Beckett CF2300A User Manual

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Page 1

MODELMODEL

MODEL

MODELMODEL

2300

Oil

Instruction Manual

Low/High Operation

Firing rate: 7.0 – 19.9 GPH Motor voltage: 120 / 60 Hz std.

2300A

Burner

Thank you

Beckett burner. With proper care and

regular maintenance, it will provide

years of trouble-free service. Please

take a few minutes to read the section

entitled “T o the owner” inside this

manual. Then, keep the manual in a

safe place where it can be easily

located if needed by your professional

service technician.

for purchasing a

Page 2

Instruction Manual – Model CF2300A Oil Burner

Please . . . read this page first

Hazard definitions

The following will be used throughout this manual to bring attention to hazards and their risk factors, or to special information.

Denotes presence of a hazard which, if ignored, will result in severe personal injury, death or substantial property damage.

Denotes presence of a hazard which, if ignored, could result in severe personal injury , death or substantial property damage.

Denotes presence of a hazard which, if ignored, could result in minor personal injury

or property damage.

To the owner —

Installation and adjustment of the burner requires technical knowledge and the use of combustion test instruments. Do not tamper with the unit or controls. Call your qualified service technician. Incorrect operation of the burner could result in severe personal injury, death or substantial property damage.

Have your equipment inspected and adjusted at least annually by your qualified service technician to assure continued proper operation.

Never attempt to use gasoline in your heating appliance or to store gasoline or combustible materials near the heating equipment. This could result in an explosion or fire, causing severe personal injury, death or substantial property damage.

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

or property damage.

To the owner —

Never burn garbage or refuse in your heating appliance or try to light the burner by tossing burning material into the appliance. This could result in severe personal injury, death or substantial property damage.

Never attempt to use crankcase or waste oil in your heating appliance. This could damage the fuel unit or heating equipment, resulting in risk of severe personal injury, death or substantial property damage.

Never restrict air openings on the burner or to the room in which the appliance is located. This could result in fire hazard or flue gas leakage, causing severe personal injury, death or substantial property damage.

To the installer —

Read all instructions before proceeding. Follow all instructions completely. Failure to follow these instructions could result in equipment malfunction, causing severe personal injury, death or substantial property damage.

This equipment must be installed, adjusted and started only by a qualified service technician – an individual or agency, licensed and experienced with all codes and ordinances, who is responsible for the installation and adjustment of the equipment. The installation must comply with all local codes and ordinances and with the National Fire Protection Standard for Oil-Burning Equipment, NFPA 31 (or CSA B139-M91).

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 4% for each 1000 feet above sea level.

To the installer —

Concealed damage - If you discover damage to the burner or controls during unpacking, notify the carrier at once and file the appropriate claim.

Contacting Beckett for service information or parts - Please record the burner serial number (and have available when calling or writing). You will find the serial number on the Underwriters Laboratories label, located on the left rear of the burner.

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 specific application data.

Form 6104 BCF-23-R0399

Page 3

Instruction Manual – Model CF2300A Oil Burner

Warranty

Beckett warrants its equipment to those who have purchased it for resale, including your dealer. If you have any problems with your equipment or its installation, you should contact your dealer for assistance.

Refer to warranty sheet in literature packet included with burner for details.

Specifications

Fuels #1 or #2 Fuel Oil Firing range 7.0 to 19.9 GPH Motor ¾ HP 3450 RPM

120/60 hz standard

12.5 amps @ 120 VAC 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. 90 lbs. Dimensions See Figure 7 (Page 7)

Contents

Please . . . read this page first ................ 2

Pre-installation checklist........................... 4

Mount the burner .......................................... 6

Connect fuel line(s) ...................................... 8

Wire the burner ............................................ 10

Sequence of operation - typical ............ 11

Prepare the burner for start-up ............. 11

Start the burner .......................................... 14

Maintenance and service......................... 15

Replacement parts................... Back cover

(See NOTICE on opposite page for 50 hz motor applications.)

Agency approvals

• Underwriters Laboratories has certified this burner to comply with ANSI Standard 296 and has listed it for use with No. 1 or No. 2 fuel oil as specified in ASTM D396. State and local approvals appear on the burner rating label.

• Certified by ULC.

• Approved by Commonwealth of Massachusetts - State Fire Marshall.

• Accepted by N.Y.C. M.E.A.

• Other approvals may be available and must be specified at time of order.

Form 6104 BCF-23-R0399

Before you begin . . .

The following resources will give you additional 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 — Alw ays follow

the appliance manufacturer’s instructions for burner installation, equipment and setup.

1–800–OIL–BURN — Beckett’s technical services hot-line. www.beckettcorp.com — Beckett’ s website.

Page 4

Instruction Manual – Model CF2300A Oil Burner

Rated gph @

100 psig

Pressure - pounds per square inch

125 150 175 250 275 300

4.50 5.04 5.51 5.95 7.11 7.46 7.79

5.00 5.59 6.12 6.61 7.91 8.29 8.66

5.50 6.15 6.74 7.28 8.70 9.12 9.53

6.00 6.71 7.35 7.94 9.49 9.95 10.39

6.50 7.27 7.96 8.60 10.28 10.78 11.26

7.00 7.83 8.57 9.26 11.07 11.61 12.12

7.50 8.39 9.19 9.92 11.86 12.44 12.99

8.00 8.94 9.80 10.58 12.65 13.27 13.86

9.00 10.06 11.02 11.91 14.23 14.92 15.59

10.00 11.18 12.25 13.23 15.81 16.58 17.32

11.00 12.30 13.47 14.55 17.39 18.24 19.05

12.00 13.42 14.70 15.87 18.97 19.90 20.78

Pre-installation checklist

❏ Combustion air supply

• The burner requires combustion air and ventilation 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 confined spaces, the room must have an air opening near the top of the room plus one near the floor, 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 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 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.

❏ Vent system

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

❏ Electrical supply

• Verify that the power connections available are correct for the burner. All power must be supplied through fused disconnect switches.

❏ Verify burner components —

• Burner box, Model CF2300A

• Air tube assembly (selected per following)

• Mounting flange kit

• Pedestal mounting assembly kit (recommended)

• Oil nozzle, per Table 1 — Use only 45° to 70° solid pat- tern nozzles unless otherwise shown by appliance manufacturer. Find the required firing rate in the 300 psig column (high fire rate). Select the corresponding nozzle from column 1 (Rated gph @ 100 psig).

❏ Fuel supply

• The fuel supply piping and tank must provide #1 or #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 b urner carton to verify allowable suction pressure.

When fuel supply is level with or higher than burner fuel unit —

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

• The fuel unit is shipped with the by-pass plug installed.

Leave the by-pass plug installed for all low/high firing burners, regardless whether one-pipe (with by-pass loop) or two-pipe. See Figure 8 for installation of the by-pass loop required for one-pipe fuel supply installations. See

Figure 9 for connections to the fuel unit for two-pipe fuel

supply installations.

When fuel supply is below the burner fuel unit —

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

T able 1 – Nozzle capacities at various pressures

Form 6104 BCF-23-R0399

Page 5

Instruction Manual – Model CF2300A Oil Burner

2304

2°

A.T.C. Codes

(A.T.C. = Air Tube Combination)

Tube KG Tube KS

(Dim T) (Dim D) (Dim F) (Dim T) (Dim D) (Dim F)

All — 6¹⁄₂” 2¹⁵⁄₁₆” All — 8¹⁄₈” 3¹¹⁄₁₆”

6¾” CF 66 KG 6¾” CF 66 KS

— — 8¾” CF 86 KS 10¼” CF 102 KG 11” CF 110 KS 13¾” CF 136 KG 14½” CF 144 KS 17¾” CF 176 KG 18½” CF 184 KS

Firebox

pressure

(In. w.c.)

Tube KG Tube KS

No reserve

air

10%

turndown

No reserve

air

10%

turndown

0.0 19.9 GPH 19.9 GPH 19.9 GPH 19.9 GPH

0.2 19.2 GPH 19.1 GPH 19.7 GPH 19.6 GPH

0.4 18.5 GPH 18.3 GPH 19.5 GPH 19.3 GPH

0.6 17.9 GPH 17.6 GPH 19.4 GPH 19.1 GPH

0.8 17.2 GPH 16.8 GPH 19.2 GPH 18.8 GPH

1.0 16.5 GPH 16.0 GPH 19.0 GPH 18.5 GPH

Note: 10% turndown indicates sufficient reserve air to reduce th e CO2 in the

flue to 90% of its value.

Note:

The above ratings may vary 5% due to variations in actual job conditions.

❏ Verify firing rate

• Refer to appliance manufacturer’s instructions (if available) for firing rate and nozzle selection. Otherwise, the maximum recommended firing rate for the burner depends on the length of the firing chamber and the distance from the burner center to the chamber floor . 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 firing rate accordingly.

❏ Verify air tube

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

• Two tube arrangements are available –

Tube KG — 7.0 to 19.9 GPH per Table 2 Tube KS — 10.0 to 19.9 GPH per Table 2

• Maximum firing capacity depends on the firebox pressure. Use Table 2 to verify the correct air tube type for the firing rate required. Use Tube KS only when Tube KG cannot provide the firing rate required.

• See Figure 2 to verify the correct air tube length and air tube combination code.

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

① Install the burner with a 2° pitch as shown.

Figure 1 – Min. combustion chamber dimensions

Firing rate

5 to 10 gph 8.0" 35.0" 8.0" 40.0" 10 to 15 gph 9.0" 40.0" 9.0" 50.0"

15 to 20 gph 11.0" 55.0" 11.0" 60.0"

Minimum dimensions

(refractory-lined) (wet-base boilers)

A L A L

Form 6104 BCF-23-R0399

T able 2 – Air tube capacity vs. firebox pressure

2305

Page 6

Instruction Manual – Model CF2300A Oil Burner

2306-2

Mount the burner

❏ Mount flange(s) on air tube

• This section does not apply to burners with welded flanges.

• Do not install air tube on burner.

• For non-pressure firing flange, refer to Figure 3: Install

gasket (item a) and flange (item d). Ignore the next paragraph.

• For pressure-firing flange, refer to Figure 3: Slide gasket

(item a) onto the air tube, making sure the top of the air tube is up. Predrill holes in the pressure firing plate (item b) to match the appliance studs. Slide the pressure firing plate (item b) and flange (item d) onto the air tube as shown. Wrap ceramic fiber rope (item c) around the air tube and press tightly into the inside diameter of the flange (item d).

• Slide the air tube (item e) into position in the appliance front. Tighten the flange-mounting-stud nuts. Set the insertion of the air tube so dimension G is ¼" nominal.

• Pitch the air tube at 2° from horizontal as shown and secure the flange to the air tube. Remove the flange-mounting stud nuts and remove the air tube from the appliance.

Figure 3 – Mount flange(s) on air tube

2°

Figure 4 – Nozzle and nozzle line assembly

Critical dimensions — S Q

(Electrode spacing)

(Nozzle to head)

= ³⁄₃₂" = ¹⁄₄"

(Nozzle center line to electrode tip)

(Nozzle face to electrode tip)

2306-1

= ¹⁄₄" = ¹⁄₈"

abd

2312

❏ 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 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 4. Install the oil nozzle in the nozzle adapter.

³⁄₄³⁄₄

Use a

³⁄₄" open-end wrench to steady the nozzle adapter

³⁄₄³⁄₄ ⁵⁄₈⁵⁄₈

and a

⁵⁄₈" open-end wrench to turn the nozzle. Tighten

⁵⁄₈⁵⁄₈

securely but do not overtighten.

• Check, and adjust if necessary, the critical dimensions P,

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.

Failure to properly set and maintain the electrode and nozzle spacing dimensions can cause incorrect burner ignition or poor combustion. This could result in severe personal injury, death or substantial property damage.

❏ Install nozzle line assembly

• Insert the nozzle line assembly into the burner air tube as in Figure 5.

• See Figures 5 and 6. Assemble the adjusting plate assembly per the instructions in the assembly packet.

• Slide the secondary adjusting plate (item f) completely to the left on the indicator adjusting plate (item e). Fingertighten acorn nut c to secure the two plates together. Slide both plates completely to the left on the primary adjusting plate (item g) and finger-tighten acorn nut d.

• Slide the completed adjusting plate assembly over the nozzle line end. Move the plate assembly and the nozzle line so the plate assembly fits into position as shown in

Figure 5.

• Install the spline nut (Figure 5, item b) on the end of the nozzle line, leaving the nut loosely placed so the plates can be moved.

• Connect the high-voltage leads from the ignition transformer to the electrodes.

Form 6104 BCF-23-R0399

Page 7

Instruction Manual – Model CF2300A Oil Burner

Figure 5 – Nozzle line assembly in burner

Measure dimension Z from the flat surface between (not on) the raised fins.

2324

Measure dimension from front (flat) face of head to end of air tube, as shown.

❏❏

❏ Set dimension Z

❏❏

• Replace the rear access door on the

• Loosen acorn nut d in Figure 5.

2308

burner, making sure that the adjusting plate assembly is now securely held in place.

Slide the nozzle line and plate assembly until dimension Z in

1³⁄₄1³⁄₄

Figure 5 is

mension Z (from end of air tube to flat area of front face of head) is correctly set, tighten acorn nut d. V erify

1³⁄₄" ±

1³⁄₄1³⁄₄

¹⁄₁₆¹⁄₁₆

¹⁄₁₆". When di-

¹⁄₁₆¹⁄₁₆

Figure 6 – Adjusting plate assy.

e f

Legend (Figures 5 and 6)

a Adjusting plate assembly b Spline nut for securing nozzle line c Bottom acorn nut d Top acorn nut (for setting dim. Z

only)

e Indicator adjusting plate f Secondary adjusting plate g Primary adjusting plate

that the adjusting plate assembly is properly seated at the rear access door, as sho wn in Figure 5.

• Attach the oil line from the oil valve to the nozzle line end. Tighten securely.

• Before proceeding, check dimension Z once again. Loosen 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 12.

2308-1

Figure 7 – Burner installed in appliance front

Legend

H Housing total length — 18½" J Center to bottom of housing — 10½ "

Form 6104 BCF-23-R0399

1¾"

2303

K Overall housing height — 15

❏ Insert burner

• Position the burner in the front of the appliance and loosely tighten the nuts on the mounting studs. The

⁵⁄₈⁵⁄₈

⁵⁄₈"

⁵⁄₈⁵⁄₈

burner should be pitched downward 2° as shown in Figures 3 and 7.

• See Figure 7. Install the pedestal support kit (recommended) by attaching the ¾" npt flange (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 11 inches less than dimension D in Fig-

ure 7

. Thread the pipe into the flange. Then slip the pipe end into the floor flange (item c).

• Secure the burner to the appliance by tightening the nuts on the burner flange mounting studs. Then secure the pedestal support floor flange set screw to the pipe.

Page 8

Instruction Manual – Model CF2300A Oil Burner

2310a

125 psig

175 psig

300 psig

Field-installed by-pass loop

2310b

300 psig

Field-installed by-pass loop

300 psig high fire

125 to 175 psig low fire

2320a

c c

Field-installed by-pass loop

Connect fuel line(s)

• Install the oil lines using the following guidelines. Failure to comply could lead to equipment damage and present a risk of severe personal injury, death or substantial property damage due to leakage of oil and potential fire hazard.

• Use only flare fittings at joints and connections. Never use compression fittings.

• Install fittings only in accessible locations to assure any leak will be detected.

• Where joint sealing is needed, use only pipe dope. Never use Teflon tape. Tape strands can break free and damage the fuel unit.

• Never use a one-pipe oil system with a lift in excess of 8 feet with a B fuel unit, or 2 feet with an H fuel unit. On two-pipe oil systems, verify that the suction line vacuum does not exceed the fuel unit manufacturer’ s recommendation.

❏ Fuel unit by-pass plug

• The CF2300A burner is shipped with a by-pass plug installed in the fuel unit. For low/high operation, the by-

pass plug must be left in the fuel unit

the fuel system used (one-pipe with by-pass loop or twopipe). Do not remove the by-pass plug.

, regardless of

Figure 8a – One-pipe oil flow, low fire, “H” pump

Figure 8b – One-pipe oil flow, high fire, “H” pump

Do not operate the burner unless a return line or by-pass loop is installed. Failure to follow this guideline will cause damage to the fuel unit seals and consequent fuel leakage. This could result in severe personal injury, death or substantial property damage.

❏ One-pipe oil system by-pass loop

• Refer to Figure 8 (item m). Note the addition of a fieldinstalled by-pass loop (use

fuel unit Return port to the Inlet port. This line is required for low/high operation. It simulates the flow of a two-pipe system at the fuel unit. Figures 8a and 8b are for type H fuel units. Figure 8c is for a type B fuel unit.

❏ Oil supply/return lines

• Install the oil tank and oil lines in accordance with all applicable codes.

• Size the oil supply and return lines using the guidelines given in the fuel unit literature included in the literature envelope. Oil line flow rate will equal the burner rate for

³⁄₈³⁄₈

³⁄₈" copper tubing) from the

³⁄₈³⁄₈

Figure 8c – One-pipe oil flow with “B” pump

Legend (see opposite page)

one-pipe systems. For two-pipe systems, refer to Table 3 for the fuel unit gearset capacity - the rate at which fuel is recirculated when connected to a two-pipe system. Size two-pipe oil lines based on this flow rate.

Form 6104 BCF-23-R0399

Page 9

Instruction Manual – Model CF2300A Oil Burner

Figure 9a – Two-pipe oil flow, low fire, “H” pump • Use continuous lengths of heavy-wall copper tubing,

routed under the floor where possible. Do not attach fuel lines to the appliance or to floor joists if possible. This

125 psig

175 psig

300 psig

reduces vibration and noise transmission problems.

• Install an oil filter sized to handle the fuel unit gearset flow capacity (Table 3) for two-pipe systems. Size the filter for the firing rate for one-pipe systems. Locate the filter immediately adjacent to the burner fuel unit.

• Install two high-quality shutoff valves in accessible 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 filter.

❏ Burner fuel flow

Figure 9b – Two-pipe oil flow, high fire, “H” pump

300 psig

2313a

• One-pipe systems – See Figure 8 for the fuel flow paths for high-fire and low-fire operation. Figures 8a and 8b are based on type H fuel units, with external by-pass pressure regulator. The low-fire by-pass regulation is done internally for type B fuel units, shown in Figure 8c. Oil supply connects to one of the fuel unit Inlet ports.

• T wo-pipe systems – See Figure 9 for the fuel flo w paths for high-fire and low-fire operation. Figures 9a and 9b are based on type H fuel units, with external by-pass pressure regulator. The low-fire by-pass regulation is done internally for type B fuel units, shown in Figure 9c. Oil supply connects to one of the fuel unit Inlet ports. Oil return connects to the fuel unit Return port.

Figure 9c – T wo-pipe oil flow with “B” pump

300 psig high fire

125 to 175 psig low fire

Legend (for Figures 8a, 8b, 8c, 9a, 9b and 9c)

a Return port b Nozzle port c Oil valves d Nozzle & adapter e By-pass valve (“H”

pump)

f By-pass pressure regulator g Inlet port h By-pass valve (“B” pump) k Return line to oil tank m One-pipe by-pass loop, p Air bleed valve

• Low-fire/high-fire operation – The fuel unit nozzle port pressure is factory set at 300 psig.

2313b

• At high fire, full pressure (300 psig) is applied at the oil

nozzle, causing full input.

• At low fire, the by-pass valve (item e) opens. For type H

fuel units, this allows oil to by-pass the nozzle path through the external by-pass pressure regulator (item f). For type B fuel units, the by-passing is done inside the

fuel unit when the by-pass valve operates.

• The by-pass oil flow is returned to the fuel unit Inlet

port for type H fuel units.

• This by-passing of oil reduces the oil pressure at the

2323a

³⁄₈³⁄₈

³⁄₈"

³⁄₈³⁄₈

nozzle (to between 125 psig and 175 psig), reducing the input.

T able 3 – Fuel unit gearset capacities

Fuel unit model number

B2TA8852 39 H4PAN-C151H 69

Gearset capacity

(gallons per hour)

Form 6104 BCF-23-R0399

Page 10

Instruction Manual – Model CF2300A Oil Burner

HNG

OR OR

Power supply 120v/60 hz

LFHS H/L

LM OP

BK = black

OR = orange

WH = white

Motor M1 wirin g 1 4 g a A ll o th e r wiring 16 ga

2311

Field wiring Factory wiring

Note 1

Note 1 Wirin g to d a mper motor end switch shown fo r ty p e

fuel unit. For type fu e l u nit, c o n n e ct wire to

Wire the burner

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.

Figure 10 – Typical wiring

Legend

FD Fused disconnect, by others LM Limit controls, by others OP Operating controls, by others PR Oil primary control, R8184 typical CC Flame sensor, cad cell typical TM Optional delay timer TR Ignition transformer M1 Burner motor S1 Primary oil valve S2 By-pass oil valve S3 Redundant oil valve DM Damper motor and end switch

∗∗

∗ H/L Insert high/low-fire control here

∗∗

LFHS Low-fire hold switch T–T 24-volt thermostat/limit terminals F-F Cad cell flame sensor terminals

Electrical shock hazard - can

cause injury or death. Disconnect power before installing or servicing. Provide ground wiring to the burner in accordance with the National Electrical Code.

Do not by-pass any safety control. By-passing a safety control could result in severe personal injury, death or substantial property damage.

See Figure 10 for a typical wiring diagram, with R8184 oil primary, for reference purposes only. The CF2300A burner is available with many different wiring configurations. Refer to the wiring diagram shipped with the burner for the actual wiring applying to your burner.

NOTE: The wiring in Figure 10 is for an R8184 primary control and a type B fuel unit (using internal by-pass pressure regulator as shown in Figures 8c and 9c). The difference in fuel units is the connection of by-pass oil valve S2 to the damper-motor end switch. When using a type H fuel unit, the by-pass oil valve wire is connected to terminal “W” instead of terminal “B” on the end switch because the by-pass pressure regulation is external to the fuel unit.

Form 6104 BCF-23-R0399

Page 11

Instruction Manual – Model CF2300A Oil Burner

Sequence of operation — typical

NOTE: The following sequence is based on using a type B fuel unit, with pump-mounted by-pass valve. The by-pass valve operation is reversed for a type H fuel unit. That is, the bypass valve is powered at low fire instead of being powered at high fire.

1. On call for heat from the appliance operating controls (and the circuit from T to T of the R8184 closed), power is applied to the R8184 black wire (BK).

2. The R8184 applies 120 volts to the orange wire (OR), activating the burner motor (M1) and the ignition transformer (TR). The oil pump is operated by the burner motor, so oil pressure is delivered to the oil valve inlets.

3. Power is applied to the oil valve circuit. If optional timer, (TM), is installed, oil flow will be delayed for the timer duration, thus providing a prepurge period. When the timer times out, oil valves (S1 and S3) are activated, allowing oil to flow to the nozzle.

4. With the low-fire hold switch (LFHS) in the “IN” position, the burner will remain at low fire. W ith no power applied to the by-pass valve (S2), oil by-passes internally in the fuel unit, reducing the pressure sent to the oil nozzle.

5. When the low-fire hold switch is moved to the “OUT” position, the damper motor (DM) will be activated. This will begin opening the air damper.

6. When the damper motor end switch is tripped, oil valve

(S2) is activated, stopping by-pass flow inside the fuel unit and providing full pressure (300 psig) at the oil nozzle. The burner is now at high fire. The damper motor end switch is set to operate before the damper has reached full open to assure a smooth transition to high fire.

7. If a high/low-fire control is installed at H/L, this control will cycle the firing rate automatically during an operating cycle.

8. At the start of the cycle, the R8184 begins checking for flame signal between F and F. Flame must be established within 15 seconds of initiation. If no flame is sensed after 15 seconds, the R8184 will terminate all power to the blower and oil circuits, shutting the burner down. The control will electrically lock out.

• To reset the control after lockout, wait 2 to 3 minutes

after lockout to give the internal switch time to cool. Then push the reset button on the primary control, al-

lowing the burner to operate in normal sequence.

• Troubleshoot the reason for flame sense failure.

9. When the call for heat signal terminates (at the black wire of the R8184), the R8184 terminates power to all circuits, closing the oil valves and stopping the burner motor.

Prepar e the burner for start-up

Start-up checklist – Verify the following before attempting to start burner.

❏ Combustion air supply and venting have been inspected

and verified 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 and external by-pass loop — from

Return port to pump Inlet — have been installed for onepipe oil systems. By-pass plug is installed for two-pipe oil systems.

❏ Fuel connection to nozzle line assembly is secure. ❏ Dimension Z has been set per this instruction manual.

Form 6104 BCF-23-R0399

❏ Fuel supply line is correctly installed, the oil tank is

sufficiently filled, and shutoff valves are open.

❏ Burner is securely mounted in appliance, with pressure

firing plate and gasket installed for pressurized chamber application.

❏ Appliance has been filled 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.

Page 12

Instruction Manual – Model CF2300A Oil Burner

95678

2307

cd f

Approximate

head settings

Firing rate, gph

Tube “KG” Tube “KS”

11.00 12.50

12.00 13.00

13.00 14.00

14.00 15.00

15.00 16.00

16.00 17.00

17.00 18.00

18.00 18.50

19.00 19.00

20.00 20.00

Prepar e the burner for start-up - continued

❏ Z dimension

• Should be set per these instructions (see page 7). The top acorn nut (Figure 11, item d) should never be loosened once the Z dimension is initially set.

❏ 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 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 firing rate (high-fire).

• Figure 11 shows a typical example, with a head setting of

• When the head position has been set, tighten the bottom 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). Set the air to the desired low-fire rate. (The numbers on this plate correspond to the approximate firing rate settings given in Table 5.)

• Rotate the air adjusting plate until the lower edge of the pointer is opposite the number from T able 5 corresponding to the desired low-fire rate.

• This initial setting should be adequate for starting the burner at low fire. Once the burner is in operation, the air setting will be adjusted for best performance as discussed later in this manual.

• The damper moves to high-fire position as the damper rod (item d) rotates the damper linkage arm (item f). You will adjust the setting of the damper linkage arm when setting the high-fire air as discussed on page 14 in Start the

burner

• Follow the procedures given later in this manual for fine tuning the air settings.

Figure 11 – Adjusting plate initial setting, typical

Legend

b Spline nut for securing nozzle line c Bottom acorn nut (for head adjust-

ments

d Top acorn nut (for setting dim. Z only

— do not loosen after setting Z)

e Indicator adjusting plate

f Secondary adjusting

plate

g Primary adjusting

plate

h Copper oil line from

oil valve to nozzle line

❏ Prepare the fuel unit for air venting

• T o vent air from one-pipe oil systems, attach a clear hose to 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, page 14.

T able 4 – Initial indicator adjustment plate

settings (head position)

❏ Set appliance limit controls

• Set the appliance limit controls in accordance with the appliance manufacturer's recommendations.

• Move the low-fire hold switch (not shown) to the “IN” position. This will hold the burner in low fire during initial start-up.

Form 6104 BCF-23-R0399

Page 13

Instruction Manual – Model CF2300A Oil Burner

Figure 12 – Air damper and damper motor assembly

CLOSE OPEN

2309-1

2309-2

T able 5 – Initial air adjusting plate settings

(damper position)

Approximate

Firing rate, gph

adjusting plate

settings

0 1 2 3 4 5 6 7 8 9

Form 6104 BCF-23-R0399

Tube “KG” Tube “KS”

-- --

7.00 10.00

10.00 11.00

13.00 13.00

14.00 14.00

15.00 16.00

16.00 17.00

17.00 18.00

18.00 18.50

19.00 19.00

20.00 20.00

Legend (Figure 12)

a Damper motor – do not adjust internal cam

b Arm assembly

c Ball joint assembly – do not adjust position of ball

joint

d Damper rod

e Damper rod guide

f Damper linkage arm - sets high-fire air position

g Damper

h Damper label - position indicator for air adjusting plate

k Damper indicator - permanently attached to damper

m Air adjusting plate - sets low-fire air position

Page 14

Instruction Manual – Model CF2300A Oil Burner

Start the burner

Do not proceed unless all prior steps in this manual have been completed. Failure to comply could result in severe personal injury, death or substantial property damage.

Do not attempt to start the burner when excess oil has accumulated, when the appliance is full of vapor or when the combustion chamber is very hot. Do not attempt to reestablish flame with the burner running if the flame should be extinguished during start-up, venting or adjustment. Allow the unit to cool off and all vapors to dissipate before attempting another start. Failure to comply with these guidelines could cause an explosion or fire, resulting in severe personal injury, death or substantial property damage.

Damper motor and motor arm assembly - Do not attempt to adjust the cam setting in the damper motor. It is factory preset. Do not mov e the ball joint assembly further out on the motor arm assembly. This would change the timing of damper opening versus fuel rate. The damper linkage arm screw must be tightened securely to assure the damper will provide sufficient air at high fire. Failure to comply could cause unreliable combustion or flame failures, leading to possible severe personal injury, death or substantial property damage.

❏ Start burner and vent air from oil line

1. Move the low-fire hold switch to the “IN” position (to

hold burner in low fire when started).

2. Verify that the air adjusting plate (Figure 12, item m) has

been set to the initial low-fire air position as described on page 12 under Initial air settings.

3. Loosen the screw on the damper linkage arm (Figure 12,

item f) and allow the damper indicator (Figure 12, item k) to rest on the air adjusting plate (Figure 12, item m).

4. Open the oil shutoff valves in the oil supply (and return)

line(s) to the burner.

3. Set the thermostat (or operating control) to call for heat.

4. Close the line switch to the burner. The burner motor

should start immediately.

5. If the burner motor does not start, reset the motor overload

switch (if so equipped) and press the reset switch of the burner primary control.

6. Vent the fuel unit as soon as the burner motor starts

rotating. To vent — ❏ Attach a clear plastic tube to the air bleed valve (Figure

8a, 8b, 9a or 9b

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 flame is not established within its time limit. This is typically 15 seconds for R8184 primary controls, but may be less for other flame supervisory controls.

• The burner may lockout several times during the period needed to purge all the air. Reset the primary control each time in order to continue purging.

• If the burner is equipped with an R8184 primary, you will need to wait about 2 minutes after each lockout to allow time for the reset switch to cool.

• Squeeze off the air bleed tubing or close the air vent valve when the pump stops running to prevent air from flowing back into the oil line.

If the fuel unit air vent valve is completely open, assuring no flow of oil to the burner oil nozzle, you can temporarily jumper the F-F terminals of an R8184 primary during the purge period to allow enough time for all air to purge. Never leave the burner unattended when doing this. Remove the jumper when purging is completed. This procedure should

only be used by a qualified burner technician, experienced in burner operation and control. Improper application of this method

can cause combustion chamber explosion, fire hazard or fuel leakage, resulting in severe personal injury, death or substantial property damage.

❏ IF burner stops after flame established —

• Additional venting is probably required. Repeat the air venting procedure.

7. Once flame is steady , proceed to Set high-fire air.

❏ Set high-fire air

1. Allow the burner to run at low fire until the appliance has warmed sufficiently.

2. Visually check the flame. The flame should not be dark orange or smoky. If the flame appears to be smoking, increase the amount of air by readjusting the damper indicator to a higher number.

3. Once the appliance has warmed, the high-fire setting can be checked and adjusted.

4. Locate the approximate air adjusting plate setting for high fire in Table 5, page 13.

5. Place the low-fire hold switch in the “OUT” position. The damper motor will begin to rotate. a. At the same time, loosen the screw securing the air

adjusting plate (Figure 12, item m) as the damper begins to move.

Form 6104 BCF-23-R0399

Page 15

Instruction Manual – Model CF2300A Oil Burner

b. Slowly rotate the air adjusting plate (increase the

amount of air) as the damper drives to high-fire.

c. Lock down air adjusting plate at the high-fire air set-

ting found in Table 5 for the high-fire rate.

6. Use combustion test instruments to adjust the burner. 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 CO2 by 2 percentage points

at a zero smoke level. (Increase O2 by 3 percentage points at a zero smoke level.) Example: Reduce CO2 from 13.5% to 11.5%, with zero smoke (or increase O2 from 2.5% to 5.5%).

c. A margin of reserve air has been added to accommo-

date variable conditions.

7. Check the breech draft pressure against the appliance manufacturer’s recommended setting (typically + 0.1" W.C.).

8. If the breech pressure is higher or lower than recommended level, adjust the appliance breech damper to achieve the specified setting. Recheck the smoke and CO2 levels. Adjust burner air if necessary.

9. Once all settings are complete and satisfactory, rotate the damper linkage arm (Figure 12, item f) until it touches the damper rod (Figure 12, item d) and tighten the damper linkage arm screw securely.

❏ Set low-fire air

1. Loosen the air adjusting plate (Figure 12, item m) screw

and set the air adjusting plate at the low-fire air setting found in Table 5, page 13. The damper should stay at the high-fire setting. The damper linkage will prevent movement of the damper plate.

2. Move the low-fire hold switch from the “OUT” to the “IN” position. a. The damper will return to the low-fire air setting.

3. Check the smoke and CO2 (O2) levels. a. Pull a smoke sample from the flue. b. The sample should be clean (zero smoke level). c. Check the CO2 (O2) level:

CO2 should be at 11 to 12% (O2 at 5.9 to 4.5%). If the CO2 is less than 11% (O2 more than 5.9%), decrease

the air and check the smoke level.

4. Operate the burner from low fire to high fire and back to verify operation.

5. Turn the b urner off. Wait one or two minutes (for chamber to clear) and then turn on again to verify starting characteristics.

6. Perform limit circuit performance test specified by appliance manufacturer to verify operation of burner/appliance combination.

Maintenance and service

The burner must be serviced at least annually by a qualified service technician to assure continued reliable operation. Operation and adjustment of the burner requires technical knowledge and the use of combustion test instruments. Do not tamper with the burner or controls. Failure to comply could result in failure of the burner or system, resulting in severe personal injury, death or substantial property damage.

Annual service

— by qualified service technician

Have the burner inspected, tested and started at least annually by a qualified service technician. This annual test/inspection should include at least the following:

❏ Replace oil nozzle. ❏ Clean burner and blower wheel (if needed to remove lint

or debris).

❏ Test ignition and combustion at low and high fire and

verify air damper settings.

❏ Test oil supply line vacuum - verify that it is within al-

lowable range indicated in fuel unit literature.

❏ Check pump pressure to nozzle at low and high fire. ❏ Inspect fuel system (including tank, lines and all connec-

tions).

❏ Inspect combustion air and vent systems. ❏ Replace oil filter. ❏ Oil motor (if not permanently lubricated).

Monthly maintenance

— by owner

❏ Observe combustion air openings and vent system for

integrity . Openings must be clean and free of any obstructions.

❏ Check the oil lines and fittings to verify there are no leaks. ❏ Observe burner ignition and performance to verify smooth

operation.

❏ Shut the system down if you observe abnormal or ques-

tionable operation. Call a qualified service agency for professional inspection and service.

Form 6104 BCF-23-R0399

Page 16

Instruction Manual – Model CF2300A Oil Burner

Replacement parts

679

SUNTEC

Type fuel unit with pump-

mounted by-pass valve

HBfuel unit

See detail of type

fuel unit at left

Item Part name Description Part number

Air tube

Flange kit Adjustable flange See

Damper motor assembly All models 51229

Electrode assembly All models 51212

Ignition leads

Nozzle line assembly Specify burner model and air tube length

Head assembly CF2300A 51203

Pressure regulator Not used with B pump 21319

Fuel lines Specify length

Specify burner model and tube length (See

Figure 2, page 5

8 ¼" long 5990082 11 ¾" long 5990116 15 ¼" long 5990152 19 ¼" long 5990192

for codes)

Figure 13

Figure 13 – Adjustable mounting plates for CF2300A

Kit #51630

16" Diameter

Kit #51313

12.44" Diameter

Kit #51498

13.92" Diameter

13 14

Item Part name Description Part number

19 20 26

Damper linkage arm All models 5984BK

Damper spring All models 4339

Timer

Adjusting plate assembly All models 51213

Knurled nut All models 3666

Fuel pump Specify B or H

Pedestal kit All models 51193

Oil valve Box mounted 7201

Damper door All models 16703GY

Damper indicator All models 5985BK

Coupling Specify pump used

Sight glass All models 31346

Rear cover assembly CF2300A 51204

Control Specify

Transformer 12,000 volt 51214

Motor Specify burner model

Blower wheel CF2300A 6.75" x 3.125" 21267

Solenoid (by-pass) valve Specify valve used

Motor relay (not shown) Specify relay used

Low/high rate Nozzle valve delay

2221

2315

21252 21295

U.S.A.: P. O. Box 1289 • Elyria, Ohio 44036 • 800-645-2876 • 440-327-1060 • FAX 440-327-1064

Canada: R. W . Beckett Canada, Ltd. • 430 Laird Road • Guelph, Ontario, N1G 3X7 • 800-665-6972 • FAX 519-763-5656

Form 6104 BCF-23-R0399