Webster Cyclonetic SG Series Installation, Startup, Operation And Maintenance Manual Download

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Webster Combustion Technology

619 Industrial Road, Winfield, KS 67156

Installation, Startup, Operation and Maintenance Manual

Cyclonetic

Series

Forced Draft Burners

SG Gas Burner

Manual Part No. 950212

www.webstercombustion.com

February, 2022

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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