Page 1
WARNING
!
Incorrect installation, adjustment, or misuse of this burner could result in death, severe
personal injury, or substantial property damage.
Potential for Fire, Smoke and Asphyxiation Hazards
To the Homeowner or Equipment
Owner:
Please read and carefully follow all instructions
y
provided in this manual regarding your responsibilities
in caring for your heating equipment.
Contact a professional, qualifi ed service agency for
y
installation, start-up or service work.
Save this manual for future reference.
y
Form 6104 BCF10-R06
To the Professional, Qualifi ed Installer
or Service Agency:
Please read and carefully follow all instructions provided
y
in this manual before installing, starting, or servicing this
burner or heating system.
The Installation must be made in accordance with all state
y
and local codes having jurisdiction.
1
Page 2
2
Form 6104 BCF10-R06
Page 3
Before you begin . . .
The following resources will give you addional information for your installation. We suggest that you consult these resources
whenever possible. Pay particular attention to the appliance manufacturer’s instructions.
Appliance manufacturer’s instructions -Always follow the appliance manufacturer’s instructions for burner installation,
equipment and set-up.
1–800–OIL–BURN - Beckett’s technical services hot-line.
www.beckettcorp.com - Beckett’s website.
Table of Contents
General Information ...............................................................................................................................4-5
To the Owner .......................................................................................................................................................4
Hazard Defi nitions ...................................................................................................................... .........................4
Agency approvals ................................................................................................................................................4
General Specifi cations ........................................................................................................................................4
Owner’s Responsibility ........................................................................................................................................5
Professional Installer/Service Agency Responsibility ..........................................................................................5
Pre-installation checklist......................................................................................................................5-7
Combustion air supply .........................................................................................................................................6
Clearances .........................................................................................................................................................6
Fuel supply .........................................................................................................................................................6
Nozzle pressure ..................................................................................................................................................6
Vent system .........................................................................................................................................................7
Electrical supply ..................................................................................................................................................7
Verify burner components ...................................................................................................................................7
Verify fi ring input range ........................................................................................................................................7
Verify air tube ......................................................................................................................................................7
Mount the burner ..................................................................................................................................8-10
Mount fl anges on air tubes ..................................................................................................................................8
Mount air tube to burner ......................................................................................................................................8
Install Nozzle .......................................................................................................................................................8
Check Electrodes ................................................................................................................................................8
Install Nozzle Line Assembly ...............................................................................................................................9
Set Dimension Z ..................................................................................................................................................9
Insert Burner ......................................................................................................................................................10
Connect fuel lines ..............................................................................................................................10-11
Fuel unit By-pass plug .......................................................................................................................................10
Oil supply/return lines ........................................................................................................................................10
Burner fuel fl ow .................................................................................................................................................11
Wire the burner ..........................................................................................................................................12
Sequence of Operation-Typical ..........................................................................................................13
Prepare the burner for start-up .....................................................................................................13-15
Start-up checklist ...............................................................................................................................................13
Z Dimension ......................................................................................................................................................13
Adjusting plate Assembly ..................................................................................................................................14
Initial head position ............................................................................................................................................14
Initial air settings ................................................................................................................................................14
Set appliance limit controls ................................................................................................................................15
Prepare the fuel unit for air venting ...................................................................................................................15
Start the burner ...................................................................................................................................15-16
Start burner and vent air ...................................................................................................................................15
Set air adjusting plate ........................................................................................................................................16
Maintenance and Service ..................................................................................................17
Annual Service ..................................................................................................................................................17
Monthly maintenance ........................................................................................................................................17
Replacement Parts.............................................................................................................................18-19
Warranty ................................................................................................................................... Back Cover
Form 6104 BCF10-R06
3
Page 4
To the Owner:
Thank you for purchasing a Beckett burner for use
with your heating appliance. Please pay attention to the
Safety W arnings 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.
Y our Beckett burner will provide years of effi cient opera-
tion 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.
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.
Agency approvals
UL listed to comply with ANSI/UL296 and certifi ed to
CSA B140.0.
Accepted by N.Y.C. M.E.A.
Other approvals may be available and must be specifi ed at
time of order.
Specifi cations
Hazard defi nitions
Indicates an imminently
hazardous situation,
which, if not avoided, will result in death,
serious injury, or property damage.
Indicates a potentially
hazardous situation,
which, if not avoided, could result in death,
severe personal injury, and/or substantial
property damage.
Indicates a potentially
hazardous situation,
which, if not avoided, may result in personal injury or property damage.
NOTICE
Intended to bring special attention to information,
but not related to personal injury or property
damage.
U.S. #1 or #2 heating
Fuels
oil only (ASTM D396)
Canada #1 stove oil or
#2 furnace oil only
Firing range 4.0 to 10.0 GPH
½ HP 3450 RPM
120/60 hz standard
6.5 amps @ 120 VAC
Motor
Optional voltages:
(60 hz or 50 hz)
• 240/1-PH
• 208/240/480/3-PH
Ignition Trans. 120V/12,000V
Housing Cast aluminum
Fuel unit 100 - 300 PSIG
Oil nozzle 45° - 70° solid
Shipping wt. 75 lbs.
Dimensions See Figure 7 (Page 10)
(See NOTICE on 50 hz motor applications.)
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
R.W. Beckett Corp.
Elyria, Ohio
Made in the U.S.A.
For use with Group 8 . . .
MP 1192 XX000 R00
4
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
L0002
Form 6104 BCF10-R06
Page 5
Owner’s Responsibility:
NOTICE
Follow These Instructions
Exactly
Failure to follow these instructions,
misuse, or incorrect adjustment of
the burner could lead to equipment
malfunction and 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.
Please carefully read and comply with the following
instructions:
Never store or use gasoline or other fl ammable liquids
y
or vapors near this burner or appliance.
Never attempt to burn garbage or refuse in this appli-
y
ance.
Never attempt to light the burner by throwing burning
y
material into the appliance.
Never attempt to burn any fuel not specifi ed and ap-
y
proved for use in this burner.
Never restrict the air inlet openings to the burner or the
y
combustion air ventilation openings in the room.
Professional Installer/Service Agency
Responsibility:
Follow These
Instructions Exactly
Failure to follow these instructions
could lead to equipment malfunction and result in asphyxiation,
explosion or fi re.
Please read all instructions before proceeding. Follow
y
all instructions completely.
This equipment must be installed, adjusted and started
y
by a qualifi ed service agency that is 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
y
ordinances having jurisdiction and the latest editions of
the NFPA 31 and CSA-B139 & B140 in Canada.
NOTICE
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 installations — Accepted industry practice
requires no derate of burner capacity up to 2,000 feet above sea
level. For altitudes higher than 2,000 feet, derate burner capacity
2% for each 1000 feet above sea level.
Pre-installation check-
list
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 in
y
order to start the burner or it will hold in the stray light
lockout mode.
Shield the burner view window from direct exposure to
y
intense light.
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.
y
Electrical controls are not protected against rain or
y
sprayed water.
Keep the installation clear of dust, dirt, corrosive va-
y
pors, and moisture.
Protective covers and more frequent maintenance may
y
be required.
Adequate Combustion
and Ventilation Air Supply
Required
Failure to provide adequate air supply could se-
riously affect the burner performance and result
in damage to the equipment, asphyxiation, explosion or fi re hazards.
The burner cannot properly burn the fuel if it is not sup-
y
plied with a reliable combustion air source.
Follow the guidelines in the latest editions of the NFPA
y
31 and CSA-B139 regarding providing adequate air for
combustion and ventilation.
Form 6104 BCF10-R06
5
Page 6
Combustion air supply
The burner requires combustion air and ventilation air for
y
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 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 NFP A 31 (CSA B1139M91 in Canada).
If there is a risk of the space being under negative pres-
y
sure 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 must be
y
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
Nozzle pressure
Correct Nozzle and Flow
Rate Required
Incorrect nozzles and fl ow rates
could result in impaired combustion,
under-fi ring, over-fi ring, sooting,
puff-back of hot gases, smoke and
potential fi re or asphyxiation haz-
ards.
Use only nozzles having the brand, fl ow rate (gph), spray
angle and pattern specifi ed by the appliance manufac-
turer.
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
y
psig.
This burner utilizes pressures higher than 100 psig, so
y
the actual nozzle fl ow rate will be greater than the gph
stamped on the nozzle body. (Example: A 5.00 gph nozzle at 150 psig = 6.12 gph and at 300 psig = 8.66 gph)
The fuel supply piping and tank must provide #1 or #2 fuel
y
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.
Oil Supply Pressure Control Required
Damage to the pump, fi lter or other compo-
nent seals could cause possible oil leakage
and potential fi re hazard.
The oil supply inlet pressure to the fuel unit cannot ex-
y
ceed 3 psig.
Do NOT install valves in return line.
y
y
Ensure that a pressure-limiting device is installed in accordance with the latest edition of the NFPA 31.
If fuel supply is level with or higher than fuel unit —
When the fuel unit is not required to lift the oil, the instal-
y
lation is usually suitable for either a one-pipe or two-pipe
oil system. The oil pressure at the inlet of the fuel unit must
not exceed 3 psig.
See Figure 8 for one-pipe fuel supply installations. See
y
Figure 9 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 lift the
y
oil more than 8 feet if burner is equipped with a B fuel unit,
or more than 2 feet if burner is equipped with an H fuel
unit. The return line provided by the two-pipe system is
needed to purge the air from the fuel lines and minimize the
likelihood of air-related problems during operation.
6
For typical nozzle fl ow rates at various pressures see ac-
companying chart.
Table 1 - Nozzle Capacities
Rated
gph
@ 100
psig
2.00
2.25
2.50
2.75
3.00
3.50
4.00
4.50
5.00
5.50
6.00
6.50
7.00
7.50
8.00
Pressure - pounds per square inch
125 150 175 200 250 275 300
2.24 2.45 2.65 2.83 3.16 3.32 3.46
2.52 2.76 2.98 3.18 3.56 3.73 3.90
2.80 3.06 3.31 3.54 3.95 4.15 4.33
3.07 3.37 3.64 3.90 4.35 4.56 4.76
3.35 3.67 3.97 4.24 4.74 4.97 5.20
3.91 4.29 4.63 4.95 5.53 5.80 6.06
4.47 4.90 5.29 5.66 6.32 6.63 6.93
5.04 5.51 5.95 6.36 7.11 7.46 7.79
5.59 6.12 6.61 7.07 7.91 8.29 8.66
6.15 6.74 7.28 7.78 8.70 9.12 9.53
6.71 7.35 7.94 8.49 9.49 9.95 10.39
7.27 7.96 8.60 9.19 10.28 10.78 11.26
7.83 8.57 9.26 9.90 11.07 11.61 12.12
8.39 9.19 9.92 10.61 11.86 12.44 12.99
8.94 9.80 10.58 11.31 12.65 13.27 13.86
Form 6104 BCF10-R06
Page 7
The fuel unit nozzle port pressure is factory set at 300 psig.
y
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.
Vent system
y
The fl ue gas venting system must be in good condition and
must comply with all applicable codes.
Electrical supply
y
Verify that the power connections available are correct for
the burner. All power must be supplied through fused disconnect switches.
Verify burner components —
y
Burner box, Model CF1000
y
Air tube assembly
y
Mounting fl ange kit
y
Pedestal mounting assembly kit (recommended)
y
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 recom-
mendation 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).
Verify fi ring rate
y
Refer to appliance manufacturer’s instructions (if available)
for fi ring rate and nozzle selection. Otherwise, the maximum
recommended fi ring rate for the burner depends on 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 1. If the appliance dimensions are smaller
than recommended, reduce the fi ring rate accordingly.
Figure 1. Min. Combustion Chamber Dimensions
Minimum Dimensions
Firing Rate
0 to 5 gph
5 to 10 gph
(refractory-lined) (wet-base boilers)
ALAL
7.0” 25.0” 7.0” 25.0”
8.0” 35.0” 8.0” 40.0”
Figure 2 - Air Tube Mounting Dimensions
E Insertion depth
G Air tube to inside of chamber
0.25” +/- 0.125
T Air tube length
D Tube diameter
Verify air tube
y
The information in this section may be disregarded if the
air tube is supplied by the appliance manufacturer.
y
Two tube arrangements are available –
Tube A — 4.0 to 10.0 GPH per Table 2
Tube B — 7.0 to 10.0 GPH per Table 2
y
Maximum fi ring capacity depends on the fi rebox pressure.
Use Table 2 to verify the correct air tube type for the fi ring
rate required. Use Tube B only when Tube A cannot provide the fi ring rate required.
y
See Figure 2 to verify the correct air tube length and air
tube combination code.
Form 6104 BCF10-R06
Install the burner with a 2 deg. pitch as shown
A.T.C. Codes
Air Tube Length
(Dimension T)
06.75”
10.25”
13.75”
17.75”
(A.T.C. = Air Tube Combination)
Tube A
(Dim. D = 5-1/2”)
CF66KD CF66KE
CF102KD CF102KE
CF136KD CF136KE
CF176KD CF176KE
Tube B
(Dim. D = 5-3/4”)
7
Page 8
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 com-
y
bustion chamber unprotected unless it has been factorytested and specifi ed by the appliance manufacturer.
Position the end of the air tube 1/4” back from fl ush with
y
the refractory inside entry wall to prevent damage from
overheating.
Mount fl ange(s) on air tube
This section does not apply to burners with welded fl ang-
y
es.
Do not install air tube on burner.
y
For non-pressure fi ring fl ange, refer to Figure 3: Install
y
gasket (item a) and fl ange (item c). Ignore the next
paragraph.
For pressure-fi ring fl ange, refer to Figure 3: Slide gasket
y
(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 appliance
y
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 secure
y
the fl ange to the air tube.
Figure 3 - Mount fl ange(s) on air tube
Mount air tube to burner
Remove the rear access door from the back of the burner
y
for improved access to the interior.
Attach the air tube to the burner with the bolts and acorn
y
nuts provided. The acorn nuts must go on the outside of the
burner, with the bolts inserted from the inside.
Table 2 - Air Tube Capacity vs. Firebox Pressure
Firebox
Pressure
(in. w.c.)
0.0
0.2
0.4
0.6
0.8
1.0
Note: 10% turndown indicates suffi cient reserve air to reduce the CO2 in the fl ue to 90% of
Note: The above ratings may vary 5% due to variations in actual job conditions.
Install nozzle
See Figure 4. Install the oil nozzle in the nozzle adapter.
y
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, and adjust if necessary, the critical dimensions P,
y
Q, R and S shown in the drawing. Verify that the oil tube
assembly and electrodes are in good condition, with no
cracks or damage.
Check electrodes
Tube A Tube B
10% turndown No reserve air 10% turndown
2.24 2.45 2.65
2.52 2.76 2.98
2.80 3.06 3.31
3.07 3.37 3.64
3.35 3.67 3.97
3.91 4.29 4.63
its value.
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.
Adjust the electrode gap and position in relation to the
y
nozzle to the specifi cations shown in Figure 4.
Check, and adjust if necessary, the critical dimensions P,
y
Q, R and S shown in the drawing. Verify that the oil tube
assembly and electrodes are in good condition, with no
cracks or damage.
8
Form 6104 BCF10-R06
Page 9
Figure 4 - Nozzle and nozzle line assembly
Critical dimensions -
(Electrode spacing) = 3/32”RNozzle center line to electrode tip) = 1/4”
P
(Nozzle to head) = 1/4”
Q
Nozzle face to electrode tip = 1/8”
S
Install nozzle line assembly
Insert the nozzle line assembly into the burner air tube as
y
in Figure 5.
See Figures 5 and 6. Assemble the adjusting plate assem-
y
bly per the instructions in the assembly packet.
Slide the secondary adjusting plate (item f) completely to
y
the left on the indicator adjusting plate (item e). Finger
tighten acorn nut c to secure the two plates together. Slide
both plates completely to the left on the primary adjusting
plate (item g) and fi nger-tighten acorn nut d.
Slide the completed adjusting plate assembly over the noz-
y
zle line end. Move the plate assembly and the nozzle line
so the plate assembly fi ts into position as shown in Figure
5.
Install the spline nut (Figure 5, item b) on the end of the
y
nozzle line, leaving the nut loosely placed so the plates can
be moved.
Connect the high-voltage leads from the ignition trans-
y
former to the electrodes.
Figure 6 - Adjusting plate assy.
Figure 5 - Nozzle line assembly in burner
Measure dimension Z from
front (fl at) face of head to
end of air tube, as shown.
Measure dimension Z from the
fl at surface between (not on) the
raised fi ns.
Legend (Figures 5 and 6)
Bottom acorn nut
c
Top acorn nut (for setting
d
dim. Z only
Indicator adjusting plate
e
Secondary adjusting plate
f
Primary adjusting plate
g
Z = 1-3/4” ± 1/16”
Set dimension Z
Replace the rear access door on the burner, making sure
y
that the adjusting plate assembly is now securely in the
groove.
Loosen acorn nut d in Figure 5. Slide the nozzle line and
y
plate assembly until dimension Z in Figure 5 is 1-3/4” ±
1/16”. When dimension Z (from end of air tube to fl at area
of front face of head) is correctly set, tighten acorn nut d.
Verify that the adjusting plate assembly is properly seated
in the adjusting groove.
Attach the oil line from the oil valve to the nozzle line end.
y
Tighten securely.
Before proceeding, check dimension Z once again. Loosen
y
acorn nut d if necessary to reposition the nozzle line. Once
dimension Z is set, do not loosen acorn nut d again. For
the setting of acorn nut c, refer to Page 13.
Form 6104 BCF10-R06
9
Page 10
Insert burner
Position the burner in the front of the appliance and loosely
y
tighten the nuts on the mounting studs. The burner should
be pitched downward 2° as shown in Figures 2 and 3.
See Figure 7. Install the pedestal support kit (recommend-
y
ed) by attaching the ¾” NPT fl ange (item a) to the bottom
of the burner using the (4) #10 screws provided. Cut and
thread (one end only) a ¾” pipe nipple (item b) with length
10 inches less than dimension D in Figure 7. Thread the
pipe into the fl ange. Then slip the pipe end into the fl oor
fl ange (item c).
Secure the burner to the appliance by tightening the nuts on
y
the burner fl ange mounting studs. Then secure the pedestal
support fl oor fl ange set screw to the pipe.
Connect Fuel Lines
Fuel unit by-pass plug
Oil supply/return lines
Install the oil tank and oil lines in accordance with all
y
applicable state and local codes.
Size the oil supply and return lines using the guidelines
y
given in the fuel unit literature included in the literature
envelope. Oil line fl ow rate will equal the burner rate for
one-pipe systems. For two-pipe systems, refer to Table 3
for the fuel unit gear set capacity - the rate at which fuel
is recirculated when connected to a two-pipe system. Size
two-pipe oil lines based on this fl ow rate.
Use continuous lengths of heavy-wall copper tubing, routed
y
under the fl oor where possible. Do not attach fuel lines to
the appliance or to fl oor joists if possible. This will reduce
vibration and noise transmission problems.
Install an oil fi lter sized to handle the fuel unit gearset fl ow
y
capacity (Table 3) for two-pipe systems. Size the fi lter
for the fi ring rate for one-pipe systems. Locate the fi lter
immediately adjacent to the burner fuel unit.
Install two high-quality shut-off valves in accessible
y
locations on the oil supply line. Locate one valve close
to the tank. Locate the other valve close to the burner,
upstream of the fuel fi lter.
Do Not Install By-pass
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.
The burner is shipped without the by-pass plug in-
y
stalled.
Intall the by-pass plug in two-pipe oil supply systems
y
ONLY.
Use a two-pipe system, one-pipe system with by-pass
y
loop, or remove the by-pass plug when using with a
one-pipe system and no by-pass loop
Figure 7 - Burner installed in appliance front
Legend
H Housing total length — 18”
J Center to bottom of housing — 10-7/8”
K Overall housing height — 13-3/8”
10
Form 6104 BCF10-R06
Page 11
Table 3 - Fuel unit gearset capacities
Figure 8 - One-pipe oil fl ow with “B” pump
Fuel unit
model number
B2TA8245
Burner fuel fl ow
Gearset capacity
(gallons per hour)
21
Install Oil Supply To
Specifi cations
Failure to properly install the oil
supply system could cause oil
leakage, equipment malfunction,
puff-back of hot gases, heavy smoke,
asphyxiation, explosion and fi re
hazards.
Carefully install the oil supply lines, fi ttings and com-
y
ponents using the guidelines provided in this section.
The oil supply must comply with the latest edition
y
of NFPA 31 (Canada CSA B139) and all applicable
codes.
Do not install valves in return line.
y
If the oil supply inlet pressure to the pump exceeds 3
y
psig or for gravity feed systems, install an oil safety or
pressure reducing valve (Webster OSV, Suntec PRV or
equivalent).
One-pipe systems – See Figure 8 for the fuel fl ow path.
y
Oil supply connects to one of the fuel unit inlet ports.
y
Two-pipe systems – See Figure 9 for the fuel fl ow paths
y
for two-pipe oil systems.
Oil supply connects to one of the fuel unit inlet ports. Oil
y
return connects to the fuel unit return port. (Install the
by-pass plug in the fuel unit for two-pipe systems.)
300 psig
300 psig
Figure 9 - Two-pipe oil fl ow with “B” pump
300 psig
300 psig
Legend
a Return port
b Nozzle port
c Oil valve
d Nozzle & adapter
Nozzle pressure – The fuel unit nozzle port pressure
y
is factory set at 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.
g Inlet port
k Return line to oil tank
p Air bleed valve
Form 6104 BCF10-R06
11
Page 12
Wire the burner — R7184
Electrical Shock Hazard
Electrical shock can cause severe personal in-
jury or death.
Disconnect electrical power before installing or servic-
y
ing the burner.
Provide ground wiring to the burner, metal control en-
y
closures and accessories. (This may also be required to
aid proper control system operation)
Perform all wiring in compliance with the National
y
Electric Code ANSI/NFPA 70 (Canada CSA C22.1).
Do Not Bypass Safety
Controls
Tampering with, or bypassing safety controls
could lead to equipment malfunction and result
in asphyxiation, explosion or fi re.
Safety controls are designed and installed to provide
y
protection.
Do not tamper with, or bypass any safety control.
y
If a safety control is not functioning properly, shut off
y
all main electrical power and fuel supply to the burner
and call a qualifi ed service agency immediately.
Professional Installation
and Service Required
Incorrect installation and mishandling of start-up
could lead to equipment malfunction and result
in asphyxiation, explosion or fi re.
This burner must be installed and prepared for start-up
y
by a qualifi ed service technician who is trained and ex-
perienced in commercial oil burner system installation
and operation.
Do not attempt to start the burner unless you are fully
y
qualifi ed.
Do not continue with this procedure until all items in
y
the “Prepare the burner for start-up” section have been
verifi ed.
Carefully follow the wiring diagrams, control instruc-
y
tion sheets, fl ame safeguard sequence of operation, test
procedures and all appliance manufacturer’s directions
that pertain to this installation.
If any of these items are not clear or are unavailable,
y
call Beckett at 1-800-645-2876 for assistance.
Figure 10 - Typical Wiring
Legend
Fused Disconnect, by others
FD
Limit controls, by others
LM
Operating controls, by others
OP
Oil primary control, R7184 typ.
PR
Flame sensor, cad cell typical
CC
Ignition transformer
TR
Burner motor
M1
Oil valve
S1
24-volt thermostat/limit terminals
T-T
Cad cell fl ame sensor terminals
F-F
Keep Service Access Cov-
ers Securely Installed
These covers must be securely in place to
prevent electrical shock, damage from external elements, and protect against injury from
moving parts.
All covers or service access plates must be in place at
y
all times except during maintenance and service.
This applies to all controls, panels, enclosures, switch-
y
es, and guards or any component with a cover as part
of its design.
Install the burner and all wiring in accordance with the National
Electrical Code and all applicable local codes or requirements.
Wire the burner in compliance with all instructions provided by
the appliance manufacturer. Verify operation of all controls in
accordance with the appliance manufacturer’s guidelines.
See Figure 10 for a typical wiring diagram, with R7184 oil
primary, for reference purposes only.
12
Form 6104 BCF10-R06
Page 13
Sequence of Oper ation
Prepare the burner for
(typical)
1
Standby — The burner is idle, waiting for a call for heat.
1.
When a call for heat is initiated, there is a 3-10 second delay
while the control performs a safe start check.
V alve-on delay — As applicable, the ignition and motor are
2.
turned on for a 15-second prepurge.
Trial for ignition (TFI) — The fuel valve is opened, as
3.
applicable. A fl ame should be estalished within the 15-
second lockout time.
Lockout — If fl ame is not sensed by the end of the TFI,
4.
the control shuts down on safety lockout and must be
manually reset. If the control locks out three times in a row,
the control enters restricted lockout. Call a qualifi ed service
technician.
Ignition carryover — Once fl ame is established, the
5.
ignition remains on for 10 seconds to ensure fl ame stability.
It then turns off.
Run — The burner runs until the call for heat is satisfi ed.
6.
The burner is then sent to burner motor-off delay, as
applicable, or it is shut down and sent to standby.
Recycle — If the fl ame is lost while the burner is fi ring, the
7.
control shuts down the burner, enters a 60-second recycle
delay, and then repeats the ignition steps outlined above. If
the fl ame is lost three times in a row, the control locks out
to prevent continuous cycling with repetitious fl ame loss
caused by poor combustion.
Burner motor-off delay — If applicable, the fuel valve
8.
is closed and the burner motor is kept on for the selected
postpurge time before the control returns the burner to
standby.
start-up
Start-up checklist - Verify the following before
attempting to start burner.
Combustion air supply and venting have been inspected
and verifi ed to be free of obstructions and installed in
accordance with all applicable codes.
Oil nozzle has been selected correctly and securely
installed in the nozzle adapter.
Fuel unit by-pass plug has not been installed for one-
pipe oil system.
By-pass plug has been installed for two-pipe oil
system.
Fuel connection to nozzle line assembly is secure.
Dimension Z has been set per this instruction manual.
Fuel supply line is correctly installed, the oil tank is
suffi ciently fi lled, and shut-off valves are open.
Burner is securely mounted in appliance, with pressure
fi ring plate and gasket installed for pressurized chamber
application.
Appliance has been fi lled with water (boilers) and
controls have been operationally checked.
Burner has been installed in accordance with appliance
manufacturer’s instructions (when available).
Also refer to appliance manufacturer’s instructions
(when available) for start-up procedures.
Z dimension
The adjusting plate should be set per these instructions
(see page 9). The top acorn nut (Figure 11, item d) should
never be loosened once the Z dimension is initially set.
Figure 11 - Adjusting plate initial setting, typical
Legend (Figure 11)
Spline nut for securing nozzle line
b
Bottom acorn nut (for head adjustment)
c
d
Top Acorn nut (for setting dimension Z only)
-do not loosen after setting dimension Z
Indicator adjusting plate
e
Secondary adjusting plate
f
Primary adjusting plate
g
Copper oil line from oil valve to nozzle line
h
Form 6104 BCF10-R06
13
Page 14
Adjusting plate assembly (Figure 11)
Make sure spline nut (item b) and bottom acorn nut (item
c) are loose.
Initial head position (Figure 11)
The indicator plate assembly (item e) markings correspond
y
to head position settings. Slide the secondary adjusting
plate (item f) toward the rear of the burner until the number
on the indicator plate corresponds to the initial head setting
given in Table 4 for the desired fi ring rate.
Figure 11 shows a typical example, with a head setting of
y
6.
When the head position has been set, tighten the bottom
y
acorn nut (item c) and the spline nut (item b).
Initial air settings (Figure 12)
Loosen the screw holding the air adjusting plate (item m).
y
Set the air to the desired rate. (The numbers on this plate
correspond to the approximate fi ring rate settings given in
Table 5.)
Rotate the air adjusting plate until the lower edge of the
y
pointer is opposite the number from Table 5 corresponding
to the desired fi ring rate.
This initial setting should be adequate for starting the burner.
y
Tighten the screw to secure the adjusting plate. Once the
burner is in operation, the air setting will be adjusted for
best performance as discussed later in this manual.
Follow the procedures given later in this manual for fi ne-
y
tuning the air settings.
Figure 12 - Air damper assembly
l
Legend
Damper label - position indicator for air adjustment plate
h
Damper indicator - permanently attached to damper
k
Air adjusting plate - sets air position
m
Air adjusting plate screw - locks plate position
l
Table 4 - Initial indicator adjustment plate
settings (head position)
Approximate
adjusting
plate setting
0 -1 -2 4.00 3 6.00 4 7.00 7.00
5 8.00 8.00
6 10.00 10.00
7 - 12 --
These settings are approximate, and
NOTE
can vary depending on actual job conditions and overfi re pressure.
Firing rate, gph
Tube “A” Tube “B”
14
Table 5 - Initial air adjusting plate settings
(damper position)
Approximate
head settings
0 4.00 4.00
1 4.50 7.50
2 5.00 8.00
3 6.00 9.00
4 7.00 10.00
5 7.50 -
6 8.00 -
7 - 10 10.00 -
These settings are approximate, and
NOTE
can vary depending on actual job conditions and overfi re pressure.
Firing rate, gph
Tube “A” Tube “B”
Form 6104 BCF10-R06
Page 15
Set appliance limit controls
Set the appliance limit controls in accordance with the
y
appliance manufacturer’s recommendations.
Prepare the fuel unit for air venting
T o vent air from one-pipe oil systems, attach a clear hose to
y
the vent plug on the fuel unit. Provide a container to catch
the oil. Loosen the vent plug.
Vent the air as described under Start the burner.
y
Start the Burner
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.
Do not attempt to start the burner when excess oil has
y
accumulated in the appliance, the appliance is full of
vapor, or when the combustion chamber is very hot.
Do not attempt to re-establish fl ame with the burner
y
running if the fl ame becomes extinguished during start-
up, venting, or adjustment.
V apor-Filled Appliance: Allow the unit to cool off and
y
all vapors to dissipate before attempting another start.
Oil-Flooded Appliance: Shut off the electrical power
y
and the oil supply to the burner and then clear all accumulated oil before continuing.
If the condition still appears unsafe, contact the Fire De-
y
partment. Carefully follow their directions.
Keep a fi re extinguisher nearby and ready for use.
y
Starting the burner and venting air
Hot Gas Puff-back and
Heavy Smoke Hazard
Failure to bleed the pump properly
could result in unstable combustion,
hot gas puff-back and heavy smoke.
Do not allow oil to intermittently spray into a hot com-
y
bustion chamber while bleeding.
Install a gauge in the nozzle discharge port tubing or
y
fully open the pump bleed valve to prevent oil spray
from accumulating in the combustion chamber when
venting air from the fuel pump.
Ensure that all bubbles and froth are purged from the
y
oil supply system before tightening the pump air bleed
valve.
Verify that the air adjusting plate (Figure 12, item m) has
1.
been set to the initial air position as described on page 14
under Initial air settings.
Open the oil shut-off valves in the oil supply (and return)
2.
line(s) to the burner.
Form 6104 BCF10-R06
Set the thermostat (or operating control) to call for heat.
3.
Close the line switch to the burner. The burner motor should
4.
start immediately.
15
Page 16
If the burner motor does not start, reset the motor overload
5.
switch (if so equipped) and press the reset switch of the
burner primary control.
V ent the fuel unit as soon as the burner motor starts rotating.
6.
To vent —
Attach a clear plastic tube to the air bleed valve (Figure
8 or 9 as applies, item p).
Place the end of the tube in a container to catch the oil.
Then loosen the fuel unit air vent valve.
Tighten the air vent valve after all air has been purged.
IF burner stops during venting —
The burner primary control will lockout if fl ame is not
y
established within its time limit. This is typically 15
seconds for R7184B primary controls, but may be less
for other fl ame supervisory controls.
The burner may lockout several times during the period
y
needed to purge all the air. Press the red reset button
for ½ second during the prepurge cycle to extend air
venting time.
IF burner stops after fl ame established —
Additional venting is probably required. Repeat the
y
air venting procedure.
7. Once fl ame is steady, proceed to Set air adjusing plate.
Set air adjusting plate (Figure 12)
Allow the burner to run until the appliance has warmed
1.
suffi ciently.
Visually check the fl ame. The fl ame should not be dark
2.
orange or smoky. If the fl ame appears to be smoking,
increase the amount of air by re-adjusting the damper
indicator to a higher number.
Once the appliance has warmed, the air setting can be
3.
checked and adjusted.
Use combustion test instruments to adjust the burner.
4.
a. Adjust the air until a trace of smoke is achieved with
CO2 level as high as possible (lowest possible O2).
Example: 13.5% CO2 (2.5% O2) with a trace of
smoke.
b. Increase the air to reduce CO
at a zero smoke level. (Increase O
points at a zero smoke level.)
Example: Reduce CO
zero smoke (or increase O2 from 2.5% to 5.5%).
c. This procedure provides a margin of reserve air to ac-
commodate variable conditions.
Check the breech draft pressure against the appliance
5.
manufacturer’s recommended setting (typically + 0.1”
W.C.).
If the breech pressure is higher or lower than recommend-
6.
ed level, adjust the appliance breech damper to achieve
the specifi ed setting. Recheck the smoke and CO2 levels.
Adjust burner air if necessary and tighten the air adjusting plate screw securely.
by 2 percentage points
2
by 3 percentage
2
from 13.5% to 11.5%, with
2
16
Form 6104 BCF10-R06
Page 17
Maintenance and Service
Inspect the igniter spring contacts.
Annual Professional
Service Required
Tampering with or making incorrect
adjustments could lead to equipment
malfunction and result in asphyxiation, explosion or fi re.
Do not tamper with the burner or controls or make
y
any adjustments unless you are a trained and qualifi ed
service technician.
To ensure continued reliable operation, a qualifi ed
y
service technician must service this burner annually.
More frequent service intervals may be required in dusty
y
or adverse environments.
Operation and adjustment of the burner requires technical
y
training and skillful use of combustion test instruments
and other test equipment.
Annual service — by qualifi ed service techni-
cian
Have the burner inspected, tested and started at least annually
by a qualifi ed service technician. This annual test/inspection
should include at least the following:
Replace the oil supply line fi lter. The line fi lter cartridge
must be replaced to avoid contamination of the fuel unit
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 if applicable.
Replace the nozzle with the exact brand, pattern, gph, fl ow
rate and spray angle.
Clean and inspect the electrodes for damage, replacing any
that are cracked or chipped.
Check electrode tip settings. Replace electrodes if tips are
rounded.
Clean the cad cell lens surface, if necessary.
Inspect all gaskets. Replace any that are damaged or would
fail to seal adequately.
Inspect the combustion head and air tube. Remove any car-
bon or foreign matter. Replace all damaged units with exact
parts.
Clean the blower wheel, air inlet, air guide, and burner
housing of any lint or foreign material.
If motor is not permanently lubricated, oil motor with a few
drops of SAE 20 nondetergent oil at each oil hole. DO NOT
over oil motor. Excessive oiling can cause motor failure.
Check motor current. The amp draw should not exceed the
nameplate rating.
Check all wiring for secure connections or insulation
breaks.
Check the pump pressure and cutoff function.
Check primary control safety lockout timing.
Check ignition system for proper operation.
Inspect the vent system and chimney for soot accumulation
or other restriction.
Clean the appliance thoroughly according to the manufac-
turer’s recommendations.
Check the burner performance. Refer to the section “Set
combustion with test instruments”.
It is good practice to make a record of the service performed
and the combustion test results.
Monthly maintenance — by owner
Observe combustion air openings and vent system for
integrity. Openings must be clean and free of obstructions.
Check oil lines and fi ttings to verify there are no leaks.
Observe burner ignition and performance to verify smooth
operation.
Shut the system down if you observe abnormal or
questionable operation. Call a qualifi ed service agency for
professional inspection and service.
Form 6104 BCF10-R06
17
Page 18
Replacement parts
Item Part Name Description Part Number
1 Timer Nozzle valve delay 21295U
2 Oil Valve Box mounted 21789U
3 Adjusting plate assembly CF10-2300 Kit 51213U
4 Knurled nut All models 3666
5 Fuel pump
6 Pedestal kit All models 51193
7 Fuel lines Specify length -
8 Damper spring All models 4339
9 Sight glass All models 31346
10 Rear cover door assembly
11 Control Specify -
12 Damper indicator All models 5985BK
13
14 Head assembly CF1000 combustion 51203P
Coupling Hole Plug
Coupling Access Door
B2TA-8245
H3PAN-C150H
Cast aluminum door*
Stamped sheet-metal door*
Use with threaded hole
Use with rectangular opening
21313U
21309U
5994U
5201301U
32439U
16703GY
15 Electrode assembly All models 51212
8-1/4” long
16 Ignition leads
17 Nozzle line assembly Refer to Figure 2, Page 7
18 Air tube Refer to Figure 2, Page 7
19 Transformer 12,000 volt 51214
20 Coupling
21 Blower wheel CF1000 5.50” x 3.09” 21268U
22 Motor
Motor relay (not shown)
Adjustable fl ange see Figure 13 on opposite page
11-3/4” long
15-1/4” long
19-1/4” long
B pump
H pump
120/208-230V single phase
208/230-460V three phase
120V single phase
208V single phase
three phase
* These doors are NOT interchangeable. Please specify what you are replacing.
5990082
5990116
5990152
5990192
21290
21308
21401U
21638U
7273
7300
21719
18
Form 6104 BCF10-R06
Page 19
1
2
3
9
10
11
4
13
8
7
5
14
15
16
17
18
6
12
Figure 13 - Adjustable Mount-
Figure 14 - Adjustable mount-
ing Plates for CF1000
ing plates for CF1000
Form 6104 BCF10-R06
19
20
21
22
19
Page 20
Limited Warranty Information
Limited
WARRANTY
For Residential, Commercial and Specialty Burners
The R. W. BECKETT CORPORATION (“Beckett”) warrants to persons who purchase its Beckett burners from Beckett for resale or for
incorporation into a product for resale (“Customers”) that its equipment is free from defects in material and workmanship under normal use and
service for 60 months from the date of manufacture for Residential Burners and 18 months from the date of manufacture for Commercial and
Specialty Burners. Residential burner models include: AF, AFG, AFII, NX, SF, SR and SMG. Commercial burner models include: CF375,
CF500, CF800, CF1400, CF2300A, CF2500, CF3500A, CG10, CG15, CG25 and CG50. Specialty burner models include: ADC, ADCP, ARV,
SDC and SM. The provisions of this warranty are extended to individual major burner components as follows:
a) 60 months from date of manufacture for all Beckett-branded major components, except for 12 Vdc components.
b) 18 months from date of manufacture for all non-Beckett-branded major components and Beckett branded 12 Vdc components.
Note: Normal service items found to be defective upon receipt by the customer are covered by this warranty.
THIS WARRANTY DOES NOT EXTEND TO EQUIPMENT SUBJECTED TO MISUSE, NEGLECT, OR ACCIDENT: NOR DOES THIS WARRANTY APPLY
UNLESS THE PRODUCT COVERED BY IT IS PROPERLY INSTALLED BY A QUALIFIED, COMPETENT TECHNICIAN, WHO IS LICENSED WHERE
STATE AND LOCAL CODES REQUIRE, AND WHO IS EXPERIENCED IN MAKING SUCH INSTALLATIONS, IN ACCORDANCE WITH THE LATEST
EDITION OF NFPA NO. 31 OF THE NATIONAL FIRE PROTECTION ASSOCIATION, THE LATEST EDITION OF THE NATIONAL FUEL GAS CODE (NFPA
NO. 54) AND IN ACCORDANCE WITH ALL APPLICABLE LOCAL, STATE AND NATIONAL CODES HAVING JURISDICTIONAL AUTHORITY.
Equipment, which is defective in material or workmanship and within the warranty period, may be returned for credit as follows:
Beckett Burners, Beckett-branded major components and non-Beckett-branded major components that came as original equipment on a Beckett burner
or were sold as a replacement part by Beckett should be returned, freight prepaid, to Beckett’s home office. Credit will be issued to the customer unless
the returned equipment is determined by Beckett to be out of warranty or damaged by user, in which case the equipment will be scrapped.
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.
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 being limited to credit as set forth above.
Beckett neither assumes nor
R.W. BECKETT CORPORATION
P.O. Box 1289 Elyria, Ohio 44036
Form No. 61545 R72905
R.W. BECKETT CORPORATION
U.S.A.: P.O. Box 1289 · Elyria, Ohio 44036
www.beckettcorp.com
Canada: R.W. Beckett Canada, Ltd. · Unit #3, 430 Laird Road · Guelph, Ontario N1G 3X
Printed in U.S.A. 12/2006
© R.W. Beckett Corporation
20
Form 6104 BCF10-R06
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