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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

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 .......................................................................................................................

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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.

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

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


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


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)



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.


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)



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



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.


(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


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”.



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.


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)



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



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.


B. COMPONENT IDENTIFICATION


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


Electric Motor

Belt Guard

Air Chamber

Air Discharge Connection

Compressor

Air Filter

Pressure Gauge

Figure B-6Air Compressor

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


Diffuser

Pilot Gas Inlet

View Port

Oil Supply Line

Backplate

Gas PilotIgnition Electrode

Pilot Gas LineOil Supply Line

Oil Nozzle(s)

Sight Tube


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

IdentificationJB Manual

Figure B-12JB1 & 2 Straight #2 Oil Drawer Assembly

with Direct Spark Ignition

Diffuser


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”

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.)

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.

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

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


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


Required Above 20 GPH if a Remote Pump is Used

1

ININ

Field Piped

2


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


Oil NozzleGauge Port

Adjustment

Oil Pump

By Others(Unless Specified on Order)

Notes & Options


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


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


Required Above 20 GPH if a Remote Pump is Used

1

2

“MR” - Modulating Return Flow Nozzles


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


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


Main Diaphragm Gas Valve

Main Solenoid Gas Valve

D

Field Piped

722091

722091


Field Piped




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


722001

722001

Field Piped




Gas Pilot Ignitor

Gas Burner Manifold

Manual Ball Valve

FieldPiped

Manual Ball Valve


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 Valve

722022

722022

Field Piped




Gas Pilot Ignitor

Gas Burner Manifold

Fuel Flow Control Valve



Gas Valve

Field Piped

Manual Ball Valve


Manual TestValve

Gas Supply

UL-FM Modulation Gas Piping Diagram - Up to 2,500 MBH Firing Rate

M

ManualTest Valve

S

S

TestConnection


ManualBall Valve

722003

722003

Field Piped




Gas Pilot Ignitor

Gas Burner Manifold

Manual Ball Valve


26 Sec.Main Solenoid Gas Valve

Field Piped

Manual Ball Valve


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


Main Reset Low Gas Pressure

Switch

Main Reset High Gas Pressure

Switch

722002

722002


Field Piped




Gas Pilot Ignitor

Gas Burner Manifold

Manual Ball Valve


26 Sec.

Man Reset Low Gas Pressure

Switch

FieldPipedManual Ball

Valve


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


L H


14 Sec.

Man Reset High Gas Pressure

SwitchVent

Field Piped

722009

722009

Field Piped




Gas Pilot Ignitor

Gas Burner Manifold

Manual Ball Valve

FieldPiped

Manual Ball Valve


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.


HFieldPiped

Vent

Man Reset High Gas Pressure Switch

L

Man Reset Low Gas Pressure Switch

722023

722023

Field Piped




Gas Pilot Ignitor

Gas Burner Manifold

Manual Ball Valve

FieldPiped

Manual Ball Valve


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.


14 sec.

HFieldPiped

Vent

Man Reset High Gas Pressure Switch

L


7722024

722024

Field PipedPilot Manual

Ball Valve



Gas Pilot Ignitor

Gas Burner Manifold



26 Sec.


Switch

Field Piped

Manual Ball Valve


Manual TestValve

Gas Supply

UL Modulation Gas Piping Diagram - 2,501 to 5,000 MBH Firing Rate

M

ManualTest Valve

S

S

TestConnection


ManualBall ValveL H



Switch

Vent

722004

722004


Field Piped




Gas Pilot Ignitor

Gas Burner Manifold


Man Reset High Pressure

Switch


Switch

Field Piped

Manual Ball Valve


Manual TestValve

Gas Supply

FM Modulation Gas Piping Diagram - 2,501 to 5,000 MBH Firing Rate

M

Manual Ball Valve

M

S

TestConnection


L H


26 Sec.

Vent

Manual Test Valve

Main Mortorized Gas Valve

14 Sec.

722010

722010

Field Piped




Gas Pilot Ignitor

Gas Burner Manifold



W/POC26 Sec.


Switch

Field Piped

Manual Ball Valve


Manual TestValve

Gas Supply

UL Modulation Gas Piping Diagram - 5,001 to 12,500 MBH Firing Rate

M

ManualTest Valve

S

S

TestConnection


ManualBall ValveL H



Switch

Vent

POC

722005

722005

Field Piped




Gas Pilot Ignitor

Gas Burner Manifold


Man Reset High Pressure

Switch


Switch

Field Piped

Manual Ball Valve


Manual TestValve

Gas Supply

FM Modulation Gas Piping Diagram - 5,001 to 12,500 MBH Firing Rate

M

Manual Ball Valve

M

S

TestConnection


L H

Main Motorized Gas ValveW/ POC26 Sec.

Vent

Manual Test Valve


14 Sec.

POC

722011

722011

Field Piped




Gas Pilot Ignitor

Gas Burner Manifold

Manual Ball Valve

Manual Ball Valve


ManualTest Valve

Gas Supply

UL Modulation Gas Piping Diagram - Over 12,500 MBH Firing Rate

Manual TestValve

S

S

TestConnection



W/POC 14 sec.


M

Field Piped

722082

Fuel Flow ControlValve


Switch

Vent

H

POC

Vent

L


S

Normally Open Vent Valve

722082


Field Piped




Gas Pilot Ignitor

Gas Burner Manifold

Manual Ball Valve

Manual Ball Valve


ManualTest Valve

Gas Supply

FM Modulation Gas Piping Diagram - Over 12,500 MBH Firing Rate

Manual TestValve

M

S

TestConnection



W/POC 14 sec.


W/POC - 14 sec.

M

Field Piped

722084

Fuel Flow ControlValve


Switch

Vent

H

POC

Vent

L


S

Normally Open Vent Valve

POC

722084

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.

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.

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

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