Page 1
MODELMODEL
MODEL
MODELMODEL
2500/3500
Oil
CF
CF
2500/
3500
Burner
Instruction Manual
Low/High Operation
Firing rate: CF2500A 17.0 – 19.9 GPH
CF2500 17.0 – 25.0 GPH
CF3500A 17.0 – 35.0 GPH
Motor voltage: 208/230 — 60 Hz std.
Thank you
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 Beckett
Page 2
Instruction Manual – Model CF2500/CF3500 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 agenc y, 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, NFP A 31 (or CSA B139-M 91).
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.
2
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-35-R0699
Page 3
Instruction Manual – Model CF2500/CF3500 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.
Specifications
Fuels #1 or #2 Fuel Oil
Firing range CF2500A 17.0 - 19.9 GPH
CF2500 17.0 - 25.0 GPH
CF3500A 17.0 - 35.0 GPH
Motor 2 HP 3450 RPM
208/230/60 hz/1-PH std.
13.4 amps @ 230 VAC
Optional voltages:
(60 hz or 50 hz) –
• 208/230/480/3-PH
Ignition Trans. 120V/12,000V
Housing Cast aluminum
Fuel unit 100 - 300 PSIG
Oil nozzle 45° - 70° solid
Shipping wt. 106 lbs.
Dimensions See Figure 7 (Page 7)
(See NOTICE on opposite page for 50 hz motor applications.)
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
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-35-R0699
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 — Always 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.
3
Page 4
Instruction Manual – Model CF2500/CF3500 Oil Burner
Rated
gph @
100 psig
Pressure - pounds per square inch
125 150 175 200 250 300
5.00 5.59 6.13 6.61 7.07 7.50 8.66
5.50 6.15 6.74 7.27 7.78 8.70 9.54
6.00 6.71 7.33 7.94 8.48 9.49 10.40
6.50 7.26 7.96 8.60 9.20 10.30 11.25
7.00 7.82 8.56 9.25 9.90 11.06 12.12
7.50 8.38 9.19 9.91 10.60 11.85 13.00
8.00 8.94 9.80 10.58 11.31 12.65 13.85
8.50 9.50 10.45 11.27 12.06 13.40 14.70
9.00 10.06 11.02 11.91 12.73 14.20 15.60
9.50 10.60 11.70 12.60 13.50 15.00 16.45
10.00 11.18 12.25 13.23 14.14 15.81 17.32
10.50 11.74 12.85 13.90 14.85 16.60 18.18
11.00 12.30 13.47 14.56 15.55 17.39 19.05
11.50 12.85 14.08 15.22 16.26 18.18 19.92
12.00 13.42 14.70 15.87 16.97 18.97 20.78
12.50 13.98 15.31 16.54 17.68 19.76 21.65
13.00 14.54 15.92 17.20 18.38 20.55 22.52
13.50 15.10 16.53 17.85 19.09 21.34 23.38
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, NFP A 31. F or 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 CF2500A/CF2500/CF3500A
• 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.
The CF2500A, CF2500 and CF3500A are dual nozzle burners. To select the nozzles, use half of the maximum firing
rate and select a nozzle under the 300 psig column (high
fire rate). Select the corresponding nozzle from column 1
(Rated gph @ 100 psig). Two nozzles will be required.
❏ 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.
• See Figure 8 for one-pipe fuel supply installations. See
Figure 9 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 2 feet. The return line provided by the twopipe system is needed to purge the air from the fuel lines
and minimize the likelihood of air-related problems during operation.
4
The fuel unit is shipped without the by-pass
plug installed. You must install this plug on
two-pipe system. DO NOT install the by-pass
plug in the fuel unit if connected to a onepipe oil system. Failure to comply could cause
fuel unit seal failure, oil leakage and potential
fire and injury hazard.
T able 1 – Nozzle capacities at various pressures
Form 6104 BCF-35-R0699
Page 5
Instruction Manual – Model CF2500/CF3500 Oil Burner
3502
E
D
G
F
T
2°
1
Firebox
pressure
(In. W.C.)
Tube KP Tube KM/KR
No
reserve
air
10%
turndown
No
reserve
air
10%
turndown
Maximum firing rate GPH
0.0 25.0 22.5 35.0 31.5
0.2 24.8 22.3 33.5 30.2
0.4 24.6 22.3 32.0 28.8
0.6 24.5 22.1 30.2 27.2
0.8 24.3 21.9 28.8 25.9
1.0 24.1 21.7 27.1 24.4
Note: 10% turndown indicates sufficient reserve air to reduce
the CO
2
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.
• The following tube arrangements are available:
Model CF2500A: Tube KP — 17.0 to 19.9 GPH
Model CF2500: Tube KP — 17.0 to 25.0 GPH
Model CF3500A: T ube KM — 17.0 to 35.0 GPH or
Tube KR — 17.0 to 35.0 GPH
• Maximum firing capacity depends on the firebox pressure.
Use Table 2 to verify the correct air tube type for the firing
rate required. (Tube KR [CF3500A] is an optional air tube
combination for maximum capacity rate. It requires a larger
I.D. flange No. 51631.)
• See Figure 2 to verify the correct air tube length and air
tube combination code.
Figure 1 – Min. combustion chamber dimensions
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.
A.T.C. Codes
(A.T.C. = Air Tube Combination)
CF2500A/
CF2500
Tube KP Tube KM Tube KR
Dimensions Dimensions Dimensions
T D F T D F T D F
All — 6 ½" 3¼" All — 8" 4 ½" All — 9 ¹⁵⁄₁₆" 5 ¹⁄₈"
6¾" CF 66 KP 8" CF 80 KM — —
— — 9 ¼" CF 92 KM — —
10¼" CF 102 KP 11 ½" CF 114 KM 11 ½" CF 114 KR
13¾" CF 136 KP 15" CF 150 KM 14" CF 140 KR
17¾" CF 176 KP 19" CF 190 KM 19" CF 190 KR
CF3500A
L
A
Minimum dimensions
A L
(all boilers)
Firing rate
Form 6104 BCF-35-R0699
17 gph 10.5" 48.0"
22 gph 11.5" 58.0"
27 gph 12.5" 66.0"
32 gph 12.5" 73.0"
35 gph 13.0" 77.0"
T able 2 – Air tube capacity vs. firebox pressure
3501
5
Page 6
Instruction Manual – Model CF2500/CF3500 Oil Burner
3505
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
gasket (item
a) and flange (item d). Ignore the next
paragraph.
• For pressure-firing flange, refer to
(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
• 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 ¹⁄₄" 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
G
Figure 3: Install
Figure 3: Slide gasket
d).
2°
Figure 4 – Nozzle and nozzle line assembly
QS
P
0.713311"
Low fire
nozzle
Critical dimensions —
S
(Electrode spacing)
Q
(Nozzle to head)
High fire
nozzle
= ³⁄₃₂"
= ¹⁄₄"
R
P
(Nozzle center line to electrode tip)
R
(Nozzle face to electrode tip)
3504
= ¹⁄₄"
= ¹⁄₈"
c
e
abd
3503
❏ 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.
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 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.
6
Form 6104 BCF-35-R0699
Page 7
Instruction Manual – Model CF2500/CF3500 Oil Burner
Figure 5 – Nozzle line assembly in burner
Z
Measure dimension Z from the flat
surface between (not on) the raised fins.
3507
Measure dimension from
front (flat) face of head to
end of air tube, as shown.
Z
❏❏
❏ Set dimension Z
❏❏
• Replace the rear access door on the
burner, making sure that the adjusting
plate assembly is now securely held in
place.
• Loosen acorn nut d in Figure 5. Slide
the nozzle line and plate assembly until dimension Z in Figure 5 is:
CF2500A/CF2500 1³⁄₄" ± ¹⁄₁₆"
CF3500A (tube KM) 2⁵⁄₈" ± ¹⁄₁₆"
CF3500A (tube KR) 3⁹⁄₁₆" ± ¹⁄₁₆"
• When dimension Z (from end of air tube
to flat area of front face of head) is cor-
Figure 6 – Adjusting plate assy.
e
d
a
b
d fc
g
3508
c
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
3506
f Secondary adjusting plate
g Primary adjusting plate
rectly set, tighten acorn nut d. V erify
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.
Figure 7 – Burner installed in appliance front
H
J
D
Legend
H Housing total length — 20"
J Center to bottom of housing — 14¹⁄₂" K Overall housing height — 22³⁄₄ "
Form 6104 BCF-35-R0699
1¾"
3509
a
b
c
K
❏ Insert burner
• Position the burner in the front of
the appliance and loosely tighten
the nuts on the mounting studs. The
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 ³⁄₄" npt flange (item a)
to the bottom of the burner using
the (4) #10 screws provided. Cut and
thread (one end only) a ³⁄₄" pipe
nipple (item b) with length 14.5
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.
7
Page 8
Instruction Manual – Model CF2500/CF3500 Oil Burner
Fuel unit
model number
Gearset capacity
(gallons per hour)
H5PAN-C100H 79
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 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 CF2500A, CF2500 and CF3500A burners
are shipped without the by-pass plug
installed. You must install this plug on twopipe systems. DO NOT install the by-pass plug
in the fuel unit if connected to a one-pipe oil
system. Failure to comply could cause fuel
unit seal failure, oil leakage and potential fire
and injury hazard.
Figure 8a
One-pipe oil flow, one nozzle, low fire, “H” pump
d
200 psig
to
300 psig
200 psig
to
300 psig
cc
b
c
g
a
p
3510
Figure 8b
One-pipe oil flow, two nozzles, high fire, “H” pump
g
a
p
d
200 psig
to
300 psig
200 psig
cc
c
to
300 psig
b
❏ 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
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.
• 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
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.
8
200 psig
to
300 psig
Legend (see opposite page)
T able 3 - Fuel unit gearset capacities
Form 6104 BCF-35-R0699
3511
Page 9
Instruction Manual – Model CF2500/CF3500 Oil Burner
Figure 9a
Two-pipe oil flow, one nozzle, low fire, “H” pump
200 psig
d
200 psig
to
300 psig
cc
c
to
300 psig
b
a
k
3512
Figure 9b
T wo-pipe oil flow, two nozzles, high fire, “H” pump
200 psig
to
300 psig
d
200 psig
to
300 psig
c
cc
b
a
• 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 .
g
❏ Burner fuel flow
• One-pipe systems – See Figure 8 for the fuel flow paths
p
g
p
for high-fire and low-fire operation. Oil supply connects to
one of the fuel unit Inlet ports.
Do not install by-pass plug in a one-pipe
system. Could cause unit seal failure, oil
leakage and potential fire and injury hazard if
ignored.
• T wo-pipe systems – See Figure 9 for the fuel flo w paths
for high-fire and low-fire operation. Oil supply connects to
one of the fuel unit Inlet ports. Oil return connects to the
fuel unit Return port.
By-pass plug must be installed in a two-pipe
system. Failure to comply could cause unit
seal failure, oil leakage and potential fire and
injury hazard.
• Low-fire/high-fire operation – The fuel unit nozzle port
pressure is factory set at 300 psig.
• At high fire, full pressure (300 psig) is applied at both
oil nozzles, causing full input.
• At low fire, full pressure (300 psig) is applied at one
nozzle, causing reduced input.
200 psig
to
300 psig
Legend (for Figures 8a, 8b, 9a and 9b)
a Return port
b Nozzle port
c Oil valves
d Nozzle & adapter
g Inlet port
k Return line to oil tank
p Air bleed valve
Form 6104 BCF-35-R0699
k
3513
9
Page 10
Instruction Manual – Model CF2500/CF3500 Oil Burner
BK
T
T
OR
F
F
WH
HNG
OR OR
WH
WH
WH
WH
BR
BL (Note 1)
RB
W
TR
TM
FD
PR
Power supply
120v/60 hz
S3
S1
DM
CC
LFHS H/L
S2
DM
M1
LM OP
BK = black
OR = orange
WH = white
Motor M1 wirin g 1 4 g a All other wiring 16 ga
3514
Field wiring
Factory wiring
T
BL
BL = blue
BR = brown/red
Wire the burner
Do not by-pass any safety control. By-passing a safety control could result in severe personal injury, death or
substantial property damage.
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 – CF2500A 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 High-fire 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
Note 1 — Indicates alternate wiring for in-
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.
Figure 10 for a typical wiring diagram for a CF2500A
terrupted ignition controls — connect
transformer to blue primary lead. For intermittent duty — connect transformer to
orange primary lead only.
burner, with R8184 oil primary, for reference purposes only.
The CF2500/CF3500A 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.
When firing over 20 GPH, the CF2500 and CF3500A will be
supplied with a flame safeguard control. An airflow switch
and low-fire start switch may also be supplied. Consult local,
state and federal codes for burner requirements above 20 GPH.
10
Form 6104 BCF-35-R0699
Page 11
Instruction Manual – Model CF2500/CF3500 Oil Burner
Sequence of operation — typical
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 low-fire nozzle.
4. With the low-fire hold switch (LFHS) in the “IN” position,
the burner will remain at low fire.
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, high-fire oil
valve (S2) is activated, providing pressure at the high-fire
oil nozzle. With both nozzles firing, 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 nozzles have been selected correctly and securely
installed in the nozzle adapter.
❏ Fuel unit by-pass plug is installed for two-pipe oil systems.
(Do not install by-pass plug for one-pipe systems.)
❏ Fuel connection to nozzle line assembly is secure.
❏ Dimension Z has been set per this instruction manual. See
Set dimension Z on page 7.
Form 6104 BCF-35-R0699
❏ 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.
11
Page 12
Instruction Manual – Model CF2500/CF3500 Oil Burner
3515
e
g
df
b
h
c
Approximate
head settings
Firing rate, gph
Tube “KP” Tube “KM”/“KR”
0
-- --
1
-- 17.00
2
-- 17.50
3
17.00 18.00
4
17.50 18.50
5
18.00 19.00
6
18.50 20.00
7
19.00 21.00
8
20.00 28.00
9
21.00 32.00
10
25.00 35.00
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
5.
• When the head position has been set, tighten the bottom
acorn nut (item c) and the spline nut (item b).
❏ In i ti a l a i r s ettings (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). Y ou 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.
• V ent 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.
12
Form 6104 BCF-35-R0699
Page 13
Instruction Manual – Model CF2500/CF3500 Oil Burner
Figure 12 – Air damper and damper motor assembly
a
CLOSE OPEN
d
e
f
g
3516
a
b
b
c
CLOSE
d
h
8
9
10
7
1
6
5
4
3
2
1
0
1
12
k
m
3517
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
10
10.5
Tube “KP” Tube “KM”/“KR”
-- --
8.00 8.00
9.00 9.00
11.00 11.00
12.00 12.00
15.00 15.00
17.00 17.00
18.00 19.00
19.00 22.00
20.00 25.00
22.00 29.00
25.00 35.00
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
Form 6104 BCF-35-R0699
13
Page 14
Instruction Manual – Model CF2500/CF3500 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 f actory preset. Do not move
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.
5. Set the thermostat (or operating control) to call for heat.
6. Close the line switch to the burner. The burner motor
should start immediately.
7. 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.
8. 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.
9. 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.
14
Form 6104 BCF-35-R0699
Page 15
Instruction Manual – Model CF2500/CF3500 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 T able 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
level as high as possible (lowest possible O2).
CO
2
Example: 13.5% CO
b. Increase the air to reduce CO2 by 2 percentage points
at a zero smoke level. (Increase O
points at a zero smoke level.)
Example: Reduce CO
smoke (or increase O
c. A margin of reserve air has been added to accommo-
(2.5% O2) with a trace of smoke.
2
by 3 percentage
2
from 13.5% to 11.5%, with zero
2
from 2.5% to 5.5%).
2
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 CO
Adjust burner air if necessary .
levels.
2
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
high-fire setting. The damper linkage will prevent movement of the damper plate.
2. Move the low-fire hold switch from 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:
4. Operate the burner from low fire to high fire and back to
verify operation.
5. Turn the burner of f. W ait 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.
Table 5, page 13. The damper should stay at the
should be at 11 to 12% (O2 at 5.9 to 4.5%).
CO
2
If the CO
the air and check the smoke level.
is less than 11% (O2 more than 5.9%), decrease
2
OUT” to the
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 nozzles.
❏ 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 nozzles 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-35-R0699
15
Page 16
Instruction Manual – Model CF2500/CF3500 Oil Burner
LOW FIRE START VALVE
12
10
11
Replacement parts
5
1
3518
2
7
4
6
9
3
8
10
11
12
13
14
15
16
17
19
LOW FIRE START VALVE
OUT IN
8
7
6
5
4
3
2
1
0
20
25
21
LOW FIRE HOLD
22
9
1
0
1
1
1
2
23
18
24
Item Part name Description Part number
Air tube
1
Flange kit Adjustable flange See
2
Damper motor assem-
3
bly
Electrode assembly All models 51212
4
Ignition leads
5
Nozzle line assembly Specify burner model and air tube length
6
Head assembly CF2500/CF3500A 51475P
7
Fuel lines Specify length
8
Specify burner model and tube length
(See
Figure 2, page 5
for codes)
Figure 13
All models 51229
9 ¼" long 5990092
10 ½" long 5990104
12 ¾" long 5990126
16 ¼" long 5990162
20 ¼" long 5990202
Figure 13
Adjustable mounting plates for CF2500/CF3500A
Kit #51631
16" Diameter
(Use only with
KR air tube)
Kit #51498
13.92" Diameter
Kit #51630
16" Diameter
Item Part name Description Part number
Damper linkage arm All models 5984BK
9
Damper spring All models 4339
10
Adjusting plate assem-
11
bly
Knurled nut All models 3666
12
Fuel pump H pump (standard) 21529
13
Pedestal kit All models 51193
14
Oil valve Box mounted 7201
15
Damper door All models 16703GY
16
Damper indicator All models 5985BK
17
Coupling Specify pump used
18
Sight glass All models 31346
19
Rear cover assembly CF2500/CF3500A 51204
20
Control Specify
21
Transformer 12,000 volt 51214
22
Motor Specify burner model
23
Blower wheel CF2500/CF3500A 21528
24
Motor relay Specify relay used
25
All models 51478
U.S.A.: P. O. Box 1289 • Elyria, Ohio 44036 • 800-645-2876 • 440-327-1060 • F AX 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-35-R0699
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