Beckett CF500, 800 User Manual 2

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

6104 BCF5 R07 1

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.

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 set-up.

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

To the Owner:

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

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

service agency for consultation.

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

Table of Contents

General Information ..............................................2-4

Hazard Defi nitions ..........................................................3

Agency approvals ..........................................................3

Specifi cations .................................................................3

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

Installer/Service Agency Responsibility .........................4

Pre-installation checklist .....................................4-7

Combustion air supply ...................................................4

Clearances .....................................................................4

Fuel supply .....................................................................5

Nozzle pressure .............................................................5

Electrical supply .............................................................5

Vent system ...................................................................5

Verify burner components ..............................................6

Verify fi ring rate ..............................................................6

Verify air tube .................................................................6

Stray light lockout ...........................................................7

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

Mount the burner ...................................................7-9

Mount fl anges on air tubes .............................................7

Mount air tube to burner .................................................8

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

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

Install Nozzle Line Assembly .........................................8

Set Dimension Z ............................................................8

Insert Burner ..................................................................8

Fuel Unit By-pass Plug ..................................................9

Oil Supply/Return Lines .................................................9

Burner Fuel Flow ............................................................9

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

Sequence of operation .......................................10

Resetting to cad cell .............................................10

Prepare the burner for start-up ......................11-12

Start-up checklist .........................................................11

Z Dimension .................................................................11

Initial head position ......................................................11

Initial air settings ..........................................................12

Set appliance limit controls ..........................................12

Prepare the fuel unit for air venting ..............................12

Start the burner..................................................12-13

Starting the burner and venting air ..............................12

CAD Cell resistance check ..........................................13

Set combustion using instruments ...............................13

Maintenance and Service ..................................... 14

Annual Service .............................................................14

Monthly maintenance ...................................................14

Replacement Parts ................................................. 15

Warranty ..................................................Back Cover

2 6104 BCF5 R07

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.

Specifi cations

U.S. #1 or #2 Fuel Oil only

Fuels

Firing range

Motor

Igniter. 120V/14,000V
Housing Cast aluminum
Fuel unit 100 - 200 PSIG
Oil nozzle 45° - 70° solid
Shipping wt. 55 lbs.

(ASTM D396)
Canada #1 Stove Oil or #2
Furnace Oil only

CF500: 1.75 to 5.50 GPH
CF800: 3.00 to 8.00 GPH

1/3 HP 3450 RPM
120/60 hz standard

4.8 amps @ 120 VAC

NOTICE

Intended to bring special attention to information,

but not related to personal injury or property
damage.

Note: 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.

6104 BCF5 R07 3

Owner’s Responsibility:

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:

y

Never store or use gasoline or other fl ammable liquids
or vapors near this burner or appliance.

y

Never attempt to burn garbage or refuse in this appli­ance.

y

Never attempt to light the burner by throwing burning
material into the appliance.

y

Never attempt to burn any fuel not specifi ed and ap-
proved for use in this burner.

y

Never restrict the air inlet openings to the burner or the
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.

NOTICE

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 checklist

Combustion air supply



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

y

supplied with a reliable combustion air source.
Follow the guidelines in the latest editions of the NFP A

y

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

The burner requires combustion air and ventilation air

y

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.

4 6104 BCF5 R07

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 NFPA 31 (CSA
B1139-M91 in Canada).

y

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

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

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

y

exceed 3 psig.
Do NOT install valves in return line.

y

Ensure that a pressure-limiting device is installed in

y

accordance with the latest edition of the NFPA 31.

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.

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

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

y

installation is usually suitable for either a one-pipe or two­pipe oil system. The oil pressure at the inlet of the fuel unit
must not exceed 3 psig.
Refer to the Mount the Burner Section of this manual for

y

one-pipe or two-pipe fuel supply installation instructions.

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. 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.

Correct Nozzle and Flow
Rate Required

Incorrect nozzles and fl ow rates could

result in impaired combustion, under­fi ring, over-fi ring, sooting, puff-back
of hot gases, smoke and potential fi re
or asphyxiation hazards.

Use only nozzles having the brand, fl ow rate (gph),
spray angle and pattern specifi ed by the appliance

manufacturer.
Follow the appliance manufacturer’s specifi cations for
the required pump outlet pressure for the nozzle, since
this affects the fl ow rate.

Nozzle manufacturers calibrate nozzle fl ow rates at

y

100 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 4.00 gph
nozzle at 140 psig = 4.70 gph.

For typical nozzle fl ow rates at various pressures

y

see accompanying chart.

The fuel unit nozzle port pressure is factory set at 140

y

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.

Electrical supply



Verify that the power connections available are correct for

y

the burner. Refer to Figure 1. All power must be supplied
through fused disconnect switches.

Vent system



The fl ue gas venting system must be in good condition and

y

must comply with all applicable codes.

Figure 1. Typical Nameplate

General Model Information

Serial Number,Including Date Code

Rating Information

Approval Agency Symbols

Primary Group and Fuel

Model “XX”

Series (Fuel) Burner

SERIAL NUMBER

050214-00000

Control Circ: 120V/60Hz 4.5A

Motor Circ: 120V/60Hz 4.0A

LISTED

(FUEL) BURNER

R.W. Beckett Corp.

Elyria, Ohio

Made in the U.S.A.

For use with Group 8 . . .

MP 1192 XX000 R00

6104 BCF5 R07 5

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

Table 1 - Nozzle Capacities

Rated gph @

100 psig

1.75 2.07 2.14

2.00 2.37 2.45

2.25 2.66 2.74

2.50 2.96 3.06

2.75 3.24 3.37

3.00 3.55 3.68

3.50 4.13 4.29

4.00 4.70 4.90

4.50 5.30 5.51

5.00 5.90 6.13

5.50 6.50 6.74

6.00 7.10 7.33

6.50 7.65 7.96

Verify burner components —



Burner, Model CF500 or CF800

y

Air tube assembly

y

Mounting fl ange kit

y

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

y

nozzles are recommended unless otherwise specifi ed
by appliance manufacturer. (See specifi c appliance
recommendation sheet or refer to OEM Spec Guide). Find
the required fi ring rate in the 140 psig column (factory-set
fuel unit pressure). Select the corresponding nozzle from
column 1 (Rated gph @ 100 psig).

Pressure - Pounds per

square inch

140 150

Verify fi ring rate



Refer to appliance manufacturer’s instructions (if

y

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

Verify air tube



The information in this section may be disregarded if the

y

air tube is supplied by the appliance manufacturer.

Two tube arrangements are available –

y

CF500 1.75 to 5.50 GPH
CF800 Tube A — 3.00 to 7.00 GPH

Tube B — 5.00 to 8.00 GPH

y

Maximum fi ring capacity depends on the fi rebox pressure.
Use Table 2 to verify the correct air tube type for the fi r-
ing rate required. Use Tube B only when Tube A cannot
provide the fi ring rate required.

See Figure 3 to verify the correct air tube length and air

y

tube combination code.

Figure 3 - Air Tube Mounting Dimensions

Figure 2.

Firing Rate

1.75 to 3.00 gph

4.00 gph

5.00 gph

6.00 gph

7.00 gph

8.00 gph

Min. Combustion Chamber Dimensions

Minimum Dimensions

(with damper) (without damper)

ALAL

7.5” 18.0” 8.0” 19.0”

8.0” 21.0” 9.5” 23.0”

9.0” 23.0” 10.5” 30.0”

10.0” 28.0” 11.5” 40.0”

11.0” 34.0” 12.0” 46.0”

14.0” 38.0” 14.0” 51.0”

u

u Install burner with 2

Air Tube

Length

(Dimension T)

6.00” CF 60 KK CF 60 KH CF 60 KJ

8.00” CF 80 KK CF 80 KH CF 80 KJ

10.00” CF 100 KK CF 100 KH CF 100 KJ

14.00” CF 140 KK CF 140 KH CF 140 KJ

16.00” CF160 KK -- --

17.00” -- CF 170 KH CF 170 KJ

CF500

o

pitch as shown.

A.T.C. Codes

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

CF800

Tube A Tube B

6 6104 BCF5 R07

Table 2 - Air tube capacities vs fi rebox pressure

Mount the burner

Firebox

pressure

(in w.c.)

0.0” 5.50 7.00 8.00 4.95 6.30 7.20

0.1” 4.75 6.25 7.50 4.27 5.62 6.75

0.2” 4.00 5.50 6.75 3.60 4.95 6.07

0.3” 3.50 4.50 6.25 3.15 4.00 5.62

0.4” 2.75 3.75 5.50 2.47 3.37 4.95

0.5” 2.00 3.00 5.00 1.80 2.70 4.50

Note: The above ratings may vary 5% due to variations in actual

job conditions.

Stray Light



CF500 CF800 CF500 CF800

Tube KKTube KHTube KJTube KKTube KHTube

KJ

No reserve air 10% Turndown

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 from direct exposure to intense

y

light.

Dust and Moisture

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.

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 facto­ry-tested and specifi ed by the appliance manufacturer.
Position the end of the air tube 1/4” back from fl ush

y

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

Mount fl ange(s) on air tube



y

This section does not apply to burners with welded fl ang-
es.

y

Do not install air tube on burner.

y

For non-pressure fi ring fl ange, refer to Figure 4: Install
gasket (item a) and fl ange (item d). Ignore the next
paragraph.

y

For pressure-fi ring fl ange, refer to Figure 4: Slide gasket
(item a) onto the air tube, making sure the top of the air
tube is up. Pre-drill holes in the pressure fi ring plate (item
b) to match the appliance studs. Slide the pressure fi ring
plate (item b) and fl ange (item d) onto the air tube as
shown. Wrap ceramic fi ber rope (item c) around the air
tube and press tightly into the inside diameter of the fl ange
(item d).

y

Slide the air tube (item e) into position in the appliance
front. Tighten the fl ange-mounting-stud nuts. Set the
insertion of the air tube so dimension G is 1/4” nominal.

y

Pitch the air tube at 2° from horizontal as shown and secure
the fl ange to the air tube.

Figure 4 - Mount fl ange(s) on air tube

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.

y

Protective covers and more frequent maintenance may
be required.

6104 BCF5 R07 7

End view Side view

Mount air tube to burner



Insert the air tube into the burner housing. Carefully align

y

the the four screw holes.
Attach the air tube to the burner using the four provided

y

screws.



Install nozzle

y

Install the oil nozzle in the nozzle adapter. Use a 3/4”
open-end wrench to steady the nozzle adapter and a 5/8”
open-end wrench to turn the nozzle. Tighten securely but

do not over-tighten.



Check electrode settings

Maintain Electrode
Specifi cations

Failure to properly maintain these specifi cations

could cause ignition malfunction, puff-back of
hot gases, heavy smoke, asphyxiation, explo­sion and fi re hazards.

Adjust the electrode gap and position in relation to the

y

nozzle to the specifi cations shown in Figure 4.

Figure 6 - Nozzle line assembly in burner

CF500
1-9/16”

CF800
1-3/4”

Set dimension Z



y

Loosen fastener c in Figure 7. Slide the nozzle line and
plate assembly until dimension Z in Figure 6 is:

CF500 - 1-9/16” ±1/16”
CF800 - 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
(item c).

Check, and adjust if necessary, the critical dimensions

y

shown in Figure 5. Verify that the oil tube assembly
and electrodes are in good condition, with no cracks or
damage.

Figure 5 - Nozzle and nozzle line assembly

3/16” - 7/32”

gap

R

Legend (Figure 5)

Nozzle centerline to electrode tip = 1/4”

P

Nozzle face to electrode tip = 1/8”

Q

Electrode spacing = 5/32” gap

R

Install nozzle line assembly



Insert the nozzle line assembly into the burner air tube.

y

Reference Figure 6.
Slide the secondary adjusting plate (Figure 7, item f) com-

y

pletely to the left on the indicator adjusting plate (item e).
Finger tighten acorn nut (item c) to secure the two plates
together. Slide both plates completely to the right (Indica­tor Plate will read 0). Tighten fastener (item d).
Install the spline nut on the end of the nozzle line, leaving

y

the nut loosely placed so the plates can be moved.

1/4” in front

of nozzle

3/16” above

P

nozzle center

Q

50001

y

Attach the oil line from the oil valve to the nozzle line
end. Tighten securely .
Before proceeding, check dimension Z once again. Loos-

y

en acorn nut c if necessary to reposition the nozzle line.
Once dimension Z is set, do not loosen the acorn nut
(item) c again. Note that for the setting of fastener d,
refer to Initial Head Position procedure on Page 11.

Figure 7 - Adjusting plate assy.

Legend (Figures 7)

e

c

Bottom acorn nut

d

Fastener



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 Figure 4.

Secure the burner to the appliance by tightening the nuts

y

on the burner fl ange mounting studs.

Indicator adjusting plate

f

Secondary adjusting plate

8 6104 BCF5 R07

Fuel unit by-pass plug

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.

The CF500 and CF800 burners are shipped without the

y

by-pass plug installed in the fuel line.
The by-pass plug must NOT be installed when using with

y

a one-pipe oil system.
The by-pass plug MUST be installed when using a two-

y

pipe oil system.

Oil supply/return lines



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 lines.

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).

Table 3. Fuel Unit gearset capacity

Fuel unit model number Gearset capacity (GPH)

A2VA-7116
A2YA-7916
B2VA-8216
B2YA-8916
B2TA-8248

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.

Burner fuel fl ow



One-pipe systems – See Figure 8 for the fuel fl ow path.

y

Figure 7 is based on type B fuel unit.

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.

Figure 9 is based on type B fuel unit .

y
y

Oil supply connects to one of the fuel unit inlet ports.
Oil return connects to the fuel unit return port. (Install

the by-pass plug in the fuel unit for two-pipe sys­tems.)

17
20
21
25
21

Figure 8 - One-pipe oil fl ow with “B” pump

125-200 psig

125-200 psig

Figure 9 - Two-pipe oil fl ow with “B” pump

125-200 psig

125-200 psig

3502

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
2 for the fuel unit gear set capacity - the rate at which
fuel is recirculated when connected to a two-pipe system.
However, size two-pipe oil lines based on this fl ow rate.
Use continuous lengths of heavy-wall copper tubing,

y

routed 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 2) for two-pipe systems. Size the fi lter

6104 BCF5 R07 9

Legend

a Return port
b Nozzle port
c Oil valve
d Nozzle & adapter
g Inlet port
k Return line to oil tank
p Air bleed valve

Nozzle pressure – The fuel unit nozzle port pressure

y

is factory set at 140 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.

3503

Wire the burner — R7184

Sequence of operation

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).

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.

Figure 10. - Typical wiring

— typical

Standby -- The burner is idle, waiting for a call for heat.

1.

When a call for heat is initiated, there is a 3- to 10-second
delay while the control performs a safe start check.

Valve-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 ap-

3.

plicable. A fl ame should be established within the 15-second
lockout time (30-second lockout time is available).

Lockout — If fl ame is not sensed by the end of the TFI, the

4.

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 ignition

5.

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. The

6.

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.

Legend (Figure 10)

FD

Fused disconnect

LM

Limit controls

OP

Operating controls

PP

Oil primary controls

CC

Flame sensor, CAD cell type

TR

Ignition transformer

M1

Burner motor

S1

Oil valve

T-T

24-volt thermostat

F-F

Flame sensor terminals

Burner motor-off delay — If applicable, the fuel valve is

8.

closed and the burner motor is kept on for the selected post­purge time before the control returns the burner to standby.

Resetting to cad cell

If the control locks out three times in a row without a com-

y

plete heat cycle between attempts, the lockout becomes re­stricted. A qualifi ed service technician should be called to
inspect the burner.

Figure 11. - Typical sequence of operation

1

Standby

2

Valve-on

delay

8

Motor-off

delay

(postpurge)

3

5

carryover

6

Trial for
ignition

Ignition

Run

4

Lockout

7

Recycle

10 6104 BCF5 R07

Prepare the burner for start-up

Oil nozzle has been selected correctly and securely

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.



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 the ‘Set Z Dimension’



instructions detailed earlier in this manual. The acorn nut
(Figure 7, item C) should never be loosened once the Z
dimension is initially set.

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.

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.

Keep Service Access

Covers Securely Installed

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.

Initial head position (Figure 7)



The indicator plate assembly markings correspond to head

y

position settings.
Loosen the fastener (Figure 7, item d) and slide the

y

indicator plate until the number on the indicator plate
corresponds to the initial head setting listed in Table 4, for
the desired fi ring rate.
When the head position has been set, tighten the fastener

y

and the spline nut.

These covers must be securely in place to
prevent electrical shock, damage from exter­nal elements, and protect against injury from

Table 4 - Initial indicator adjustment plate settings
(head position)

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.

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.

6104 BCF5 R07 11

Rate GPH

1.75 0 -- --

2.25 0

3.00 4 0 --

3.50 5 1 --

4.00 5 2 --

5.00 6 4 3

5.50 6 4 4

6.00 -- 4 4

7.00 -- 6 5

8.00 -- -- 6

Approximate head settings

CF500

Tube A Tube B

CF800

Table 5 - Initial air shutter and band settings

Start the Burner

Approximate air settings
Rate
GPH

1.75 1 0 -- -- -- --

2.25 2 0 -- -- -- --

3.00 10 1 1 0 -- --

3.50 10 2 3 0 -- --

4.00 10 3 4 0 -- --

5.00 10 5 9 0 8 2

5.50 10 10 9 5 9 4

6.00 -- -- 10 3 10 3

7.00 -- -- 10 8 10 5

8.00 -- -- -- -- 10 10

Note: These settings are appoximate, and can vary depending on
actual job conditions and overfi re pressure

Initial air settings (Table 5)



Loosen the air band and shutter, and adjust to the

y

approximate fi ring rate settings given in Table 5.
These initial settings should be adequate for starting the

y

burner. Once the burner is in operation, the air settings
will be adjusted for best performance as discussed later in
this manual.
Follow the procedures described later in this manual for

y

fi ne-tuning the air settings.

Set appliance limit controls



y

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

Prepare the fuel unit for air venting



To vent air from the oil supply line, attach a clear hose

y

to the pump air bleed valve (fi gure 9) on the fuel unit.
Provide a container to catch the oil. Loosen the pump air
bleed valve.
Vent the air as described in the next section under Start

y

the burner.

CF500

Shutter Band Shutter Band Shutter Band

Tube A Tube B

CF800

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

y

Department. Carefully follow their directions.
Keep a fi re extinguisher nearby and ready for use.

y

Starting the burner and venting air



Priming the pump

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.

Initiate a call for heat

y

While the ignition is on, press and release the reset button

y

on the R7184 control (hold 1/2 second or less). If the
control has not locked out since it’s most recent complete
heat cycle, the lockout time will be extended to 4 minutes
(45 seconds in earlier units), and the ignition will remain
on the entire heat cycle.
Bleed the pump until all froth and bubbles are purged. If

y

prime is not established within the extended lockout time,

12 6104 BCF5 R07

the control will lock out. Press the reset button to reset the
control and return to the functions listed in the previous
step.

y

Repeat the previous steps if needed, until the pump is
fully primed and the oil is free of bubbles. Then terminate
the call for heat, and the control will resume normal
operation.

Disable function

Any time the motor is running, press and hold the reset

y

button to disable the burner. The burner will remain off as
long as the button is held and will return to standby when
released.

CAD cell resistance check

While the burner is fi ring, and after the ignition has been

y

turned off, press and release the reset button (hold 1/2 sec­ond or less) to check the cad cell resistance. The LED will
fl ash 1 to 4 times, depending on the cad cell resistance
(refer to the table below).

Number of LED

fl ashes

1 Strong (0 to 400)
2 Normal (400 to 800)
3 Weak (800 to 1600)
4 Poor (1600 or higher)*

* Lockout is likely to occur.

Cad Cell Resistance (ohms)

Step 1: Adjust the air shutter/band until a trace of smoke

is achieved.

Step 2: At the trace of smoke level, measure the CO

(or O2) . This is the vital reference point for further
adjustments. Example: 13.5% CO

Step 3: Increase the air to reduce the CO

2 percentage points. (O2 will be increased by
approximately 2.0 to 2.7 percentage points.)
Example: Reduce CO2 from 13.5% to 11.5% (2.6%
to 5.3% O2).

Step 4: Recheck smoke level. It should be Zero.

This procedure provides a margin of reserve air

y

to accommodate variable conditions.
If the draft level has changed, recheck the

y

smoke and CO2 (or O2) levels and readjust the
burner, if necessary

Once combustion is set, tighten all fasteners on air band, air

4.
shutter and escutcheon plate.

Start and stop the burner several times to ensure satisfactory

5.
operation. Test the primary control and all other appliance
safety controls to verify that they function according to the
manufacturer’s specifi cations.

Check the breech draft pressure against the appliance man-

6.
ufacturer’s recommended setting (typically + 0.1” W.C.). If
the breech pressure is higher or lower than recommended
level, adjust the appliance breech damper to achieve the
specifi ed setting. Recheck the smoke and CO
Adjust burner air if necessary.

(2.6% O

2

by 1.5 to

2

(or O2) levels.

2

)

2

2

LED Indicator Status

On Flame sensed
Off Flame not sensed

Flashing (1/2 sec off - 1/2

sec on)

Flashing (2 sec off - 2 sec

on)

Set combustion using instruments



Lockout/Restricted

Lockout
Recycle

Allow the burner to run for approximately 5 to 10 minutes.

1.
Set the stack or over-fi re draft to the level specifi ed by the

2.
appliance manufacturer.

Natural Draft Applications; typically over-fi re draft

y

is -0.01” or -0.02” w.c.
Direct Venting; typically may not require draft adjust-

y

ment.
High Effi ciency/Positive Pressure Appliances; also

y

vary from traditional appliances (see manufacturer’s
recommendations).

Follow these four steps to properly adjust the burner:

3.

6104 BCF5 R07 13

Maintenance and Service

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

y

dusty or adverse environments.
Operation and adjustment of the burner requires

y

technical 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.
Inspect the igniter spring contacts.



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



carbon or foreign matter. Replace all damaged units with
exact parts.
Clean the blower wheel, air inlet, air guide, burner hous-



ing and static plate 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 accumula-



tion 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 per-



formed 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.

Figure 12 - Adjustable mounting plates for CF500
and CF800

14 6104 BCF5 R07

Replacement parts

2

1

10

9

Item Part Name/Description Part Number

1 Air Tube Specify
2 Spline Nut 3666
3 Adjusting plate assembly 51286U
4 Blocking Oil Solenoid Valve 2182602U
5 Igniter 51771U
6 Control Specify
7 Air Band 3819
8 Air Shutter 3215
9 Fuel Pump Specify

10 Fuel lines Specify Lengths

5

3

4

8

7

6

12

11

13

Head Assembly:
CF500 - KK

11

CF800 - KH (Tube A)
CF800 - KJ (Tube B)

12 Electrode Assembly Specify
13 Nozzle Line Assembly Specify
14 Motor - 1/3 PSC 21341U

Blower Wheel:

15

CF500 - 5-19/32” x 2-13/32”
CF800 - 6-5/16” x 2-3/8”

16 Coupling 2433
17 Flange Kit See Figure 12

18 Pedestal Kit Not Shown

51401U
51252P
51302P

21448U
21339U

16

15

14

6104 BCF5 R07 15

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 3X7

Printed in U.S.A. 12/2006 © R.W. Beckett Corporation

16 6104 BCF5 R07