Beckett | CF 2500/ 3500 | Instruction manual | Beckett CF 2500/ 3500 Instruction manual

COMMERCIAL PRODUCTS
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.
To the Professional, Qualified 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.
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 qualified service agency for consultation.
We recommend annual inspection/service of your
oil heating system by a qualified 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
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.
Special Requirements - The
installation of a burner shall be
in accordance with the regulations of authorities having
Jurisdiction.
○ For recommended installation practices in the U.S.
refer to the latest edition of NFPA 31.
(CSA-B139 and CSA-B140 in Canada.
Impaired Burner
Performance & Fire Hazard
Do NOT operate the burner beyond specifications
outlined in the Table on Page 3.
y For applications beyond these limits, consult Beckett
Technical Services 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.
2
Contents
General Information .................................................... 3
Hazard Definitions ......................................................................... 3
Specifications ................................................................................ 3
Owner’s Responsibility: ................................................................. 3
Service Agency Responsibility: ..................................................... 3
Combustion Air Supply .................................................................. 4
Clearances .................................................................................... 4
Fuel Supply ................................................................................... 4
Nozzle Pressure ............................................................................ 5
Electrical Supply............................................................................ 5
Vent System .................................................................................. 5
Verify Burner Components ............................................................ 5
Verify Firing Rate........................................................................... 5
Verify Air Tube ............................................................................... 6
Dust and Moisture ......................................................................... 7
Mount the Burner......................................................... 7
Mount Flange(s) on Air Tube ......................................................... 7
Mount Air Tube to Burner .............................................................. 8
Install Nozzle ................................................................................. 8
Check Electrode Settings .............................................................. 8
Install Nozzle Line Assembly......................................................... 8
Set Dimension Z............................................................................ 9
Insert Burner ................................................................................. 9
Connect Fuel Lines ................................................... 10
Fuel Unit By-pass Plug............................................................... 10
One-pipe Oil System By-pass Loop ........................................... 10
Oil Supply/Return Lines ............................................................. 10
Burner Fuel Flow ........................................................................ 10
Wire the Burner ......................................................... 12
Typical Burner Sequence of Operation - GeniSys 7505 ............ 12
Cad Cell Resistance Measurement:........................................... 13
Typical Burner Sequence of Operation - RM7897A Control ......... 15
Z Dimension ............................................................................... 17
Adjusting Plate Assembly ........................................................... 17
Initial Head Position ................................................................... 17
Initial Air Settings........................................................................ 18
Set Appliance Limit Controls ...................................................... 19
Prepare the Fuel Unit for Air Venting.......................................... 19
Start the Burner ......................................................... 19
Start Burner and Vent Air from Oil Line ...................................... 19
Set High-fire Air .......................................................................... 20
Set Low-fire Air ........................................................................... 20
Perform Regular Maintenance.................................. 21
Annual Service — by qualified service technician...................... 21
Monthly Maintenance — by owner ............................................. 21
Replacement Parts .................................................... 22
Limited Warranty Information .................................. 24
Agency Approvals
○
○
○
UL listed to comply with ANSI/UL296
and certified to CSA B140.0.
Accepted by N.Y.C. M.E.A.
Other approvals may be available and
must be specified at time of order.
Section: General Information
General Information
Owner’s Responsibility:
Hazard Definitions
Indicates a hazardous
situation which, if not
avoided, will result in death or serious injury.
Indicates a hazardous
situation, which, if not
avoided, could result in death, or serious
injury.
Follow these instructions
exactly.
Failure to follow these instructions, misuse, or incorrect
adjustment of the burner could result in asphyxiation,
explosion or fire.
Contact a professional, qualified service agency for the
installation, adjustment and service of your oil 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.
y Never store or use gasoline or other flammable liquids or
vapors near this burner or appliance.
Used with the safety
alert symbol, indicates a
hazardous situation, which, if not avoided,
may result in minor or moderate injury.
y Never attempt to burn garbage or refuse in this appliance.
y Never attempt to light the burner 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
Used to address practices not
related to personal injury.
Specifications
Fuels
U.S. #1 or #2 heating oil only (ASTM D396)
Canada #1 stove oil or #2 furnace oil only
DO NOT USE
GASOLINE,
CRANKCASE OIL, OR ANY OIL
CONTAINING GASOLINE.
Firing Range
CF2500A - 17.0 to 19.9 gph
CF2500 - 17.0 to 25.0 gph
CF3500A - 17.0 to 35.0 gph
Motor
2 HP 3450 rpm
208/230/60 Hz Standard
13.4 amps @ 230 VAC
Optional Voltages:
208, 230, 480, 575 VAC/3-PH,
50 or 60 Hz
Ignition Trans.
Continuous Duty, 120V/12,000V
Housing
Cast aluminum
Fuel Unit
100 to 300 psig
Oil Nozzle
45o to 70o Solid
Dimensions
Refer to Figure 8.
50 Hz Motors - The burner ratings,
air settings and nozzle ratings are
based on standard 60 Hz motors (at 3450 rpm). Derate
all ratings 20% when using 50 Hz motors. Consult
factory for specific application data.
CF2500/CF3500 Burner Manual
combustion air ventilation openings in the room.
Frozen Plumbing and
Water Damage Hazard
If the facility 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 security agency.
Service Agency Responsibility:
Follow these instructions
exactly.
Failure to follow these instructions could result in
asphyxiation, explosion or fire.
y Please read all instructions before proceeding. Follow
all instructions completely.
y This equipment must be installed, adjusted and started
by a qualified service agency that is licensed and
experienced with all applicable codes and ordinances
and responsible for the installation and commission of
the equipment.
y The installation must comply with all local codes and
ordinances having jurisdiction and the latest editions of
the NFPA 31 and CSA-B139 & B140 in Canada.
High altitude installation - Accepted
industry practice requires no derate
of burner capacity up to 2000 feet above sea level. For
altitudes higher than 2000 feet, derate burner capacity
2% for each 1000 feet above sea level.
3
Section: Pre-installation Checklist
Pre-installation Checklist
Fuel Supply
Combustion Air Supply
Oil Supply Pressure
Control Required
Damage to the filter or pump seals could cause oil
leakage and a fire hazard.
Adequate Combustion 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.
The burner requires combustion air and ventilation air
for reliable operation. Assure that the building and/or
combustion air openings comply with National Fire
Protection Standard for Oil-Burning Equipment, NFPA 31.
For appliance/burner units in confined spaces, the room
must have an air opening near the top of the room plus
one near the floor, each with a free area at least one
square inch per 1,000 Btu/hr input of all fuel burning
equipment in the room.
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 return line.
y Gravity Feed Systems: Always install an anti-siphon
valve in the oil supply line or a solenoid valve (RWB
Part # 21789) in the pump/nozzle discharge tubing
to provide backup oil flow cut-off protection.
The fuel supply piping and tank must provide #1 or #2
fuel oil at pressure or vacuum conditions suitable for
the fuel unit (oil pump) on the burner. Refer to fuel unit
literature in the literature envelope in the burner carton to
verify allowable suction pressure.
If fuel supply is level with or higher than fuel unit —
○
For other conditions, refer to the latest edition of NFPA 31
(CSA B1139-M91 in Canada).
If there is a risk of the space being under negative
pressure or of exhaust fans or other devices depleting
available air for combustion and ventilation, the appliance/
burner should be installed in an isolated room provided
with outside combustion air.
○
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 all local codes and with the
appliance manufacturer’s recommendations.
When the fuel unit is not required to lift the oil, the
installation is usually suitable for either a one-pipe or
two-pipe oil system. The oil pressure at the inlet of
the fuel unit must not exceed 3 psig.
The fuel unit is shipped with the by-pass plug
installed. Leave the by-pass plug installed for all
low/high firing burners, regardless whether onepipe (with by-pass loop) or two-pipe. See Figure
9 for installation of the by-pass loop required for
one-pipe fuel supply installations. See Figure 10 for
connections to the fuel unit for two-pipe fuel supply
installations.
When fuel supply is below the burner fuel unit —
Use a two-pipe oil system when the fuel unit must lift
the oil more than 8 feet. The return line provided by the
two-pipe system is needed to minimize the effects of airrelated problems during operation.
Figure 1 – Typical Nameplate
General Model Information
Serial Number, Including Date Code
Rating Information
Approval Agency Symbols
Model “XX”
Series (Fuel) Burner
SERIAL NUMBER
050214-00000
Control Circ: 120V/60Hz 4.5A
Motor Circ: 120V/60Hz 4.0A
LISTED
(FUEL) BURNER
MFR’S SETTINGS
X
X
X
X
X
X
XX000 R00
050214-00000
R.W. Beckett Construction &
Setting Data
R.W. Beckett Specification
Number and Revision
NO.P100000
Boiler Manufacturer and
Model, When Applicable
For use with Group 8 . . .
Primary Group and Fuel
Additional Codes
MP 1192
4
XX000
R00
Section: Pre-installation Checklist
Nozzle Pressure
Electrical Supply
Correct Nozzle and Flow
Rate Required
Incorrect nozzles and flow rates could
result in impaired combustion, underfiring, over-firing, sooting, puff-back of
hot gases, smoke and potential fire or
asphyxiation hazards.
Verify that the power connections available are correct
for the burner. Refer to Figure 1. All power must be
supplied through fused disconnect switches.
Vent System
The flue gas venting system must be in good condition
and must comply with all applicable codes.
Fire, Smoke & Asphyxiation
Hazard
Use only nozzles having the brand, flow rate (gph), spray
angle and pattern specified by the appliance manufacturer.
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 This burner utilizes pressures higher than 100 psig,
so the actual nozzle flow rate will be greater than
the gph stamped on the nozzle body.
(Example: A 12.00 gph nozzle at 200 psig = 16.97
gph and at 300 psig = 20.78 gph)
y For typical nozzle flow rates at various pressures
refer to Table 1.
The fuel unit nozzle port pressure is factory set at 300
psig. Some original equipment manufacturer burner
applications may call for a lower pressure to obtain a
required firing rate. Do not change this pressure unless
directed to do so by the appliance manufacturer.
Table 1 - Nozzle Capacities
Rated
gph
@ 100
psig
Pressure - Pounds per square inch
125
150
175
200
250
300
5.00
5.59
6.13
6.61
7.07
7.50
8.66
5.50
6.15
6.74
7.27
7.78
8.70
9.54
6.00
6.71
7.33
7.94
8.48
9.49
10.40
6.50
7.26
7.96
8.60
9.20
10.30
11.25
7.00
7.82
8.56
9.25
9.90
11.06
12.12
7.50
8.38
9.19
9.91
10.60
11.85
13.00
8.00
8.94
9.80
10.58
11.31
12.65
13.85
8.50
9.50
10.45
11.27
12.06
13.40
14.70
9.00
10.06
11.02
11.91
12.73
14.20
15.60
9.50
10.60
11.70
12.60
13.50
15.00
16.45
10.00
11.18
12.25
13.23
14.14
15.81
17.32
10.50
11.74
12.85
13.90
14.85
16.60
18.18
11.00
12.30
13.47
14.56
15.55
17.39
19.05
12.00
13.42
14.70
15.87
16.97
18.97
20.78
12.50
13.98
15.31
16.54
17.68
19.76
21.65
13.00
14.54
15.92
17.20
18.38
20.55
22.52
13.50
15.10
16.53
17.85
19.09
21.34
23.38
CF2500/CF3500 Burner Manual
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 CSAB140 in Canada).
y Regulation by these authorities take precedence
over the general instructions provided in this
installation manual.
Verify Burner Components
○
○
○
○
○
Burner nameplate (Figure 1), Model CF2500A/
CF2500/CF3500A
Air tube assembly
Mounting flange kit
Pedestal mounting assembly kit (recommended)
Oil nozzle, per Table 1 — Use only 45° to 70°
solid pattern nozzles unless otherwise shown by
appliance manufacturer or on the burner nameplate
rating label.
The CF2500A, CF2500, and CF3500A are dual nozzle
burners. To select the nozzles, use half of the maximum
firing rate and select a nozzle under the 300 psig column.
Select the corresponding nozzle from column 1 (Rated gph
@ 100 psig) two nozzles will be required.
Example: a 5.00 gph nozzle at 300 psig = 8.66 gph
Verify Firing Rate
Refer to appliance manufacturer’s instructions (if available)
for firing rate and nozzle selection. Otherwise, the maximum
recommended firing rate for the burner depends on the length
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 than recommended, reduce
the firing rate accordingly.
5
Section: Pre-installation Checklist
Verify Air Tube
Figure 2 - Dimensions: Minimum Combustion
Chamber and Air Tube Mounting.
* Install burner with
2° pitch as shown.
The information in this section may be disregarded if the
air tube is supplied by the appliance manufacturer.
The following tube arrangements are available –
H
D
○
○
○
T
1/4” ± 1/8”
Maximum firing capacity depends on the firebox
pressure. Use Table 2 to verify the correct air tube type
for the firing rate required. (Tube KR [CF3500A] is an
optional air tube combination for maximum capacity rate.
It requires a larger I.D. flange Number 51631.)
*2°
L
CF2500 - Tube KP -17.0.0 to 19.9 GPH
CF2500A - Tube KP -17.0 to 25.0 GPH
CF3500A - Tube KM -17.0 to 35.0 GPH or
Tube KR -17.0 to 35.0 GPH
E
See Figure 2 to verify the correct air tube length and air
tube combination code.
Minimum Dimensions
L
17
10.5”
48.0”
22
11.5”
58.0”
27
12.5”
66.0”
32
12.5”
73.0”
35
13.0”
77.0”
Air Tube Combination Codes
CF2500A/
CF2500
Model
Tube
KP
CF3500
KM
KR
Dimension
T
Dimension
D
Code
Dimension
E
6-3/4”
6-1/2”
CF 66 KP
3-1/4”
10-1/4”
6-1/2”
CF 102 KP
3-1/4”
13-3/4”
6-1/2”
CF 136 KP
3-1/4”
17-3/4”
6-1/2”
CF 176 KP
3-1/4”
8”
8”
CF 80 KM
4-1/2”
9-1/4”
8”
CF 92 KM
4-1/2”
11-1/2”
8”
CF 114 KM
4-1/2”
15”
8”
CF 150 KM
4-1/2”
19”
8”
CF 190 KM
4-1/2”
11-1/2”
9-15/16”
CF 114 KR
5-1/8”
14”
9-15/16”
CF 140 KR
5-1/8”
19”
9-15/16”
CF 190 KR
5-1/8”
Maximum Firing Rate U.S. GPH
Figure 3a - Firebox Pressure: CF2500A with no Reserve Air
H
25
24
KP
23
22
0.0
0.2
0.4
0.6
0.8
Figure 3b - Firebox Pressure: CF3500 with no Reserve Air
35
30
KR
25
KM
20
0.0
0.2
0.4
0.6
0.8
Firebox Pressure in Inches Water Column (W.C.)
6
1.0
Firebox Pressure in Inches Water Column (W.C.)
Maximum Firing Rate U.S. GPH
Firing Rate
(gph)
1.0
Section: Mount the Burner
Table 2 - Air Tube Capacity Versus Firebox Pressure
Maximum Firing Rate GPH
Tube
CF3500A
CF2500 &
CF2500A
Model
Firebox
Pressure
(In W.C.)
No
Reserve
Air
10% Turndown
(GPH)
0.0
25.0
22.5
0.2
24.8
22.3
0.4
24.6
22.3
0.6
24.5
22.1
0.8
24.3
21.9
1.0
24.1
21.7
0.0
35.0
31.5
0.2
33.5
30.2
0.4
32.0
28.8
0.6
30.2
27.2
0.8
28.8
25.9
1.0
27.1
24.4
KP
KM/
KR
Note: 10% turndown indicates sufficient reserve air to reduce
the CO2 in the flue to 90% of its value.
Mount the Burner
Protect the Air Tube From
Overheating
Overheating could cause damage to the air tube and
other combustion components leading to equipment
malfunction and impaired combustion performance.
y The end of the air tube must not extend into the
combustion chamber unprotected unless it has
been factory-tested and specified by the appliance
manufacturer.
y Position the end of the air tube 1/4” back from
flush with the refractory inside entry wall to prevent
damage from overheating.
Mount Flange(s) on Air Tube
This section does not apply to burners with welded
flanges.
Note: The above ratings may vary 5% due to variations in
actual job conditions.
○
○
Stray Light
○
Protect Against Stray Light
Lockout. Failure to follow
these instructions could cause loss of burner
operation resulting in no heat, an unplanned
process interruption, work stoppage and the
potential for frozen plumbing or other cold
weather property damage.
○
○
The control must detect a dark, no-flame condition
in order to start the burner or it will hold in the stray
light lockout mode.
Shield the burner view window from direct exposure
to intense light.
Dust and Moisture
○
○
Do not install air tube on burner.
For non-pressure firing flange, refer to Figure 4:
Install gasket (item a) and flange (item c). Ignore the
next paragraph.
For pressure-firing flange, refer to Figure 4: Slide
gasket (item a) onto the air tube, making sure the
top of the air tube is up. Predrill holes in the pressure
firing plate (item b) to match the appliance studs.
Slide the pressure firing plate (item b) and flange
(item c) onto the air tube as shown. Wrap ceramic
fiber rope (not shown) around the air tube and press
tightly into the inside diameter of the flange (item c).
Slide the air tube (item d) into position in the
appliance front. Tighten the flange-mounting-stud
nuts. Set the insertion of the air tube so dimension G
is 1/4” nominal.
Pitch the air tube at 2° from horizontal as shown and
secure the flange to the air tube.
Figure 4 – Mount Flange(s) on Air Tube
Protect Against Dust and
Moisture
Wet, dusty environments could lead to blocked air
passages, corrosion damage to components, impaired
combustion performance and result in asphyxiation,
explosion or fire.
y This burner is designed for clean, dry installations.
y Electrical controls are not protected against rain or sprayed
water.
y Keep the installation clear of dust, dirt, corrosive vapors,
and moisture.
y Protective covers and more frequent maintenance may be
required.
CF2500/CF3500 Burner Manual
7
Section: Mount the Burner
Mount Air Tube to Burner
○
○
Figure 5 – Nozzle and Nozzle Line Assembly
Remove the rear access door from the back of the
burner for improved access to the interior.
Attach the air tube to the burner with the bolts and
acorn nuts provided. The acorn nuts must go on the
outside of the burner, with the bolts inserted from the
inside.
S
Q
P
Install Nozzle
See Figure 5. Install the oil nozzle in the nozzle adapter.
Use a 3/4” open-end wrench to steady the nozzle
adapter and a 5/8” open-end wrench to turn the nozzle.
Tighten securely but do not overtighten.
Check Electrode Settings
Maintain Electrode
Specifications
Failure to properly maintain these specifications could
cause ignition malfunction, puff-back of hot gases, heavy
smoke, asphyxiation, explosion and fire hazards.
Check, and adjust if necessary, the critical dimensions
P, Q, R and S shown in Figure 5. Verify that the oil tube
assembly and electrodes are in good condition, with no
cracks or damage.
Low fire
nozzle
High fire
nozzle
R
3504
Legend for Critical Dimensions
P Nozzle centerline to electrode tip - 1/4”
Q Nozzle to head - 1/4”
R Nozzle face to electrode tip - 1/8”
S Electrode spacing - 3/32”
Figure 6 – Nozzle Line Assembly in Burner
Measure dimension ‘Z’ from front (flat)
face of head to end of air tube, as shown.
Install Nozzle Line Assembly
○
○
○
○
○
○
8
Insert the nozzle line assembly into the burner air
tube as in Figure 6.
See Figures 6 and 7. Assemble the adjusting
plate assembly per the instructions in the assembly
packet.
Slide the secondary adjusting plate (item f)
completely to the left on the indicator adjusting plate
(item e). Finger-tighten acorn nut (item c) to secure
the two plates together. Slide both plates completely
to the left on the primary adjusting plate (item g) and
finger-tighten acorn nut (item d).
Slide the completed adjusting plate assembly
over the nozzle line end. Move the plate assembly
and the nozzle line so the plate assembly fits into
position as shown in Figure 6.
Install the spline nut (Figure 6, item b) on the end of
the nozzle line, leaving the nut loosely placed so the
plates can be moved.
Connect the high-voltage leads from the ignition
transformer to the electrodes.
Measure dimension ‘Z’ from the flat surface
between (not on) the raised fins.
Z Dimensions
CF2500A/CF2500 = 1-3/4 ±1/16”
CF3500A (tube KM) = 2-5/8” ±1/16”
CF3500A (tube KR)= 3-9/16” ±1/16”
Section: Mount the Burner
Figure 7 – Adjusting Plate Assembly
d
e
f
c
Legend (Figures 6 & 7)
a Adjusting plate assembly
b Spline nut for securing nozzle line
c Bottom acorn nut
d Top acorn nut (for setting dim. Z only)
e Indicator adjusting plate
f Secondary adjusting plate
g Primary adjusting plate
g
Set Dimension Z
Insert Burner
○
○
Replace the rear access door on the burner, making
sure that the adjusting plate assembly is now
securely in the groove.
Loosen acorn nut (item d) in Figure 6. Slide the
nozzle line and plate assembly until dimension Z in
Figure 6 is:
CF2500A/CF2500 = 1-3/4 ±1/16”
CF3500A (tube KM) = 2-5/8” ±1/16”
CF3500A (tube KR)= 3-9/16” ±1/16”
When dimension Z (from end of air tube to flat area
of front face of head) is correctly set, tighten acorn
nut (item d). Verify that the adjusting plate assembly
is properly seated in the groove.
Attach the oil line from the oil valve to the nozzle line
end. Tighten securely.
Before proceeding, check dimension Z once again.
Loosen acorn nut (item d) if necessary to reposition
the nozzle line. Once dimension Z is set, do not
loosen acorn nut (item d) again.
○
○
○
○
○
○
Position the burner in the front of the appliance and
loosely tighten the nuts on the mounting studs. The
burner should be pitched downward 2° as shown in
Figures 3 and 4.
See Figure 8. Install the pedestal support kit
(recommended) by attaching the 3/4” NPT flange
(item a) to the bottom of the burner using the (4) #10
screws provided. Cut and thread (one end only) a
3/4” pipe nipple (item b) with length 11 inches less
than dimension D in Figure 8. Thread the pipe into
the flange.
Secure the burner to the appliance by tightening the
nuts on the burner flange mounting studs.
Figure 8 – Burner Installed in Appliance Front
Legend
H
J
K
Description
Housing total length
Center to bottom of housing
Overall housing height
CF2500/CF3500 Burner Manual
Inches
20”
14-1/2”
22-3/4”
9
Section: Connect Fuel Lines
Connect Fuel Lines
Fuel Unit By-pass Plug
Factory-Installed Pump
Bypass Plug
Failure to follow these guidelines will cause the
fuel pump seals to rupture and result in oil leakage,
burner malfunction and potential fire and injury
hazards.
y Models CF2500A/CF2500/CF3500 are shipped with
the pump by-pass plug installed.
Oil Supply/Return Lines
○
○
○
y Do not remove the by-pass plug from the pump. It is
required for step-firing (Lo/Hi) operation.
y Do not operate the burner unless a return line or bypass loop is installed or the pump seal will rupture.
○
y Carefully comply with the following instructions
provided in this section of the manual.
Install Oil Supply To
Specifications
Failure to properly install the oil supply
system could cause oil leakage,
equipment malfunction, puff-back of
hot gases, heavy smoke, asphyxiation,
explosion and fire hazards.
y Carefully install the oil supply lines, fittings and
components using the guidelines provided in this
section.
y The oil supply must comply with the latest edition
of NFPA 31 (Canada CSA B139) and all applicable
codes.
y Do NOT install valves in the return line.
y If the oil supply inlet pressure to the pump exceeds 3
psig or for gravity feed systems, install an oil safety
or pressure reducing valve (Webster OSV, Suntec
PRV or equivalent).
○
Install the oil tank and oil lines in accordance with all
applicable codes.
Size the oil supply and return lines using the
guidelines given in the fuel unit literature included in
the literature envelope. Oil line flow rate will equal
the burner rate for one-pipe systems. For two-pipe
systems, refer to Table 3 for the fuel unit gearset
capacity - the rate at which fuel is recirculated when
connected to a two-pipe system. Size two-pipe oil
lines based on this flow rate.
Use continuous lengths of heavy-wall copper tubing,
routed under the floor where possible. Do not attach
fuel lines to the appliance or to floor joists if possible.
This reduces vibration and noise transmission
problems.
Install an oil filter sized to handle the fuel unit
gearset flow capacity (Table 3) for two-pipe
systems. However, size the filter for the firing rate
for one-pipe systems. Locate the filter immediately
adjacent to the burner fuel unit.
Install two high-quality shutoff valves in accessible
locations on the oil supply line. Locate one valve
close to the tank. Locate the other valve close to the
burner, upstream of the fuel filter.
Burner Fuel Flow
One-pipe systems – See Figure 9 for the fuel flow
paths for high-fire and low-fire operation. Oil supply
connects to one of the fuel unit Inlet ports. A fieldinstalled bypass loop (Figure 9 Item K) must be
installed.
Two-pipe systems – See Figure 10 for the fuel flow
paths for high-fire and low-fire operation. Oil supply
connects to one of the fuel unit Inlet ports. Oil return
connects to the fuel unit Return port.
Low-fire/high-fire operation – The fuel unit nozzle port
pressure is factory set at 300 psig.
○
○
At high fire, full pressure (300 psig) is applied at both
oil nozzles, causing full input.
At low fire, full pressure (300 psig) is applied at one
nozzle, causing reduced input.
One-pipe Oil System By-pass Loop
Refer to Figure 9 (item k). Note the addition of a fieldinstalled by-pass loop (use 3/8” copper tubing) from the
fuel unit Return port to the Inlet port. This line is required
for low/high operation. It simulates the flow of a two-pipe
system at the fuel unit.
10
Table 3 – Fuel Unit Gearset Capacities
Fuel Unit Model
Number
Gearset Capacity
(gph)
H5PAN-C100H
79
Section: Connect Fuel Lines
Figure 9 – One-pipe Oil Flow
200 psig
to
300 psig
200 psig
to
300 psig
Nozzle Pressure – The fuel unit nozzle port
pressure is factory set at 300 psig. Some
original equipment manufacturer burner
applications may call for a lower pressure to
obtain a required firing rate. Do not change
this pressure unless directed to do so by the
appliance manufacturer.
Figure 10 – Two-pipe Oil Flow
200 psig
to
300 psig
Legend (Figures 9 & 10)
a Return port
b Pump outlet
c Solenoid valve
d Nozzle
g Pump inlet
k By-pass loop
p Bleed port
200 psig
to
300 psig
CF2500/CF3500 Burner Manual
11
Section: Wire the Burner
Wire the Burner
Electrical Shock Hazard
Electrical shock can cause severe personal injury or death.
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:
y Disconnect electrical power before installing or
servicing the burner.
a. The trial for ignition (lockout) time expired
without flame being established.
y Provide ground wiring to the burner, metal control
enclosures and accessories. (This may also be
required to aid proper control system operation)
b. The cad cell detected flame at the end of the
Valve On Delay state.
y Perform all wiring in compliance with the National
Electric Code ANSI/NFPA 70 (Canada CSA C22.1).
Install the burner and all wiring in accordance with the
National Electrical Code and all applicable local codes or
requirements.
Wire the burner in compliance with all instructions
provided by the appliance manufacturer. Verify operation
of all controls in accordance with the appliance
manufacturer’s guidelines.
See Figure 11a (7505P) or 11b (RM7897A) for a typical
wiring diagram (Diagrams are for reference purposes only).
Incorrect Wiring Will
Result in Improper Control
Operation
y GeniSys 7505 Control 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.
Fire or Explosion Hazard
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.
Typical Burner Sequence of Operation GeniSys 7505
Refer to the appliance manufacturer’s wiring
diagram for actual specifications. Note: GeniSys
7505 Control on CF2500A only.
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.
12
To reset the control from lockout click the button
1-second.
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.
5. Ignition Carryover: Once flame is established,
the igniter remains on for 10 additional seconds to
ensure flame stability.
6. Run: With a flame established and the control
continuing to detect a flame, the burner will operate
in the RUN mode until the load demand is satisfied
or a limit opens.
a. If terminals RC1 and RC2 are jumpered, the
burner operates in the Low-High-Off Mode. The
burner starts at Low, goes to High after the flame
stabilization period. Flame is extinguished when
the load is satisfied or a limit opens, and the
burner is sent to Motor-Off Delay.
b. If a high/low control has been wired between
terminals RC1 and RC2 the burner starts at
Low and is released to go High after the flame
stabilization period. It can repeatedly cycle
between low and high as necessary to meet load
demand until the load is satisfied or a limit opens.
The burner is then sent to Motor-off Delay.
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: 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.
Section: Wire the Burner
Figure 11 - Typical Burner Sequence of Operation - 7505
9
1
Standby
2
Valve-on
Delay
3
5
Trial for
Ignition
Cad Cell Resistance Measurement:
Pump
Prime
If the Beckett 7505 control is equipped with the
GeniSys Display Module, part 52067U, the cad cell
resistance can be selected and read on the LCD
screen. Also, the GeniSys Contractor Tool, part
52082U, can be used for this purpose.
4
Lockout
If these are not available, the cad cell leads can
be unplugged from the control and the resistance
measured with a meter in the conventional way.
Conduct these tests with flame present.
Ignition
Carryover
Table 5 - 7505 Status Light Explanation Table
8
Motor-Off
Delay
6
7
Run
Relight
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 N/A
or Reset button currently held
for 15+ seconds.
Table 4 - 7505 Flame Detection
Flame Detection Range
Normal = 0 to 1600 ohms
Limited = 1600 ohms to lockout
Figure 12 - GeniSys 7505 Control with Optional Components
Wiring
Connections
Reset Button
with Red Light
Yellow Light
Green Light
Cad Cell
Connections
Thermostat Terminals
Communication Port 2
Communication Port 1
Optional Components:
Contractor’s Tool:
Hand-held device for
programming and diagnostics
Display Module:
Permanent device for
programming and diagnostics
Alarm Module:
For adding isolated low voltage
alarm contacts to the base control.
See Alarm Module Instructions for
specifications.
CF2500/CF3500 Burner Manual
13
Section: Wire the Burner
Figure 13 –Typical Wiring (7505P)
14
Section: Wire the Burner
Typical Burner Sequence of Operation RM7897A Control
When firing over 20 GPH the CF2500 and CF3500A will
be supplied with a flame safeguard control. An airflow
switch and low-fire start relay will also be supplied.
Consult local, state, and federal codes for burner
requirements above 20GPH.
Install the burner and all wiring in accordance with the
National Electrical Code and all applicable local codes or
requirements.
Wire the burner in compliance with all instructions
provided by the appliance manufacturer. Verify operation
of all controls in accordance with the appliance
manufacturer’s guidelines.
b. If a high/low control has been wired between
terminals RC1 and RC2 the burner starts at
Low and is released to go High after the flame
stabilization period. It can repeatedly cycle
between low and high as necessary to meet
load demand until the load is satisfied or a limit
opens. The burner is then sent to post purge.
6. Post purge - The control enters a post purge cycle
to clear the combustion chamber of gases. Length
of the post purge is factory programmed at 15
seconds.
Figure 14 - Typical Burner Sequence of
Operation - RM7897A
1. Initiate - Power is supplied to the control. The
control performs a self-check to ensure proper
operation.
1
Initiate
2. Standby - the burner is idle waiting for a call for
heat. When the call for heat is initiated, the burner
will proceed to step 3.
3. Pre-purge - the burner will begin a 60 second prepurge to clear the combustion chamber. The burner
checks the air flow interlock to see if air is being
provided. If the air flow is not present the burner
will lockout if jumper JR3 is cut or recycle if the
jumper is intact.
4. Trial for Ignition - The RM7897A has two trial
periods. The first is for light off the second is for
main flame establishing. The burner must see
flame within 10 seconds if jumper 1 is intact or 4
seconds if jumper 1 is clipped. If the flame is not
established, the burner will lockout if jumper 2 is
clipped or recycle if the jumper is intact. The burner
will then proceed to main flame establishing. If
flame is not sensed within 3 seconds the burner
will lockout or recycle depending on the status of
jumper 2.
2
Stand by
3
Prepurge
4
Recycle
Trial for
Ignition
Lockout
5
Run
6
Post Purge
5. Run: With a flame established and the control
continuing to detect a flame, the burner will operate
in the RUN mode until the load demand is satisfied
or a limit opens.
a. If terminals RC1 and RC2 are jumpered, the
burner operates in the Low-High-Off Mode.
The burner starts at Low, goes to High after the
flame stabilization period. Flame is extinguished
when the load is satisfied or a limit opens, and
the burner is sent to post purge.
CF2500/CF3500 Burner Manual
15
Section: Prepare the Burner for Start-up
Figure 15 –Typical Wiring (RM7897A)
Prepare the Burner for
Start-up
Professional Installation
and Service Required
Incorrect installation and mishandling of start-up
could lead to equipment malfunction and result in
asphyxiation, explosion or fire.
y This burner must be installed and prepared for startup by a qualified service technician who is trained
and experienced in commercial oil burner system
installation and operation.
y Do not attempt to start the burner unless you are
fully qualified.
y Do not continue with this procedure until all items in
the “Prepare the Burner for Start-up” section have
been verified.
y Carefully follow the wiring diagrams, control
instruction sheets, flame safeguard sequence
of operation, test procedures and all appliance
manufacturer’s directions that pertain to this
installation.
y If any of these items are not clear or are unavailable,
call Beckett at 1-800-645-2876 for assistance.
16
Do Not Bypass Safety
Controls
Tampering with, or bypassing safety controls
could lead to equipment malfunction and result in
asphyxiation, explosion or fire.
y Safety controls are designed and installed to provide
protection.
y Do not tamper with, or bypass any safety control.
y If a safety control is not functioning properly, shut
off all main electrical power and fuel supply to
the burner and call a qualified service agency
immediately.
Keep Service Access
Covers Securely Installed
These covers must be securely in place to prevent
electrical shock, damage from external elements, and
protect against injury from moving parts.
y All covers or service access plates must be in place
at all times except during maintenance and service.
y This applies to all controls, panels, enclosures,
switches, and guards or any component with a cover
as part of its design.
Section: Prepare the Burner for Start-up
□ Combustion air supply and venting have been
inspected and verified to be free of obstructions and
installed in accordance with all applicable codes.
□ Oil nozzle has been selected correctly and securely
installed in the nozzle adapter.
□ Fuel unit by-pass plug has not been installed for
one-pipe oil system without a by-pass loop. Refer to
Figure 9.
□ By-pass plug has been installed for two-pipe oil
system.
□ Fuel connection to nozzle line assembly is secure.
□ Dimension Z has been set per the ‘Set Z
Dimension’ instructions detailed earlier in this
manual. The top acorn nut (Figure 16, item d)
should never be loosened once the Z dimension is
initially set.
□ Fuel supply line is correctly installed, the oil tank is
sufficiently filled, and shut-off valves are open.
□ Burner is securely mounted in appliance, with
pressure firing plate and gasket installed for
pressurized chamber application.
□ Appliance has been filled with water (boilers) and
Z Dimension
The Z Dimension should be set per the instructions
detailed under the heading ‘Set Z Dimension’ previously
in this manual. The top acorn nut (Figure 16, item d)
should never be loosened once the Z dimension has
initially been set.
Adjusting Plate Assembly
Make sure spline nut (item b) and bottom acorn nut (item
c) are loose before proceeding to next section (Figure 16).
Initial Head Position
The indicator plate assembly (item e) markings
correspond to head position settings (Figure 16).
○ Slide the secondary adjusting plate (item f) toward the
rear of the burner until the number on the indicator plate
corresponds to the initial head setting given in Table 6 for
the desired firing rate and burner (high-fire).
○ Figure 16 shows a typical example, with a 6 head setting.
When the head position has been set, tighten the
bottom acorn nut (item c) and the spline nut (item b).
Table 6. Initial Indicator Adjustment Plate Settings
for Head & Damper
Head Position
Tube
Start-up Checklist – Verify the following before
attempting to start burner.
controls have been operationally checked.
□ Also refer to appliance manufacturer’s instructions
(when available) for start-up procedures.
Figure 16 – Adjusting Plate Initial Setting, Typical
Legend
b Spline nut for securing nozzle line
c Bottom acorn nut (for head adjustments)
d Top acorn nut (for setting dim. Z only - do not
e
f
g
h
loosen after setting Z)
Indicator adjusting plate
KM / KR (CF3500A)
appliance manufacturer’s instructions (when
available).
KP (CF2500A / CF2500)
□ Burner has been installed in accordance with
Damper Position
Approximate
Head Setting
Firing Rate
(gph)
Approximate
Air Damper
Setting
Firing Rate
(gph)
0
--
0
--
1
--
10
8.00
2
--
20
9.00
3
17.00
30
11.00
4
17.50
40
12.00
5
18.00
50
15.00
6
18.50
60
17.00
7
19.00
70
18.00
8
20.00
80
19.00
9
21.00
90
20.00
10
25.00
100
22.00
--
--
105
25.00
0
--
00
--
1
17.00
10
8.00
2
17.50
20
9.00
3
18.00
30
11.00
4
18.50
40
12.00
5
19.00
50
15.00
6
20.00
60
17.00
7
21.00
70
19.00
8
28.00
80
22.00
9
32.00
90
25.00
Primary adjusting plate
10
35.00
100
29.00
Copper oil line from oil valve to nozzle line
--
--
105
35.00
Secondary adjusting plate
CF2500/CF3500 Burner Manual
17
Section: Prepare the Burner for Start-up
Initial Air Settings
If your burner was built for a specific OEM application,
the “Mfr’s Settings” label (see Figure 1) will indicate
the application and the initial air settings made at
Beckett. Please verify those settings using the following
procedure.
If your burner was not built for a specified application,
the following steps outline the procedure for initially
setting the damper (these settings may be different from
settings specific to a particular OEM).
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 17B) and rotate the damper plate to its full closed
position. The position indicator should point to 0° within
+ 5° tolerance.
Figure 17A - Damper Motor with Cover
Refer to Figure 17A/B and Table 4 for this procedure.
1. Remove the cover screw (A) then the cover (B) and
set aside.
2. Push in on pin (G) to disengage the motor from the
damper shaft and cam stack. Rotate the damper
shaft by hand to place the adjustment cams in a
position where their adjustment scale can be easily
seen. Release pin (G) to secure the damper shaft
and cam stack to the motor.
3. Using the wrench (C) supplied with the damper
motor, adjust the blue low fire cam (D) to the initial
setting listed in Table 6.
4. Using the same wrench, adjust the red high fire
cam (H) to the initial settings listed in Table 6.
5. To adjust the high fire transition, use a small straight
edge screwdriver. Turn the white adjustment screw
located in the orange transition cam (J) until the
cam indicator is half way between the high and low
settings on the scale.
Figure 17B - Damper Motor
6. After setting all the cams, make sure the damper
shaft and cam stack is set between its low fire
setting and its high fire setting. (If you don’t it may
not move when it is powered.) Push in pin (G),
move the damper by hand so that notch (E) is
between the low fire setting and high fire setting
on scale (F), then release pin (G) to re-engage the
motor. When the motor is powered it will go to its
low fire setting.
This initial setting should be adequate for starting the
burner at low fire. Once the burner is in operation,
the air setting will be adjusted for best performance as
discussed later in this manual. Don’t forget to re-install
the cover after all adjustments have been made.
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
18
Legend (Figures 17A & 17B)
A Cover screw
B Cover
C Wrench
D Low fire cam (blue)
E Cam notch
F Damper motor scale
G Disengaging pin
H High fire cam (red)
J Transition cam (orange)
Section: Prepare the Burner for Start-up
Set Appliance Limit Controls
○
○
Set the appliance limit controls in accordance with
the appliance manufacturer’s recommendations.
Move the low-fire hold switch (not shown) to the low
fire hold position. This will hold the burner in low fire
during initial start-up.
Prepare the Fuel Unit for Air Venting
1. To vent air from one-pipe oil systems, attach a clear
hose to the pump bleed port (item p in Figures 9 &
10) on the fuel unit. Provide a container to catch the
oil. Loosen the pump bleed port.
2. Vent the air as described in the ‘Start the Burner’
Section.
Explosion and Fire Hazard
Failure to follow these instructions could lead
to equipment malfunction and result in heavy
smoke emission, soot-up, hot gas puff-back,
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.
Start the Burner
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 B140 in Canada).
Regulation by these authorities take precedence over
the general instructions provided in this installation
manual.
Do not proceed unless all prior steps in this manual
have been completed.
CF2500/CF3500 Burner Manual
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.
Start Burner and Vent Air from Oil Line
Hot Gas Puff-back and
Heavy Smoke Hazard
Failure to bleed the pump properly could result in
unstable combustion, hot gas puff-back and heavy
smoke.
y Do not allow oil to intermittently spray into a hot
combustion chamber while bleeding.
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 when
venting air from the fuel pump.
y Ensure that all bubbles and froth are purged from
the oil supply system before tightening the pump air
bleed valve.
1. Move the low-fire hold switch to the low fire hold
position (to hold burner in low fire when started).
2. Verify that the air adjusting cam (Figure 17B, item
d) has been set to the initial low-fire air setting as
described in the ‘Initial Air Settings’ Section.
3. Open the oil shutoff valves in the oil supply line to
the burner.
4. Set the thermostat (or operating control) to call for
heat.
5. Close the line switch to the burner. The burner
motor should start immediately.
19
Section: Prepare the Burner for Start-up
6. If the burner motor does not start, reset the motor
overload switch (if so equipped) and press the reset
switch of the burner primary control.
number to reduce CO2 by 2 percentage points
at a zero smoke level. (Increase O2 by 3
percentage points at a zero smoke level.)
7. Vent the fuel unit as soon as the burner motor starts
rotating. To vent —
Example: Reduce CO2 from 13.5% to 11.5%,
with zero smoke (or increase O2 from 2.5% to
5.5%).
○ Attach a clear plastic tube to the air bleed valve
(Figure 9 or 10 as applies, item p).
○ Place the end of the tube in a container to catch
the oil. Then loosen the fuel unit air vent valve.
○ Tighten the air vent valve after all air has been
purged.
○ IF burner stops during venting —
- The burner primary control will lockout if
flame is not established within its time limit.
This is typically 15 seconds for 7505 primary
controls, but may be less for other flame
supervisory controls.
-
The burner may lockout several times during
the period needed to purge all the air. To
extend air venting time, press the red reset
button for 1/2 second during the prepurge
cycle to continue purging with 7505 controls.
○ IF burner stops after flame established —
- Additional venting is probably required.
Repeat the air venting procedure.
8. Once flame is steady, proceed to the ‘Set High-fire
Air’ Section air.
Set High-fire Air
1. Allow the burner to run at low fire until the
appliance has warmed sufficiently.
2. Visually check the flame. The flame should not be
dark orange or smoky. If the flame appears to be
smoking, increase the amount of air by readjusting
the damper indicator to a higher number.
3. Once the appliance has warmed, the high-fire
setting can be checked and adjusted.
4. Locate the approximate air adjusting plate setting
for high fire in Table 4.
5. Place the low-fire hold switch in the high-fire
position. The damper motor will begin to rotate
after four seconds.
6. Use combustion test instruments to adjust the
burner.
a. Adjust the air by moving the red cam to a lower
number until a trace of smoke is achieved with
CO2 level as high as possible (lowest possible
O2).
Example: 13.5% CO2 (2.5% O2) with a trace of
smoke.
b. Increase the air by increasing the red cam
20
c. A margin of reserve air has been added to
accommodate variable conditions.
7. Check the breech draft pressure against the
appliance manufacturer’s recommended setting
(typically + 0.1” W.C.).
8. If the breech pressure is higher or lower than
recommended level, adjust the appliance breech
damper to achieve the specified setting. Recheck
the smoke and CO2 (or O2) levels. Adjust burner air
if necessary.
9. Once all settings are complete and satisfactory,
proceed to ‘Set Low-fire Air’ Section.
Set Low-fire Air
1. Move the low-fire hold switch from the high fire
position to the low fire hold position.
a. The damper will return to the low-fire air
setting.
2. Check the smoke and CO2 (O2) levels.
a. Pull a smoke sample from the flue.
b. The sample should be clean (zero smoke level).
c. Check the CO2 (O2) level:
d. CO2 should be at 11 to 12% (O2 at 5.9 to 4.5%).
e. If the CO2 is less than 11% (O2 more than
5.9%), decrease the air and check the smoke
level.
3. Operate the burner from low fire to high fire and
back to verify operation.
4. Turn the burner off. Wait one or two minutes (for
chamber to clear) and then turn on again to verify
starting characteristics.
5. Perform limit circuit performance test specified
by appliance manufacturer to verify operation of
burner/appliance combination.
Section: Perform Regular Maintenance
Perform Regular Maintenance
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 burner or controls or make
any adjustments unless you are a trained and
qualified service technician.
□ Inspect the combustion head and air tube. Remove
any carbon or foreign matter. Replace all damaged
units with exact parts.
□ Clean the blower wheel, air inlet, air guide, burner
housing, and static plate of any lint or foreign
material.
□ 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.
y To ensure continued reliable operation, a qualified
service technician must service this burner annually.
□ Check motor current. The amp draw should not
y More frequent service intervals may be required in
dusty or adverse environments.
□ Check all wiring for secure connections or insulation
y Operation and adjustment of the burner requires
technical training and skillful use of combustion test
instruments and other test equipment.
Annual Service — by qualified service
technician
□ Replace the oil supply line filter. The line filter
cartridge must be replaced to avoid contamination
of the fuel unit and nozzle.
□ Inspect the oil supply system. All fittings should be
leak-tight. The supply lines should be free of water,
sludge, and other restrictions.
□ Remove and clean the pump strainer if applicable.
□ Replace both nozzles with the specified brand,
pattern, gph, flow rate, and spray angle specified by
the appliance manufacturer.
□ Clean and inspect the electrodes for damage,
replacing any that are cracked or chipped.
□ Check electrode tip settings. Replace electrodes if
tips are rounded.
□ Inspect the igniter spring contacts.
□ Clean the cad cell lens or other sensor surface, if
necessary.
□ Inspect all gaskets. Replace any that are damaged
or would fail to seal adequately.
exceed the nameplate rating.
breaks.
□ Check the pump pressure and cutoff function.
□ Check primary control safety lockout timing.
□ Check ignition system for proper operation.
□ Inspect the vent system and chimney for soot
accumulation or other restriction.
□ Clean all flue passages and flue pipe. Replace
corroded or damaged pipes.
□ Clean the appliance thoroughly according to the
manufacturer’s recommendations.
□ Check the burner performance. Refer to the section
‘Set High-fire Air’.
□ It is good practice to make a record of the service
performed and the combustion test results.
Monthly Maintenance — by owner
□ Observe combustion air openings and vent system
for integrity. Openings must be clean and free of
obstructions.
□ Check oil lines and fittings to verify there are no
leaks.
□ Observe burner ignition and performance to verify
smooth operation.
□ Shut the system down if you observe abnormal
or questionable operation. Call a qualified service
agency for professional inspection and service.
CF2500/CF3500 Burner Manual
21
Replacement Parts
For best performance specify genuine
Item Description
Beckett replacement parts
Description
CF2500 Part No. CF3500 Part No.
1
Oil Valve
Mounted on Junction Box
21789U
21789U
2
Knurled Nut
All Models
3666
3666
3
Adjusting Plate Assembly
w/ Stamped Sheet Metal Door
5201703U
5201703U
4
Fuel Pump
J4PA-C10506
21529U
21529U
5
Damper Motor
2 Stage
750601U
750601U
6
Fuel Lines
Specify Length
-
-
7
Timer
Nozzle Valve Delay
21295U
21295U
8
Air Proving Switch
4” W.C.
22182U
22182U
51214
51214
31346
31346
9
Transformer
12,000 Volts
10
Control
Refer to UL Label for Model Numbers
11
Pedestal Kit
All Models
12
Coupling Hole Plug
Use with Threaded Holes
32439U
32439U
13
Rear Cover Door Assembly
w/ Cast Aluminum Door
5994U
51204U
5201301U
5201302U
14
Sight Glass
15
Head Assembly
16
Electrode Assembly
17
Ignition Leads
w/ Stamped Sheet Metal Door
All Models
31346
31346
51475P
51475P
-
51637P
All Models
51212
51212
9-1/4” Long
5990092
5990092
10-1/2” Long
5990104
5990104
12-3/4” Long
5990126
5990126
16-1/4” Long
5990162
5990162
20-1/4” Long
5990202
5990202
KP/KM
KR
18
Air Tube
Refer to Figure 2
19
Nozzel Line Assembly
Refer to Figure 5
20
Coupling
H Pump
21
Blower Wheel
8.25” X 4.18”
22
Mounting Flange
23
Motor
Motor Relay (Not Shown)
21514
21514
21268U
21267U
31449U
31449U
120/208-230 Single Phase
21527U
21527U
208-230/460 Three Phase
21547U
21547U
575 Three Phase
21733U
21733U
120V Single Phase
752804
752804
208V Single Phase
7300
7300
2194301
2194301
Three Phase
Adjustable Flange
22
Refer to Figure 19
Figure 18 - Burner Replacement Parts
1
10
14
2
13
3
6
12
4
5
11
7
20
8
21
22
23
9
17
16
15
Figure 19 – Adjustable Mounting Plates
19
18
Flange A
Air Tube
Model
Flange A
Flange B
KP
51498
51630
KM
51498
51630
KR
N/A
51631
Flange B
CF2500/CF3500 Burner Manual
23
Limited Warranty Information
The R. W. BECKETT CORPORATION (“Beckett”) warrants to persons who purchase its “Products” from
Beckett for resale, or for incorporation into a product for resale (“Customers”), that its equipment is free
from defects in material and workmanship. To qualify for warranty benefits, products must be installed by a
qualified service agency in full compliance with all codes and authorities having jurisdiction, and used within
the tolerances of Beckett’s defined product specifications.
To review the complete warranty policy and duration of coverage for a specific product, or obtain a written
copy of warranty form 61545, please choose one of the following options:
1. Visit our website at: www.beckettcorp.com/warranty
2. Email your request to: rwb-customer-service@beckettcorp.com
3. Write to: R. W. Beckett Corporation, P. O. Box 1289, Elyria, OH 44036
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 is limited to the cost of the product.
USA: P.O. Box 1289 ● Elyria, Ohio 44036
Canada: R.W. Beckett Canada, Ltd. ● Unit #3, 430 Laird Road ● Guelph, Ontario N1G 3X7
www.beckettcorp.com
Part Number 6104 BCF35 R14, Printed in the U.S.A. 09/10
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