Beckett CG50 User Manual

COMMERCIAL PRODUCTS

GAS-FIRED

Fire, Explosion and Asphyxiation Hazards

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

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

What to do if you smell gas:

- Do not try to light any appliance.

- Do not touch any electrical switch.

- Do not use any phone in your building. Immediately call your gas supplier from a telephone outside the building.

- Follow the gas supplier’s instructions.

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

Contents

General Information ....................................................4

Hazard Deﬁ nitions .........................................................................4

Professional Installer’s Responsibility ...........................................5

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

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

Combustion Air Supply .................................................................. 5

Clearances .................................................................................... 5

Fuel Gas Supply ........................................................................... 5

Flue Vent System .......................................................................... 5

Electrical Supply ............................................................................ 7

Verify Burner Components ............................................................ 7

Verify Firing Input Range ............................................................... 7

Verify Burner Air Tube Assembly ...................................................7

Mount the Burner ....................................................... 10

Connect Gas Piping .................................................. 10

Gas Trains ................................................................................... 11

Wire the Burner .......................................................... 14

Sequence of Operation ............................................. 14

Prepare the Burner for Start-up ............................... 17

Start-up Checklist ....................................................................... 17

Start the Burner ........................................................ 18

Burner Start Procedure ...............................................................18

Initial Air Settings .........................................................................18

Optional Modulation Linkage Adjustment Instructions ................20

Adjustment Procedure .................................................................20

Modulation Control ......................................................................22

Verify Input Firing Rate ................................................................ 23

Estimating Rate ........................................................................... 24

Clocking a Gas Meter ..................................................................24

Uncorrected Flow Rate ...............................................................24

Pressure Correction ....................................................................24

Temperature Correction ..............................................................24

BTU’s and MBH...........................................................................24

Check Operation and Safety Controls .........................................26

Use Test Instruments to Set Combustion ....................................27

Recommended Combustion Test Sequence ...............................27

Maintenance and Service.......................................... 28

Annual Maintenance ..................................................................28

Appliance ....................................................................................28

Gas Supply Piping .......................................................................29

Installation Area ........................................................................... 29

Adjust the Burner for Proper Combustion ..................................29

Flame Safeguard .........................................................................29

Manual Shutdown for Long Periods ............................................29

Ignition Reliability ........................................................................29

Propane Restrictor Description ..................................................31

Installation ..................................................................................31

For the Operator ..........................................................................33

Replacement Parts .................................................... 34

Limited Warranty Information .................................. 36

CG15, CG25, CG50 Burner Manual

Section: General Information

General Information

Hazard Deﬁ nitions

Indicates a hazardous situation which, if not

avoided, will result in death or serious injury.

Indicates a hazardous

situation, which, if not avoided, could result in death, or serious injury.

Used with the safety

alert symbol, indicates a hazardous situation, which, if not avoided, may result in minor or moderate injury.

Within the boundaries of the hazard warning, there will be information presented describing consequences if the warning is not headed and instructions on how to avoid the hazard.

Used to address practices not related

to personal injury.

Owner’s Responsibility

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

Contact a professional, qualiﬁ ed service agency for the installation, adjustment, and service of your gas burning system. Thereafter, have your equipment adjusted and inspected at least annually to ensure reliable operation. This work requires technical training, trade experience, licensing or certiﬁ cation in some states and the proper use of special combustion test instruments.

Please carefully read and comply with the following instructions:

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

Never store or use gasoline or other ﬂ ammable liquids

or vapors near this burner or appliance.

Never attempt to burn garbage or refuse in this

appliance.

Never attempt to light the burner/appliance by throwing

burning material into the appliance.

Never attempt to burn any fuel not speciﬁ ed and

approved for use in this burner.

Never restrict the air inlet openings to the burner or

the combustion air ventilation openings in the room.

To the Owner:

Thank you for purchasing a Beckett burner for use with your heating appliance. Please pay attention to the Safety Warnings contained within this instruction manual. Keep this manual for your records and provide it to your qualiﬁ ed service agency for use in professionally setting up and maintaining your burner.

Your CG series gas burner will provide years of efﬁ cient operation if it is professionally installed and maintained by a qualiﬁ ed service technician. If at any time the burner does not appear to be operating properly, immediately contact your qualiﬁ ed

service agency for consultation.

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

Frozen Plumbing and Water Damage Hazard

If the facility 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 security agency.

Section: Pre-installation Checklist

Professional Installer’s Responsibility

Follow these instructions exactly

Failure to follow these instructions could lead to equipment malfunction and result in asphyxiation, explosion or ﬁ re.

Please read all instructions before proceeding. Follow

all instructions completely.

This equipment must be installed, adjusted, and

started by a qualiﬁ ed service agency that is licensed and experienced with all applicable codes and ordinances and responsible for the installation and commissioning of the equipment.

The installation must comply with all local codes and ordinances having jurisdiction and the latest edition of the National Fuel Gas Code ANSI Z223.1 (NFPA 54) and CAN1-B149.1 in Canada.

Concealed damage – If you discover

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

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

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

Pre-installation Checklist

Combustion Air Supply

The burner requires combustion air and ventilation air for reliable operation. Assure that the building and/or combustion air openings comply with the latest edition of the National Fuel Gas Code ANSI Z223.1 (NFPA 54). For appliance/burner units in conﬁ ned spaces, the room must have an air opening near the top of the room, plus one near the ﬂ oor, each with a free area at least one square inch per 1000 Btu/hr input for all fuel-burning equipment in the room. For Canadian installations, refer to latest edition of CAN1B149.1 standard.

If there is risk of the space being under negative pressure, or of exhaust fans or other devices depleting available air for combustion and ventilation, the appliance/burner should be installed in an isolated room provided with outside combustion air.

Clearances

With the burner installed in the appliance, there must be adequate space in front of and on the sides of the burner to allow access and operation. Verify that the clearance dimensions comply with local codes and with the appliance manufacturer’s recommendations.

Fuel Gas Supply

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

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

Table 1.

Indoor Installation

Protect against Dust and

Moisture

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

This burner is designed for clean, dry installations.

Electrical controls are not protected against rain or

sprayed liquids.

Keep the installation clear of dust, dirt, corrosive

vapors, and moisture.

Protective covers and more frequent maintenance

may be required.

CG15, CG25, CG50 Burner Manual

Flue Vent System

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

Section: Pre-installation Checklist

Table 1 – Burner Speciﬁ cations

CG15 CG25 CG50

Input Firing Range†:

High Fire (Max.) High Fire (Min.) Low Fire (Max.) Low Fire (Min.)

Fuel:

Natural Gas Propane (LP)

Gas Train:

Standard Options

Gas Train Inlet Pressure:

Minimum Maximum

Manifold to Furnace Pressure Drop:**

Highest High Fire Lowest High Fire

Firing Modes Available: Low Fire Start

Standard Flame Safeguard:

Low Fire Start High / Low Modulation

Flame Detector:

Standard UV UV UV

Airﬂ ow Proving Switch: Standard Standard Standard

Gas Pressure Switches: Standard High and Low Standard High and Low Standard High and Low

Ignition: Direct Ignition of Main Flame Direct Ignition of Main Flame Direct Ignition of Main Flame

Motor:

HP RPM Standard Voltage Motor FLA Optional Voltages

Weight: 125 lbs. 145 lbs. 165 lbs.

Dimensions: Refer to Figures 4 & 5.

*See manufacturer’s nameplate settings for speciﬁ ** See Figures 14A, 14B, & 14C. † Canada High Fire rate is reduced to accomodate 25% reserve air.

USA Canada USA Canada USA Canada

1,500 MBH

800 MBH 560 MBH 350 MBH

0.6 Speciﬁ c Gravity Typical

1.53 Speciﬁ c Gravity Typical

UL Listed / CSD-1 conﬁ guration IRI, FM

3.7” WC* 10 PSI

3.7” WC

2.7” WC

High/Low Modulation

RM7897A RM7897C RM7897C

1/2HP 3450 RPM 120 volt, 1 ph, 60 Hz

6.4 Amps @120 volt AC 208/230v, 1 ph, 60 Hz 208/230v, 3 ph, 60 Hz 460v, 3 ph, 60 Hz 575v, 3 ph, 60 Hz

1,370 MBH

800 MBH 560 MBH 350 MBH

c minimum gas pressure requirements.

2,700 MBH 1,300 MBH

990 MBH 550 MBH

0.6 Speciﬁ c Gravity Typ.

1.53 Speciﬁ c Gravity Typ.

UL Listed / CSD-1 conﬁ guration IRI, FM

3.5” WC* 10 PSI

3.5” WC

2.5” WC

High/Low Modulation

RM7897C RM7840L

3/4 HP 3450 RPM 120 volt, 1 ph, 60 Hz

10.4 Amps @120 volt AC 208/230v, 1 ph, 60 Hz 208/230v, 3 ph, 60 Hz 460v, 3 ph, 60 Hz 575v, 3 ph, 60 Hz

2,300 MBH 1,300 MBH

990 MBH 550 MBH

5,000 MBH 2,000 MBH 1,400 MBH

730 MBH

0.6 Speciﬁ c Gravity Typ.

1.53 Speciﬁ c Gravity Typ.

UL Listed / CSD-1 conﬁ guration IRI, FM

3.5” WC* 10 PSI

3.5” WC

2.5” WC

High/Low Modulation

RM7897C RM7840L

2 HP 3450 RPM 208/230v, 1 ph, 60 Hz

13.4 Amps @230 volt AC 208/230v, 3 ph, 60 Hz 460v, 3 ph, 60 Hz 575v, 3 ph, 60 Hz

4,000 MBH 2,000 MBH 1,400 MBH

730 MBH

Figure 1 - Burner Label Location

General Model Information

Serial Number,

Including Date Code

Rating Information

Approval Agency Symbols

Fuel

R.W. Beckett Construction & Setting Data

R.W. Beckett Speciﬁ cation Number and Revision

Boiler Manufacturer and Model, When Applicable

Additional Codes

Test For Gas Pipe Leaks

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

The gas supply piping must be absolutely leak-free.

Pressure test the gas piping with air that is at least

three times greater than the gas pressure being used.

Verify that there are no leaks before proceeding.

Figure 2 - Minimum Combustion Chamber Dimensions

Minimum Inside Dimensions (inches)

Burner

Model

CG15.1S 15 16 42 7

CG15.2S 16 17 45 8

CG15.3S 17 18 47 8

CG15.4S 18 19 50 9

CG25.1S 19 20 45 9

CG25.2S 20 21 48 10

CG25.3S 21 22 50 10

CG25.4S 22 23 52 11

CG25.5S 23 25 55 11

CG50.1S 21 23 55 10

CG50.2S 22 24 58 11

CG50.3S 24 26 62 12

CG50.4S 25 27 65 12

CG50.5S 27 29 70 13

Width

‘W’

Height

‘H’

Length

‘L’ at Min

H & W*

Dimensions shown are for cast

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

Burner

Head Centerline to ﬂ oor ‘A’

Section: Pre-installation Checklist

Electrical Supply

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

Verify Burner Components

Burner model can be checked from burner carton or rating label on burner. Flange mounting arrangement (Includes high-temperature gasket and/or ﬁ ber rope for pressure ﬁ ring).

Verify Firing Input Range

Refer to appliance manufacturer’s instructions (if available) for the ﬁ ring input range. Otherwise the maximum recommended ﬁ ring range for the burner depends on the length and width of the ﬁ ring chamber and the distance from the burner center to the chamber ﬂ oor. Verify that the chamber dimensions are at least as large as the minimum values given in Figure 2. If the appliance dimensions are smaller, reduce the ﬁ ring rate accordingly.

Flames are shaped by their furnaces

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

The volume of the furnace also

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

Verify Burner Air Tube Assembly

The information in this section may be disregarded if

○

the burner supplied by the appliance manufacturer is a matched component.

Maximum ﬁ ring capacity depends on the furnace

○

pressure. Use the charts shown in Figure 3A, Figure 3B, and Figure 3C, to verify the correct burner

conﬁ guration for the input rate.

CG15, CG25, CG50 Burner Manual

Refer to Figures 4 & 5 to verify the air tube assembly

○

length and mounting insertion dimensions.

Section: Pre-installation Checklist

Figure 3A - Maximum Capacity (at 3% O2) vs Furnace Pressure - CG15, 60Hz.

Figure 3B - Maximum Capacity (at 3% O2) vs Furnace Pressure - CG25, 60Hz.

Figure 3C - Maximum Capacity (at 3% O2) vs Furnace Pressure - CG50, 60Hz.

Section: Pre-installation Checklist

Figure 4 - Burner Dimensions

DIM. A

O.D.

Model Dim. A Dim. B Dim. C Dim. D Dim. E Dim. F Dim. G Dim. H O.D. Pipe Thread

CG15 20.8 9.4 32.7 13.7 5.2 18.4 6.2 10.8 5.6 1-1/4 NPT

CG25 20.9 9.3 33.2 13.4 6.8 17.8 6.7 12.6 6.9 2 NPT

CG50 24.4 10.5 33.6 13.5 7.5 17.4 6.7 14.6 7.7 2-1/2 NPT

DIM. B

DIM. D

DIM. E

DIM. F

DIM. C

DIM. G

DIM. H

NOTE: All dimensions are in inches.

Figure 5 - Panel and Modulating Valve Dimensions

16.00

2.9

6.00

12.4

DIM. A

FEMALE PIPE THREAD

CG15, CG25, CG50 Burner Manual

DIM. B

Model Dim. A Dim. B Pipe Thread

CG15 5.12 11.75 1-1/4 NPT

CG25 5.12 11.75 2 NPT

CG50 5.81 13.25 2-1/2 NPT

*Dimensions are in inches

Section: Mount the Burner & Connect Gas Piping

Mount the Burner

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

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

Protect the Air Tube from Overheating

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

The end of the air tube must not extend into the

combustion chamber unprotected unless it has been factory-tested and speciﬁ ed by the appliance manufacturer.

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

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

Refer to the instructions outlined in this section for

methods of additional protection.

If this dimension cannot be achieved, protect the

○

end of the air tube by installing a suitable ceramic refractory material such as a refractory mill board capable of withstanding at least 2300 degrees F. The entry hole diameter in the appliance should be 1” larger than the air tube to facilitate ease of installation and provide adequate protection.

Referring to Figure 6, if the front plate opening (C)

○

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

Attach the plate and gasket to the boiler and tighten

○

the mounting nuts or bolts securely.

Verify that the air tube is ¼” back from ﬂ ush (see

○

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

Figure 6 - Custom Mounting Plate

Key:

A = Burner mounting ﬂ ange

B = Gasket

C = Appliance mounting plate

Connect Gas Piping

Do Not Use Teﬂ on Tape on Gas Piping

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

Pieces of tape can be cut loose during installation and

lodge in gas valves causing cutoff seal problems.

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

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

Use only pipe sealant compounds that are resistant to

the gas being used.

All gas piping installation must

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

The gas supply system must be sized to deliver at least the minimum required pressure to the gas train inlet. Contact your local gas utility for veriﬁ cation of gas pressures, allowable pressure drops, and any local piping code requirements. Refer to Figure 7 for an illustration of a gas piping layout and refer to Table 2 for pipe sizing.

Install a Drip Leg in Gas Supply Piping

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

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

Gas Trains

Gas Leaks and Explosion Hazards

Section: Connect Gas Piping

Pressure Drop curves of Figures 14A, 14B, and 14C are correct for both propane and natural gas. That is also why a gas train adjusted for the burner’s natural gas requirements will be correctly adjusted for its propane requirements. R. W. Beckett provides the same pressure regulating safety shutoff valve in the gas train (usually a Honeywell V4944B) for both natural gas and propane. The valve is marked for natural gas due to its primary usage in a pressure range normally used by natural gas appliances. It is safe and effective for propane usage in this design application.

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

Provide Over-pressure Protection

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

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

Propane (LP) – When the correct propane restrictor is added to a burner’s gas pipe assembly it changes the burner’s gas pressure drop so that the propane pressure drop is equal to the natural gas pressure drop of the same BTU ﬁ ring rate. That is why the Manifold to Furnace

Figure 7 - Typical Gas Piping Layout

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

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

ABBREV.

ITEM DESCRIPTION

HGPS

HIGH GAS PRESSURE SWITCH

LGPS

LOW GAS PRESSURE SWITCH

MSC

MAIN SHUTOFF COCK

MLTC

MAIN LEAK TEST COCK

PRESSURE GAUGE

STRAINER

SSOV1

SAFETY SHUTOFF VALVE #1

TEST COCK

UNION

2PRV

TWO POSITION REGULATING VALVE

METER

REGULATOR

GAS UTILITY PIPING

CG15, CG25, CG50 Burner Manual

DRIP LEG

FACILITY PIPING

(IF USED)

MSC

LGPS

SSOV1

2PRV

GAS TRAIN BURNER

MLTC

HGPS

BURNER

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