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JB Burner O&M Manual - Webster Engineering

1. _ we i we Li op op Overfire Draft WC Breeching Draft WC na __ D ol A A I I _ esse a i 0 I el _ 111 _ci Fi O O O VO O CO Midi ii Os i i a Mer Running Motor Amps amp Volts Having read the Manufacturer s service manual as to the proper installation start up and service of the unit above 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 amp Manufacturing Co Winfield KS 67156 to validate equipment warranty JB Manual Page 49 Warranty Validation Form 113 4 02 NOTES JB Manual Page 50 Notes NOTES JB Manual Page 51 Notes NOTES WEBSTER COMBUSTION TECHNOLOGY 619 Industrial Road Winfield KS 67156 Phone 620 221 7464 Fax 620 221 9447 sales webster engineering com service webster engineering com www webster engineering com JB Manual Page 52 Notes
2. WEBSTER COMBUSTION A Selas Heat Technology Company Webster Combustion Technology 619 Industrial Road Winfield KS 67156 Installation Startup Operation and Maintenance Manual Cyclonetic JB Series Forced Draft Burners JB1 JB2 JB3 Gas Oil Gas Oil Manual Part No 950063 R1 www webster engineering com September 2014 2014 All Rights Reserved SAFETY PRECAUTIONS Good safety practices must be used when working on burner eguipment 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 THI
3. 1 Pressure atomized oil systems GA Main Oil Safety Oil A On Off Solenoid Valve Solenoid Valve Tappi ET Gauge Port Oil Nozzle F Adjustment lt Oil Pump _ AT se Check Valve Return to Tank No Manual Valves lt in this line By Others Notes amp Options Check AN These Lines are Field ene ee ME Piped if a Remote Suction a Pump is Used Supply Line w By Others Unless Specified on Order Field Piped lt L Low Fire Start or H Low Hi Low N O Low Fire Low Fire Bypass Regulator Eames Main Oil Bypass Oil Valve Adjustment for Low Fire Press Sw Solenoid Safety Oil Approx 100 125 PSI Valve Solenoid Valve ni A i oo He i a EA 20r3 1 IN T_T out i High Fire Cylinder Louver Actuator Field Piped lt T A Port Oil Nozzle a ne cA Oil Pump Return to Tank Check Valve No Manual Valves ae hi IN RISE PP OMe Notes amp Options Check Shutoff Valve Valve Strainer These Lines are Field Suction gt pn po TT Piped if a Remote Pump Supply Line i kadi Required Above 20 GPH By Others if a Remote Pump is Used Unless Specified on Order Field Piped lt JB Manual Page 20 Fuel Systems MP Modulating Simplex Nozzle A Low Oil Oil Metering Press T Switch AN Gauge Port A Pa LAT x Jt lt Oil Pump Return to Tank No Manual
4. Main Motorized Vent Gas Valve 26 Sec Man Reset Low Gas Pressure Switch Manual Test Valve Gas Pilot Ignitor Man Reset High Gas Pressure Main Motorized vemi Gas Valve 26 Sec gt lt Manual VY Test Valve Main Motorized Gas Valve 26 Sec Dad V A Manual Test Valve Main Motorized Gas Valve 26 Sec gt lt V Manual Test Field Kt Valve Piped Man Reset High Gas Pressure Switch Manual Ball Valve SC A hans Manual Test Valve Field Piped Page 25 Field Piped Switch Test Connection A Gas Burner Manifold DK Manual Ball Valve 722009 Gas Pilot Ignitor Man Reset High Gas Pressure Switch Test Connection i Field Piped Manual Ball Valve Gas Burner Manifold 722023 Gas Pilot Ignitor Man Reset High Gas Pressure Switch Test Connection Gas Burner Manifold Manual Ball Valve 7722024 Gas Pilot Ignitor Test Connection s a Fuel Flow Gas Burner Manifold Control Valve 722004 Fuel Systems 722010 Field Piped Pilot Gas Pressure Pilot Solenoid Pilot Manual Regulator Valve Ball Valve DI G i as Pilot 2a S lt S Ignitor i Man Reset Low Vent To Outside Gas Pressure Atmosphere Switch Vent Main Motorized Man Reset Main Mortorized Gas Valve High Pressure Tesi Gas Valve 26 Sec Switch Manual Ball a Connection Valve Gas A Gas Burner Supply PE A gt
5. 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
6. x EEE anm STD when using remote oil pump Oi Pressure Gauge T Oil Metering Valve modulating x systems Remote Control Panel Future Gas Combustion Head OPT opt Fuel Metering CAM NETIC II X 1 The configuration of each unit will vary with specific job reguirements 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 Ignition n DC Model JB1 Sizing and Application Data contact Webster for complete information Maximum Burner Firing Capability Burner Motor HP Oil Pump Number Pals hii Gas Only 3 Oil or Pipe Size 4 Inlet Pressure NIDIOREE Gas scn 20igph __ Combination On Off LES Modulation 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 90 F 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
7. 090054 xxx Gas orifice 5 16 brass no radial holes 1 axial hole xxx hole dia 090055 xxx Gas orifice 5 16 steel no radial holes 1 axial hole xxx hole dia oe 090069 xxx Gas orifice 5 16 brass 4 40 radial holes 1 axial hole xxx hole dia 40x4x__ FB SF 090184 xxx Gas orifice 5 16 steel 4 40 radial holes 1 axial hole xxx hole dia 40x 4x 090185 000 Gas orifice 5 16 steel blank no radial or axial holes ff 090185 098 Gas orifice 5 16 steel 2 radial 40 holes no axial hole 40 x 2 ss 090227 xxx Gas orifice 5 16 brass 4 48 radial holes 1 axial hole xxx hole dia 48 x4x___ 090284 xxx Gas orifice 1 4 steel no radial holes 1 axial hole xxx hole dia e 000267 Offs extention she OD sel ube 16F ing 5 090288 Orie extention 5 16 OD steel tube 275mg 090318 Orie extention 5 16 OD brass ube 118800 JF 9031 Onto extention 5 16 OD rass ube 2750 SYS OT open ube No oie used no oles part number gen n BOM asune 0 T_T Note 1 Part numbers ending in xxx use the drilled hole diameter as the last three digits or FB Firebox the xxx A number 40 drill would be 098 SF Scotch Firetube 2 Part numbers ending in OOO 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 t
8. Introduction MODEL JB X BURNER MODEL CONFIGURATION FIGURE A 2 JBX1G 05 RM7800L M 25 M A UL CSD 1 BURNER SERIES JB SERIES FGR or NOx CONE USED NOT USED BLANK La CT s sx o joi Air or Steam Atomization BLOWER MOTOR Air Atomization HORSEPOWER Steam Atomization GAS TRAIN VENDOR ASCO sto 30 3 FLAME SAFEGUARD RUEDO V Mark TANANA ETP or ma LMV52 The above represents the common model designations Contact the factory for other options and special applications JB Manual Page 5 Identification Model JB1 Specification Data 400 2500 MBH Input Fuel Burned Fuel Burned 5 2L STANDARD UL EQUIPMENT 5 L AND IMPORTANT OPTIONS 1 STANDARD UL EQUIPMENT AND IMPORTANT OPTIONS No 2 Oil pressur atomized No 2 Oil atomized Motor Fan and Air Inlet Control X Air Flow Switch also with oil sys x tems using remote pump Switch and Indicator Lights High and Low Gas Pressure Motor Controller single phase x Opt vole de Switches st d over 2500 MBH i Metering Valve nodulation ony A Proven Gas Pit nio x Direct Spark Oil Ignition Transformer Inverted Housing Alternate Control Cabinet Positioning Main Manual Shutoff Valve X Main Safety Shutoff Valve X Second Safety Shutoff Valve X X X Main Gas Regulator Gas Checking Valve Oil Drawer Assembly with Diffuser five Main Safety ShutofVawe x Second Safely Shut vave
9. Valves in this Line By Others Check Valve Shutoff Valve Strainer Sucton gt Supply Line Fa j mf By Others Unless Specified on Order Field Piped i MR Modulating Return Flow Nozzles LN Back Pressure Low Oil Pressure Gauge Main Oil Solenoid Valve Solenoid Valve w E e T Main Oil Safety Oil Oil Nozzle Notes amp Options AN These Lines are Field Piped if a Remote Pump is Used Usage Reguirement Varies with Code Safety Oil Solenoid Valve Solenoid Valve Shutoff Valve Suction m Supply Line Check Valve By Others Unless Specified in Order Return to Tank No Manual lt Valves in this Line Field Piped lt JB Manual Page 21 Inline Oil Nozzle Bypassing Notes amp Options These Lines are Field Piped if a Remote Pump is Used Required Above 20 GPH if a Remote Pump is Used Pressure Gauge Fuel Systems 2 Air Atomized Oil Systems Air Filter i Ball Valve man set to adjust air volume amp high fire air pressure r q Pressure Gauge Oil Metering Valve Li Low Oil Pressure Gauge LE 2 Air Filter Ball Valve man set to adjust gi air volume amp high fire air pressure Pressure Gauge al Metering 1 1 High Oil Low Oil Temp Sw ae Sw High Oil Low Oil Temp Sw Temp Sw A H gt h eee olen emen ___oil temp switch Drain MA
10. 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 VAIA RNIN THE MINIMUM PILOT TEST REQUIRES CLOSE SUPERVISION OF THE COMBUSTION PROCESS FAILURE TO CLOSELY MONITOR THE MAIN FLAME TEST TIME COULD RESULT IN DAMAGE INJURY OR DEATH i If the pilot does not light the main flame under these test conditions check and adjust the pilot as shown in section H j The infrared detector must be tested for hot 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 operat
11. or MS Compressor iP eil Air pipe same size Low as discharge open Atomizing ing in air chamber Pressure field Piped B N C i Main Oil fees Valve L ab MA a Modulating 2 Oil Check Gauge Valve r 7 2 i Nozzle e a E Oil Ga Z Flexible Metal Hoses or Copper Tubing uge Relief a Valve Ball or Gate Valve Chamber Air pipe same as ow Air discharge open Press Sw ing in air chamber field piped ig Check Valve vile Ball Valve N C Main Oil Valve Safety Oil Valve N O Return Oil Valve Oil Supply for Preheat Housing Ball or Pressure Gate Valve Supply a Heating 3 valve bypass optional for back pressure valve Note For a single burner i with the pump set close to the burner the back pressure valve can be furnished piped with the oil pump set Ball or Gate Valve Modulating House Air or Steam MA si Compound Gauge M Gauge 2 Flexible M Check Valve y Return to Tank Check Gate Valve Valve Strainer 7 aa z Oil Suction Field Piped odulating 4 6 Oil Nozzle Dr e 7 ni Oil Preheat Housing Metal Hoses or Copper Tubing 1 4 Ball Valve Relief Valve Gauge ji 7 e Oil Return from Preheat Housing Cheek Kj ve Return nail to Tank Compound Gauge n Gate Check i Valv
12. 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 JB Manual Page 33 Startup and Operating Adjustments eguipped 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 s
13. ADJUSTING SCREWS DO NOT HAVE aa camper RESISTANCE TO TURNING THE CAM SHOULD FGR Valve BE REPLACED AS THE SCREWS MAY CHANGE POSITION FAILURE TO CHANGE A DEFECTIVE CAM MAY RESULT IN INJURY OR DEATH Dim Smaller Larger Angle A Slower LF Ta Faster LF ih arm travel arm travel CAUTION Length B Reduce n Increase i LARGE CHANGES FROM ONE ADJUSTING arm travel D arm travel D SCREW TO ANOTHER WILL RESULT IN PREMA Length C Increase driven Reduce driven TURE FAILURE OF THE CAM AND MAY PREVENT arm travel D arm travel D THE BURNER FROM OPERATING PROPERLY Figure l 1 Linkage Adjustments 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 b Decreasing the angle of the drive arm will slow the ini air damper to open slower make the jackshaft drive tial valve travel and speed up the travel at high fire This arm more parallel to the linkage rod Likewise the op would be done to get the air damper to match the fuel valve Posite contour can be corrected by speeding up the air action damper drive Figure l 1 The final cam screw profile should be close to the profile of the cam with no abrupt 3 Fuel Cam Adjustments changes The cam is used to adjust the intermediate fuel rate with 4 FGR Adjustments the low and high fire settings done by the linkage connec tions The intermediate rates can be adjusted by
14. 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 80 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 Ifa 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
15. Is the combustion chamber of proper size and is the center line height of the burner head adequate See charts C 2 amp C 3 Installation Pilot Pilot Gas Shutoff Pressure Pilot Solenoid Valve lc VA Valve EYA z E I FY Normally open vent valve Gas Supply Low Gas Gas Pressure Pressure aa r_ High Gas Regulator KA i Pressure Switch Switch Manual Gas N i l Shutoff Shutoff Leak Test Val Valve If applicable Webster iig supplied gas train Drip Leg Figure C 1 Typical Gas Piping Chart C 2 Chart C 3 TYPICAL COMBUSTION CHAMBER SIZE TYPICAL COMBUSTION CHAMBER SIZE FOR FIREBOX BOILERS WATERTUBE amp FOR SCOTCH MARINE FIRETUBE BOILERS CAST IRON SECTIONAL TYPES 0 LU T O n Z O O z 5 or Z LLI E Zz LU 0 tf lt lt 5 LU zZ Q Lu G d LLI ili uj O O Q lt D Z 2 XC E 5 Li LL PH o 90 120 MBH 42M 8 4M 12 86M 16 8M MBH 4 2M 8 4M 12 6M 16 8M D SPECIAL INSTRUCTIONS FOR CANADIAN INSTALLATIONS 1 The installation of a burner shall be in accordance with the Canadian Electrical Code Part I the regulations of the provincial installation requirements or in their absence the following shall govern Gas Burners CGAB149 1 and CGAB149 2 3 The installer shall identify label the main electrical power disconnect and the manual shut off valve on the Oil Burners CSA Standard B139 gas and or oil supply drop line to the burner Aut
16. Manifold Gas Pressure Manual Test X Manual Test anual Pe Vave Fuel Flow Regulator Valve Valve A Field Piped Control Valve FM Modulation Gas Piping Diagram 2 501 to 5 000 MBH Firing Rate 722010 722005 Field Piped Pilot Gas Pressure Pilot Solenoid Pilot Manual Regulator Valve Ball Valve I Gas Pilot De DK DX Ignitor Vent To Outside Atmosphere Main Motorized Vent Man Reset High Man Reset Low Gas Valve Gas Pressure Gas Pressure W POC Switch a Fuel Flow Connection ce Control Valve D C Gas Burner Manifold Gas Pressure Maalis Manual Field Piped Regulator Main Solenoid L Valve Test Valve Gas Valve UL Modulation Gas Piping Diagram 5 001 to 12 500 MBH Firing Rate 722005 722011 Field Piped Pilot Gas Pressure Pilot Solenoid Pilot Manual Regulator Valve Ball Valve DI Gas Pilot DE DX DK Ignitor i Man Reset Low Vent To Outside Gas Pressure Atmosphere j i i veni Switch Main Motorized Man Reset Main Motorized Gas Valve High Pressure Gas Valve W POC j Switch lest 26 Sec A Manual Ball Connection JA Gas Burner DS gt Manifold Manual Test Manual Ball Valve Fuel Flow Regulator A Valve 3 Valve Field Piped CONtrol Valve Gas Pressure V A Manual Test FM Modulation Gas Piping Diagram 5 001 to 12 500 MBH Firing Rate 722011 722082 Field Piped Pilot Gas Pressure Pilot Solenoid Pilot Manual Regulator Valve Ball Val a t M CA Gas Pilot DES PN gt lt Ignitor Vent To Outside Normally Op
17. OR EXPERIENCE FAILURE TO USE KNOWLEDGE ABLE TECHNICIANS CAN RESULT IN EQUIPMENT DAMAGE PERSONAL INJURY OR DEATH FUEL NATURAL GAS 2 FUEL OIL 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 VOLTS AMPS HERTZ PHASE HP or adjust this burner SONTROL CIRCUIT Every attempt has been made to accurately reflect the BURNER MOTOR burner construction however product upgrades and spe OLPUNP NOTOR E cial order reguirements may result in differences between the content of this manual and the actual eguipment Ld L_ These special components will be described in the infor mation provided with the burner and should be used as the controlling document The serial number represents the unique number for that burner and is a critical number that will be needed for any NOTE This manual must be readily available to all op Communications with Webster Engineering erators and maintained in legible condition The input rates define the maximum and minimum inputs 1 Nameplate Information for that burner given in MBH for gas and GPH for oil Air A l atomized burners show both the oil pressure and air pres Each burner has a nameplate with important job details sure Pressure atomized burners only list the oil pres JB Manual Page 3 Introduction sure For gas firing the gas manifold pressure is
18. complete the oil setup Then setup the gas input as defined in section Startup and Operating Adjustments 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 eguipped 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 setthe 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 fi
19. fuel cam needs to be checked for correct travel and alignment Positions can change during shipment and installation and they must be reviewed prior to startup The fuel cams are mounted to the ends of the jackshaft assembly A cam follower link follows the profile established by the adjusting screws and drives the fuel valve A thin metal band is used between the screw and cam follower to provide a smooth profile The adjusting screws are backed by compressed nylon inserts which provide a resistance to turning The cam Figure G 3 should be checked for the following conditions a At the low fire position the roller should be between the first two adjusting screws If not adjust the position of the cam accordingly making sure to maintain the same low fire fuel valve position b When the linkage is modulated from low to high fire the roller must stay in the center of the adjusting screws within 1 8 If needed the two cam set screws can be loosened and the cam moved to center it on the roller JB Manual Page 29 PILOT GAS GAS E SNES da VALVE DIL METERING VALVE ADJUSTABLE AIR LOUVER STOP AIR LOUVER DRIVEN BY MOD MOTOR OIL PUMP PRESSURE MODULATING GAS OIL SYSTEM c At high fire the roller should be between the last two adjusting screws d The adjusting screws should form a smooth contour with no jumps between the screws e In preparation of startup the retention plate can be removed tempora
20. inch of furnace pressure Capacity decreases by 2 for each 10 F increase in air temperature over 90 F Gas input ratings based on 1000 BTU cu ft and 0 64 specific gravity Sizes and pressure will vary with gas Oil input ratings are based on 140 000 BTU gal for ASTM 2 fuel oil Essential Ordering Information and Data Power Supply Confirm 120 60 1 for control circuit and electrical supply for burner motor s voltage frequency and phase Describe Boiler or Heater to be Fired Including the manufacturer model number furnace pressure and furnace size Firing Rate Define firing rates in MBH for gas and GPH for oil Fuel to be Burned Type of gas and or oil including the BTU value Approval Agency UL FM IRI GE GAP CSD 1 NFPA Mil spec and local codes if applicable Flame Safety Control Preferred Honeywell or Fireye controls Gas Train Components Preferred ASCO ITT Honeywell or Landis Control System ON OFF Low Fire Start Low High Low Modulation Posi Control Required Options Mounting plate limit controls etc JB Manual Page 6 Specification Model JB1 Dimentional Data 400 2500 MBH Input Dimensions are 1 4 inch 9 TO 24 TT 5 5 16 lt 11 7 16 Standard Arrangement Elevation 21 7 8 Standard Arrangement End View __ 36 15 16 19 3 8 F m 11 3 8 o E Standard Arrangement Inverted Arrangement Elevation Elevation W Optional Back Mount Control Cabin
21. position b 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 al
22. 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 Startup and Operating Adjustments the air proving switch Turn the adjusting screw cw in until the burner trips out shutdown caused by the air flow switch Turn the adjustment screw cew out 1 72 turns from the point of shutdown Checkthe 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 equ
23. 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 Ifa gas burner will there be adequate gas pressure to assure the specified firing rate 6 Ifa 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 Ifan 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 CAUTION The oil burner shall only burn that grade of oil shown on the UL rating plate DO NOT USE GASOLINE CRANKCASE OIL OR ANY OIL CONTAINING 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 T
24. 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 NOTE Always give Webster Engineering Serial Number and or UL Serial Number when ordering parts N WARRANTY VALIDATION amp 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 amp 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 JB Manual Page 48 Extended Shutdown Replacement Parts Start Up Report WARRANTY VALIDATION FIELD START UP REPORT CUSTOMER W O BURNER MODEL BOILER MODEL CONTROL CIRCUIT COMPONENT OPERATIONAL TESTING Check if Okay Primary LWCO High Limit 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 FIELD OIL FIRED GASFIRED COMBUSTION SETTINGS Low Med High Low Med High ina Ret CI I I I KAA NOx pom
25. 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 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 The following guidelines should be used for adjusting the levels as a result Generally the NOx levels only apply cam to gas firing and oil firing is not adjusted for NOx levels a When adjusting the screws the adjacent screws must There may be exceptions to this and the orders details also be adjusted to provide a smooth contour from screw to Should be reviewed to identify any special combustion screw When complete the flexible strip between the adjust requirements 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 Dual fuel units may need additional adjustments and compensation to handle the different FGR rates be tween natural gas and
26. 2 and Up Modulating 722084 NOTE Pressure Drops Pressure drop through a given gas train will vary somewhat in relation to the individual items used the specific gravity of the gas to be burned and the overall length 722091 Field Piped Pilot Gas Pressure Pilot Solenoid Pilot Manual Regulator Valve Ball Valve SY DSG Dx Vent To Outside Atmosphere Main Diaphragm Gas Valve Main Solenoid Gas Valve Manual Ball DK Field Piped Manual Ball Gas Supply Gas Pressure V7 Manual V Regulator A Test Valve A Manual Test Valve UL FM On Off Gas Piping Diagram Up to 2 500 MBH Firing Rate JB Manual Page 23 Test Connection 1 2 PSI Max Gas Pilot Ignitor Gas Burner Manifold Fuel Systems 722001 Field Piped Pilot Manual Ball Valve BC Pilot Gas Pressure Regulator CD SA Pd Pilot Solenoid Valve Vent To Outside Atmosphere Main Motorized Gas Valve 26 Sec Main Solenoid Gas Valve Manual Ball Valve Dad pid X lt Manual Test Valve Manual Ball Gas Supply gt K Manual V Test Valve gt 2 Field Piped Gas Pressure 7 Regulator Test Connection UL FM Low Fire Start Gas Piping Diagram Up to 2 500 MBH Firing Rate Pilot Gas Pressure Pilot Solenoid Regulator Valve CS RA DK 722022 Field Piped Pilot Manual Ball Valve p lt Vent To Outside Atmosphere Main Motorized Gas Valve 26 Sec A SX 4 ManualTest Manual Ball AS Val
27. 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 e Air inlet louver box e Fan and fan housing Burner housing e Firing head and blast tube JB Manual Page 46 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 lf 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 rota
28. B1 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 cific requirements of IRI FM GE GAP NFPA MIL spec or other special insurance or local code requirements JB Manual Page 9 Specification Model JB3 Specification Data 12 600 MBH Maximum Input STANDARD UL EQUIPMENT cl 3 O 5 No 2 Oil 1 STANDARD UL EQUIPMENT AND IMPORTANT OPTIONS AND IMPORTANT OPTIONS Pressure Air Atomized No 4 6 Oil Air Atomized Pressure Atomized NO 4 6 Oil Air Atomized Motor Fan and Air Inlet Control Main Manual Shutoff Valve Air Flow Switch Main Safety Shutoff Valve EI X 2 Burner Mounted Control Panel X Ultra Violet Scanner High and Low Gas Pressure Switches Motor Starter with Overloads Metering Valve modulating systems X Fuel Selector Switch Duel Fuel Burners Only Normal Open Vent Valve above x 12 500 MBH Proven Gas Pilot Ignition x Tx x Oil Drawer Assembly with Diffuser Pilot Solenoid Gas Valve x Tx x Oil Nozzles Pilot Gas Regulator amp Manual Valve Lx sex Oil Heater with Integral Thermostat O A O Ignition n Do m Pict Gas anton Transformer x x x Remote ourume Two Safety Sf vanes righ OF Temperature Swich FTF J amp Ese i ON Pressure Gauge i 1 The configuration of each unit will vary with specific job req
29. ROLS 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 List Before 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 JB Manual Page 32 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
30. S PRODUCT COULD EXPOSE YOU TO SUBSTANCES IN FUEL OR FROM FUEL COMBUSTION WHICH CAN CAUSE DEATH OR SERIOUS ILLNESS AND WHICH ARE KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM IMPROPER SERVICING OF THIS EQUIPMENT MAY CREATE A POTENTIAL HAZARD TO EQUIPMENT AND OPERATORS SERVICING MUST BE DONE BY A FULLY TRAINED AND QUALIFIED PERSONNEL BEFORE DISCONNECTING OR OPENING UP A FUEL LINE AND BEFORE CLEANING OR REPLACING PARTS OF ANY KIND TURN OFF THE MAIN MANUAL FUEL SHUTOFF VALVES INCLUDING THE PILOT COCK IF APPLICABLE IF A MULTIPLE FUEL BURNER SHUT OFF ALL FUELS TURN OFF ALL ELECTRICAL DISCONNECTS TO THE BURNER AND ANY OTHER EQUIPMENT OR SYSTEMS ELECTRICALLY INTERLOCKED WITH THE BURNER Date of Start Service Organization Information EO EIHEE Company Name Address Lead Technician Phone Number JB Manual Page 2 Safety Precautions TABLE OF CONTENTS Salley ad 51072 U11 10 NS rientra trai zo 2 A HALOS WOM rin RI a A E EE EEEE 3 Burner Model INUMADEE a stem 05 m aita n rken MAA kkk a tee a ll A riia Ait amil i 5 JBT Oe GING AOS iaia EOE E E E E E EE E E 6 UIBZ SPEGlIcaloAS ia inrunner rie nt 8 JBSSPECHICAloOnNS e ici io esi 10 B COMPONEHNFIASAHIGAlO lizzare errata mmm 12 C JEEE 10793 p BEEE EEEN E N A EEA ee a T 17 D Special Instructions For Canadian Installations ei 18 BOISE Mounting Crtead ccctaciincesenasateaeceistecosiaasnaaescnsets
31. annot obtain rated input on Oil nozzles plugged Replace nozzles oil firing pressure atomized By pass seal on nozzle leaking Replace nozzles a JJ lt Q gt E v Page 43 Troubleshooting OU G KAAR fee eC OO oo oo Oo Oo OO l Flow valve set too low Adjust oil control valve i m Ji KN i JI a a a La gt su mn gt a N in JB Manual Page 44 Troubleshooting K GENERAL MAINTENANCE AND CARE General Physical Inspection Fuel Air Ratio Gas Fuel Systems Oil Fuel Systems FGR System Combustion Air Fan MP M 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 ofthe besttools for a good maintenance programis 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
32. arm 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 I Press the reset button and restart the burner When the pilot has started open the manual gas valve to allow 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 l 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 adeguate 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
33. ase mounted directly to the panel back plate Figure B 5 Control Panel Hard Wired Design Burner Motor Starter Flame Safeguard Terminal Strip Pressure Gauge Air Filter Compressor JB Manual Control Relays Figure B 6 Air Compressor Page 13 Transformer Fuses Control Transformer Switch Light Panel Air Chamber Belt Guard Electric Motor Air Discharge Connection Identification Air Inlet Electrical Junction Box Louver Box Low Atomizing Drawer Assembly Air Press Sw Jack Shaft Oil C eee Atomizing Air GI KEHA Bleed Muffler Switch Air Bleed Valve Atomizing Air Press Gauge Blower Motor Oil Temp oS GG 1 E o Atomizing Line Gauge ATT 7 2 to Nozzle Supply Oil Press Gauge Trim Heater Safety Relief Valve Drawer Assm JAS ASI Pre heat Oil Lines Oil Supply To Nozzle Thermostat Control Nozzle Oil Switch 8 Cold Oil Press Gauge Interlock Switch Low Oil Press N O Return Safety Oil Switch Oil Valve Valves Figure B 7 JB Burner 4 6 Fuel Oil Choke Cone JB1 8 JB2 Only Primary Gas Orifices Behind Retention Plate Diffuser Assembly Oil Nozzle s Gas Pilot Secondary Gas Orifices Retention Plate Figure B 8 JB Combustion Head Dual Fuel JB Manual Page 14 Identification Mounting ln OS Orifice Plate Gas Manifold Nose Choke Cone Secondary Gas Orifices Primary Gas Ori
34. aused by the air flow switch Turn the adjustment screw ccw out 1 turns from the point of shutdown Check the operation at higher rates t Adjust the oil pressure switch to trip and shutdown the burner at a pressure that is 10 lower than the supply oil pressure 12 Air Atomized 2 oil Setup The air atomized oil system has the potential for a large turndown range similar to gas and has the potential to be adjusted to different low fire rates See the burner 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 Turnthe electrical power for the burner boiler and re lated components on e Verify that the oil metering valve is at the nearly cl
35. be between 0 1 and 0 1 we Essential Ordering Information and Data Power Supply Confirm 120 60 1 for control circuit and electrical supply for burner motor s voltage frequency and phase Describe Boiler or Heater to be Fired Including the manufacturer model number furnace pressure and furnace size Firing Rate Define firing rates in MBH for gas and GPH for oil Fuel to be Burned Type of gas and or oil including the BTU value Approval Agency UL FM IRI GE GAP CSD 1 NFPA Mil spec and local codes if applicable Flame Safety Control Preferred Honeywell or Fireye controls Gas Train Components Preferred ASCO ITT Honeywell or Landis Control System ON OFF Low Fire Start Low High Low Modulation Posi Control Required Options Mounting plate limit controls etc JB Manual Page 8 Specification Model JB2 Dimensional Data 6000 MBH Maximum Input Dimensions are 1 4 inch 6 24 OTT 5 5 16 28 5 8 4 4 19 1 16 19 17 3 4 e 30 11 16 Standard Arrangement Standard Arrangement Elevation End View 19 1 2 Standard Arrangement Elevation W Optional Back Mount Control Cabinet Inverted Arrangement Elevation Fuels Burned and Control Systems Natural Gas Propane Digester or Mixed Gases Light 2 through Heavy 6 Fuel Oil Low Fire Start Low High Low Modulating or Micro Modulation Control Circuit Requires 120 vac 60 Hz Single Phase Voltage Supply Model J
36. ch 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 seguence 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 JB Manual Page 37 cause it must fill the oil lines before providing oil to the nozzle Press the reset button on the flame safeguard to restart the burner WARNING DO NOT ATTEMPT TO START THE BURNER WHEN EXCESS OIL HAS ACCUMULATED WHEN THE UNIT IS FULL OF VAPOR OR WHEN THE COMBUSTION CHAMBER IS HOT j After a fe
37. dimension e 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 JB Manual Page 34 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 e 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
38. direct spark is 20 GPH at low fire or 35 GPH at high fire standard on straight oil burners pressure atomized X Integral Oil Pump JB2 07 to JB2 20 Remote Oil Pump JB2 30 to JB2 50 O Ignition Two Safety Shutoff Valves IN Low Oil Pressure Switch STD when ed wa using remote oil pump Oil Pressure Gauge Oil Metering Valve modulating system X O X 17 1 Power Call for Heat Ignition Model JB2 Sizing and Application Data contact Webster for complete information Model Maximum Burner Firing Oil Pump Motor HP Air number i Capability Range Pipe Size 3 Inlet Press in wc Pressure Air eee ae 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 90 F 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 10 F increase in air temperature over 90 F 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
39. e Strainer Valve Oil Suction Oil Pump Field Piped Low Atomizing Pressure Switch a N C dl Atomizing Check Valve Valve A 4 1 AN Steam Steam Syphon Syphon 300 Ib A Gauge I Steam Syphon EJ Pressure l i Reducing Ball or Gate it Valve Metering Lever Ball Valve Linked Valve Steam A 125 PSIG Strainer A i to Mod Motor Max I moatt A m n Atomizing Eki aa ae i 2 D i LE Steam I Steam pi all or Gate l i b alve t Trap Condensate Pe A Return q TAL in Drip Le s Re a wee e TII preg FieldPiped __ JB Manual Page 22 NOTE House air does not use steam Syphon or Steam Trap Fuel Systems 3 Gas Systems Illustrated Gas Trains by Capacity and Code The following illustrations show the Webster configuration for UL FM and IRI as grouped by UL capacity ratings Refer to the legend below for component part identification These illustrations are not to be used for field erection and or system design purposes Webster Designation UL Capacity Range BTU Hr Operation Mode On Off Low Fire Start To 2 500 000 teverina Modulating Low Fire Start Low Fire Start SRI Low Hi Low to 5 000 000 Low Hi Low Modulating Modulation 9 000 001 to 12 500 000 Modulating Z Z Z ZII rcr cles IT E lt Modulating 722091 722001 722022 722003 722002 722009 722023 722024 722004 722010 722005 722011 12 500 001 72208
40. eck operation of shutoff FGR valve for full rotation and position proving MEI switch FGR Duct Inspect and clean FGR duct FINN Combustion Air Fan Clean combustion air fan and housing KI E So a EA page or other unusual indication Bumer Mounting Check burner mounting camps and brackelsfortghiness x Refraciory and Seals Check burner refractory for cracks or signs ofeekage CX oi nozze Cheskandeeanoineze Tx Air Compressor Check air compressor tor tubricaton i and armor x Ar Compressor Check aircompressorrelsfvalve operation x_ Manual Page 47 General Maintenance amp Care Boiler Operator N c 5 lt I d AS E KS S co E 9 D lt E x gt xx gt e f XI Xx x X X XX X xX X X X XxX X X et ttt eA T T TL eee fpf day PT ttt tt e PITT bel Et vee bebe DIL Pte tT tT TT TTT Tt gt gt Monty LISI tt Pe T ep TT Seasona et ttt ttt ttt ty Pele Pp gt EE net X ls WU L CARE OF THE BURNER DURING EXTENDED SHUTDOWN Heating eguipment 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 Always keep the main fuel valve s OFF
41. eflon 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 JB Manual Page 17 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 FGRis 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 WARNING DO NOT USE TEFLON TAPE OR COMPOUNDS CONTAINING TEFLON THIS COULD DAMAGE THE VALVES CREATING AN UNSAFE OPERATION 21 Is the burner mounting plate and burner head sealed with rope gasket See Figure E 2 22 Has the new gas and oil piping been purged to remove debris 23 Is there a drop leg in the gas supply to capture foreign material See Figure C 1 24 Is the piping between the gas train and burner done in a manner that will minimize the pressure drop 25 Has all of the piping been pressure checked for leaks 26
42. en Vent l Vent Man Reset High Gas Pressure Atmosphere Vent Valve Main Moiorizeg Gas Pressure Regulator Gas Valve Switch Main Solenoid W POC Fuel Flow Test Gas Valve 14 sec Connection Manual Ball Manual Ball Control Valve Valve Gas Burner sun gt DEC gt lt EL a Manifold Man Reset Low Gas v7g Manual cz Manual Test Field Piped Pressure Switch A Test Valve Valve UL Modulation Gas Piping Diagram Over 12 500 MBH Firing Rate 722082 JB Manual Page 26 Fuel Systems 722084 Pilot Gas Pressure Pilot Solenoid Regulator Valve Field Piped Pilot Manual Ball Valve A E vA DK Dec Normally Open Veni Vent Valve l l Vent Man Reset High Main Motorized Gas Pressure Gas Valve Switch W POC 14 sec Vent To Outside Gas Pressure Atmosphere Regulator Main Motorized Gas Valve W POC 14 sec Manual Ball Valve DSC Field Piped Manual Ball V Manual Test V Manual Man Reset Low Gas X Valve Pressure Switch Test Valve Gas Pilot Ignitor Fuel Flow Test Control Connection Valve Ne Gas Burner Manifold FM Modulation Gas Piping Diagram Over 12 500 MBH Firing Rate JB Manual Page 27 Fuel Systems G INITIAL SETTINGS The 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 specific ap plication These general settings are covered in this chapt
43. equence 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 JB Manual Page 35 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
44. er as a means of checking the burner linkage and settings can move in shipment or readjusting the burner if the settings are lost 1 Oil nozzle position The oil nozzle initial position is shown in Figure OIL NOZZLE G 2 The oil nozzle will be adjusted at start up AIR DIFFUSER and may be moved in or out from this initial set Figure G 1 ting In some cases the oil nozzle may be inside Oil Nozzle Position the diffuser Gas Pilot Chart G 2 INNER FIRE CYLINDER Return Springs HA 11 0 Cam Set Screws VII VOT is Adjusting Screws Aluminum Strip 5 DI ayy yay NINA 4 4 7 G N a m fat vd A A AA A End Screws M VONN Spring N UNNI End Screw Adjusting Nut UV Cam Follower Retention Roller Washers Plate Roller o Follower Figure G 3 Fuel Cam Adjustment JB Manual Page 28 Initial Settings COMBUSTION AIR CONTROL Panel Adjusting ScreW Air Proving Switch 2 AIR PROVING SWITCH The air proving switch has been adjusted at the factory for an initial setting Ifthe switch trips during initial start up turn the adjustment screw ccw two full turns to re duce the trip pressure setting AIR FLOW INTERLOCKING SWITCH 3 TYPICAL AIR AND FUEL ADJUSTMENT LOCATIONS LOW FIRE OIL PAESSURE OIL CYLINDER MOTORIZED DRIVEN AIR LOUVER GAS VALVE DRIVEN AIR LOUVER LOW FIRE START GAS OIL SYSTEM 4 Fuel Cam Adjustments if applicable The
45. et Optional Fuels Burned and Control Systems Natural Gas Propane Digester or Mixed Gases Light 2 Oil Mechanical Pressure On Off Low Fire Start Low High Low Modulating or Micro Modulation Control Circuit Requires 120 vac 60 Hz Single Phase Voltage Supply Model JB1 burners are listed by Underwriters Laboratories Inc UL ULC Also by the State of Massachusetts Fire Marshal City of New York Board of Standards and Appeals State of Minnesota and can be packaged to meet specific requirements of IRI FM GE GAP NFPA MIL spec or other special insurance or local code requirements JB Manual Page 7 Specification Model JB2 Specification Data 6000 MBH Maximum Input STANDARD UL EQUIPMENT AND IMPORTANT OPTIONS a 1 STANDARD UL EQUIPMENT AND IMPORTANT OPTIONS Motor Fan and Air Inlet Control X Air Flow Switch X 2 Burner Mounted Control Panel x Pressure Air Atomized Pressure Air Atomized X X X x Transformer Positioning x 1 The configuration of each unit will vary with specific job reguirements 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 On and Fuel On for circuit board panels 3 Maximum rate for
46. every shift while operating b Air compressor belt tight and in good condition c 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 General Maintenance amp Care a good seal The basket can be lifted out and cleaned with a soft brush and cleaning solution d Vacuum higher than the 10 limit on suction side of pump indicates need to clean strainer as described above If cleaning the strainer does not resolve this check the other valves between the tank and gauge for plugged or closed position e Air atomized oil nozzles should be cleaned periodically depending on the type of operation and the observed need for cleaning Extended operation at very low rates less then 15 of capacity can cause carbon buildup on the outside of the nozzle This can be cleaned with a rag and cleaning solution If the fire is showing some 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
47. fice Drawer Assembly Retention plate Assembly mener aU KL Diffuser Ignition Electrode Figure B 9 Standard Head Arrangement Section View Pilot Assembly EE TITTI i Gas Inlet Gas Manifold inner cylinder Retention Plate Assembly This connection between the retention plate as sembly and the gas manifold inner cylinder must be properly made for proper performance Oil Supply Line Diffuser Mounting Bracket Back Mounting Plate w View Port l Oil Return Line Oil Nozzle s To Oil System Adapter Return Oil Nozzle s l Diffuser Oil Supply Line VOWEr pipe Pilot Gas Supply Line Gas Pilot Pilot Gas Supply Ignition Electrode Figure B 10 JB3 Combination or Straight Oil Drawer Assembly with Proven Gas Pilot Oil Supply Line Pilot Gas Line Ignition Electrode Gas Pilot Pilot Gas Inlet Oil Nozzle s Adapter Oil Nozzle s Oil Supply Line Backplate Figure B 11 JB1 amp 2 Combination Drawer Assembly with Proven Gas Pilot Ignition JB Manual Page 15 Identification Oil Supply Line Oil Ignition Electrodes Diffuser Oil Nozzle S Oil Supply Line Diffuser Clamp Sight Tube Ke lee apter Back Plate Figure B 12 JB1 8 2 Straight 2 Oil Drawer Assembly with Direct Spark Ignition Gas Orifice Part Number and Description Part No Description Sketch Vessel a ee Foe 090002 098_ Gas ori co 5116 brass 2 radial 40 holes no axial hole Goxa FB
48. fuel input increasing the O2 level If eguipped with FGR the NOx level should be close to the desired NOx as reguired 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 input HHV Higher heating value of gas BTU cubic feet Patm Atmospheric pressure in inches Hg Pgas Gas pressure before gas meter in inches Hg inches HG PSIG x 2 04 Tgas Gas temperature at the flow meter in degrees F Measured ft volume of gas measured by meter sec Time for measured ft to flow through mete
49. given in in wc which is inches of water column The electrical ratings of the burner are given with the volt age current load freguency 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 72 the FGR is closed during oil firing The burner can also be equipped with a NOx cone for lo
50. he 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 Startup and Operating Adjustments according to the type of system limiting potentiometer or matching gas r Re adjust the midfire points for the correct O2 levels The linkage may need to be readjusted to obtain the correct relationship between the fuel valve and air damper See Figure l 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 reguired 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 cew out 1 turns from the point of shutdown Check the operation at higher rates FIGURE 1 4 Typical Atomizing Air Pressure Rate Minimum 2 10 25 13 Heavy Oil Setup CAUTION WHEN WORKING WITH HEATED OIL PROTEC TIVE CLOTHING INCLUDING GLOVES SHOULD BE WORN TO PROTECT FROM BURNS The ai
51. he outside 4 Radial Holes 2 Radial Holes 1 Axial Hole 2 2 6 IE i Slot A Slot Orifice Sum E Orifice Example oA Orifice Example p No Radial Holes 1 Axial Hole 4 Radial Holes Axial Hole xxx 2 Radial Holes No Axial Holes If the radial drill size is a 40 drill this If the radial drill size is a 40 drill this The threads run the full length would be called a 40 by 4 orifice would be called a 40 by 2 orifice of the orifice This orifice cannot which is common in the JB burner line which is common in the JB burner line have radial holes JB Manual Page 16 Identification C INSTALLATION Prior 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
52. he 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 e Remove the gauge or manometer and plug the open ing e Cycle the burner on and off to determine if the limit works properly e 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 e 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 e 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 e Remove the gauge or manometer and plug the open ing e Cycle the burner on and off to determine if the limit works properly e If the limit causes nuisance shutdowns because of small pressure changes during startup increase the pressure setting an additional 5 Startu
53. horities having jurisdiction should be consulted before installations are made 4 Oil and gas burning equipment shall be connected to flues having sufficient draft at all times to assure safe 2 All electrical wiring shall be done in accordance with and proper operation of the burner JB Manual Page 18 Installation Canadian Installations E BURNER MOUNTING CRITERIA It is of vital importance that the burner be properly mounted to the boiler or appliance being fired Improper mounting can cause leakage of the hot gases back around the burner head resulting in warpage and deterioration The following illustrations show the proper way the burner must be installed to validate warranty conditions YPICAL JB1 2 3 BURNER REFRACTORY FRONTPLATE B Dimensions Inches Bolt Circle Use minimum Minimum 7 gauge MODEL DIM A of four 4 1 2 7 5 8 10 3 4 i 2 Minimum studs with lugs 2 Minimum 9 5 8 12 3 4 11 5 8 14 3 4 Note For JB burners equipped See Note 3 with a low NOx cone refer to ad dendum number 950064 am 2 ve I Contact Webster for more detailed pie S AS OV refractory drawings Minimum of six 6 holes for boiler mtg studs 1 2 or larger Refractory OD is sized to fit vessel opening with 1 4 to 1 2 gap Refractory must A extend 2 beyond tube Figure E 1 sheet for scotch boilers Refractory Dimension Minimum 14 Gauge This surface must be a sealed against the vessel Fill voids be Check
54. hould be used A60 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 e 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 e 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
55. if the burner is shut down for an extended period of time 2 Turn off the main electrical disconnect to the burner OFF Follow tagout lockout procedures 3 Place a notification tag or label at the main manual fuel valve giving reason for shutdown Follow tagout lockout procedures 4 If the burner is in an area subject to sweating and condensation cover the control cabinet and electrical 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 M REPLACEMENT PARTS be stocked to support uninterrupted burner operation Pilot Electrode Blower Wheel Oil Pump if oil burner Oil Pump Coupling if oil burner Pilot Ignition Transformer Oil Ignition Transformer if used Gas Pilot Solenoid Valve Flame Scanner Items with greater life expectancy and or greater dollar 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 An illustrated parts drawing is included within the Burner Instructions Manual to aid in parts identification The noun name of
56. il Pressure and Tem Check oil pressure and temperature switch for smooth operation and correct x perature Interlocks action Atomizing Air Pressure Check air atomizing pressure interlock switch for smooth operation and cor x rect action Interlock Controls Check other interlocks that may be used on the burner for smooth operation and correct action Firing Rate Control Check firing rate control and verify settings x Combustion Tuning Conduct a combustion test verify setting and NOx emission levels x Pilot and Main Fuel Valves Make visual and manual check for proper seguencing of valves Pilot and Main Fuel Valves Check all coils diaphragms interlock switch 8 other parts of all safety shutoff MES valves Pilot and Main Fuel Valves Perform leak tests on all safety shutdown control valves x Low Pressure Air Switch Test low air pressure switch for proper operation and adjustment AT or Mod Damper Switch Check damper low fire proving switch per manufacturers instructions Linkage and Fuel Cams Check linkage and cams for wear and replace any items with wear indication or stress cracks FER Contrai Vave Vivalinspeciontor soom ana fee i OO a EGR Control vawe Cieanand ubicate FGR contolvane x EGR Shuto Vave Visual spect tor smoot and compete ve x EGR Shuto ave Cieanand ubicate FGR sito vive x EGR Condensate Drain Open FOR condensate orains remove ali condensata x FGR Shutoff Valve Switch Ch
57. ing 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 Startup and Operating Adjustments It is recommended that the burner be manually driven to low fire before turning the burner off as this reduces the dynamic and thermal stress If the burner will remain off for some time the manual fuel valves fuel pumps and power supply should be turned off CAUTION ALWAYS KEEP THE FUEL SUPPLY VALVE SHUT OFF WHEN THE BURNER IS SHUT DOWN FOR AN EXTENDED PERIOD OF TIME 18 Restarting after Extended Shutdown Extended shutdowns require the same startup process as those outlined above In addition the following advanced cleaning must be done a The air atomized oil nozzle should be removed and cleaned if pressure atomized they should be replaced Use care in cleaning to preserve the sharp edges of the nozzle which are required to maintain good atomization b The oil filter and strainer must be removed and cleaned pr
58. inkage 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
59. ior to starting CAUTION DO NOT START THE BURNER UNLESS ALL CLEANOUT DOORS ARE SECURED IN PLACE JB Manual Page 41 Startup and Operating Adjustments J TROUBLESHOOTING System Cause Correction PAN Z 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 N 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 Check location of scanner tube flame present Scanner tube not positioned correctly Scanner tube dirty or wet oil film Clean scanner tube scanner Scanner or amplifier faulty Replace Pilot improperly positioned Check pilot position Incorrect gas pressure to pilot Readjust pressure Combustion air flow rate too high Readjust damper No main gas flame Clean scanner lens and tube pilot OK Weak scanner signal Damper or fuel control valve setting incorrect Readjust Fuel valve s not opening Check wiring to valves No mai
60. ipment 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 p
61. kage 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 Startup and Operating Adjustments ible strip is required to move to a screw position where it is initially not in contact with the screw Also the Drive Arm 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 Jackshaft 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 Modulating Range 90 Driven Arm WARNING IF THE CAM
62. ld be 100 psi for simplex systems and 65 psi for return flow nozzles The high fire position should be about 45 to 60 travel from low fire For air atomizing the low fire should be on about 2 po sition and the high fire should be about the 8 position Ignition Systems FigureH 3 JB1 and JB2 i Po i OIL NOZZLES x D C FIGURE H 6 TRIPLE NOZZLE SPRAY ANGLE W INNER FIRE CYLINDER DIRECT SPARK OIL IGNITION See Table Below Note These represent initial nozzle settings The final position will be determined in the start up process FIGURE H 7 DIMENSION TABLE FOR DIRECT SPARK OIL IGNITION Pressure Atomizing BURNER DATA ADJUSTMENT SETTINGS Inches 45 4 e JB Manual Page 31 Ignition Systems f o ay I STARTUP AND OPERATING ADJUSTMENTS Pre start Checkout Linkage Adjustments Fuel Cam Adjustments FGR Adjustment Burner Drawer Adjustments Single Fuel Setups Combination Gas and Pressure Atomized Oil Combination Gas and Air Atomized 2 Oil Combination Gas and Heavy Oil 10 Gas Setup 11 Pressure Atomized Oil Setup 12 Air Atomized 2 Oil Setup 13 Heavy Oil Setup 14 Operating Control Adjustments 15 Limit Tests 16 Pilot Test 17 Burner Shutdown 18 Restart After Extended Shutdown CoN OL dra This section covers the startup and operating adjustments of the Webster Models JB and JBX burners WARNING BURNER STARTUP COMBUSTION ADJUSTMENTS AND LIMIT CONT
63. linkage and tighten all joints Fuel cam screws have moved Replace fuel cam Fuel line plugged Check and clean lines strainers amp 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 AA AS z ad 3 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 amp 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 4 annot obtain capacity on Wrong spring range in regulator Install higher spring range 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 Q 42 5 C
64. lt aaneuserodaisaniecaisetiesetuedanconeccandamaonmenduaedeeetamenneaaeseslcouneeds 19 E ak 1S ae II ua ER i tn 20 G IGES fe ARR RE REA 28 H EITM CUO SyS OS SM A a m mm m Tu ua a au 30 l Start up amp Operating Adjustments iiii a kli miki kt 32 J TOUDE MOON siii ora 42 K General Maintenance and Care iaia rc 45 L Care of The Burner During Extended Shutdown mimernnenennnunue vanne nnnanennnane nn nnnnannnan annae 48 M REPIACEMEnE Pars i ii de 1 aai Eiai a i aiae 48 N Warranty Validation amp Field Start up Report iii 48 DIARY REPORT 49 A INTRODUCTION similar to the nameplates shown in Figure A 1 An This manual covers the Models JB1 JB2 and JB3 CYCLO X in the model number refers to a low NOx burner NETIC burners offered by Webster Engineering 8 Manu where FGR or a NOx cone is used to reduce the NOx facturing Co LLC These burners can be used in a wide in the combustion gases If the burner is not a low NOx variety of Cast Iron Firebox Firetube Flextube and other burner there is no X in the model applications They can fire gas oil and combination gas and oil with several different operating systems Figure A 1 Nameplate READ AND SAVE THESE INSTRUCTIONS FOR REFER MODEL NUMBER SERIAL NUMBER ENCE WARNING DO NOT ATTEMPT TO START ADJUST OR MAIN TAIN THIS BURNER WITHOUT PROPER TRAINING GAS INPUT RATING OIL INPUT RATING MBTU HR IN WC GPH PS
65. n oil flame Clean scanner lens and tube pilot OK Weak scanner signal 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 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 N 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 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 High CO at low fire firing gas Input too low for burner components Improper excess air level Readjust excess air Check input compare to rating label _ UU lt Q gt E v Page 42 Troubleshooting System Cause Correction High CO at l
66. nd 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 02 level should be between 4 and 7 See Figure 1 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 e 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 e The atomizing air pressure can be adjusted using the air bleed valve Figure l 4 e The oil temperature can be adjusted to obtain the best atomization I 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
67. number furnace pressure and furnace size Firing Rate Define firing rates in MBH for gas and GPH for oil Fuel to be Burned Type of gas and or oil including the BTU value Approval Agency UL FM IRI GE GAP CSD 1 NFPA Mil spec and local codes if applicable Flame Safety Control Preferred Honeywell or Fireye controls Gas Train Components Preferred ASCO ITT Honeywell or Landis Control System ON OFF Low Fire Start Low High Low Modulation Posi Control Required Options Mounting plate operating controls limit controls etc JB Manual Page 10 Specification Model JB3 Dimensional Data 12 600 MBH Maximum Input Dimensions are 1 4 inch 38 1 4 _________ 4 n 15 15 16 Standard Arrangement Standard Arrangement Elevation End View 22 1 2 Standard Arrangement Elevation W Optional Back Mount Control Cabinet 11 1 4 Fuels Burned and Control Systems Natural Gas Propane Digester or Mixed Gases Light 2 through Heavy 6 Fuel Oil Inverted Arrangement Modulating Control System Micro Modulation or Linkage Elevation 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 cific requirements of IRI FM GE GAP NFPA MIL s
68. 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 JB Manual Page 45 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 l
69. osed position f Turn the burner switch on This will start the blower mo tor and initiate the purge cycle g When the prepurge seguence 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 JB Manual Page 38 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 l 3 for O2 rates and the nozzle oil press should be between 5 and 15 PSIG see Figure 1 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 f
70. ow 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 1 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 1 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 Stabilize draft Adjust the nozzle to diffuser position High stack draft especially at low fire Incorrect nozzle position Fluxuating oil pressures regulator not holding Check regulator pressure and oil supply Poor air flow distribution off center flame Too much FGR if equipped Reduce FGR rate Adjust air straightener blade N Fuel Air Ratios are Linkage flexing Realign linkage straighten rods not consistent Linkage slip Check
71. p and Operating Adjustments Natural Gas Natural Gas With FGR No FGR Figure l 3 O2 levels Min 02 Min 02 Min 02 Max 02 Max 02 Max O2 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 swit
72. pec or other special insurance or local code requirements JB Manual Page 11 Specification B COMPONENT IDENTIFICATION This secion shows the different common components used in the JB burner line and should be helpful to identify parts described elsewhere in this manual Light 8 Switch Panel Control Cabinet Mod Motor Control Transformer Figure B 1 JB2 Burner i Sight Glass Oil Fuel A Drawer Assembly Blower Motor Linkage Gas Valve Louver Box Oil Pressure Switch Oil Valve Oil Pressure Gauge Pilot Solenoid Pilot Gas Regulator Gas Actuator Combustion Head gg n 4 f ae Gas Valve i ie Manual Ball Valve a sf Figure B 2 JB1G Left Side View Ignition Transformer Air Flow Switch AN kis EE Pilot Gas Regulator MN 27 M Gas Actuator High Gas ci aR 3 Pressure Switch Figure B 3 Gas Pressure Gauge JB1G Right Side View JB Manual Page 12 Identification Board to Light Panel Cable Switch Light Panel Figure B 4 Control Panel Circuit Board Design Panel Wiring Terminal Strip Combination Flame SafeGuard Base and Circuit Board Field Wiring Terminal Strips Light Panel Circuit Board Flame SafeGuard Base Board to Light Panel Cable Electrical Panel Identification The above pictures show the flame safeguard base mounted on a circuit board Connections are wired via cable to light switch circuit board Picture below shows the flame safeguard b
73. 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 Position On a straight gas burner the air damper should be open about 1 4 at low fire and close to full open at high fire In JB Manual Page 30 Natural Gas Pressure 4 6 wc LP Gas Pressure ee tete Rt a aS 0 eee see ta 24420 INSULATOR ASS Y some applications the pilot requires an orifice in the pilot gas supply line With the exception of the JB3 this ori fice is located external of the blower housing The pilot to diffuser dimension is the distance of the face of the pilot to the outer diameter of the diffuser For an oil or combination burner the air damper should be open about 3 8 at low fire and close to full open at high fire 4 Gas Modualting Control Valve Position The gas valve should be open about 10 at low fire and stroked to abput 60 open at high fire 5 Oil Modulatining Control Valve Position For pressure atomizing the low fire position should be adjusted to get the correct low fire presure as stated on the rating label Typically this wou
74. r Note Some gas meters require a 6 inch wc correction to Pgas Consult your meter calibration data JB Manual Page 36 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 e At the lowest gas pressure adjust the low gas pressure setting up until the switch breaks and causes the burner to shutdown From t
75. r 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 Startup and Operating Adjustments p Adjust the low fire input using the fuel cam or low fire regulator on LO HI LO systems and air damper adjust ments Ifthe burner is eguipped 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 l 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 c
76. r 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 150 F for 4 oil 180 F for 5 oil and 200 F for 6 oil a Priorto startup the oil system must be operating with the oil temperature to the burner before the trim heater within 20 F ofthe 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 JB Manual Page 39 WARNING DO 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 a
77. ressure 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 JB Manual Page 40 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
78. rily to make it easier to adjust the Screws THE RETENTION PLATE MUST BE REPLACED WHEN SETUP IS COMPLETE If the unit is equipped with a parallel positioning system linkageless the control valves can be positioned and operated in a similar manner but accomplished through the controller Refer to the instruction manual for details CAUTION LINKAGE AND ACTUATOR MOUNTINGS CAN BE BENT OR MOVED DURING SHIPMENT AND INSTALLATION THEY MUST BE CHECKED PRIOR TO OPERATION AND FAILURE TO CORRECT A ANY FAULTS CORRECTED MISALIGNED CONTROL WILL RESULT IN PREMATURE FAILURE Initial Settings H Electrode Clamg Figure H 1 JB1 amp JB2 Gas IGNITION SYSTEMS Spark Gap 1 10 Pilot Note Required 2 1 2 3 wc pressure for natural gas ans 1 2 2 for LP as measured at the Pilot last solenoid in the pilot train Figure H 2 JB3 PILOT ASSEMBLY SUPPORT TUBE MOUNTED PILOT RAW GAS ORIFICE ACCESS PLUG RAW GAS TUBE E 4 ref E p VENTURI AIR ANNA ELECTRODE amp 1 Gas Pilot Assembly A crucial part of reliable burner operation is a dependable pilot which must be properly adjusted and kept clean A gas pilot is standard for all models except JB1 through JB2 20 straight oil pressure atomizing burners which have direct spark ignition as standard The following illustrations show the typical configuration and nominal adjustment parame ters of each pilot Figure H 1 showns the JB1 amp JB2 gas
79. ring 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 s
80. t Ignitor Gas Burner Manifold 722002 Fuel Systems Pilot Gas Pressure Regulator X 722009 Field Piped Pilot Manual Ball Valve Ded Vent To Outside Atmosphere Pilot Solenoid Valve Pd Man Reset Low Gas Pressure Switch Manual Ball Gas Pressure R iat Manual Test egulator Valve FM LowFire Start Gas Piping Diagram 2 501 to 5 000 MBH Firing Rate Field Piped Pilot Gas Pressure Regulator Dee 722023 Pilot Manual Ball Valve De Vent To Outside Gas Pressure Atmosphere Regulator Main Motorized Field Piped Pilot Solenoid Valve DK Main Solenoid Manual Ball Man Reset Low Gas Pressure Switch UL Low Hi Low Gas Piping Diagram 2 501 to 5 000 MBH Firing Rate 722024 Field Piped Pilot Gas Pressure Regulator o Pilot Manual Ball Valve BC Vent To Outside Gas Pressure Atmosphere Regulator Gas Valve Field Piped Test Valve Pilot Solenoid Valve DK Main Motorized Gas Valve Manual Ball gt Gas Supply a Pressure Switch FM Low Hi Low Gas Piping Diagram 2 501 to 5 000 MBH Firing Rate Pilot Gas Pressure Regulator TA Dad Field Piped Pilot Manual Ball Valve Pe Vent To Outside Atmosphere Manual Ball Gas Pressure Regulator Main Solenoid Gas Valve UL Modulation Gas Piping Diagram 2 501 to 5 000 MBH Firing Rate JB Manual 14 sec Manual A Test Valve Pilot Solenoid Valve S Dad
81. te 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 amp Care 8 Inspection and Maintenance Schedule Component Item Recommended Action or Test a Visual inspection for smooth and free travel ae airDamper Visualinspestiontorsmooih and fee travel OO Fuel Metering Valves Visual inspection for smooth and tee tave Draft Controls Stack Visual inspection for smooth andres wave TX Gas Fuel Pressure Recordinlog book compere ends TXT oi Pressure Recordin log book compere vent Jx atomizing Ar Pressure Recordin logbook compere ends TXT Pe Visulyinspeckpiot lame check and record lame signal avengihifmeteres x Flame SafeGuard Pilot Close manual fuel valve on pilot during cycle and check for safety shutdown Test recording time Flame SafeGuard Main Close manual fuel valve on pilot during cycle and check for safety shutdown X Flame recording time Flame SafeGuard Check flame safeguard components including scanner i Flame SafeGuard Replace flame safeguard components in accordance with manufacturers instructions Pilot Turndown Test Conduct pilot turndown test annually or after any component change KI a Hot Refractory Test Conduct hot refractory hold in test This test is required annually or after any component change O
82. 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 Aload 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 lin
83. uel making it richer and reducing the O2 level Turning the cam screw out will reduce the fuel input increasing the O2 level e The air damper should be positioned for the correct low fire settings e 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 I 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 t
84. uirements 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 O O 2 O x x Model JB3 Sizing and Application Data contact Webster for complete information Model Maximum Burner Firing Capability Range 2 Oil Pump Motor HP 4 6 Air Number Furnace Pump Compressor The above maximum ratings are based on 0 furnace pressure an altitude of 1000 feet 90 F 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 10 F increase in air temperature over 90 F 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 we 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
85. ve Valve Main Solenoid Gas Val Manual Ball li Gas Pressure Field Regulator Piped Vea Manual Test Valve UL FM Low Hi Low Gas Piping Diagram Up to 2 500 MBH Firing Rate Pilot Gas Pressure Regulator 722003 Field Piped Pilot Solenoid Valve Dee Dad Pilot Manual Ball Valve Dex Vent To Outside Atmosphere Main Motorized Gas Valve 26 Sec Main Solenoid Gas Valve Manual Ball Manual Ball Valve Gas Pressure Regulator Manual Test Valve VV Manual Test M Valve UL FM Modulation Gas Piping Diagram Up to 2 500 MBH Firing Rate Field Piped 722002 Pilot Gas Pressure Regulator Field Piped Pilot Manual Ball Valve Dec Pilot Solenoid Valve A SI A XI Vent To Outside Atmosphere Vent Main Motorized Gas Valve 26 Sec Main Reset Low Gas Pressure i i GA Field Piped H gt K Main Reset High Manual 7 Gas Pressure Test A Switch Valve Main Solenoid Gas Valve Manual Ball Gas Supply gt lt Gas Pressure Field Piped Regulator D 9 cha Test Valve UL Low Fire Start Gas Piping Diagram 2 501 to 5 000 MBH Firing Rate JB Manual Page 24 Test Connection Test Connection o f Fuel Flow Control Valve Test Connection a Manual Ball Valve Gas Pilot Ignitor Gas Burner Manifold 722001 Gas Pilot Ignitor Gas Burner Manifold 722022 Gas Pilot Ignitor Gas Burner Manifold 722003 Gas Pilo
86. vessel mounting tween front plate requirements and vessel with ceramic blanket 4 deep or as defined by vessel manufacturer Tighten clamp bolts uniformly check after firing for several hours If gap is over 3 16 wrap burner nose The burner must with high tempera be level ture ceramic insulat Fiberglas rope Pe gasket must be coiled to cover Refractory the full mounting Front Plate flange surface Attachment to vessel varies with manu facturer follow vessel manufacturers recommendation l l The gas piping from the burner to the Te Pipe support required train should have as few elbows as pos i TT Flange secured to floor sible to reduce presure drop Figure E 2 Burner Mounting Instruction JB Manual Page 19 Burner Mounting Criteria F FUEL SYSTEMS The JB burner can be eguipped 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 gualified in the basics of mechanical know how The following illustrations and information is supplied to identify the various fuel air and ignition devices that have Adjustment Features All adjustments can be done with common place tools normally carried by burner and boiler service personnel NOTE Refer to the bulletins included in the manufacturer s data section of the burner instructions manual for items shown below
87. w NOx on gas which does not reguire 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 JB Manual Page 4 e Catalog cuts of the major components These provide details on the installation adjustment and maintenance of the components used on the burner 5 Service Parts and other Information Service and parts are available from your local Webster Representative For a list of Webster Representatives please visit the Webster web site at www webster engineering com or call 620 221 7464
88. w 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 I 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 Fo

JB Burner O&M Manual - Webster Engineering

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JB Burner O&amp;M Manual - Webster Engineering

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JB Burner O&M Manual - Webster Engineering