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.

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.

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

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.

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.

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

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

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

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”

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

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

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