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 and result in

death, severe personal injury or property damage.

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 BOGS0 RoB 11

Table of Contents

Please...read this page first

Hazard Definitions ............................................................................................................................................................. 3

To the Owner ..................................................................................................................................................................... 3

To the Installer ................................................................................................................................................................... 3

Warranty 3

Pre-instatlation checklist ......................................................................................................................................................... 4

Indoor Installation .............................................................................................................................................................. 4

Combustion air supply ....................................................................................................................................................... 4

Clearances ........................................................................................................................................................................ 4

Fuel gas supply ................................................................................................................................................................. 4

Flue vent system ............................................................................................................................................................... 5

Electrical supply ................................................................................................................................................................. 5

Figure 1 - Burner nameplate ............................................................................................................................................. 5

Verify burner components .................................................................................................................................................. 5

Verify firing input range ...................................................................................................................................................... 5

Figure 2 - Minimum combustion chamber dimensions ..................................................................................................... 5

Verify burner air tube assembly ......................................................................................................................................... 6

Figure 3 - Maximum capacity vs furnace pressure, Step spud ......................................................................................... 6

Figure 4 - Maximum capacity vs furnace pressure, Swirler head ..................................................................................... 6

Figure 5 - Burner dimensions ........................................................................................................................................... 7

Mount the burner .................................................................................................................................................................... 7

Figure 6 - Custom mounting plate .................................................................................................................................... 8

Connect gas piping ................................................................................................................................................................. 8

Figure 7 - Typical gas piping layout .................................................................................................................................. 8

Table 1 - Gas supply piping capacity ................................................................................................................................ 9

Gas trains 9

Figure 8 - UL gas train configuration ................................................................................................................................ 9

Wire the burner ..................................................................................................................................................................... 10

Figure 9- Typical burner wiring ...................................................................................................................................... 10

Sequence of operation .......................................................................................................................................................... 11

Prepare the burner for start-up ............................................................................................................................................. 11

Start-up checklist ............................................................................................................................................................. 11

General ........................................................................................................................................................................ 11

Gas supply piping ............................................................................................................................................................ 11

Electrical 11

Boiler or appliance ........................................................................................................................................................... 12

Burner ........................................................................................................................................................................ 12

Figure 10 - CG10 Component familiarization ................................................................................................................. 12

Test instruments .............................................................................................................................................................. 12

Start the Burner .................................................................................................................................................................... 13

Burner start procedure ..................................................................................................................................................... 14

Figure 11- Shutter and band location ............................................................................................................................. 14

Table 2 - Initial burner settings ......................................................................................................................................... 15

Verify input firing rate ....................................................................................................................................................... 15

Figure 12 - Manifold to furnace pressure drop vs rate, Stepped spud ............................................................................ 15

Figure 13 - Manifold to furnace pressure drop vs rate, Swirl vane head ........................................................................ 16

Check operation and safety controls ............................................................................................................................... 17

Use test instruments to set combustion ........................................................................................................................... 18

Recommended combustion test sequence ..................................................................................................................... 18

Maintenance and Service

Annual maintenance ........................................................................................................................................................ 19

Figure 14A- Gas Gun assembly .................................................................................................................................... 20

Figure 14B - Gas Gun assembly ................................................................................................................................... 20

Figure 15 - Gas Gun assembly installation ..................................................................................................................... 21

For the operator .................................................................................................................................................................... 22

Table 3 - Periodic inspection checklist ............................................................................................................................ 22

Replacement Parts

Burner exploded view ...................................................................................................................................................... 23

Burner Configurations ........................................................................................................................................................... 24

Low Rate Burner Configuration; 300 to 800 MBH Applications ....................................................................................... 24

High Rate Burner Configuration; 600 to 1200 MBH Applications .................................................................................... 24

Burner Configuration Table .............................................................................................................................................. 25

2 6104 BCGSO R08

hera| rrn ion

Hazard Definitions:

indicates an imminently

hazardous situation,

which, if not avoided, will result in death,

serious injury, or property damage.

indicates apotentially

hazardous situation,

which, if not avoided, could result in death,

severe personal injury, and/or substantial

property damage.

indicates apotentially

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.

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 pro-

vide it to your qualified service agency for use in pro-

fessionally setting up and maintaining your burner.

Your burner will provide years of efficient operation if

it is professionally installed and maintained by a quali-

fied service technician. If at any time the burner does

not appear to be operating properly, immediately__

contact ov_o_M_Lqualifiedservice_ for consulta-

tion.

We recommend annual inspection/service of your

gas heating system by a qualified service agency.

Owner's Responsibility

Failure to follow these instructions,

misuse, or incorrect adjustment of

the burner could lead to equipment

malfunction and result in asphyxia-

tion, 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 in-

structions:

• See the front cover for 'What to do if you smell

gas'.

• Never store or use gasoline or other flammable liq-

uids or vapors near this burner or appliance.

• Never attempt to burn garbage or refuse in this ap-

pliance.

• Never attempt to light the burner/appliance by throw-

ing burning material into the appliance.

• Never attempt to burn any fuel not specified and ap-

proved for use in this burner.

• Never restrict the air inlet openings to the burner

or the combustion air ventilation openings in the

room.

61 04 BCGSO RoB 3

General nforrn ion

Professional Ir|staller's Responsibility Pre-installation checklist

Follow these instructions

exactly.

Failure to follow these instructions

could lead to equipment malfunc-

tion and result in asphyxiation,

explosion or fire.

• Please read all instructions before proceeding. Follow

all instructions completely.

• This equipment must be installed, adjusted and start-

ed by a qualified service agency that is licensed and

experienced with all applicable codes and ordinances

and responsible for the installation and commission-

ing 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 burn-

er or controls during unpacking, notify the carrier at once

and file the appropriate claim forms.

High altitude installations- Accepted industry practice re-

quires 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. Con-

sult factory for specific application data.

indoor Installation

Protect against Dust and

Moisture

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 va-

pors, and moisture.

• Protective covers and more frequent maintenance

may be required.

[3 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 ap-

pliance/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 edi-

tion 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 out-

side 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 appli-

ance 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 provid-

ing at least the minimum pressure required to the burner

gas train inlet at the burner's full capacity rating. Refer to

Table 1.

46104 BCGSO RoB

Table1 = Burner Specifications

CG25 ICGS0

input firing range:

High Fire (Max.) 1500 MBH 2700 MBH 5000 MBH

High Fire (Min.) 800 MBH 1300 MBH 2000 MBH

Low Fire (Max.) 560 MBH 990 MBH 1400 MBH

Low Fire (Min.) 350 MBH 550 MBH 730 MBH

Fuel: i Natural gas z 0.6 Specific gravity typical

Gas Train:

Standard U.L. Listed /CSD-1 configuration

Options IRI, FM

Gas Train inlet Pressure:

Minimum &5!' WC*

Maximum 10 PSi 10 PSi 10 PSi

Manifold pressure:

Highest High Fire 3.7" WC 3.5" WC 3.5" WC

Lowest High Fire 2.7" WC 2.5" WC 2.5" WC

HighiLow HighiL0w

Modulation Modulation Modulation

Standard Flame Safeguard:

Low Fire Start RM7895A

High /Low RM7895C RM7895C RM7895C

Modulation RM7895C RM7840L RM7840L

Flame Detector:

Standard

Optional UV -

Airflow Proving Switch: Standard Standard Standard

Gas pressure switches: i Standard high and low

ignition: Direct ignition of Main Flame

1i2HP

3450 RPM 3450 RPM

Standard Voltage 120 volt, i phl 60 Hz 120 vo!t, ! phl 60 HZ 208!230v, 1 ph, 60 Hz

Current Draw 6.4 Amps @! 20 volt AC !0.4 Amps @!20 vo!t AC 1&4 Amps @230 volt AC

OptionalVo!tages 208/230V ! ph 60Hz 208/230v i ph 60Hz 208!230V, 3Phi60Hz

208/230VI 3 ph; 60 Hz 2081230V, 3 ph, 60 Hz 460V, 3 ph, 60 Hz

460V, 3 phl 60 Hz 460V, 3 phl 60 Hz

575v, 3 phl 60 HZ 575v, 3 ph 60Hz

Weight: 125 lbs. 145 lbs. 165 Ibs.

Dimensions: Refer to Figures 4 & 5.

*See manufacturer's nameplate settings for specific minimum gas pressure requirements.

Figure 1. Burner label location

General model information _ _._,_ CC50

}.................._ _.:_!_....................

Serial number, including date code _ 4. 0

I HWii

Rating information _*_ i_:_c:_::_"_-_'__',

Approval agency symbols _.

Primary group and fuel _ ::" ;

,: ,)4 1

M 1:

:¢* :'":_'_ R.W. Beckett construction

and setting data

(i!i'i_/4 i:_t_: _ R.W. Beckett specification number

..........................................*; ............ and revision

,c : _ Boiler manufacturer and model

(when applicable)

Additional codes

61 04 BCGSO RoB

Test For Gas Pipe Leaks

Leaking gas could result in asphyxiation, explo-

sion, or fire hazard.

* 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.

[3 Flue vent 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 jurisdic-

tion for vent construction, capacity, and sizing.

Figure 2. Minimum Combustion Chamber Dimensions

[3 Electrical supply

Check the nameplate on the burner to verify that the pow-

er connections available are correct for the burner. Refer

to Figure 1. All power must be supplied through fused dis-

connect switches and comply with the latest edition of Na-

tional 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 high-

temperature gasket and/or fiber rope for pressure

firing)

[3 Verify firing input range

Refer to appliance manufacturer's instructions (if avail-

able) 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.

Minimum Inside Dimensions (inches)

Burner Wdth Height Length Burner Head

Model 'W! 'H' 'L' at Min Centerline to

H & W* floor 'A'

CG15.1S 15 16 42 7

CG15.2S 16 17 45 8

CGIS.3S 17 18 47 8

CGIS.4S 18 19 50 9

CGS0.1S 21 23 55 10

CGS0.2S 22 24 58 11

CGS0.3S 24 26 62 12

CGS0.4S 25 27 65 12

CGS0.SS 27 29 70 13

j 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.

Flames are shaped by their furnaces and by its flue lo-

cations. Increased height and width can decrease the

length requirement. When shaping is too severe flames

impinge on the walls. Impingement causes CO and car-

bon 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 fac-

tory testing of all new burner/furnace combinations by the

furnace manufacturer and/or R. W. Beckett Corp.

NOTICE j

The volume of the furnace also influences the combus-

tion process. R. W. Beckett Corp. recommends at least

1 cubic foot of furnace volume for each 150,000 BTU/Hr

of firing rate.

Verify 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, Fig-

ure 3B, and Figure 3C, to verify the correct burner

configuration for the input rate.

Refer to Figures 4 & 5 to verify the air tube assem-

bly length and mounting insertion dimensions.

6 61 04 80G50 RoB

Figure 3A. Maximum Capacity (at 3% 02) vs Furnace Pressure -CG15

1500

1400

1300

"3"

- 1200

¢,t-'

1100

lOOO

9OO

L =

m A

= A i

0 0.2 0.4 0.6 0.8

Furnace Pressure, In. WC

CG 15.4S

_CG15.3S

= A -CG15.2S

_:: _ CG15.1S

Figure 3B. Maximum Capacity (at 3% 02) vs Furnace Pressure -CG25

26OO

2500

2400

2300

m 2200

2100

2000

1900

1800

1700

-÷

0 0.2 0.4 0.6 0.8

Furnace Pressure, In. WC

--'._-- CG25.5S

_CG25.4S

_ CG25.39

_':: _ CG25.2S

--_¢: - CG25.1S

Figure 3C. Maximum Capacity (at 3% 02) vs Furnace Pressure =CGSO

5OOO

4500

-1-

4000

35OO

3OOO

_CG50.59

_ 6G50.4S

A = CGS0 3S

-""_:- CG50,28

- CGS0,1S

0 0.2 0.4 0.6 0.8

Furnace Pressure, In. WC

61 04 BOGS0 R08 7

Figure 4. Burner Dimensions

_I_ LL HPL I tI_Li_U

_i)l_£t',_S_©_S ARE bi_!N_:HE$

Figure 5. Panel and Modulating Valve Dimensions

THREAD

15 6104 BOGS0 R08

U 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

Overheating could cause damage to the air tube

and other combustion components leading to

equipment malfunction and impaired combus-

tion performance.

•The end of the air tube must not extend into the com-

bustion chamber unprotected unless it has been fac-

tory-tested and specified by the appliance manufac-

turer.

•The end of the air tube should be set back ¼" from

flush with the refractory inside wall to prevent dam-

age 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 instal-

lation 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-temper-

ature refractory material anchored on the fire-side. A

suitable high-temperature gasket (B) must be used

for an effective seal.

Attach the plate and gasket to the boiler and tighten

the mounting nuts or bolts securely.

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.

Key:

A Burner mouning flange

B Gasket

C Appliance mounting plate

Connect as ipin!

NOTICE 1

All gas piping installation must comply with the latest edi-

tion of the National Fuel Gas Code ANSI Z223.1 (NFPA

54) and other applicable local codes.

The gas supply system must be sized to deliver at least

the minimum required pressure to the gas train inlet. Con-

tact your local gas utility for verification of gas pressures,

allowable pressure drops, and any local piping code re-

quirements. Refer to Figure 7 for an illustration of a gas

piping layout and refer to Table 1 for pipe sizing.

Do Not Use Teflon Tape

on Gas Piping

Damage to gas valve cutoff seals and valve bod-

ies could cause gas leaks and result in asphyxi-

ation, explosion 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.

61 04 80G50 RoB 9

Install a Drip Leg in

Gas Supply Piping

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 di-

rectly ahead of the main shutoff valve to capture foreign

matter.

OGas Trains

Standard -An Underwriters Laboratories (UL) listed gas

train is standard for the CGI0 gas burner. This configu-

ration also meets CSD-1 requirements. See Figures 8A

and 8B for typical component layout.

Optional - Gas trains for IRI and FM are available and

must be specified when ordering a burner.

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.

Vent lines - Install vent lines to any gas valve compo-

nent 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.

Figure 7. Typical Gas Piping Layout

REGULATOR PG DRIPLEG

ABBREV, ITEM DESCRIPTION

HGPS HIGH GAS PRESSURE SWITCH

LGPS LOW GAS PRESSURE SWITCH

MSC MAIN SHUTOFF COCK

MLTC MAIN LEAK TEST COCK

PG PRESSURE GAUGE

S STRAINER

SSOV1 SAFETY SHUTOFF VALVE #1

TC TEST COCK

U UNION

2PRV TWO POSITION REGULATING VALVE

LGPS HGPS

(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)

30 152

13o

11550

60 lO5

70 96

0175"

278 520

90"350

285

245

215

!95

180

1050

730

590

500

44O

400 610

370 560

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

1;5" 2.5' 3!0;' 4:0'

1600 3050 4800 8500 17500

1100 2100 x 3300 " 5900 " t2000

800

760

67O

1650 2700

1450" 2300

1270 2000

,1150 i850

1050 1700

4700 9700

00 8300

3600 7400

3250 "i 6800

3000 6200

1oo

125

15o

175

2oo

90' i70 350

84 160 320

79 !50 " 305

72 130 275

64 "120 250

59 110 225

55 i00 210

530 990 1600

490 930 1500

460 ' 870 ,1400 2500

410 780 1250 2200

380 710 ,1130" 2000

350 650 1050 1850

320 _ 6i0 980

2800 5800

2600 5400

5100

4500

4,1oo

3800

1700 3500

11O 61 04 BCGSO RoB

Figure 8A. UL gas train -High/Low and Low Fire Start

LGP_ HGPS

MSC U8SOV_ TC 2PRV TC MLTC U

LGPS HGPS

MSC U

Figure 8B. UL gas train =Modulating

• i ;i!ili!i!iiiii!iliiiiiiiiii ili!i

_ U PRV _OV_ TC _0_ TC M_YC: U M'V TC

ABBREV. ITEM DESCRIPTION

HGPS HIGH GAS PRESSURE SWITCH

LGPS LOW GAS PRESSURE SWITCH

MSC MAIN SHUTOFF COCK

MLTC MAIN LEAK TEST COCK

PG PRESSURE GAUGE

S STRAINER

SSOV1 SAFETY SHUTOFF VALVE #1

SSOV2 SAFETY SHUTOFF VALVE #2

TC TEST COCK

U UNION

2PRV TWO POSITION REGULATING VALVE

j NOTICE i

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:

Pipe Size Maximum Length

1" 12"

1-1/4" 15"

1-1/2" 18"

2" 24"

re rner

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 Safety

Controls

Tampering with, or bypassing safety controls

could lead to equipment malfunction and result

in asphyxiation, 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.

iNOTICE j

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.

Electrical Shock Hazard

Electrical shock can cause severe

personal injury or death.

• Disconnect electrical power before installing or ser-

vicing the burner.

• Provide ground wiring to the burner, metal control

enclosures and accessories. (This may also be re-

quired to aid proper control system operation.)

• Perform all wiring in compliance with the National

Electrical Code ANSI/NFPA 70 (Canada CSA C22.1)

Keep Service Access

Covers Securely installed

These covers must be securely in place to pre-

vent electrical shock, damage from external ele-

ments, and protect against injury from moving

parts.

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.

61 04 BCGSO RoB 11 11

Sequence of Operation

- (typica| for RM7895C 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.

.Standby - The control enters STANDBY until the

limits, operating limit control, burner switch, and

all microcomputer-monitored circuits are in the

correct state.

3. Load demand - Operating limit control contacts

close on drop in temperature (or pressure) and

initiates the start sequence.

.Prepurge - The control will signal the PRE-

PURGE 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).

.Trial for ignition (TFI) - After the Prepurge se-

quence 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.

6. Flame Stabilization - The burner will operate in

low fire for 10 seconds before initiating high fire.

.Run - With a flame established and the control

continuing to detect a flame, the burner will oper-

ate in the RUN mode until the load demand is

satisfied or a limit opens.

.Load Satisfied - The burner switches to idle un-

til the next call for operation.

I I

This operation sequence is typical and for reference only.

The primary control could vary, depending on the cus-

tomer specification and code requirements. For the spe-

cific operating sequence that applies to your installation,

consult the appliance manufacturer's directions, wiring in-

structions, and control manufacturer's literature supplied

with your burner.

Figure 9A. Typical wiring using Model RM7897C for High/Low Control (for reference only)

G_4@

$ _,_

L£G_ND:

Ii _OVl_}# if717Sl_.f _

@ _ _ _'_ & _04:_ ¸

I 2 6104 80G50 RoB

Figure 9B. Typical wiring using Model RM7840L for Modulating Control (for reference only)

++7+++L

Prepare burner for start-up

Professional Installation

and Service Required

Incorrect installation and mishan-

dling of start-up could lead to equip-

ment malfunction and result in

asphyxiation, explosion or fire.

• This burner must be installed and prepared for start-

up by a qualified service technician who is trained

and experienced in commercial gas burner system

installation and operation.

• Carefully follow the wiring diagrams, control instruc-

tion sheets, flame safeguard sequence of operation,

test procedures and all appliance manufacturer's di-

rections 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.

Start-up check|ist -Verify the following be-

fore attempting to start the burner.

General

CI Carefully read and become familiar with the

manual, flame safeguard control instructions, se-

quence of operation, pertinent wiring diagrams,

gas system layout, insurance requirements, other

controls and valve literature pertinent to the instal-

lation.

[El Follow the appliance manufacturer's start-up pro-

cedures (when available).

CI Inspect the combustion air supply and exhaust

venting and verify that they are free of obstruc-

tions and installed and sized in accordance with

all applicable codes.

CI Notify appropriate personnel to schedule start-

up (gas utility, owner, operators, subcontractors,

etc.).

2. 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.

61 04 BCGSO !:tO8 113

Insure that the fuel gas being supplied is compat-

ible 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 termi-

nated.

Electrical

Insure that all wiring has been completed and

complies with the National Electric Code NFPA 70

and local requirements.

Refer to Figure 1 and verify that the electrical sup-

ply to the burner matches the voltage specifica-

tion on the label.

4. Boiler or Appliance

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 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 appli-

ance is compatible with the specified burner input

firing rate.

5. Burner - See Figure 10 for familiarization

CI Insure that the gas burner model and capacity

meet the requirements for the installation.

CI Insure that the gas train meets operating specifi-

cations, all safety codes and insurance require-

ments.

CI Refer to Table 2 and Figures 11A and 11B to in-

sure that the burner air damper is positioned for

initial start-up preliminary settings.

CI Insure that the burner is securely mounted in the

appliance with the pressure firing plate and all

gaskets in place for pressurized chamber applica-

tions.

CI Before operating insure that all protective cover

plates, enclosures and guards are in place and

securely fastened.

CI When available, refer to the appliance manufac-

turer's instructions and install the burner accord-

ingly.

6. Test instruments

CI The following calibrated test equipment is required

to properly install the appliance. Whether these

are included in one kit or are individual test com-

ponents, they should be calibrated and in good

working order.

CI A combustion analyzer capable of measuring oxy-

gen (or carbon dioxide), carbon monoxide, stack

temperature, ambient temperature, and appliance

efficiency.

CI Electrical multi-meter capable of measuring volt-

age, 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.

CI 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.

114, 6104 BOG50 R08

Start the Burner

Professional installation

and Service Required

Incorrect installation and mishan=

dling of start=up could lead to equip=

ment malfunction and result in

asphyxiation, explosion or fire.

• This burner must be installed and prepared for start-

up 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 instruc-

tion sheets, flame safeguard sequence of operation,

test procedures and all appliance manufacturer's di-

rections 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.

[: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.

.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 Ta-

ble 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.

Figure 10. Component Famifiarization (CG50 shown, CG15 & CG25 similar.)

Major Components:

1. Damper Motor

2. Primary Control

3. Blower Motor

4. Ignition Transformer

5. Gas Gun Assembly

6. Air Flow Proving Switch

7. High Gas Pressure Switch

8. Test Connection

9. UV Scanner

61 04 BOG50 R08 115

.If component operation sequence and function is

correct, reset the flame safeguard and initiate a

new cycle. Monitor the start-up cycle and manu-

ally 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 con-

trolled by the valves and that they operate prop-

erly. With this test passed you may safely initiate

automatic start-ups on subsequent cycles.

Initial air settings

The following steps outline the procedure for initially set-

ting 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 ini-

tial 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 posi-

tion. The cam notch (E) should align with the Low

fire setting on the damper motor scale (F).

.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, lo-

cated in the orange transition cam, either clock-

wise or counterclockwise until the cam indicator

is half way between the high and low settings on

the scale.

NOTICE

Figure 11A. Damper Motor with Cover

Figure 11B. Damper Motor

D H

Legend (Figures 11A& 11B)

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 Linkage Adjustment

instructions

The optional modulation linkage assembly has been de-

signed 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.

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 po-

sition.

Figure 12A. Modulation Assembly

RIGHT HANDED GAS, ENTRY

Opt_ona! Censtructien

_CGS0 SHOWN oCG25 AND CGt5 ARE SIMILAR

!utterly Va|ve Sha_

Figure 12B. Modulation Assembly

LEFT HANDED GAS ENTRY

Sta_da_ Construction

*CG_ SHOWN oC@25 AND CG15 ARE 8_MtLAR

'Valve Shaft

OAdjustment 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. Adjustthegaspressureregulatortoabout½"WC 6. Topreventthe burnerfrommodulatingto high

higherthantheanticipatedhighfiregaspressure fire,setthe modulationcontrollerto themanual

(seeTable2). controlmode.If necessary,referto themanual

suppliedwiththemodulationcontroller.

iVlodulation Control

Figure 13A. Display Meaning

ACTUAL VALUE

(CURRENT OPERATION

SET

BURNER RELEASED WHEN LIT

DAMPER OPENING

DAMPER CLOSING (MODULATE UP)

(MODULATE DOWN

INCREASE VALUE

Figure 13C. Manual Operation

Operation in manual mode:

Once in Manual Mode, the

damper motor can be driven from

high to low using the up/down

arrows.

• To return to the automatic mode,

press and hold exit button for ten

seconds.

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 mode:

- Press and hold exit button for

10 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

Manual operation light will

uliminate. 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.

The damper motor can be manually operated for

set-up and service of the burner by placing the con-

troller 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.

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 control-

ler is provided with the burner to allow programming

at that level.

118 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 swiv-

el on the butterfly valve arm. If insufficient ad-

justment 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 control-

ler to manually step the burner up to its high fire

rate.

.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 previ-

ously.)

.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 pro-

cedure to make adjustments as necessary.

.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 link-

age 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 mid-

range 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 term-

perature to get SCFH and calculate the input fir-

ing rate. Compare the calculated rate to the spec-

ified 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 in-

put for the boiler.

.Attach a manometer to the manifold test port,

clock the meter, and adjust the regulated pres-

sure 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.

6104 BCGS0 ROB 119

Table 2. Initial burner settings

...............................................................................................L;ur ceP=ssu eat,,0hF, e ...........

O"W.C. 0.25" W.C. 0.50" W.C. 1.00" W.C.

C_3

800 468 CG15.1S 0.9 9 2.7 25 1.0 9 2.9 26 1.1 9 3.2 27 1.3 10 3.7 31

" I I I i I II I Ii I I I I I I I I

900 468 CG15.1S 0:9 9 314 32 110 9 3.7 34 1.1 9 3.9 37 112 10 414 43

950 548 CG15.2S 0.9 12 2.6

i I II

1050 548 CG15.2S 0.9 12 '312

1150 641 CG15.3S 0.9 16 2.8

'i250 " 64i CG15.3S 0.9 16 3.3

1300 750 CG15.4S 0.9 20 2.7

IIII

1400 750 CG15.4S 019 20 31i

i350 "669 cc25._s o.7 "2.7j

1450 669 CG25.!sI0.ZI!T 3.1

i550 774 CG25.2S 017 20 2.7 i

2000 896

'2100 i037

2300 1037

12400 i2oo

2500 1200

30 0.9 13 2.9 33 1.0 13 3.1 36 1.2 14 3.6 42

o:9 i3 314' 'i:o' 3.7 58 1.1 i4 4!2 84

42 0.9 17 3.1 49 1.0 17 3.3 56 1.2 19 3.8 74

52 _ 0:9 u 17 316 68 I i10 I i7 318 85 . I .

51 1.0 21 2.9 66 1.0 22 3.2 80

I I I I

66 1:0 21 3.3 100

38 0.7 i7 3.0 38 0.8 i7 3.2 39 '&9 317 4i

41 0.7 17 3.4 41 0.8 17 3.6 42 0.9 18 4.1 41

017 20 219 018 21 I 3.2 I 43 I 0.9 I 23 I 3.7 " 46

1700 774 CG25.2S 0.7 20 3.2

I I I

1800 896 CG25.3S 0:7 23 '217

CG25.3S 0.7 23 3.3

cG25.4s 017 27 ' 2.8

CG25.4S 0.7 27 3.4

I li

CG25.5S 0.6 30 2.5

CG25.5S 0.6 30 3.0

48 0.7 20 3.4

54 0.7 23 2.9

66 0.7 23 3.6 68 0.8 24 3.8 70

I I i

66 0.7 27 3.1 71'018 28 3.3 76

84 0.7 27 3.6 93 0.8 28 3.9 102

'0i7 30 2!8 ioo 08 31 310 ii5

100 0.7 30 3.2 115

49 0.8 21 3.7 51 0.9 23 4.2 56

55 .... '

0.8 24 3.2 56 0.9 26 3.7 60

0.9 26 4.3 78

I I

0.9 30 3.8 90

mmm mmmmmmmmm mmmm

CG50.1S

CG50AS

CG50.2S

cG5oi2s

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 chart are for reference only. The actual conditions at the installation may require further adjust-

merit by the fully qualified and experienced start=up technician.

20 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 agas 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 down-

stream 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 under-

ground 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 i

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

1400

1200

"I-

W1000

m800

600

4OO

2OO

.4J

0 0.5 1 1.5 2 2.5 3 3.5 4 4.5

Pressure Drop, In. WC

-CG15.4S

-@° 'CG15.3S

CG15.2S

CG15.1S

Figure 14B. Manifold to Furnace Pressure Drop vs Rate CG25

3500

3000

2500

"I-

W2000

m1500

1000

500

F" °_j_

0 0.5 1 1.5 2 2.5 3 3.5 4.5

Pressure Drop, In. WC

"CG25.5S

"CG25.4S

"_°CG25.2S

"CG25.1S

22 6104 BCGSO RoB

Figure 14C. Manifold to Furnace Pressure Drop vs Rate CG50

6000

5000

4000

.I-

3000

2OOO

1000

0.5 1 1.5 2 2.5 3

Pressure Drop, In. WC

,.4

"CG50.5S

°CG50.4S

_°CG50.3S

°CG50.2S

3.5 4 4.5

Check operation and safety controls:

Testing by Qualified Tech-

nician Required.

Failure to properly test and verify the correct

function of operation and safety controls could

lead to equipment malfunction and result in as-

phyxiation, explosion or fire,

•The testing of operation and safety controls requires

technical training and experience with commercial

gas burning systems.

•Carefully follow the manufacturer's instructions sup-

plied with the controls.

•Verify the correct function of all operation and safety

controls used in the installation.

•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 compo-

nent locations.

.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 oper-

ating control shuts it off. If necessary, make adjust-

ments to ensure the control cycles the burner in the

desired temperature or pressure range.

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 opera-

tion 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 safe-

guard 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 pres-

sure 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.

6104 BCGSO RoB 23

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 ma-

nometer 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.

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.

Use test instruments to set 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.

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 re-

sults. 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

results

in the start-up log for future reference.

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 be-

cause high levels of carbon monoxide can be cre-

ated 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 appli-

ance manufacturer. It is influenced by input firing

rate, flame shape, excess air ratio, and cleanli-

ness of boiler flue passages. This temperature,

combined with the ambient temperature, and

02% (or CO2) is used in calculating the appliance

efficiency.

Recommended combustion test sequence:

1. Adjust the draft or breech pressure to the appli-

ance manufacturer's recommended level.

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).

.Open the air adjustment until the 02 level is in-

creased 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 specifica-

tions. If a major change in draft is required, re-

peat 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.

24, 6104 80G50 RoB

Maintenance and Service

Annual Professional Ser-

vice Required

Tampering with or making incorrect

adjustments could lead to equipment

malfunction and result in asphyxia-

tion, explosion or fire.

• Do not tamper with the burner or controls or make

any adjustments unless you are a trained and quali-

fied service technician.

• 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 and Gas

Supply Before Servicing

Failure to turn off electric and gas supply could

result in electrical shock, gas leakage, explo-

sion, or fire hazards.

• 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 tech-

nician only.)

[3 Burner;

.Run the burner and perform a complete combus-

tion test using the proper instruments before pro-

ceeding. If necessary refer to the section labeled

Start the Burner. Record the results for refer-

ence.

Inspect and clean all dirt accumulation from the

gas train, burner exterior, burner air damper, and

surrounding area.

Remove the blower motor and clean any accu-

mulated matter from the blower wheel and motor

end bell.

.Check wheel for damage and the hub setscrew

for tightness. If the blower wheel must be re-

moved from the motor shaft, insure that clear=

ance specifications are maintained (blower wheel

hub to motor clearance should be .020").

10.

11.

12.

13.

14.

15.

16.

Clean the inside surfaces of the burner housing

scroll and especially the air intake area and air-

flow proving switch suction tube.

If the blower motor does not have permanently

lubricated bearings, oil the motor. Clear any de-

bris 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 recommenda-

tions.

Remove the gas gun assembly and clean the

entire unit, paying special attention to the air dif-

fuser and spuds.

Inspect the flame rod (if used) for oxidation or

distortion. Clean all surfaces, set the probe po-

sition, and insure that the flame rod is securely

fastened. Refer to Figures 15A, and 15B.

Inspect the ignition electrode for any damage.

Clean all surfaces, set the proper electrode gap,

and make sure it is securely fastened.

Clean the inside of the air tube and inspect the

combustion end for any deterioration. Referring

to Figure 2, check the recess dimension from re-

fractory.

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 lubrica-

tion.)

Inspect the condition of the appliance mounting

plate and burner mounting flange gaskets and

replace any damaged materials. See Figure 6.

Inspect all burner control wiring and the burner

control panel for damaged insulation and loose

terminals/connections.

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)

6104 BCGSO RoB 25

OAppliance - (Follow appliance manufacturer's

service procedures. The following steps are em-

phasized because they relate to burner opera-

tion)

1. Check the condition of the combustion chamber

refractory, the front-plate insulation, and all gas-

kets and seals. Repair or replace as necessary

2. Insure that the flue passages, flue vent pipes,

and chimney flues are clean and unobstructed.

3. Check barometric damper or draft hood for prop-

er operation.

4. Inspect boiler sections and system load piping for

possible leaks. Make all necessary repairs.

5. Check all operating and safety controls on the

boiler for proper installation and operation.

.Perform all maintenance and tests according to

the burner control manufacturer's instructions

(limits, controllers, low water cutoff, relief valves,

feed valves, etc.)

OGas supply piping:

Inspect all piping for leakage and proper installation. Per-

form necessary repairs to comply with all codes.

O Installation area:

1. Insure that there are no combustible materials,

flammable liquids or vapors in the vicinity of the

heating appliance.

2. Verify that the combustion air supply is function-

ing properly, adequately sized, clean, and prop-

erly lubricated.

[] Adjust the burner for proper combustion:

Follow the guidelines under "Start the Burner" to set the

combustion levels using test instruments.

[] 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 sys-

tem.

2. Turn off all electrical power to the burner.

3. Protect the burner and controls from moisture

and dirt.

Figure 15B- Gas Gun Assembly

SPUDS AIR DIFFUSER

FLAME ROD

(CROSSES CENTER-

LINE OF HEAD

ASSEMBLY)'-........\

ELECTRODES /

VERIFY O-RING IS LUBRICATED* AND IN P_CE

BEFORE P_CING ASSEMBLY" INTO BURNER.

26 6104 BCGSO RoB

Figure 15B- Gas Gun Assembly

VERIFY ALIGNMENT

VERIFY BURNER MODEL

ON ADJUSTMENT SCALE

BURNER

MODEL ON HEAD

VERIFY O-RING IN PLACE

AND LUBRICATED*

* Automotive chassis or bearing grease is a satisfactory o-ring lubricant.

-Disassembly of gas gun is not required for cleaning,

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 27

Thegunassemblyis securedinsidethe airtubeby

a spring-loadedjackingscrew. It is springloadedin

orderto controltheforceit canimposeon thegun

assembly.Thescrewcanbetightenedfirmlywith-

out puttingexcessivepressureonthegunassembly

thatmightdistortthegunordamageitsO-ringseals.

Wheninstallingthejackingscrewlookinsidetheair

tubeto verifythatthepointedtipof thejackingscrew

pinisseatedintothesmallholeonthelocatingpadon

topof thegun. Thereis alsoanexternalverification

of correctassembly:whenthescrewisfullytightened,

the e-cliponthetoponthecenterpinshouldcome

flushwiththetopofthescrew.

inspect Heating System

Regularly

Lack of regular inspections and inadequate

maintenance could lead to equipment

malfunction and result in asphyxiation, explo-

sion or fire.

(Always follow the appliance manufacturer's recommend-

ed service instructions, when available.)

* The following checklist is intended to be used as a

minimum reference guide only and does not super-

sede or replace the heating appliance manufacturer's

recommended service and maintenance instructions

or any code requirements.

* Consult the installation and service instructions pro-

vided by the individual control or component manu-

facturer and carefully follow their directions.

* Maintenance and testing may be required more fre-

quently due to dusty or severe operating conditions.

* If unusual or questionable performance is observed,

shut the system down and contact your qualified ser-

vice agency immediately.

28 6104 BCGSO R08

Table 3. Periodic inspection Sheet

Inspect area surrounding heating plant

Inspect gas supply System for leakS

Inspect appliance & piping for water leaks

Inspect gauges: indicators, monitors

Check temperature and pressure levels

Frequency

Daily Keep area clean and free of clutter

DailY Use ViSual and electronic leak detection

Daily Keep burner and controls dry at all times

Daily Note condition. Replace defective parts

Daily Compare to manufacturer's specifications

Make visual inspection of flame Daily Look for changes in shape, size, and color:

Monitor burner start-up Daily Verify prompt ignition and flame stability.

M0nit0r stack temperature Daily _Compare to start,up and trend level.

Test low water cutoff and alarm

calculate fuel gas input firing rate

Check flame safeguard sequence of opera-

tion.

Flame failure resp0nse &loCkout timing!

Flame sensor signal level (if meter is hard- Weekly

wired)

Main fuel gas valves Weekly

Inspect exhaust vent system for blockage Weekly

inpect combUstion air supply Monthly

Check high and low gas pressure interlocks Monthly

Daily Follow control manufacturer's instructions & procedures

in ASME Boiler & pressure vessel Code, Section Vl -

Recommended rules for care and operation of heating

boilers.

Weekly Compare to appliance manufacturer s Specifications

Weekly Follow control manufacturer's instructions

weekly FollOW control manUfactUrer's instructiOns

Compare to control manufacturer's specifications

open high limit and verify cut0ff 0perati0n

Remove any restrictions

RemOve any restficti0ns

Follow control manufacturer's instructions

CheCk safety ValVes As needed Foliow control manufactUrei,s instructions &proCedures

in ASME Boiler Pressure Vessel Code Section VI

Recommended for care and operation of

Heating Boilers:

6104 BOGS0 Roe 29

p|acement Parts

For best performance specify genuine __ replacement parts.

Note 1: See Burner Configuration Table.

6104 BOGS0 R08

-°'itern-'!'_=_DesCription " CGt5 Part No, °°7°=_

1 Air Proving Switch 2190901U

2 UV Sensor ( f not us ngF ame Rod) 7247U

3 RearAccess Door* for UV 5201303U

for Flame Rod 5201301U

spring Latch (Dzus fastener) 32444u

Sight Glass** 31346U

7 Control Subbase

8 Ignition Transformer

9 High Gas Pressure Switch

10 Damper Motor LoiH!

' Modulation

14 /

¸¸¸¸¸¸¸¸¸161¸¸¸¸

/18¸¸¸¸¸¸¸¸

iiii i

Nylon Bushing (Damper Rod)

CG25 Part No: "_ CG50 Part No,

2190901U 2190901U

5201304U 5201304U

5201302U 5201302U

32444U " 32444U

31346U 31346U

Refer to UL Label for MOdel Numbers

Refer to UL Label for Model Numbers

7503U 7503U 7503U

2190903 U 2190903 U 2190903 U

75060iU 750601U 75060iU

750603U 750603U 750603U

32294U 32294U

21402U

21499U

21734U

32294U

2i527U

21547

21733U

31449U

2t528U

2191302U

Mounting Flange N/A 31347U

Blower Wheel 21268U 2t267U

Flame Rod 2191302U 2191302U

GrOUnd Electrode ......

219!106U 2191107U 2!91108U

Head, Welded Assembly Specify Model

Cable, Flame Rod(if used) panel 5990480U 5990480U

nO panel 5990360u 5990360u 5990360u

O-ring set (2 included) 3226402U 3226403U 3226404U

u_H

Gas Tube, Welded Assembly 5193202BKU 5193203BKU 5193204BKU

21 Cable, Ignition Electrode 5990184U 5990184U 5990184U

22 Jacking Screw Assembly 5!93402U 5193403U 5193403U

23 Air Tube Specify Application

24 4474U 4474U 4474U

25 Ignition Electrode 2191206U 2191207U 2191208U

*Includes sight glass, label, gaskets, and fasteners. **Includes Beckett label and window gasket.

61 04 BCGSO RoB 311

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[ Obzcrner 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) 60 months from date of manut:acture £\_r all Beckett-branded major components, except £\_r 12 Vdc components.

b) 18 months from date of manufacture t\_r all non-Beckett-branded major components and Beckett branded 12 Vdc components.

Note: Normal ser',ice items t\_und to be defccti'_ e upon receipt by the customer are co'_ ered by this warranty.

THIS WARRANTY DOES NOT EXTEND TO EQUIPMENT SUBJECTED TO MIS[ SE, NEGLECT, OR 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 IS LIMITED TO THE PRECISE TERMS SET FORTH ABOVE, AND PROVIDES EXCLUSI_'E REMEDIES EXPRESSLY IN LIEU OF ALL OTHER

REMEDIES AND IN PARTICULAR THERE SHALL BE EXCLUDED THE IMPLIED WARRANTIES OF MERCHANT_MBILITY AND FITNESS FOR A PARTICULAR

PURPOSE. IN NO EVENT WILL BECKETT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGE OF ANW NATURE. Beckett neither assumes nor

authorizes any person to assume _\_r Beckett any other liability or obligation in colmection with the sale of this equipmenL Beckett's liability and Customer's

exclusive remedy being limited to credit 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*

3_ 61 04 BCGSO R08

BECKETT Burner, Furnace Manual L0805076

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