Installation, Startup, Operation and Maintenance Manual

Installation, Startup, Operation and Maintenance Manual

Model FDR BurnerFor Gas, Oil And Combination Burners With And Without Low NOx IFGR

Manual Part No. 950093www.webster-engineering.comJanuary 2016

SAFETY PRECAUTIONS

Page 2 Safety PrecautionsFDR Manual

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 potentialdeath.

Throughout this manual, the following symbols are used to identify potential problems.

WARNINGThis indicates a potential hazardous situation, which if not avoided, could result in personal injury or death.

CAUTIONThis indicates a potentially hazardous situation, which if not avoided, could result in damage to the equipment.

The following general safety precautions apply to all equipment work.

WARNING

IF YOU SMELL GAS, OPEN WINDOW, EXTINGUISH ANY OPEN FLAMES, STAY AWAY FROM ELECTRICALSWITCHES, EVACUATE THE BUILDING AND IMMEDIATELY CALL THE GAS COMPANY.

IN ACCORDANCE WITH OSHA STANDARDS, ALL EQUIPMENT, MACHINES AND PROCESSES SHALL BELOCKED OUT PRIOR TO SERVICING.

IF THIS EQUIPMENT IS NOT INSTALLED, OPERATED AND MAINTAINED IN ACCORDANCE WITH THEMANUFACTURERS INSTRUCTIONS, THIS PRODUCT COULD EXPOSE YOU TO SUBSTANCES IN FUEL ORFROM FUEL COMBUSTION WHICH CAN CAUSE DEATH OR SERIOUS ILLNESS AND WHICH ARE KNOWNTO THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OROTHER REPRODUCTIVE HARM.

IMPROPER SERVICING OF THIS EQUIPMENT MAY CREATE A POTENTIAL HAZARD TO EQUIPMENT ANDOPERATORS.

SERVICING MUST BE DONE BY A FULLY TRAINED AND QUALIFIED PERSONNEL.

BEFORE DISCONNECTING OR OPENING UP A FUEL LINE AND BEFORE CLEANING OR REPLACINGPARTS 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.

Page 3 Section A - GeneralFDR Manual

TABLE OF CONTENTS

A. General1. Nameplate Information ...........................2. Ratings ...................................................3. Product Offering .....................................4. Your Complete Manual ...........................5. Service and Parts ...................................

B. Component Description1. General ...................................................2. Combustion Air .......................................3. Burner Drawer ........................................4. Gas Fuel Components ...........................5. Oil Fuel Components .............................6. Flue Gas Recirculation (FGR).................7. Fuel-Air-Ratio Controls ...........................8. Electrical Controls ..................................

C. Installation1. General Considerations .........................2. Gas Piping ..............................................3. General Oil Piping ..................................4. Air Atomized #2 Oil..................................5. Heavy Oil ................................................6. Gas Pilot..................................................7. FGR Duct System ...................................8. Draft and Stacks......................................9. Electrical System....................................

D. Fuel and Electrical Systems1. Gas Systems ..........................................2. Gas Pilot .................................................3. Air Atomizing #2 Oil.................................4. Fuel-Air-Ratio Controls............................5. Electrical Controls ...................................6. Operating and Modulating Controls........7. Flame Safeguards...................................

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Page 36

F. Startup and Operating Adjustments1. Pre-Start Check List ................................2. FGR Adjustments ....................................3. Register Assembly Adjustments .............4. Fuel Setups .............................................5. Combination Gas and Air

Atomized #2 Oil .......................................6. Gas Setup ...............................................7. Air Atomized #2 Oil Setup .......................8. Heavy Oil Setup ......................................9. Operating Control Adjustments................10. Limit Tests ..............................................11. Pilot Test .................................................12. Burner Shutdown ....................................

H. Troubleshooting

E. Preliminary Adjustments1. Visual Inspection ....................................2. Burner Drawer Set Up ............................3. Motor Rotation ........................................4. Fuel, FGR and Air Control ......................5. Air Damper Adjustments ........................6. Pilot and Scanner Set Up .......................7. Gas System Adjustments .......................8. Oil System Adjustments..........................9. Air Proving Switch ..................................10. Operating and Modulating Controls .......

Page 25Page 25Page 25Page 25Page 25Page 25Page 26Page 26Page 26Page 27Page 27


A. GENERAL1. Nameplate Information 2. Ratings3. Product Offering4. Your Complete Manual5. Service and Parts

This manual covers the Models FDR and FDRX burn ersoffered by Webster Combustion. These burners areintended for industrial applications on watertube boilers.They can fire gas, oil or combinations of gas and oil.

READ AND SAVE THESE INSTRUCTIONS FORREFERENCE

WARNINGDO NOT ATTEMPT TO START, ADJUST OR MAIN TAINTHIS BURNER WITHOUT PROPER TRAINING OREXPERIENCE. FAILURE TO USE KNOWLEDGE ABLETECHNICIANS CAN RESULT IN EQUIPMENTDAMAGE, PERSONAL INJURY OR DEATH.

The startup and maintenance of the FDR and FDRXburners requires the skills of an experienced and prop erlytrained burner technician. Inexperienced individualsshould not attempt to start or adjust this burner.

THE INSTALLATION OF THE EQUIPMENT SHALL BE IN ACCORDANCE WITH THE REGULATION OF AU THORITIES HAVING JURISDICTION, INCLUDINGTHE NATIONAL ELECTRICAL CODE, CSA STANDARDS139 AND 140, THE CANADIAN NATIONAL ELECTRICCODE, PART I AND ALL LOCAL CODES.

Every attempt has been made to accurately reflect theburner construction, however, product upgrades and spe cial order requirements may result in differencesbetween the content of this manual and the actualequipment. These special components will be describedin the infor mation provided with the burner and should be used as the controlling document.

NOTE: This manual must be readily available to all op erators and maintained in legible condition.

1. Nameplate Information

Each burner has a nameplate with important job details.The “X” in the FDRX refers to a low NOx burner, whereFGR is used to reduce the NOx in the combustion gases.If the burner is not a low NOx burner, there is no “X” in the model.

The serial number represents the unique number for thatburner and is a critical number that will be needed for anycommunications with Webster Combustion.

The input rates define the maximum and minimum inputsfor that burner, given in MBH for gas and GPH for oil. Air atomized burners show both the oil pres sure andair pressure. For gas firing, the gas manifold pressure isgiven in “psi” which is pounds per square inch.

The electrical ratings of the burner are given, with the volt age, current load, frequency and phase (this will eitherbe single or 3-phase). For motors, the motor HP is listed.

2. Ratings

The ratings for each specific burner are given on thenameplate (Figure A-3). The general burner rat ings aregiven in Figure A-3. The maximum and minimum inputsare given, based on the type of fuel. Other con ditions,like the supply gas pressure or the combination of fuels,emission requirements and control systems may limit theturndown.

Turndown is defined as the ratio of the maximum input tothe minimum input. For example, a burner with a maxi -mum input of 120 GPH and a minimum input of 12 GPHhas a 10:1 turndown.

3. Product OfferingThe FDR burner is intended for watertube boilerapplica tions. The burner can fire natural gas, propane anddigest er 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 ANYOIL CONTAINING GASOLINE.

This burner is also available as a low emission burner, andwill have model designation FDRX. The “X” in the FDRXrefers to a low NOx burner, where FGR is used to reducethe NOx in the combustion gases. If the burner is not a lowNOx burner, there is no “X” in the model name.


The above represents the common model designations. Contact the factory for other options and special applications.

CSD-1FMIRI

NFPA-85

RM7800L HoneywellM Mark 7/8 AutoFlame – Mini MarkMark 7/8 AutoFlameE110/EP170 FireyeNexus FireyeLMV51 SiemensLMV52 Siemens

.25 2 1/2 inches

.30 3 inches

.40 4 inches

M Full Modulation

CODES ANDLISTINGS

GAS TRAIN SIZE

OPERATION

FLAME SAFEGUARD VENDORDESIGNATION

FUELSG GasO OilC Gas / Oil

MODEL FDR(X) BURNER MODELCONFIGURATION FIGURE A-1

FDRX40-C LMV52-M .30-MA-NFPA85

BURNER SERIESFDR No FGRFDRX With FGR

MBH LEVEL15 15,000 MBH20 20,000 MBH25 25,000 MBH30 35,000 MBH35 35,000 MBH40 40,000 MBH45 45,000 MBH50 50,000 MBH55 55,000 MBH60 60,000 MBH65 65,000 MBH70 70,000 MBH75 75,000 MBH80 80,000 MBH85 85,000 MBH90 90,000 MBH95 95,000 MBH100 100,000 MBH110 110,000 MBH120 120,000 MBH130 130,000 MBH140 140,000 MBH150 150,000 MBH160 160,000 MBH170 170,000 MBH180 180,000 MBH190 190,000 MBH200 200,000 MBH

OIL SYSTEM

MODULATED AIR ATOMIZATION

MODULATED STEAM ATOMIZATION

MA

MS

Figure A-2 General Ratings


4. Your Complete Manual

In addition to this manual, there are several otherdocu ments that should be considered as part of thecomplete manual for the burner. All of these documents areneeded to support the installation and startup of the unit.These additional items include:

a. The wiring diagram, which shows the limits and inter connection of the burner and vessel controls.

b. The gas and oil piping schematics, which show the components and their positions in the piping train.

c. The unit material list which provides an overview of the burner requirements and a complete bill of material,in cluding part numbers and description for each item.

d. The flame safeguard manual provides the operating sequence for the burner management system. Thiswill be a critical document for troubleshooting anyfuture problems.

e. Catalog cuts of the major components. Theseprovide details on the installation, adjustment andmaintenance of the components used on the burner.

5. Service, Parts And Other InformationService and parts are available from your local WebsterRepresentative. For a list of Webster Representatives,please visit the Webster web site at: www.webster-engineering.com or call 620-221-7464.

ModelMax. Min. Max. Min.

FDR30 30,000 3,000 215 27FDR45 45,000 4,000 320 40FDR60 60,000 6,000 430 53FDR75 75,000 7,500 535 67FDR90 90,000 9,000 645 80FDR110 110,000 11,000 785 98FDR130 130,000 13,000 930 115FDR150 150,000 15,000 1070 130FDR170 170,000 17,000 1215 150FDR190 190,000 19,000 1360 170FDR200 200,000 20,000 1430 180

Gas MBH #2 Oil (GPH)

Figure A-3 Nameplate

FDRX60-C LMV52-M.30-MA-NFPA85 U237000A-01MODEL NUMBER SERIAL NUMBER

BOULDER, CO

MAXIMUM 60,000

6,000

NATURAL GAS #2 OIL/AIR

5.0 430 28/31

12/21530.1

60 15115

MBTU/HR PSI GPH PSI

VOLTS AMPS HERTZ PHASE

60 320.1460 40

60 32.9460 1.5

HP

MINIMUM

FUEL

CONTROL CIRCUIT

BURNER MOTOR

OIL PUMP MOTOR

20-JUL-2001JOB LOCATION DATE MFG

GAS INPUT RATING OIL INPUT RATING

Page 7 Section B - Component DescriptionsFDR Manual

B. COMPONENT DESCRIPTION

1. General2. Combustion Air3. Burner Drawer4. Gas Fuel Components

5. Oil Fuel Components6. Flue Gas Recirculation (FGR)7. Fuel-Air-Ratio Controls8. Electrical Controls

This section describes the components of the FDR andFDRX burner lines and provides some details on theirapplication and operation. Other sections of this manual

provide a more detailed review of how the componentswork as a system and explain the overall operation ofthe burner.

Gas Pilot Train

Main Gas Train

Access Opening

Air Damper

Blower Housing

Register Adjustment Arm

Figure B-1 FDR Burner

Flame Scanner

Windbox

1. GeneralThe FDR and FDRX burner lines (Fig. B-1) are configuredfrom a common group of components that may vary insize and style depending on the capacity, NOx level, fuelsand ap plication. These common groups of componentsare de scribed in this section, however the exact detailof any specific burner must be taken from the unit specificinfor mation provided with each burner. This would includethe material list, wiring diagram, catalog cuts and fueltrain drawings.

2. Combustion AirFanA backward curved fan (Fig. B-2) is used to supply thecombustion air to burn the fuel. If the burner is equippedwith FGR for low NOx, the fan will also provide therecirculated flue gas. The fan diameter and width will varyto match the required combustion air flow rate, FGR rate,burner altitude and vessel backpressure. The fan canoperate at either 1750 or 3550 rpm. Generally, smallerburners operate at 3550 rpm and larger units operate at1750 rpm.

An inlet cone is used with the fan to provide a smooth airflow transition to the fan. Each fan has a matching inletcone. In some cases, the inlet cone bolts directly to thehousing and in other cases, it bolts to an adapter that boltsto the housing. The inlet cone should extend into the faninlet about 1/4 inch.

Fan and Motor AssemblyThe combustion air fan and motor are assembled togetheron a motor support plate that attaches to the blowerhousing. The fan can be adjusted on the shaft to providethe correct overlap between the fan and inlet cone (anyfan adjustments or assembly must follow the installationprocedures for that fan arrangement).

All combustion air motors are braced to minimizevibrations. Larger motors are mounted on a box which issecured to the floor. Smaller motors are braced with pipebrackets.

Several different motor styles can be used depending onthe application. An Open-Drip-Proof style is most commonand used in a typical enclosed, clean environment. ATEFC (Totally Enclosed Fan Cooled) would typically beused in a dirty or wet environment. Other styles are alsoavailable for special applications. The motor dimensions,including the shaft diameter can vary by motor type.

Fan HousingThe fan housing is an enclosure that routes the combus -tion air from the fan to the windbox. The combustion air fanand inlet cone are contained within the fan housing.

Windbox And RegisterThe burner windbox connects the fan housing to the firing head, and contains the register and mounting for the burner drawer.

The register is a multi-vane, circular assembly usingcurvatured louvers for precise distribution and control ofcombustion air. The position of the registers is manuallyadjusted to impart swirl to the air flow. By adjusting theregister adjustment arm, the air can be rotated either in aclockwise or counter clockwise direction. This rotatingcombustion air creates a thorough mixing of the fuel andair before it enters the combustion zone, resulting incomplete and efficient combustion.

Air DamperThe air damper (Fig. B-3) regulates the flow of air to theburner. It has multiple blades to control the air flow. Theair damper is typically located on the inlet to the fan or atthe outlet of the fan between the windbox and burnerhousing.

3. Burner Drawer

The burner drawer (Fig. B-4) contains the pilot, scanner,guide tube and oil gun. These components are allattached to the backplate. The burner drawer can beremoved as a complete unit for adjustment andinspection. The burner drawer slides through the burnerwindbox and register and into the head. It is attached tothe burner by bolting the backplate to the windbox.


RegisterBlades

Figure B-3 Multi-blade damper

Figure B-2 Fan Housing


The oil gun position can be adjusted (in and out) bysliding the oil gun through the guide tube. Setscrews areused to lock these tubes into position. The oil gun can beremoved for inspection or extended gas firing withoutremoving the burner drawer. The scanner is adjustable by way of its ball and swivel mounting.

DiffuserThe diffuser (Fig. B-5) provides the directional control ofthe combustion air for mixing and combustion stability.The diffuser is mounted tothe guide tube and canbe adjusted by loosening theset screws on the drawer assembly and moving theguide tube.

Figure B-5 Diffuser

ScannerThe scanner is an electronic sensor that detects the flameand acts as a safety switch with the flame safeguard. It isaligned to see the end of the pilot flame and the mainflame on both gas and oil. The scanner is mounted on anadjustable ball and views the flame through a pipe. Thisallows the scanner to be positioned to see the end of thepilot, which ignites the main flame.

PilotThe pilot ( F i g . B - 6 ) uses a machined casting toprovide a venturi to pull in air and mix the gas and airprior to burning. A perforated screen is used on the outletof the venturi to shield the base of the pilot flame fromhigh velocity air. A raw gas tube is used to provideadditional gas to the pilot and generate the proper pilotflame size. The ignition electrode provides a spark withinthe perforated screen to ignite the pilot flame.

The pilot is positioned about 2 inches behind the diffuser,so that the pilot flame passes through the diffuser to ignitethe main flame. The pilot should never be operated forlonger than 60 seconds at a time as it can damage thediffuser.

Figure B-6 Pilot

4. Gas Fuel Components

Gas TrainThe gas train contains the safety shut-off valves,manual shut-off valves, pressure switches and othercomponents that may be required for the specificinstallation, available gas pressure, insurance codesand local regulations. The details of the gas traincan vary greatly from burner to burner. Gas trainstend to be designed for each application and a unit-specific gas train assembly drawing is provided foreach unit, identifying the major components. Detailsare provided in the burner manual included with eachburner.

The gas train shown in Figure B-7 uses a gas pressureregulator upstream of two safety shutoff valves.

Figure B-4 Burner Drawer Assembly

Electrode

Raw Gas Tube Clamp

ElectrodeClamp

Pilot Line

Insulator

Venturi

WindScreen

Pilot

Raw Gas Tube

Guide Tube

Figure B-7 Gas Train

Gas Safety Shutoff ValveEach gas train has two shutoff valves in the gas train.These shutoff valves are usually motorized to openand spring return to close. They may contain a proofof closure switch to prove that the valve is in the closedposition prior to starting the burner.

High Gas Pressure SwitchThis switch is located after the last shutoff valve andbefore the gas flow control valve. It is set at a pressurethat is greater than the highest gas pressure expected atthis location. If the gas pressure rises above this level,it will trip the switch and cause the burner to shut down.

Pilot Line Connection

Safety ShutoffValves

High GasPressSwitch

Gas Pressure Regulator

Low Pressure Gas Switch

Vent Valve

Manual BallValve (Qty 2)

Low Gas Pressure SwitchThis switch is located before the first shutoff valve. It is set toa pressure that is below the expected gas pressure at thislocation. If the gas pressure falls below this setting, theswitch will trip and cause the burner to shut down.

Gas Pressure RegulatorEach gas train must have a gas pressure regulator. Theregulator insures a consistent supply pressure to the burner.Often the gas pressure regulator is the first item in the gastrain or can be integrated into the second shutoff valve.

Gas Control ValveThe gas control valve is used to modulate the flow of gas fuel to the burner. With a parallel positioning system(linkageless), an actuator is connected to the gas controlvalve and modulated by electronic control to the desiredposition. The gas control valve is located on the pipe thatconnects to the gas manifold.

Gas ManifoldThe gas manifold, shown in Fig. B-1 of the FDR(X), is eitheran internal or external gas ring. The internal ring is standardunless conditionsexist such ascontaminated fuel,high combustion airtemperatures, oruse of multiple fuels. The precisiondrilled gas spudsare accessible onboth internal and external designs.

Gas SpudsA series of gas spuds are used to direct the gas into the air stream. These gas spuds are located around thecircumference of the gas manifold. The gas spuds arearranged in a manner that gives good mixing of the air and fuel in conjunction with the diffuser.

5. Oil Fuel ComponentsThe oil system uses air or steam to atomize the oil. An aircompressor is typically used for atomization but plant air orsteam can be used as an alternate. Any grade of oil can befired from #2 through #6 oil.

Oil Pump (Optional)The oil pump (Figure B-9) is used to supply the oil to thenozzle at sufficient flow and pressure for the nozzle. The oilpump is provided as a separate item that must be mounted,wired and piped. The assembly consists of the pump, motor,coupling, pump-motor bracket and oil pressure regulator.The motor base mount is used to secure the assembly.

Figure B-8 Gas Spuds in Gas Manifold


Figure B-9 Oil Pump

Oil Pressure RegulatorAn oil pressure regulator is used to maintain constant oilpressure to the burner. It is adjusted to provide the oilpressure needed at the nozzle.

Oil Supply Pressure GaugeThis indicates the oil supply pressure from the pump.

Oil TrainThe oil train contains the safety shut-off valves, pressureswitches and other components that may be required forthe specific installation, insurance codes and localregulations and can vary greatly from burner to burner. Oiltrains tend to be designed for each application and a unitspecific oil train drawing is provided with each unit. Detailsof the actual components are provided with each burner.

Oil Safety Shutoff ValveEach oil train has two shutoff valves. The valves can beeither solenoid or motorized type and can have anoptional POC (proof of closure) switch.

Low Oil Pressure SwitchThis switch is set to a pressure below the expected oilpressure and will trip if the oil pressure drops below thislevel, shutting down the burner.

High Oil Pressure SwitchThis optional switch is set to a pressure above theexpected oil pressure and will trip if the oil pressure risesabove this level, shutting down the burner.

Oil Heater Trim Heater (Heavy Oil Only)This is an electric heater that is sized to increase the oiltemperature by up to 30º F and provides final temperatureadjustments close to the burner.

Low Oil Temperature Switch (Heavy Oil Only)This switch is used on residual oil burners and set to atemperature that is below the expected oil temperature. Ifthe oil temperature drops below this temperature, it willshut down the burner. If the burner is equipped with a trimheater, this switch is located on the trim heater.

High Oil Temperature Switch (Heavy Oil Only)This switch is used on residual oil burners and set to atemperature above the expected oil temperature. If the oiltemperature rises above this, the burner will shut down.

Gas Spuds

Diffuser


Manual Ball ValveA manual valve is provided in the oil line to perform testingof the safety controls as part of normal startup procedures.

Oil Flow Control ValveThe oil flow control valve regulates the flow of oil to thenozzle. The oil flow control valve modulates with the airdamper to provide different input rates. With a parallelpositioning system (linkageless), an actuator is connectedto the oil control valve and modulated by electronic controlto the desired position.

Oil NozzleSeveral types of oil nozzles may be used depending onthe oil system, burner size, turndown and application. Theyall share a common purpose of atomizing the oil into smalldroplets so that they will easily and quickly burn. The oilnozzles use either air or steam to atomize the oil. Thenozzle is mounted to the end of the oil gun and is insertedinto the support tube. The position of the nozzle can beadjusted by moving the gun in the tube. The oil nozzlesand gun have a “top and bottom” position that is critical forcorrect operation. The end of the oil gun is marked with the word “TOP”.Figure B-10 shows the components of typical air atomizingnozzles. The nozzle tip and swirler are lapped together toform a perfect fit and can only be used together as amatched set. Other air atomizing nozzles may have slightlydifferent construction.

Nozzle Tip

Oil Gun The oil gun consists of the oil nozzle and pipe connectionsfor the nozzle. The oil gun slides into the guide tube. Twoblocks are used to keep the gun centered in the guidetube and lock the gun to the end of the guide tube.The gun assembly must be mounted in the correctposition, with the word “TOP” located on top of the gunassembly. This will allow for even oil distribution andprevent oil dripping out of the gun and lines after shutoff.

Nozzle Oil Pressure GaugeThis gauge indicates the oil pressure at the oil nozzle.This reading is important in determining proper operationof the nozzle for atomization at any given firing rate.There is a wide range of possible pressures, but typicallyit is in the range of 15 to 60 psi.

Nozzle Atomizing Air Pressure GaugeThis indicates the atomizing air (or steam) pressure at thenozzle. This reading is important in determining properoperation of the nozzle for atomizing the oil. The pressurecan vary widely depending on the nozzle and rate, buttypically it will be in the range of 15 psi at low fire to as highas 55 psi at high fire.

Air CompressorThe air compressor, if used, provides air to the oil nozzle toatomize the oil. The assembly includes the compressormotor, relief valve and flexible connection to isolate thevibration of the air compressor. The large air compressor(Figure B-11) is equipped with rubber mounts that must beused when mounting the compressor to a base.

Atomizing Media ControlThe atomizing media can be controlled in different ways.House air and steam are controlled by a modulating flowcontrol valve. If an air compressor is used, the flow will becontrolled by bleeding some air off, with either a fixed valveor modulating valve. An air muffler is provided to reduce thenoise from bleeding off air.

6. Flue Gas Recirculation (FGR) The flue gas recirculation components in this section onlyapply to the FDRX model that uses recirculated flue gas toreduce the NOx emissions.

FGR Control Valve The FGR control valve controls the flow of recirculated fluegas. The valve is connected to the FGR inlet tube at thecombustion air inlet. The FGR inlet tube is in a negativepressure zone, which creates the pressure differential forFGR flow.

The FGR control valve modulates in conjunction with thefuel and air valves to provide different input rates. With aparallel positioning system (linkageless), an actuator isconnected to the FGR control valve and modulated byelectronic control to the desired position.

Motor

FlexibleHose Air Supply

Connection

Figure B-11 Air Compressor

Air Filter

Body Swirler

Figure B-10 Typical Large Air Atomizing Oil Nozzle

FGR DuctThe FGR duct provides the connection between the boileroutlet and the control or shut-off valve. The design of thisduct is very important for proper operation and to preventmaintenance problems (see Section C).

7. Fuel-Air-Ratio ControlsThe burner is equipped with a parallel positioning system(linkageless). This system provides the basic fuel-air-ratiocontrol required for good combustion.

The Posi-Control system is a parallel positioning system(linkageless) that uses individual actuators for each controlvalve and a computer controller that directs each actuator toprovide the input change from minimum to maximumcapacity. The control provides more flexibility in setting eachfuel rate.

8. Electrical Controls

Control PanelThe control panel (Figure B-12) contains a flame safeguardcontrol, relays, terminal strips for electrical connections andother components required for the control of the unit. Othercomponents may be included for the operation of the boiler,for example, a low water cutout relay.

Flame SafeguardThe flame safeguard provides operational control and safetysequencing for the burner. Safety limits are tied to the unitand it controls the operation of the fuel valves. The flamescanner is part of this control and can detect a flame failurecausing a safety shutdown. There are several flamesafeguard models available with different features and cost levels. They can provide fault annunciation andcommunication with other controls. The details of the controlused in the burner are supplied with the unit.

On-Off Switch This switch is used to start/stop the burner by opening orclosing the limit circuit to the flame safeguard control.

Fuel Transfer Switch This switch selects the proper fuel for firing. It has a centeroff position that prevents moving the switch from oneposition to the other, without momentarily stoppingin the center off position.

Power On LightIndicates power is applied to the control panel.

Call For Heat LightIndicates the burner On-Off switch is closed and theboiler limits are closed.

Fuel On LightIndicates the main fuel valve circuit has been energized.

Alarm LightIndicates the flame safeguard control is in a safety shut -down and lockout condition. The flame safeguard controlreset button must be pressed before the burner canoperate again. On some burners the Alarm light mayalso be used to indicate other failure conditions such aslow water, high limit, etc. See the burner wiring diagramfor more details.

Control Transformer (Optional)The control circuit transformer is used to reduce themain power input to 115 VAC for the control circuit. If thiselectrical supply could be provided as a separate input,this transformer would not be required. The transformerhas two fuses located on the transformer box.

Alarm BellThe alarm bell (or buzzer) provides an audible noise ifthe burner were to lock out due to an alarm condition.

Control RelaysRelays are provided to support electrical options. Thenumber and type of relays will vary with the equipment.and will be indicated on the wiring diagram/material list.

Motor StartersAt least one motor starter, for the combustion air fan, will be included in each control panel (unless a VFD isused). If other motors are used, for an oil pump or aircompressor, these will also be located in the controlpanel.

Junction BoxThe junction box contains the electrical connections thatare required between the burner and control panel.



Figure B-12 Control Panel (Gas Shown)


This section covers the installation procedures for each ofthe standard systems offered on the FDR (FDR andFDRX) burner line. Your specific burner will not have eachof these systems and may be supplied to you as aninstalled system. If you receive the burner as part of anew boiler for example, the burner may be installed in thevessel with much of the piping already done. For thisreason, a complete review of the installation is required todetermine which tasks are complete and which need to bedone.

THE INSTALLATION OF THE EQUIPMENT SHALL BE IN ACCORDANCE WITH THE REGULATION OF AU THORITIES HAVING JURISDICTION, INCLUDINGTHE NATIONAL ELECTRICAL CODE, INSURANCEREGULA TIONS, CSA STANDARDS 139 AND 140, THECANADIAN NATIONAL ELECTRIC CODE AND ALLLOCAL CODES.

The equipment shall be installed in accordance with thestate and local requirements and in Canada, inaccordance with Provincial Installation Requirements, or in their absence, the CGA B149.1 and B149.2 codes shall prevail. Authorities having jurisdiction should beconsulted before installations are made.

NOTE TO INSTALLER: The main power disconnect forthis equipment must be conspicuously labeled and placedwithin sight of the operating system and equipped withlockout provisions.

1. General Considerations

In the initial planning of the installation, several itemsmust be covered: a. Prior to starting the installation, all the technicalliterature should be collected and reviewed to identifyrequirements. As a minimum, these should include theInstallation and Operating Manuals for the burner andvessel, the wiring diagrams, the fuel schematics andtechnical literature on supplied controls. b. A general overview of the equipment should be madeprior to the installation. Check the location of accessdoors and insure that they will be able to function properlywhen all equipment is installed. The burner and controlpanel should have sufficient clearance for the operator tomonitor, inspect and perform maintenance. A minimumclearance of 36 inches all around the burner should beprovided for maintenance. The burner drawer and oil gunis pulled out from the front of the burner and there needsto be sufficient space for this activity.

c. A source of combustion air must be provided for theburner. Local codes often determine minimum require -ments, and these must be followed. In absence of othercodes, the following can be used.

Webster recommends two air sources be provided, one located high and one low. Each air source must be at least 1ft2. If there are multiple burners, the area must consider allburner requirements. Exhaust fans are not recommend ed asthey create additional air flow requirements that must beincluded in the area calculation.

The quantity of air required for combustion and ventilation is0.24 cfm/MBH. The maximum air velocity is 250 ft/minfrom the floor to 7 feet high, and 500 ft/min above 7 feethigh. Outdoor louvers may restrict the open area, and ifthe exact restriction is unknown, a restriction of 20% canbe used. Add 3.5% to the area for each 1000 ft above sealevel. The calculations are,

Total air required (cfm) = MBH * 0.24Open area = cfm / velocityLouvered area = open area x 1.2 (or actual)Area of opening = louvered area / 2

For example, with duct located under 6’ high for a 20,900 MBH boiler, what would the area need to be? Thetotal air is (20,900 MBH * 0.24 cfm/MBH) = 5016 cfm. The maximum ve locity is 250 ft/min, so the open area mustbe = (5000 cfm / 250 ft/min) = 20 ft2. Since these openingwill have louvers, the actual openings must be = (20 ft2 x1.2) = 24 ft2. There will be two opening, so each will be = (24 ft2 / 2) = 12 ft2.

The location of the combustion air source must not createa condition where the burner or vessel comes in contactwith very cold air (under 40oF) or causes large fluctuationsin combustion air temperature. Cold air can cause con -densation below 40oF in a standard burner and below 50oFwhen equipped with FGR.

There should be no large variations in combustion air tem -perature supplied to the burner. The burner can be adjust edto handle temperature variations of 30oF, but may not beable to handle temperature swings of 50oF without com -bustion deterioration. In conditions where this can occur,some conditioning of the combustion air must be done bylocation, baffling or pre-heating of the air. Seasonal tune upscan also help cover the larger temperature swings.d. There are several people that should be notified beforestarting, including the owners representative, the mechani -cal contractor, the electrical contractor, the service organi -

C. Installation

1. General Considerations2. Gas Piping3. General Oil Piping4. Atomized #2 Oil5. Heavy Oil

6. Gas Pilot7. FGR Duct System8. Drafts & Stacks9. Electrical System

Page 15 Section C - InstallationFDR Manual

2. Gas Piping

WARNINGDO NOT USE TEFLON TAPE OR COMPOUNDS CON TAINING TEFLON. THIS COULD DAMAGE THE VALVES CREATING AN UNSAFE OPERATION.

NOTE TO INSTALLER: The manual shutoff valve on thegas supply drop line to the burner must be clearly labeled.

Figure C-1 shows a typical gas piping schematic, althoughsome components can vary based on size, insurance andother requirements. Consult the job specific gas train pip -ing schematic (provided with the burner if train is suppliedby Webster), along with a detailed list of components forspecific details. This must be followed to properly locatethe components in the gas train.

The gas piping must comply with all local and state codesand must be in accordance with the local gas companyand insurance requirements.

If the gas train has not been factory assembled, the com ponents should be assembled as indicated on the gaspip ing schematic furnished with the burner. A drip legshould be provided upstream of the first manual valve tocollect any moisture or contaminates. Some generalconsiderations for this installation are:

a. The piping to the burner must be sized to provide gas atthe pressure and volume indicated on the order. b. The gas piping should be installed according to localregulations and any applicable insurance requirements.c. The gas pressure regulator usually requires a minimumstraight length of pipe leading into and from the valve forproper operation. Also some regulating valves require adownstream pressure tap that must also be located at acertain dimension from the valve. These details are pro -vided in the job specific details provided with the burner.d. The piping between the train and burner must be donein a manner that will minimize the pressure drop. The pipesize should be the larger of the two connection points (onthe train or the burner connection) and must use a mini -mum amount of elbows.e. The gas piping should be cleaned to remove filings andother debris common in the construction process.f. The piping should be pressure tested with inert gas attwo times normal operating pressure before use. Checkmain and pilot regulators for maximum inlet pressure.

3. General Oil Piping

WARNINGDO NOT USE TEFLON TAPE OR COMPOUNDSCONTAIN ING TEFLON. THIS COULD DAMAGE THEVALVES CREATING AN UNSAFE OPERATION.

The amount of oil piping required in the field will dependon the type of system and how the burner was purchased.If the burner was factory mounted to the boiler, much ofthe installation work may already be complete. Units withheavy oil have more complexity built into them and willrequire more installation effort. The items identified in thismanual assume that none of the installation work hasbeen done by others.The oil piping must be constructed to provide the flow andmaintain the pressure required for proper system opera -tion. Refer to the previous section for details on each ofthe different types of oil systems and how they operate.

Some of the actions required for successful piping sys tems are:a. Oil storage tanks and piping must conform to theNa tional Fire Protection Association “Standard for theInstal lation of Oil Burning Equipment NFPA-31”, localordinanc es and EPA underground storage tankrequirements. b. Oil lines shall be substantially supported and protectedagainst physical damage. Buried lines shall also bepro tected against corrosion.c. After installation and before covering, buried linesshould be pressure tested for leakage.d. Cast iron fittings should not be used.e. Aluminum tubing should not be used.f. Proper allowance should be made for expansion andcontraction, jarring, vibration and tank settling.g. Always run full size lines.h. Suction and return lines shall be as short as possible.i. The oil lines must be cleaned to remove water, rust andforeign matter. j. The standard oil pumps supplied on the FDR(X) areViking Model SG operating at 1750 rpm. These pumpscan pro vide suction (vacuum) of 10 inch of Hg whenused to pull from a tank. If a transfer pump is used, themaximum inlet pressure that the pump can tolerate is 15PSIG, although most regulations require a maximumtransfer loop pres sure of 3 PSIG.

Figure C-1: Typical Gas Train Arrangements


Figure C-2 Typical #2 Oil Field Piping

Figure C-3 Oil Piping, Multiple Burners

FDR Manual Section C- InstallationPage 17

Figure C-4 Oil Schematic, Multiple Burners with Remote Oil Pumps

k. A strainer is required to protect the pump, valves and oilnozzle. This strainer is not part of the standard equip mentsupplied by Webster, but is intended to be sup plied andinstalled by others. The strainer should have a maximumfilter opening of 0.027” for #2 oil and sized to handle the fullflow rate of the pump. The strainer must also handle thepressure (max. 25” vacuum). Retain and follow the strainerinstructions supplied by the manu facturer. It is essential thatthese instructions be followed to insure proper filtration toprotect the pump, valves and nozzle.

l. In Canada, refer to CSA Standard B139, “InstallationCode for Oil Burning Equipment” for recommended instal lation procedures.

m. The oil lines and most valves are sized to handle the fullpump capacity. The pumps are selected for a capacity of atleast 1.5 times the maximum nozzle rate.

The selection of the oil pipe line size is critical for properoperation of the system.

To determine the equivalent length of the oil piping, use thestraight length of piping and add the equivalent length ofstraight pipe given for each fitting.

CAUTION: PUMP FAILURES CAUSED BY FOREIGNMATTER IN THE OIL LINES WILL NOT BE COVERED BYWARRANTY

5. Heavy Oil The standard FDR burner equipped for heavy oil willinclude a trim heater and controls, but not the pump orprimary heater. Oil is to be delivered to the burner at 125PSIG and at a temperature that is within 30ºF of the final oil temperature. The pressure regulating valve must becapable of controlling the pressure anywhere in the rangeof 75 to 125 psi, as required for proper burner operation.

The primary oil heater (provided by others) may be requiredto reach the temperatures needed for good atomization.This can be accomplished with a heat exchanger that usessteam , hot water or electrical energy, or it could be done bysimply heating the oil tank. In either case, the oil must beprovided to the burner at a temperature that is within 30ºFof the required atomization temperature.

A supply and return line connection are required. The linesmust be sized correctly to provide the required flow withminimal pressure drop. The pressure in the return lineshould not exceed 3 PSIG. The oil supply and return lines must be piped to the burner.The motor base of the oil pump and air compressor shouldbe bolted securely to the floor or some rigid base.6. Gas PilotThe typical piping schematic for the gas pilot is shown inFigure C-5. The supply is connected upstream of the firstmanual gas valve. Actual gas pilot arrangement andconstruction may differ depending on agency listings andlocal building codes.

7. FGR Duct SystemIf the burner is equipped with Induced Flue Gas Recircula tion (IFGR), it will require a duct connectionbetween the stack outlet of the boiler and the air inlet ofthe burner. FGR is used to reduce NOx emissions.There can be dif ferent levels of NOx emissions that requiredifferent quan tities of flue gas and different FGR duct andvalve sizes. Proper sizing and installation of the FGR ductmust be done to provide the required emission control and burner performance. The FGR control valve is already installed on the burnerand the duct will connect to this point. A flange is suppliedon the burner that the pipe can be welded to. Depending onthe duct size required, a pipe reducer may be required tomatch the control valve to the duct. The control valve isusually a smaller pipe size.

4. Air Atomized #2 OilThe standard FDR air atomized burner equipped for light oilmay not include the optional oil pump. Oil is to be deliveredto the burner at a constant 125 PSIG and with a flowcapacity that is at least 50% higher than the rated nozzlecapacity.

The oil supply and return lines must be piped to the burn er,with the components installed as shown in the sche matic.The oil pressure regulator must be located close to theburner to provide a constant oil supply pressure.

Page 18FDR Manual Section C - Installation

a. The duct should be routed in a manner that has theminimum number of elbows and provides for the normalexpansion and contraction of the piping. Long duct runs canchange length by over 1” and can put an extreme load onthe connecting points that could cause component failures.The design must include offsets that will allow for therequired movement of the piping without undue force on the burner or stack. b. A condensation drip leg must be provided upstream ofthe FGR control valve. There must be sufficient condensatedrip legs and catch space (volume of drip legs) to preventthe condensation from flowing through the control valvesand into the fan. In cases of heavy condensation, acondensate drip leg may be required on the bottom of thehousing, to remove condensate. CAUTION: UNCONTROLLED CONDENSATION CANCAUSE PREMATURE FAILURE OF THE CONTROLVALVES, FAN AND MOTOR. ADEQUATE MEANS MUSTBE PROVIDED TO REMOVE CONDENSATION FROMTHE SYSTEM. COLD STARTUP WILL GENERATESIGNIFICANT AMOUNTS OF CONDENSATION.c. Determine the duct size, as indicated above. Rememberthat changing the fitting type and number of elbows canhave a large impact on the pressure drop. If the pressuredrop is too high, the unit will not make the required NOx orinput due to the increased pressure drop.The burnercapacity is reduced about 6% for each 1” of pressure drop.d. Determine if pipe reducers are needed for the connectionto the FGR control valve. e. The duct must be properly supported, handling both theweight of the duct and to control the thermal expansion and contraction. The supports may need to be anchored toprovide this stability in the FGR duct. f. The FGR duct is normally made from schedule 40 pipebecause it is easily obtainable and inexpensive. Schedule20 pipe can also be used for this application.g. The duct components must be seal welded, flanged orscrewed together to provide an air tight duct. Air leakageinto the duct will prevent the system from working properly.It is sufficient to only inspect the welds for a proper seal,they do not need to be leak tested.

8. Drafts And StacksStacks and breechings must be designed to maintain arelatively constant draft at the boiler outlet without largevariations. The draft at the boiler outlet should be main-tained within +/- 0.1” wc. at low fire and up to +/- 0.25” athigh fire, with intermediate draft proportional to firing rate.More important than the actual draft is the variation in draftat any given firing rate. For example, a tall stack or multipleunits in a single stack may have different draft conditionsdepending on the outside temperature and the number ofunits running. The draft variation at any given firing rateshould be controlled to within +/- 0.1” wc. The stack should be designed to avoid wind influences fromadjacent structures as well as preventing the flue productsfrom entering inlet ducts, windows or other occupied areas.It should be of sufficient height to extend above the roof ofthe building or adjoining buildings to avoid down drafts in thestack or the possibility of carrying combustion gases toundesirable locations. Local codes should be checked forcriteria on heights and exit velocities. The breeching should be designed to be as straight andshort as practical, to minimize pressure fluctuations. Smoothbends, gradual transitions, low velocities and tightconstruction are all important. Round breechings arepreferred to square or rectangular ducts because they aremore efficient and less likely to generate noise on the flatside due to resonance. CAUTION: OIL BURNING EQUIPMENT SHALL BECONNECTED TO FLUES HAVING SUFFICIENT DRAFTAT ALL TIMES, TO ASSURE SAFE AND PROPEROPERATION OF THE BURNER. Circular elbows should be at least a four piece constructionwith a centerline radius that is at least double the ductdiameter (use three times the duct width for square ducts).The breeching should have a slight upward elevation (about1” per foot) towards the stack to help induce a draft. The breeching connection to the stack or multiple boilers toa common breeching or stack must be done with care. Theducts should never be connected at a 90º angle, but rather a45º angle where the flows will easily join each other. Whenconnecting multiple boilers into a single breeching, thebreeching size must be increased to accommodate thelarger flow rates before the introduction of the added flow.

Figure C-5 Typical Pilot Gas Piping Schematic

Total MBH

16 200

18 300

20 400


22 500

24 700

26 900

28 1100

30 1400

32 1600

34 1900

36 2200

38 2500

40 2900

42 3200

These breeching size changes must be gradual, with nomore then a 10 degree slope change in the duct. Whenmultiple breechings are connected into a common stack,their locations must be staggered to prevent the flow of onebreeching interfering with another. Tall stacks can generatelarge drafts, and in fact the amount of the draft is related tothe stack height. Also, systems with multiple boilers canhave draft variations that are well beyond the desired level.These conditions must be corrected to allow the burner towork properly, or the draft variations will cause combustionproblems. Controls can be added to compensate for thisdraft, and bring it back into the desired level. Thebarometric damper is the most common and leastexpensive control. Several barometric dampers can beadded to provide the total correction to the system draft. Draft controls are also available to regulate the draft bycontrolling an outlet damper. The speed of response iscritical to allow these units to work correctly. If the draftcontrol does not operate much quicker than the burnerchanges rate, the result may be large swings in draft as thecontrol attempts to catch up with the burner. If there arelarge drafts due to tall buildings, special consideration mustbe given to the type of damper needed to regulate the draft,and the response of the control to maintain the proper draft.

Figure C-6 Maximum MBH in a Breeching

Breeching Dia. (in)

9. Electrical SystemThe burner is supplied as standard, with a remote controlpanel. The panel is either intended for floor or wallmounting. A proper location will allow the operator to seethe burner operate while manning the controls. In someareas, there are local regulations that define where thecontrol panel must be mounted in relation to the vessel. The control panel must be securely attached to either thefloor or wall with lag bolts. The wiring diagram for the specific job should be followedfor connections to the panels and external equipment. TheNational Electric Code, Canadian Electrical Code, Part 1 orsimilar code for other jurisdictions should be followed.

The following list covers the standard acronyms andabbreviations typically found on wiring diagrams.AUX. - Auxiliary L.F.H. - Low Fire Hold Switch C.B. - Circuit Breaker L.W.C.O. - Low Water Cut OffC.C.W. - Counter Clock-Wise MR - Manual ResetC.W. - Clock-Wise N. - 120 V Neutral CR( ) - Control Relay N.C. - Normally ClosedFGR - Flue Gas Recirculation N.O. - Normally Open FTS - Fuel Transfer Switch P.L.F.S. - Proven Low Fire GND - Ground Terminal Start H.W.C.O. - High Water Cutoff P.O.C.S. - Proof Of Closure INT - Interlock SwitchL - 120V Line SW. - SwitchTDR - Time Delay Relay

Figure C-7 MBH Max Inlet 4” 5” 6” 8” 10” 12” 14” 16”

Press.

8,400 1.00 1.4 0.4 0.110,500 1.00 2.1 0.6 0.212,600 1.25 3.1 0.9 0.314,700 1.25 4.2 1.2 0.516,800 1.25 5.5 1.6 0.618,900 1.25 7.0 2.0 0.8 0.221,000 1.50 2.5 0.9 0.223,100 1.50 3.0 1.1 0.225,200 1.50 3.6 1.3 0.329,400 1.50 4.9 1.8 0.431,500 1.50 5.6 2.1 0.533,600 1.50 6.4 2.4 0.5 0.233,600 2.00 8.1 3.0 0.7 0.242,000 2.00 3.7 0.8 0.246,200 2.00 4.5 1.0 0.350,400 2.00 5.4 1.2 0.3

Pressure Drop for 60ppm NOx – Natural Gas Firing

Pressure Drop per 100 Feet of Duct (in wc)

Pressure Drop for 30ppm NOx – Natural Gas Firing8,400 1.00 1.9 0.4 0.110,500 1.00 2.9 0.6 0.212,600 1.25 4.2 0.9 0.314,700 1.25 5.8 1.3 0.416,800 1.25 7.5 1.7 0.5 0.218,900 1.25 2.1 0.6 0.3 0.121,000 1.50 2.6 0.8 0.3 0.223,100 1.50 3.1 0.9 0.4 0.225,200 1.50 3.7 1.1 0.5 0.229,400 1.50 5.1 1.5 0.7 0.331,500 1.50 5.8 1.7 0.8 0.333,600 1.50 6.6 2.0 0.9 0.433,600 2.00 8.4 2.5 1.1 0.542,000 2.00 3.1 1.3 0.646,200 2.00 3.7 1.6 0.750,400 2.00 4.4 1.9 0.9

Pressure Drop for 20ppm NOx – Natural Gas Firing8,400 1.00 4.6 1.0 0.310,500 1.00 7.2 1.6 0.5 0.212,600 1.25 2.3 0.7 0.314,700 1.25 3.1 0.9 0.416,800 1.25 4.0 1.2 0.5 0.218,900 1.25 5.1 1.5 0.7 0.321,000 1.50 6.3 1.9 0.8 0.4 0.223,100 1.50 7.6 2.3 1.0 0.5 0.225,200 1.50 2.7 1.2 0.5 0.229,400 1.50 3.7 1.6 0.7 0.431,500 1.50 4.2 1.8 0.8 0.433,600 1.50 4.8 2.1 1.0 0.533,600 2.00 6.1 2.7 1.2 0.642,000 2.00 7.5 3.3 1.5 0.846,200 2.00 4.0 1.8 0.950,400 2.00 4.7 2.2 1.1

Page 20 Section D - Fuel And Electrical SystemsFDR Manual

D. Fuel and Electrical Systems1. Gas Systems2. Gas Pilot3.Air Atomized #2 Oil4. Fuel-Air-Ratio Controls

5. Electrical Controls6. Operating and Modulating Controls7. Flame Safeguards

1. Gas SystemsAll gas fuel systems have a common group of compo nents, including the pressure regulator, shutoffvalves, gas control valve and pressure switches. Inaddition, some systems use a vent valve, pressureswitches and proof of closure switches. The type andlocation of these compo nents can vary with thedifferent applicable regulations, insurance andcomponent supplier.

Figure D-1 shows a typical gas train arrangement usedon the FDR(X) burner line. There may be other local orjob site requirements that can alter the components inaddition to those outlined in this summary.

All gas and oil systems for the FDR(X) burner are full modulating. The two gas safety shutoff valves aremo torized and are controlled by the flame safeguard toprovide safe control of the fuel flow.

The gas control valve is a butterfly valve used to controlthe flow of gas from the low fire to the high fire input.

The butterfly valve is driven by a fuel cam (linkage system) ora direct coupled actuator. There are different types of gascontrol valves used, which may use mechanical low firestops and may be internally ported as a smaller size.

A vent valve is provided in some applications to allow gasthat may leak past the first valve to escape to a safe point ofdischarge. Vent valves are not used on propane fuelsthat are heavier than air or fuels that could be toxic.

Customer GasSupply

Burner U.L., FM & IRI (old) - >12,600 MBH

POC POC

L M M H

Gas PressureRegulator(Integral toShutoff Valve)

Figure D-1: Typical Gas Train Arrangements

Not Used onU.L. System

The burner can be equipped with a variety of fuel andoperating systems to control the fuel, air, modulation andsafety. This section describes how these systems operate. Each of the applicable systems must be completely under -stood prior to operating any equipment. In addition to thebasic principles defined here, the component details andspecific combination of components on your specific unitmust be fully studied and understood. The fuel diagrams,wiring diagram, component manuals and bill of materialsfor the unit must be included in the study.

FDR Manual Page 21 Section D - Fuel And Electrical Systems

A gas pressure regulator is used to provide a constantsupply pressure to the gas train and butterfly control valve.This constant pressure through a variable orifice in the gascontrol valve obtains consistent gas flow rates. The regu -lator must be capable of operating through the full range offlows and pressure with consistent and steady pressures.The regulator may be located upstream of the safety shut -off valves or integral with the second safety shutoff valve.The high and low gas pressure switches are used to de -tect an improper gas pressure situation and will preventthe burner from firing under these conditions. The low gaspressure switch is located near the supply of gas to thegas train, to detect a loss of supply pressure. The highgas pressure switch is located before the metering valveto detect a surge in pressure to the burner.The gas train is designed to work with the pressure avail -able at the job site. This supply pressure generally refersto the pressure available at the entrance to the gas train,which is the pressure supplied to the gas trains shown inFigure D-1. The supply pressure may vary depending onthe operation of the unit, in which case a minimum andmaximum pressure are needed to define the supply pres -sure. The maximum pressure is the static pressure, or thepressure in the line when there is no flow. The leadingcomponents of the gas train are selected to operate upto these pressures. The minimum, or dynamic pressure isthat pressure available when the unit is operating a fullrate, or the reduced pressure due to the flow in the line.The gas train is sized to this pressure, so that it can deliverthe required flow to the burner with this available pressure.The job site supply pressures must be consistent with thepressures listed on the burner material list.

The regulated gas pressure is that pressure required toovercome the pressure drops in the piping, firing head andfurnace pressure to deliver the required flow at high fire.

Usually, one of the first steps in setting up gas combustionis to adjust the regulator to get rated capacity. This regu -lator is usually at the beginning of the train, but in somecases, it can be integral to the second shutoff valve. Thepressure drops and regulated pressures will be different inthese two designs.

The manual valves lock out the fuel flow during off timesand during initial startup checkout. They provide an addedlevel of safety and simplify mainte nance.

The gas piping can play a critical role in the operation ofthe system. Throughout the system, the piping must carrythe required flow without significant loss of pressure. If thedrop is too high, there may not be enough pressure tooperate the burner at full capacity. This is especially truebetween the gas train and the burner, where the pressureis lowest. The piping between the train and burner shouldhave a minimum number of elbows and / or turns topre vent high pressure drops.

2. Gas Pilot

Figure D-2 show the typical gas pilot systems. Like the gastrains above, they have the common components of apressure regulator and shutoff valve. The gas line con nectsupstream of the pressure regulator in the gas train.

The gas pilot is positioned behind the diffuser, with thepilot flame passing through the diffuser. The flame must belarge enough to pass in front of the scanner tube for theFlame Safeguard to detect the pilot flame and allow theburner to start. This also insures that there is sufficientpilot flame to ignite the main fuel.

The gas pilot can operate with either natural gas or pro -pane. Different internal orifices are used to regulate the gas flow and maintain the same pilot size with the twodifferent fuels.

Manual BallValve

ShutoffValve

Gas PressureRegulator

VentValve

ShutoffValve

Customer GasSupply

Burner IRI >12,5000 MBH

Figure D-2Gas Pilot Train Arrangements

Manual 1/4 TurnValve (Canada

Only)

Page 22FDR Manual Section D - Fuel And Electrical Systems

3. Air Atomizing #2 Oil

An air atomizing system uses compressed air to atomizethe oil. The oil pump and oil pressure regulating valve areoptional and may be provided by others.

Figure D-3 shows a schematic of the air atomizing #2 oilsystem. The oil nozzle has two inputs, oil and air. Oil issupplied to the system at 125 PSIG. An optional remotepump assembly may be used, or it can be provided byother systems. In either case, a backpressure regulator isrequired to provide a constant pressure to the system.

The oil metering valve regulates the flow of oil to the noz zleand is used to vary the oil flow rate from low to high fire.Modulation is obtained by a fuel cam (linkage system) orby a direct drive actuator.

An air compressor is used to supply air for atomization.The air compressor is provided as a separate assemblyand is field piped to the burner. The compressor should belocated as close as possible to the burner to prevent lossof airflow. Also, the piping should be done to minimize theuse of elbows and turns that result in pressure loss. Thefollowing chart should be used to determine the minimumsize (Figure D-4).

Figure D-3: Air Atomizing Light Oil Schematic

Pressure Regulating Valve


Atomizing Air Line Minimum Pipe SizePiping Length (feet)

MBH 0 - 100 feet 100 - 200 feet

8400-14700 1 inch 1 1/4 inch

16800-25200 1 1/2 inch 2 inch

25200-50400 1 1/2 inch 2 inch

Figure D-4 Air Atomizing Pipe SizeThe atomizing airflow rate is regulated by the bleed valve,which can bleed off the excess air not required for goodatomization. In some systems, especially with lower turn -down rates, the bleed valve is set manually and does notvary. In other systems, especially with higher turndowns,the bleed valve is modulated with firing rate, by connection tothe jackshaft or by a direct drive actuator.

4. Fuel-Air-Ratio ControlsAll FDR(X) burners are full modulation. That means thatthey can modulate from a lower input to a higher input, basedon a measured need for more or less input. The systemthat adjusts the fuel and air flow is called fuel-air-ratiocontrols and is covered in this section.

For proper operation, the rate of fuel and air flow must beclosely matched for clean and efficient combustion. Too littlecombustion air and not all of the fuel will be burned,wasting fuel and increasing emissions. Too much air andthe energy is wasted in heating this excess air to a relativelyhigh stack temperature.

There are two common types of fuel-air-ratio controls,sin gle point positioning (linkage) and parallel positioning(link ageless). The linkage system uses mechanical shaftsand connection links to physically tie the air and fuel controlvalves together. Amodulating motor is used to modulate thevalves from low to high fire by providing a 90 degree rotationthat matches the firing rate required.

A long jackshaft is used to distribute this 90º rotation toeach valve. Linkage arms are connected from thejackshaft to the valve. By adjusting the positioning of thelinkage, the air and fuel valves can be set to match eachother. A fuel cam is used to pro vide some improvedflexibility in adjusting the intermedi ate fuel rates, to matchthe air damper settings. If the unit has FGR, the FGRcontrol valve will be tied together with the other valves toprovide the correct flow at each firing rate.The linkageless system uses independent electric actua -tors for each fuel, air and FGR valve. These are drivenby a controller, which is programmed to set the correctposition of each valve at multiple firing rates. The link -ageless system offers more flexibility in adjusting thevalves, including low and high fire positions and differentFGR rates for each fuel.

5. Electrical ControlsThe burner is provided with a junction box on the burnerand free standing control panel as standard. An integralcontrol panel is provided as an option. The unit specificwiring diagram shows the wiring details of all these com -ponents, including the interconnecting wiring that may berequired in the field. The motor starters for the oil pumpand air compressor are also included inside the controlpanel. In some cases, the burner wiring diagram showsthe inter connection of all the vessel safety and operatingcontrols, like the low water cutoff. In other cases, theseare shown on a separate diagram supplied by the vesselmanufac turer. In all cases, these controls are integrated.


6. Operating and Modulating ControlBurner operations for on-off cycling and modulation arecontrolled by the boiler steam pressure or hot water tem -perature variation from set point. Parallel positioning sys -tems use sensors to measure temperature or pressureand are programmed by a unique method, not coveredin this manual. Refer to the control manual, pro vided withthe burner, for complete details on setting the controls.

The standard equipment will include a high limit control,an operating control and a modulating control (notsupplied with the burner). All of these controls are piped tothe steam or hot water piping connected to the vessel.These three controls must be adjusted to function togeth -er or the burner will operate inefficiently and provide poorsystem response. If excessive on-off cycling occurs, thecomponents will wear out prematurely. D-5 shows therelationship between the temperature or pressure andburner firing rates.

The high limit control senses the hot water temperature(vessel outlet) or steam pressure. It is used as a safetylimit to turn the burner off if the operating control fails. Ifthis limit is tripped, the burner will remain off and will haveto be manually reset. The high limit control should be setsufficiently above the operating control (pressure or tem -perature) to avoid nuisance shutdowns. The high limitcontrol cannot be set above the temperature rating of thevessel or connected piping. This point is indicated on thefar right of Figure D-5 and represents the highesttemperature or pressure available. The operating control senses the temperature or pres sureand automatically turns the burner on to initiate thestartup sequence when the temperature or pressure drops

below the “Burner On” point (“B” on Figure D-5) andiniti ates the shut down sequence when the load issatisfied and the temperature or pressure rises abovethe “Burner Off” point (“A” on Figure D-5). The modulatingcontrol senses the temperature or pres sure and signalsthe modulating motor to set the fuel and air input rates ata level consistent with the indicated tem perature orpressure. An increasing load will cause the temperatureor pressure to drop and the modulating motor will sensethis lower level and increase the fuel and air inputaccordingly, starting modulation from low fire at point “C”and arriving at high fire at point “D” (Figure D-5). Thiscontrol must be set to allow normal shutdown at low fire.As Figure D-5 shows, there should be clear separationbetween each of the control points for the system to workproperly. If the controls are positioned too close to eachother, or even overlapping, the burner will have exces -sive ON-OFF cycling that reduces efficiency, increaseswear and can cause premature failure of the components.Standard burner motors in the FDR size range should notcycle on and off any more than 2 to 4 times per hour.

7. Flame SafeguardsSeveral different Flame Safeguards are offered for theFDR(X). They all perform the common function of con -trolling the process of pre-purge, pilot trial for ignition, maintrial for ignition and flame safety as well as monitoring limitswitches and sensors. The actual details of operation canvary. The manual for the specific Flame Safeguard isincluded with the burner and should be studied carefullyprior to installation, startup or operation. The operatingsequence, especially the sequence when the limit switchesare checked will be important in troubleshooting the burner.

0 %

100 %

Burner Off

Minimum Input(Low Fire)

(High Fire)

Firing Rate Increasing

Modulating FiringRange

D

Modulation Control(Modulated Burner Input in Response toTemperature or Pressure Change)

C B A

Operating ControlCycle Burner On and Off at theseTemperatures or Pressures

High Limit Control SafetyShutdownTurn Burner Off at this Tem -perature or Pressure

“ON - OFF”Differential

Falling Temp.or Pressure

Rising Temp.or Pressure

(Burner OFF)(Burner OFF)(Burner ON)

Boiler Water Temperature or Steam Pressure Increasing

Figure D-5: Operating and Modulating Control

Page 25FDR Manual Section E- Preliminary Adjustments

1. Visual Inspection2. Burner Drawer Setup3. Motor Rotation4. Fuel, FGR and Air Control5. Air Damper Adjustments6. Pilot and Scanner Adjustments

The burner combustion setting are not set at the factory.The burner will need to be adjusted for the specific application. In addition, several checks and adjustmentsare required prior to startup. This section covers thesepreliminary checks and adjustments.

WARNING: ADJUSTMENTS DEFINED IN THIS SECTION ARE ONLY INTENDED TO COVER THE INITIALBURNER STARTUP. FINAL ADJUSTMENTS AS DEFINEDIN SECTION F MUST BE DONE TO PROVIDE THE FULLSAFETY OF THE SYS TEM. FAILURE TO PROPERLY ADJUST THE CONTROLS COULD RESULT IN INJURY OR DEATH.

CAUTION: BURNER ADJUSTMENTS SHOULD ONLY BE PERFORMED BY TECHNICIANS TRAINED AND EXPERIENCED IN THIS WORK. FAILURE TO USE PROPERLY TRAINED AND EX PERIENCED TECHNICIANS COULD RESULT IN EQUIP MENT DAMAGE, PERSONNEL INJURY OR DEATH.

E. PRELIMINARY ADJUSTMENTS

1. Visual InspectionThe shipment and installation of the burner can result inloose connections, bent arms and other changes. Theburner should be visually inspected for any unusualconditions before operating. • All wiring connections are tight. Test pulls on wire show them to be tight. • All fuel lines are tight.• Burner is securely mounted to vessel and floor. • The air damper, FGR line and control valves are tight. • The oil lines are tight.

2. Burner Drawer Set UpThe burner drawer must be inspected to insure that thecomponents have not shifted or come loose during transitor installation. The following is a list of checks that shouldbe done. • The scanner tube should be aimed above the pilot and towards the main flame. It must not be able to see a small pilot flame that would not ignite the main flame. A pilot turndown test must be performed to insure this safe operation.

• The diffuser should not be crooked and must have the same spacing to the gas spuds throughout its circumference.

7. Gas SystemAdjustments8. Oil SystemAdjustments9. Air Proving Switch10. Operating and Modulating Controls

3. Motor Rotation

The combustion air fan and pump motors must bechecked for proper rotation. The combustion air fan rotation is marked with an arrowon the blower housing. The rotation can be observedwithin the motor to verify correct rotation. The oil pumphas a slot between the motor and pump where therotation can be observed. An arrow on the pump showsthe correct rotation. The direct drive air compressor canrotate in either direction, but belt driven compressor mustrotate as the arrow indicates.

4. Fuel, FGR and Air Control

The fuel and air valves have initial positions set at thefactory. Differences in air density, fuel properties andsupply pressure will require tuning of the burner. Theinitial positions of the air damper, FGR valve, gas valveand oil valve should be adequate for initial startup, butmust be checked so that movement did not occur duringshipment or installation. If the burner is equipped with FGR, the FGR valve willmodulate with the fuel and air valves and it should travelfrom the near closed low fire position to a position that isabout 45º to 90º open at high fire. 5. Air Damper Adjustments Low fire is set at the factory to a near closed position.High fire position is typically 60º to 85º open, dependingon the application. The combustion settings willdetermine final position.

Figure E-1 Gas Pilot Regulator Adjustment

Use screwdriver to adjust regulation

Removable cover

Page 26 Section E- Preliminary AdjustmentsFDR Manual

The electrode is positioned 1/16” from the end of the gas nozzle of the pilot, to generate the spark to ignite the pilot. Thewind screen protects the pilot flame base from air turbulence,and the raw gas tube provide extra gas for a larger pilot flame. The venturi is adjustable to allow air to mix with the gas in thepilot prior to ignition. The venturi is normally set for a 1/8” airgap, but is adjustable to more or less air. The gas pilot regulator should be adjusted for gas pressure.The pilot flame should be large enough to easily pass throughthe diffuser and rise above the pilot. The scanner is mounted to a pipe that is attached to a rotatingball. The scanner can be positioned to see the swirl flame fromthe pilot, but to drop out if the pilot flame is too small. 7. Gas System Adjustments The gas pressure regulator should be set to the required gaspressure. If this value is not known, a value of approximately50% over the high fire gas manifold pressure (given on burnernameplate) can be used for the initial setting. It will be adjustedat startup to obtain the rated capacity during setup (Figure E-2). The low gas pressure switch (if provided) should be set for aninitial value of 50% below the lowest expected gas pressure.The high gas pressure switch (if provided) should be initiallyset at 50% above the highest valve expected at that point.

8. Oil System Adjustments The oil pressure supply to the burner should be set at100 PSIG initially, and final adjustments made tosupport the high fire oil input, similar to the gaspressure regulator. The regulator is adjusted byremoving the cap and turning the regulator screwclockwise (cw) to increase pressure and counter-clockwise (ccw) to decrease pressure (Figure E-5). Thelow oil pressure switch (Figure E-6) should be set for a pressure of about 25 PSIG lower than the regulatedpressure. #4 oil 150ºF, #5 oil 180ºF, #6 oil 200ºF The low oil temperature switch (Figure E-7) shouldinitially be adjusted to 25ºF below the value listed andthe high oil temperature switch should be set at 25ºFabove the values listed.

Pressure Setting(Screwdriver isadjusting setting)

DifferentialPressure

Regulator

Pump

Figure E-2 Main Gas Pressure Regulator Adjustment

Figure E-5 Oil Pressure Regulator Adjustment

6. Pilot and Scanner Set Up The pilot assembly is located on the end of a gas pipe that isinserted through the burner drawer assembly (Figure E-1). Abracket mounted to the guide tube is used to hold the pilot endin the correct position. A separate gas tube and ignition wireruns parallel to the pilot pipe, with brackets and insulatorsthroughout the length.

Removable cap

Use screwdriverto adjust regulator

Figure E-6 Low Oil Pressure SwitchFigure E-3 Pilot Assembly

Adjusting knob

Removablecover

Figure E-4 Gas Pressure Switch Adjustment

Tip of Electrode

View Rotated to Show True Perspective

1/16

1/16

30º

Raw Gas Tube

View A

Wire Mesh

Page 27 Section E- Preliminary Adjustments FDR Manual

Adjusting Screw

Air ProvingSwitch

Panel

Figure E-8 Air Proving Switch

9. Air Proving Switch The air proving switch has been adjusted at the factory foran initial setting. If this switch trips during initial startup, turnthe adjustment screw CCW two full turns to reduce the trippressure setting (Figure E-8). The air proving switch may be located on the burner. Insome cases, a pressure sensor may be used in place of theswitch, depending on the type of controls used.

10. Operating and Modulating Controls The operating controls will not be used during the burnersetup, except that the high limit and operating controls cancycle the burner off and should be set for the highestallowable pressure for the application. The high limit control should be set at the maximumtemperature or pressure allowed for the boiler vessel orpiping. The operating control should be set at a high enoughpressure to prevent this control from turning the burner offunless the operating temperature or pressure is at themaximum value. The modulating control should be set at avalue below the operating control to prevent the unit frommodulating immediately after starting.On heavy oil units, the electric trim heater should be set for atemperature that corresponds to the grade of fuel beingburned.

Oil HeaterTemperature Control Contacts

Low Oil TemperatureAdjustment

Temperature Contacts

Figure E-7 Low Oil Temperature Switch

Page 28 Section F- Start-Up & Operating AdjustmentsFDR Manual

1. Pre-Start Check List 2. FGR Adjustment 3. Register Assembly Adjustments 4. Fuel Setups 5. Combination Gas and Air Atomized #2 Oil 6. Gas Setup 7. Air Atomized #2 Oil Setup 8. Heavy Oil Setup9. Operating Control Adjustments10. Limit Tests 11.Pilot Test 12. Burner Shutdown

This section covers the startup and operating adjustmentsof the Webster Models FDR burners.

F. STARTUP AND OPERATING ADJUSTMENTS

WARNINGBURNER STARTUP, COMBUSTION ADJUSTMENTSAND LIMIT CONTROLS ADJUSTMENTS SHOULDONLY BE PERFORMED BY TRAINED ANDEXPE RIENCED SERVICE TECHNICIANS.ATTEMPTING TO PERFORM THESE FUNCTIONSWITHOUT THE PROPER TRAINING ANDEXPERIENCE CAN RE SULT IN EQUIPMENTDAMAGE, PERSONAL INJURY OR DEATH.

Before proceeding with the startup and adjustment, besure that the overall installation is complete. Review theboiler operating and installation manual, as well as allcontrol manuals to verify that all equipment is ready foroperation. These manuals must be read and understoodprior to starting the equipment.

If you are not qualified to service this equipment, DO NOTTAMPER WITH THE UNIT OR CONTROLS - CALL YOURSERVICEMAN.

At the conclusion of the startup, document valve,pressures and settings for future reference.

READ AND SAVE THESE INSTRUCTIONS FORFU TURE REFERENCE.

1. Pre-Start Check ListBefore starting the burner, a complete review of theinstallation, wiring and piping of the burner, boiler and allsupporting equipment must be complete and all of theseitems must be ready for operation prior to starting. Thefollowing is a general review:

______All wiring is connected. Test pulls on wire showthem to be tight.______All fuel lines are connected and tight.______Pilot gas is connected.

______Burner is mounted to vessel and floor, with all boltssecured.______The stack is connected and routed to the outside.Draft controls are installed and operational.______Gas vent lines are connected and routed to outside.______All cleanout doors are in place and secured.______The vessel is completely installed, filled with waterand operating controls checked.______Support equipment is in place and ready (feedpumps, draft controls, steam/hot water systems, boilerlimits and controls and feedwater systems).______A load must be available for the burner startup andadjustment process. The burner must be operated at highrates for extended periods of time and the load must becapable of using this energy.______A combustion analyzer with O2 and CO (for gas)must be available to tune combustion. A smoke spot tes termust be available for oil firing. If this is a low NOx burner, aNOx analyzer must be available. All of these analyzersmust be recently calibrated and able to provide accuratereadings.______Other test equipment, including manometers,gauges and volt meter shall be available.______Manometer or gauge on the gas manifold.______Manometer or gauge before and after gas pres sureregulator.______Draft gauge or manometer (at stack outlet).______Draft gauge or manometer for furnace pressure.

2. FGR AdjustmentsFlue gas is recirculated back into the burner to reduce theflame temperature, which reduces the NOx level. Highquantities of flue gas result in lower NOx levels, but canalso result in flame instability if there is too much FGR.Generally, the NOx levels only apply to gas firing and oilfiring is not adjusted for NOx levels. There may beexceptions to this, and the order details should be reviewedto identify any special combustion requirements.The quantity of recirculated flue gas can be adjusted withthe FGR valve, the relationship of the settings of the airlouver, air register and FGR valve will also change theamount of FGR. The quantity of recirculated flue gas can be adjusted withthe inlet tube on the FGR line. To reduce the quantity ofFGR, push the tube into the FGR line (loosen the two setscrews to adjust the position of the tube, and tighten whendone). Moving the tube into the air stream will increase thequantity of FGR. An access cover is provided opposite theFGR line for this adjustment.

On a dual fuel unit, the natural gas should be done first toproperly set the FGR inlet tube. Once gas is setup, oil canbe set.

Page 29 Section F- Start-Up & Operating AdjustmentsFDR Manual

3. Register Assembly Adjustments The register is a multi-vane, circular assembly usingcurvature designed louvers for precision distribution andcontrol of combustion air. By adjusting the register doorpositioner, the air can be rotated either in a clockwise orcounter-clockwise direction. In addition, the amount ofspin to the air can be adjusted by how far the registerlouvers are opened. The more open the lovers arepositioned the flame produced will be longer and narrower.Conversely, the less the louver is opened the flameproduced will be shorter and wider. This rotatingcombustion air creates a thorough mixing of the fuel andair before it enters the combustion zone, resulting incomplete and efficient low excess air combustion thatmaximizes furnace geometry. a. To adjust the diffuser to gas spud dimension, loosen thetwo screws on the center guide tube. The diffuser can nowbe moved in or out. Tighten the screws and nuts beforeoperating the unit.

b. To adjust the oil nozzle to diffuser position: • Loosen the two setscrews locking the oil gun lines to the aluminum end cap of the oil gun.

• Adjust the oil nozzle to obtain the best combustion. • Watch for spray back on the diffuser when the gun is pulled too far back. The flame may appear good but carbon will quickly develop on the diffuser.

• Tighten the two setscrews on the oil tubes locking it into position.

4. Fuel Setups Single fuel or combination fuel burners can be adjustedfollowing the procedures outlined in Section 8 for gas firing;Section 9 for air atomized oil #2, and Section 10 for heavyoil firing. The procedures for each of the systems must becompletely understood and followed as part of the setupprocess.

Page 30FDR Manual Section F - Start-Up And Operating Adjustments

5. Combination Gas and Air Atomized #2 OilParallel positioning (linkageless) systems allow forflexibility in the fuel, air and FGR settings on each fuel, andcan be tuned to match each fuel’s needs. Each fuel curveis independent of the other fuel curves.6. Gas Setup a. Place the burner switch in the “OFF” position b. If this is a combination fuel burner, make sure the fuelselector switch is on “GAS”. c. Close the downstream manual shutoff valve (closest tothe modulating valve) on the gas train. d. Turn the electrical power on for the burner, boiler andrelated components. e. Verify that the gas metering valve is nearly closed, thevent valve (if equipped) is operating and the gas pilot valve is not open. f. If equipped with FGR, verify that the FGR control valve is in the near closed position. g. Turn the burner switch on and follow the parallelpositioning controls instructions on commissioning theburner. This will start the blower motor and initiate theprepurge cycle. h.When the prepurge sequence is complete and the lowfire start switch is made, the pilot valve and ignitiontransformer will be energized and the pilot flame should be visible through the sight port. The flame signal should be strong and steady. i.When the pilot flame is established, the flame safeguardwill energize the main gas valve (indicated with the Fuel On Light). This operation of the main fuel valves must bevisually checked by observing the valve stem operation. j. After the timer has completed the trial for main flame, the burner will go out on alarm (the closed manual gasvalve prevented the burner from lighting). At this time, thegas valves must be visually checked to verify that theyhave closed. This test sequence proves the properoperation of the primary control.k. Press the reset button and restart the burner. When thepilot has started, open the manual gas valve to allow themain flame to start. l. The control valve of the linkageless system should movefrom closed to a low flow position after the light off orgolden start has timed out. NOTE: If the burner is not operating as indicated, follow thetroubleshooting guide steps to determine the problem andcorrections required. m. After a few seconds, the combustion analyzer shouldhave an accurate reading of the O2 in the stack. Figure F-2shows the typical range of O2 at different firing rates, andthe burner should be adjusted to be within this range.

Rough settings for low and mid fire combustion settings areadequate at this time. Once the high fire is set, the othersettings can be fine tuned. • Operate the burner until the boiler is warmed up, and nearthe operating pressure or temperature. Follow the Parallelpositioning controls instructions to commission the burner,while monitoring and adjusting the O2 level. Adjust the gaspressure regulator as needed to reach the high fire input. n. If equipped with FGR, adjust the FGR valve as neededto obtain the approximate NOx level. o. Adjust the high fire input to match the maximum inputlisted on the rating label. At high fire, the gas butterfly valveshould be at least 70 degrees open (more if available gaspressure is low), and the gas pressure regulator adjusted toobtain the rating. The input should be measured using thefollowing equation: Calculating Natural Gas InputGas MBH = HHV x [(Patm + Pgas)/29.92] x [520/(Tgas+460)] x [measured ft3/sec] x [3600 sec/hr] Where: MBH = 1000’s of BTU/M input HHV = Higherheating value of gas, BTU/cubic feet Patm = Atmosphericpressure in inches Hg Pgas = Gas pressure before gasmeter in inches Hg (inches HG = PSIG x 2.04) Tgas = Gas temperature at theflow meter, in degrees F Measured ft3 = volume of gasmeasured by meter sec = Time for measured ft3 to flowthrough meter NOTE: Some gas meters require a 6 inch wc correction toPgas. Consult your meter calibration data.

NOTE: THE LISTED MANIFOLD PRESSURE IS ONLY AN APPROXIMATE VALUE AND CAN VARY WITHOPERATING CONDITIONS AND NORMALTOLERANCES. THE FUEL FLOW RATE MUST BEMEASURED TO OBTAIN AN ACCURATE INPUT VALUE.p. Adjust the air damper to obtain the correct O2 level. q. If equipped with FGR, adjust the NOx level to be about10% below any guaranteed NOx performance. A balance ofthe FGR control valve and air damper are required toobtain the final result, as each can impact the other.Modulate the burner to low fire, adjusting the O2 level asthe burner modulates. r. Adjust the low fire point for proper combustion.v. Re-adjust the midfire points for the correct O2 level. w. If equipped with FGR, adjust the NOx levels at low andmidfire rates to be about 10% under the guaranteed levels. x. Adjust the low gas pressure switch to be 10% below thelowest expected gas pressure. • With a gauge or manometer at the same location as thelow gas pressure switch, modulate the burner to determinethe firing rate with the lowest gas pressure.


• At the lowest gas pressure, adjust the low gas pressuresetting up until the switch breaks and causes the burner toshutdown. • From the scale reading of the switch, adjust the setting toa pressure that is 10% lower than the shutdown pressure.For example, if the switch opened at 10 inches as indicatedon the low gas pressure switch, the switch should beadjusted to a reading of 9 inches. • Remove the gauge or manometer and plug the opening.Cycle the burner on and off to determine if the limit worksproperly. • If the limit causes nuisance shutdowns because of smallpressure drops during startup, reduce the pressure settingan additional 5%. Note, the pressure cannot be set lowerthan 50% below the expected gas pressure. • Adjust the high gas pressure switch to be 10% above thehighest expected gas pressure. • With a gauge or manometer at the same location as thehigh gas pressure switch, modulate the burner to determinethe firing rate with the highest gas pressure. • At the highest gas pressure, adjust the high gas pressuresetting down until the switch opens and causes the burnerto shutdown. • From the scale reading of the switch, adjust the setting toa pressure that is 10% higher than the shutdown pressure.For example, if the switch opened at 10 inches as indicatedon the high gas pressure switch, the switch should beadjusted to a reading of 11 inches. • Remove the gauge or manometer and plug the opening. • Cycle the burner on and off to determine if the limit worksproperly. • If the limit causes nuisance shutdowns because of smallpressure changes during startup, increase the pressuresetting an additional 5%. Note, the pressure cannot be setlower than 50% above the expected gas pressure.• The burner should be operating at low fire to adjust the airproving switch. Turn the adjusting screw cw (in) until theburner trips out (shutdown caused by the air flow switch).Turn the adjustment screw ccw (out) 1 1/2 turns from thepoint of shutdown. Check the operation at higher rates.

7. Air Atomized, #2 Oil Setup The air atomized oil system has the potential for a largeturndown range similar to gas and has the potential to beadjusted to different low fire rates. See the burnernameplate for details on actual rates for this burner. a. Place the burner switch in the “OFF” position. b. If this is a combination fuel burner, make sure the fuelselector switch is on “OIL”. c. Turn the electrical power for the burner, boiler andrelated components on. d. Verify that the oil metering valve is at the nearly closedposition. e. Turn the burner switch on and follow the parallelpositioning controls instructions on commissioning theburner. This will start the blower motor and initiate thepurge cycle. f.When the prepurge sequence is complete and the lowfire start switch is made, the pilot valve and ignitiontransformer will be energized and the pilot flame should bevisible through the burner sight port. The flame signalshould be strong and steady. g.When the pilot flame is established, the flame safeguardwill energize the main oil valves (indicated with the Fuel OnLight), and the burner should ignite at low fire. Thisoperation of the main fuel valves must be visually checkedby observing the valve stem moving up with a motorizedvalve or hearing the clicking noise from a sole¬solenoidvalve. h. If equipped with FGR, the control valve of the linkagelesssystem should move from closed to a low flow/low fireposition after the light off or golden start timing is over. NOTE: If the burner is not operating as indicated, follow thetroubleshooting steps to determine the problem andcorrective action. WARNING: DO NOT ATTEMPT TO START THE BURNER WHEN EXCESS OIL HAS ACCUMULATED,WHEN THE UNIT IS FULL OF VAPOR, OR WHEN THECOMBUSTION CHAMBER IS HOT.

FDR Manual Page 32 Section F - Start-Up And Operating Adjustments

i. After a few seconds, the combustion analyzer shouldhave an accurate reading of the O2 in the stack. The O2level should be between 4% and 8% (see Figure F-2 for O2rates), and the nozzle oil press should be between 5 and15 PSIG. Do not attempt to fine tune combustion until thehigh fire input has been set. If the burner is equipped withFGR, the FGR control valve should be set for theapproximate NOx level required. • The air damper should be positioned for the correct lowfire settings. • The atomizing air pressure can be adjusted using the airbleed valve. • Operate the burner until the boiler is warmed up, and nearthe operating pressure or temperature (Figure F-3). • Follow the Parallel positioning controls instructions tocommission the burner, while monitoring and adjusting theO2 level. Adjust the oil pressure and atomizing air pressureas needed to reach the high fire input. • If the burner is equipped with FGR, adjust the FGRcontrol valve as required to maintain the NOx level. •At high fire adjust the high fire input to match themaximum input listed on the rating label. Using a flowmeter, the fuel input may be measured using the followingequation,

Oil GPH = [Gal end – Gal start] x [3600 sec/hr] / [measured sec] Where Gal end = meter gallons at end of test Gal start

= gallons at start of the test Measured sec = measured time of test GPH = Gallons of oil per hour

n. If equipped with FGR, adjust the NOx level to be about10% below any guaranteed NOx performance or if noperformance guarantee exists adjust the FGR to providesome added turbulence but not high enough to impactflame stability. A balance of the FGR control valve and airdamper are required to obtain the final result, as each canimpact the other. o. Modulate the burner to low fire, adjusting the O2 level asthe burner modulates. p. Adjust the low fire input, following the parallel positioningcontrols instructions. q. If the burner is equipped with FGR, adjust the NOx levelaccording to the required level. r. Re-adjust the midfire points for the correct O2 levels. s. If equipped with FGR, adjust the NOx levels at low andmidfire rates to be about 10% under the guaranteed levels. t. The burner should be operating at low fire to adjust theair proving switch. Turn the adjusting screw cw (in) until theburner trips out (shutdown caused by the air flow switch).Turn the adjustment screw ccw (out) 1 ½ turns from thepoint of shutdown. Check the operation at higher rates.

Natural Gas With FGR

Natural Gas No FGR

Oil

% Rate Min% O2

Max %O2

Min%O2

Max%O2

Min%O2

Max%O2

8 5.0 9.0 7.0 13 NA NA10 5.0 9.0 5.5 12 6.0 10.015 4.0 8.0 4.5 10 5.0 9.020 3.0 8.0 3.0 9 3.5 8.030 2.0 7.0 3.0 8 3.5 7.540 2.0 7.0 2.5 7 3.0 7.050 2.0 6.0 2.5 6 3.0 7.0100 2.0 6.0 2.5 6 3.0 6.5

Figure F-2 O2 levels


CAUTION WHEN WORKING WITH HEATED OIL,PROTECTIVE CLOTHING, INCLUDING GLOVES,SHOULD BE WORN TO PROTECT FROM BURNS.

% Rate Air Pressure10 5 - 1515 7 - 2020 10 - 2530 12 - 3040 15 - 3550 20 - 40100 25 - 60

a. Prior to startup, the oil system must be operating with theoil temperature to the burner (before the trim heater) within20ºF of the final temperature. b. Place the burner switch in the “OFF” position. If this is acombination fuel burner, make sure the fuel selector switchis on “OIL” and that the oil pump is running. e. Turn the electrical power on for the burner, boiler andrelated components. f. The oil may take some time to get up to temperature. Ifthe oil is cool, the ball valve downstream of the N.O. oilreturn valve (Figure F-4) can be opened to make it easierfor the oil to circulate and reach operating temperature. g. Verify that the oil metering valve is at the closed position.

WARNING DO NOT ATTEMPT TO START THE BURNERWHEN EXCESS OIL HAS ACCUMULATED, WHEN THEUNIT IS FULL OF VAPOR, OR WHEN THE COMBUSTIONCHAMBER IS HOT.h. Turn the burner switch on and follow the parallelpositioning controls instructions on commissioning the burner.This will start the blower motor and initiate the purge cycle.

Figure F-4 Heavy Oil Schematic

Figure F-3 Typical Atomizing Air Pressure

8. Heavy Oil Setup The air atomized heavy oil system requires the additionaladjustment of oil temperature in the burner setup. Thetemperature is adjusted to improve the viscosity for goodatomization. Typically, this will be about 150ºF for #4 oil,180ºF for #5 oil and 200ºF for # 6 oil.

Page 34 Section F - Startup and Operating InstructionsFDR Manual

9. Operating Control Adjustments The operating controls must be adjusted to properly cyclethe burner “ON and OFF” and provide modulation. SeeSection D-6 & E-19 for details. The controls should not forcethe burner into rapid “ON-OFF” cycles, as this will causepremature failure of the motor and operating equipment. The operating control must be adjusted to provide the “ON”pressure or temperature desired. It must allow the burner tocome on and start before the temperature or pressure dropsinto the modulating range. The “OFF” pressure ortemperature must be sufficiently above the “ON” point toallow a reasonable run time. The modulating control mustbe adjusted to start modulation at some reasonable pointbelow the “ON” temperature or pressure and providemodulation to high fire at the lowest temperature orpressure. 10. Limit Tests Once the burner has been started and the operatingpressures and temperatures have been set, the limitswitches need to be adjusted so that they will trip if thepressure or temperature exceeds the operating value, butwill not trip with normal variations. The switch should bechecked for proper operation by allowing the temperature orpressure to vary below (or above) the recommended levelto insure that they provide safe shutdown before the burneroperation is affected. In some high pressure or temperatureswitches, where the temperature or pressure cannot be sethigh enough to trip the switch, the switch can be checked bylowering the set point to prove that the switch will provide asafe shutdown. The limit switches would include the air proving switch onthe burner. Limits for gas operation could include the highand low gas pressure switches and for oil firing, the highand low oil pressure switches, high and low oil temperatureswitches and the atomizing air pressure switch. If in doubtabout which limits are on a burner, refer to the wiringdiagram that will show each item. Limit switches need to be checked at regular intervals toensure they are operating properly. See the maintenancesection for details. 11. Pilot TestOnce the burner has been set for the firing rates intendedfor the burner, the pilot must be checked for properoperation and safety. The minimum pilot test is done to insure that a pilot whichcan be seen by the scanner will light the main flame. a. During a startup sequence, measure the time required to light the main flame after the fuel valves have beenenergized. This will be used to monitor the test with reducedpilot. b. Lock the flame safeguard into the pilot position (refer tothe manual for the flame safeguard for this setting)

i.When the prepurge sequence is complete and the low firestart switch is made, the pilot valve and ignition transformerwill be energized and the pilot flame should be visiblethrough the burner sight port. The flame signal should bestrong and steady. j.When the pilot flame is established, the main oil valveswill be energized (indicated with the Fuel On Light), and theburner should ignite at low fire. This operation of the mainfuel valves must be visually checked by observing the valvestem moving up with a motorized valve or hearing theclicking noise from a solenoid valve. k. After a few seconds, the combustion analyzer shouldhave an accurate reading of the O2 in the stack. The O2level should be between 4% and 8% (See Figure F-2 for O2rates) and the nozzle oil press should be between 10 and20 PSIG. Do not attempt to fine tune combustion until thehigh fire input has been set. • The air damper should be positioned for the correct lowfire settings. • The atomizing air pressure can be adjusted using the airbleed valve (Figure F-3). • Oil temperature can be adjusted to obtain best atomization.• Operate the burner until the boiler is warmed up and nearthe operating pressure or temperature. • Follow the Parallel positioning controls instructions tocommission the burner, while monitoring and adjusting theO2 level. Adjust the oil pressure and atomizing air pressureas needed to reach the high fire input. • At high fire, adjust the high fire input to match the max.input listed on the rating label. Using a flow meter, the fuelinput may be measured with the following equation, Oil GPH = [Gal end – Gal start] x [3600 sec/hr] / [measured sec] Where Gal end = meter gallons at end of test Gal start = gallons at start of the test Measured sec = measured time of test GPH = Gallons per hour

o. Modulate the burner to low fire, adjusting the O2 level asthe burner modulates. p. Readjust the low fire input. q. Re-adjust the midfire points for the correct O2 levels.r. The burner should be operating at low fire to adjust the airproving switch. Turn the adjusting screw cw(in) until theburner trips out (shutdown caused by the air flow switch).Turn the adjustment screw ccw (out) 1 ½ turns from thepoint of shutdown. Check the operation at higher rates.

FDR Manual Section F - Start-Up And Operating Adjustments

c. Adjust the gas pressure regulator to the pilot for aminimum value while still holding the minimum signalstrength for the scanner. d. Release the flame safeguard from the pilot position andallow it to cycle though the main flame proving sequence. e. This reduced pilot must reliably light the main flame.Monitor the time from the main fuel valve opening and donot allow the burner to continue if the time is more than anadditional two to three seconds from the initial timemeasured above. f. Run through two or three cycles. g. If this is a combination fuel burner, repeat the test on theother fuel. h. Failures due to reduced scanner signal are acceptable. WARNING: THE MINIMUM PILOT TEST REQUIRESCLOSE SUPERVISION OF THE COMBUSTIONPROCESS. FAILURE TO CLOSELY MONITOR THE MAINFLAME TEST TIME COULD RESULT IN DAMAGE,INJURY OR DEATH. i. If the pilot does not light the main flame under these test conditions, check and adjust the pilot as shown inFigure E-1. The scanner must be tested for hot refractory pickup. Thistest is performed to make sure that the scanner does notsee hot refractory that could be mistaken for a flame. a. After the burner has been operating for some time at highinput levels and the refractory in the vessel is hot, theburner should be cycled off while monitoring the scannersignal. b. The flame signal should drop off quickly as the flamegoes out and should be well below the minimum level(indicating a flame) at the end of the post purge cycle. c. If the flame signal does not drop out as required, checkthe location of the pilot and scanner. This may also indicatea faulty scanner or amplifier. 12. Burner Shutdown Normal operation of the burner will allow the operatingcontrols to shut the burner down when the load demand issatisfied. If the burner needs to be shut down for anyreason, the “ON-OFF” switch can be used to quickly turnthe burner off. This will instantly cause the fuel valves toclose and start a post purge cycle to remove any unburnedfuel from the vessel. In an emergency shutdown, all fuel and electrical powershould be de-energized or turned off to secure the burner.This would include the main power disconnect, the manualgas shutoff valve at the drop down line and if equipped, themanual oil valve to the nozzle.

Page 35

FDR Manual Page 36 Section H - Troubleshooting

No. System Cause Correction1 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

2 No Ignition Lack of fuel, no gas pressure, closed fuel valve Check fuel supply and valves

(spark, no flame) No voltage to pilot solenoid Check electrical connections

Defective pilot solenoid valve Replace

Incorrect location of pilot Check location of pilot

Improper raw gas tube position Check location of raw gas tube

Improperly positioned electrodes Recheck dimensions

Too much combustion air flow Check air damper position

3 Pilot not detected Scanner tube not positioned correctly Check location of scanner tube

(flame present) Scanner tube dirty Clean scanner tube

Scanner or amplifier faulty Replace

Pilot improperly positioned Check pilot position

Incorrect gas pressure to pilot Readjust pressure

Combustion air flow rate too high Readjust damper

4 No main gas flame 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 flame Weak scanner signal Clean scanner lense 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 fire Manual pot in low fire position (low fire hold) Readjust to high fire position

Manual-auto switch in wrong position Change position of switch

Modulating 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

9 High CO at low fire Improper excess air level Readjust excess air

(firing gas) Input too low for burner components Check input, compare to rating label

H. TROUBLESHOOTING

Page 37 Section H - TroubleshootingFDR Manual

No. System Cause Correction

High CO at low fire (con’t) High stack draft (especially at low fire) Stabalize 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

Flucuating gas pressure (regulator not holding pressure) Check regulator pressure, sensing line

and supply pressure: sized properly

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 fire) Stabalize draft

Diffuser not in optimum position Adjust diffuser position in or outPoor air flow distribution (off center flame) Adjust air straightner 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 fire) Stabalize draft

Incorrect nozzle position Adjust the nozzle to diffuser position

Fluxuating oil pressures (regulator not holding) Check regulator pressure and oil supply

Poor air flow distribution (off center flame) Adjust air straightner blade

Too much FGR (if equipped) Reduce FGR rate

12 Fuel-Air-Ratios are Servo coupling loose or worn Check/replace couplers

not consistent Fuel line plugged Check and clean lines, stariners & filters

Fuel supply pressure changing Check and/or replace pressure regulator

Combustion air temperature changed Retune burner

Draft condition changed Check draft and outlet damper

Plugged or leaky FGR line Clean / repair

Gas control valve - low fire stop not set Adjust low fire stop

13 Fuel-Air-Ratios have changed Air damper seal worn Replace air damper seals

over time Fuel lines plugged Check and clean lines, strainers & filters

Fuel control valve worn Replace fuel control valve

Gas orifices or gas manifold plugged Clean and/or replace

Combustion air temperature changed Retune burner

Draft condition changed Check draft and outlet damper

Vessel plugged Clean vessel

Plugged or leaky FGR valve Clean / repair

14 Cannot obtain capacity on Wrong spring range in regulator Install higher spring rangegas Too many elbows before control valve Rework piping to reduce elbows

Gas line too small, high pressure drop Use larger pipe sizeSupply pressure lower then stated Increase supply pressureSupply pressure drops too low at high fire Use larger gas line sizes / orifice in

service regulatorRegulator too small for flow and pressure Change regulator

FDR Manual Page 38 Section H - Troubleshooting

No. System Cause Correction15 Cannot obtain rated input on Oil nozzles plugged Replace nozzles

oil firing (air atomized) Air pressure too low Replace nozzles

Oil pressure too low Increase oil pressure

Flow valve set too low Adjust oil control valve

16 Cannot obtain NOx levels on Inlet tube in wrong position Adjust inlet tube to center of fan inlet

gas “ “ Taper FGR valve to be full open

FGR valve not full open Adjust FGR valve to full open

FGR valve full of condensate Clean duct and add drains

FGR duct not directed to flue stream Add angle cut in center of stack

FGR line too small Check sizing, use fittings 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

NOTES

FDR Manual Page 39 Notes

NOTES

FDR Manual

NOTES

Webster CombustionTechnology, L.L.C. 619 Industrial Road, Winfield, KS 67156

www.webster-engineering.com

Page 40 Notes

Documents

Installation, Startup, Operation and Maintenance Manual