Webster Cyclonetic SG Series Guide de l'utilisateur
Webster Combustion Technology
619 Industrial Road, Wineld, 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
SAFETY PRECAUTIONS
Page 2 Safety PrecautionsSG 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.
• 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
Safety Precautions ...............................................................................................................................
A. Introduction ..........................................................................................................................................
Burner Model Number .............................................................................................................
Specications & Sizing ............................................................................................................
Dimensions .............................................................................................................................
B. Installation ............................................................................................................................................
C. Special lnstructions For Canadian lnstallations .....................................................................................
D. Burner Mounting Criteria ......................................................................................................................
E. Fuel Sytems..........................................................................................................................................
F. Start-up & Operating Adjustments ........................................................................................................
G. Trouble Shooting ...................................................................................................................................
H. General Maintenance and Care ...........................................................................................................
I. Care of Burner During Extended Shutdown .........................................................................................
J. Replacement Parts ..............................................................................................................................
K. Warranty Validation & Field Start-up Report ........................................................................................
2
3
4
5
6
7
7
8
9
12
16
18
20
20
20
TABLE OF CONTENTS
A. INTRODUCTION
Page 3 Introduction
SG Manual
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 SG burner requires the
skills of an experienced and properly trained burner techni-
cian. Inexperienced individuals should not attempt to start
or adjust this burner.
Every attempt has been made to accurately reect 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
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 serial number represents the unique number for that
burner and is a critical number that will be needed for any
communications with Webster Combustion.
The input rates dene the maximum/minimum inputs for
that burner, given in MBH for gas. The gas manifold pres-
sure 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 SERIAL NUMBER
GAS INPUT RATING
MBTU/HR IN.WC
MAXIMUM
MINIMUM
FUEL
HP
VOLTS
CONTROL CIRCUIT
BURNER MOTOR
AMPS HERTZ PHASE
DATE MFG.
Cyclonetic
MAX OVERFIRE
DRAFT
BURNER
MOTOR
GAS BTU/CUFT
This manual covers the SG Model CYCLONETIC burners offered by Webster Combustion. These burners cabe used
in a wide variety of Cast Iron, Firebox, Firetube, Flextube and other applications. They re gas with several different
operating systems.
SG8-05 - RM7897C - A.20 - USL/CSD-1
66” Head
88” Head
05 1/2 HP Motor
03 1/3 HP Motor
RM7897C Honeywell RM7897C
MEP235 Fireye MicroM
LMV37 Siemens LMV37
A On/Off
LLow Fire Start
HLo-Hi-Lo
M Modulation
10 1.0” NG Pipe
12 1.25” NG Pipe
15 1.5” NG Pipe
20 2.0” NG Pipe
USL Code UL/CSD-1
CNL Code ULC
The above represents the common model designations.
Contact the factory for other options and special applications.
2. Ratings
The ratings for each specic burner are given on the name-
plate. The general burner ratings are given in Specication
Sheets that follow this section. The maximum inputs are
given. Other conditions, like the supply gas pressure and
control systems, may prevent the burner from reaching the
lowest ring rate.
3. Product Offering
The burner can re natural gas.
Figure A-2 lists the common variations and options avail-
able on this product. The minimum furnace conditions are
given in Section C.
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:
Page 4 Introduction – Burner Model NumberSG 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 components 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 ame 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.webstercombustion.com or call 1-620-221-7464.
Page 5 Introduction – Specications & SizingSG Manual
(1) STANDARD UL EQUIPMENT
AND IMPORTANT OPTIONS
Fuel
STANDARD UL EQUIPMENT
AND IMPORTANT OPTIONS
Fuel
Gas
Gas
General
Motor, Fan and Air Inlet Control X
Gas Fuel
Main Manual Shutoff Valve X
Air Flow Switch X Main Safety Shutoff Valve X
Burner Mounted Control Panel,
Switch and Indicator Lights X Second Safety Shutoff Valve X
Flame Safety Control X Main Gas Regulator X
Ultra Violet Scanner X Gas Checking Valve X
Motor Controller (single phase
voltage) XHigh and Low Gas Pressure
Switches Opt.
Ignition
Direct Spark Gas Ignition X
Direct Spark Gas Ignition
Transformer X
1. The conguration of each unit will vary with specic requirements such as input rating, electrical specication and special
agency approval codes. The above chart shows items standard to a basic burner plus a few options that may be added.
Model SG – Sizing & Application Data (contact Webster for complete information)
Model
Number
Maximum
Furnace
Pressure
Burner Firing
Capability Range
Burner
Motor HP
Gas Train Capacity Ratings
Gas Only
HP
Pipe Size (4) Inlet Pressure Min. Gas
Press. Req
Stand Gas
Train Sz
Max Firing
Rate, MBH
Fan Motor
HP
Gas scfh On-Off, 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 HZ
electrical supply. Use the following corrections for higher temperatures and altitude. Capacity decreases by 17% for 50 Hertz.
Capacity decreases by 4% for each 1000 feet above 1000 foot altitude.
Capacity decreases by 6% for each 1 inch of furnace pressure.
Capacity decreases by 2% for each 10oF increase in air temperature over 90oF.
Gas input ratings based on 1000 BTU/cu ft. and 0.64 specic gravity. Sizes and pressure will vary with gas.
Essential Ordering Information and Data:
Power Supply - Conrm 120-60-1 for control circuit and electrical supply for burner motor(s) (voltage, frequency and phase).
Describe Boiler or Heater to be Fired - Including the manufacturer, model number, furnace pressure and furnace size.
Firing Rate - Dene ring rates in MBH for gas.
Flame Safety Control Preferred - Honeywell or Fireye controls.
Gas Train Components Preferred - ASCO or Honeywell
Control System - ON-OFF, Low Fire Start, Low-High-Low, Modulation
Model SG - Specication Data (400 - 2500 MBH Input)
Page 6 Introduction – Dimensional DataSG Manual
Model SG - Dimensional Data (250 - 2500 MBH Input)
Model SG burners are listed by Underwriters Laboratories, Inc. (UL / ULC).
(Dimensions are +/- 1/4 inch)
* Based o standard burner insertion. For insertion dierent 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 7SG Manual
B. INSTALLATION
Prior to installing the burner, the site conditions and utili-
ties need to be evalulated. This section provides some
general questions that can help the review process.
Inspect the burner for any undetected damage that may
have occurred during shipment or by job-site handling.
Special attention should be given to the control panel
and protruding parts such as linkages. Check linkages,
air louver stops, wiring connections and fasteners for
tightness.
Verify that all ship loose (or separately shipped) items
are on hand. This normally will be: gas train components,
mounting lugs and insulating rope. Also, front mounting
plate, if supplied. The burner material list included with
the instruction manual serves as a good checklist for this
purpose.
1. Is there adequate outside ventilation to supply the
needed air for safe combustion as required by your
local regulatory agency?
2. If a burner mounting plate is required, is it available
and does it meet specications? (See Section E)
3. Is 120-60-1 voltage available for the control circuit
and is the correct voltage available for the blower
motor?
4. Will the burner properly t the boiler or heater with
ample clearance on top, bottom and sides?
5. Will there be adequate gas pressure to assure the
specied ring rate?
6. Are there adequate ue provisions to assure SAFE
and proper venting of the burner?
7. All manuals should be reviewed, understood and stored
in a convenient place.
8. Teon tape should not be used on any eld piping.
9. Rope gaskets should be used between vessel and
mounting plate, and between mounting plate and burner.
10. Gas piping should be ushed (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 conditions.
WARNING
DO NOT USE TEFLON TAPE OR COMPOUNDS
CONTAINING TEFLON. THIS COULD DAMAGE THE
VALVES CREATING AN UNSAFE OPERATION
14. Is the burner mounting plate and burner head sealed
with rope gasket? (See Figure E-2)
15. Has the new gas piping been purged to remove debris?
16. Is there a drop leg in the gas supply to capture foreign
material? (See Figure C-1)
17. Is the piping between the gas train and burner done in
a manner that will minimize the pressure drop?
18. Has all of the piping been pressure checked for leaks?
19. Is the combustion chamber of proper size and is the
center-line height of the burner head adequate? (See
charts C-2 & C-3.)
C. SPECIAL INSTRUCTIONS FOR CANADIAN INSTALLATIONS
1. The installation of a burner shall be in accordance with
the regulations of the provincial installation requirements,
or in their absence, the following shall govern:
Gas Burners--CGAB149.1 and CGAB149.2
Authorities having jurisdiction should be consulted before
installations are made.
2. All electrical wiring shall be done in accordance with th
Canadian Electrical Code, Part I.
3. The installer shall identify (label) the main electrical
power disconnect and the manual shut-off valve on the
gas drop-line to the burner.
4. Gas burning equipment shall be connected to ues
having sufcient draft at all times, to assure safe and
proper operation of the burner.
Installation / Canadian Installation
Page 8 Burner Mounting Criteria
SG Manual
D. BURNER MOUNTING CRITERIA
It is of vital importance that the burner be properly mounted to the boiler or appliance being red. Improper mounting
can cause leakage of the hot gases back around the burner head resulting in warpage and deterioration. The following
illustrations show the proper way the burner must be installed to validate warranty conditions.
TYPICAL SG BURNER REFRACTORY FRONTPLATE
B - Bolt Circle
A - Opening
Minimum of six (6) holes for
boiler mtg. studs, 1/2” or larger
Minimum
7 gauge
Dimensions - Inches
MODEL DIM. A DIM. B
SG6 6 5/8 10 1/8
SG8 8 5/8 12 1/8
4”
A
Minimum
14 Gauge
A Vessel
Specic
Use minimum
of four (4) 1/2”
studs with lugs
Refractory OD is sized to
t 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 (follow vessel
manufacturer’s recommendation)
If gap is over 3/16”, wrap
burner nose with high
temperature ceramic
insulating rope
Tighten clamp bolts
uniformly – check after
ring for several hours
Fiberglass rope
gasket must be
coiled to cover
the full mounting
ange surface
Figure D-2
Burner Mounting Instruction
A
2”
This surface must be
sealed against the vessel;
check vessel mounting
for requirements
This surface must be sealed against the
vessel; check vessel mounting for
requirements
Page 9 Fuel Systems
SG Manual
Illustrated Gas Trains by Capacity and Code: The following illustrations show the Webster conguration for UL,
FM and IRI as grouped by UL capacity ratings. Refer to the legend below for component part identication. These
illustrations are not to be used for eld erection and/or system design purposes.
UL Capacity Range
BTU/Hr.
Operation Mode Webster
Designation
Code Illustration
UL / GE
GAP
FM
To 2,500,000
On-Off A X X 722196
Low Fire Start LX X 722195
Low Hi Low H X X 722197
Modulating M X X 722198
NOTE: Pressure Drops: Pressure drop through a given gas train will vary somewhat in relation to the individual
items used, the specic gravity of the 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
GAS BURNER
MANIFOLD
VENT
VENT TO OUTSIDE ATMOSPHERE
722196
1
4
6
5
4
11
SD
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
Ball Valve
Adjustable Bleed Orice
(35)
Main Diaphragm
Gas Valve
E. FUEL SYSTEMS
UL-FM Low Fire Start Gas Piping Diagram - Up to 2,500 MBH Firing Rate
722195
GAS
SUPPLY
GAS BURNER
MANIFOLD
VENT TO OUTSIDE ATMOSPHERE
1
4
6
5
4
1
SM
7
11
722195
Manual Ball
Valve
Gas Pressure
Regulator
Gas
Supply
Gas
Burner
Manifold
Vent to Outside
Atmosphere
Manual Ball
Valves
Manual
Test Valve
Manual
Test Valve
Gas
Pressure
Regulator
Main Solenoid
Gas Valve
Main Motorized
Gas Valve Manual Ball
Valve
GAS
SUPPLY
GAS BURNER
MANIFOLD
VENT TO OUTSIDE ATMOSPHERE
722197
1
4
6
5
4
7
1
11
SM
Page 10 Fuel SystemsSG Manual
Manual Ball
Valve
Gas
Supply
UL-FM Low-Hi-Low Gas Piping Diagram - Up to 2,500 MBH Firing Rate
722197
UL-FM Modulation Gas Piping Diagram - Up to 2,500 MBH Firing Rate
722198
GAS
SUPPLY
GAS BURNER
MANIFOLD
1
6
44
7
5
VENT TO OUTSIDE ATMOSPHERE
110
722198
1
SM
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 Valve
Main Motorized
Gas Valve Manual Ball
Valve
Manual Ball
Valve
Fuel Flow
Control Valve
E. FUEL SYSTEMS (continued)
Ce manuel convient aux modèles suivants
3
Table des matières
Autres manuels Webster Brûleur
