Beckett CF1000 User Manual

COMMERCIAL PRODUCTS

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:

Please read and carefully follow all instructions

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

Contact a professional, qualiﬁ ed service agency for

installation, start-up or service work.

Save this manual for future reference.

To the Professional, Qualiﬁ ed Installer or Service Agency:

Please read and carefully follow all instructions provided

in this manual before installing, starting, or servicing this burner or heating system.

The Installation must be made in accordance with all state

and local codes having jurisdiction.

To the Owner:

Thank you for purchasing a Beckett burner for use with your heating appliance.

Please pay attention to the Safety Warnings contained within this instruction manual. Keep this manual for your records and provide it to your qualiﬁ ed service agency for use in professionally setting up and maintaining your oil burner.

Your Beckett burner will provide years of efﬁ cient operation if it is professionally installed and maintained by a qualiﬁ ed service technician. If at any time the burner does not appear to be operating properly,

immediately contact your qualiﬁ ed service agency for consultation.

We recommend annual inspection/ service of your oil heating system by a qualiﬁ ed service agency.

Daily – Check the room in which your

burner/appliance is installed. Make sure:

Air ventilation openings are clean and

unobstructed

Nothing is blocking burner inlet air

openings

No combustible materials are stored

near the heating appliance

There are no signs of oil or water

leaking around the burner or appliance

Weekly

Check your oil tank level. Always

keep your oil tank full, especially during the summer, in order to prevent condensation of moisture on the inside surface of the tank.

Contents

General Information ....................................................3

Owner’s Responsibility: .................................................................4

Service Agency Responsibility: .....................................................4

Pre-installation Checklist............................................5

Combustion Air Supply ..................................................................5

Clearances ....................................................................................5

Fuel Supply ...................................................................................5

Nozzle Pressure ............................................................................5

Electrical Supply ............................................................................6

Vent System ..................................................................................6

Verify Burner Components ............................................................6

Verify Firing Input Range ............................................................... 6

Verify Air Tube ...............................................................................6

Stray Light .....................................................................................7

Dust and Moisture .........................................................................7

Mount the Burner .........................................................8

Mount Flange on Air Tube .............................................................8

Mount Air Tube to Burner ..............................................................8

Install Nozzle .................................................................................8

Check Electrode Settings ..............................................................8

Install Nozzle Line Assembly ......................................................... 9

Set Dimension Z ............................................................................9

Insert Burner .................................................................................9

Fuel Unit By-pass Plug ............................................................... 10

Oil Supply/Return Lines ............................................................. 10

Burner Fuel Flow ........................................................................ 10

Burner Controls ......................................................... 11

Typical Burner Sequence of Operation - GeniSys 7505 .............11

Wire the Burner (GeniSys 7505) ................................................ 12

Typical Burner Sequence of Operation - Honeywell 7184 ......... 14

Restricted Lockout ..................................................................... 14

Wire the Burner (R7184) ............................................................ 14

Prepare the Burner for Start-up ...............................16

Start-up Checklist ....................................................................... 16

Z Dimension ............................................................................... 17

Adjusting Plate Assembly ........................................................... 17

Initial Head Position ................................................................... 17

Initial Air Settings ........................................................................ 17

Set Appliance Limit Controls ...................................................... 18

Prepare the Fuel Unit for Air Venting .......................................... 18

Start the Burner .........................................................18

Starting the Burner and Venting Air ............................................ 18

Priming the Pump ....................................................................... 19

Disable Function ........................................................................ 19

Cad Cell Resistance Measurement: ........................................... 19

Set Air Adjusting Plate ................................................................ 20

Maintenance and Service..........................................21

Monthly Maintenance — by owner ............................................. 21

Replacement Parts ....................................................22

Limited Warranty Information ..................................24

Section: General Information

General Information

Hazard Deﬁ nitions

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

in death or serious injury.

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.

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:

Never store or use gasoline or other ﬂ ammable

liquids or vapors near this burner or appliance.

Never attempt to burn garbage or refuse in this

appliance.

Never attempt to light the burner/appliance by

throwing burning material into the appliance.

Never attempt to burn any fuel not speciﬁ ed and

approved for use in this burner.

Never restrict the air inlet openings to the burner or

the combustion air ventilation openings in the room.

Agency Approvals

UL certiﬁ ed to comply with ANSI/UL296 and

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tested to CSA B140.0. Accepted by N.Y.C. M.E.A.

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Other approvals may be available and must

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be speciﬁ ed at time of order.

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Frozen Plumbing and Water Damage Hazard

If the residence is unattended in severely cold weather, burner primary control safety lockout, heating system component failures, power outages or other electrical system failures could result in frozen plumbing and water damage in a matter of hours. For protection, take preventive actions such as having a security system installed that operates during power outages, senses low temperature and initiates an effective action. Consult with your heating contractor or a home security agency.

50 Hz Motors - The burner ratings,

air settings and nozzle ratings are based on standard 60 Hz motors (at 3450 rpm). Derate all ratings 20% when using 50 Hz motors. Consult factory for speciﬁ c application data.

High altitude installation - Accepted

industry practice requires no derate of burner capacity up to 2000 feet above sea level. For altitudes higher than 2000 feet, derate burner capacity 2% for each 1000 feet above sea level.

CF1000 Burner Manual

Section: General Information

Owner’s Responsibility:

Follow these instructions exactly.

Failure to follow these instructions, misuse, or incorrect adjustment of the burner could result in asphyxiation, explosion or ﬁ re.

Contact a professional, qualiﬁ ed service agency for the installation, adjustment and service of your oil burning system. Thereafter, have your equipment adjusted and inspected at least annually to ensure reliable operation. This work requires technical training, trade experience, licensing or certiﬁ cation in some states and the proper use of special combustion test instruments.

Never store or use gasoline or other ﬂ ammable

liquids or vapors near this burner or appliance.

Never attempt to burn garbage or refuse in this

appliance.

Never attempt to light the burner by throwing burning

material into the appliance.

Never attempt to burn any fuel not speciﬁ ed and

approved for use in this burner.

Never restrict the air inlet openings to the burner or the combustion air ventilation openings in the room.

Frozen Plumbing and Water Damage Hazard

If the facility is unattended in severely cold weather, burner primary control safety lockout, heating system component failures, power outages or other electrical system failures could result in frozen plumbing and water damage in a matter of hours. For protection, take preventive actions such as having a security system installed that operates during power outages, senses low temperature and initiates an effective action. Consult with your heating contractor or security agency.

Service Agency Responsibility:

Follow these instructions exactly.

Failure to follow these instructions could result in asphyxiation, explosion or ﬁ re.

Please read all instructions before proceeding.

Follow all instructions completely.

This equipment must be installed, adjusted and

started by a qualiﬁ ed service agency that is licensed and experienced with all applicable codes and ordinances and responsible for the installation and commission of the equipment.

The installation must comply with all local codes and

ordinances having jurisdiction and the latest editions of the NFPA 31 and CSA-B139 & B140 in Canada.

Speciﬁ cations

U.S. #1 or #2 heating oil only (ASTM D396) Canada #1 stove oil or #2 furnace oil only

Fuels

DO NOT USE GASOLINE, CRANKCASE

OIL, OR ANY OIL CONTAINING

GASOLINE.

Firing Range 4.0 to 10.0 GPH

½ HP 3450 RPM 120/60 Hz standard

Motor

Ignition Trans. Continuous Duty, 120V/12,000V

Housing Cast aluminum

Fuel Unit 100 - 300 PSIG

6.5 amps @ 120 VAC Optional voltages:(60 Hz or 50 Hz)

• 240 VAC/1-PH

• 208/240/480 VAC/3-PH

Impaired Burner Performance & Fire Hazard

Do NOT operate the burner beyond speciﬁ cations outlined in the table on this page.

For applications beyond these limits, consult Beckett

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Technical Services at 1-800-645-2876. NOTE: Some packaged appliances with burners

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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.

Oil Nozzle 45° - 70° solid

Shipping Weight

Dimensions See Figure 8.

75 lbs.

Pre-installation Checklist

Combustion Air Supply

Adequate Combustion and Ventilation Air Supply Required

Failure to provide adequate air supply could result in asphyxiation, explosion or ﬁ re hazards.

The burner cannot properly burn the fuel if it is not

supplied with a reliable combustion air source.

Follow the guidelines in the latest editions of the FPA

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

The burner requires combustion air and ventilation

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air for reliable operation. Assure that the building and/or combustion air openings comply with National Fire Protection Standard for Oil-Burning Equipment, NFPA 31. For appliance/burner units in conﬁ ned spaces, the

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room must have an air opening near the top of the room plus one near the ﬂ oor, each with a free area at least one square inch per 1,000 Btu/hr input of all fuel burning equipment in the room. For other conditions, refer to NFPA 31 (CSA B1139-

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M91 in Canada). If there is a risk of the space being under negative pressure or of exhaust fans or other devices depleting available air for combustion and ventilation, the appliance/burner should be installed in an isolated room provided with outside combustion air.

Clearances

With the burner installed in the appliance, there

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must be adequate space in front of and on the sides of the burner to allow access and operation. Verify that the clearance dimensions comply with all local codes and with the appliance manufacturer’s recommendations.

Fuel Supply

Oil Supply Pressure Control Required

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

The oil supply inlet pressure to the burner cannot

exceed 3 psig.

Do not install valves in return line.

Insure that a pressure limiting device is installed in

accordance with the latest edition of NFPA 31.

Gravity Feed Systems: Always install an antisiphon

valve in the oil supply line or a solenoid valve (RWB Part # 21789) in the pump/nozzle discharge tubing to provide backup oil ﬂ ow cut-off protection.

Section: Pre-installation Checklist

The fuel supply piping and tank must provide #1 or

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#2 fuel oil at pressure or vacuum conditions suitable for the fuel unit (oil pump) on the burner. Refer to fuel unit literature in the literature envelope in the burner carton to verify allowable suction pressure.

If fuel supply is level with or higher than fuel unit -

When the fuel unit is not required to lift the oil, the

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installation is usually suitable for either a one-pipe or two-pipe oil system. The oil pressure at the inlet of the fuel unit must not exceed 3 psig.

See Figure 9 for one-pipe fuel supply installations.

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See Figure 10 for two-pipe fuel supply installations.

If fuel supply is below the fuel unit -

Use a two-pipe oil system when the fuel unit must

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lift the oil more than 8 feet, The return line provided by the two-pipe system is needed to purge the air from the fuel lines and minimize the likelihood of airrelated problems during operation.

Nozzle Pressure

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.

Nozzle manufacturers calibrate nozzle ﬂ ow rates at

100 psig.

This burner utilizes pressures higher than 100 psig,

so the actual nozzle ﬂ ow rate will be greater than the gph stamped on the nozzle body. (Example: A 8.00 gph nozzle at 150 psig = 9.80 gph and at 300 psig =

13.86 gph)

For typical nozzle ﬂ ow rates at various pressures refer to

Table 1.

The fuel unit nozzle port pressure is factory set at

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300 psig. Some original equipment manufacturer burner applications may call for a lower pressure to obtain a required ﬁ ring rate. Do not change this pressure unless directed to do so by the appliance manufacturer.

CF1000 Burner Manual

Section: Pre-installation Checklist

Electrical Supply

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Verify that the power connections available are

correct for the burner. Refer to Figure 1. All power

must be supplied through fused disconnect switches.

Vent System

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The ﬂ ue gas venting system must be in good condition and must comply with all applicable codes.

Verify Burner Components

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Burner nameplate (Figure 1), Model CF1000

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Air tube assembly

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Mounting ﬂ ange kit

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Pedestal mounting assembly kit (recommended)

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Oil nozzle, per Table 1 — Only 45° to 70° solid

pattern nozzles are recommended unless otherwise speciﬁ ed by appliance manufacturer. (See speciﬁ c appliance recommendation sheet or refer to OEM Spec Guide). Find the required ﬁ ring rate in the 300 psig column (factory-set fuel unit pressure). Select the corresponding nozzle from column 1 (Rated gph @ 100 psig).

(Example: 5.00 gph nozzle @ 300 psig = 8.66 gph)

Table 1 - Nozzle Capacities (GPH)

Rated

Pressure - pounds per square inch

gph

@ 100

125 150 175 200 250 275 300

psig

2.00 2.24 2.45 2.65 2.83 3.16 3.32 3.46

2.25 2.52 2.76 2.98 3.18 3.56 3.73 3.90

2.50 2.80 3.06 3.31 3.54 3.95 4.15 4.33

2.75 3.07 3.37 3.64 3.90 4.35 4.56 4.76

3.00 3.35 3.67 3.97 4.24 4.74 4.97 5.20

3.50 3.91 4.29 4.63 4.95 5.53 5.80 6.06

4.00 4.47 4.90 5.29 5.66 6.32 6.63 6.93

4.50 5.04 5.51 5.95 6.36 7.11 7.46 7.79

5.00 5.59 6.12 6.61 7.07 7.91 8.29 8.66

5.50 6.15 6.74 7.28 7.78 8.70 9.12 9.53

6.00 6.71 7.35 7.94 8.49 9.49 9.95 10.39

6.50 7.27 7.96 8.60 9.19 10.28 10.78 11.26

7.00 7.83 8.57 9.26 9.90 11.07 11.61 12.12

7.50 8.39 9.19 9.92 10.61 11.86 12.44 12.99

8.00 8.94 9.80 10.58 11.31 12.65 13.27 13.86

Verify Firing Input Range

Refer to appliance manufacturer’s instructions

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(if available) for ﬁ ring rate and nozzle selection. Otherwise, the maximum recommended ﬁ ring rate for the burner is limited by the length of the ﬁ ring chamber and the distance from the burner center to the chamber ﬂ oor. Verify that the chamber dimensions are at least as large as the

minimum values given in Figure 2. If the appliance

dimensions are smaller than recommended, reduce the ﬁ ring rate accordingly.

Figure 1 - Typical Nameplate

General Model Information

Serial Number, Including Date Code

Rating Information

Approval Agency Symbols

Primary Group and Fuel

Model “XX”

Series (Fuel) Burner

SERIAL NUMBER

050214-00000

Control Circ: 120V/60Hz 4.5A

Motor Circ: 120V/60Hz 4.0A

LISTED

(FUEL) BURNER NO.P100000

R.W. Beckett Corp.

Elyria, Ohio

Made in the U.S.A.

For use with Group 8 . . .

MP 1192 XX000 R00

Verify Air T ube

Note: The information in this section may be disregarded if the air tube is supplied by the appliance manufacturer.

Air tube arrangement –

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Tube A — 4.0 to 10.0 GPH per Figure 2.

Maximum ﬁ ring capacity depends on the ﬁ rebox

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pressure, see Table 2. See Figure 2 to verify the correct air tube length and

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air tube combination code.

MFR’S SETTINGS

X X X X X X

XX000 R00

050214-00000

R.W. Beckett Construction & Setting Data

R.W. Beckett Speciﬁ cation Number and Revision

Boiler Manufacturer and Model, When Applicable

Additional Codes

Section: Pre-installation Checklist

Figure 2 - Dimensions: Minimum Combustion Chamber and Air Tube Mounting.

* Install burner with

2° pitch as shown.

1/4” ± 1/8”

*2°

Minimum Dimensions

Firing Rate

(refractory-lined) (wet-base boilers)

HLHL

0 to 5 gph 7.0” 25.0” 7.0” 25.0”

5 to 10 gph 8.0” 35.0” 8.0” 40.0”

A.T.C. Codes

Air Tube

Length

(Dimension T)

Minimum

Insertion Depth

(Dimension E)

(A.T.C. = Air Tube

Combination)

Tube A

(Dim. D = 5.5”)

06.75” 2.94” CF66KD

10.25” 2.94” CF102KD

13.75” 2.94” CF136KD

17.75” 2.94” CF176KD

Figure 3 - Firebox Pressure: CF1000 with no Reserve Air

Maximum Firing Rate U.S. GPH

0.0

0.2 0.4 0.6 0.8

Firebox Pressure in Inches Water Column (W.C.)

1.0

Stray Light

Protect Against Stray Light Lockout. Failure to follow these instructions could cause loss of burner operation resulting in no heat, an unplanned process interruption, work stoppage and the potential for frozen plumbing or other cold weather property damage.

The control must detect a dark, no-ﬂ ame condition

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in order to start the burner or it will hold in the stray light lockout mode. Shield the burner view window from direct exposure

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to intense light.

Dust and Moisture

Table 2 -

Firebox Pressure

Air Tube Capacity (GPH) vs. Firebox Pressure

10%Turndown

(GPH)

(In W.C.)

No Reserve Air

0.0 11.0 10.00

0.2 10.5 9.45

0.4 10.1 9.10

0.6 9.6 8.64

0.8 9.2 8.30

1.0 8.7 7.83

Note: 10% turndown indicates sufﬁ cient reserve air to reduce the CO2 in the ﬂ ue to 90% of its value. Note: The above ratings may vary 5% due to variations in actual job conditions.

CF1000 Burner Manual

Protect Against Dust and

Moisture

Wet, dusty environments could lead to blocked air passages, corrosion damage to components, impaired combustion performance and result in asphyxiation, explosion or ﬁ re.

This burner is designed for clean, dry installations.

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Electrical controls are not protected against rain or

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sprayed water. Keep the installation clear of dust, dirt, corrosive

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vapors, and moisture. Protective covers and more frequent maintenance

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may be required.

Section: Mount the Burner

Mount the Burner

Protect the air tube from overheating.

Overheating could cause damage to the air tube and other combustion components leading to equipment malfunction and impaired combustion performance.

The end of the air tube must not extend into the

combustion chamber unprotected unless it has been factory-tested and speciﬁ ed by the appliance manufacturer.

Position the end of the air tube 1/4” back from

ﬂ ush with the refractory inside entry wall to prevent damage from overheating.

Mount Flange on Air Tube

Note: This section does not apply to burners with welded ﬂ anges.

Do not install air tube on burner.

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For non-pressure ﬁ ring ﬂ ange, refer to Figure 4:

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Install gasket (item a) and ﬂ ange (item c). Ignore the

next paragraph.

For pressure-ﬁ ring ﬂ ange, refer to Figure 4: Slide

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gasket (item a) onto the air tube, making sure

the top of the air tube is up. Pre-drill holes in the

pressure ﬁ ring plate (item b) to match the appliance studs. Slide the pressure ﬁ ring plate (item b) and ﬂ ange (item c) onto the air tube as shown. Wrap

ceramic ﬁ ber rope around the air tube and press

tightly into the inside diameter of the ﬂ ange (item c). Slide the air tube (item d) into position in the

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appliance front. Tighten the ﬂ ange-mounting stud

nuts. Set the insertion of the air tube so dimension G

is 1/4” nominal. Pitch the air tube at 2° from horizontal as shown and

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secure the ﬂ ange to the air tube.

Mount Air Tube to Burner

Remove the rear access door from the back of the

○

burner for improved access to the interior. Attach the air tube to the burner with the bolts and

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acorn nuts provided. The acorn nuts must go on the outside of the burner, with the bolts inserted from the inside.

Install Nozzle

See Figure 5. Install the oil nozzle in the nozzle adapter.

Use a 3/4” open-end wrench to steady the nozzle adapter and a 5/8” open-end wrench to turn the nozzle. Tighten securely but do not over-tighten.

Check Electrode Settings

Maintain Electrode Speciﬁ cations

Failure to properly maintain these speciﬁ cations could cause ignition malfunction, puff-back of hot gases, heavy smoke, asphyxiation, explosion and ﬁ re hazards.

Check, and adjust if necessary, the critical dimensions

P, Q, R and S shown in Figure 5. Verify that the oil tube

assembly and electrodes are in good condition, with no cracks or damage.

Figure 5 - Nozzle and Nozzle Line Assembly

Figure 4 - Mount Flange on Air Tube

Legend (Figure 5)

P Nozzle centerline to electrode tip = 1/4” Q Nozzle to head = 1/4” R Nozzle face to electrode tip = 1/8” S Electrode spacing = 3/32”

+ 16 hidden pages