Beckett CG4 User Manual

Operation On/Off Rate: 80 to 250 MBH

Fire or Explosion Hazard

Can cause severe injury, death or property damage

If the information in these instructions is not followed exactly, a re or explosion may

result causing personal injury, death or property damage.

─ Do not store or use gasoline or other ammable vapors and liquids in the vicinity of this

or any other appliance.

─ WHAT TO DO IF YOU SMELL GAS y Do not try to light any appliance y Do not touch any electrical switch; do not use any phone in your building. y Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s

instructions.

y If you cannot reach your gas supplier, call the re department. y Installation and service must be performed by a qualied installer, service agency or the

gas supplier.

Contents

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

To the Owner: ................................................................................ 3

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

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

Specications ................................................................................ 4

Inspect/Prepare Installation Site ............................... 6

Indoor Installation .......................................................................... 6

Inspect Chimney and Vent System ...............................................6

Combustion Air Supply .................................................................. 8

Buildings with Adequate Air Inltration .......................................... 8

Buildings with Less Than Adequate Air Inltration ........................ 8

Clearances to Burner and Appliance .............................................8

Fuel Gas Supply ............................................................................ 9

Electrical Supply ............................................................................ 9

Verify Burner Components ............................................................9

Verify Burner Selection ..................................................................9

Prepare the Appliance ................................................11

Assemble the Burner ................................................ 12

Gather the Necessary Parts ........................................................12

Prepare the Chassis ....................................................................12

Prepare and Install the Air Tube ..................................................12

Assemble the Gas Valve and Manifold .......................................12

Install the Valve and Manifold to the Burner ................................13

Propane Applications ..................................................................13

Mount the Burner ...................................................... 16

Connect Gas Piping .................................................. 16

Wire the Burner .......................................................... 17

Sequence of Operation ............................................. 18

Prepare the Burner for Start-up ............................... 19

Start-up Checklist ........................................................................19

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

Burner Start Procedure ..............................................................19

Verify the Firing Rate ...................................................................20

Check Operation and Safety Controls .........................................21

Use Test Instruments to Set Combustion ....................................22

Recommended Combustion Adjustment Procedure ...................22

Maintenance and Service.......................................... 23

Annual Maintenance ..................................................................23

Replace the Blower Wheel ..........................................................25

Replacement Parts .................................................... 26

Limited Warranty Information .................................. 28

Before Calling Beckett . . .

Before contacting us about your burner, you must have a completely lled out copy of the Contractor Start-Up Form (Located inside of last page). This information is crucial for troubleshooting and obtaining the correct replacement part.

Section: GENERAL INFORMATION

General Information

To the Owner:

This equipment must be installed, adjusted and started

by a qualied service agency that is licensed and

experienced with all applicable codes and ordinances and responsible for the installation and commissioning of the equipment.

Thank you for purchasing a Beckett CG4 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 qualied service agency for use in professionally

setting up and maintaining your burner.

Your CG4 burner will provide years of efcient operation if it is professionally installed and maintained by a qualied

service technician. If at any time the burner does not appear to be operating properly, immediately contact

your qualied service agency for consultation.

We recommend annual inspection/service of your gas heating system by a qualied service agency.

Burn Hazard, Hot Surface

Burner ange and air tube are hot

when burner is in operation. Do not service this area during or immediately

after operation. Allow area to cool.

Owner’s Responsibility:

Explosion, Fire, Asphyxiation Hazard

Failure to follow these instructions, misuse, or incorrect adjustment of the burner could lead to equipment malfunction and result in

asphyxiation, explosion or re.

Contact a professional, quali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 certication

in some states and the proper use of special combustion test instruments.

Please carefully read and comply with the following instructions:

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

y Never store or use gasoline or other ammable

liquids or vapors near this burner or appliance.

y Never attempt to burn garbage or refuse in this

appliance.

y Never attempt to light the burner/appliance by

throwing burning material into the appliance.

y Never attempt to burn any fuel not specied and

approved for use in this burner.

y Never restrict the air inlet openings to the burner or

the combustion air ventilation openings in the room.

CG4 Burner Manual

Frozen Plumbing and Water Damage Hazard

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

Contact a professional, qualied

service agency to replace any

component that has been exposed to water.

Section: GENERAL INFORMATION

Professional Installer’s Responsibility:

Professional Service Required

Failure to follow these instructions could lead to equipment malfunction and result in asphyxiation, explosion

or re.

y Please read all instructions before proceeding.

Follow all instructions completely.

y This equipment must be installed, adjusted

and started by a qualied service agency that

is licensed and experienced with all applicable codes and ordinances and responsible for the installation and commissioning of the equipment.

y 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.

Fire Hazard: Overheating

Should over-heating occur:

y Shut off the manual gas control to

the appliance.

y DO NOT shut off power to the

equipment, allow the blower and pumps to continue running.

Specications

Table 1 – Burner Specications

Input Firing Rate 80,000 - 250,000 BTU/hr

Firing Mode On-Off Only

Fuel

Required Input Gas Supply Pressure

Input Voltage 120 Vac + 10% / -15%; 60 Hz

Input Current 2.75 A (Run); 12.0 ALR

Gas Valve

Burner Control Beckett 7590D Direct Ignition

Flame Detection Flame Rectication

Igniter Beckett 7474001 Gas Igniter

Motor 1/7 Hp; PSC

Combustion Air Proving Differential Pressure Switch

Weight 55 lbs.

Mounting Orientation

Dimensions 10.3” x 13.1” x 15.8”

Acceptable Ambient Temperature Range

Acceptable Ambient Humidity 5% - 95% RH non-condensing

For altitudes higher than 2,000 feet, derate the burner capacity 4%

for each 1,000 feet above sea level.

Burner is not approved for use in 50 Hz applications.

Natural gas - 0.64 specic gravity LP gas - 1.53 specic gravity

4.5” WC minimum 14” WC maximum

24 Vac Dual Seat with integral regulator set to 3.5” WC for both natural gas and LP

Up to 90° from upright with motor shaft horizontal

-40°F to 150°F

Special Requirements:

When contacting Beckett for service information — Please have the burner serial number and contractor start-up form available when

calling or writing. You will nd the serial number on

the label located on the left rear of the burner. Refer to Figure 2.

Concealed damage – If you

discover damage to the burner or controls during unpacking, notify the carrier at

once and le the appropriate claim forms. Do not

install a burner or control that has been damaged.

If any of these instructions are not clear,

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

For use only on approved

applications. See www. beckettcorp.com/cg4apps for the list of approved applications.

ETL listed for use in the US or Canada per ANSI Z21.17(a) / CSA

2.7(a) For use with natural gas or propane.

1.13

Figure 1 – Burner Dimensions

8.3”

Section: GENERAL INFORMATION

15.8”

9.5”

8.0”

7.6”

13.1”

Figure 2 – Burner Nameplate

Your burner will have labels that are specic to its construction. This is for reference only.

General Model Information

Serial Number

R.W. Beckett Specication

Number and Revision

Approvals / Certications

Model “CG4”

Gas ConversionBurner

Brûleur de conversion

SERIAL NUMBER

140121-08157

CG4001 Rev.A 00

#########

Conforms to ANSI Std

Z21.17

Certified to CSA Std

En conformité avec la norme

Homologation en vertu de la

2.7

ANSI Z21.17

norme CSA 2.7

14.4”

10.3”

6.0”

80 TO 250 MBH, 24 to 73 kW

120V/60Hz, 3A run, 12A LR

For use with natural gas or propane. A conversion kit supplied by the manufacturer shall be used to convert to the alternate fuel. Manifold pressure: 3.5” W.C. Max press. to valve: 1/2 PSI Min press. to valve: 4.5” W.C.

A utiliser avec du gas naturel ou du propane. Se servir de la trousse de conversion fournie par le fabricant pour paser d’un type decarburant à l’autre. Pression d’admission: 870 Pa Pression max.’ à la soupape: 3450 Pa Pression min. à la soupape: 1120 Pa

Elyria, Ohio

Made in the U.S.A.

Rating Information

Fuel, Construction,

and Setting Data

CG4 Burner Manual

Section: INSPECT/PREPARE INSTALLATION SITE

Inspect/Prepare

Installation Site

Indoor Installation

Explosion, Fire, Asphyxiation Hazard

Wet or dusty environments could lead to blocked air passages, corrosion damage to components, impaired combustion performance and result in

asphyxiation, explosion or re.

y This burner is designed for clean, dry

installations.

y Electrical controls are not protected against rain

or sprayed liquids.

y Keep the installation clear of dust, dirt, corrosive

vapors, and moisture.

y Protective covers and frequent maintenance may

be required.

Fire, Smoke & Asphyxiation Hazard

y Carefully inspect the chimney,

chimney liner & exhaust vent system.

y Make sure it is properly sized and in

good working condition.

y Follow the instructions supplied by

the appliance manufacturer.

y If a draft regulator is required, it must be a

double-acting type, agency recognized for use with gas vent systems.

y The chimney installation and vent sizing

must strictly comply with all applicable codes, authorities having jurisdiction and the latest revision of the National Fuel Gas Code (ANSI Z223.1, or NFPA54) or CAN/CGA B/49 Canada. Remove any vent damper device.

y Regulation by these authorities take precedence

over the general instructions provided in this installation manual.

Examine the installation site for conditions that could adversely affect the health and safety of installation personnel and the user of the appliance or proper operation of the burner and appliance, and correct any defects found.

○ The area around the appliance should be

unobstructed and dry.

○ Wiring must be in good condition and meet code

requirements.

○ If the burner is replacing an existing oil burner, old

piping and the tank must be secured or removed to prevent leakage or unintended deliveries of oil.

○ Local jurisdictions may require removal of oil tanks.

See NFPA-30 ammable and combustible liquids

code for approved procedures.

Inspect Chimney and Vent System

1. Any accumulation of soot or debris in chimney

offsets must be removed

2. Any obstructions such as a protruding joint or a

piece of broken tile wedged in the chimney must be removed.

3. No other appliance connection should be made to

the same ue pipe.

4. The ue pipe should have an upward pitch toward

the chimney of at least 1/4” per foot of length. It

should t tightly and should not project into the

chimney, see Figure 3.

Figure 3 – Vent Pipe with Draft Regulator

Barometric Draft Control

Flue Pipe Ell

Heating Unit

1/4” per Foot

Minimum

Section: INSPECT/PREPARE INSTALLATION SITE

5. Any leakage between tiles, around clean-out doors, or around the vent pipe should be sealed.

6. A Draft regulator is required, it shall be a double- acting type, agency recognized for use with gas vent systems.

7. The design and sizing of the appliance’s vent system shall comply with the requirements of NFPA 54 Chapters 12 and 13.

8. A chimney ue shall extend at least 3 feet above the highest point at which the chimney comes in contact with the roof, and not less than 2 feet above the highest roof surface or structure within 10 feet horizontally of the chimney. Refer to Figure 4.

Some local codes and gas

utilities require the installation of a thermal Safety switch on the double-acting draft control, or draft hood. This is a very good practice and provides the following protection:

The thermal safety switch senses ue gas spillage caused by blocked ue exhaust, prolonged down-draft, or insufcient draft. The safety is wired in series with the

burner control circuit and shuts the burner off, when the

spillage of hot ue gases is detected.

Insulated stainless steel chimney liners

The new designs of furnaces and boilers in conjunction

with ame retention gas burners are more efcient. One result of increased efciency is lower ue gas temperatures. As ue gases rise in the chimney, they

cool and condense when they reach the dew point.

The condensation mixes with sulphur in the ue gases

creating sulfuric acid. The acid attacks the chimney mortar, brick and clay liners causing corrosion, deterioration and blockage of the chimney. Eventually

the blockage could prevent exhausting the ue gases. Instead, the ue gases vent out the barometric damper

into the living space.

Therefore it is strongly recommended that an approved insulated stainless steel chimney liner be installed. The installing contractor is solely responsible for installation of the proper vent system.

○ For those installations not requiring a chimney, such

as through-the-wall vented appliances, follow the instructions given by the appliance and power venter (if used) manufacturers.

Figure 4 – Chimney Design - Above the Roof

Minimum Clearence: 2 FT.

NOTE: Correct chimney design is shown by dotted lines. Incorrect chimney design, as shown by the solid lines, may result in down-drafts.

CG4 Burner Manual

Section: INSPECT/PREPARE INSTALLATION SITE

Combustion Air Supply

Some local codes and

gas utilities require the installation of a CO detector, this is

strongly recommended in all applications.

Carbon Monoxide

Hazard

Do not block combustion air inlet. 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.

Buildings with Adequate Air Inltration

In many cases, a burner operating in an unconned

space of a conventional frame, brick or stone building will receive adequate air supply from leakage in the

building itself. But if the burner is located in a conned

space such as a furnace or boiler room, that space must have one permanent opening toward the top of the space and one near the bottom of the space.

One method to accomplish this is through a permanent opening(s) in an exterior wall. The opening, or openings, must have a total free area of not less than one sq. in. per 5,000 BTU per hour. All appliances must be taken into consideration. Refer to NFPA 54 & 58.

Another method is to supply outside air directly to the burner through round, smooth duct work (See Figure

5). Some manufacturers offer accessories which allow outside combustion air duct work to be coupled to the burner. These kits must meet the engineered system requirements of NFPA54. For safety reasons it is important that you comply strictly with their installation instructions.

Figure 5 – Outdoor Air Ducted to Burner

Each opening must have a free area of not less than one sq. in. per 1,000 BTU per hour of the highest input rating listed for the appliance (refer to NFPA 54 & 58).

Remember to take the total input of all air-using

appliances into consideration when guring the

openings. The openings must connect with the inside of

the building, which should have adequate inltration from

the outside.

As an example:

If a gas burner was ring at 175,000 BTU/Hr and a water heater was ring at 70,000 BTU/Hr, in an enclosed room

in a building each opening in the enclosure should be 245 sq. in. (245,000/1,000 x 1 sq. in. = 245 sq. in.) A 245 sq. in. opening would typically be 10” x 25” or 16” x 16”.

Buildings with Less Than Adequate Air Inltration

If the burner is located in a tightly constructed building

where there is inadequate outside air inltration, outside

combustion air must be supplied by some other means.

Clearances to Burner and Appliance

○ Provide space around burner and appliance for easy

service and maintenance.

○ Check minimum clearances against those shown

by the appliance manufacturer and by applicable building codes.

○ The recommended clearance around the burner

itself is 12” minimum for service access.

Section: INSPECT/PREPARE INSTALLATION SITE

Fuel Gas Supply

Explosion, Fire, Asphyxiation Hazard

Leaking gas could result in asphyxiation,

explosion, or re hazard.

Prior to burner installation all gas supply piping must be inspected, tested and purged in accordance with the requirements of the National Fuel Gas Code ANSI Z

223.1 (NFPA 54). The burner valve must not be exposed to pressure exceeding 1/2 PSI under any circumstances.

Insure that the supply gas pipe size is capable of providing at least 4.5” W.C. pressure to the burner gas train inlet at the burner’s full capacity rating. Refer to

Tables 2 and 3.

Table 2

Gas Supply Pressure Requirements (Natural or Propane)

Maximum 14” WC (1/2 PSI)

Minimum 4.5” WC

Explosion, Fire, and Gas Leak Hazard

A Drip Leg is required in Gas Supply Piping. Foreign matter could lodge in gas valve cutoff seals, resulting in gas leak-

through, explosion or re.

Insure that a full-size drip leg or dirt pocket has been installed in the piping directly ahead of the main shutoff valve to capture foreign matter.

Electrical Supply

Check the nameplate on the burner to verify that the power connections available are correct for the burner. Refer to Figure 2 on Page 5. All power must be supplied through a disconnect switch fused at 20A maximum and comply with the latest edition of National Electric Code NFPA 70 (Canada CSA C22.1) and all other local or applicable codes.

Verify Burner Components

Your CG4 burner is shipped in two boxes. Verify that you received all the necessary components.

Table 3 – Gas supply piping capacity, CFH

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 specic gravity.

Pipe

Length

(ft.)

10 132 278 520 1050 1600

20 92 190 350 730 1100

30 73 152 285 590 890

40 63 130 245 500 760

50 56 115 215 440 670

60 50 105 195 400 610

70 46 96 180 370 560

80 43 90 170 350 530

90 40 84 160 320 490

100 38 79 150 305 460

110 34 72 130 275 410

120 31 64 120 250 380

150 28 59 110 225 350

1/2” 3/4” 1” 1-1/4” 1-1/2”

Pipe size (inches) IPS

The larger box contains:

○ The burner chassis ○ The literature package, which includes the burner

manual ○ The gas valve ○ A small parts bag, containing a reducing tee, a pipe

plug, a union and a bafe (P/N 5880)

The smaller box contains:

○ The air tube ○ The burner head and its (2) mounting screws ○ A blank air band (only packaged with tubes using the

F3G head) ○ A box containing the manifold assembly, the natural

gas orices, an O-ring, a packet of O-ring lubricant

and 10 mounting screws.

Verify Burner Selection

If the burner is supplied as an original equipment part of a boiler or furnace appliance the information in this section may be disregarded. Instead, use the appliance

manufacturer’s specications.

If the gas supply pressure is not correct, it must be corrected before starting the CG4 installation. Contact

your gas utility or qualied contractor.

CG4 Burner Manual

Verify that the proper burner chassis and air tube assembly have been selected.

○ Determine the appliance’s design ring rate from the

appliance rating plate. The appliance rating plate will

probably have an input rating and an output rating.

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