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WEBSTER COMBUSTION TECHNOLOGY

619 Industrial Road - Winfield, KS  67156

Phone 620-221-7464   Fax 620-221-9447

[email protected]   [email protected] 

www.webstercombustion.com

WARRANTY MATTERS AND EXCLUSION OF IMPLIED WARRANTIES

The following warranty applies:  All Products manufactured by the Company are warranted to be free from defects in 
material and workmanship under normal use and service for a period of eighteen months from the date of shipment 
or twelve months from the date of start-up; whichever should occur first. Products which are purchased by the Company 
and resold without further processing by the Company are not covered by the Company’s warranty. The Company shall 
pass to the Buyer whatever warranty the Company receives on such products. The Company will repair or replace, at its 
option, its products which prove to be defective within the warranty period, F.O.B. the factory. The Company’s warranty 
shall be voided by any abuse, misuse, or neglect of the products by use not in accordance with the Company’s published 
instructions. The remedies for any failure of the Company’s product to meet warranty specified herein shall be those 
remedies herein  and no others; these remedies being exclusive remedies as a condition of sale irrespective of the theory 
upon which any claim might be based, including negligence, breach of contract or strict liability.
IN ALL EVENTS, THE COMPANY WILL NOT BE LIABLE FOR AND WILL NOT REIMBURSE ANY LABOR, MATERIAL, 
OR OTHER REPAIR CHARGES INCURRED BY ANYONE OTHER THAN THE COMPANY ON ANY WARRANTY 
EQUIPMENT, UNLESS SUCH CHARGES HAVE BEEN SPECIFICALLY AUTHORIZED IN ADVANCE IN WRITING, BY 
THE COMPANY. THIS PARAGRAPH CONTAINS THE COMPANY’S SOLE WARRANTY. THE COMPANY MAKES NO 
IMPLIED WARRANTY, AND THERE IS NO IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY 
PARTICULAR PURPOSE.

DAMAGE LIMITATION

Under no circumstances shall the Company be liable for any loss of profits, down time, or any incidental, consequential, 
special, punitive, exemplary, enhanced, or indirect damages of any kind with respect to its products or the transaction 
by which its products are sold. 
IN NO EVENT SHALL THE COMPANY’S AGGREGATE LIABILITY ARISING OUT OF OR RELATED TO THE 
EQUIPMENT OR THE TRANSACTION BY WHICH THE EQUIPMENT IS SOLD, WHETHER ARISING OUT OF OR 
RELATED TO BREACH OF CONTRACT, TORT (INCLUDING NEGLIGENCE), OR OTHERWISE, EXCEED THE 
TOTAL OF THE AMOUNTS PAID TO THE COMPANY WITH RESPECT TO SUCH EQUIPMENT.

 EXCUSE

In no event shall the Company be liable for any loss or damage resulting from any delay or failure in shipment or 
other failure, loss or damage that is the proximate result of any act of government authority, revolution, riot, civil 
disorder or disturbance, act of enemies, delay or default in transportation, inability to obtain materials or facilities from 
normal sources of fire, flood, act of God, or any cause not within the reasonable control of the Company, whether 
of the class of causes enumerated or otherwise. Without limiting the generality of the foregoing, the Company may, 
without causing a breach or incurring liability, allocate goods which are in short supply irrespective of the reasons 
therefore among customers in any manner which the Company in its sole discretion deems advisable. If an event 
occurs that is beyond the control of the Company’s performance and causes its cost of production to increase 
because of the delay, the Company may pass such increase on to the Buyer.

Summary of Contents for Cyclonetic SG Series

Page 1: ...9 Industrial Road Winfield KS 67156 Installation Startup Operation and Maintenance Manual Cyclonetic SG Series Forced Draft Burners SG Gas Burner Manual Part No 950212 www webstercombustion com February 2022 2022 All Rights Reserved C ...

Page 2: ...D IMMEDIATELY CALL THE GAS COMPANY IN ACCORDANCE WITH OSHA STANDARDS ALL EQUIPMENT MACHINES AND PROCESSES SHALL BE LOCKED OUT PRIOR TO SERVICING IF THIS EQUIPMENT IS NOT INSTALLED OPERATED AND MAINTAINED IN ACCORDANCE WITH THE MAN UFACTURERS INSTRUCTIONS THIS PRODUCT COULD EXPOSE YOU TO SUBSTANCES IN FUEL OR FROM FUEL COMBUSTION WHICH CAN CAUSE DEATH OR SERIOUS ILLNESS AND WHICH ARE KNOWN TO THE S...

Page 3: ...the actual equipment These special components will be described in the infor mation provided with the burner and should be used as the controlling document NOTE This manual must be readily available to all operators and maintained in legible condition 1 Nameplate Information Each burner has a nameplate with important job details similar to the nameplate shown in Figure A 1 Figure A 1 Nameplate The...

Page 4: ...ral other docu ments that should be considered as part of the complete manual for the burner All of these documents are needed to support the installation and startup of the unit These additional items include Page 4 Introduction Burner Model Number SG Manual a The wiring diagram which shows the limits and inter connection of the burner and vessel controls b The gas schematic which shows the compo...

Page 5: ... LFS Modulation SG6 03 25 400 1000 1 3 1 6 14 7 14 6 wc 1 1 000 1 3 SG8 03 25 600 1500 1 3 1 1 4 8 14 9 14 8 wc 1 1 4 1 500 1 3 SG8 05 25 800 2100 1 2 1 1 2 7 14 8 14 8 wc 1 1 2 2 500 1 2 3 Larger motors may be required for single phase or 208 volts 4 Contact Webster for complete details The above maximum ratings are based on 0 furnace pressure an altitude of 1000 feet 90oF air temperature and 60 ...

Page 6: ...c UL ULC Dimensions are 1 4 inch Based off standard burner insertion For insertion different from 4 contact Webster for dimensions All dimensions are for reference only Webster reserves the right to change dimensions without notice MODEL A B C D E F G H I J SG6 4 12 1 23 5 10 3 14 1 14 3 6 1 5 0 10 3 6 1 SG8 4 12 1 23 5 10 3 14 1 14 3 6 1 5 0 10 3 8 1 ...

Page 7: ...etween mounting plate and burner 10 Gas piping should be flushed cleaned prior to use 11 Check minimum straight lengths for gas pressure regulator and or sensing line 12 If multiple vessels connect to a single stack are they sized and designed to maintain 0 1 wc draft at the vessel outlet under all operating conditions 13 Is stack designed to maintain 0 1 wc at outlet during all operating conditio...

Page 8: ... lugs Refractory OD is sized to fit vessel opening with 1 4 to 1 2 gap refractory must extend 2 beyond tube sheet for scotch boilers Figure E 1 Refractory Dimension Contact Webster for more detailed refractory drawings The burner must be level The gas piping from the burner to the train should have as few elbows as possible to reduce pressure drop Attachment to vessel varies with manufacturer foll...

Page 9: ...he gas to be burned and the overall length UL FM On Off Gas Piping Diagram Up to 2 500 MBH Firing Rate 1 2 PSI Max 722196 GAS SUPPLY GASBURNER MANIFOLD VENT VENTTOOUTSIDEATMOSPHERE 722196 1 4 6 5 4 1 1 S D 3 35 Gas Supply Vent to Outside Atmosphere Vent Manual Ball Valve Manual Ball Valve Gas Burner Manifold Gas Pressure Regulator Main Solenoid Gas Valve Manual Test Valve Manual Test Valve Manual ...

Page 10: ...D 1 6 4 4 7 5 VENTTOOUTSIDEATMOSPHERE 1 10 722198 1 S M Gas Supply Gas Burner Manifold Gas Burner Manifold Manual Ball Valve Manual Ball Valve Manual Test Valve Manual Test Valve Main Motorized Gas Valve Main Solenoid Gas Valve Vent to Outside Atmosphere Gas Pressure Regulator Manual Ball Valve Vent to Outside Atmosphere Gas Pressure Regulator Manual Test Valve Main Solenoid Gas Valve Manual Test ...

Page 11: ... factory for an initial setting If the switch trips during initial start up turn the adjustment screw ccw two full turns to reduce the trip pressure setting TYPICAL AIR AND FUEL ADJUSTMENT LOCATIONS Mounting flange Combustion head Control cabinet Mod motor Flame scanner Louver box Linkage Gas valve ...

Page 12: ... and all of these items must be ready for operation prior to starting The following is a general review ______All wiring is connected Test pulls on wire show them to be tight ______All fuel lines are connected and tight ______Burner is mounted to vessel and floor with all bolts secured ______The linkage is correct in low fire position and tight ______The stack is connected and routed to the outsid...

Page 13: ...ntrol j Press the reset button and restart the burner When the pilot has started open the manual gas valve to allow the main flame to start k After a few seconds the combustion analyzer should have an accurate reading of the O2 in the stack Figure 1 3 shows the typical range of O2v at different firing rates and the burner should be adjusted to be within this range Rough settings for low and mid fi...

Page 14: ...O2 30 5 0 7 0 40 4 0 7 0 50 3 0 5 0 100 3 0 5 0 Figure I 3 O2 levels s Adjust the high gas pressure switch to be 10 above the highest expected gas pressure With a gauge or manometer at the same location as the high gas pressure switch modulate the burner to deter mine the firing rate with the highest gas pressure At the highest gas pressure adjust the high gas pres sure setting down until the swit...

Page 15: ...il firing the high and low oil pressure switches high and low oil tem perature switches and the atomizing air pressure switch If in doubt about which limits are on a burner refer to the wiring diagram that will show each item Limit switches need to be checked at regular intervals to ensure they are operating properly See the mainte nance section for details 6 Burner Shutdown Normal operation of th...

Page 16: ...ion air flow rate too high Readjust damper 4 Burner stays at low fire Manual pot in low fire position low fire hold Readjust to high fire position Manual auto switch or low fire hold switch in wrong position Change position of switch Modulating Control or Lo Hi Lo Control Check wiring or replace Loose linkage Readjust and tighten Binding linkage or valve Readjust or replace 5 Burner shuts down Loo...

Page 17: ...moved Replace fuel cam Fuel line plugged Check and clean lines strainers 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 Gas control valve low fire stop not set if used Adjust low fire stop 10 Fuel Air Ratios have changed Linkage wear Check linkage and tighten all jo...

Page 18: ...Fuel Air Ratio Controls The fuel air ratio controls must be maintained in good operating condition Over time these items will wear and may not operate smoothly Corrective action must be taken There are several different types of controls and the cor rective action of each could be different The following general guidelines can be used for initial steps Linkage based controls should be inspected fo...

Page 19: ... annually or after any component change X X Interlock Controls Check other interlocks that may be used on the burner for smooth operation and correct action X X Firing Rate Control Check firing rate control and verify settings X X Combustion Tuning Conduct a combustion test verify setting and NOx emission levels X X Main Fuel Valves Make visual and manual check for proper sequencing of valves X X ...

Page 20: ... As a final step forward the top copy of the Warranty Validation and Field Startup Report Form 113 to WEBSTER COMBUSTION TECHNOLOGY LLC 619 Industrial Road Winfield KS 67156 WEBSTER Series SG Burners are listed by Underwriters Laboratories Inc U L Also by the State of Massachusetts Fire Marshall City of New York Board of Standards and Appeals State of Minnesota and can be packaged to meet specific...

Page 21: ...pm NOx ppm Stack Temp Net oF Room Temperature oF Overfire Draft WC Breeching Draft WC Water Temp oF Steam Press Air Inlet Shutter Open Flame Signal Main Manual Gas Pressure Combustion Efficiency Running Motor Amps Volts L1 L2 L3 Comments Having read the Manufacturer s service manual as to the proper installation start up and service of the unit above I verify that the burner has been put into oper...

Page 22: ...Page 22 SG Manual Notes NOTES ...

Page 23: ...Page 23 SG Manual Notes NOTES ...

Page 24: ...ED IN ADVANCE IN WRITING BY THE COMPANY THIS PARAGRAPH CONTAINS THE COMPANY S SOLE WARRANTY THE COMPANY MAKES NO IMPLIED WARRANTY AND THERE IS NO IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE DAMAGE LIMITATION Under no circumstances shall the Company be liable for any loss of profits down time or any incidental consequential special punitive exemplary enhanced or indire...

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