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

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.

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.

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

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.

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