Weil-McLain CG10 Instruction manual

R02 01/09
AF/AFG
Oil Burner Manual
RESIDENTIAL BURNERS
Potential for Fire, Smoke and Asphyxiation Hazards
Incorrect installation, adjustment, or misuse of this burner could result in death, severe personal
injury, or substantial property damage.
To the Homeowner or Equipment Owner:
y Please read and carefully follow all instructions
provided in this manual regarding your
responsibilities in caring for your heating
equipment.
y Contact a professional, qualified service agency
for installation, start-up or service work.
y Save this manual for future reference.
6104BAFG R05
To the Professional, Qualif ed Installer or
Service Agency:
y Please read and carefully follow all instructions
provided in this manual before installing,
starting, or servicing this burner or heating
system.
y The Installation must be made in accordance
with all state and local codes having jurisdiction.
Page 1
Table of Contents
Hazard Def nitions and Owner’s Information ........................................................................................ 3
Information To Be Used Only By Qualif ed Service Technicians
General Information ......................................................................................................................................... 4
Table 1 Burner Specification................................................................................................................................ 4
Notice Special Requirements .............................................................................................................................. 5
Table 2 Air Tube Combination (ATC) Codes ………………………………………………………….. ..................... 5
Inspect/Prepare Installation Site................................................................................................................. 6
Inspect Chimney or Direct Vent System .............................................................................................................. 6
Combustion Air Supply ........................................................................................................................................ 7
Clearances to burner and appliance ................................................................................................................... 7
Combustion chamber - Burner Retrofitting .......................................................................................................... 7
Prepare the Burner ........................................................................................................................................... 8
Low Firing Rate Baffle ......................................................................................................................................... 8
Burner Fuel Unit .................................................................................................................................................. 8
Attach Air Tube .................................................................................................................................................... 8
Nozzle and Pump Pressure................................................................................................................................. 8
Install Burner Nozzle ........................................................................................................................................... 8
Check/Adjust Electrodes ..................................................................................................................................... 9
Servicing nozzle line assembly ........................................................................................................................... 9
Check/Adjust ‘Z’ Dimension - F Heads ............................................................................................................. 10
Check/Adjust ‘Z’ Dimension - L & V Heads ....................................................................................................... 11
Mount burner on appliance ........................................................................................................................... 9
Mounting Options ................................................................................................................................................ 9
Mounting Dimensions .......................................................................................................................................... 9
Installing the Oil Tank & Supply System ............................................................................................................ 12
Fuel Line Valves & Filter .................................................................................................................................... 12
Wire Burner ....................................................................................................................................................... 13
Burner Packaged with Appliance....................................................................................................................... 13
Burner Installed at Job Site ............................................................................................................................... 13
Special Wiring Required with Covered Burners ................................................................................................ 13
Burner Control ................................................................................................................................................. 14
GeniSys Model 7505 Control ............................................................................................................................ 14
Wiring ................................................................................................................................................................ 14
Typical Burner Sequence of Operation for GeniSys 7505 Control .................................................................... 15
Typical Burner Sequence of Operation for R7184P Control .............................................................................. 17
Start-up Burner/Set Combustion .............................................................................................................. 18
Startup/checkout ............................................................................................................................................... 19
Set Combustion with Instruments...................................................................................................................... 19
Perform Regular Maintenance ................................................................................................................... 20
Parts Diagram ................................................................................................................................................... 22
Beckett Limited Warranty Information ................................................................................................... 24
Page 2
6104BAFG R06
General Information
Hazard Definitions
Indicates a hazardous situation, which, if not avoided,
will result in death or serious injury.
! DANGER
Indicates a hazardous
situation, which, if not
avoided, could result in death or serious
injury.
! WARNING
Indicates a hazardous
situation, which, if not
avoided, could result in minor or moderate
injury.
!
CAUTION
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.
NOTICE
Intended to bring special attention to
information, but not related to personal injury or property
damage.
! WARNING
Owner’s Responsibility
Incorrect installation, adjustment,
and use of this burner could result in
severe personal injury, death, or substantial property damage from fire,
carbon monoxide poisoning, soot or explosion.
Contact a professional, qualified service agency for the
installation, adjustment and service of your oil heating
system. 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:
y Never store or use gasoline or other flammable
liquids or vapors near this burner or appliance.
y Never attempt to burn garbage or refuse in this
appliance.
y Never attempt to light the burner/appliance by
throwing burning material into the appliance.
y Never attempt to burn any fuel not specified and
approved for use in this burner.
y Never restrict the air inlet openings to the burner
or the combustion air ventilation openings in the
room.
NOTICE
This manual contains information that applies to both AF and AFG burners. These burners may
appear to be basically identical, but there are differences in design and performance. Please review the comparison
chart below:
Feature
AF
AFG
Static Pressure Capability
Conventional - Low range
Enhanced - Medium range
Blower Wheel Design
Standard strip
Special tablock
Inlet Airflow Design
Standard inlet bell
Special airguide
UL Air Tube Combinations
“F” Series ONLY
“F” or “M” Series
Igniter Gaskets Baseplate/Barrier
Optional, as specified
Required, always specified
Low Firing Rate Baffle
Not required
Required, per specification
Figure 1. Burner label location
6104BAFG R06
Page 3
General Information
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 oil
burner.
Your Beckett 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 your quali f ed service agency
for consultation.
! WARNING Impaired Burner Performance and Fire Hazard.
Do NOT operate the burner beyond specif cations outlined in the following Table.
y For applications beyond these limits, consult
Beckett Technical Service at 1-800-645-2876.
y NOTE: Some packaged appliances with burners
may be agency listed as a unit to operate beyond
these limits. Consult the appliance manufacturer’s specifications and agency approvals for
verification.
Table 1 – Burner Specif cations
Capacity
(Note 1)
We recommend annual inspection/service of your
oil heating system by a qualif ed service agency.
Daily – Check the room in which your burner/appliance is installed. Make sure:
• Air ventilation openings are clean and unobstructed
• Nothing is blocking burner inlet air openings
• No combustible materials are stored near the heating appliance
• There are no signs of oil or water leaking around
the burner or appliance
‘L1’ Head (AFG Only)
Firing rate range: ..................0.40 - 1.10 GPH
Input: ..................... 56,000 – 154,000 Btu/h
‘L2’ Head (AFG Only)
Firing rate range: .................0.50 - 1.00 GPH
Input: ...................... 70,000 – 140,000 Btu/h
‘V1’ Head (AFG Only)
Firing rate range: .................0.75 - 2.75 GPH
Input: .................... 105,000 – 385,000 Btu/h
Certifications/ UL listed to comply with ANSI/UL296 and CSA-B140.0
Approvals
Fuels
U. S No. 1 or No. 2 heating oil only (ASTM D396)
Canada No. 1 stove oil or No. 2 furnace oil only
Weekly
• Check your oil tank level. Always keep your oil tank
full, especially during the summer, in order to prevent condensation of moisture on the inside surface
of the tank.
! WARNING
Maintain the design to its original configuration.
Only use parts specified for AF or AFG Burners
Do NOT remove the air guide from the AFG chassis.
Do NOT use ‘M’ Series air tube combinations on AF Burners.
Never try to convert an AF to an AFG or vice versa
Any design alteration will:
y Void UL Listing
y Void manufacturer’s warranties
y Seriously impact burner performance
y Greatly increase your liability risk
Page 4
!
CAUTION
DO NOT USE GASOLINE, CRANKCASE OIL,
OR ANY OIL CONTAINING GASOLINE.
Electrical
Power supply:............ 120 volts AC, 60 Hz single phase
Operating load: .......... Amps max
Motor: .........................1/7 hp, 3450 rpm, NEMA 48M frame
PSC rotation CCW when facing
shaft end
Ignition: ......................Continuous duty solid-state igniter
Fuel pump
Outlet pressure: ..................................Note 2
Air tube
ATC code: ...................................See Table 2
Dimensions
(with cover)
Ambient
Operating
Temperature
Height (maximum) ....................... 12.5 inches
Width (maximum) .......................... 15 inches
Depth ......................................... 9.25 inches
Air tube diameter ....................... 4.00 inches
+32o F. (0 C.) Minimum
+115o F. (+46 C.) Maximum
(See above Warning)
Moisture
5% to 95% RH, non-condensing and non-crystallizing
Do NOT Alter the Original
Burner Design
Tampering with or altering the burner design
could seriously impair performance, resulting
in loss of static pressure, damage to the system
components, reduced air volume, heavy smoke,
flame impingement, appliance sooting, hot gas
puff-back, and asphyxiation or fire hazards.
‘F’ Head (AF & AFG)
Firing rate range: ..............0.40 – 3.00 GPH
Input: ....................... 56,000 – 420,000 Btu
Note 1: Approval agency listed rating for these burners is 0.40 to 3.00
gph. However, the firing rate range is limited by the specific
air tube combination being used. Refer to Table 2.
Note 2. See appliance manufacturer’s burner specifications for recommended pump discharge pressure.
6104BAFG R06
General Specifications
Table 2 – Air Tube Combination (ATC) codes
Firing
Rate
(gph)
Head
(minmax)
Static
plate
size
Venturi
(inches)
ATC Codes for usable air tube lengths
(‘A’ in inches; See Figure 3.)
4-1/2
5
5-3/8
6-5/8
7
7-1/4
9
10-1/2
13
16
0.50-0.75
F0
3-3/8U
None
AF44XR
-
AF53XR
AF65XR
-
AF72XR
AF90XR
AF104XR
AF130XR
A160XR
0.75-1.25
F3
2-3/4U
None
AF44XN
-
AF53XN
AF65XN
-
AF72XN
AF90XN
AF104XN
AF130XN
AF160XN
0.85-1.35
F4
2-3/4U
None
AF44WH
-
AF53WH
AF65WH
-
AF72WH
AF90WH
AF104WH
AF130WH
AF160WH
0.85-1.65
F6
2-3/4U
None
AF44YB
-
AF53YB
AF65YB
-
AF72YB
AF90YB
AF104YB
AF130YB
AF160YB
1.10-2.00
F12
2-3/4U
None
AF44XO
-
AF53XO
AF65XO
-
AF72XO
AF90XO
AF104XO
AF130XO
AF160XO
1.65-2.50
F22
2-3/4U
None
AF44XP
-
AF53XP
AF56XP
-
AF72XP
AF90XP
AF104XP
AF130XP
AF160XP
2.50-3.00
F31
None
None
AF44XS
-
AF53XS
AF65XS
-
AF72XS
AF90XS
AF104XS
AF130XS
AF160XS
0.50-1.10
L1
3-3/8U
8hole
-
AFG50MB
-
-
AFG70MB
-
AFG90MB
-
-
-
0.50-1.00
L2
2-3/4U
8hole
AFG50MP
-
-
AFG70MP
-
AFG90MP
-
-
-
0.75-2.75
V1
2-3/4U
8hole
-
AFG50MD
-
-
AFG70MD
-
AFG90MD
-
-
-
0.40-0.75
F0
3-1/2U
None
AF44WG
-
AF53WG
AF65WG
-
AF72WG
AF90WG
AF104WG
AF130WG
A160WG
Notice Special Requirements
y THE INSTALLATION OF A BURNER SHALL BE
IN ACCORDANCE WITH THE REGULATIONS
OF AUTHORITIES HAVING JURISDICTION.
y For recommended installation practices in the
U.S. refer to the latest edition of NFPA 31. (CSAB139 and CSA-B140 in Canada.
y Concealed damage — If you discover damage to
the burner or controls during unpacking, notify the
carrier at once and file the appropriate claim.
y When contacting Beckett for service information
— Please record the burner serial number (and
have available when calling or writing). You will
find the serial number on the silver label located
on the left rear of the burner. Refer to Figure 1.
6104BAFG R06
!
WARNING Professional Service
Required
Incorrect installation, adjustment,
and use of this burner could result
in severe personal injury, death, or
substantial property damage from
fire, carbon monoxide poisoning, soot or explosion.
Please read and understand the manual supplied with
this equipment. This equipment must be installed, adjusted and put into operation only by a qualified individual or service agency that is:
y Licensed or certified to install and provide technical service to oil heating systems.
y Experienced with all applicable codes, standards
and ordinances.
y Responsible for the correct installation and commission of this equipment.
y Skilled in the adjustment of oil burners using
combustion test instruments.
The installation must strictly comply with all applicable
codes, authorities having jurisdiction and the latest revision of the National Fire Protection Association Standard
for the installation of Oil-burning Equipment, NFPA 31
(or CSA-B139 and CSA-B140 in Canada).
Regulation by these authorities take precedence over
the general instructions provided in this installation
Page 5
Inspect/Prepare Installation Site
Inspect Chimney or Direct Vent System
!
WARNING Fire, Smoke & Asphyxiation Hazard
y Carefully inspect the chimney or exhaust vent
system.
y Make sure it is properly sized and in good working condition.
y Follow the instructions supplied by the appliance
manufacturer.
y The installation must strictly comply with all applicable codes, authorities having jurisdiction and
the latest revision of the National Fire Protection
Association Standard NFPA 31 for the installation of chimneys and vent sizing, (or CSA-B139
and CSA-B140 in Canada).
y Regulation by these authorities take precedence
over the general instructions provided in this installation manual.
1. Starting with minimum gph firing rate, the minimum size recommended is 6” flue pipe with 8” X
8” inside chimney, unless specified otherwise by
the appliance manufacturer.
2. A chimney flue shall extend at least 3 feet above
the highest point at which the chimney comes
in contact with the roof, and not less than 2 feet
above the highest roof surface or structure within
10 feet horizontally of the chimney. Refer to Figure 2.
3. Any accumulation of soot or debris in chimney
offsets should be removed
4. Any obstructions such as a protruding joint or a
piece of broken tile wedged in the chimney should
be removed.
5. No other appliance connection should be made to
the same flue pipe.
6. The flue pipe should have an upward pitch toward
the chimney of at least 1/4” per foot of length. It
should fit tightly and should not project into the
chimney.
7. Any leakage between tiles, around clean-out
doors, or around the vent pipe should be sealed.
INSULATED STAINLESS STEEL CHIMNEY LINERS
The new designs of high efficiency oil furnaces
and boilers in conjunction with flame retention oil
burners are more efficient. One result of increased
efficiency is lower flue gas temperatures. As
flue gases rise in the chimney, they will cool and
condense when they reach the dew point. The
condensation will mix with the sulphur in the flue
gases creating sulphuric acid. The acid will attack
the chimney mortar, brick and clay liners causing corrosion, deterioration and blockage of the
chimney. Eventually the blockage could prevent
exhausting the flue gases. Instead, the flue gases
could vent out the barometric damper into the living space.
Therefore, it is strongly recommended that an approved insulated stainless steel liner be installed.
y For those installations not requiring a chimney,
such as through-the-wall vented appliances, follow the instructions given by the appliance and
power venter (if used) manufacturers.
Figure 2 – Chimney Design - Above the Roof
NOTE: Correct
chimney design is
shown by dotted
lines. Incorrect
chimney design,
as shown by the
solid lines, may
result in downdrafts.
Page 6
6104BAFG R06
Inspect/Prepare Installation Site
Combustion air supply
!
Adequate Combustion
WARNING
and Ventilation Air Supply
Required
Failure to provide adequate air supply could
seriously affect the burner performance and result in damage to the equipment, asphyxiation,
explosion or fire hazards.
y The burner cannot properly burn the fuel if it is not
supplied with a reliable combustion air source.
y Follow the guidelines in the latest editions of the
NFPA 31 and CSA-B139 regarding providing adequate air for combustion and ventilation.
Appliance located in confined space
The confined space should have two (2) permanent
openings: one near the top of the enclosure and
one near the bottom of the enclosure. Each opening shall have a free area of not less than (1) one
square inch per 1,000 BTU’s per hour of the total
input rating of all appliances within the enclosure.
The openings shall have free access to the building interior, which should have adequate infiltration
from the outside.
Exhaust fans and other air-using devices
Size air openings large enough to allow for all airusing devices in addition to the minimum area required for combustion air. If there is any possibility
of the equipment room developing negative pressure (because of exhaust fans or clothes dryers, for
example), either pipe combustion air directly to the
burner or provide a sealed enclosure for the burner
and supply it with its own combustion air supply.
Direct air supply and sidewall venting
y Some AFG burners are equipped with combustion air boots to allow use of outside air for combustion.
y When sidewall venting appliances, carefully follow appliance and power venter instructions for
installation and wiring.
Outside air kit applications
Refer to separate instruction sheet supplied with
AF/AFG outside air kit for installation. This optional
kit allows combustion air to be piped directly to the
burner (Beckett part number 51747).
Clearances to burner and appliance
y Provide space around burner and appliance for
easy service and maintenance.
y Check minimum clearances against those shown
by the appliance manufacturer and by applicable
building codes.
!
WARNING Protect Steel Combustion
Chamber From Burnout
Failure to comply could result in damage to the
heating equipment and result in fire or asphyxiation hazards.
y When retrofitting appliances that have unlined
stainless steel combustion chambers, protect
the chamber by lining the inside surfaces with a
ceramic fiber blanket, such as a wet-pac or other
suitable refractory material.
y Some steel chambers may not require liners
because the appliance was designed and tested
for use with flame retention burners. Refer to the
manufacturer’s instructions.
Combustion chamber — Burner retrof tting
Verify that the appliance combustion chamber provides at least the minimum dimensions given in
Table 3.
Table 3. Chamber Dimensions
Chamber Dimensions (inches)
Firing Rate
(GPH)
Round
I.D.
0.50
Rectangular
Height
Floor to
nozzle
Width
Length
8
7
8
12
5-6
0.75
9
8
9
12
5-6
WARNING Follow the Outside Air Kit
1.00
10
9
10
12.5
5-6
1.25
11
10
11
12.5
5-6
Failure to comply could result in impaired combustion, appliance soot-up, puffback of smoke,
and fire or asphyxiation hazards.
1.50
12
11
12
13
6-7
2.00
14
12
15
13.5
6-7
2.50
16
13
17
14
7-8
3.00
18
14
18
15
7-8
!
Instructions Exactly
y Do not attempt to install outside air piping to
the burner without using the outside air kit and
instructions.
6104BAFG R06
Page 7
Inspect/Prepare Installation Site
Prepare the Burner
Low Firing Rate Baff e
The AFG Low Firing Rate Baffle (LFRB) reduces
the air flow and pressure. The LFRB is sometimes
used for firing rates under 1.00 gph as listed in
Table 4. Refer to the appliance manufacturer’s instructions. Do not omit the LFRB when specified.
Omitting the baffle when specified or installing the
baffle when not specified could result in impaired
burner performance.
Burner fuel unit
Table 4. AFG Reduced Firing Rates (with
LFRB)
Burner head type
Low Firing Rate Baffle installed
F0
up to 0.65 gph
F3 or L1
up to 0.85 gph
F4 or F6
up to 0.90 gph
V1
up to 1.00 gph
Table 5. Nozzle Flow Rate by Size
Nozzle f ow rate U. S. gallons per hour of No. 2 fuel oil when
pump pressure (psig) is:
Nozzle
size
(rated at
100 psig)
125
psi
140 psi
150 psi
175 psi
200 psi
0.40
0.45
0.47
0.49
0.53
0.56
0.50
0.56
0.59
0.61
0.66
0.71
0.60
0.67
0.71
0.74
0.79
0.85
0.65
0.73
0.77
0.80
0.86
0.92
0.75
0.84
0.89
0.92
0.99
1.06
0.85
0.95
1.01
1.04
1.13
1.20
0.90
1.01
1.07
1.10
1.19
1.27
1.00
1.12
1.18
1.23
1.32
1.41
1.10
1.23
1.30
1.35
1.46
1.56
1.20
1.34
1.42
1.47
1.59
1.70
1.25
1.39
1.48
1.53
1.65
1.77
Incorrect nozzles and flow rates
could result in impaired combustion, under-firing, over-firing, sooting, puff-back of hot gases, smoke
and potential fire or asphyxiation hazards.
1.35
1.51
1.60
1.65
1.79
1.91
1.50
1.68
1.77
1.84
1.98
2.12
1.65
1.84
1.95
2.02
2.18
2.33
1.75
1.96
2.07
2.14
2.32
2.48
2.00
2.24
2.37
2.45
2.65
2.83
Use only nozzles having the brand, flow rate (gph), spray
angle and pattern specified by the appliance manufacturer.
2.25
2.52
2.66
2.76
2.98
-
2.50
2.80
2.96
-
-
-
y Verify that the burner fuel unit is compatible with
the oil supply system. For more details, refer to
the pump manufacturer’s instructions provided
with the burner.
Attach air tube (if not already installed)
If using a flange and gasket, slide them onto the air
tube. Then attach the air tube to the burner chassis
using the four sheet metal screws provided. Refer
to Figure 4 for details.
Nozzle and Pump Pressure
!
WARNING Correct Nozzle and Flow
Rate Required
Follow the appliance manufacturer’s specifications for
the required pump outlet pressure for the nozzle, since
this affects the flow rate.
y Nozzle manufacturers calibrate nozzle flow rates
at 100 psig.
y When pump pressures are higher than 100 psig,
the actual nozzle flow rate will be greater than
the gph stamped on the nozzle body. (Example:
A 1.00 gph nozzle at 140 psig = 1.18 gph)
Securely tighten the nozzle (90 torque inch pounds). For
typical nozzle flow rates at various pressures refer to
Table 5.
Page 8
Install burner nozzle (if not already installed)
1. Remove the plastic plug protecting the nozzle
adapter threads
2. Place a 3/4” open-end wrench on the nozzle
adapter. Insert the nozzle into the adapter and finger tighten. Finish tightening with a 5/8” open-end
wrench. Use care to avoid bending the burner head
support legs or electrodes. If you remove the head
to replace the nozzle (type “L1”/“L2” or “V1” heads),
carefully reconnect the head to the nozzle adapter,
making sure that the head support makes contact
with the nozzle adapter shoulder. Refer to Figure
5 or 6.
6104BAFG R06
Prepare the Burner
3. If the nozzle is already installed, remove the nozzle line assembly to verify that the nozzle size and
spray pattern are correct for the application (per appliance manufacturer’s information). Verify that the
electrode tip settings comply with Figure 3.
4. If the nozzle is not installed, obtain a nozzle from
the manufacturer, having the capacity and spray
angle specified in the appliance manufacturer’s information. For conversions or upgrades, when information is not available for the application:
y Refer to Table 6 to select the mid-range nozzle
spray angle for the head type being used.
y Fire the burner and make sure the combustion
is acceptable and the flame is not impinging on
chamber surfaces.
y If a shorter flame is needed, select a wider spray
angle. If a longer flame is needed, select a narrower spray angle.
y Either hollow or solid spray patterns may be used.
If combustion results are not satisfactory with the
selected spray pattern, try the other pattern.
Figure 3. – Electrode Tip Adjustment
Standard Dimensions for F, L1, and V1 Heads.
The Dimensions shown below are for use with L2 heads
and M series air tube combinations ending with an ‘N’ suffix (example: AFG70MDAQN)
Table 6. Nozzle Spray Angles
Recommended nozzle spray angles
“F” head
70° or 80° nozzle
“L1” & “L2” head
45°, 60°, or 70° nozzle
“V1” head
45°, 60°, or 70° nozzle
Check/adjust electrodes
Check the electrode tip settings. Adjust if necessary to comply with the dimensions shown in Figure 3. To adjust, loosen the electrode clamp screw
and slide/rotate electrodes as necessary. Securely
tighten the clamp screw when finished.
Servicing nozzle line assembly
1. Turn off power to burner before proceeding.
2. Disconnect oil connector tube from nozzle line.
3. Loosen the two screws securing igniter retaining clips and rotate both clips to release igniter
baseplate. Then tilt igniter back on its hinge.
4. Remove splined nut.
5. “F” head air tube. - Remove nozzle line assembly from burner, being careful not to
damage the electrodes or insulators while
handling. To ease removal of long assemblies
(over 9 inches), rotate assembly 180° from
installed position after pulling partially out of
tube.
6. “L1”, “L2”, and “V1” head air tubes. - Slide
nozzle line assembly forward (further into air
tube) so the head clears the venturi opening.
Then rotate the nozzle line assembly 90° so
the nozzle line end points up. Pull the nozzle
line assembly toward you and remove assembly from burner.
7. To replace the nozzle assembly, reverse the
above steps.
6104BAFG R06
Mount burner on appliance
Mounting options
1. Bolt the burner to the appliance using the factory-mounted flange or an adjustable flange.
Mounting dimensions
1. When using the Beckett universal adjustable
flange, mount the air tube at a 2° downward
pitch unless otherwise specified by the appliance manufacturer.
2. Verify that the air tube installed on the burner
provides the correct insertion depth. See Figure 7.
3. The end of the air tube should normally be ¼”
back from the inside wall of the combustion
chamber. Never allow the leading edge of the
head assembly to extend into the chamber, unless otherwise specified by the heating appliance manufacturer. Carefully measure the insertion depth when using an adjustable flange.
Verify the insertion depth when using a welded
flange.
Page 9
Prepare the Burner
Figure 4. Check/Adjust ‘Z’ Dimension for ‘F’ Heads
1-1/8”
1-3/8”
!
WARNING Adjust the ‘Z’ dimension to the required
specif cation.
Incorrect Adjustments could cause combustion problems, carbon deposition from flame
impingement, heavy smoke generation and
fire hazard.
y Make all adjustments exactly as outlined in
the following information.
Check/Adjust ‘Z’ Dimension - ‘F’ heads
1.
The important ‘Z’ dimension is the distance from the face of the nozzle
to the flat face of the head (or heat shield, if applicable). This distance for F heads is 1-⅛” (1-⅜” if the air tube has a heat shield). The
“Z” dimension is factory set for burners shipped with the air tube installed. Even if factory set, verify that the “Z” dimension has not been
changed.
2. Use the following procedure to adjust the “Z” dimension, if it is not
correct:
y Turn off power to the burner.
y Disconnect the oil connector tube from the nozzle line
y See above figure. Loosen the splined nut from the nozzle line.
Loosen the hex head screw securing the escutcheon plate to the
burner housing.
y Place the end of a ruler at the face of the nozzle and, using a
straight edge across the head, measure the distance to the face of
the head. A Beckett T501 gauge may also be used.
y Slide the nozzle line forward or back until this dimension for F
heads is 1-⅛” (1-⅜” to the face of the heat shield, if applicable).
y Tighten the hex head screw to secure the escutcheon plate to the
burner chassis. Then tighten the splined nut and attach the oil connector tube.
3. Recheck the “Z” dimension periodically when servicing to ensure the
escutcheon plate has not been moved. You will need to reset the “Z”
dimension if you replace the air tube or nozzle line assembly. The
Beckett Z gauge (part number Z-2000) is available to permit checking
the F head “Z” dimension without removing the burner from the appliance.
Page 10
Burner Dimensions
For usable length A (inches)
F Head
L1
Head
L2
Head
V1
Head
N/A
1/4
7/32
1/4
A+1/2
A+1/2
A+1/2
A+1/2
R (electrode length), + 1/4
A+2-1/4
A+1-1/8
A+1-1/8
A+1-1/8
S (adapter to static plate), +
(Note 1)
1-3/8
1-3/8
1-3/8
A+ 15/16
A+ 3/16
A+ 3/16
A+ 3/16
Z (F head-no heat shield)
(F head-with heat shield)
1-1/8
1-3/8
N/A
N/A
N/A
N/A
N/A
N/A
Z (L1 head w/straight
shroud) (L1/L2/V1 head
w/conic shroud)
N/A
N/A
1-3/8
1-3/4
N/A
1-3/4
N/A
1-3/4
Dimension (inches)
H (nozzle to head), +1/32
L (Total tube length)
1/16
Q (nozzle line length),
Note 1: 1-3/8 for dimension A less than 4”; 1-5/8 for dimension A from 4”
through 4-1/2 “, 2-13/32 for dimension A greater than 4-1/2”.
6104BAFG R06
Prepare the Burner
Figure 5. Check/Adjust ‘Z’ Dimension - L1 &
L2 Heads
L1/L2 heads (see Table 7 and Figure 3 for dimensions)
1.
See figure above. The important “Z” dimension is the distance from
the leading edge of the head to the end of the air tube. This distance
for L1 & L2 heads is 1-⅜” if the tube has a straight shroud or 1-¾” if
the air tube has a conic shroud. The “Z” dimension is factory set for
Figure 6. Check/Adjust ‘Z’ Dimension - V1
Heads
V1 heads (see Table below and Figure above for dimensions)
1. See figure above. The important “Z” dimension is the distance from
the leading edge of the head to the end of the air tube. This distance
for V1 heads is 1-¾”. The “Z” dimension is factory set for burners
shipped with the air tube installed. Even if factory set, verify that the
“Z” dimension has not been changed.
Set head position adjusting plate (V1 head only)
1. After setting “Z” dimension, loosen head adjusting plate hex head
screw and nozzle line splined nut. Move the nozzle line assembly until
the burner reference indicator lines up with the head adjusting plate
setting number given in Table shown below.
2. Tighten the hex head screw and splined nut. (DO NOT loosen the
acorn nut when setting head position.) Refer to the manufacturer’s instructions for OEM settings.
3. The position of the head affects air flow volume and pattern. For most
applications, the burner will perform satisfactorily with the air adjustment plate setting of Table shown below.
4. If combustion results indicate the need for change, adjust the head position adjusting plate forward or back one position at a time to optimize
combustion.
6104BAFG R06
burners shipped with the air tube installed. Even if factory set, verify
that the “Z” dimension has not been changed.
2. Use the following procedure to adjust the “Z” dimension, if it is not
correct:
y Turn off power to the burner.
y Disconnect the oil connector tube from the nozzle line.
y Refer to figure. Loosen the splined nut from the nozzle line.
Loosen the hex head screw securing the escutcheon plate to the
burner housing.
y Place the end of a ruler at the leading edge of the head and, using a straight edge across the end of the air tube, measure the
distance to the end of the tube. A Beckett T501 gauge may also
be used.
y Slide the nozzle line forward or back until this dimension is 1-⅜”
for L1 & L2 heads if the tube has a straight shroud, or 1-¾” if the
air tube has a conic shroud.
y Tighten the hex head screw to secure the escutcheon plate to
the burner chassis. Then tighten the splined nut and attach the
oil connector tube.
3. Recheck the “Z” dimension periodically when servicing to ensure
the escutcheon plate has not been moved. You will need to reset
the “Z” dimension if you replace the air tube or nozzle line assembly.
2. Use the following procedure to adjust the “Z” dimension, if it is not
correct:
y Turn off power to the burner.
y Disconnect the oil connector tube from the nozzle line.
y See figure above. Loosen the splined nut from the nozzle line.
Loosen the hex head screw securing the head adjusting plate to
the burner housing.
y Loosen the acorn nut. Move the head adjusting plate until the “0”
lines up with the reference indicator on the housing, and retighten
the hex head screw. Place the end of a ruler at the leading edge of
the head and, using a straight edge across the end of the air tube,
measure the distance to the end of the tube. A Beckett T501 gauge
may also be used.
y Slide the nozzle line forward or back until this dimension is 1-¾” for
V1 heads. Tighten the acorn nut.
y Tighten the hex head screw to secure the head adjusting plate to
the burner chassis. Then tighten the splined nut and attach the oil
connector tube.
3. Recheck the “Z” dimension periodically when servicing to ensure the
escutcheon plate has not been moved. You will need to reset the “Z”
dimension if you replace the air tube or nozzle line assembly.
Table for initial adjusting plate settings for V1
Head
V1 Adjusting
Plate Setting
AFG with V1
Head
Burner Firing
Rates
0
0.75-1.00
1
1.00-1.50
2
1.50-1.75
3
1.75-2.00
4
2.00-2.25
5
2.25-2.50
6
2.50-2.75
Page 11
Mount burner on appliance
Figure 7. – Mounting Burner in Appliance
Figure 8. – Inside Tank Gravity Feed System
If space between burner
air tube and opening
exceeds 1/2 inch, pack
burner opening with ceramic fiber refractory.
Tilt down 2
o
SK8745
Installing the Oil Tank and Supply System
!
WARNING
Oil Leak and Fire Hazard
Figure 9. – Outside Buried Tank-Lift System
Install the oil tank following applicable standards in the U.S. by referring to the latest
edition of NFPA 31 or CSA-B139 & CSA-B140
in Canada, and all authorities having jurisdiction.
!
CAUTION Do Not Use Tef on Tape
Damage to the pump could cause impaired
burner operation, oil leakage and appliance
soot-up.
y Never use Teflon tape on fuel oil fittings.
y Tape fragments can lodge in fuel line components and fuel unit, damaging the equipment
and preventing proper operation.
y Use oil-resistant pipe sealant compounds.
Note: to determine the proper fuel line size, refer
to the fuel pump manufacturer’s instructions provided with the burner. Refer to Figure 8 or Figure 9
for typical installation layouts.
NOTICE
To further protect the fuel supply system and reduce nozzle orifice plugging with firing rates
below 0.75 gph, a dual filtration system can be installed.
This typically consists of a 50 micron primary filter,
located near the fuel tank and a secondary filter rated for
at least 10 microns located near the burner.
Fuel supply level with or above burner –
Fuel Line Valves and Filter
Install two high quality, oil duty rated, fusible
handle design shutoff valves in accessible locations on the oil supply line. Locate one close to the
tank and the other close to the burner, upstream of
the filter for service access.
Install a generous capacity filter inside the building
between the fuel tank shutoff valve and the burner,
locating both the filter and the valve close to the
burner for ease of servicing. Filter should be rated
for 50 microns or less.
Page 12
!
WARNING
Do Not Install By-pass Plug
with 1-Pipe System
Failure to comply could cause Immediate pump
seal failure, pressurized oil leakage and the
potential for a fire and injury hazard.
y The burner is shipped without the by-pass plug
installed.
y Install the by-pass plug in two-pipe oil supply
systems ONLY.
6104BAFG R06
Wire burner
!
CAUTION Oil Supply Pressure
Control Required
Damage to the filter or pump seals could cause
oil leakage and a fire hazard.
y The oil supply inlet pressure to the burner cannot exceed 3 psig.
y Insure that a pressure limiting device is installed
in accordance with the latest edition of NFPA 31.
y Do NOT install valves in the return line.
(NFPA 31, Chapter 8.)
y Gravity Feed Systems: Always install an antisiphon valve in the oil supply line or a solenoid
valve (RWB Part # 2182602U) in the pump/nozzle discharge tubing to provide backup oil flow
cut-off protection.
The burner may be equipped with a single-stage
fuel unit for these installations. Connect the fuel
supply to the burner with a single supply line if you
want a one-pipe system (making sure the bypass
plug is NOT installed in the fuel unit.) Manual bleeding of the fuel unit is required on initial start-up. If
connecting a two-pipe fuel supply, install the fuel
unit bypass plug.
Fuel supply below the level of the burner –
When the fuel supply is more than eight feet below
the level of the burner, a two-pipe fuel supply system is required. Depending on the fuel line diameter and horizontal and vertical length, the installation may also require a two-stage pump. Consult
the fuel unit manufacturer’s literature, included with
the burner, for lift and vacuum capability.
Fuel line installation –
y Continuous lengths of heavy wall copper tubing
are recommended. Always use f are f ttings.
Never use compression f ttings.
y Always install fittings in accessible locations.
Proper routing of fuel lines is required to prevent
air cavitation and vibration.
Frozen Plumbing and
Water Damage Hazard
If the residence is unattended in severely cold
weather, burner primary control safety lockout,
heating system component failures, power
outages or other electrical system failures
could result in frozen plumbing and water
damage in a matter of hours. For protection,
take preventive actions such as having a
security system installed that operates during
power outages, senses low temperature and
initiates an effective action. Consult with your
heating contractor or a home security agency.
6104BAFG R06
Wire burner
Burner packaged with appliance
!
WARNING Electrical Shock Hazard
Electrical shock can cause severe
personal injury or death.
y Disconnect electrical power before installing or
servicing the burner.
y Provide ground wiring to the burner, metal control enclosures and accessories. (This may also
be required to aid proper control system operation.)
y Perform all wiring in compliance with the National Electrical Code ANSI/NFPA 70 (Canada
CSA C22.1)
y Refer to appliance manufacturer’s wiring diagram
for electrical connections.
Burner installed at jobsite
y Refer to Figures 11a and 11b, for typical burner
wiring, showing cad cell primary controls. Burner
wiring may vary, depending on primary control
actually used.
y Refer to the appliance manufacturer’s wiring diagram prior to connecting the burner wiring. All wiring must be in accordance with the latest revision
of National Electric Code NFPA 70 and all local
codes and regulations. In Canada, all wiring is
to be in accordance with the Canadian Electrical
Code, Part 1.
The 7505 primary control with valve-on delay (pretime) and burner motor-off delay (post-time) requires a constant 120 volts AC power source supplied to the BLACK wire on the control. The RED
wire goes to the appliance limit circuit. Please note
that other control manufacturers may use different
wire colors for power and limit connections.
Special wiring required with covered
burners
The mounting plate is not a conduit connection point. Pass conduit and attached connector
through the opening in the mounting plate and attach it directly to the burner-mounted 4x4 electrical
box.
If attaching a burner cover to a previously installed
burner, attach the mounting plate and then slide the
conduit into the “J” shaped conduit slot.
Page 13
Burner Controls
GeniSys Model 7505 Control
Wiring
Explosion, Fire, Scald,
and Burn Hazard
Fire or Explosion Hazard
All heating appliances must have
HIGH LIMIT protection to interrupt
electrical power and shutdown the
burner if operating or safety controls
fail and cause a runaway condition.
Can cause severe injury, death, or
property damage.
y The control can malfunction if it gets wet,
leading to accumulation of oil or explosive oil
vapors.
y Never install where water can flood, drip or
condense on the control.
y Never use a control that has been wet - replace it.
y Follow the appliance manufacturer’s wiring
diagrams and note all required safety controls.
y Typical safety controls include high temperature
or pressure limits, low water cutoffs, pressure
relief valves and blocked flue sensing switches.
y Verify all limit and safety controls are installed
and functioning correctly, as specified by the
manufacturer, applicable safety standards,
codes and all authorities having jurisdiction.
y Ensure that the appliance is free of oil and oil
vapor before starting or resetting the burner.
Features
•
•
•
•
•
•
•
•
•
•
•
•
Thermostat / Operating and Limit Control Compatible
Welded Relay Protection
Limited Recycle
Limited Reset
3 Status Lights
Valve-On Delay / Motor-Off Delay (Field
programmable with 52067 GeniSys Display)
15 Second Lockout Time
Interrupted or Intermittent Duty Ignition
Technician Pump Priming Mode
Disable Function
Cad Cell Resistance Indicator
Communication Ports
Operation
Incorrect Wiring Will Result in Improper Control
y GeniSys wiring label colors may not match the
wire colors of the burner or other manufacturers’
controls.
y The GeniSys Control should be wired according
to the appliance manufacturer’s instructions.
Figure 10.
Yellow Light
Wiring
Connections
Green Light
Reset Button
with Red Light
Communication Port 2
Cad Cell
Connections
Communication Port 1
Thermostat Terminals
Display Module:
For programming and
diagnostics
Page 14
Alarm Module:
For adding isolated
low voltage alarm
contacts to the base
control. See Alarm
Module Instructions for
specifications.
6104BAFG R06
Burner Controls
Typical Burner Sequence of Operation for GeniSys 7505 Control.
Refer to the appliance manufacturer’s wiring diagram for actual specifications.
9
1
Pump
prime
Standby
3
2
4
Trial for
ignition
Valve-on delay
Lockout
5
Ignition carryover
6
8
Motor-off delay
1. Standby: The burner is idle, waiting for a call for
heat.
2. Valve-On Delay: The igniter and motor are on while
the control delays turning on the oil solenoid valve
for the programmed time.
3. Trial For Ignition : The oil solenoid valve is
energized. A flame should be established within the
factory set trial for ignition time (lockout time).
4. Lockout: The control has shut down for one of the
following safety reasons:
a. The trial for ignition (lockout) time expired without
flame being established.
b. The cad cell detected flame at the end of the
Valve On Delay state.
To reset the control from lockout click the button 1second.
NOTE: A recurrence of the above failure modes or a
failed welded relay check could cause the control to
enter a Hard Lockout state that must be reset only
by a qualified service technician.
To reset from Hard Lockout, hold the reset button for
15 seconds until the yellow light turns on.
7
Run
Recycle
6. Run: The flame is sustained until the call for heat
is satisfied. The burner is then sent to Motor-Off
Delay, if applicable, or it is shut down and sent to
Standby.
7. Recycle: If the flame is lost while the burner is
firing, the control shuts down the burner, enters a
60 second recycle delay, and repeats the ignition
sequence. The control will continue to Recycle
each time the flame is lost, until it reaches a pre-set
time allotment. The control will then go into Hard
Lockout instead of recycle. This feature prevents
excessive accumulation of oil in the appliance firing
chamber.
8. Motor-Off Delay: If applicable, the oil solenoid
valve is turned off and the control delays turning the
motor off for the set motor-off delay time before the
control returns to standby.
9. Pump Prime: The igniter and motor are on with the
oil solenoid valve energized for 4 minutes. During
Pump Prime mode, the cad cell is disregarded,
allowing the technician to prime the pump without
having to jumper the cad cell.
5. Ignition Carryover: Once flame is established,
the igniter remains on for 10 additional seconds to
ensure flame stability.
6104BAFG R06
Page 15
Burner Controls
Figure 1 1a. – Interrupted ignition, valve-on delay
Figure 1 1b. – Interrupted ignition, valve-on delay
only (no motor-off delay)
W
L1
R
L2
80
50
60
50
SAFETY AND
OPERATING
LIMITS
70
60
70
60
70
W
R
50
80
SAFETY AND
OPERATING
LIMITS
70
80
L2
60
80
50
L1
and motor-off delay
THERMOSTAT
THERMOSTAT
IGNITER
IGNITER
MOTOR
IGNITER
IGNITER
L2 (IGN)
L2 (IGN)
MOTOR
L2 (MTR)
MOTOR
L2 (MTR)
L1LIMIT
LIMIT
L2
OIL VALVE
VALVE
TR
TW
CAD CELL
L1
LIMIT
JUMPER
L2 (VLV)
CAD
CELL
MOTOR
L1 - LIMIT
JUMPER
TR-TW
L2
OIL VALVE
VALVE
TR
L2 (VLV)
TW
CAD
CELL
TR-TW TERMINALS
LOCATED ON OPPOSITE
SIDE OF CONTROL
CAD CELL
TR-TW
JUMPER
TR-TW TERMINALS
LOCATED ON OPPOSITE
SIDE OF CONTROL
Reset Button Operation
Table 2 explains what action the control will take when the reset button is pressed for different lengths of time
during the various burner operating states.
Table 2 - Reset Button Operation
If the burner is in the
below state:
Pushing the reset button will:
Button Click
(press < 1 second)
Lockout
Button Hold
(press > 1 second)
Button Hold
(press 15+ seconds)
Reset from Restricted (Hard)
Lockout
Reset from Soft Lockout
Valve-on Delay, Trial for
Ignition, Ignition Carryover
Go to Pump Prime (see
“Priming the Pump” above)
Run (igniter is shut off)
Yellow light flashes to indicate
cad cell resistance. See “Cad
Cell Resistance Indicator” for
table of resistance values.
Motor-Off Delay,
Standby
No action
Pump Prime
No action
Disable the Burner:
Any time the burner is running,
press and hold the reset button
to disable the burner. The
burner will remain off as long
as the button is held.
Enables Pump Priming:
After the reset button has been
held for 15 seconds, the button
can then be clicked during the
next ignition sequence to enter
Pump Prime mode.
Exit Pump Prime mode and return to Standby
Table 3 - Status Lights
Light Color
On Continuously
Flashing
Red
Restricted (Hard) Lockout
Soft Lockout
Green
Flame Sensed during normal operation (Could
be stray light during standby)
Recycle
Yellow
Control is in Pump Prime mode or
Reset button currently held for 15+ seconds.
Cad Cell resistance. See “Cad Cell Resistance
Indicator” on page 18 for a table of resistance
values.
Page 16
6104BAFG
6104BAFGR06
R05
Burner Controls
Typical Burner Wiring & Burner Sequence of Operation for R7184P Control.
Refer to the appliance manufacturer’s wiring diagram for actual specifications.
Figure 10. – Typical Burner Wiring
1. STANDBY. The burner is idle, waiting for a call for
heat. When a call for heat is initiated, there is a 310 second delay while the control performs a safe
start check.
2. VALVE-ON DELAY. The ignition and motor are
turned on for a 15 second valve-on delay.
3. TRIAL FOR IGNITION (TFI). The fuel valve is
opened. A flame should be established within the
15 second lockout time.
4. LOCKOUT. If flame is not sensed by the end of
the TFI, the control shuts down on safety lockout
and must be manually reset. If the control locks out
three times in a row, the control enters restricted
lockout.
5. IGNITION CARRYOVER. Once flame is established, the ignition remains on for 10 seconds to
ensure flame stability before turning off. If the control is wired for intermittent duty ignition, the ignition
unit stays on the entire time the motor is running.
6. RUN. The burner runs until the call for heat is satified. The burner is then sent to burner motor off
delay, if applicable, or it is shut down and sent to
standby.
7. RECYCLE. If the flame is lost while the burner is
firing, the control shuts down the burner, enters a 60
second recycle delay, and then repeats the above
ignition sequence. If flame is lost three times in a
row, the control locks out to prevent cycling with
repetitious flame loss due to poor combustion.
8. BURNER MOT OR-OFF DELA Y. The fuel valve
is closed and the burner motor is kept on for the
selected motor-off delay time before the control returns the burner to standby.
61351
Control System Features
Feature
Interrupted
ignition
Limited reset,
Limited recycle
Diagnostic LED,
cad cell indicator
Valve-on
delay
Burner motor
off delay
Alarm Contacts
R7184A
YES
YES
YES
—
—
—
R7184B
YES
YES
YES
YES
—
—
R7184P
YES
YES
YES
YES
YES
Optional
6104BAFG R0
Page 17
Wire burner
Some Thermostats Are Polarity Sensitive. Reversed polarity
could cause erratic cycling of the burner control.
3. Set the thermostat substantially above room temperature.
4. Close the line voltage switch to start the burner.
If the burner does not start immediately you may
have to reset the burner primary control.
5. Initiate a call for heat.
6. After the burner starts, press and hold the reset
button for 15 seconds until the yellow light turns on.
This indicates that the button has been held long
enough.
7. Release the reset button. The yellow light will turn
off and the burner will start up again.
8. At burner start up, click the reset button while the
igniter is still on. This will transition the control to a
dedicated Pump Prime mode, during which the motor, igniter, and valve are powered for four minutes.
The yellow light will be on.
9. Bleed the pump until all froth and bubbles are
purged. If desired, terminate the call for heat or
hold the reset button for at least one second to exit
Pump Prime mode and return to Standby.
10. At the end of 4 minutes, the yellow light will turn off
and the control will automatically return to standby
mode.
11. If prime is not established during the four minute
pump prime mode, return to step 8 to re-enter Pump
Prime mode. Repeat steps 8 through 10 until the
pump is fully primed and the oil is free of bubbles.
12. Terminate the call for heat, and the control will resume normal operation.
NOTICE
y Connect the wire from the RH or R terminal on the
thermostat to the TR terminal on the control.
y Connect the wire from the W terminal on the
thermostat to the TW terminal on the control.
○ Make connections to the control’s terminals as shown
in Figures 11a and 11b. Refer to the label on the underside of the control for wiring details.
○ Note: Motor-off delay on a 7505P will be disabled if
the safety and operating limits as shown in Figures
11a and 11b interrupt power to the control terminal
L1.
○ Connect thermostat leads to the TR and TW
terminals on the control or jumper the TR and
TW terminals on the control, as directed by the
appliance wiring diagram.
▪ Thermostat anticipator Current: 0.1 amp
▪ Thermostat voltage: 24 volts AC
Note that if the thermostat short cycles or operates
improperly, it may require an isolation relay for proper
operation. The Beckett A/C Ready Kit (part no. 51950U)
provides this function. Wiring instructions are included
with the A/C Ready Kit.
▪
○ During the burner Run state, click the reset button
(less than 1 second) to check the cad cell resistance
range. The yellow light will flash 1 to 4 times, depending on the amount of light detected by the cad
cell. See chart below:
Start up burner/set combustion
Yellow Light Flashes
Hot Gas Puff-Back and
Heavy Smoke Hazard
Failure to prime the pump properly could result
in unstable combustion, hot gas puff-back and
heavy smoke.
y Do not allow oil to spray into a hot combustion
chamber while bleeding air from the pump.
y Install a gauge in the nozzle discharge port
tubing or fully open the pump bleed valve to
prevent oil spray from accumulating in the combustion chamber during the air bleed procedure.
y Ensure that all bubbles and froth are purged
from the oil supply system before tightening the
pump bleed valve.
y Ensure that the appliance is free of oil and oil
vapor before starting or resetting the burner.
1. Open the shutoff valves in the oil supply line to the
burner.
2. Close air band and partially open air shutter. This
is an initial air setting for the pump bleeding procedure only. Additional adjustments must be made
with instruments.
Page 18
Cad Cell Resistance Indicator
▪
Flame Detection Range
1
Normal (0 - 400 ohms)
2
Normal (400 - 800 ohms)
3
Normal (800 - 1600 ohms)
4
Limited (1600 ohms - Lockout)
Resetting From Restricted or Hard Lockout
○ If the control continues to lockout without a satisfied
call for heat, or fails the motor relay check, the control
enters Hard (restricted) Lockout in order to limit accumulation of unburned oil in the combustion chamber.
○ To reset, hold the button down for 15 seconds until
the red light turns off and the yellow light turns on.
○ Always verify the control functions according to all
specifications before leaving the installation site.
○ Replace the control if it does not operate as specified.
6104BAFG R0
Startup/Checkout
Startup / Checkout
!
4. After the 60 second recycle period, the control
will try to restart the system.
WARNING Explosion and Fire Hazard
5. After the 15 second lockout time, the control
will lock out the burner and the reset button will
flash. Verify that the burner motor and igniter
are off and that the burner oil solenoid valve (if
used) is not energized.
Failure to follow these instructions
could lead to equipment malfunction and result in heavy smoke
emission, soot-up, hot gas puffback, fire and asphyxiation hazards.
y Do not attempt to start the burner when excess
oil has accumulated in the appliance, the appliance is full of vapor, or when the combustion
chamber is very hot.
y Do not attempt to re-establish flame with the
burner running if the flame becomes extinguished during start-up, venting, or adjustment.
y Vapor-Filled Appliance: Allow the unit to cool
off and all vapors to dissipate before attempting
another start.
y Oil-Flooded Appliance: Shut off the electrical
power and the oil supply to the burner and then
clear all accumulated oil before continuing.
y If the condition still appears unsafe, contact the
Fire Department. Carefully follow their directions.
y Keep a fire extinguisher nearby and ready for
use.
If the burner or control fails any of the following tests,
recheck control wiring. If the burner or control still fails
any tests, replace the control.
▪
Check Safety Features
○ Safe Start Check
6. Open the hand valve in the oil line.
7. Click the reset button and verify that the red light
in the reset button shuts off and that the burner
lights.
8. End the call for heat.
○ Before leaving the installation, verify that all thermostat and boiler/furnace control wiring is correct. Consult heating appliance manual for directions.
Set combustion with instruments
!
CAUTION
OIL-BURNING EQUIPMENT
SHALL BE CONNECTED TO
FLUES HAVING SUFFICIENT DRAFT AT ALL TIMES
TO ENSURE SAFE AND PROPER OPERATION OF
THE BURNER.
1. Allow the burner to run for approximately 5 to 10
minutes.
2. Set the stack or over-fire draft to the level specified
by the appliance manufacturer.
1. Place a jumper across the cad cell terminals.
y Natural Draft Applications; typically over-fire
draft is -0.01” or -0.02” w.c.
2. Refer to the steps for “Start up burner/set
combustion” and have the system call for heat.
y Direct V enting; typically may not require draft
adjustment.
3. Burner must not start. Verify that the green light
is on continuously and that the control remains
in Standby mode.
4. End the call for heat and remove the cad cell
jumper.
○ Simulate Flame Failure and Ignition Failure
1. Refer to the steps for “Start up burner/set
combustion” and have the system call for heat.
2. After flame is established and the burner igniter
turns off, close the hand valve in the oil supply
line.
3. At flame loss, the control will enter Recycle
mode. Verify that the green light is flashing. The
control will remain in Recycle for 60 seconds.
6104BAFG R0
y High Eff ciency/Positive Pressure Appliances;
also vary from traditional appliances (see manufacturer’s recommendations).
3. Follow these four steps to properly adjust the burner:
Step 1: Adjust the air shutter/band until a trace of
smoke is achieved.
Step 2: At the trace of smoke level, measure the
CO2 (or O2) . This is the vital reference
point for further adjustments. Example:
13.5% CO2 (2.6% O2)
Step 3: Increase the air to reduce the CO2 by
1.5 to 2 percentage points. (O2 will be increased by approximately 2.0 to 2.7 percentage points.) Example: Reduce CO2
from 13.5% to 11.5% (2.6% to 5.3% O2).
Page 19
Perform regular maintenance
Step 4: Recheck smoke level. It should be Zero.
• This procedure provides a margin of
reserve air to accommodate variable
conditions.
• If the draft level has changed, recheck
the smoke and CO2 levels and readjust
the burner if necessary
ˆ Verify the nozzle is the one originally specified by
the appliance manufacturer and replace the nozzle with one having the exact specifications from
the same manufacturer.
ˆ Clean and inspect the electrodes for damage, replacing any that are cracked or chipped.
ˆ Check electrode tip settings. Replace electrodes
if tips are rounded.
ˆ Inspect the igniter spring contacts. Clean or replace if corroded.
ˆ Clean the cad cell grid surface, if necessary.
ˆ Make sure Low Firing Rate Baffle is in place if
required for the burner application. Omitting the
baffle can result in unacceptable burner combustion.
ˆ Inspect all gaskets. Replace any that are damaged or would fail to seal adequately.
ˆ Inspect the combustion head and air tube. Remove any carbon or foreign matter. Replace all
damaged units with exact parts.
ˆ Clean the blower wheel, air inlet, air guide, burner
housing and static plate of any lint or foreign material.
ˆ If motor is not permanently lubricated, oil motor
with a few drops of SAE 20 nondetergent oil at
each oil hole. DO NOT over oil motor. Excessive
oiling can cause motor failure.
ˆ Check motor current. The amp draw should not
exceed the nameplate rating.
ˆ Check all wiring for secure connections or insulation breaks.
ˆ Check the pump pressure and cutoff function.
ˆ Check primary control safety lockout timing.
ˆ Check ignition system for proper operation.
ˆ Inspect the vent system and chimney for soot accumulation or other restriction.
ˆ Clean all flue passages and flue pipe. Replace
corroded or damaged pipes.
ˆ Clean the appliance thoroughly according to the
manufacturer’s recommendations.
ˆ Check the burner performance. Refer to the section “Set combustion with test instruments”.
ˆ It is good practice to make a record of the service
performed and the combustion test results.
4. Once combustion is set, tighten all fasteners on air
band, air shutter and head adjusting plate or escutcheon plate.
5. Burner equipped with cover - Reinstall the cover
and repeat Steps 2 and 4. If CO2 increases (O2
decreases), remove the cover and adjust the air
setting so the CO2 (O2) with cover on meets requirements of Step 3.
6. Start and stop the burner several times to ensure
satisfactory operation. Test the primary control and
all other appliance safety controls to verify that they
function according to the manufacturer’s specifications.
Perform regular maintenance
!
WARNING Annual Professional Service Required
Tampering with or making incorrect
adjustments could lead to equipment malfunction and result in
asphyxiation, explosion or fire.
y DO NOT TAMPER WITH THE UNIT OR CONTROLS - CALL YOUR QUALIFIED SERVICE
TECHNICIAN OR SERVICEMAN.
y To ensure continued reliable operation, a qualified service technician must service this burner
annually.
y More frequent service intervals may be required
in dusty or adverse environments.
y Operation and adjustment of the burner requires
technical training and skillful use of combustion
test instruments and other test equipment.
ˆ Replace the oil supply line filter. The line filter cartridge must be replaced to avoid contamination of
the fuel unit and nozzle.
ˆ Inspect the oil supply system. All fittings should
be leak-tight. The supply lines should be free of
water, sludge and other restrictions.
ˆ Remove and clean the pump strainer if applicable.
Page 20
Shutting the Burner Off
!
CAUTION
IF THE BURNER IS SHUT DOWN
FOR AN EXTENDED PERIOD OF
TIME, ALWAYS KEEP THE VALVE SHUT OFF.
Turn off all electric power to the burner.
Note: There could be more than one disconnect
switch.
6104BAFG R0
Perform regular maintenance
Replace the blower wheel:
1. Turn off all power to the burner before servicing.
2. Disconnect the burner motor wires.
3. Remove the bolts securing the motor to the
burner housing.
4. Remove the motor and blower wheel.
5. Remove the existing blower wheel.
6. Referring to the figure below, slide the new
blower wheel onto the shaft.
y Use a feeler gauge to set the wheel-to-motor
gap, as shown below. (AF = 0.125 +1/64 inch,
AFG = 0.030 +1/64 inch)
y Slide blower wheel toward motor until it contacts feeler gauge.
y Rotate the blower wheel until the setscrew is
centered on the flat of the motor shaft. Tighten
the setscrew to secure the wheel.
7. DO NOT use a motor that has endshield openings outside the blower wheel circumference
(represented by the dashed line).
8. Install the motor on the burner housing. Tighten
screws. Reconnect wires.
9. Restore power, start the burner and perform
combustion tests. Refer to the section “Set
combustion with test instruments”.
6104BAFG R0
Figure 12. Blower wheel assembly
Use a Feeler Gauge to set
the gap to;
AF = 0.125 +1/64 inch
AFG = 0.030 +1/64 inch
SK9190
Page 21
21
23
24
6
For best performance specify genuine
#
Part No.
1
Beckett
replacement parts
Description
#
Part No.
Description
Burner Housing Assembly
16
51771U
Igniter & Base Plate
17 & 18
51304
Igniter Gasket Kit
2
Specify*
Air Band - Specify # of slots
3
Specify*
Air Shutter - Specify # of slots
19
5880
Low Firing Rate Baffle
4
21807U
Valve Cordset
20
7006U
Cad Cell Detector
Not Shown
21887U
PD Timer Delay Cordset
5
2184404U
CleanCut Pump
6
5394
Copper Oil Line - 8”
5940
Electrode Kit - M Head up to 9”
7
3666
Splined Nut
22
8
3493
Escutcheon (F & L1/L2 heads)
Specify *
3811
Welded Flange
Gasket Only
23
Specify *
Retention Head Assembly
Hole Plug
24
Specify *
Nozzle Line Electrode & Head Assembly
5685
Pedestal Kit
9
2139
21
10
2454
Coupling
25
11
31231U (AFG)
31841U (AF)
Air Guide (AFG)
Air Inlet Bell (AF)
26
2182602U
Solenoid Valve Kit (delay)
27
32395U
Cover
12
2999U (AFG)
2459U (AF)
Blower Wheel (AFG)
Blower Wheel (AF)
13
21805U
4189
PSC Motor
Mounting Screws
14
5770
Electrical Box
7505P
Replaces R7184P - Pre and Posttime**
15
6104BAFG R06
* Contact your Beckett Representative for part number and pricing.
** Contact your Beckett Representative for available
pre and post time settings.
Page 23
Limited
WARRANTY
For Residential, Commercial and Specialty Burners
The R. W. BECKETT CORPORATION (“Beckett”) warrants to persons who purchase its Beckett burners from Beckett for resale or for
incorporation into a product for resale (“Customers”) that its equipment is free from defects in material and workmanship under normal use and
service for 60 months from the date of manufacture for Residential Burners and 18 months from the date of manufacture for Commercial and
Specialty Burners. Residential burner models include: AF, AFG, AFII, NX, SF, SR and SMG. Commercial burner models include: CF375,
CF500, CF800, CF1400, CF2300A, CF2500, CF3500A, CG10, CG15, CG25 and CG50. Specialty burner models include: ADC, ADCP, ARV,
SDC and SM. The provisions of this warranty are extended to individual major burner components as follows:
a) 60 months from date of manufacture for all Beckett-branded major components, except for 12 Vdc components.
b) 18 months from date of manufacture for all non-Beckett-branded major components and Beckett branded 12 Vdc components.
Note: Normal service items found to be defective upon receipt by the customer are covered by this warranty.
THIS WARRANTY DOES NOT EXTEND TO EQUIPMENT SUBJECTED TO MISUSE, NEGLECT, OR ACCIDENT: NOR DOES THIS WARRANTY APPLY
UNLESS THE PRODUCT COVERED BY IT IS PROPERLY INSTALLED BY A QUALIFIED, COMPETENT TECHNICIAN, WHO IS LICENSED WHERE
STATE AND LOCAL CODES REQUIRE, 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 FUEL GAS CODE (NFPA
NO. 54) AND IN ACCORDANCE WITH ALL APPLICABLE LOCAL, STATE AND NATIONAL CODES HAVING JURISDICTIONAL AUTHORITY.
Equipment, which is defective 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 determined 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 EXCLUSIVE REMEDIES EXPRESSLY IN LIEU OF ALL OTHER
REMEDIES, AND IN PARTICULAR THERE SHALL BE EXCLUDED THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE. IN NO EVENT WILL BECKETT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGE OF ANY NATURE. Beckett neither assumes nor
authorizes any person to assume for Beckett any other liability or obligation in connection with the sale of this equipment, Beckett’s liability and Customer’s
exclusive remedy being limited to credit as set forth above.
R.W.
BECKETT CORPORATION
P.O. Box 1289 Elyria, Ohio 44036
Form No. 61545 R72905
The Oilheat Manufacturers’ Association supports the use of low sulfur fuels as defined by ASTM D396, Grades No. 1 Low Sulfur
and No. 2 Low Sulfur, as the preferred heating fuel for the following reasons:
• Low sulfur fuels reduce deposits on heat exchanger surfaces, extending the service interval between cleanings.
• The reduced deposits increase the efficiency of the appliance.
• Low sulfur fuels reduce particulate emissions.
• Low sulfur fuels reduce oxides of nitrogen emissions.
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
Form Number 6104 BAFG R06
Printed in U.S.A.
01/14/09
Page 24
© 2008 R.W. Beckett Corporation
6104BAFG R06