BECKETT Burner, Furnace Manual L0805076

User Manual: BECKETT BECKETT Burner, Furnace Manual BECKETT Burner, Furnace Owner's Manual, BECKETT Burner, Furnace installation guides

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Fire, Explosion

and Asphyxiation

Hazards

Failure to follow these instructions
exactly could lead to fire or explosion
death, severe personal
injury or property
damage.

and result

1. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appli=
ance.
2. What to do if you smefl gas:
• Do not try to light any appliance.
• Do not touch any electrical switch.
• Do not use any phone in your building.
• Immediately call your gas supplier from a telephone outside the building.
• Follow the gas supplier's instructions.
• Call the fire department if you cannot contact your supplier.
3. Installation and service must be performed by a qualified installer, service agency, or the gas supplier.
6104

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Table of Contents
Please...read this page first
Hazard Definitions .............................................................................................................................................................
To the Owner .....................................................................................................................................................................
To the Installer ...................................................................................................................................................................
Warranty 3
Pre-instatlation checklist .........................................................................................................................................................
Indoor Installation ..............................................................................................................................................................
Combustion air supply .......................................................................................................................................................
Clearances ........................................................................................................................................................................
Fuel gas supply .................................................................................................................................................................
Flue vent system ...............................................................................................................................................................
Electrical supply .................................................................................................................................................................
Figure 1 - Burner nameplate .............................................................................................................................................
Verify burner components ..................................................................................................................................................
Verify firing input range ......................................................................................................................................................
Figure 2 - Minimum combustion chamber dimensions .....................................................................................................
Verify burner air tube assembly .........................................................................................................................................
Figure 3 - Maximum capacity vs furnace pressure, Step spud .........................................................................................
Figure 4 - Maximum capacity vs furnace pressure, Swirler head .....................................................................................
Figure 5 - Burner dimensions ...........................................................................................................................................
Mount the burner ....................................................................................................................................................................
Figure 6 - Custom mounting plate ....................................................................................................................................
Connect gas piping .................................................................................................................................................................
Figure 7 - Typical gas piping layout ..................................................................................................................................
Table 1 - Gas supply piping capacity ................................................................................................................................
Gas trains 9
Figure 8 - UL gas train configuration ................................................................................................................................
Wire the burner .....................................................................................................................................................................
Figure 9- Typical burner wiring ......................................................................................................................................
Sequence of operation ..........................................................................................................................................................
Prepare the burner for start-up .............................................................................................................................................
Start-up checklist .............................................................................................................................................................
General
........................................................................................................................................................................
Gas supply piping ............................................................................................................................................................
Electrical 11
Boiler or appliance ...........................................................................................................................................................
Burner
........................................................................................................................................................................
Figure 10 - CG10 Component familiarization .................................................................................................................
Test instruments ..............................................................................................................................................................
Start the Burner ....................................................................................................................................................................
Burner start procedure .....................................................................................................................................................
Figure 11 - Shutter and band location .............................................................................................................................
Table 2 - Initial burner settings .........................................................................................................................................
Verify input firing rate .......................................................................................................................................................
Figure 12 - Manifold to furnace pressure drop vs rate, Stepped spud ............................................................................
Figure 13 - Manifold to furnace pressure drop vs rate, Swirl vane head ........................................................................
Check operation and safety controls ...............................................................................................................................
Use test instruments to set combustion ...........................................................................................................................
Recommended combustion test sequence .....................................................................................................................
Maintenance and Service
Annual maintenance ........................................................................................................................................................
Figure 14A- Gas Gun assembly ....................................................................................................................................
Figure 14B - Gas Gun assembly ...................................................................................................................................
Figure 15 - Gas Gun assembly installation .....................................................................................................................
For the operator ....................................................................................................................................................................
Table 3 - Periodic inspection checklist ............................................................................................................................
Replacement Parts
Burner exploded view ......................................................................................................................................................
Burner Configurations ...........................................................................................................................................................
Low Rate Burner Configuration; 300 to 800 MBH Applications .......................................................................................
High Rate Burner Configuration; 600 to 1200 MBH Applications ....................................................................................
Burner Configuration Table ..............................................................................................................................................

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3
3
4
4
4
4
4
5
5
5
5
5
5
6
6
6
7
7
8
8
8
9
9
10
10
11
11
11
11
11
12
12
12
12
13
14
14
15
15
15
16
17
18
18
19
20
20
21
22
22
23
24
24
24
25

R08

hera|
Hazard

rrn

ion

Definitions:

indicates an imminently
hazardous situation,
which, if not avoided, will result in death,
serious injury, or property damage.

indicates a potentially
hazardous situation,
which, if not avoided, could result in death,
severe personal injury, and/or substantial
property damage.

To the Owner:
Thank you for purchasing a Beckett burner for use
with your heating appliance. Please pay attention to
the Safety Warnings contained within this instruction
manual. Keep this manual for your records and provide it to your qualified service agency for use in professionally setting up and maintaining your burner.
Your burner will provide years of efficient operation if
it is professionally installed and maintained by a qualified service technician. If at any time the burner does
not appear to be operating properly, immediately__
contact v_o_M_Lqualifiedservice_
o
for consultation.
We recommend annual inspection/service of your
gas heating system by a qualified service agency.

Owner's
indicates a potentially
hazardous situation,
which, if not avoided, may result in
personal injury or property damage.

Within the boundaries
of the hazard warning,
there will be information
presented
describing
consequences
if the warning is not heeded and
instructions
on how to avoid the hazard.

Intended to bring special attention to information, but not
related to personal injury or property damage.

61 04 BCGSO

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Responsibility

Failure to follow these instructions,
misuse, or incorrect
adjustment
of
the burner could lead to equipment
malfunction
and result in asphyxiation, explosion
or fire,
Contact a professional, qualified service agency for the
installation, adjustment and service of your gas burning
system. Thereafter, have your equipment adjusted and
inspected at least annually to ensure reliable operation.
This work requires technical training, trade experience,
licensing or certification in some states and the proper
use of special combustion test instruments.
Please carefully read and comply with the following instructions:
• See the front cover for 'What to do if you smell
gas'.
• Never store or use gasoline or other flammable liquids or vapors near this burner or appliance.
• Never attempt to burn garbage or refuse in this appliance.
• Never attempt to light the burner/appliance by throwing burning material into the appliance.
• Never attempt to burn any fuel not specified and approved for use in this burner.
• Never restrict the air inlet openings to the burner
or the combustion air ventilation openings in the
room.

General
Professional

nforrn
Ir|staller's
Follow

ion

Responsibility
these

Pre-installation
indoor

instructions

checklist

Installation

exactly.
Failure

could lead to equipment malfunction and result in asphyxiation,
explosion or fire.
•
•

•

Protect against
Moisture

to follow these instructions

Please read all instructions before proceeding. Follow
all instructions completely.
This equipment must be installed, adjusted and started by a qualified service agency that is licensed and
experienced with all applicable codes and ordinances
and responsible for the installation and commissioning of the equipment.
The installation must comply with all local codes and
ordinances having jurisdiction and the latest edition
of the National Fuel Gas Code ANSI Z223.1 (NFPA
54) and CAN1=B149.1 in Canada.

Concealed damage - If you discover damage to the burner or controls during unpacking, notify the carrier at once
and file the appropriate claim forms.
High altitude installations- Accepted industry practice requires no derate of burner capacity up to 2000 feet above
sea level. For altitudes higher than 2000 feet, derate the
burner capacity 2% for each 1000 feet above the 2000
feet.
50 Hz motors - The burner ratings, air settings and other
adjustments are based on 60 hz motors at 3450 rpm. De=
rate firing capacity 20% when using 50 hz motors. Consult factory for specific application data.

Dust and

Wet or dusty environments
could lead to blocked
air passages,
corrosion damage to components,
impaired combustion
performance
and result in
asphyxiation,
•
•
•
•

explosion

or fire.

This burner is designed for clean, dry installations.
Electrical controls are not protected against rain or
sprayed liquids.
Keep the installation clear of dust, dirt, corrosive vapors, and moisture.
Protective covers and more frequent maintenance
may be required.
Combustion

air

supply

The burner requires combustion air and ventilation air for
reliable operation. Assure that the building and/or com=
bustion air openings comply with the latest edition of the
National Fuel Gas Code ANSI Z223.1 (NFPA 54). For appliance/burner units in confined spaces, the room must
have an air opening near the top of the room, plus one
near the floor, each with a free area at least one square
inch per 1000 Btu/hr input for all fuel-burning equipment
in the room. For Canadian installations, refer to latest edition of CAN1- B149.1 standard.
If there is risk of the space being under negative pressure,
or of exhaust fans or other devices depleting available
air for combustion and ventilation, the appliance/burner
should be installed in an isolated room provided with outside combustion air.
[3

Clearances

With the burner installed in the appliance, there must be
adequate space in front of and on the sides of the burner
to allow access and operation. Verify that the clearance
dimensions comply with local codes and with the appliance manufacturer's recommendations.
[3

Fuel

gas

supply

Verify that the gas supply piping complies with all appli=
cable local codes and the latest edition of the National
Fuel Gas Code ANSI Z223.1 (NFPA 54).
Insure that the supply gas pipe size is capable of providing at least the minimum pressure required to the burner
gas train inlet at the burner's full capacity rating. Refer to
Table 1.
4

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Table 1

= Burner Specifications
CG25

CGS0

input firing range:
High Fire (Max.)
High Fire (Min.)
Low Fire (Max.)
Low Fire (Min.)
Fuel:

1500 MBH
800 MBH
560 MBH
350 MBH

2700 MBH
1300 MBH
990 MBH
550 MBH

5000 MBH
2000 MBH
1400 MBH
730 MBH

Natural gas z 0.6 Specific gravity typical

Gas Train:
Standard
Options

U.L. Listed / CSD-1 configuration
IRI, FM

Gas Train inlet Pressure:
Minimum
Maximum

10 PSi

&5!' WC*
10 PSi

Manifold pressure:
Highest High Fire
Lowest High Fire

3.7" WC
2.7" WC

3.5" WC
2.5" WC

HighiLow
Modulation
Standard

Flame Safeguard:
Low Fire Start

RM7895A

High / Low
Modulation

RM7895C
RM7895C

HighiL0w
Modulation

Modulation

RM7895C
RM7840L

Standard

Flame Detector:
Standard
Optional
Airflow

Proving

Gas pressure

Switch:

Standard

switches:

Standard high and low

ignition:

Direct ignition of Main Flame

Standard Voltage
Current Draw
OptionalVo!tages

1i2HP
3450 RPM
120 volt, i phl 60 Hz
6.4 Amps @! 20 volt AC
208/230V ! ph 60Hz
208/230VI 3 ph; 60 Hz
460V, 3 phl 60 Hz
575v, 3 phl 60 HZ

120 vo!t, ! phl 60 HZ
!0.4 Amps @!20 vo!t AC
208/230v i ph 60Hz
2081230V, 3 ph, 60 Hz
460V, 3 phl 60 Hz
575v, 3 ph 60Hz

125 lbs.

145 lbs.

Weight:
Dimensions:
*See

165 Ibs.

Refer to Figures

manufacturer's

nameplate

settings

for specific

minimum

gas pressure

3450 RPM
208!230v, 1 ph, 60 Hz
1&4 Amps @230 volt AC
208!230V, 3Phi60Hz
460V, 3 ph, 60 Hz

4 & 5.

requirements.

Figure 1. Burner label location

General model information

Serial number, including date code

_._,_

CC50

}..................
_ _.:_!_
.................... :¢*
_
4. 0

:' ":_'_

I HWii
Rating information
Approval agency symbols

_*_ i_:_c:_::_"_-_'_
_',

(i!i'i_/4

i:_t_: _

R.W. Beckett construction
and setting data
R.W. Beckett specification

..........................................
*; ............
,c

and revision
Boiler manufacturer
(when applicable)

Primary group and fuel

::"

;

,: ,)4

61 04 BCGSO

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number

Additional codes
1

and model

Test For Gas Pipe Leaks
Leaking gas could result in asphyxiation,
sion, or fire hazard.
*
*

*
[3

explo-

The gas supply piping must be absolutely leak-free.
Pressure test the gas piping with air that is at least
three times greater than the gas pressure being
used.
Verify that there are no leaks before proceeding.
Flue

vent

Electrical

Figure 2. Minimum Combustion Chamber Dimensions

Minimum Inside Dimensions
Wdth
'W!

(inches)

Height
'H'

Length
'L' at Min
H & W*

Burner Head
Centerline to
floor 'A'

CG15.1S

CG15.2S

CGIS.3S

CGIS.4S

supply

Check the nameplate on the burner to verify that the power connections available are correct for the burner. Refer
to Figure 1. All power must be supplied through fused disconnect switches and comply with the latest edition of National Electric Code NFPA 70 (Canada CSA C22.1) and
all other local or applicable codes.
[3

Verify

burner

components

Burner model can be checked from burner carton or
rating label on burner
Flange mounting arrangement
(Includes hightemperature gasket and/or fiber rope for pressure
firing)

system

The flue gas vent system must be in good condition and
must comply with National Fuel Gas Code ANSI Z223.1
(NFPA 54) and all other applicable codes having jurisdiction for vent construction, capacity, and sizing.

Burner
Model

Verify

firing

input

range

Refer to appliance manufacturer's instructions (if available) for the firing input range. Otherwise the maximum
recommended firing range for the burner depends on the
length and width of the firing chamber and the distance
from the burner center to the chamber floor. Verify that the
chamber dimensions are at least as large as the minimum
values given in Figure 2. If the appliance dimensions are
smaller, reduce the firing rate accordingly.

Flames are shaped by their furnaces and by its flue locations. Increased height and width can decrease the
length requirement. When shaping is too severe flames
impinge on the walls. Impingement causes CO and carbon deposits and may damage the wall. Maintaining
these minimum dimensions should prevent impingement,
but smaller furnaces may be acceptable depending upon
the results of applications testing. We recommend factory testing of all new burner/furnace combinations by the
furnace manufacturer and/or R. W. Beckett Corp.

NOTICE

CGS0.1S

CGS0.2S

CGS0.3S

CGS0.4S

CGS0.SS

NOTICE

]

Dimensions shown are for cast iron sectional boilers with
uptakes between sections. For minimum dimensions of
other furnace types consult R.W. Beckett Corporation.
6

The volume of the furnace also influences the combustion process. R. W. Beckett Corp. recommends at least
1 cubic foot of furnace volume for each 150,000 BTU/Hr
of firing rate.
[3

Verify
e

burner

air

tube

assembly

The information in this section may be disregarded
if the burner supplied by the appliance manufacturer
is a matched component.
Maximum firing capacity depends on the furnace
pressure. Use the charts shown in Figure 3A, Figure 3B, and Figure 3C, to verify the correct burner
configuration for the input rate.
Refer to Figures 4 & 5 to verify the air tube assembly length and mounting insertion dimensions.
61 04 80G50

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Figure 3A. Maximum

Capacity (at 3% 02) vs Furnace Pressure - CG15

1500

L
1400

1300

=
4,

"3"
m

C G 15.4S

- 1200

_CG15.3S
= A -CG15.2S

¢,t-'

m A

_::

_ CG15.1S

1100

lOOO

9OO
0

0.2

0.4

0.6

Furnace

Figure 3B. Maximum

Pressure,

0.8

In. WC

Capacity (at 3% 02) vs Furnace Pressure - CG25

26OO
2500
2400
2300
I
m

--'._-2200

CG25.5S
_CG25.4S
_ CG25.39

2100
_'::
2000

_ CG25.2S

--_¢: - CG25.1S

1900

1800
1700
0

0.2

0.4
Furnace

Figure 3C. Maximum

0.6
Pressure,

0.8

In. WC

Capacity (at 3% 02) vs Furnace Pressure = CGSO

5OOO

4500

_CG50.59

-1-

_ 6G50.4S
4000

A = CGS0
-""_:-

CG50,28
- CGS0,1S

35OO

3OOO
0

0.2

0.4
Furnace

61 04 BOGS0

R08

0.6
Pressure,

0.8

In. WC

Figure 4. Burner Dimensions

F
E

_I_ LL

HPL

I tI_Li_U

_i)l_£t',_S_©_S ARE bi_!N_:HE$

Figure 5. Panel and Modulating

Valve Dimensions

THREAD

6104

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urneF

Figure 6. Custom Mounting

Plate

Mount the burner to the appliance. The burner specified
for packaged equipment will have a flange welded for the
required insertion. Follow the appliance manufacturer's
instructions for mounting.
In the absence of instructions, or for retrofits, make sure
that the air tube insertion dimension, measured along the
side of the air tube from the welded flange to the end of
burner air tube, is correct.

_!
___________________________________________________________________________________________________________
Overheating
Key:
Overheating
could cause damage to the air tube
A Burner mouning flange
and other combustion
components
leading to
B Gasket
equipment
malfunction
and impaired
combusC Appliance mounting plate
tion performance.
•

•

The end of the air tube must not extend into the combustion chamber unprotected unless it has been factory-tested and specified by the appliance manufacturer.
The end of the air tube should be set back ¼" from
flush with the refractory inside wall to prevent damage from overheating.
Refer to the instructions outlined in this section for
methods of additional protection.

If this dimension cannot be achieved, protect the
end of the air tube by installing a suitable ceramic
refractory material such as a refractory mill board
capable of withstanding at least 2300 degrees F.
The entry hole diameter in the appliance should be
1" larger than the air tube to facilitate ease of installation and provide adequate protection.
Referring to Figure 6, if the front plate opening (C) in
the boiler is larger than the burner flange bolt circle,
then a custom mounting plate (A) of at least 1/4"
thickness must be used with a suitable high-temperature refractory material anchored on the fire-side. A
suitable high-temperature gasket (B) must be used
for an effective seal.

Connect

NOTICE

The gas supply system must be sized to deliver at least
the minimum required pressure to the gas train inlet. Contact your local gas utility for verification of gas pressures,
allowable pressure drops, and any local piping code requirements. Refer to Figure 7 for an illustration of a gas
piping layout and refer to Table 1 for pipe sizing.

Do Not Use Teflon
on Gas Piping
Damage
ies could

to gas valve cutoff
cause

ation, explosion
•
•

Verify that the air tube is ¼" back from flush (see
Figure 2), and there is nothing blocking the flame
zone that could cause flame impingement.

•

RoB

All gas piping installation must comply with the latest edition of the National Fuel Gas Code ANSI Z223.1 (NFPA
54) and other applicable local codes.

Attach the plate and gasket to the boiler and tighten
the mounting nuts or bolts securely.

61 04 80G50

ipin!

Tape

seals and valve bod-

gas leaks and result

in asphyxi-

or fire.

Pieces of tape can be cut loose during installation and
lodge in gas valves causing cutoff seal problems.
Teflon tape 'lubricates' pipe threads, allowing iron
pipes to penetrate too deeply into aluminum valve
bodies causing distortion and leakage.
Use only pipe sealant compounds that are resistant
to the gas being used.

Install

Optional - Gas trains for IRI and FM are available and
must be specified when ordering a burner.

a Drip Leg in

Gas Supply Piping
Verify- Verify that the train components are not damaged
and all piping and fittings are clean inside and out. The
gas train is normally shipped as components and must be
assembled and installed at the site.

Foreign matter could lodge in gas
valve cutoff seals, resulting
in gas
leak-through,
explosion or fire.
Install a full-size drip leg or dirt pocket in the piping directly ahead of the main shutoff valve to capture foreign
matter.
O

Gas

Vent lines - Install vent lines to any gas valve component that requires atmospheric air pressure to balance
a diaphragm. Vent lines must be run to the outdoors,
with the termination point away from fresh air intakes and
windows. The terminal opening must be fitted with a wire
mesh screen to block insects and other contaminants
from entering the vent and must be mounted in such a
position that water, ice, dirt, or any other foreign matter
cannot infiltrate and block the vent piping. Make sure the
final assembly is anchored securely.

Trains

Standard -An Underwriters Laboratories (UL) listed gas
train is standard for the CGI0 gas burner. This configuration also meets CSD-1 requirements. See Figures 8A
and 8B for typical component layout.

Figure 7. Typical Gas Piping Layout
ABBREV,
HGPS
LGPS
MSC
MLTC
PG
S
SSOV1
TC
U
2PRV

LGPS

REGULATOR PG

DRIP LEG

ITEM DESCRIPTION
HIGH GAS PRESSURE
SWITCH
LOW GAS PRESSURE
SWITCH
MAIN SHUTOFF
COCK
MAIN LEAK TEST COCK
PRESSURE GAUGE
STRAINER
SAFETY SHUTOFF
VALVE #1
TEST COCK
UNION
TWO POSITION REGULATING
VALVE

HGPS

s
(IF USED)

Table 1. Gas supply

piping

capacity

Schedule 40 metallic pipe with 0:50 psi or less inlet pressure and 0:30" w.c: pressure drOp
Maximum capacity in cubic feet of gas per hour (CFH). Natural gas with 0:60 specific gravity. Pipe size (inches) IPS

-F;Tr;e:ien;i777
(feet)

0175"

278

30
50

90'

90
125

15o

175

11O

i70

59
55

160
"
130

"120
110
i00

1100

2.5'
3050
2100

800

1650

760

1450"

3!0;'

4800
x

3300
2700

4:0'

8500
"

5900
4700

2300

67O

1270

2000

3600

610

,1150

i850

3250

370

560

1050

1700

3000

350

530

320

490

400

180

!50

730

44O

! 95

84
79

1600

590

215

1050

500

245

lO5

2oo

285

115

1oo

520

152

13o

:77777:-77-T::7
====================

1;5"

90"350

:::::::::::::::

305
275

250

460

990
930
' 870

410

780

380

225

350

210

320

710
_

1600

2800

17500
"

t2000
9700
8300
7400

"i 6800
6200
5800

1500

2600

,1400

2500

5100

1250

2200

4500

2000

4,1oo
3800

,1130"

650

1050

1850

6i0

980

1700

5400

3500

61 04 BCGSO

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Figure 8A. UL gas train - High/Low

and Low Fire Start

LGP_

MSC

HGPS

8SOV_

2PRV

MLTC

LGPS

MSC

ABBREV.
HGPS
LGPS
MSC
MLTC
PG
S
SSOV1
SSOV2
TC
U
2PRV

HGPS

ITEM DESCRIPTION
HIGH GAS PRESSURE SWITCH
LOW GAS PRESSURE SWITCH
MAIN SHUTOFF COCK
MAIN LEAK TEST COCK
PRESSURE GAUGE
STRAINER
SAFETY SHUTOFF VALVE #1
SAFETY SHUTOFF VALVE #2
TEST COCK
UNION
TWO POSITION REGULATING VALVE

Figure 8B. UL gas train =Modulating

i ;i!ili!i!iiiii!iliiiiiiiiii ili!i
U

PRV

_OV_

_0_

M_YC:

M'V

Pipe Size
1"
1-1/4"
1-1/2"
2"

Install the burner and all wiring in accordance with the
National Electric Code ANSI/NFPA 70 (Canada CSA
C22.1) and all applicable codes and requirements.
Wire the burner in compliance with all instructions and
diagrams provided by the appliance manufacturer. Verify
operation of all controls in accordance with the appliance
manufacturer's guidelines.

Do Not Bypass
Controls

Safety

Electrical
Electrical
personal

•
•

Tampering
with, or bypassing
safety
controls
could lead to equipment
malfunction
and result
in asphyxiation,

•
•

Maximum Length
12"
15"
18"
24"

rner

•

When pressure reducing safety shutoff valves are used,
the distance from the final shutoff valve (2PRV in Fig. 8) to
the burner manifold must be kept to a minimum for good
light-off reliability• R.W. Beckett recommends the following
maximum lengths:

•
_

NOTICE

explosion

or fire.

Safety controls are designed and installed to provide
protection.
Do NOT tamper with or bypass any safety control.
If a safety control is not functioning properly, shut off
all main electrical power and gas supply to the burner
and call a qualified service agency immediately.

•

shock
injury

Shock
can

Hazard

cause

severe

or death.

Disconnect electrical power before installing or servicing the burner.
Provide ground wiring to the burner, metal control
enclosures and accessories. (This may also be required to aid proper control system operation.)
Perform all wiring in compliance with the National
Electrical Code ANSI/NFPA 70 (Canada CSA C22.1)

Keep
Covers

Service

Access

Securely

installed

These covers must be securely
in place to prevent electrical
shock, damage from external
elements, and protect
against
injury from moving
parts.

NOTICE

See Figures 9A & 9B for typical wiring diagrams, with the
flame safeguard control, for reference purposes only.
Check the literature that was packaged with the burner for
the primary control manufacturer's instructions and the
exact wiring diagram for your specific burner.

61 04 BCGSO

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All covers or service access plates must be in place
at all times except during maintenance and service.
This applies to all controls, panels, enclosures,
switches, and guards or any component with a cover
as part of its design.

11 11

Sequence
- (typica|

for RM7895C

of Operation
flame

safeguard

primary

control)

Initiate-The
primary control enters the INITIATE
sequence when the control is first powered on or
power returns after an interruption. The initiate
sequence is a ten second delay during which the
control verifies line voltage stability.

6. Flame Stabilization - The burner will operate in
low fire for 10 seconds before initiating high fire.

Standby - The control enters STANDBY until the
limits, operating limit control, burner switch, and
all microcomputer-monitored
circuits are in the
correct state.

Prepurge - The control will signal the PREPURGE sequence when the airflow interlock and
all switches are in the correct state. The Prepurge
sequence is the amount of time the blower motor
runs prior to the ignition start sequence. Timing
for the Prepurge sequence is determined by a
card mounted inside the control module (typically
30 seconds).

Run - With a flame established and the control
continuing to detect a flame, the burner will operate in the RUN mode until the load demand is
satisfied or a limit opens.

3. Load demand - Operating limit control contacts
close on drop in temperature (or pressure) and
initiates the start sequence.
.

Trial for ignition (TFI) - After the Prepurge sequence has timed out, the ignition and main gas
valves will be energized.
Because the burner
has direct spark ignition for the main flame, the
flame must be established and detected by the
control within 4 seconds or lockout will occur.

Load Satisfied - The burner switches to idle until the next call for operation.

This operation sequence is typical and for reference only.
The primary control could vary, depending on the customer specification and code requirements. For the specific operating sequence that applies to your installation,
consult the appliance manufacturer's directions, wiring instructions, and control manufacturer's literature supplied
with your burner.

Figure 9A. Typical wiring using Model RM7897C for High/Low

Control (for reference only)

L£G_ND:

i|
|
|

I 2

if717Sl_.f

I
|

@_ _

G_4@

_OVl_}#

_'_ & _04:_

$ _,_

6104

80G50

RoB

Figure 9B. Typical wiring using Model RM7840L for Modulating

Control (for reference only)

++7+++L

Prepare

burner

for start-up
,

Professional
Incorrect

and Service

Required

installation

and mishan-

dling of start-up
ment malfunction
asphyxiation,
•

•

Installation

could lead to equipand result in

explosion

Start-up
check|ist
- Verify the following
fore attempting to start the burner.
!:tO8

Carefully read and become familiar with the
manual, flame safeguard control instructions, sequence of operation, pertinent wiring diagrams,
gas system layout, insurance requirements, other
controls and valve literature pertinent to the installation.

or fire.

This burner must be installed and prepared for startup by a qualified service technician who is trained
and experienced in commercial gas burner system
installation and operation.
Carefully follow the wiring diagrams, control instruction sheets, flame safeguard sequence of operation,
test procedures and all appliance manufacturer's directions that pertain to this installation.
If any of these items are not clear or are unavailable,
call Beckett at 1-800-645-2876 for assistance.

61 04 BCGSO

General

be-

[El Follow the appliance manufacturer's
cedures (when available).

start-up pro-

Inspect the combustion air supply and exhaust
venting and verify that they are free of obstructions and installed and sized in accordance with
all applicable codes.

Notify appropriate personnel to schedule startup (gas utility, owner, operators, subcontractors,
etc.).

Gas Supply Piping
[El Insure that the gas piping is properly sized and
has been inspected by the gas utility, leak tested
at all joints, and purged.
[El To protect the gas train and controls, insure that a
drip leg or dirt pocket has been properly installed.
113

Insure that the fuel gas being supplied is compatible with the burner specification and is available
at the correct regulated pressure. (See burner
name plate and specification sheets).

Insure that the vent lines for the diaphragm valves
have been run to the outside and properly terminated.

Electrical

E3 Insure that all wiring has been completed and
complies with the National Electric Code NFPA 70
and local requirements.
E3 Refer to Figure 1 and verify that the electrical supply to the burner matches the voltage specification on the label.
4.

Boiler or Appliance
CI

Fill the appliance with water (boilers).

CI Check all safety and operating controls for correct
application, installation, wiring, and operation.
CI

Insure that the maximum capacity of the appliance is compatible with the specified burner input
firing rate.

Burner - See Figure 10 for familiarization
CI

114,

Refer to Table 2 and Figures 11A and 11B to insure that the burner air damper is positioned for
initial start-up preliminary settings.

Insure that the burner is securely mounted in the
appliance with the pressure firing plate and all
gaskets in place for pressurized chamber applications.

Before operating insure that all protective cover
plates, enclosures and guards are in place and
securely fastened.

When available, refer to the appliance manufacturer's instructions and install the burner accordingly.

Test instruments
CI

Insure that the flue passages and combustion
area have been thoroughly cleaned and are in
good condition.

CI Set the breech damper to the required position for
system operation.
CI

Insure that the gas burner model and capacity
meet the requirements for the installation.
Insure that the gas train meets operating specifications, all safety codes and insurance requirements.

The following calibrated test equipment is required
to properly install the appliance. Whether these
are included in one kit or are individual test components, they should be calibrated and in good
working order.

CI A combustion analyzer capable of measuring oxygen (or carbon dioxide), carbon monoxide, stack
temperature, ambient temperature, and appliance
efficiency.
CI

Electrical multi-meter capable of measuring voltage, ohms, amps, and DC micro-ammeter for
measuring the flame signal.
These could be
included in one meter or separate meters, but
should be calibrated and accurate.

Calibrated manometers and gauges capable of
measuring all pressure ranges in the gas supply
and appliance draft. This could typically range
from a few psi to 0.01" W. C.
Having several manometers or U tubes with the
correct range can simplify the testing and set up
procedures.

6104

BOG50

R08

Start

the

Burner

Professional

installation

and Service
Incorrect

installation

dling of start=up
ment malfunction
asphyxiation,
•

•
•

•

[:3 Burner start procedure=
(Before proceeding,
turn off and lock out electrical power and close the
main leak test cock to shut off gas to the burner.)
1. With the power and main gas supply to the burner
turned off, make sure gas has not accumulated in
the boiler or flues.

Required
and mishan=

could lead to equip=
and result in

explosion

or fire.

This burner must be installed and prepared for startup by a qualified service technician who is trained
and experienced in commercial gas burner system
installation and operation.
Do not attempt to start the burner unless you are fully
qualified.
Do not continue with this procedure until all items in
the 'Prepare the Burner for Start-up' section have
been verified.
Carefully follow the wiring diagrams, control instruction sheets, flame safeguard sequence of operation,
test procedures and all appliance manufacturer's directions that pertain to this installation.
If any of these items are not clear or are unavailable,
call Beckett at 1-800-645-2876 for assistance.

Figure 10. Component

Famifiarization

(CG50 shown,

Check the initial air settings for the input firing
rate. Check the manufacturer's settings either on
the nameplate shown in Figure 1 or listed in Table 2. If adjustment is necessary refer to Figures
11A& 11B and set the damper motor cam so that
the indicator points to the values shown on the
nameplate or listed in Table 2.
With the main gas supply valve closed. Set the
limit or controller to call for heat then apply power
to start the burner. Reset the high and low gas
pressure switches if necessary.
In order to check the function of each component
(i.e: flame safeguard sequence, airflow proving
switch, ignition transformer, gas valves, safety
lockout timing, etc.), with the gas supply closed
off, monitor a complete burner run sequence.
Note that the flame safeguard control will lock out
since the fuel supply has been closed off.

CG15 & CG25 similar.)

Major Components:
1.
2.
3.
4.
5.

Damper Motor
Primary Control
Blower Motor
Ignition Transformer
Gas Gun Assembly

61 04 BOG50

R08

6. Air Flow Proving Switch
7. High Gas Pressure Switch
8. Test Connection
9. UV Scanner

115

If component operation sequence and function is
correct, reset the flame safeguard and initiate a
new cycle. Monitor the start-up cycle and manually open the main leak test cock as soon as the
flame safeguard powers the safety shutoff valves.
If the boiler room is quiet you may be able to hear
the valve open, if not you can generally place
your hand on the valve and feel it open. After
you have observed main flame for a brief time,
trip any of the switches in the limit string to shut
the burner down. Monitor the flame and safety
shutoff valves to assure that shutdown is controlled by the valves and that they operate properly. With this test passed you may safely initiate
automatic start-ups on subsequent cycles.

Initial

air settings

Figure 11A. Damper Motor with Cover
B

Figure 11B. Damper Motor

The following steps outline the procedure for initially setting the damper. Refer to Figures 11Aand 11B and Table
2 for this procedure.

1. Remove the cover screw (A) then the cover (B)
and place to one side.
.

Using the wrench (C) supplied with the damper
motor, adjust the blue Low fire cam (D) to the initial setting listed in Table 2. The appliance manu=
facturer's literature will provide furnace pressure
data.

3. Using the same wrench, adjust the red High fire
cam (H) to the initial setting listed in Table 2.
4. Ensure the damper plate is in the correct position. The cam notch (E) should align with the Low
fire setting on the damper motor scale (F).
.

Legend (Figures 11A& 11B)

If the damper plate is not in the correct position,
disengage the motor by pushing in on the motor
pin (G), then rotating the damper plate until the
cam notch and motor scale setting are aligned.
Re-engage the pin.
On High/Low units only, use a small straight edge
screw driver, turn the white adjustment screw, located in the orange transition cam, either clockwise or counterclockwise until the cam indicator
is half way between the high and low settings on
the scale.
NOTICE

A
B
C
D
E
F
G
H
J

Cover screw
Cover
Wrench
Low fire cam (blue)
Cam notch
Damper motor scale
Disengaging pin
High fire cam (red)
Transition cam (orange)

The damper plate is attached by screws to its shaft, and bears against a flat on the shaft for alignment. The shaft is
secured to the damper motor by a sleeve coupling with two setscrews bearing against the damper shaft and two more
against the motor shaft. The motor shaft has a flat matching the one on the damper shaft. The flats on the damper
shaft and the motor shaft should be aligned so that the position indicator in the damper motor reads accurately. The
best way to align the flats is to tighten the setscrews that bear against the flats on the shafts first, and then tighten the
ones that bear against the round surface of the shafts afterward.
The test for proper alignment is to disengage the damper motor from its shaft using the disengaging pin (Item G in Figure 11B) and
rotate the damper plate to its full closed position. The position indicator should point to 0° within +/- 5° tolerance.

116

6104

BCGSO

RoB

Optional
Modulation
instructions

Linkage

Adjustment

Figure 12B. Modulation Assembly
LEFT HANDED

The optional modulation linkage assembly has been designed as an economic means to adjust the damper and
the butterfly valve to maintain air to gas ratios. When the
optional Modulation linkage assembly is supplied with the
burner, initial adjustments will be made at the factory. To
ensure optimum operation, minor additional adjustments
must be made after the burner is fired on a boiler.

GAS ENTRY

Sta_da_ Construction
*CG_

SHOWN

o C@25 AND CG15 ARE 8_MtLAR

' Valve Shaft

The following adjustment will be pre-set at the factory, but
may require minor adjustment at start-up:
• The damper motor high fire and low fire cams will
be preset
• The linkage between the damper and the butterfly
valve will be preset as illustrated in the manual.
• The butterfly valve shaft will be set to a nominal position.

Figure 12A. Modulation

RIGHT

HANDED

Assembly

GAS, ENTRY

Opt_ona! Censtructien
_CGS0 SHOWN o CG25 AND CGt5 ARE SIMILAR

!utterly

Va|ve Sha_

Adjustment

Procedure:

Referring to the appliance manufacturer's literature, insure
that all preliminary adjustments and calibrations required
for the burner and appliance have been performed.
A) Prior to starting the burner
1. Verify that the damper motor high fire and low fire
cam settings match the nameplate (Figure 1) or
Table 2.
2.

Examine the linkage for signs of damage.

3. Referring to the illustrations in Figures 12A or
12B, verify that the linkage is installed as shown.
4. Prior to adjusting the burner, have available all
the necessary test equipment.
• A manometer to check pressures downstream
of the gas pressure regulator; at the manifold
pressure test connection and in the furnace
• A draft gauge to check breeching pressure
• A flue gas analyzer that can measure 02 (or
CO2) and CO.

61 04 BOGS0

RoB

11"2'

5. Adjustthegaspressureregulator
toabout½"WC
higherthantheanticipated
highfiregaspressure
(seeTable2).

iVlodulation

6. Topreventthe burnerfrommodulatingto high
fire,setthe modulation
controllerto the manual
controlmode. If necessary,
referto the manual
suppliedwiththe modulation
controller.

Control
Figure 13C. Manual Operation

Figure 13A. Display Meaning

Operation

mode:

Once in Manual Mode, the
damper motor can be driven from
high to low using the up/down
arrows.

ACTUAL VALUE
(CURRENT OPERATION

SET
BURNER RELEASED

WHEN LIT
DAMPER OPENING

DAMPER CLOSING
(MODULATE DOWN

•

(MODULATE UP)
INCREASE VALUE

Modulation of the burner's firing rate is accomplished
by driving the damper motor in small increments to
either increase or decrease rate in response to boiler
demand. A pressure transducer (for steam boilers)
or temperature sensor (for water boilers) senses
boiler demand and communicates it to the controller.
Display and programming functions for the Siemens
RWF40 controller are shown in Figure 13Awith the
controller in the basic display mode.
Figure 13B. Manual Mode
Putting
-

in manual

light

will

The damper motor can be manually operated for
set-up and service of the burner by placing the controller in the manual mode, as shown in Figure 13B.
Press and hold the EXIT button for 10 seconds to
enter the manual mode. The manual operation light
will illuminate.

To return to the automatic mode,
press and hold exit button for ten
seconds.

The damper motor can be driven from low to high or
high to low by pressing the up and down arrows as
shown in Figure 13C. Pressing EXIT for 10 seconds
returns the controller to the automatic mode.
Figure 13D. Operation

Set Point

Setting

operation

set point:

•

From the original display, press
program
button
once.
(user
level)

•

Set point 1 is displayed

•

Use up/down arrows to change
setting.

•

When finished, press exit

mode:

Press and hold exit button for
10 seconds.
Manual operation
uliminate.

118

in manual

The operating set point can be changed as shown
in Figure 13D. Pressing the PGM button accesses
the User Level of the software, where this change
is made. The up and down arrow buttons raise and
lower the operating set point. Pressing EXIT returns
the control to the Basic Display level and saves your
changes.
Programming functions within the software are used
to match its settings to the connected hardware, and
to adjust the control's response to unusual job site
requirements if necessary. A manual for the controller is provided with the burner to allow programming
at that level.

6104

BCGSO

R08

B) At burner start=up - Note, as soon as the burner
lights, be prepared to adjust the butterfly valve to
set the low fire rate adjustment.
.

Monitor the flame through the observation port.
If it appears to be too rich (yellow-orange flame),
move the butterfly valve shaft slot setting toward a
more vertical position. (This adjustment is made
by turning the nut holding the spring-loaded swivel on the butterfly valve arm. If insufficient adjustment is available by this method the butterfly
valve shaft can be repositioned in the arm. Care
must be taken to make only small changes.)
Use a flue gas analyzer to check the flue gas rat=
ings for 02 and CO. Your target should be 4% 02
and CO should be well below 50PPM. (Note that
the CO is usually near 0 at 4% 02. )

3. If the 02 and CO levels are not on target, turn the
low fire adjustment nut as required to meet the
target listed in Step 2.
.

Check the low fire rate. Either clock the meter
or compare the manifold pressure drop to factory
standards. Adjust the low fire cam setting in the
damper motor (if necessary refer to the Initial Air
Setting procedure described previously) and the
butterfly valve shaft slot position as described in
Step 1. Refer to Step 2 and double check the 02
and CO readings.

5. When low fire is set, use the modulation controller to manually step the burner up to its high fire
rate.
.

6104

Check flue gas 02 and CO. Your target should
be 3% 02. CO should be well below 50PPM, and
is usually near 0 for that 02. Adjust the regulated
gas pressure as required to meet the target.

Check the high fire rate and adjust the high fire
cam setting and regulated gas pressure as re=
quired to meet the target. (If necessary, refer to
the Initial Air Setting procedure described previously.)

Using the modulation controller, manually step
the burner back down to low fire and verify the
02 and CO ratings. If the high fire adjustments
were significant they may have affected the low
fire settings as well. Refer to Step 4 in this procedure to make adjustments as necessary.

BCGS0

ROB

Using the modulation controller, manually step
the burner through its range, stopping at several
points to check 02 and CO measurements.

10. After you are satisfied with the modulation linkage adjustments secure all linkage fasteners and
continue the start-up procedure.

It is acceptable for a burner with linkage control of the fuel
to show 2% variation in 02 through the range as long as
02 stays above the target points. If the 02 drops below
the target points it may lead to a CO problem. Moving the
damper arm position on the damper shaft changes midrange 02 . Loosening the clamping screws and moving
the swivel end of the arm downward increases midrange
02 , upward decreases it. This change will affect the low
fire 02 setting, and you'll need to re-set it.

Verify

input

firing

rate:

Clock the meter, correct for pressure and termperature to get SCFH and calculate the input firing rate. Compare the calculated rate to the specified input for the boiler found on the specification
sheets and on the rating plates for the burner and
boiler. Do not exceed the specified maximum input for the boiler.

Attach a manometer to the manifold test port,
clock the meter, and adjust the regulated pressure until the specified input level is achieved.
Refer to Table 2.

3. Be sure to set the breech or furnace pressure to
the correct value, since this will have an effect on
the manifold pressure.

119

Table 2. Initial burner

settings

...............................................................................................
L;ur P=ssu
ce at,,0h
e F, e
...........
O" W.C.

0.25" W.C.

0.50" W.C.

1.00" W.C.

8
E
C_3

800
900

468
"

950
1050

CG15.1S
I

548
i

548

1150
'i250

468

641

1300

750
750

0:9

CG15.2S
I

" 64i

1400

0.9
I

CG15.1S

0.9
II

CG15.2S

0.9

i350 "669

2.6

'312

1700

2.9

1.1
I

34
33

314'

1.1
1.0

0.9

3.1

1.0

_ 0:9

u 17

316

I i10

0.9
I

CG15.4S

019

20
I

CG25.2S

017

2.7
I

1:0

"2.7j 38

0.7

3.1i
2.7

3.2

'217

2000

896

CG25.3S

0.7

3.3

cG25.4s

1037

CG25.4S

017
0.7
I

1.0

i037

31i

' 2.8

3.4

0.6

2.5

CG25.5S

0.6

3.0

mmm

0.7

0.7
I

0.7
0.7

'0i7
100

3.3

3.0
3.4

0.7

2.9
I

017

0.7

CG25.5S

21
I

0.7

9
I

66
I

1.0

27
I

3.1

1.3
I

37
36

3.7 58
17
I i7
22

3.3

318

112

0.8

219

3.6

4!2

3.8

317

1.2
.

'&9

0.8

i7
17

3.2
3.6

0.9

018

I 3.2

I 43

4.1

I 0.9

I 23

I 3.7

" 46

4.2

3.7

0.8

3.7

0.9

2.9

....
0.8

3.2

0.9

3.6

0.8

3.8

0.9

71'018
93

3.4

3.1

31
I

414

1.2

3.7
I

1.1

3.2

10
I

100

3.2
3.9

'i:o'

0:7

1200

o:9

26
I

3.7

3.3

0.7

2500

0.9

2.9
Ii

2.8

12400 i2oo

9
I

CG25.3S

2300

110

896

'2100

1.0
II

0.9

CG25.2S

774

0.9

1800

25
I

CG15.3S

cc25._s o.7

774

314

1450 669 CG25.!sI0.ZI!T
i550

2.7
i

CG15.3S

CG15.4S
I

9
I

3.6

0.8

2!8 ioo 08

3.2

3.3
3.9

4.3
I

0.9

78
I

3.8

102

310 ii5

115

mmmmmmmmm

mmmm

CG50.1S
CG50AS
CG50.2S

cG5oi2s
CG50.3S
CG50.3S
CG50.4S
CG5&4S
CG50.5S

CG5O15S
CG50.5S
Gas pressures are as measured at the manifold test connection.
Notice:

The settings

in this

merit by the fully qualified

chart are for reference
and experienced

only.

start=up

The actual

conditions

at the installation

may require

further

adjust-

technician.

6104

80G50

R08

Estimating

Rate

Manifold to Furnace Pressure information can be used to estimate the burner's firing rate when it is not possible to clock
a meter for the rate.
To estimate the burner's firing rate:
• Measure the furnace pressure over fire
• Measure the manifold pressure (at the manifold pressure test connection in Figure 10).
• Subtract the furnace pressure from the manifold pressure
• Compare the result to the data in Figures 14A, 14B or 14C as appropriate for your burner.

Clocking

a gas

meter

Before you clock the meter you must make sure that the burner is operating at a steady rate, and that it is the only
thing that is using gas that would flow through the meter.
Uncorrected
flow
rate
• Locate the dial that moves the fastest and determine how many cubic feet are represented by one revolution of
its dial.
• Use your watch for timing and observe how many cubic feet are used in one minute.
• Multiply by 60
Example: The dial is a one cubic foot dial, and goes around 7 ½ times in one minute. That gives 7.5 cubic feet per
minute. Multiply by 60 to get 450 cubic feet per hour (CFH) as your uncorrected flow rate.

Pressure

correction

Gas is compressible, the higher the pressure on it, the smaller the number of cubic feet it occupies. To correct for
that you will need to know the gas pressure at the meter.
• If there's a gauge at the meter, read it while the gas is flowing. (If not, measure the gas pressure in the line downstream of the meter before any valves or regulators, with no gas flowing.)
• Convert the gas pressure to PSI if you measure it in any other units. (1 PSI = 27.7 inches water column)
• Add 14.7 to the meter pressure, divide their sum by 14.7, and multiply that result times the uncorrected flow rate
to obtain the pressure corrected flow rate.
Example: The meter in the example above is operating at 14" WC.
14 / 27.7 = 0.5 PSI at the gauge; 14.7 + 0.5 =15.2; 15.2 / 14.7 = 1.034 correction factor;
1.034 x 450 = 465 CFH corrected for pressure

Temperature

correction

Gas volume also changes with the temperature of the gas. Most gas meters are temperature compensated. They
say so on the face of the index and don't require temperature correction. The temperature we correct to is 60 ° F.
That's close to the temperature of the ground, so usually it's not necessary to correct for temperature from underground lines.
• Measure the gas temperature at the meter.
• Add 460 to the gas temperature and divide 520 by the result to obtain the correction factor.
• Multiply the pressure corrected flow rate times the temperature correction factor.
Example: The meter in the example is connected to an above ground line on a hot day and shows 100 ° F gas
temperature.
460 + 100 = 560; 520 / 560 = 0.929; 465 x 0.929 = 432 CFH corrected for pressure and temperature.
NOTICE
BTU's

and

MBH

The BTU content of natural gas varies from one location to another, and even from day to day at a fixed location. For
firing estimates it is usually assumed to be 1000 BTU's per standard cubic foot.
To calculate BTU/Hr firing rates multiply SCFH times 1000.
Example: 432 SCFH x 1000 = 432,000 BTU/Hr.
MBH stands for thousands of BTU's per hour. Since 1 cubic foot of natural gas contains 1000 BTU, 1 MBH equals 1
SCFH of gas flow.
Example: 432 SCFH = 432 MBH
61 04 BCGSO

ROB

2 11

Figure 14A. Manifold

to Furnace Pressure

Drop vs Rate CG15

1800
1600
I
I

1400

.4J

I
I

1200

"IW 1000

-CG15.4S
- @° 'CG15.3S
CG15.2S

800

CG15.1S
600

A
_g

4OO
2OO

0.5

1.5

2.5

3.5

4.5

Pressure Drop, In. WC

Figure 14B. Manifold

to Furnace Pressure

Drop vs Rate CG25

3500

3000

2500

"CG25.5S

"IW 2000

° _

"CG25.4S

I
w

m 1500
r_

" _

°CG25.2S
"CG25.1S

1000

500

0.5

1.5

2.5

3.5

4.5

Pressure Drop, In. WC

6104

BCGSO

RoB

Figure 14C. Manifold

to Furnace Pressure

Drop vs Rate CG50

6000

5000

,.4
f

4000
.Ira

"CG50.5S

°CG50.4S

3000

°CG50.3S
°CG50.2S

tY
2OOO
4

I
1000

0.5

1.5

Pressure

Check

operation

and

safety

to properly

test and verify

the

function
of operation
and safety controls
lead to equipment
malfunction
and result
phyxiation,
explosion
or fire,
•

Drop,

•
•

6104

BCGSO

RoB

4.5

Low water cutoff (LWCO) - With the burner firing,
open the blow down valve on the low water cutoff,
if applicable. As the water level drops, the LWCO
switch contacts open and shut the burner off. When
the water level rises, the LWCO contacts close and
restart the burner. Monitor the LWCO switch operation in relation to the water level in the sight-glass
for synchronization.

Airflow proving switch - With the burner firing at
its lowest rate, loosen the tubing connection to the
airflow proving switch. A loss in air pressure at the
tubing should immediately cause the diaphragm in
the switch to open and recycle or lockout the safeguard control.

Low gas pressure switch - With the burner firing
and a manometer attached to a test port near the
low pressure switch, gradually close the main leak
test cock to shut off the gas supply. Note the pressure at which the low gas pressure switch opens
and shuts the burner off. Manually reset the switch.
The low gas pressure switch should be set at half
of the normal supply pressure in the line.

correct
could
in as-

High limit - To check the High Limit, raise the
temperature or pressure of the operating control to
a higher level and lower the limit to a setting less
than the operating control. Run the burner until the
high limit opens and shuts the burner off. Adjust the
controls back to the desired settings.

Operating control - Run the burner until the operating control shuts it off. If necessary, make adjustments to ensure the control cycles the burner in the
desired temperature or pressure range.

If instructions are not available, use the following
recommended procedures and record all results in
a start-up log.
Refer to Figure 7 for typical test points and component locations.

•

3.5

Tech-

The testing of operation and safety controls requires
technical training and experience with commercial
gas burning systems.
Carefully follow the manufacturer's instructions supplied with the controls.
Verify the correct function of all operation and safety
controls used in the installation.

•

In. WC

controls:

Testing by Qualified
nician Required.
Failure

2.5

results in the start-up log for future reference.
.

High gas pressure switch - With the burner firing
and a manometer attached to the test port nearest
the high pressure switch, gradually increase the
gas pressure until the high pressure switch opens
and shuts the burner off. Note the pressure and
manually reset the switch. The high gas pressure
switch should be set at one and one half times the
high fire manifold pressure (see nameplate data in
Figure 1 or set switch as determined by testing).
Leak-test valve - With the burner firing and manometer attached to the leak-test valve port, turn
the burner electrical switch off and observe that
the gas pressure does not increase after several
minutes. This proves total closure of the main gas
valve.

Draft - Set the breech or furnace pressure to the
level specified by the appliance manufacturer.
Typical example: +0.10" W. C.

Oxygen - It is recommended that you measure
the oxygen (02) early in the test sequence because high levels of carbon monoxide can be created at very low or even very high 02 levels. The
typical operating range is between 2.5% - 4.5 %.
The equivalent carbon dioxide (CO2) operating
range is 9% - 10.5%.

Carbon monoxide (CO) -An operating range of
0 -50 PPM is recommended for the burner. The
maximum carbon monoxide (CO)level permitted
in the flue gas by the UL 795 Standard is 400 PPM
(0.04%).

Stack Temperature
- The stack temperature
should be within the range specified by the appliance manufacturer. It is influenced by input firing
rate, flame shape, excess air ratio, and cleanliness of boiler flue passages. This temperature,
combined with the ambient temperature, and
02% (or CO2) is used in calculating the appliance
efficiency.

Flame safeguard safety lockout - Simulate a
flame failure by turning the main gas supply off.
The control should shut the burner off on safety
within the safety lockout time.
Flame sensor circuit (flame rod) - With the
burner power switch turned off, refer to the wiring
diagram supplied with the control and locate the
sensor connection terminals. Place DC voltmeter
probes in the flame amplifier test jacks. With the
burner firing, the flame signal should be steady and
at least 1.25 VDC.

10. Flame sensor circuit (UV scanner) - With the
burner power switch turned off, refer to the wiring
diagram supplied with the control and locate the
sensor connection terminals. Place DC voltmeter
probes in the flame amplifier test jacks. With the
burner firing, the flame signal should be steady and
at least 1.25 VDC.

Recommended

test

instruments

to set

Verify that all boiler sections, canopy, and access plates or
doors are fully equipped with gaskets and sealed against
any leakage, which could affect the combustion test results. Before making these tests, operate the burner for
several minutes to allow the heating system temperature
to stabilize or nearly reach steady-state levels. Record all
24,

sequence:

2. Measure the carbon monoxide level and adjust
air settings, if necessary, to regulate it to about 50
PPM for a starting point.
3. Measure the 02 or CO2 at the 50 PPM CO level.
For this discussion, assume the 02 is 1.5% (11%
CO2).

combustion:

Always use calibrated test instruments to set combustion
levels. Verify that test instruments are calibrated and in
good working condition. If not already provided, drill test
access holes in the flue pipe near the breech (or upstream
of the boiler breech damper, if applicable) and in the front
mounting plate area for firebox pressure.
Be careful not
to damage any water-backed
surface.

test

1. Adjust the draft or breech pressure to the appliance manufacturer's recommended level.

Use

combustion

Open the air adjustment until the 02 level is increased by at least 1% or to 3% 02 (whichever
is higher). This should reduce the CO level and
provide a margin of reserve air to accommodate
variable conditions.

5. Sample the CO level again. It should be in the 0
to 20 PPM range.
6. Check the draft to ensure it still meets specifications. If a major change in draft is required, repeat the above steps.
.

Perform any final adjustments and lock the air
settings securely. Run the burner through several
cycles to verify prompt ignition and stable burner
operation.

6104

80G50

RoB

Maintenance

and Service

Annual
vice
Tampering

Professional

tion, explosion

or making

could lead to equipment
and result
in asphyxia-

•

To ensure continued reliable operation, a qualified
service technician must service this burner annually.
More frequent service intervals may be required in
dusty or adverse environments.
Operation and adjustment of the burner requires
technical training and skillful use of combustion test
instruments and other test equipment.

Turn Off Electric
Supply

Before

and Gas
Servicing

Failure to turn off electric and gas supply
result in electrical
shock, gas leakage,
sion, or fire hazards.
•

could
explo-

Turn main gas valves and electric power off before
performing any maintenance.
If a maintenance procedure requires electrical power,
use extreme caution.

•

Annual
maintenance
(The following
should be performed by a qualified service technician only.)
[3

Burner;
.

6104

or fire.

Do not tamper with the burner or controls or make
any adjustments unless you are a trained and qualified service technician.

•

Clean the inside surfaces of the burner housing
scroll and especially the air intake area and airflow proving switch suction tube.

incorrect

•

Required

with

adjustments
malfunction

Ser-

Run the burner and perform a complete combustion test using the proper instruments before proceeding. If necessary refer to the section labeled
Start the Burner. Record the results for reference.
Inspect and clean all dirt accumulation from the
gas train, burner exterior, burner air damper, and
surrounding area.

If the blower motor does not have permanently
lubricated bearings, oil the motor. Clear any debris from the air vents on the motor body.
Clean the ignition transformer, baseplate, and
terminal bushings. Inspect the ignition leads for
signs of deterioration and loose terminals.
If the burner flame detection is a UV scanner, in=
spect the mounting and clean the lens according
to the component manufacturer's recommendations.
Remove the gas gun assembly and clean the
entire unit, paying special attention to the air diffuser and spuds.

10. Inspect the flame rod (if used) for oxidation or
distortion. Clean all surfaces, set the probe position, and insure that the flame rod is securely
fastened. Refer to Figures 15A, and 15B.
11. Inspect the ignition electrode for any damage.
Clean all surfaces, set the proper electrode gap,
and make sure it is securely fastened.
12. Clean the inside of the air tube and inspect the
combustion end for any deterioration. Referring
to Figure 2, check the recess dimension from refractory.
13. Inspect gas tube O-ring condition and replace if
damaged. Install gas gun assembly back into the
burner and use the jacking screw to tighten the
gas gun securely in place. (Automotive chassis
or bearing grease is suitable for o-ring lubrication.)
14. Inspect the condition of the appliance mounting
plate and burner mounting flange gaskets and
replace any damaged materials. See Figure 6.

Remove the blower motor and clean any accumulated matter from the blower wheel and motor
end bell.

15. Inspect all burner control wiring and the burner
control panel for damaged insulation and loose
terminals/connections.

Check wheel for damage and the hub setscrew
for tightness. If the blower wheel must be removed from the motor shaft, insure that clear=
ance specifications are maintained (blower wheel
hub to motor clearance should be .020").

16. Verify that the source voltage to the burner and
control panel is within 10% of the burner rating as
listed on the nameplate. (Figure 1)

BCGSO

RoB

Appliance
- (Follow appliance manufacturer's
service procedures. The following steps are emphasized because they relate to burner operation)

3. Check barometric damper or draft hood for proper operation.

2. Verify that the combustion air supply is functioning properly, adequately sized, clean, and properly lubricated.
[]

5. Check all operating and safety controls on the
boiler for proper installation and operation.
.

Gas

Perform all maintenance and tests according to
the burner control manufacturer's
instructions
(limits, controllers, low water cutoff, relief valves,
feed valves, etc.)
supply

piping:

the

burner

for

proper

combustion:

Flame

safeguard:

Follow the control manufacturer's instructions and verify
that the control is functioning to specifications. See Page
12 for typical sequence of operation and Items 8 through
10 on Page 24 for control system checks.
[]

Manual

shutdown

for ion@ periods:

1. Close all gas valves in the gas supply piping system.
2. Turn off all electrical power to the burner.

Inspect all piping for leakage and proper installation.
form necessary repairs to comply with all codes.

Figure 15B-

Adjust

Follow the guidelines under "Start the Burner" to set the
combustion levels using test instruments.
[]

4. Inspect boiler sections and system load piping for
possible leaks. Make all necessary repairs.

area:

1. Insure that there are no combustible materials,
flammable liquids or vapors in the vicinity of the
heating appliance.

1. Check the condition of the combustion chamber
refractory, the front-plate insulation, and all gaskets and seals. Repair or replace as necessary
2. Insure that the flue passages, flue vent pipes,
and chimney flues are clean and unobstructed.

Installation

Per-

3. Protect the burner and controls from moisture
and dirt.

Gas Gun Assembly

SPUDS

AIR DIFFUSER

FLAME ROD
(CROSSES CENTERLINE OF HEAD
ASSEMBLY)'-........\

/
ELECTRODES

VERIFY O-RING IS LUBRICATED* AND IN P_CE
BEFORE P_CING ASSEMBLY" INTO BURNER.

6104

BCGSO

RoB

Figure 15B-

Gas Gun Assembly

VERIFY ALIGNMENT
VERIFY BURNER MODEL
ON ADJUSTMENT SCALE

BURNER
MODEL ON HEAD

* Automotive
chassis or bearing grease is a satisfactory
- Disassembly
of gas gun is not required for cleaning,

VERIFY O-RING IN PLACE
AND LUBRICATED *

o-ring

lubricant.

Burner Head Adjustment - There is an optimum gas orifice size and burner head setting for each firing rate of the
burner. The gas orifice size sets the gas flow velocity; the head setting establishes the airflow velocity. When
those velocities are properly matched the burner provides its best performance and stability.
The gas orifice size is built into the burner head. You can verify the correct selection by looking for the burner
model number stamped on the top centerline of the stainless steel tube that forms the base of the burner head. It
should match the model number on the Beckett burner data label on the blower housing.
The head setting is established by a notched sleeve on the gas tube that can be rotated to positions on a scale
marked by the burner's model number. The scale should normally be set to the model number on the Beckett
burner data label. (If specific application requirements dictate an alternate head setting it will be noted by a label
on the gun assembly.)
For normal service requirements it is not necessary to disassemble the head from the gas tube. If you disassemble
the gas gun, make sure that when you re-assemble it:
1) The adjustment scale is set to the correct position as indicated by the burner model number or Gun Label.
2) The alignment marks on the head, scale and stop are in alignment.
3) The O-ring between the head and the adjustment scale is in place, is lubricated with grease, and is compressed
between the head and scale as the setscrews that retain the head are tightened.

6104

8CGSO

R08

inspect

Heating

System

Regularly
Lack of regular
inspections
and
maintenance
could lead to equipment
malfunction
sion or fire.

The gunassemblyis securedinsidethe air tubeby
a spring-loaded
jackingscrew. It is springloadedin
orderto controlthe forceit canimposeon the gun
assembly.The screwcan be tightenedfirmlywithout puttingexcessivepressureon thegunassembly
thatmightdistortthegunor damageitsO-ringseals.
Wheninstallingthejackingscrewlookinsidethe air
tubeto verifythatthe pointedtip of thejackingscrew
pinisseatedintothesmallholeonthelocatingpadon
top of thegun. Thereis alsoanexternalverification
of correctassembly:
whenthescrewis fullytightened,
the e-clipon the top on the centerpinshouldcome
flushwiththetopofthescrew.

and

result

inadequate

in asphyxiation,

explo-

(Always follow the appliance manufacturer's recommended service instructions, when available.)
* The following checklist is intended to be used as a
minimum reference guide only and does not supersede or replace the heating appliance manufacturer's
recommended service and maintenance instructions
or any code requirements.
* Consult the installation and service instructions provided by the individual control or component manufacturer and carefully follow their directions.
* Maintenance and testing may be required more frequently due to dusty or severe operating conditions.
* If unusual or questionable performance is observed,
shut the system down and contact your qualified service agency immediately.

6104

BCGSO

R08

Table 3. Periodic

inspection

Sheet
Frequency

Inspect area surrounding heating plant

Daily

Keep area clean and free of clutter

Inspect gas supply System for leakS

DailY

Use ViSual and electronic leak detection

Inspect appliance & piping for water leaks

Daily

Keep burner and controls dry at all times
u

Inspect gauges: indicators, monitors
Check temperature and pressure levels
Make visual inspection of flame

Daily

Note condition. Replace defective parts

Daily

Compare to manufacturer's

Daily

Monitor burner start-up

Daily

M0nit0r stack temperature

Daily

Test low water cutoff and alarm

Daily

specifications

Look for changes in shape, size, and color:
Verify prompt ignition and flame stability.
_Compare to start,up and trend level.
Follow control manufacturer's instructions & procedures
in ASME Boiler & pressure vessel Code, Section Vl Recommended rules for care and operation of heating
boilers.
li

calculate fuel gas input firing rate

Weekly

Compare to appliance manufacturer s Specifications

Check flame safeguard sequence of operation.

Weekly

Follow control manufacturer's

Flame failure resp0nse &loCkout timing!

weekly

instructions

FollOW control manUfactUrer's instructiOns

Flame sensor signal level (if meter is hardwired)

Weekly

Compare to control manufacturer's specifications

Main fuel gas valves

Weekly

open high limit and verify cut0ff 0perati0n

Inspect exhaust vent system for blockage

Weekly

Remove any restrictions

inpect combUstion air supply
Check high and low gas pressure interlocks
CheCk safety ValVes

Monthly
Monthly
As needed

RemOve any restficti0ns
Follow control manufacturer's

instructions

Foliow control manufactUrei,s instructions &proCedures
in Recommended
ASME Boiler

Pressure
Codeoperation
Section VI
for Vessel
care and
of

Heating Boilers:

6104

BOGS0

Roe

p|acement
For best performance specify genuine __

Parts
replacement parts.

Note 1: See Burner Configuration
30

6104

Table.

BOGS0

R08

-°'itern -'!'_=_DesCription
1

CGt5 Part No, °°7°=_ CG25 Part No: "_

Air Proving Switch
Ii

2
3

UV Sensor ( f not us ngF ame Rod)
RearAccess

2190901U

Door*

CG50 Part No,

2190901U

5201304U
5201302U

7247U

for UV
for Flame Rod

5201303U
5201301U

spring Latch (Dzus fastener)

32444u

Sight Glass**

31346U

32444U

31346U

Refer to UL Label for MOdel Numbers
7

Control Subbase

Ignition Transformer

7503U

High Gas Pressure Switch

2190903 U

Damper Motor
'

Refer to UL Label for Model Numbers

Mounting Flange

/ Blower Wheel

Flame Rod

¸¸¸¸¸¸¸¸¸16
1 ¸¸¸¸
GrOUnd
17

N/A
21268U
219!106U

panel
panel

31449U
2t528U
2191302U
2!91108U

5990480U
5990360u

3226402U

Gas Tube, Welded Assembly

5193202BKU

Cable, Ignition Electrode

5990184U

Jacking Screw Assembly

5!93402U

Air Tube

*Includes sight glass, label, gaskets, and fasteners.

3226404U
H

5193203BKU
5990184U
5193403U

5193204BKU
5990184U
5193403U

Specify Application
4474U

Ignition Electrode

5990360u

3226403U
_

RoB

31347U

2191107U

5990480U
5990360u

O-ring set (2 included)

61 04 BCGSO

32294U
2i527U
21547
21733U

Specify Model

32294U
21402U
21499U
21734U

2191302U
......

Head, Welded Assembly

/18¸¸¸¸¸¸¸¸ Cable, Flame Rod(if used)
i

75060iU
750603U

2t267U

2191302U

Electrode

2190903 U

750601U
750603U

32294U

Nylon Bushing (Damper Rod)

iiii

75060iU
750603U

LoiH!
Modulation

7503U

2191206U

4474U

2191207U

2191208U

**Includes Beckett label and window gasket.

3 11

Limited

Warranty

information

Limited

WARRANTY
For Residential,

Commercial and Specialty Burners

The R. W. BECKETT
CORPORATION
("Beckett")
warrants
to persons
who purchase
its Beckett burners
from Beckett
_r resale or _r
incorporation
into a product _r resale ("Customers")
that its equipment
is free from defects in material
and workmanship
under normal use and
service t\_r 60 months from the date of manufacture
t_r Residential
Burners
and 18 months from the date of manufacture
_r Commercial
and
Specialty
Burners.
Residential
bz_rner models, inclz_de:
AF, AFG, AFII, NX, SF, SR and SMG.
Commercial
bz_rner models ineh_de:
CF375,
CF500, CFS00, CF1400,
CF2300A,
CF2500,
CF3500A,
CG10, CG15, CG25 and CG50.
3_eeia[ O bzcrner models' inch€de: ADC, ADCP, ARV,
SDC and SM. The provisions of this wan'anty are extended to individual major burner components
as t\_llows:
a)
b)

60 months
18 months

Note:

THIS

Normal

from date of manut:acture
from date of manufacture

ser',ice

WARRANTY

items

DOES

£\_r all Beckett-branded
major components,
except £\_r 12 Vdc components.
t\_r all non-Beckett-branded
major components
and Beckett branded 12 Vdc components.

t\_und to be defccti'_ e upon receipt

NOT

EXTEND

TO EQUIPMENT

by the customer

SUBJECTED

MIS[

are co'_ ered by this warranty.

SE, NEGLECT,

ACCIDENT:

NOR

DOES

THIS

_2&RRANTY

APPLY

UNLESS
THE PRODUCT
COVERED
BY IT IS PROPERLY
INSTALLED
BY A QUALIFIED,
COMPETENT
TECHNICIAN,
'WHO
IS LICENSED
WHERE
STATE AND LOCAL
CODES
REQ[ IRE, AND WHO IS EXPERIENCED
IN MAKING
SUCH INSTALLATIONS,
IN ACCORDANCE
'WITH
THE LATEST
EDITION
OF NFPA NO. 31 OF THE NATIONAL
FIRE PROTECTION
ASSOCIATION,
THE LATEST
EDITION
OF THE NATIONAL
FILL
GAS CODE (NFPA
NO. $4) AND

IN ACCORDANCE

WITH

ALL APPLICABLE

LOCAL,

STATE

AND

NATIONAL

(;ODES

HA_TNG

31TRISDICTIONAL

AUTHORITY.

Equipment, which is detective in material or workmanship and within the warranty period, may be returned for credit as follows:
Beckett Burners, Beckett-branded
major components and non-Beckett-branded
major components that came as original equipment on a Beckett burner
or were sold as a replacement part by Beckett should be returned, freight prepaid, to Beckett's home office. Credit will be issued to the customer unless
the returned equipment is detemlined by Beckett to be out of warranty or damaged by user, in which case the equipment will be scrapped.
Note: Beckett is not responsible for any labor cost for removal and replacement
of equipment.
THIS WARRANTY
REMEDIES
AND
PURPOSE.

IS LIMITED
TO THE PRECISE TERMS SET FORTH ABOVE, AND PROVIDES
IN PARTICULAR
THERE SHALL BE EXCLUDED
THE IMPLIED
WARRANTIES

IN NO EVENT

authorizes

any

exclusive

remedy

person

WILL

to assume

being

limited

BECKETT

BE LIABLE

_\_r Beckett
to credit

any other

FOR ANY INCIDENTAL
liability

or obligation

EXCLUSI_'E
REMEDIES
OF MERCHANT_MBILITY

OR CONSEQUENTIAL
in colmection

with

DAMAGE
the sale

EXPRESSLY
IN LIEU OF ALL OTHER
AND FITNESS FOR A PARTICULAR

OF ANW NATURE.

of this equipmenL

Beckett's

Beckett

neither

liability

assumes

nor

and Customer's

as set _\)rth above.

Form No61545

R72905

R.W. BECKETT CORPORATION
U.S.A.: P.O. Box 1289. Elyria, Ohio 44036
www.beckettcorp.com
Canada: R.W. Beckett Canada, Ltd.. Unit #3,430 Laird Road • Guelph, Ontario N1G 3X7

*6104BCG50*

Printed in U.S.A.
3_

R08

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BECKETT Burner, Furnace Manual L0805076

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