Beckett Jets 1000, homeappliance

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ModelNX Oil Burner ! 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 responsi bilities in caring for your heating equipment. • Contact a professional, qualifi ed service agency • for installation, start-up or service work. 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. RWB 6104 BNX R02 Page 1 Table of Contents General Information Hazard Defi nitions ........................................................................................................................................3 Owner's Responsibility ................................................................................................................................3 Information To Be Used Only By Qualifi ed Service Technicians General Information .........................................................................................................................................4 General Specifi cations………………………………………………………….. ....................................................4 Notice Special Requirements ...........................................................................................................................4 Inspect/Prepare Installation Site .................................................................................................................4 Clearances to Burner and Appliance ...............................................................................................................4 Inspect Chimney or Direct Vent System .........................................................................................................4 Combustion Air Supply .....................................................................................................................................5 Direct/Sidewall Venting Application ................................................................................................................5 Fuel Line Installation .........................................................................................................................................5 Fuel Line Valves and Filters .............................................................................................................................5 Prepare the Burner ...........................................................................................................................................6 General .........................................................................................................................................................6 Low Fire Rate Baffl e (if specifi ed) ....................................................................................................................6 Mount Burner on Appliance .............................................................................................................................6 Connect Fuel Lines ...........................................................................................................................................6 Wiring Connection Diagram .............................................................................................................................7 Start the Burner and Set Combustion ......................................................................................................8 Start-up and Initial Settings ..............................................................................................................................8 Set Combustion with Test Instruments .........................................................................................................10 Cover Installation ............................................................................................................................................10 Trained Service Technician's Regular Maintenance .........................................................................10 Removing Nozzle Line for Service ................................................................................................................. 11 Nozzle Installation ...........................................................................................................................................12 Check/Adjust Electrodes ................................................................................................................................12 Check Retention Head Alignment and Cad Cell Sighting ............................................................................13 Check/Adjust "Zero" Calibration ...................................................................................................................13 Blower Wheel Replacement ...........................................................................................................................14 Replacement Parts Diagram .......................................................................................................................15 Replacement Parts Diagram ...........................................................................................................................15 Replacement Parts List ...................................................................................................................................15 Beckett Limited Warranty Information ...................................................................................................16 Page 2 RWB 6104 BNX R02 General Information ! WARNING General Information Owner's Responsibility To the Owner: Thank you for purchasing a Beckett NX burner for use with your heating appliance. Please pay atten tion to the Safety Warnings contained within this in struction 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 NX burner. Your NX burner will provide years of effi cient operation if it is professionally installed and maintained by a quali fi ed service technician. If at any time the burner does not appear to be operating properly, immediately con Incorrect installation, adjustment, and use of this burner could result in severe personal injury, death, or sub stantial property damage from fi re, carbon monoxide poisoning, soot or explosion. Contact a professional, qualifi ed service agency for the installation, adjustment and service of your oil heating system. This work requires technical training, trade ex perience, licensing or certifi cation in some states and the proper use of special combustion test instruments. Please carefully read and comply with the following in structions: • tact your qualifi ed service agency for consultation. • We recommend annual inspection/service of your oil heating system by a qualifi ed service agency. • • • Hazard Defi nitions • Never store or use gasoline or other fl ammable liquids or vapors near this burner or appliance. Never attempt to burn garbage or refuse in this appliance. Never attempt to light the burner/appliance by throwing burning material into the appliance. Never attempt to burn any fuel not specifi ed and approved for use in this burner. Never restrict the air inlet openings to the burner ! DANGER Indicates an imminently haz ardous situation, which, if not or the combustion air ventilation openings in the room. avoided, will result in death, serious injury, or property damage. ! WARNING Professional Service Required ! WARNING Indicates a potentially hazardous situation, which, Incorrect installation, adjustment, and use of this burner could result if not avoided, could result in death, severe personal injury, and/or substantial property damage. Indicates a potentially haz in severe personal injury, death, or substantial property damage from fi re, carbon monoxide poisoning, soot or explo sion. Please read and understand the manual supplied with this equipment. This equipment must be installed, adjust ed and put into operation only by a qualifi ed individual or ! CAUTION ardous situation, which, if service agency that is: • not avoided, may result in personal injury or • property damage. • Within the boundaries of the hazard warning, • there will be information presented describing consequences if the warning is not heeded and Licensed or certifi ed to install and provide technical service to oil heating systems. Experienced with all applicable codes, standards and ordinances. Responsible for the correct installation and commis sion of this equipment. Skilled in the adjustment of oil burners using combus tion test instruments. instructions on how to avoid the hazard. NOTICE NOTICE Intended to bring special attention to information, but not related to personal injury or property damage. The installation must strictly comply with all applicable codes, authorities having jurisdiction and the latest revi sion 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 the general instructions provided in this installation manual. RWB 6104 BNX R02 Page 3 General Information • Notice Special Requirements General Specifi cations • For recommended installation practice in Canada, Table 1 – Burner Specifi cations Capacity Firing rate: - 0.40 – 1.75 GPH Input: Min. - 56,000 Btu Max - 245,000 Btu refer to the latest version of CSA Standard B139 & B140. Concealed damage — If you discover damage to the burner or controls during unpacking, notify the Certifi cation/ Approvals UL certifi ed to comply with ANSI/UL296 & tested to CSA B140.0 carrier at once and fi le the appropriate claim. Fuels U. S No. 1 or No. 2 heating oil only (ASTM D396) Canada No. 1 stove oil or No. 2 furnace oil only Electrical Power supply - 120 volts AC, 60 Hz, single phase Operating load - 5.8 Amps max Motor - 1/7 hp, 3450 rpm, NEMA 48M frame PSC rotation CCW when When contacting Beckett for service information — Please record the burner serial number (and have available when calling or writing). You will fi nd the serial number on the silver label located on the left rear of the burner. Refer to Figure 1. Inspect/Prepare Installation Site facing shaft end • Ignition - Continuous duty solid-state igniter Clearances to Burner and Appliance Fuel pump Outlet pressure - Note 1 Air tube ATC code - See Table 2 Provide space around burner and appliance for ease of service and maintenance. Check the mini Dimensions (with cover) Height (maximum) - 12-1/2 inches Width (maximum) - 15 inches Depth - 9-1/4 inches Air tube diameter - 3-1/4 inches mum clearances against those shown by the ap pliance manufacturer and by applicable building codes. • *Note 1. See appliance manufacturer's burner specifi cations for recommended outlet pressure. Inspect Chimney or Direct Vent System Adequate Combustion Table 2 – Air Tube Combinations (ATC) ! WARNING and Ventilation Air Supply Firing rate (gph) Head ATC codes for usable air tube lengths: Required Failure to provide adequate air supply could se (min-max) 5" 7" 9" 0.40-1.00 9-Slot NX50LG NX70LG NX90LG 0.40-1.00 6-Slot NX50LH NX50LH NX90LH riously affect the burner performance and result in damage to the equipment, asphyxiation, ex plosion or fi re hazards. 0.40-1.35 9-Slot NX50LB NX70LB NX90LB • 0.40-1.35 6-Slot NX50LC NX70LC NX90LC • 1.10-1.75 9-Slot NX50LD NX70LD NX90LD 1.10-1.75 6-Slot NX50LF NX70LF NX90LF 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 ad equate air for combustion and ventilation. Figure 1. Burner label location Inspect the chimney or vent. Make sure it is prop erly sized and in good working condition. Follow the instructions supplied by the appliance manufactur er. Page 4 RWB 6104 BNX R02 Inspect/Prepare Installation Site Combustion Air Supply Information • • Fuel Line Installation See NFPA Standard 31 for complete details. Appliances located in confi ned spaces: All confi ned spaces should have two (2) permanent openings; one near the top of the enclosure and Do Not Use Tefl on Tape ! CAUTION Damage to the pump could cause impaired burn er operation, oil leakage and appliance soot-up. one near the bottom of the enclosure. Each open •• ing must have a free area of not less than one (1) square inch per 1,000 BTU's per hour of the total input rating of all appliances within the enclosure. The openings should have free access to the build • ing interior, which should have adequate infi ltration from the outside. Never use Tefl on tape on fuel oil fi ttings. Tape fragments can lodge in fuel line components and fuel unit, damaging the equipment and pre venting proper operation. Use oil-resistant pipe sealant compounds. Exhaust fans and other air-using devices: Size air openings large enough to supply all air-using devices in addition to the minimum size required for combustion air. If there is any possibility of the equipment room developing a negative pressure due to exhaust fans, clothes dryers, etc., either pipe combustion air directly to the burner or provide a sealed enclosure for the burner and supply it with Route the fuel line through the opening in the bottom of the burner cover. Continuous lengths of heavy wall copper tubing are recommended. Always use fl are fi ttings. Never use compression fi ttings. Always install fi ttings in accessible locations. To avoid vibration noise, fuel lines should not run against the appliance or ceiling joists. its own combustion air supply. • Fuel Line Valves and Filter Direct/Sidewall Venting Application • Install two high quality fusible-handle design shutoff ! WARNING Connect Outside Air Duct to NX Adapter valves in accessible locations on the oil supply line to comply with the NFPA31 Standard. Locate one close to the tank and the other close to the burner, Failure to install adapter properly could result in impaired combustion, appliance soot-up, puffback of smoke, and fi re or asphyxiation hazards. • The outside air adapter must be installed by strictly following the kit installation instructions. • DO NOT attempt to install outside air piping without using the outside air adapter and instructions pro vided. • Abundant fresh air is required for proper combus tion. For direct vent installations, follow instructions pro vided with appliance and direct vent system. Out side combustion air is required for direct venting. When installing an NX outside air adapter (Beckett Part Number 1014U), refer to the instruction sheet supplied with the adapter. This kit allows combus tion air to be piped directly to the burner. The NX outside air adapter kit may also be used for chim ney vent applications that require outside combus tion air. upstream of the fi lter. Install a generous capacity fi lter inside the building between the fuel tank shutoff valve and the burner, locating both the fi lter and the valve close to the burner for ease of servicing. Filter should be rated for 50 microns or less. NOTICE To further protect the fuel supply system and re duce nozzle orifi ce plugging with fi ring rates below 0.75 gph, a dual fi ltration system can be installed. This typically consists of a 50 micron primary fi lter, located near the fuel tank and a secondary fi lter rat ed for at least 10 microns located near the burner. RWB 6104 BNX R02 Page 5 Inspect/Prepare Installation Site • Prepare the Burner Mount Burner on Appliance • General Verify that the air tube installed on the burner pro vides the correct insertion depth. Refer to Figure 3. In most cases, the burner is ready to mount to the appliance. There can be situations where the burn er needs to be reconfi gured to perform properly in the appliance. Review the appliance manufactur er's specifi cations prior to installing to determine if any modifi cation is required to properly confi gure the burner. Instruction on how to perform the following burner preparation tasks can be found in the Professional Maintenance section. The end of the air tube should normally be 1/4" back from the inside wall of the combustion cham ber. Never allow the leading edge of the retention ring to extend into the chamber, unless otherwise specifi ed by the appliance manufacturer. Bolt the burner to the appliance using the factory welded fl ange. Figure 3. – Mounting Burner in Appliance • Remove / install burner nozzle • Check head/air adjusting plate Low Firing Rate Baffl e (If specifi ed) • The NX Low Firing Rate Baffl e (LFRB), refer to Fig ure 2, reduces the burner airfl ow and pressure. Re fer to the appliance manufacturer's instructions or the Beckett OEM Specifi cation Guide part number 6711. To avoid poor burner performance, do not omit the baffl e when specifi ed or install the baffl e when not specifi ed. Note: The Low Firing Rate Baffl e may have been factory SK9668 • Connect Fuel Lines installed. If fi eld installation is required, insert the Low Fire Rate Baffl e into the housing, aligning the mounting screw hole with the notched hole in the burner housing. Make note that the curved end of the baffl e should be below the motor bolt boss. Tighten the thread cutting screw to 12-24 in-lbs. Do Not Install By-pass Plug with 1-Pipe System ! WARNING Failure to comply could cause immediate pump seal failure, pressurized oil leakage and the po tential for a fi re and injury hazard. • • Figure 2. – Mounting Low Fire Rate Baffl e in burner housing. The burner is shipped without the by-pass plug in stalled. Install the by-pass plug in two-pipe oil supply systems ONLY. Oil Supply Pressure ! Control Required CAUTION Damage to the fi lter or pump seals could cause oil leakage and a fi re hazard. • • • • SK9698 The oil supply inlet pressure to the burner cannot exceed 3 psig. Insure that a pressure limiting device is installed in accordance with the latest edition of NFPA 31. Do not install valves in return line. Gravity Feed Systems: Always install an anit siphon valve in the oil supply line or a solenoid valve (RWB Part # 2182602U) in the pump/noz zle discharge tubing to provide backup oil fl ow cut-off protection. Page 6 RWB 6104 BNX R02 Start the Burner and Set Combustion The burner is supplied with either a one-stage • pump or a two-stage pump based on the oil supply Wiring Connections Diagram system requirements. Consult the instructions pro vided with the pump for installation specifi cations. When installing a one-pipe system, connect the inlet line to the pump inlet. The fuel pump may be installed with gravity feed or lift. The maximum al lowable lift for a single pipe installation is 8 ft. When installing a two-pipe system, remove the 1/16" pipe by-pass plug from plastic bag attached to fuel unit. Remove 1/4" plug from return port. Insert and tighten the by-pass plug. Attach return and inlet lines. The return line should terminate ap proximately 3 to 4" above supply line inlet. Failure to do this may introduce air into the system and could result in loss of prime. Figure 4a. – Typical Burner Control Wiring Refer to the appliance manufacturer's wiring dia gram prior to connecting the burner wiring. All wir ing must be in accordance with the latest revision of National Electric Code NFPA 70 and all local codes and regulations. The R7184 primary control with valve-on delay and burner motor-off delay, shown in Figure 4, requires a constant 120 volt AC power source supplied to the black wire on the control. (Refer to the appli ance manufacturer's instructions.) The red wire goes to the appliance limit circuit. Please note that other control manufacturers may use different wire colors for power and limit connections. Refer to the appliance manufacturer's wiring diagram for actual specifi cations. RWB 6104 BNX R02 Page 7 Start the Burner and Set Combustion Figure 4b. – Typical Burner Sequence of Op eration 1. STANDBY. The burner is idle, waiting for a call for heat. When a call for heat is initiated, there is a 3- 10 second delay while the control performs a safe start check. 2. VALVE-ON DELAY. The ignition and motor are turned on for a 15 second valve-on delay. Start the Burner and Set Combustion WARNING Explosion and Fire Hazard ! Failure to follow these instructions could lead to equipment malfunc tion and result in heavy smoke emission, soot-up, hot gas puff back, fi re and asphyxiation hazards. 3. TRIAL FOR IGNITION (TFI). The fuel valve is • opened. A fl ame should be established within the 15 second lockout time. 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 row, the control enters restricted • lockout. 5. IGNITION CARRYOVER. Once fl ame is estab lished, the ignition remains on for 10 seconds to • ensure fl ame stability before turning off. If the con trol is wired for intermittent duty ignition, the ignition • unit stays on the entire time the motor is running. 6. RUN. The burner runs until the call for heat is sat • isfi ed. The burner is then sent to burner motor off delay, if applicable, or it is shut down and sent to standby. • 7. RECYCLE. If the fl ame is lost while the burner is Do not attempt to start the burner when excess oil has accumulated in the appliance, the appliance is full of vapor, or when the combustion chamber is very hot. Do not attempt to re-establish fl ame with the burner running if the fl ame becomes extinguished during start-up, venting, or adjustment. Vapor-Filled Appliance: Allow the unit to cool off and all vapors to dissipate before attempting another start. Oil-Flooded Appliance: Shut off the electrical power and the oil supply to the burner and then clear all accumulated oil before continuing. If the condition still appears unsafe, contact the Fire Department. Carefully follow their directions. Keep a fi re extinguisher nearby and ready for use. Start-up and Initial Settings 1. fi ring, the control shuts down the burner, enters a 60 second recycle delay, and then repeats the above ignition sequence. If fl ame is lost three times in a 2. row, the control locks out to prevent cycling with repetitious fl ame loss due to poor combustion. 8. BURNER MOTOR-OFF DELAY. The fuel valve is closed and the burner motor is kept on for the se lected motor-off delay time before the control re turns the burner to standby. 3. 4. 5. 6. 61351 Open the shutoff valves in the oil supply line to the burner. Referencing Figure 5a or 5b, verify and/or set the Head/Air Adjustment Pointer to the value speci fi ed by the Appliance Manufacturer. If the Appli ance Manufacturer's values are not available, refer to Table 3a or 3b. (This is an initial air set ting for the pump bleeding procedure only.) Calibrated test instruments must be used for the fi nal head/air adjustment. Adjust the thermostat or temperature controller to call for heat. (Note: return controller(s) to the original settings upon completion of burner instal lation or service.) Close the line voltage switch to start the burner. If the burner does not start within the 3 to 10 second safety start check timing, you may have to reset the safety switch on the burner primary control. Bleed the air from the fuel pump as soon as the burner motor begins rotating. Prepare for combustion tests by drilling a 1/4" sampling hole in the fl ue pipe between the appli ance and the barometric draft regulator. Seal this hole when testing is complete. (See appliance manufacturer's instructions for location.) Page 8 RWB 6104 BNX R02 Start Burner and Set Combustion Figure 5a. – Old Style Head/air Adjustment 7. Plate Scale Check/Adjust Zero Calibration for older style Head/Air Adjustment Mechanism. Refer to Figure 5a. Upper Acorn Nut (Lock Zero Calibration) Pointer Splined Nut Adjustment a. Loosen the splined nut and lower acorn nut approximately one turn. (DO NOT loosen the upper acorn nut. This is used only for setting the zero adjustment.) (See Figure 5a.) b. A 5/16" nut driver or fl at blade screwdriver can be used to turn the adjustment screw for head/air setting. Lower Acorn Nut (Lock Air Setting) Nut SK9667 8. Check/Adjust Zero Calibration for newer style Head/Air Adjustment Mechanism. Refer to Figure 5b. a. b. Figure 5b. – New Style Head/air Adjustment Plate c. d. e. Pointer Zero Setting f. Locking Nut g. h. Adjustment Screw Am52000 Table 3a. – NX Burners NX Air Tube & Head Combinations Slightly loosen the zero setting acorn. Turn the screw until the reading is set to zero. (Mid-point of pointer should line up with zero. Turn the air adjustment screw counterclock wise to adjust the plate with the pointer to the zero position. Slide the nozzle line assembly forward until the retention head engages the fi xed stops in the retention ring at the end of the air tube. Tighten the zero setting acorn nut. The rear door must be closed. The adjustment screw may now be turned clockwise to adjust the head/air setting. Turn the adjusting screw to a setting 1/2 num ber lower than the proper setpoint as indicated in Tables 3a and 3b. Then turn the adjusting screw counterclockwise to the proper setting. Tighten the spline nut after the head/air setting has been adjusted. NOTICE The NX burner has a reduced diam Head/Air Setting LG - (9-slot head) LH - (6-slot head) LB - (9-slot head) LC - (6-slot head) LD - (9-slot head) LF - (6-slot head) eter air tube, precision-designed air throttle cup and combustion head for improved performance. This design 0.5 0.40 – 0.50 -- 1.10 – 1.25 1.0 0.45 – 0.60 -- 1.20 – 1.35 2.0 0.55 – 0.70 0.85 – 1.05 1.30 – 1.45 3.0 0.65 – 0.80 0.95 – 1.15 1.40 – 1.55 4.0 0.75 – 0.90 1.05 – 1.25 1.50 – 1.65 5.0 0.85 – 1.00 1.15 – 1.35 1.60 – 1.75 Table 3b. – NX Burner with Low Fire Rate Baffl e (LFRB) provides very accurate control of the air/fuel ratio, but the light reaching the cad cell through small holes in these components is limited. Be cause of this, the average cad cell resistance may be higher than conventional burners with larger openings. NOTICE InstalledUse factory-set or manufacturer's NX Air Tube & Head Combinations recommended Head/Air Setting Head/Air Setting LG - (9-slot head) LH - (6-slot head) LB - (9-slot head) LC - (6-slot head) LD - (9-slot head) LF - (6-slot head) for 'Starting the Burner and Set ting Combustion'. The Head/Air 0.5 – 0.40 – 0.60 – 1.0 0.40 – 0.55 0.50 – 0.70 1.10 – 1.25 2.0 0.50 – 0.65 0.60 – 0.80 1.20 – 1.35 3.0 0.60 – 0.75 0.70 – 0.90 1.30 – 1.45 4.0 0.70 – 0.85 0.80 – 1.00 1.40 – 1.55 5.0 0.80 – 0.95 0.90 – 1.10 – Settings shown in Figures 3, are provided for reference purposes and represent a general range of rates and settings. Individual ap pliances, vent systems, and fi eld conditions will impact the overall burner set up required for satis factory combustion performance. RWB 6104 BNX R02 Page 9 Trained Service Technician's Regular Maintenance • Set Combustion with Test Instruments Trained Service Technician's Regular 1. Allow the burner to run for approximately 5 to 10 minutes. 2. Set the stack or over-fi re draft to the level speci Maintenance ! WARNING Professional Service Required fi 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 adjustment. • High Effi ciency/Positive Pressure Appliances; also vary from traditional appliances (see manu facturer's recommendations). 3. Follow these fi ve steps to properly adjust the burner: Incorrect installation, adjustment, and use of this burner could result in severe personal injury, death, or substantial property damage from fi re, carbon monoxide poisoning, soot or explo sion. Please read and understand the manual supplied with this equipment. This equipment must be installed, adjust ed and put into operation only by a qualifi ed individual or Step 1: Adjust the head/air until a trace of smoke service agency that is: • is achieved. This can be accomplished by turn ing the screw on the head/air adjustment plate • assembly to increase air (CCW) or decrease air (CW). • 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) Licensed or certifi ed to install and provide technical service to oil heating systems. Experienced with all applicable codes, standards and ordinances. Responsible for the correct installation and commis sion of this equipment. Skilled in the adjustment of oil burners using combus tion test instruments. Step 3: Increase the air to reduce the CO2 by 1.5 to 2 percentage points. (O2 will be increased by approximately 2.0 to 2.7 percentage points.) Ex ample: Reduce CO2 from 13.5% to 11.5% (2.6% to 5.3% O2). Step 4: Recheck smoke level. It should be Zero. This procedure provides a margin of reserve air to accommodate variable conditions. If the draft level has changed, recheck the smoke and CO2 levels and readjust burner, if necessary. Step 5: Once the combustion has been set, tighten the lower acorn nut and splined nut on the air ad justment assembly. See Figure 5. The installation must strictly comply with all applicable codes, authorities having jurisdiction and the latest revi sion 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 the general instructions provided in this installation manual. The following guidelines are provided for routine maintenance. Chimney Vent Systems: Install the burner cover 4. ⑧ and repeat Steps 2 and 4 above. If CO2 increas es (O2 decreases), remove the cover and adjust the air setting so the CO2 (O2) with the cover installed meets the requirements of Step 3. ⑧ Direct Vent Systems with outside air ducted to 5. burner: Install the burner cover. ⑧ Start and stop the burner several times to ensure 6. satisfactory operation. Test the primary control ⑧ and all other appliance safety controls to verify that they function according to the manufactur er's specifi cations. ⑧ Cover Installation • ⑧ Install the four cover mounting thumb screws in 1. the cover mounting plate. ⑧ Install the cover over the mounting plate while 2. ⑧ aligning the side slots with the installed cover mounting screws. Replace the oil supply line filter. The line filter car tridge must be replaced to avoid contamination of the fuel pump and nozzle. Inspect the oil supply system. All fittings should be tight and leak-free. The supply lines should be free of water, sludge and other restrictions. Remove and clean the pump strainer if applica ble. Replace the used nozzle with a new nozzle that conforms to the appliance manufacturer's speci fications. Clean and inspect the electrodes for damage, re placing 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. Page 10 RWB 6104 BNX R02 Trained Service Technician's Regular Maintenance ⑧ Make sure Low Firing Rate Baffle is in place if • required for the burner application. Omitting the baffle can result in unacceptable burner combus tion. ⑧ Inspect all gaskets. Replace any that are dam aged or would fail to seal adequately. ⑧ Clean the blower wheel, air inlet, air guide, reten tion head, throttle cup and throttle ring of any lint or foreign material. Removing Nozzle Line for Service (Refer ence the Replacement Parts Diagram.) ! WARNING Correct Nozzle and Flow Rate Required Incorrect nozzles and fl ow rates could result in impaired combus tion, under-fi ring, over-fi ring, soot ing, puff-back of hot gases, smoke ! WARNING Do Not Puncture, Scratch, or Remove Flame Sight ing Windows 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 manufactur er or Beckett Residential Burner OEM Spec Guide, Part #6711. If a window is punctured, signifi - cantly scratched or removed from the throttle cup, the burner perfor Follow the appliance manufacturer's specifi cations for the required pump outlet pressure for the nozzle, since this affects the fl ow rate. • mance could be impaired, resulting in safety lockout, appliance soot-up, equipment damage, • hot gas puff-back and asphyxiation 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 Use a clean soft cloth and degreaser, on an an • nual basis, to remove any build-up or dark stains from the windows. • If damaged, replace the nozzle line assembly with an assembly that has a windowed throttle cup. than the gph stamped on the nozzle body. (Exam ple: A 1.00 gph nozzle @ 140 psig = 1.18 gph) For typical nozzle fl ow rates at various pressures see ac companying chart. 1. ⑧ Use a clean soft cloth with a degreaser to clean any accumulated soot or oil stains from the throttle cup sight windows. 2. ⑧ Check motor current. The amp draw should not exceed the nameplate rating. 3. ⑧ Check all wiring for secure connections or insula tion breaks. ⑧ Check the pump pressure and cutoff function. 4. ⑧ Check primary control safety lockout timing. ⑧ Check ignition system for proper operation. ⑧ Inspect and clear the vent system and chimney of any soot accumulation or other restriction. 5. ⑧ Clean the appliance thoroughly according to the manufacturer's recommendations. 6. ⑧ Check the burner performance. Refer to the sec tion "Set combustion with test instruments". 7. ⑧ It is good practice to keep a record of the service performed and the combustion test results. 8. Before proceeding, turn off the main power switch to the burner. Remove the burner cover by loosening the four thumb screws (two on each side of burner). Disconnect the copper connector tube assembly from the nozzle line bulkhead fi tting. Loosen the two screws securing the igniter re taining clips and rotate both clips to release the igniter baseplate. The igniter should pop up and be supported by the prop spring. Loosen the two screws securing the rear door. Swing the door to the right and down. Loosen the splined nut. Remove the nozzle line electrode and head as sembly from the burner by drawing it straight back and out the rear door opening. The adjust ment mechanism is still attached. Be careful not to damage the electrodes or insulators while han dling. To replace the nozzle assembly, reverse the above procedure. RWB 6104 BNX R02 Page 11 Trained Service Technician's Regular Maintenance • Nozzle Installation 4. Protect Nozzle from ! Damage CAUTION 5. A damaged nozzle could cause impaired com bustion, sooting, puffback of hot gases, smoke, oil leakage and potential fi re or asphyxiation hazards. Use a 5/8" open-end wrench to carefully remove the existing nozzle. Inspect the nozzle adapter before installing the new nozzle. If it is grooved or scratched on the sealing surface, replace the nozzle line assem bly. If the surface is damaged, oil could leak at the nozzle to adapter joint, causing serious com bustion problems. 6. • Use care when handling, removing and installing oil nozzles. • Carefully follow the guidelines provided in this sec tion. 7. Protect the nozzle orifi ce and strainer when in stalling. If the orifi ce gets dirt in it or is scratched, the nozzle will not function properly. To install a new nozzle, place a 3/4" open-end wrench on the nozzle adapter. Insert the nozzle Perform the following steps when replacing a nozzle. into the adapter and secure fi nger tight. Finish tightening with a 5/8" open-end wrench. Use care 1. Remove the nozzle line assembly to gain access to the nozzle. 2. Use a 3/4" open-end wrench to hold the nozzle adapter. DO NOT attempt to remove or replace the nozzle without securing the adapter, as noz zle alignment could be seriously affected. 3. Do not squeeze the electrodes when handling the nozzle line assembly. Excessive force could change the electrode tip settings or damage the ceramic electrode insulators. Nozzle Flow Rate by Size 8. 9. 10. to avoid bending the burner head support legs or electrodes. Do not over-torque the nozzle when install ing. This will cause deep grooves in the nozzle adapter, preventing a seal when a new nozzle is installed. Carefully check and realign the electrode tips af ter replacing a nozzle, ensuring the electrode set tings comply with Figure 7. If the head was removed when replacing the noz zle, carefully reconnect the head to the nozzle adapter. Make sure to align the key in the support leg with the keyway in the nozzle adapter and to butt the head support to the nozzle adapter Nozzle fl ow rate U. S. gallons per hour of No. 2 fuel oil when pump pressure (psig) is: shoulder, see Figure 8. Nozzle size (rated at 100 psig) 125 psi 140 psi (factory std.) 150 psi 175 psi 200 psi • Check/Adjust Electrodes Check the electrode tip settings, as shown in Fig ure 7. If necessary, adjust by loosening the elec trode clamp screw (Figure 8) and slide/rotate the electrodes as necessary. When the adjustment is 0.40 0.45 0.47 0.49 0.53 0.56 0.50 0.56 0.59 0.61 0.66 0.71 0.60 0.67 0.71 0.74 0.79 0.85 0.65 0.73 0.77 0.80 0.86 0.92 0.75 0.84 0.89 0.92 0.99 1.06 0.85 0.95 1.01 1.04 1.13 1.20 0.90 1.01 1.07 1.10 1.19 1.27 1.00 1.12 1.18 1.23 1.32 1.41 1.10 1.23 1.30 1.35 1.46 1.56 1.20 1.34 1.42 1.47 1.59 1.70 1.25 1.39 1.48 1.53 1.65 1.77 1.35 1.51 1.60 1.65 1.79 - 1.50 1.68 1.77 1.84 - - 1.65 1.84 - - - - 1.75 - - --- complete, securely tighten the clamp screw. Note that if the throttle cup is moved be sure to re position it with no gap between the nozzle adapter and hub. Figure 6. – Electrode tip gap and spacing 5/32" GAP 1/4" above nozzle center 3/32" Nozzle-to-tip Spacing SK9664 Page 12 RWB 6104 BNX R02 Trained Service Technician's Regular Maintenance Figure 7. – Nozzle Line/Head/Air Tube As sembly (Low fi ring rate shown.) Retention Head Electrode Clamp If the zero calibration has not been set, perform the following procedure: Head Support Legs Electrode Tips Nozzle Adapter Nozzle Stops in Retention Ring Retention Ring 1. Electrode Bracket Electrode Insulator Electrode Extension Rods 2. SK9666A Bulkhead Fitting 3. Throttle Cup Nozzle Line Throttle Ring Throttle Ring 4. Throttle Cup Hub SK9666A Install the nozzle line, with the adjustment plate assembly attached, into the burner. Install and tighten the rear door to hold the air adjustment plate assembly in position. Slightly loosen the upper acorn nut, the splined nut, and the lower acorn nut. Turn the air adjustment screw clockwise to adjust the plate with the pointer to the zero position. 5. Check Retention Head Alignment and • Cad Cell Sighting (Refer to Figure 8.) The cad cell sighting holes in the throttle cup and the retention head must be aligned to allow the cad 6. cell to detect the fl ame. Make sure the stamped key in the retention head collar lines up with the keyway 7. in the nozzle adapter when mounting the retention head. Note that in specifi c applications, the reten tion head may not have a sighting hole. 8. • Check/Adjust "Zero" Calibration On burners with factory-installed air tubes, the zero calibration has been factory set. Make sure the retention head (Figure 8) is securely against 9. the stops in the retention ring when the adjustment plate pointer is at "0" (Figure 5). Referring to Figure 8, slide the nozzle line as sembly forward until the retention head engages the fi xed stops in the retention ring at the end of the air tube. Tighten the upper acorn nut securely. The rear door must be kept tightly closed. The adjustment screw may now be turned to adjust the head/air setting. Turn the adjusting screw to a setting that is 1/2 number lower than the proper set point as indi cated in Table 1. Then turn the adjusting screw counterclockwise to the proper setting. Tighten the splined nut and lower acorn nut after the head/air setting has been adjusted. Figure 8 – Retention Head/Throttle Cup Alignment *  RWB 6104 BNX R02 Page 13 • Blower Wheel Replacement For installation or replacement of a blower wheel, insure that there is a space between the blower wheel and the motor face of 0.115". Refer to Figure 9. Figure 9. – Blower wheel assembly SK9670 Page 14 RWB 6104 BNX R02 Replacement Parts Diagram For best performance specify genuine Beckett replacement parts Replacement Parts List SK967101 Item Description Part No. 1 Air guide 101101U Item Description Part No. 17 Igniter, electronic 51771U 2 Head/Air adjustment mechanism assembly 51794U 18 18a Gasket, Igniter Kit Gasket, igniter baseplate 51942U 3 Splined nut 3666 4 Coupling 2454 18b 18c Gasket, wiring hinge Gasket, igniter baseplate 5 CleanCut Fuel Pump, (Includes Mounting Screws ¼ -20 x 2184404U 18d hinge Gasket, rear access door 7/8" - Part # 4189) 6 Connector tube assembly, 11" 51127 7 Inlet air box 1010U 8 Inlet air louvers 1013U 9 Inlet Air Adapter, Outside air kit 1014U 19 Low Fire Rate Baffl e (per specifi ca tion) 20 Primary control R7184P Valve-on/Motor Delay R7184P With Alarm Contacts 21 PSC Motor, 32229U 7457U 7458U 21805U 10 Retention head assembly, 6 -slot * 11 Retention head assembly, 9 -slot * 12 Air tube combination, (Includes Screws, air tube mount ing #8 x 3/8 - Part # 4396) 51785U 51815U Specify (Requires Mounting screws ¼ -20 x 7/8" - Part # 4189) 22 Electrical box 5770 23 Blower wheel 2999U 24 Door, rear access 32119U 25 Cover, Burner 51812U 26 Mounting Plate, Burner Cover 32103U 13 Heat Shield (per specifi cation) Specify 27 Thumbscrews, Cover mounting 21899U 14 Nozzle Line Electrode and Head Assembly, with window Specify * For retention head assemblies that do NOT have a sight 15 Electrode insulator kit 51811U 16 Spring, igniter prop 32058U ing hole, contact Beckett's customer service for appropri ate part number. RWB 6104 BNX R02 Page 15 Limited Warranty InformationLimited 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 The Oilheat Manufacturers' Association supports the use of low sulfur fuels as defi ned by ASTM D396, Grades No. 1 Low Sulfur and No. 2 Low Sulfur, as the preferred heating fuel for the following reasons: • Low sulfur fuels reduce deposits on heat exchanger surfaces, extending the service interval between cleanings. • The reduced deposits increase the effi ciency of the appliance. • Low sulfur fuels reduce particulate emissions. • Low sulfur fuels reduce oxides of nitrogen emissions. 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 Form Number 6104 BNX R02 Printed in the U.S.A. Jan. 2007 Page 16 RWB 6104 BNX R02