-
W£8ST£R COMBUSTION A Se las 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 - R 1
www.webster-engineering.com
September, 2014 © 2014 All Rights Reserved
www.webster-engineering.com
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SAFETY PRECAUTIONS
Page 2 Safety PrecautionsJB Manual
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 MAN-UFACTURERS 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.
Service Organization Information:
Company Name
Address
Phone Number
Date of Startup
Lead Technician
-
Safety Precautions
...............................................................................................................................A.
Introduction
..........................................................................................................................................
Burner Model Number
.............................................................................................................JB1
Specifications
...................................................................................................................JB2
Specifications
...................................................................................................................JB3
Specifications
...................................................................................................................
B. Component ldentification
......................................................................................................................C.
Installation
............................................................................................................................................D.
Special lnstructions For Canadian lnstallations
.....................................................................................E.
Burner Mounting Criteria
......................................................................................................................F.
Fuel Systems
........................................................................................................................................G.
Initial Settings
.......................................................................................................................................H.
Ignition Systems
.................................................................................................................................I.
Start-up & Operating Adjustments
.......................................................................................................J.
TroubleShooting
..................................................................................................................................K.
General Maintenance and Care
...........................................................................................................L.
Care of The Burner During Extended Shutdown
..................................................................................M.
Replacement Parts
..............................................................................................................................N.
Warranty Validation & Field Start-up Report
........................................................................................
Start-Up Report
.......................................................................................................................
23568101217181920283032424548484849
TABLE OF CONTENTS
A. INTRODUCTION
Page 3 IntroductionJB Manual
This manual covers the Models JB1, JB2 and JB3 CYCLO-NETIC
burners offered by Webster Engineering & Manu-facturing 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.
READ AND SAVE THESE INSTRUCTIONS FOR REFER-ENCE
WARNINGDO NOT ATTEMPT TO START, ADJUST OR MAIN-TAIN THIS BURNER
WITHOUT PROPER TRAINING OR EXPERIENCE. FAILURE TO USE
KNOWLEDGE-ABLE TECHNICIANS CAN RESULT IN EQUIPMENT DAMAGE, PERSONAL
INJURY OR DEATH.
The startup and maintenance of the JB burner requires the skills
of an experienced and properly trained burner techni-cian.
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 spe-cial order
requirements may result in differences between the content of this
manual and the actual equipment. These special components will be
described in the infor-mation provided with the burner and should
be used as the controlling document.
NOTE: This manual must be readily available to all op-erators
and maintained in legible condition.
1. Nameplate Information
Each burner has a nameplate with important job details,
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 NameplateMODEL NUMBER
JB2C-15-RM7840L-UL-IRISERIAL NUMBERU81375A-018-06
OIL INPUT RATINGGAS INPUT RATING
MBTU/HR IN.WC GPH PSI
2940 2.8 21 300MAXIMUM
1680 1.0 12 100MINIMUM
NATURAL GAS #2 FUEL OILFUEL
VOLTS AMPS HERTZ PHASE HP
115CONTROL CIRCUIT 5.0 60 1
208BURNER MOTOR 5.9 60 3 1.5
208OIL PUMP MOTOR 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 pres-sure. Pressure atomized
burners only list the oil pres-
-
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
volt-age, current load, frequency and phase (this will either be
single or 3-phase). For motors, the motor HP is listed.
2. Ratings
The ratings for each specific burner are given on the
name-plate. The general burner ratings are given in Specifica-tion
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, emis-sion 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 stan-dard 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 Adden-dum 950064).
Figure A-2 lists the common variations and options avail-able 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 docu-ments
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
inter-connection of the burner and vessel controls.b. The gas and
oil piping schematics, which show thecomponents and their relative
positions in the piping train.c. The unit material list which
provides an overview ofthe 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 se-quence
for the burner management system. This will be acritical document
for troubleshooting any future problems.
Page 4 IntroductionJB Manual
e. Catalog cuts of the major components. These providedetails on
the installation, adjustment and maintenance ofthe components used
on the burner.
5. Service, Parts and other InformationService and parts are
available from your local Webster Representative. For a list of
Webster Representatives, please visit the Webster web site at:
www.webster-engineering.com or call 620-221-7464.
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MODEL JB(X) BURNER MODEL CONFIGURATIONFIGURE A-2
JBX1G -05-RM7800L-M.25-M-A-UL/CSD-1
BURNER SERIESJB JB SERIES
FGR or NOx CONEUSED XNOT USED BLANK
HEAD SIZE (INCHES)JB JBX
1 7 1/8 7 1/22 9 1/8 9 1/23 11 1/8 11 1/2
FUELSG GasO OilC Gas / Oil
BLOWER MOTOR HORSEPOWER
02 1/403 1/305 1/207 3/410 115 1 1/220 230 350 575 7 1/2100
10
FLAME SAFEGUARDVENDOR DESIGNATION
RM7800L Honeywell M Mark AutoFlame - mini mark
E110/EP170 FireyeNexus FireyeLMV51 SiemensLMV52 Siemens
CODES AND LISTINGS
ULULcCSD-1FMIRINFPA-85
OIL SYSTEMSPressure Atomizing
A On - OffL Low Fire StartH Low - Hi - LowMP Modulation
SimplexMR Modulation By-Pass
Air or Steam AtomizationMA Air AtomizationMS Steam
Atomization
GAS TRAIN VENDORVGD SiemensVGG SiemensM Maxon
Blank All Others (ASCO) - (std)
GAS TRAIN SIZE.15 1 1/2 inches.20 2 inches.25 2 1/2 inches.30 3
inches.40 4 inches
GAS SYSTEMA On-OffL Low Fire StartH Low-Hi-LowM Modulation
The above represents the common model designations. Contact the
factory for other options and special applications.
Page 5 IdentificationJB Manual
-
(1) STANDARD UL EQUIPMENTAND IMPORTANT OPTIONS
Fuel Burned
STANDARD UL EQUIPMENTAND IMPORTANT OPTIONS
Fuel Burned
Gas
No.
2 O
il pr
essu
re
atom
ized
Gas
No.
2 O
il pr
essu
re
atom
ized
Gen
eral
Motor, Fan and Air Inlet Control X X
Gas
Fue
l
Main Manual Shutoff Valve X
Air Flow Switch (also with oil sys-tems using remote pump) X
Main Safety Shutoff Valve X
(2) Burner Mounted Control Panel,Switch and Indicator Lights
X X Second Safety Shutoff Valve X
Flame Safety Control X X Main Gas Regulator X
Ultra Violet Scanner X X Gas Checking Valve X
Motor Controller (single phase voltage) X X
High and Low Gas Pressure Switches (st’d over 2500 MBH) Opt.
Fuel Selector Switch Duel Fuel Burners Only Metering Valve
(modulation only) X
Igni
tion
Proven Gas Pilot Ignition X
Oil
Fuel
Oil Drawer Assembly with Diffuser 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 Main Safety Shutoff Valve X
Direct Spark Oil Ignition X Second Safety Shutoff Valve X
Direct Spark Oil Ignition Transformer X
Low Oil Pressure Switch (STD when using remote oil pump)
Opt.
Opt
iona
l
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 Opt.
Fuel Metering CAM-NETIC II X X
1. The configuration of each unit will vary with specific job
requirements such as input rating, electrical specification and
special agency approvalcodes. 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 forHeat”, “Ignition On”, and “Fuel On” for circuit board
light panels.
Model JB1 - Sizing and Application Data (contact Webster for
complete information)Model
NumberMaximum Furnace Pressure
Burner Firing Capability Range
Burner Motor HP Gas Train Oil Pump Motor HPGas Only
HP(3) Oil or
CombinationPipe Size (4) Inlet Pressure
Gas scfh #2 Oil gph 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. Usethe 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 LandisControl System
- ON-OFF, Low Fire Start, Low-High-Low, Modulation,
Posi-ControlRequired Options - Mounting plate, limit controls,
etc.
Model JB1 - Specification Data (400 - 2500 MBH Input)
Page 6 SpecificationJB Manual
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Page 7 Specifi cationJB Manual
Model JB1 - Dimentional Data (400 - 2500 MBH Input)
9 1/2 24 5 5/16
1015
11 7/16
21 7/8
18 3/8
26 5/8 4
8 1/4
15 11/16
36 15/16 4
19 3/8 7 1/4 O.D.
36 15/16
4 14 3/8
11 3/8
18 3/8
Standard ArrangementElevation
Standard ArrangementEnd View
Standard ArrangementElevation
W/ Optional Back Mount Control Cabinet
Inverted ArrangementElevation(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 specifi c requirements of IRI, FM, GE GAP,
NFPA, MIL spec. or other special insurance or local code
requirements.
(Dimensions are +/- 1/4 inch)
-
(1) STANDARD UL EQUIPMENTAND IMPORTANT OPTIONS G
as
No. 2 OilSTANDARD UL EQUIPMENTAND IMPORTANT OPTIONS G
as
No. 2 Oil
Pre
ssur
e A
tom
ized
Air
Ato
miz
ed
Pre
ssur
e A
tom
ized
Air
Ato
miz
ed
Gen
eral
Motor, Fan and Air Inlet Control X X X
Gas
Fue
l
Main Manual Shutoff Valve X
Air Flow Switch X 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) X
Motor Starter w/Overloads (3 PH volt) X X X Normally Open Vent
Valve Opt.
Fuel Selector Switch Duel Fuel Burners Only
Igni
tion
Proven Gas Pilot Ignition X X
Oil
Fuel
Oil Drawer Assembly with Diffuser X X
JB2-30 and JB2-50 X X X Oil Nozzles X X
Pilot Solenoid Gas Valve X X Integral Oil Pump (JB2-07 to
JB2-20) X
Pilot Gas Regulator & Manual Valve X X Remote Oil Pump
(JB2-30 to JB2-50) X Opt.
Pilot Gas Ignition Transformer X X Two Safety Shutoff Valves X
X
Direct Spark Oil Ignition (3) Low Air Atomizing Switch X
Direct Spark Oil Ignition Transformer (3)
Low Oil Pressure Switch (STD when using remote oil pump) X X
Opt
ions
Inverted Housing X X X Oil Pressure Gauge X X
Alternate Control Cabinet Positioning X X X
Oil Metering Valve (modulating system) X X
Remote Control Panel X X X Future Gas Combustion Head Opt.
Opt.
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”, “IgnitionOn”, 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
NumberMaximum Furnace Pressure
Burner FiringCapability Range
Burner Motor
HP
Gas Train Oil Pump Motor HP AirCompressor
Motor HPPipe Size (3) Inlet Press (in wc) Pressure
AtomizingAir
AtomizingGas scfh #2 Oil gph LFS, LHL Modulation
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 2JB2-30 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 follow-ing 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 LandisControl System
- ON-OFF, Low Fire Start, Low High Low, Modulation, Posi-Control.
Required Options - Mounting plate, limit controls, etc.
Model JB2 - Specification Data (6000 MBH Maximum Input)
Page 8 SpecificationJB Manual
-
Page 9 Specifi cationJB Manual
Model JB2 - Dimensional Data (6000 MBH Maximum Input)
6 1/2 24 5 5/16
1015
17 3/4
30 11/16
19 1/16
28 5/8 4
9 1/2
19
39 1/4 4
19 1/2 9 1/8O.D.
39 1/4414
12 1/8
18 1/2
Standard ArrangementElevationStandard Arrangement
End View
Standard ArrangementElevation
W/ Optional Back Mount Control Cabinet
Inverted ArrangementElevation
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 spe-cifi c requirements of IRI, FM, GE GAP,
NFPA, MIL spec. or other special insurance or local code
requirements.
(Dimensions are +/- 1/4 inch)
-
(1) STANDARD ULEQUIPMENT
AND IMPORTANT OPTIONS
Gas
No. 2 Oil
No.
4 -
6 O
il A
ir A
tom
ized
STANDARD UL EQUIPMENTAND IMPORTANT OPTIONS G
as
No. 2 Oil
N0.
4 -
6 O
il A
ir A
tom
ized
Pre
ssur
e At
omiz
ed
Air
Atom
ized
Pre
ssur
e At
omiz
ed
Air
Atom
ized
Gen
eral
Motor, Fan and Air Inlet Control X X X X
Gas
Fue
l
Main Manual Shutoff Valve X
Air Flow Switch X X X X Main Safety Shutoff Valve X
(2) Burner Mounted Control Panel,Switch and Four Indicator
Lights X X X X
Second Safety Shutoff Valve X
Main Gas Regulator X
Flame Safety Control X X X X Gas Checking Valve X
Ultra Violet Scanner X X X X High and Low Gas Pressure Switches
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
Igni
tion
Proven Gas Pilot Ignition X X X
Oil
Fuel
Oil Drawer Assembly with Diffuser X X X
Pilot Solenoid Gas Valve X X X Oil Nozzles X X X
Pilot Gas Regulator & Manual Valve X X X Oil Heater with
Integral Thermostat X
Pilot Gas Ignition Transformer X X X Remote Oil Pump X Opt.
Opt.
Two Safety Shutoff Valves X X X
High Oil Temperature Switch X
Low Air Atomizing Switch X
Opt
ions
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
NumberMaximum Furnace Pressure
Burner Firing Capability Range Burner Motor
HP
Gas Train #2 Oil Pump Motor HP #4 - 6Pump
Motor HP
AirCompressor
Motor HPPipeSize
InletPress
Pressure Atomizing
AirAtomizing
Gas scfh #2 Oil gph
#4-6 Oil gph
JB3-30 3.5 1400 / 6300 10.2 / 45 10 / 42 3 2 1/2” 12 / 27” 1
Optional Optional 2
JB3-50 3.5 1400 / 8300 11 / 59.2 10 / 55.3 5 3” 15 / 27” 1 1/2
Optional Optional 2
JB3-75 3.5 1600 / 10500 12.3 / 75 11 / 70 7 1/2 3” 23 / 27” 1
Optional Optional 2
JB3-100 3.5 1800 / 12600 20.3 / 90 12 / 84 10 3” 2-5 psi 1
Optional Optional 2
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 follow-ing 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 LandisControl System
- ON-OFF, Low Fire Start, Low High Low, Modulation,
Posi-ControlRequired Options - Mounting plate, operating controls,
limit controls, etc.
Model JB3 - Specification Data (12,600 MBH Maximum Input)
Page 10 SpecificationJB Manual
-
Page 11 Specifi cationJB Manual
Model JB3 - Dimensional Data (12,600 MBH Maximum Input)
6 1/2 24 5 5/16
1015
16
27
19 15/16
38 1/4 4
15 15/16
22 1/2
Standard ArrangementElevationStandard Arrangement
End View
48 4
22 1/2
11 1/4O.D.
484
19 1/4
14 3/4
19 9/16
Standard ArrangementElevation
W/ Optional Back Mount Control Cabinet
Inverted ArrangementElevation
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
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 spe-cifi c requirements of IRI, FM, GE GAP,
NFPA, MIL spec. or other special insurance or local code
requirements.
(Dimensions are +/- 1/4 inch)
-
B. COMPONENT IDENTIFICATION
Page 12 IdentificationJB Manual
Control Cabinet
Mod Motor
Blower Motor
Drawer Assembly
Light & Switch Panel
Oil Valve
Linkage
Oil Pressure SwitchLouver Box
Control Transformer
Oil Pressure Gauge
Figure B-1JB2 Burner
Oil Fuel Sight Glass
Gas Valve
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.
Figure B-3JB1G Right Side View
Air Flow Switch
Pilot Gas Regulator
Gas Actuator
Gas Pressure GaugeHigh GasPressure Switch
Ignition Transformer
Figure B-2JB1G Left Side View
Pilot Solenoid
Pilot Gas Regulator
Gas Actuator
Gas Valve
Manual Ball Valve
Combustion Head
-
Panel Wiring Terminal Strip
Switch / Light Panel
Combination Flame SafeGuard Base and Circuit Board
Field WiringTerminal Strips
Board to Light Panel Cable
Light Panel Circuit Board Flame SafeGuard
Base
Board to Light Panel Cable
Figure B-4Control PanelCircuit Board Design
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.
Terminal Strip
Control Transformer
Transformer Fuses
Flame Safeguard
Burner Motor Starter
Control Relays
Switch / Light Panel
Figure B-5Control PanelHard Wired Design
Page 13 IdentificationJB Manual
Electric Motor
Belt Guard
Air Chamber
Air Discharge Connection
Compressor
Air Filter
Pressure Gauge
Figure B-6Air Compressor
-
Page 14 IdentificationJB Manual
Figure B-8JB Combustion Head - Dual Fuel
Choke ConeJB1 & JB2 Only
Primary Gas Orifices(Behind Retention Plate)
Diffuser Assembly
Retention Plate
Oil Nozzle(s)
Gas Pilot
Secondary Gas Orifices
Blower Motor
Drawer Assembly
Air InletLouver Box
Supply Oil Press. Gauge
Jack ShaftOil Cam
Figure B-7JB Burner
#4 - 6 Fuel Oil
Electrical Junction Box
High Oil Temp. Switch
Low AtomizingAir Press. Sw.
Atomizing Air Bleed Muffler
Atomizing Air Press. Gauge
Trim Heater Safety Relief Valve
Oil Supply To Nozzle
Nozzle Oil Press. Gauge
Low Oil Press. SwitchSafety Oil
Valves
Oil Temp. Gauge
N.O. ReturnOil Valve
Thermostat Control Switch & Cold Oil Interlock Switch
Drawer Assm. Pre-heat Oil Lines
Oil Metering Valve
Atomizing Line to Nozzle
Trim Heater
Air Bleed Valve
-
Figure B-10JB3 Combination or Straight Oil Drawer Assembly
with Proven Gas Pilot
Oil Nozzle(s)
Diffuser
Gas PilotPilot Gas Supply Line
To Oil System Return
Back Mounting Plate w/View Port
Oil Supply Line(lower pipe)
Pilot Gas Supply Ignition Electrode
Oil Nozzle(s) Adapter
Diffuser Mounting Bracket
Oil Return Line
Oil Supply Line
Figure B-11JB1 & 2 Combination Drawer Assembly
with Proven Gas Pilot Ignition
Oil Nozzle(s) Adapter
Diffuser
Pilot Gas Inlet
View Port
Oil Supply Line
Backplate
Gas PilotIgnition Electrode
Pilot Gas LineOil Supply Line
Oil Nozzle(s)
Sight Tube
Page 15 IdentificationJB Manual
Figure B-9Standard Head Arrangement
Section View
Drawer Assembly
Gas Manifold (inner cylinder)
Gas Inlet
Ignition Electrode
Pilot Assembly
This connection between the retention plate as-sembly and the
gas manifold inner cylinder must be properly made for proper
performance.
Primary Gas Orifice
Orifice PlateSecondary Gas Orifices
Retention Plate Assembly
Gas Manifold
Nose Choke Cone
Mounting Flange
Retention plate Assembly
Diffuser
-
Page 16 IdentificationJB Manual
Figure B-12JB1 & 2 Straight #2 Oil Drawer Assembly
with Direct Spark Ignition
Diffuser
Oil Nozzle(s) Adapter
View Port
Oil Supply Line
Back Plate
Oil Ignition Electrodes
Diffuser Clamp
Oil Supply Line
Oil Nozzle(s)
Sight Tube
Gas Orifice Part Number and DescriptionPart No. Description
Sketch
ExampleVessel
090002 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 FB
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 FB, SF
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
SF
090319 Orifice extention, 5/16” OD brass tube, 2.75” long D
OT (open tube) 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.
FB = FireboxSF = Scotch Firetube
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.
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.
2 Radial Holes
2 Radial Holes, No Axial Holes
Orifice Example “B”
The threads run the full length of the orifice. This orifice
cannot have radial holes.
Orifice Example “E”No Radial Holes, 1 Axial Hole
1 Axial Hole4 Radial Holes
4 Radial Holes, Axial Hole -xxxOrifice Example “A”
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Page 17 InstallationJB Manual
C. INSTALLATIONPrior to installing the burner, the site
conditions and utili-ties need to be evalulated. This section
provides some general questions that can help the review process.
In-spect 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 theneeded air
for safe combustion as required by your localregulatory agency?2.
If a burner mounting plate is required, is it availableand does it
meet specifications? (See Section E)3. Is 120-60-1 voltage
available for the control circuitand is the correct voltage
available for the blower motoras well for the remote oil pump set
and air compressor,if used?4. Will the burner properly fit the
boiler or heater withample clearance on top, bottom and sides?5. If
a gas burner, will there be adequate gas pressure toassure the
specified firing rate?6. If a straight oil burner with gas pilot,
is gas available atthe burner location?7. If an oil burner, what is
the age and condition of theoil tank(s) and will there be special
piping arrangementsneeded to deliver the oil to the
burner?Important Note: The JB series burners must be oper-ated with
a two-pipe system.8. If an oil burner, what grade of fuel oil is in
the tank(s) oron order? If a retrofit installation, has the same
oil gradealways been used? Does it meet the grade specified onthe
burner’s UL rating plate?
CAUTIONThe 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 GAS-OLINE OR TOXIC CONTAMINANTS.
9. Is there adequate flue provisions to assure SAFE andproper
venting of the burner?10. All manuals should be reviewed and
understood andstored in a convenient place.11. Teflon tape should
not be used on any field piping.12. Rope gaskets should be used
between vessel andmounting plate, and between mounting plate and
burn-er.13. Gas piping should be flushed (cleaned) prior to use.14.
Check minimum straight lengths for gas pressure
regulator and/or sensing line.15. Oil piping to be flushed
(cleaned) prior to use.16. Check pump suction pressure (max 10” Hg)
or maxpress (3 psig) if transfer pump is used or tank elevation
ishigher than the pump.17. Strainer before oil pump, sized for max
pump suctioncapacity.18. If FGR is used, does it follow Webster
guidelines. (seeaddendum 950064)19. If multiple vessels connect to
a single stack, are theysized and designed to maintain +/- 0.1” wc
draft at the ves-sel outlet under all operating conditions.20. Is
stack designed to maintain +/- 0.1” wc at outlet duringall
operating conditions.
WARNINGDO 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 sealedwith rope
gasket? (See Figure E-2)22. Has the new gas and oil piping been
purged to removedebris?23. Is there a drop leg in the gas supply to
capture foreignmaterial? (See Figure C-1)24. Is the piping between
the gas train and burner done ina 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
thecenter-line height of the burner head adequate? (Seecharts C-2
& C-3.)
-
Page 18 Installation / Canadian InstallationsJB Manual
Drip Leg
Manual Gas Shutoff Valve
Gas Pressure Regulator
Low Gas Pressure Switch
ShutoffValve
ShutoffValve
High Gas Pressure Switch
Normally open vent valve
Leak Test Valve
Pilot GasPressureRegulator
Pilot Solenoid Valve
Pilot Shutoff Valve
Figure C-1Typical Gas Piping
Gas Supply
Burner
If applicable, Webster supplied gas train
D. SPECIAL INSTRUCTIONS FOR CANADIAN INSTALLATIONS1. The
installation of a burner shall be in accordance withthe regulations
of the provincial installation requirements,or in their absence,
the following shall govern:
Gas Burners--CGAB149.1 and CGAB149.2Oil Burners--CSA Standard
B139
Authorities having jurisdiction should be consulted before
installations are made.
2. All electrical wiring shall be done in accordance with
Chart C-2 Chart C-3
FUR
NA
CE
DIA
ME
TER
- I
NC
HE
S
Width
Height - Floor to Center of Burner
Length
Length
Diameter
TYPICAL COMBUSTION CHAMBER SIZE FOR FIREBOX BOILERS, WATERTUBE
&
CAST IRON SECTIONAL TYPES
TYPICAL COMBUSTION CHAMBER SIZE FOR SCOTCH MARINE FIRETUBE
BOILERS
the Canadian Electrical Code, Part I.
3. The installer shall identify (label) the main electricalpower
disconnect and the manual shut-off valve on thegas and/or oil
supply drop-line to the burner.
4. Oil and gas burning equipment shall be connected tofl ues
having suffi cient draft at all times, to assure safeand proper
operation of the burner.
-
Page 19 Burner Mounting CriteriaJB Manual
E. BURNER MOUNTING CRITERIAIt is of vital importance that the
burner be properly mounted to the boiler or appliance being fi red.
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 FRONTPLATEB - Bolt
Circle
A - Opening
Minimum of six (6) holes for boiler mtg. studs, 1/2” or
larger
Minimum 7 gauge
Dimensions - Inches MODEL DIM. A DIM. B
JB1 7 5/8 10 3/4JB2 9 5/8 12 3/4JB3 11 5/8 14 3/4
4”
30o to 45o taper, see note 4
2” Minimum
2” Minimum
A
Minimum 14 Gauge
ASee Note 3
Use minimum of four (4) 1/2” studs with lugs.
Refractory OD is sized to fi t vessel opening with 1/4” to 1/2”
gap, Refractory must extend 2” beyond tube sheet for scotch
boilers.Figure E-1
Refractory Dimension
Note: For JB burners equipped with a low NOx cone, refer to
ad-dendum number 950064
Contact Webster for more detailed refractory drawings
The burner must be level
Pipe support requiredFlange secured to fl oor
The gas piping from the burner to the train should have as few
elbows as pos-sible to reduce presure drop.
Attachment to vessel varies with manu-facturer (follow vessel
manufacturers recommendation.
If gap is over 3/16”, wrap burner nose with high tempera-ture
ceramic insulat-ing rope.
Tighten clamp bolts uniformly - check after fi ring for several
hours
Fiberglas rope gasket must be coiled to cover the full mounting
fl ange surface
This surface must be sealed against the vessel. Check vessel
mounting requirements
Fill voids be-tween front plate and vessel with ceramic blanket
4” deep or as defi ned by vessel manufacturer.
RefractoryFront Plate
Figure E-2Burner Mounting Instruction
-
Page 20 Fuel SystemsJB Manual
F. FUEL SYSTEMSThe 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 per-sonnel 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.
NOTERefer to the bulletins included in the manufacturer’s data
section of the burner instructions manual for items shown
below.
1. Pressure atomized oil systems
“A” - On - Off
Field Piped
Check Valve
Suction Supply Line
Shutoff Valve
By Others
StrainerCheckValve
Gauge Port
Oil Pump
Adjustment
Return to Tank (No Manual Valves
in this line)
Main OilSolenoid Valve
Oil Nozzle
Safety Oil Solenoid Valve
By OthersUnless Specified on Order
Notes & Options
These Lines are Field Piped if a Remote Pump is Used
1
1
1
“L” - Low Fire Start or “H” - Low - Hi - Low
Shutoff ValveCheckValve
Field Piped
Strainer
By OthersUnless Specified on Order
Suction Supply Line
Return to Tank (No Manual Valves
in this line)
Check Valve
By Others
Main OilSolenoid
Valve
Oil Nozzle
Safety Oil Solenoid Valve
Gauge Port
Oil Pump
Adjustment
1
1
2
High Fire Cylinder Louver Actuator
Low Fire Bypass Regulator (Adjustment for Low Fire Approx. 100 -
125 PSI)
N.O. Low Fire Bypass Oil Valve
Low Oil Press. Sw
.
2 or 3 1 (IN) (out)
Notes & Options
These Lines are Field Piped if a Remote Pump is Used
Required Above 20 GPH if a Remote Pump is Used
1
ININ
Field Piped
2
-
Page 21 Fuel SystemsJB Manual
Field Piped
Suction Supply Line
Check Valve
Shutoff Valve Strainer
Check Valve
By Others
Return to Tank, (No Manual
Valves in this Line)
Oil Metering Valve
11
1
Low Oil Pressure Switch
2
Main Oil Solenoid Valve
Safety Oil Solenoid Valve
Oil NozzleGauge Port
Adjustment
Oil Pump
By Others(Unless Specified on Order)
Notes & Options
These Lines are Field Piped if a Remote Pump is Used
Usage RequirementVaries with Code
2
1
“MP” - Modulating Simplex Nozzle
Strainer
Back Pressure Reg. Valve
Low Oil Press. Sw
.Pressure Gauge Main Oil
Solenoid Valve
Safety Oil Solenoid Valve
2
Oil Nozzle (Bypassing)
InlineCheckValve
Gauge Port
Oil PumpCheckValve
ShutoffValve
Suction Supply Line
CheckValve
Field Piped
Return to Tank(No Manual
Valves in this Line
By Others(Unless Specified in Order) Pressure
GaugeOil Metering Valve
CheckValve
1
1
1
Notes & Options
These Lines are Field Piped if a Remote Pump is Used
Required Above 20 GPH if a Remote Pump is Used
1
2
“MR” - Modulating Return Flow Nozzles
-
Page 22 Fuel SystemsJB Manual
Pressure Reducing
Valve
300 lb. Gauge
SteamSyphon
Ball or Gate Valve Steam
Strainer125 PSIG
Max.Atomizing
Steam
Condensate Return
SteamTrap
Ball or Gate Valve
Field PipedDrip Leg
Metering Lever Ball Valve Linked
to Mod. Motor
N.CAtomizing Valve
Low Atomizing Pressure Switch
SteamSyphon
CheckValve
SteamSyphon
Gauge
“MA” or “MS” - Modulating House Air or Steam
NOTE: House air does not use steam Syphon or Steam Trap
Air Filter
Ball Valve (man. set to adjust air volume & high fire air
pressure)
Relief Valve
Compressor
Pressure Gauge
Air Chamber
Air pipe same as discharge open-
ing in air chamber (field piped)
Low Air Press Sw
CheckValve
Air Gauge
Nozzle
Oil Preheat Housing
Flexible Metal Hoses or Copper Tubing
Oil GaugeBall
ValveSafety
Oil ValveN.C. Main Oil Valve
OilMetering
Valve
Thermometer
High Oil Temp. Sw.
1 1Low Oil
Temp. Sw.
N.O. Return Oil Valve
BallValve
Oil Supply for Preheat Housing
1/4” Ball Valve
1/4” Ball Valve
Oil Return from Preheat Housing
Return to Tank
CheckValve
Ball or Gate Valve
Plug Opening
GaugeRelief Valve Back
Pressure Valve
Ball or Gate Valve
Oil Supply Heating System Check
Valve
Relief Valve Gauge
Compound Gauge
StrainerCheck Valve
Gate Valve
OilSuction
Field Piped
Oil PumpBall or
Gate 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.
High Oil Temp. Sw.
1 1Low Oil
Temp. Sw.
Electric oil heater w/integral low oil temp. switch
Drain
“MA” - Modulating #4 - 6 Oil
2. Air Atomized Oil Systems
Field Piped
Compressor
SafetyValveAir Filter
Ball Valve(man. set to adjust air volume & high fire air
pressure)
Pressure Gauge
LowAtomizingPressure
Air pipe same size as discharge open-ing in air chamber
(field Piped) Check Valve
GaugeNozzle
Ball Valve
Oil Gauge Flexible Metal Hoses or
Copper Tubing
N.C. Main Oil
Valve
Safety Oil
Valve
Oil Metering
Valve
GaugeLow Oil
Pressure
Relief Valve
Ball or Gate Valve
Compound GaugeGauge
Oil Pump
Check Valve
Return to Tank
Oil Suction
Check Valve
Gate Valve
Strainer
“MA” - Modulating #2 Oil
Field Piped
AirChamber
-
3. Gas SystemsIllustrated Gas Trains by Capacity and Code: The
following illustrations show the Webster confi guration for UL, FM
and IRI as grouped by UL capacity ratings. Refer to the legend
below for component part identifi cation. These illustrations are
not to be used for fi eld erection and/or system design
purposes.
Page 23 Fuel SystemsJB Manual
UL Capacity Range BTU/Hr.
Operation Mode WebsterDesignation
Code IllustrationUL / GE
GAPFM
To 2,500,000
On-Off A X X 722091Low Fire Start L X X 722001Low Hi Low H X X
722022Modulating M X X 722003
2,500,001to
5,000,000
Low Fire Start L X 722002Low Fire Start L X 722009Low Hi Low H X
722023Low Hi Low H X 722024Modulating M X 722004Modulation M X
722010
5,000,001to 12,500,000
Modulating M X 722005Modulating M X 722011
12,500,001and Up
Modulating M X 722082Modulating M X 722084
NOTE: Pressure Drops; Pressure drop through a given gas train
will vary somewhat in relation to the individual items used, the
specifi c gravity of the gas to be burned and the overall
length.
Field Piped
Pilot Manual Ball Valve
Pilot Gas Pressure Regulator
Pilot Solenoid Valve
Gas Pilot Ignitor
Gas Burner Manifold
Manual Ball Valve
Manual Ball Valve
Vent To Outside Atmosphere
ManualTest Valve
Gas Supply
UL-FM On-Off Gas Piping Diagram - Up to 2,500 MBH Firing Rate
1/2 PSI Max
Manual TestValve
S
S
TestConnection
Gas Pressure Regulator
Main Diaphragm Gas Valve
Main Solenoid Gas Valve
D
Field Piped
722091
722091
-
Page 24 Fuel SystemsJB Manual
Field Piped
Pilot Manual Ball Valve
Pilot Gas Pressure Regulator
Pilot Solenoid Valve
Gas Pilot Ignitor
Gas Burner Manifold
Manual Ball Valve
Main Motorized Gas Valve
26 Sec.Main Solenoid
Gas Valve
FieldPiped
Manual Ball Valve
Gas PressureRegulator
ManualTest Valve
Gas Supply
UL-FM Low Fire Start Gas Piping Diagram - Up to 2,500 MBH Firing
Rate
S
S
M
TestConnection
Manual Test Valve
Vent To Outside Atmosphere
722001
722001
Field Piped
Pilot Manual Ball Valve
Pilot Gas Pressure Regulator
Pilot Solenoid Valve
Gas Pilot Ignitor
Gas Burner Manifold
Manual Ball Valve
FieldPiped
Manual Ball Valve
Vent To Outside Atmosphere
ManualTest Valve
Gas Supply
UL-FM Low-Hi-Low Gas Piping Diagram - Up to 2,500 MBH Firing
Rate
M
Manual TestValve
S
S
TestConnection
Gas Pressure Regulator
Main Motorized Gas Valve
26 Sec.Main Solenoid
Gas Valve
722022
722022
Field Piped
Pilot Manual Ball Valve
Pilot Gas Pressure Regulator
Pilot Solenoid Valve
Gas Pilot Ignitor
Gas Burner Manifold
Fuel Flow Control Valve
Main Motorized Gas Valve
26 Sec.Main Solenoid
Gas Valve
Field Piped
Manual Ball Valve
Vent To Outside Atmosphere
Manual TestValve
Gas Supply
UL-FM Modulation Gas Piping Diagram - Up to 2,500 MBH Firing
Rate
M
ManualTest Valve
S
S
TestConnection
Gas Pressure Regulator
ManualBall Valve
722003
722003
Field Piped
Pilot Manual Ball Valve
Pilot Gas Pressure Regulator
Pilot Solenoid Valve
Gas Pilot Ignitor
Gas Burner Manifold
Manual Ball Valve
Main Motorized Gas Valve
26 Sec.Main Solenoid Gas Valve
Field Piped
Manual Ball Valve
Vent To Outside Atmosphere
Manual Test Valve
Gas Supply
UL Low Fire Start Gas Piping Diagram - 2,501 to 5,000 MBH Firing
Rate
Field-Piped
Vent
HM
ManualTest
Valve
SL
S
TestConnection
Gas Pressure Regulator
Main Reset Low Gas Pressure
Switch
Main Reset High Gas Pressure
Switch
722002
722002
-
Page 25 Fuel SystemsJB Manual
Field Piped
Pilot Manual Ball Valve
Pilot Gas Pressure Regulator
Pilot Solenoid Valve
Gas Pilot Ignitor
Gas Burner Manifold
Manual Ball Valve
Main Motorized Gas Valve
26 Sec.
Man Reset Low Gas Pressure
Switch
FieldPipedManual Ball
Valve
Vent To Outside Atmosphere
Manual TestValve
Gas Supply
FM Low Fire Start Gas Piping Diagram - 2,501 to 5,000 MBH Firing
Rate
M
ManualTest Valve
M
S
TestConnection
Gas Pressure Regulator
L H
Main Motorized Gas Valve
14 Sec.
Man Reset High Gas Pressure
SwitchVent
Field Piped
722009
722009
Field Piped
Pilot Manual Ball Valve
Pilot Gas Pressure Regulator
Pilot Solenoid Valve
Gas Pilot Ignitor
Gas Burner Manifold
Manual Ball Valve
FieldPiped
Manual Ball Valve
Vent To Outside Atmosphere
ManualTest Valve
Gas Supply
UL Low-Hi-Low Gas Piping Diagram - 2,501 to 5,000 MBH Firing
Rate
M
Manual TestValve
S
S
TestConnection
Gas Pressure Regulator Main Motorized
Gas Valve26 Sec.
Main Solenoid Gas Valve
HFieldPiped
Vent
Man Reset High Gas Pressure Switch
L
Man Reset Low Gas Pressure Switch
722023
722023
Field Piped
Pilot Manual Ball Valve
Pilot Gas Pressure Regulator
Pilot Solenoid Valve
Gas Pilot Ignitor
Gas Burner Manifold
Manual Ball Valve
FieldPiped
Manual Ball Valve
Vent To Outside Atmosphere
ManualTest Valve
Gas Supply
FM Low-Hi-Low Gas Piping Diagram - 2,501 to 5,000 MBH Firing
Rate
M
Manual TestValve
M
S
TestConnection
Gas Pressure Regulator Main Motorized
Gas Valve26 Sec.
Main Motorized Gas Valve
14 sec.
HFieldPiped
Vent
Man Reset High Gas Pressure Switch
L
Man Reset Low Gas Pressure Switch
7722024
722024
Field PipedPilot Manual
Ball Valve
Pilot Gas Pressure Regulator
Pilot Solenoid Valve
Gas Pilot Ignitor
Gas Burner Manifold
Fuel Flow Control Valve
Main Motorized Gas Valve
26 Sec.
Man Reset Low Gas Pressure
Switch
Field Piped
Manual Ball Valve
Vent To Outside Atmosphere
Manual TestValve
Gas Supply
UL Modulation Gas Piping Diagram - 2,501 to 5,000 MBH Firing
Rate
M
ManualTest Valve
S
S
TestConnection
Gas Pressure Regulator
ManualBall ValveL H
Main Solenoid Gas Valve
Man Reset High Gas Pressure
Switch
Vent
722004
722004
-
Page 26 Fuel SystemsJB Manual
Field Piped
Pilot Manual Ball Valve
Pilot Gas Pressure Regulator
Pilot Solenoid Valve
Gas Pilot Ignitor
Gas Burner Manifold
Fuel Flow Control Valve
Man Reset High Pressure
Switch
Man Reset Low Gas Pressure
Switch
Field Piped
Manual Ball Valve
Vent To Outside Atmosphere
Manual TestValve
Gas Supply
FM Modulation Gas Piping Diagram - 2,501 to 5,000 MBH Firing
Rate
M
Manual Ball Valve
M
S
TestConnection
Gas Pressure Regulator
L H
Main Motorized Gas Valve
26 Sec.
Vent
Manual Test Valve
Main Mortorized Gas Valve
14 Sec.
722010
722010
Field Piped
Pilot Manual Ball Valve
Pilot Gas Pressure Regulator
Pilot Solenoid Valve
Gas Pilot Ignitor
Gas Burner Manifold
Fuel Flow Control Valve
Main Motorized Gas Valve
W/POC26 Sec.
Man Reset Low Gas Pressure
Switch
Field Piped
Manual Ball Valve
Vent To Outside Atmosphere
Manual TestValve
Gas Supply
UL Modulation Gas Piping Diagram - 5,001 to 12,500 MBH Firing
Rate
M
ManualTest Valve
S
S
TestConnection
Gas Pressure Regulator
ManualBall ValveL H
Main Solenoid Gas Valve
Man Reset High Gas Pressure
Switch
Vent
POC
722005
722005
Field Piped
Pilot Manual Ball Valve
Pilot Gas Pressure Regulator
Pilot Solenoid Valve
Gas Pilot Ignitor
Gas Burner Manifold
Fuel Flow Control Valve
Man Reset High Pressure
Switch
Man Reset Low Gas Pressure
Switch
Field Piped
Manual Ball Valve
Vent To Outside Atmosphere
Manual TestValve
Gas Supply
FM Modulation Gas Piping Diagram - 5,001 to 12,500 MBH Firing
Rate
M
Manual Ball Valve
M
S
TestConnection
Gas Pressure Regulator
L H
Main Motorized Gas ValveW/ POC26 Sec.
Vent
Manual Test Valve
Main Motorized Gas Valve
14 Sec.
POC
722011
722011
Field Piped
Pilot Manual Ball Valve
Pilot Gas Pressure Regulator
Pilot Solenoid Valve
Gas Pilot Ignitor
Gas Burner Manifold
Manual Ball Valve
Manual Ball Valve
Vent To Outside Atmosphere
ManualTest Valve
Gas Supply
UL Modulation Gas Piping Diagram - Over 12,500 MBH Firing
Rate
Manual TestValve
S
S
TestConnection
Gas Pressure Regulator
Main Motorized Gas Valve
W/POC 14 sec.
Main Solenoid Gas Valve
M
Field Piped
722082
Fuel Flow ControlValve
Man Reset High Gas Pressure
Switch
Vent
H
POC
Vent
L
Man Reset Low Gas Pressure Switch
S
Normally Open Vent Valve
722082
-
Page 27 Fuel SystemsJB Manual
Field Piped
Pilot Manual Ball Valve
Pilot Gas Pressure Regulator
Pilot Solenoid Valve
Gas Pilot Ignitor
Gas Burner Manifold
Manual Ball Valve
Manual Ball Valve
Vent To Outside Atmosphere
ManualTest Valve
Gas Supply
FM Modulation Gas Piping Diagram - Over 12,500 MBH Firing
Rate
Manual TestValve
M
S
TestConnection
Gas Pressure Regulator
Main Motorized Gas Valve
W/POC 14 sec.
Main Motorized Gas Valve
W/POC - 14 sec.
M
Field Piped
722084
Fuel Flow ControlValve
Man Reset High Gas Pressure
Switch
Vent
H
POC
Vent
L
Man Reset Low Gas Pressure Switch
S
Normally Open Vent Valve
POC
722084
-
Page 28 Initial Settings JB Manual
G. INITIAL SETTINGSThe burner will be set at the factory for
normal ini-tial settings. These are only rough settings that must
be adjusted at startup to match the furnace, fuel pressure and
environment of the specifi c ap-plication. 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 positionThe oil nozzle initial position is shown
in FigureG-2. The oil nozzle will be adjusted at start-upand may be
moved in or out from this initial set-ting. In some cases, the oil
nozzle may be insidethe diffuser
PRESSURE ATOMIZED NOZZLE AIR ATOMIZED NOZZLEModel Diffuser
I.D.Qty. Spray
AngleDimension
InchesDiffuser
I.D.Nozzle Type
Spray Angle
Dim. A
Dim. B
JB1 1 1/2”2
30 3/8
NA NA NA NA NA45 1/4
130 7/845 3/4
JB21 3/4” 2
30 3/42” Single Port 60
o 1/4” NA45 5/860 1/2
JB3 2 1/2” 3 60 5/8 2 1/2 Multi Port 80
o NA 3/82 7/8” 3 60 5/8 2 7/8
INNER FIRE CYLINDER
B
Figure G-1Oil Nozzle Position,
Gas Pilot
Chart G-2
Flexible Strip
Cam
Cam Set Screws
Adjusting Screws
Aluminum Strip
End Screws
Spring
End Screw Adjusting Nut
Cam Follower
Retention Plate
Roller Washers
Roller Cam Follower
Return Springs
JackShaft
Figure G-3Fuel Cam Adjustment
High Fire
Position
Low
Fire
Pos
ition
-
COMBUSTION AIR CONTROL
Panel
AdjustingScrew
Air ProvingSwitch
AIR FLOW INTERLOCKING SWITCH
2. AIR PROVING SWITCH
The air proving switch has been adjusted at the factory for an
initial setting. If the switch trips during initial start-up, turn
the adjustment screw ccw two full turns to re-duce the trip
pressure setting.
3. TYPICAL AIR AND FUEL ADJUSTMENT LOCATIONS
4. Fuel Cam Adjustments (if applicable)The fuel cam needs to be
checked for correct traveland alignment. Positions can change
during shipmentand installation and they must be reviewed prior
tostartup. The fuel cams are mounted to the ends of thejackshaft
assembly. A cam follower link follows the profi leestablished by
the adjusting screws and drives the fuelvalve. A thin metal band is
used between the screw andcam follower to provide a smooth profi
le. The adjustingscrews are backed by compressed nylon inserts,
whichprovide a resistance to turning.
The cam (Figure G-3) should be checked for the following
conditions:a. At the low fi re position, the roller should be
betweenthe fi rst two adjusting screws. If not, adjust the
positionof the cam accordingly, making sure to maintain the samelow
fi re fuel valve position.b. When the linkage is modulated from low
to high fi re,the roller must stay in the center of the adjusting
screwswithin 1/8”. If needed, the two cam set screws can beloosened
and the cam moved to center it on the roller.
c. At high fi re, the roller should be between the last
twoadjusting screws.d. The adjusting screws should form a smooth
contourwith no jumps between the screws.e. In preparation of
startup, the retention plate canbe removed temporarily to make it
easier to adjust thescrews.
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.
CAUTIONLINKAGE 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 JB Manual
-
H. IGNITION SYSTEMS
Page 30 Ignition SystemsJB Manual
1. Gas Pilot AssemblyA crucial part of reliable burner operation
is a dependablepilot, which must be properly adjusted and kept
clean. A gaspilot is standard for all models except JB1 through
JB2-20straight oil pressure atomizing burners which have
directspark ignition as standard. The following illustrations
showthe typical confi guration and nominal adjustment parame-ters
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 locat-ed
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 igni-tion and nozzle positions.
These are initial settings and willbe adjusted at start-up.
3. Air Damper PositionOn a straight gas burner, the air damper
should be openabout 1/4” at low fi re and close to full open at
high fi re. In
Figure H-2 JB3 PILOT ASSEMBLYNatural Gas Pressure;4 - 6” wcLP
Gas Pressure;1.5 - 2.5” wc
some applications, the pilot requires an orifi ce in the pilot
gas supply line. With the exception of the JB3, this ori-fi ce 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 fi re and close to full open at high fi re.
4. Gas Modualting Control Valve PositionThe gas valve should be
open about 10% at low fi re andstroked to abput 60% open at high fi
re.
5. Oil Modulatining Control Valve Position.For pressure
atomizing, the low fi re position should beadjusted to get the
correct low fi re presure, as statedon the rating label. Typically,
this would be 100 psi forsimplex systems and 65 psi for return fl
ow nozzles. Thehigh fi re position should be about 45o to 60o
travel fromlow fi re.
For air atomizing, the low fi re should be on about #2 po-sition
and the high fi re should be about the #8 position.
Electrode
PilotElectrode Clamp
Figure H-1JB1 & JB2 Gas Pilot
Spark Gap = 1/16”
Note: Required 2 1/2” - 3” wc pressure for natural gas ans 1/2”
- 2” for LP, as measured at thelast solenoid in the pilot
train.
-
Page 31 Ignition SystemsJB Manual
(2 1/2”) (3 1/2”)
7/8”Figure H-3
Figure H-4
FIGURE H-7 DIMENSION TABLE FOR DIRECT SPARK OIL IGNITION
(Pressure Atomizing)BURNER DATA NOZZLE DATA ADJUSTMENT SETTINGS
(Inches)
Model Diffuser I.D. Qty. Spray Angleo A B C D E
JB1
11 30
1/81/2 1/2
5/16 1/41 45 3/8 3/8
1 1/2”
1 30
1/8 1 1/2
7/8
5/16 1/41 45 3/4
2 30 1/4
2 45 1.4
JB2 1 3/4” 230
1/8 1 1/23/4
5/16 1/445 5/8
60 1/2
JB3 2 7/8 360
1/8 1 1/25/8
3/8 1/880 7/16
DiffuserID
FIGURE H-6TRIPLE NOZZLE
FIGURE H-5 DIRECT SPARK PRESSURE ATOMIZING OIL IGNITION (See
Table Below)
DIRECT SPARK OIL IGNITION (See Table Below)Note: These represent
initial nozzle settings. The final position will be determined in
the start-up process.
-
Page 32 Startup and Operating AdjustmentsJB Manual
1. Pre-start Checkout2. Linkage Adjustments3. Fuel Cam
Adjustments4. FGR Adjustment5. Burner Drawer Adjustments6. Single
Fuel Setups7. Combination Gas and Pressure Atomized Oil8.
Combination Gas and Air Atomized #2 Oil9. Combination Gas and Heavy
Oil10. Gas Setup11. Pressure Atomized Oil Setup12. Air Atomized #2
Oil Setup13. Heavy Oil Setup14. Operating Control Adjustments15.
Limit Tests16. Pilot Test17. Burner Shutdown18. Restart After
Extended Shutdown
This section covers the startup and operating adjustments of the
Webster Models JB and JBX burners.
WARNINGBURNER STARTUP, COMBUSTION ADJUSTMENTS AND LIMIT CONTROLS
ADJUSTMENTS SHOULD ONLY BE PERFORMED BY TRAINED AND EXPE-RIENCED
SERVICE TECHNICIANS. ATTEMPTING TO PERFORM THESE FUNCTIONS WITHOUT
THE PROPER TRAINING AND EXPERIENCE CAN RE-SULT 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 con-trol manuals to verify
that all equipment is ready for opera-tion. 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 refer-ence.
READ AND SAVE THESE INSTRUCTIONS FOR FU-TURE REFERENCE.
1. Pre-Start Check ListBefore starting the burner, a complete
review of the instal-lation, wiring and piping of the burner,
boiler and all sup-porting equipment must be complete and all of
these itemsmust be ready for operation prior to starting. The
followingis a general review:
______All wiring is connected. Test pulls on wire show them to
be tight.
______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 tes-ter 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 pres-sure
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 link-age
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 thevalve, from low to
high fire. Increasing the length of thedrive crank arm (B) or
decreasing the length of the drivencrank arm (C) will increase the
valve travel. To reducevalve travel, decrease B or increase C
(Figure I-1).
I. STARTUP AND OPERATING ADJUSTMENTS
-
B
Low Fire
High Fire
Modulating Range 90o
ADrive Arm
Jackshaft
DrivenArm
D
C
Valve(Air Damper, FGR Valve...)
Linkage Arm
Dim Smaller LargerAngle 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)
b. Decreasing the angle of the drive arm will slow the ini-tial
valve travel (and speed up the travel at high fire). Thiswould be
done to get the air damper to match the fuel valveaction.
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 connec-tions. 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. Turn-ing 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 mustalso be adjusted
to provide a smooth contour from screw toscrew. When complete, the
flexible strip between the adjust-ing screws and the roller must
come in contact with eachscrew, providing a smooth transition from
low fire to highfire.b. The end screws (or nuts) can be adjusted to
hold the stripagainst the screws, but should not deform the
strip.c. There should be no upsets in the profile, where the
flex-
Figure I-1Linkage Adjustments
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
adjust-ment. They can be turned in until they are flush withthe
aluminum bar and adjusted out until the side wash-ers of the roller
contact the aluminum bar.e. If any adjusting screw does not turn
with some re-sistance, the cam must be replaced.f. When the cam
adjustment is complete, the retentionplate 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.
WARNINGIF 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.
CAUTIONLARGE CHANGES FROM ONE ADJUSTING SCREW TO ANOTHER WILL
RESULT IN PREMA-TURE FAILURE OF THE CAM AND MAY PREVENT THE BURNER
FROM OPERATING PROPERLY.
g. If the contour has a sharp rise in the cam screw pro-file,
trying to open the valve very quickly in the first fewscrews, the
linkage should be readjusted to cause theair damper to open slower
(make the jackshaft drivearm more parallel to the linkage rod).
Likewise, the op-posite contour can be corrected by speeding up the
airdamper drive (Figure I-1). The final cam screw profileshould be
close to the profile of the cam with no abruptchanges.
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 quanti-ties 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 be-tween 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
addi-tional controls or adjustments are needed. Burners
Page 33 Startup and Operating AdjustmentsJB Manual
-
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 op-erating
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 op-tional
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 rateon
both fuels. The FGR control valve is set on gas and oilfollows that
setting.• A 30 ppm system uses the FGR limiting
potentiometer(located in the control panel) to obtain a partial
flow of FGRwhen firing oil. The FGR control valve is set when
firinggas. The FGR limiting potentiometer is adjusted to
improvecombustion but not cause instability. The combustion needsto
be checked at several firing rates.• Under 30 ppm, separate gas and
oil operating points areestablished in the modulating motor.
Parallel positioning(linkageless) systems allow all of the valves
to be positionedindependently for each fuel. For this reason, the
setup se-quence can be more flexible.
5. Burner Drawer Adjustments
The burner drawer has several adjustments built into the de-sign
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 se-quence listed to perform
the adjustments.
Before any adjustments are made, the position of each com-ponent
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
ofthe oil gun tube. This dimension, along with the initial
posi-tion will determine the limit of the adjustment. For
example,if the diffuser is 1 inch behind the fire end of the inner
firecylinder, then it can be adjusted in 3/4 inch or out 1/2 inch
tostay within the limits of 1/4 inch to 1 1/2 inch diffuser to
fire
end of the inner fire cylinder dimension.• Loosen the two
setscrews locking the pilot gas lineand gun tube to the backplate.•
Adjust the diffuser by moving the oil gun tube in andout the amount
determined above. When the best posi-tion is found, lock into place
with the two setscrews onthe 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 noz-zle is pulled too far back. The flame may appear goodbut
carbon will quickly develop on the diffuser.• The drawer assembly
must be removed to adjust theoil nozzle to diffuser position.
The burner drawer must be removed for access to com-ponents,
follow the following steps:
a. Disconnect the gas pilot line. Move the pilot line sothe
drawer can be pulled out without interference.b. If equipped with
oil, disconnect the oil line(s), andmove the oil line out of the
way to allow the drawer tobe pulled.c. Loosen and remove the screws
on the burner draw-er.d. Disconnect the ignition cable from the
drawer assem-bly. It is attached with a snap-on fitting.e. Pull the
drawer out, holding the drawer centered inthe opening to prevent it
from hanging up while beingpulled out.f. Disconnect the scanner by
screwing it off of the scan-ner tube. In some cases, the scanner
simply pulls out,with a spring tension. Secure the scanner so that
it isprotected from shock.g. Set the drawer down horizontally, do
not set it on thediffuser as it may flatten some fins or change
positions.
To re-install the burner drawer, simply work the proce-dure in
reverse.
6. Single Fuel Setups
Single fuel burners can be adjusted following the proce-dures
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.
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. Fol-low 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 AdjustmentsJB Manual
-
10, using the air damper positions defined by oil, and
adjust-ing 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 accord-ingly. The procedures
given are for linkage systems. Par-allel 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 posi-tions.
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 con-trols for
both fuels. Air atomized #2 oil firing can have turn-downs 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 po-sitions 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
proce-dures 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 ligh-toff
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 accord-ingly. The procedures
given are for linkage systems. Par-allel 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 posi-tions.
9. Combination Gas and Heavy Oil
Combination burners, firing both gas and oil, require some
compromises in the setup because they share common con-trols for
both fuels. Heavy oil burners cannot operate with
FGR and do not have this adjustment. If the burner does not have
a multiple setpoint modulating motor or link-ageless control, oil
must be set first, as the air damper positions will be determined
by this setup. With the mul-tiple 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 Sec-tion 13 for
air atomized heavy oil setup.
There are several different options available that can al-ter
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 sys-tems. 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 fu-els 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” positionb. Place the
“Auto-Manual” switch in the manual posi-tion, for modulation or low
fire hold, switch in low fire po-sition for Lo-Hi-Lo operation. If
this is a combination fuelburner, make sure the fuel selector
switch is on “GAS”.c. Place the manual flame control potentiometer
in theMIN (low fire) position on modulating units.d. Close the
downstream manual shutoff valve (closestto the burner head) on the
gas train.e. Turn the electrical power on for the burner, boiler
andrelated components.f. Verify that the gas metering valve is
nearly closed, thevent valve (if equipped) is operating and the gas
pilotvalve is not open (the solenoid will hum and feel warm).g. If
equipped with FGR, verify that the FGR controlvalve is in the near
closed position. A linkage systemshould have the shutoff FGR valve
in the closed posi-tion.h. Turn the burner switch on. This will
start the blowermotor and initiate the prepurge cycle.i. When the
prepurge sequence is complete and thelow fire start switch (if
used) is made, the pilot valve willopen and the pilot flame should
be visible through thesight port.j. When the pilot flame is
established, the flame safe-guard will energize the main gas valve
(indicated withthe Fuel Valve Light). This operation of the main
fuelvalves must be visually checked by observing the valvestem
operation.k. After the timer has completed the trial for main
flame,the b