WEBSTER COMBUSTION HDRMB User guide

W£8S
COMBUSTION
A Selas Heat Technology Company
Webster Combustion Technology
619 Industrial Road, Winfield, KS 67156
Installation, Startup, Operation and Maintenance Manual
Model HDRMB Burner
Ultra Low NOx Burner
Manual Part No. 950087
www.webstercombustion.com
September, 2014 @2014 All Rights Reseed

SAFETY PRECAUTIONS
Page 2 Safety PrecautionsHDRMB 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 potential
death.
Throughout this manual, the following symbols are used to identify potential problems.
WARNING
This indicates a potential hazardous situation, which if not avoided, could result in personal injury or death.
CAUTION
This indicates a potentially hazardous situation, which if not avoided, could result in damage to the equipment.
The following general safety precautions apply to all equipment work.
WARNING
IF YOU SMELL GAS, OPEN WINDOW, EXTINGUISH ANY OPEN FLAMES, STAY AWAY FROM ELECTRICAL
SWITCHES, EVACUATE THE BUILDING AND IMMEDIATELY CALL THE GAS COMPANY.
IN ACCORDANCE WITH OSHA STANDARDS, ALL EQUIPMENT, MACHINES AND PROCESSES SHALL BE
LOCKED OUT PRIOR TO SERVICING.
IF THIS EQUIPMENT IS NOT INSTALLED, OPERATED AND MAINTAINED IN ACCORDANCE WITH THE MAN-
UFACTURERS INSTRUCTIONS, THIS PRODUCT COULD EXPOSE YOU TO SUBSTANCES IN FUEL OR FROM
FUEL COMBUSTION WHICH CAN CAUSE DEATH OR SERIOUS ILLNESS AND WHICH ARE KNOWN TO THE
STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM.
IMPROPER SERVICING OF THIS EQUIPMENT MAY CREATE A POTENTIAL HAZARD TO EQUIPMENT AND
OPERATORS.
SERVICING MUST BE DONE BY A FULLY TRAINED AND QUALIFIED PERSONNEL.
BEFORE DISCONNECTING OR OPENING UP A FUEL LINE AND BEFORE CLEANING OR REPLACING
PARTS OF ANY KIND,
• TURN OFF THE MAIN MANUAL FUEL SHUTOFF VALVES INCLUDING THE PILOT COCK, IF
APPLICABLE. IF A MULTIPLE FUEL BURNER, SHUT OFF ALL FUELS.
• TURN OFF ALL ELECTRICAL DISCONNECTS TO THE BURNER AND ANY OTHER EQUIPMENT OR
SYSTEMS ELECTRICALLY INTERLOCKED WITH THE BURNER.
Service Organization Information:
Company Name
Address
Phone Number
Date of Startup
Lead Technician

Page 3 Section A - GeneralHDRMB Manual
Table of Contents
A. General
1. Nameplate Information ..........................
2. Ratings ..................................................
3. Product Offering .....................................
4. Your Complete Manual ..........................
5. Service and Parts .................................
B. Components
1. General ..................................................
2. Combustion Air ......................................
3. Burner Drawer .......................................
3.5 Refractory Front Plate ............................
4. Gas Fuel Components ..........................
5. Oil Fuel Components .............................
6. Flue Gas Recirculation (FGR).................
7. Fuel-Air-Ratio Controls ..........................
8. Electrical Controls .................................
C. Installation
1. General Considerations .........................
2. Refractory Frontplate .............................
3. Burner Mounting ....................................
4. Gas Piping ..............................................
5. Gas Pilot ................................................
6. General Oil Piping ..................................
7. Air Atomized #2 Oil ................................
8. FGR System ..........................................
9. Draft and Stacks ....................................
10. Electrical System ....................................
D. Fuel and Control Systems
1. Gas Systems .........................................
2. Gas Pilot ................................................
3. Air Atomized #2 Oil ................................
4. Fuel-Air-Ratio Controls ..........................
5. Electrical Controls .................................
6. Operating and Modulating Controls ......
7. Flame Safeguards .................................
E. Preliminary Adjustments
1. Visual Inspection ...................................
2. Motor Rotation .......................................
3. Oil Gun Setup .........................................
4. Fuel, FGR and Air Control .....................
5. Fuel Cam Adjustments ..........................
6. Air Damper Adjustments ........................
7. Pilot and Scanner Setup ........................
8. Gas System Adjustments ......................
9. Oil System Adjustments ........................
10. Air Proving Switch .................................
11. Operating and Modulating Controls ......
F. Startup and Operating Adjustments
1. Pre-Start Check List ..............................
2. Linkage Adjustments .............................
3. Fuel Cam Adjustments ..........................
4. FGR Adjustments ..................................
5. Burner Drawer Adjustments ..................
6. Single Fuel Setups ................................
7. Combination Gas and Air
Atomized #2 Oil ......................................
8. Gas Setup .............................................
9. Air Atomized #2 Oil Setup ......................
10. Operating Control Adjustments ..............
11. Limit Tests ..............................................
12. Pilot Test..................................................
13. Burner Shutdown ....................................
14. Restarting After Extended Shutdown .....
G. Maintenance
1. General ..................................................
2. Physical Inspection ...............................
3. Fuel-Air-Ratio Controls ...........................
Page 4
Page 4
Page 4
Page 4
Page 6
Page 6
Page 8
Page 10
Page 10
Page 11
Page 12
Page 12
Page 13
Page 15
Page 16
Page 17
Page 18
Page 18
Page 19
Page 19
Page 20
Page 21
Page 21
Page 24
Page 24
Page 27
Page 28
Page 29
Page 29
Page 30
Page 31
Page 31
Page 31
Page 31
Page 32
Page 34
Page 34
Page 34
Page 34
Page 34
Page 35
Page 35
Page 36
Page 36
Page 37
Page 37
Page 37
Page 38
Page 38
Page 38
Page 39
Page 40
Page 40
Page 40
Page 40
Page 41
Page 42
Page 43
Page 44
Page 44
Page 44
Page 44
Page 46
Page 46
Page 46
Page 46
4. Gas Fuel System ....................................
5. Oil Fuel System ......................................
6. FGR Systems ........................................
7. Combustion Air Fan .................................
8. Burner Refractory and Internals ................
9. Inspection and Maintenance Schedule ....
10. Combustion Chart ....................................
H. Trouble Shooting ................................................
Page 47
Page 47
Page 47
Page 47
Page 47
Page 48
Page 49
Page 50

Page 4 Section A - General
HDRMB Manual
A. GENERAL
1. Nameplate Information
2. Ratings
3. Product Offering
4. Your Complete Manual
5. Service and Parts
This manual covers the Model HDRMB burner offered
by Webster Engineering & Manufacturing Co., LLC. This
burner is intended for commercial and industrial applica-
tions for Firetube and Watertube type boilers (Firetube,
Flextube, “D” Type, etc.). They can fire gas, oil or combi-
nations of gas and oil.
READ AND SAVE THESE INSTRUCTIONS FOR
REFERENCE
WARNING
DO NOT ATTEMPT TO START, ADJUST OR MAIN-
TAIN THIS BURNER WITHOUT PROPER TRAINING
OR EXPERIENCE. FAILURE TO USE KNOWLEDGE-
ABLE TECHNICIANS CAN RESULT IN EQUIPMENT
DAMAGE, PERSONAL INJURY OR DEATH.
The startup and maintenance of the HDRMB burner re-
quires the skills of an experienced and properly trained
burner technician. Inexperienced individuals should not
attempt to start or adjust this burner.
THE INSTALLATION OF THE EQUIPMENT SHALL BE IN
ACCORDANCE WITH THE REGULATION OF AUTHORI-
TIES HAVING JURISDICTION, INCLUDING THE NA-
TIONAL ELECTRICAL CODE, AND ALL LOCAL CODES.
Every attempt has been made to accurately reflect the
burner construction, however, product upgrades and spe-
cial order requirements may result in differences between
the content of this manual and 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 op-
erators 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.
The serial number represents the unique number for that
burner and is a critical number that will be needed for any
communications with Webster Engineering.
The input rates define the maximum and minimum inputs
for that burner, given in MBH for gas and GPH for oil. Air
atomized burners (Figure A-1) show both the oil pressure
and air pressure. For gas firing, the gas manifold pressure
is given in “in wc” which is inches of water column.
The electrical ratings of the burner are given, with the volt-
age, current load, frequency and phase (this will either be
single or 3-phase). For motors, the motor HP is listed.
2. Ratings
The ratings for each specific burner are given on the
nameplate (Figure A-1). The general burner ratings are
given in Figure A-3. The maximum and minimum inputs
are given, based on the type of fuel. Other conditions,
like the supply gas pressure or the combination of fuels,
emission requirements and control systems may limit the
turndown.
Turndown is defined as the ratio of the maximum input to
the minimum input. For example, a burner with a maxi-
mum input of 120 GPH and a minimum input of 12 GPH
has a 10:1 turndown.
3. Product Offering
The burner can fire natural gas, #2 oil or combination of
natural gas and #2 oil.
DO NOT USE GASOLINE, CRANKCASE OIL OR ANY
OIL CONTAINING GASOLINE.
This burner is a low emission burner, and can operate at
NOx levels of 9, 12 or 15ppm. It is also capable of low CO
emissions.
Figure A-2 lists the common variations and options avail-
able on this product.
The minimum furnace conditions for this burner will
vary with performance requirements, and cannot be
stated in simple dimensions. Each job is analyzed to
provide the correct burner design and compares that
to the furnace and operating conditions. The figure
in A-3 show typical minimum values for furnace siz-
es. In addition, the volume heat release rates would
be limited to about 185,000 btu/ft3 on firetubes and
85,000 btu/ft3 on watertube boilers.
MODEL NUMBER
HDRMBC-400B-5V 150 RM7800L-M.25 VGD
SERIAL NUMBER
U73586A-02
JOB LOCATION
Georgia
DATE MFG
30 - Nov - 04
OIL INPUT RATING
GAS INPUT RATING
MBTU/HR IN.WC GPH PSI
16738 8.4 119.6 28/31
MAXIMUM
2790 0.15 23 12/21
MINIMUM
NATURAL GAS #2 OIL / AIR
FUEL
VOLTS AMPS HERTZ PHASE HP
115
CONTROL CIRCUIT 560 1
460
BURNER MOTOR 20.1 60 3 15
460
OIL PUMP MOTOR 2.9 60 3 1.5
Figure A-1 Nameplate

MODEL HDRMB BURNER MODEL CONFIGURATION
FIGURE A-2
HDRMB C - 500 - 19 - 9 SR - 600
MODEL
HDRMB
FUELS
G Gas
O Oil
C Gas / Oil
BOILER HP -- BTU
80.0 3348
84.0 3515
90.0 3766
96.0 4017
100.0 4184
108.0 4519
110.0 4603
120.0 5021
125.0 5230
130.0 5440
131.0 5482
140.0 5858
143.0 5984
150.0 6277
160.0 6695
167.0 6988
170.0 7113
175.0 7323
180.0 7532
191.2 8000
203.1 8500
215.1 9000
225.0 9415
240.0 10043
250.9 10500
275.0 11507
301.1 12600
322.6 13500
325.0 13599
350.0 14645
375.0 15691
400.0 16738
406.6 17000
450.0 18830
478.0 20000
500.0 20922
550.0 23014
600.0. 25106
650.0 27198
700.0 29292
750.0 31383
800.0 33475
MOTOR HP
50 = 5 HP
75 = 7.5 HP
100 = 10 HP
150 = 15 HP
200 = 20 HP
250 = 25 HP
300 = 30 HP
400 = 40 HP
500 = 50 HP
600 = 60 HP
750 = 75 HP
1000 = 100 HP
1250 = 125 HP
1500 = 150 HP
HOUSING ORIENTATION
V Vertical
SR Slant Right (45o)
SL Slant Left (45o)
LR Laydown Right
LL Laydown Left
INV Inverted
HOUSING SIZE
5
7
9
11
HEAD SIZE
7
9
10
11
12
13
14
15
16
17
19
20
21
22
23
24
Page 5 Section A - GeneralHDRMB Manual

Figure A-3
Typical Ratings for High Pressure Steam Firetube Boilers
Gas Input MBH Oil Input GPH Firetube Boiler, High Pressure Steam
9ppm NOx
BHP MIN MAX MIN MAX FURNACE
PRESS
HEAD
DIA.
MOTOR
HP
MIN
FURN
DIA.
HDRMB - 100-8-5-100 100 1046 4184 7.5 29.9 2.5 8.0 10.0 19.5
HDRMB - 125-9-5-150 125 1308 5230 9.3 37.4 2.6 9.0 15.0 21.0
HDRMB - 150-10-5-150 150 1569 6277 11.2 44.8 2.8 10.0 15.0 22.5
HDRMB - 200-11-7-100 200 2092 8369 14.9 59.8 3.0 11.0 20.0 25.0
HDRMB - 250-11-7-150 250 2615 10461 18.7 74.7 3.3 12..0 30.0 27.0
HDRMB - 300-13-7-150 300 3138 12553 22.4 89.7 3.5 14.0 30.0 29.0
HDRMB - 350-14-7-200 350 3661 14645 26.2 104.6 3.8 15.0 40.0 30.5
HDRMB - 400-15-7-200 400 4184 16738 29.9 119.5 4.0 16.0 40.0 32.0
HDRMB - 450-16-7-250 450 4707 18830 33.6 134.5 4.3 17.0 50.0 33.5
HDRMB - 500-16-7-250 500 5230 20922 37.4 149.4 4.5 18.0 50.0 35.0
HDRMB - 550-17-9-250 550 5754 23014 41.1 164.4 4.8 19.0 50.0 36.5
HDRMB - 600-18-9-300 600 6277 25106 44.8 179 5.0 20.0 50.0 38.0
HDRMB - 650-19-9-400 650 6800 27198 48.6 194 5.3 20.0 75.0 39.0
HDRMB - 700-20-9-400 700 7323 29291 52.3 209 5.5 21.0 75.0 40.0
HDRMB - 750-20-9-400 750 7846 31383 56.0 224 5.8 22.0 100.0 41.0
HBRMB - 800-21-9-500 800 8369 33475 59.8 239 6.0 23.0 100.0 42.0
HDRMB - 1000-23-11-1250 1000 10461 41844 74.7 299 7.0 25.0 125.0 46.0
Figure A-4
Typical Ratings for Hot Water Flextube Boilers
Gas Input MBH Oil Input GPH Watertube Boiler, Hot Water
9ppm NOx
BHP MIN MAX MIN MAX FURNACE
PRESS
HEAD
DIA.
MOTOR
HP
MIN
FURN
WIDTH
MIN
FURN
HEIGHT
HDRMB - 100-7.5-50 100 1046 4184 7.5 29.9 0.8 7.0 5.0 26.6 25.0
HDRMB - 125-8.5-75 125 1308 5230 9.3 37.4 0.8 8.0 7.5 31.7 29.8
HDRMB - 150-9.5-75 150 1569 6277 11.2 44.8 0.9 9.0 7.5 35.9 33.8
HDRMB - 200-10-7-100 200 2092 8369 14.9 59.8 1.0 10.0 10.0 42.5 40.0
Page 6 Section A - GeneralHDRMB Manual
4. Your Complete Manual
In addition to this manual, there are several 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:
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 com-
ponents and their relative positions in the piping train.
c. The unit material list which provides an overview of
the burner requirements and a complete bill of material,
including the part numbers and description for each item.
d. The flame safeguard manual provides the operating
sequence for the burner management system. This will
be a critical document for troubleshooting any future prob-
lems.
e. Catalog cuts of the major components. These provide
details on the installation, adjustment and maintenance of
the components used on the burner.
5. Service, Parts and other Information
Service and parts are available from your local Webster
Representative. For a list of Webster Representatives,
please visit the Webster web site at:
www.webster-engineering.com or call 620-221-7464.

Page 7 Section A - GeneralHDRMB Manual
HDRMB - 250-11-7-150 250 2615 10461 18.7 74.7 1.1 11.0 15.0 47.6 44.8
HDRMB - 300-13-7-150 300 3138 12553 22.4 89.7 1.3 13.0 15.0 51.8 48.7
HDRMB - 350-14-7-200 350 3661 14645 26.2 104.6 1.4 14.0 20.0 55.3 52.1
HDRMB - 400-15-7-200 400 4184 16738 29.9 119.5 1.5 15.0 20.0 58.4 55.0
HDRMB - 450-16-7-250 450 4707 18830 33.6 134.5 1.6 15.0 25.0 61.1 57.5
HDRMB - 500-16-7-250 500 5230 20922 37.4 149.4 1.8 16.0 25.0 63.5 59.8
HDRMB - 550-17-9-250 550 5754 23014 41.1 164.4 1.9 17.0 25.0 65.7 61.8
HDRMB - 600-18-9-300 600 6277 25106 44.8 179 2.0 18.0 30.0 67.7 63.7
HDRMB - 650-19-9-400 650 6800 27198 48.6 194 2.1 19.0 40.0 69.5 65.4
HDRMB - 700-20-9-400 700 7323 29291 52.3 209 2.3 20.0 40.0 71.2 67.0
HDRMB - 750-20-9-400 750 7846 31383 56.0 224 2.4 20.0 40.0 72.8 68.5
HBRMB - 800-21-9-500 800 8369 33475 59.8 239 2.5 21.0 50.0 74.3 69.9
HDRMB - 1000-23-11-1250 1000 10461 41844 74.7 299 3.0 23.0 50.0 79.4 74.7

Ignition Transformer
Oil Gun Switch
Atomizing Air Solenoid Valve
FGR Duct Flange
Air Damper
FGR Valve
Junction Box
Atomizing Air Pressure Switch
Windbox
Air Line
Oil Line
Center Gas Piping
Center Gas Balancing Valve
Gauge
Check Valve
FGR Servo
FGR Adapter
Pilot Gas
Connection
Combustion Air
Proving Switch
Mounting
Flange
Head Extension
Atomizing Air (AA) Servo
and Control Valve
B. COMPONENT DESCRIPTIONS
1. 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
This section describes the components of the HDRMB
burner line and provides some details on their application
and operation. Other sections of this manual provide a
more detailed review of how the components work as a
system and explain the overall operation of the burner.
Page 8 Section B - Component DescriptionsHDRMB Manual
Figure B-1
HDRMB General Arrangement
Dual Fuel, Plant Air

Page 9 Section B - Component DescriptionsHDRMB Manual
Damper Servo
Fan Housing
Condensate
Drains Support Pipes (field
installed)
Swirl Vanes
Burner Mounting Flange and Rope Gasket
Main Gas Orifice Holes
Rope Gasket
Front Wall of
Vessel
Center Fire Gas
Oil Nozzle
Front Plate Mounting Flange
Inlet Cone
Head Extension
Oil Line
Air Straightening
Vanes
Refractory Front Plate
Gas Pilot
(opposite
side, not
shown
Sight Port
Combustion
Air Motor
Figure B-3
HDRMB General Arrangement
Center Fire Gas Balance Valve
Oil Gun Cooling Air Line
Silencer
Air Damper
Atomizing Air Line
(to oil nozzle)
Scanner Port
Center Fire Gas Line
FGR Valve
FGR Adapter
Combustion Air Fan
Oil Gun Switch Assembly Firing Head
Figure B-2
HDRMB General Arrangement, Dual Fuel
Center Gas Line
Main Gas Line
Oil SafetyShutoff Valve
Center Gas Balancing Valve
Oil Nozzle
Gas Flow Control Valve & Servo
Combustion Fan Motor
Oil Flow Control Valve & Servo
Oil Manual
Shutoff Valves
Oil Gun Cooling Air & Manual Valve
Oil Pressure Switch
Head Extension
Oil (supply)
Pressure Gauge
Mounnting Flange

Terminal Strip
Alarm Light
Alarm Buzzer
Call for Heat Light
Low Boiler Water
Level Light (Optional)
Control Transformer
Transformer Fuses
Manual - Auto
Selector Switch
Flame Safeguard
Burner Motor
Starter
Alarm Silencing Switch
(Optional)
On - Off Switch
Manual Potentiometer
Rate Control
Power On Light
Fuel On Light
Control Relays
Figure B-5
Control Panel (Gas Shown)
Page 10 Section B - Component DescriptionsHDRMB Manual
1. General
The HDRMB burner line is configured from a common
group of components that may vary in size and style de-
pending on the capacity, NOx level, fuels and application.
These common groups of components are described in
this section, however the exact detail of any specific burner
must be taken from the unit specific information provided
with each burner. This would include the material list, wir-
ing diagram, catalog cuts and fuel train drawings.
2. Combustion Air
Fan
A backward curved fan is used to supply the combustion
air to burn the fuel. The fan also provides the recirculated
flue gas. The fan diameter and width will vary to match
the required combustion air flow rate, FGR rate, burner
altitude and vessel backpressure.
An inlet cone (Figure B3) is used with the fan to provide
a smooth air flow transition to the fan. Each fan has a
matching inlet cone. In some cases, the inlet cone bolts
directly to the housing and in other cases, it bolts to an
adapter that bolts to the housing. The inlet cone should
extend into the fan inlet about 1/4 inch.
Fan and Motor Assembly
The combustion air fan and motor are assembled together
on a motor support plate that attaches to the windbox.
This assembly, as shown in the photo (Figure B-6), is built
and balanced as a sub-assembly that can be removed for
maintenance and repair.
The fan can have either a taper lock hub or the fan is ma-
chined to match the motor shaft diameter. Setscrews are
used to lock the fan to the hub. The fan can be adjusted
on the shaft to provide the correct overlap between the fan
and inlet cone.
Several different motor styles can be used depending on
the application. An Open-Drip-Proof style is most com-
mon and used in a typical enclosed, clean environment.
A TEFC (Totally Enclosed Fan Cooled) would typically be
used in a dirty or wet environment. Other styles are also
available for special applications. The motor dimensions,
including the shaft diameter can vary by motor type.
Figure B4 not pictured

Motor
Motor Support Plate
Fan
Windbox
The windbox is an enclosure that routes the combustion
air from the fan to the firing head and provides the primary
mechanical structure for all of the components of the burner.
The combustion air fan and inlet cone are contained within
the windbox. The firing head is connected by the head
extension. The FGR adapter and air damper are also
connected to the windbox, opposite the combustion air
motor.
The windbox serves as the building block of the burner. It
requires good structural support to the boiler and floor to
handle the weight and movement of rotating components.
Head Extension
The head extension connects the firing head to the
windbox. It also allows different combinations of firing
heads to be used with different fan and windbox sizes.
Firing Head
The firing head is that area of the burner front where the
combustion originates, just downstream of the swirl vanes
and center gas ports, and at the entrance of the refractory.
This is the same location if firing oil, where the flame will
originate downstream of the oil nozzle. This is where the
fuel and air are mixed and start burning.
Air Damper
The air damper regulates the flow of air to the burner.
On a single point positioning system (linkage), the damper
shaft is connected by linkage to the jackshaft. On a parallel
positioning system (linkageless), the shaft is directly
coupled to the actuator for the air damper.
The air damper is connected to the FGR adapter plate,
so that the flue gas can enter down-stream of the damper
where there is a negative pressure. If an optional silencer
were used, it would be mounted to the inlet of the air
damper.
Blades
3. Burner Drawer
The burner drawer contains the gas manifold, swirl vanes
and oil gun. These components are all attached to the
backplate. The burner drawer slides through the windbox
and head extension. It is attached to the burner by bolting
the backplate to the windbox.
Refractory
Guide Tube
(for oil gun)
Center Gas
Main Gas
Ports
Swirl Vanes
Air Straightening Vanes
Figure B-9 Burner Drawer Assembly
The oil gun position can be adjusted (in and out) by sliding
the gun tube through the backplate. Setscrews are used to
lock these tubes into position. The oil gun can be removed
for inspection or extended gas firing without removing the
burner drawer.
The refractory front plate acts to shape the flame, protect
the burner face from the flame temperatures and also
contains the scanner, pilot and sight port. The firing head
is designed to have as near perfect fuel and air mixing as
possible, so these components are moved to a location
where they do not disturb the fuel and air flows.
The refractory front plate is attached to the vessel, usually
by bolts but sometimes by seal welding. If it is bolted, there
must be a good seal between the vessel and front plate.
The burner is bolted to the front plate, and it also must
have a good seal. Webster recommends and supplies a
fiberglass rope for this purpose, which should be used to
cover the full width of the flange.
Gas Manifold
The gas manifold is built into the burner drawer, and
provides the gas passage from the entry at the back of the
burner drawer to the main gas and center gas ports at the
front of the firing head. In a Firetube burner, the main gas
ports are holes positioned radially just downstream of the
swirl vanes (see Figure B-15). In a Watertube burner, the
main gas ports are in a small tube at the end of the swirl
vanes called riser tubes (see Figure B-15.1)
Swirl Vanes and main gas ports
The swirl vanes provide the “spin” of the combustion air
used to improve the fuel and air mixing. All the combustion
air passes through the swirl vanes. Just downstream of
the swirl vanes are the main gas ports, where most of the
natural gas enters the firing head for combustion. There
are two different types of main gas ports. On Firetube
boilers, the main gas ports are on the outer tube of the gas
manifold, in a pattern of multiple rows and hole sizes. On
Figure B-6
Fan and Motor
Assembly
Page 11 Section B - Component DescriptionsHDRMB Manual
Figure B-8
Multi-blade
Damper

Figure B-12 Pilot
Air Straightening Vanes
The air straightener (Figure B-9) consists of multiple plates
in the burner drawer used to straighten the air before the
swirl vanes.
4. Gas Fuel Components
Gas Train
The gas train contains the safety shut-off valves, manual
shut-off valves, pressure switches and other components
that may be required for the specific installation, available
Figure B-14.1 Center Gas Balancing Valve
gas pressure, insurance codes and local regulations
(Figure D-1). The details of the gas train can vary greatly
from burner to burner. Gas trains tend to be designed
Page 12 Section B - Component DescriptionsHDRMB Manual
Watertube boilers, there is a riser tube at the end of the
swirl vane which has a series of small holes for gas flow.
In both cases, the design provides excellent mixing of the
fuel and air, and a very stable flame front.
Center Gas
A small amount of gas is provided to the center gas ports,
close to the flame front. This small amount of gas is used
to improve the visibility of the flame with a small less
turbulent mix at the base of the flame. The balancing
valve can be adjusted to vary the flow of center gas, as a
% of main gas flow.
3.5 Refractory Front Plate
The refractory front plate is used to connect the burner
to the vessel, and provides both the mechanical support
as well as the refractory shield for heat protection. The
refractory has a special shape used to control the flame
geometry. Gaskets must be applied to both the attachment
to the vessel and the burner attachment to the refractory
front plate. The HDRMB also has the scanner, pilot and
view port in the refractory front plate, so there is more
uniform mixing of the fuel and air.
Scanner
The scanner is mounted to a sight tube in the refractory
front plate. It requires a cooling air line.
Pilot
The pilot is mounted in the refractory plate. Gas and air
are piped into the pilot, and additional raw gas is piped
into the pilot mounting tube to increase the flame size.
Mounting Flange
The primary support for the burner is the mounting flange
on the head extension. This provides a clamping surface
to attach the burner to the vessel. A fiberglass rope
gasket (3/8” dia) is used to seal the mounting flange to
the refractory front plate. The rope is wrapped around the
flange several times to seal the full diameter and surface
area of the flange.
Manual Shutoff Valve
Pressure Gauge
(optional)
High Gas Pressure Switch
Pressure Sensing Line
Combustion Safety Shutoff Valve
& Gas Pressure Regulator
Safety Shutoff Valve
Leak Test Ports
Junction Box
Vent Valve
Manual Shutoff Valve
Pressure Gauge
(optional)
Low Gas Pressure Switch
Figure B-13
Typical Gas Train

for each application and a unit specific gas train assembly
drawing is provided for each unit, identifying the major
components. Details are provided in the burner manual
included with each burner.
The gas train shown in Figure C-4 uses a gas pressure
regulator upstream of two safety shutoff valves. Another
common style is to have the gas pressure regulation built
into the second safety shutoff valve. The gas train in Figure
B-13 uses a combination shutoff and regulator in the second
safety shutoff valve.
Center Gas Balancing Valve
The amount of gas flowing to the center gas ports is regulated
by the center gas balancing valve. This valve allows the
flow to be increased or decreased proportional to the main
gas flow. This is the only adjustment for the natural gas
combustion flame shape.
Gas Safety Shutoff Valve
Each gas train has two shutoff valves in the gas train.
These shutoff valves are usually motorized to open and
spring return to close. They may contain a proof of closure
switch to prove that the valve is in the closed position prior
to starting the burner.
High Gas Pressure Switch
This switch is located after the last shutoff valve and before
the gas flow control valve. It is set at a pressure that is
greater than the highest gas pressure expected at this
location. If the gas pressure rises above this level, it will trip
the switch and cause the burner to shut down.
Low Gas Pressure Switch
This switch is located before the first shutoff valve. It is set
to a pressure that is below the expected gas pressure at
this location. If the gas pressure falls below this setting, the
switch will trip and cause the burner to shut down.
Gas Pressure Regulator
Each gas train must have a gas pressure regulator. The
regulator insures a consistent supply pressure to the burner.
Often the gas pressure regulator is the first item in the gas
train or can be integrated into the second shutoff valve.
Gas Control Valve
The gas control valve is used to modulate the flow of gas
fuel to the burner. On a single point positioning system
(linkage), it is connected to the jackshaft and uses a fuel
cam to make fine adjustments to fuel flow. With a parallel
positioning system (linkageless), an actuator is connected to
the gas control valve, and modulated by electronic control to
the desired position. The gas control valve is located on the
pipe that connects to the gas manifold.
Pilot Port
Burner Mounting
Studs
Sight Port
Scanner Port
Figure B-15 Typical Refractory Plate
Swirl Vanes
Main Gas
Orifices
Figure B-15 Firetube Style Gas Manifold
Lower Tubes,
Main Gas
Orificces
Figure B-15.1 Watertube Style Gas Manifold
5. Oil Fuel Components
Air / steam atomized oil systems are used on all oil
burners. An air compressor is normally supplied for the
air source, but house air or steam can be used.
Oil Pump
The oil pump is used to supply the oil to the nozzle
at sufficient flow and pressure for the nozzle. The
oil pump 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.
Page 13 Section B - Component DescriptionsHDRMB Manual

The oil flow control valve modulates with the air damper to
provide different input rates. On a single point positioning
system (linkage), it is connected to the jackshaft and uses
a fuel cam to make fine adjustments to fuel flow. With
a parallel positioning system (linkageless), an actuator
is connected to the oil control valve and modulated by
electronic control to the desired position.
Oil Nozzle
Several different types of oil nozzles may be used
depending on the type of oil system, burner size, turndown
and application. They all share a common purpose of
atomizing the oil into small droplets so that they will easily
and quickly burn. All of the nozzles are mounted to the
end of the oil gun and are inserted into the support tube.
The position of the nozzle can be adjusted by moving the
gun in the tube. The oil nozzles and gun have a “Top and
Bottom” position that is critical for correct operation. The
end of the oil gun is marked with the word “TOP”.
Figures B-17 and B-18 shows the components of typical air
atomizing nozzles. The nozzle tip and swirler are lapped
together to form a perfect fit and can only be used together
as a matched set. Other air atomizing nozzles may have
slightly different construction.
Figure B-17 Multiport Atomizing Oil Nozzle
Body Swirler
Nozzle Tip
Spring
Washer Swirler Tip
Body
Figure B-18 Deep Groove Atomizing Oil Nozzle
Page 14 Section B - Component Descriptions
Motor
Oil Pressure
Regulator
Oil Pump
Motor Base
Figure B-16 Oil Pump and Regulator
Oil Pressure Regulator
An oil pressure regulator is used to maintain constant oil
pressure to the burner. It is adjusted to provide the oil
pressure needed at the nozzle.
Oil Supply Pressure Gauge
This indicates the oil supply pressure from the pump.
Oil Train
The oil train contains the safety shut-off valves, pressure
switches and other components that may be required
for the specific installation, insurance codes and local
regulations and can vary greatly from burner to burner.
Oil trains tend to be designed for each application and a
unit specific oil train drawing is provided with each unit.
Details of the actual components are provided with each
burner.
Oil Safety Shutoff Valve
Each oil train has two shutoff valves. The valves can be
either solenoid or motorized type and can have an optional
POC (proof of closure) switch.
Low Oil Pressure Switch
This switch is set to a pressure below the expected oil
pressure and will trip if the oil pressure drops below this
level, shutting down the burner.
High Oil Pressure Switch (optional)
This optional switch is set to a pressure above the expected
oil pressure and will trip if the oil pressure rises above this
level, shutting down the burner.
Manual Ball Valve
A manual valve is provided in the oil line to perform
testing of the safety controls as part of the normal startup
procedures.
Oil Flow Control Valve
The oil flow control valve regulates the flow of oil to the
nozzle. The control valve is in the piping to the nozzle,
directly regulating the flow of oil to the nozzle.
HDRMB Manual

Oil Gun
The oil gun (B-9) consists of the oil nozzle and pipe
connections for the nozzle. The oil gun slides into the guide
tube. Two blocks are used to keep the gun centered in the
guide tube and lock the gun to the end of the guide tube.
The gun assembly must be mounted in the correct (vertical)
position, with the word “TOP” located on top of the gun
assembly. This will allow for even oil distribution and prevent
oil dripping out of the gun and lines after shutoff.
Nozzle Oil Pressure Gauge
This gauge indicates the oil pressure at the oil nozzle. This
reading is important in determining proper operation of the
nozzle for atomization at any given firing rate. There is a
wide range of possible pressures, but typically it is in the
range of 15 to 60 psi.
Nozzle Atomizing Air Pressure Gauge
This indicates the atomizing air pressure at the nozzle. This
reading is important in determining proper operation of the
nozzle for atomizing the oil.
Air Compressor
The air compressor, if used, provides air to the oil nozzle
to atomize the oil. The compressor assembly includes the
compressor motor, relief valve and flexible connection to
isolate the vibration of the air compressor. The large air
compressor (Figure B-20) is equipped with rubber mounts
that must be used when mounting the compressor to a
base.
Air Filter
Motor
Flexible
Hose Air
Supply
Connection
Figure B-20 Large Air Compressor
Compressor
Motor
Base
Belt Guard
Figure B-21 Small Air Compressor
Air Bleed Valve and Muffler
An air bleed valve is provided with air atomizing systems to
allow some of the air to bleed off and lower the atomizing
air pressure to optimize the oil atomization. An air muffler
is provided to reduce the noise from this air flow. In some
cases, the bleed valve modulates with firing rate.
6. Flue Gas Recirculation (FGR)
FGR Adapter
The FGR adapter provides an interconnection between
the housing and air damper, placed in the air flow stream
to introduce the FGR. This location allows the FGR to
be “induced” into the air stream, because of the negative
pressure downstream of the air damper and created by
the burner blower wheel.
FGR Control Valve
The FGR control valve controls the flow of recirculated
flue gas. The valve is connected to the FGR adapter,
which creates the pressure differential for flow.
FGR
Adapter
FGR Control
Valve
Figure B-23 FGR Control Valve
The FGR control valve modulates in conjunction with the
fuel and air valves to provide different input rates. On a
single point positioning system (linkage), it is connected
to the jackshaft. With a parallel positioning system
(linkageless), an actuator is connected to the FGR control
valve and modulated by electronic control to the desired
position.
Smaller FGR Valves are built into the FGR duct as shown
in Figure B-1. Larger valves are wafer type, bottled
between two flanges as shown in Figure B-23.
FGR Shutoff Valve (Linkage Units)
Single point positioning systems (linkage) require a
separate FGR shut-off valve that prevents flow during
the purge cycle. The valve is driven by a motor to close
the FGR line during the purge cycle. Parallel positioning
systems will modulate the control valve shut during purge
and do not require a shut-off valve.
Page 15 Section B - Component DescriptionsHDRMB Manual

Motor
FGR Valve
Drive Linkage
Valve Stem
Horizontal
Figure B-24 FGR Shutoff Valve
The shutoff valve should be installed in the FGR duct
close to the boiler connection. The valve stem should
be horizontal, to prevent condensate from building in the
shaft bore, causing it to seize.
When firing oil, this valve may be closed or it may
be partially open to provide some FGR. If the valve is
intended to be partly open, there will be a potentiometer in
the control panel to adjust the position of this valve.
FGR Duct
The FGR duct provides the connection between the boiler
outlet and the control or shut-off valve. The design of this
duct is very important for proper operation and to prevent
maintenance problems (see Section C). This duct is not
included with the burner.
7. Fuel-Air-Ratio Controls
The burner may be equipped with single point positioning
(linkage), multiple setting modulating motor, parallel
positioning system (linkageless) or fully metered systems.
All of these systems provide the basic fuel-air-ratio control
required for good combustion, however they can provide
different features and setup capabilities.
Modulating Control
The burner modulates to match the energy requirements
of the load. It does this by using a sensor that measures
the pressure or temperature of the system and a matching
sensor in the modulating motor that moves to match the
readings of the sensor.
In some optional systems, a similar process is used with
an external control that provides a signal to the motor to
go to a certain rate. These systems may include multiple
burner sequencing, outside temperature compensation
and numerous other control strategies.
Single Point Positioning (Linkage)
Single point positioning systems use a single modulating
motor to vary the fuel input, air flow and other flow
changes like FGR and atomizing air flow. Linkage is used
to connect these flow control elements together to provide
a unified fuel-air-ratio control system. Other elements in
this system would typically include a jackshaft, fuel cam
and modulating motor.
Jackshaft
The jackshaft is a shaft that is used to tie the fuel, air
and FGR valves together with linkage, to provide a
uniform change in the flow as the burner modulates. A
modulating motor is used to drive the jackshaft, driven by
the requirement for heat in the system and as allowed to
operate by the flame safeguard.
The jackshaft is a 3/4” shaft that rotates and is mounted
in bearing supports. This provides a common means of
modulating all of the valves from a single drive mechanism.
The length can vary to meet overall dimensions and
individual drive arms are used to connect to each valve.
Fuel Cam
A fuel cam is a mechanical linkage that allows for small
fuel rate changes without changing the linkage setting.
It can simplify the fuel-air-ratio adjustments during the
burner setup (Figure B-3 and B-4).
Modulating Motor
The jackshaft is driven by a modulating motor that
rotates 90o to modulate the burner input from minimum
rate to maximum rate. Linkage is used to connect the
modulating motor to the jackshaft and the fuel cams along
with connecting the fuel, air and FGR control valves to the
jackshaft.
The standard modulating motor has two internal proving
switches. One switch, the Low Fire switch, proves the
low fire position where the burner will light. This is also
the position the modulating motor will travel to when the
burner shuts down. The second switch, the High Fire
Purge switch, proves the high fire purge position during
pre-purge.
Multiple Setting Modulating Motor
In some burner configurations, there are different ideal
settings for oil and gas firing, especially when higher
turndown is desired. This can be accommodated with an
optional modulating motor that has different low fire and
high fire positions for gas vs oil.
Removable
Cover
Drive
Arm
Modulating
Motor
Page 16 Section B - Component DescriptionsHDRMB Manual

Figure B-25 Landis Mod Motor Adjustments
This optional modulating motor uses four to eight internal
switches. One switch is used to prove the high fire purge
position during pre-purge. A second switch is used to prove
the fully closed position. This is the position of the motor
when the burner is off. A third switch is used to prove the
ignition position. This is the point at which the burner will
light. A fourth switch is the low fire position. This is the
position of the lowest firing rate of the burner. It can be
different from the ignition position, if desired. If the burner
is a combination gas-oil burner, two additional switches may
be used. These switches do the same function as the third
and fourth switches already listed, but can be set up to allow
for different ignition and low fire positions for gas and oil
operation. There is also a 7th and 8th switch that can be
used to accommodate two different high fire settings. See
the burner wiring diagram to determine the switch numbers
and functions.
Parallel Positioning System (Linkageless)
The Posi-Control system is a parallel positioning system
(linkageless) that uses individual actuators for each control
valve and a computer controller that directs each actuator
to provide the input change from minimum to maximum
capacity. The control provides more flexibility in setting each
fuel rate (Figures B-1 and B-2).
Fully metered control system
This system uses flow measurements to determine valve
position. These controls require special training to use.
8. Electrical Controls
Control Panel
The control panel (Figure B-5) contains the flame safeguard
control, relays, terminal strips for electrical connections and
other components required for the control of the unit. Other
components may be included for the operation of the boiler,
for example, a low water cutout relay.
Flame Safeguard
The flame safeguard (Figure B-5) provides operational
control and safety sequencing for the burner. Safety limits
are tied to the unit and it controls the operation of the fuel
valves. The flame scanner is part of this control and can
detect a flame failure causing a safety shutdown. There
are several different flame safeguard models available with
different features and cost levels. They can provide fault
annunciation and communications with other controls. The
details of the control used in the burner are supplied with
the unit.
On-Off Switch
This switch is used to start and stop the burner by opening or
closing the limit circuit to the flame safeguard control.
Manual-Auto Switch and Potentiometer
The Man-Auto switch is used to select what signal source is
used for modulation control of the burner. With the switch in
the “Man” position, the burner firing rate is determined by the
position of the manual potentiometer. With the switch in the
“Auto” position, the burner firing rate is determined by
the signal from the boiler modulating controller. When
in the “Auto” position, the manual potentiometer can
limit the firing rate of the burner from anywhere between
low fire and high fire. The modulating motor will always
drive open and closed during pre-purge, regardless of
the position of the Man-Auto switch and potentiometer.
Fuel Transfer Switch
This switch selects the proper fuel for firing. It has a
center off position that prevents moving the switch from
one position to the other, without momentarily stopping
in the center off position.
Power On light
Indicates power is applied to the control panel.
Call For Heat light
Indicates the burner On-Off switch is closed and the
boiler limits are closed.
Fuel On light
Indicates the main fuel valve circuit has been
energized.
Alarm light
Indicates the flame safeguard control is in a safety
shutdown and lockout condition. The flame safeguard
control reset button must be pressed before the burner
can operate again.
On some burners the Alarm light may also be used to
indicate other failure conditions such as low water, high
limit, etc. See the burner wiring diagram for details of
what other controls may be wired to the Alarm light.
Junction Box
The junction box contains the electrical connections that
are required between the burner and control panel.
Control Transformer (Optional)
The control circuit transformer is used to reduce the
main power input to 115 VAC for the control circuit. If this
electrical supply could be provided as a separate input,
this transformer would not be required. The transformer
has two fuses located on the transformer box.
Alarm Bell
The alarm bell (or buzzer) provides an audible noise if
the burner were to lock out due to an alarm condition.
Control Relays
Relays are provided to support electrical options. The
number and type of relays will vary with the equipment.
These relays will be indicated on both the wiring diagram
and material list.
Motor Starters
A motor starter for the combustion air fan may be in the
panel if a VFD is not used. If other motors are used, for
an oil pump or air compressor, these will also be located
in the control panel.
Page 17 Section B - Component DescriptionsHDRMB Manual

1. General Considerations
2. Refractory Frontplate
3. Burner Mounting
4. Gas Piping
5. Gas Pilot
6. General Oil Pipiing
7. Air Atomized #2 oil
8. FGR System
9. Draft and Stacks
10. Electrical System
C. Installation
This section covers the installation procedures for each of
the standard systems offered on the HDRMB burner line.
Your specific burner will not have each of these systems
and may be supplied to you as an installed burner assem-
bly. If you receive the burner as part of a new boiler for ex-
ample, the burner will be installed in the vessel with much
of the piping already done. For this reason, a complete
review of the installation is required to determine which
tasks are complete and which need to be done.
THE INSTALLATION OF THE EQUIPMENT SHALL BE
IN ACCORDANCE WITH THE REGULATION OF AU-
THORITIES HAVING JURISDICTION, INCLUDING THE
NATIONAL ELECTRICAL CODE, INSURANCE REGULA-
TIONS.
The equipment shall be installed in accordance with the
state and local requirements. Authorities having jurisdic-
tion should be consulted before installations are made.
NOTE TO INSTALLER: The main power disconnect for
this equipment must be conspicuously labeled and placed
within sight of the operating system and equipped with
lockout provisions.
1. General Considerations
In the initial planning of the installation, several items must
be covered:
a. Prior to starting the installation, all the technical litera-
ture should be collected and reviewed to identify require-
ments. As a minimum, these should include the Installa-
tion and Operating Manuals for the burner and vessel, the
wiring diagrams, the fuel schematics and technical litera-
ture on supplied controls.
b. A general overview of the equipment should be made
prior to the installation. Check the location of access
doors and insure that they will be able to function properly
when all equipment is installed. The burner and control
panel should have sufficient clearance for the operator to
monitor, inspect and perform maintenance. A minimum
clearance of 24 inches all around the burner should be
provided for maintenance. The burner drawer and oil gun
is pulled out from the front of the burner and there needs
to be sufficient space for this activity.
c. A source of combustion air must be provided for the
burner. Local codes often determine minimum require-
ments, and these must be followed. In absence of other
codes, the following can be used.
Webster recommends two air sources be provided, one lo-
cated high and one low. Each air source must be at least 1
ft2. If there are multiple burners, the area must consider all
burner requirements. Exhaust fans are not recommended
as they create additional air flow requirements that must
be included in the area calculation.
The quantity of air required for combustion and ventilation
is 10 cfm/BHP. The maximum air velocity is 250 ft/min
from the floor to 7 feet high, and 500 ft/min above 7 feet
high. Outdoor louvers may restrict the open area, and if
the exact restriction is unknown, a restriction of 20% can
be used. Add 3.5% to the area for each 1000 ft above sea
level. The calculations are,
Total air required (cfm) = BHP x 10
Open area = cfm / velocity
Louvered area = open area x 1.2 (or actual)
Area of opening = louvered area / 2
For example, with duct located under 6’ high for a 500 HP
boiler, what would their area need to be? The total air is
(500 BHP x 10 cfm/BHP) = 5000 cfm. The maximum ve-
locity is 250 ft/min, so the open area must be = (5000 cfm /
250 ft/min) = 20 ft2. Since these opening will have louvers,
the actual openings must be = (20 ft2 x 1.2) = 24 ft2. There
will be two opening, so each will be = (24 ft2 / 2) = 12 ft2.
The combustion air should not be below 50oF or large
amounts of condensation can be generated, causing pre-
mature failure of the burner. Depending on the actual
temperatures, it can fill the fan housing and destroy the
fan and motor. If cool temperatures are experienced infre-
quently, the condensate can be collected and removed by
using the drain tappings on the bottom of the FGR adaptor
and fan housing. If cool temperatures are experienced
with some frequency, the combustion air should be pre-
heated to prevent the condensation.
A TEMP-A-TRIM control is offered as standard equip-
ment on the HDRMB burner. This product will provide an
automatic correction for changes in combustion air tem-
perature that would otherwise require combustion tuning
to prevent problems like rumbling due to high excess air
(with cooler temperatures) or high CO due to low excess
air (due to high temperatures). This allows the burners to
work within a wide range of combustion air temperatures
without frequent combustion tuning. If your burner does
not have the TEMP A TRIM option, then you may need to
have seasonal tuning performed.
d. There are several people that should be notified be-
fore starting, including the owners representative, the me-
chanical contractor, the electrical contractor, the service
organization and the boiler manufacturer.
e. DO NOT USE TEFLON TAPE or compounds with Tef-
lon content as an oil or gas pipe sealant. Teflon can cause
valves to fail creating a safety hazard. Warranties are nul-
lified and liability rests solely with installer when evidence
of Teflon is found.
f. Installer must clearly identify the main electrical power
Page 18 Section C - InstallationHDRMB Manual

disconnect and the manual shutoff valve on the gas supply
drop line to the burner.
2. Refractory Frontplate
The refractory front plate is used to adapt the burner to the
vessel. While the specific dimensions will vary with differ-
ent vessel and burner configurations, all will be similar in
shape to that shown in Figure C-1. A mounting flange on
the frontplate is used to clamp the frontplate to the vessel.
Bolts on the frontplate are used to clamp the burner to the
frontplate. Fiberglass rope gaskets are used to seal each
connection.
The rope gasket is applied to full surface of the frontplate
mounting flange (it must cover the full face of the flange)
to seal the refractory front plate to the vessel (a spray ad-
hesive can be used to hold the gasket in place temporar-
ily). The refractory frontplate is inserted into the furnace
and bolted or clamped to the end of the furnace. The re-
fractory must be centered in the furnace, so that the gap
between the refractory and furnace is uniform. Clamp the
frontplate to the furnace with uniform tension on the bolts,
starting with a low torque for all bolts and then repeating
with higher torque levels until tight.
Pack the gap between the refractory front plate and fur-
nace with ceramic blanket insulation (or ceramic rope) for
at least 4 inches from the end of the refractory (Figure
C-3). This can be accomplished by reaching in from the
center hole, and placing the insulation between the refrac-
tory and furnace, then pushing it in with a block.
3. Burner Mounting
A rope gasket is applied to the burner mounting flange,
completely covering the flange (the 3/8” fiberglass gas-
ket is provided with the burner). A spray adhesive can be
used to hold these in place prior to installation.
The burner is then inserted into the frontplate, centered
evenly (the 2 inch recess will center the burner) and
clamped into position. Clamp the burner to the frontplate
with uniform tension on the bolts, starting with a low torque
for all bolts and then repeating with higher torque levels
Page 19 Section C - InstallationHDRMB Manual
Rope Gasket Should
Cover this Flange
Pilot Flange
Scanner Tube
Sight Tube
Lifting Lugs
Mounting Flange (Position varies to
Keep Face Flush with Front Wall or
Past Tubesheet)
Can be High Temperature Re-
fractory (Plicast 36 or Equal) or
THERMOBOND
Interior Dimensions Vary with
Head Size, but all have this
Shape
Outside Diameter Varies
to Match Application
4”
4”
Burner
Head
Dia.
Figure C-1
Refractory
Frontplate
Floor Mount
Pipe Supports (field installed)
Burner Should be Level &
Square to Boiler Front
Union (optional)
Burner Head
Should Fit Inside
Refractory with
a Gas Tight Seal
at the Mounting
Flange
Refractory Front
Plate to be Cen-
tered in Opening
and Flush with
Front Wall
Fill Gap with
Ceramic Blanket
and Face with
Refractory
Boiler Front Wall
Wrap Face of Flange
with Rope Gasket,
Should Cover Full
Face
Tighten Nuts Uniformly & Check
After Firing
Figure C-3
Burner Mounting

until tight.
Pilot Gas Line
Manual
Valve
Raw Gas
Line
Pilot Gas
Line
Pilot Air
Pilot
Pilot Port
Refractory
Front Plate
Scanner Port
Cooling Air Line
Air can be from
separate fan as shown
or from a taping in the
head extension
Figure C3.3
Pilot & Scanner Piping Schematic
The burner should be checked for level and must be per-
pendicular to the vessel. If the burner is not level or per-
pendicular, loosen the mounting clamps, reposition the
burner and retighten. This will properly align the burner
flame with the furnace and allow the proper flow of liquid.
Oil combustion will not work properly if not level.
The burner is equipped with mounting supports to secure
it to the floor. These are pipe couplings attached to the
burner. There are two on the housing and for larger burn-
ers, one or two in the motor mounting plate. To secure
the burner to the floor, pipe sections are installed to these
couplings and a flange mount is secured to the floor, as
shown in Figure C-3.
WARNING
DO NOT USE TEFLON TAPE OR COMPONDS CON-
TAINING TEFLON. THIS COULD DAMAGE THE
VALVES CREATING AN UNSAFE OPERATION
NOTE TO INSTALLER: The manual shutoff valve on the
gas supply drop line to the burner must be conspicuously
labeled.
4. Gas Piping
Figure C-4 shows a typical gas piping schematic, although
some components can vary based on size, insurance and
other requirements. Consult the job specific gas train pip-
ing schematic (provided with the burner if train is supplied
by Webster), along with a detailed list of components for
specific details. This must be followed to properly locate
the components in the gas .
The gas piping must comply with all local and state codes
and must be in accordance with the local gas company and
insurance requirements.
If the gas train has not been factory assembled, the compo-
nents should be assembled as indicated on the gas piping
schematic furnished with the burner. The section between
the two manual shutoff valves is mounted securely to the
base rail on the side of the vessel. A drip leg should be
provided upstream of the first manual valve to collect any
moisture or contaminates.
Some general considerations for this installation are:
a. The piping to the burner must be sized to provide gas
at the pressure and volume indicated on the order.
b. The gas piping should be installed according to local
regulations and any applicable insurance requirements.
c. The gas pressure regulator usually requires a mini-
Page 20HDRMB Manual Section C- Installation
Drip Leg
Manual Gas
Shutoff Valve
Gas Pressure
Regulator
Low Gas
Pressure
Switch
Shutoff
Valve
Shutoff
Valve
High Gas
Pressure
Switch
Normally
open vent
valve
Leak Test
Valve
Pilot Gas
Pressure
Regulator
Pilot Solenoid
Valve
Pilot
Shutoff
Valve
Figure C4
Typical Gas Piping
Gas Supply
If applicable, Webster
supplied gas train
Control Valve