Professional Documents
Culture Documents
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.
Lead Technician
Address
Phone Number
JB Manual
Page
Safety Precautions
TABLE OF CONTENTS
Safety Precautions ............................................................................................................................... 2
A.
Introduction .......................................................................................................................................... 3
Burner Model Number ............................................................................................................. 5
JB1 Specifications ................................................................................................................... 6
JB2 Specifications ................................................................................................................... 8
JB3 Specifications ................................................................................................................... 10
B.
Component ldentification ...................................................................................................................... 12
C. Installation ............................................................................................................................................ 17
D. Special lnstructions For Canadian lnstallations .....................................................................................18
E.
Burner Mounting Criteria ...................................................................................................................... 19
F.
Fuel Systems ........................................................................................................................................ 20
G.
Initial Settings ....................................................................................................................................... 28
H.
Ignition Systems ................................................................................................................................. 30
I.
Start-up & Operating Adjustments ....................................................................................................... 32
J.
Trouble Shooting .................................................................................................................................. 42
K.
General Maintenance and Care ........................................................................................................... 45
L.
Care of The Burner During Extended Shutdown .................................................................................. 48
M. Replacement Parts .............................................................................................................................. 48
N. 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.
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
MBTU/HR
IN.WC
GPH
PSI
MAXIMUM
2940
2.8
21
300
MINIMUM
1680
1.0
12
100
FUEL
MODEL NUMBER
JB2C-15-RM7840L-UL-IRI
#2 FUEL OIL
NATURAL GAS
HP
VOLTS
AMPS
HERTZ
PHASE
CONTROL CIRCUIT
115
5.0
60
BURNER MOTOR
208
5.9
60
1.5
208
4.3
60
1/2
Page
Introduction
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.
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 % (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
CODES AND
LISTINGS
JB SERIES
UL
NOT USED
BLANK
ULc
CSD-1
FM
IRI
JBX
7 1/8
7 1/2
9 1/8
9 1/2
11 1/8
11 1/2
NFPA-85
OIL SYSTEMS
Pressure Atomizing
FUELS
G
Gas
Oil
Gas / Oil
On - Off
Low - Hi - Low
MP
Modulation Simplex
MR
Modulation By-Pass
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
Maxon
15
1 1/2
20
Blank
All Others
(ASCO) - (std)
30
50
75
7 1/2
100
10
FLAME SAFEGUARD
VENDOR DESIGNATION
RM7800L
Honeywell
M 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
On-Off
Low-Hi-Low
Modulation
Page
Identification
Air Flow Switch (also with oil systems using remote pump)
Optional
Ignition
Opt.
Oil Nozzle(s)
Oil Fuel
General
Gas
No. 2 Oil
pressure
atomized
STANDARD UL EQUIPMENT
AND IMPORTANT OPTIONS
Gas Fuel
Gas
Fuel Burned
No. 2 Oil
pressure
atomized
Fuel Burned
Opt.
Inverted Housing
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
#2 Oil gph
Burner Motor HP
Gas Train
Gas Only
HP
(3) Oil or
Combination
Pipe Size
Oil Pump
Motor HP
Modulation
JB1-02
1.25
400 / 1000
3.0 / 7.1
1/4
1/3
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
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.
Page
Specification
24
5 5/16
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)
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
Oil Nozzles
Opt.
X
Opt.
(3)
Oil Fuel
General
Ignition
Air
Atomized
Pressure
Atomized
Gas
Air
Atomized
Gas Fuel
Pressure
Atomized
Opt.
Opt.
(3)
Inverted Housing
Options
STANDARD UL EQUIPMENT
AND IMPORTANT OPTIONS
Gas
No. 2 Oil
Air Compressor
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
Pipe Size
LFS, LHL
Modulation
Pressure
Atomizing
Air
Atomizing
Air
Compressor
Motor HP
JB2-07
900 / 2800
10 / 20
3/4
1 1/2
10 / 14
13
Integral
N/A
N/A
JB2-10
900 / 3500
10 / 25
8 / 14
9 / 14
Integral
Optional
JB2-15
900 / 3500
10 / 25
1 1/2
8 / 14
9 / 14
Integral
Optional
JB2-20
1200 / 4200
12 / 30
(4) 12 / 14
(3) 13 / 14
Integral
Optional
JB2-30
2.5
1200 / 5300
12 / 37.8
2 1/2
N/A
13 / 14
3/4
Optional
JB2-50
2.5
1200 / 6000
12 / 42.8
2 1/2
N/A
2-5 psi
3/4
Optional
JB Manual
Page
Specification
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
39 1/4
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
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
Pressure
Atomized
Air
Atomized
N0. 4 - 6 Oil
Air Atomized
Oil Nozzles
Opt.
Opt.
Gas
STANDARD UL EQUIPMENT
AND IMPORTANT OPTIONS
Gas Fuel
Oil Fuel
Options
Gas
X
X
Air
Atomized
X
X
Pressure
Atomized
EQUIPMENT
AND IMPORTANT OPTIONS
General
No. 2 Oil
No. 4 - 6 Oil
Air Atomized
No. 2 Oil
(1) STANDARD UL
Ignition
Inverted Housing
Opt.
Opt.
Opt.
Posi-Control
Air Compressor
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
#2 Oil
gph
JB3-30
3.5
1400 / 6300
10.2 / 45
10 / 42
2 1/2
JB3-50
3.5
1400 / 8300
11 / 59.2
10 / 55.3
JB3-75
3.5
1600 / 10500
12.3 / 75
11 / 70
7 1/2
JB3-100
3.5
1800 / 12600
20.3 / 90
12 / 84
10
#4-6
Oil gph
Burner
Motor
HP
Gas Train
Pipe
Size
Inlet
Press
#4 - 6
Pump
Motor HP
Air
Compressor
Motor HP
Optional
Optional
Optional
Optional
Optional
Optional
Optional
Optional
Pressure
Atomizing
Air
Atomizing
12 / 27
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.
JB Manual
Page 10
Specification
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
22 1/2
48
19 1/4
19 9/16
Standard Arrangement
Elevation
W/ Optional Back Mount Control Cabinet
11 1/4
O.D.
14 3/4
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
Louver Box
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
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
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
Low Atomizing
Air Press. Sw.
Drawer Assembly
Jack Shaft
Atomizing Air
Bleed Muffler
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
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
Drawer Assembly
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
To Oil System
Return
Oil Nozzle(s)
Diffuser
Pilot Gas
Supply Line
Gas Pilot
Ignition Electrode
Figure B-10
JB3 Combination or Straight Oil Drawer Assembly
with Proven Gas Pilot
View Port
Ignition Electrode
Gas Pilot
Diffuser
Sight Tube
Backplate
JB Manual
Figure B-11
JB1 & 2 Combination Drawer Assembly
with Proven Gas Pilot Ignition
Page 15
Identification
View Port
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
Description
090002
Vessel
FB
090002-076
Gas orifice, 5/16 brass, (2) radial #48 holes, no axial hole (48 x 2)
090002-098
Gas orifice, 5/16 brass, (2) radial #40 holes, no axial hole (40 x 2)
FB
090054-xxx
Gas orifice, 5/16 brass, no radial holes, (1) axial hole (xxx = hole dia.)
FB, SF
090055-xxx
Gas orifice, 5/16 steel, no radial holes, (1) axial hole (xxx = hole dia.)
090069-xxx
Gas orifice, 5/16 brass, (4) #40 radial holes, (1) axial hole (xxx = hole dia.) (40 x 4 x __ )
090184-xxx
Gas orifice, 5/16 steel, (4) #40 radial holes, (1) axial hole (xxx = hole dia.) (40 x 4 x __ )
090185-000
090185-098
Gas orifice, 5/16 steel, (2) radial #40 holes, no axial hole (40 x 2)
FB, SF
090227-xxx
Gas orifice, 5/16 brass, (4) #48 radial holes, (1) axial hole (xxx = hole dia.) (48 x 4 x __ )
090284-xxx
Gas orifice, 1/4 steel, no radial holes, (1) axial hole (xxx = hole dia.)
090287
090288
090318
090319
OT (open tube)
Sketch
Example
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
Orifice Example B
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 burners UL rating plate?
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
Page 18
Dimensions - Inches
Minimum 7 gauge
2 Minimum
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
See Note 3
A - Opening
Minimum of six (6) holes for
boiler mtg. studs, 1/2 or larger
Minimum 14 Gauge
Figure E-1
Refractory Dimension
Refractory
Front Plate
Fiberglas rope
gasket must be
coiled to cover
the full mounting
flange surface
Figure E-2
Burner Mounting Instruction
JB Manual
Page 19
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 manufacturers data section of the burner instructions manual for items shown
below.
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
Strainer
Piped if a Remote
Pump is Used
By Others
Unless Specified on Order
Field Piped
2 or 3 1 (IN)
(out)
Low Oil
Press. Sw
IN
Return to Tank
(No Manual Valves
in this line)
IN
Gauge Port
Oil Nozzle
Adjustment
Oil Pump
Field Piped
Check Valve
By Others
Shutoff Valve
Check
Valve
Suction
Supply Line
Field Piped
JB Manual
Main Oil
Safety Oil
Solenoid
Valve Solenoid Valve
By Others
Unless Specified on Order
Page 20
Fuel Systems
Low Oil
Pressure Switch
Oil Metering
Valve
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
By Others
Shutoff
Valve
Suction
Supply Line
Field Piped
Strainer
By Others
(Unless Specified on Order)
Usage Requirement
Varies with Code
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
Field Piped
JB Manual
Page 21
Fuel Systems
Air Filter
Ball Valve
(man. set to adjust air
volume & high fire air
pressure)
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
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
Low Oil
High Oil
Temp. Sw. Temp. Sw.
Relief
Valve
Air
Gauge
Gauge
High Oil
Low Oil
Temp. Sw. Temp. Sw.
Drain
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.
Nozzle
Oil
Gauge
Ball
Valve
Thermometer
MA - Modulating #4 - 6 Oil
Compressor
Pressure
Gauge
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
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
722091
722001
Low Hi Low
722022
Modulating
722003
Low Hi Low
Low Hi Low
Modulating
Modulation
Modulating
Modulating
Modulating
Modulating
722002
X
722009
722023
X
X
722024
722004
X
X
722010
722005
X
X
722011
722082
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
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
Vent To Outside
Atmosphere
Gas
Supply
Main Motorized
Gas Valve
26 Sec.
Main Solenoid
Gas Valve
Manual Ball
Valve
Gas Burner
Manifold
Field
Piped
Manual
Test Valve
Gas Pressure
Regulator
Test
Connection
Manual Ball
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
Vent To Outside
Atmosphere
Gas
Supply
Main Motorized
Gas Valve
26 Sec.
Main Solenoid
Gas Valve
Manual Ball
Valve
Test
Connection
Gas Pressure
Regulator
Manual Ball
Valve
Manual Test
Valve
Field
Piped
Manual
Test Valve
Gas Burner
Manifold
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.
Gas Pressure
Regulator
Manual
Ball Valve
Manual
Test Valve
Manual Test
Valve
Test
Connection
Gas Burner
Manifold
Fuel Flow
Control Valve
Field Piped
Field Piped
Pilot Manual
Ball Valve
Pilot Gas
Pressure
Regulator
Gas
Supply
Gas Pressure
Regulator
Pilot Solenoid
Valve
S
Vent To Outside
Atmosphere
Manual Ball
Valve
Gas Pilot
Ignitor
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
Vent To Outside
Atmosphere
Gas
Supply
Manual Ball
Valve
Pilot Solenoid
Valve
Gas Pilot
Ignitor
Gas Pressure
Manual Test
Regulator
Valve
Vent
Main Motorized
Gas Valve
26 Sec.
Main Motorized
Gas Valve
14 Sec.
Field Piped
Test
Connection
Field
Piped
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.
L
Man Reset
Low Gas
Pressure
Switch
Manual Test
Valve
Field
Piped
Manual
Test Valve
Man Reset
High Gas
Pressure
Switch
Field
Piped
Test
Connection
Gas Burner
Manifold
Manual Ball
Valve
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.
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
Pilot Gas
Pressure
Regulator
Gas
Supply
Pilot Solenoid
Valve
Gas Pilot
Ignitor
Vent To Outside
Atmosphere
Manual Ball
Valve
Main Motorized
Gas Valve
26 Sec.
Gas Pressure
Regulator
Main Solenoid
Gas Valve
Manual Test
Valve
Vent
Manual
Test Valve
Test
Connection
Manual
Ball Valve
Field Piped
Fuel Flow
Control Valve
7722024
Page 25
Gas Burner
Manifold
722004
Fuel Systems
722010
Field Piped
Pilot Manual
Ball Valve
Pilot Gas
Pressure
Regulator
Vent To Outside
Atmosphere
Gas
Supply
Pilot Solenoid
Valve
Gas Pilot
Ignitor
Vent
Main Motorized
Gas Valve
26 Sec.
Main Mortorized
Gas Valve
14 Sec.
Manual Ball
Valve
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
Field Piped
Pilot Manual
Ball Valve
Pilot Gas
Pressure
Regulator
Pilot Solenoid
Valve
Gas Pilot
Ignitor
Vent To Outside
Atmosphere
Gas
Supply
722010
Manual Ball
Valve
Main Motorized
Gas Valve
W/POC
26 Sec.
POC
Gas Pressure
Regulator Main Solenoid
Manual
Test Valve
Manual Test
Valve
Gas Valve
Vent
Test
Connection
Fuel Flow
Control Valve
Field Piped
Field Piped
Pilot Manual
Ball Valve
Pilot Gas
Pressure
Regulator
Gas
Supply
722005
Pilot Solenoid
Valve
S
Vent To Outside
Atmosphere
Manual Ball
Valve
Gas Pilot
Ignitor
Main Motorized
Gas Valve
W/ POC
26 Sec.
M
POC
Gas Pressure
Regulator
Manual Test
Valve
Vent
Man Reset
High Pressure
Switch
Test
Connection
H
Manual Test
Valve
Gas Burner
Manifold
Fuel Flow
Control Valve
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
Manual
Test Valve
M
POC
Vent
H
Manual Test
Valve
Manual Ball
Valve
Fuel Flow
Control
Valve
Page 26
Test
Connection
Gas Burner
Manifold
Field Piped
722011
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.
POC
M
POC
Manual
Test Valve
Vent
H
Manual Test
Valve
Manual Ball
Valve
Fuel Flow
Control
Valve
Page 27
Gas Burner
Manifold
Field Piped
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
Figure G-1
Oil Nozzle Position,
Gas Pilot
INNER FIRE CYLINDER
Chart G-2
Diffuser
I.D.
Qty.
2
JB1
1 1/2
1
JB2
JB3
1 3/4
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
Nozzle
Type
Spray
Angle
Dim.
A
Dim.
B
NA
NA
NA
NA
NA
Single
Port
60o
1/4
NA
Multi
Port
80o
NA
3/8
2 1/2
60
5/8
2 1/2
2 7/8
60
5/8
2 7/8
Flexible Strip
Return
Springs
Fire
Pos
it
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
Panel
Adjusting
Screw
Air Proving
Switch
Page 29
Initial Settings
H. IGNITION SYSTEMS
Electrode
Spark
Gap = 1/16
Electrode Clamp
Pilot
Figure H-1
JB1 & JB2 Gas Pilot
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
BURNER DATA
Model
Diffuser I.D.
1
JB1
1 1/2
JB2
1 3/4
NOZZLE DATA
Qty.
Spray Angleo
30
45
30
45
30
45
1/2
1/2
3/8
3/8
JB Manual
2 7/8
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
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.
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
Page 32
Low
Fire
Drive Arm
B
Modulating
Range 90o
Jackshaft
D
High
Fire
Driven
Arm
Linkage Arm
Valve
(Air Damper,
FGR Valve...)
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
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
Page 34
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
Page 35
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
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
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.
Page 37
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 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.
Oil GPH =
[Gal end Gal start] x [3600 sec/hr] /
[measured sec]
Page 38
Minimum
20
10 - 25
30
12 - 30
40
15 - 35
50
20 - 40
100
25 - 60
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,
Page 39
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 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
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
JB Manual
Page 41
J. TROUBLESHOOTING
No.
1
System
Cause
Correction
No Ignition
Replace
(lack of spark)
Recheck dimensions
Reconnect or tighten
No Ignition
(spark, no flame)
Replace
Recheck dimensions
(flame present)
Replace
Readjust pressure
Readjust damper
(pilot OK)
Readjust
(pilot OK)
Readjust
Readjust
Loose linkage
Readjust or replace
during operation
Close switch
(firing gas)
JB Manual
Page 42
Troubleshooting
No.
10
11
12
13
14
15
System
Cause
Correction
Stabilize draft
(firing gas)
(rumbling)
Stabilize draft
Stabilize draft
Fuel-Air-Ratios are
Linkage flexing
not consistent
Linkage slip
Retune burner
Clean / repair
Gas control valve - low fire stop not set (if used)
Linkage wear
over time
Retune burner
Vessel plugged
Clean vessel
Clean / repair
gas
Change regulator
Replace nozzles
Replace nozzles
JB Manual
Page 43
Troubleshooting
No.
16
17
System
Cause
Correction
Clean nozzle
Replace nozzle
gas
JB Manual
Page 44
Troubleshooting
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.
2. Physical Inspection
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.
Page 45
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
Trained
Burner
Technician
Component / Item
Boiler
Operator
Performed By
Annual As
Required
Annual
Seasonal
Weekly
Monthly
Daily
Frequency
Burner Flame
Air Damper
Oil Pressure
Pilot
Visually inspect pilot flame, check and record flame signal strength if metered.
Close manual fuel valve on pilot during cycle and check for safety shutdown,
recording time.
Close manual fuel valve on pilot during cycle and check for safety shutdown,
recording time.
Flame SafeGuard
Flame SafeGuard
X
X
X
Conduct hot refractory hold in test. This test is required annually or after any
component change.
Check oil pressure and temperature switch for smooth operation and correct
action.
Check air atomizing pressure interlock switch for smooth operation and correct action.
Interlock Controls
Check other interlocks that may be used on the burner for smooth operation
and correct action.
Combustion Tuning
Check all coils, diaphragms, interlock switch & other parts of all safety shutoff
valves.
Test low air pressure switch for proper operation and adjustment.
Check linkage and cams for wear and replace any items with wear indication
or stress cracks.
X
X
X
X
X
X
X
Check operation of shutoff FGR valve for full rotation and position proving
switch.
FGR Duct
Burner Components
Visually check the burner components for signs of cracks, deformation, slippage or other unusual indication.
Burner Mounting
Oil Nozzle
Air Compressor
Air Compressor
X
X
JB Manual
Page 47
X
X
X
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.
M. REPLACEMENT PARTS
be stocked to support uninterrupted burner operation.
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.
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
W.O. _________________
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 Manufacturers 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
NOTES
JB Manual
Page 50
Notes
NOTES
JB Manual
Page 51
Notes