COMBUSTION. Webster Combustion Technology 619 Industrial Road, Winfield, KS Installation, Startup, Operation and Maintenance Manual

Transcription

1 W 8ST R COMBUSTION A Se las Heat Technology Company Webster Combustion Technology 619 Industrial Road, Winfield, KS Installation, Startup, Operation and Maintenance Manual Cyclonetic J B Series Forced Draft Burners JB1-JB2-JB3 Gas - Oil - Gas/Oil Manual Part No R 1 September, All Rights Reserved

2 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. The following general safety precautions apply to all equipment work. WARNING IF YOU SMELL GAS, OPEN WINDOW, ETINGUISH 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 EPOSE YOU TO SUBSTANCES IN FUEL OR FROM FUEL COMBUSTION WHICH CAN CAUSE DEATH OR SERIOUS ILLNESS AND WHICH ARE KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM. IMPROPER SERVICING OF THIS EQUIPMENT MAY CREATE A POTENTIAL HAZARD TO EQUIPMENT AND OPERATORS. SERVICING MUST BE DONE BY A FULLY TRAINED AND QUALIFIED PERSONNEL. BEFORE DISCONNECTING OR OPENING UP A FUEL LINE AND BEFORE CLEANING OR REPLACING PARTS OF ANY KIND, TURN OFF THE MAIN MANUAL FUEL SHUTOFF VALVES INCLUDING THE PILOT COCK, IF APPLICABLE. IF A MULTIPLE FUEL BURNER, SHUT OFF ALL FUELS. TURN OFF ALL ELECTRICAL DISCONNECTS TO THE BURNER AND ANY OTHER EQUIPMENT OR SYSTEMS ELECTRICALLY INTERLOCKED WITH THE BURNER. Service Organization Information: Company Name Address Date of Startup Lead Technician Phone Number Page 2 Safety Precautions

3 TABLE OF CONTENTS Safety Precautions... 2 A. Introduction... 3 Burner Model Number... 5 JB1 Specifications... 6 JB2 Specifications... 8 JB3 Specifications B. Component ldentification C. Installation D. Special lnstructions For Canadian lnstallations E. Burner Mounting Criteria F. Fuel Systems G. Initial Settings H. Ignition Systems I. Start-up & Operating Adjustments J. Trouble Shooting K. General Maintenance and Care L. Care of The Burner During Extended Shutdown M. Replacement Parts N. Warranty Validation & Field Start-up Report Start-Up Report This manual covers the Models JB1, JB2 and JB3 CYCLO- NETIC burners offered by Webster Engineering & Manufacturing Co., LLC. These burners can be used in a wide variety of Cast Iron, Firebox, Firetube, Flextube and other applications. They can fire gas, oil and combination gas and oil with several different operating systems. A. INTRODUCTION similar to the nameplates shown in Figure A-1. An in the model number refers to a low NOx burner, where FGR or a NOx cone is used to reduce the NOx in the combustion gases. If the burner is not a low NOx burner, there is no in the model. Figure A-1 Nameplate READ AND SAVE THESE INSTRUCTIONS FOR REFER- ENCE MODEL NUMBER JB2C-15-RM7840L-UL-IRI SERIAL NUMBER U81375A WARNING DO NOT ATTEMPT TO START, ADJUST OR MAIN- TAIN THIS BURNER WITHOUT PROPER TRAINING OR EPERIENCE. FAILURE TO USE KNOWLEDGE- ABLE TECHNICIANS CAN RESULT IN EQUIPMENT DAMAGE, PERSONAL INJURY OR DEATH. MAIMUM MINIMUM GAS INPUT RATING OIL INPUT RATING MBTU/HR IN.WC GPH PSI The startup and maintenance of the JB burner requires the skills of an experienced and properly trained burner technician. Inexperienced individuals should not attempt to start or adjust this burner. Every attempt has been made to accurately reflect the burner construction, however, product upgrades and special order requirements may result in differences between the content of this manual and the actual equipment. These special components will be described in the information provided with the burner and should be used as the controlling document. NOTE: This manual must be readily available to all operators and maintained in legible condition. 1. Nameplate Information Each burner has a nameplate with important job details, FUEL NATURAL GAS #2 FUEL OIL VOLTS AMPS HERTZ PHASE HP CONTROL CIRCUIT BURNER MOTOR OIL PUMP MOTOR /2 The serial number represents the unique number for that burner and is a critical number that will be needed for any communications with Webster Engineering. The input rates define the maximum and minimum inputs for that burner, given in MBH for gas and GPH for oil. Air atomized burners show both the oil pressure and air pressure. atomized burners only list the oil pres- Page 3 Introduction

4 sure. For gas firing, the gas manifold pressure is given in in wc which is inches of water column. The electrical ratings of the burner are given, with the voltage, current load, frequency and phase (this will either be single or 3-phase). For motors, the motor HP is listed. 2. Ratings The ratings for each specific burner are given on the nameplate. The general burner ratings are given in Specification Sheets that follow this section. The maximum inputs are given, based on the type of fuel. Other conditions, like the supply gas pressure or the combination of fuels, emission requirements and control systems may prevent the burner from reaching the lowest firing rate. e. Catalog cuts of the major components. These provide details on the installation, adjustment and maintenance of the components used on the burner. 5. Service, Parts and other Information Service and parts are available from your local Webster Representative. For a list of Webster Representatives, please visit the Webster web site at: or call Product Offering The JB burner can fire natural gas, propane and digester gas as well as all grades of light and heavy oil (#2, #4, #5 and #6 oils as defined by ASTM D396). DO NOT USE GASOLINE, CRANKCASE OIL OR ANY OIL CONTAINING GASOLINE. This burner is also available as a low emission burner, and will have model designation JB. Several low NOx rates are available for all gas and light oil burners, with the standard offering of 60 ppm and 30 ppm when firing natural gas. Heavy oil is not allowed in combination with low NOx, as the high sulfur content can recirculate from the vessel through the burner when switched from heavy oil to gas. Low sulfur heavy oil can be used with gas FGR, when the sulfur is under ½% (the FGR is closed during oil firing). The burner can also be equipped with a NOx cone for low NOx on gas, which does not require FGR. (See Addendum ). Figure A-2 lists the common variations and options available on this product. The minimum furnace conditions are given in Section C. 4. Your Complete Manual In addition to this manual, there are several other documents that should be considered as part of the complete manual for the burner. All of these documents are needed to support the installation and startup of the unit. These additional items include: a. The wiring diagram, which shows the limits and interconnection of the burner and vessel controls. b. The gas and oil piping schematics, which show the components and their relative positions in the piping train. c. The unit material list which provides an overview of the burner requirements and a complete bill of material, including the part numbers and description for each item. d. The flame safeguard manual provides the operating sequence for the burner management system. This will be a critical document for troubleshooting any future problems. Page 4 Introduction

5 MODEL JB() BURNER MODEL CONFIGURATION FIGURE A-2 JB1G -05-RM7800L-M.25-M-A-UL/CSD-1 BURNER SERIES JB JB SERIES FGR or NOx CONE USED NOT USED BLANK HEAD SIZE (INCHES) JB JB 1 7 1/8 7 1/ /8 9 1/ /8 11 1/2 G O C FUELS Gas Oil Gas / Oil BLOWER MOTOR HORSEPOWER 02 1/4 03 1/3 05 1/2 07 3/ / / RM7800L M Mark E110/EP170 Nexus LMV51 LMV52 FLAME SAFEGUARD VENDOR DESIGNATION Honeywell AutoFlame - mini mark Fireye Fireye Siemens Siemens CODES AND LISTINGS UL ULc CSD-1 FM IRI NFPA-85 OIL SYSTEMS Atomizing A On - Off L Low Fire Start H Low - Hi - Low MP Modulation Simplex MR Modulation By-Pass Air or Steam Atomization MA Air Atomization MS Steam Atomization GAS TRAIN VENDOR VGD Siemens VGG Siemens M Maxon All Others Blank (ASCO) - (std) A L H M GAS TRAIN SIZE /2 inches.20 2 inches /2 inches.30 3 inches.40 4 inches GAS SYSTEM On-Off Low Fire Start Low-Hi-Low Modulation The above represents the common model designations. Contact the factory for other options and special applications. Page 5 Identification

6 Model JB1 - Specification Data (1) STANDARD UL EQUIPMENT AND IMPORTANT OPTIONS Gas Fuel Burned No. 2 Oil pressure atomized ( MBH Input) STANDARD UL EQUIPMENT AND IMPORTANT OPTIONS Gas Fuel Burned No. 2 Oil pressure atomized General Ignition Optional Motor, Fan and Air Inlet Control Main Manual Shutoff Air Flow Switch (also with oil systems using remote pump) Main Safety Shutoff (2) Burner Mounted Control Panel, Switch and Indicator Lights Second Safety Shutoff Flame Safety Control Main Gas Ultra Violet Scanner Gas Checking Motor Controller (single phase voltage) Gas Fuel High and Low Gas Switches (st d over 2500 MBH) Fuel Selector Switch Duel Fuel Burners Only Metering (modulation only) Proven Gas Pilot Ignition Oil Drawer Assembly with Diffuser Pilot Solenoid Gas Oil Nozzle(s) Pilot Gas & Manual Integral Oil Pump Pilot Gas Ignition Transformer Main Safety Shutoff Direct Spark Oil Ignition Second Safety Shutoff Direct Spark Oil Ignition Transformer Oil Fuel Low Oil Switch (STD when using remote oil pump) Inverted Housing Oil Gauge Alternate Control Cabinet Positioning Oil Metering (modulating systems) Remote Control Panel Future Gas Combustion Head-OPT Opt. Fuel Metering CAM-NETIC II 1. The configuration of each unit will vary with specific job requirements such as input rating, electrical specification and special agency approval codes. The above chart shows those items standard to a basic burner plus a few options that may be added. 2. Indicator lights are Power On, Call for Heat, Fuel On and Flame Fail for hard wired panels. Alarm, Low Water, Power, Call for Heat, Ignition On, and Fuel On for circuit board light panels. Opt. Opt. 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 HP Combination Gas scfh #2 Oil gph On-Off, LFS Modulation JB / / 7.1 1/4 1/3 1 6 / 14 7 /14 Integral JB / / /3 1/2 1 1/4 8 / 14 9 / 14 Integral JB / / /2 1/2 1 1/2 7 / 14 8 / 14 Integral JB / / /4 3/4 1 1/2 9 / / 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, 90 o F air temperature and 60 HZ electrical supply. Use the following corrections for higher temperatures and altitude. Capacity decreases by 17% for 50 Hertz. Capacity decreases by 4% for each 1000 feet above 1000 foot altitude. Capacity decreases by 6% for each 1 inch of furnace pressure. Capacity decreases by 2% for each 10 o F increase in air temperature over 90 o F. Gas input ratings based on 1000 BTU/cu ft. and 0.64 specific gravity. Sizes and pressure will vary with gas. Oil input ratings are based on 140,000 BTU/gal for ASTM #2 fuel oil. Essential Ordering Information and Data: Power Supply - Confirm for control circuit and electrical supply for burner motor(s) (voltage, frequency and phase). Describe Boiler or Heater to be Fired - Including the manufacturer, model number, furnace pressure and furnace size. Firing Rate - Define firing rates in MBH for gas and GPH for oil. Fuel to be Burned - Type of gas and/or oil, including the BTU value. Approval Agency - UL, FM, IRI (GE GAP), CSD-1, NFPA, Mil spec and local codes, if applicable. Flame Safety Control Preferred - Honeywell or Fireye controls. Gas Train Components Preferred - ASCO/ITT, Honeywell or Landis Control System - ON-OFF, Low Fire Start, Low-High-Low, Modulation, Posi-Control Required Options - Mounting plate, limit controls, etc. Page 6 Specification

7 Model JB1 - Dimentional Data (Dimensions are +/- 1/4 inch) ( MBH Input) 9 1/ / / / / / /8 11 7/16 Standard Arrangement End View Standard Arrangement Elevation 36 15/ / /8 18 3/8 19 3/8 7 1/4 O.D. 11 3/8 Standard Arrangement Elevation W/ Optional Back Mount Control Cabinet Inverted Arrangement Elevation (Optional) Fuels Burned and Control Systems - Natural Gas, Propane, Digester or Mixed Gases - Light #2 Oil, Mechanical - On-Off, Low Fire Start, Low-High-Low, Modulating or Micro Modulation - Control Circuit Requires 120 vac, 60 Hz, Single Phase Voltage Supply Model JB1 burners are listed by Underwriters Laboratories, Inc. (UL / ULC). Also by the State of Massachusetts Fire Marshal, City of New York Board of Standards and Appeals, State of Minnesota and can be packaged to meet specific requirements of IRI, FM, GE GAP, NFPA, MIL spec. or other special insurance or local code requirements. Page 7 Specifi cation

8 Model JB2 - Specification Data (1) STANDARD UL EQUIPMENT AND IMPORTANT OPTIONS Gas No. 2 Oil Atomized (6000 MBH Maximum Input) Air Atomized STANDARD UL EQUIPMENT AND IMPORTANT OPTIONS Gas No. 2 Oil Atomized Air Atomized General Ignition Options Motor, Fan and Air Inlet Control Gas Fuel Main Manual Shutoff Air Flow Switch Main Safety Shutoff (2) Burner Mounted Control Panel, Switch and Indicator Lights Second Safety Shutoff Main Gas Flame Safety Control Gas Checking Ultra Violet Scanner High and Low Gas Switches Motor Controller (single phase voltage) Metering (modulating systems) Motor Starter w/overloads (3 PH volt) Normally Open Vent Opt. Fuel Selector Switch Duel Fuel Burners Only Proven Gas Pilot Ignition Oil Fuel Oil Drawer Assembly with Diffuser JB2-30 and JB2-50 Oil Nozzles Pilot Solenoid Gas Integral Oil Pump (JB2-07 to JB2-20) Pilot Gas & Manual Remote Oil Pump (JB2-30 to JB2-50) Opt. Pilot Gas Ignition Transformer Two Safety Shutoff s Direct Spark Oil Ignition (3) Low Air Atomizing Switch Direct Spark Oil Ignition Transformer (3) Low Oil Switch (STD when using remote oil pump) Inverted Housing Oil Gauge Alternate Control Cabinet Positioning Oil Metering (modulating system) Remote Control Panel Future Gas Combustion Head Opt. Opt. Fuel Metering CAM-NETIC II Air Compressor 1. The configuration of each unit will vary with specific job requirements such as input rating, electrical specification and special agency approval codes. The above chart shows those items standard to a basic burner plus a few options that may be added. 2. Indicator lights are Power On, Call for Heat, Fuel On and Flame Fail for hard wired panels. Alarm, Low Water, Power, Call for Heat, Ignition On, and Fuel On for circuit board panels. 3. Maximum rate for direct spark is 20 GPH at low fire or 35 GPH at high fire. (standard on straight oil burners, pressure atomized) 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) Air HP Motor HP Atomizing Atomizing Gas scfh #2 Oil gph LFS, LHL Modulation JB / / 20 3/4 1 1/2 10 / Integral N/A N/A JB / / / 14 9 / 14 Integral Optional 2 JB / / /2 2 8 / 14 9 / 14 Integral Optional 2 JB / / (4) 12 / 14 (3) 13 / 14 Integral Optional 2 JB / / /2 N/A 13 / 14 3/4 Optional 2 JB / / /2 N/A 2-5 psi 3/4 Optional 2 3. Lower pressures may apply to reduced inputs with IRI and LFS or LHL with IRI and modulation. 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. Capacity decreases by 17% for 50 Hertz. Capacity decreases by 4% for each 1000 feet above 1000 foot altitude. Capacity decreases by 6% for each 1 inch of furnace pressure. Capacity decreases by 2% for each 10 o F increase in air temperature over 90 o F. Gas input ratings based on 1000 BTU/cu ft. and 0.64 specific gravity. Sizes and pressure will vary with different gas properties. Oil input ratings are based on 140,000 BTU/gal. for ASTM #2 fuel oil. The vessel draft must be between -0.1 and +0.1 wc. Essential Ordering Information and Data: Power Supply - Confirm for control circuit and electrical supply for burner motor(s) (voltage, frequency and phase). Describe Boiler or Heater to be Fired - Including the manufacturer, model number, furnace pressure and furnace size. Firing Rate - Define firing rates in MBH for gas and GPH for oil. Fuel to be Burned - Type of gas and/or oil, including the BTU value. Approval Agency - UL, FM, IRI (GE GAP), CSD-1, NFPA, Mil spec and local codes, if applicable. Flame Safety Control Preferred - Honeywell or Fireye controls. Gas Train Components Preferred - ASCO/ITT, Honeywell or Landis Control System - ON-OFF, Low Fire Start, Low High Low, Modulation, Posi-Control. Required Options - Mounting plate, limit controls, etc. Page 8 Specification

9 Model JB2 - Dimensional Data (Dimensions are +/- 1/4 inch) (6000 MBH Maximum Input) 6 1/ / / / / / /16 Standard Arrangement End View Standard Arrangement Elevation 39 1/ /4 18 1/2 19 1/2 9 1/8 O.D. 12 1/8 Standard Arrangement Elevation W/ Optional Back Mount Control Cabinet Inverted Arrangement Elevation Fuels Burned and Control Systems - Natural Gas, Propane, Digester or Mixed Gases - Light #2 through Heavy #6 Fuel Oil - Low Fire Start, Low-High-Low, Modulating or Micro Modulation - Control Circuit Requires 120 vac, 60 Hz, Single Phase Voltage Supply Model JB1 burners are listed by Underwriters Laboratories, Inc. (UL/ULC). Also by the State of Massachusetts Fire Marshal, City of New York Board of Standards and Appeals, State of Minnesota and can be packaged to meet specific requirements of IRI, FM, GE GAP, NFPA, MIL spec. or other special insurance or local code requirements. Page 9 Specifi cation

10 Model JB3 - Specification Data (12,600 MBH Maximum Input) (1) STANDARD UL EQUIPMENT AND IMPORTANT OPTIONS Gas No. 2 Oil Atomized Air Atomized No. 4-6 Oil Air Atomized STANDARD UL EQUIPMENT AND IMPORTANT OPTIONS Gas No. 2 Oil Atomized Air Atomized N Oil Air Atomized General Ignition Options Motor, Fan and Air Inlet Control Gas Fuel Main Manual Shutoff Air Flow Switch Main Safety Shutoff (2) Burner Mounted Control Panel, Switch and Four Indicator Lights Second Safety Shutoff Main Gas Flame Safety Control Gas Checking Ultra Violet Scanner High and Low Gas Switches Motor Starter with Overloads Metering (modulating systems) Fuel Selector Switch Duel Fuel Burners Only Normal Open Vent (above 12,500 MBH) Proven Gas Pilot Ignition Oil Fuel Oil Drawer Assembly with Diffuser Pilot Solenoid Gas Oil Nozzles Pilot Gas & Manual Oil Heater with Integral Thermostat Pilot Gas Ignition Transformer Remote Oil Pump Opt. Opt. Two Safety Shutoff s High Oil Temperature Switch Low Air Atomizing Switch Inverted Housing Low Oil Switch Alternate Control Cabinet Positioning Oil Gauge Remote Control Panel Oil Metering Fuel Metering CAM-NETIC II Future Gas Combustion Head Opt. Opt. Opt. Posi-Control Air Compressor 1. The configuration of each unit will vary with specific job requirements such as input rating, electrical specification and special agency approval codes. The above chart shows those items standard to a basic burner plus a few options that may be added. 2. Indicator lights are Power On, Call for Heat, Fuel On and Flame Fail. Model JB3 - Sizing and Application Data (contact Webster for complete information) Model Number Maximum Furnace Burner Firing Capability Range Gas scfh #2 Oil gph #4-6 Oil gph Burner Motor HP Pipe Size Gas Train #2 Oil Pump Motor HP #4-6 Inlet Press Atomizing Air Atomizing Pump Motor HP Air Compressor Motor HP JB / / / /2 12 / 27 1 Optional Optional 2 JB / / / / /2 Optional Optional 2 JB / / / / / 27 1 Optional Optional 2 JB / / / psi 1 Optional Optional 2 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. Capacity by 17% for 50 Hertz. Capacity decreases by 4% for each 1000 feet above 1000 foot altitude. Capacity decreases by 6% for each 1 inch of furnace pressure. Capacity decreases by 2% for each 10 o F increase in air temperature over 90 o F. Gas input ratings based on 1000 BTU/cu ft. and 0.64 specific gravity. Sizes and pressure will vary with gas. Oil input ratings are based on 140,000 BTU/gal. for ASTM #2 fuel oil and 150,000 BTU/gal for ASTM #4-6 fuel oil. The vessel draft must be between -0.1 and +0.1 wc. Essential Ordering Information and Data: Power Supply - Confirm for control circuit and electrical supply for burner motor(s) (voltage, frequency and phase). Describe Boiler or Heater to be Fired - Including the manufacturer, model number, furnace pressure and furnace size. Firing Rate - Define firing rates in MBH for gas and GPH for oil. Fuel to be Burned - Type of gas and/or oil, including the BTU value. Approval Agency - UL, FM, IRI (GE GAP), CSD-1, NFPA, Mil spec and local codes, if applicable. Flame Safety Control Preferred - Honeywell or Fireye controls. Gas Train Components Preferred - ASCO/ITT, Honeywell or Landis Control System - ON-OFF, Low Fire Start, Low High Low, Modulation, Posi-Control Required Options - Mounting plate, operating controls, limit controls, etc. Page 10 Specification

11 Model JB3 - Dimensional Data (12,600 MBH Maximum Input) (Dimensions are +/- 1/4 inch) 6 1/ / / / / / Standard Arrangement End View Standard Arrangement Elevation / Standard Arrangement Elevation W/ Optional Back Mount Control Cabinet 11 1/4 O.D. 19 1/4 19 9/ /4 Fuels Burned and Control Systems - Natural Gas, Propane, Digester or Mixed Gases - Light #2 through Heavy #6 Fuel Oil - Modulating Control System - Micro Modulation or Linkage - Control Circuit Requires 120 vac, 60 Hz, Single Phase Voltage Supply Inverted Arrangement Elevation 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 specific requirements of IRI, FM, GE GAP, NFPA, MIL spec. or other special insurance or local code requirements. Page 11 Specifi cation

12 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 Oil Fuel Sight Glass Drawer Assembly Linkage Blower Motor Gas Louver Box Oil Oil Switch Oil Gauge Pilot Solenoid Pilot Gas Combustion Head Gas Actuator Gas Manual Ball Figure B-2 JB1G Left Side View Ignition Transformer Air Flow Switch Pilot Gas Gas Actuator High Gas Switch Figure B-3 JB1G Right Side View Gas Gauge Page 12 Identification

13 Switch / Light Panel Board to Light Panel Cable Combination Flame SafeGuard Base and Circuit Board Light Panel Circuit Board Flame SafeGuard Base Figure B-4 Control Panel Circuit Board Design Panel Wiring Terminal Strip Field Wiring Terminal Strips Board to Light Panel Cable Electrical Panel Identification: The above pictures show the flame safeguard base mounted on a circuit board. Connections are wired via cable to light / switch circuit board. Picture below shows the flame safeguard (base) mounted directly to the panel back plate. Figure B-5 Control Panel Hard Wired Design Control Relays Transformer Fuses Burner Motor Starter Control Transformer Flame Safeguard Switch / Light Panel Terminal Strip Air Chamber Gauge Belt Guard Air Filter Electric Motor Compressor Figure B-6 Air Compressor Air Discharge Connection Page 13 Identification

14 Oil Cam Electrical Junction Box Jack Shaft Air Inlet Louver Box Drawer Assembly High Oil Temp. Switch Low Atomizing Air Press. Sw. Atomizing Air Bleed Muffler Oil Temp. Gauge Air Bleed Atomizing Air Press. Gauge Blower Motor Atomizing Line to Nozzle Oil Metering Drawer Assm. Pre-heat Oil Lines Supply Oil Press. Gauge Trim Heater Safety Relief Trim Heater Oil Supply To Nozzle Thermostat Control Switch & Cold Oil Interlock Switch N.O. Return Oil Safety Oil s Low Oil Press. Switch Nozzle Oil Press. Gauge Figure B-7 JB Burner #4-6 Fuel Oil Choke Cone JB1 & JB2 Only Primary Gas Orifices (Behind Retention Plate) Diffuser Assembly Oil Nozzle(s) Gas Pilot Secondary Gas Orifices Retention Plate Figure B-8 JB Combustion Head - Dual Fuel Page 14 Identification

15 Nose Choke Cone Mounting Flange Orifice Plate Gas Manifold Secondary Gas Orifices Primary Gas Orifice Retention plate Assembly Diffuser Figure B-9 Standard Head Arrangement Section View Drawer Assembly Ignition Electrode Pilot Assembly Gas Inlet Back Mounting Plate w/view Port To Oil System Return Retention Plate Assembly Oil Supply Line Oil Return Line Gas Manifold (inner cylinder) This connection between the retention plate assembly and the gas manifold inner cylinder must be properly made for proper performance. Diffuser Mounting Bracket Oil Nozzle(s) Adapter Oil Nozzle(s) Oil Supply Line (lower pipe) Pilot Gas Supply Pilot Gas Supply Line Gas Pilot Figure B-10 JB3 Combination or Straight Oil Drawer Assembly with Proven Gas Pilot Ignition Electrode Diffuser View Port Oil Supply Line Pilot Gas Line Ignition Electrode Gas Pilot Pilot Gas Inlet Oil Nozzle(s) Adapter Oil Nozzle(s) Oil Supply Line Diffuser Backplate Figure B-11 JB1 & 2 Combination Drawer Assembly with Proven Gas Pilot Ignition Sight Tube Page 15 Identification

16 View Port Oil Supply Line Oil Ignition Electrodes Diffuser Oil Supply Line Oil Nozzle(s) Back Plate Diffuser Clamp Sight Tube Figure B-12 JB1 & 2 Straight #2 Oil Drawer Assembly with Direct Spark Ignition Oil Nozzle(s) Adapter Gas Orifice Part Number and Description Part No. Description Sketch Example Vessel Gas orifice, 5/16 brass blank, no holes Gas orifice, 5/16 brass, (2) radial #48 holes, no axial hole (48 x 2) B FB Gas orifice, 5/16 brass, (2) radial #40 holes, no axial hole (40 x 2) B FB xxx Gas orifice, 5/16 brass, no radial holes, (1) axial hole (xxx = hole dia.) E FB, SF xxx Gas orifice, 5/16 steel, no radial holes, (1) axial hole (xxx = hole dia.) E xxx Gas orifice, 5/16 brass, (4) #40 radial holes, (1) axial hole (xxx = hole dia.) (40 x 4 x ) A FB, SF xxx Gas orifice, 5/16 steel, (4) #40 radial holes, (1) axial hole (xxx = hole dia.) (40 x 4 x ) A Gas orifice, 5/16 steel blank, no radial or axial holes Gas orifice, 5/16 steel, (2) radial #40 holes, no axial hole (40 x 2) B xxx Gas orifice, 5/16 brass, (4) #48 radial holes, (1) axial hole (xxx = hole dia.) (48 x 4 x ) A xxx Gas orifice, 1/4 steel, no radial holes, (1) axial hole (xxx = hole dia.) E Orifice extention, 5/16 OD steel tube, long D Orifice extention, 5/16 OD steel tube, 2.75 long D Orifice extention, 5/16 OD brass tube, long D SF Orifice extention, 5/16 OD brass tube, 2.75 long D OT (open tube) No orifice used (If no orifice part number given in BOM, asume OP) Note: 1. Part numbers ending in -xxx use the drilled hole diameter as the last three digits, or the -xxx. A number 40 drill would be Part numbers ending in 000 indicate no drilled hole. 3. Sketches show general appearance only, not number or type of holes. 4. Secondary orifices are closest to the burner center. primary orifices are on the outside. FB = Firebox SF = Scotch Firetube 4 Radial Holes 2 Radial Holes 1 Axial Hole Orifice Example A 4 Radial Holes, Axial Hole -xxx Orifice Example B 2 Radial Holes, No Axial Holes Orifice Example E No Radial Holes, 1 Axial Hole If the radial drill size is a # 40 drill, this would be called a 40 by 4 orifice, which is common in the JB burner line. If the radial drill size is a # 40 drill, this would be called a 40 by 2 orifice, which is common in the JB burner line. Page 16 The threads run the full length of the orifice. This orifice cannot have radial holes. Identification

17 Prior to installing the burner, the site conditions and utilities need to be evalulated. This section provides some general questions that can help the review process. Inspect the burner for any undetected damage that may have occurred during shipment or by job-site handling. Special attention should be given to the control panel and protruding parts such as linkages. Check linkages, air louver stops, wiring connections and fasteners for tightness. Verify that all ship loose (or separately shipped) items are on hand. This normally will be: gas train components, mounting lugs and insulating rope. Also, front mounting plate and remote oil pump set, if supplied. The burner material list included with the instruction manual serves as a good checklist for this purpose. 1. Is there adequate outside ventilation to supply the needed air for safe combustion as required by your local regulatory agency? 2. If a burner mounting plate is required, is it available and does it meet specifications? (See Section E) 3. Is voltage available for the control circuit and is the correct voltage available for the blower motor as well for the remote oil pump set and air compressor, if used? 4. Will the burner properly fit the boiler or heater with ample clearance on top, bottom and sides? 5. If a gas burner, will there be adequate gas pressure to assure the specified firing rate? 6. If a straight oil burner with gas pilot, is gas available at the burner location? 7. If an oil burner, what is the age and condition of the oil tank(s) and will there be special piping arrangements needed to deliver the oil to the burner? Important Note: The JB series burners must be operated with a two-pipe system. 8. If an oil burner, what grade of fuel oil is in the tank(s) or on order? If a retrofit installation, has the same oil grade always been used? Does it meet the grade specified on the burner s UL rating plate? CAUTION The oil burner shall only burn that grade of oil shown on the UL rating plate. DO NOT USE GASOLINE, CRANKCASE OIL, OR ANY OIL CONTAINING GAS- OLINE OR TOIC CONTAMINANTS. C. INSTALLATION regulator and/or sensing line. 15. Oil piping to be flushed (cleaned) prior to use. 16. Check pump suction pressure (max 10 Hg) or max press (3 psig) if transfer pump is used or tank elevation is higher than the pump. 17. Strainer before oil pump, sized for max pump suction capacity. 18. If FGR is used, does it follow Webster guidelines. (see addendum ) 19. If multiple vessels connect to a single stack, are they sized and designed to maintain +/- 0.1 wc draft at the vessel outlet under all operating conditions. 20. Is stack designed to maintain +/- 0.1 wc at outlet during all operating conditions. WARNING DO NOT USE TEFLON TAPE OR COMPOUNDS CONTAINING TEFLON. THIS COULD DAMAGE THE VALVES CREATING AN UNSAFE OPERATION 21. Is the burner mounting plate and burner head sealed with rope gasket? (See Figure E-2) 22. Has the new gas and oil piping been purged to remove debris? 23. Is there a drop leg in the gas supply to capture foreign material? (See Figure C-1) 24. Is the piping between the gas train and burner done in a manner that will minimize the pressure drop? 25. Has all of the piping been pressure checked for leaks? 26. Is the combustion chamber of proper size and is the center-line height of the burner head adequate? (See charts C-2 & C-3.) 9. Is there adequate flue provisions to assure SAFE and proper venting of the burner? 10. All manuals should be reviewed and understood and stored in a convenient place. 11. Teflon tape should not be used on any field piping. 12. Rope gaskets should be used between vessel and mounting plate, and between mounting plate and burner. 13. Gas piping should be flushed (cleaned) prior to use. 14. Check minimum straight lengths for gas pressure Page 17 Installation

18 Pilot Shutoff Pilot Gas Pilot Solenoid Normally open vent valve Gas Supply Gas Manual Gas Shutoff Low Gas Switch High Gas Switch Burner Drip Leg If applicable, Webster supplied gas train Shutoff Figure C-1 Typical Gas Piping Shutoff Leak Test Chart C-2 Chart C-3 TYPICAL COMBUSTION CHAMBER SIZE FOR FIREBO BOILERS, WATERTUBE & CAST IRON SECTIONAL TYPES TYPICAL COMBUSTION CHAMBER SIZE FOR SCOTCH MARINE FIRETUBE BOILERS Length Width Height - Floor to Center of Burner Diameter Length FURNACE DIAMETER - INCHES D. SPECIAL INSTRUCTIONS FOR CANADIAN INSTALLATIONS 1. The installation of a burner shall be in accordance with the regulations of the provincial installation requirements, or in their absence, the following shall govern: Gas Burners--CGAB149.1 and CGAB149.2 Oil Burners--CSA Standard B139 Authorities having jurisdiction should be consulted before installations are made. 2. All electrical wiring shall be done in accordance with the Canadian Electrical Code, Part I. 3. The installer shall identify (label) the main electrical power disconnect and the manual shut-off valve on the gas and/or oil supply drop-line to the burner. 4. Oil and gas burning equipment shall be connected to fl ues having suffi cient draft at all times, to assure safe and proper operation of the burner. Page 18 Installation / Canadian Installations

19 E. BURNER MOUNTING CRITERIA It is of vital importance that the burner be properly mounted to the boiler or appliance being fi red. Improper mounting can cause leakage of the hot gases back around the burner head resulting in warpage and deterioration. The following illustrations show the proper way the burner must be installed to validate warranty conditions. TYPICAL JB1, 2, 3 BURNER REFRACTORY FRONTPLATE B - Bolt Circle Use minimum Minimum 7 gauge of four (4) 1/2 studs with lugs. 2 Minimum A 2 Minimum Dimensions - Inches MODEL DIM. A DIM. B JB1 7 5/8 10 3/4 JB2 9 5/8 12 3/4 JB3 11 5/8 14 3/4 4 A See Note 3 Note: For JB burners equipped with a low NOx cone, refer to addendum number A - Opening 30 o to 45 o taper, see note 4 Contact Webster for more detailed refractory drawings Minimum of six (6) holes for boiler mtg. studs, 1/2 or larger Minimum 14 Gauge Figure E-1 Refractory Dimension Refractory OD is sized to fi t vessel opening with 1/4 to 1/2 gap, Refractory must extend 2 beyond tube sheet for scotch boilers. This surface must be sealed against the vessel. Check vessel mounting requirements Tighten clamp bolts uniformly - check after fi ring for several hours Fill voids between front plate and vessel with ceramic blanket 4 deep or as defi ned by vessel manufacturer. The burner must be level Refractory Front Plate Fiberglas rope gasket must be coiled to cover the full mounting fl ange surface If gap is over 3/16, wrap burner nose with high temperature ceramic insulating rope. Attachment to vessel varies with manufacturer (follow vessel manufacturers recommendation. Pipe support required Flange secured to fl oor The gas piping from the burner to the train should have as few elbows as possible to reduce presure drop. Figure E-2 Burner Mounting Instruction Page 19 Burner Mounting Criteria

20 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 personnel who are qualified in the basics of mechanical know-how. The following illustrations and information is supplied to identify the various fuel; air and ignition devices that have Adjustment Features. All adjustments can be done with common place tools normally carried by burner and boiler service personnel. NOTE Refer to the bulletins included in the manufacturer s data section of the burner instructions manual for items shown below. 1. atomized oil systems A - On - Off Main Oil Solenoid Safety Oil Solenoid 1 Gauge Port Adjustment Oil Nozzle Return to Tank (No Manual s in this line) Check By Others 1 Oil Pump Notes & Options Suction Supply Line Shutoff Check Strainer 1 These Lines are Field Piped if a Remote Pump is Used By Others Unless Specified on Order L - Low Fire Start or H - Low - Hi - Low N.O. Low Fire Bypass Oil Low Fire Bypass (Adjustment for Low Fire Approx PSI) 2 Low Oil Press. Sw. Main Oil Solenoid Safety Oil Solenoid 2 or 3 1 (IN) (out) High Fire Cylinder Louver Actuator 1 IN Gauge Port Adjustment IN Oil Nozzle Oil Pump Return to Tank (No Manual s in this line) Suction Supply Line Check By Others Check Shutoff 1 Strainer By Others Unless Specified on Order 1 2 Notes & Options These Lines are Field Piped if a Remote Pump is Used Required Above 20 GPH if a Remote Pump is Used Page 20 Fuel Systems

21 MP - Modulating Simplex Nozzle Oil Metering 2 Low Oil Switch Main Oil Solenoid Safety Oil Solenoid 1 1 Gauge Port Adjustment Oil Nozzle Return to Tank, (No Manual s in this Line) Suction Supply Line Check By Others Shutoff Check 1 Strainer By Others (Unless Specified on Order) Oil Pump 1 2 Notes & Options These Lines are Field Piped if a Remote Pump is Used Usage Requirement Varies with Code MR - Modulating Return Flow Nozzles Back Reg. 2 Low Oil Press. Sw. Gauge 1 Main Oil Solenoid Safety Oil Solenoid Suction Supply Line Shutoff 1 Check Strainer Gauge Port Oil Pump Inline Check Oil Nozzle (Bypassing) Notes & Options By Others (Unless Specified in Order) Return to Tank (No Manual s in this Line Check 1 Check Oil Metering Gauge 1 2 These Lines are if a Remote Pump is Used Required Above 20 GPH if a Remote Pump is Used Page 21 Fuel Systems

22 2. Air Atomized Oil Systems Air Filter Ball (man. set to adjust air volume & high fire air pressure) Compressor Safety Air Chamber Air pipe same size as discharge opening in air chamber (field Piped) Low Atomizing MA - Modulating #2 Oil Check Gauge Nozzle Gauge Oil Metering N.C. Main Oil Safety Oil Ball Oil Gauge Flexible Metal Hoses or Copper Tubing Low Oil Gauge Ball or Gate Gauge Relief Oil Pump Compound Gauge Strainer Check Check Gate Return to Tank Oil Suction Air Filter Ball (man. set to adjust air volume & high fire air pressure) Relief Compressor Air Chamber Air pipe same as discharge opening in air chamber (field piped) Low Air Press Sw MA - Modulating #4-6 Oil Check Air Gauge Nozzle Gauge Oil Metering N.C. Main Oil Safety Oil Ball Oil Gauge Oil Preheat Housing Thermometer 1 1 High Oil Low Oil Temp. Sw. Temp. Sw. N.O. Return Oil Ball Oil Supply for Preheat Housing Flexible Metal Hoses or Copper Tubing 1/4 Ball 1/4 Ball Oil Return from Preheat Housing Relief 1 1 High Oil Low Oil Temp. Sw. Temp. Sw. Electric oil heater w/integral low oil temp. switch Gauge Drain Back Plug Opening Ball or Gate 3 valve bypass optional for back pressure valve. Note: For a single burner with the pump set close to the burner the back pressure valve can be furnished piped with the oil pump set. Ball or Gate Oil Supply Heating System Ball or Gate Check Relief Compound Gauge Gauge Oil Pump Strainer Check Check Gate Return to Tank Oil Suction MA or MS - Modulating House Air or Steam 125 PSIG Max. Atomizing Steam Condensate Return Steam Trap Ball or Gate Steam Syphon Steam Strainer Drip Leg 300 lb. Gauge Reducing Ball or Gate Metering Lever Ball Linked to Mod. Motor N.C Atomizing Steam Syphon Low Atomizing Switch Check Steam Syphon Gauge NOTE: House air does not use steam Syphon or Steam Trap Page 22 Fuel Systems

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 eld erection and/or system design purposes. UL Capacity Range BTU/Hr. To 2,500,000 2,500,001 to 5,000,000 5,000,001 to 12,500,000 12,500,001 and Up Operation Mode Webster Designation UL / GE GAP Code FM Illustration On-Off A Low Fire Start L Low Hi Low H Modulating M Low Fire Start L Low Fire Start L Low Hi Low H Low Hi Low H Modulating M Modulation M Modulating M Modulating M Modulating M Modulating M NOTE: Drops; drop through a given gas train will vary somewhat in relation to the individual items used, the specifi c gravity of the gas to be burned and the overall length Pilot Manual Ball Pilot Gas Pilot Solenoid S Gas Pilot Ignitor Vent To Outside Atmosphere Gas Supply Manual Ball Gas Main Solenoid Gas S Manual Test Main Diaphragm Gas D Manual Test Manual Ball Test Connection Gas Burner Manifold UL-FM On-Off Gas Piping Diagram - Up to 2,500 MBH Firing Rate 1/2 PSI Max Page 23 Fuel Systems

24 Pilot Manual Ball Pilot Gas Pilot Solenoid S Gas Pilot Ignitor Gas Supply Manual Ball Gas Vent To Outside Atmosphere Manual Test Main Solenoid Gas S Field Piped Main Motorized Gas 26 Sec. Manual Ball UL-FM Low Fire Start Gas Piping Diagram - Up to 2,500 MBH Firing Rate M Manual Test Test Connection Gas Burner Manifold Pilot Manual Ball Pilot Gas Pilot Solenoid S Gas Pilot Ignitor Gas Supply Manual Ball Vent To Outside Atmosphere Gas Main Solenoid Gas S Manual Test Field Piped Main Motorized Gas 26 Sec. Manual Ball UL-FM Low-Hi-Low Gas Piping Diagram - Up to 2,500 MBH Firing Rate M Manual Test Test Connection Gas Burner Manifold Pilot Manual Ball Pilot Gas Pilot Solenoid S Gas Pilot Ignitor Gas Supply Manual Ball Vent To Outside Atmosphere Gas Main Solenoid Gas S Main Motorized Gas 26 Sec. Manual Test UL-FM Modulation Gas Piping Diagram - Up to 2,500 MBH Firing Rate M Manual Test Manual Ball Test Connection Fuel Flow Control Gas Burner Manifold Pilot Manual Ball Pilot Gas Pilot Solenoid S Gas Pilot Ignitor Gas Supply Manual Ball Vent To Outside Atmosphere Gas L Main Reset Low Gas Switch S Main Solenoid Gas Manual Test Page 24 Main Motorized Gas 26 Sec. Field-Piped UL Low Fire Start Gas Piping Diagram - 2,501 to 5,000 MBH Firing Rate Manual Test M Vent H Main Reset High Gas Switch Test Connection Manual Ball Gas Burner Manifold Fuel Systems

25 Gas Supply Manual Ball Pilot Manual Ball Gas Pilot Gas Vent To Outside Atmosphere L Manual Test Pilot Solenoid S Man Reset Low Gas Switch M Main Motorized Gas 14 Sec. Main Motorized Gas 26 Sec. Manual Test M Vent H Man Reset High Gas Switch Field Piped Manual Ball Test Connection Gas Pilot Ignitor Gas Burner Manifold FM Low Fire Start Gas Piping Diagram - 2,501 to 5,000 MBH Firing Rate Gas Supply Manual Ball Pilot Manual Ball Gas Pilot Gas Vent To Outside Atmosphere L Man Reset Low Gas Switch Main Solenoid Gas S Pilot Solenoid Manual Test Field Piped Manual Ball UL Low-Hi-Low Gas Piping Diagram - 2,501 to 5,000 MBH Firing Rate S Main Motorized Gas 26 Sec. M Vent H Manual Test Man Reset High Gas Switch Field Piped Test Connection Gas Pilot Ignitor Gas Burner Manifold Gas Supply Manual Ball Pilot Manual Ball Gas Pilot Gas Vent To Outside Atmosphere Main Motorized Gas 14 sec. L M Man Reset Low Gas Switch Pilot Solenoid S Manual Test Field Piped Main Motorized Gas 26 Sec. M Manual Test Manual Ball FM Low-Hi-Low Gas Piping Diagram - 2,501 to 5,000 MBH Firing Rate Vent H Man Reset High Gas Switch Field Piped Test Connection Gas Pilot Ignitor Gas Burner Manifold Pilot Manual Ball Pilot Gas Pilot Solenoid S Gas Pilot Ignitor Gas Supply Manual Ball Vent To Outside Atmosphere Gas L Man Reset Low Gas Switch S Main Solenoid Gas Main Motorized Gas 26 Sec. M Manual Test Manual Test Fuel Flow Control UL Modulation Gas Piping Diagram - 2,501 to 5,000 MBH Firing Rate Vent H Man Reset High Gas Switch Manual Ball Test Connection Gas Burner Manifold Page 25 Fuel Systems

26 Pilot Manual Ball Pilot Gas Pilot Solenoid S Gas Pilot Ignitor Gas Supply Manual Ball Gas Vent To Outside Atmosphere L Manual Test Man Reset Low Gas Switch Main Mortorized Gas 14 Sec. M Manual Test Main Motorized Gas 26 Sec. M Vent H Man Reset High Switch Manual Ball Fuel Flow Control Test Connection Gas Burner Manifold FM Modulation Gas Piping Diagram - 2,501 to 5,000 MBH Firing Rate Pilot Manual Ball Pilot Gas Pilot Solenoid S Gas Pilot Ignitor Gas Supply Manual Ball Vent To Outside Atmosphere Gas L Main Solenoid Gas Man Reset Low Gas Switch S Main Motorized Gas W/POC 26 Sec. POC Manual Test Fuel Flow Control UL Modulation Gas Piping Diagram - 5,001 to 12,500 MBH Firing Rate M Vent H Manual Test Man Reset High Gas Switch Manual Ball Test Connection Gas Burner Manifold Pilot Manual Ball Pilot Gas Pilot Solenoid S Gas Pilot Ignitor Gas Supply Manual Ball Vent To Outside Atmosphere Gas L Man Reset Low Gas Switch Main Motorized Gas 14 Sec. M Main Motorized Gas W/ POC 26 Sec. POC Manual Test Man Reset High Switch Fuel Flow Control FM Modulation Gas Piping Diagram - 5,001 to 12,500 MBH Firing Rate M Vent H Manual Test Manual Ball Test Connection Gas Burner Manifold Pilot Manual Ball Pilot Gas Pilot Solenoid S Gas Pilot Ignitor Gas Supply Gas Manual Ball Vent To Outside Atmosphere L Man Reset Low Gas Switch Normally Open Vent Main Solenoid Gas S Manual Test Main Motorized Gas W/POC 14 sec. Manual Test Manual Ball UL Modulation Gas Piping Diagram - Over 12,500 MBH Firing Rate Vent S M POC Vent H Man Reset High Gas Switch Fuel Flow Control Test Connection Gas Burner Manifold Page 26 Fuel Systems

27 Pilot Manual Ball Pilot Gas Pilot Solenoid S Gas Pilot Ignitor Gas Supply Gas Manual Ball Vent To Outside Atmosphere L Man Reset Low Gas Switch Normally Open Vent Main Motorized Gas W/POC - 14 sec. M POC Manual Test Manual Test Manual Ball FM Modulation Gas Piping Diagram - Over 12,500 MBH Firing Rate Vent Main Motorized Gas W/POC 14 sec. S M POC Vent H Man Reset High Gas Switch Fuel Flow Control Test Connection Gas Burner Manifold Page 27 Fuel Systems

28 G. INITIAL SETTINGS The burner will be set at the factory for normal initial settings. These are only rough settings that must be adjusted at startup to match the furnace, fuel pressure and environment of the specifi c application. These general settings are covered in this chapter as a means of checking the burner (linkage and settings can move in shipment) or readjusting the burner if the settings are lost. B 1. Oil nozzle position The oil nozzle initial position is shown in Figure G-2. The oil nozzle will be adjusted at start-up and may be moved in or out from this initial setting. In some cases, the oil nozzle may be inside the diffuser Figure G-1 Oil Nozzle Position, Gas Pilot INNER FIRE CYLINDER Chart G-2 PRESSURE ATOMIZED NOZZLE AIR ATOMIZED NOZZLE Model Diffuser Qty. Spray Dimension Diffuser Nozzle Spray Dim. Dim. I.D. Angle Inches I.D. Type Angle A B 30 3/8 2 JB1 1 1/2 45 1/4 NA NA NA NA NA 30 7/ /4 30 3/4 Single 1 3/ / JB2 Port 1/4 NA 60 1/2 2 1/ /8 2 1/2 JB3 Multi 80 Port NA 3/8 2 7/ /8 2 7/8 Cam Flexible Strip High Fire Position Low Fire Position Cam Set Screws Adjusting Screws Return Springs Jack Shaft Aluminum Strip End Screws Spring End Screw Adjusting Nut Cam Follower Retention Plate Figure G-3 Fuel Cam Adjustment Roller Washers Roller Cam Follower Page 28 Initial Settings

29 COMBUSTION AIR CONTROL Panel Adjusting Screw Air Proving Switch 2. AIR PROVING SWITCH The air proving switch has been adjusted at the factory for an initial setting. If the switch trips during initial startup, turn the adjustment screw ccw two full turns to reduce the trip pressure setting. 3. TYPICAL AIR AND FUEL ADJUSTMENT LOCATIONS AIR FLOW INTERLOCKING SWITCH 4. Fuel Cam Adjustments (if applicable) The fuel cam needs to be checked for correct travel and alignment. Positions can change during shipment and installation and they must be reviewed prior to startup. The fuel cams are mounted to the ends of the jackshaft assembly. A cam follower link follows the profi le established by the adjusting screws and drives the fuel valve. A thin metal band is used between the screw and cam follower to provide a smooth profi le. The adjusting screws are backed by compressed nylon inserts, which provide a resistance to turning. The cam (Figure G-3) should be checked for the following conditions: a. At the low fi re position, the roller should be between the fi rst two adjusting screws. If not, adjust the position of the cam accordingly, making sure to maintain the same low fi re fuel valve position. b. When the linkage is modulated from low to high fi re, the roller must stay in the center of the adjusting screws within 1/8. If needed, the two cam set screws can be loosened and the cam moved to center it on the roller. Page 29 c. At high fire, the roller should be between the last two adjusting screws. d. The adjusting screws should form a smooth contour with no jumps between the screws. e. In preparation of startup, the retention plate can be removed temporarily to make it easier to adjust the screws. THE RETENTION PLATE MUST BE REPLACED WHEN SETUP IS COMPLETE. If the unit is equipped with a parallel positioning system (linkageless), the control valves can be positioned and operated in a similar manner, but accomplished through the controller. Refer to the instruction manual for details. CAUTION LINKAGE AND ACTUATOR MOUNTINGS CAN BE BENT OR MOVED DURING SHIPMENT AND INSTALLATION. THEY MUST BE CHECKED PRIOR TO OPERATION AND ANY FAULTS CORRECTED. FAILURE TO CORRECT A MISALIGNED CONTROL WILL RESULT IN PREMATURE FAILURE. Initial Settings