Beckett Burner CF500, 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. 6104 BCF5 R07 1 Before you begin . . . The following resources will give you additional 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. 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 operation 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. Table of Contents General Information ..............................................2-4 Hazard Defi nitions ..........................................................3 Agency approvals ..........................................................3 Specifi cations .................................................................3 Owner's Responsibility ..................................................4 Installer/Service Agency Responsibility .........................4 Pre-installation checklist .....................................4-7 Combustion air supply ...................................................4 Clearances .....................................................................4 Fuel supply .....................................................................5 Nozzle pressure .............................................................5 Electrical supply .............................................................5 Vent system ...................................................................5 Verify burner components ..............................................6 Verify fi ring rate ..............................................................6 Verify air tube .................................................................6 Stray light lockout ...........................................................7 Dust and Moisture ..........................................................7 Mount the burner ...................................................7-9 Mount fl anges on air tubes .............................................7 Mount air tube to burner .................................................8 Install Nozzle ..................................................................8 Check Electrode Settings ...............................................8 Install Nozzle Line Assembly .........................................8 Set Dimension Z ............................................................8 Insert Burner ..................................................................8 Fuel Unit By-pass Plug ..................................................9 Oil Supply/Return Lines .................................................9 Burner Fuel Flow ............................................................9 Wire the burner ....................................................... 10 Sequence of operation .......................................10 Resetting to cad cell .............................................10 Prepare the burner for start-up ......................11-12 Start-up checklist .........................................................11 Z Dimension .................................................................11 Initial head position ......................................................11 Initial air settings ..........................................................12 Set appliance limit controls ..........................................12 Prepare the fuel unit for air venting ..............................12 Start the burner..................................................12-13 Starting the burner and venting air ..............................12 CAD Cell resistance check ..........................................13 Set combustion using instruments ...............................13 Maintenance and Service ..................................... 14 Annual Service .............................................................14 Monthly maintenance ...................................................14 Replacement Parts................................................. 15 Warranty .................................................. Back Cover 2 6104 BCF5 R07 Hazard defi nitions Indicates an imminently hazardous situation, which, if not avoided, will result in death, Specifi cations Fuels U.S. #1 or #2 Fuel Oil only (ASTM D396) Canada #1 Stove Oil or #2 Furnace Oil only serious injury, or property damage. Firing range CF500: 1.75 to 5.50 GPH CF800: 3.00 to 8.00 GPH 1/3 HP 3450 RPM Indicates a potentially hazardous situation, Motor 120/60 hz standard 4.8 amps @ 120 VAC which, if not avoided, could result in death, severe personal injury, and/or substantial property damage. 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. Note: 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 Igniter. 120V/14,000V Housing Cast aluminum Fuel unit 100 - 200 PSIG Oil nozzle 45° - 70° solid Shipping wt. 55 lbs. ⑨ UL listed to comply with ANSI/UL296 and certifi ed to CSA B140.0. ⑨⑨ Accepted by N.Y.C. M.E.A. Other approvals may be available and must be specifi ed at time of order. 6104 BCF5 R07 3 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. Professional Installer/Service Agency Responsibility: Follow These Instructions Exactly Failure to follow these instructions could lead to equipment malfunc tion and 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. ⮹ Please carefully read and comply with the following instructions: 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 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. ⮹ 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. ⮹ Never restrict the air inlet openings to the burner or the combustion air ventilation openings in the room. 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. 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 checklist ⑨ Combustion air supply Adequate Combustion and Ventilation Air Supply Required 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 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. 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 ⮹ 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 ⑨ combustion and ventilation. ⮹ 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 ⮹ The burner requires combustion air and ventilation air for reliable operation. Assure that the building and/or combustion air openings comply with National Fire Protection Standard for Oil-Burning Equipment, NFPA 31. 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. 4 6104 BCF5 R07 ⑨ Fuel supply Oil Supply Pressure Control Required ⑨ Nozzle pressure Correct Nozzle and Flow Rate Required Damage to the pump, fi lter or other compo nent seals could cause possible oil leakage and potential fi re hazard. Incorrect nozzles and fl ow rates could result in impaired combustion, under fi ring, over-fi ring, sooting, puff-back ⮹ The oil supply inlet pressure to the fuel unit cannot exceed 3 psig. ⮹ Do NOT install valves in return line. ⮹ Ensure that a pressure-limiting device is installed in accordance with the latest edition of the NFPA 31. 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 ⮹ 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 manufacturer. Follow the appliance manufacturer's specifi cations for the required pump outlet pressure for the nozzle, since this affects the fl ow rate. ⮹ allowable suction pressure. ⮹ If fuel supply is level with or higher than fuel unit — 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 ⮹ When the fuel unit is not required to lift the oil, the installation is usually suitable for either a one-pipe or two ⮹ pipe oil system. The oil pressure at the inlet of the fuel unit must not exceed 3 psig. ⮹ Refer to the Mount the Burner Section of this manual for stamped on the nozzle body. (Example: A 4.00 gph nozzle at 140 psig = 4.70 gph. For typical nozzle fl ow rates at various pressures see accompanying chart. ⮹ one-pipe or two-pipe fuel supply installation instructions. If fuel supply is below the fuel unit — The fuel unit nozzle port pressure is factory set at 140 psig. Some original equipment manufacturer burner appli cations may call for a lower pressure to obtain a required ⮹ 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. The return line provided by the two-pipe system is ⑨⮹ needed to purge the air from the fuel lines and minimize the likelihood of air-related problems during operation. ⑨ ⮹ 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. Vent system The fl ue gas venting system must be in good condition and must comply with all applicable codes. Figure 1. Typical Nameplate 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 6104 BCF5 R07 5 Table 1 - Nozzle Capacities ⑨⮹ Verify fi ring rate Refer to appliance manufacturer's instructions (if Rated gph @ 100 psig Pressure - Pounds per square inch 140 150 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 1.75 2.07 2.14 2.00 2.37 2.45 2.25 2.66 2.74 2.50 2.96 3.06 2.75 3.24 3.37 ⑨ 3.00 3.55 3.68 3.50 4.13 4.29 ⮹ 4.00 4.70 4.90 4.50 5.30 5.51 5.00 5.90 6.13 ⮹ 5.50 6.50 6.74 6.00 7.10 7.33 6.50 7.65 7.96 ⮹ ⑨ Verify burner components — ⮹⮹⮹ Burner, Model CF500 or CF800 Air tube assembly Mounting fl ange kit ⮹ Oil nozzle, per Table 1 — Only 45° to 70° solid pattern ⮹ nozzles are recommended unless otherwise specifi ed by appliance manufacturer. (See specifi c appliance 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. 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 – CF500 1.75 to 5.50 GPH CF800 Tube A — 3.00 to 7.00 GPH Tube B — 5.00 to 8.00 GPH Maximum fi ring capacity depends on the fi rebox pressure. Use Table 2 to verify the correct air tube type for the fi r ing 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 air tube combination code. recommendation sheet or refer to OEM Spec Guide). Find the required fi ring rate in the 140 psig column (factory-set fuel unit pressure). Select the corresponding nozzle from column 1 (Rated gph @ 100 psig). Figure 2. Min. Combustion Chamber DimensionsMinimum Dimensions Figure 3 - Air Tube Mounting Dimensions u u Install burner with 2o pitch as shown. A.T.C. Codes Firing Rate (with damper) (without damper) ALAL Air Tube Length (Dimension T) (A.T.C. = Air Tube Combination) CF500CF800 Tube A Tube B 1.75 to 3.00 gph 7.5" 18.0" 8.0" 19.0" 4.00 gph 8.0" 21.0" 9.5" 23.0" 5.00 gph 9.0" 23.0" 10.5" 30.0" 6.00 gph 10.0" 28.0" 11.5" 40.0" 7.00 gph 11.0" 34.0" 12.0" 46.0" 8.00 gph 14.0" 38.0" 14.0" 51.0" 6.00" CF 60 KK CF 60 KH CF 60 KJ 8.00" CF 80 KK CF 80 KH CF 80 KJ 10.00" CF 100 KK CF 100 KH CF 100 KJ 14.00" CF 140 KK CF 140 KH CF 140 KJ 16.00" CF160 KK -- -- 17.00" -- CF 170 KH CF 170 KJ 6 6104 BCF5 R07 Table 2 - Air tube capacities vs fi rebox pressure CF500 CF800 CF500 CF800 Mount the burner Protect the Air Tube From Firebox pressure (in w.c.) Tube KK Tube KH Tube KJ Tube KK Tube KH Tube KJ Overheating Overheating could cause damage to the air No reserve air 10% Turndown 0.0" 5.50 7.00 8.00 4.95 6.30 7.20 0.1" 4.75 6.25 7.50 4.27 5.62 6.75 tube and other combustion components lead ing to equipment malfunction and impaired combustion performance. 0.2" 4.00 5.50 6.75 3.60 4.95 6.07 ⮹ 0.3" 3.50 4.50 6.25 3.15 4.00 5.62 0.4" 2.75 3.75 5.50 2.47 3.37 4.95 ⮹ 0.5" 2.00 3.00 5.00 1.80 2.70 4.50 Note: The above ratings may vary 5% due to variations in actual job conditions. The end of the air tube must not extend into the com bustion chamber unprotected unless it has been facto ry-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. ⑨ Stray Light ⑨ ⮹ Protect Against Stray Light Lockout ⮹⮹ Mount fl ange(s) on air tube This section does not apply to burners with welded fl ang es. 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. 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 d). 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 ⮹ 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 from direct exposure to intense light. ⮹ 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 d) onto the air tube as shown. Wrap ceramic fi ber rope (item c) around the air tube and press tightly into the inside diameter of the fl ange (item d). Slide the air tube (item e) into position in the appliance ⑨ Dust and Moisture ⮹ Protect Against Dust and Moisture front. Tighten the fl ange-mounting-stud nuts. Set the insertion of the air tube so dimension G is 1/4" nominal. Pitch the air tube at 2° from horizontal as shown and secure the fl ange to the air tube. 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 va pors, and moisture. ⮹ Protective covers and more frequent maintenance may be required. 6104 BCF5 R07 7 ⑨ Mount air tube to burner ⮹ Insert the air tube into the burner housing. Carefully align the the four screw holes. ⮹ Attach the air tube to the burner using the four provided screws. ⑨ Install nozzle ⮹ 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. ⑨ Check electrode settings Figure 6 - Nozzle line assembly in burner CF500 1-9/16" CF800 1-3/4" Maintain Electrode ⑨ Specifi cations ⮹ Failure to properly maintain these specifi cations could cause ignition malfunction, puff-back of hot gases, heavy smoke, asphyxiation, explo sion and fi re hazards. Set dimension Z Loosen fastener c in Figure 7. Slide the nozzle line and plate assembly until dimension Z in Figure 6 is: CF500 - 1-9/16" ±1/16" CF800 - 1-3/4" ±1/16". ⮹ Adjust the electrode gap and position in relation to the nozzle to the specifi cations shown in Figure 4. ⮹ When dimension Z (from end of air tube to fl at area of front face of head) is correctly set, tighten acorn nut (item c). Attach the oil line from the oil valve to the nozzle line ⮹ Check, and adjust if necessary, the critical dimensions ⮹ shown in Figure 5. Verify that the oil tube assembly and electrodes are in good condition, with no cracks or damage. end. Tighten securely. Before proceeding, check dimension Z once again. Loos en acorn nut c if necessary to reposition the nozzle line. Once dimension Z is set, do not loosen the acorn nut (item) c again. Note that for the setting of fastener d, Figure 5 - Nozzle and nozzle line assembly End view Side view 3/16" - 7/32" R refer to Initial Head Position procedure on Page 11. gap 1/4" in front of nozzle 3/16" above P nozzle center Legend (Figure 5) P Nozzle centerline to electrode tip = 1/4" Q Nozzle face to electrode tip = 1/8" R Electrode spacing = 5/32" gap Q 50001 Figure 7 - Adjusting plate assy. Legend (Figures 7) ⑨ Install nozzle line assembly ⮹ Insert the nozzle line assembly into the burner air tube. Reference Figure 6. ⑨ ⮹ Slide the secondary adjusting plate (Figure 7, item f) com c Bottom acorn nut d Fastener Insert burner e Indicator adjusting plate f Secondary adjusting plate pletely 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 right (Indica tor Plate will read 0). Tighten fastener (item d). ⮹ ⮹ Install the spline nut on the end of the nozzle line, leaving the nut loosely placed so the plates can be moved. 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 Figure 4. Secure the burner to the appliance by tightening the nuts on the burner fl ange mounting studs. 8 6104 BCF5 R07 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. Table 3. Fuel Unit gearset capacity Fuel unit model number Gearset capacity (GPH) A2VA-7116 17 A2YA-7916 20 B2VA-8216 21 B2YA-8916 25 ⮹ The burner is shipped without the by-pass plug in stalled. ⮹ Intall the by-pass plug in two-pipe oil supply systems ONLY. ⮹ B2TA-8248 21 for the fi ring rate for one-pipe systems. Locate the fi lter immediately adjacent to the burner fuel unit. Install two high-quality shut-off valves in accessible ⮹ The CF500 and CF800 burners are shipped without the by-pass plug installed in the fuel line. ⮹ The by-pass plug must NOT be installed when using with a one-pipe oil system. ⑨ ⮹ The by-pass plug MUST be installed when using a two 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. Burner fuel fl ow ⑨ pipe oil system. Oil supply/return lines ⮹ ⮹ One-pipe systems – See Figure 8 for the fuel fl ow path. Figure 7 is based on type B fuel unit. ⮹ Oil supply connects to one of the fuel unit inlet ports. ⮹ Install Oil Supply To Specifi cations Two-pipe systems – See Figure 9 for the fuel fl ow paths for two-pipe oil systems. ⮹ ⮹ Failure to properly install the oil supply system could cause oil leakage, equipment malfunction, puff-back of hot gases, heavy smoke, Figure 9 is based on type B fuel unit . 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 sys tems.) asphyxiation, explosion and fi re hazards. ⮹ 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. ⮹ Do NOT install valves in return lines. ⮹ 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). Figure 8 - One-pipe oil fl ow with "B" pump 125-200 psig 125-200 psig 3502 Figure 9 - Two-pipe oil fl ow with "B" pump 125-200 psig 125-200 psig ⮹ 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 2 for the fuel unit gear set capacity - the rate at which fuel is recirculated when connected to a two-pipe system. However, size two-pipe oil lines based on this fl ow rate. Legend 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 3503 ⮹ ⮹ 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 2) for two-pipe systems. Size the fi lter Nozzle pressure – The fuel unit nozzle port pressure is factory set at 140 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. 6104 BCF5 R07 9 Wire the burner — R7184 Electrical Shock Hazard Sequence of operation — typical 1. Electrical shock can cause severe personal in jury or death. 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. ⮹ Disconnect electrical power before installing or servic 2. ing the burner. ⮹ Provide ground wiring to the burner, metal control en 3. 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). 4. Valve-on delay — As applicable, the ignition and motor are turned on for a 15-second prepurge. Trial for ignition (TFI) — The fuel valve is opened, as ap plicable. A fl ame should be established within the 15-second lockout time (30-second lockout time is available). Lockout — If fl ame is not sensed by the end of the TFI, the control shuts down on safety lockout and must be manually Install the burner and all wiring in accordance with the National Electrical Code and all applicable local codes or requirements. 5. 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. 6. See Figure 10 for a typical wiring diagram, with R7184 oil primary, for reference purposes only. 7. Figure 10. - Typical wiring 8. 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 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. 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 control shuts down the burner, enters a 60-second recycle de lay, and then repeats the ignition steps outlined above. If the fl ame is lost three times in a row, the control locks out to pre vent continuous cycling with repetitious fl ame loss caused by poor combustion. Burner motor-off delay — If applicable, the fuel valve is closed and the burner motor is kept on for the selected post purge time before the control returns the burner to standby. Resetting to cad cell ⮹ If the control locks out three times in a row without a com plete heat cycle between attempts, the lockout becomes re stricted. A qualifi ed service technician should be called to inspect the burner. Figure 11. - Typical sequence of operation 1 Standby Legend (Figure 10) FD Fused disconnect LM Limit controls OP Operating controls PP Oil primary controls CC Flame sensor, CAD cell type TR Ignition transformer M1 Burner motor S1 Oil valve T-T 24-volt thermostat F-F Flame sensor terminals 2 8 Valve-on delay Motor-off delay (postpurge) 3 5 6 Trial for ignition Ignition carryover Run 4 7 Lockout Recycle 10 6104 BCF5 R07 Prepare the burner for start-up ⑨ Professional Installation and Service Required ⑨ Incorrect installation and mishandling of start up could lead to equipment malfunction and re sult in asphyxiation, explosion or fi re. ⑨ 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 ⮹ This burner must be installed and prepared for start-up by a qualifi ed service technician who is trained and ex ⑨ perienced in commercial oil burner system installation and operation. ⑨ ⮹ 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 ⑨ verifi ed. ⮹ Carefully follow the wiring diagrams, control instruc tion sheets, fl ame safeguard sequence of operation, test ⑨ procedures and all appliance manufacturer's directions that pertain to this installation. ⮹ If any of these items are not clear or are unavailable, call Beckett at 1-800-645-2876 for assistance. ⑨ Do Not Bypass Safety ⑨ Controls system. Fuel connection to nozzle line assembly is secure. Dimension Z has been set per the 'Set Z Dimension' instructions detailed earlier in this manual. The acorn nut (Figure 7, item C) should never be loosened once the Z dimension is initially set. 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). Tampering with, or bypassing safety controls ⑨ could lead to equipment malfunction and result in asphyxiation, explosion or fi re. Also refer to appliance manufacturer's instructions (when available) for start-up procedures. ⮹ Safety controls are designed and installed to provide ⑨ 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 ⮹ Covers Securely Installed Initial head position (Figure 7) The indicator plate assembly markings correspond to head position settings. Loosen the fastener (Figure 7, item d) and slide the indicator plate until the number on the indicator plate corresponds to the initial head setting listed in Table 4, for the desired fi ring rate. When the head position has been set, tighten the fastener and the spline nut. These covers must be securely in place to prevent electrical shock, damage from exter nal elements, and protect against injury from moving parts. Table 4 - Initial indicator adjustment plate settings (head position) ⮹ 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 Rate GPH Approximate head settings CF500CF800 Tube A Tube B of its design. Start-up checklist - Verify the following before attempting to start burner. 1.75 0 -- -- 2.25 0 3.00 4 0 -- 3.50 5 1 -- 4.00 5 2 -- 5.00 6 4 3 ⑨ Combustion air supply and venting have been inspected and verifi ed to be free of obstructions and installed in accordance with all applicable codes. 5.50 6 4 4 6.00 -- 4 4 7.00 -- 6 5 8.00 -- -- 6 6104 BCF5 R07 11 Table 5 - Initial air shutter and band settings Approximate air settings Start the Burner Explosion and Fire Rate GPH CF500CF800 Tube A Tube B Shutter Band Shutter Band Shutter Band Hazard Failure to follow these instructions could lead to equipment malfunction 1.75 1 0 -- -- -- -- 2.25 2 0 -- -- -- -- 3.00 10 1 1 0 -- -- ⮹ 3.50 10 2 3 0 -- -- 4.00 10 3 4 0 -- -- 5.00 10 5 9 0 8 2 ⮹ 5.50 10 10 9 5 9 4 6.00 -- -- 10 3 10 3 ⮹ 7.00 -- -- 10 8 10 5 8.00 -- -- -- -- 10 10 ⮹ Note: These settings are appoximate, and can vary depending on actual job conditions and overfi re pressure ⮹ ⑨ Initial air settings (Table 5) ⮹ ⮹ Loosen the air band and shutter, and adjust to the and result in heavy smoke emission, soot-up, hot gas puff-back, fi re and asphyxiation hazards. Do not attempt to start the burner when excess oil has accumulated in the appliance, the appliance is full of vapor, or when the combustion chamber is very hot. Do not attempt to re-establish fl ame with the burner running if the fl ame becomes extinguished during start up, venting, or adjustment. Vapor-Filled Appliance: Allow the unit to cool off and all vapors to dissipate before attempting another start. Oil-Flooded Appliance: Shut off the electrical power and the oil supply to the burner and then clear all ac cumulated 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. approximate fi ring rate settings given in Table 5. ⮹ These initial settings should be adequate for starting the ⑨ burner. Once the burner is in operation, the air settings Starting the burner and venting air will be adjusted for best performance as discussed later in this manual. ⮹ Follow the procedures described later in this manual for fi ne-tuning the air settings. Priming the pump Hot Gas Puff-back and Heavy Smoke Hazard 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 the oil supply line, attach a clear hose to the pump air bleed valve (fi gure 9) on the fuel unit. Provide a container to catch the oil. Loosen the pump air ⮹ bleed valve. ⮹ Vent the air as described in the next section under Start the burner. 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. ⮹⮹ Initiate a call for heat While the ignition is on, press and release the reset button on the R7184 control (hold 1/2 second or less). If the control has not locked out since it's most recent complete heat cycle, the lockout time will be extended to 4 minutes (45 seconds in earlier units), and the ignition will remain on the entire heat cycle. ⮹ Bleed the pump until all froth and bubbles are purged. If prime is not established within the extended lockout time, 12 6104 BCF5 R07 the control will lock out. Press the reset button to reset the control and return to the functions listed in the previous step. ⮹ Repeat the previous steps if needed, until the pump is fully primed and the oil is free of bubbles. Then terminate the call for heat, and the control will resume normal operation. Step 1: Adjust the air shutter/band until a trace of smoke is achieved. Step 2: At the trace of smoke level, measure the CO2 (or O2) . This is the vital reference point for further adjustments. Example: 13.5% CO2 (2.6% O2) Step 3: Increase the air to reduce the CO2 by 1.5 to 2 percentage points. (O2 will be increased by Disable function approximately 2.0 to 2.7 percentage points.) Example: Reduce CO2 from 13.5% to 11.5% (2.6% ⮹ Any time the motor is running, press and hold the reset button to disable the burner. The burner will remain off as to 5.3% O2). Step 4: Recheck smoke level. It should be Zero. long as the button is held and will return to standby when ⮹ released. ⮹ CAD cell resistance check This procedure provides a margin of reserve air to accommodate variable conditions. If the draft level has changed, recheck the smoke and CO2 (or O2) levels and readjust the burner, if necessary ⮹ While the burner is fi ring, and after the ignition has been turned off, press and release the reset button (hold 1/2 sec 4. ond or less) to check the cad cell resistance. The LED will fl ash 1 to 4 times, depending on the cad cell resistance (refer to the table below). 5. Once combustion is set, tighten all fasteners on air band, air shutter and escutcheon plate. Start and stop the burner several times to ensure satisfactory operation. Test the primary control and all other appliance Number of LED fl ashes Cad Cell Resistance (ohms) safety controls to verify that they function according to the manufacturer's specifi cations. 1 Strong (0 to 400) 6. 2 Normal (400 to 800) 3 Weak (800 to 1600) 4 Poor (1600 or higher)* * Lockout is likely to occur. LED Indicator Status On Flame sensed Off Flame not sensed Check the breech draft pressure against the appliance man ufacturer'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 (or O2) levels. Adjust burner air if necessary. Flashing (1/2 sec off - 1/2 sec on) Flashing (2 sec off - 2 sec on) Lockout/Restricted Lockout Recycle ⑨ Set combustion using instruments 1. Allow the burner to run for approximately 5 to 10 minutes. 2. Set the stack or over-fi re draft to the level specifi ed by the appliance manufacturer. ⮹ Natural Draft Applications; typically over-fi re draft is -0.01" or -0.02" w.c. ⮹ Direct Venting; typically may not require draft adjust ment. ⮹ High Effi ciency/Positive Pressure Appliances; also vary from traditional appliances (see manufacturer's recommendations). 3. Follow these four steps to properly adjust the burner: 6104 BCF5 R07 13 Maintenance and Service ⑧ Annual Professional Service Required ⑧⑧⑧⑧ Tampering with or making incorrect adjustments could lead to equip ment malfunction and result in asphyxiation, 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 ⑧ service technician must service this burner annually. ⮹ More frequent service intervals may be required in 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. Inspect the vent system and chimney for soot accumula tion 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". It is good practice to make a record of the service per formed and the combustion test results. dusty or adverse environments. ⮹ Operation and adjustment of the burner requires technical training and skillful use of combustion test instruments and other test equipment. Monthly maintenance — by owner ⑨ Observe combustion air openings and vent system for integrity. Openings must be clean and free of obstructions. ⑨ Annual service — by qualifi ed service techni ⑨ cian Have the burner inspected, tested and started at least annually ⑨ by a qualifi ed service technician. This annual test/inspection should include at least the following: 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. 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. ⑧ Inspect the oil supply system. All fi ttings should be leak tight. The supply lines should be free of water, sludge and other restrictions. ⑧⑧ Remove and clean the pump strainer if applicable. Replace the nozzle with the exact brand, pattern, gph, fl ow rate and spray angle. ⑧ Clean and inspect the electrodes for damage, replacing any that are cracked or chipped. ⑧ Check electrode tip settings. Replace electrodes if tips are rounded. ⑧⑧⑧ 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. ⑧ Inspect the combustion head and air tube. Remove any carbon or foreign matter. Replace all damaged units with exact parts. ⑧ Clean the blower wheel, air inlet, air guide, burner hous ing and static plate of any lint or foreign material. ⑧ 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 mo tor failure. ⑧ Check motor current. The amp draw should not exceed the nameplate rating. Figure 12 - Adjustable mounting plates for CF500 and CF800 14 6104 BCF5 R07 Replacement parts 2 3 1 4 10 9 8 Item Part Name/Description Part Number 1 Air Tube Specify 2 Spline Nut 3666 3 Adjusting plate assembly 51286U 4 Blocking Oil Solenoid Valve 2182602U 5 Igniter 51771U 6 Control Specify 7 Air Band 3819 8 Air Shutter 3215 9 Fuel Pump Specify 10 Fuel lines Specify Lengths Head Assembly: 5 6 7 11 12 13 11 CF500 - KK CF800 - KH (Tube A) CF800 - KJ (Tube B) 51401U 51252P 51302P 12 Electrode Assembly Specify 13 Nozzle Line Assembly Specify 14 Motor - 1/3 PSC 21341U Blower Wheel: 1514 15 CF500 - 5-19/32" x 2-13/32" CF800 - 6-5/16" x 2-3/8" 21448U 21339U 16 16 Coupling 2433 17 Flange Kit See Figure 12 18 Pedestal Kit Not Shown 6104 BCF5 R07 15 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 3X7 Printed in U.S.A. 12/2006 © R.W. Beckett Corporation 16 6104 BCF5 R07