Beckett AFII 85, homeappliance

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! WARNING 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: To the Professional, Qualifi ed Installer or Service Agency: ⮹ ⮹ 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. ⮹ Save this manual for future reference. Please read and carefully follow all instructions provided in this manual 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. Form 6104 BCF10-R06 1 2 Form 6104 BCF10-R06 Before you begin . . . The following resources will give you addional information for your installation. We suggest that you consult these resources whenever possible. Pay particular attention to the appliance manufacturer's instructions. Appliance manufacturer's instructions -Always follow the appliance manufacturer's instructions for burner installation, equipment and set-up. 1–800–OIL–BURN - Beckett's technical services hot-line. www.beckettcorp.com - Beckett's website. Table of Contents General Information ...............................................................................................................................4-5 To the Owner .......................................................................................................................................................4 Hazard Defi nitions ...............................................................................................................................................4 Agency approvals ................................................................................................................................................4 General Specifi cations ........................................................................................................................................4 Owner's Responsibility ........................................................................................................................................5 Professional Installer/Service Agency Responsibility ..........................................................................................5 Pre-installation checklist......................................................................................................................5-7 Combustion air supply .........................................................................................................................................6 Clearances .........................................................................................................................................................6 Fuel supply .........................................................................................................................................................6 Nozzle pressure ..................................................................................................................................................6 Vent system .........................................................................................................................................................7 Electrical supply ..................................................................................................................................................7 Verify burner components ...................................................................................................................................7 Verify fi ring input range ........................................................................................................................................7 Verify air tube ......................................................................................................................................................7 Mount the burner .................................................................................................................................. 8-10 Mount fl anges on air tubes ..................................................................................................................................8 Mount air tube to burner ......................................................................................................................................8 Install Nozzle .......................................................................................................................................................8 Check Electrodes ................................................................................................................................................8 Install Nozzle Line Assembly ...............................................................................................................................9 Set Dimension Z ..................................................................................................................................................9 Insert Burner ......................................................................................................................................................10 Connect fuel lines .............................................................................................................................. 10-11 Fuel unit By-pass plug .......................................................................................................................................10 Oil supply/return lines ........................................................................................................................................10 Burner fuel fl ow ................................................................................................................................................. 11 Wire the burner..........................................................................................................................................12 Sequence of Operation-Typical ..........................................................................................................13 Prepare the burner for start-up.....................................................................................................13-15 Start-up checklist ...............................................................................................................................................13 Z Dimension ......................................................................................................................................................13 Adjusting plate Assembly ..................................................................................................................................14 Initial head position ............................................................................................................................................14 Initial air settings ................................................................................................................................................14 Set appliance limit controls ................................................................................................................................15 Prepare the fuel unit for air venting ...................................................................................................................15 Start the burner ...................................................................................................................................15-16 Start burner and vent air ...................................................................................................................................15 Set air adjusting plate ........................................................................................................................................16 Maintenance and Service ..................................................................................................17 Annual Service ..................................................................................................................................................17 Monthly maintenance ........................................................................................................................................17 Replacement Parts.............................................................................................................................18-19 Warranty ................................................................................................................................... Back Cover Form 6104 BCF10-R06 3 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 qualifi ed service agency for use in professionally setting up and maintaining your oil burner. Your Beckett burner will provide years of effi cient opera 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. Agency approvals tion if it is professionally installed and maintained by a ⑨ qualifi ed service technician. If at any time the burner does not appear to be operating properly, immediately contact ⑨⑨ your qualifi ed service agency for consultation. We recommend annual inspection/service of your oil UL listed to comply with ANSI/UL296 and certifi ed to CSA B140.0. Accepted by N.Y.C. M.E.A. Other approvals may be available and must be specifi ed at time of order. heating system by a qualifi ed service agency. Hazard defi nitions Indicates an imminently hazardous situation, Specifi cations Fuels U.S. #1 or #2 heating oil only (ASTM D396) Canada #1 stove oil or #2 furnace oil only which, if not avoided, will result in death, serious injury, or property damage. Indicates a potentially Firing range 4.0 to 10.0 GPH ½ HP 3450 RPM 120/60 hz standard 6.5 amps @ 120 VAC hazardous situation, which, if not avoided, could result in death, severe personal injury, and/or substantial property damage. Motor Optional voltages: (60 hz or 50 hz) • 240/1-PH • 208/240/480/3-PH Indicates a potentially hazardous situation, which, if not avoided, may result in person al injury or property damage. NOTICE Intended to bring special attention to information, but not related to personal injury or property damage. Ignition Trans. 120V/12,000V Housing Cast aluminum Fuel unit 100 - 300 PSIG Oil nozzle 45° - 70° solid Shipping wt. 75 lbs. Dimensions See Figure 7 (Page 10) (See NOTICE on 50 hz motor applications.) General Model Information Serial Number,Including Date Code Rating Information Approval Agency Symbols Primary Group and Fuel L0002 Model "XX" Series (Fuel) Burner SERIAL NUMBER 050214-00000 Control Circ: 120V/60Hz 4.5A Motor Circ: 120V/60Hz 4.0A LISTED (FUEL) BURNER R.W. Beckett Corp. Elyria, Ohio Made in the U.S.A. For use with Group 8 . . . MP 1192 XX000 R00 MFR'S SETTINGS X X X X X X XX000 R00 050214-00000 R.W. Beckett Construction & Setting Data R.W. Beckett Specifi cation Number and Revision Boiler Manufacturer and Model, When Applicable Additional Codes 4 Form 6104 BCF10-R06 Owner's Responsibility: Follow These Instructions Exactly Failure to follow these instructions, misuse, or incorrect adjustment of the burner could lead to equipment malfunction and result in asphyxia tion, explosion or fi re. Contact a professional, qualifi ed 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 certifi cation in some states and the proper use of special combustion test instruments. Please carefully read and comply with the following NOTICE High altitude installations — Accepted industry practice requires no derate of burner capacity up to 2,000 feet above sea level. For altitudes higher than 2,000 feet, derate burner capacity 2% for each 1000 feet above sea level. Pre-installation check list 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. instructions: ⮹ The control must detect a dark, no-fl ame condition in ⮹ 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 appli ance. ⮹ Never attempt to light the burner by throwing burning material into the appliance. ⮹ Never attempt to burn any fuel not specifi ed and ap proved for use in this burner. ⮹ 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. Protect Against Dust and Moisture Never restrict the air inlet openings to the burner or the combustion air ventilation openings in the room. Professional Installer/Service Agency Wet, dusty environments could lead to blocked air passages, corrosion damage to components, impaired combustion performance and result in asphyxiation, explosion or fi re. Responsibility: ⮹⮹ Follow These ⮹ Instructions Exactly This burner is designed for clean, dry installations. Electrical controls are not protected against rain or sprayed water. Keep the installation clear of dust, dirt, corrosive va Failure to follow these instructions ⮹ could lead to equipment malfunc tion and result in asphyxiation, explosion or fi re. ⮹ Please read all instructions before proceeding. Follow all instructions completely. ⮹ This equipment must be installed, adjusted and started pors, and moisture. Protective covers and more frequent maintenance may be required. Adequate Combustion and Ventilation Air Supply Required by a qualifi ed service agency that is experienced with all applicable codes and ordinances and responsible for the installation and commission of the equipment. ⮹ The installation must comply with all local codes and Failure to provide adequate air supply could se riously affect the burner performance and result in damage to the equipment, asphyxiation, ex plosion or fi re hazards. ordinances having jurisdiction and the latest editions of ⮹ the NFPA 31 and CSA-B139 & B140 in Canada. ⮹ NOTICE 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 specifi c application data. The burner cannot properly burn the fuel if it is not sup plied 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. Form 6104 BCF10-R06 5 ⑨ Combustion air supply ⮹ The burner requires combustion air and ventilation air for reliable operation. Assure that the building and/or com bustion air openings comply with National Fire Protec tion Standard for Oil-Burning Equipment, NFPA 31. For appliance/burner units in confi ned spaces, the room must have an air opening near the top of the room plus one near the fl oor, each with a free area at least one square inch per 1,000 Btu/hr input of all fuel burning equipment in the room. For other conditions, refer to NFPA 31 (CSA B1139- M91 in Canada). ⮹ If there is a risk of the space being under negative pres sure or of exhaust fans or other devices depleting available air for combustion and ventilation, the appliance/burner should be installed in an isolated room provided with out side combustion air. ⑨ Clearances ⮹ With the burner installed in the appliance, there must be ⑨ Nozzle pressure 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 haz ards. Use only nozzles having the brand, fl ow rate (gph), spray angle and pattern specifi ed by the appliance manufac turer. Follow the appliance manufacturer's specifi cations for the required pump outlet pressure for the nozzle, since this affects the fl ow rate. ⮹ adequate space in front of and on the sides of the burner to allow access and operation. Verify that the clearance di ⮹ mensions comply with all local codes and with the appli ance manufacturer's recommendations. ⑨ Fuel supply Nozzle manufacturers calibrate nozzle fl ow rates at 100 psig. This burner utilizes pressures higher than 100 psig, so the actual nozzle fl ow rate will be greater than the gph stamped on the nozzle body. (Example: A 5.00 gph noz zle at 150 psig = 6.12 gph and at 300 psig = 8.66 gph) ⮹ 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 allow able suction pressure. For typical nozzle fl ow rates at various pressures see ac companying chart. Table 1 - Nozzle Capacities Oil Supply Pressure Con trol Required Damage to the pump, fi lter or other compo nent seals could cause possible oil leakage Rated gph @ 100 psig Pressure - pounds per square inch 125 150 175 200 250 275 300 and potential fi re hazard. 2.00 2.24 2.45 2.65 2.83 3.16 3.32 3.46 ⮹ The oil supply inlet pressure to the fuel unit cannot ex ceed 3 psig. ⮹⮹ Do NOT install valves in return line. Ensure that a pressure-limiting device is installed in ac cordance with the latest edition of the NFPA 31. 2.25 2.52 2.76 2.98 3.18 3.56 3.73 3.90 2.50 2.80 3.06 3.31 3.54 3.95 4.15 4.33 2.75 3.07 3.37 3.64 3.90 4.35 4.56 4.76 3.00 3.35 3.67 3.97 4.24 4.74 4.97 5.20 If fuel supply is level with or higher than fuel unit — 3.50 3.91 4.29 4.63 4.95 5.53 5.80 6.06 ⮹ When the fuel unit is not required to lift the oil, the instal lation 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. ⮹ See Figure 8 for one-pipe fuel supply installations. See Figure 9 for two-pipe fuel supply installations. 4.00 4.47 4.90 5.29 5.66 6.32 6.63 6.93 4.50 5.04 5.51 5.95 6.36 7.11 7.46 7.79 5.00 5.59 6.12 6.61 7.07 7.91 8.29 8.66 5.50 6.15 6.74 7.28 7.78 8.70 9.12 9.53 6.00 6.71 7.35 7.94 8.49 9.49 9.95 10.39 If fuel supply is below the fuel unit — 6.50 7.27 7.96 8.60 9.19 10.28 10.78 11.26 ⮹ Use a two-pipe oil system when the fuel unit must lift the oil more than 8 feet if burner is equipped with a B fuel unit, or more than 2 feet if burner is equipped with an H fuel unit. The return line provided by the two-pipe system is needed to purge the air from the fuel lines and minimize the likelihood of air-related problems during operation. 7.00 7.83 8.57 9.26 9.90 11.07 11.61 12.12 7.50 8.39 9.19 9.92 10.61 11.86 12.44 12.99 8.00 8.94 9.80 10.58 11.31 12.65 13.27 13.86 6 Form 6104 BCF10-R06 ⮹ 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 fi ring rate. Do not change this pressure unless directed to do so by the appliance manufacturer. ⑨ Vent system ⮹ The fl ue gas venting system must be in good condition and must comply with all applicable codes. ⑨⮹ Electrical supply Verify that the power connections available are correct for the burner. All power must be supplied through fused dis connect switches. ⑨ Verify burner components — ⮹ Burner box, Model CF1000 ⮹ Air tube assembly ⮹ Mounting fl ange kit Figure 1. Min. Combustion Chamber Dimensions Minimum Dimensions ⮹ Pedestal mounting assembly kit (recommended) ⮹ Oil nozzle, per Table 1 — Only 45° to 70° solid pattern Firing Rate (refractory-lined) (wet-base boilers) A L AL nozzles are recommended unless otherwise specifi ed by appliance manufacturer. (See specifi c appliance recom mendation sheet or refer to OEM Spec Guide). Find the required fi ring rate in the 300 psig column (factory-set fuel unit pressure). Select the corresponding nozzle from col umn 1 (Rated gph @ 100 psig). ⑨⮹ Verify fi ring rate Refer to appliance manufacturer's instructions (if available) for fi ring rate and nozzle selection. Otherwise, the maximum recommended fi ring rate for the burner depends on the length of the fi ring chamber and the distance from the burner center to the chamber fl oor. Verify that the chamber dimensions are at least as large as the minimum values given in Figure 1. If the appliance dimensions are smaller than recommended, reduce the fi ring rate accordingly. ⑨ Verify air tube ⮹ The information in this section may be disregarded if the air tube is supplied by the appliance manufacturer. ⮹ Two tube arrangements are available – 0 to 5 gph 7.0" 25.0" 7.0" 25.0" 5 to 10 gph 8.0" 35.0" 8.0" 40.0" Figure 2 - Air Tube Mounting Dimensions E Insertion depth G Air tube to inside of chamber 0.25" +/- 0.125 T Air tube length D Tube diameter ⦸ Install the burner with a 2 deg. pitch as shown Tube A — 4.0 to 10.0 GPH per Table 2 Tube B — 7.0 to 10.0 GPH per Table 2 ⮹ Air Tube Length A.T.C. Codes (A.T.C. = Air Tube Combination) Maximum fi ring capacity depends on the fi rebox pressure. Use Table 2 to verify the correct air tube type for the fi ring (Dimension T) Tube A (Dim. D = 5-1/2") Tube B (Dim. D = 5-3/4") rate required. Use Tube B only when Tube A cannot pro vide the fi ring rate required. ⮹ See Figure 2 to verify the correct air tube length and air tube combination code. 06.75" CF66KD CF66KE 10.25" CF102KD CF102KE 13.75" CF136KD CF136KE 17.75" CF176KD CF176KE Form 6104 BCF10-R06 7 Mount the burner ⑨ ⮹ ⮹ Protect the Air Tube From Overheating Overheating could cause damage to the air tube and other combustion components lead Mount air tube to burner 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. ing to equipment malfunction and impaired combustion performance. Table 2 - Air Tube Capacity vs. Firebox Pressure ⮹ The end of the air tube must not extend into the com bustion chamber unprotected unless it has been factory Firebox Pressure (in. w.c.) Tube A Tube B 10% turndown No reserve air 10% turndown tested and specifi ed by the appliance manufacturer. ⮹ Position the end of the air tube 1/4" back from fl ush with the refractory inside entry wall to prevent damage from overheating. 0.0 2.24 2.45 2.65 0.2 2.52 2.76 2.98 0.4 2.80 3.06 3.31 0.6 3.07 3.37 3.64 ⑨ Mount fl ange(s) on air tube ⮹ This section does not apply to burners with welded fl ang es. ⮹⮹ Do not install air tube on burner. For non-pressure fi ring fl ange, refer to Figure 3: Install 0.8 3.35 3.67 3.97 1.0 3.91 4.29 4.63 Note: 10% turndown indicates suffi cient reserve air to reduce the CO2 in the fl ue to 90% of its value. Note: The above ratings may vary 5% due to variations in actual job conditions. gasket (item a) and fl ange (item c). Ignore the next ⑨ paragraph. ⮹ For pressure-fi ring fl ange, refer to Figure 3: Slide gasket ⮹ (item a) onto the air tube, making sure the top of the air tube is up. Pre-drill holes in the pressure fi ring plate (item b) to match the appliance studs. Slide the pressure fi ring plate (item b) and fl ange (item c) onto the air tube as shown. ⮹ Wrap ceramic fi ber rope around the air tube and press tightly into the inside diameter of the fl ange (item c). ⮹ Slide the air tube (item d) into position in the appliance front. Tighten the fl ange-mounting-stud nuts. Set the ⑨ 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 fl ange to the air tube. Install nozzle See Figure 4. 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 over-tighten. Check, and adjust if necessary, the critical dimensions P, Q, R and S shown in the drawing. Verify that the oil tube assembly and electrodes are in good condition, with no cracks or damage. Check electrodes Maintain Electrode Specifi cations Figure 3 - Mount fl ange(s) on air tube Failure to properly maintain these specifi cations could cause ignition malfunction, puff-back of hot gases, heavy smoke, asphyxiation, explosion and fi re hazards. ⮹ Adjust the electrode gap and position in relation to the nozzle to the specifi cations shown in Figure 4. ⮹ Check, and adjust if necessary, the critical dimensions P, Q, R and S shown in the drawing. Verify that the oil tube assembly and electrodes are in good condition, with no cracks or damage. 8 Form 6104 BCF10-R06 Figure 4 - Nozzle and nozzle line assembly ⑨ ⮹ ⮹ ⮹ ⮹ ⮹ ⮹ Install nozzle line assembly Insert the nozzle line assembly into the burner air tube as in Figure 5. See Figures 5 and 6. Assemble the adjusting plate assem bly 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 c to secure the two plates together. Slide both plates completely to the left on the primary adjusting plate (item g) and fi nger-tighten acorn nut d. Slide the completed adjusting plate assembly over the noz zle line end. Move the plate assembly and the nozzle line so the plate assembly fi ts into position as shown in Figure 5. Install the spline nut (Figure 5, 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 trans former to the electrodes. Critical dimensions - P (Electrode spacing) = 3/32" R Nozzle center line to electrode tip) = 1/4" Q (Nozzle to head) = 1/4" S Nozzle face to electrode tip = 1/8" Figure 5 - Nozzle line assembly in burner Measure dimension Z from front (fl at) face of head to end of air tube, as shown. Figure 6 - Adjusting plate assy. Measure dimension Z from the fl at surface between (not on) the raised fi ns. Z = 1-3/4" ± 1/16" ⑨ Set dimension Z ⮹ Replace the rear access door on the burner, making sure that the adjusting plate assembly is now securely in the groove. ⮹ Loosen acorn nut d in Figure 5. Slide the nozzle line and plate assembly until dimension Z in Figure 5 is 1-3/4" ± 1/16". When dimension Z (from end of air tube to fl at area of front face of head) is correctly set, tighten acorn nut d. Verify that the adjusting plate assembly is properly seated in the adjusting 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 d if necessary to reposition the nozzle line. Once Legend (Figures 5 and 6) 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 dimension Z is set, do not loosen acorn nut d again. For the setting of acorn nut c, refer to Page 13. Form 6104 BCF10-R06 9 ⑨ Insert burner ⑨ ⮹ 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 2 and 3. ⮹ ⮹ See Figure 7. Install the pedestal support kit (recommend ed) by attaching the ¾" NPT fl ange (item a) to the bottom of the burner using the (4) #10 screws provided. Cut and thread (one end only) a ¾" pipe nipple (item b) with length 10 inches less than dimension D in Figure 7. Thread the pipe into the fl ange. Then slip the pipe end into the fl oor fl ange (item c). ⮹ ⮹ Secure the burner to the appliance by tightening the nuts on the burner fl ange mounting studs. Then secure the pedestal support fl oor fl ange set screw to the pipe. ⮹ Oil supply/return lines Install the oil tank and oil lines in accordance with all applicable state and local codes. Size the oil supply and return lines using the guidelines given in the fuel unit literature included in the literature envelope. Oil line fl ow rate will equal the burner rate for one-pipe systems. For two-pipe systems, refer to Table 3 for the fuel unit gear set capacity - the rate at which fuel is recirculated when connected to a two-pipe system. Size two-pipe oil lines based on this fl ow rate. Use continuous lengths of heavy-wall copper tubing, routed under the fl oor where possible. Do not attach fuel lines to the appliance or to fl oor joists if possible. This will reduce vibration and noise transmission problems. Install an oil fi lter sized to handle the fuel unit gearset fl ow capacity (Table 3) for two-pipe systems. Size the fi lter for the fi ring rate for one-pipe systems. Locate the fi lter Connect Fuel Lines ⮹⑨ Fuel unit by-pass plug Do Not Install By-pass Plug with 1-Pipe System Failure to comply could cause immediate pump seal failure, pressurized oil leakage and the po tential for a fi re and injury hazard. immediately adjacent to the burner fuel unit. Install two high-quality shut-off 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 fi lter. ⮹ The burner is shipped without the by-pass plug in stalled. ⮹ Intall the by-pass plug in two-pipe oil supply systems ONLY. ⮹ Use a two-pipe system, one-pipe system with by-pass loop, or remove the by-pass plug when using with a one-pipe system and no by-pass loop Figure 7 - Burner installed in appliance front Legend H Housing total length — 18" J Center to bottom of housing — 10-7/8" K Overall housing height — 13-3/8" 10 Form 6104 BCF10-R06 Table 3 - Fuel unit gearset capacities Figure 8 - One-pipe oil fl ow with "B" pump Fuel unit model number Gearset capacity (gallons per hour) 300 psig B2TA8245 21 ⑨ Burner fuel fl ow Install Oil Supply To Specifi cations Failure to properly install the oil supply system could cause oil leakage, equipment malfunction, puff-back of hot gases, heavy smoke, asphyxiation, explosion and fi re hazards. 300 psig Figure 9 - Two-pipe oil fl ow with "B" pump 300 psig 300 psig Legend ⮹ Carefully install the oil supply lines, fi ttings and com ponents using the guidelines provided in this section. ⮹ The oil supply must comply with the latest edition of NFPA 31 (Canada CSA B139) and all applicable codes. ⮹⮹ a Return port b Nozzle port c Oil valve d Nozzle & adapter g Inlet port k Return line to oil tank p Air bleed valve ⮹ Do not install valves in return line. 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). ⮹ ⮹ ⮹ 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 fi ring rate. Do not change this pressure unless directed to do so by the appliance manufacturer. One-pipe systems – See Figure 8 for the fuel fl ow path. Oil supply connects to one of the fuel unit inlet ports. Two-pipe systems – See Figure 9 for the fuel fl ow paths for two-pipe oil systems. ⮹ Oil supply connects to one of the fuel unit inlet ports. Oil return connects to the fuel unit return port. (Install the by-pass plug in the fuel unit for two-pipe systems.) Form 6104 BCF10-R06 11 Wire the burner — R7184 Electrical Shock Hazard Professional Installation and Service Required Incorrect installation and mishandling of start-up could lead to equipment malfunction and result in asphyxiation, explosion or fi re. ⮹ Electrical shock can cause severe personal in jury or death. This burner must be installed and prepared for start-up by a qualifi ed service technician who is trained and ex ⮹ Disconnect electrical power before installing or servic ing the burner. ⮹ ⮹ Provide ground wiring to the burner, metal control en closures and accessories. (This may also be required to ⮹ aid proper control system operation) ⮹ Perform all wiring in compliance with the National Electric Code ANSI/NFPA 70 (Canada CSA C22.1). ⮹ Do Not Bypass Safety ⮹ Controls perienced in commercial oil burner system installation and operation. Do not attempt to start the burner unless you are fully qualifi ed. Do not continue with this procedure until all items in the "Prepare the burner for start-up" section have been verifi ed. Carefully follow the wiring diagrams, control instruc tion sheets, fl ame safeguard sequence of operation, test procedures and all appliance manufacturer's directions that pertain to this installation. If any of these items are not clear or are unavailable, Tampering with, or bypassing safety controls could lead to equipment malfunction and result in asphyxiation, explosion or fi re. call Beckett at 1-800-645-2876 for assistance. Figure 10 - Typical Wiring ⮹ Safety controls are designed and installed to provide protection. ⮹⮹ Do not tamper with, or bypass any safety control. If a safety control is not functioning properly, shut off all main electrical power and fuel supply to the burner and call a qualifi ed service agency immediately. Keep Service Access Cov ers Securely Installed Legend FD Fused Disconnect, by others TR Ignition transformer LM Limit controls, by others M1 Burner motor OP Operating controls, by others S1 Oil valve PR Oil primary control, R7184 typ. T-T 24-volt thermostat/limit terminals CC Flame sensor, cad cell typical F-F Cad cell fl ame sensor terminals These covers must be securely in place to prevent electrical shock, damage from exter nal elements, and protect against injury from moving parts. ⮹ All covers or service access plates must be in place at all times except during maintenance and service. ⮹ This applies to all controls, panels, enclosures, switch es, and guards or any component with a cover as part of its design. 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 10 for a typical wiring diagram, with R7184 oil primary, for reference purposes only. 12 Form 6104 BCF10-R06 Sequence of Operation (typical) 1 Prepare the burner for start-up Start-up checklist - Verify the following before attempting to start burner. ⑨ ⑨ ⑨ ⑨ ⑨⑨⑨ ⑨ ⑨ Standby — The burner is idle, waiting for a call for heat. 1. When a call for heat is initiated, there is a 3-10 second delay ⑨ while the control performs a safe start check. Valve-on delay — As applicable, the ignition and motor are 2. ⑨ turned on for a 15-second prepurge. Trial for ignition (TFI) — The fuel valve is opened, as 3. Combustion air supply and venting have been inspected and verifi ed 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. 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 this instruction manual. Fuel supply line is correctly installed, the oil tank is suffi ciently fi lled, and shut-off valves are open. Burner is securely mounted in appliance, with pressure fi ring plate and gasket installed for pressurized chamber application. Appliance has been fi lled with water (boilers) and controls have been operationally checked. Burner has been installed in accordance with appliance manufacturer's instructions (when available). Also refer to appliance manufacturer's instructions (when available) for start-up procedures. applicable. A fl ame should be estalished within the 15- ⑨ second lockout time. Z dimension Lockout — If fl ame is not sensed by the end of the TFI, 4. the control shuts down on safety lockout and must be manually reset. If the control locks out three times in a row, the control enters restricted lockout. Call a qualifi ed service technician. Ignition carryover — Once fl ame is established, the 5. ignition remains on for 10 seconds to ensure fl ame stability. It then turns off. Run — The burner runs until the call for heat is satisfi ed. 6. The burner is then sent to burner motor-off delay, as applicable, or it is shut down and sent to standby. Recycle — If the fl ame is lost while the burner is fi ring, the 7. control shuts down the burner, enters a 60-second recycle delay, and then repeats the ignition steps outlined above. If the fl ame is lost three times in a row, the control locks out to prevent continuous cycling with repetitious fl ame loss caused by poor combustion. 8. Burner motor-off delay — If applicable, the fuel valve is closed and the burner motor is kept on for the selected postpurge time before the control returns the burner to standby. The adjusting plate should be set per these instructions (see page 9). The top acorn nut (Figure 11, item d) should never be loosened once the Z dimension is initially set. Figure 11 - Adjusting plate initial setting, typical Legend (Figure 11) b Spline nut for securing nozzle line c Bottom acorn nut (for head adjustment) d Top Acorn nut (for setting dimension Z only) -do not loosen after setting dimension Z e Indicator adjusting plate f Secondary adjusting plate g Primary adjusting plate h Copper oil line from oil valve to nozzle line Form 6104 BCF10-R06 13 ⑨ Adjusting plate assembly (Figure 11) Make sure spline nut (item b) and bottom acorn nut (item c) are loose. ⑨ Initial head position (Figure 11) ⮹ The indicator plate assembly (item e) markings correspond to head position settings. 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 4 for the desired fi ring rate. ⮹ Figure 11 shows a typical example, with a head setting of 6. ⮹ When the head position has been set, tighten the bottom acorn nut (item c) and the spline nut (item b). ⑨ Initial air settings (Figure 12) ⮹ Loosen the screw holding the air adjusting plate (item m). Set the air to the desired rate. (The numbers on this plate correspond to the approximate fi ring rate settings given in Table 5.) ⮹ Rotate the air adjusting plate until the lower edge of the pointer is opposite the number from Table 5 corresponding to the desired fi ring rate. ⮹ This initial setting should be adequate for starting the burner. Tighten the screw to secure the adjusting plate. Once the burner is in operation, the air setting will be adjusted for best performance as discussed later in this manual. ⮹ Follow the procedures given later in this manual for fi ne tuning the air settings. Figure 12 - Air damper assembly lLegend h Damper label - position indicator for air adjustment plate k Damper indicator - permanently attached to damper m Air adjusting plate - sets air position l Air adjusting plate screw - locks plate position Table 4 - Initial indicator adjustment plate settings (head position) Table 5 - Initial air adjusting plate settings (damper position) Approximate adjusting plate setting Firing rate, gph Tube "A" Tube "B" Approximate head settings Firing rate, gph Tube "A" Tube "B" 0 - - 1 - - 2 4.00 - 3 6.00 - 4 7.00 7.00 5 8.00 8.00 6 10.00 10.00 7 - 12 - - These settings are approximate, and 0 4.00 4.00 1 4.50 7.50 2 5.00 8.00 3 6.00 9.00 4 7.00 10.00 5 7.50 - 6 8.00 - NOTE can vary depending on actual job con ditions and overfi re pressure. 7 - 10 10.00 - These settings are approximate, and NOTE can vary depending on actual job con ditions and overfi re pressure. 14 Form 6104 BCF10-R06 ⑨ Set appliance limit controls ⮹ Set the appliance limit controls in accordance with the appliance manufacturer's recommendations. ⑨ Prepare the fuel unit for air venting ⮹ To vent air from one-pipe oil systems, attach a clear hose to the vent plug on the fuel unit. Provide a container to catch the oil. Loosen the vent plug. Start the Burner 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. ⮹ ⮹ Vent the air as described under Start the burner. ⮹ ⮹ ⮹ ⮹ ⮹ 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 ac cumulated oil before continuing. If the condition still appears unsafe, contact the Fire De partment. Carefully follow their directions. Keep a fi re extinguisher nearby and ready for use. ⑨ Starting the burner and venting air 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. ⮹ Do not allow oil to intermittently spray into a hot com bustion chamber while bleeding. ⮹ 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. ⮹ Ensure that all bubbles and froth are purged from the oil supply system before tightening the pump air bleed valve. Verify that the air adjusting plate (Figure 12, item m) has 1. been set to the initial air position as described on page 14 under Initial air settings. 2. Open the oil shut-off valves in the oil supply (and return) line(s) to the burner. Set the thermostat (or operating control) to call for heat. 3. Close the line switch to the burner. The burner motor should 4. start immediately. Form 6104 BCF10-R06 15 ⑨ If the burner motor does not start, reset the motor overload 5. switch (if so equipped) and press the reset switch of the Set air adjusting plate (Figure 12) burner primary control. 1. Vent the fuel unit as soon as the burner motor starts rotating. 6. 2. To vent — Allow the burner to run until the appliance has warmed suffi ciently. Visually check the fl ame. The fl ame should not be dark orange or smoky. If the fl ame appears to be smoking, increase the amount of air by re-adjusting the damper ⑨ Attach a clear plastic tube to the air bleed valve (Figure 8 or 9 as applies, item p). 3. ⑨ Place the end of the tube in a container to catch the oil. 4. Then loosen the fuel unit air vent valve. ⑨ Tighten the air vent valve after all air has been purged. ⑨ IF burner stops during venting — ⮹ The burner primary control will lockout if fl ame is not established within its time limit. This is typically 15 seconds for R7184B primary controls, but may be less for other fl ame supervisory controls. indicator to a higher number. Once the appliance has warmed, the air setting can be checked and adjusted. Use combustion test instruments to adjust the burner. a. Adjust the air 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 to reduce CO2 by 2 percentage points at a zero smoke level. (Increase O2 by 3 percentage points at a zero smoke level.) Example: Reduce CO2 from 13.5% to 11.5%, with ⮹ The burner may lockout several times during the period needed to purge all the air. Press the red reset button for ½ second during the prepurge cycle to extend air venting time. zero smoke (or increase O2 from 2.5% to 5.5%). c. This procedure provides a margin of reserve air to ac commodate variable conditions. ⑨ IF burner stops after fl ame established — 5. Check the breech draft pressure against the appliance ⮹ Additional venting is probably required. Repeat the air venting procedure. manufacturer's recommended setting (typically + 0.1" W.C.). 6. 7. Once fl ame is steady, proceed to Set air adjusing plate. If the breech pressure is higher or lower than recommend ed level, adjust the appliance breech damper to achieve the specifi ed setting. Recheck the smoke and CO2 levels. Adjust burner air if necessary and tighten the air adjust ing plate screw securely. 16 Form 6104 BCF10-R06 Maintenance and Service ⑧⑧⑧ Annual Professional Service Required Tampering with or making incorrect ⑧ adjustments could lead to equipment malfunction and result in asphyxia tion, explosion or fi re. ⑧ ⮹ Do not tamper with the burner or controls or make any adjustments unless you are a trained and qualifi ed ⑧ service technician. ⮹ To ensure continued reliable operation, a qualifi ed service technician must service this burner annually. ⑧ ⮹ More frequent service intervals may be required in dusty or adverse environments. ⑧ ⮹ Operation and adjustment of the burner requires technical training and skillful use of combustion test instruments ⑧⑧⑧⑧ and other test equipment. Inspect the igniter spring contacts. Clean the cad cell lens surface, if necessary. Inspect all gaskets. Replace any that are damaged or would fail to seal adequately. Inspect the combustion head and air tube. Remove any car bon or foreign matter. Replace all damaged units with exact parts. Clean the blower wheel, air inlet, air guide, and burner housing 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. Check motor current. The amp draw should not exceed the nameplate rating. Check all wiring for secure connections or insulation breaks. Check the pump pressure and cutoff function. Check primary control safety lockout timing. Check ignition system for proper operation. Annual service — by qualifi ed service techni cian ⑧ Have the burner inspected, tested and started at least annually by a qualifi ed service technician. This annual test/inspection ⑧ should include at least the following: ⑧ Inspect the vent system and chimney for soot accumulation or other restriction. Clean the appliance thoroughly according to the manufac turer's recommendations. Check the burner performance. Refer to the section "Set combustion with test instruments". ⑧ Replace the oil supply line fi lter. The line fi lter cartridge must be replaced to avoid contamination of the fuel unit and nozzle. ⑧ Inspect the oil supply system. All fi ttings should be leak It is good practice to make a record of the service performed and the combustion test results. Monthly maintenance — by owner tight. The supply lines should be free of water, sludge and ⑨ other restrictions. ⑧⑧ Remove and clean the pump strainer if applicable. ⑨ Replace the nozzle with the exact brand, pattern, gph, fl ow rate and spray angle. ⑨ ⑧ Clean and inspect the electrodes for damage, replacing any that are cracked or chipped. ⑨ ⑧ Check electrode tip settings. Replace electrodes if tips are rounded. Observe combustion air openings and vent system for integrity. Openings must be clean and free of obstructions. Check oil lines and fi ttings 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 qualifi ed service agency for professional inspection and service. Form 6104 BCF10-R06 17 Replacement parts Item Part Name Description Part Number 1 Timer Nozzle valve delay 21295U 2 Oil Valve Box mounted 21789U 3 Adjusting plate assembly CF10-2300 Kit 51213U 4 Knurled nut All models 3666 5 Fuel pump B2TA-8245 H3PAN-C150H 21313U 21309U 6 Pedestal kit All models 51193 7 Fuel lines Specify length - 8 Damper spring All models 4339 9 Sight glass All models 31346 10 Rear cover door assembly Cast aluminum door* Stamped sheet-metal door* 5994U 5201301U 11 Control Specify - 12 Damper indicator All models 5985BK 13 Coupling Hole Plug Coupling Access Door Use with threaded hole Use with rectangular opening 32439U 16703GY 14 Head assembly CF1000 combustion 51203P 15 Electrode assembly All models 51212 16 Ignition leads 8-1/4" long 11-3/4" long 15-1/4" long 19-1/4" long 5990082 5990116 5990152 5990192 17 Nozzle line assembly Refer to Figure 2, Page 7 18 Air tube Refer to Figure 2, Page 7 19 Transformer 12,000 volt 51214 20 Coupling B pump H pump 21290 21308 21 Blower wheel CF1000 5.50" x 3.09" 21268U 22 Motor 120/208-230V single phase 208/230-460V three phase 120V single phase 21401U 21638U 7273 Motor relay (not shown) 208V single phase three phase 7300 21719 Adjustable fl ange see Figure 13 on opposite page * These doors are NOT interchangeable. Please specify what you are replacing. 18 Form 6104 BCF10-R06 1 2 3 4 87 16 15 1417 18 19 20 21 13 5 6 22 9 10 11 12 Figure 13 - Adjustable Mount Figure 14 - Adjustable mount ing Plates for CF1000 ing plates for CF1000 Form 6104 BCF10-R06 19 Limited Warranty Information Limited WARRANTY For Residential, Commercial and Specialty Burners The R. W. BECKETT CORPORATION ("Beckett") warrants to persons who purchase its Beckett burners from Beckett for resale or for incorporation into a product for resale ("Customers") that its equipment is free from defects in material and workmanship under normal use and service for 60 months from the date of manufacture for Residential Burners and 18 months from the date of manufacture for Commercial and Specialty Burners. Residential burner models include: AF, AFG, AFII, NX, SF, SR and SMG. Commercial burner models include: CF375, CF500, CF800, CF1400, CF2300A, CF2500, CF3500A, CG10, CG15, CG25 and CG50. Specialty burner models include: ADC, ADCP, ARV, SDC and SM. The provisions of this warranty are extended to individual major burner components as follows: a) 60 months from date of manufacture for all Beckett-branded major components, except for 12 Vdc components. b) 18 months from date of manufacture for all non-Beckett-branded major components and Beckett branded 12 Vdc components. Note: Normal service items found to be defective upon receipt by the customer are covered by this warranty. THIS WARRANTY DOES NOT EXTEND TO EQUIPMENT SUBJECTED TO MISUSE, NEGLECT, OR ACCIDENT: NOR DOES THIS WARRANTY APPLY UNLESS THE PRODUCT COVERED BY IT IS PROPERLY INSTALLED BY A QUALIFIED, COMPETENT TECHNICIAN, WHO IS LICENSED WHERE STATE AND LOCAL CODES REQUIRE, AND WHO IS EXPERIENCED IN MAKING SUCH INSTALLATIONS, IN ACCORDANCE WITH THE LATEST EDITION OF NFPA NO. 31 OF THE NATIONAL FIRE PROTECTION ASSOCIATION, THE LATEST EDITION OF THE NATIONAL FUEL GAS CODE (NFPA NO. 54) AND IN ACCORDANCE WITH ALL APPLICABLE LOCAL, STATE AND NATIONAL CODES HAVING JURISDICTIONAL AUTHORITY. Equipment, which is defective in material or workmanship and within the warranty period, may be returned for credit as follows: Beckett Burners, Beckett-branded major components and non-Beckett-branded major components that came as original equipment on a Beckett burner or were sold as a replacement part by Beckett should be returned, freight prepaid, to Beckett's home office. Credit will be issued to the customer unless the returned equipment is determined by Beckett to be out of warranty or damaged by user, in which case the equipment will be scrapped. Note: Beckett is not responsible for any labor cost for removal and replacement of equipment. THIS WARRANTY IS LIMITED TO THE PRECISE TERMS SET FORTH ABOVE, AND PROVIDES EXCLUSIVE REMEDIES EXPRESSLY IN LIEU OF ALL OTHER REMEDIES, AND IN PARTICULAR THERE SHALL BE EXCLUDED THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT WILL BECKETT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGE OF ANY NATURE. Beckett neither assumes nor authorizes any person to assume for Beckett any other liability or obligation in connection with the sale of this equipment, Beckett's liability and Customer's exclusive remedy being limited to credit as set forth above. R.W. BECKETT CORPORATION P.O. Box 1289 Elyria, Ohio 44036 Form No. 61545 R72905 R.W. BECKETT CORPORATION U.S.A.: P.O. Box 1289 · Elyria, Ohio 44036 www.beckettcorp.com Canada: R.W. Beckett Canada, Ltd. · Unit #3, 430 Laird Road · Guelph, Ontario N1G 3X Printed in U.S.A. 12/2006 © R.W. Beckett Corporation 20 Form 6104 BCF10-R06