Beckett Burner CF800, homeappliance

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CF 1400 OilBurner MODEL Instruction Manual ON/OFF Operation Firing rate: 4.0 – 10.0 GPH Motor voltage: 120 / 60 Hz std. Thank you for purchasing a Beckett burner. With proper care and regular maintenance, it will provide years of trouble-free service. Please take a few minutes to read the section entitled "To the owner" inside this manual. Then, keep the manual in a safe place where it can be easily located if needed by your professional service technician. 14 00 Instruction Manual – Model CF1400 Oil Burner Please . . . read this page first Hazard definitions The following will be used throughout this manual to bring attention to hazards and their risk factors, or to special information. Denotes presence of a hazard which, if ignored, will result in severe personal injury, death or substantial property damage. Denotes presence of a hazard which, if ignored, could result in minor personal injury or property damage. To the owner — Installation and adjustment of the burner requires technical knowledge and the use of combustion test instruments. Do not tamper with the unit or controls. Call your qualified service technician. Incorrect operation of the burner could result in severe personal injury, death or substantial property damage. Have your equipment inspected and adjusted at least annually by your qualified service technician to assure continued proper operation. Never attempt to use gasoline in your heating appliance or to store gasoline or combustible materials near the heating equipment. This could result in an explosion or fire, causing severe personal injury, death or substantial property damage. To the installer — Read all instructions before proceeding. Follow all instructions completely. Failure to follow these instructions could result in equipment malfunction, causing severe personal injury, death or substantial property damage. This equipment must be installed, adjusted and started only by a qualified service technician – an individual or agency, licensed and experienced with all codes and ordinances, who is responsible for the installation and adjustment of the equipment. The installation must comply with all local codes and ordinances and with the National Fire Protection Standard for Oil-Burning Equipment, NFPA 31 (or CSA B139-M91). Denotes presence of a hazard which, if ignored, could result in severe personal injury, death or substantial property damage. Intended to bring special attention to information, but not related to personal injury or property damage. To the owner — Never burn garbage or refuse in your heating appliance or try to light the burner by tossing burning material into the appliance. This could result in severe personal injury, death or substantial property damage. Never attempt to use crankcase or waste oil in your heating appliance. This could damage the fuel unit or heating equipment, resulting in risk of severe personal injury, death or substantial property damage. Never restrict air openings on the burner or to the room in which the appliance is located. This could result in fire hazard or flue gas leakage, causing severe personal injury, death or substantial property damage. To the installer — Concealed damage - If you discover damage to the burner or controls during unpacking, notify the carrier at once and file the appropriate claim. Contacting Beckett for service information or parts - Please record the burner serial number (and have available when calling or writing). You will find the serial number on the Underwriters Laboratories label, located on the left rear of the burner. 50 Hz motors — The burner ratings, air settings and nozzle ratings are based on standard 60 hz motors (at 3450 rpm). Derate all ratings 20% when using 50 hz motors. Consult factory for specific application data. 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 4% for each 1000 feet above sea level. 2 Form 6104 BCF14N-R0299 Warranty Instruction Manual – Model CF1400 Oil Burner Contents Beckett warrants its equipment to those who have purchased it for resale, including your dealer. If you have any problems with your equipment or its installation, you should contact your dealer for assistance. Refer to warranty sheet in literature packet included with burner for details. Specifications Fuels #1 or #2 Fuel Oil Firing range 4.0 to 10.0 GPH Motor ½ HP 3450 RPM 120/60 hz standard 6.5 amps @ 120 VAC Optional voltages: (60 hz or 50 hz) – • 240/1-PH • 208/240/480/3-PH Ignition Trans. 120V/12,000V Housing Cast aluminum Fuel unit 100 - 300 PSIG Oil nozzle 45° - 70° solid Shipping wt. 75 lbs. Dimensions See Figure 7 (Page 7) (See NOTICE on opposite page for 50 hz motor applications.) Agency approvals • Underwriters Laboratories has certified this burner to comply with ANSI Standard 296 and has listed it for use with No. 1 or No. 2 fuel oil as specified in ASTM D396. State and local approvals appear on the burner rating label. • Certified by ULC. • Approved by Commonwealth of Massachusetts - State Fire Marshall. • Accepted by N.Y.C. M.E.A. • Other approvals may be available and must be specified at time of order. Please . . . read this page first ................ 2 Pre-installation checklist........................... 4 Mount the burner .......................................... 6 Connect fuel line(s)...................................... 8 Wire the burner ............................................ 10 Sequence of operation - typical ............ 11 Prepare the burner for start-up............. 11 Start the burner .......................................... 14 Maintenance and service......................... 15 Replacement parts................... Back cover 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. Form 6104 BCF14N-R0299 3 Instruction Manual – Model CF1400 Oil Burner Pre-installation checklist ❏ Combustion air supply • The burner requires combustion air and ventilation air for reliable operation. Assure that the building and/or com bustion air openings comply with National Fire Protection Standard for Oil-Burning Equipment, NFPA 31. For appli ance/burner units in confined spaces, the room must have an air opening near the top of the room plus one near the floor, each with a free area at least one square inch per 1,000 Btu/hr input of all fuel burning equipment in the room. 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 out side 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 di mensions comply with all local codes and with the appli ance manufacturer's recommendations. ❏ Fuel supply • 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 litera ture in the literature envelope in the burner carton to verify allowable suction pressure. The fuel unit is shipped without the by-pass plug installed for CF1400 ON/OFF burners. You must install this plug on two-pipe systems. DO NOT install the by-pass plug in the fuel unit if connected to a one-pipe oil system. Failure to comply could cause fuel unit seal failure, oil leakage and potential fire and injury hazard. If fuel supply is level with or higher than fuel unit — • When the fuel unit is not required to lift the oil, the instal lation is usually suitable for either a one-pipe or two-pipe oil system. The oil pressure at the inlet of the fuel unit must not exceed 3 psig. • See Figure 8 for one-pipe fuel supply installations. See Figure 9 for two-pipe fuel supply installations. If fuel supply is below the fuel unit — • Use a two-pipe oil system when the fuel unit must lift the oil more than 8 feet if burner is equipped with a B fuel unit — or more than 2 feet if burner is equipped with an H fuel unit. The return line provided by the two-pipe system is needed to purge the air from the fuel lines and minimize the likelihood of air-related problems during operation. ❏ Vent system • The flue gas venting system must be in good condition and must comply with all applicable codes. ❏ Electrical supply • Verify that the power connections available are correct for the burner. All power must be supplied through fused dis connect switches. ❏ Verify burner components — • Burner box, Model CF1400 • Air tube assembly (selected per following) • Mounting flange kit • Pedestal mounting assembly kit (recommended) • Oil nozzle, per Table 1 — Use only 45° to 70° solid pat tern nozzles unless otherwise shown by appliance manu facturer. Find the required firing rate in the 300 psig column (fac tory-set fuel unit pressure). Select the corresponding nozzle from column 1 (Rated gph @ 100 psig). Table 1 - Nozzle capacitites Rated gph @ 100 psig Pressure - pounds per square inch 125 150 175 250 275 300 2.00 2.24 2.45 2.65 3.16 3.32 3.46 2.25 2.52 2.76 2.98 3.56 3.73 3.90 2.50 2.80 3.06 3.31 3.95 4.15 4.33 2.75 3.07 3.37 3.64 4.35 4.56 4.76 3.00 3.35 3.67 3.97 4.74 4.97 5.20 3.50 3.91 4.29 4.63 5.53 5.80 6.06 4.00 4.47 4.90 5.29 6.32 6.63 6.93 4.50 5.04 5.51 5.95 7.11 7.46 7.79 5.00 5.59 6.12 6.61 7.91 8.29 8.66 5.50 6.15 6.74 7.28 8.70 9.12 9.53 6.00 6.71 7.35 7.94 9.49 9.95 10.39 6.50 7.27 7.96 8.60 10.28 10.78 11.26 7.00 7.83 8.57 9.26 11.07 11.61 12.12 7.50 8.39 9.19 9.92 11.86 12.44 12.99 8.00 8.94 9.80 10.58 12.65 13.27 13.86 4 Form 6104 BCF14N-R0299 ❏ Verify firing rate Instruction Manual – Model CF1400 Oil Burner Figure 2 - Air tube mounting dimensions • Refer to appliance manufacturer's instructions (if avail able) for firing rate and nozzle selection. Otherwise, the T maximum recommended firing rate for the burner depends on the length of the firing chamber and the distance from 2° E Insertion depth G Air tube to inside of chamber – 0.25" ± 0.125" T Air tube length the burner center to the chamber floor. Verify that the cham ber dimensions are at least as large as the minimum values given in Figure 1. If the appliance dimensions are smaller than recommended, reduce the firing 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 – Tube A — 4.0 to 11.0 GPH per Table 2 Tube B — 7.0 to 13.6 GPH per Table 2 G 1 D E D Tube diameter 1404 • Maximum firing capacity depends on the firebox pressure. Use Table 2 to verify the correct air tube type for the firing rate required. Use Tube B only when Tube A cannot pro vide the firing rate required. • See Figure 2 to verify the correct air tube length and air tube combination code. Figure 1 - Min. Combustion chamber dimensions ① Install the burner with a 2° pitch as shown. Air tube length (Dimension T) A.T.C. Codes (A.T.C. = Air Tube Combination) Tube A (Dim. D = 5½") Tube B (Dim. D = 5¾") 6.75" CF 66 KD CF 66 KE 10.25" CF 102 KD CF 102 KE 13.75" CF 136 KD CF 136 KE 17.75" CF 176 KD CF 176 KE Table 2 - Air tube capacity vs. firebox pressure L A 1405 Firebox pressure (In. w.c.) Tube A Tube B 10% turndown No reserve air 10% turndown 0.0 11.0 GPH 13.6 GPH 12.2 GPH 0.2 10.5 GPH 13.1 GPH 11.7 GPH 0.4 10.1 GPH 12.5 GPH 11.2 GPH 0.6 9.6 GPH 12.0 GPH 10.8 GPH 0.8 9.2 GPH 11.4 GPH 10.3 GPH 1.0 8.7 GPH 10.9 GPH 9.8 GPH Note: 10% turndown indicates sufficient reserve air to reduce the CO2 in the flue to 90% of its value. Note: The above ratings may vary 5% due to variations in actual job conditions. Firing rate Minimum dimensions (refractory-lined) (wet-base boilers) A L A L 0 to 5 gph 7.0" 25.0" 7.0" 25.0" 5 to 10 gph 8.0" 35.0" 8.0" 40.0" Form 6104 BCF14N-R0299 5 Instruction Manual – Model CF1400 Oil Burner Mount the burner ❏ Mount flange(s) on air tube • This section does not apply to burners with welded flanges. • Do not install air tube on burner. • For non-pressure firing flange, refer to Figure 3: Install gasket (item a) and flange (item d). Ignore the next paragraph. • For pressure-firing flange, refer to Figure 3: Slide gasket (item a) onto the air tube, making sure the top of the air tube is up. Pre-drill holes in the pressure firing plate (item b) to match the appliance studs. Slide the pressure firing plate (item b) and flange (item d) onto the air tube as shown. Wrap ceramic fiber rope (item c) around the air tube and press tightly into the inside diameter of the flange (item d). • Slide the air tube (item e) into position in the appliance front. Tighten the flange-mounting-stud nuts. Set the insertion of the air tube so dimension G is ¼" nominal. • Pitch the air tube at 2° from horizontal as shown and secure the flange to the air tube. Figure 3 - Mount flange(s) on air tube Figure 4 - Nozzle and nozzle line assembly S Q P R Critical dimensions — 1406-1 1406-2 G 2° S (Electrode spacing) = ³⁄₃₂" Q (Nozzle to head) = ¹⁄₄" P (Nozzle center line to electrode tip) = ¹⁄₄" R (Nozzle face to electrode tip) = ¹⁄₈" d a b c ❏ Mount air tube to burner Failure to properly set and maintain the electrode and nozzle spacing dimensions can cause incorrect burner ignition or poor combustion. This could result in severe personal injury, death or substantial property damage. ❏ Install nozzle line assembly 1412 • Insert the nozzle line assembly into the burner air tube as in Figure 5. • 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 4. Install the oil nozzle in the nozzle adapter. Use a ³⁄₄" open-end wrench to steady the nozzle adapter and a ⁵⁄₈" open-end wrench to turn the nozzle. Tighten securely but do not over-tighten. • Check, and adjust if necessary, the critical dimensions P, Q, R and S shown in the drawing. Verify that the oil tube assembly and electrodes are in good condition, with no cracks or damage. • See Figures 5 and 6. Assemble the adjusting plate assem bly per the instructions in the assembly packet. • Slide the secondary adjusting plate (item f) completely to the left on the indicator adjusting plate (item e). Finger tighten acorn nut c to secure the two plates together. Slide both plates completely to the left on the primary adjusting plate (item g) and finger-tighten acorn nut d. • Slide the completed adjusting plate assembly over the nozzle line end. Move the plate assembly and the nozzle line so the plate assembly fits into position as shown in Figure 5. • Install the spline nut (Figure 5, item b) on the end of the nozzle line, leaving the nut loosely placed so the plates can be moved. • Connect the high-voltage leads from the ignition trans former to the electrodes. 6 Form 6104 BCF14N-R0299 Instruction Manual – Model CF1400 Oil Burner Figure 5 - Nozzle line assembly in burner Figure 6 - Adjusting plate assy. Z Measure dimension from d d e f c g Z b front (flat) face of head to end of air tube, as shown. a 1408-1 c Legend (Figures 5 and 6) a Adjusting plate assembly 1408 ❏ Set dimension Z b Spline nut for securing nozzle line c Bottom acorn nut d Top acorn nut (for setting dim. Z only) e Indicator adjusting plate f Secondary adjusting plate g Primary adjusting plate that the adjusting plate assembly is properly seated at the rear access Measure dimension Z from the flat surface between (not on) the raised fins. 1424 • Replace the rear access door on the burner, making sure that the adjust ing plate assembly is now securely held in place. • Loosen acorn nut d in Figure 5. Slide the nozzle line and plate as sembly until dimension Z in Figure 5 is 1³⁄₄" ± ¹⁄₁₆". When di mension Z (from end of air tube to flat area of front face of head) is cor rectly set, tighten acorn nut d. Verify door, as shown in Figure 5. • Attach the oil line from the oil valve to the nozzle line end. Tighten se curely. • Before proceeding, check dimen sion Z once again. Loosen acorn nut d if necessary to reposition the nozzle line. Once dimension Z is set, do not loosen acorn nut d again. For the setting of acorn nut c, refer to page 12. ❏ Insert burner Figure 7 - Burner installed in appliance front D 1403 Legend H Housing total length — 18" H K J a b c • 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 7. • See Figure 7. Install the pedestal support kit (recommended) by at taching the ¾" npt flange (item a) to the bottom of the burner using the (4) #10 screws provided. Cut and thread (one end only) a ¾" pipe nipple (item b) with length 11 inches less than dimension D in Fig ure 7. Thread the pipe into the flange. Then slip the pipe end into the floor flange (item c). • Secure the burner to the appliance by tightening the nuts on the burner flange mounting studs. Then secure the pedestal support floor flange set J Center to bottom of housing — 10⁷⁄₈" K Overall housing height — 13³⁄₈" screw to the pipe. Form 6104 BCF14N-R0299 7 Instruction Manual – Model CF1400 Oil Burner Connect fuel line(s) Install the oil lines using the following guidelines. Failure to comply could lead to equipment damage and present a risk of severe personal injury, death or substantial property damage due to leakage of oil and potential fire hazard. Use only flare fittings at joints and connections. Never use compression fittings. Install fittings only in accessible locations to assure any leak will be detected. Where joint sealing is needed, use only pipe dope. Never use Teflon tape. Tape strands can break free and damage the fuel unit. Figure 8a – One-pipe oil flow with "H" pump g c d 300 psig 300 psig b p 1410ao Figure 8b – One-pipe oil flow with "B" pump Never use a one-pipe oil system with a lift in excess of 8 feet with B fuel unit, or 2 feet with H fuel unit. On two-pipe oil systems, verify that the suction line vacuum does not exceed the fuel unit manufacturer's recommendation. The fuel unit is shipped without the by-pass plug installed for CF1400 ON/OFF burners. You must install this plug on two-pipe systems. DO NOT install the by-pass plug in the fuel unit if connected to a one-pipe oil system. Failure to comply could cause fuel unit seal failure, oil leakage and potential fire and injury hazard. d 300 psig Legend b Nozzle port c Oil valve(s) c g 300 psig b p 1420ao d Nozzle & adapter g Inlet port p Air bleed valve ❏ Fuel unit by-pass plug • The CF1400 burner is shipped without the by-pass plug installed in the fuel unit. • The by-pass plug must not be installed in the fuel unit for one-pipe oil systems. • You must install the by-pass plug if using on a two-pipe oil system. ❏ Oil supply/return lines • Install the oil tank and oil lines in accordance with all applicable codes. • Size the oil supply and return lines using the guidelines given in the fuel unit literature included in the literature envelope. Oil line flow rate will equal the burner rate for one-pipe systems. For two-pipe systems, refer to Table 3 8 Form 6104 BCF14N-R0299 Instruction Manual – Model CF1400 Oil Burner Figure 9a – Two-pipe oil flow with "H" pump g for the fuel unit gearset capacity - the rate at which fuel is recirculated when connected to a two-pipe system. Size two-pipe oil lines based on this flow rate. • Use continuous lengths of heavy-wall copper tubing, d 300 psig c 1413ao 300 psig b p a k routed under the floor where possible. Do not attach fuel lines to the appliance or to floor joists if possible. This will reduce vibration and noise transmission problems. • Install an oil filter sized to handle the fuel unit gearset flow capacity (Table 3) for two-pipe systems. Size the filter for the firing rate for one-pipe systems. Locate the filter immediately adjacent to the burner fuel unit. • Install two high-quality shut-off valves in accessible loca tions on the oil supply line. Locate one valve close to the Figure 9b – Two-pipe oil flow with "B" pump c tank. Locate the other valve close to the burner, upstream of the fuel filter. d 300 psig Legend a Return port 300 psig b g Inlet port a k g p 1423ao ❏ Burner fuel flow • One-pipe systems – See Figure 8 for the fuel flow path. • Figure 8a is based on type H fuel units. • Figure 8b is based on type B fuel units. • Oil supply connects to one of the fuel unit inlet ports. b Nozzle port c Oil valve d Nozzle & adapter k Return line to oil tank p Air bleed valve • Two-pipe systems – See Figure 9 for the fuel flow paths for two-pipe oil systems. • Figure 9a is based on type H fuel units. • Figure 9b is based on type B fuel units. Table 3 – Fuel unit gearset capacities Fuel unit model number Gearset capacity (gallons per hour) B2TA8245 21 H3PAN-C150H 61 H4PAN-C151H 69 • 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.) • Nozzle pressure – The fuel unit nozzle port pressure is factory set at 300 psig. Some original equipment manufac turer burner applications may call for a lower pressure to obtain a required firing rate. Do not change this pressure unless directed to do so by the appliance manufacturer. Form 6104 BCF14N-R0299 9 Instruction Manual – Model CF1400 Oil Burner Wire the burner 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 Do not by-pass any safety control. By-passing a safety control could result in severe personal injury, death or substantial property damage. in accordance with the appliance manufacturer's guidelines. See Figure 10 for a typical wiring diagram, with R8184 oil primary, for reference purposes only. The CF1400 burner is available with many different wiring configurations. Refer to the wiring diagram shipped with the burner for the actual wiring applying to your burner. Electrical shock hazard - can cause injury or death. Disconnect power before installing or servicing. Provide ground wiring to the burner in accordance with the National Electrical Code. Figure 10 – Typical wiring Legend FD Fused disconnect, by others LM Limit controls, by others OP Operating controls, by others PR Oil primary control, R8184 typical CC Flame sensor, cad cell typical TM Delay timer TR Ignition transformer M1 Burner motor S1 Oil valve S2 Redundant oil valve — supplied only if burner is equipped with type H fuel unit. T-T 24-volt thermostat/limit terminals F-F Cad cell flame sensor terminals HNG FD LM OP BK PR T T OR Power supply 120v/60 hz BK OR OR TM T Field wiring Factory wiring BK = black OR = orange WH = white Motor M1 wiring 14 ga All other wiring 16 ga TR WH S1 WH F CC M1 BK WH F WH WH 1411o 10 Form 6104 BCF14N-R0299 Instruction Manual – Model CF1400 Oil Burner Sequence of operation — typical 1. On call for heat from the appliance operating controls (and the circuit from T to T of the R8184 closed), power is applied to the R8184 black wire (BK). 2. The R8184 applies 120 volts to the orange wire (OR), acti vating the burner motor (M1) and the ignition transformer (TR). The oil pump is operated by the burner motor, so oil pres sure is delivered to the oil valve inlet. 3. Power is applied to the oil valve circuit. If optional timer, (TM), is installed, oil flow will be delayed for the timer duration, thus providing a prepurge period. When the timer times out, the oil valve(s) (S1, and S2 if supplied) is activated, allowing oil to flow to the nozzle. 4. At the start of the cycle, the R8184 begins checking for flame signal between F and F. Flame must be established within 15 seconds of initiation. If no flame is sensed after 15 seconds, the R8184 will terminate all power to the blower and oil circuits, shutting the burner down. The con trol will electrically lock out. • To reset the control after lockout, wait 2 to 3 minutes after lockout to give the internal switch time to cool. Then push the reset button on the primary control, al lowing the burner to operate in normal sequence. • Troubleshoot the reason for flame sense failure. 5. When the call for heat signal terminates (at the black wire of the R8184), the R8184 terminates power to all circuits, closing the oil valve and stopping the burner motor. Prepare the burner for start-up Start-up checklist – Verify the following before attempting to start burner. ❏ Combustion air supply and venting have been inspected and verified to be free of obstructions and installed in accordance with all applicable codes. ❏ Oil nozzle has been selected correctly and securely installed in the nozzle adapter. ❏ Fuel unit by-pass plug has not been installed for one-pipe oil system. By-pass plug has been installed for two-pipe oil system. ❏ Fuel connection to nozzle line assembly is secure. ❏ Dimension Z has been set per this instruction manual. ❏ Fuel supply line is correctly installed, the oil tank is sufficiently filled, and shut-off valves are open. ❏ Burner is securely mounted in appliance, with pressure firing plate and gasket installed for pressurized chamber application. ❏ Appliance has been filled with water (boilers) and 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. Form 6104 BCF14N-R0299 11 Instruction Manual – Model CF1400 Oil Burner Prepare the burner for start-up - continued ❏ Z dimension • Should be set per these instructions (see page 7). The top acorn nut (Figure 11, item d) should never be loosened once the Z dimension is initially set. ❏ Adjusting plate assembly (Figure 11) • Make sure spline nut (item b) and bottom acorn nut (item c) are loose. ❏ Initial head position (Figure 11) • The indicator plate assembly (item e) markings correspond to head position settings. • Slide the secondary adjusting plate (item f) toward the rear of the burner until the number on the indicator plate corre sponds to the initial head setting given in Table 4 for the desired firing rate. • Figure 11 shows a typical example, with a head setting of 5. Figure 11 – Adjusting plate initial setting, typical d e f h b c g 9 3 8 7 6 5 4 Legend (Figure 11) b Spline nut for securing nozzle line c Bottom acorn nut (for head adjustments) d Top acorn nut (for setting dimension Z only — do not loosen after setting dimension Z) e Indicator adjusting plate f Secondary adjusting plate g Primary adjusting plate h Copper oil line from oil valve to nozzle line 1407 • When the head position has been set, tighten the bottom acorn nut (item c) and the spline nut (item b). ❏ Initial air settings (Figure 12) • Loosen the screw holding the air adjusting plate (item m). Set the air to the desired rate. (The numbers on this plate correspond to the approximate firing rate settings given in Table 5.) • Rotate the air adjusting plate until the lower edge of the pointer is opposite the number from Table 5 corresponding to the desired firing rate. • This initial setting should be adequate for starting the burner. Once the burner is in operation, the air setting will be adjusted for best performance as discussed later in this manual. • Follow the procedures given later in this manual for fine tuning the air settings. Table 4 – Initial indicator adjustment plate settings (head position) Approximate adjusting plate settings Firing rate, gph Tube "A" Tube "B" 0 1 2 3 4 5 6 7 – 12 NOTE — — — — 4.00 — 6.00 — 7.00 7.00 8.00 8.00 10.00 10.00 — fire pressure. — These settings are approximate, and can very depending on actual job conditions and over 12 Form 6104 BCF14N-R0299 Instruction Manual – Model CF1400 Oil Burner Figure 12 – Air damper assembly Table 5 – Initial air adjusting plate settings (damper position) h 5 6 7 8 9 10 11 4 3 2 1 0 k Approximate head settings Firing rate, gph Tube "A" Tube "B" 0 4.00 4.00 1 4.50 7.50 2 5.00 8.00 3 6.00 9.00 4 7.00 10.00 5 7.50 — 6 8.00 — 7 – 10 — — NOTE These settings are approximate, and can vary depending on actual job conditions and overfire pressure. 12 m ❏ Set appliance limit controls 1409o-2 Legend (Figure 12) h Damper label - position indicator for air adjusting plate k Damper indicator - permanently attached to damper m Air adjusting plate - sets air position • Set the appliance limit controls in accordance with the appliance manufacturer's recommendations. ❏ Prepare the fuel unit for air venting • To vent air from one-pipe oil systems, attach a clear hose to the vent plug on the fuel unit. Provide a container to catch the oil. Loosen the vent plug. • Vent the air as described under Start the burner, page 14. Form 6104 BCF14N-R0299 13 Instruction Manual – Model CF1400 Oil Burner Start the burner Do not proceed unless all prior steps in this manual have been completed. Failure to comply could result in severe personal injury, death or substantial property damage. Do not attempt to start the burner when excess oil has accumulated, when the appliance is full of vapor or when the combustion chamber is very hot. Do not attempt to re-establish flame with the burner running if the flame should be extinguished during start-up, venting or adjustment. Allow the unit to cool off and all vapors to dissipate before attempting another start. Failure to comply with these guidelines could cause an explosion or fire, resulting in severe personal injury, death or substantial property damage. ❏ Starting the burner and venting air 1. Verify that the air adjusting plate (Figure 12, item m) has been set to the initial air position as described on page 12 under Initial air settings. 2. Open the oil shut-off valves in the oil supply (and return) line(s) to the burner. 3. Set the thermostat (or operating control) to call for heat. 4. Close the line switch to the burner. The burner motor should start immediately. 5. 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. 6. Vent the fuel unit as soon as the burner motor starts rotating. To vent — ❏ Attach a clear plastic tube to the air bleed valve (Figure 8a, 8b, 9a or 9b as applies, item p). ❏ Place the end of the tube in a container to catch the oil. Then loosen the fuel unit air vent valve. ❏ Tighten the air vent valve after all air has been purged. ❏ IF burner stops during venting — • The burner primary control will lockout if flame is not established within its time limit. This is typically 15 seconds for R8184 primary controls, but may be less for other flame supervisory controls. • The burner may lockout several times during the period needed to purge all the air. Reset the primary control each time in order to continue purging. • If the burner is equipped with an R8184 primary, you will need to wait about 2 minutes after each lockout to allow time for the reset switch to cool. • Squeeze off the air bleed tubing or close the air vent valve when the pump stops running to prevent air from flowing back into the oil line. If the fuel unit air vent valve is completely open, assuring no flow of oil to the burner oil nozzle, you can temporarily jumper the F-F terminals of an R8184 primary during the purge period to allow enough time for all air to purge. Never leave the burner unattended when doing this. Remove the jumper when purging is completed. This procedure should only be used by a qualified burner technician, experienced in burner operation and control. Improper application of this method can cause combustion chamber explosion, fire hazard or fuel leakage, resulting in severe personal injury, death or substantial property damage. ❏ IF burner stops after flame established — • Additional venting is probably required. Repeat the air venting procedure. 7. Once flame is steady, proceed to Set air adjusing plate. 14 Form 6104 BCF14N-R0299 Instruction Manual – Model CF1400 Oil Burner ❏ Set air adjusting plate (Figure 12) 1. Allow the burner to run until the appliance has warmed sufficiently. 2. Visually check the flame. The flame should not be dark orange or smoky. If the flame appears to be smoking, increase the amount of air by re-adjusting the damper indicator to a higher number. 3. Once the appliance has warmed, the air setting can be checked and adjusted. 4. Use combustion test instruments to adjust the burner. a. Adjust the air until a trace of smoke is achieved with CO2 level as high as possible (lowest possible O2). Example: 13.5% CO2 (2.5% O2) with a trace of smoke. b. Increase the air to reduce CO2 by 2 percentage points at a zero smoke level. (Increase O2 by 3 percentage points at a zero smoke level.) Example: Reduce CO2 from 13.5% to 11.5%, with zero smoke (or increase O2 from 2.5% to 5.5%). c. This procedure provides a margin of reserve air to ac commodate variable conditions. 5. Check the breech draft pressure against the appliance manufacturer's recommended setting (typically + 0.1" W.C.). 6. If the breech pressure is higher or lower than recommended level, adjust the appliance breech damper to achieve the specified setting. Recheck the smoke and CO2 levels. Ad just burner air if necessary. Maintenance and service The burner must be serviced at least annually by a qualified service technician to assure continued reliable operation. Operation and adjustment of the burner requires technical knowledge and the use of combustion test instruments. Do not tamper with the burner or controls. Failure to comply could result in failure of the burner or system, resulting in severe personal injury, death or substantial property damage. Annual service — by qualified service technician Have the burner inspected, tested and started at least annually by a qualified service technician. This annual test/inspection should include at least the following: ❏ Replace oil nozzle. ❏ Clean burner and blower wheel (if needed to remove lint or debris). ❏ Test ignition and combustion and verify air damper settings. ❏ Test oil supply line vacuum - verify that it is within allowable range indicated in fuel unit literature. ❏ Check pump pressure to nozzle. ❏ Inspect fuel system (including tank, lines and all connections). ❏ Inspect combustion air and vent systems. ❏ Replace oil filter. ❏ Oil motor (if not permanently lubricated). Monthly maintenance — by owner ❏ Observe combustion air openings and vent system for integrity. Openings must be clean and free of obstruc tions. ❏ Check oil lines and fittings to verify there are no leaks. ❏ Observe burner ignition and performance to verify smooth operation. ❏ Shut the system down if you observe abnormal or ques tionable operation. Call a qualified service agency for professional inspection and service. Form 6104 BCF14N-R0299 15 Instruction Manual – Model CF1400 Oil Burner Replacement parts 1 2 3 9 4 10 11 12 14 15 18 19 20 21 6 5 7 8 13 16 17 23 22 Item 1 2 3 4 5 6 7 8 Part name Air tube Flange kit Electrode assembly Ignition leads Nozzle line assembly Head assembly Fuel lines Damper spring Description Part number Specify burner model and tube length Adjustable flange See Figure 13 All models 51212 8 ¼" long 5990082 11 ¾" long 5990116 15 ¼" long 5990152 19 ¼" long 5990192 Specify burner model and tube length CF1400 combustion Specify length All models 4339 Figure 13 – Adjustable mounting plates for CF1400 12¼" Kit #51312 Kit #51629 10" Item 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Part name Timer Adjusting plate assembly Knurled nut Fuel pump Pedestal kit Oil valve Damper door Damper indicator Coupling Sight glass Rear cover assemblyControl Transformer Motor Blower wheel Motor relay (not shown) Description Part number Nozzle valve delay 21295 All models 51213 All models 3666 Specify All models 51193 Box mounted 7201 All models 16703GY All models 5985BK Specify pump used All models 31346 CF1400 5994 Specify 12,000 volt 51214 Specify burner model CF1400 5.50" x 3.09" 21268 Specify relay used U.S.A.: P. O. Box 1289 • Elyria, Ohio 44036 • 800-645-2876 • 440-327-1060 • FAX 440-327-1064 Canada: R. W. Beckett Canada, Ltd. • 430 Laird Road • Guelph, Ontario, N1G 3X7 • 800-665-6972 • FAX 519-763-5656 Form 6104 BCF14N-R0299