Beckett ADC 24Vdc User Manual

24Vdc Oil Burner Manual

CORPORATION

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:

y Please read and carefully follow all instructions

provided in this manual regarding your responsibilities
in caring for your heating equipment.

y Contact a professional, qualifi ed service agency for

installation, start-up or service work.

y READ THESE INSTRUCTIONS AND SAVE FOR

REFERENCE.

To the Professional, Qualifi ed Installer or Service
Agency:

y Please read and carefully follow all manual instructions

and any supplements provided, before installing,
starting, or servicing this burner or heating system.

y The Installation must be made in accordance with all

state and local codes having jurisdiction.

Contents

Burner Application Scope and Intended Use ...........2

Prepare Before Installing ............................................ 3

Notice Special Requirements.............................................3

Specifi cations .....................................................................3

Hazard Defi nitions

Indicates a hazardous situation,
which, if not avoided, will result

in death or serious injury.

General Information ....................................................4

A. Equipment Located in Confi ned Space ......................... 4

B.

Exhaust Fans and Other Air-Using Devices. ...................... 4

C. Clearances to Burner and Equipment ...........................4

D. Exhausting Hazardous Fumes ......................................5

E. Low Firing Rate Baffl e. ..................................................5

Nozzle Assembly Maintenance .................................. 5

A. Replace the Burner Nozzle............................................5

B. Check/Adjust Electrodes ...............................................5

C. Igniter Maintenance .......................................................5

D. Servicing Nozzle Line Assembly ...................................6

E. Check/Adjust “Z” Dimension ..........................................6

Fuel Supply ..................................................................7

A. Connect Fuel Lines........................................................7

B. Fuel Supply Level with or Above Burner........................7

C. Fuel Supply Below Level of Burner ...............................7

D. Fuel Line Replacement (Remote Tank Only) ................7

E. Fuel Line Valve and Filter ............................................. 7

Burner Wiring ...............................................................8

A. Burner installed on equipment .......................................8

B. Burner Replacement......................................................8

Drive Component Maintenance .................................. 9

A. Motor, Blower Wheel, and Coupling Replacement ........9

B. Pump Maintenance........................................................9

C. Valve Coil and Stem Replacement ..............................10

Indicates a hazardous situation,
which, if not avoided, could

result in death or serious injury.

Indicates a hazardous situation,
which, if not avoided, could

result in minor or moderate injury.

Within the boundaries of the hazard warning, there will
be information presented describing consequences if the
warning is not heeded and instructions on how to avoid
the hazard.

Intended to bring special attention
to information, but not related to

personal injury or property damage.

Start Up Burner & Set Combustion .......................... 11

A. Basic Burner Operation ............................................... 11

B. Combustion Set-up ...................................................... 11

C. Set Combustion with Instruments................................ 11

Maintain & Service Burner ........................................ 12

A. Owner’s Information ....................................................12

B. Owner Service and Maintenance ...............................12

Extended Down Time ....................................................... 12

Regular Service/Maintenance ..........................................12

Troubleshooting ........................................................13

Replacement Parts ....................................................15

Limited Warranty Information ..................................16

2

Burner Application Scope

and Intended Use

The ADC burner is designed for use in road
maintenance equipment applications that
have DC voltage charging systems capable of
sustaining the specifi ed voltage requirements.
For other equipment applications, please contact
Beckett Technical Services at 1-800-645-2876.

Section: Prepare Before Installing

Prepare Before Installing

Owner’s Responsibility

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 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
experience, licensing or certifi cation in some states and
the proper use of special combustion test instruments.

Please carefully read and comply with the following
instructions:

y Never store or use gasoline or other fl ammable liquids

or vapors near this burner or appliance.

y Never attempt to burn garbage or refuse in this

appliance.

y Never attempt to light the burner/appliance by throwing

burning material into the appliance.

y Never attempt to burn any fuel not specifi ed and

approved for use in this burner.

y Never restrict the air inlet openings to the burner or

the combustion air ventilation openings in the room.

Impaired Burner Performance
and Fire Hazard.

Do NOT operate the burner beyond specifi cations
outlined in the table to the right.

y For applications beyond these limits, consult Beckett

Technical Service at 1-800-645-2876.

y NOTE: Some packaged appliances with burners

may be agency listed as a unit to operate beyond
these limits. Consult the appliance manufacturer’s
specifi cations and agency approvals for verifi cation.

Notice Special Requirements

If you discover damage to the burner
or controls during unpacking, notify

the carrier at once and fi le the appropriate claim.

Specifi cations

See ‘Adequate Voltage Required’ warning on page 4

Rated Voltage: 27Vdc (Nominal Charging System Voltage)
Reference Voltage: 24V DC (Battery Discharge Voltage)

Capacity Firing Rate (27V): 0.75 – 3.00 GPH

Input: 105,000 - 420,000 Btu/h

Firing Rate (24V)*: 0.75 - 2.50 GPH
Input: 105,000 - 350,000 Btu/h

Fuels USA: No. 1 or No. 2 diesel fuel or kerosene;

No.1 or No. 2 heating oil (ASTM D396)

DO NOT USE GAS-

OLINE, CRANKCASE OIL, OR ANY
OIL CONTAINING GASOLINE.

Electrical Burner Voltage (nominal): 27 Vdc

Voltage Range: 21.6V - 28V

Operating Load
w/ igniter on: 9 Amps

w/ igniter off: 6 - 8 Amps

Motor Voltage (nominal): 27Vdc
Voltage Range: 21.6V - 30V

Full Load Amps: 6.1 Amps
Starting Amps: 50 Amps
1/7 HP, 3500 RPM, NEMA “M” Flange

Igniter Voltage (nominal): 24Vdc
Voltage range: 21.6V - 32V

Current: 1.2 Amps
Ign. Secondary: 19kVpk 35mA
Interrupted OR intermittent duty

Valve Coil Voltage: 24 Vdc
Current: < 0.5A

Pump Outlet pressure: Note 1

Dimensions Height (maximum): 11 ½ inches

Width (maximum): 14 3/8 inches
Depth (chassis only): 6 9/16 inches
Air tube diameter: 4 inches

Ambient
Operating
Temperature

*Firing rate capacity is based on airfl ow volume. In the ADC burner, airfl ow
volume and motor speed are proportional to the DC voltage. This results in a
lower maximum fi ring rate at 24V.

Note 1. See equipment manufacturer’s burner specifi cations for recommended
outlet pressure. Pressure is 100 psig unless otherwise noted.

+32° F. (0° C.) Minimum
+115° F. (+46° C.) Maximum
(See Warning on Impaired Burner
Performance and Fire Hazard.)

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. See Figure 1.

24 Vdc ADC Burner Manual

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 the burner capacity
2% for each 1,000 feet above the 2,000 feet.

3

Section: General Information

Adequate Voltage Required

A low or erratic power supply could result in impaired
burner operation, severe delayed ignition or an
explosion inside the heat exchanger resulting in a
burn and/or asphyxiation hazard.

y The Model ADC requires a continuous supply of 21.6 to

28 volts DC measured at the burner during operation with
a minimum supply & circuit capacity of 15A. See page 3
for maximum capacity and voltage specifi cations.

y An automotive or small engine charging system that is

capable of supplying the required continuous voltage/
amperage is recommended with certain road equipment,
such as asphalt hot patchers and similar applications.

y This is especially true while maintaining nominal load

temperatures during idle periods.

y Once the burner is set-up at a specifi c voltage, a voltage

regulator shall be used to maintain that voltage within
+/- 1 Vdc during burner operation.

Adequate Combustion
and Ventilation Air Supply
Required

Failure to provide adequate air supply could seriously
affect the burner performance and result in damage to
the equipment, asphyxiation, explosion or fi re hazards.

y The burner cannot properly burn the fuel if it is not

supplied with a reliable combustion air source.

y Follow the guidelines in the latest editions of the NFPA

31 and CSA-B139 regarding providing adequate air
for combustion and ventilation.

Table 1. Low Firing Rate Baffl e

Head Type

F3 up to 0.85 gph

F4 or F6 up to 0.90gph

Low Firing Rate Baffl e (if specifi ed)

General Information

Refer to the Troubleshooting section of this manual when
experiencing a possible fault condition.

A. Equipment Located in Confi ned Space

The confi ned space should have two permanent openings:
one near the top of the enclosure and one near the
bottom of the enclosure. Each opening shall have a free
area of not less then one square inch per 1,000 BTU’s
per hour of the total input rating of all equipment within
the enclosure. The openings shall have free access to the
building interior, which should have adequate infi ltration
from the outside.

B.

Exhaust Fans and Other Air-Using Devices.

Size air openings large enough to allow for all air using
devices in addition to the minimum area required for
combustion air. If there is any possibility of the equipment
room developing negative pressure (because of exhaust
fans, for example), either pipe combustion directly to the
burner or provide a sealed enclosure for the burner and
provide it with its own combustion air supply.

C. Clearances to Burner and Equipment

Provide space around burner and equipment for easy
service and maintenance. Check minimum clearances
against those shown by the equipment manufacturer and
by applicable codes.

Table 2. Air Tube Combination (ATC) Codes

Firing

Rate
GPH

Head

min-max inches 4-1/2 5-3/8 6-5/8

0.75 - 1.25 F3 2-3/4 AF44XNDC AF53XNDC AF65XNDC

0.85 - 1.35 F4 2-3/4 AF44WHDC AF53WHDC AF65WHDC

0.85 - 1.65 F6 2-3/4 AF44YBDC AF53YBDC AF65YBDC

1.10 - 2.00 F12 2-3/4 AF44XODC AF53XODC AF65XODC

1.65 - 2.50 F22 2-3/4 AF44XPDC AF53XPDC AF56XPDC

2.50 - 3.00 F31* 2-3/4 AF44XVDC AF53XVDC AF56XVDC

*See page 3 for capacity and voltage specifi cations.

Static

Plate

Size

ATC Codes for Usable Air

Tube Lengths:

(‘A’ in inches see Fig. 2)

Figure 1. Typical Burner Nameplate

General Model Information

Serial Number

Including Date Code

Rating Information

Primary Group

and Fuel Oil

4

R.W. Beckett
Manufacturer’s Settings

R.W. Beckett Specification
Number and Revision

Can Be Customized by
Individual Specification

State & Local Approvals

RWB

Model " AFG "
Series Oil Burner

000405-62736

R.W.Beckett Corp.

ELYRIA

OHIO U.S.A.

MFR'S SETTINGS

ATC:

AF65XN

FIRING RNG:

0.75-1.35 GPH
F3HEAD:

SERIAL NUMBER

STC PLT:

2-3/4U

NOZZLE:

1.0 X 80B DLVN

PUMP PRS: 100 PSI

BJB3001 R00
000405-62736

Elyria, Ohio

Made in the U.S.A.

SK10090

Section: Nozzle Assembly Maintenance

D. Exhausting Hazardous Fumes

See warning on this page. Also be conscious of any fumes
produced by the materials that are being heated. Always
ensure adequate ventilation to exhaust all fumes.

E. Low Firing Rate Baffl e.

The low fi ring rate baffl e (See LFRB in Replacement Parts)
reduces the air fl ow and pressure. The LFRB is sometimes
used for fi ring rates under 1.00 gph as listed in Table 1.
Refer to the equipment manufacturer’s instructions. Do
not omit the LFRB when specifi ed. Omitting the baffl e
when specifi ed or installing the baffl e when not specifi ed
could result in poor burner performance.

Nozzle Assembly

Maintenance

Correct Nozzle and Flow
Rate Required

Incorrect nozzles and fl ow rates could
result in impaired combustion, under­fi ring, over-fi ring, sooting, puff-back of
hot gases, smoke and potential fi re or
asphyxiation hazards.

Use only nozzles having the brand, fl ow rate (gph),
spray angle and pattern specifi ed by the appliance
manufacturer.

Follow the appliance manufacturer’s specifi cations for the
required pump outlet pressure for the nozzle, since this
affects the fl ow rate.

y Nozzle manufacturers calibrate nozzle fl ow rates at

100 psig.

y When pump pressures are higher than 100 psig, the

actual nozzle fl ow rate will be greater than the gph
stamped on the nozzle body. (Example: A 1.00 gph
nozzle at 140 psig = 1.18 gph)

Securely tighten the nozzle (90 torque inch pounds). For typical
nozzle fl ow rates at various pressures refer to Table 3.

Use care when removing or

installing an oil nozzle

A damaged nozzle could cause impaired combustion,
sooting, puffback of hot gases, oil leakage and
potential fi re or asphyxiation hazards.

y Inspect the nozzle adapter to insure that the sealing

surface is not grooved or scratched.

y To insure that the nozzle functions properly, check the

orifi ce and strainer for dirt, scratches or other damage
before installation.

y Do NOT attempt to install or remove a nozzle without

securing the adapter to prevent seriously damaging
the alignment.

y Use care when handling the nozzle line assembly

to prevent changing the electrode tip settings or
damaging the ceramic electrode insulators.

y Ensure that the electrode settings match the values

shown in Figure 2.

Figure 2. Electrode Tip Setting

5/32” GAP

1/4” ABOVE

CENTER

1/8” NOZZLE-TO-TIP

SPACING

B. Check/Adjust Electrodes

Check the electrode tip settings. Adjust if necessary
to comply with the dimensions shown in Figure 2. To
adjust, loosen the electrode clamp screw and slide/rotate
electrodes as necessary. Securely tighten the clamp
screw when fi nished.

A. Replace the Burner Nozzle.

1. If applicable, remove the plastic plug protecting the
nozzle adapter threads.

2. Place a 3/4” open-end wrench on the nozzle adapter.
Insert the nozzle into the adapter and fi nger tighten.
Finish tightening with a 5/8” open-end wrench.

3. If the nozzle is already installed, remove the nozzle
line assembly to verify that the nozzle size and spray
pattern are correct for the application (per equipment
manufacturer’s information). Verify that the electrode
tip settings comply with Figure 2.

24 Vdc ADC Burner Manual

C. Igniter Maintenance

The igniter assembly does not require any adjustments
beyond making sure the springs and the burner electrode
rods make solid contact when the igniter is in the closed
position. The sealing surfaces of the gaskets should be
checked and replaced at the fi rst signs of any damage or
deterioration. Clean any dirt or residue from the porcelain
bushings, springs, and baseplate.

The simplest way to check igniter operation is by supplying
voltage to the input and checking to see whether an arc
is produced. Check by either looking or listening to see if
there is an arc across the electrodes while the burner is
running and the igniter is energized.

5

Section: Nozzle Assembly Maintenance

Figure 3. Igniter Hinge & Retainer Clips

a

b

c

Figure 4. ‘Z’ Dimensions Using Gauge

The igniter must be grounded to the burner before
checking the following. To check the igniter, ensure all
power to the burner is off and use an ohmmeter to check
the resistance between the two springs. The meter should
read between 480 - 580 ohms.

The igniter should be replaced if the meter indicates an
open circuit, or the spring-to-spring resistance exceeds
the 480 - 580 ohms range by more than 10%..

D. Servicing Nozzle Line Assembly

Before proceeding, turn off power to the burner.

1. Disconnect the oil connector tube from the nozzle
line.

2. Referring to Figure 3, loosen the two screws securing
the igniter retaining clips (a) and rotate both clips to
release the igniter baseplate. Then tilt the igniter
back on its hinge.

3. Remove the splined nut (b).

4. Remove the nozzle line assembly from the burner,
being careful not to damage the electrodes or
insulators while handling. To ease removal of short
assemblies, it may be necessary to loosen the
escutcheon plate (c). Reset to the edge of the label.

5. To replace the nozzle line assembly, reverse the
above steps.

Figure 5. Nozzle, Line & Electrode Assembly

Contacts to be parallel with

Electrode gap to be centered
with nozzle center.

Item # Description

1 Electrode Contact (3” ATC or extension over 3”)
2 Nozzle Line
3 Spider spacer assembly
4 Static Plate
5 Electrode clamp
6 Electrode clamp retaining screws

horizontal center line within 2°.

E. Check/Adjust “Z” Dimension

Refer to Figure 4. The critical “Z” dimension is the
distance from the face of the nozzle to the fl at face of
the head. This distance for F heads is 1-1/8”. The “Z”
dimension is factory set for burners shipped with the air

6

8

1

11

10

9

4

Item # Description

7 Nozzle line setscrew
8 Electrode Insulator

9 Nozzle adapter
10 Nozzle tip
11 Electrode tip

2

7

90°

3

5

4

6

Section: Fuel Supply

tube installed but should always be verifi ed during service
and installation. If the “Z” dimension is out of adjustment,
perform the following steps.

Before proceeding, turn off power to the burner.

1. Disconnect the oil connector tube from the nozzle
line.

2. Referring to Figure 5, loosen the splined nut from
the nozzle line. Loosen the hex head screw securing
the escutcheon plate to the burner housing.

3. A Beckett T650 gauge should be used to set the Z
dimension.

4. Place the end of a ruler at the face of the nozzle and,
using a straight edge across the head, measure the
distance to the face of the head.

5. Slide the nozzle line forward or back until this
dimension for F heads is 1-1/8”.

6. Tighten the hex head screw to secure the escutcheon
plate to the burner chassis. Then tighten the splined
nut and attach the oil connector tube.

7. Recheck the “Z” dimension periodically when
servicing to ensure the escutcheon plate has not
shifted. You will need to reset the “Z” dimension if
you replace the air tube or nozzle line assembly.

The Beckett Z gauge (part number Z-

2000) is available to permit checking

the F head “Z” dimension without removing the burner.

Fuel Supply

Do Not Install Bypass Plug
with 1-Pipe System

Failure to comply could cause Immediate pump seal
failure, pressurized oil leakage and the potential for a
fi re and injury hazard.

y The burner is shipped without the bypass plug installed.

y Install the bypass plug in two-pipe oil supply systems

ONLY.

not installed in the pump, then connect the fuel supply
to the burner with a single supply line Note that manual
bleeding of the pump is required on initial start-up or when
the equipment runs out of fuel. When connecting a two­pipe fuel system, install the pump bypass plug.

C. Fuel Supply Below Level of Burner

Oil Supply Pressure
Control Required

Damage to the fi lter or pump seals could cause oil
leakage and a fi re hazard.

y The oil supply inlet pressure to the burner cannot

exceed 3 psig.

y Ensure that a pressure limiting device is installed in

accordance with the latest edition of NFPA 31.

y Do NOT install valves in the return line. (NFPA 31,

Chapter 8.)

y Gravity Feed Systems: Always install an anti-siphon

valve in the oil supply line or a solenoid valve (RWB
Part # 22246U) in the pump/nozzle discharge tubing
to provide backup oil fl ow cut-off protection.

When the fuel supply is more than eight feet below the level
of the burner, a two-pipe fuel supply system is required.
Depending on the fuel line diameter and the horizontal
and vertical length, the installation may also require a
two-stage pump. Consult the fuel unit manufacturer’s
literature for lift and vacuum capability.

D. Fuel Line Replacement (Remote Tank Only)

When replacing fuel lines, continuous lengths of heavy
wall copper tubing is recommended. To ensure a tight
seal, always use fl are fi ttings. Never use compression
fi ttings. Always install fi ttings in an accessible location. To
avoid vibration noise, fuel lines should not run against the
appliance or the ceiling joists.

E. Fuel Line Valve and Filter

A. Connect Fuel Lines

For oil supply system specifi cations for tanks not mounted
on machines, carefully follow the pump manufacturer’s
literature and the latest edition of the National Fire
Protection Association (NFPA) 31 standard.

Pumps with automatic bypass do
not require a bypass plug. Verify by

referring to the pump manufacturer’s instructions.

B. Fuel Supply Level with or Above Burner

The burner may be equipped with a single stage pump.
If a one-pipe system is installed, verify a bypass plug is

24 Vdc ADC Burner Manual

Do Not Use Tefl on Tape

Damage to the pump could cause impaired burner
operation, oil leakage and appliance soot-up.

y Never use Tefl on tape on fuel oil fi ttings.

y Tape fragments can lodge in fuel line components

and fuel unit, damaging the equipment and preventing
proper operation.

y Use oil-resistant pipe sealant compounds.

Shutoff valves should be located in the oil supply line. Do
not install valves in the return line.

7

Section: Burner Wiring

Burner Wiring

Explosion, Fire, Scald, &
Burn Hazard

All heating equipment must have HIGH
LIMIT controls to protect against excessive

temperature and/or pressure. The control
must interrupt electrical power and shutdown the
burner, if operating or safety controls fail and cause a
runaway condition.

y Follow the equipment manufacturer’s wiring diagrams

and note all required safety controls.

y Typical safety controls include high temperature or

pressure limits, low water cutoffs, pressure relief
valves and blocked fl ue sensing switches.

y Verify all limit and safety controls are installed and

functioning correctly, as specifi ed by the manufacturer,
applicable safety standards, codes and all authorities
having jurisdiction.

y Ensure the equipment is free of oil and oil vapor

before starting or resetting the burner.

y Do not wire power directly to the burner motor. Only

wire the motor as shown in Figure 6. If instant burner
heat is required by the application, purchase or
program a control with a long motor-off delay time,
which will ensure instant heat if a new call for heat
is received within the motor-off delay time.

Electrical Shock Hazard

Electrical shock can cause severe personal injury or
death.

y Remove all jewelry, such as rings and watches before

performing service.

y Disconnect electrical power before installing or

servicing the burner.

y Provide ground wiring to the burner, metal control

enclosures and accessories. (This may also be
required to aid proper control system operation.)

A. Burner installed on equipment

Refer to appliance manufacturer’s wiring diagram for
electrical connections. Refer to “Maintain & Service
Burner” section near the end of this manual.

B. Burner Replacement

Burner wiring may vary, depending on the actual
primary control and furnished options. Refer to Figure 6
for typical burner wiring.

Figure 6. Wiring with 7559 Control

Notes:

1. Wires are to be sized to prevent a
voltage drop between the battery and
the burner with the burner running at
full load.

2. Fuse Sizes(inside control):
Motor = 20 Amp; Igniter, Control,
Valve, & Alarm = 7.5 Amp

3. Hard-wire burner ground to battery.
Do NOT use chassis ground system.

4. Input power to the control’s +24 volt
wire shall be provided from a fused
service switch, rated at 50 amps or
less.

5. Motor-off delay on a 7559P will be
disabled if the safety and operating
limits as shown in Figure 6 interrupt
power to the control’s red +24 volt
wire.

6. Do not wire power directly to the
burner motor. Only wire the motor as
shown in Figure 6. If instant burner
heat is required by the application,
purchase or program a control with a
long motor-off delay time, which will
ensure instant heat if a new call for
heat is received within the motor-off
delay time.

MAIN
POWER
24V

IGNITER

MOTOR

ON/OFF/RESET

VALV E

HIGH
LIMIT

OIL

RED WIRE

BLACK WIRE

ALARM

VALV E

GND (VLV)

IGNITER

GND (IGN)

MOTOR

GND (MTR)

CAD

CELL

ENABLE

THERMOSTAT

CAD CELL

8

Section: Drive Component Maintenance

Drive Component

Maintenance

A. Motor, Blower Wheel, and Coupling
Replacement

The motor will require replacement if the proper voltage is
measured at the motor input, and the motor will either not
run, or the current draw with a free running pump exceeds
10% of the rated current.

To replace the burner motor, coupling and/or blower wheel
perform the following steps.

1. Before servicing, turn off and/or disconnect all power
to the burner.

2. Disconnect the burner motor wires.

3. Remove the bolts securing the motor to the burner
housing.

4. Remove the motor, coupling, and blower wheel.

5. Loosen the set screw on the blower wheel to slide
the existing wheel off the shaft.

6. Slide the new blower wheel onto the old shaft (after
thoroughly cleaning housing) and/or slide the old
blower wheel onto the new motor shaft.

7. Place a .030” (1/32” ± 1/64”) feeler gauge between
the blower wheel and the motor housing.

8. Slide the blower wheel toward the motor until it
contacts the feeler gauge.

9. Rotate the blower wheel until the setscrew is centered
on the fl at of the motor shaft. Tighten the setscrew to
secure the wheel.

10. Slide the motor coupling on the motor shaft, then
install the motor on the burner housing. Ensure that
the motor coupling fi ts between the motor shaft and
the pump shaft inside the housing. Tighten the motor
retaining screws. Reconnect the wires.

11. Restore power, start the burner and perform
the combustion test described previously in this
manual.

B. Pump Maintenance

General Pump Information

Important information - Long or oversized inlet lines may
require the pump to operate dry during initial bleeding
period. In such cases, the priming may be assisted
by injecting fuel oil in the pump gear set. Under lift
conditions, lines and fi ttings must be air tight. To assure
this, “Pipe Dope” may be applied to both the used and
unused inlet and return fi ttings. Do NOT use Tefl on tape

or compression fi ttings
Mounting Position - Beckett CleanCut pump may be

mounted in any position (except upside-down in a single
pipe installation).
Vacuum Check - A Vacuum Gauge may be installed in
either of the 1/4” NPT inlet ports.
Pressure Check- When a pressure check is made, use
the nozzle port. If the bleed port is used, the reading on
the gauge should be approximately 5 psig higher than the
pressure reading on the nozzle port. See Figure 8.
Cutoff Check - To check cutoff pressure dead head a
pressure gauge in the nozzle port. Run the burner for a
short period of time. Shut the burner off. The pressure
will drop and hold above zero. Pressurized or gravity feed
installations must not exceed 3 psig on inlet line or return
line at the pump per NFPA 31. A pressure greater than 10
psig may cause damage to the shaft seal.

Figure 7. – Blower Wheel

Insert feeler gauge between

blower and motor

24 Vdc ADC Burner Manual

Flat face on motor shaft

Access hole to set screw

9

Section: Drive Component Maintenance

C. Valve Coil and Stem Replacement

To determine if the valve coil requires replacement perform
the following steps.

1. Remove the cord set from the valve.

2. Place the leads from an ohmmeter across the coil.

3. A 24Vdc volt coil should measure between 60 and
75 ohms.

4. If the meter indicates an open circuit, replace the coil.

To check pump operation perform the following.

1. Check the operating pressure by removing the copper
tubing from the nozzle line and installing a pressure
gauge in the line. With the motor running and the coil
energized, check the gauge. The pressure should read
100 psig unless otherwise stated.

2. To check the cutoff function, deadhead the pressure
gauge onto the copper connector tube attached to the
nozzle port. Run the burner for a short period of time.
Shut the burner off; the pressure should drop and hold.

To replace the coil and/or pump assembly perform the
following steps.

1. Before servicing, turn off and/or disconnect all power
to the burner.

2. Remove the copper tube assembly when replacing
the pump or when removing the coil and the tube
blocks the coil.

3. Using a fl at tip screwdriver, press the fl at tip into the
spring washer to prevent it from rotating.

4. Using a 10mm wrench or adjustable wrench, remove
the nut and spring washer.

5. Remove the coil by lifting it straight up.

6. Remove the two base plate screws, then the base
plate by lifting straight up.

7. Remove valve stem assembly by pulling straight up.

8. To install the new stem and coil assemblies, follow
the above steps in reverse order, tightening each
part as you go.

9. Restore power, start the burner and perform
the combustion test described previously in this
manual.

Figure 8. – Pump and Valve Assemblies

10mm Nut

Coil

Base Plate

Stem Assembly

Spring Washer

Cordset

Pump Assembly

10

Nozzle Port

Fitting

Bleed Valve

SK9810

Section: Start Up Burner & Set Combustion

Start Up Burner & Set

Combustion

A. Basic Burner Operation

With 7559 Control - The 7559 control provides the

benefi ts of added safety, convenience, and performance.
It adds a valve on delay and motor-off delay to the burner’s
operation sequence that promote clean burner operation.
It has a lock-out function that shuts the burner down if it
is not operating properly. The control adds fusing at the
burner to protect against component failures. The control
also has redundant motor relays that are checked for
proper operation every heat cycle.

Variations to the burner circuits may occur due to optional
temperature, pressure, and vacuum switches that control
burner operation. Note that when external switches
are used to control motor operation they must be sized
correctly for the rated current or a relay should be installed
to isolate the switches from the motor’s full load current.

B. Combustion Set-up

Explosion and Fire Hazard

Failure to follow these instructions could
lead to equipment malfunction and result
in heavy smoke emission, soot-up, hot gas
puff-back, fi re and asphyxiation hazards.

y 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.

y Do not attempt to re-establish fl ame with the burner

running if the fl ame becomes extinguished during
start-up, venting, or adjustment.

y Vapor-Filled Appliance: Allow the unit to cool off

and all vapors to dissipate before attempting another
start.

y Oil-Flooded Appliance: Shut off the electrical power

and the oil supply to the burner and then clear all
accumulated oil before continuing.

y If the condition still appears unsafe, contact the Fire

Department. Carefully follow their directions.

y Keep a fi re extinguisher nearby and ready for use.

from the supply system. Note: If the burner stops after a
fl ame is established, the unit probably requires additional
bleeding. Continue to bleed the system until the pump is
primed and a fl ame is established when the bleed valve
is closed.

C. Set Combustion with Instruments

1. Allow the burner to run for approximately 5 to 10
minutes.

2. Follow these four steps to properly adjust the
burner:

Step 1: Adjust the air until a trace smoke level is

achieved.

Step 2: At the trace of smoke level, measure the

CO

(or O2). This is the vital reference

2

point for further adjustments.

Step 3: Increase the air to reduce CO2 by 1

percentage point (O
approximately 1.4 percentage points).

Step 4: Recheck the smoke level. It should be zero.

3. This procedure provides a margin of reserve air to
accommodate variable conditions.

4. Once the combustion level is set, tighten the fasteners
on the air band and air shutter.

5. Start and stop the burner several times to ensure
satisfactory operation.

6. Test the equipment safety controls to verify
they function according to the manufacturer’s
specifi cations.

Figure 9. – Air supply components

Air band position

indicator

will be increased by

2

As soon as burner motor starts rotating bleed all the air
from the pump. (Required with single-pipe systems.)

To bleed the pump, attach a clear plastic hose over the
vent fi tting. Loosen the fi tting and catch the oil in an empty
container. Tighten the fi tting when all air has been purged

24 Vdc ADC Burner Manual

Shutter position indicator

11

Section: Maintain & Service Burner

Maintain & Service

Burner

A. Owner’s Information

Professional Service
Required

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 explosion.

Please read and understand the manual supplied with this
equipment. This equipment must be installed, adjusted
and put into operation only by a qualifi ed individual or
service agency that is:

y Licensed or certifi ed to install and provide technical

service to oil heating systems.

y Experienced with all applicable codes, standards and

ordinances.

y Responsible for the correct installation and commission

of this equipment.

y Skilled in the adjustment of oil burners using

combustion test instruments.

The installation must strictly comply with all applicable
codes, authorities having jurisdiction and the latest revision
of the National Fire Protection Association Standard for
the installation of Oil-burning Equipment, NFPA 31 (or
CSA-B139 and CSA-B140 in Canada).
Regulation by these authorities take precedence over the
general instructions provided in this installation manual.

This equipment should be serviced only by a qualifi ed
service agency. The appropriate test instruments must be
used.

Daily

Check the area around your burner/equipment to make
sure:

○ Nothing is blocking the burner inlet air openings.
○ Air ventilation openings are clean and unobstructed

and the exhaust is not crusted.

○ No combustible materials are stored near the

equipment.

○ There are no signs of oil or water leakage around the

burner or equipment.

Extended Down Time

If the equipment will be stored for an extended period
of time, insure that the fuel tank is full and add a fuel
stabilizer to the tank.

Regular Service/Maintenance

Use only Beckett replacement parts
for continued safe operation of the
burner.

Have your burner, serviced annually by your qualifi ed
service agency. The following components/assemblies
should be checked/adjusted/replaced on a regular basis.
Refer to the Replacement Parts exploded view for part
locations.

Have your equipment inspected at regular intervals
by a qualifi ed service agency to assure continued
proper operation. The burner should be adjusted using
dedicated combustion test equipment. Failure to properly
set the burner could result in ineffi cient operation, and/or
conditions that could potentially cause severe personal
injury, death or substantial property damage.

B. Owner Service and Maintenance

Properly installed and maintained, your ADC burner will
provide years of effi cient, trouble-free operation. Please
take care of your equipment by following the warnings
provided and by immediately contacting your qualifi ed
service agency if your burner is not operating properly.

□ Replace the oil supply line fi lter, if applicable.

The line fi lter cartridge must be replaced to avoid
contamination of the pump and nozzle.

□ Inspect the oil supply system. All fi ttings should be

leak-tight. The supply lines should be free of water,
sludge and other restrictions.

□ Remove and clean the pump strainer.

□ Verify the nozzle is the one originally specifi ed by the

appliance manufacturer and replace the nozzle with
one having the exact specifi cations from the same
manufacturer.

□ Clean and inspect the electrodes for damage,

replacing any that are cracked or chipped.

□ Check electrode tip settings. Replace electrodes if

tips are rounded.

□ Inspect the igniter spring contacts. Clean or replace

if corroded.

12

Section: Troubleshooting

□ Clean the cad cell, if applicable.

□ Make sure Low Firing Rate Baffl e is in place, if

required, for the burner application. Omitting the baffl e
can result in unacceptable burner combustion.

□ Inspect all gasket including the igniter base plate

gasket. Replace any that are damaged or missing.

□ Clean the blower wheel, air inlet, air guide, retention

head and static plate of any dirt, asphalt or other
material.

□ Check motor current. The amp draw should not

exceed the nameplate rating. Check all wiring for
loose connections or damaged insulation.

□ Check the pump pressure and cutoff function.

□ Check primary control safety lockout timing, if

applicable. Refer to the information supplied by the
control manufacturer for procedures.

□ Check ignition system for proper operation.

□ Inspect the exhaust system for soot accumulation or

other restriction.

□ Clean the equipment thoroughly according to the

manufacturer’s recommendations.

□ Check the burner performance using test

instruments.

□ It is good practice to make a record of the service

performed and the combustion test results.

Table 3. Nozzle Flow Rate by Size

Nozzle fl ow rate U. S. gallons per hour of No. 2 fuel oil
when pump pressure (psig) is:

Nozzle

Size
(rated
at 100

psig)

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 1.91

1.50 1.68 1.77 1.84 1.98 2.12

1.65 1.84 1.95 2.02 2.18 2.33

1.75 1.96 2.07 2.14 2.32 2.48

2.00 2.24 2.37 2.45 2.65 2.83

2.25 2.52 - - - -

125

psi

140

psi

150

psi

175

psi

200

psi

Troubleshooting

Oil burners that are designed for use on road maintenance
equipment are built to take temperature extremes,
vibration, and rough handling. When performing the
following troubleshooting steps, we assume that the oil
burner motor and ignition transformer operate continuously
and the oil solenoid valve, which controls oil fl ow, is cycled
by the equipment controls. We also assume that there is
power to the burner and fuel in the tank.

In addition to typical mechanics tools, it is recommended
to have the following equipment on hand.

○ Meter capable of measuring volts, ohms and amps,
○ ignition transformer tester,
○ smoke pump tester,
○ combustion analyzer, and
○ 0 to 200 psi pressure gauge.

See Table 4 on following page for troubleshooting steps.

24 Vdc ADC Burner Manual

13

Section: Troubleshooting

Table 4. Troubleshooting Chart

Symptom Possible Cause

If the burner is not igniting, the burner motor, drive coupling, and oil pump are operating and oil is
fl owing to the nozzle through the solenoid valve, check the following possibilities.

1. Check the air shutter adjustment. If the air shutter is opened too far, the fl ow of air may prevent the arc from

Oil Not

Igniting

No Flame

reaching the oil spray. This may appear as a white vapor exhaust from the heater. [Refer to section “Start

up burner and set combustion”]

2. The ignition system may have failed to supply an adequate arc to ignite the oil. Check the battery and
charging system to insure a continuous supply of 21.6 to 28 volts DC (15 amps). [Refer to section

“Nozzle Assembly Maintenance”]

3. Check the electrodes for wear and damage. Insure that the electrodes are adjusted properly. [Refer to

section “Nozzle Assembly Maintenance”]

If there is no fl ame, the burner motor and igniter operate continuously and the oil solenoid valve is
functional, check the following possibilities.

1. Check for a plugged oil nozzle. [Refer to section 3]

2. If the coil on the solenoid valve is actuating, insure that the valve is opening or closing properly. [Refer to

section “Fuel Supply”]

3. Check for suffi cient fuel pressure. Pressure is 100 psig with valve energized, unless otherwise noted.

[Refer to section “Drive Component Maintenance”]

4. Check the pump pressure. Check for air in fuel lines.

5. Check burner for broken motor coupling. If the coupling is broken check pump rotation prior to replacing the
coupling. [Refer to section “Drive Component Maintenance”]

6. Check for contaminated fuel and/or partially plugged fuel fi lter. [Refer to section “Fuel Supply”]

Motor Not
Operating

No Oil Spray

Fluctuating

or No Pump

Pressure

If the blower motor is not operating, check the following possibilities.

1. Check voltage at the motor to insure that switches and relays, in line with the motor, are operating properly.

[Refer to section “Burner Wiring”]

2. Check pump and motor shaft operation. They should work freely without binding. [Refer to section “Drive

Component Maintenance”]

If the blower motor is operating, there is fuel in the tank, but oil does not spray out the end of the
nozzle, check the following possibilities.

1. Check for a broken or stripped coupling between the pump and the motor. [Refer to section “Drive

Component Maintenance”]

2. Check the pump output for oil. [Refer to section “Drive Component Maintenance”]

3. Check operation of the oil valve. [Refer to section “Drive Component Maintenance”]

4. Check for a plugged nozzle. [Refer to section “Nozzle Assembly Maintenance”]

5. Check for air in the oil line. [Refer to section “Nozzle Assembly Maintenance”]

6. Check for fuel contamination or plugged fi lter. [Refer to section “Nozzle Assembly Maintenance”]

If the pump pressure, as determined by a pressure gauge, is erratic or does not exist, check the
following possibilities.

1. Check motor rotational speed. Low rpm can cause erratic or no pump pressure. [Refer to section “Drive

Component Maintenance”]

2. Check for a broken or worn motor coupling. [Refer to section “Drive Component Maintenance”]

3. Check that the pump turns freely. [Refer to section “Drive Component Maintenance”]

4. Check for air leaks in the lines. [Refer to section “Fuel Supply”]

5. Check for oil froth at the bleed point. [Refer to section “Fuel Supply”]

6. Check voltage at the motor. [Refer to section voltage rating on nameplate]

7. Check for fuel contamination or partially plugged fi lter.

Slow Motor

Rotation

14

If the blower motor is not operating at the rpm’s listed on the nameplate, check the following.

1. Check the supply voltage to the motor. [Refer to section voltage rating on nameplate]

2. Check for free operation of the motor shaft and pump assembly. [Refer to section “Drive Component

Maintenance”]

Replacement Parts

Section: Replacement Parts

21

12

23

20

22

17

19

15

16

18

14

10

13

1

11

2

3

4

8

9

7

6

5

Illustration

10 Valve Stem 21877U

11 12 Volt Coil 22245U

12 8” Copper Tubing 5394

* ‘X’s indicate timing options. Contact Beckett for available part numbers.

24 Vdc ADC Burner Manual

Description Part#

#

1 DC Motor 21773U

2 Blower Wheel 2999U

3 Coupling 2140501

4 Air Guide 31231U

5 Burner Housing - Black 5874BKU

6 Air Band 5151501

7 Air Shutter - 4 Slot

Air Shutter - 8 Slot

8 Cord set 21807

9 Pump (CleanCut) 2184407U

3709
3494

Illustration

#

13 Escutcheon Plate Spline Nut 3666

14 Escutcheon Plate 3493

15 Electrode Kit over 3-

16 Cad Cell Detector 7492/7006U

17 Igniter Gasket Kit 51411

18 4X4 Wiring Box Kit 5770

19 Control Kit 7559x-xxxxU*

20 Igniter Assy with baseplate 5218501U

21 Igniter only 5218503U

22 Air Tube Ass’y Specify

23 Flange Mounting Gasket Specify

Not

Shown

Description Part#

5/8

” 578731

Tune-up Kit for 30 & 35 Air
Tube Lengths

578730

15

Limited Warranty Information

The R. W. BECKETT CORPORATION (“Beckett”) warrants to persons who purchase its “Products” from Beckett
for resale, or for incorporation into a product for resale (“Customers”), that its equipment is free from defects
in material and workmanship. To qualify for warranty benefi ts, products must be installed by a qualifi ed service
agency in full compliance with all codes and authorities having jurisdiction, and used within the tolerances of
Beckett’s defi ned product specifi cations.

To review the complete warranty policy and duration of coverage for a specifi c product, or obtain a written copy
of warranty form 61545, please choose one of the following options:

1. Visit our website at: www.beckettcorp.com/warranty

2. Email your request to: [e-mail]

3. Write to: R. W. Beckett Corporation, P. O. Box 1289, Elyria, OH 44036

NOTE: Beckett is not responsible for any labor cost for removal and replacement of equipment.

THIS WARRANTY IS LIMITED TO THE PRECISE TERMS SET FORTH ABOVE, AND PROVIDES EXCLUSIVE
REMEDIES EXPRESSLY IN LIEU OF ALL OTHER REMEDIES, AND IN PARTICULAR THERE SHALL BE
EXCLUDED THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE. IN NO EVENT WILL BECKETT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL
DAMAGE OF ANY NATURE. Beckett neither assumes, nor authorizes any person to assume for Beckett,
any other liability or obligation in connection with the sale of this equipment. Beckett’s liability and Customer’s
exclusive remedy is limited to the cost of the product.

USA: P.O. Box 1289 ● Elyria, Ohio 44036

Canada: R.W. Beckett Canada, Ltd.

www.beckettcorp.com

●

Unit #3, 430 Laird Road ● Guelph, Ontario N1G 3X7

Part Number 6104 B24ADC R03, Printed in the U.S.A. 04/12