Table of Contents
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W£8ST£R
COMBUSTION
A Se las Heat Technology Company
Webster Combustion Technology
619 Industrial Road, Winfield, KS 67156
Installation, Startup, Operation and Maintenance Manual
Cyclonetic J B Series
Forced Draft Burners
JB1-JB2-JB3
Gas - Oil - Gas/Oil
Manual Part No. 950063 - R 1
www.webster-engineering.com
September, 2014
©
2014 All Rights Reserved
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Table of Contents
Related Manuals for Webster JB1
Summarization of Contents
Safety Precautions and Warnings
Hazard Identification Symbols
Explains WARNING and CAUTION symbols for hazard identification.
General Safety Guidelines
Covers gas leaks, lockout/tagout, and safe servicing practices.
JB1 Burner Specification Data
Standard UL Equipment and Options
Lists standard and optional equipment for JB1 burners.
JB1 Sizing and Application Data
Provides capability, HP, and gas/oil train information for JB1 models.
Essential Ordering Information
Details required information for ordering JB1 burners.
JB1 Burner Dimensional Data
Burner Arrangement Views
Shows end, elevation, and inverted views of the JB1 burner.
JB1 Fuels and Control Systems
Lists the types of fuels and control systems compatible with JB1.
JB2 Burner Specification Data
Standard UL Equipment and Options
Lists standard and optional equipment for JB2 burners.
JB2 Sizing and Application Data
Provides capability, HP, and gas/oil train information for JB2 models.
Essential Ordering Information
Details required information for ordering JB2 burners.
JB2 Burner Dimensional Data
Burner Arrangement Views
Shows end, elevation, and inverted views of the JB2 burner.
JB2 Fuels and Control Systems
Lists the types of fuels and control systems compatible with JB2.
JB3 Burner Specification Data
Standard UL Equipment and Options
Lists standard and optional equipment for JB3 burners.
JB3 Sizing and Application Data
Provides capability, HP, and gas/oil train information for JB3 models.
Essential Ordering Information
Details required information for ordering JB3 burners.
JB3 Burner Dimensional Data
Burner Arrangement Views
Shows end, elevation, and inverted views of the JB3 burner.
JB3 Fuels and Control Systems
Lists the types of fuels and control systems compatible with JB3.
Component Identification
JB Burner Component Views
Illustrates major components of JB burners with labels.
Control Panel Configurations
Details circuit board and hard-wired control panel designs.
Air Compressor Components
Shows and labels the air compressor parts.
Fuel System Components (#4-6 Oil)
Identifies parts of the #4-6 fuel oil system.
Combustion Head Components (Dual Fuel)
Identifies parts of the dual fuel combustion head.
Standard Head Arrangement Details
Illustrates the standard head arrangement section view.
Drawer Assembly Configurations
Shows drawer assemblies for combination burners.
Drawer Assembly with Direct Spark Ignition
Illustrates the #2 oil drawer assembly.
Gas Orifice Specifications
Lists part numbers and descriptions for gas orifices.
Installation Procedures
Site, Item, and Ventilation Checks
Covers site evaluation, item checks, ventilation, and power.
Fuel System and Piping Integrity
Focuses on oil tank, fuel grade, flue provisions, and piping prep.
Critical Installation Warnings
Includes safety notes on Teflon tape and fuel type.
Canadian Installation Instructions
Compliance with Canadian Codes
Adherence to provincial and CSA regulations.
Electrical and Flue Requirements
Canadian electrical code and flue connection guidelines.
Burner Mounting Criteria
Refractory Frontplate Dimensions
Provides dimensions for JB1, JB2, JB3 refractory frontplates.
Burner Mounting and Sealing
Covers sealing, tightening, leveling, and support.
Fuel Systems Overview
Pressure Atomized Oil Systems
Explains On-Off and Low-Hi-Low pressure atomized oil systems.
Oil System Notes and Options
Highlights field piping and remote pump considerations.
Fuel Systems Overview
Modulating Oil Nozzle Systems
Describes Simplex and Return Flow modulating oil systems.
Fuel Systems Overview
Air Atomized Oil Systems
Details Modulating #2 and #4-6 Oil air atomized systems.
House Air or Steam Systems
Describes modulating systems using house air or steam.
Gas Systems and Piping Diagrams
Gas Train Configurations
Links BTU/Hr, Operation Mode, Code, and Illustration for gas trains.
On-Off Gas Piping Diagram
Shows UL-FM On-Off gas piping for up to 2,500 MBH.
Gas Systems and Piping Diagrams
Low Fire Start Gas Piping Diagrams
Covers UL-FM and UL Low Fire Start gas piping diagrams.
Low-Hi-Low Gas Piping Diagrams
Covers UL-FM and UL Low-Hi-Low gas piping diagrams.
Modulation Gas Piping Diagrams
Covers UL-FM and UL Modulation gas piping diagrams.
Gas Systems and Piping Diagrams
FM Gas Piping Diagrams (2,501-5,000 MBH)
Shows FM Low Fire Start and Low-Hi-Low gas piping diagrams.
UL Gas Piping Diagrams (2,501-5,000 MBH)
Shows UL Low-Hi-Low and Modulation gas piping diagrams.
Gas Systems and Piping Diagrams
FM Modulation Gas Piping Diagrams
Covers FM Modulation gas piping diagrams for two ranges.
UL Modulation Gas Piping Diagrams
Covers UL Modulation gas piping diagrams for a specific range.
Gas Systems and Piping Diagrams
UL/FM Modulation Gas Piping Diagrams (Over 12,500 MBH)
Shows UL and FM Modulation gas piping diagrams for over 12,500 MBH.
Initial Settings and Adjustments
Oil Nozzle Position
Describes initial oil nozzle position and adjustments.
Fuel Cam Adjustment
Details fuel cam adjustment and components.
Initial Settings and Adjustments
Combustion Air and Switch Adjustments
Covers air proving switch and air flow interlock adjustments.
Fuel Cam Adjustment Details
Provides guidelines for fuel cam adjustments.
Critical Retention Plate Note
Emphasizes the importance of the retention plate during adjustments.
Ignition Systems
Gas Pilot Assembly
Describes gas pilot assembly and parameters.
Oil Ignition and Damper Settings
Covers direct spark oil ignition and air damper settings.
Control Valve Positioning
Details gas and oil modulating control valve positions.
Ignition Systems
Pilot Positioning Diagrams
Illustrates pilot positioning for JB1, JB2, and JB3.
Direct Spark Oil Ignition Settings
Details settings and tables for direct spark oil ignition.
Startup and Operating Adjustments
Pre-Start Checkout and Safety
Lists essential checks and critical warnings before startup.
Linkage, Cam, and FGR Adjustments
Details adjustments for linkage, fuel cams, and FGR.
Startup and Operating Adjustments
Linkage Adjustment Details
Continues linkage adjustments with guidelines.
Fuel Cam and FGR Adjustment Guidelines
Provides guidelines for fuel cam and FGR adjustments.
Startup and Operating Adjustments
Burner Drawer and Single Fuel Setups
Explains drawer adjustments and single fuel setup procedures.
Combination Fuel Setup Procedures
Procedures for dual fuel setups.
Startup and Operating Adjustments
Dual Fuel Setup Details
Covers combination gas/air atomized oil and gas/heavy oil setups.
Gas Setup Step-by-Step
Provides a detailed procedure for gas setup.
Startup and Operating Adjustments
Gas Input Calculation and Pressure Switch Adjustment
Covers calculating gas input and setting pressure switches.
Startup and Operating Adjustments
Pressure Atomized Oil Setup Guide
Step-by-step guide for pressure atomized oil setup.
Critical Oil Accumulation Warning
Safety warning regarding excess oil accumulation.
Startup and Operating Adjustments
Air Atomized #2 Oil Setup Guide
Step-by-step guide for air atomized #2 oil setup.
Oil Input Calculation
Formula for calculating oil input in GPH.
Startup and Operating Adjustments
Heavy Oil Setup Guide
Step-by-step guide for heavy oil setup.
Startup and Operating Adjustments
Operating Control and Limit Adjustments
Adjusting controls and testing limit switches.
Pilot Test Procedures and Safety
Checking pilot operation, safety, and warnings.
Startup and Operating Adjustments
Burner Shutdown and Restart Procedures
Covers normal shutdown and restart after extended periods.
Boiler Burner Troubleshooting
Troubleshooting: Ignition and Flame Issues
Covers no spark, no flame, pilot detection, and no gas/oil flame issues.
Troubleshooting: Operation and Shutdown Issues
Addresses staying at low fire, shutdowns, and start-up problems.
Troubleshooting: CO and Gas Issues
Covers high CO and gas combustion noise.
Boiler Burner Troubleshooting
Troubleshooting: Oil Combustion and Air Ratio Issues
Addresses smoking, inconsistent ratios, and changed ratios.
Troubleshooting: Capacity and Input Issues
Covers inability to obtain capacity or rated input.
Boiler Burner Troubleshooting
Troubleshooting: Oil Input and NOx Issues
Addresses oil input and NOx level problems.
General Maintenance and Care
Maintenance Program Fundamentals
Importance of logs, inspections, and parameters for maintenance.
Physical Inspection and Fuel-Air-Ratio Controls
Visual checks and maintenance of linkage/cams.
Gas Fuel System Maintenance
Safety interlocks and drip leg cleaning.
General Maintenance and Care
Oil Fuel System Maintenance
Maintenance for air compressor, strainer, and nozzles.
FGR and Combustion Air Fan Maintenance
Inspecting FGR systems and combustion air fan.
Inspection and Maintenance Schedule
Flame, Linkage, and Fuel System Checks
Visual inspection and pressure monitoring of flame, linkage, and fuel systems.
Flame Safeguard and Control Checks
Testing safety systems and controls.
Valve, FGR, and Fan System Checks
Checking valves, FGR, and fan components.
Extended Shutdown, Replacement Parts, and Warranty
Extended Shutdown Procedures
Guidelines for shutting down the burner for extended periods.
Replacement Parts and Ordering
Information on common replacement parts and ordering.
Warranty Validation and Start-Up Report
Procedures for submitting the warranty validation report.
Warranty Validation and Field Start-Up Report
Control Circuit Component Testing
Checklist for operational testing of control components.
Field Combustion Settings Recording
Table for recording combustion settings during startup.
Start-Up Verification Statement
Installer's statement of proper operation.
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