Beckett 800, homeappliance

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CORPORATION 12Vdc Oil Burner Manual 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: ⮹ Please read and carefully follow all instructions provided in this manual regarding your responsibilities in caring for your heating equipment. ⮹ Contact a professional, qualifi ed service agency for installation, start-up or service work. ⮹ READ THESE INSTRUCTIONS AND SAVE FOR REFERENCE. To the Professional, Qualifi ed Installer or Service Agency: ⮹ Please read and carefully follow all manual instructions and any supplements provided, before installing, starting, or servicing this burner or heating system. ⮹ The Installation must be made in accordance with all state and local codes having jurisdiction. Contents Burner Application Scope and Intended Use ...........2 Prepare Before Installing ............................................3 Specifi cations .....................................................................3 Notice Special Requirements.............................................3 General Information ....................................................4 A. Equipment Located in Confi ned Space .........................4 B. Exhaust Fans and Other Air-Using Devices. ...................... 4 C. Clearances to Burner and Equipment ...........................4 D. Exhausting Hazardous Fumes ......................................4 E. Low Firing Rate Baffl e. ..................................................5 Nozzle Assembly Maintenance ..................................5 A. Replace the Burner Nozzle............................................5 B. Check/Adjust Electrodes ...............................................6 C. Igniter Maintenance .......................................................6 D. Servicing Nozzle Line Assembly ...................................6 E. Check/Adjust "Z" Dimension ..........................................6 Fuel Supply ..................................................................7 A. Connect Fuel Lines........................................................7 B. Fuel Supply Level with or Above Burner........................7 C. Fuel Supply Below Level of Burner ...............................7 D. Fuel Line Replacement (Remote Tank Only) ................7 E. Fuel Line Valve and Filter .............................................7 Burner Wiring ...............................................................7 A. Burner installed on equipment .......................................7 B. Burner Replacement......................................................7 Drive Component Maintenance ..................................9 A. Motor, Blower Wheel, and Coupling Replacement ........9 B. Pump Maintenance......................................................10 C. Valve Coil and Stem Replacement ..............................10 Start Up Burner & Set Combustion ..........................10 A. Basic Burner Operation ...............................................10 B. Combustion Set-up ...................................................... 11 C. Set Combustion with Instruments................................ 11 Maintain & Service Burner ........................................12 A. Owner's Information ....................................................12 B. Owner Service and Maintenance ...............................12 Extended Down Time .......................................................12 Regular Service/Maintenance ..........................................12 Troubleshooting ........................................................13 Replacement Parts ....................................................15 Limited Warranty Information ..................................16 Hazard Defi nitions 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. Indicates a hazardous situation, which, if not avoided, could result in minor or moderate injury. Within the boundaries of the hazard warning, there will be information presented describing consequences if the warning is not heeded and instructions on how to avoid the hazard. Intended to bring special attention to information, but not related to personal injury or property damage. Burner Application Scope and Intended Use The ADC burner is designed for use in road maintenance equipment applications that have DC voltage charging systems capable of sustaining the specifi ed voltage requirements. For other equipment applications, please contact Beckett Technical Services at 1-800-645-2876. 2 Prepare Before Installing Section: Prepare Before Installing Specifi cations Owner's Responsibility Incorrect installation, adjustment, and use of this burner could result in severe personal injury, death, or substantial property damage from fi re, carbon monoxide poisoning, soot or explosion. Contact a professional, qualifi ed service agency for the installation, adjustment and service of your oil heating system. This work requires technical training, trade experience, licensing or certifi cation in some states and the proper use of special combustion test instruments. Please carefully read and comply with the following instructions: ⮹ Never store or use gasoline or other fl ammable liquids or vapors near this burner or appliance. ⮹ Never attempt to burn garbage or refuse in this appliance. ⮹ Never attempt to light the burner/appliance by throwing burning material into the appliance. ⮹ Never attempt to burn any fuel not specifi ed and approved for use in this burner. ⮹ Never restrict the air inlet openings to the burner or the combustion air ventilation openings in the room. Impaired Burner Performance Capacity 'F' Head Firing Rate: 0.75 - 2.50 GPH Input: 105,000 - 350,000 Btu/h Fuels USA: No. 1 or No. 2 diesel fuel or kerosene; No.1 or No. 2 heating oil (ASTM D396) DO NOT USE GAS OLINE, CRANKCASE OIL, OR ANY OIL CONTAINING GASOLINE. Electrical Power Supply: 13.5 Vdc Operating Load w/ igniter on: 15 Amps w/ igniter off: 8 - 10 Amps Motor: 13.5Vdc, 1/6 hp, 3450 RPM, 10 Amps (max.) NEMA "M" Flange, rotation CCW when facing shaft end. Ignition Secondary: 20KVpk 25mA Interrupted duty OR optional continuous duty. Pump Outlet pressure: Note 1 Dimensions Height (maximum): 11 ½ inches Width (maximum): 14 3/8 inches Depth (chassis only): 6 9/16 inches Air tube diameter: 4 inches and Fire Hazard. Do NOT operate the burner beyond specifi cations outlined in the table to the right. ⮹ For applications beyond these limits, consult Beckett Ambient Operating Temperature +32° F. (0° C.) Minimum +115° F. (+46° C.) Maximum (See Warning on Impaired Burner Performance and Fire Hazard.) Technical Service at 1-800-645-2876. ⮹ NOTE: Some packaged appliances with burners may be agency listed as a unit to operate beyond these limits. Consult the appliance manufacturer's specifi cations and agency approvals for verifi cation. Note 1. See equipment manufacturer's burner specifi cations for recommended outlet pressure. Pressure is 100 psig unless otherwise noted. Notice Special Requirements If you discover damage to the burner or controls during unpacking, notify the carrier at once and fi le the appropriate claim. When contacting Beckett for service information — Please record the burner serial number (and have available when calling or writing). You will fi nd the serial number on the silver label located on the left rear of the burner. See Figure 1. 12 Vdc ADC Burner Manual 3 Section: General Information Adequate Voltage Required A low or erratic power supply could result in impaired burner operation, severe delayed ignition or an explosion inside the heat exchanger resulting in a burn and/or asphyxiation hazard. ⮹ The Model ADC requires a continuous supply of 11 to 16 volts DC at 15 amps measured at the burner during operation. ⮹ An automotive or small engine charging system that is capable of supplying the required continuous voltage/ amperage is recommended with certain road equipment, such as asphalt hot patchers and similar applications. ⮹ This is especially true while maintaining nominal load temperatures during idle periods. 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 fi re hazards. ⮹ The burner cannot properly burn the fuel if it is not supplied with a reliable combustion air source. ⮹ Follow the guidelines in the latest editions of the NFPA 31 and CSA-B139 regarding providing adequate air for combustion and ventilation. Table 2. Air Tube Combination (ATC) Codes General Information Refer to the Troubleshooting section of this manual when experiencing a possible fault condition. A. Equipment Located in Confi ned Space The confi ned space should have two 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 then one square inch per 1,000 BTU's per hour of the total input rating of all equipment within the enclosure. The openings shall have free access to the building interior, which should have adequate infi ltration from the outside. B. Exhaust Fans and Other Air-Using Devices. Size air openings large enough to allow for all air using 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, for example), either pipe combustion directly to the burner or provide a sealed enclosure for the burner and provide it with its own combustion air supply. C. Clearances to Burner and Equipment Provide space around burner and equipment for easy service and maintenance. Check minimum clearances against those shown by the equipment manufacturer and by applicable codes. D. Exhausting Hazardous Fumes See warning on this page. Also be conscious of any fumes produced by the materials that are being heated. Always Firing Rate GPH Head Static Plate Size ATC Codes for Usable Air Tube Lengths: ('A' in inches see Fig. 2) ensure adequate ventilation to exhaust all fumes. min-max inches 4-1/2 5-3/8 6-5/8 0.40 - 0.75 F0 3-3/8U AF44XR AF53XR AF65XR 0.75 - 1.25 F3 2-3/4 AF44XN AF53XN AF65XN 0.85 - 1.35 F4 2-3/4 AF44WH AF53WH AF65WH 0.85 - 1.65 F6 2-3/4 AF44YB AF53YB AF65YB 1.10 - 2.00 F12 2-3/4 AF44XO AF53XO AF56XO 1.65 - 2.50 F22 2-3/4 AF44XP AF53XP AF56XP *See page 3 for capacity and voltage specifi cations. Figure 1. Typical Burner Nameplate General Model Information Serial Number Including Date Code Table 1. Low Firing Rate Baffl e Head Type Low Firing Rate Baffl e (if specifi ed) F0 up to 0.65 gph F3 up to 0.85 gph F4 or F6 up to 0.90 gph R.W. Beckett Manufacturer's Settings RWB R.W. Beckett Specification Rating Information Number and Revision Can Be Customized by Model " AFG " ELYRIA OHIO U.S.A. MFR'S SETTINGS Series Oil Burner ATC: FIRING RNG: AF65XN 0.75-1.35 GPH SERIAL NUMBER HEAD: F3 000405-62736 STC PLT: NOZZLE: 2-3/4U 1.0 X 80B DLVN Primary Group and Fuel Oil Individual Specification State & Local Approvals PUMP PRS: 100 PSI BJB3001 R00 000405-62736 R.W.Beckett Corp. Elyria, Ohio Made in the U.S.A. SK10090 4 E. Low Firing Rate Baffl e. The low fi ring rate baffl e (See LFRB in Replacement Parts) reduces the air fl ow and pressure. The LFRB is sometimes used for fi ring rates under 1.00 gph as listed in Table 1. Refer to the equipment manufacturer's instructions. Do not omit the LFRB when specifi ed. Omitting the baffl e when specifi ed or installing the baffl e when not specifi ed could result in poor burner performance. Nozzle Assembly Maintenance Correct Nozzle and Flow Rate Required Incorrect nozzles and fl ow rates could result in impaired combustion, under fi ring, over-fi ring, sooting, puff-back of hot gases, smoke and potential fi re or asphyxiation hazards. Use only nozzles having the brand, fl ow rate (gph), spray angle and pattern specifi ed by the appliance manufacturer. Follow the appliance manufacturer's specifi cations for the required pump outlet pressure for the nozzle, since this affects the fl ow rate. ⮹ Nozzle manufacturers calibrate nozzle fl ow rates at 100 psig. ⮹ When pump pressures are higher than 100 psig, the actual nozzle fl ow 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 fl ow rates at various pressures refer to Table 3. A. Replace the Burner Nozzle. 1. If applicable, remove the plastic plug protecting the nozzle adapter threads. Figure 5. Nozzle, Line & Electrode Assembly Contacts to be parallel with Section: Nozzle Assembly Maintenance 2. Place a 3/4" open-end wrench on the nozzle adapter. Insert the nozzle into the adapter and fi nger tighten. Finish tightening with a 5/8" open-end wrench. 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 equipment manufacturer's information). Verify that the electrode tip settings comply with Figure 2. Use care when removing or installing an oil nozzle A damaged nozzle could cause impaired combustion, sooting, puffback of hot gases, oil leakage and potential fi re or asphyxiation hazards. ⮹ Inspect the nozzle adapter to insure that the sealing surface is not grooved or scratched. ⮹ To insure that the nozzle functions properly, check the orifi ce and strainer for dirt, scratches or other damage before installation. ⮹ Do NOT attempt to install or remove a nozzle without securing the adapter to prevent seriously damaging the alignment. ⮹ Use care when handling the nozzle line assembly to prevent changing the electrode tip settings or damaging the ceramic electrode insulators. ⮹ Ensure that the electrode settings match the values shown in Figure 2. Figure 2. Electrode Tip Setting 5/32" GAP 1/4" ABOVE CENTER 1/8" NOZZLE-TO-TIP SPACING 6 Electrode gap to be centered with nozzle center. Item # Description horizontal center line within 2°. 11 10 9 8 1 2 7 4 Item # Description 90° 3 5 4 1 Electrode Contact (3" ATC or extension over 3") 2 Nozzle Line 3 Spider spacer assembly 4 Static Plate 5 Electrode clamp 6 Electrode clamp retaining screws 7 Nozzle line setscrew 8 Electrode Insulator 9 Nozzle adapter 10 Nozzle tip 11 Electrode tip 12 Vdc ADC Burner Manual 5 Section: Nozzle Assembly Maintenance B. Check/Adjust Electrodes Check the electrode tip settings. Adjust if necessary to comply with the dimensions shown in Figure 2. To adjust, loosen the electrode clamp screw and slide/rotate electrodes as necessary. Securely tighten the clamp screw when fi nished. C. Igniter Maintenance The igniter assembly does not require any adjustments beyond making sure the springs and the burner electrode rods make solid contact when the igniter is in the closed position. The sealing surfaces of the gaskets should be checked and replaced at the fi rst signs of any damage or deterioration. Clean any dirt or residue from the porcelain bushings, springs, and baseplate. The simplest way to check igniter operation is by supplying voltage to the input and checking to see whether an arc is produced. Check by either looking or listening to see if there is an arc across the electrodes while the burner is running and the igniter is energized. The igniter must be grounded to the burner before checking the following. To check the igniter, ensure all power to the burner is off and use an ohmmeter to check the resistance between the two springs. The meter should read between 480 - 580 ohm. The igniter should be replaced if the meter indicates an open circuit, or the spring-to-spring resistance exceeds the 480 - 580 ohm range by more than 10%. D. Servicing Nozzle Line Assembly Before proceeding, turn off power to the burner. 1. Disconnect the oil connector tube from the nozzle line. 2. Referring to Figure 3, loosen the two screws securing the igniter retaining clips (a) and rotate both clips to Figure 3. Igniter Hinge & Retainer Clips a release the igniter baseplate. Then tilt the igniter back on its hinge. 3. Remove the splined nut (b). 4. Remove the nozzle line assembly from the burner, being careful not to damage the electrodes or insulators while handling. To ease removal of short assemblies, it may be necessary to loosen the escutcheon plate (c). Reset to the edge of the label. 5. To replace the nozzle line assembly, reverse the above steps. E. Check/Adjust "Z" Dimension Refer to Figure 4. The critical "Z" dimension is the distance from the face of the nozzle to the fl at face of the head. This distance for F heads is 1-1/8". The "Z" dimension is factory set for burners shipped with the air tube installed but should always be verifi ed during service and installation. If the "Z" dimension is out of adjustment, perform the following steps. Before proceeding, turn off power to the burner. 1. Disconnect the oil connector tube from the nozzle line. 2. Referring to Figure 5, loosen the splined nut from the nozzle line. Loosen the hex head screw securing the escutcheon plate to the burner housing. 3. A Beckett T650 gauge should be used to set the Z dimension. 4. 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. 5. Slide the nozzle line forward or back until this dimension for F heads is 1-1/8". 6. 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. 7. Recheck the "Z" dimension periodically when servicing to ensure the escutcheon plate has not shifted. You will need to reset the "Z" dimension if you replace the air tube or nozzle line assembly. Figure 4. 'Z' Dimensions Using Gauge c b SK9787 6 The Beckett Z gauge (part number Z 2000) is available to permit checking the F head "Z" dimension without removing the burner. Fuel Supply A. Connect Fuel Lines Do Not Install Bypass Plug with 1-Pipe System Failure to comply could cause Immediate pump seal failure, pressurized oil leakage and the potential for a fi re and injury hazard. ⮹ The burner is shipped without the bypass plug installed. ⮹ Install the bypass plug in two-pipe oil supply systems ONLY. For oil supply system specifi cations for tanks not mounted on machines, carefully follow the pump manufacturer's literature and the latest edition of the National Fire Protection Association (NFPA) 31 standard. Pumps with automatic bypass do not require a bypass plug. Verify by referring to the pump manufacturer's instructions. B. Fuel Supply Level with or Above Burner The burner may be equipped with a single stage pump. If a one-pipe system is installed, verify a bypass plug is not installed in the pump, then connect the fuel supply to the burner with a single supply line Note that manual bleeding of the pump is required on initial start-up or when the equipment runs out of fuel. When connecting a two pipe fuel system, install the pump bypass plug. Oil Supply Pressure Control Required Damage to the fi lter or pump seals could cause oil leakage and a fi re hazard. ⮹ The oil supply inlet pressure to the burner cannot exceed 3 psig. ⮹ Ensure that a pressure limiting device is installed in accordance with the latest edition of NFPA 31. ⮹ Do NOT install valves in the return line. (NFPA 31, Chapter 8.) ⮹ Gravity Feed Systems: Always install an anti-siphon valve in the oil supply line or a solenoid valve (RWB Part # 22246U) in the pump/nozzle discharge tubing to provide backup oil fl ow cut-off protection. Section: Fuel Supply C. Fuel Supply Below Level of 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 the horizontal and vertical length, the installation may also require a two-stage pump. Consult the fuel unit manufacturer's literature for lift and vacuum capability. D. Fuel Line Replacement (Remote Tank Only) When replacing fuel lines, continuous lengths of heavy wall copper tubing is recommended. To ensure a tight seal, always use fl are fi ttings. Never use compression fi ttings. Always install fi ttings in an accessible location. To avoid vibration noise, fuel lines should not run against the appliance or the ceiling joists. E. Fuel Line Valve and Filter Do Not Use Tefl on Tape Damage to the pump could cause impaired burner operation, oil leakage and appliance soot-up. ⮹ Never use Tefl on tape on fuel oil fi ttings. ⮹ Tape fragments can lodge in fuel line components and fuel unit, damaging the equipment and preventing proper operation. ⮹ Use oil-resistant pipe sealant compounds. Shutoff valves should be located in the oil supply line. Do not install valves in the return line. Burner Wiring A. Burner installed on equipment Refer to appliance manufacturer's wiring diagram for electrical connections. Electrical Shock Hazard Electrical shock can cause severe personal injury or death. ⮹ Disconnect electrical power before installing or servicing the burner. ⮹ Provide ground wiring to the burner, metal control enclosures and accessories. (This may also be required to aid proper control system operation.) B. Burner Replacement Burner wiring may vary, depending on the actual primary control and furnished options. Refer to Figure 6 for typical burner wiring, showing cad cell primary controls. Note that the relay and control, shown in the wiring diagram are optional features. 12 Vdc ADC Burner Manual 7 Section: Burner Wiring Figure 6A. Typical Wiring For Constant Duty Ignition - With No Primary Control 50A FUSE SAFETY AND LIMIT CONTROLS 30A FUSE ORANGE OPERATING CONTROLS BLUE WITH WHITE STRIPE YELLOW 10A FUSE SOLID WHITE VIOLET(+) MOTOR CAPPED (NOT USED) BLACK IGNITER VALVE GND BLACK WHITE(-) Notes: FROM 12 - 13.5 Vdc POWER SUPPLY 1. Wires are to be sized to prevent a voltage drop between battery and burner with burner running at full load. 2. Motor runs continuously in normal confi guration. 3. Hard-wire burner ground to battery. DO NOT USE CHASSIS GROUND SYSTEM. SK10087 Figure 6B. Typical Wiring For Interrupted Ignition - With No Primary Control 50A FUSE SAFETY AND LIMIT CONTROLS 30A FUSE OPERATING CONTROLS ORANGE VIOLET(+) SOLID WHITE 10A FUSE BLUE W/ WHITE STRIPE MOTOR VALVE YELLOW CAD BLACK WHITE(-) Notes: CELL IGNITER YELLOW BLACK GND FROM 12 - 13.5 Vdc POWER SUPPLY 1. Wires aret to be sized to prevent a voltage drop between battery and burner with burner running at full load. 2. Hard-wire burner ground to battery. DO NOT USE CHASSIS GROUND SYSTEM. SK10088 8 Figure 6C. Typical Wiring with 7556 Primary Safety Control Notes: Section: Drive Component Maintenance 1. Wires are to be sized to prevent a voltage drop between the battery and the burner with the burner running at full load. 2. Fuse Sizes (inside control): Motor = 30 Amp Igniter, Control, Valve, & Alarm = 10 Amp 3. Hard-wire burner ground to battery. Do NOT use chassis ground system. 4. Input power to the control's +12 Volt wire shall be provided from a fused service switch, rated at 50 amps or less. 5. Motor-off delay on a 7556P will be disabled if the safety and operating limits as shown in Figure 6C interrupt power to the control's red +12 Volt wire. OIL VALVE IGNITER Note 7 Note 8 ALARM VALVE GND (VLV) IGNITER GND (IGN) MOTOR GND (MTR) 9 800 1KS 6. Do not wire power directly to the burner motor. Only wire the motor as shown in Figure 6C. If instant burner heat is required by the application, purchase or program a control with a long motor off delay time, which will ensure instant heat if a new call for heat is received within the motor-off delay time. 7. Igniter Yellow leads are capped and not used. Bundle with the other leads in the wiring box with a cable tie. 8. The igniter Blue-White striped MOTOR ON/OFF/RESET HIGH LIMIT RED WIRE BLACK WIRE CAD CELL CAD CELL ENABLE THERMOSTAT and solid White leads are combined with the 3274001 "Y" connector and attached to the primary control igniter spade terminal. MAIN POWER 24V Drive Component Maintenance A. Motor, Blower Wheel, and Coupling Replacement The motor will require replacement if the proper voltage is measured at the motor input, and the motor will either not run, or the current draw with a free running pump exceeds 10% of the rated current. To replace the burner motor, coupling and/or blower wheel perform the following steps. 1. Before servicing, turn off and/or disconnect all power to the burner. 8. Slide the blower wheel toward the motor until it contacts the feeler gauge. 9. Rotate the blower wheel until the setscrew is centered on the fl at of the motor shaft. Tighten the setscrew to secure the wheel. 10. Slide the motor coupling on the motor shaft, then install the motor on the burner housing. Ensure that the motor coupling fi ts between the motor shaft and the pump shaft inside the housing. Tighten the motor retaining screws. Reconnect the wires. 11. Restore power, start the burner and perform the combustion test described previously in this manual. Figure 7. – Blower Wheel Flat face on 2. Disconnect the burner motor wires. 3. Remove the bolts securing the motor to the burner housing. 4. Remove the motor, coupling, and blower wheel. 5. Loosen the set screw on the blower wheel to slide the existing wheel off the shaft. 6. Slide the new blower wheel onto the old shaft (after thoroughly cleaning housing) and/or slide the old blower wheel onto the new motor shaft. 7. Place a .030" (1/32" ± 1/64") feeler gauge between the blower wheel and the motor housing. Insert feeler gauge between blower and motor motor shaft Access hole to set screw 12 Vdc ADC Burner Manual 9 Section: Drive Component Maintenance B. Pump Maintenance General Pump Information Important information - Long or oversized inlet lines may require the pump to operate dry during initial bleeding period. In such cases, the priming may be assisted by injecting fuel oil in the pump gear set. Under lift conditions, lines and fi ttings must be air tight. To assure this, "Pipe Dope" may be applied to both the used and unused inlet and return fi ttings. Do NOT use Tefl on tape or compression fi ttings Mounting Position - Beckett CleanCut pump may be mounted in any position (except upside-down in a single pipe installation). Vacuum Check - A Vacuum Gauge may be installed in either of the 1/4" NPT inlet ports. Pressure Check- When a pressure check is made, use the nozzle port. If the bleed port is used, the reading on the gauge should be approximately 5 psig higher than the pressure reading on the nozzle port. See Figure 8. Cutoff Check - To check cutoff pressure dead head a pressure gauge in the nozzle port. Run the burner for a short period of time. Shut the burner off. The pressure will drop and hold above zero. Pressurized or gravity feed installations must not exceed 3 psig on inlet line or return line at the pump per NFPA 31. A pressure greater than 10 psig may cause damage to the shaft seal. C. Valve Coil and Stem Replacement To determine if the valve coil requires replacement perform the following steps. 1. Remove the cord set from the valve. 2. Place the leads from an ohmmeter across the coil. 3. A 12Vdc volt coil should measure between 15 and 25 ohms. 4. If the meter indicates an open circuit, replace the coil. Figure 8. – Pump and Valve Assemblies Spring Washer 10mm Nut Cordset Coil Base Plate Stem Assembly Pump Assembly Nozzle Port Fitting Bleed Valve SK9810 To check pump operation perform the following. 1. Check the operating pressure by removing the copper tubing from the nozzle line and installing a pressure gauge in the line. With the motor running and the coil energized, check the gauge. The pressure should read 100 psig unless otherwise stated. 2. To check the cutoff function, deadhead the pressure gauge onto the copper connector tube attached to the nozzle port. Run the burner for a short period of time. Shut the burner off; the pressure should drop and hold. To replace the coil and/or pump assembly perform the following steps. 1. Before servicing, turn off and/or disconnect all power to the burner. 2. Remove the copper tube assembly when replacing the pump or when removing the coil and the tube blocks the coil. 3. Using a fl at tip screwdriver, press the fl at tip into the spring washer to prevent it from rotating. 4. Using a 10mm wrench or adjustable wrench, remove the nut and spring washer. 5. Remove the coil by lifting it straight up. 6. Remove the two base plate screws, then the base plate by lifting straight up. 7. Remove valve stem assembly by pulling straight up. 8. To install the new stem and coil assemblies, follow the above steps in reverse order, tightening each part as you go. 9. Restore power, start the burner and perform the combustion test described previously in this manual. Start Up Burner & Set Combustion A. Basic Burner Operation Typical Constant Duty Ignition Confi guration - With this Beckett ADC oil burner confi guration, the motor and igniter operate continuously while the valve that controls oil fl ow is cycled by the switches on the power washer. The motor is used to drive the blower and pump. The rotational speed of the motor is determined by the voltage supplied and the load placed on the motor. Pump pressure and air settings are the main factors affecting the motor load. The igniter converts battery DC voltage into a high voltage spark to ignite the oil. The igniter is capable of running continuously as long as the blower wheel is circulating air across the igniter base. The pump and solenoid valve are used to control the fl ow of oil from the reservoir to the nozzle. 10 Igniter with Interrupted Duty Ignition - This optional control circuit is available to reduce current draw on the charging system by turning the igniter off after a fl ame has been established. This option controls igniter operation based on a signal from a light sensing cad cell. When light hits the cell the control will sense a decrease in resistance across the sensor. A few seconds delay will occur prior to the igniter switching off. As long as suffi cient light is reaching the cell eye, the igniter will remain off. If light is removed from the sensor, the igniter will turn on until light is again sensed by the cad cell. With 7556 Primary Safety Control - The 7556 control provides the same benefi ts as the ignition control board as described above as well as added safety, convenience, and performance features. It adds a valve on delay and motor-off delay to the burner's operation sequence that promote clean burner operation. It has a lock-out function that shuts the burner down if it is not operating properly. The control adds fusing at the burner to protect against component failures. The control also has redundant motor relays that are checked for proper operation every heat cycle. Variations to the burner circuits may occur due to optional temperature, pressure, and vacuum switches that control burner operation. Note that when external switches are used to control motor operation they must be sized correctly for the rated current or a relay should be installed to isolate the switches from the motor's full load current. B. Combustion Set-up As soon as burner motor starts rotating bleed all the air from the pump. (Required with single-pipe systems.) 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, fi re and asphyxiation hazards. ⮹ 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. ⮹ Do not attempt to re-establish fl ame with the burner running if the fl ame becomes extinguished during start-up, venting, or adjustment. ⮹ Vapor-Filled Appliance: Allow the unit to cool off and all vapors to dissipate before attempting another start. ⮹ Oil-Flooded Appliance: Shut off the electrical power and the oil supply to the burner and then clear all accumulated oil before continuing. ⮹ If the condition still appears unsafe, contact the Fire Department. Carefully follow their directions. ⮹ Keep a fi re extinguisher nearby and ready for use. Section: Start Up Burner & Set Combustion To bleed the pump, attach a clear plastic hose over the vent fi tting. Loosen the fi tting and catch the oil in an empty container. Tighten the fi tting when all air has been purged from the supply system. Note: If the burner stops after a fl ame is established, the unit probably requires additional bleeding. Continue to bleed the system until the pump is primed and a fl ame is established when the bleed valve is closed. C. Set Combustion with Instruments 1. Allow the burner to run for approximately 5 to 10 minutes. 2. Follow these four steps to properly adjust the burner: Step 1: Adjust the air until a trace smoke level is achieved. Step 2: At the trace of smoke level, measure the CO2 (or O2). This is the vital reference point for further adjustments. Step 3: Increase the air to reduce CO2 by 1 percentage point (O2 will be increased by approximately 1.4 percentage points). Step 4: Recheck the smoke level. It should be zero. 3. This procedure provides a margin of reserve air to accommodate variable conditions. 4. Once the combustion level is set, tighten the fasteners on the air band and air shutter. 5. Start and stop the burner several times to ensure satisfactory operation. 6. Test the equipment safety controls to verify they function according to the manufacturer's specifi cations. Figure 9. – Air supply components Air band position indicator Shutter position indicator 12 Vdc ADC Burner Manual 11 Section: Maintain & Service Burner Maintain & Service Burner A. Owner's Information Professional Service Required Incorrect installation, adjustment, and use of this burner could result in severe personal injury, death, or substantial property damage from fi re, 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 qualifi ed individual or service agency that is: ⮹ Licensed or certifi ed to install and provide technical service to oil heating systems. ⮹ Experienced with all applicable codes, standards and ordinances. ⮹ Responsible for the correct installation and commission of this equipment. ⮹ 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 manual. Have your equipment inspected at regular intervals by a qualifi ed service agency to assure continued proper operation. The burner should be adjusted using dedicated combustion test equipment. Failure to properly set the burner could result in ineffi cient operation, and/or conditions that could potentially cause severe personal injury, death or substantial property damage. B. Owner Service and Maintenance Properly installed and maintained, your ADC burner will provide years of effi cient, trouble-free operation. Please take care of your equipment by following the warnings provided and by immediately contacting your qualifi ed service agency if your burner is not operating properly. This equipment should be serviced only by a qualifi ed service agency. The appropriate test instruments must be used. Daily Check the area around your burner/equipment to make sure: ○ Nothing is blocking the burner inlet air openings. ○ Air ventilation openings are clean and unobstructed and the exhaust is not crusted. ○ No combustible materials are stored near the equipment. ○ There are no signs of oil or water leakage around the burner or equipment. Extended Down Time If the equipment will be stored for an extended period of time, insure that the fuel tank is full and add a fuel stabilizer to the tank. Regular Service/Maintenance Have your burner, serviced annually by your qualifi ed service agency. The following components/assemblies should be checked/adjusted/replaced on a regular basis. Refer to the Replacement Parts exploded view for part locations. □ Replace the oil supply line fi lter, if applicable. The line fi lter cartridge must be replaced to avoid contamination of the pump and nozzle. □ Inspect the oil supply system. All fi ttings should be leak-tight. The supply lines should be free of water, sludge and other restrictions. □ Remove and clean the pump strainer. □ Verify the nozzle is the one originally specifi ed by the appliance manufacturer and replace the nozzle with one having the exact specifi cations from the same 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 or replace if corroded. 12 □ Clean the cad cell, if applicable. □ Make sure Low Firing Rate Baffl e is in place, if required, for the burner application. Omitting the baffl e can result in unacceptable burner combustion. □ Inspect all gasket including the igniter base plate Section: Troubleshooting Table 2. Nozzle Flow Rate by Size Nozzle fl ow rate U. S. gallons per hour of No. 2 fuel oil when pump pressure (psig) is: Nozzle gasket. Replace any that are damaged or missing. □ Clean the blower wheel, air inlet, air guide, retention head and static plate of any dirt, asphalt or other material. Size (rated at 100 psig) 125 psi 140 psi 150 psi 175 psi 200 psi □ Check motor current. The amp draw should not exceed the nameplate rating. Check all wiring for loose connections or damaged insulation. □ Check the pump pressure and cutoff function. □ Check primary control safety lockout timing, if applicable. Refer to the information supplied by the control manufacturer for procedures. □ Check ignition system for proper operation. □ Inspect the exhaust system for soot accumulation or other restriction. □ Clean the equipment thoroughly according to the manufacturer's recommendations. □ Check the burner performance using test instruments. □ It is good practice to make a record of the service performed and the combustion test results. Troubleshooting Oil burners that are designed for use on road maintenance equipment are built to take temperature extremes, vibration, and rough handling. When performing the following troubleshooting steps, we assume that the oil burner motor and ignition transformer operate continuously and the oil solenoid valve, which controls oil fl ow, is cycled by the equipment controls. We also assume that there is power to the burner and fuel in the tank. In addition to typical mechanics tools, it is recommended to have the following equipment on hand. ○ Meter capable of measuring volts, ohms and amps, ○ ignition transformer tester, ○ smoke pump tester, ○ combustion analyzer, and ○ 0 to 200 psi pressure gauge. See Table 4 on following page for troubleshooting steps. 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 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 2.25 2.52 - - - - 12 Vdc ADC Burner Manual 13 Section: Troubleshooting Table 4. Troubleshooting Chart Symptom Possible Cause If the burner is not igniting, the burner motor, drive coupling, and oil pump are operating and oil is fl owing to the nozzle through the solenoid valve, check the following possibilities. 1. Check the air shutter adjustment. If the air shutter is opened too far, the fl ow of air may prevent the arc from Oil Not Igniting No Flame Motor Not Operating No Oil Spray Fluctuating or No Pump Pressure Slow Motor Rotation reaching the oil spray. This may appear as a white vapor exhaust from the heater. [Refer to section "Start up burner and set combustion"] 2. The ignition system may have failed to supply an adequate arc to ignite the oil. Check the battery and charging system to insure a continuous supply of 11 to 16 volts DC (15 amps). [Refer to section "Nozzle Assembly Maintenance"] 3. Check the electrodes for wear and damage. Insure that the electrodes are adjusted properly. [Refer to section "Nozzle Assembly Maintenance"] If there is no fl ame, the burner motor and igniter operate continuously and the oil solenoid valve is functional, check the following possibilities. 1. Check for a plugged oil nozzle. [Refer to section 3] 2. If the coil on the solenoid valve is actuating, insure that the valve is opening or closing properly. [Refer to section "Fuel Supply"] 3. Check for suffi cient fuel pressure. Pressure is 100 psig with valve energized, unless otherwise noted. [Refer to section "Drive Component Maintenance"] 4. Check the pump pressure. Check for air in fuel lines. 5. Check burner for broken motor coupling. If the coupling is broken check pump rotation prior to replacing the coupling. [Refer to section "Drive Component Maintenance"] 6. Check for contaminated fuel and/or partially plugged fuel fi lter. [Refer to section "Fuel Supply"] If the blower motor is not operating, check the following possibilities. 1. Check voltage at the motor to insure that switches and relays, in line with the motor, are operating properly. [Refer to section "Burner Wiring"] 2. Check pump and motor shaft operation. They should work freely without binding. [Refer to section "Drive Component Maintenance"] If the blower motor is operating, there is fuel in the tank, but oil does not spray out the end of the nozzle, check the following possibilities. 1. Check for a broken or stripped coupling between the pump and the motor. [Refer to section "Drive Component Maintenance"] 2. Check the pump output for oil. [Refer to section "Drive Component Maintenance"] 3. Check operation of the oil valve. [Refer to section "Drive Component Maintenance"] 4. Check for a plugged nozzle. [Refer to section "Nozzle Assembly Maintenance"] 5. Check for air in the oil line. [Refer to section "Nozzle Assembly Maintenance"] 6. Check for fuel contamination or plugged fi lter. [Refer to section "Nozzle Assembly Maintenance"] If the pump pressure, as determined by a pressure gauge, is erratic or does not exist, check the following possibilities. 1. Check motor rotational speed. Low rpm can cause erratic or no pump pressure. [Refer to section "Drive Component Maintenance"] 2. Check for a broken or worn motor coupling. [Refer to section "Drive Component Maintenance"] 3. Check that the pump turns freely. [Refer to section "Drive Component Maintenance"] 4. Check for air leaks in the lines. [Refer to section "Fuel Supply"] 5. Check for oil froth at the bleed point. [Refer to section "Fuel Supply"] 6. Check voltage at the motor. [Refer to section voltage rating on nameplate] 7. Check for fuel contamination or partially plugged fi lter. If the blower motor is not operating at the rpm's listed on the nameplate, check the following. 1. Check the supply voltage to the motor. [Refer to section voltage rating on nameplate] 2. Check for free operation of the motor shaft and pump assembly. [Refer to section "Drive Component Maintenance"] 14 Section: Replacement Parts Replacement Parts 21 23 12 10 11 9 Illustration 8 20 22 15 1314 6 7 19 17 16 18 1 2 3 4 5 24 Illustration # Description Part# 1 DC Motor n/a 2 Blower Wheel 2999U 3 Coupling 2140501 4 Air Guide 31231U 5 Burner Housing - Black 5874BKU 6 Air Band 5151501 # Description Part# 14 Escutcheon Plate 3493 15 Electrode Kit over 3-5/8" 578731 16 Cad Cell Detector 7492/7006U 17 Igniter Gasket Kit 51411 18 4X4 Wiring Box Kit 5770 19 Control Kit 7556x-xxxxU* 7 Air Shutter - 4 Slot Air Shutter - 8 Slot 3709 3494 20 Igniter Assy with baseplate 5218301U 21 Igniter only 5218309 8 Cord set 21807 9 Pump (CleanCut) 2184402U 10 Valve Stem 21877U 11 12 Volt Coil 21754U 22 Air Tube Ass'y Specify 23 Flange Mounting Gasket Specify 24 Motor Kit with Blower Wheel and Coupling 52145U 12 8" Copper Tubing 5394 13 Escutcheon Plate Spline Nut 3666 Not Shown Tune-up Kit for 30 & 35 Air Tube Lengths 578730 * 'X's indicate timing options. Contact Beckett for available part numbers. 12 Vdc ADC Burner Manual 15 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 benefi ts, products must be installed by a qualifi ed service agency in full compliance with all codes and authorities having jurisdiction, and used within the tolerances of Beckett's defi ned product specifi cations. To review the complete warranty policy and duration of coverage for a specifi c 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 B12ADC2 R02, Printed in the U.S.A. 04/12