Beckett ADC 24Vdc User Manual

Page 1

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.

Page 2

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

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

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.

Page 3

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.

Page 4

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.

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

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

Page 5

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.

Page 6

Section: Nozzle Assembly Maintenance

Figure 3. Igniter Hinge & Retainer Clips

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

Item # Description

7 Nozzle line setscrew 8 Electrode Insulator

9 Nozzle adapter 10 Nozzle tip 11 Electrode tip

90°

Page 7

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.

Page 8

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

Page 9

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

Page 10

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

Nozzle Port

Fitting

Bleed Valve

SK9810

Page 11

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

(or O2). This is the vital reference

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

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

Page 12

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.

Page 13

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

Page 14

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

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”]

Page 15

Replacement Parts

Section: Replacement Parts

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

Page 16

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: rwb-customer-service@beckettcorp.com

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