WEBSTER COMBUSTION HDS 200A User guide

W£8S
COMBUSTION
A Selas Heat Technology Company
Webster Combustion Technology
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Model HDS and HDSX Burner
HDS 200A THROUGH HDS - 600C
HDSX 200A THROUGH HDSX 600C
200 to 600 BHP, Gas and Oil Firing

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  @2014 All Rights Reseed

SAFETY PRECAUTIONS
Page 2 Safety PrecautionsHDS 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 - GeneralHDS 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 .......................................
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. General Oil Piping .................................
6. Pressure Atomized Oil System................
7. Air Atomized #2 Oil ................................
8. Gas Pilot ................................................
9. FGR Duct System .................................
10. Draft and Stacks ...................................
11. Electrical System ....................................
D. Fuel and Control Systems
1. Gas Systems .........................................
2. Gas Pilot ................................................
3. Pressure Atomized Oil System................
4. Air Atomized #2 Oil ................................
5. Fuel-Air-Ratio Controls ..........................
6. Electrical Controls .................................
7. Operating and Modulating Controls ......
8. Flame Safeguards .................................
E. Preliminary Adjustments
1. Visual Inspection ...................................
2. Burner Drawer Checkout .......................
3. Motor Rotation .......................................
4. Fuel, FGR and Air Control .....................
5. Fuel Cam Adjustments ..........................
6. Air Damper Adjustments ........................
7. Pilot and Scanner Adjustments .............
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 Pressure
Atomized Oil ..........................................
8. Combination Gas and Air
Atomized #2 Oil ......................................
9. Gas Setup .............................................
10. Pressure Atomized Oil Setup ................
11. Air Atomized #2 Oil Setup ......................
12. Operating Control Adjustments ..............
13. Limit Tests ..............................................
14. Pilot Test..................................................
15. Burner Shutdown ....................................
16. Restarting After Extended Shutdown .....
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G. Maintenance
1. General ....................................................
2. Physical Inspection ..................................
3. Fuel-Air-Ratio ..........................................
4. Gas Fuel Systems ...................................
5. Oil Fuel Systems .....................................
6. FGR Systems ..........................................
7. Combustion Air Fan .................................
8. Inspection and Maintenance Schedule ....
9. Combustion Chart ....................................
H. Trouble Shooting ................................................
Page 49
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Page 4 Section A - General
HDS Manual
A. GENERAL
1. Nameplate Information
2. Ratings
3. Product Offering
4. Your Complete Manual
5. Service and Parts
This manual covers the Models HDS and HDSX burners
offered by Webster Engineering & Manufacturing Co., LLC.
These burners are intended for commercial and industrial
applications for Scotch Marine Firetube boilers. They can
fire gas, oil or combinations 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 HDS and HDSX burner
requires 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 AU-
THORITIES HAVING JURISDICTION, INCLUDING THE
NATIONAL ELECTRICAL CODE, CSA STANDARDS 139
AND 140, THE CANADIAN NATIONAL ELECTRIC CODE,
PART I 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 nameplates shown in Figure A-1A and
A-1B. The “X” in the HDSX refers to a low NOx burner,
where FGR 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.
MODEL NUMBER
HDSXC-400B-5V 150 RM7800L-M.25 VGD
SERIAL NUMBER
CUL73586A-02
JOB LOCATION
Canada
DATE MFG
30 - Nov - 04
OIL INPUT RATINGGAS INPUT RATING
MBTU/HR IN.WC GPH PSI
16738 8.4 120 150
MAXIMUM
2790 0.15 40 65
MINIMUM
NATURAL GAS #2 OIL
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-1B Nameplate - Canadian Applications
3.8”
(2) 24, (1) 22
1000
300 PSI
36”
MAX OVERFIRE DRAFT
OIL NOZZLES (QTY) GPH @ 100 PSI
REQ’D GAS INLET PRESS GAS BTU/CUFT
REQ’D OIL PUMP PRESS
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-1A) show both the oil pres-
sure and air pressure. Pressure atomized burners (Figure
A-1B) only list the oil 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.
MODEL NUMBER
HDSXC-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-1A Nameplate - US Applications

MODEL HDS(X) BURNER MODEL CONFIGURATION
FIGURE A-2
HDSC - 250 A -5-SL-75-RM7800L- M .25 VGD-MA-UL/CSD-1
BURNER SERIES
HDS No FGR
HDSX With FGR
FUELS
G Gas
O Oil
C Gas / Oil
BOILER HP
200 200 HP
250 250 HP
300 300 HP
350 350 HP
400 400 HP
450 450 HP
500 500 HP
600 600 HP
HEAD SIZE
A 12 inches
B 16 inches
HOUSING SIZE
55
77
HOUSING
ROTATION
SL Slant left
SR Slant right
VVertical (std)
CODES AND
LISTINGS
UL
ULc
CSD-1
FM
IRI
NFPA-85
PRESSURE, AIR or STEAM
ATOMIZING
MR Pressure atomizing
MA Air atomizing
GAS TRAIN VENDOR
VGD Seimens
VGG Seimens
M Maxon
Blank All Others
(ASCO) - (std)
GAS TRAIN SIZE
.15 1 1/2 inches
.20 2 inches
.25 2 1/2 inches
.30 3 inches
.40 4 inches
MODULATION
M Full modulation
FLAME SAFEGUARD
VENDOR DESIGNATION
RM7800L Honeywell
M Mark AutoFlame - mini mark
E110/EP170 Fireye
Nexus - N Fireye
LMV51-S Siemens
LMV52-S Siemens
The above represents the common model designations.
Contact the factory for other options and special applications.
Page 5 Section A - GeneralHDS Manual
MOTOR HORSEPOWER
50 5 HP 200 20 HP
75 7.5 HP 250 25 HP
100 10 HP 300 30 HP
150 15 HP

Figure A-3
General Ratings
Model Ratings for USA and International Model Ratings for Canadian Market
BHP
Gas Input
MBH
Air Atom. #2
Oil Input (GPH)
Press. Atom. #2
Oil Input (GPH)
Gas Input
MBH
Air Atom.
Oil Input (GPH)
Press. Atom.
Oil Input (GPH)
Min Max Min Max Min Max Min Max Min Max Min Max
Standard Gas - Oil - Combination Burner (No Low NOx)
200 697 8400 6.0 60 17.0 60 697 8400 6.0 60 20 60
250 872 10500 7.5 75 21.4 75 872 10500 7.5 75 25 75
300 1046 12600 9.0 90 25.0 90 1046 12600 9.0 90 30 90
350 1220 14700 10.5 105 30.0 105 1220 14700 10.5 105 35 105
400 1395 16800 12.0 120 NA NA 1395 16800 12.0 120 NA NA
450 1569 18900 13.5 135 NA N A 1569 18900 13.5 135 NA NA
500 1743 21000 15.0 150 NA NA 1743 21000 15.0 150 NA NA
600 2092 25200 18.0 180 NA NA 2092 25200 18.0 180 NA NA
Low NOx Burner with Induced FGR - 30 ppm
200 697 8400 6.0 60 17.0 60 697 8400 6.0 60 17.0 60
250 872 10500 7.5 75 21.4 75 872 10500 7.5 75 21.4 75
300 1046 12600 9.0 90 25.0 90 1046 12600 9.0 90 25.0 90
350 1220 14700 10.5 105 30.0 105 1220 14700 10.5 105 30.0 105
400 1395 16800 12.0 120 NA NA 1395 16800 12.0 120 NA NA
450 1569 18900 13.5 135 NA NA 1569 18900 13.5 135 NA NA
500 1743 21000 15.0 150 NA NA 1743 21000 15.0 150 NA NA
600 2092 25200 18.0 180 NA NA 2092 25200 18.0 180 NA NA
Page 6 Section A - GeneralHDS Manual
2. Ratings
The ratings for each specific burner are given on the
nameplate (Figure A-1A & A-1B). The general burner rat-
ings are given in Figure A-3. The maximun and minimum
inputs are 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 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. Burners equipped for high turn-
down (greater than 6:1) can have different equipment to
improve fuel, air and FGR flow control.
3. Product Offering
The HDS burner is intended for Scotch Marine Firetube
boiler applications. The round furnace is required to con-
tain the flame and make the best use of the high swirl
action. The burner can fire natural gas, #2 oil or combina-
tion of natural gas and #2 oil.
DO NOT USE GASOLINE, CRANKCASE OIL OR ANY
OIL CONTAINING GASOLINE.
This burner is also available as a low emission burner, and
will have model designation HDSX. Several low NOx rates
are available for all gas and light oil burners, with the stan-
dard offering of 60 ppm, 30 ppm and 20 ppm when firing
natural gas.
Figure A-2 lists the common variations and options avail-
able on this product.
The minimum furnace conditions are given in Figure A-
4. All three furnace criteria must be met, including the
minimum inside diameter (not including the corrugations),
the minimum furnace length (this includes the length of
the turnaround chamber) and the maximum heat release
(which may require a larger diameter or length). These are
general minimum conditions, and certain application test-
ing can allow for special furnace sizes and operation.
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, includ-
ing the part numbers and description for each item.
d. The flame safeguard manual provides the operating se-
quence for the burner management system. This will be a
critical document for troubleshooting any future problems.
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.webstercombustion.com or call 620-221-7464.
Page 7 Section A - GeneralHDS Manual
Figure A-4 Furnace Conditions
BHP Input
Kbtu/hr
Min. Furn.
Length
No FGR 30 & 60 ppm NOx 20 ppm NOx
Min
Furn. Dia.
Max
Heat Rel.
Min
Furn. Dia.
Max
Heat Rel.
Min
Furn. Dia.
Max
Heat Rel.
200 8369 116 26 185000 26 175000 28 165000
250 10461 128 27 185000 28 175000 29 165000
300 12553 138 29 185000 30 175000 31 165000
350 14645 146 31 185000 32 175000 35 165000
400 16738 154 33 185000 35 175000 36 165000
450 18830 160 34 185000 36 175000 39 165000
500 20922 166 35 185000 37 175000 42 165000
600 25106 177 38 185000 39 175000 44 165000

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 HDS 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 sys-
tem and explain the overall operation of the burner.
Page 8 Section B - Component DescriptionsHDS Manual
Gas Manifold
Muffler
Atomizing Air
Bleed Valve
Atomizing Air
Pressure Switch
Gas Pilot
Vent Valve
Atomizing Air
Check Valve
Atomizing Air
Pressure
Gauge
Combustion Air
Proving Switch
Gas Pilot Safety
Shutoff Valves
Gas Pilot
Regulator
Junction Box
Damper
Actuator
Oil Safety
Shutoff
Valves
Air Damper
Oil Metering
Valve
Oil Valve
Actuator
Combustion
Air Motor
Gas Control
Valve
Gas Valve
Actuator
Figure B-1
HDSX General Arrangement, Left Side
(Shown With Optional Linkageless Control)
Head Extension Windbox
Oil Supply
Pressure
Gauge
Oil Pressure
Switch
Mounting
Flange
Gas
Spuds
Firing
Head

Scanner
Pilot
Oil Gun
Assembly Burner Drawer
Backplate
Site Port
Access Cover
to Firing Head Gas Manifold
Pressure Tap
Windbox
Combustion
Air Motor
FGR Valve
FGR Adapter
FGR Valve Actuator
Air Damper
Figure B-2
HDSX General Arrangement, Right Side
(Shown With Optional Linkageless Control)
Oil Line
Ignition
Transformer
Atomizing
Air Line
Page 9 Section B - Component DescriptionsHDS Manual
(Optional) Silencer
Air Damper Oil Metering
Valve Oil Shutoff Valves
Floor Support Couplings
Fan & Motor Assembly
Combustion Air
Motor
Gas Control Valve
Scanner
Tube
Pilot
Oil Nozzle
Diffuser
Gas Spud
Burner
Mounting
Flange
Fuel Cam
Burner Drawer
Scanner Tube
Oil Gun
Air Straightener
Vane
Gas Manifold
Burner Drawer
Access Cover
Gas Manifold
Pressure Tap
Windbox
Head Extension
Fan
Fan Inlet
Cone
Figure B-3
HDS General Arrangement
Air
Oil
Low Fire Damper
Stop
Fuel Cam
Pilot Gas Connection
Oil Gun Tube
Air Straightener Adjusting Tube

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 DescriptionsHDS Manual
1. General
The HDS and HDSX burner lines are configured from a
common group of components that may vary in size and
style depending 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 infor-
mation provided with each burner. This would include the
material list, wiring 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. If the burner is equipped with FGR for
low NOx, the fan will also provide 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. The fan operates at 3550 rpm.
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 has a hub that is machined to match the motor
shaft diameter and key. 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.
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 DescriptionsHDS Manual
1. General
The HDS and HDSX burner lines are configured from a
common group of components that may vary in size and
style depending 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 infor-
mation provided with each burner. This would include the
material list, wiring 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. If the burner is equipped with FGR for
low NOx, the fan will also provide 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. The fan operates at 3550 rpm.
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 has a hub that is machined to match the motor
shaft diameter and key. 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.