Beckett CF800 User Manual

COMMERCIAL PRODUCTS

Potential for Fire, Smoke and Asphyxiation Hazards

Incorrect installation, adjustment, or misuse of this burner could result in death, severe personal injury, or substantial property damage.

To the Homeowner or Equipment Owner:

Please read and carefully follow all instructions

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

Contact a professional, qualiﬁ ed service agency for

installation, start-up or service work.

Save this manual for future reference.

To the Professional, Qualiﬁ ed Installer or Service Agency:

Please read and carefully follow all instructions provided

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

The Installation must be made in accordance with all state

and local codes having jurisdiction.

To the Owner:

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

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

READ THESE INSTRUCTIONS AND SAVE FOR REFERENCE

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

immediately contact your qualiﬁ ed service agency for consultation.

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

Daily – Check the room in which your

burner/appliance is installed. Make sure:

Air ventilation openings are clean and

unobstructed

Nothing is blocking burner inlet air

openings

No combustible materials are stored

near the heating appliance

There are no signs of oil or water

leaking around the burner or appliance

Weekly

Check your oil tank level. Always

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

Contents

General Information ....................................................4

Hazard Deﬁ nitions ........................................................................ 4

Agency approvals .......................................................................... 4

Speciﬁ cations ................................................................................ 4

Owner’s Responsibility: ................................................................. 5

Professional Installer/Service Agency Responsibility: ................... 5

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

Combustion air supply ................................................................... 5

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

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

Nozzle Pressure ............................................................................ 6

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

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

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

Verify Firing Rate ........................................................................... 7

Verify air tube ................................................................................ 7

Stray Light ..................................................................................... 8

Dust and Moisture ......................................................................... 8

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

Mount ﬂ ange(s) on air tube ........................................................... 9

Mount air tube to burner ................................................................ 9

Install nozzle ................................................................................. 9

Check electrode settings ............................................................... 9

Install nozzle line assembly ........................................................... 9

Set dimension Z .......................................................................... 10

Insert burner ................................................................................ 10

Fuel unit by-pass plug ................................................................. 10

Oil supply/return lines .................................................................. 10

Burner fuel ﬂ ow ............................................................................11

Wire the Burner .......................................................... 11

Typical Burner Sequence of Operation - 7505 Control. .............. 14

Typical Burner Wiring - 7505 Control .......................................... 15

Reset Button Operation ............................................................... 15

Typical Burner Sequence of Operation - R7184P Control. ......... 16

Prepare the Burner for Start-up ...............................17

Initial air settings (Table 5) .......................................................... 18

Set appliance limit controls ......................................................... 18

Prepare the fuel unit for air venting ............................................. 18

Start the Burner .........................................................19

Starting the burner and venting air .............................................. 19

Disable function ........................................................................... 19

Cad Cell Resistance Measurement ............................................. 20

Resetting From Restricted or Hard Lockout ................................ 20

Set combustion using instruments .............................................. 20

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

Replacement parts ....................................................22

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

CF500/CF800 Burner Manual

Section: General Information

General Information

Hazard Deﬁ nitions

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

in death or serious injury.

Indicates a hazardous situation, which, if not avoided, could

result in death or serious injury.

Indicates a hazardous situation, which, if not avoided, could

result in minor or moderate injury.

Within the boundaries of the hazard warning, there will be information presented describing consequences if the warning is not heeded and instructions on how to avoid the hazard.

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

personal injury or property damage.

Agency approvals

Speciﬁ cations

DO NOT USE GASOLINE, CRANKCASE OIL, OR ANY OIL CONTAINING

Fuels

Firing range

Motor

Igniter 120V/14,000V

Housing Cast aluminum

Fuel unit 100 - 200 PSIG

Oil nozzle 45° - 70° solid

Shipping weight 55 lbs.

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.

GASOLINE

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

(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

50 Hz Motors — The burner ratings, air settings and nozzle

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.

Frozen Plumbing and Water Damage Hazard

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

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.

Section: Pre-installation Checklist

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:

Never store or use gasoline or other ﬂ ammable

liquids or vapors near this burner or appliance.

Never attempt to burn garbage or refuse in this

appliance.

Never attempt to light the burner by throwing burning

material into the appliance.

Never attempt to burn any fuel not speciﬁ ed and

approved for use in this burner.

Never restrict the air inlet openings to the burner or

the combustion air ventilation openings in the room.

Pre-installation Checklist

Combustion air supply

Adequate Combustion and Ventilation Air Supply Required

Failure to provide adequate air supply could seriously 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

supplied with a reliable combustion air source.

Follow the guidelines in the latest editions of the

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

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 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).

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.

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 all instructions completely.

This equipment must be installed, adjusted

and started 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

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

CF500/CF800 Burner Manual

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.

Fuel supply

Oil Supply Pressure Control Required

Damage to the pump, ﬁ lter or other component seals could cause possible oil leakage and potential ﬁ re hazard.

The oil supply inlet pressure to the fuel unit cannot

exceed 3 psig.

Ensure that a pressure-limiting device is installed in

accordance with the latest edition of the NFPA 31.

The fuel supply piping and tank must provide #1 or #2 fuel oil at pressure or vacuum conditions suitable for

Section: Pre-installation Checklist

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 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. Refer to the Mount the Burner Section of this manual for 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 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.

Nozzle Pressure

Correct Nozzle and Flow Rate Required

The fuel unit nozzle port pressure 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.

Electrical Supply

Verify that the power connections available are correct for the burner. Refer to Figure 1. All power must be supplied through fused disconnect switches.

Verify Burner Components

Burner, Model CF500 or CF800

○

Air tube assembly

○

Mounting ﬂ ange kit

○

Oil nozzle, per Table 1

○

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).

— Only 45° to 70° solid pattern

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

Use only nozzles having the brand, ﬂ ow rate (gph), spray angle and pattern speciﬁ ed by the appliance manufacturer. Follow the appliance manufacturer’s speciﬁ cations for the required pump outlet pressure for the nozzle, since this affects the ﬂ ow rate.

Nozzle manufacturers calibrate nozzle ﬂ ow rates at

100 psig.

This burner utilizes pressures higher than 100 psig,

so the actual nozzle ﬂ ow rate will be greater than the gph stamped on the nozzle body. (Example: A 2.00 gph nozzle at 140 psig = 2.37 gph.

For typical nozzle ﬂ ow rates at various pressures

see Table 1.

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

For use with Group 8 . . .

MP 1192 XX000 R00

Vent System

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

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

MFR’S SETTINGS

X X X X X X

XX000 R00

050214-00000

L0002

Pressure - Pounds per square inch

140 150

R.W. Beckett Construction & Setting Data

R.W. Beckett Speciﬁ cation Number and Revision

Boiler Manufacturer and Model, When Applicable

Additional Codes

Section: Pre-installation Checklist

Inspect Chimney or Direct Vent System

Fire, Smoke & Asphyxiation Hazard

Carefully inspect the chimney or exhaust vent system.

Make sure it is properly sized and in good working

condition.

Follow the instructions supplied by the appliance

manufacturer.

The installation must strictly comply with all applicable

codes, authorities having jurisdiction and the latest revision of the National Fire Protection Association Standard NFPA 31 for the installation of chimneys and vent sizing, (or CSA-B139 and CSA-B140 in Canada).

Regulation by these authorities take precedence over

the general instructions provided in this manual.

Starting with minimum gph ﬁ ring rate, the minimum size recommended is 8” ﬂ ue pipe with 8” X 8” inside chimney, unless speciﬁ ed otherwise by the appliance manufacturer.

A chimney ﬂ ue shall extend at least 3 feet above the highest point at which the chimney comes in contact with the roof, and not less than 2 feet above the highest roof surface or structure within 10 feet horizontally of the chimney. Refer to Figure 2.

Any accumulation of soot or debris in chimney offsets should be removed

Any obstructions such as a protruding joint or a piece of broken tile wedged in the chimney should be removed.

No other appliance connection should be made to the same ﬂ ue pipe.

The ﬂ ue pipe should have an upward pitch toward the

6. chimney of at least 1/4” per foot of length. It should ﬁ t tightly and should not project into the chimney.

Any leakage between tiles, around clean-out doors,

7. or around the vent pipe should be sealed.

INSULATED STAINLESS STEEL CHIMNEY LINERS

Verify Firing Rate

Refer to appliance manufacturer’s instructions (if available) for ﬁ ring rate and nozzle selection. Otherwise, the maximum recommended ﬁ ring rate for the burner depends on the length of the ﬁ ring chamber and the distance from the burner center to the chamber ﬂ oor. Verify that the chamber dimensions are at least as large as the minimum values given in Figure 2. If the appliance dimensions are smaller than recommended, reduce the ﬁ ring rate accordingly.

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

*2°

* Install burner with 2° pitch as shown.

Firing Rate

1.75 to 3.00 gph

4.00 gph

5.00 gph

6.00 gph

7.00 gph

8.00 gph

1/4”

Minimum Dimensions

(with damper) (without damper)

HLHL

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”

The new designs of high efﬁ ciency oil furnaces and boilers in conjunction with ﬂ ame retention oil burners are more efﬁ cient. One result of increased efﬁ ciency is lower ﬂ ue gas temperatures. As ﬂ ue gases rise in the chimney, they will cool and condense when they reach the dew point. The condensation will mix with the sulphur in the ﬂ ue gases creating sulphuric acid. The acid will attack the chimney mortar, brick and clay liners causing corrosion, deterioration and blockage of the chimney. Eventually the blockage could prevent exhausting the ﬂ ue gases. Instead, the ﬂ ue gases could vent out the barometric damper into the living space.

Therefore, it is strongly recommended that an approved insulated stainless steel liner be installed.

CF500/CF800 Burner Manual

Air Tube Length

(Dimension T)

6.00”

8.00”

10.00”

14.00”

16.00”

17.00”

A.T.C. Codes

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

CF500

CF 60 KK CF 60 KH CF 60 KJ

CF 80 KK CF 80 KH CF 80 KJ

CF 100 KK CF 100 KH CF 100 KJ

CF 140 KK CF 140 KH CF 140 KJ

CF160 KK -- --

-- CF 170 KH CF 170 KJ

Tube A Tube B

CF800

Section: Mount the Burner

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 –

CF500 1.75 to 5.50 GPH

○

CF800 Tube A — 3.00 to 7.00 GPH

○

Tube B — 5.00 to 8.00 GPH

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

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

Table 2 - Air tube capacities vs ﬁ rebox pressure

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.

Figure 3a - Firebox Pressure: CF500 with no Reserve Air

CF500 CF800 CF500 CF800

Tube KKTube KHTube KJTube KKTube KHTube

No reserve air 10% Turndown

Stray Light

Protect Against Stray Light Lockout

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

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

order to start the burner or it will hold in the stray light lockout mode.

Shield the burner from direct exposure to intense 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.

This burner is designed for clean, dry installations.

Electrical controls are not protected against rain or

sprayed water.

Keep the installation clear of dust, dirt, corrosive

vapors, and moisture.

Protective covers and more frequent maintenance

may be required.

0.0

Maximum Firing Rate U.S. GPH

0.1 0.2 0.3 0.4 0.5

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

Figure 3b - Firebox Pressure: CF800 with no Reserve Air

Maximum Firing Rate U.S. GPH

0.0

0.1 0.2 0.3 0.4 0.5

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

Mount the Burner

Protect the Air Tube From Overheating

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

The end of the air tube must not extend into the

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

Position the end of the air tube ¼” back from ﬂ ush with the refractory inside entry wall to prevent damage from overheating.

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