Beckett Boiler, homeappliance

Download!

COMMERCIAL PRODUCTS Potential for Fire, Smoke and Asphyxiation Hazards Incorrect installation, adjustment, or misuse of this burner could result in death, severe personal injury, or substantial property damage. To the Homeowner or Equipment Owner: 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. 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 profes sionally setting up and maintaining your oil burner. Your Beckett burner will provide years of effi cient oper ation if it is professionally installed and maintained by a qualifi ed service technician. If at any time the burner does not appear to be operating properly, immediately contact your qualifi ed service agency for consultation. We recommend annual inspection/service of your oil heating system by a qualifi ed service agency. Daily – Check the room in which your burner/ap pliance is installed. Make sure: Air ventilation openings are clean and unob structed Nothing is blocking burner inlet air openings No combustible materials are stored near the heating appliance There are no signs of oil or water leaking around the burner or appliance Weekly - Check your oil tank level. Always keep your oil tank full, especially during the summer, in order to prevent condensation of moisture on the inside surface of the tank. Special Requirements - The installation of a burner shall be in accordance with the regulations of authorities having Jurisdiction. Contents General Information ....................................................3 Hazard Defi nitions .........................................................................3 Specifi cations ................................................................................3 Owner's Responsibility: .................................................................3 Service Agency Responsibility: .....................................................3 Pre-Installation Checklist............................................4 Combustion Air Supply ..................................................................4 Clearances ....................................................................................4 Fuel Supply ...................................................................................4 Nozzle Pressure ............................................................................4 Electrical Supply ............................................................................5 Vent System ..................................................................................5 Verify Burner Components ............................................................5 Verify Firing Rate ...........................................................................5 Verify Air Tube ...............................................................................6 Stray Light .....................................................................................6 Dust and Moisture .........................................................................7 Mount the Burner .........................................................7 Mount Flange(s) on Air Tube .........................................................7 Mount Air Tube to Burner ..............................................................8 Install Nozzle .................................................................................8 Check Electrode Settings ..............................................................8 Install Nozzle Line Assembly .........................................................8 Set "Z" Dimension .........................................................................9 Insert Burner .................................................................................9 Fuel Unit By-pass Plug ..................................................................9 One-pipe Oil System By-pass Loop ........................................... 10 Oil Supply/Return Lines ............................................................. 10 Burner Fuel Flow ........................................................................ 10 Wire the Burner .......................................................... 11 Typical Burner Sequence of Operation - 7505 Control ...............11 Typical Burner Sequence of Operation - 7184B Control ............ 14 Restricted Lockout ..................................................................... 14 ○ For recommended installation practices in the U.S. refer to the latest edition of NFPA 31. (CSA-B139 and CSA-B140 in Canada. Impaired Burner Performance & Fire Hazard Prepare the Burner for Start-up ...............................15 Start-up checklist ........................................................................ 15 Z Dimension ............................................................................... 15 Adjusting Plate Assembly ........................................................... 15 Initial Head Position ................................................................... 16 Initial Air Settings ........................................................................ 17 Do NOT operate the burner beyond specifi cations outlined in the Table on Page 3. Set Appliance Limit Controls ...................................................... 17 Prepare the Fuel Unit for Air Venting .......................................... 17 ⮹ For applications beyond these limits, consult Beckett Technical Services 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. Start the Burner .........................................................18 Start Burner and Vent Air From Oil Line .................................... 18 Disable Function ........................................................................ 18 Cad Cell Resistance Measurement: ........................................... 18 Operating the Burner .................................................................. 19 Set High-fi re Air .......................................................................... 19 Set Low-fi re Air ........................................................................... 19 Annual Service ........................................................................... 20 Agency Approvals Monthly Maintenance — by Owner ............................................ 20 ○ 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. Replacement Parts ....................................................20 Limited Warranty Information ..................................24 2 General Information 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. Section: General Information Owner's Responsibility: Follow these instructions exactly. Failure to follow these instructions, misuse, or incorrect adjustment of the burner could result in asphyxiation, 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. ⮹ ⮹ Used with the safety ⮹ alert symbol, indicates a hazardous situation, which, if not avoided, ⮹ may result in minor or moderate injury. ⮹ Used to address practices not related to personal injury. Specifi cations 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 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. Frozen Plumbing and Water Damage Hazard Fuels U.S. #1 or #2 heating oil only (ASTM D396) Canada #1 stove oil or #2 furnace oil only DO NOT USE GASOLINE, CRANKCASE OIL, OR ANY OIL CONTAINING GASOLINE. Firing Range CF1400 - 4.0 to 13.6 gph CF2300 - 7.0 to 19.9 gph Motor CF1400: 1/2 HP 3450 rpm 120/60 Hz Standard 6.5 amps @ 120 VAC CF2300: 3/4 HP 3450 rpm 120/60 Hz Standard 12.5 amps @ 120 VAC Optional Voltages (CF1400 & CF2300): If the facility is unattended in severely cold weather, burner primary control safety lockout, heating system component failures, power outages or other electrical system failures could result in frozen plumbing and water damage in a matter of hours. For protection, take preventive actions such as having a security system installed that operates during power outages, senses low temperature and initiates an effective action. Consult with your heating contractor or security agency. Service Agency Responsibility: Follow these instructions exactly. Failure to follow these instructions could result in asphyxiation, explosion or fi re. ⮹ 240 VAC/1-PH, 208, 240, 480 VAC/3-PH, 50 or 60Hz ⮹ Ignition Trans. Continuous Duty, 120V/12,000V Housing Cast aluminum Fuel Unit 100 to 300 psig ⮹ Oil Nozzle 45o to 70o Solid Dimensions Refer to Figure 8. 50 Hz Motors - The burner ratings, air settings and nozzle ratings are Please read all instructions before proceeding. Follow all instructions completely. This equipment must be installed, adjusted and started by a qualifi ed service agency that is licensed and 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 ordinances having jurisdiction and the latest editions of the NFPA 31 and CSA-B139 & B140 in Canada. High altitude installation - Accepted industry practice requires no derate 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. of burner capacity up to 2000 feet above sea level. For altitudes higher than 2000 feet, derate burner capacity 2% for each 1000 feet above sea level. CF1400/CF2300 Burner Manual 3 Section: Pre-Installation Checklist Pre-Installation Checklist Combustion Air Supply Adequate Combustion and Ventilation Air Supply Required The fuel supply piping and tank must provide #1 or #2 fuel oil at pressure or vacuum conditions suitable for the fuel unit (oil pump) on the burner. Refer to fuel unit literature in the literature envelope in the burner carton to verify allowable suction pressure. If fuel supply is level with or higher than fuel unit: ○ Failure to provide adequate air supply could result in asphyxiation, explosion or fi re hazards. When the fuel unit is not required to lift the oil, the installation is usually suitable for either a one-pipe or two-pipe oil system. The oil pressure at the inlet of ⮹ The 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. the fuel unit must not exceed 3 psig. The fuel unit is shipped with the by-pass plug installed. Leave the by-pass plug installed for all low/high fi ring burners, regardless whether one pipe (with by-pass loop) or two-pipe. See Figure 9 for installation of the by-pass loop required for one-pipe fuel supply installations. See Figure 10 for The burner requires combustion air and ventilation air for reliable operation. Assure that the building and/or combustion air openings comply with National Fire connections to the fuel unit for two-pipe fuel supply installations. When fuel supply is below the burner fuel unit: Protection 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 Use a two-pipe oil system when the fuel unit must lift the oil more than 8 feet. The return line provided by the two-pipe system is needed to minimize the effects of air-related problems during operation. 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 pressure or of exhaust fans or other devices depleting available air for combustion and ventilation, the appliance/burner should be installed in an isolated room provided with outside combustion air. Clearances With the burner installed in the appliance, there must be adequate space in front of and on the sides of the burner to allow access and operation. Verify that the clearance dimensions comply with all local codes and with the appliance manufacturer's recommendations. Fuel Supply 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 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. ⮹ Oil Supply Pressure Control Required ⮹ Damage to the fi lter or pump seals could cause oil leakage and a fi re hazard. 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: An 8.00 gph nozzle at 150 psig = 9.80 gph and at 300 psig = ⮹ The oil supply inlet pressure to the burner cannot exceed 3 psig. ⮹ ⮹ Do not install valves in return line. ⮹ Insure that a pressure limiting device is installed in accordance with the latest edition of NFPA 31. Gravity Feed Systems: Always install an anti-siphon ⮹ valve in the oil supply line or a solenoid valve (RWB Part # 21789) in the pump/nozzle discharge tubing to provide backup oil fl ow cut-off protection. 13.86 gph) For typical nozzle fl ow rates at various pressures refer to Table 1. 4 Table 1 – Nozzle Capacities Vent System Section: Pre-Installation Checklist Rated gph @100 psig Pressure - Pounds per square inch 125 140 150 175 200 250 275 300 3.00 3.50 4.00 4.50 5.00 5.50 6.00 6.50 7.00 7.50 8.00 8.50 9.00 9.50 10.00 10.50 11.00 12.00 3.35 3.91 4.47 5.04 5.59 6.15 6.71 7.26 7.82 8.38 8.94 9.50 10.06 10.60 11.18 11.74 12.30 13.42 3.55 4.14 4.73 5.32 5.92 6.51 7.10 7.69 8.28 8.87 9.47 10.06 10.65 11.24 11.83 12.42 13.02 14.20 3.67 4.29 4.90 5.51 6.12 6.74 7.35 7.96 8.57 9.19 9.80 10.41 11.02 11.64 12.25 12.86 13.47 14.70 3.97 4.63 5.29 5.95 6.61 7.27 7.94 8.60 9.25 9.91 10.58 11.27 11.91 12.60 13.23 13.89 14.55 15.88 4.24 4.95 5.66 6.36 7.07 7.78 8.49 9.19 9.90 10.61 11.31 12.02 12.73 13.44 14.14 14.85 15.56 16.97 4.74 5.53 6.32 7.11 7.91 8.70 9.49 10.28 11.07 11.86 12.65 13.44 14.23 15.02 15.81 16.60 17.39 18.97 4.97 5.80 6.63 7.46 8.29 9.12 9.95 10.78 11.61 12.44 13.27 14.10 14.93 15.75 16.58 17.41 18.24 19.90 5.20 6.06 6.93 7.79 8.66 9.53 10.39 11.26 12.12 12.99 13.86 14.72 15.59 16.45 17.32 18.19 19.05 20.79 The fl ue gas venting system must be in good condition and must comply with all applicable codes. Verify Burner Components Burner nameplate (Figure 1), Model CF1400 or ○ CF2300A Air tube assembly ○ Mounting fl ange kit ○ Pedestal mounting assembly kit (recommended) ○ Oil nozzle, per Table 1 — Use only 45° to 70° ○ solid pattern nozzles unless otherwise shown by appliance manufacturer or on the burner nameplate rating label. The 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. Electrical Supply Verify that the power connections available are correct for the burner. Refer to Figure 1. All power must be supplied through fused disconnect switches. Figure 1 – Typical Nameplate Find the required fi ring rate in the 300 psig column (high fi re rate). Select the corresponding nozzle from column 1 (Rated gph @ 100 psig). (Example: a 5.00 gph nozzle @ 300 psi = 8.66 gph) Verify Firing 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 2. If the appliance dimensions are smaller than recommended, reduce the fi ring rate accordingly. General Model Information Serial Number, Including Date Code Rating Information Approval Agency Symbols Primary Group and Fuel Model "XX" Series (Fuel) Burner SERIAL NUMBER 050214-00000 Control Circ: 120V/60Hz 4.5A Motor Circ: 120V/60Hz 4.0A LISTED (FUEL) BURNER NO.P100000 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 CF1400/CF2300 Burner Manual 5 Section: Pre-Installation Checklist Figure 2 - Dimensions: Minimum Combustion ○ Chamber and Air Tube Mounting. * Install burner with 2° pitch as shown. The CF1400 maximum fi ring capacity depends on the fi rebox pressure. Use Table 2 to verify the correct air tube type for the fi ring rate required. Use Tube B only when Tube A cannot provide the fi ring rate required. ○ T 1/4" ± 1/8" ○ H *2° D L E ○ On the CF2300, there are two tube arrangements available – - Tube A — 7.0 to 19.9 GPH per Figure 3. - Tube B — 10.0 to 19.9 GPH per Figure 3. The CF2300 maximum fi ring capacity depends on the fi rebox pressure. Use Table 2 to verify the correct air tube type for the fi ring rate required. Use Tube B only when Tube A cannot provide the fi ring rate required. See Figure 3 to verify the correct air tube length and Model Firing Rate (gph) Minimum Dimensions Refractory Lined Wet-based Boilers HLHL air tube combination code. Table 2 – Air Tube Capacity Versus Firebox Pressure CF1400 0 to 5 7.0" 25.0" 7.0" 25.0" Air Tube Capacity vs Firebox Pressure 5 to 10 8.0" 35.0" 8.0" 40.0" CF2300 5 to 10 8.0" 35.0" 8.0" 40.0" Model Tube Firebox Pressure (In W.C.) No Reserve Air 10% Turndown (GPH) 10 to 15 9.0" 40.0" 9.0" 50.0" 15 to 20 11.0" 55.0" 11.0" 60.0" A Air Tube Combination Codes 0.0 11.0 10.0 0.2 10.5 9.45 0.4 10.1 9.10 0.6 9.6 8.64 Model Tube Dimension T Dimension D Code Dimension E 0 0.8 9.2 8.30 1.0 8.7 7.83 0 041 FC 0 0 32 FC 6.75" 5.5" CF 66 KD 2.88" 0 4 1 10.25" 5.5" CF 102 KD 2.88" F A C 13.75" 5.5" CF 136 KD 2.88" 17.75" 5.5" CF 176 KD 2.88" B 6.75" 5.75" CF 66 KE 3.38" 10.25" 5.75" CF 102 KE 3.38" B 13.75" 5.75" CF 136 KE 3.38" 17.75" 5.75" CF 176 KE 3.38" 6.75" 6.5" CF 66 KG 2.94" 10.25" 6.5" CF 102 KG 2.94" A A 13.75" 6.5" CF 136 KG 2.94" 17.75" 6.5" CF 176 KG 2.94" 0 6.75" 8.125" CF 66 KS 3.69" 0 3 2 8.375" 8.125" CF 86 KS 3.69" F B C 11.0" 8.125" CF 110 KS 3.69" 14.5" 8.125" CF 144 KS 3.69" B 18.5" 8.125" CF 184 KS 3.69" 0.0 13.6 12.20 0.2 13.1 11.70 0.4 12.5 11.20 0.6 12.0 10.80 0.8 11.4 10.30 1.0 10.9 9.80 0.0 19.9 19.90 0.2 19.2 19.10 0.4 18.5 18.30 0.6 17.9 17.60 0.8 17.2 16.80 1.0 16.5 16.00 0.0 19.9 19.90 0.2 19.7 19.60 0.4 19.5 19.30 0.6 19.4 19.10 0.8 19.2 18.80 Verify Air Tube The information in this section may be disregarded if the air tube is supplied by the appliance manufacturer. 1.0 19.0 18.50 Note: 10% turndown indicates suffi cient reserve air to reduce the CO2 in the fl ue to 90% of its value. The ○ On the CF1400, there are two tube arrangements available – - Tube A — 4.0 to 11.0 GPH per Figure 3. - Tube B — 7.0 to 13.6 GPH per Figure 3. above ratings may vary 5% due to variations in actual job conditions. *CF2300 can fi re higher but is limited by UL requirements. 6 Figure 3a - Firebox Pressure: CF1400 with no Reserve Air Section: Mount the Burner Mount the Burner H P G . S. U e ta R g n i r i F 1514 13 12 11 Protect the air tube from overheating. Overheating could cause damage to the air tube and other combustion components leading to equipment KE malfunction and impaired combustion performance. KD m u m i x a M ⮹ 10 9 0.0 0.2 0.4 0.6 0.8 1.0 Firebox Pressure in Inches Water Column (W.C.) ⮹ The end of the air tube must not extend into the combustion chamber unprotected unless it has been factory-tested and specifi ed by the appliance manufacturer. Position the end of the air tube 1/4" back from Figure 3b - Firebox Pressure: CF2300 with no Reserve Air fl ush with the refractory inside entry wall to prevent damage from overheating H P G . S. U e ta R 21 20 19 18 Mount Flange(s) on Air Tube KS This section does not apply to burners with welded fl anges. KG g n i r i F m u m ix a M ○ 17 ○ 16 15 ○ 0.0 0.2 0.4 0.6 0.8 1.0 Firebox Pressure in Inches Water Column (W.C.) Do not install air tube on burner. For non-pressure fi ring fl ange, refer to Figure 4: Install gasket (item a) and fl ange (item c). Ignore the next paragraph. For pressure-fi ring fl ange, refer to Figure 4: Slide gasket (item a) onto the air tube, making sure the top of the air tube is up. Predrill holes in the pressure fi ring plate (item b) to match the appliance studs. Stray Light Protect Against Stray Light Lockout Failure to follow these Slide the pressure fi ring plate (item b) and fl ange (item d) onto the air tube as shown. Wrap ceramic fi ber rope (not shown) around the air tube and press 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. 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 insertion of the air tube so dimension G ○ The control must detect a dark, no-fl ame condition ○ in order to start the burner or it will hold in the stray light lockout mode. ○ Shield the burner view window from direct exposure is 1/4" nominal. Pitch the air tube at 2° from horizontal as shown and secure the fl ange to the air tube. to intense light. Dust and Moisture Protect Against Dust and Moisture Wet, dusty environments could lead to blocked air passages, corrosion damage to components, impaired combustion performance and result in asphyxiation, explosion or fi re. Figure 4 – Mount fl ange(s) on air tube ⮹ 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 vapors, and moisture. ⮹ Protective covers and more frequent maintenance may be required. CF1400/CF2300 Burner Manual 7 Section: Mount the Burner 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. ○ Install Nozzle See Figure 5. Install the oil nozzle in the nozzle adapter. ○ Use a 3/4" open-end wrench to steady the nozzle adapter and a 5/8" open-end wrench to turn the nozzle. Tighten securely but do not overtighten. ○ Check Electrode Settings Slide the secondary adjusting plate (item f) completely to the left on the indicator adjusting plate (item e). Finger-tighten acorn nut (item c) to secure the two plates together. Slide both plates completely to the left on the primary adjusting plate (item g) and fi nger-tighten acorn nut (item d). Slide the completed adjusting plate assembly over the nozzle line end. Move the plate assembly and the nozzle line so the plate assembly fi ts into position as shown in Figure 6. Install the spline nut (item b) on the end of the nozzle line, leaving the nut loosely placed so the plates can be moved. Connect the high-voltage leads from the ignition transformer to the electrodes. Figure 6 – Nozzle Line Assembly in Burner Maintain Electrode z Specifi cations Failure to properly maintain these specifi cations could cause ignition malfunction, puff-back of hot gases, heavy smoke, asphyxiation, explosion and fi re hazards. Check, and adjust if necessary, the critical dimensions P, Q, R and S shown in Figure 5. Verify that the oil tube assembly and electrodes are in good condition, with no cracks or damage. Figure 5 – Nozzle and Nozzle Line Assembly (Measured from the fl at front surface of the head to the end of the air tube, as shown). a Legend (Figure 5) P Nozzle centerline to electrode tip - 1/4" Q Nozzle to head - 1/4" R Nozzle face to electrode tip - 1/8" S Electrode spacing - 3/32" Install Nozzle Line Assembly Measure dimension Z from the fl at surface between (not on) the raised fi ns. Z = 1-3/4" ± 1/16" Legend (Figures 6 & 7) a Adjusting plate assembly b Spline nut for securing nozzle line ○ Insert the nozzle line assembly into the burner air tube as in Figure 6. ○ See Figures 6 and 7. Assemble the adjusting plate assembly per the instructions in the assembly packet. 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 8 Figure 7 – Adjusting Plate Assy. d b e f c g #9 SettingSet "Z" Dimension Section: Mount the Burner Figure 8 – Burner Installed in Appliance Front 1. Replace the rear access door on the burner, making sure that the adjusting plate assembly is seated in the recessed area in the housing. 2. Loosen acorn nut (item c) and spline nut (item b). Move nozzle line forward to the maximum head setting #9 and tighten acorn nut (item c). 3. Loosen acorn nut (item d). Slide the nozzle line and plate assembly until dimension "Z" in Figure 6 is 1-3/4" ±1/16" (CF1400 and CF2300). When dimension "Z" (from end of air tube to fl at area of front face of head) is correctly set, tighten acorn nut (item d). Verify that the adjusting plate assembly is properly seated in the recessed area in the housing. Legend H Housing total length (CF1400 - 18", CF2300 - 18.5") J Center to bottom of housing (CF1400 - 10.88", CF2300 - 10.5") K Overall housing height (CF1400 - 13.63", CF2300 - 15.63") Fuel Unit By-pass Plug Factory-Installed Pump Bypass Plug Failure to follow these guidelines will cause the fuel pump seals to rupture and result in oil leakage, burner malfunction and potential fi re and injury hazards. Tighten spline nut (item b) fi nger tight. ⮹ 4. Attach the oil line from the oil valve to the nozzle line end. Tighten securely. ⮹ 5. Before proceeding, check dimension "Z" once again. Loosen acorn nut (item d) if necessary to ⮹ reposition the nozzle line. Once dimension "Z" is set, do not loosen acorn nut (item d) again. ⮹ 6. Loosen acorn nut (item c) to set the head at the proper setting for the application and tighten splined nut securely. Models CF1400 and CF2300 are shipped with the pump bypass plug installed. Do not remove the bypass plug from the pump. It is required for step-fi ring (Lo/Hi) operation. Do not operate the burner unless a return line or bypass loop is installed or the pump seal will rupture. Carefully comply with the following instructions provided in this section of the manual. Install Oil Supply To Specifi cations Insert Burner Position the burner in the front of the appliance and loosely tighten the nuts on the mounting studs. The burner should be pitched downward 2° as shown in Figures 3 and 4. ⮹ See Figure 8. Install the pedestal support kit (recommended) by attaching the 3/4" NPT fl ange (item a) to the bottom of the burner using the (4) #10 ⮹ screws provided. Cut and thread (one end only) a 3/4" pipe nipple (item b) with length 11 inches less than dimension D in Figure 8. Thread the pipe into the fl ange. ⮹ Secure the burner to the appliance by tightening the nuts ⮹ on the burner fl ange mounting studs. 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. Carefully install the oil supply lines, fi ttings and components 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. Do NOT install valves in the 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). CF1400/CF2300 Burner Manual 9 Section: Mount the Burner ○ Special Note: The burner is shipped with a by pass plug installed in the fuel unit. For low/high operation, the by-pass plug must be left in the fuel unit, regardless of the fuel system used (one-pipe with by-pass loop or two-pipe). Do not remove the ○ by-pass plug. One-pipe Oil System By-pass Loop Refer to Figure 9 (item m). Note the addition of a fi eld ○ installed by-pass loop (use 3/8" copper tubing) from the fuel unit Return port to the Inlet port. This line is required for low/high operation. It simulates the fl ow of a two-pipe system at the fuel unit. 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 reduces 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. However, size the fi lter for the fi ring rate for one-pipe systems. Locate the fi lter immediately adjacent to the burner fuel unit. Install two high-quality shutoff valves in accessible locations on the oil supply line. Locate one valve close to the tank. Locate the other valve close to the burner, upstream of the fuel fi lter. Oil Supply/Return Lines Burner Fuel Flow ○ Install the oil tank and oil lines in accordance with all applicable codes. ○ Size the oil supply and return lines using the guidelines given in the fuel unit literature included in the literature envelope. Oil line fl ow rate will equal the burner rate for one-pipe systems. For two-pipe systems, refer to Table 3 for the fuel unit gearset capacity - the rate at which fuel is recirculated when connected to a two-pipe system. Size two-pipe oil lines based on this fl ow rate. One-pipe systems – See Figure 9 for the fuel fl ow paths for high-fi re and low-fi re operation. The low-fi re by-pass regulation is done internally for type B fuel units. Oil supply connects to one of the fuel unit Inlet ports. Two-pipe systems – See Figure 10 for the fuel fl ow paths for high-fi re and low-fi re operation. The low-fi re by-pass regulation is done internally for type B fuel units. Oil supply connects to one of the fuel unit Inlet ports. Oil return connects to the fuel unit Return port. Do NOT install valves in the return line. Figure 9 – One-pipe Oil Flow with "B" Pump SK9940 Figure 10 – Two-pipe Oil Flow with "B" Pump SK9939 Legend (Figure 9 & 10) a Return port b Nozzle port c Oil valves d Nozzle & adapter f By-pass/Low fi re pressure regulator g Inlet port h By-pass valve ("B" pump) k Return line to oil tank m One-pipe by-pass loop, 3/8" p Air bleed valve 10 Low-fi re/high-fi re operation – The fuel unit nozzle port pressure is factory set at 300 psig. Section: Wire the Burner Incorrect Wiring Will Result in Improper Control Operation ○ At high fi re, full pressure (300 psig) is applied at the oil nozzle, causing full input. ⮹ ○ At low fi re, the by-passing is done inside the fuel unit when the by-pass valve operates. ⮹ ○ This by-passing of oil reduces the oil pressure at the nozzle (to between 125 psig and 175 psig), reducing the input. GeniSys 7505 Control wiring label colors may not match the wire colors of the burner or other manufacturers' controls. The GeniSys Control should be wired according to the appliance manufacturer's instructions. Table 3 – Fuel Unit Gearset Capacities Model Fuel Unit Model Number Gearset Capacity (gph) Fire or Explosion Hazard Can cause severe injury, death, or property damage. ⮹ CF1400 B2TA-8245 23 ⮹ CF2300 B2TA-8852 39 ⮹ The fuel unit nozzle port pressure The control can malfunction if it gets wet, leading to accumulation of explosive vapors. Never install where water can fl ood, drip or condense on the control. Never use a control that has been wet - replace it. 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. Typical Burner Sequence of Operation - 7505 Control Refer to the appliance manufacturer's wiring diagram for actual specifi cations. 1. Wire the Burner 2. Electrical Shock Hazard 3. Electrical shock can cause severe personal injury or death. Standby: The burner is idle, waiting for a call for heat. Valve-On Delay: The igniter and motor are on while the control delays turning on the oil solenoid valve for the programmed time. Trial For Ignition: The oil solenoid valve is energized. A fl ame should be established within the factory set trial for ignition time (lockout time). ⮹ Disconnect electrical power before installing or 4. servicing the burner. Lockout: The control has shut down for one of the following safety reasons: ⮹ Provide ground wiring to the burner, metal control a. enclosures and accessories. (This may also be required to aid proper control system operation) b. Perform all wiring in compliance with the National ⮹ Electric Code ANSI/NFPA 70 (Canada CSA C22.1). The trial for ignition (lockout) time expired without fl ame being established. The cad cell detected fl ame at the end of the Valve On Delay state. To reset the control from lockout click the button 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 13 (7505P) or 14 (7184B) for a typical wiring 5. diagram (for reference purposes only). 1-second. NOTE: A recurrence of the above failure modes or a failed welded relay check could cause the control to enter a Hard Lockout state that must be reset only by a qualifi ed service technician. To reset from Hard Lockout, hold the reset button for 15 seconds until the yellow light turns on. Ignition Carryover: Once fl ame is established, the igniter remains on for 10 additional seconds to ensure fl ame stability. CF1400/CF2300 Burner Manual 11 Section: Wire the Burner 6. Run: With a fl ame established and the control 8. continuing to detect a fl ame, the burner will operate in the RUN Mode until the load demand is satisfi ed or a limit opens. Motor-Off Delay: The oil solenoid valve is turned off and the control delays turning the motor off for the set motor-off delay time before the control returns to standby. 9. a. If terminals RC1 and RC2 are jumpered, the burner operates in the Low-High-Off Mode. The burner starts at Low, goes to High after the fl ame stabilization period. Flame is extinguished when the load is satisfi ed or a limit opens, and Pump Prime: The igniter and motor are on with the oil solenoid valve energized for 4 minutes. During Pump Prime mode, the cad cell is disregarded, allowing the technician to prime the pump without having to jumper the cad cell. the burner is sent to motor off delay. b. If a high/low control has been wired between Figure 11 - Typical Burner Sequence of Operation - 7505 1 terminals RC1 and RC2 the burner starts at Low and is released to go High after the fl ame stabilization period. It can repeatedly cycle between low and high as necessary to meet 3 2 load demand until the load is satisfi ed or a limit Standby 9 Pump prime 4 opens. The burner is then sent to Motor-off Delay. 7. Recycle: If the fl ame is lost while the burner is fi ring, the control shuts down the burner, enters a 60 second recycle delay, and repeats the ignition sequence. The control will continue to Recycle each time the fl ame is lost, until it reaches a pre-set time Valve-on delay Trial for ignition 5 Ignition carryover 8 6 7 Lockout allotment. The control will then go into Hard Lockout instead of recycle. This feature prevents excessive accumulation of oil in the appliance fi ring chamber. Figure 12 - GeniSys 7505 Control with Optional Components Reset Button Motor-off delay Wiring Run Recycle with Red Light Yellow Light Green Light Thermostat Terminals Connections Communication Port 2 Communication Port 1 Optional Components: Contractor's Tool: Hand-held device for programming and diagnostics Display Module: Permanent device for programming and diagnostics Alarm Module: For adding isolated low voltage alarm contacts to the base control. See Alarm Module Instructions for specifi cations. Cad Cell Connections 12 Section: Wire the Burner ) P 5 0 5 7 ( g n i r i W l a c i p y T – 3 1 e r u g i F CF1400/CF2300 Burner Manual 13 Section: Wire the Burner Typical Burner Sequence of Operation - 7184B Control Refer to the appliance manufacturer's wiring diagram for actual b. specifi cations. period. Flame is extinguished when the load is satisfi ed or a limit opens, and the burner is sent to Motor-Off Delay. If a high/low control has been wired between terminals RC1 and RC2 the burner starts at Low and 1. Standby — The burner is idle, waiting for a call for heat. When a call for heat is initiated, there is a 3- to 10-second delay while the control performs a safe start check. 2. Valve-on delay — As applicable, the ignition and motor are turned on for a 15-second prepurge. 7. 3. Trial for ignition (TFI) — The fuel valve is opened, as applicable. A fl ame should be established within the 15- second lockout time (30-second lockout time is available). 4. Lockout — If fl ame is not sensed by the end of the TFI, the control shuts down on safety lockout and must be manually reset. If the control locks out three times in a 8. row, the control enters restricted lockout. Call a qualifi ed service technician. 5. Ignition carryover — Once fl ame is established, the ignition remains on for 10 seconds to ensure fl ame stability. It then turns off. 6. Run — With a fl ame established and the control continuing to detect a fl ame, the burner will operate in the RUN Mode until the load demand is satisfi ed or a limit is released to go High after the fl ame stabilization period. It can repeatedly cycle between low and high as necessary to meet load demand until the load is satisfi ed or a limit opens. The burner is then sent to Motor-off Delay. Recycle — If the fl ame is lost while the burner is fi ring, the 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. Burner motor-off delay — 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. Cad Cell Resistance Indicator: During the burner run state, click the reset button (less than 1 second) to check the cad cell resistance range. The yellow light will fl ash 1 to 4 times, depending on the amount of light detected by the cad cell. opens. See Figure 15 for Sequence of Operation illustration. a. If terminals RC1 and RC2 are jumpered, the burner operates in the Low-High-Off Mode. The burner starts at Low, goes to High after the fl ame stabilization Restricted Lockout If the control locks out three times in a row without a Figure 14 – Typical Wiring (R7184B) 14 complete heat cycle between attempts, the lockout becomes restricted. A qualifi ed service technician should be called to inspect the burner. Figure 15 - Typical Burner Sequence of Operation - 7184 1 Standby Section: Prepare the Burner for Start-up Keep Service Access Covers Securely Installed These covers must be securely in place to prevent electrical shock, damage from external elements, and protect against injury from moving parts. 2 Valve-on delay ⮹ 3 4 Trial for Trial for ⮹ ignitionLockout 5 Ignition carryover All covers or service access plates must be in place at all times except during maintenance and service. This applies to all controls, panels, enclosures, switches, and guards or any component with a cover as part of its design. 86 7 Motor-off Start-up checklist delay (postpurge) Run Recycle Verify the following before attempting to start burner. □ Prepare the Burner for □ Start-up Professional Installation □ and Service Required Incorrect installation and mishandling of start-up □ could lead to equipment malfunction and result in asphyxiation, explosion or fi re. □ Combustion air supply and venting have been inspected and verifi ed to be free of obstructions and installed in accordance with all applicable codes. Fuel unit by-pass plug has not been installed for one-pipe oil system, without a by-pass loop. (See Figure 9.) By-pass plug has been installed for two-pipe oil system. Fuel connection to nozzle line assembly is secure. Dimension Z has been set per this instruction ⮹ This burner must be installed and prepared for start up by a qualifi ed service technician who is trained and □ experienced 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 instruction □ sheets, fl ame safeguard sequence of operation, test procedures and all appliance manufacturer's directions that pertain to this installation. □ Do Not Bypass Safety Controls 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. Tampering with, or bypassing safety controls could lead to equipment malfunction and result in asphyxiation, explosion or fi re. Z Dimension The Z Dimension should be set per the instructions detailed under the heading 'Set Z Dimension' previously ⮹ 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. in this manual. The top acorn nut (Figure 16, item d) should never be loosened once the Z dimension has initially been set. Adjusting Plate Assembly Make sure spline nut (item b) and bottom acorn nut (item c) are loose before proceeding to next section (Figure 16). CF1400/CF2300 Burner Manual 15 Section: Prepare the Burner for Start-upInitial Head Position The indicator plate assembly (item e) markings correspond to head position settings (Figure 16). Figure 16 – Adjusting Plate Initial Setting, Typical ○ 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 Tables 4a and 4b for the desired fi ring rate and burner (high-fi re). ○ Figure 16 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). Legend b Spline nut for securing nozzle line c Bottom acorn nut (for head adjustments) d Top acorn nut (for setting dim. Z only - do not loosen after setting Z) e Indicator adjusting plate Table 4A – CF1400 Initial Indicator Adjustment Plate Settings Head Position Damper Position f Secondary adjusting plate g Primary adjusting plate h Copper oil line from oil valve to nozzle line Tube Approximate Head Setting Firing Rate (gph) Approximate Air Damper Setting Firing Rate (gph) Table 4B – CF2300 Initial Indicator Adjustment Plate 0 4.00 0 -- 1 4.50 10 -- Settings Head Position Damper Position 2 5.00 20 4.00 3 6.00 30 5.00 Tube Approximate Head Setting Firing Rate (gph) Approximate Air Damper Setting Firing Rate (gph) 0 041 FC 4 7.00 40 7.00 5 7.50 50 8.00 A 6 8.00 60 10.00 7 9.00 70 11.00 8 9.50 80 -- 9 10.00 90 -- A 10 11.00 100 -- -- -- 110 -- -- -- 120 -- 0 0 0 7.00 0 -- 3 2 F C 1 7.50 10 -- 2 8.00 20 -- 3 9.00 30 -- 4 10.00 40 7.00 5 10.50 50 8.00 6 11.00 60 10.00 B B 7 12.00 70 11.00 8 13.00 80 12.00 9 13.25 90 12.50 10 13.60 100 13.00 -- -- 110 13.25 -- -- 120 13.60 0 11.0 0 -- 1 12.0 10 7.0 2 13.0 20 10.0 3 14.0 30 13.0 4 15.0 40 14.0 5 16.0 50 15.0 6 17.0 60 16.0 7 18.0 70 17.0 8 19.0 80 18.0 9 20.0 90 19.0 -- -- 100 20.0 0 12.5 0 -- 1 13.0 10 10.0 2 14.0 20 13.0 3 15.0 30 14.0 4 16.0 40 15.0 5 17.0 50 16.0 6 18.0 60 17.0 7 18.5 70 18.0 8 19.0 80 18.5 9 20.0 90 19.0 -- -- 100 20.0 16 Initial Air Settings If your burner was built for a specifi c OEM (Original Equipment Manufacturer) application, the "Mfr's Settings" label (see Figure 1) will indicate the application and the initial air settings made at Beckett. Please verify those settings using the following procedure. If your burner was not built for a specifi ed application, the following steps outline the procedure for initially setting the damper (these settings may be different from settings specifi c to a particular OEM). Refer to Figure 17 and Tables 4a or 4b, for this procedure. Section: Prepare the Burner for Start-up round surface of the shafts afterward. The test for proper alignment is to disengage the damper motor from its shaft using the disengaging pin (Item G in Figure 17) and rotate the damper plate to its full closed position. The position indicator should point to 0° within + 5° tolerance. Figure 17 – Damper Motor Remove the cover screw (A) then the cover (B) and 1. set aside. Push in on pin (B) to disengage the motor from the 2. damper shaft and cam stack. Rotate the damper shaft by hand to place the adjustment cams in a position where their adjustment scale can be easily seen. Release pin (G) to secure the damper shaft and cam stack to the motor. Using the wrench (C) supplied with the damper 3. motor, adjust the blue low fi re cam (D) to the initial setting listed in Table 4. Using the same wrench, adjust the red high fi re 4. cam (H) to the initial settings listed in Table 4. To adjust the high fi re transition, use a small straight 5. edge screwdriver. Turn the white adjustment screw located in the orange transition cam (J) until the cam indicator is half way between the high and low settings on the scale. After setting all the cams, make sure the damper 6. shaft and cam stack is set between its low fi re setting and its high fi re setting. (If you don't it may not move when it is powered.) Push in pin (G), move the damper by hand so that notch (E) is between the low fi re setting and high fi re setting on scale (F), then release pin (G) to re-engage the motor. When the motor is powered it will go to its low fi re setting. Legend (Figure 17) A Cover screw F Damper motor scale B Cover G Disengaging pin This initial setting should be adequate for starting the burner at low fi re. Once the burner is in operation, the air setting will be adjusted for best performance as discussed later in this manual. Don't forget to re-install the cover after all adjustments have been made. C Wrench H High fi re cam (red) D Low fi re cam (blue) J Transition cam (orange) E Cam notch Set Appliance Limit Controls ⮹ The damper plate is attached by screws to its shaft, and bears ⮹ against a fl at on the shaft for alignment. The shaft is secured to the damper motor by a sleeve coupling with two setscrews bearing against the damper shaft and two more against the motor shaft. The motor shaft has a Set the appliance limit controls in accordance with the appliance manufacturer's recommendations. Move the low-fi re hold switch (not shown) to the low fi re hold position. This will hold the burner in low fi re during initial start-up. fl at matching the one on the damper shaft. The fl ats on the damper shaft and the motor shaft should be aligned Prepare the Fuel Unit for Air Venting so that the position indicator in the damper motor reads ○ accurately. The best way to align the fl ats is to tighten the set screws that bear against the fl ats on the shafts fi rst, and then tighten the ones that bear against the ○ 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. Vent the air as described under 'Start the Burner'. CF1400/CF2300 Burner Manual 17 Section: Start the Burner Start the Burner Start Burner and Vent Air From Oil Line 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 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 combustion 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. 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. ⮹ Professional Service Required Incorrect installation, adjustment, and use of this burner could result in severe personal injury, death, or substantial property Disable Function Any time the motor is running, press and hold the reset button to disable the burner. The burner will remain off as long as the button is held and will return to standby when released. Cad Cell Resistance Measurement: If the Beckett 7505 control is equipped with the GeniSys Display Module, part 52067U, the cad cell resistance can be selected and read on the LCD screen. Also, the GeniSys Contractor Tool, part 52082U, can be used for this purpose. If these are not available, the cad cell leads can be unplugged from the control and the resistance measured with a meter in the conventional way. Conduct these tests with fl ame present. Table 5 - 7505 Flame Detection Flame Detection Range Normal = 0 to 1600 ohms 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: Limited = 1600 ohms to lockout Table 6 - 7184 Status Light Explanation Licensed or certifi ed to install and provide technical ⮹ service to oil heating systems. Experienced with all applicable codes, standards ⮹ and ordinances. LED Indicator Status On Flame sensed Off Flame not sensed (1/2 sec off - 1/2 sec on)Lockout/ Responsible for the correct installation and ⮹ commission of this equipment. Flashing Flashing Restricted Lockout ⮹ Skilled in the adjustment of oil burners using combustion test instruments. (2 sec off - 2 sec on) Recycle Table 7 - 7505 Status Light Explanation The installation must strictly comply with all applicable codes, authorities having jurisdiction and the latest revision of the National Fire Protection Association Standard for the installation of Oil-burning Equipment, NFPA 31 (or CSA B139 and B140 in Canada). Regulation by these authorities take precedence over Light Color On Continuously Flashing Red Restricted (Hard) Lockout Soft Lockout GreenFlame Sensed during normal operation (Could be stray light during standby)Recycle the general instructions provided in this installation manual. YellowControl is in Pump Prime mode or Reset button currently held for 15+ seconds. N/A 18 Operating the Burner Section: Start the Burner 5. Place the low-fi re hold switch in the high-fi re 1. Move the low-fi re hold switch to the low fi re hold position (to hold burner in low fi re when started). 6. 2. Verify that the air adjusting cam (Figure 17, item position. The damper motor will begin to rotate after four seconds. Use combustion test instruments to adjust the burner. d) has been set to the initial low-fi re air setting as a. described under the 'Initial Air Settings' section. 3. Open the oil shutoff valves in the oil supply line to the burner. 4. Set the thermostat (or operating control) to call for heat. b. 5. Close the line switch to the burner. The burner motor should start immediately. 6. If the burner motor does not start, reset the motor overload switch (if so equipped) and press the reset switch of the burner primary control. 7. Vent the fuel unit as soon as the burner motor starts rotating. (For GeniSys 7505 control refer to the control manual for Priming the Pump procedure.) c. To vent: Adjust the air by moving the red cam to a lower number until a trace of smoke is achieved with CO2 level as high as possible (lowest possible O2). Example: 13.5% CO2 (2.5% O2) with a trace of smoke. Increase the air by increasing the red cam number 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 zero smoke (or increase O2 from 2.5% to 5.5%). A margin of reserve air has been added to accommodate variable conditions. ○ Attach a clear plastic tube to the air bleed valve 7. (Figure 9 or 10 as applies, item p). ○ Place the end of the tube in a container to catch the oil. Then loosen the fuel unit air vent valve. 8. ○ Tighten the air vent valve after all air has been purged. ○ IF burner stops during venting — Check the breech draft pressure against the appliance manufacturer's recommended setting (typically + 0.1" W.C.). If the breech pressure is higher or lower than recommended level, adjust the appliance breech damper to achieve the specifi ed setting. Recheck the smoke and CO2 levels. Adjust burner air if - The burner primary control will lockout if fl ame is not established within its time limit. 9. This is typically 15 seconds for R7184B primary controls, but may be less for other fl ame supervisory controls. necessary. Once all settings are complete and satisfactory, proceed to 'Set Low-fi re Air'. - The burner may lockout several times during Set Low-fi re Air the period needed to purge all the air. To 1. extend air venting time, press the red reset button for 1/2 second during the prepurge Move the low-fi re hold switch from the "High Fire position" to the "Low Fire Hold" position. cycle to continue purging. a. ○ IF burner stops after fl ame is established — The damper will return to the low-fi re air setting. - Additional venting is probably required. 2. Check the smoke and CO2 (O2) levels. Repeat the air venting procedure. a. 8. Once fl ame is steady, proceed to 'Set High-fi re Air'. b. Pull a smoke sample from the fl ue. The sample should be clean (zero smoke level). Set High-fi re Air c. Check the CO2 (O2) level: Allow the burner to run at low fi re until the 1. appliance has warmed suffi ciently. Visually check the fl ame. The fl ame should not be 2. 3. dark orange or smoky. If the fl ame appears to be smoking, increase the amount of air by readjusting 4. the damper indicator to a higher number. Once the appliance has warmed, the high-fi re 3. setting can be checked and adjusted. 5. Locate the approximate air adjusting plate setting 4. for high fi re in Table 4a or 4b. CO2 should be at 11 to 12% (O2 at 5.9 to 4.5%). If the CO2 is less than 11% (O2 more than 5.9%), decrease the air and check the smoke level. Operate the burner from low fi re to high fi re and back to verify operation. Turn the burner off. Wait one or two minutes (for chamber to clear) and then turn on again to verify starting characteristics. Perform limit circuit performance test specifi ed by appliance manufacturer to verify operation of burner/appliance combination. CF1400/CF2300 Burner Manual 19 Section: Maintenance and Service Maintenance and Service □ □ Annual Professional □ Service Required □ Tampering with or making incorrect adjustments could lead to equipment □ malfunction and result in asphyxiation, explosion or fi re. Check the pump pressure and cutoff function. Check primary control safety lockout timing. Check ignition system for proper operation. Inspect the vent system and chimney for soot accumulation or other restriction. Clean the appliance thoroughly according to the manufacturer's recommendations. □ ⮹ Do not tamper with the burner or controls or make any adjustments unless you are a trained and qualifi ed service technician. To ensure continued reliable operation, a qualifi ed ⮹ □ service technician must service this burner annually. Check the burner performance. Refer to 'Set High-fi re Air' section and set combustion with test instruments. It is good practice to make a record of the service performed and the combustion test results. ⮹ More frequent service intervals may be required in dusty or adverse environments. Monthly Maintenance — by Owner □ Operation and adjustment of the burner requires ⮹ technical training and skillful use of combustion test instruments and other test equipment. Observe combustion air openings and vent system for integrity. Openings must be clean and free of obstructions. Annual Service □ Check oil lines and fi ttings to verify there are no leaks. □ □ Replace the oil supply line fi lter. The line fi lter cartridge must be replaced to avoid contamination □ of the fuel unit 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. 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. □ Remove and clean the pump strainer if applicable. □ Replace the used nozzle with a new nozzle that conforms to the appliance manufacturer's specifi cations. □ Clean and inspect the electrodes for damage, replacing any that are cracked or chipped. □ Check electrode tip settings. Replace electrodes if tips are rounded. □ Inspect the igniter spring contacts. □ Clean the cad cell lens 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 carbon or foreign matter. Replace all damaged units with exact parts. □ Clean the blower wheel, air inlet, air guide, burner housing and static plate of any lint or foreign material. □ If motor is not permanently lubricated, oil motor with a few drops of SAE 20 nondetergent oil at each oil hole. DO NOT over oil motor. Excessive oiling can cause motor failure. □ Check motor current. The amperage draw should Replacement Parts Figure 18 – Adjustable Mounting Plates Flange A Flange B Flange C Model Flange A Flange B Flange C CF1400 51312 (10.00" DIA.) n/a 51629 (12.25" DIA.) not exceed the nameplate rating. □ Check all wiring for secure connections or insulation breaks. CF2300 51313 (12.44" DIA.) 51498 (13.92" DIA.) 51630 (16.00" DIA.) 20 Section: Replacement Parts Figure 19a – Burner Replacement Parts 1 2 3 4 6 5 SK9930 8 7 9 SK9931 CF1400/CF2300 Burner Manual 21 Replacement Parts For best performance specify genuine Beckett replacement parts Item Part Name Description CF1400 Part No. CF2300 Part No. 1 Oil Valve Mounted on Junction Box 21789U 21789U 2 Knurled Nut All models 3666 3666 3 Adjusting plate assembly w/ cast aluminum door w/ stamped sheet-metal door 51213U 5201701U 51213U 5201701U 4 Fuel pump B2TA-8245 21313U 21313U 5 Damper motor 2-stage 750601U 750601U 6 Fuel lines Specify length – – 7 Air Proving Switch 2" W.C. 22181U 22181U 8 Timer Nozzle Valve Delay 21295U 21295U 9 Transformer 12,000 volt 51214 51214 10 Control Specify – – 11 Pedestal kit All models 51193 51193 12 Coupling hole plug use with threaded hole 32439U 32439U 13 Rear cover door as semblyw/ cast aluminum door* w/ stamped sheet-metal door* 5994U 5201301U 51204U 5201302U 14 Sight glass All models 31346 31346 15 Head assembly 5978 51203 16 Electrode assembly All models 51212 51212 17 Ignition leads 8-1/4" long 11-3/4" long 15-1/4" long 19-1/4" long 5990082 5990116 5990152 5990192 5990082 5990116 5990152 5990192 18 Air tube Refer to Figure 4 19 Nozzle line assembly Refer to Figure 5 20 Coupling B Pump 21290 21549 21 Blower wheel CF1400 - 5.59" x 3.09" CF2300 - 6.75" x 3.13" 21268U 21267U 22 Motor Mounting Flange N/A 31347U 23 Motor 120/208-230 single phase 208-230/460 three phase 120V single phase 21401U 21638U 752804 21402U 21499U 752804 Motor relay (not shown) 208V single phase Three phase 7300 2194301 7300 2194301 Adjustable fl ange See Figure 18 on previous page * These doors are NOT interchangeable. Please specify when ordering. 22 Figure 19b – Burner Replacement Parts (Continued) 14 10 13 12 11 SK9930 17 16 15 19 18 SK9936 20 21 22 23 SK9932 CF1400/CF2300 Burner Manual 23 Limited Warranty Information The R. W. BECKETT CORPORATION ("Beckett") warrants to persons who purchase its "Products" from Beckett for resale, or for incorporation into a product for resale ("Customers"), that its equipment is free from defects in material and workmanship. To qualify for warranty 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 Write to: R. W. Beckett Corporation, P. O. Box 1289, Elyria, OH 44036 3. 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 BCF23 R14, Printed in the U.S.A. 08/10