Beckett CG4 User Manual

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Page 1

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.

Page 2

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.

Page 3

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.

Page 4

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.

Page 5

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

Page 6

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

Page 7

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

Page 8

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.

Page 9

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.

Page 10

Section: INSPECT/PREPARE INSTALLATION SITE

Table 4 – Minimum Combustion Chamber Dims.

Chamber Dimensions (Inches)

Firing

Rate MBH

80 8 8 9 13 4

105 9 9 10 13.5 4.5

140 10.5 10.5 12 14 5.3

175 11.5 11.5 13 14.5 5.8

210 13 13 14.5 15 6.5

250 15 15 16 16 7.5

Rectangular

Width

(W)

Height

(H)

Horizontal

Cylinder

I. D.

Length

(L)

Floor to

Tube (A)

Table 5 – Firing Rates and Congurations

Fuel Orices

Firing Rate BTU/Hr.

80,000 0.219 0.166 F3G 01 32910-001 5880 Blank 2-1/2 Blank

90,000 0.234 0.177 F3G 01 32910-001 5880 Blank 4 Blank

100,000 0.25 0.189 F3G 01 32910-001 5880 Blank 5-1/2 Blank

110,000 0.277 0.206 F3G 01 32910-001 5880 Blank 7-1/2 Blank

120,000 0.316 0.219 F3G 01 32910-001 5880 4-slot 9 0

130,000 0.364 0.234 F3G 01 32910-001 n/a 4-slot 5-1/2 0

140,000 N/A 0.242 F3G 01 32910-001 n/a 4-slot 7-1/2 0

130,000 0.281 0.217 F4G 02 32910-001 5880 4-slot 8 0

145,000 0.316 0.234 F4G 02 32910-001 5880 4-slot 10 0

160,000 0.348 0.246 F4G 02 32910-001 n/a 4-slot 6-1/2 0

175,000 0.406 0.261 F4G 02 32910-001 n/a 4-slot 8-1/2 0

190,000 N/A 0.281 F4G 02 32910-001 n/a 4-slot 10 0

180,000 0.332 0.246 F6G 03 n/a n/a 4-slot 5-1/2 0

190,000 0.354 0.256 F6G 03 n/a n/a 4-slot 7 0

205,000 0.377 0.266 F6G 03 n/a n/a 4-slot 8-1/2 0

220,000 0.422 0.281 F6G 03 n/a n/a 4-slot 10 0

235,000 0.484 0.295 F6G 03 n/a n/a 4-slot 10 2

250,000 N/A 0.312 F6G 03 n/a n/a 4-slot 10 4

Natural Gas

Orice Dia.

Inches

L P Orice

Dia. Inches

Air Tube Components

Burner

Head

Nozzle Static Plate Bafe Band Shutter Band

Chassis

Components

Initial Settings

- Firing rates are based on 3.5” WC manifold gas pressure and use of the appropriate orice for the fuel being red.

- Air tube assemblies are provided with a full selection of the natural gas orices appropriate to the burner head.

- LP orices are provided in kits containing all the LP orices for the burner head size. The installer is responsible

for selecting and installing the appropriate orice for the application.

- Burner heads and nozzles are identied with the markings shown to assure the use of compatible combinations.

- Burner chassis are built for the highest rate conguration. The installer is responsible to add the bafe and/or

change the band as required for the application.

- Initial settings are intended for use only as a starting point for burner adjustments. They can not make provision

for all installation possibilities. It is important that you adjust your burner to your installation requirements using

properly calibrated ue gas analysis instruments.

Page 11

Section: INSPECT/PREPARE INSTALLATION SITE

The burner’s ring rate is the input rating. If it is

given in GPH of oil, multiply by 140,000 to get BTU/ Hr for gas or by 140 to get MBH.

○ The burner’s ring rate must be no more than 5%

higher than the appliance’s stated input rate (based on industry tolerance) and no more than 10% lower than the appliance’s stated input rate (based on the potential for low stack temperature condensation hazards).

○ Determine the burner’s appropriate chassis and air

tube components from Table 5, being sure to apply the altitude adjustment from Table 1 on Page 4, if applicable.

○ Verify that the chassis has the correct air band and

bafe (if required)

○ Verify that the air tube has the correct head and

nozzle (markings are visible without disassembly) and static plate (there is only one choice, and it is visible without disassembly).

○ Verify that you have the correct fuel orice for the

intended ring rate (Table 5) – sizes are stamped on the orices

○ Examine the appliance’s combustion chamber and

compare its dimensions to the rate-appropriate line in Table 4 to verify that the chamber is large enough

to handle the ame size.

○ Examine the appliance’s mounting dimensions and

compare them to those of the mounting ange on

the air tube, making sure that the distance from

the ange to the furnace end of the burner head

provides for the ¼” set-back shown in Figure 11 on Page 16.

Carbon Monoxide

Hazard

DO NOT INSTALL a Beckett gas burner and air

tube combination with a ring rate more than 10%

lower than the appliance name plate’s input BTU rating. The appliance and vent system could be

damaged due to condensation, leading to ue gas

leakage.

Prepare the Appliance

Breathing Hazard

Ceramic ber or Fiberglass insulation

Ceramic ber materials, such as chamber

liners, may contain carcinogenic particles (crystalline silica) after exposure to

heat. Airborne particles from berglass or ceramic ber components have been

listed as potentially carcinogenic by the State of California. Take the following precautions when removing, replacing and handling these items.

Avoid breathing dust and avoid contact with skin or eyes. Wear long-sleeved, loose-tting clothing,

gloves and eye protection. Use a NIOSH N95 certied

respirator. This respirator meets requirements for protection from crystalline silica. Actual job requirements for NIOSH regulations may require other or additional protection. For information, refer to the NIOSH website, http://www.cdc.gov/niosh/homepage.html.

Ceramic ber removal: To prevent airborne dust,

thoroughly wet ceramic ber with water before handling. Place ceramic ber materials in a plastic

bag and seal to dispose.

Avoid blowing, tearing, sawing or spraying

berglass or ceramic ber materials. If such

operations are necessary, wear extra protection to prevent breathing dust.

Wash work clothes separately from other laundry. Rinse clothes washer thoroughly afterwards to prevent contamination of other clothing.

NIOSH First aid procedures:

y Eye exposure - irrigate eyes immediately y Breathing - fresh air

Asbestos Hazard

DO NOT INSTALL a Beckett gas burner and air tube

combination with a ring rate more than 5% above

the appliance name plate’s maximum input BTU rating.

CG4 Burner Manual

NEVER attempt to retrot an

appliance containing asbestos. Contact a professional to remove the asbestos prior to installation. If

unsure call a qualied contractor to

verify if asbestos is present.

Thoroughly clean appliance heat exchanger and replace damaged combustion chamber materials, if necessary.

○ Seal all clean-outs, burner mounting plate and vent

pipe connections.

○ Verify all appliance operating and safety controls are

functional and operating correctly. Replace any that are questionable.

○ Verify all wiring and controls comply with National/Local

codes and authorities having jurisdiction.

Page 12

Section: PREPARE THE APPLIANCE

Fire and Asphyxiation

Hazard

Failure to comply with manufacturer’s instructions could result in damage to the stainless steel combustion chamber

which can result in re or asphyxiation

hazards.

If retrotting a CG4 to a stainless steel combustion

chamber, check the appliance manufacturers instructions to determine if a lining is required and comply with their recommendations.

Assemble the Burner

Gather the Necessary Parts

1. You have already veried that you received all the components shipped with the burner.

2. In addition to the parts provided with the burner you will need ¾” pipe nipples (schedule 40, black iron – do not use galvanized) to make up the connection to the supply piping, and pipe joint compound. Pipe

lengths must be selected to t your installation. We

recommend a 3” to 6” length between the gas valve and the union.

Prepare the Chassis

1. Determine whether you must add a bafe using the appliance’s ring rate and Table 5 on Page 10.

2. If a bafe must be added, open the burner’s top access cover by loosening the two front screws and pivoting their clips out of the way.

3. Align the bafe between the two pins on the motor side of the housing (Figure 6 on Page 13) and against the housing partition and tap it securely onto the partition.

4. Determine whether you must change from the 4-slot air band shipped on the chassis to the blank air band using the appliance’s ring rate and Table 5.

5. If the air band must be changed, remove the air proving switch, the shutter and the slotted band (Figure 7 on Page 14).

6. Install the blank band and return the shutter and air proving switch in the reverse order from step 5, tightening the screws securely.

Prepare and Install the Air Tube

1. The air tube may be shipped without the head installed. If so, align the openings in the swirl vanes

with the ame rod and ignition electrodes and

press the head onto the OD of the air tube until the

head is seated and the screw holes on the sides align. Use care to avoid bending the swirl vanes or the front edge of the shroud. Install the retaining screws packed with the head and tighten securely.

2. Remove 2 screws from the housing end of the air tube that secure the rear edge of the gas gun.

3. Install the air tube onto the housing with the gas connection on the top side of the air tube (Figure

8). Install the (4) ¼-20 screws nger tight. Install

the remaining 4 screws. After all 8 screws are in place tighten them all securely.

4. Route the ignition (black) and ame sensing (yellow) wires from the air tube into the chassis.

5. Connect the yellow (ame sense) wire from the air tube to the yellow wire in the chassis, and take up all slack in the wire by pushing it back into the electrical box.

6. Connect the black (ignitor) wire to the igniter with the access cover partially closed. Close the cover, secure it with its retaining clips, and tighten the clip screws securely.

Assemble the Gas Valve and Manifold

1. You will need to provide a ¾” schedule 40 black iron pipe nipple (3” to 6” long is convenient) and joint compound to complete this assembly. Refer to Figure 9 on Page 15.

2. Install the factory assembled burner manifold (mounting block, 2 nipples and elbow)on the outlet side of the valve (the side the arrows point towards), following the valve manufacturer’s piping instructions supplied with the valve.

3. Install a ¾” pipe nipple and union on the inlet side of the valve, following the valve manufacturer’s piping instructions supplied with the valve.

The gas valve is sensitive to

its installation orientation. It must only be installed in horizontal piping with its electrical connections on top as shown in Figures 9 and 10.

Explosion, Fire, and Gas

Leak Hazard

y Do not disassemble gas valve

y Do not use Teon tape on gas piping.

Damage to gas valve seats and bodies

could cause gas leaks and result in

asphyxiation, explosion, or re.

y Valve must be installed with ow direction arrow

pointing to burner.

Page 13

Section: ASSEMBLE THE BURNER

Pieces of tape can be cut loose during installation and lodge in gas valves causing cutoff seal problems.

Te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.

Verify that the gas valve

is not damaged and that all piping and ttings are de-burred and clean inside and out.

Install the Valve and Manifold to the Burner

1. Determine the correct fuel orice using the

appliance’s fuel type, ring rate and Table 5 on

Page 10, and insert it into the recess in the manifold adapter on the top of the burner’s air tube (Figure 10 on Page 15). Notice in Table 5 that

not all natural gas applications use a fuel orice.

2. Lubricate the O-ring with the small packet of

lubricant provided and install it into the groove on the bottom of the manifold mounting block.

3. You may mount the manifold assembly with the

valve on either the right or left side of the burner (Figure 10). Tighten its screws securely.

4. Connect the violet and white wires (from the

electrical box adjacent to the air tube) to their mating spade terminals on the top of the gas valve. The white wire goes to the terminal marked “C” and

the violet wire goes to the terminal marked “MP”.

With the propane orice

installed, as shown in Figure 10 , Page 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 further technical assistance is required, call 800-645-2876, Monday thru Friday, 8AM to 5PM EST.

Explosion, Fire and Asphyxiation Hazard

This

conversion kit must be installed

by a quali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 re, explosion, or production of carbon

monoxide may result causing property damage,

personal injury or loss of life. The quali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 specied in the manufacturer’s

instructions supplied with the kit.

Figure 6 – Bafe Installation

Propane Applications

Beckett CG4 burners are designed to re either natural gas or propane gas by changing only the fuel orice

(Figure 10, Page 15). Table 5 on Page 10 lists the

correct fuel orices for both fuels by ring rate together

with the other rate-variable components of the burner. All the burner’s adjustments and settings for propane will be the same as for natural gas when the appropriate fuel restrictors are in place. For ANSI Z21.17a purposes, the propane restrictors listed in Table 5 are considered to be Beckett’s propane conversion kits.

Use authorized replacement

parts only. Fuel orices are

precision-machined parts and O-rings are rated for

fuel contact. Do not attempt to replicate or modify any

parts. Refer to Table 5 on Page 10.

CG4 Burner Manual

Partition

Alignment

Pins

Page 14

Section: ASSEMBLE THE BURNER

Figure 7 – Installation of air band, shutter, and air provings switch

Slotted Air Band

Air Proving Switch

Blank Air Band

Figure 8 – Air Tube Installation

Air Tube

Shutter

#10-24 x 1/2” Button Socket

Head Screws (Qty: 2)

#8 x 7/16” Hex Washer

Head Screws (Qty: 2)

Gas Connection on Top

1/4-20 x 5/8” Hex Head Screws (Qty:4)

Page 15

Figure 9 – Gas Manifold

3/4” Pipe Nipple

(Installer Provided)

Section: ASSEMBLE THE BURNER

Manifold (Factory Assembled)

Union

Figure 10 – Gas Manifold Installation

#10-24 x 1-1/4” Button Socket

Head Screws (Qty: 4)

Flow Arrow Points

This Way

O-Ring (Lubricate Before Installing)

Fuel Orice (If Used)

CG4 Burner Manual

Page 16

Section: MOUNT THE BURNER

Mount the Burner

Mount the burner to the appliance. The burner specied for packaged equipment will have a ange welded for the

required insertion. Follow the appliance manufacturer’s instructions for mounting.

Protect the Air Tube from Overheating

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

1. Verify the Burner’s Insertion Depth

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

from ush with the refractory inside wall to prevent

damage from overheating (See Figure 11).

The end of the air tube must not extend into the combustion chamber unprotected unless it has

been factory-tested and specied by the appliance

manufacturer.

Connect Gas Piping

Install the test cock tee, its plug, and the union (provided with the burner) into the supply piping and connect them to the burner valve and manifold (Figure 12).

Gas supply piping must be

structurally supported independant of the burner. The burner manifold and gas valve are not designed to support piping loads.

Figure 12 – Typical Gas Piping Layout

KEY

Abbrev. Item Description

MSC Main Shutoff Cock

TC Test Cock

U Union

GV Gas Valve

DL Drip Leg

Provided by Installer

2. Bolt the burner to the appliance using the factory-

mounted ange and gasket.

3. Provide support under the burner if required.

Some Local codes require the burner to have a stand. If this is

required use Beckett Part #5685 Pedestal Kit.

Figure 11

9.5”1/4”

BURNER

MSC

TEE

Explosion and Gas Leak

Hazard

Provide Over-pressure Protection

The National Fuel Gas Code, ANSI Z223.1 (NFPA

54) and ASME CSD-1 require that if gas pressure

entering the building exceeds the rating of any gas train component an overpressure protection device must be installed.

Page 17

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.

Section: WIRE THE BURNER

Electrical Shock Hazard

Electrical shock can cause severe personal injury or death.

Disconnect electrical power before installing or servicing the

burner.

See Figure 13 for a typical wiring diagram, with the GeniSys 7590.

Maximum fuse size for the 120 Vac 60 Hz electrical power supply to the burner is 20 Amps.

Keep Service Access Covers Securely Installed

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

All covers or service access plates must be in place at all times except during maintenance and service.

This applies to all controls, panels, enclosures, switches, and guards or any component with a cover as part of its design.

Provide ground wiring to the burner, metal control enclosures and accessories. (This may also be required to aid proper control system operation.)

Perform all wiring in compliance with the National Electrical Code ANSI/NFPA 70 (Canada CSA C22.1)

Explosion, Fire and Asphyxiation Hazard

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

explosion or re.

Safety controls are designed and installed to provide protection.

Do NOT tamper with or bypass any safety control.

If a safety control is not functioning properly, shut off all main electrical power and gas supply to the burner and

call a qualied service agency immediately.

Figure 13 – Typical CG4 Wiring (Boiler Applications)

Y/W

Y BK

Gas

Valve

Igniter

Burner

Motor

CG4 Burner Manual

120 Vac 60 Hz

Transformer

W W

Limit

(If Required)

Provided by

Installer

LWCO

(1/4” QC)

L2 (IGN)

Igniter

L2 (MTR)

Motor

Valve Common

Sense

(3/16” QC)

Flame Sensor

W/R

Valve

24V

24V GROUND

Air Pressure

Switch

AP2

AP1

Burner Ground

Beckett

7590

Control

Com Port (COM 1)

on side of control

Thermal

Switch

Field Wiring

TT Terminals on top of control

Page 18

Section: SEQUENCE OF OPERATION

Sequence of Operation

Delayed Ignition, Explosion, and Fire

Hazards

Use only the Beckett 7590 Control on

the CG4 Burner.

This operation sequence is

typical for operation with a 7590 control. This is the only control approved for use on the CG4 Gas Power Burner.

Do not start the burner yet.

(Reference Table 6 )

○ Call for heat, Status LED is turned on.

─ Control performs safe-start check

─ If safe-start fails, control locks out.

─ If safe-start passes, control checks for presence

of ame.

─ If ame is present, control will enter hold state

until ame is no longer present. Flame LED and Status LED will ash until ame is no longer

present.

─ If ame is not present, control will check status of

air proving switch. If switch is closed, (indicating the pressure switch is stuck) control will enter lockout.

○ If the air proving switch is open, the motor will start.

Once the air proving switch closes, pre-purge will begin (lasting 30 seconds). Pre-purge or ignition timings will not start until the air proving switch closes.

─ The air proving switch must close to prove

combustion air is present. If switch fails to close

during the specied period, the control will enter

lockout.

○ When pre-purge is completed, the control turns on the

igniter and the gas valve. MV LED will turn on.

─ Spark continues until end of ignition timing or

until ame is proved.

○ Once ame is proved, The Flame LED is turned on

and the spark is turned off. The gas valve and MV LED

remain energized.

─ If ame is not proved, the control will lockout or

enter the inter-trial waiting period. Status LED will ash rapidly for lockout or slowly for inter-trial

waiting.

─ If multiple trial logic is used, the control will

complete the trials for ignition

─ When ame is proved the control will

continue in

run mode until the end of the call for heat.

○ When the call for heat is ended, the gas valve, MV

LED, Flame LED, Status LED and motor turn off.

Additional information on control operation is available in the GeniSys 7590 Control Manual (61981-001).

Table 6 – Operating Sequence

Call for Heat

LEDs

Timers & Timings

Flame Check On On On On On

Motor/Blower Blower Starts On On On Off

Air Switch Check On Air Switch Closes On On On

Igniter On Off Off

Gas Valve On On Off

FLAME

MV STATUS

Status LED

turns on

Motor Start

FLAME

MV STATUS

Status LED

Pre-purge

FLAME

MV STATUS

Status LED

Flashes

Pre-purge Timer 1 - 240 Seconds

Ignition

FLAME

MV STATUS

Status, MV

LEDs On

Ignition Trial

Timer

4 - 15 Seconds

Run

FLAME

MV STATUS

Status, MV,

Flame LEDs On

End Call for Heat

FLAME

MV STATUS

LEDs Off

Page 19

Section: PREPARE THE BURNER FOR START-UP

Prepare the Burner for

Start-up

Asphyxiation, Explosion/

Fire

Professional Installation & Service Required. Incorrect installation and mishandling of start-up could lead to equipment malfunction.

This burner must be installed and prepared for start-

up by a qualied service technician who is trained and

experienced in gas burner system installation and operation.

Do not attempt to start the burner unless you are fully qualied.

Carefully follow the wiring diagrams, control instruction sheets, control sequence of operation, test procedures and all appliance manufacturer’s directions that pertain to this installation.

Start the Burner

Asphyxiation, Explosion/

Fire

Professional Installation & Service Required. Incorrect installation and set up

could lead to equipment malfunction.

This burner must be installed and prepared for start-

up by a qualied service technician who is trained

and experienced in gas burner system installation and operation.

Do not attempt to start the burner unless you are fully qualied.

Do not continue with this procedure until all items in

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

veried.

Carefully follow the wiring diagrams, control instruction sheets, control sequence of operation, test procedures and all appliance manufacturer’s directions that pertain to this installation.

Start-up Checklist

Verify the following before attempting to start the burner:

1. 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 efciency.

○ Electrical multi-meter capable of measuring

voltage, ohms, amps, and DC micro-amps for measuring the 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 0.1” W.C.

Burner Start Procedure

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

1. With the power and main gas supply to the burner turned off, make sure gas has not accumulated in

the boiler or ues.

2. Check the initial air settings (shutter & band) for

input ring rate. If adjustment is necessary refer to

Figure 14 and loosen the adjustment screws then twist the shutter and/or air band until the indicators point to the values listed in Table 5 on Page 10.

3. With the main shutoff cock closed. Set the limit or controller to call for heat then apply power to start the burner.

4. In order to check the function of each component

(i.e.: 7590 sequence, airow proving switch, ignition

transformer, gas valves, safety lockout timing, etc.), with the main shutoff cock closed, monitor a complete burner run sequence. Note that the 7590 control will lock out following the 3rd try for ignition since the fuel supply has been closed off. Reset the control by pressing the reset button while the control is powered or by removing power from the control for 10 seconds or more.

5. If 7590 operation sequence and function is correct, turn off power and remove sensor wire from bottom of 7590 control. Turn on power and fuel and initiate

CG4 Burner Manual

Page 20

Section: START THE BURNER

Call for Heat. Verify that burner res up and the gas valve closes. After control locks out, ame

shall go off.

6. Turn power off and reattach sensor wire. Turn power back on. Control should reset. Initiate Call for Heat.

7. After you have observed main ame for a brief time, press the reset button on the control for 1 second to shut down and re-start the burner. Monitor the

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.

8. While the burner is ring, examine the vent system for evidence of leaks, obstructions, and for correct function of the barometric draft control. Leak test all gas piping from the burner to the utility supply piping. If leaks are found, correct them immediately.

Figure 14 – Shutter and Band

Tighten locking screws securely after adjustments have been made

Verify the Firing Rate

The primary method for verifying the burner’s ring

rate, for either natural gas or propane, is to assure that

the correct fuel orice is properly installed and that the

gas valve outlet pressure is accurately set to 3.5” water column.

1. Turn off electrical power to the burner and close the main shutoff cock supplying gas to the burner.

2. Remove the plug from the outlet pressure tap on the outlet end of the gas valve (Figure 15) and

install a hose barb tting and manometer.

3. Turn on system power and gas supply and initiate a call for heat to light the burner.

4. The manometer should show 3.5” water column pressure. If it does, turn off the burner and skip ahead to step 6. If it doesn’t, let the burner continue to run and adjust the gas valve pressure regulator in the following steps.

5. Remove the regulator cover screw (see Figure

15) from the regulator adjustment tower and turn the regulator adjust screw clockwise to increase pressure or counterclockwise to decrease pressure. Set the regulator to produce a 3.5” water column reading in the manometer. Check the appliance breech or draft setting and adjust if necessary as it can affect the setting. Replace the regulator cover screw.

6. Turn off the burner and turn off all electrical power to the system.

7. Remove the manometer hose and barb tting from the gas valve outlet pressure tap.

8. Replace the outlet pressure tap plug and tighten (clockwise 40 – 60 in-lbs.).

9. Turn on system power and start the burner.

10. Check for leaks at the gas valve outlet pressure tap plug using a leak detection solution or soapsuds. Bubbles forming indicate a leak. SHUT OFF GAS

AND FIX ALL LEAKS IMMEDIATELY.

If the burner is ring natural gas it may be possible to

verify the ring rate by “clocking” the gas meter:

The shutter and band both

control the amount of ow area

available for air inlet to the burner. The greater their

combined ow area, the higher the ring rate. The

primary differences between the two are their ease of

adjustment and their total airow area. The shutter turns more easily and has a smaller net ow area. As a

result we have found the shutter to be better suited for 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.

1. Locate the gas meter and examine its display to be sure that you can determine a 1 cubic foot usage of gas and that the meter is temperature compensated.

2. Contact the gas utility to nd the heating value of the gas. It can vary from about 950 BTU/Ft3 to about 1,100 BTU/Ft3.

3. Examine the gas piping to know of any other gas appliances connected to it. Turn them off so that only this burner is using gas from the meter.

Page 21

Section: START THE BURNER

4. Start the burner and use a stopwatch to measure the number of timed seconds it takes for the

burner to re 1 cubic foot of gas.

5. Calculate the ring rate in BTU/Hr. using the following equation:

Firing rate BTU/Hr. = Heating value (BTU/Ft3) x 3,600 ÷ Timed seconds

For example, if the heating value is 1,050 BTU/Ft3 and you timed 1 cubic foot of gas at 42 seconds

then ring rate BTU/Hr = 1050 x 3,600 ÷ 42 which

calculates to 90,000 BTU/Hr.

If the burner is ring LP gas, a meter is usually not available. Contact your LP supplier for recommendations.

Figure 15 – Gas Valve Pressure Adjustment

Regulator

Cover Screw

Regulator

Adjust Screw

Check Operation and Safety Controls

Explosion, Fire and Asphyxiation Hazard

Testing by Quali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 re.

The testing of operating and safety controls requires technical training and experience with power gas burners and appliances.

Carefully follow the manufacturer’s instructions supplied with the appliance and the controls.

Verify the correct function of all operating and safety controls used in the installation.

If instructions are not available, use the following recommended procedures and record all results in a start-up log.

1. High limit/ Pressure Control – To check the High Limit, raise the temperature or pressure of the operating control to a higher level and lower the limit to a setting less than the operating control. Run the burner until the high limit opens and shuts the burner off. Adjust the controls back to the desired settings.

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

CG4 Burner Manual

Operating controls should be set to minimize the

number of ring cycles that the burner runs.

High cycling rates increase the possibility of light-off lock outs.

3. Low water cutoff (LWCO) – With the burner ring,

open the blow down valve on the low water cutoff,

Outlet Pressure TapGas Valve

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.

Page 22

Section: START THE BURNER

Use Test Instruments to Set Combustion

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 ue pipe near the breech

(or upstream of the boiler breech damper, if applicable) and in the front mounting plate area for

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 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 stack or over-re draft to the level

specied by the appliance manufacturer.

─ Natural Draft Applications; typically over-re

draft is -0.01” or -0.02” W.C.

─ Direct Venting; typically may not require draft

adjustment.

─ High Efciency/Positive Pressure Appliances;

(see manufacturer’s recommendations).

○ Oxygen – It is recommended that you measure the

oxygen (O2) early in the test sequence because high levels of carbon monoxide can be created at very low or even very high O2 levels. The typical operating range is between 3% – 5%.

○ Carbon monoxide (CO) – An operating range of 0

-50 PPM is recommended for the CG4 burner. The maximum carbon monoxide (CO) level permitted in the

ue gas by the UL 795 Standard is 400 PPM (.04%).

○ Stack Temperature – The stack temperature must

be within the range specied by the appliance

manufacturer. Generally a 325°F stack temperature is high enough to avoid corrosive condensation in the vent system, however a large cross sectional

ow area chimney or a very tall chimney may require

a higher temperature. See ANSI Z 223.1/NFPA 54 for design requirements.

Recommended Combustion Adjustment Procedure

1. Initiate a call for heat.

2. Adjust the draft or breech pressure to the appliance

manufacturer’s recommended level after ame has

stabilized. A breech pressure that does not exceed

-0.04 to -0.06”W.C. is generally acceptable.

3. Measure the carbon monoxide level and adjust air settings, if necessary, to temporarily raise CO to about 50 PPM for a test point.

4. Measure the O2 or CO2 at the 50 PPM CO level. For this discussion, assume the O2 is 1.5% (11% CO2).

5. Open the air adjustment until the O2 level is 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.

6. Sample the CO level again. It should be in the 0 to 20 PPM range.

7. Check the draft to ensure it still meets

specications. If a major change in draft is

required, repeat the above steps.

8. Check draft regulator for spillage. Conrm the condition of the chimney if spillage is present.

9. Verify stack temperature meets appliance manufacturer’s recommendations.

10. Perform any nal adjustments and lock the air settings securely. Run the burner through several cycles to verify prompt ignition and stable burner operation.

11. Record the combustion performance readings, burner settings and appliance data on the start-up form in the back of this manual and on the start-

up tag. If the burner is ring LP gas you must

also record set-up information on the propane conversion label and attach it to the appliance.

12. Hang the start-up tag in a prominent, safe location on or near the burner for future reference.

CO Leakage, Asphyxiation

Failure to maintain proper stack temperature could

result in ue gas condensing and cause chimney

damage which could result in CO leakage into dwelling.

Page 23

Section: MAINTENANCE AND SERVICE

Maintenance and Service

Explosion, Fire and Asphyxiation Hazard

Annual Professional Service Required. Tampering with or making incorrect adjustments could lead to equipment malfunction and result in

asphyxiation, explosion or re.

Do not tamper with the burner or controls or make any adjustments unless you are a trained and qualied

service technician.

To ensure continued reliable operation, a qualied

service technician must service this burner annually.

More frequent service intervals may be required in dusty or adverse environments.

Operation and adjustment of the burner requires technical training and skillful use of combustion test instruments and other test equipment.

Electrical Shock and

Explosion Hazard

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

re hazards.

Turn main gas valves and electric power off before performing any maintenance.

If a maintenance procedure requires electrical power, use extreme caution.

Label all wires prior to

disconnecting when servicing controls. Wiring errors can cause improper and dangerous operation.

Verify proper operation after servicing.

Explosion, Fire,

Asphyxiation Hazard

Use authorized replacement parts only. Do not

attempt to replicate or modify any parts.

Annual Maintenance

Explosion, Fire and Asphyxiation Hazard

Inspect Heating System Regularly. Lack of regular inspections and inadequate maintenance could lead to equipment malfunction and result in asphyxiation,

explosion or re.

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

y The following checklist is intended to be used

as a minimum reference guide only and does not supersede or replace the heating appliance manufacturer’s recommended service and maintenance instructions or any code requirements.

y Consult the installation and service instructions

provided by the individual control or component manufacturer and carefully follow their directions.

y 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 qualied

service agency immediately.

(The following should be performed by a qualied

service technician only.)

○ Inspect and Clean the Burner

1. Inspect and clean all dirt accumulation from the gas train, burner exterior, burner air band/shutter, and surrounding area.

2. Remove the blower motor and clean any accumulated matter from the blower wheel and motor end bell.

3. Check wheel for damage and the hub setscrew for tightness. If the blower wheel must be removed from the motor shaft, insure that

clearance specications are maintained. See

Figure 16 on Page 25.

4. Clean the inside surfaces of the burner housing scroll and especially the air intake area and

airow proving switch suction tube.

5. Clear any debris from the air vents on the motor body.

6. Clean the ignition transformer, baseplate, and terminal bushing. Inspect the ignition lead for signs of deterioration and loose terminals.

7. Remove the gas gun assembly and clean the entire unit, paying special attention to the air

diffuser and gas orices. Do not loosen or

disassemble the mounting blocks from the gas

tube. Their settings are important and difcult to produce under eld conditions. See Figure 17

on Page 25.

CG4 Burner Manual

Page 24

Section: MAINTENANCE AND SERVICE

8. Inspect the ame rod for oxidation or distortion. Clean all surfaces, set the probe position, and

insure that the ame rod is securely fastened.

Refer to Figure 17.

9. Inspect the ignition electrode for any damage. Clean all surfaces, set the proper electrode gap, and make sure it is securely fastened.

10. Clean the inside of the air tube and inspect the combustion end for any deterioration. Referring to Figure 11 on Page 16, check the recess dimension from refractory.

11. Inspect gas tube O-ring condition and replace if damaged. Install gas gun assembly back into the burner and tighten the gas gun securely in place. (Automotive chassis or bearing grease is suitable for o-ring lubrication.)

12. Inspect the condition of the appliance mounting

plate and burner mounting ange gaskets and

replace any damaged materials.

13. Inspect all burner control wiring and the burner control for damaged insulation and loose terminals/connections.

14. Verify that the source voltage to the burner and control panel is within 10% of the burner rating as listed on the nameplate (Figure 2 on Page 5).

○ Appliance – (Follow appliance manufacturer’s

service procedures. The following steps are emphasized because they relate to burner operation)

○ Installation area:

1. Insure that there are no combustible materials,

ammable liquids or vapors in the vicinity of the

heating appliance.

2. Verify that the combustion air supply is adequate.

○ Adjust the burner for proper combustion:

1. Run the burner and perform a complete combustion test using the proper instruments. If necessary refer to the section labeled Start the Burner. Record the results for reference.

2. Visually inspect the ame. Look for changes in shape, size, and color.

3. Monitor several burner start-up cycles. Verify

prompt ignition and ame stability.

4. Calculate the input ring rate and compare to the appliance specications.

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

○ 7590 GeniSys Primary Control:

Follow the instructions in Beckett GeniSys Model

7590 manual (available at www.beckettcorp.com or by calling 1-800-645-2876). Verify that the control

is functioning to specications. See “Check for

Normal Operation” section.

○ Manual shutdown for long periods:

1. Insure that the ue passages, ue vent pipes,

and chimney ues are clean and unobstructed.

2. Check barometric damper or draft hood for proper operation.

3. Check the condition of the combustion chamber refractory, the front-plate insulation, and all gaskets and seals. Repair or replace as necessary.

4. Inspect boiler sections and system load piping for possible leaks. Make all necessary repairs.

5. Check all operating and safety controls on the boiler for proper installation and operation.

6. Perform all maintenance and tests according to the burner control manufacturer’s instructions (limits, controllers, low water cutoff, relief valves, feed valves, etc.).

○ Gas supply piping:

1. Inspect all piping for leakage and proper installation.

2. Perform necessary repairs to comply with all codes.

3. Check inlet pressure to the gas valve.

1. Close all gas valves in the gas supply piping system.

2. Turn off all electrical power to the burner.

3. Protect the burner and controls from moisture and dirt.

○ Gas Valve

The gas valve has a cycle rating of 100,000 (10 years of 6 cycles per hr.). When valve has exceeded this value, it should be replaced.

Page 25

Figure 16 – Blower wheel assembly

Use a Feeler Gauge to set

the gap to 0.030 ±1/64 inch

Replace the Blower Wheel

1. Turn off all power to the burner before servicing.

2. Disconnect the burner motor wires.

3. Remove the bolts securing the motor to the burner housing.

4. Remove the motor and blower wheel.

5. Remove the existing blower wheel.

Section: MAINTENANCE AND SERVICE

6. Referring to the illustration to the left, slide the new blower wheel onto the shaft.

○ Use a feeler gauge to set the wheel-to-motor

gap, 0.030 ±1/64 inch.

○ Slide blower wheel toward motor until it

contacts feeler gauge.

○ Rotate the blower wheel until the setscrew is

centered on the at of the motor shaft. Tighten

the set screw 45 to 80 in.-lbs. to secure the wheel.

7. DO NOT use a motor that has endshield openings outside the blower wheel circumference (represented by the dashed line).

8. Install the motor on the burner housing. Tighten screws. Reconnect wires.

9. Restore power, start the burner and perform combustion tests. Refer to the section “Recommended Combustion Adjustment Procedure” on page 22.

Figure 17 – Gas Gun Assembly

Delayed Ignition, Explosion, and/or

Fire Hazard

DO NOT loosen or remove these screws.

They secure important factory settings.

Ignition Electrode AdjustmentFlame Rod Position

Electrode

Gas Nozzle

1-5/8”

CG4 Burner Manual

+1/16”

-0”

Align electrode point

with nozzle point.

1/8”±1/32”

Page 26

Section: REPLACEMENT PARTS

Replacement Parts

Figure 18 – Replacement Parts

See Inset

= Complete Assembly

Item Description Part #

1 Head F3GU, F4GU, or F6GU

2 Air Tube Assy Specify*

3 Cover Plate 32282U

4 Transformer 52310U

5 Air Proving Switch & Cover Assy 52264U

6 Shutter (4-slot) 3709U

8 Air Bafe 5880

9 Electrical Box 5770

10 Air Guide 31231U

11 Blower Wheel 2999U

12 Motor 21805U

13 GeniSys Primary Control 7590D0001U

14 Igniter & Gasket 7474U

*Contact your Beckett representative for part number and pricing.

Air band (Blank) 5151502

Air Band (4-Slot) 5151504

Explosion, Fire, Asphyxiation

Use authorized replacement parts only. Do

not attempt to replicate or modify any parts.

Item Description Part #

Natural Gas Orice pk (F3G) F3GNATU

Natural Gas Orice pk (F4G) F4GNATU

16 O-Ring, square 32933001U

17 Pipe Nipple Assy 52296001U

18 Gas Valve 22470U

19 Gas Gun Assy Specify*

20 Electrode/Wire Assy 5784U

22 Flame Rod/Wire Assy 7590FRU

Natural Gas Orice pk (F6G) F6GNATU

LP Orice Kit (F3G) F3GLPU

LP Orice Kit (F4G) F4GLPU

LP Orice Kit (F6G) F6GLPU

Nozzle (F3G) F3GNOZU

Nozzle (F4G) F4GNOZU

Nozzle (F6G) F6GNOZU

Hazard

Page 27

Contractor Start-Up Form

Installation Name:_________________________________________ Installation Date:___________________

Installation Address:_________________________________________________________________________

Start-Up Company’s Name_________________________________ Phone:__________________________

Name of Technician_________________________________________________________________________

■ Appliance (Below information can be obtained from appliance name plate)

Manufacturer:______________________________________________________________________________

Type (circle one): [ Boiler / Furnace / Other ] Model #:_______________ Serial #:____________________

Input MBH:_______________ Original Appliance Designed for (circle one): [ Oil / Natural Gas / Propane ]

Output MBH:______________

Limits

Temperature YES / NO

Pressure YES / NO

LWCO YES / NO

Other Limits YES / NO / n/a

(Indicate n/a if not required by the appliance manuf.)

Limit Model No.

Operation Veried

■ Burner

Fuel: [ Natural Gas / Propane ] Model #:________________ Serial #:_________________________

Combustion Head: [ F3G / F4G / F6G ] Fuel Orice Size:________ Air Shutter Setting:____________

Air Band Setting:____________ [ or Blank Band Installed ] Bafe: [ Installed / Not Required ]

■ Chimney/Smoke Pipe

Chimney Type:[ Masonry / Metal Vent / Direct Vent ] Location (circle one): [ Inside / Outside ]

Chimney Height:_____________ Flue Pipe Size:______________ Flue Pipe Length:________________

Number of Elbows:____________ Conrm Double Acting Draft Regulator Installed: [ Yes / No ]

Thermal Safety Switch Installed [ Yes / No ] Voltage: [ 120V / 24V ]

Gas Supply Piping

Pipe Diameter:________ Length of Pipe from Burner to Meter:_________ Number of Elbows:__________

Gas Pressure to Burner Gas Valve While Burner is Operating ____________ Inches W.C.

■ Combustion Readings

_________% CO:__________ PPM CO

2 :

Manifold Gas Pressure:______________ (Inches W.C.) Draft at Breech___________________________W.C.

_________% Stack Temperature (325°F MIN.):__________°F

2 :

Page 28

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 benets, products must be installed by a qualied service agency in full compliance with all codes and authorities having jurisdiction, and used within the tolerances of Beckett’s dened product specications.

To review the complete warranty policy and duration of coverage for a specic product, or obtain a written

copy of warranty form 61545, please choose one of the following options:

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

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

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

NOTE: Beckett is not responsible for any labor cost for removal and replacement of equipment.

THIS WARRANTY IS LIMITED TO THE PRECISE TERMS SET FORTH ABOVE, AND PROVIDES EXCLUSIVE REMEDIES EXPRESSLY IN LIEU OF ALL OTHER REMEDIES, AND IN PARTICULAR THERE SHALL BE EXCLUDED THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT WILL BECKETT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGE OF ANY NATURE. Beckett neither assumes, nor authorizes any person to

assume for Beckett, any other liability or obligation in connection with the sale of this equipment. Beckett’s liability and Customer’s exclusive remedy is limited to the cost of the product.

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

Canada: R.W. Beckett Canada, Ltd. ● Unit #3, 430 Laird Road ● Guelph, Ontario N1G 3X7

www.beckettcorp.com

Part Number 6104 BCG4 R01, Printed in the U.S.A. 05/14

Beckett CG4 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual