Webster JB Series Installation, Startup, Operation And Maintenance Manual

Cyclonetic forced draft burners , gas - oil - gas/oil

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W£8ST£R

COMBUSTION

A Se las Heat Technology Company

Webster Combustion Technology

619 Industrial Road, Winfield, KS 67156

Installation, Startup, Operation and Maintenance Manual

Cyclonetic J B Series

Forced Draft Burners

JB1-JB2-JB3

Gas - Oil - Gas/Oil

Manual Part No. 950063 - R 1

www.webster-engineering.com

September, 2014

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Summary of Contents for Webster JB Series

Page 1 W£8ST£R COMBUSTION A Se las Heat Technology Company Webster Combustion Technology 619 Industrial Road, Winfield, KS 67156 Installation, Startup, Operation and Maintenance Manual Cyclonetic J B Series Forced Draft Burners JB1-JB2-JB3 Gas - Oil - Gas/Oil Manual Part No. 950063 - R 1 www.webster-engineering.com...
Page 2: Safety Precautions
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.
Page 3: Table Of Contents
This manual covers the Models JB1, JB2 and JB3 CYCLO- where FGR or a NOx cone is used to reduce the NOx NETIC burners offered by Webster Engineering & Manu- in the combustion gases. If the burner is not a low NOx facturing Co., LLC.
Page 4 Service, Parts and other Information age, current load, frequency and phase (this will either be 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...
Page 5: Burner Model Number
MODEL JB(X) BURNER MODEL CONFIGURATION FIGURE A-2 JBX1G -05-RM7800L-M.25-M-A-UL/CSD-1 BURNER SERIES CODES AND JB SERIES LISTINGS FGR or NOx CONE USED CSD-1 NOT USED BLANK HEAD SIZE (INCHES) NFPA-85 7 1/8 7 1/2 OIL SYSTEMS 9 1/8 9 1/2 Pressure Atomizing...
Page 6: Jb1 Specifications
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 o F air temperature and 60 HZ electrical supply. Use the following corrections for higher temperatures and altitude.
Page 7 Model JB1 - Dimentional Data (400 - 2500 MBH Input) (Dimensions are +/- 1/4 inch) 5 5/16 26 5/8 9 1/2 8 1/4 18 3/8 15 11/16 Standard Arrangement 11 7/16 Elevation 21 7/8 Standard Arrangement End View 36 15/16 36 15/16 14 3/8 18 3/8...
Page 8: Jb2 Specifications
On”, and “Fuel On” for circuit board panels. 3. Maximum rate for direct spark is 20 GPH at low fire or 35 GPH at high fire. (standard on straight oil burners, pressure atomized) Model JB2 - Sizing and Application Data (contact Webster for complete information) Model Maximum...
Page 9 Model JB2 - Dimensional Data (6000 MBH Maximum Input) (Dimensions are +/- 1/4 inch) 5 5/16 28 5/8 6 1/2 9 1/2 19 1/16 17 3/4 Standard Arrangement 30 11/16 Elevation Standard Arrangement End View 39 1/4 39 1/4 18 1/2 19 1/2 9 1/8 O.D.
Page 10: Jb3 Specifications
The above chart shows those items standard to a basic burner plus a few options that may be added. 2. Indicator lights are “Power On”, “Call for Heat”, ”Fuel On” and ”Flame Fail”. Model JB3 - Sizing and Application Data (contact Webster for complete information) Model Maximum...
Page 11 Model JB3 - Dimensional Data (12,600 MBH Maximum Input) (Dimensions are +/- 1/4 inch) 38 1/4 6 1/2 5 5/16 15 15/16 19 15/16 22 1/2 Standard Arrangement Elevation Standard Arrangement End View 22 1/2 19 1/4 19 9/16 Standard Arrangement Elevation W/ Optional Back Mount Control Cabinet 11 1/4...
Page 12: Component Ldentification
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...
Page 13 Light Panel Board to Light Combination Flame Flame SafeGuard Circuit Board Panel Cable SafeGuard Base Base and Circuit Board Switch / Light Panel Figure B-4 Control Panel Circuit Board Design Field Wiring Panel Wiring Board to Light Terminal Strips Terminal Strip Panel Cable Electrical Panel Identification: The above pictures show the flame safeguard base mounted on a circuit board.
Page 14 Air Inlet Louver Box Electrical Junction Box Low Atomizing Drawer Assembly Air Press. Sw. Jack Shaft Oil Cam Atomizing Air High Oil Temp. Bleed Muffler Switch Air Bleed Valve Atomizing Air Press. Gauge Blower Motor Oil Temp. Atomizing Line Gauge to Nozzle Supply Oil Press.
Page 15 Gas Manifold Mounting Flange Orifice Plate Secondary Gas Orifices Nose Choke Cone Primary Gas Orifice Drawer Assembly Retention plate Assembly Ignition Electrode Diffuser Figure B-9 Pilot Assembly Standard Head Arrangement Section View Gas Inlet Gas Manifold (inner cylinder) Retention Plate Assembly This connection between the retention plate as- sembly and the gas manifold inner cylinder must...
Page 16 Oil Supply Line Oil Ignition Electrodes View Port Diffuser Oil Nozzle(s) Oil Supply Line Oil Nozzle(s) Sight Tube Diffuser Clamp Adapter Back Plate Figure B-12 JB1 & 2 Straight #2 Oil Drawer Assembly with Direct Spark Ignition Gas Orifice Part Number and Description Part No.
Page 17: Installation
Check linkages, capacity. air louver stops, wiring connections and fasteners for 18. If FGR is used, does it follow Webster guidelines. (see tightness. addendum 950064) 19. If multiple vessels connect to a single stack, are they Verify that all ship loose (or separately shipped) items sized and designed to maintain +/- 0.1”...
Page 18: Special Lnstructions For Canadian Lnstallations
Manual Gas Shutoff Valve Burner Shutoff Shutoff Leak Test Valve Valve Valve If applicable, Webster supplied gas train Figure C-1 Drip Leg Typical Gas Piping Chart C-2 Chart C-3 TYPICAL COMBUSTION CHAMBER SIZE TYPICAL COMBUSTION CHAMBER SIZE FOR FIREBOX BOILERS, WATERTUBE &...
Page 19: Burner Mounting Criteria
See Note 3 with a low NOx cone, refer to ad- dendum number 950064 to 45 taper, Contact Webster for more detailed see note 4 refractory drawings - Opening Minimum of six (6) holes for Refractory OD is sized to ﬁ t boiler mtg.
Page 20: Fuel Systems
F. FUEL SYSTEMS The JB burner can be equipped with a wide range of fuel and operating systems to control the fuel, air, modulation and pilots. This section describes how these systems operate. Burner start-up is expected to be done by service per- sonnel who are qualified in the basics of mechanical know-how.
Page 21 “MP” - Modulating Simplex Nozzle Low Oil Pressure Switch Main Oil Safety Oil Oil Metering Solenoid Valve Solenoid Valve Valve Oil Nozzle Gauge Port Adjustment Oil Pump Check Return to Tank, Valve (No Manual Valves in this By Others Notes & Options Line) Check Shutoff...
Page 22 2. Air Atomized Oil Systems Safety Air Filter Valve “MA” - Modulating #2 Oil Chamber Ball Valve Air pipe same size (man. set to adjust air as discharge open- Atomizing volume & high fire air ing in air chamber Pressure pressure) Gauge (field Piped)
Page 23 3. Gas Systems Illustrated Gas Trains by Capacity and Code: The following illustrations show the Webster conﬁ guration for UL, FM and IRI as grouped by UL capacity ratings. Refer to the legend below for component part identiﬁ cation. These illustrations are not to be used for ﬁ...
Page 24 722001 Field Piped Pilot Gas Pilot Solenoid Pressure Pilot Manual Valve Regulator Ball Valve Gas Pilot Ignitor Vent To Outside Atmosphere Main Motorized Main Solenoid Gas Valve Test Gas Valve 26 Sec. Connection Manual Ball Manual Ball Valve Valve Gas Burner Manifold Supply Field...
Page 25 722009 Pilot Gas Field Piped Pressure Pilot Solenoid Pilot Manual Regulator Valve Ball Valve Gas Pilot Ignitor Man Reset High Gas Pressure Vent To Outside Man Reset Low Switch Atmosphere Vent Main Motorized Gas Pressure Gas Valve Switch Test 26 Sec. Main Motorized Field Connection...
Page 26 722010 Field Piped Pilot Gas Pilot Solenoid Pressure Pilot Manual Valve Regulator Ball Valve Gas Pilot Ignitor Man Reset Low Vent To Outside Gas Pressure Vent Atmosphere Switch Man Reset Main Motorized Main Mortorized High Pressure Gas Valve Test Gas Valve Switch 26 Sec.
Page 27 722084 Field Piped Pilot Gas Pilot Solenoid Pressure Pilot Manual Valve Regulator Ball Valve Gas Pilot Ignitor Normally Open Vent Vent To Outside Vent Valve Vent Man Reset High Atmosphere Main Motorized Gas Pressure Gas Pressure Main Motorized Gas Valve Regulator Switch Fuel Flow...
Page 28: Initial Settings
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 speciﬁ c ap- plication.
Page 29 COMBUSTION AIR CONTROL 2. AIR PROVING SWITCH Panel The air proving switch has been adjusted at the factory Adjusting for an initial setting. If the switch trips during initial start- Screw up, turn the adjustment screw ccw two full turns to re- duce the trip pressure setting.
Page 30: Ignition Systems
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;...
Page 31 Figure H-3 7/8” Figure H-4 (3 1/2”) (2 1/2”) FIGURE H-5 DIRECT SPARK PRESSURE ATOMIZING OIL IGNITION (See Table Below) Diffuser FIGURE H-6 TRIPLE NOZZLE 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...
Page 32: Start-Up & Operating Adjustments
This section covers the startup and operating adjustments rates for extended periods of time and the load must be of the Webster Models JB and JBX burners. capable of using this energy. ______A combustion analyzer with O2 and CO (for gas) WARNING must be available to tune combustion.
Page 33 ible strip is required to move to a screw position where Fire it is initially not in contact with the screw. Also, the movement from one screw to the next cannot be too Drive Arm large (more then 1/8”). This will cause the strip to flex and will lead to premature failure of the strip.
Page 34 equipped with Posi-Control can be adjusted for individual air end of the inner fire cylinder dimension. and FGR settings on both fuels and can easily handle these • Loosen the two setscrews locking the pilot gas line variations, even with lower NOx levels. Linkage burners op- and gun tube to the backplate.
Page 35 10, using the air damper positions defined by oil, and adjust- FGR and do not have this adjustment. If the burner does ing the gas input to match the air damper settings. not have a multiple setpoint modulating motor or link- ageless control, oil must be set first, as the air damper If the burner is equipped with an optional multiple set-point positions will be determined by this setup.
Page 36 the main flame to start. NOTE: The listed manifold pressure is only an ap- m. If equipped with FGR, the shutoff FGR valve should proximate value and can vary with operating condi- open on a linkage system, after the main flame has been tions and normal tolerances.
Page 37 Natural Gas Natural Gas With FGR No FGR % Rate Figure I-3 % O2 % O2 O2 levels z. The burner should be operating at low fire to adjust cause it must fill the oil lines before providing oil to the the air proving switch.
Page 38 p. Adjust the low fire input, using the fuel cam or low fire corrective action. regulator on LO-HI-LO systems and air damper adjust- WARNING ments. If the burner is equipped with FGR, adjust the NOx DO NOT ATTEMPT TO START THE BURNER WHEN EX- level according to the type of system (limiting potentiom- CESS OIL HAS ACCUMULATED, WHEN THE UNIT IS FULL eter or matching gas).
Page 39 according to the type of system (limiting potentiometer or WARNING matching gas). DO NOT ATTEMPT TO START THE BURNER WHEN r. Re-adjust the midfire 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.
Page 40 the air proving switch. Turn the adjusting screw cw(in) until the manual for the flame safeguard for this setting) the burner trips out (shutdown caused by the air flow switch). c. Adjust the gas pressure regulator to the pilot for a Turn the adjustment screw ccw (out) 1 ½...
Page 41 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.
Page 42: Troubleshooting
BOILER BURNER TROUBLESHOOTING, Model JB System Cause Correction 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 No Ignition Lack of fuel, no gas pressure, closed fuel valve Check fuel supply and valves (spark, no flame)
Page 43 System Cause Correction High CO at low fire (con’t) High stack draft (especially at low fire) Stabilize draft (firing gas) Poor air flow distribution (off center flame) Adjust air straightener blade Diffuser not in optimum position Adjust diffuser position in or out Fluxuating gas pressure (regulator not holding pressure) Check regulator pressure, sensing line and supply pressure: sized properly...
Page 44 System Cause Correction Cannot obtain rated input on Oil pressure too low Increase oil pressure oil firing (pres. atom.) (con’t) Flow valve set too low (should be closed at high fire) Adjust oil control valve Cannot obtain rated input on Oil nozzles plugged Clean nozzle oil firing (air atomized)
Page 45: General Maintenance And Care
(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...
Page 46 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.
Page 47 8 - Inspection and Maintenance Schedule Frequency Performed By Component / Item Recommended Action or Test Burner Flame Visual inspection of burner flame. Jackshaft and Linkage Visual inspection for smooth and free travel. Air Damper Visual inspection for smooth and free travel. Fuel Metering Valves Visual inspection for smooth and free travel.
Page 48: Care Of The Burner During Extended Shutdown
Items with greater life expectancy and/or greater dollar val- ordering parts. 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. N. WARRANTY VALIDATION & FIELD START-UP REPORT...
Page 49: Start-Up Report
START-UP BY _______________________________________________ Date _________________________ Company ___________________________________________ Phone No. ____________________________ Address ___________________________________________________________________________________ NOTE: Warranty Validation - Field Start-up report must be completed, signed, dated and the top copy sent to Webster Engineering & Manufacturing Co., Winfield, KS 67156, to validate equipment warranty. JB Manual...
Page 50 NOTES JB Manual Page 50 Notes...
Page 51 NOTES JB Manual Page 51 Notes...
Page 52 NOTES WEBSTER COMBUSTION TECHNOLOGY 619 Industrial Road - Winfield, KS 67156 Phone 620-221-7464 Fax 620-221-9447 sales@webster-engineering.c o m service@webster-engineering.com www.webster-engineering.com JB Manual Page 52 Notes...

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