does not see hot refractory that could be
mistaken for a flame.
k. After the burner has been operating for some time
at high input levels and the refractory in the vessel is
hot, the burner should be cycled off while monitoring the
scanner signal.
h. The flame signal should drop off quickly as the flame
goes out and should be well below the minimum level
(indicating a flame) at the end of the post purge cycle.
i. The UV detector must be tested for spark pick-up.
Turn the burner on, with the pilot shut off, during the
ignition cycle the flame signal should be well below the
minimum level (indicating a flame).
j. If the flame signal does not drop out as required,
check the location of the pilot and scanner, as shown in
section “H”. This may also indicate a faulty scanner or
amplifier.
17. Burner Shutdown
Normal operation of the burner will allow the operating
controls to shut the burner down when the load demand
is satisfied. If the burner needs to be shut down for any
reason, the “ON-OFF” switch can be used to quickly turn
the burner off. This will instantly cause the fuel valves
to close and start a post purge cycle to remove any unburned fuel from the vessel.
In an emergency shutdown, all fuel and electrical power
should be de-energized or turned off to secure the burner. This would include the main power disconnect, the
manual gas shutoff valve at the drop down line and if
equipped, the manual oil valve to the nozzle.
Page 40
Startup and Operating Adjustments
It is recommended that the burner be manually driven to
low fire before turning the burner off, as this reduces the
dynamic and thermal stress. If the burner will remain off
for some time, the manual fuel valves, fuel pumps and
power supply should be turned off.
CAUTION
ALWAYS KEEP THE FUEL SUPPLY VALVE SHUT OFF WHEN THE
BURNER IS SHUT DOWN FOR AN EXTENDED PERIOD OF TIME.
18. Restarting after Extended Shutdown
Extended shutdowns require the same startup process as
those outlined above. In addition, the following advanced
cleaning must be done,
a. The air atomized oil nozzle should be removed and
cleaned, if pressure atomized they should be replaced.
Use care in cleaning to preserve the sharp edges of the
nozzle, which are required to maintain good atomization.
b. The oil filter and strainer must be removed and cleaned
prior to starting.
CAUTION
DO NOT START THE BURNER UNLESS ALL CLEANOUT DOORS
ARE SECURED IN PLACE.
JB Manual
Page 41
Startup and Operating Adjustments
J. TROUBLESHOOTING
No.
1
2
3
4
5
6
7
8
9
System
Cause
Correction
No Ignition
Electrode is grounded. Porcelain is cracked.
Replace
(lack of spark)
Improperly positioned electrode
Recheck dimensions
Loose ignition wire connection
Reconnect or tighten
Defective ignition transformer
Check transformer, replace
No Ignition
Lack of fuel, no gas pressure, closed fuel valve
Check fuel supply and valves
(spark, no flame)
No voltage to pilot solenoid
Check electrical connections
Defective pilot solenoid valve
Replace
Incorrect location of pilot
Check location of pilot
Improper raw gas tube position
Check location of raw gas tube
Improperly positioned electrodes
Recheck dimensions
Too much combustion air flow
Check air damper position
Pilot not detected
Scanner tube not positioned correctly
Check location of scanner tube
(flame present)
Scanner tube dirty or wet (oil film)
Clean scanner tube / scanner
Scanner or amplifier faulty
Replace
Pilot improperly positioned
Check pilot position
Incorrect gas pressure to pilot
Readjust pressure
Combustion air flow rate too high
Readjust damper
No main gas flame
Weak scanner signal
Clean scanner lens and tube
(pilot OK)
Damper or fuel control valve setting incorrect
Readjust
Fuel valve(s) not opening
Check wiring to valves
No main oil flame
Weak scanner signal
Clean scanner lens and tube
(pilot OK)
Damper or fuel control valve setting incorrect
Readjust
Fuel valve(s) not opening
Check wiring to valves
Oil nozzle or line obstructed
Check nozzle and lines, clean
No atomizing air pressure
Check compressor wiring
Compressor pressure too low or high
Readjust
Burner not level, oil is draining into vessel
Check level, adjust as required.
Manual pot in low fire position (low fire hold)
Readjust to high fire position
Manual-auto switch or low fire hold switch in wrong position
Change position of switch
Modulating Control or Lo-Hi-Lo Control
Check wiring or replace
Loose linkage
Readjust and tighten
Binding linkage or valve
Readjust or replace
Burner shuts down
Loose electrical connection
Check and tighten connections
during operation
Loss of fuel supply
Replenish fuel supply
Limit switch breaks (opens)
Readjust limit switch
Main disconnect switch is open
Close switch
Loose electrical connection
Check electrical connections
Operating controls are tripped
Check and reset operating limits
High or low fuel pressure
Check fuel supply - reset switches
High CO at low fire
Improper excess air level
Readjust excess air
(firing gas)
Input too low for burner components
Check input, compare to rating label
Burner stays at low fire
Burner does not start
JB Manual
Page 42
Troubleshooting
No.
10
11
12
13
14
15
System
Cause
Correction
High CO at low fire (con’t)
High stack draft (especially at low fire)
Stabilize draft
(firing gas)
Poor air flow distribution (off center flame)
Adjust air straightener blade
Diffuser not in optimum position
Adjust diffuser position in or out
Fluxuating gas pressure (regulator not holding pressure)
Check regulator pressure, sensing line
and supply pressure: sized properly
Gas combustion noise
Input too low for burner components
Check input, compare to rating label
(rumbling)
Improper excess air
Readjust excess air
Fluxuating gas pressure (regulator not holding pressure)
Check regulator pressure and supply
High stack draft (especially at low fire)
Stabilize draft
Diffuser not in optimum position
Adjust diffuser position in or out
Poor air flow distribution (off center flame)
Adjust air straightener blade
Oil nozzle dirty or plugged
Clean oil nozzle
Improper excess air
Readjust excess air
Input too low for burner components
Check input, compare to rating label
High stack draft (especially at low fire)
Stabilize draft
Incorrect nozzle position
Adjust the nozzle to diffuser position
Fluxuating oil pressures (regulator not holding)
Check regulator pressure and oil supply
Poor air flow distribution (off center flame)
Adjust air straightener blade
Too much FGR (if equipped)
Reduce FGR rate
Fuel-Air-Ratios are
Linkage flexing
Realign linkage, straighten rods
not consistent
Linkage slip
Check linkage and tighten all joints
Fuel cam screws have moved
Replace fuel cam
Fuel line plugged
Check and clean lines, strainers & filters
Fuel supply pressure changing
Check and/or replace pressure regulator
Combustion air temperature changed
Retune burner
Draft condition changed
Check draft and outlet damper
Plugged or leaky FGR line
Clean / repair
Gas control valve - low fire stop not set (if used)
Adjust low fire stop
Fuel-Air-Ratios have changed
Linkage wear
Check linkage and tighten all joints
over time
Fuel cam screws have moved
Replace fuel cam
Air damper seal worn
Replace air damper seals
Fuel lines plugged
Check and clean lines, strainers & filters
Fuel control valve worn
Replace fuel control valve
Gas orifices or gas manifold plugged
Clean and/or replace
Combustion air temperature changed
Retune burner
Draft condition changed
Check draft and outlet damper
Vessel plugged
Clean vessel
Plugged or leaky FGR valve
Clean / repair
Cannot obtain capacity on
Wrong spring range in regulator
Install higher spring range
gas
Too many elbows before control valve
Rework piping to reduce elbows
Gas line too small, high pressure drop
Use larger pipe size
Supply pressure lower then stated
Increase supply pressure
Supply pressure drops too low at high fire
Use larger gas line sizes / orifice in
service regulator
Regulator too small for flow and pressure
Change regulator
Cannot obtain rated input on
Oil nozzles plugged
Replace nozzles
oil firing (pressure atomized)
By-pass seal on nozzle leaking
Replace nozzles
Oil combustion smoking
JB Manual
Page 43
Troubleshooting
No.
16
17
System
Cause
Correction
Cannot obtain rated input on
Oil pressure too low
Increase oil pressure
oil firing (pres. atom.) (con’t)
Flow valve set too low (should be closed at high fire)
Adjust oil control valve
Cannot obtain rated input on
Oil nozzles plugged
Clean nozzle
oil firing (air atomized)
Air pressure too low
Replace nozzle
Oil pressure too low
Increase oil pressure
Flow valve set too low
Adjust oil control valve
Cannot obtain NOx levels on
FGR valve not full open
Adjust FGR valve to full open
gas
FGR valve full of condensate
Clean duct and add drains
FGR duct not directed to flue stream
Add angle cut in center of stack
FGR line too small
Check sizing, use fittings with less drop
Operating on propane, not natural gas
Resize FGR for propane operation
Shutoff valve is not full open
Check FGR shutoff valve position
JB Manual
Page 44
Troubleshooting
K. GENERAL MAINTENANCE AND CARE
1.
2.
3.
4.
5.
6.
7.
General
Physical Inspection
Fuel-Air-Ratio
Gas Fuel Systems
Oil Fuel Systems
FGR System
Combustion Air Fan
There are several different types of controls and the corrective action of each could be different. The following
general guidelines can be used for initial steps.
Linkage based controls should be inspected for wear. If
there is any noticeable play in the linkage rod ends or
shaft bearing, they should be replaced. Likewise, any
control valves that exhibit sloppy or hard to turn movement should also be replaced.
1. General
This burner has been designed to provide many years of
trouble free operation. The reliability can be greatly improved with some simple inspection and maintenance programs.
One of the best tools for a good maintenance program is to
keep a log on the key parameters of the burner and boiler.
These would include operating temperatures, pressures,
inspections and preventative maintenance activities. This
document can be used to detect any changes in the operating characteristics of the burner, which can be used for
preventative maintenance.
The maintenance schedule can be used to help generate this log. There are also many other good references
that can be use to help develop your log. Adding check
points for other equipment into a common log can help. It
is common to integrate the boiler and burner log, so that
all components are checked at the same time.
Fuel cams should have adjusting screws that are held
firmly in position and can not move due to normal vibrations. The moving parts must be in good condition with
no noticeable wear or play. Worn connections will result
in hysteresis and reduced combustion efficiency.
The cam and jackshaft should be visually checked on a
frequent or daily basis for obvious problems, including
free movement, no loose parts and correct position of
components.
On a monthly basis, the linkage and cams should be
inspected for wear and loose parts. Annually, the cam
and linkage should be operated manually to check the
movement of all components and valves. Any worn parts
should be replaced immediately.
4. Gas Fuel System
The frequency of inspection given in the following charts
is only a guideline. Initial results should be used to adjust
the time intervals to be more frequent when problems or
potential problems are observed.
The safety interlocks must be checked at regular intervals
to ensure that they provide the proper safety. See the
Inspection and Maintenance Schedule Chart (Figure 8)
for frequencies.
2. Physical Inspection
The drip leg should be cleaned annually.
Listening and looking at the burner can detect many problems. For example, leakage can usually be seen early
with a small buildup of oil . Valve and linkage problems
can usually be detected early on by simply watching the
movement and detecting rough uneven changes. The
jackshaft, linkage and valve movement should occur
smoothly with no rough jerks.
Monitoring the outlet gas pressure from the regulator will
verify this control is working properly.
The flame condition can often be a good indicator of the
firing head. If the flame does not look correct, there may
be a problem with the hardware. The firing head is exposed to the high temperatures of combustion and can
have reduced life due to the thermal stress. In particular,
the diffuser, oil nozzle, gas orifices, gas manifold, refractory and burner mounting plate should all be inspected.
3. Fuel-Air-Ratio Controls
The fuel-air-ratio controls must be maintained in good operating condition. Over time, these items will wear and
may not operate smoothly. Corrective action must be
taken.
JB Manual
5. Oil Fuel System
The oil system has additional components that require
regular maintenance, depending on the type of system
used.
a. Oil added to air compressor. The air compressor has
a visual sight glass showing the oil level. This must be
inspected every shift (while operating).
b. Air compressor belt tight and in good condition
c. The oil strainer should be checked and cleaned periodically. A high vacuum reading on the suction side of
the pump (over 10”) is a good indication that the strainer
needs to be cleaned. Strainers provided by Webster will
use a wire mesh basket inside a canister. After turning
the pump off (and making sure there is no pressure on the
strainer), unscrew the yoke to gain access to the basket.
The canister does not need to be drained. Be careful with
the gasket when removing or replacing the cover to insure
Page 45
General Maintenance & Care
a good seal. The basket can be lifted out and cleaned with
a soft brush and cleaning solution.
d. Vacuum higher than the 10” limit on suction side of pump
(indicates need to clean strainer, as described above). If
cleaning the strainer does not resolve this, check the other
valves between the tank and gauge for plugged or closed
position.
e. Air atomized oil nozzles should be cleaned periodically,
depending on the type of operation and the observed need
for cleaning. Extended operation at very low rates (less
then 15% of capacity) can cause carbon buildup on the
outside of the nozzle. This can be cleaned with a rag and
cleaning solution. If the fire is showing some deterioration, and the external surfaces are clean, then the nozzle
should be removed, disassembled and cleaned using a
soft brush and cleaning solution.
f. If the edges of the air atomizing nozzle are not sharp,
or the nozzle shows sign of wear and the combustion is
deteriorated, the nozzle should be replaced. The nozzle
part number is given on the material list of the unit. In
general, a single port (center hole) uses a 80o nozzle or
multiport (multiple hole at the spray angle) nozzle with a
spray angle of 70 degrees will work well for light oil. Heavy
oil should use a spray angle of about 60 degrees.
g. Pressure atomized oil nozzles have a filter feeding the
nozzle that can be plugged over time. The filter can be
unscrewed from the back and cleaned, using a soft brush
and cleaning solution. When the nozzle(s) are removed
form the nozzle body (BPS nozzles), the plastic seals at
the end of the nozzle must be replaced, or the nozzle may
not seal correctly. The seal can be slid off of the nozzle
and a new one installed. Use extreme care to not put any
cuts or nicks in the seal. Once the seal is on, the nozzle
can be inserted and screwed into the nozzle body.
h. If a pressure atomized oil nozzle needs to be replaced,
it should be a Delevan Veriflow type, using a 60 degree
spray angle (JB3 BPS nozzle(s)).
i. Check safety limits, including pressure and temperature
switches
Other checks:
a. The condensation traps must work properly and be
installed to capture all of the condensation. If condensation passes through to the burner windbox, a condensate
drain should be added to the bottom of the windbox.
b. Linkage and valve movement must operate freely and
smoothly.
c. If the FGR valve is modulated partly open (oil firing on
dual fuel burner) check position of FGR valve.
d. NOx emission levels.
e. Other general items like the refractory.
f. Stack temperature of boiler - high temperatures will
increase NOx levels.
g. Operation of safety equipment.
h. Time delay on FGR on-off valve (if equipped).
7. Combustion Air Fan
If the fan and motor are ever removed, the following
should be observed in re-assembly.
a. There should be about 1/16” overlap of inlet cone and
fan.
b. Never re-use the fan to motor shaft set screws, always
use new screws of the same type and style to maintain
balance and fan retention.
c. When tightening the fan hub set screws, rotate the fan
to place the screws on the bottom. This way the screw
is not lifting the fan.
d. The motor shaft and fan hub must be clean and free
of burrs.
6. FGR Systems
The flue gas is corrosive and requires regular inspection of
the equipment to ensure proper and safe operation. The
potential for corrosion and frequency of the inspection can
vary greatly based on the application. Applications with
condensation will have more corrosion and will need more
maintenance. Frequent cycling, cold startups, cool operating temperatures, cool air temperatures and outdoor
installations are good examples of where high levels of
condensation can occur.
Areas to inspect for corrosion:
• FGR control valves(s)
• FGR Duct
• Air inlet louver box
• Fan and fan housing
• Burner housing
• Firing head and blast tube
JB Manual
As a minimum, the following replacement parts should
Page 46
General Maintenance & Care
8 - Inspection and Maintenance Schedule
Recommended Action or Test
Trained
Burner
Technician
Component / Item
Boiler
Operator
Performed By
Annual As
Required
Annual
Seasonal
Weekly
Monthly
Daily
Frequency
X
Burner Flame
Visual inspection of burner flame.
X
X
Jackshaft and Linkage
Visual inspection for smooth and free travel.
X
X
Air Damper
Visual inspection for smooth and free travel.
X
X
Fuel Metering Valves
Visual inspection for smooth and free travel.
X
X
Draft Controls (Stack)
Visual inspection for smooth and free travel.
X
X
Gas Fuel Pressure
Record in log book, compare trends.
X
X
Oil Pressure
Record in log book, compare trends.
X
X
Atomizing Air Pressure
Record in log book, compare trends.
X
X
Pilot
Visually inspect pilot flame, check and record flame signal strength if metered.
X
X
Flame SafeGuard - Pilot
Test
Close manual fuel valve on pilot during cycle and check for safety shutdown,
recording time.
X
X
Flame SafeGuard - Main
Flame
Close manual fuel valve on pilot during cycle and check for safety shutdown,
recording time.
X
Flame SafeGuard
Check flame safeguard components, including scanner.
X
Flame SafeGuard
Replace flame safeguard components in accordance with manufacturers
instructions.
X
X
X
X
X
Pilot Turndown Test
Conduct pilot turndown test annually or after any component change.
X
X
X
Hot Refractory Test
Conduct hot refractory hold in test. This test is required annually or after any
component change.
X
X
Oil Pressure and Temperature Interlocks
Check oil pressure and temperature switch for smooth operation and correct
action.
X
X
Atomizing Air Pressure
Check air atomizing pressure interlock switch for smooth operation and correct action.
X
Interlock Controls
Check other interlocks that may be used on the burner for smooth operation
and correct action.
X
X
Firing Rate Control
Check firing rate control and verify settings.
X
X
Combustion Tuning
Conduct a combustion test, verify setting and NOx emission levels.
X
Pilot and Main Fuel Valves
Make visual and manual check for proper sequencing of valves.
X
X
Pilot and Main Fuel Valves
Check all coils, diaphragms, interlock switch & other parts of all safety shutoff
valves.
X
X
Pilot and Main Fuel Valves
Perform leak tests on all safety shutdown control valves.
X
X
Low Pressure Air Switch
Test low air pressure switch for proper operation and adjustment.
X
X
Mod Damper Switch
Check damper low fire proving switch per manufacturers instructions.
X
X
Linkage and Fuel Cams
Check linkage and cams for wear and replace any items with wear indication
or stress cracks.
X
FGR Control Valve
Visual inspection for smooth and free travel.
X
FGR Control Valve
Clean and lubricate FGR control valve.
X
FGR Shutoff Valve
Visually inspect for smooth and complete travel.
X
FGR Shutoff Valve
Clean and lubricate FGR shutoff valve
X
X
X
X
X
X
X
X
X
X
FGR Condensate Drain
Open FGR condensate drains, remove all condensate.
X
FGR Shutoff Valve Switch
Check operation of shutoff FGR valve for full rotation and position proving
switch.
X
FGR Duct
Inspect and clean FGR duct.
X
Combustion Air Fan
Clean combustion air fan and housing
Burner Components
Visually check the burner components for signs of cracks, deformation, slippage or other unusual indication.
X
X
Burner Mounting
Check burner mounting clamps and brackets for tightness.
X
X
Refractory and Seals
Check burner refractory for cracks or signs of leakage.
X
X
Oil Nozzle
Check and clean oil nozzle.
X
Air Compressor
Check air compressor for lubrication oil and air filter.
X
Air Compressor
Check air compressor relief valve operation.
X
X
X
JB Manual
Page 47
X
X
X
X
General Maintenance & Care
L. CARE OF THE BURNER DURING EXTENDED SHUTDOWN
Heating equipment is oftentimes located in an environment conducive to corrosion and general deterioration if
not properly protected and periodically checked, especially
during an extended period of shut down. The following
procedures should be followed if the burner is going to be
placed out of service even for a short period of time.
1. Turn the main manual fuel valve OFF.
CAUTION
Always keep the main fuel valve(s) OFF if the burner
is shut down for an extended period of time.
2. Turn off the main electrical disconnect to the burner
OFF. Follow tagout / lockout procedures.
3. Place a notification tag or label at the main manual
fuel valve giving reason for shutdown. Follow tagout /
lockout procedures.
4. If the burner is in an area subject to sweating and
condensation, cover the control cabinet and electrical devises with plastic and secure with twine or tape.
5. Should the burner be out of service for more than thirty
(30) days, a complete operational safety check must be
made at the time of restart. The restart must be treated
as a new burner start-up (see burner start-up section in
this manual).
6. The oil nozzle(s), if pressure atomized should be replaced. If air atomized, clean the nozzle with cleaning
fluid and a soft brush.
M. REPLACEMENT PARTS
be stocked to support uninterrupted burner operation.
An illustrated parts drawing is included within the Burner
Instructions Manual to aid in parts identification. The noun
name of the part needed should be established from the
drawing, then the part number can be obtained from the
burner material list contained in the Burner Instructions
and Service Manual.
Pilot Electrode
Blower Wheel
Oil Pump (if oil burner)
Oil Pump Coupling (if oil burner)
Pilot Ignition Transformer
Oil Ignition Transformer (if used)
Gas Pilot Solenoid Valve
Flame Scanner
Items with greater life expectancy and/or greater dollar value, such as flame safety controls, main gas or oil valves and
blower motors should be obtained from your local Webster
representative when a need arises.
NOTE
Always give Webster Engineering Serial
Number and/or UL Serial Number when
ordering parts.
N. WARRANTY VALIDATION & FIELD START-UP REPORT
As a final step, forward the top copy of the Warranty Validation and Field Startup Report, Form 113, to:
WEBSTER ENGINEERING & MFG. CO., LLC, 619 Industrial Road, Winfield, KS 67156.
WEBSTER Series JB Burners are listed by Underwriters Laboratories, Inc. (U.L.). Also by the
State of Massachusetts Fire Marshall, City of New
York Board of Standards and Appeals, State of
Minnesota, and can be packaged to meet specific
requirements of CSD-1, GE GAP, IRI, FM, NFPA,
MIL or other special insurance or local code requirements.
JB Manual
Page 48
Extended Shutdown / Replacement Parts / Start-Up Report
WARRANTY VALIDATION FIELD START-UP REPORT
CUSTOMER:_________________________________
W.O. _________________
BURNER MODEL: ____________________________ BOILER MODEL: ________________________________
CONTROL CIRCUIT COMPONENT OPERATIONAL TESTING (Check if Okay)
Primary LWCO _______________ High Limit ____________________
Secondary LWCO _____________ Operational Control ____________
High Gas Press. Switch _________ Oil Press. Switch ______________
Low Gas Press. Switch _________ Air Flow Switch _______________
Firing Rate Control __________________
Low Fire Start Switch ________________
High Fire Purge Switch _______________
Other _____________________________
OIL FIRED
FIELD
COMBUSTION SETTINGS
Low
GAS FIRED
Med.
High
Low
Med.
High
Firing Rate
CO2
O2
Smoke or CO (ppm)
NOx (ppm)
Stack Temp. Net oF
Room Temperature oF
Overfire Draft “ WC
Breeching Draft “ WC
Water Temp. oF/Steam Press.
Air Inlet Shutter (“ Open)
Flame Signal Pilot
Flame Signal Main
Oil Noz. Press/Man. Gas Pres.
By-Pass Oil Pressure
Atomizing Air Pressure
Combustion Efficiency
Running Motor Amps & Volts
L1
L2
L3
Comments:
Having read the Manufacturer’s service manual as to the proper installation, start-up and service of the unit above, I
verify that the burner has been put into operation as specified, and that the above information and checks are complete and correct.
START-UP BY _______________________________________________ Date _________________________
Company ___________________________________________ Phone No. ____________________________
Address ___________________________________________________________________________________
NOTE: Warranty Validation - Field Start-up report must be completed, signed, dated and the top copy sent to Webster
Engineering & Manufacturing Co., Winfield, KS 67156, to validate equipment warranty.
JB Manual
Page 49
Warranty Validation - Form #113 (4-02)
NOTES
JB Manual
Page 50
Notes
NOTES
JB Manual
Page 51
Notes
NOTES
WEBSTER COMBUSTION TECHNOLOGY
619 Industrial Road - Winfield, KS 67156
Phone 620-221-7464 Fax 620-221-9447
sales@webster-engineering.co m service@webster-engineering.com
www.webster-engineering.com
JB Manual
Page 52
Notes
Download PDF