Professional Documents
Culture Documents
00 US
$75.00 Canadian
Cyclonetic JB Series
Forced Draft Burners
JB1 - JB2 - JB3
Gas - Oil - Gas/Oil
www.webster-engineering.com
July, 2006
C 2006 All Rights Reserved
SAFETY PRECAUTIONS
Good safety practices must be used when working on burner equipment. The potential energy in the electrical supply,
fuel and related equipment must be handled with extreme care to prevent equipment failures, injuries and potential
death.
Throughout this manual, the following symbols are used to identify potential problems.
WARNING
This indicates a potential hazardous situation, which if not avoided, could result in personal injury or death.
CAUTION
This indicates a potentially hazardous situation, which if not avoided, could result in damage to the equipment.
WARNING
IF YOU SMELL GAS, OPEN WINDOW, EXTINGUISH ANY OPEN FLAMES, STAY AWAY FROM ELECTRICAL
SWITCHES, EVACUATE THE BUILDING AND IMMEDIATELY CALL THE GAS COMPANY.
IN ACCORDANCE WITH OSHA STANDARDS, ALL EQUIPMENT, MACHINES AND PROCESSES SHALL BE
LOCKED OUT PRIOR TO SERVICING.
IF THIS EQUIPMENT IS NOT INSTALLED, OPERATED AND MAINTAINED IN ACCORDANCE WITH THE MAN-
UFACTURERS INSTRUCTIONS, THIS PRODUCT COULD EXPOSE YOU TO SUBSTANCES IN FUEL OR FROM
FUEL COMBUSTION WHICH CAN CAUSE DEATH OR SERIOUS ILLNESS AND WHICH ARE KNOWN TO THE
STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM.
IMPROPER SERVICING OF THIS EQUIPMENT MAY CREATE A POTENTIAL HAZARD TO EQUIPMENT AND
OPERATORS.
Date of Startup
Service Organization Information:
Company Name
Lead Technician
Address
Phone Number
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 & 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 re 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
Every attempt has been made to accurately reect the BURNER MOTOR 208 5.9 60 3 1.5
burner construction, however, product upgrades and spe- OIL PUMP MOTOR 208 4.3 60 3 1/2
cial order requirements may result in differences between
the content of this manual and the actual equipment.
These special components will be described in the infor-
mation provided with the burner and should be used as the The serial number represents the unique number for that
controlling document. 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 dene the maximum and minimum inputs
1. Nameplate Information for that burner, given in MBH for gas and GPH for oil. Air
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 ring, the gas manifold pressure is given in e. Catalog cuts of the major components. These provide
in wc which is inches of water column. details on the installation, adjustment and maintenance of
the components used on the burner.
The electrical ratings of the burner are given, with the volt-
age, current load, frequency and phase (this will either be 5. Service, Parts and other Information
single or 3-phase). For motors, the motor HP is listed. Service and parts are available from your local Webster
Representative. For a list of Webster Representatives,
2. Ratings please visit the Webster web site at:
The ratings for each specic burner are given on the name-
plate. The general burner ratings are given in Specica- www.webster-engineering.com or call 620-221-7464.
tion Sheets that follow this section. The maximun 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 ring rate.
3. Product Offering
JBX1G -05-RM7800L-M.25-M-A-UL/CSD-1
atomized
atomized
No. 2 Oil
pressure
No. 2 Oil
pressure
Gas
Gas
AND IMPORTANT OPTIONS AND IMPORTANT OPTIONS
Motor, Fan and Air Inlet Control X X Main Manual Shutoff Valve X
Air Flow Switch (also with oil sys-
X Main Safety Shutoff Valve X
tems using remote pump)
(2) Burner Mounted Control Panel, X X Second Safety Shutoff Valve X
Gas Fuel
General
X X X
Positioning systems)
Remote Control Panel X X Future Gas Combustion Head-OPT Opt.
Fuel Metering CAM-NETIC II X X
1. The conguration of each unit will vary with specic job requirements such as input rating, electrical specication and special agency approval
codes. The above chart shows those items standard to a basic burner plus a few options that may be added.
2. Indicator lights are Power On, Call for Heat, Fuel On and Flame Fail for hard wired panels. Alarm, Low Water, Power, Call for
Heat, Ignition On, and Fuel On for circuit board light panels.
Model JB1 - Sizing and Application Data (contact Webster for complete information)
Model Maximum Burner Firing Capability Burner Motor HP Gas Train Oil Pump
Number Furnace Range Motor HP
Gas Only (3) Oil or Pipe Size (4) Inlet Pressure
Pressure
HP Combination
Gas scfh #2 Oil gph On-Off, LFS Modulation
JB1-02 1.25 400 / 1000 3.0 / 7.1 1/4 1/3 1 6 / 14 7 /14 Integral
JB1-03 1.25 600 / 1500 4.0 / 10.7 1/3 1/2 1 1/4 8 / 14 9 / 14 Integral
JB1-05 1.25 800 / 2100 6.0 / 14.8 1/2 1/2 1 1/2 7 / 14 8 / 14 Integral
JB1-07 1.25 900 / 2500 7.0 / 17.8 3/4 3/4 1 1/2 9 / 14 11 / 14 Integral
3. Larger motors may be required for single phase or 208 volts 4. Contact Webster for more complete details
The above maximum ratings are based on 0 furnace pressure, an altitude of 1000 feet, 90oF air temperature and 60 HZ electrical supply. Use
the following corrections for higher temperatures and altitude. Capacity decreases by 17% for 50 Hertz.
Capacity decreases by 4% for each 1000 feet above 1000 foot altitude.
Capacity decreases by 6% for each 1 inch of furnace pressure.
Capacity decreases by 2% for each 10oF increase in air temperature over 90oF.
Gas input ratings based on 1000 BTU/cu ft. and 0.64 specic gravity. Sizes and pressure will vary with gas.
Oil input ratings are based on 140,000 BTU/gal for ASTM #2 fuel oil.
8 1/4
10
15
18 3/8
15 11/16
36 15/16 4 36 15/16
4 14 3/8
18 3/8
7 1/4 O.D.
19 3/8
11 3/8
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
specic requirements of IRI, FM, GE GAP, NFPA, MIL spec. or other special insurance or local code requirements.
JB Manual Page 7 Specication
Model JB2 - Specication Data (6000 MBH Maximum Input)
No. 2 Oil No. 2 Oil
(1) STANDARD UL EQUIPMENT STANDARD UL EQUIPMENT
Atomized
Atomized
Atomized
Atomized
Gas
Gas
Pressure
Pressure
AND IMPORTANT OPTIONS AND IMPORTANT OPTIONS
Air
Air
Motor, Fan and Air Inlet Control X X X Main Manual Shutoff Valve X
Air Flow Switch X X X Main Safety Shutoff Valve X
(2) Burner Mounted Control Panel, Second Safety Shutoff Valve X
Switch and Indicator Lights X X X
Main Gas Regulator X
Gas Fuel
General
Pilot Gas Regulator & Manual Valve X X Remote Oil Pump (JB2-30 to JB2-50) X Opt.
Pilot Gas Ignition Transformer X X Two Safety Shutoff Valves X X
Direct Spark Oil Ignition (3) Low Air Atomizing Switch X
Oil Fuel
Direct Spark Oil Ignition Low Oil Pressure Switch (STD when
(3) X X
Transformer using remote oil pump)
Inverted Housing X X X Oil Pressure Gauge X X
Alternate Control Cabinet Oil Metering Valve (modulating
Options
X X X X X
Positioning system)
Remote Control Panel X X X Future Gas Combustion Head Opt. Opt.
Fuel Metering CAM-NETIC II X X X Air Compressor X
1. The conguration of each unit will vary with specic job requirements such as input rating, electrical specication and special agency approval codes.
The above chart shows those items standard to a basic burner plus a few options that may be added.
2. Indicator lights are Power On, Call for Heat, Fuel On and Flame Fail for hard wired panels. Alarm, Low Water, Power, Call for Heat, Ignition
On, and Fuel On for circuit board panels.
3. Maximum rate for direct spark is 20 GPH at low re or 35 GPH at high re. (standard on straight oil burners, pressure atomized)
Model JB2 - Sizing and Application Data (contact Webster for complete information)
Model Maximum Burner Firing Burner Gas Train Oil Pump Motor HP Air
Number Furnace Capability Range Motor Compressor
Pipe Size (3) Inlet Press (in wc) Pressure Air
Pressure HP Motor HP
Atomizing Atomizing
Gas scfh #2 Oil gph LFS, LHL Modulation
JB2-07 2 900 / 2800 10 / 20 3/4 1 1/2 10 / 14 13 Integral N/A N/A
JB2-10 2 900 / 3500 10 / 25 1 2 8 / 14 9 / 14 Integral Optional 2
JB2-15 2 900 / 3500 10 / 25 1 1/2 2 8 / 14 9 / 14 Integral Optional 2
JB2-20 2 1200 / 4200 12 / 30 2 2 (4) 12 / 14 (3) 13 / 14 Integral Optional 2
JB2-30 2.5 1200 / 5300 12 / 37.8 3 2 1/2 N/A 13 / 14 3/4 Optional 2
JB2-50 2.5 1200 / 6000 12 / 42.8 5 2 1/2 N/A 2-5 psi 3/4 Optional 2
3. Lower pressures may apply to reduced inputs. 4. 11-14 with IRI and LFS or LHL. 12-14 with IRI and modulation.
The above maximum ratings are based on 0 furnace pressure, an altitude of 1000 feet, 90oF air temperature and 60 HZ electrical supply. Use the follow-
ing corrections for higher temperatures and altitude. Capacity decreases by 17% for 50 Hertz.
Capacity decreases by 4% for each 1000 feet above 1000 foot altitude.
Capacity decreases by 6% for each 1 inch of furnace pressure.
Capacity decreases by 2% for each 10oF increase in air temperature over 90oF.
Gas input ratings based on 1000 BTU/cu ft. and 0.64 specic gravity. Sizes and pressure will vary with different gas properties.
Oil input ratings are based on 140,000 BTU/gal. for ASTM #2 fuel oil.
The vessel draft must be between -0.1 and +0.1 wc.
9 1/2
10
15
19 1/16
19
17 3/4
30 11/16 Standard Arrangement
Elevation
Standard Arrangement
End View
39 1/4 4
4 39 1/4
14
18 1/2
19 1/2 9 1/8
O.D.
12 1/8
Standard Arrangement
Inverted Arrangement
Elevation
Elevation
W/ Optional Back Mount Control Cabinet
Model JB1 burners are listed by Underwriters Laboratories, Inc. (UL/ULC). Also by the State of Massachusetts Fire
Marshal, City of New York Board of Standards and Appeals, State of Minnesota and can be packaged to meet spe-
cic requirements of IRI, FM, GE GAP, NFPA, MIL spec. or other special insurance or local code requirements.
Air Atomized
Air Atomized
No. 4 - 6 Oil
N0. 4 - 6 Oil
(1) STANDARD UL STANDARD UL EQUIPMENT
Gas
Gas
Atomized
Atomized
Atomized
Atomized
Pressure
Pressure
EQUIPMENT
AND IMPORTANT OPTIONS
Air
Air
AND IMPORTANT OPTIONS
Motor, Fan and Air Inlet Control X X X X Main Manual Shutoff Valve X
Air Flow Switch X X X X Main Safety Shutoff Valve X
(2) Burner Mounted Control Panel, Second Safety Shutoff Valve X
Switch and Four Indicator Lights X X X X
Main Gas Regulator X
Gas Fuel
General
Oil Fuel
High Oil Temperature Switch X
Low Air Atomizing Switch X
Inverted Housing X X X X Low Oil Pressure Switch X X X
Alternate Control Cabinet Positioning X X X X Oil Pressure Gauge X X X
Options
Model JB3 - Sizing and Application Data (contact Webster for complete information)
Model Maximum Burner Firing Capability Range Burner Gas Train #2 Oil Pump Motor HP #4 - 6 Air
Number Furnace Motor Pump Compressor
Gas scfh #2 Oil #4-6 Pipe Inlet Pressure Air
Pressure HP Motor HP Motor HP
gph Oil gph Size Press Atomizing Atomizing
15 15/16
10
15
19 15/16
22 1/2
16
27 Standard Arrangement
Elevation
Standard Arrangement
End View
48 4
22 1/2
48
4
19 1/4
19 9/16
Standard Arrangement
Elevation
W/ Optional Back Mount Control Cabinet 11 1/4
O.D.
14 3/4
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-
cic requirements of IRI, FM, GE GAP, NFPA, MIL spec. or other special insurance or local code requirements.
JB Manual Page 11 Specication
B. COMPONENT IDENTIFICATION
This secion shows the different common components used in the JB burner line and should be helpful to identify parts
described elsewhere in this manual.
Light & Switch Panel Control Cabinet
Mod Motor
Control Transformer
Figure B-1
JB2 Burner
Sight Glass
Oil Fuel
Drawer Assembly
Blower Motor
Linkage
Gas Valve
Pilot Solenoid
Pilot Gas Regulator
Gas Actuator
Combustion
Head
Gas Valve
Figure B-2
JB1G Left Side View
Ignition
Transformer
Air Flow Switch
Pilot Gas Regulator
Gas Actuator
High Gas
Pressure Switch Figure B-3 Gas Pressure Gauge
JB1G Right Side View
Figure B-4
Control Panel
Circuit Board
Design
Burner Motor
Control Transformer
Starter
Terminal Strip
Air Chamber
Electric Motor
Air Filter
Compressor
Air Discharge
Connection
Figure B-6
Air Compressor
Supply Oil
Press. Gauge
Oil Metering
Valve
Trim Heater
Safety Relief
Valve
Trim Heater
Drawer Assm.
Pre-heat Oil
Lines Oil Supply To
Nozzle
Figure B-7
JB Burner
#4 - 6 Fuel Oil
Choke Cone
JB1 & JB2 Only
Oil Nozzle(s)
Gas Pilot
Retention Plate
Figure B-8
JB Combustion Head - Dual Fuel
Figure B-9
Pilot Assembly
Standard Head Arrangement
Section View
Gas Inlet
Oil Nozzle(s)
Diffuser
Oil Supply Line
(lower pipe)
Pilot Gas
Gas Pilot
Supply Line
Pilot Gas Supply
Ignition Electrode
Figure B-10
JB3 Combination or Straight Oil Drawer Assembly
with Proven Gas Pilot
Sight Tube
Backplate Figure B-11
JB1 & 2 Combination Drawer Assembly
with Proven Gas Pilot Ignition
Diffuser
Oil Nozzle(s)
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 000 indicate no drilled hole.
3. Sketches show general appearance only, not number or type of holes.
4. Secondary orices are closest to the burner center. primary orices are on the outside.
Orice Example E
Orice Example B No Radial Holes, 1 Axial Hole
Orice Example A
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 orice, would be called a 40 by 2 orice, of the orice. This orice cannot
which is common in the JB burner line. which is common in the JB burner line. have radial holes.
Normally
open vent
valve
Burner
Width
ter
ner Diame
enter of Bur
Heigh t - Floor to C
Figure E-2
Burner Mounting Instruction
Adjustment
Oil Pump
Check Valve
Return to Tank 1
(No Manual Valves
in this line) By Others Notes & Options
By Others
Unless Specied on Order
Field Piped
2 or 3 1 (IN)
(out) IN IN
Oil Nozzle
High Fire Cylinder 1 Gauge Port
Louver Actuator
Adjustment
Oil Nozzle
1 Gauge Port
1
Adjustment
Oil Pump
Check
Return to Tank,
Valve 1
(No Manual
Valves in this
By Others Notes & Options
Line)
Shutoff Check
Strainer 1 These Lines are Field
Valve Valve
Piped if a Remote Pump
Suction is Used
Supply Line
2 Usage Requirement
By Others Varies with Code
(Unless Specied on Order)
Field Piped
2
Back Pressure Low Oil Pressure Safety Oil
Reg. Valve Press. Sw. Gauge Main Oil Solenoid Valve
Solenoid Valve
1
Gauge Port
1 Inline Oil Nozzle
Check (Bypassing)
Valve
Shutoff Check Oil Pump
Valve Valve Strainer
Suction
Supply Line Notes & Options
Field Piped
Pressure
Gauge
Oil Safety Oil
N.C. Flexible Metal Hoses or
Metering Main Oil Oil Ball Gauge
Valve Valve Copper Tubing
Valve Valve
Relief Check
Valve Valve
Return
Low Oil to Tank
Compound
Pressure Gauge Ball or Gauge Gauge Check Gate
Gate Valve
Valve
Valve Strainer Oil
Suction
Field Piped
Oil Pump
Field Piped
Relief Valve
Air Filter Air
Chamber MA - Modulating #4 - 6 Oil
Ball Valve Air pipe same as Low Air
(man. set to adjust discharge open-
air volume & high
Press Sw Air
ing in air chamber
re air pressure) (eld piped) Check Gauge
Compressor Valve Nozzle
Pressure
Oil Oil
Gauge N.C. Main Safety Ball Oil Preheat Housing
Metering Gauge
Valve Oil Valve Oil Valve Valve
NOTE: Pressure Drops; Pressure drop through a given gas train will vary somewhat in relation to the individual items
used, the specic gravity of the gas to be burned and the overall length.
Vent To Outside
Atmosphere
UL-FM On-Off Gas Piping Diagram - Up to 2,500 MBH Firing Rate 1/2 PSI Max 722091
JB Manual Page 23 Fuel Systems
722001 Field Piped Pilot Gas
Pressure Pilot Solenoid
Pilot Manual Regulator Valve
Ball Valve S Gas Pilot
Ignitor
Vent To Outside
Atmosphere
Main Motorized
Main Solenoid Gas Valve Test
Gas Valve 26 Sec. Manual Ball Connection
Manual Ball
Valve S M Valve
Gas Gas Burner
Supply Manifold
Gas Pressure Manual Field Manual Test Valve
Regulator Test Valve Piped
UL-FM Low Fire Start Gas Piping Diagram - Up to 2,500 MBH Firing Rate 722001
Vent To Outside
Atmosphere
Main Motorized
Main Solenoid Gas Valve Test
Gas Valve 26 Sec. Connection
Manual Ball
Valve S M
Gas Gas Burner
Supply Manifold
Gas Pressure
Field
Manual Test Manual Ball
Manual
Regulator Test Valve Piped
Valve Valve
UL-FM Low-Hi-Low Gas Piping Diagram - Up to 2,500 MBH Firing Rate 722022
Vent To Outside
Atmosphere Main Reset Low Vent
Gas Pressure Main Motorized
Switch Gas Valve Field-Piped Test
Manual Ball Main Solenoid
26 Sec. Connection
Valve L S Gas Valve M H
Gas Gas Burner
Supply Main Reset High Manifold
Gas Pressure Field Piped Manual Gas Pressure
Test Switch
Manual Ball
Regulator Valve Valve
Manual Test Valve
UL Low Fire Start Gas Piping Diagram - 2,501 to 5,000 MBH Firing Rate 722002
JB Manual Page 24 Fuel Systems
722009 Field Piped Pilot Gas
Pressure Pilot Solenoid
Pilot Manual Regulator Valve
Ball Valve S
Gas Pilot
Ignitor
Man Reset High
Vent To Outside Gas Pressure
Atmosphere Man Reset Low Vent Switch
Gas Pressure Main Motorized
Switch Gas Valve Test
Main Motorized 26 Sec. Field Connection
Manual Ball Gas Valve Piped
Valve L M 14 Sec. M H
Gas Gas Burner
Supply Manifold
Gas Pressure Field Piped Manual Ball
Manual Test Manual
Regulator Valve Test Valve Valve
FM Low Fire Start Gas Piping Diagram - 2,501 to 5,000 MBH Firing Rate 722009
UL Low-Hi-Low Gas Piping Diagram - 2,501 to 5,000 MBH Firing Rate 722023
FM Low-Hi-Low Gas Piping Diagram - 2,501 to 5,000 MBH Firing Rate 7722024
722004
Pilot Gas
Field Piped
Pressure Pilot Solenoid
Pilot Manual Regulator Valve
Ball Valve S Gas Pilot
Ignitor
Vent To Outside
Atmosphere Main Motorized Vent Man Reset High
Man Reset Low Gas Pressure
Gas Pressure Gas Valve Switch Test
Switch 26 Sec. Connection
Manual Ball Manual
Valve L S M H Ball Valve
Gas Gas Burner
Supply Manifold
Gas Pressure Fuel Flow
Regulator
Manual Test Manual Field Piped Control Valve
Main Solenoid Valve Test Valve
Gas Valve
UL Modulation Gas Piping Diagram - 2,501 to 5,000 MBH Firing Rate 722004
Valve L M M H
Gas Gas Burner
Supply Manifold
Gas Pressure Manual Ball Valve Fuel Flow
Manual Test Manual Test
Regulator Valve Valve Control Valve
Field Piped
FM Modulation Gas Piping Diagram - 2,501 to 5,000 MBH Firing Rate 722010
UL Modulation Gas Piping Diagram - 5,001 to 12,500 MBH Firing Rate 722005
FM Modulation Gas Piping Diagram - 5,001 to 12,500 MBH Firing Rate 722011
UL Modulation Gas Piping Diagram - Over 12,500 MBH Firing Rate 722082
FM Modulation Gas Piping Diagram - Over 12,500 MBH Firing Rate 722084
Cam
Return
Cam Set Screws Springs
ition
ire
hF
Pos
Hig ition
s Jack
Po
Fire
Shaft
Adjusting Screws
Low
Flexible Strip
Aluminum Strip
End Screws
Spring
End Screw
Adjusting Nut
Cam Follower
Retention Roller Washers
Plate
Roller Cam Follower
Figure G-3
Fuel Cam Adjustment
JB Manual Page 28 Initial Settings
COMBUSTION AIR CONTROL
Adjusting The air proving switch has been adjusted at the factory
Screw for an initial setting. If the switch trips during initial start-
up, turn the adjustment screw ccw two full turns to re-
Air Proving duce the trip pressure setting.
Switch
4. Fuel Cam Adjustments (if applicable) c. At high re, the roller should be between the last two
The fuel cam needs to be checked for correct travel adjusting screws.
and alignment. Positions can change during shipment d. The adjusting screws should form a smooth contour
and installation and they must be reviewed prior to with no jumps between the screws.
startup. The fuel cams are mounted to the ends of the e. In preparation of startup, the retention plate can
jackshaft assembly. A cam follower link follows the prole be removed temporarily to make it easier to adjust the
established by the adjusting screws and drives the fuel screws.
valve. A thin metal band is used between the screw and THE RETENTION PLATE MUST BE REPLACED WHEN
cam follower to provide a smooth prole. The adjusting SETUP IS COMPLETE.
screws are backed by compressed nylon inserts, which
provide a resistance to turning. If the unit is equipped with a parallel positioning system
(linkageless), the control valves can be positioned and
The cam (Figure G-3) should be checked for the following operated in a similar manner, but accomplished through
conditions: the controller. Refer to the instruction manual for details.
a. At the low re position, the roller should be between
the rst two adjusting screws. If not, adjust the position CAUTION
of the cam accordingly, making sure to maintain the same LINKAGE AND ACTUATOR MOUNTINGS CAN BE BENT
low re fuel valve position. OR MOVED DURING SHIPMENT AND INSTALLATION.
b. When the linkage is modulated from low to high re, THEY MUST BE CHECKED PRIOR TO OPERATION AND
the roller must stay in the center of the adjusting screws ANY FAULTS CORRECTED. FAILURE TO CORRECT A
within 1/8. If needed, the two cam set screws can be MISALIGNED CONTROL WILL RESULT IN PREMATURE
FAILURE.
loosened and the cam moved to center it on the roller.
JB Manual Page 29 Initial Settings
H. IGNITION SYSTEMS
Electrode
Spark
Gap = 1/16
Electrode Clamp
Pilot
Note: Required 2 1/2 - 3 wc
pressure for natural gas ans 1/2
Figure H-1 - 2 for LP, as measured at the
JB1 & JB2 Gas Pilot last solenoid in the pilot train.
Figure H-2 JB3 PILOT ASSEMBLY
Natural Gas Pressure;
4 - 6 wc
LP Gas Pressure;
1.5 - 2.5 wc
1. Gas Pilot Assembly some applications, the pilot requires an orice in the pilot
A crucial part of reliable burner operation is a dependable gas supply line. With the exception of the JB3, this ori-
pilot, which must be properly adjusted and kept clean. A gas ce is located external of the blower housing.
pilot is standard for all models except JB1 through JB2-20
straight oil pressure atomizing burners which have direct The pilot to diffuser dimension is the distance of the face
spark ignition as standard. The following illustrations show of the pilot to the outer diameter of the diffuser.
the typical conguration and nominal adjustment parame- For an oil or combination burner, the air damper should
ters of each pilot. be open about 3/8 at low re and close to full open at
Figure H-1 showns the JB1 & JB2 gas pilot. Figure H-2 high re.
shows the JB3 gas pilot. Figure H-3 shows how the pilots 4. Gas Modualting Control Valve Position
are positioned in the burner drawer. The gas valve should be open about 10% at low re and
Pilot gas pressure should be measured at the 1/8 port locat- stroked to abput 60% open at high re.
ed on the downstream side of the last pilot solenoid valve. 5. Oil Modulatining Control Valve Position.
2. Oil Nozzle Positiion, Direct Spark Oil. For pressure atomizing, the low re position should be
Figures H-5 and H-6 show the position of direct spark igni- adjusted to get the correct low re presure, as stated
tion and nozzle positions. These are initial settings and will on the rating label. Typically, this would be 100 psi for
be adjusted at start-up. simplex systems and 65 psi for return ow nozzles. The
high re position should be about 45o to 60o travel from
3. Air Damper Position low re.
On a straight gas burner, the air damper should be open
about 1/4 at low re and close to full open at high re. In For air atomizing, the low re should be on about #2 po-
sition and the high re should be about the #8 position.
JB Manual Page 30 Ignition Systems
Figure H-3
7/8
Figure H-4
(2 1/2) (3 1/2)
FIGURE H-5 DIRECT SPARK PRESSURE ATOMIZING OIL IGNITION (SEE TABLE BELOW)
Diffuser
ID
FIGURE H-6
The cam is used to adjust the intermediate fuel rate with 4. FGR Adjustments
the low and high re settings done by the linkage connec- Flue gas is recirculated back into the burner to reduce
tions. The intermediate rates can be adjusted by turning the the ame temperature, which reduces the NOx level.
adjusting screws in the clockwise direction to increase fuel High quantities of ue gas result in lower NOx levels,
input and decrease the % O2 level in the ue gases. Turn- but can also result in ame instability if there is too
ing the adjustment screws counterclockwise will decrease much FGR. Natural gas fuel can handle larger quanti-
fuel input and increase % O2 in the ue gases. ties of ue 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 ring and oil ring 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 exible strip between the adjust- requirements.
ing screws and the roller must come in contact with each Dual fuel units may need additional adjustments and
screw, providing a smooth transition from low re to high compensation to handle the different FGR rates be-
re. tween natural gas and #2 fuel oil. Units that require
b. The end screws (or nuts) can be adjusted to hold the strip gas NOx levels above about 45 ppm can operate with
against the screws, but should not deform the strip. the same quantity of FGR on both fuels and no addi-
c. There should be no upsets in the prole, where the ex- tional controls or adjustments are needed. Burners
JB Manual Page 33 Startup and Operating Adjustments
equipped with Posi-Control can be adjusted for individual air a. To adjust the diffuser to inner re cylinder dimen-
and FGR settings on both fuels and can easily handle these sion:
variations, even with lower NOx levels. Linkage burners op- Measure the dimension from the backplate to the end
erating at 30 ppm NOx (natural gas) are equipped with a of the oil gun tube. This dimension, along with the initial
potentiometer in the control panel that will allow the shut-off position will determine the limit of the adjustment. For
valve to partially open and allows a small amount of FGR to example, if the diffuser is 1 inch behind the re end of
ow when ring oil. This keeps the oil inputs close to the gas the inner re cylinder, then it can be adjusted in 3/4 inch
input (lower FGR rates increases the combustion air rate). or out 1/2 inch to stay within the limits of 1/4 inch to 1 1/2
The oil combustion is generally better when FGR is used at inch diffuser to re end of the inner re cylinder dimen-
low rates resulting is a lower NOx level. Linkage levels with sion.
NOx levels under 30 ppm will also use a multiple modulation Loosen the two setscrews locking the pilot gas line
motor to provide separate gas and oil low re and high re and gun tube to the backplate.
positions. Adjust the diffuser by moving the oil gun tube in and
out the amount determined above. When the best posi-
Linkage dual fuel units may also be equipped with the op- tion is found, lock into place with the two setscrews on
tional multiple set point (Landis) modulation motor in addition the oil and pilot tubes.
to the above potentiometer. This motor allows for different b. To adjust the oil nozzle to diffuser position:
low and high re settings on gas vs oil to obtain the correct Adjust the oil nozzle to obtain the best combustion.
airow for each fuel and optimize the turndown on gas. Watch for spray back on the diffuser when the oil noz-
The quantity of recirculated ue gas can be adjusted with the zle is pulled too far back. The ame may appear good
inlet tube on the FGR line. To reduce the quantity of FGR, but carbon will quickly develop on the diffuser.
push the tube into the FGR line (loosen the two set screws The drawer assembly must be removed to adjust the
to adjust the position of the tube, and tighten when done). oil nozzle to diffuser position.
Moving the tube into the air stream will increase the quantity
of FGR. An access cover is provided opposite the FGR line The burner drawer must be removed for access to com-
for this adjustment. ponents, follow the following steps:
On a dual fuel unit, the natural gas should be done rst to a. Disconnect the gas pilot line. Move the pilot line so
properly set the FGR inlet tube. Once gas is setup, oil can the drawer can be pulled out without interference.
be set. b. If equipped with oil, disconnect the oil line(s), and
For dual fuel linkage systems, the following guidelines move the oil line out of the way to allow the drawer to
should be used: be pulled.
A 60 ppm system can be adjusted with the same FGR rate c. Loosen and remove the screws on the burner draw-
on both fuels. The FGR control valve is set on gas and oil er.
follows that setting. d. Disconnect the ignition cable from the drawer assem-
A 30 ppm system uses the FGR limiting potentiometer bly. It is attached with a snap-on tting.
(located in the control panel) to obtain a partial ow of FGR e. Pull the drawer out, holding the drawer centered in
when ring oil. The FGR control valve is set when ring the opening to prevent it from hanging up while being
gas. The FGR limiting potentiometer is adjusted to improve pulled out.
combustion but not cause instability. The combustion needs f. Disconnect the scanner by screwing it off of the scan-
to be checked at several ring rates. ner tube. In some cases, the scanner simply pulls out,
Under 30 ppm, separate gas and oil operating points are with a spring tension. Secure the scanner so that it is
established in the modulating motor. Parallel positioning protected from shock.
(linkageless) systems allow all of the valves to be positioned g. Set the drawer down horizontally, do not set it on the
independently for each fuel. For this reason, the setup se- diffuser as it may atten some ns or change positions.
quence can be more exible. To re-install the burner drawer, simply work the proce-
5. Burner Drawer Adjustments dure in reverse.
The burner drawer has several adjustments built into the de- 6. Single Fuel Setups
sign that allow the combustion to be tuned. While this can Single fuel burners can be adjusted following the proce-
simplify the combustion tuning process, care must be used dures outlined in Section 10 for gas ring; Section 11 for
to retain the relative position of other components during this pressure atomized oil, Section 12 for Air atomized #2 oil
sequence. If these adjustments are required, follow the se- and Section 13 for heavy oil ring.
quence listed to perform the adjustments.
The procedures for each of the systems (linkage, cams,
Before any adjustments are made, the position of each com- FGR) must be completely understood and followed as
ponent must be marked. A felt tip pen or a combination of part of the setup process.
masking tape and another type of pen can be used.
Mark the distance of the oil gun tube from the backplate. 7. Combination Gas and Pressure Atomized Oil
Mark the distance of the gas pilot line to the backplate.
JB Manual Page 34 Startup and Operating Adjustments
Combination burners, ring both gas and oil, require some can be tuned to better match each fuels needs. The
compromises in the setup because they share common con- setup details for linkageless controls will follow the same
trols for both fuels. In this case, linkage units must have the general sequence, but differ in specics for setting the
gas input adjusted to match the oil inputs because there is valve positions.
little exibility in adjusting the oil rates. Oil will be setup rst
9. Combination Gas and Heavy Oil
and will set the air damper positions to support the low and
high re oil inputs. Follow the procedure outlined in section Combination burners, ring both gas and oil, require
11 to complete the oil setup. Then setup the gas input as some compromises in the setup because they share
dened in section 10, using the air damper positions dened common controls for both fuels. Heavy oil burners can-
by oil, and adjusting the gas input to match the air damper not operate with FGR and do not have this adjustment.
settings. If the burner does not have a multiple setpoint modu-
lating motor or linkageless control, oil must be set rst,
If the burner is equipped with an optional multiple set-point as the air damper positions will be determined by this
modulating motor or parallel positioning, the low and high setup. With the multiple setpoint modulating motor, gas
re rates, as well as lightoff rates, can be set independently must be set rst, as it will dictate the damper positions.
for each fuel. In this case, the gas is adjusted rst, to set the In either case, setup cannot be nalized until both fuels
air damper locations for gas ring, as dened in Section 10. have been reviewed to determine the air damper posi-
Once gas is set, oil is setup as dened in Section 11, except tions. Follow the setup procedures dened in Section
that the multipoint modulating damper motor is adjusted to 10 for gas setup and Section 13 for air atomized heavy
bring the low re air setting to match the oil needs. oil setup.
There are several different options available that can alter There are several different options available that can al-
the exact setup details, and these must be evaluated prior ter the exact setup details, and these must be evaluated
to startup so that the procedures can be adjusted accord- prior to startup so that the procedures can be adjusted
ingly. The procedures given are for linkage systems. Par- accordingly. The procedures given are for linkage sys-
allel positioning (linkageless) systems allow for much more tems. Parallel positioning (linkageless) systems allow
exibility in the fuel, air and FGR settings on each fuel, and for much more exibility in the fuel, air and FGR settings
can be tuned to better match each fuels needs. The setup on each fuel, and can be tuned to better match each fu-
details for linkageless controls will follow the same general els needs. The setup details for linkageless controls will
sequence, but differ in specics for setting the valve posi- follow the same general sequence, but differ in specics
tions. for setting the valve positions.
8. Combination Gas and Air Atomized #2 Oil 10. Gas Setup
Combination burners, ring both gas and oil, require some a. Place the burner switch in the OFF position
compromises in the setup because they share common con- b. Place the Auto-Manual switch in the manual posi-
trols for both fuels. Air atomized #2 oil ring can have turn- tion, for modulation or low re hold, switch in low re po-
downs and air damper positions very similar to gas ring, sition for Lo-Hi-Lo operation. If this is a combination fuel
simplifying the setup. If the burner is equipped with FGR, burner, make sure the fuel selector switch is on GAS.
gas must be started rst to set the FGR control valve po- c. Place the manual ame control potentiometer in the
sitions to obtain the correct NOx performance. If there is MIN (low re) position on modulating units.
no FGR, either fuel can be started rst, however the setup d. Close the downstream manual shutoff valve (closest
cannot be nalized until both fuels have been reviewed to to the burner head) on the gas train.
determine the air damper positions. Follow the setup proce- e. Turn the electrical power on for the burner, boiler and
dures dened in Section 10 for gas setup and Section 12 for related components.
air atomized oil setup. f. Verify that the gas metering valve is nearly closed, the
vent valve (if equipped) is operating and the gas pilot
If the burner is equipped with an optional multiple set-point
valve is not open (the solenoid will hum and feel warm).
modulating motor, the low and high re rates, as well as ligh-
g. If equipped with FGR, verify that the FGR control
toff rates, can be set independently for each fuel. In this
valve is in the near closed position. A linkage system
case, the gas is adjusted rst, to set the air damper locations
should have the shutoff FGR valve in the closed posi-
for gas ring, as dened in Section 10. Once gas is set, oil
tion.
is setup as dened in Section 12, except that the multipoint
h. Turn the burner switch on. This will start the blower
modulating damper motor is adjusted to bring the low re air
motor and initiate the prepurge cycle.
setting to match the oil needs.
i. When the prepurge sequence is complete and the
There are several different options available that can alter low re start switch (if used) is made, the pilot valve will
the exact setup details, and these must be evaluated prior open and the pilot ame should be visible through the
to startup so that the procedures can be adjusted accord- sight port.
ingly. The procedures given are for linkage systems. Par- j. When the pilot ame is established, the ame safe-
allel positioning (linkageless) systems allow for much more guard will energize the main gas valve (indicated with
exibility in the fuel, air and FGR settings on each fuel, and the Fuel Valve Light). This operation of the main fuel
the highest expected gas pressure. e. Verify that the oil metering valve is nearly opened (the
With a gauge or manometer at the same location as the valve will be closed at high re).
high gas pressure switch, modulate the burner to deter- f. Turn the burner switch on. This will start the blower mo-
mine the ring rate with the highest gas pressure. tor and initiate the purge cycle.
At the highest gas pressure, adjust the high gas pres- g. When the prepurge sequence is complete and the low
sure setting down until the switch opens and causes the re start switch (if used) is made, the pilot valve will open
burner to shutdown. and the pilot ame should be visible through the burner
From the scale reading of the switch, adjust the set- sight port.
ting to a pressure that is 10% higher than the shutdown h. When the pilot ame is established, the ame safe-
pressure. For example, if the switch opened at 10 inches guard will energize the main oil valves (indicated with the
as indicated on the high gas pressure switch, the switch Fuel Valve Light), and the burner should ignite at low re.
should be adjusted to a reading of 11 inches. This operation of the main fuel valves must be visually
Remove the gauge or manometer and plug the open- checked by observing the valve stem moving up with a
ing. motorized valve or hearing the clicking noise from a sole-
Cycle the burner on and off to determine if the limit works noid valve.
properly. NOTE: If the burner is not operating as indicated, follow
If the limit causes nuisance shutdowns because of small the troubleshooting steps to determine the problem and
pressure changes during startup, increase the pressure corrective action.
setting an additional 5%. i. The main ame may not light on the rst attempt, be-
z. The burner should be operating at low re to adjust cause it must ll the oil lines before providing oil to the
the air proving switch. Turn the adjusting screw cw (in) nozzle. Press the reset button on the ame safeguard to
until the burner trips out (shutdown caused by the air ow restart the burner.
switch). Turn the adjustment screw ccw (out) 1 1/2 turns WARNING
from the point of shutdown. Check the operation at higher DO NOT ATTEMPT TO START THE BURNER WHEN EXCESS OIL
rates. HAS ACCUMULATED, WHEN THE UNIT IS FULL OF VAPOR, OR
WHEN THE COMBUSTION CHAMBER IS HOT.
11. Pressure Atomized Oil Setup
The pressure atomized oil system has a limited range of j. After a few seconds, the combustion analyzer should
adjustment for low and high re, dictated by the operation have an accurate reading of the O2 in the stack. The O2
of the oil nozzle. The combustion air and FGR must be level should be between 4% and 7%, and the nozzle oil
adjusted to match these rates. pressure should be between 50 and 70 PSIG return line
pressure for the JB3. JB1 and JB2 burner low re oil pres-
If the burner is equipped with FGR, and is a linkage sys- sure should be 100 psig. Do not attempt to ne tune com-
tem, the type of FGR control must be determined prior bustion until the high re has been set.
to starting. If this is a dual fuel burner, the FGR rate is If the burner is equipped with FGR, the FGR control valve
determined by the NOx performance on gas. A 60 ppm should be set for the approximate NOx level required.
burner will operate with the same FGR rate on gas and oil. 1. Turning the cam screw in will add fuel, making it richer
A 30 ppm unit will use the limiting potentiometer to slightly and reducing the O2 level.
reduce the FGR rate on oil ring. For Oil only combustion, 2. Turning the cam screw out will reduce the fuel input,
the NOx level will be given on the burner detail sheet, and increasing the O2 level.
should be used to set the FGR control valve. 3. The air damper should be positioned for the correct
a. Place the burner switch in the OFF position. low re settings.
b. Place the Auto-Manual switch in the manual position k. Operate the burner until the boiler is warmed up, and
or low re hold switch in the low re position fo LO-HI-LO near the operating pressure or temperature.
operation. If this is a combination fuel burner, make sure l. Increase the ring rate, using the manual potentiom-
the fuel selector switch is on OIL. eter or put the low re hold switch in auto position, while
c. Place the manual ame control potentiometer in the monitoring and adjusting the O2 level. Adjust the cam as
min (low re) position on modulation units. needed to reach the high re input.
d. Turn the electrical power for the burner, boiler and re- If the burner is equipped with FGR, adjust the FGR control
lated components on. valve as required to maintain the NOx level.
JB Manual Page 37 Startup and Operating Adjustments
m. At high re (end of the modulating motor travel), adjust min (low re) position.
the high re input (open or close the fuel valve) to match d. Turn the electrical power for the burner, boiler and re-
the maximum input and/or pressure listed on the rating lated components on.
label. The fuel metering valve should be nearly closed e. Verify that the oil metering valve is at the nearly closed
(or closed) at this point and the nozzle pressure should position.
be about 150 PSIG (return line) for JB3. For JB1 and JB2 f. Turn the burner switch on. This will start the blower mo-
250 to 300 psig. tor and initiate the purge cycle.
n. If equipped with FGR, adjust the NOx level to be about g. When the prepurge sequence is complete and the low
10% below any guaranteed NOx performance or if perfor- re start switch is made, the pilot valve will open and the
mance guarantee exists adjust the FGR to provide some pilot ame should be visible through the burner sight port.
added turbulence but not high enough to impact ame sta- h. When the pilot ame is established, the ame safeguard
bility. A balance of the FGR control valve and air damper will energize the main oil valves (indicated with the Fuel
are required to obtain the nal result, as each can impact Valve Light), and the burner should ignite at low re. This
the other. If this is a 30 ppm system, the FGR limiting pot operation of the main fuel valves must be visually checked
should be adjusted to reduce the FGR rate for stable com- by observing the valve stem moving up with a motorized
bustion, with the FGR control valve set when ring gas. If valve or hearing the clicking noise from a solenoid valve.
this is a 60 ppm system, no adjustment is necessary. NOTE: If the burner is not operating as indicated, follow
o. Modulate the burner to low re, adjusting the O2 level the troubleshooting steps to determine the problem and
as the burner modulates. corrective action.
p. Adjust the low re input, using the fuel cam or low re WARNING
regulator on LO-HI-LO systems and air damper adjust- DO NOT ATTEMPT TO START THE BURNER WHEN EX-
ments. If the burner is equipped with FGR, adjust the NOx CESS OIL HAS ACCUMULATED, WHEN THE UNIT IS FULL
level according to the type of system (limiting potentiom- OF VAPOR, OR WHEN THE COMBUSTION CHAMBER IS
eter or matching gas). HOT.
q. Re-adjust the midre points for the correct O2 levels. i. After a few seconds, the combustion analyzer should
The linkage may need to be readjusted to obtain the cor- have an accurate reading of the O2 in the stack. The O2
rect relationship between the fuel valve and air damper. level should be between 4% and 7% (see Figure I-3 for
(Figure I-1) O2 rates), and the nozzle oil press should be between 5
r. If equipped with FGR, adjust the NOx levels at low and and 15 PSIG (see Figure I-4). Do not attempt to ne tune
midre rates to be about 10% under the guaranteed levels combustion until the high re input has been set.
or as required for the gas ring. If the burner is equipped with FGR, the FGR control valve
s. The burner should be operating at low re to adjust or limiting potentiometer should be set for the approximate
the air proving switch. Turn the adjusting screw cw (in) NOx level required.
until the burner trips out (shutdown caused by the air ow Turning the cam screw in will add fuel, making it richer
switch). Turn the adjustment screw ccw (out) 1 turns and reducing the O2 level.
from the point of shutdown. Check the operation at higher Turning the cam screw out will reduce the fuel input,
rates. increasing the O2 level.
t. Adjust the oil pressure switch to trip and shutdown the The air damper should be positioned for the correct low
burner at a pressure that is 10% lower than the supply oil re settings.
pressure. The atomizing air pressure can be adjusted using the air
12. Air Atomized, #2 oil Setup bleed valve.
j. Operate the burner until the boiler is warmed up, and
The air atomized oil system has the potential for a large near the operating pressure or temperature.
turndown range similar to gas and has the potential to be k. Increase the ring rate, using the manual potentiome-
adjusted to different low re rates. See the burner name- ter, while monitoring and adjusting the O2 level. Adjust the
plate for details on actual rates for this burner. cam, oil pressure and atomizing air pressure as needed to
If the burner is equipped with FGR and is a linkage sys- reach the high re input.
tem, the type of FGR control must be determined prior l. If the burner is equipped with FGR, adjust the FGR con-
to starting. If this is a dual fuel burner, the FGR rate is trol valve or potentiometer as required to maintain the NOx
determined by the NOx performance on gas. A 60 ppm level.
burner will operate with the same FGR rate on gas and oil. m. At high re (end of the modulating motor travel), adjust
A 30 ppm unit will use the limiting potentiometer to slightly the high re input to match the maximum input listed on
reduce the FGR rate on oil ring. For Oil only combustion, the rating label. Using a ow meter, the fuel input may be
the NOx level will be given on the burner detail sheet, and measured using the following equation,
should be used to set the FGR control valve.
a. Place the burner switch in the OFF position. Oil GPH =
b. Place the Auto-Manual switch in the manual position. [Gal end Gal start] x [3600 sec/hr] /
If this is a combination fuel burner, make sure the fuel se- [measured sec]
lector switch is on OIL.
c. Place the manual ame control potentiometer in the Where Gal end = meter gallons at end of test
JB Manual Page 38 Startup and Operating Adjustments
Gal start = gallons at start of the test 20oF of the nal temperature.
Measured sec = measured time of test b. Place the burner switch in the OFF position. If this
GPH = Gallons of oil per hour is a combination fuel burner, make sure the fuel selector
switch is on OIL and that the oil pump is running.
n. If equipped with FGR, adjust the NOx level to be about
c. Place the Auto-Manual switch in the manual posi-
10% below any guaranteed NOx performance or if no per-
tion.
formance guarantee exists adjust the FGR to provide some
d. Place the manual ame control potentiometer in the
added turbulence but not high enough to impact ame sta-
MIN (low re) position.
bility. A balance of the FGR control valve and air damper
e. Turn the electrical power on for the burner, boiler and
are required to obtain the nal result, as each can impact
related components.
the other. If this is a 30 ppm system, the FGR limiting pot
f. The oil may take some time to get up to temperature.
should be adjusted to reduce the FGR rate for stable com-
If the oil is cool, the ball valve downstream of the N.O. oil
bustion, with the FGR control valve set when ring gas. If
return valve (Figure B-7) can be opened to make it easier
this is a 60 ppm system, no adjustment is necessary.
for the oil to circulate and reach operating temperature.
o. Modulate the burner to low re, adjusting the O2 level as
g. Verify that the oil metering valve is at the nearly closed
the burner modulates.
position.
p. Adjust the low re input, using the fuel cam and air
h. Turn the burner switch to ON. This will start the
damper adjustments.
blower motor and initiate the prepurge cycle.
q. If the burner is equipped with FGR, adjust the NOx level
according to the type of system (limiting potentiometer or WARNING
matching gas). DO NOT ATTEMPT TO START THE BURNER WHEN
r. Re-adjust the midre points for the correct O2 levels. EXCESS OIL HAS ACCUMULATED, WHEN THE
The linkage may need to be readjusted to obtain the correct UNIT IS FULL OF VAPOR, OR WHEN THE COM-
relationship between the fuel valve and air damper. See BUSTION CHAMBER IS HOT.
Figure I-1. i. When the prepurge sequence is complete and the low
s. If equipped with FGR, adjust the NOx levels at low and re start switch is made, the pilot valve will open and
midre rates to be about 10% under the guaranteed levels the pilot ame should be visible through the burner sight
or as required for the gas ring. port.
t. The burner should be operating at low re to adjust the j. When the pilot ame is established, the ame safe-
air proving switch. Turn the adjusting screw cw (in) until the guard will energize the main oil valves (indicated with
burner trips out (shutdown caused by the air ow switch). the Fuel Valve Light), and the burner should ignite at low
Turn the adjustment screw ccw (out) 1 turns from the re. This operation of the main fuel valves must be visu-
point of shutdown. Check the operation at higher rates. ally checked by observing the valve stem moving up with
a motorized valve or hearing the clicking noise from a
solenoid valve.
FIGURE I-4
k. After a few seconds, the combustion analyzer should
Typical Atomizing Air Pressure
have an accurate reading of the O2 in the stack. The O2
% Rate Minimum level should be between 4% and 7% (See Figure I-3 for
O2 rates) and the nozzle oil press should be between 10
20 10 - 25
and 20 PSIG. Do not attempt to ne tune combustion
30 12 - 30 until the high re input has been set.
40 15 - 35 Turning the cam screw in will add fuel, making it richer
50 20 - 40 and reducing the O2 level.
Turning the cam screw out will reduce the fuel input,
100 25 - 60
increasing the O2 level.
The air damper should be positioned for the correct low
13. Heavy Oil Setup re settings.
The atomizing air pressure can be adjusted using the
CAUTION
air bleed valve (Figure I-4).
WHEN WORKING WITH HEATED OIL, PROTEC-
The oil temperature can be adjusted to obtain the best
TIVE CLOTHING, INCLUDING GLOVES, SHOULD BE
atomization.
WORN TO PROTECT FROM BURNS.
l. Operate the burner until the boiler is warmed up and
near the operating pressure or temperature.
The air atomized heavy oil system requires the additional m. Increase the ring rate, using the manual potentiom-
adjustment of oil temperature in the burner setup. The tem- eter, while monitoring and adjusting the O2 level. Adjust
perature is adjusted to improve the viscosity for good atomi- the cam, oil and atomizing air pressure and oil tempera-
zation. Typically, this will be about 150oF for #4 oil, 180oF ture as needed to reach the high re input.
for #5 oil and 200oF for # 6 oil. n. At high re (end of the modulating motor travel), ad-
a. Prior to startup, the oil system must be operating with the just the high re input to match the maximum input listed
oil temperature to the burner (before the trim heater) within on the rating label. Using a ow meter, the fuel input may
JB Manual Page 39 Startup and Operating Adjustments
be measured using the following equation, about which limits are on a burner, refer to the wiring
diagram that will show each item.
Oil GPH = [Gal end Gal start] x [3600 sec/hr]
/ [measured sec] Limit switches need to be checked at regular intervals
to ensure they are operating properly. See the mainte-
Where Gal end = meter gallons at end of test nance section for details.
Gal start = gallons at start of the test
Measured sec = measured time of test 16. Pilot Test
GPH = Gallons per hour Once the burner as been set for the ring rates intended
o. Modulate the burner to low re, adjusting the O2 level as for the burner, the pilot must be checked for proper op-
the burner modulates. eration and safety.
p. Readjust the low re input, using the fuel cam and air The minimum pilot test is done to insure that a pilot which
damper adjustments. can be seen by the scanner will light the main ame.
q. Re-adjust the midre points for the correct O2 levels. a. During a startup sequence, measure the time re-
The linkage may need to be readjusted to obtain the correct quired to light the main ame after the fuel valves have
relationship between the fuel valve and air damper. (Figure been energized. This will be used to monitor the test
I-1) with reduced pilot.
r. The burner should be operating at low re to adjust the b. Lock the ame safeguard into the pilot position (refer
air proving switch. Turn the adjusting screw cw(in) until the to the manual for the ame safeguard for this setting)
burner trips out (shutdown caused by the air ow switch). c. Adjust the gas pressure regulator to the pilot for a
Turn the adjustment screw ccw (out) 1 turns from the point minimum value while still holding the minimum signal
of shutdown. Check the operation at higher rates. strength for the scanner.
14. Operating Control Adjustments d. Release the ame safeguard from the pilot position
and allow it to cycle though the main ame proving se-
The operating controls must be adjusted to properly cycle quence.
the burner ON and OFF and provide modulation. The con- e. This reduced pilot must reliably light the main ame.
trols should not force the burner into rapid ON-OFF cycles, Monitor the time from the main fuel valve opening and
as this will cause premature failure of the motor and operat- do not allow the burner to continue if the time is more
ing equipment. than an additional two to three seconds from the initial
The operating control must be adjusted to provide the ON time measured above.
pressure or temperature desired. It must allow the burner f. Run through two or three cycles.
to come on and start before the temperature or pressure g. If this is a combination fuel burner, repeat the test on
drops into the modulating range. The OFF pressure or the other fuel.
temperature must be sufciently above the ON point to al- h. Failures due to reduced scanner signal are also ac-
low a reasonable run time. ceptable.
WARNING
The modulating control must be adjusted to start modulation THE MINIMUM PILOT TEST REQUIRES CLOSE SUPERVISION
at some reasonable point below the ON temperature or OF THE COMBUSTION PROCESS. FAILURE TO CLOSELY
pressure and provide modulation to high re at the lowest MONITOR THE MAIN FLAME TEST TIME COULD RESULT IN
temperature or pressure. DAMAGE, INJURY OR DEATH.
CAUTION
ALWAYS KEEP THE FUEL SUPPLY VALVE SHUT OFF WHEN THE
BURNER IS SHUT DOWN FOR AN EXTENDED PERIOD OF TIME.
CAUTION
DO NOT START THE BURNER UNLESS ALL CLEANOUT DOORS
ARE SECURED IN PLACE.
2 No Ignition Lack of fuel, no gas pressure, closed fuel valve Check fuel supply and valves
(spark, no ame) 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 ow Check air damper position
3 Pilot not detected Scanner tube not positioned correctly Check location of scanner tube
(ame present) Scanner tube dirty or wet (oil lm) Clean scanner tube / scanner
Scanner or amplier faulty Replace
Pilot improperly positioned Check pilot position
Incorrect gas pressure to pilot Readjust pressure
Combustion air ow rate too high Readjust damper
4 No main gas ame Weak scanner signal Clean scanner lens and tube
(pilot OK) Damper or fuel control valve setting incorrect Readjust
Fuel valve(s) not opening Check wiring to valves
5 No main oil ame Weak scanner signal Clean scanner lens and tube
(pilot OK) Damper or fuel control valve setting incorrect Readjust
Fuel valve(s) not opening Check wiring to valves
Oil nozzle or line obstructed Check nozzle and lines, clean
No atomizing air pressure Check compressor wiring
Compressor pressure too low or high Readjust
Burner not level, oil is draining into vessel Check level, adjust as required.
6 Burner stays at low re Manual pot in low re position (low re hold) Readjust to high re position
Manual-auto switch or low re hold switch in wrong position Change position of switch
Modulating Control or Lo-Hi-Lo Control Check wiring or replace
Loose linkage Readjust and tighten
Binding linkage or valve Readjust or replace
7 Burner shuts down Loose electrical connection Check and tighten connections
during operation Loss of fuel supply Replenish fuel supply
Limit switch breaks (opens) Readjust limit switch
8 Burner does not start Main disconnect switch is open Close switch
Loose electrical connection Check electrical connections
Operating controls are tripped Check and reset operating limits
High or low fuel pressure Check fuel supply - reset switches
10 Gas combustion noise Input too low for burner components Check input, compare to rating label
(rumbling) Improper excess air Readjust excess air
Fluxuating gas pressure (regulator not holding pressure) Check regulator pressure and supply
High stack draft (especially at low re) Stabilize draft
Diffuser not in optimum position Adjust diffuser position in or out
Poor air ow distribution (off center ame) Adjust air straightener blade
11 Oil combustion smoking Oil nozzle dirty or plugged Clean oil nozzle
Improper excess air Readjust excess air
Input too low for burner components Check input, compare to rating label
High stack draft (especially at low re) Stabilize draft
Incorrect nozzle position Adjust the nozzle to diffuser position
Fluxuating oil pressures (regulator not holding) Check regulator pressure and oil supply
Poor air ow distribution (off center ame) Adjust air straightener blade
Too much FGR (if equipped) Reduce FGR rate
13 Fuel-Air-Ratios have changed Linkage wear Check linkage and tighten all joints
over time Fuel cam screws have moved Replace fuel cam
Air damper seal worn Replace air damper seals
Fuel lines plugged Check and clean lines, strainers & lters
Fuel control valve worn Replace fuel control valve
Gas orices or gas manifold plugged Clean and/or replace
Combustion air temperature changed Retune burner
Draft condition changed Check draft and outlet damper
Vessel plugged Clean vessel
Plugged or leaky FGR valve Clean / repair
14 Cannot obtain capacity on Wrong spring range in regulator Install higher spring range
gas Too many elbows before control valve Rework piping to reduce elbows
Gas line too small, high pressure drop Use larger pipe size
Supply pressure lower then stated Increase supply pressure
Supply pressure drops too low at high re Use larger gas line sizes / orice in
service regulator
Regulator too small for ow and pressure Change regulator
17 Cannot obtain NOx levels on FGR valve not full open Adjust FGR valve to full open
gas FGR valve full of condensate Clean duct and add drains
FGR duct not directed to ue stream Add angle cut in center of stack
FGR line too small Check sizing, use ttings with less drop
Operating on propane, not natural gas Resize FGR for propane operation
Shutoff valve is not full open Check FGR shutoff valve position
The frequency of inspection given in the following charts The safety interlocks must be checked at regular intervals
is only a guideline. Initial results should be used to adjust to ensure that they provide the proper safety. See the
the time intervals to be more frequent when problems or Inspection and Maintenance Schedule Chart (Figure 8)
potential problems are observed. for frequencies.
Listening and looking at the burner can detect many prob- Monitoring the outlet gas pressure from the regulator will
lems. For example, leakage can usually be seen early verify this control is working properly.
with a small buildup of oil . Valve and linkage problems
can usually be detected early on by simply watching the 5. Oil Fuel System
movement and detecting rough uneven changes. The
jackshaft, linkage and valve movement should occur The oil system has additional components that require
smoothly with no rough jerks. regular maintenance, depending on the type of system
used.
The ame condition can often be a good indicator of the a. Oil added to air compressor. The air compressor has
ring head. If the ame does not look correct, there may a visual sight glass showing the oil level. This must be
be a problem with the hardware. The ring head is ex- inspected every shift (while operating).
posed to the high temperatures of combustion and can b. Air compressor belt tight and in good condition
have reduced life due to the thermal stress. In particular, c. The oil strainer should be checked and cleaned pe-
the diffuser, oil nozzle, gas orices, gas manifold, refrac- riodically. A high vacuum reading on the suction side of
tory and burner mounting plate should all be inspected. the pump (over 10) is a good indication that the strainer
needs to be cleaned. Strainers provided by Webster will
3. Fuel-Air-Ratio Controls use a wire mesh basket inside a canister. After turning
the pump off (and making sure there is no pressure on the
The fuel-air-ratio controls must be maintained in good op- strainer), unscrew the yoke to gain access to the basket.
erating condition. Over time, these items will wear and The canister does not need to be drained. Be careful with
may not operate smoothly. Corrective action must be the gasket when removing or replacing the cover to insure
taken.
JB Manual Page 45 General Maintenance & Care
a good seal. The basket can be lifted out and cleaned with Other checks:
a soft brush and cleaning solution. a. The condensation traps must work properly and be
d. Vacuum higher than the 10 limit on suction side of pump installed to capture all of the condensation. If condensa-
(indicates need to clean strainer, as described above). If tion passes through to the burner windbox, a condensate
cleaning the strainer does not resolve this, check the other drain should be added to the bottom of the windbox.
valves between the tank and gauge for plugged or closed b. Linkage and valve movement must operate freely and
position. smoothly.
e. Air atomized oil nozzles should be cleaned periodically, c. If the FGR valve is modulated partly open (oil ring on
depending on the type of operation and the observed need dual fuel burner) check position of FGR valve.
for cleaning. Extended operation at very low rates (less d. NOx emission levels.
then 15% of capacity) can cause carbon buildup on the e. Other general items like the refractory.
outside of the nozzle. This can be cleaned with a rag and f. Stack temperature of boiler - high temperatures will
cleaning solution. If the re is showing some deteriora- increase NOx levels.
tion, and the external surfaces are clean, then the nozzle g. Operation of safety equipment.
should be removed, disassembled and cleaned using a h. Time delay on FGR on-off valve (if equipped).
soft brush and cleaning solution.
f. If the edges of the air atomizing nozzle are not sharp, 7. Combustion Air Fan
or the nozzle shows sign of wear and the combustion is
deteriorated, the nozzle should be replaced. The nozzle If the fan and motor are ever removed, the following
part number is given on the material list of the unit. In should be observed in re-assembly.
general, a single port (center hole) uses a 80o nozzle or a. There should be about 1/16 overlap of inlet cone and
multiport (multiple hole at the spray angle) nozzle with a fan.
spray angle of 70 degrees will work well for light oil. Heavy b. Never re-use the fan to motor shaft set screws, always
oil should use a spray angle of about 60 degrees. use new screws of the same type and style to maintain
g. Pressure atomized oil nozzles have a lter feeding the balance and fan retention.
nozzle that can be plugged over time. The lter can be c. When tightening the fan hub set screws, rotate the fan
unscrewed from the back and cleaned, using a soft brush to place the screws on the bottom. This way the screw
and cleaning solution. When the nozzle(s) are removed is not lifting the fan.
form the nozzle body (BPS nozzles), the plastic seals at d. The motor shaft and fan hub must be clean and free
the end of the nozzle must be replaced, or the nozzle may of burrs.
not seal correctly. The seal can be slid off of the nozzle
and a new one installed. Use extreme care to not put any
cuts or nicks in the seal. Once the seal is on, the nozzle
can be inserted and screwed into the nozzle body.
h. If a pressure atomized oil nozzle needs to be replaced,
it should be a Delevan Veriow type, using a 60 degree
spray angle (JB3 BPS nozzle(s)).
i. Check safety limits, including pressure and temperature
switches
6. FGR Systems
Technician
Annual As
Seasonal
Required
Operator
Monthly
Trained
Weekly
Annual
Burner
Boiler
Daily
M. REPLACEMENT PARTS
be stocked to support uninterrupted burner operation.
An illustrated parts drawing is included within the Burner
Pilot Electrode Instructions Manual to aid in parts identication. The noun
Blower Wheel name of the part needed should be established from the
Oil Pump (if oil burner) drawing, then the part number can be obtained from the
Oil Pump Coupling (if oil burner) burner material list contained in the Burner Instructions
Pilot Ignition Transformer and Service Manual.
Oil Ignition Transformer (if used)
Gas Pilot Solenoid Valve NOTE
Flame Scanner
Always give Webster Engineering Serial
Items with greater life expectancy and/or greater dollar val- Number and/or UL Serial Number when
ue, such as ame safety controls, main gas or oil valves and ordering parts.
blower motors should be obtained from your local Webster
representative when a need arises.
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 _____________________________
Comments:
Having read the Manufacturers service manual as to the proper installation, start-up and service of the unit above, I
verify that the burner has been put into operation as specied, and that the above information and checks are com-
plete and correct.
START-UP BY _______________________________________________ Date _________________________
Address ___________________________________________________________________________________
NOTE: Warranty Validation - Field Start-up report must be completed, signed, dated and the top copy sent to Webster
Engineering & Manufacturing Co., Wineld, KS 67156, to validate equipment warranty.
JB Manual Page 49 Warranty Validation - Form #113 (4-02)
NOTES