Beckett CG10 User Manual

Page 1

COMMERCIAL PRODUCTS

Fire, Explosion and Asphyxiation Hazards

Failure to follow these instructions exactly could lead to ﬁ re or explosion and result in death, severe personal injury or property damage.

Do not store or use gasoline or other ﬂ ammable vapors and liquids in the vicinity of this or any other appliance.

What to do if you smell gas:

- Do not try to light any appliance.

- Do not touch any electrical switch.

- Do not use any phone in your building.

- Immediately call your gas supplier from a telephone outside the building.

- Follow the gas supplier’s instructions.

- Call the ﬁ re department if you cannot contact your supplier. Installation and service must be performed by a qualiﬁ ed installer, service agency, or the gas supplier.

Page 2

Contents

General Information ....................................................3

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

Owner’s Responsibility: ................................................................. 3

Professional Installer’s Responsibility: ..........................................4

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

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

Indoor Installation .......................................................................... 5

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

Clearances .................................................................................... 6

Fuel gas supply .............................................................................6

Flue vent system ...........................................................................6

Electrical supply ............................................................................ 6

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

Verify ﬁ ring input range ................................................................. 6

Verify burner air tube assembly ..................................................... 7

Mount the Burner ......................................................... 9

Connect Gas Piping ....................................................9

Gas Trains ...................................................................................10

Wire the Burner .......................................................... 12

Sequence of Operation ............................................. 13

Prepare the Burner for Start-up ............................... 13

Start-up checklist .........................................................................14

Start the Burner ........................................................ 16

Burner start procedure ...............................................................16

Verify input ﬁ ring rate ..................................................................16

Check operation and safety controls ........................................... 20

Use test instruments to set combustion: .....................................21

Recommended combustion test sequence: ................................21

Maintenance and Service.......................................... 22

Annual maintenance ..................................................................22

Propane Restrictor Description ..................................................25

Installation ..................................................................................25

For the OPERATOR ....................................................................27

Replacement Parts .................................................... 28

Burner Conﬁ gurations .............................................. 29

Limited Warranty Information .................................. 32

Page 3

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.

Used with the safety

alert symbol, indicates a hazardous situation, which, if not avoided, may 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 headed and instructions on how to avoid the hazard.

Used to address practices not

related to personal injury.

To the Owner:

Thank you for purchasing a Beckett CG10 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 burner.

Your CG10 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 gas heating system by a qualiﬁ ed service agency.

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 gas 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:

CG10 Burner Manual

See the front cover for ‘What to do if you smell gas’.

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/appliance 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.

Page 4

Section: General Information

Professional Installer’s 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 licensed and experienced with all applicable codes and ordinances and responsible for the installation and commissioning of the equipment.

The installation must comply with all local codes and

ordinances having jurisdiction and the latest edition of the National Fuel Gas Code ANSI Z223.1 (NFPA

54) and CAN1-B149.1 in Canada.

Concealed damage – If you

discover damage to the burner or controls during unpacking, notify the carrier at once and ﬁ le the appropriate claim forms.

High altitude installations – Accepted industry practice requires no derate of burner capacity up to 2000 feet above sea level. For altitudes higher than 2000 feet, derate the burner capacity 2% for each 1000 feet above the 2000 feet.

Speciﬁ cations

Table 1 – Burner Speciﬁ cations

Input ﬁ ring range 300 to 1200 MBh

Fuel Natural gas - 0.6 speciﬁ c gravity typical

Gas train Standard: UL listed/CSD-1 Conﬁ guration

Options: IRI and FM

Manifold pressure 1.0 to 4.6 inches W.C. typical

Firing mode On/Off or On/Off with Low Fire Start

Flame safeguard RM7895A Standard (Options available)

Flame detection Standard: Flame rod rectiﬁ cation

Optional: Ultraviolet scanner

Air proving switch Standard

Gas pressure switches

Ignition Direct spark main ﬂ ame

Motor Standard: 1/3 HP; 3450 RPM; 120

Weight 55 lbs.

Dimensions Refer to Figure 5.

service information — Please record the burner serial number (and have available when calling or writing). You will ﬁ nd the serial number on the silver label located on the left rear of the burner. Refer to Figure 1.

Standard high and low

volt/60 hz, single phase Optional motor: 50 or 60 hz (see notice for 50 hz), 240 volt single phase

Special Requirements:

When contacting Beckett for

50 Hz motors – The burner ratings, air settings and other adjustments are based on 60 hz motors at 3450 rpm. Derate ﬁ ring capacity 20% when using 50 hz motors. Consult factory for speciﬁ c application data.

Agency Approvals

Underwriters Laboritories Certiﬁ ed by C-UL Accepted by N.Y.C.M.E.A. Other approvals may be available and must be speciﬁ ed at time of order.

Page 5

Figure 1. Burner Nameplate

General Model Information

Serial Number,

Including Date Code

Section: Pre-installation Checklist

R.W. Beckett Construction and Setting Data

Rating Information

Approval Agency

Symbols

Primary Group

and Fuel

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 and emission of poisonous carbon monoxide gas.

The burner cannot properly burn the fuel if it is not

supplied with a reliable combustion air source.

Follow the guidelines in the latest edition of National

Fuel Gas Code ANSI Z223.1 (NFPA 54) and CAN1-B149.1 regarding providing adequate air for combustion and ventilation.

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 1000 Btu/hr input for all fuel-burning equipment in the room.

R.W. Beckett Speciﬁ cation Number and Revision

Boiler Manufacturer and Model, When Applicable

Additional Codes

Indoor Installation

Protect against Dust and Moisture

Wet or 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 liquids.

Keep the installation clear of dust, dirt, corrosive

vapors, and moisture.

Protective covers and more frequent maintenance

may be required.

If there is 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.

CG10 Burner Manual

Page 6

Section: Pre-installation Checklist

Test For Gas Pipe Leaks

Leaking gas could result in asphyxiation, explosion, or ﬁ re hazard.

The gas supply piping must be absolutely leak-free.

Pressure test the gas piping with air that is at least

three times greater than the gas pressure being used.

Verify that there are no leaks before proceeding.

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 local codes and with the appliance manufacturer’s recommendations.

○

Flange mounting arrangement (Includes hightemperature gasket and /or ﬁ ber rope for pressure ﬁ ring).

Verify ﬁ ring input range

Refer to appliance manufacturer’s instructions (if available) for the ﬁ ring input range. Otherwise the maximum recommended ﬁ ring range for the burner depends on the length and width 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, reduce the ﬁ ring rate accordingly.

Dimensions shown are for cast

iron sectional boilers with uptakes between sections. For minimum dimensions of other furnace types consult R.W. Beckett Corporation.

Fuel gas supply

Verify that the gas supply piping complies with all applicable local codes and the latest edition of the National Fuel Gas Code ANSI Z223.1 (NFPA 54).

Insure that the supply gas pipe size is capable of providing at least the minimum pressure required to the burner gas train inlet at the burner’s full capacity rating. Refer to Table 1.

Flue vent system

The ﬂ ue gas vent system must be in good condition and must comply with National Fuel Gas Code ANSI Z223.1 (NFPA 54) and all other applicable codes having jurisdiction for vent construction, capacity, and sizing.

Electrical supply

Check the nameplate on the burner to verify that the power connections available are correct for the burner. Refer to Figure 1. All power must be supplied through fused disconnect switches and comply with the latest edition of National Electric Code NFPA 70 (Canada CSA C22.1) and all other local or applicable codes.

Figure 2. Minimum Combustion Chamber Dimensions

Minimum Combustion

Chamber Dimensions (inches)

Input Firing Rate in MBH

300-400 18 12 12 6

400-600 22 14 14 7

600-900 26 16 16 8

Length

‘L’

Width

‘W’

Height

‘H’

Burner Head Centerline to

ﬂ oor ‘A’

Verify burner components

Burner model can be checked from burner carton or

○

rating label on burner.

900-1200 30 18 18 9

Page 7

Section: Pre-installation Checklist

Verify burner air tube assembly

○

The information in this section may be disregarded if the burner supplied by the appliance manufacturer is a matched component. Maximum ﬁ ring capacity depends on the furnace

○

pressure. Use the charts shown in Figure 3 and Figure 4, to verify the correct burner conﬁ guration for

the input rate. Refer to Figure 5 to verify the air tube assembly

○

length and mounting insertion dimensions.

The volume of the furnace

also inﬂ uences the combustion process. R. W. Beckett Corp. recommends at least 1 cubic foot of furnace volume for each 150,000 BTU/Hr of ﬁ ring rate.

Figure 3. Maximum Capacity (at 3% O

1400 1300 1200 1100 1000

900 800 700 600

Maximum Capacity, MBH

500 400

0 0.2 0.4 0.6 0.8 1

) vs Furnace Pressure - Step Spud Conﬁ guration

Flames are shaped by their

furnaces and by its ﬂ ue locations. Increased height and width can decrease the length requirement. When shaping is too severe ﬂ ames impinge on the walls. Impingement causes CO and carbon deposits and may damage the wall. Maintaining these minimum dimensions should prevent impingement, but smaller furnaces may be acceptable depending upon the results of applications testing. We recommend factory testing of all new burner/furnace combinations by the furnace manufacturer and/or R. W. Beckett Corp.

CG10.6S CG10.5S CG10.4S CG10.3S CG10.2S CG10.1S

Furnace Pressure, In. W.C.

Figure 4. Maximum Capacity (at 3% O2) vs Furnace Pressure - Swirler Head Conﬁ guration

800

700

600

500

400

Maximum Capacity, MBH

300

0 0.2 0.4 0.6 0.8 1

Furnace Pressure, In. WC

CG10 Burner Manual

CG10.3 CG10.2 CG10.1

Page 8

Section: Pre-installation Checklist

Figure 5. Burner Dimensions

Burner Model Airtube Dim. A Dim. B O.D.

10.1 - 10.3, 10.1S - 10.3S 51927 25.0” 11.7” 4.43”

10.4 - 10.6 51928 26.0” 12.7” 4.86”

10.4S - 10.6S 51961 25.7” 12.5” 4.61”

Page 9

Mount the Burner

Mount the burner to the appliance. The burner speciﬁ ed for packaged equipment will have a ﬂ ange welded for the required insertion. Follow the appliance manufacturer’s instructions for mounting.

In the absence of instructions, or for retroﬁ ts, make sure that the air tube insertion dimension, measured along the side of the air tube from the welded ﬂ ange to the end of burner air tube, is correct.

Protect the Air Tube from Overheating

Section: Mount the Burner & Connect Gas Piping

Figure 6. Custom Mounting Plate

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.

The end of the air tube should be set back ¼”

from ﬂ ush with the refractory inside wall to prevent damage from overheating.

Refer to the instructions outlined in this section for methods of additional protection.

If this dimension cannot be achieved, protect the end of the air tube by installing a suitable ceramic refractory material such as a refractory mill board capable of withstanding at least 2300°F. The entry hole diameter in the appliance should be 1” larger than the air tube to facilitate ease of installation and provide adequate protection.

Referring to Figure 6, if the front plate opening (C) in the boiler is larger than the burner ﬂ ange bolt circle, then a custom mounting plate (A) of at least 1/4” thickness must be used with a suitable high-temperature refractory material anchored on the ﬁ re-side. A suitable high- temperature gasket (B) must be used for an effective seal.

Attach the plate and gasket to the boiler and tighten

○

the mounting nuts or bolts securely. Verify that the air tube is ¼” back from ﬂ ush (see

○

Figure 2), and there is nothing blocking the ﬂ ame zone that could cause ﬂ ame impingement.

Key:

A Burner mouning ﬂ ange

B Gasket

C Appliance mounting plate

Connect Gas Piping

All gas piping installation must

comply with the latest edition of the National Fuel Gas Code ANSI Z223.1 (NFPA 54) and other applicable local codes.

The gas supply system must be sized to deliver at least the minimum required pressure to the gas train inlet. Contact your local gas utility for veriﬁ cation of gas pressures, allowable pressure drops, and any local piping code requirements. Refer to Figure 7 for an illustration of a gas piping layout and refer to Table 1 for pipe sizing.

Do Not Use Teﬂ on Tape on Gas Piping

Damage to gas valve cutoff seals and valve bodies could cause gas leaks and result in asphyxiation, explosion or ﬁ re.

Pieces of tape can be cut loose during installation

and lodge in gas valves causing cutoff seal problems.

Te ﬂ on tape ‘lubricates’ pipe threads, allowing iron

pipes to penetrate too deeply into aluminum valve bodies causing distortion and leakage.

Use only pipe sealant compounds that are resistant

to the gas being used.

CG10 Burner Manual

Page 10

Section: Connect Gas Piping

Figure 7. Typical Gas Piping Layout

ABBREV.

ITEM DESCRIPTION

HGPS

HIGH GAS PRESSURE SWITCH

LGPS

LOW GAS PRESSURE SWITCH

MSC

MAIN SHUTOFF COCK

MLTC

MAIN LEAK TEST COCK

PRESSURE GAUGE

STRAINER

SSOV1

SAFETY SHUTOFF VALVE #1

TEST COCK

UNION

2PRV

TWO POSITION REGULATING VALVE

REGULATOR

GAS UTILITY PIPING

METER

LGPS

DRIP LEG

FACILITY PIPING

(IF USED)

MSC

SSOV1

2PRV

GAS TRAIN BURNER

MLTC

HGPS

BURNER

Table 1. Gas supply piping capacity

Schedule 40 metallic pipe with 0.50 psi or less inlet pressure and 0.30” W.C. pressure drop

Maximum capacity in cubic feet of gas per hour (CFH). Natural gas with 0.60 speciﬁ c gravity. Pipe size (inches) IPS

Pipe Length (ft.) 0.75” 1.0” 1.25” 1.5” 2.0” 2.5” 3.0” 4.0”

10 278 520 1050 1600 3050 4800 8500 17500

20 190 350 730 1100 2100 3300 5900 12000

30 152 285 590 800 1650 2700 4700 9700

40 130 245 500 760 1450 2300 4100 8300

50 115 215 440 670 1270 2000 3600 7400

60 105 195 400 610 1150 1850 3250 6800

70 96 180 370 560 1050 1700 3000 6200

80 90 170 350 530 990 1600 2800 5800

90 84 160 320 490 930 1500 2600 5400

100 79 150 305 460 870 1400 2500 5100

125 72 130 275 410 780 1250 2200 4500

150 64 120 250 380 710 1130 2000 4100

175 59 110 225 350 650 1050 1850 3800

200 55 100 210 320 610 980 1700 3500

Install a Drip Leg in Gas Supply Piping

Foreign matter could lodge in gas valve cutoff seals, resulting in gas leak-through, explosion or ﬁ re.

Install a full-size drip leg or dirt pocket in the piping directly ahead of the main shutoff valve to capture foreign matter.

Gas Trains

Gas Leaks and Exposion Hazards

Provide Over-pressure Protection

CSD-1 requires that if gas pressure entering the building exceeds the rating of any gas train component an overpressure protection device must be installed.

Standard – An Underwriters Laboratories (UL) listed gas train is standard for the CG10 gas burner. This conﬁ guration also meets CSD-1 requirements. See Figure 8 for typical component layout.

Propane (LP) – When the correct propane restrictor is added to a burner’s gas pipe assembly it changes the burner’s gas pressure drop so that the propane pressure drop is equal to the natural gas pressure drop of the same BTU ﬁ ring rate. That is why the Manifold to Furnace Pressure Drop curves of Figures 12 and 13 are correct for both propane and natural gas. That is also why a gas train adjusted for the burner’s natural gas requirements will be correctly adjusted for its propane requirements. R. W. Beckett provides the same pressure regulating safety shutoff valve in the gas train (usually a Honeywell V4944B) for both natural gas and propane. The valve is marked for natural gas due to its primary usage in a pressure range normally used

Page 11

Section: Connect Gas Piping

by natural gas appliances. It is safe and effective for propane usage in this design application.

Optional – Gas trains for IRI and FM are available and must be speciﬁ ed when ordering a burner.

Verify – Verify that the train components are not damaged and all piping and ﬁ ttings are clean inside and out. The gas train is normally shipped as components and must be assembled and installed at the site.

Figure 8. UL gas train conﬁ guration

MSC

LGPS

SSOV1 PRSSOV MLTC

TC TC

Vent lines –

Install vent lines to any gas valve component that requires atmospheric air pressure to balance a diaphragm. Vent lines must be run to the outdoors, with the termination point away from fresh air intakes and windows. The terminal opening must be ﬁ tted with a wire mesh screen to block insects and other contaminants from entering the vent and must be mounted in such a position that water, ice, dirt, or any other foreign matter cannot inﬁ ltrate and block the vent piping. Make sure the ﬁ nal assembly is anchored securely.

HGPS

MSC

ABBREV.

HGPS

LGPS

MSC

MLTC

PRSSOV

SSOV1

TC TP

C6097A

LGPS

SSOV1

ITEM DESCRIPTION

HIGH GAS PRESSURE SWITCH LOW GAS PRESSURE SWITCH MAIN SHUTOFF COCK MAIN LEAK TEST COCK PRESSURE REGULATING SAFETY SHUTOFF VALVE SAFETY SHUTOFF VALVE #1 TEST COCK TEST PORT

UNION

PRSSOV

MLTC U

C6097B

HGPS

When pressure

reducing safety shutoff valves are used, the distance from the ﬁ nal shutoff valve (PRSSOV in Fig. 8) to the burner manifold must be kept to a minimum for good light-off reliability. R.W. Beckett recommends the following maximum lengths:

Pipe Size

1-1/4” 1-1/2”

Max. Length

1”

12” 15” 18”

2”

24”

If a Normally Open Vent Valve (not shown) is used, the distance between the SSOVs must be kept to a minimum using the shortest practical nipples.

BURNER

CG10 Burner Manual

Page 12

Section: Wire the Burner

Wire the Burner

Install the burner and all wiring in accordance with the National Electric Code ANSI/NFPA 70 (Canada CSA C22.1) and all applicable codes and requirements. Wire the burner in compliance with all instructions and diagrams provided by the appliance manufacturer. Verify operation of all controls in accordance with the appliance manufacturer’s guidelines.

See Figure 9 for a typical wiring

diagram, with the RM7895A ﬂ ame safeguard control, for reference purposes only. Check the literature that was packaged with the burner for the primary control manufacturer’s instructions and the exact wiring diagram for your speciﬁ c burner.

Keep Service Access Covers Securely Installed

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

All covers or service access plates must be in place

at all times except during maintenance and service.

This applies to all controls, panels, enclosures,

switches, and guards or any component with a cover as part of its design.

Electrical Shock Hazard

Electrical shock can cause severe personal injury or death.

Disconnect electrical power before installing or

servicing the burner.

Provide ground wiring to the burner, metal control

enclosures and accessories. (This may also be required to aid proper control system operation.)

Perform all wiring in compliance with the National

Electrical Code ANSI/NFPA 70 (Canada CSA C22.1)

Do Not Bypass Safety Controls

Tampering with, or bypassing safety controls could lead to equipment malfunction and result in asphyxiation, explosion or ﬁ re.

Safety controls are designed and installed to provide

protection.

Do NOT tamper with or bypass any safety control.

If a safety control is not functioning properly, shut

off all main electrical power and gas supply to the burner and call a qualiﬁ ed service agency immediately.

Figure 9. Typical wiring using Model RM7897A (for reference only)

Page 13

Section: Sequence of Operation & Prepare the Burner for Start-up

Sequence of Operation

(Typical for RM7897A ﬂ ame safeguard primary control)

Initiate – The primary control enters the INITIATE

sequence when the control is ﬁ rst powered on or power returns after an interruption. The initiate sequence is a ten second delay during which the control veriﬁ es line voltage stability.

Standby – The control enters STANDBY until the

limits, operating limit control, burner switch, and all microcomputer-monitored circuits are in the correct state.

Load demand – Operating limit control contacts

close on drop in temperature (or pressure) and initiates the start sequence.

Prepurge – The control will signal the PREPURGE

sequence when the airﬂ ow interlock and all switches are in the correct state. The Prepurge sequence is the amount of time the blower motor runs prior to the ignition start sequence. Timing for the Prepurge sequence is determined by a card mounted inside the control module (typically 30 seconds).

Trial for ignition (TFI) – After the Prepurge

sequence has timed out, the ignition and main gas valves will be energized. Because the burner has direct spark ignition for the main ﬂ ame, the ﬂ ame must be established and detected by the control within 4 seconds or lockout will occur.

Run – With a ﬂ ame established and the control

continuing to detect a ﬂ ame, the burner will operate in the RUN mode until the load demand is satisﬁ ed or a limit opens.

Load Satisﬁ ed – The fuel valves are closed. After

a 15 second post purge, the burner switches to idle until the next call for operation.

This operation sequence is

typical and for reference only. The primary control could vary, depending on the customer speciﬁ cation and code requirements. For the speciﬁ c operating sequence that applies to your installation, consult the appliance manufacturer’s directions, wiring instructions, and control manufacturer’s literature supplied with your burner.

Prepare the Burner for

Start-up

Professional Installation & 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 by a qualiﬁ ed service technician who is trained and experienced in commercial gas burner system installation and operation.

Do not attempt to start the burner unless you are

fully qualiﬁ ed.

Carefully follow the wiring diagrams, control

instruction 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,

call Beckett at 1-800-645-2876 for assistance.

Delayed Ignition, Explosion and Fire Hazards

This is a direct spark ignition burner and by code requirements must have a primary control with a 4-second ﬂ ame establishment period. Exceeding 4 seconds could result in delayed ignition, explosions and ﬁ re.

Always verify the primary control has a 4-second ﬂ ame establishment period by carefully following the control manufacturers’ conﬁ guration instructions.

Example: Honeywell RM Series requires clipping and removing the JR1 resistor.

CG10 Burner Manual

Page 14

Section: Prepare the Burner for Start-up

Start-up checklist

Verify the following before attempting to start the burner:

1. General

Carefully read and become familiar with the CG10

○

Manual, Flame Safeguard Control Instructions, sequence of operation, pertinent wiring diagrams, gas system layout, insurance requirements, other controls and valve literature pertinent to the installation. Follow the appliance manufacturer’s start-up

○

procedures (when available). Inspect the combustion air supply and exhaust

○

venting and verify that they are free of obstructions and installed and sized in accordance with all applicable codes. Notify appropriate personnel to schedule start-up

○

(gas utility, owner, operators, subcontractors, etc.).

2. Gas Supply Piping

Insure that the gas piping is properly sized and has

○

been inspected by the gas utility, leak tested at all joints, and purged. To protect the gas train and controls, insure that a

○

drip leg or dirt pocket has been properly installed. Insure that the fuel gas being supplied is compatible

○

with the burner speciﬁ cation and is available at the correct regulated pressure. (See burner name plate and speciﬁ cation sheets). Insure that the vent lines for the diaphragm valves

○

have been run to the outside and properly terminated. Use R.W. Beckett recommended maximum pipe

○

lengths for good lightoff (Figure 8).

3. Electrical

Insure that all wiring has been completed and

○

complies with the National Electric Code NFPA 70 and local requirements. Refer to Figure 1 and verify that the electrical supply

○

to the burner matches the voltage speciﬁ cation on the label.

4. Boiler or Appliance

Insure that the ﬂ ue passages and combustion area

○

have been thoroughly cleaned and are in good condition.

Set the breech damper to the required position for

○

system operation. Fill the appliance with water (boilers).

○

Check all safety and operating controls for correct

○

application, installation, wiring, and operation. Insure that the maximum capacity of the appliance is

○

compatible with the speciﬁ ed burner input ﬁ ring rate.

5. Burner - See Figure 10 for familiarization

Insure that the gas burner model and capacity meet

○

the requirements for the installation.

○

Insure that the gas train meets operating speciﬁ cations, all safety codes and insurance requirements.

○

Refer to Table 2 and Figure 11 to insure that the burner air shutter and band are positioned for initial start-up preliminary settings.

○

Insure that the burner is securely mounted in the appliance with the pressure ﬁ ring plate and all gaskets in place for pressurized chamber applications. For propane-ﬁ ring burners, insure that the propane

○

restrictor has been correctly selected for your burner model (see Table 3) and properly installed (see Propane Restrictor Installation instructions). Before operating insure that all protective cover

○

plates, enclosures and guards are in place and securely fastened. When available, refer to the appliance

○

manufacturer’s instructions and install the burner accordingly.

6. Test instruments

The following calibrated test equipment is required

○

to properly install the appliance. Whether these are included in one kit or are individual test components, they should be calibrated and in good working order. A combustion analyzer capable of measuring

○

oxygen (or carbon dioxide), carbon monoxide, stack temperature, ambient temperature, and appliance efﬁ ciency. Electrical multi-meter capable of measuring voltage,

○

ohms, amps, and DC micro-ammeter for measuring the ﬂ ame signal. These could be included in one meter or separate meters, but should be calibrated and accurate. Calibrated manometers and gauges capable of

○

measuring all pressure ranges in the gas supply and appliance draft. This could typically range from a few psi to 0.01” W. C.

Page 15

Figure 10. CG10 component familiarization

Section: Prepare the Burner for Start-up

Major Components

Item Description

1 Jacking Screw

2 Ignition Transformer

3 Primary Control

4 Blower Motor

5 Air Flow Proving Switch

6 Electrode Cable*

7 UV Flame Detector (if used)

8 Shutter

9 Air Band

10 High Gas Pressure Switch

11 Manifold Pressure Test Connection

12 Gas Gun Assembly

*Unplug form transformer when servicing

CG10 Burner Manual

Page 16

Section: Start the Burner

Start the Burner

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 by a qualiﬁ ed service technician who is trained and experienced in commercial gas burner system installation and operation.

Do not attempt to start the burner unless you are

fully qualiﬁ ed.

Do not continue with this procedure until all items in

the ‘Prepare the Burner for Start-up’ section have been veriﬁ ed.

Carefully follow the wiring diagrams, control

instruction 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,

call Beckett at 1-800-645-2876 for assistance.

In order to check the function of each component

4. (i.e: ﬂ ame safeguard sequence, airﬂ ow proving switch, ignition transformer, gas valves, safety lockout timing, etc.), with the gas supply closed off, monitor a complete burner run sequence. Note that the ﬂ ame safeguard control will lock out since the fuel supply has been closed off.

If component operation sequence and function is

5. correct, reset the ﬂ ame safeguard and initiate a new cycle. Monitor the start-up cycle and manually open the main leak test cock as soon as the ﬂ ame safeguard powers the safety shutoff valves. If the boiler room is quiet you may be able to hear the valve open, if not you can generally place your hand on the valve and feel it open. After you have observed main ﬂ ame for a brief time, trip any of the switches in the limit string to shut the burner down. Monitor the ﬂ ame and safety shutoff valves to assure that shutdown is controlled by the valves and that they operate properly. With this test passed you may safely initiate automatic start-ups on subsequent cycles.

Verify input ﬁ ring rate

Burner start procedure

(Before proceeding, turn off and lock out electrical power and close the main leak test cock to shut off gas to the burner.)

With the power and main gas supply to the burner

1. turned off, make sure gas has not accumulated in the boiler or ﬂ ues.

Check the initial air settings (shutter & band) for

2. input ﬁ ring rate. Check the manufacturer’s settings either on the nameplate shown in Figure 1 or listed in Table 2. If adjustment is necessary refer to Figure 11 and loosen the adjustment screws then twist the shutter and/or air band until the indicators point to the values shown on the nameplate or listed in Table 2.

With the main gas supply valve closed. Set the

3. limit or controller to call for heat then apply power to start the burner. Reset the high and low gas pressure switches if necessary.

Clock the meter for CFH and calculate the

1. input ﬁ ring rate. Compare the calculated rate to the speciﬁ ed input for the boiler found on the speciﬁ cation sheets and on the rating plates for the burner and boiler. Do not exceed the speciﬁ ed maximum input for the boiler.

Attach a manometer to the manifold test port, clock

2. the meter, and adjust the regulated pressure until the speciﬁ ed input level is achieved. Refer to Table 2.

Be sure to set the breech or furnace pressure to the

3. correct value, since this will have an effect on the manifold pressure.

Page 17

Section: Start the Burner

Figure 11. Shutter and Band

The shutter and band both control the amount of ﬂ ow area

BAND INDICATOR MARK

available for air inlet to the burner. The greater their combined ﬂ ow area, the higher the ﬁ ring rate. The

SHUTTER INDICATOR

primary differences between the two are their ease of adjustment and their total airﬂ ow area. The shutter turns more easily and has a smaller net ﬂ ow area. As a result we have found the shutter to be better suited for

◄

SHUTTER

(for low rate adjustments) adjust this with band fully

CLOSED

Tighten locking screws securely after adjustments have been made

◄

AIR BAND

(for high rate adjustments)

adjust this with shutter fully

OPEN

ADJUSTMENT SCALE

(FOR SHUTTER AND BAND)

low rate adjustments, and the band better suited for high rate adjustments. We recommend that at low rates the band be left completely closed until the shutter has been fully opened, and that for higher rates the shutter is left completely open as the band is opened.

Table 2. Initial burner settings

Furnace Pressure 0” W.C. 0.25” W.C. 0.50” W.C. 1.00” W.C.

Firing Rate MBH

Stepped Spud Head Conﬁ guration

300 CG10.1S 1.0 0.5 3 0 1.3 0.6 3 0 1.5 0.8 4 0 2.0 1.0 6 0

350 CG10.1S 1.4 0.7 4 0 1.6 0.8 4 0 1.9 0.9 5 0 2.4 1.2 7 0

400 CG10.2S 1.1 0.5 4 0 1.3 0.7 4 0 1.6 0.8 5 0 2.1 1.0 6 0

450 CG10.2S 1.4 0.7 5 0 1.7 0.8 6 0 1.9 1.0 7 0 2.4 1.2 9 0

500 CG10.3S 1.2 0.6 6 0 1.5 0.7 7 0 1.7 0.9 8 0 2.2 1.1 10 1

550 CG10.3S 1.3 0.7 8 0 1.6 0.8 9 0 1.8 0.9 10 0 - - - -

600 CG10.4S 2.5 1.3 5 0 2.8 1.4 6 0 3.0 1.5 7 0 3.5 1.8 9 0

700 CG10.4S 3.4 1.7 7 0 3.6 1.8 9 0 3.9 1.9 10 0 4.4 2.2 10 3

800 CG10.5S 3.1 1.6 8 0 3.4 1.7 9 0 3.6 1.8 10 1 4.1 2.1 10 3

900 CG10.5S 4.0 2.0 10 1 4.2 2.1 10 2 4.5 2.2 10 4 5.0 2.5 10 6

1000 CG10.6S 3.2 1.6 10 0 3.4 1.7 10 2 3.7 1.8 10 3 4.2 2.1 10 6

1100 CG10.6S 3.9 1.9 10 2 4.1 2.1 10 4 4.4 2.2 10 5 4.9 2.4 10 10

1200 CG10.6S 4.6 2.3 10 6 4.9 2.4 10 8 5.1 2.6 10 10 - - - -

Spinner Head Conﬁ guration

300 CG10.1 1.5 0.8 3 0 1.8 0.9 3 0 2.0 1.0 4 0 2.5 1.3 5 0

350 CG10.1 2.0 1.0 5 0 2.3 1.1 6 0 2.5 1.3 8 0 3.0 1.5 10 1

400 CG10.2 1.6 0.8 4 0 1.8 0.9 4 0 2.1 1.0 5 0 2.6 1.3 6 0

450 CG10.2 2.0 1.0 4 0 2.2 1.1 4 0 2.5 1.2 5 0 3.0 1.5 8 0

500 CG10.3 1.5 0.8 5 0 1.8 0.9 5 0 2.0 1.0 6 0 2.5 1.3 8 0

550 CG10.3 1.9 0.9 7 0 2.1 1.1 8 0 2.4 1.2 9 0 2.9 1.4 10 1

Burner Model

Running Manifold

Gas Press. in WC

Low Fire Start Gas

Press. in WC

Shutter Setting

Band Setting

Running Manifold

Gas Press. in WC

Low Fire Start Gas

Press. in WC

Shutter Setting

Band Setting

Running Manifold

Gas Press. in WC

Low Fire Start Gas

Press. in WC

Shutter Setting

Band Setting

Running Manifold

Gas Press. in WC

Low Fire Start Gas

Press. in WC

Shutter Setting

Band Setting

Notice: The settings in this chart are for reference only. The actual conditions at the installation may require further adjustment by the fully qualiﬁ ed and experienced start-up technician. Notice: The light-off rate must not be set below the low ﬁ re recommendation. Lower rates will lengthen the time it takes for gas to get to the burner head and may cause ignition failures.

CG10 Burner Manual

Page 18

Section: Start the Burner

Estimating Rate

Manifold to Furnace Pressure information can be used to estimate the burner’s ﬁ ring rate when it is not possible to clock a meter for the rate.

To estimate the burner’s ﬁ ring rate: Measure the furnace pressure over ﬁ re Measure the manifold pressure (at the manifold pressure test connection in Figure 10). Subtract the furnace pressure from the manifold pressure Compare the result to the data in Figure 12 or 13 as appropriate for your burner.

Clocking a gas meter

Before you clock the meter you must make sure that the burner is operating at a steady rate, and that it is the only thing that is using gas that would ﬂ ow through the meter.

Uncorrected ﬂ ow rate

Locate the dial that moves the fastest and determine how many cubic feet are represented by one revolution of its dial. Use your watch for timing and observe how many cubic feet are used in one minute. Multiply by 60 Example: The dial is a one cubic foot dial, and goes around 7 ½ times in one minute. That gives 7.5 cubic feet per minute. Multiply by 60 to get 450 cubic feet per hour (CFH) as your uncorrected ﬂ ow rate.

Pressure correction

Gas is compressible, the higher the pressure on it, the smaller the number of cubic feet it occupies. To correct for that you will need to know the gas pressure at the meter. If there’s a gauge at the meter, read it while the gas is ﬂ owing. (If not, measure the gas pressure in the line downstream of the meter before any valves or regulators, with no gas ﬂ owing.) Convert the gas pressure to PSI if you measure it in any other units. (1 PSI = 27.7 inches water column) Add 14.7 to the meter pressure, divide their sum by 14.7, and multiply that result times the uncorrected ﬂ ow rate to obtain the pressure corrected ﬂ ow rate. Example: The meter in the example above is operating at 14” WC. 14 / 27.7 = .5 PSI at the gauge; 14.7 + .5 =15.2; 15.2 / 14.7 = 1.034 correction factor;

1.034 x 450 = 465 CFH corrected for pressure

Temperature correction

Gas volume also changes with the temperature of the gas. Most gas meters are temperature compensated, and say so on the face of the index and don’t require temperature correction. The temperature we correct to is 60° F. That’s close to the temperature of the ground, so usually it’s not necessary to correct for temperature from underground lines.

Measure the gas temperature at the meter. Add 460 to the gas temperature and divide 520 by the result to obtain the correction factor. Multiply the pressure corrected ﬂ ow rate times the temperature correction factor. Example: The meter in the example is connected to an above ground line on a hot day and shows 100° F gas temperature. 460 + 100 = 560; 520 / 560 = .929; 465 x .929 = 432 CFH corrected for pressure and temperature. This ﬁ gure is often called SCFH (for standard cubic feet per hour).

BTU’s and MBH

The BTU content of natural gas varies from one location to another, and even from day to day at a ﬁ xed location. For ﬁ ring estimates it is usually assumed to be 1000 BTU’s per standard cubic foot. To calculate BTU/Hr ﬁ ring rates multiply SCFH times 1000.

Example: 432 SCFH x 1000 = 432,000 BTU/Hr. MBH stands for thousands of BTU’s per hour. Since 1 cubic foot of natural gas contains 1000 BTU, 1 MBH equals 1 SCFH of gas ﬂ ow. Example: 432 SCFH = 432 MBH

Page 19

Figure 12. Manifold to Furnace Pressure Drop vs. Rate - Stepped Spud Design

1400

1200

Section: Start the Burner

1000

800

Rate, MBH

600

400

200

0123456

Pressure Drop, In. WC

Figure 13. Manifold to Furnace Pressure Drop vs. Rate - Swirl Vane Head Design

CG10.6S CG10.5S CG10.4S CG10.3S CG10.2S CG10.1S

900

800

700

600

500

400

Rate, MBH

300

200

100

012345

CG10.3 CG10.2 CG10.1

Pressure Drop, In. WC

CG10 Burner Manual

Page 20

Section: Start the Burner

Check operation and safety controls

Testing by Qualiﬁ ed Technician Required.

Failure to properly test and verify the correct function of operation and safety controls could lead to equipment malfunction and result in asphyxiation, explosion or ﬁ re.

The testing of operation and safety controls requires

technical training and experience with commercial gas burning systems.

Carefully follow the manufacturer’s instructions

supplied with the controls.

Verify the correct function of all operation and safety

controls used in the installation.

If instructions are not available, use the following

recommended procedures and record all results in a start-up log.

Refer to Figure 7 and Figure 10 for typical test

points and component locations.

High limit – To check the High Limit, raise the

temperature or pressure of the operating control to a higher level and lower the limit to a setting less than the operating control. Run the burner until the high limit opens and shuts the burner off. Adjust the controls back to the desired settings.

Operating control – Run the burner until the

operating control shuts it off. If necessary, make adjustments to ensure the control cycles the burner in the desired temperature or pressure range.

Operating controls should be

set to minimize the number of ﬁ ring cycles that the burner runs. High cycling rates increase the possibility of light-off lock outs.

Low water cutoff (LWCO) – With the burner ﬁ ring,

open the blow down valve on the low water cutoff, if applicable. As the water level drops, the LWCO switch contacts open and shut the burner off. When the water level rises, the LWCO contacts close and restart the burner. Monitor the LWCO switch operation in relation to the water level in the sightglass for synchronization.

Airﬂ ow proving switch – With the burner ﬁ ring at

its lowest rate, loosen the tubing connection to the airﬂ ow proving switch. A loss in air pressure at the tubing should immediately cause the diaphragm in the switch to open and recycle or lockout the safeguard control.

Low gas pressure switch – With the burner ﬁ ring

and a manometer attached to a test port near the low pressure switch, gradually close the main leak test cock to shut off the gas supply. Note the pressure at which the low gas pressure switch opens and shuts the burner off. Manually reset the switch. The low gas pressure switch should be set at half of the normal supply pressure in the line.

High gas pressure switch – With the burner ﬁ ring

and a manometer attached to the test port nearest the high pressure switch, gradually increase the gas pressure until the high pressure switch opens and shuts the burner off. Note the pressure and manually reset the switch. The high gas pressure switch should be set at one and one half times the high ﬁ re manifold pressure (see nameplate data in Figure 1 or set switch as determined by testing).

Leak-test valve – With the burner ﬁ ring and

manometer attached to the leak-test valve port, turn the burner electrical switch off and observe that the gas pressure does not increase after several minutes. This proves total closure of the main gas valve.

Flame safeguard safety lockout – Simulate a

ﬂ ame failure by turning the main gas supply off. The control should shut the burner off on safety within the safety lockout time.

Flame sensor circuit (ﬂ ame rod) – With the

burner power switch turned off, refer to the wiring diagram supplied with the control and locate the sensor connection terminals. Place DC voltmeter probes in the ﬂ ame ampliﬁ er test jacks. With the burner ﬁ ring, the ﬂ ame signal should be steady and at least 1.25 VDC.

Flame sensor circuit (UV scanner) – With the

10.

Page 21

Section: Start the Burner

Use test instruments to set combustion: Recommended combustion test sequence:

Always use calibrated test

instruments to set combustion levels. Verify that test instruments are calibrated and in good working condition. If not already provided, drill test access holes in the ﬂ ue pipe near the breech (or upstream of the boiler breech damper, if applicable) and in the front mounting plate area for ﬁ rebox pressure. Be careful not to damage any water-backed surface.

Verify that all boiler sections, canopy, and access plates or doors are fully equipped with gaskets and sealed against any leakage, which could affect the combustion test results. Before making these tests, operate the burner for several minutes to allow the heating system temperature to stabilize or nearly reach steady-state levels. Record all results in the start-up log for future reference.

○

Draft – Set the breech or furnace pressure to the level speciﬁ ed by the appliance manufacturer. Typical example: +0.10” W. C.

○

Oxygen – It is recommended that you measure the oxygen (O high levels of carbon monoxide can be created at very low or even very high O2 levels. The typical operating range is between 2.5% – 4.5 %. The equivalent carbon dioxide (CO2) operating range is 9% – 10.5%.

) early in the test sequence because

Adjust the draft or breech pressure to the appliance

1. manufacturer’s recommended level.

Measure the carbon monoxide level and adjust

2. air settings, if necessary, to regulate it to about 50 PPM for a starting point.

Measure the O2 or CO2 at the 50 PPM CO level.

3. For this discussion, assume the O2 is 1.5% (11% CO2).

Open the air adjustment until the O

4. increased by at least 1% or to 3% O2 (whichever is higher). This should reduce the CO level and provide a margin of reserve air to accommodate variable conditions.

Sample the CO level again. It should be in the 0 to

5. 20 PPM range.

Check the draft to ensure it still meets

6. speciﬁ cations. If a major change in draft is required, repeat the above steps.

Perform any ﬁ nal adjustments and lock the air

7. settings securely. Run the burner through several cycles to verify prompt ignition and stable burner operation.

level is

High excess air levels reduce the ﬂ ames UV output and the

scanner signal that proves the burner is ﬁ ring.

Carbon monoxide (CO) – An operating range of 0

○

-50 PPM is recommended for the CG10 burner. The maximum carbon monoxide (CO) level permitted in the ﬂ ue gas by the UL 795 Standard is 400 PPM (.04%). Stack Temperature – The stack temperature should

○

be within the range speciﬁ ed by the appliance manufacturer. It is inﬂ uenced by input ﬁ ring rate, ﬂ ame shape, excess air ratio, and cleanliness of boiler ﬂ ue passages. This temperature, combined with the ambient temperature, and O2% (or CO2) is used in calculating the appliance efﬁ ciency.

CG10 Burner Manual

Page 22

Section: Maintenance and Service

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

any adjustments unless you are a trained and qualiﬁ ed service technician.

To ensure continued reliable operation, a qualiﬁ ed

service technician must service this burner annually.

More frequent service intervals may be required in

dusty or adverse environments.

Operation and adjustment of the burner requires

technical training and skillful use of combustion test instruments and other test equipment.

Turn Off Electric and Gas Supply Before Servicing

Failure to turn off electric and gas supply could result in electrical shock, gas leakage, explosion, or ﬁ re hazards.

Turn main gas valves and electric power off before

performing any maintenance.

If a maintenance procedure requires electrical

power, use extreme caution.

Annual maintenance

(The following should be performed by a qualiﬁ ed service technician only.)

Burner:

○

Run the burner and perform a complete

1. combustion test using the proper instruments before proceeding. If necessary refer to the section labeled Start the Burner. Record the results for reference.

Inspect and clean all dirt accumulation from the

2. gas train, burner exterior, burner air band/shutter, and surrounding area.

Remove the blower motor and clean any

3. accumulated matter from the blower wheel and motor end bell.

Check wheel for damage and the hub setscrew

4. for tightness. If the blower wheel must be removed from the motor shaft, insure that clearance speciﬁ cations are maintained.

Clean the inside surfaces of the burner housing

5. scroll and especially the air intake area and airﬂ ow proving switch suction tube.

If the blower motor does not have permanently

6. lubricated bearings, oil the motor. Clear any debris from the air vents on the motor body.

Clean the ignition transformer, baseplate, and

7. terminal bushings. Inspect the ignition leads for signs of deterioration and loose terminals.

If the burner ﬂ ame detection is a UV scanner,

8. inspect the mounting and clean the lens according to the component manufacturer’s recommendations.

Remove the gas gun assembly and clean the

9. entire unit, paying special attention to the air diffuser and spuds.

Inspect the ﬂ ame rod for oxidation or distortion.

10. Clean all surfaces, set the probe position, and insure that the ﬂ ame rod is securely fastened. Refer to Figures 14A and 14B.

Inspect the ignition electrode for any damage.

11. Clean all surfaces, set the proper electrode gap, and make sure it is securely fastened.

Clean the inside of the air tube and inspect the

12. combustion end for any deterioration. Referring to Figure 2, check the recess dimension from refractory.

Inspect gas tube O-ring condition and replace if

13. damaged. Install gas gun assembly back into the burner and use the jacking screw to tighten the gas gun securely in place. (Automotive chassis or bearing grease is suitable for o-ring lubrication.)

Page 23

Inspect the condition of the appliance mounting

14. plate and burner mounting ﬂ ange gaskets and replace any damaged materials. See Figure 6.

Inspect all burner control wiring and the burner

15. control panel for damaged insulation and loose terminals/connections.

Verify that the source voltage to the burner and

16. control panel is within 10% of the burner rating as listed on the nameplate. (Figure 1)

○

Appliance – (Follow appliance manufacturer’s service procedures. The following steps are emphasized because they relate to burner operation)

Check the condition of the combustion chamber

1. refractory, the front-plate insulation, and all gaskets and seals. Repair or replace as necessary

Insure that the ﬂ ue passages, ﬂ ue vent pipes,

2. and chimney ﬂ ues are clean and unobstructed.

Check barometric damper or draft hood for

3. proper operation.

Inspect boiler sections and system load piping

4. for possible leaks. Make all necessary repairs.

Check all operating and safety controls on the

5. boiler for proper installation and operation.

Perform all maintenance and tests according to

6. the burner control manufacturer’s instructions (limits, controllers, low water cutoff, relief valves, feed valves, etc.)

Gas supply piping:

○

Inspect all piping for leakage and proper installation. Perform necessary repairs to comply with all codes.

Section: Maintenance and Service

Adjust the burner for proper combustion:

○

Follow the guidelines under “Start the Burner” to set the combustion levels using test instruments.

Flame safeguard:

○

Follow the control manufacturer’s instructions and verify that the control is functioning to speciﬁ cations. See Page 13 for typical sequence of operation and Items 8 through 10 on Page 20 for control system checks.

Manual shutdown for long periods:

○

Close all gas valves in the gas supply piping

1. system.

Turn off all electrical power to the burner.

Protect the burner and controls from moisture

3. and dirt.

Ignition Reliability

○

Examine ignition electrode inslators for cracks.

Examine ignition wires for worn insulation.

Examine ignition electrodes for wear.

Check ignition transformer functionality.

Verify that the head is centered in the airtube and

5. that the head is not damaged.

Check inlet pressure to the gas train SSOVs.

Verify maximum recommended pipe lenghts

7. used in gas trains (Figure 8)

Verify low ﬁ re light-off rate (Table 2)

Installation area:

○

Insure that there are no combustible materials,

1. ﬂ ammable liquids or vapors in the vicinity of the heating appliance.

Verify that the combustion air supply is

2. functioning properly, adequately sized, clean, and properly lubricated.

CG10 Burner Manual

Page 24

Section: Maintenance and Service

Figure 14A – Gas Gun Assembly

Figure 14B – Gas Gun Assembly

Burner Head Adjustment - There is an optimum gas oriﬁ ce size and burner head setting for each ﬁ ring rate of the CG10 burner. The gas oriﬁ ce size sets the gas ﬂ ow velocity; the head setting establishes the airﬂ ow velocity. When those velocities are properly matched the burner provides its best performance and stability.

The gas oriﬁ ce size is built into the burner head. You can verify the correct selection by looking for the burner model number stamped on the top centerline of the stainless steel tube that forms the base of the burner head. It should match the model number on the Beckett burner data label on the blower housing. The head setting is established by a notched sleeve on the gas tube that can be rotated to positions on a scale marked by the burner’s model number. The scale should normally be set to the model number on the Beckett burner data label. (If speciﬁ c application requirements dictate an alternate head setting it will be noted by a label on the gun assembly.)

For normal service requirements it is not necessary to disassemble the head from the gas tube. If you disassemble the gas gun, make sure that when you re-assemble it:

The adjustment scale is set to the correct position as indicated by the burner model number or Gun Label.

The alignment marks on the head, scale and stop are in alignment.

The O-ring between the head and the adjustment scale is in place, is lubricated with grease, and is

3. compressed between the head and scale as the setscrews that retain the head are tightened.

Page 25

Section: Maintenance and Service

Propane Restrictor Description

The Beckett Propane Restrictor Conversion Kit allows for the conversion of CG10 burners for use with propane gas. With the proper installation of the restrictor and attached O-ring, adjustments and settings for propane use will be the same as the adjustments and settings for natural gas use as detailed in the burner manual.

This conversion kit shall

be installed by a qualiﬁ ed service agency in accordance with the manufacturer’s instructions and all applicable codes and requirements of the authority having jurisdiction. (In Canada, in accordance with the requirements

of the CAN/CGA-B149 Installation Code.) If the information in these instructions is not followed exactly, a ﬁ re, explosion, or production of carbon monoxide may result causing property damage, personal injury or loss of life. The qualiﬁ ed service agency is responsible for the proper installation of this kit. The installation is not proper and complete until the operation of the converted appliance is checked, as speciﬁ ed in the manufacturer’s instructions supplied with the kit.

Installation

Note that Steps 1 and 2 on the following page refer to fully assembled burners. Skip to Step 3 when converting a burner without the air tube assembly installed.

Figure 16 – Component Locations

Figure 15 – Propane Conversion Major Components

Major Component Key for

Figure 16 & 17

A Air Tube

B Jacking Screw

C Internal Gas Tube

D External Gas Manifold

E Propane Restrictor

F Union

G Restrictor O-ring

H Gas Tube O-ring

CG10 Burner Manual

Page 26

Section: Maintenance and Service

Use authorized replacement parts

only. Restrictors are precisionmachined parts and O-rings are rated for fuel contact. Do not attempt to replicate or modify any parts. Refer to Table 3.

The gun assembly is secured inside

the air tube by a spring-loaded jacking screw. It is spring loaded in order to control the force it can impose on the gun assembly. When installing the jacking screw look inside the air tube to verify that the pointed tip of the jacking screw pin is seated into the small slot on the locating pad on top of the gun. There is also an external veriﬁ cation of correct assembly: when the screw is fully tightened, the e-clip on the top of the center pin should come ﬂ ush with the top of the screw. Refer to Figure 17.

Refer to Figures 15 and 16 when performing the following steps.

Remove the jacking screw (B) from the air tube/

1. manifold assembly to free the internal gas tube (C).

Gently rock the internal gas tube (C) to loosen the

2. tube from

Inspect the O-rings and insure that they are

the union (F).

properly lubricated. (A silicon O-ring lubricant is recommended, but automotive chassis or bearing grease is an acceptable substitute.)

Referring to Figure 16, place the restrictor (E)

4. with pre-attached, pre-lubricated O-ring (G) into the internal gas tube (C). Use your hand to press the restrictor into the tube. The O-ring will hold the restrictor in place.

Insure that the O-ring (H), attached to the outside

5. diameter of internal gas tube, is properly lubricated and seated against the ﬂ ange on the internal gas tube.

Install the internal gas tube (C) back into the air

6. tube (A) housing, refer to Figure 15. Fit the end of the tube into the union (F) on the air tube.

Re-install the jacking screw (B). (Refer to the above

7. notice for installation details.)

Fill out and place the supplied Conversion Data

8. Plate adjacent to the rating plate.

Complete and attach the supplied Adjustment Data

With the gas restrictor installed, as

shown in Figure 15, all burner air adjustments and gas manifold pressure adjustments for propane will be approximately the same as the natural gas adjustments shown in the burner manual, or printed on the “Mfr’s Settings” label on the burner housing. For a copy of the current burner manual go to http://www. beckettcorp.com/protect/tech.asp. If furtherTechnical assistance is required, call 800-645-2876, Monday thru Friday, 8AM to 5PM EST.

Figure 17 – Gas Gun Assembly Installation

Table 3 - Propane Restrictors Replacement Part Numbers

Burner Model

CG10.1 3246700U 0.401 3226409U

CG10.2 3246701U 0.432 3226409U

CG10.3, CG10.2S 3246702U 0.470 3226409U

CG10.1S 3246703U 0.418 3226409U

CG10.3S, CG10.6S 3246705U 0.510 3226409U

CG10.4S 3246706U 0.459 3226409U

CG10.5S 3246707U 0.482 3226409U

Restrictor

Part Number

Restrictor

Inside

Diameter

O-Ring Part

Number

The gun assembly is secured inside the air tube by a spring-loaded jacking screw. It is spring loaded in order to control the force it can impose on the gun assembly. The screw can be tightened ﬁ rmly without putting excessive pressure on the gun assembly that might distort the gun or damage its O-ring seals. When installing the jacking screw look inside the air tube to verify that the pointed tip of the jacking screw pin is seated into the small hole on the locating pad on top of the gun. There is also an external veriﬁ cation of correct assembly: when the screw is fully tightened, the e-clip on the top on the center pin should come ﬂ ush with the top of the screw.

Page 27

Section: Maintenance and Service

For the OPERATOR

Inspect Heating System Regularly

Lack of regular inspections and inadequate maintenance could lead to equipment malfunction and result in asphyxiation, explosion or ﬁ re.

(Always follow the appliance manufacturer’s recommended service instructions, when available.)

The following checklist is intended to be used as a minimum reference guide only and does not supersede

or replace the heating appliance manufacturer’s recommended service and maintenance instructions or any code requirements.

Consult the installation and service instructions provided by the individual control or component

manufacturer and carefully follow their directions.

Maintenance and testing may be required more frequently due to dusty or severe operating conditions.

If unusual or questionable performance is observed, shut the system down and contact your qualiﬁ ed

service agency immediately.

Table 4 - Periodic Inspection Sheet

Test/Inspection Frequency Comments

Inspect area surrounding heating plant Daily Keep area clean and free of clutter

Inspect gas supply system for leaks Daily Use visual and electronic leak detection

Inspect appliance & piping for water leaks Daily Keep burner and controls dry at all times

Inspect gauges, indicators, monitors Daily Note condition. Replace defective parts

Check temperature and pressure levels Daily Compare to manufacturer’s speciﬁ cations

Make visual inspection of ﬂ ame Daily Look for changes in shape, size, and color.

Monitor burner start-up Daily Verify prompt ignition and ﬂ ame stability.

Monitor stack temperature Daily Compare to start-up and trend level.

Test low water cutoff and alarm Daily Follow control manufacturer’s instructions & procedures

in ASME Boiler & Pressure Vessel Code, Section VI

- Recommended Rules for Care and Operation of Heating Boilers.

Calculate fuel gas input ﬁ ring rate Weekly Compare to appliance manufacturer’s Speciﬁ cations

Check ﬂ ame safeguard sequence of operation.

Flame failure response & lockout timing. Weekly Follow control manufacturer’s instructions

Flame sensor signal level (if meter is hardwired)

Main fuel gas valves Weekly Open high limit and verify cutoff operation

Weekly Follow control manufacturer’s instructions

Weekly Compare to control manufacturer’s speciﬁ cations

Inspect exhaust vent system for blockage Weekly Remove any restrictions

Inpect compbustion air supply Monthly Remove any restrictions

Check high and low gas pressure interlocks Monthly Follow control manufacturer’s instructions

Check safety valves As needed Follow control manufacturer’s instructions & procedures

in ASME Boiler & Pressure Vessel Code, Section VI

- Recommended Rules for Care and Operation of Heating Boilers.

CG10 Burner Manual

Page 28

Section: Replacement Parts

Replacement Parts

For best performance specify genuine Beckett replacement parts.

Item Description Part #

1 Ignition Transformer 7503U

2 Control Subbase See Note 1

3 Primary Control See Note 1

4 Suction Line 32359U

5 Shutter 3215U

6 High Gas Pressure Switch 2190903U

7 Air Band 3819A

8 Motor - 120v

- 220v

9 Blower Wheel -

- CG10A or CG10B

10 Air Proving Switch 32359U

11 Electrode Set Spec. Applic.

12 Spring Clamps (4 in pckg.) 3236501U

CG10

21341U 21654U

21448U 21339U

Item Description Part #

13 Head Spec. Applic.

14 Cable, Ignition Electrode 5990130U

15 O-ring set (2 in package) 32264U

16 Gas Tube assembly 5193201U

17 Jacking Screw 5193401U

18 Air Tube Spec. Applic.

19 Cable, Flame Rod (if used) 5990280U

20 Flame Rod (if used) 2191301U

UV Scanner (not shown) 7247U

21 Restrictor O-Ring (LP Only) 3226409U

22 Propane Restrictor (LP Only) See Table 3

Note 1:

Refer to the UL Label for controller model number.

Page 29

Section: Burner Conﬁ gurations

Burner Conﬁ gurations

The CG10 burner is offered in conﬁ gurations that allow it to be customized to the capacity and furnace size needs of many different appliances. Two blower wheel sizes provide airﬂ ow capacity through the range. An air guide provides static pressure augmentation at low rates and an inlet sleeve maximizes ﬂ ow capacity at high rates. Three air tube shrouds shape and stabilize the base of the ﬂ ame. Twelve gun assemblies provide mixing control and retain the ﬂ ame. See chart on opposite page.

Low Rate Burner Conﬁ guration; 300 to 800 MBH Applications

High Rate Burner Conﬁ guration; 600 to 1200 MBH Applications

CG10 Burner Manual

Page 30

Section: Burner Conﬁ gurations

The table below shows proven combinations of the components and the nominal ﬁ ring rate ranges they serve. These

combinations may vary and may be used outside of the nominal listed ranges based on results of speciﬁ c applications tests conducted for OEM appliance manufacturers.

Air Platform Conﬁ gurations

Air Platform Blower Wheel Air Inlet

CG10 21448 189 Air Guide

CG10A 21339 32336 Straight Inlet

CG10B 21339 178 Air Guide

Burner Conﬁ gurations

Burner Model

CG10.1 31728

CG10.2 31728

CG10

Chassis

CG10.3 31728

CG10.4 32297

CG10.5 32297

Chassis

CG10 A or B

Note: “s” sufﬁ x refers to the Step Spud Design

CG10.6 32297

Air Tube

Shroud

Gas Gun

Assembly

CG10.1S

CG10.1

CG10.2S

CG10.2

CG10.3S

CG10.3

CG10.4S

CG10.4

CG10.5S

CG10.5

CG10.6S

CG10.6

Nominal

Capacity, MBH

300-378

379-476

477-600

601-756

757-952

953-1200

Page 31

CG10 Burner Manual

Page 32

Limited Warranty Information

The R. W. BECKETT CORPORATION (“Beckett”) warrants to persons who purchase its “Products” from Beckett for resale, or for incorporation into a product for resale (“Customers”), that its equipment is free from defects in material and workmanship. To qualify for warranty beneﬁ ts, products must be installed by a qualiﬁ ed service agency in full compliance with all codes and authorities having jurisdiction, and used within the tolerances of Beckett’s deﬁ ned product speciﬁ cations.

To review the complete warranty policy and duration of coverage for a speciﬁ c product, or obtain a written copy of warranty form 61545, please choose one of the following options:

Visit our website at: www.beckettcorp.com/warranty

Email your request to: rwb-customer-service@beckettcorp.com

Write to: R. W. Beckett Corporation, P. O. Box 1289, Elyria, OH 44036

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. Beckett neither assumes, nor 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 is limited to the cost of the product.

USA: P.O. Box 1289 ● Elyria, Ohio 44036

Canada: R.W. Beckett Canada, Ltd.

www.beckettcorp.com

●

Unit #3, 430 Laird Road ● Guelph, Ontario N1G 3X7

Part Number 6104 BCG10 R13, Printed in the U.S.A. 05/10