Beckett Model AF Oil CF 1400, homeappliance

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MODEL2300AOilBurner MODEL CF Instruction Manual Low/High Operation Firing rate: 7.0 – 19.9 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. 23 00 Instruction Manual – Model CF2300A 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 BCF-23-R0399 Instruction Manual – Model CF2300A Oil Burner Warranty 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 7.0 to 19.9 GPH Motor ¾ HP 3450 RPM 120/60 hz standard 12.5 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. 90 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. Contents 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 setup. 1–800–OIL–BURN — Beckett's technical services hot-line. www.beckettcorp.com — Beckett's website. Form 6104 BCF-23-R0399 3 Instruction Manual – Model CF2300A 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. When fuel supply is level with or higher than burner 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. • The fuel unit is shipped with the by-pass plug installed. Leave the by-pass plug installed for all low/high firing burners, regardless whether one-pipe (with by-pass loop) or two-pipe. See Figure 8 for installation of the by-pass loop required for one-pipe fuel supply installations. See Figure 9 for connections to the fuel unit for two-pipe fuel supply installations. When fuel supply is below the burner 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 CF2300A • 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 (high fire rate). Select the corresponding nozzle from column 1 (Rated gph @ 100 psig). Table 1 – Nozzle capacities at various pressures Rated gph @ 100 psig Pressure - pounds per square inch 125 150 175 250 275 300 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 9.00 10.06 11.02 11.91 14.23 14.92 15.59 10.00 11.18 12.25 13.23 15.81 16.58 17.32 11.00 12.30 13.47 14.55 17.39 18.24 19.05 12.00 13.42 14.70 15.87 18.97 19.90 20.78 4 Form 6104 BCF-23-R0399 ❏ Verify firing rate Instruction Manual – Model CF2300A 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 maximum recommended firing rate for the burner depends on the length of the firing chamber and the distance from G 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. D ❏ Verify air tube • The information in this section may be disregarded if the air tube is supplied by the appliance manufacturer. T 2° 1 F E Insertion depth G Air tube to inside of chamber – 0.25" ± 0.125" T Air tube length D Tube diameter • Two tube arrangements are available – Tube KG — 7.0 to 19.9 GPH per Table 2 Tube KS — 10.0 to 19.9 GPH per Table 2 • 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 KS only when Tube KG cannot provide 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 E 2304 ① Install the burner with a 2° pitch as shown. A.T.C. Codes (A.T.C. = Air Tube Combination) Tube KG Tube KS (Dim T) (Dim D) (Dim F) (Dim T) (Dim D) (Dim F) All — 6¹⁄₂" 2¹⁵⁄₁₆" All — 8¹⁄₈" 3¹¹⁄₁₆" 6¾" CF 66 KG 6¾" CF 66 KS — — 8¾" CF 86 KS 10¼" CF 102 KG 11" CF 110 KS 13¾" CF 136 KG 14½" CF 144 KS 17¾" CF 176 KG 18½" CF 184 KS Table 2 – Air tube capacity vs. firebox pressure L A 2305 Firebox pressure (In. w.c.) Tube KG Tube KS No reserve air 10% turndown No reserve air 10% turndown 0.0 19.9 GPH 19.9 GPH 19.9 GPH 19.9 GPH 0.2 19.2 GPH 19.1 GPH 19.7 GPH 19.6 GPH 0.4 18.5 GPH 18.3 GPH 19.5 GPH 19.3 GPH 0.6 17.9 GPH 17.6 GPH 19.4 GPH 19.1 GPH 0.8 17.2 GPH 16.8 GPH 19.2 GPH 18.8 GPH 1.0 16.5 GPH 16.0 GPH 19.0 GPH 18.5 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 5 to 10 gph 8.0" 35.0" 8.0" 40.0" 10 to 15 gph 9.0" 40.0" 9.0" 50.0" 15 to 20 gph 11.0" 55.0" 11.0" 60.0" Form 6104 BCF-23-R0399 5 Instruction Manual – Model CF2300A 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. Predrill 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. Remove the flange-mounting stud nuts and remove the air tube from the appliance. Figure 3 – Mount flange(s) on air tube Figure 4 – Nozzle and nozzle line assembly S Q P R Critical dimensions — 2306-1 2306-2 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" ce abd ❏ 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 2312 • 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 overtighten. • 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 BCF-23-R0399 Instruction Manual – Model CF2300A 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 2308-1 c Legend (Figures 5 and 6) a Adjusting plate assembly 2308 ❏ 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. 2324 • 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. Figure 7 – Burner installed in appliance front 1¾" D 2303 Legend H Housing total length — 18½" H K J a b c ❏ Insert burner • Position the burner in the front of the appliance and loosely tighten the nuts on the mounting studs. The burner should be pitched downward 2° as shown in Figures 3 and 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 — 10½" K Overall housing height — 15⁵⁄₈" screw to the pipe. Form 6104 BCF-23-R0399 7 Instruction Manual – Model CF2300A 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 substan Figure 8a – One-pipe oil flow, low fire, "H" pump g tial property damage due to leakage of oil and potential fire hazard. • Use only flare fittings at joints and con nections. 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 d 125 psig to 175 psig f c c p e m 300 psig b a unit. • Never use a one-pipe oil system with a lift in excess of 8 feet with a B fuel unit, or 2 feet with an H fuel unit. On two-pipe oil systems, verify that the suction line vacuum does not exceed the fuel unit manufacturer's recommendation. Field-installed by-pass loop Figure 8b – One-pipe oil flow, high fire, "H" pump 2310a ❏ Fuel unit by-pass plug • The CF2300A burner is shipped with a by-pass plug in stalled in the fuel unit. For low/high operation, the by pass plug must be left in the fuel unit, regardless of the fuel system used (one-pipe with by-pass loop or two pipe). Do not remove the by-pass plug. Do not operate the burner unless a return line or by-pass loop is installed. Failure to follow this guideline will cause damage to the fuel unit seals and consequent fuel leakage. This could result in severe personal injury, death d 300 psig f c c e 300 psig b Field-installed by-pass loop a g p m 2310b or substantial property damage. ❏ One-pipe oil system by-pass loop • Refer to Figure 8 (item m). Note the addition of a field installed by-pass loop (use ³⁄₈" copper tubing) from the fuel unit Return port to the Inlet port. This line is required for low/high operation. It simulates the flow of a two-pipe system at the fuel unit. Figures 8a and 8b are for type H Figure 8c – One-pipe oil flow with "B" pump f h d c c g b p a fuel units. Figure 8c is for a type B fuel unit. ❏ Oil supply/return lines 300 psig high fire 2320a 125 to 175 psig low fire Legend (see opposite page) Field-installed by-pass loop m • 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 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. 8 Form 6104 BCF-23-R0399 Instruction Manual – Model CF2300A Oil Burner Figure 9a – Two-pipe oil flow, low fire, "H" pump • Use continuous lengths of heavy-wall copper tubing, routed under the floor where possible. Do not attach fuel lines to the appliance or to floor joists if possible. This d 125 psig to 175 psig f c c e 300 psig g b pa reduces 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 shutoff valves in accessible loca tions on the oil supply line. Locate one valve close to the tank. Locate the other valve close to the burner, upstream of the fuel filter. ❏ Burner fuel flow k Figure 9b – Two-pipe oil flow, high fire, "H" pump c c 300 psig d b 300 psig a f e k Figure 9c – Two-pipe oil flow with "B" pump f h 2313a g p 2313b • One-pipe systems – See Figure 8 for the fuel flow paths for high-fire and low-fire operation. Figures 8a and 8b are based on type H fuel units, with external by-pass pres sure regulator. The low-fire by-pass regulation is done in ternally for type B fuel units, shown in Figure 8c. Oil supply connects to one of the fuel unit Inlet ports. • Two-pipe systems – See Figure 9 for the fuel flow paths for high-fire and low-fire operation. Figures 9a and 9b are based on type H fuel units, with external by-pass pres sure regulator. The low-fire by-pass regulation is done in ternally for type B fuel units, shown in Figure 9c. Oil supply connects to one of the fuel unit Inlet ports. Oil return connects to the fuel unit Return port. • Low-fire/high-fire operation – The fuel unit nozzle port pressure is factory set at 300 psig. • At high fire, full pressure (300 psig) is applied at the oil nozzle, causing full input. • At low fire, the by-pass valve (item e) opens. For type H fuel units, this allows oil to by-pass the nozzle path through the external by-pass pressure regulator (item f). For type B fuel units, the by-passing is done inside the fuel unit when the by-pass valve operates. c c g d b p a • The by-pass oil flow is returned to the fuel unit Inlet port for type H fuel units. • This by-passing of oil reduces the oil pressure at the nozzle (to between 125 psig and 175 psig), reducing the input. 300 psig high fire k 125 to 175 psig low fire 2323a Legend (for Figures 8a, 8b, 8c, 9a, 9b and 9c) Table 3 – Fuel unit gearset capacities Fuel unit model number Gearset capacity (gallons per hour) B2TA8852 39 H4PAN-C151H 69 a Return port b Nozzle port c Oil valves d Nozzle & adapter e By-pass valve ("H" pump) f By-pass pressure regulator g Inlet port h By-pass valve ("B" pump) k Return line to oil tank m One-pipe by-pass loop, ³⁄₈" p Air bleed valve Form 6104 BCF-23-R0399 9 Instruction Manual – Model CF2300A Oil Burner Wire the burner Do not by-pass any safety control. By-passing a safety control could result in severe personal injury, death or substantial property damage. Install the burner and all wiring in accordance with the National Electrical Code and all applicable local codes or requirements. Wire the burner in compliance with all instructions provided by the appliance manufacturer. Verify operation of all controls in accordance with the appliance manufacturer's guidelines. See Figure 10 for a typical wiring diagram, with R8184 oil primary, for reference purposes only. The CF2300A 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. NOTE: The wiring in Figure 10 is for an R8184 primary control and a type B fuel unit (using internal by-pass pressure regulator as shown in Figures 8c and 9c). The difference in fuel units is the connection of by-pass oil valve S2 to the damper-motor end switch. When using a type H fuel unit, the by-pass oil valve wire is connected to terminal "W" instead of terminal "B" on the end switch because the by-pass pressure regulation is external to the fuel unit. 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 Optional delay timer TR Ignition transformer M1 Burner motor S1 Primary oil valve S2 By-pass oil valve S3 Redundant oil valve DM Damper motor and end switch ∗ H/L Insert high/low-fire control here LFHS Low-fire hold switch 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 S3 S1 WH DM LFHS H/L T–T 24-volt thermostat/limit terminals S2 DM W Note 1 F-F Cad cell flame sensor terminals Electrical shock hazard - can CC F F R B BK M1 WH cause injury or death. Disconnect power before installing or servicing. Provide ground wiring to the burner in accordance with the National Electrical Code. WH Note 1 Wiring to damper motor end switch shown for type B fuel unit. For type fuel unit, connect wire to H WH 2311 10 Form 6104 BCF-23-R0399 Instruction Manual – Model CF2300A Oil Burner Sequence of operation — typical NOTE: The following sequence is based on using a type B fuel unit, with pump-mounted by-pass valve. The by-pass valve operation is reversed for a type H fuel unit. That is, the by pass valve is powered at low fire instead of being powered at high fire. 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 pressure is delivered to the oil valve inlets. 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, oil valves (S1 and S3) are activated, allowing oil to flow to the nozzle. 4. With the low-fire hold switch (LFHS) in the "IN" position, the burner will remain at low fire. With no power applied to the by-pass valve (S2), oil by-passes internally in the fuel unit, reducing the pressure sent to the oil nozzle. 5. When the low-fire hold switch is moved to the "OUT" position, the damper motor (DM) will be activated. This will begin opening the air damper. 6. When the damper motor end switch is tripped, oil valve (S2) is activated, stopping by-pass flow inside the fuel unit and providing full pressure (300 psig) at the oil nozzle. The burner is now at high fire. The damper motor end switch is set to operate before the damper has reached full open to assure a smooth transition to high fire. 7. If a high/low-fire control is installed at H/L, this control will cycle the firing rate automatically during an operat ing cycle. 8. 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. 9. When the call for heat signal terminates (at the black wire of the R8184), the R8184 terminates power to all circuits, closing the oil valves 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 and external by-pass loop — from Return port to pump Inlet — have been installed for one pipe oil systems. By-pass plug is installed for two-pipe oil systems. ❏ 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 shutoff 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 BCF-23-R0399 11 Instruction Manual – Model CF2300A 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) Figure 11 – Adjusting plate initial setting, typical d e f h b c g 9 8 7 6 5 Legend 2307 • 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 (high-fire). • Figure 11 shows a typical example, with a head setting of b Spline nut for securing nozzle line c Bottom acorn nut (for head adjust ments d Top acorn nut (for setting dim. Z only — do not loosen after setting Z) e Indicator adjusting plate f Secondary adjusting plate g Primary adjusting plate h Copper oil line from oil valve to nozzle line 5. • 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 low-fire 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 low-fire rate. • This initial setting should be adequate for starting the burner at low fire. Once the burner is in operation, the air setting will be adjusted for best performance as discussed later in this manual. • The damper moves to high-fire position as the damper rod (item d) rotates the damper linkage arm (item f). You will adjust the setting of the damper linkage arm when setting the high-fire air as discussed on page 14 in Start the burner. • Follow the procedures given later in this manual for fine tuning the air settings. ❏ Set appliance limit controls • Set the appliance limit controls in accordance with the appliance manufacturer's recommendations. • Move the low-fire hold switch (not shown) to the "IN" position. This will hold the burner in low fire during initial start-up. ❏ 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. Table 4 – Initial indicator adjustment plate settings (head position) Approximate head settings Firing rate, gph Tube "KG" Tube "KS" 0 11.00 12.50 1 12.00 13.00 2 13.00 14.00 3 14.00 15.00 4 15.00 16.00 5 16.00 17.00 6 17.00 18.00 7 18.00 18.50 8 19.00 19.00 9 20.00 20.00 12 Form 6104 BCF-23-R0399 Instruction Manual – Model CF2300A Oil Burner Figure 12 – Air damper and damper motor assembly a b CLOSE OPEN d b d c a h CLOSE e f g 5 6 7 8 9 10 11 4 3 2 1 0 k 12 m 2309-1 Table 5 – Initial air adjusting plate settings (damper position) Approximate adjusting plate settings Firing rate, gph Tube "KG" Tube "KS" 0 -- -- 1 7.00 10.00 2 10.00 11.00 3 13.00 13.00 4 14.00 14.00 5 15.00 16.00 6 16.00 17.00 7 17.00 18.00 8 18.00 18.50 9 19.00 19.00 10 20.00 20.00 2309-2 Legend (Figure 12) a Damper motor – do not adjust internal cam b Arm assembly c Ball joint assembly – do not adjust position of ball joint d Damper rod e Damper rod guide f Damper linkage arm - sets high-fire air position g Damper h Damper label - position indicator for air adjusting plate k Damper indicator - permanently attached to damper m Air adjusting plate - sets low-fire air position Form 6104 BCF-23-R0399 13 Instruction Manual – Model CF2300A 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 reestablish 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. Damper motor and motor arm assembly - Do not attempt to adjust the cam setting in the damper motor. It is factory preset. Do not move the ball joint assembly further out on the motor arm assembly. This would change the timing of damper opening versus fuel rate. The damper linkage arm screw must be tightened securely to assure the damper will provide sufficient air at high fire. Failure to comply could cause unreliable combustion or flame failures, leading to possible severe personal injury, death or substantial property damage. ❏ Start burner and vent air from oil line 1. Move the low-fire hold switch to the "IN" position (to hold burner in low fire when started). 2. Verify that the air adjusting plate (Figure 12, item m) has been set to the initial low-fire air position as described on page 12 under Initial air settings. 3. Loosen the screw on the damper linkage arm (Figure 12, item f) and allow the damper indicator (Figure 12, item k) to rest on the air adjusting plate (Figure 12, item m). 4. Open the oil shutoff 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 high-fire air. ❏ Set high-fire air 1. Allow the burner to run at low fire 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, in crease the amount of air by readjusting the damper indi cator to a higher number. 3. Once the appliance has warmed, the high-fire setting can be checked and adjusted. 4. Locate the approximate air adjusting plate setting for high fire in Table 5, page 13. 5. Place the low-fire hold switch in the "OUT" position. The damper motor will begin to rotate. a. At the same time, loosen the screw securing the air adjusting plate (Figure 12, item m) as the damper be gins to move. 14 Form 6104 BCF-23-R0399 Instruction Manual – Model CF2300A Oil Burner b. Slowly rotate the air adjusting plate (increase the amount of air) as the damper drives to high-fire. c. Lock down air adjusting plate at the high-fire air set ting found in Table 5 for the high-fire rate. 6. 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. A margin of reserve air has been added to accommo date variable conditions. 7. Check the breech draft pressure against the appliance manufacturer's recommended setting (typically + 0.1" W.C.). 8. 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. Adjust burner air if necessary. 9. Once all settings are complete and satisfactory, rotate the damper linkage arm (Figure 12, item f) until it touches the damper rod (Figure 12, item d) and tighten the damper linkage arm screw securely. ❏ Set low-fire air 1. Loosen the air adjusting plate (Figure 12, item m) screw and set the air adjusting plate at the low-fire air setting found in Table 5, page 13. The damper should stay at the high-fire setting. The damper linkage will prevent move ment of the damper plate. 2. Move the low-fire hold switch from the "OUT" to the "IN" position. a. The damper will return to the low-fire air setting. 3. Check the smoke and CO2 (O2) levels. a. Pull a smoke sample from the flue. b. The sample should be clean (zero smoke level). c. Check the CO2 (O2) level: CO2 should be at 11 to 12% (O2 at 5.9 to 4.5%). If the CO2 is less than 11% (O2 more than 5.9%), decrease the air and check the smoke level. 4. Operate the burner from low fire to high fire and back to verify operation. 5. Turn the burner off. Wait one or two minutes (for chamber to clear) and then turn on again to verify starting charac teristics. 6. Perform limit circuit performance test specified by appli ance manufacturer to verify operation of burner/appli ance combination. 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 at low and high fire and verify air damper settings. ❏ Test oil supply line vacuum - verify that it is within al lowable range indicated in fuel unit literature. ❏ Check pump pressure to nozzle at low and high fire. ❏ Inspect fuel system (including tank, lines and all connec tions). ❏ 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 any obstruc tions. ❏ Check the 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 BCF-23-R0399 15 Instruction Manual – Model CF2300A Oil Burner Replacement parts 1 2 4 5 3 12 13 14 17 18 7 9 6 8 21 22 23 24 SU NC TE 27 15 10 H 11 fuel unit 15 25 See detail of type fuel unit at left Type fuel unit with pump B B mounted by-pass valve 16 19 20 26 2315 Item Part name Description Part number 1 2 3 4 5 6 7 8 9 Air tube Flange kit Damper motor assemblyElectrode assembly Ignition leads Nozzle line assembly Head assembly Pressure regulator Fuel lines Specify burner model and tube length (See Figure 2, page 5 for codes) Adjustable flange See Figure 13 All models 51229 All models 51212 8 ¼" long 5990082 11 ¾" long 5990116 15 ¼" long 5990152 19 ¼" long 5990192 Specify burner model and air tube length CF2300A 51203 Not used with B pump 21319 Specify length Figure 13 – Adjustable mounting plates for CF2300A Kit #51630 16" Diameter Item 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Part name Damper linkage armDamper spring Timer Adjusting plate assembly All modelsKnurled nut Fuel pump Pedestal kit Oil valve Damper door Damper indicator Coupling Sight glass Rear cover assemblyControl Transformer Motor Blower wheel Solenoid (by-pass) valve Motor relay (not shown) Description Part number All models 5984BK All models 4339 Low/high rate 21252 Nozzle valve delay 21295 51213 All models 3666 Specify B or H All models 51193 Box mounted 7201 All models 16703GY All models 5985BK Specify pump used All models 31346 CF2300A 51204 Specify 12,000 volt 51214 Specify burner model CF2300A 6.75" x 3.125" 21267 Specify valve used Specify relay used Kit #51313 12.44" Diameter Kit #51498 13.92" Diameter 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 BCF-23-R0399