Beckett CG10 User Manual

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.

1.

What to do if you smell gas:

2.

- 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.

3.

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

2

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’.

y

Never store or use gasoline or other fl ammable

y

liquids or vapors near this burner or appliance.

Never attempt to burn garbage or refuse in this

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appliance.

Never attempt to light the burner/appliance by

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throwing burning material into the appliance.

Never attempt to burn any fuel not specifi ed and

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approved for use in this burner.

Never restrict the air inlet openings to the burner or

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the combustion air ventilation openings in the room.

3

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.

y

Follow all instructions completely.

This equipment must be installed, adjusted and

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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

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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.

4

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

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supplied with a reliable combustion air source.

Follow the guidelines in the latest edition of National

y

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

y

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.

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Electrical controls are not protected against rain or

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sprayed liquids.

Keep the installation clear of dust, dirt, corrosive

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vapors, and moisture.

Protective covers and more frequent maintenance

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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

5

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.

y

Pressure test the gas piping with air that is at least

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three times greater than the gas pressure being
used.

Verify that there are no leaks before proceeding.

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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.

6

900-1200 30 18 18 9

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

2

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

7

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”

8

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

C

B

A

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

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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”

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

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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

y

and lodge in gas valves causing cutoff seal
problems.

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

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

Use only pipe sealant compounds that are resistant

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to the gas being used.

CG10 Burner Manual

9

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

PG

PRESSURE GAUGE

S

STRAINER

SSOV1

SAFETY SHUTOFF VALVE #1

TC

TEST COCK

U

UNION

2PRV

TWO POSITION REGULATING VALVE

REGULATOR

GAS UTILITY PIPING

PG

METER

LGPS

U

DRIP LEG

FACILITY PIPING

S

(IF USED)

MSC

U

TC

SSOV1

2PRV

GAS TRAIN BURNER

TC

MLTC

U

HGPS

BURNER

TC

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.

10

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

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

U

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

U

TP

MSC

U

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

U

UNION

TC

PRSSOV

TC

MLTC U

C6097B

HGPS

TP

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

11

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

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at all times except during maintenance and service.

This applies to all controls, panels, enclosures,

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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

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servicing the burner.

Provide ground wiring to the burner, metal control

y

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

Perform all wiring in compliance with the National

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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

y

protection.

Do NOT tamper with or bypass any safety control.

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If a safety control is not functioning properly, shut

y

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)

12

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

1.

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

2.

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

Load demand – Operating limit control contacts

3.

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

Prepurge – The control will signal the PREPURGE

4.

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

5.

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

6.

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

7.

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-

y

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

y

fully qualifi ed.

Carefully follow the wiring diagrams, control

y

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,

y

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

13

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.

14

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

15

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-

y

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

y

fully qualifi ed.

Do not continue with this procedure until all items in

y

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

Carefully follow the wiring diagrams, control

y

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,

y

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.

16

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

17

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

18

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

19

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

y

technical training and experience with commercial
gas burning systems.

Carefully follow the manufacturer’s instructions

y

supplied with the controls.

Verify the correct function of all operation and safety

y

controls used in the installation.

If instructions are not available, use the following

y

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

Refer to Figure 7 and Figure 10 for typical test

y

points and component locations.

High limit – To check the High Limit, raise the

1.

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

2.

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,

3.

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

4.

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

5.

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

6.

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

7.

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

8.

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

9.

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.

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.

20

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

2

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

2

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

21

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

y

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

To ensure continued reliable operation, a qualifi ed

y

service technician must service this burner annually.

More frequent service intervals may be required in

y

dusty or adverse environments.

Operation and adjustment of the burner requires

y

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

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

y

performing any maintenance.

If a maintenance procedure requires electrical

y

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.)

22

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.

2.

Protect the burner and controls from moisture

3.
and dirt.

Ignition Reliability

○

Examine ignition electrode inslators for cracks.

1.

Examine ignition wires for worn insulation.

2.

Examine ignition electrodes for wear.

3.

Check ignition transformer functionality.

4.

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.

6.

Verify maximum recommended pipe lenghts

7.
used in gas trains (Figure 8)

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

8.

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

23

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.

1.

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

2.

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.

24

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

B

A

Figure 15 – Propane Conversion Major Components

A

B

C

H

G

F

E

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

D

C

H

G

E

CG10 Burner Manual

25

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

3.

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

9.

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.

26

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

y

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

y

manufacturer and carefully follow their directions.

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

y

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

y

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

27

Section: Replacement Parts

Replacement Parts

For best performance specify genuine Beckett replacement parts.

7

17

17

17

12

3

13

14

4

5

15

1

2

6

16

11

10

8

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

9

CG10

21341U
21654U

21448U
21339U

20

19

18

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.

28

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

29

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

30

CG10 Burner Manual

31

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

1.

Email your request to: [e-mail]

2.

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

3.

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