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SAFETY PRECAUTIONS

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. Trouble Shooting ..................................................................................................................................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

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 the components and their relative positions in the piping train.c. The unit material list which provides an overview of the burner requirements and a complete bill of material, including the part numbers and description for each item.d. The flame safeguard manual provides the operating se-quence for the burner management system. This will be a critical document for troubleshooting any future problems.

IntroductionJB Manual

e. Catalog cuts of the major components. These provide details on the installation, adjustment and maintenance of the components used on the burner.

5. Service, Parts and other 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 CONE

USED 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.

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 approval codes. The above chart shows those items standard to a basic burner plus a few options that may be added.2. Indicator lights are “Power On”, “Call for Heat”, ”Fuel On” and ”Flame Fail” for hard wired panels. “Alarm”, “Low Water”, “Power”, “Call for Heat”, “Ignition On”, and “Fuel On” for circuit board light panels.

Model JB1 - Sizing and Application Data (contact Webster for complete information)Model

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. Use the following corrections for higher temperatures and altitude. Capacity decreases by 17% for 50 Hertz. Capacity decreases by 4% for each 1000 feet above 1000 foot altitude. Capacity decreases by 6% for each 1 inch of furnace pressure. Capacity decreases by 2% for each 10oF increase in air temperature over 90oF.Gas input ratings based on 1000 BTU/cu ft. and 0.64 specific gravity. Sizes and pressure will vary with gas.Oil input ratings are based on 140,000 BTU/gal for ASTM #2 fuel oil.

Essential Ordering Information and Data: Power Supply - Confirm 120-60-1 for control circuit and electrical supply for burner motor(s) (voltage, frequency and phase). Describe Boiler or Heater to be Fired - Including the manufacturer, model number, furnace pressure and furnace size. Firing Rate - Define firing rates in MBH for gas and GPH for oil. Fuel to be Burned - Type of gas and/or oil, including the BTU value. Approval Agency - UL, FM, IRI (GE GAP), CSD-1, NFPA, Mil spec and local codes, if applicable. Flame Safety Control Preferred - Honeywell or Fireye controls. Gas Train Components Preferred - ASCO/ITT, Honeywell or Landis Control System - ON-OFF, Low Fire Start, Low-High-Low, Modulation, Posi-Control Required Options - Mounting plate, limit controls, etc.

Model JB1 - Specification Data (400 - 2500 MBH Input)

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”, “Ignition On”, and “Fuel On” for circuit board panels.3. Maximum rate for direct spark is 20 GPH at low fire or 35 GPH at high fire. (standard on straight oil burners, pressure atomized)



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 2

JB2-30 2.5 1200 / 5300 12 / 37.8 3 2 1/2” N/A 13 / 14” 3/4 Optional 2

JB2-50 2.5 1200 / 6000 12 / 42.8 5 2 1/2” N/A 2-5 psi 3/4 Optional 2

3. Lower pressures may apply to reduced inputs. 4. 11-14” with IRI and LFS or LHL. 12-14” with IRI and modulation.The above maximum ratings are based on 0 furnace pressure, an altitude of 1000 feet, 90oF air temperature and 60 HZ electrical supply. Use the 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 Landis Control 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 UL EQUIPMENT

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. Capacity decreases by 4% for each 1000 feet above 1000 foot altitude. Capacity decreases by 6% for each 1 inch of furnace pressure. Capacity decreases by 2% for each 10oF increase in air temperature over 90oF.Gas input ratings based on 1000 BTU/cu ft. and 0.64 specific gravity. Sizes and pressure will vary with gas.Oil input ratings are based on 140,000 BTU/gal. for ASTM #2 fuel oil and 150,000 BTU/gal for ASTM #4-6 fuel oil.The vessel draft must be between -0.1 and +0.1 wc.

Essential Ordering Information and Data: Power Supply - Confirm 120-60-1 for control circuit and electrical supply for burner motor(s) (voltage, frequency and phase). Describe Boiler or Heater to be Fired - Including the manufacturer, model number, furnace pressure and furnace size. Firing Rate - Define firing rates in MBH for gas and GPH for oil. Fuel to be Burned - Type of gas and/or oil, including the BTU value. Approval Agency - UL, FM, IRI (GE GAP), CSD-1, NFPA, Mil spec and local codes, if applicable. Flame Safety Control Preferred - Honeywell or Fireye controls. Gas Train Components Preferred - ASCO/ITT, Honeywell or Landis Control System - ON-OFF, Low Fire Start, Low High Low, Modulation, Posi-Control Required Options - Mounting plate, operating controls, limit controls, etc.

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 1/4 O.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


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


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 the needed air for safe combustion as required by your local regulatory agency?2. If a burner mounting plate is required, is it available and does it meet specifications? (See Section E)3. Is 120-60-1 voltage available for the control circuit and is the correct voltage available for the blower motor as well for the remote oil pump set and air compressor, if used?4. Will the burner properly fit the boiler or heater with ample clearance on top, bottom and sides? 5. If a gas burner, will there be adequate gas pressure to assure the specified firing rate?6. If a straight oil burner with gas pilot, is gas available at the burner location?7. If an oil burner, what is the age and condition of the oil tank(s) and will there be special piping arrangements needed to deliver the oil to the burner?Important Note: The JB series burners must be oper-ated with a two-pipe system.8. If an oil burner, what grade of fuel oil is in the tank(s) or on order? If a retrofit installation, has the same oil grade always been used? Does it meet the grade specified on the burner’s UL rating plate?

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 and proper venting of the burner?10. All manuals should be reviewed and understood and stored in a convenient place.11. Teflon tape should not be used on any field piping.12. Rope gaskets should be used between vessel and mounting plate, and between mounting plate and 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 max press (3 psig) if transfer pump is used or tank elevation is higher than the pump.17. Strainer before oil pump, sized for max pump suction capacity.18. If FGR is used, does it follow Webster guidelines. (see addendum 950064)19. If multiple vessels connect to a single stack, are they sized and designed to maintain +/- 0.1” wc draft at the ves-sel outlet under all operating conditions.20. Is stack designed to maintain +/- 0.1” wc at outlet during all 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 sealed with rope gasket? (See Figure E-2)22. Has the new gas and oil piping been purged to remove debris?23. Is there a drop leg in the gas supply to capture foreign material? (See Figure C-1)24. Is the piping between the gas train and burner done in a manner that will minimize the pressure drop?25. Has all of the piping been pressure checked for leaks?26. Is the combustion chamber of proper size and is the center-line height of the burner head adequate? (See charts C-2 & C-3.)

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 with the regulations of the provincial installation requirements, or in their absence, the following shall govern: Gas Burners--CGAB149.1 and CGAB149.2 Oil Burners--CSA Standard B139Authorities 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 electrical power disconnect and the manual shut-off valve on the gas and/or oil supply drop-line to the burner.

4. Oil and gas burning equipment shall be connected to fl ues having suffi cient draft at all times, to assure safe and proper operation of the burner.

Burner Mounting CriteriaJB Manual

E. BURNER MOUNTING CRITERIA It 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.


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 Figure G-2. The oil nozzle will be adjusted at start-up and may be moved in or out from this initial set-ting. In some cases, the oil nozzle may be inside the 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 60o 1/4” NA45 5/860 1/2

JB3 2 1/2” 3 60 5/8 2 1/2 Multi Port 80o NA 3/8

2 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 travel and alignment. Positions can change during shipment and installation and they must be reviewed prior to startup. The fuel cams are mounted to the ends of the jackshaft assembly. A cam follower link follows the profi le established by the adjusting screws and drives the fuel valve. A thin metal band is used between the screw and cam follower to provide a smooth profi le. The adjusting screws are backed by compressed nylon inserts, which provide a resistance to turning.

The cam (Figure G-3) should be checked for the following conditions:a. At the low fi re position, the roller should be between the fi rst two adjusting screws. If not, adjust the position of the cam accordingly, making sure to maintain the same low 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 screws within 1/8”. If needed, the two cam set screws can be loosened and the cam moved to center it on the roller.

c. At high fi re, the roller should be between the last two adjusting screws.d. The adjusting screws should form a smooth contour with no jumps between the screws.e. In preparation of startup, the retention plate can be removed temporarily to make it easier to adjust the screws.

THE RETENTION PLATE MUST BE REPLACED WHEN SETUP IS COMPLETE.If the unit is equipped with a parallel positioning system (linkageless), the control valves can be positioned and operated in a similar manner, but accomplished through the controller. Refer to the instruction manual for details.

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.

Initial Settings JB Manual

H. IGNITION SYSTEMS

Ignition SystemsJB Manual

1. Gas Pilot AssemblyA crucial part of reliable burner operation is a dependable pilot, which must be properly adjusted and kept clean. A gas pilot is standard for all models except JB1 through JB2-20 straight oil pressure atomizing burners which have direct spark ignition as standard. The following illustrations show the typical 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 will be adjusted at start-up.

3. Air Damper PositionOn a straight gas burner, the air damper should be open about 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 and stroked to abput 60% open at high fi re.

5. Oil Modulatining Control Valve Position.For pressure atomizing, the low fi re position should be adjusted to get the correct low fi re presure, as stated on the rating label. Typically, this would be 100 psi for simplex systems and 65 psi for return fl ow nozzles. The high fi re position should be about 45o to 60o travel from low 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 the last 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 items must be ready for operation prior to starting. The following is a general review:

______All wiring is connected. Test pulls on wire show them to be tight.

______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 the valve, from low to high fire. Increasing the length of the drive crank arm (B) or decreasing the length of the driven crank arm (C) will increase the valve travel. To reduce valve travel, decrease B or increase C (Figure I-1).

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). This would be done to get the air damper to match the fuel valve action.

3. Fuel Cam Adjustments

The cam is used to adjust the intermediate fuel rate with the low and high fire settings done by the linkage 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 must also be adjusted to provide a smooth contour from screw to screw. When complete, the flexible strip between the adjust-ing screws and the roller must come in contact with each screw, providing a smooth transition from low fire to high fire.b. The end screws (or nuts) can be adjusted to hold the strip against the screws, but should not deform the strip.c. There should be no upsets in the profile, where the 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 with the 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 retention plate must be installed. The retention plate will help insure that the fuel valve position will not get far from its ideal position, even with interference or sticky valve operation.

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 few screws, the linkage should be readjusted to cause the air damper to open slower (make the jackshaft drive arm more parallel to the linkage rod). Likewise, the op-posite contour can be corrected by speeding up the air damper drive (Figure I-1). The final cam screw profile should be close to the profile of the cam with no abrupt changes.

4. FGR Adjustments

Flue gas is recirculated back into the burner to reduce the flame temperature, which reduces the NOx level. High quantities of flue gas result in lower NOx levels, but can also result in flame instability if there is too much FGR. Natural gas fuel can handle larger 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


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 rate on both fuels. The FGR control valve is set on gas and oil follows that setting.• A 30 ppm system uses the FGR limiting potentiometer (located in the control panel) to obtain a partial flow of FGR when firing oil. The FGR control valve is set when firing gas. The FGR limiting potentiometer is adjusted to improve combustion but not cause instability. The combustion needs to be checked at several firing rates. • Under 30 ppm, separate gas and oil operating points are established in the modulating motor. Parallel positioning (linkageless) systems allow all of the valves to be positioned independently for each fuel. For this reason, the setup 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 of the 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 fire cylinder, then it can be adjusted in 3/4 inch or out 1/2 inch to stay within the limits of 1/4 inch to 1 1/2 inch diffuser to fire

end of the inner fire cylinder dimension.• Loosen the two setscrews locking the pilot gas line and gun tube to the backplate.• Adjust the diffuser by moving the oil gun tube in and out the amount determined above. When the best posi-tion is found, lock into place with the two setscrews on the oil and pilot tubes.b. To adjust the oil nozzle to diffuser position:• Adjust the oil nozzle to obtain the best combustion.• Watch for spray back on the diffuser when the oil noz-zle is pulled too far back. The flame may appear good but carbon will quickly develop on the diffuser.• The drawer assembly must be removed to adjust the oil nozzle to diffuser position.

The burner drawer must be removed for access to com-ponents, follow the following steps:

a. Disconnect the gas pilot line. Move the pilot line so the drawer can be pulled out without interference.b. If equipped with oil, disconnect the oil line(s), and move the oil line out of the way to allow the drawer to be pulled.c. Loosen and remove the screws on the burner 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 in the opening to prevent it from hanging up while being pulled 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 is protected from shock.g. Set the drawer down horizontally, do not set it on the diffuser as it may flatten some fins or change positions.

To re-install the burner drawer, simply work the 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


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 fuel burner, make sure the fuel selector switch is on “GAS”.c. Place the manual flame control potentiometer in the MIN (low fire) position on modulating units.d. Close the downstream manual shutoff valve (closest to the burner head) on the gas train.e. Turn the electrical power on for the burner, boiler and related components.f. Verify that the gas metering valve is nearly closed, the vent valve (if equipped) is operating and the gas pilot valve is not open (the solenoid will hum and feel warm). g. If equipped with FGR, verify that the FGR control valve is in the near closed position. A linkage system should have the shutoff FGR valve in the closed posi-tion.h. Turn the burner switch on. This will start the blower motor and initiate the prepurge cycle.i. When the prepurge sequence is complete and the low fire start switch (if used) is made, the pilot valve will open and the pilot flame should be visible through the sight port.j. When the pilot flame is established, the flame safe-guard will energize the main gas valve (indicated with the Fuel Valve Light). This operation of the main fuel valves must be visually checked by observing the valve stem operation. k. After the timer has completed the trial for main flame, the burner will go out on alarm (the closed manual gas valve prevented the burner from lighting). At this time, the gas valves must be visually checked to verify that they have closed. This test sequence proves the proper operation of the primary control.l. Press the reset button and restart the burner. When the pilot has started, open the manual gas valve to allow

JB Manual Startup and Operating Adjustments

the main flame to start.m. If equipped with FGR, the shutoff FGR valve should open on a linkage system, after the main flame has been proven. The timing can be adjusted with the time delay in-side the control panel, so that the FGR shutoff valve opens 5 to 10 seconds after the main flame is established. The control valve of the linkageless system should move from closed to a low flow position after light off timing has ex-pired.NOTE: If the burner is not operating as indicated, follow the troubleshooting guide steps to determine the problem and corrections required.n. After a few seconds, the combustion analyzer should have an accurate reading of the O2 in the stack. Figure I-3 shows the typical range of O2 at different firing rates, and the burner should be adjusted to be within this range. Rough settings for low and mid fire combustion settings are adequate at this time. Once the high fire is set, the other settings can be fine tuned.• Turning the cam screw in will add fuel, making it richer and reducing the O2 level.• Turning the cam screw out will reduce the fuel input, increasing the O2 level.If equipped with FGR, the NOx level should be close to the desired NOx, as required by the specific order. The FGR valve can be opened to decrease the NOx level, or closed to increase the NOx level.o. Operate the burner until the boiler is warmed up, and near the operating pressure or temperature. Increase the firing rate, using the manual potentiometer, or put low fire hold switch in auto mode, while monitoring and adjusting the O2 level. Adjust the gas pressure regulator as needed to reach the high fire input.p. If equipped with FGR, adjust the FGR valve as needed to obtain the approximate NOx level.q. Adjust the high fire input to match the maximum input listed on the rating label. At high fire, the gas butterfly valve should be at least 75 degrees open (more if avail-able gas pressure is low), and the gas pressure regulator adjusted to obtain the rating. The input should be measured using the following equation:

Calculating Natural Gas Input

Gas MBH = HHV x [(Patm + Pgas)/29.92] x [520/(Tgas +460)] x [measured ft3/sec] x [3600 sec/hr]

Where:MBH = 1000’s of BTU/M inputHHV = Higher heating value of gas, BTU/cubic feetPatm = Atmospheric pressure in inches HgPgas = Gas pressure before gas meter in inches Hg (inches HG = PSIG x 2.04)Tgas = Gas temperature at the flow meter, in degrees FMeasured ft3 = volume of gas measured by metersec = Time for measured ft3 to flow through meter

Note: Some gas meters require a 6 inch wc correction to Pgas. Consult your meter calibration data.

NOTE: The listed manifold pressure is only an ap-proximate value and can vary with operating condi-tions and normal tolerances. The fuel flow rate must be measured to obtain an accurate input value.

r. Adjust the air damper to obtain the correct O2 level. s. If equipped with FGR, adjust the NOx level to be about 10% below any guaranteed NOx performance. A balance of the FGR control valve and air damper are required to obtain the final result, as each can impact the other. t. Modulate the burner to low fire, adjusting the O2 level as the burner modulates.u. Adjust the low fire input, using the fuel cam and air damper adjustments. The linkage may need to be read-justed to obtain the correct relationship between the fuel valve and air damper. (Figure I-1)v. Re-adjust the midfire points for the correct O2 level.w. If equipped with FGR, adjust the NOx levels at low and midfire rates to be about 10% under the guaranteed levels.x. Adjust the low gas pressure switch to be 10% below the lowest expected gas pressure.• With a gauge or manometer at the same location as the low gas pressure switch, modulate the burner to deter-mine the firing rate with the lowest gas pressure.• At the lowest gas pressure, adjust the low gas pressure setting up until the switch breaks and causes the burner to shutdown.• From the scale reading of the switch, adjust the set-ting to a pressure that is 10% lower than the shutdown pressure. For example, if the switch opened at 10 inches as indicated on the low gas pressure switch, the switch should be adjusted to a reading of 9 inches.• Remove the gauge or manometer and plug the open-ing.• Cycle the burner on and off to determine if the limit works properly.• If the limit causes nuisance shutdowns because of small pressure drops during startup, reduce the pressure setting an additional 5%.y. Adjust the high gas pressure switch to be 10% above the highest expected gas pressure.• With a gauge or manometer at the same location as the high gas pressure switch, modulate the burner to deter-mine the firing rate with the highest gas pressure.• At the highest gas pressure, adjust the high gas pres-sure setting down until the switch opens and causes the burner to shutdown.• From the scale reading of the switch, adjust the set-ting to a pressure that is 10% higher than the shutdown pressure. For example, if the switch opened at 10 inches as indicated on the high gas pressure switch, the switch should be adjusted to a reading of 11 inches.• Remove the gauge or manometer and plug the open-ing.• Cycle the burner on and off to determine if the limit works properly.• If the limit causes nuisance shutdowns because of small pressure changes during startup, increase the pressure setting an additional 5%.

JB Manual Startup and Operating Adjustments

z. The burner should be operating at low fire to adjust the air proving switch. Turn the adjusting screw cw (in) until the burner trips out (shutdown caused by the air flow switch). Turn the adjustment screw ccw (out) 1 1/2 turns from the point of shutdown. Check the operation at higher rates.

11. Pressure Atomized Oil Setup

The pressure atomized oil system has a limited range of adjustment for low and high fire, dictated by the operation of the oil nozzle. The combustion air and FGR must be adjusted to match these rates.

If the burner is equipped with FGR, and is a linkage sys-tem, the type of FGR control must be determined prior to starting. If this is a dual fuel burner, the FGR rate is determined by the NOx performance on gas. A 60 ppm burner will operate with the same FGR rate on gas and oil. A 30 ppm unit will use the limiting potentiometer to slightly reduce the FGR rate on oil firing. For Oil only combustion, the NOx level will be given on the burner detail sheet, and should be used to set the FGR control valve.a. Place the burner switch in the “OFF” position.b. Place the “Auto-Manual” switch in the manual position or low fire hold switch in the low fire position fo LO-HI-LO operation. If this is a combination fuel burner, make sure the fuel selector switch is on “OIL”.c. Place the manual flame control potentiometer in the min (low fire) position on modulation units.d. Turn the electrical power for the burner, boiler and re-lated components on.e. Verify that the oil metering valve is nearly opened (the valve will be closed at high fire).f. Turn the burner switch on. This will start the blower mo-tor and initiate the purge cycle.g. When the prepurge sequence is complete and the low fire start switch (if used) is made, the pilot valve will open and the pilot flame should be visible through the burner sight port.h. When the pilot flame is established, the flame safe-guard will energize the main oil valves (indicated with the Fuel Valve Light), and the burner should ignite at low fire. This operation of the main fuel valves must be visually checked by observing the valve stem moving up with a motorized valve or hearing the clicking noise from a sole-noid valve. NOTE: If the burner is not operating as indicated, follow the troubleshooting steps to determine the problem and corrective action.i. The main flame may not light on the first attempt, be-

cause it must fill the oil lines before providing oil to the nozzle. Press the reset button on the flame safeguard to restart the burner.

WARNINGDO NOT ATTEMPT TO START THE BURNER WHEN EXCESS OIL HAS ACCUMULATED, WHEN THE UNIT IS FULL OF VAPOR, OR WHEN THE COMBUSTION CHAMBER IS HOT.

j. After a few seconds, the combustion analyzer should have an accurate reading of the O2 in the stack. The O2 level should be between 4% and 7%, and the nozzle oil pressure should be between 50 and 70 PSIG return line pressure for the JB3. JB1 and JB2 burner low fire oil pres-sure should be 100 psig. Do not attempt to fine tune com-bustion until the high fire has been set.If the burner is equipped with FGR, the FGR control valve should be set for the approximate NOx level required. 1. Turning the cam screw in will add fuel, making it richer and reducing the O2 level. 2. Turning the cam screw out will reduce the fuel input, increasing the O2 level. 3. The air damper should be positioned for the correct low fire settings.k. Operate the burner until the boiler is warmed up, and near the operating pressure or temperature. l. Increase the firing rate, using the manual potentiom-eter or put the low fire hold switch in auto position, while monitoring and adjusting the O2 level. Adjust the cam as needed to reach the high fire input.If the burner is equipped with FGR, adjust the FGR control valve as required to maintain the NOx level.m. At high fire (end of the modulating motor travel), adjust the high fire input (open or close the fuel valve) to match the maximum input and/or pressure listed on the rating label. The fuel metering valve should be nearly closed (or closed) at this point and the nozzle pressure should be about 150 PSIG (return line) for JB3. For JB1 and JB2 250 to 300 psig.n. If equipped with FGR, adjust the NOx level to be about 10% below any guaranteed NOx performance or if perfor-mance guarantee exists adjust the FGR to provide some added turbulence but not high enough to impact flame sta-bility. A balance of the FGR control valve and air damper are required to obtain the final result, as each can impact the other. If this is a 30 ppm system, the FGR limiting pot should be adjusted to reduce the FGR rate for stable com-bustion, with the FGR control valve set when firing gas. If this is a 60 ppm system, no adjustment is necessary.o. Modulate the burner to low fire, adjusting the O2 level as the burner modulates.


Natural GasWith FGR

Natural GasNo FGR

Oil

% Rate Min% O2

Max% O2

Min %O2

Max %O2

Min %O2

Max %O2

30 5.0 7.0 5.0 7.0 3.5 7.540 4.0 7.0 4.0 7.0 3.0 7.050 3.0 5.0 3.0 5.0 3.0 5.0100 3.0 5.0 3.0 5.0 3.0 5.0

Figure I-3O2 levels

p. Adjust the low fire input, using the fuel cam or low fire regulator on LO-HI-LO systems and air damper adjust-ments. If the burner is equipped with FGR, adjust the NOx level according to the type of system (limiting potentiom-eter or matching gas).q. Re-adjust the midfire points for the correct O2 levels. The linkage may need to be readjusted to obtain the cor-rect relationship between the fuel valve and air damper. (Figure I-1)r. If equipped with FGR, adjust the NOx levels at low and midfire rates to be about 10% under the guaranteed levels or as required for the gas firing.s. The burner should be operating at low fire to adjust the air proving switch. Turn the adjusting screw cw (in) until the burner trips out (shutdown caused by the air flow switch). Turn the adjustment screw ccw (out) 1 ½ turns from the point of shutdown. Check the operation at higher rates.t. Adjust the oil pressure switch to trip and shutdown the burner at a pressure that is 10% lower than the supply oil pressure.

12. Air Atomized, #2 oil Setup

The air atomized oil system has the potential for a large turndown range similar to gas and has the potential to be adjusted to different low fire rates. See the burner name-plate for details on actual rates for this burner.If the burner is equipped with FGR and is a linkage sys-tem, the type of FGR control must be determined prior to starting. If this is a dual fuel burner, the FGR rate is determined by the NOx performance on gas. A 60 ppm burner will operate with the same FGR rate on gas and oil. A 30 ppm unit will use the limiting potentiometer to slightly reduce the FGR rate on oil firing. For Oil only combustion, the NOx level will be given on the burner detail sheet, and should be used to set the FGR control valve.a. Place the burner switch in the “OFF” position.b. Place the “Auto-Manual” switch in the manual position. If this is a combination fuel burner, make sure the fuel se-lector switch is on “OIL”.c. Place the manual flame control potentiometer in the min (low fire) position.d. Turn the electrical power for the burner, boiler and re-lated components on.e. Verify that the oil metering valve is at the nearly closed position.f. Turn the burner switch on. This will start the blower mo-tor and initiate the purge cycle.g. When the prepurge sequence is complete and the low fire start switch is made, the pilot valve will open and the pilot flame should be visible through the burner sight port.h. When the pilot flame is established, the flame safe-guard will energize the main oil valves (indicated with the Fuel Valve Light), and the burner should ignite at low fire. This operation of the main fuel valves must be visually checked by observing the valve stem moving up with a motorized valve or hearing the clicking noise from a sole-noid valve. NOTE: If the burner is not operating as indicated, follow the troubleshooting steps to determine the problem and

corrective action.WARNING

DO NOT ATTEMPT TO START THE BURNER WHEN EX-CESS OIL HAS ACCUMULATED, WHEN THE UNIT IS FULL OF VAPOR, OR WHEN THE COMBUSTION CHAMBER IS HOT.

i. After a few seconds, the combustion analyzer should have an accurate reading of the O2 in the stack. The O2 level should be between 4% and 7% (see Figure I-3 for O2 rates), and the nozzle oil press should be between 5 and 15 PSIG (see Figure I-4). Do not attempt to fine tune combustion until the high fire input has been set.If the burner is equipped with FGR, the FGR control valve or limiting potentiometer should be set for the approximate NOx level required.• Turning the cam screw in will add fuel, making it richer and reducing the O2 level.• Turning the cam screw out will reduce the fuel input, increasing the O2 level.• The air damper should be positioned for the correct low fire settings.• The atomizing air pressure can be adjusted using the air bleed valve.j. Operate the burner until the boiler is warmed up, and near the operating pressure or temperature. k. Increase the firing rate, using the manual potentiome-ter, while monitoring and adjusting the O2 level. Adjust the cam, oil pressure and atomizing air pressure as needed to reach the high fire input.l. If the burner is equipped with FGR, adjust the FGR con-trol valve or potentiometer as required to maintain the NOx level.m. At high fire (end of the modulating motor travel), adjust the high fire input to match the maximum input listed on the rating label. Using a flow meter, the fuel input may be measured using the following equation,

Oil GPH = [Gal end – Gal start] x [3600 sec/hr] / [measured sec]

Where Gal end = meter gallons at end of test Gal start = gallons at start of the test Measured sec = measured time of test GPH = Gallons of oil per hour

n. If equipped with FGR, adjust the NOx level to be about 10% below any guaranteed NOx performance or if no per-formance guarantee exists adjust the FGR to provide some added turbulence but not high enough to impact flame sta-bility. A balance of the FGR control valve and air damper are required to obtain the final result, as each can impact the other. If this is a 30 ppm system, the FGR limiting pot should be adjusted to reduce the FGR rate for stable com-bustion, with the FGR control valve set when firing gas. If this is a 60 ppm system, no adjustment is necessary.o. Modulate the burner to low fire, adjusting the O2 level as the burner modulates.p. Adjust the low fire input, using the fuel cam and air damper adjustments.q. If the burner is equipped with FGR, adjust the NOx level


according to the type of system (limiting potentiometer or matching gas).r. Re-adjust the midfire points for the correct O2 levels. The linkage may need to be readjusted to obtain the correct relationship between the fuel valve and air damper. See Figure I-1.s. If equipped with FGR, adjust the NOx levels at low and midfire rates to be about 10% under the guaranteed levels or as required for the gas firing.t. The burner should be operating at low fire to adjust the air proving switch. Turn the adjusting screw cw (in) until the burner trips out (shutdown caused by the air flow switch). Turn the adjustment screw ccw (out) 1 ½ turns from the point of shutdown. Check the operation at higher rates.

FIGURE I-4 Typical Atomizing Air Pressure

% Rate Minimum20 10 - 2530 12 - 3040 15 - 3550 20 - 40100 25 - 60

13. Heavy Oil SetupCAUTION

WHEN WORKING WITH HEATED OIL, PROTEC-TIVE CLOTHING, INCLUDING GLOVES, SHOULD BE WORN TO PROTECT FROM BURNS.

The air atomized heavy oil system requires the additional adjustment of oil temperature in the burner setup. The tem-perature is adjusted to improve the viscosity for good atomi-zation. Typically, this will be about 150oF for #4 oil, 180oF for #5 oil and 200oF for # 6 oil.a. Prior to startup, the oil system must be operating with the oil temperature to the burner (before the trim heater) within 20oF of the final temperature.b. Place the burner switch in the “OFF” position. If this is a combination fuel burner, make sure the fuel selector switch is on “OIL” and that the oil pump is running.c. Place the “Auto-Manual” switch in the manual position.d. Place the manual flame control potentiometer in the MIN (low fire) position.e. Turn the electrical power on for the burner, boiler and related components.f. The oil may take some time to get up to temperature. If the oil is cool, the ball valve downstream of the N.O. oil re-turn valve (Figure B-7) can be opened to make it easier for the oil to circulate and reach operating temperature.g. Verify that the oil metering valve is at the nearly closed position.h. Turn the burner switch to “ON”. This will start the blower motor and initiate the prepurge cycle.

WARNINGDO NOT ATTEMPT TO START THE BURNER WHEN EXCESS OIL HAS ACCUMULATED, WHEN THE UNIT IS FULL OF VAPOR, OR WHEN THE COM-BUSTION CHAMBER IS HOT.

i. When the prepurge sequence is complete and the low fire start switch is made, the pilot valve will open and the pilot flame should be visible through the burner sight port.j. When the pilot flame is established, the flame safe-guard will energize the main oil valves (indicated with the Fuel Valve Light), and the burner should ignite at low fire. This operation of the main fuel valves must be visu-ally checked by observing the valve stem moving up with a motorized valve or hearing the clicking noise from a solenoid valve. k. After a few seconds, the combustion analyzer should have an accurate reading of the O2 in the stack. The O2 level should be between 4% and 7% (See Figure I-3 for O2 rates) and the nozzle oil press should be between 10 and 20 PSIG. Do not attempt to fine tune combustion until the high fire input has been set.• Turning the cam screw in will add fuel, making it richer and reducing the O2 level.• Turning the cam screw out will reduce the fuel input, increasing the O2 level.• The air damper should be positioned for the correct low fire settings.• The atomizing air pressure can be adjusted using the air bleed valve (Figure I-4).• The oil temperature can be adjusted to obtain the best atomization.l. Operate the burner until the boiler is warmed up and near the operating pressure or temperature. m. Increase the firing rate, using the manual potentiom-eter, while monitoring and adjusting the O2 level. Adjust the cam, oil and atomizing air pressure and oil tempera-ture as needed to reach the high fire input.n. At high fire (end of the modulating motor travel), ad-just the high fire input to match the maximum input listed on the rating label. Using a flow meter, the fuel input may be measured using the following equation,

Oil GPH = [Gal end – Gal start] x [3600 sec/hr] / [measured sec]

Where Gal end = meter gallons at end of test Gal start = gallons at start of the test Measured sec = measured time of test GPH = Gallons per hour

o. Modulate the burner to low fire, adjusting the O2 level as the burner modulates.p. Readjust the low fire input, using the fuel cam and air damper adjustments.q. Re-adjust the midfire points for the correct O2 levels. The linkage may need to be readjusted to obtain the cor-rect relationship between the fuel valve and air damper. (Figure I-1) r. The burner should be operating at low fire to adjust


the air proving switch. Turn the adjusting screw cw(in) until the burner trips out (shutdown caused by the air flow switch). Turn the adjustment screw ccw (out) 1 ½ turns from the point of shutdown. Check the operation at higher rates.

14. Operating Control Adjustments

The operating controls must be adjusted to properly cycle the burner “ON and OFF” and provide modulation. The con-trols should not force the burner into rapid “ON-OFF” cycles, as this will cause premature failure of the motor and operat-ing equipment.

The operating control must be adjusted to provide the “ON” pressure or temperature desired. It must allow the burner to come on and start before the temperature or pressure drops into the modulating range. The “OFF” pressure or temperature must be sufficiently above the “ON” point to al-low a reasonable run time. The modulating control must be adjusted to start modulation at some reasonable point below the “ON” temperature or pressure and provide modulation to high fire at the lowest temperature or pressure.

15. Limit Tests

Once the burner has been started and the operating pres-sures and temperatures have been set, the limit switches need to be adjusted so that they will trip if the pressure or temperature exceeds the operating value, but will not trip with normal variations. The switch should be checked for proper operation by allowing the temperature or pressure to vary below (or above) the recommended level to insure that they provide safe shutdown before the burner operation is affected. In some high pressure or temperature switch-es, where the temperature or pressure cannot be set high enough to trip the switch, the switch can be checked by low-ering the set point to prove that the switch will provide a safe shutdown.

The limit switches would include the air proving switch on the burner. Limits for gas operation could include the high and low gas pressure switches and for oil firing, the high and low oil pressure switches, high and low oil temperature switches and the atomizing air pressure switch. If in doubt about which limits are on a burner, refer to the wiring dia-gram that will show each item.

Limit switches need to be checked at regular intervals to ensure they are operating properly. See the maintenance section for details.

16. Pilot Test

Once the burner as been set for the firing rates intended for the burner, the pilot must be checked for proper operation and safety.

The minimum pilot test is done to insure that a pilot which can be seen by the scanner will light the main flame.a. During a startup sequence, measure the time required to light the main flame after the fuel valves have been en-ergized. This will be used to monitor the test with reduced pilot.b. Lock the flame safeguard into the pilot position (refer to


the manual for the flame safeguard for this setting)c. Adjust the gas pressure regulator to the pilot for a minimum value while still holding the minimum signal strength for the scanner.d. Release the flame safeguard from the pilot position and allow it to cycle though the main flame proving se-quence.e. This reduced pilot must reliably light the main flame. Monitor the time from the main fuel valve opening and do not allow the burner to continue if the time is more than an additional two to three seconds from the initial time measured above.f. Run through two or three cycles.g. If this is a combination fuel burner, repeat the test on the other fuel.h. Failures due to reduced scanner signal are also ac-ceptable.

WARNINGTHE MINIMUM PILOT TEST REQUIRES CLOSE SUPERVISION OF THE COMBUSTION PROCESS. FAILURE TO CLOSELY MONITOR THE MAIN FLAME TEST TIME COULD RESULT IN DAMAGE, INJURY OR DEATH.

i. If the pilot does not light the main flame under these test conditions, check and adjust the pilot as shown in section “H”.

j. The infrared detector must be tested for hot refrac-tory pickup. This test is performed to make sure that the scanner does not see hot refractory that could be mistaken for a flame.k. After the burner has been operating for some time at high input levels and the refractory in the vessel is hot, the burner should be cycled off while monitoring the scanner signal.h. The flame signal should drop off quickly as the flame goes out and should be well below the minimum level (indicating a flame) at the end of the post purge cycle.i. The UV detector must be tested for spark pick-up. Turn the burner on, with the pilot shut off, during the ignition cycle the flame signal should be well below the minimum level (indicating a flame).j. If the flame signal does not drop out as required, check the location of the pilot and scanner, as shown in section “H”. This may also indicate a faulty scanner or amplifier.

17. Burner Shutdown

Normal operation of the burner will allow the operating controls to shut the burner down when the load demand is satisfied. If the burner needs to be shut down for any reason, the “ON-OFF” switch can be used to quickly turn the burner off. This will instantly cause the fuel valves to close and start a post purge cycle to remove any un-burned fuel from the vessel.

In an emergency shutdown, all fuel and electrical power should be de-energized or turned off to secure the burn-er. This would include the main power disconnect, the manual gas shutoff valve at the drop down line and if equipped, the manual oil valve to the nozzle.

It is recommended that the burner be manually driven to low fire before turning the burner off, as this reduces the dynamic and thermal stress. If the burner will remain off for some time, the manual fuel valves, fuel pumps and power supply should be turned off.

CAUTIONALWAYS KEEP THE FUEL SUPPLY VALVE SHUT OFF WHEN THE BURNER IS SHUT DOWN FOR AN EXTENDED PERIOD OF TIME.

18. Restarting after Extended Shutdown

Extended shutdowns require the same startup process as those outlined above. In addition, the following advanced cleaning must be done,a. The air atomized oil nozzle should be removed and cleaned, if pressure atomized they should be replaced. Use care in cleaning to preserve the sharp edges of the nozzle, which are required to maintain good atomization.b. The oil filter and strainer must be removed and cleaned prior to starting.

CAUTIONDO NOT START THE BURNER UNLESS ALL CLEANOUT DOORS ARE SECURED IN PLACE.


No. System Cause Correction1 No Ignition Electrode is grounded. Porcelain is cracked. Replace

(lack of spark) Improperly positioned electrode Recheck dimensions

Loose ignition wire connection Reconnect or tighten

Defective ignition transformer Check transformer, replace

2 No Ignition Lack of fuel, no gas pressure, closed fuel valve Check fuel supply and valves

(spark, no flame) No voltage to pilot solenoid Check electrical connections

Defective pilot solenoid valve Replace

Incorrect location of pilot Check location of pilot

Improper raw gas tube position Check location of raw gas tube

Improperly positioned electrodes Recheck dimensions

Too much combustion air flow Check air damper position

3 Pilot not detected Scanner tube not positioned correctly Check location of scanner tube

(flame present) Scanner tube dirty or wet (oil film) Clean scanner tube / scanner

Scanner or amplifier faulty Replace

Pilot improperly positioned Check pilot position

Incorrect gas pressure to pilot Readjust pressure

Combustion air flow rate too high Readjust damper

4 No main gas flame Weak scanner signal Clean scanner lens and tube

(pilot OK) Damper or fuel control valve setting incorrect Readjust

Fuel valve(s) not opening Check wiring to valves

5 No main oil flame Weak scanner signal Clean scanner lens and tube

(pilot OK) Damper or fuel control valve setting incorrect Readjust

Fuel valve(s) not opening Check wiring to valves

Oil nozzle or line obstructed Check nozzle and lines, clean

No atomizing air pressure Check compressor wiring

Compressor pressure too low or high Readjust

Burner not level, oil is draining into vessel Check level, adjust as required.

6 Burner stays at low fire Manual pot in low fire position (low fire hold) Readjust to high fire position

Manual-auto switch or low fire hold switch in wrong position Change position of switch

Modulating Control or Lo-Hi-Lo Control Check wiring or replace

Loose linkage Readjust and tighten

Binding linkage or valve Readjust or replace

7 Burner shuts down Loose electrical connection Check and tighten connections

during operation Loss of fuel supply Replenish fuel supply

Limit switch breaks (opens) Readjust limit switch

8 Burner does not start Main disconnect switch is open Close switch

Loose electrical connection Check electrical connections

Operating controls are tripped Check and reset operating limits

High or low fuel pressure Check fuel supply - reset switches

9 High CO at low fire Improper excess air level Readjust excess air

(firing gas) Input too low for burner components Check input, compare to rating label

TroubleshootingJB Manual

J. TROUBLESHOOTING

No. System Cause CorrectionHigh CO at low fire (con’t) High stack draft (especially at low fire) Stabilize draft

(firing gas) Poor air flow distribution (off center flame) Adjust air straightener blade

Diffuser not in optimum position Adjust diffuser position in or out

Fluxuating gas pressure (regulator not holding pressure) Check regulator pressure, sensing line and supply pressure: sized properly

10 Gas combustion noise Input too low for burner components Check input, compare to rating label

(rumbling) Improper excess air Readjust excess air

Fluxuating gas pressure (regulator not holding pressure) Check regulator pressure and supply

High stack draft (especially at low fire) Stabilize draft

Diffuser not in optimum position Adjust diffuser position in or out

Poor air flow distribution (off center flame) Adjust air straightener blade

11 Oil combustion smoking Oil nozzle dirty or plugged Clean oil nozzle

Improper excess air Readjust excess air

Input too low for burner components Check input, compare to rating label

High stack draft (especially at low fire) Stabilize draft

Incorrect nozzle position Adjust the nozzle to diffuser position

Fluxuating oil pressures (regulator not holding) Check regulator pressure and oil supply

Poor air flow distribution (off center flame) Adjust air straightener blade

Too much FGR (if equipped) Reduce FGR rate

12 Fuel-Air-Ratios are Linkage flexing Realign linkage, straighten rods

not consistent Linkage slip Check linkage and tighten all joints

Fuel cam screws have moved Replace fuel cam

Fuel line plugged Check and clean lines, strainers & filters

Fuel supply pressure changing Check and/or replace pressure regulator

Combustion air temperature changed Retune burner

Draft condition changed Check draft and outlet damper

Plugged or leaky FGR line Clean / repair

Gas control valve - low fire stop not set (if used) Adjust low fire stop

13 Fuel-Air-Ratios have changed Linkage wear Check linkage and tighten all joints

over time Fuel cam screws have moved Replace fuel cam

Air damper seal worn Replace air damper seals

Fuel lines plugged Check and clean lines, strainers & filters

Fuel control valve worn Replace fuel control valve

Gas orifices or gas manifold plugged Clean and/or replace

Combustion air temperature changed Retune burner

Draft condition changed Check draft and outlet damper

Vessel plugged Clean vessel

Plugged or leaky FGR valve Clean / repair

14 Cannot obtain capacity on Wrong spring range in regulator Install higher spring range

gas Too many elbows before control valve Rework piping to reduce elbows

Gas line too small, high pressure drop Use larger pipe size

Supply pressure lower then stated Increase supply pressure

Supply pressure drops too low at high fire Use larger gas line sizes / orifice in service regulator

Regulator too small for flow and pressure Change regulator

15 Cannot obtain rated input on Oil nozzles plugged Replace nozzles

oil firing (pressure atomized) By-pass seal on nozzle leaking Replace nozzles


No. System Cause CorrectionCannot obtain rated input on Oil pressure too low Increase oil pressure

oil firing (pres. atom.) (con’t) Flow valve set too low (should be closed at high fire) Adjust oil control valve

16 Cannot obtain rated input on Oil nozzles plugged Clean nozzle

oil firing (air atomized) Air pressure too low Replace nozzle

Oil pressure too low Increase oil pressure

Flow valve set too low Adjust oil control valve

17 Cannot obtain NOx levels on FGR valve not full open Adjust FGR valve to full open

gas FGR valve full of condensate Clean duct and add drains

FGR duct not directed to flue stream Add angle cut in center of stack

FGR line too small Check sizing, use fittings with less drop

Operating on propane, not natural gas Resize FGR for propane operation

Shutoff valve is not full open Check FGR shutoff valve position


General Maintenance & CareJB Manual

K. GENERAL MAINTENANCE AND CARE1. General2. Physical Inspection3. Fuel-Air-Ratio4. Gas Fuel Systems5. Oil Fuel Systems6. FGR System7. Combustion Air Fan

1. General

This burner has been designed to provide many years of trouble free operation. The reliability can be greatly im-proved with some simple inspection and maintenance pro-grams.

One of the best tools for a good maintenance program is to keep a log on the key parameters of the burner and boiler. These would include operating temperatures, pressures, inspections and preventative maintenance activities. This document can be used to detect any changes in the oper-ating characteristics of the burner, which can be used for preventative maintenance.

The maintenance schedule can be used to help gener-ate this log. There are also many other good references that can be use to help develop your log. Adding check points for other equipment into a common log can help. It is common to integrate the boiler and burner log, so that all components are checked at the same time.

The frequency of inspection given in the following charts is only a guideline. Initial results should be used to adjust the time intervals to be more frequent when problems or potential problems are observed.

2. Physical Inspection

Listening and looking at the burner can detect many prob-lems. For example, leakage can usually be seen early with a small buildup of oil . Valve and linkage problems can usually be detected early on by simply watching the movement and detecting rough uneven changes. The jackshaft, linkage and valve movement should occur smoothly with no rough jerks.

The flame condition can often be a good indicator of the firing head. If the flame does not look correct, there may be a problem with the hardware. The firing head is ex-posed to the high temperatures of combustion and can have reduced life due to the thermal stress. In particular, the diffuser, oil nozzle, gas orifices, gas manifold, refrac-tory and burner mounting plate should all be inspected.

3. Fuel-Air-Ratio Controls

The fuel-air-ratio controls must be maintained in good op-erating condition. Over time, these items will wear and may not operate smoothly. Corrective action must be taken.

There are several different types of controls and the cor-rective action of each could be different. The following general guidelines can be used for initial steps.

Linkage based controls should be inspected for wear. If there is any noticeable play in the linkage rod ends or shaft bearing, they should be replaced. Likewise, any control valves that exhibit sloppy or hard to turn move-ment should also be replaced.

Fuel cams should have adjusting screws that are held firmly in position and can not move due to normal vibra-tions. The moving parts must be in good condition with no noticeable wear or play. Worn connections will result in hysteresis and reduced combustion efficiency.

The cam and jackshaft should be visually checked on a frequent or daily basis for obvious problems, including free movement, no loose parts and correct position of components.

On a monthly basis, the linkage and cams should be inspected for wear and loose parts. Annually, the cam and linkage should be operated manually to check the movement of all components and valves. Any worn parts should be replaced immediately.

4. Gas Fuel System

The safety interlocks must be checked at regular intervals to ensure that they provide the proper safety. See the Inspection and Maintenance Schedule Chart (Figure 8) for frequencies.

The drip leg should be cleaned annually.

Monitoring the outlet gas pressure from the regulator will verify this control is working properly.

5. Oil Fuel System

The oil system has additional components that require regular maintenance, depending on the type of system used. a. Oil added to air compressor. The air compressor has a visual sight glass showing the oil level. This must be inspected every shift (while operating).b. Air compressor belt tight and in good conditionc. The oil strainer should be checked and cleaned pe-riodically. A high vacuum reading on the suction side of the pump (over 10”) is a good indication that the strainer needs to be cleaned. Strainers provided by Webster will use a wire mesh basket inside a canister. After turning the pump off (and making sure there is no pressure on the strainer), unscrew the yoke to gain access to the basket. The canister does not need to be drained. Be careful with the gasket when removing or replacing the cover to insure

JB Manual

a good seal. The basket can be lifted out and cleaned with a soft brush and cleaning solution.d. Vacuum higher than the 10” limit on suction side of pump (indicates need to clean strainer, as described above). If cleaning the strainer does not resolve this, check the other valves between the tank and gauge for plugged or closed position.e. Air atomized oil nozzles should be cleaned periodically, depending on the type of operation and the observed need for cleaning. Extended operation at very low rates (less then 15% of capacity) can cause carbon buildup on the outside of the nozzle. This can be cleaned with a rag and cleaning solution. If the fire is showing some deteriora-tion, and the external surfaces are clean, then the nozzle should be removed, disassembled and cleaned using a soft brush and cleaning solution.f. If the edges of the air atomizing nozzle are not sharp, or the nozzle shows sign of wear and the combustion is deteriorated, the nozzle should be replaced. The nozzle part number is given on the material list of the unit. In general, a single port (center hole) uses a 80o nozzle or multiport (multiple hole at the spray angle) nozzle with a spray angle of 70 degrees will work well for light oil. Heavy oil should use a spray angle of about 60 degrees.g. Pressure atomized oil nozzles have a filter feeding the nozzle that can be plugged over time. The filter can be unscrewed from the back and cleaned, using a soft brush and cleaning solution. When the nozzle(s) are removed form the nozzle body (BPS nozzles), the plastic seals at the end of the nozzle must be replaced, or the nozzle may not seal correctly. The seal can be slid off of the nozzle and a new one installed. Use extreme care to not put any cuts or nicks in the seal. Once the seal is on, the nozzle can be inserted and screwed into the nozzle body.h. If a pressure atomized oil nozzle needs to be replaced, it should be a Delevan Veriflow type, using a 60 degree spray angle (JB3 BPS nozzle(s)).i. Check safety limits, including pressure and temperature switches

6. FGR Systems

The flue gas is corrosive and requires regular inspection of the equipment to ensure proper and safe operation. The potential for corrosion and frequency of the inspection can vary greatly based on the application. Applications with condensation will have more corrosion and will need more maintenance. Frequent cycling, cold startups, cool op-erating temperatures, cool air temperatures and outdoor installations are good examples of where high levels of condensation can occur.

Areas to inspect for corrosion:• FGR control valves(s)• FGR Duct• Air inlet louver box• Fan and fan housing• Burner housing• Firing head and blast tube

Other checks:a. The condensation traps must work properly and be installed to capture all of the condensation. If condensa-tion passes through to the burner windbox, a condensate drain should be added to the bottom of the windbox.b. Linkage and valve movement must operate freely and smoothly.c. If the FGR valve is modulated partly open (oil firing on dual fuel burner) check position of FGR valve.d. NOx emission levels.e. Other general items like the refractory.f. Stack temperature of boiler - high temperatures will increase NOx levels.g. Operation of safety equipment.h. Time delay on FGR on-off valve (if equipped).

7. Combustion Air Fan

If the fan and motor are ever removed, the following should be observed in re-assembly.a. There should be about 1/16” overlap of inlet cone and fan.b. Never re-use the fan to motor shaft set screws, always use new screws of the same type and style to maintain balance and fan retention.c. When tightening the fan hub set screws, rotate the fan to place the screws on the bottom. This way the screw is not lifting the fan.d. The motor shaft and fan hub must be clean and free of burrs.

As a minimum, the following replacement parts should General Maintenance & Care

8 - Inspection and Maintenance ScheduleFrequency Performed By

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Component / Item Recommended Action or Test

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X Burner Flame Visual inspection of burner flame. X

X Jackshaft and Linkage Visual inspection for smooth and free travel. X

X Air Damper Visual inspection for smooth and free travel. X

X Fuel Metering Valves Visual inspection for smooth and free travel. X

X Draft Controls (Stack) Visual inspection for smooth and free travel. X

X Gas Fuel Pressure Record in log book, compare trends. X

X Oil Pressure Record in log book, compare trends. X

X Atomizing Air Pressure Record in log book, compare trends. X

X Pilot Visually inspect pilot flame, check and record flame signal strength if metered. X

X Flame SafeGuard - Pilot Test

Close manual fuel valve on pilot during cycle and check for safety shutdown, recording time.

X

X Flame SafeGuard - Main Flame

Close manual fuel valve on pilot during cycle and check for safety shutdown, recording time.

X

X Flame SafeGuard Check flame safeguard components, including scanner. X

X Flame SafeGuard Replace flame safeguard components in accordance with manufacturers instructions. X

X X Pilot Turndown Test Conduct pilot turndown test annually or after any component change. X

X X Hot Refractory Test Conduct hot refractory hold in test. This test is required annually or after any component change. X

X Oil Pressure and Tem-perature Interlocks

Check oil pressure and temperature switch for smooth operation and correct action. X

X Atomizing Air Pressure Check air atomizing pressure interlock switch for smooth operation and cor-rect action. X

X Interlock Controls Check other interlocks that may be used on the burner for smooth operation and correct action. X

X Firing Rate Control Check firing rate control and verify settings. X

X Combustion Tuning Conduct a combustion test, verify setting and NOx emission levels. X

X Pilot and Main Fuel Valves Make visual and manual check for proper sequencing of valves. X

X Pilot and Main Fuel Valves Check all coils, diaphragms, interlock switch & other parts of all safety shutoff valves. X

X Pilot and Main Fuel Valves Perform leak tests on all safety shutdown control valves. X

X Low Pressure Air Switch Test low air pressure switch for proper operation and adjustment. X

X Mod Damper Switch Check damper low fire proving switch per manufacturers instructions. X

X Linkage and Fuel Cams Check linkage and cams for wear and replace any items with wear indication or stress cracks. X

X FGR Control Valve Visual inspection for smooth and free travel. X

X FGR Control Valve Clean and lubricate FGR control valve. X

X FGR Shutoff Valve Visually inspect for smooth and complete travel. X

X FGR Shutoff Valve Clean and lubricate FGR shutoff valve X

X FGR Condensate Drain Open FGR condensate drains, remove all condensate. X

X FGR Shutoff Valve Switch Check operation of shutoff FGR valve for full rotation and position proving switch. X

X FGR Duct Inspect and clean FGR duct. X

X Combustion Air Fan Clean combustion air fan and housing X

X X Burner Components Visually check the burner components for signs of cracks, deformation, slip-page or other unusual indication. X

X Burner Mounting Check burner mounting clamps and brackets for tightness. X

X Refractory and Seals Check burner refractory for cracks or signs of leakage. X

X Oil Nozzle Check and clean oil nozzle. X

X Air Compressor Check air compressor for lubrication oil and air filter. X

X Air Compressor Check air compressor relief valve operation. X

JB Manual General Maintenance & Care

Extended Shutdown / Replacement Parts / Start-Up ReportJB Manual

be stocked to support uninterrupted burner operation.

Pilot ElectrodeBlower WheelOil Pump (if oil burner)Oil Pump Coupling (if oil burner)Pilot Ignition TransformerOil Ignition Transformer (if used)Gas Pilot Solenoid ValveFlame Scanner

Items with greater life expectancy and/or greater dollar val-ue, such as flame safety controls, main gas or oil valves and blower motors should be obtained from your local Webster representative when a need arises.

L. CARE OF THE BURNER DURING EXTENDED SHUTDOWNHeating equipment is oftentimes located in an environ-ment conducive to corrosion and general deterioration if not properly protected and periodically checked, especially during an extended period of shut down. The following procedures should be followed if the burner is going to be placed out of service even for a short period of time.

1. Turn the main manual fuel valve OFF.

CAUTIONAlways keep the main fuel valve(s) OFF if the burner is shut down for an extended period of time.

2. Turn off the main electrical disconnect to the burner OFF. Follow tagout / lockout procedures.

M. REPLACEMENT PARTS

3. Place a notification tag or label at the main manual fuel valve giving reason for shutdown. Follow tagout / lockout procedures.4. If the burner is in an area subject to sweating and condensation, cover the control cabinet and electrical de-vises with plastic and secure with twine or tape.5. Should the burner be out of service for more than thirty (30) days, a complete operational safety check must be made at the time of restart. The restart must be treated as a new burner start-up (see burner start-up section in this manual).6. The oil nozzle(s), if pressure atomized should be re-placed. If air atomized, clean the nozzle with cleaning fluid and a soft brush.

An illustrated parts drawing is included within the Burner Instructions Manual to aid in parts identification. The noun name of the part needed should be established from the drawing, then the part number can be obtained from the burner material list contained in the Burner Instructions and Service Manual.

NOTEAlways give Webster Engineering Serial Number and/or UL Serial Number when

ordering parts.

N. WARRANTY VALIDATION & FIELD START-UP REPORT

As a final step, forward the top copy of the Warranty Valida-tion and Field Startup Report, Form 113, to: WEBSTER ENGINEERING & MFG. CO., LLC, 619 Indus-trial Road, Winfield, KS 67156.

WEBSTER Series JB Burners are listed by Un-derwriters Laboratories, Inc. (U.L.). Also by the State of Massachusetts Fire Marshall, City of New York Board of Standards and Appeals, State of Minnesota, and can be packaged to meet specific requirements of CSD-1, GE GAP, IRI, FM, NFPA, MIL or other special insurance or local code re-quirements.

Warranty Validation - Form #113 (4-02)JB Manual

WARRANTY VALIDATION FIELD START-UP REPORTCUSTOMER:_________________________________ W.O. _________________

BURNER MODEL: ____________________________ BOILER MODEL: ________________________________

CONTROL CIRCUIT COMPONENT OPERATIONAL TESTING (Check if Okay)

Primary LWCO _______________ High Limit ____________________ Firing Rate Control __________________Secondary LWCO _____________ Operational Control ____________ Low Fire Start Switch ________________High Gas Press. Switch _________ Oil Press. Switch ______________ High Fire Purge Switch _______________Low Gas Press. Switch _________ Air Flow Switch _______________ Other _____________________________

FIELDCOMBUSTION SETTINGS

OIL FIRED GAS FIREDLow Med. High Low Med. High

Firing Rate

CO2

O2

Smoke or CO (ppm)

NOx (ppm)

Stack Temp. Net oF

Room Temperature oF

Overfire Draft “ WC

Breeching Draft “ WC

Water Temp. oF/Steam Press.

Air Inlet Shutter (“ Open)

Flame Signal Pilot

Flame Signal Main

Oil Noz. Press/Man. Gas Pres.

By-Pass Oil Pressure

Atomizing Air Pressure

Combustion Efficiency

Running Motor Amps & Volts L1 L2 L3

Comments:

Having read the Manufacturer’s service manual as to the proper installation, start-up and service of the unit above, I verify that the burner has been put into operation as specified, and that the above information and checks are com-plete and correct.

START-UP BY _______________________________________________ Date _________________________

Company ___________________________________________ Phone No. ____________________________

Address ___________________________________________________________________________________

NOTE: Warranty Validation - Field Start-up report must be completed, signed, dated and the top copy sent to Webster Engineering & Manufacturing Co., Winfield, KS 67156, to validate equipment warranty.

NotesJB Manual

NOTES

safety precautions burn… · safety precautions jb manual. page 2 safety precautions. good safety...

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