Weil-McLain UO-3 CV, UO-5 CV, UO-4 CV User Manual

R02 01/09

AF/AFG

AF/AFG

Oil Burner Manual

Oil Burner Manual

RESIDENTIAL BURNERS

Potential for Fire, Smoke and Asphyxiation Hazards

Incorrect installation, adjustment, or misuse of this burner could result in death, severe personal

injury, or substantial property damage.

To the Homeowner or Equipment Owner:

Please read and carefully follow all instructions

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provided in this manual regarding your
responsibilities in caring for your heating
equipment.
Contact a professional, qualifi ed service agency

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for installation, start-up or service work.
Save this manual for future reference.

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6104BAFG R05 Page 1

To the Professional, Qualif ed Installer or
Service Agency:

Please read and carefully follow all instructions

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provided in this manual before installing,
starting, or servicing this burner or heating
system.
The Installation must be made in accordance

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with all state and local codes having jurisdiction.

Table of Contents

Hazard Def nitions and Owner’s Information ........................................................................................3

Information To Be Used Only By Qualif ed Service Technicians

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

Table 1 Burner Specifi cation ................................................................................................................................4

Notice Special Requirements ..............................................................................................................................5

Table 2 Air Tube Combination (ATC) Codes ………………………………………………………….. .....................5

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

Inspect Chimney or Direct Vent System ..............................................................................................................6

Combustion Air Supply ........................................................................................................................................7

Clearances to burner and appliance ...................................................................................................................7

Combustion chamber - Burner Retrofi tting ..........................................................................................................7

Prepare the Burner ...........................................................................................................................................8

Low Firing Rate Baffl e ............................................................................................................................ .............8

Burner Fuel Unit ..................................................................................................................................................8

Attach Air Tube ....................................................................................................................................................8

Nozzle and Pump Pressure .................................................................................................................................8

Install Burner Nozzle ...........................................................................................................................................8

Check/Adjust Electrodes .....................................................................................................................................9

Servicing nozzle line assembly ...........................................................................................................................9

Check/Adjust ‘Z’ Dimension - F Heads .............................................................................................................10

Check/Adjust ‘Z’ Dimension - L & V Heads .......................................................................................................11

Mount burner on appliance ...........................................................................................................................9

Mounting Options ................................................................................................................................................9

Mounting Dimensions ..........................................................................................................................................9

Installing the Oil Tank & Supply System ............................................................................................................12

Fuel Line Valves & Filter ....................................................................................................................................12

Wire Burner .......................................................................................................................................................13

Burner Packaged with Appliance .......................................................................................................................13

Burner Installed at Job Site ...............................................................................................................................13

Special Wiring Required with Covered Burners ................................................................................................13

Burner Control .................................................................................................................................................14

GeniSys Model 7505 Control ............................................................................................................................14

Wiring ................................................................................................................................................................14

Typical Burner Sequence of Operation for GeniSys 7505 Control ....................................................................15

Typical Burner Sequence of Operation for R7184P Control ..............................................................................17

Start-up Burner/Set Combustion ..............................................................................................................18

Startup/checkout ...............................................................................................................................................19

Set Combustion with Instruments ......................................................................................................................19

Perform Regular Maintenance ...................................................................................................................20

Parts Diagram ...................................................................................................................................................22

Beckett Limited Warranty Information ...................................................................................................24

Page 2 6104BAFG R06

Hazard Defi nitions

!

!

General Information

!

DANGER

Indicates a hazardous situ-

ation, which, if not avoided,

will result in death or serious injury.

!

WARNING

Indicates a hazardous

situation, which, if not

avoided, could result in death or serious
injury.

!

CAUTION

Indicates a hazardous

situation, which, if not

avoided, could 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 heeded and instructions on how to avoid

the hazard.

NOTICE

information, but not related to personal injury or property

damage.

Intended to bring special attention to

WARNING

!

Incorrect installation, adjustment,

and use of this burner could result in
severe personal injury, death, or sub­stantial property damage from fi re,

carbon monoxide poisoning, soot or explosion.

Contact a professional, qualifi ed service agency for the

installation, adjustment and service of your oil heating
system. 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:

Never store or use gasoline or other fl ammable

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liquids or vapors near this burner or appliance.
Never attempt to burn garbage or refuse in this

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appliance.
Never attempt to light the burner/appliance by

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throwing burning material into the appliance.
Never attempt to burn any fuel not specifi ed and

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approved for use in this burner.
Never restrict the air inlet openings to the burner

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or the combustion air ventilation openings in the
room.

Owner’s Responsibility

NOTICE

appear to be basically identical, but there are differences in design and performance. Please review the comparison

chart below:

Feature AF AFG

Static Pressure Capability Conventional - Low range Enhanced - Medium range
Blower Wheel Design Standard strip Special tablock

Inlet Airfl ow Design Standard inlet bell Special airguide
UL Air Tube Combinations “F” Series ONLY “F” or “M” Series
Igniter Gaskets Baseplate/Barrier Optional, as specifi ed Required, always specifi ed
Low Firing Rate Baffl e Not required Required, per specifi cation

This manual contains information that applies to both AF and AFG burners. These burners may

Figure 1. Burner label location

6104BAFG R06 Page 3

General Information

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 oil
burner.

Your Beckett burner will provide years of effi cient op-

eration 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, im-
mediately contact your quali f ed service agency
for consultation.

We recommend annual inspection/service of your

oil heating system by a qualif ed service agency.

Daily – Check the room in which your burner/appli-

ance is installed. Make sure:

Air ventilation openings are clean and unobstruct-

•
ed
Nothing is blocking burner inlet air openings

•
No combustible materials are stored near the heat-

•
ing appliance
There are no signs of oil or water leaking around

•
the burner or appliance

Weekly

Check your oil tank level. Always keep your oil tank

•
full, especially during the summer, in order to pre­vent condensation of moisture on the inside surface
of the tank.

!

WARNING

Impaired Burner Perfor-

mance and Fire Hazard.

Do NOT operate the burner beyond specif ca-

tions outlined in the following Table.

For applications beyond these limits, consult

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Beckett Technical Service at 1-800-645-2876.
NOTE: Some packaged appliances with burners

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may be agency listed as a unit to operate beyond
these limits. Consult the appliance manufac­turer’s specifi cations and agency approvals for
verifi cation.

Table 1 – Burner Specif cations

Capacity
(Note 1)

Certifi cations/

Approvals

Fuels U. S No. 1 or No. 2 heating oil only (ASTM D396)

‘F’ Head (AF & AFG)

Firing rate range: ..............0.40 – 3.00 GPH

Input: ....................... 56,000 – 420,000 Btu

‘L1’ Head (AFG Only)

Firing rate range: ..................0.40 - 1.10 GPH

Input: .....................56,000 – 154,000 Btu/h

‘L2’ Head (AFG Only)

Firing rate range: .................0.50 - 1.00 GPH

Input: ......................70,000 – 140,000 Btu/h

‘V1’ Head (AFG Only)

Firing rate range: .................0.75 - 2.75 GPH

Input: ....................105,000 – 385,000 Btu/h

UL listed to comply with ANSI/UL296 and CSA-B140.0

Canada No. 1 stove oil or No. 2 furnace oil only

CAUTION

!!

DO NOT USE GASOLINE, CRANKCASE OIL,

OR ANY OIL CONTAINING GASOLINE.

Electrical Power supply:............ 120 volts AC, 60 Hz single phase

WARNING

!

Do NOT Alter the Original

Burner Design

Tampering with or altering the burner design

could seriously impair performance, resulting
in loss of static pressure, damage to the system
components, reduced air volume, heavy smoke,
fl ame impingement, appliance sooting, hot gas
puff-back, and asphyxiation or fi re hazards.

Maintain the design to its original confi guration.
Only use parts specifi ed for AF or AFG Burners
Do NOT remove the air guide from the AFG chassis.
Do NOT use ‘M’ Series air tube combinations on AF Burn-

ers.
Never try to convert an AF to an AFG or vice versa
Any design alteration will:

Void UL Listing

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Void manufacturer’s warranties

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Seriously impact burner performance

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Greatly increase your liability risk

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Page 4 6104BAFG R06

Fuel pump

Air tube ATC code: ...................................See Table 2

Dimensions
(with cover)

Ambient

Operating
Temperature

Moisture 5% to 95% RH, non-condensing and non-crystallizing

Operating load: .......... Amps max

Motor: .........................1/7 hp, 3450 rpm, NEMA 48M frame

PSC rotation CCW when facing
shaft end

Ignition: ......................Continuous duty solid-state igniter

Outlet pressure: ..................................Note 2

Height (maximum) .......................12.5 inches

Width (maximum) ..........................15 inches

Depth .........................................9.25 inches

Air tube diameter ....................... 4.00 inches

+32o F. (0 C.) Minimum
+115o F. (+46 C.) Maximum

(See above Warning)

Note 1: Approval agency listed rating for these burners is 0.40 to 3.00

gph. However, the fi ring rate range is limited by the specifi c
air tube combination being used. Refer to Table 2.

Note 2. See appliance manufacturer ’s burner specifi cations for rec-

ommended pump discharge pressure.

General Specifi cations

Table 2 – Air Tube Combination (ATC) codes

Firing

Rate

(gph)

(min-

max)

0.50-0.75 F0 3-3/8U None AF44XR - AF53XR AF65XR - AF72XR AF90XR AF104XR AF130XR A160XR

0.75-1.25 F3 2-3/4U None AF44XN - AF53XN AF65XN - AF72XN AF90XN AF104XN AF130XN AF160XN

0.85-1.35 F4 2-3/4U None AF44WH - AF53WH AF65WH - AF72WH AF90WH AF104WH AF130WH AF160WH

0.85-1.65 F6 2-3/4U None AF44YB - AF53YB AF65YB - AF72YB AF90YB AF104YB AF130YB AF160YB

1.10-2.00 F12 2-3/4U None AF44XO - AF53XO AF65XO - AF72XO AF90XO AF104XO AF130XO AF160XO

1.65-2.50 F22 2-3/4U None AF44XP - AF53XP AF56XP - AF72XP AF90XP AF104XP AF130XP AF160XP

2.50-3.00 F31 None None AF44XS - AF53XS AF65XS - AF72XS AF90XS AF104XS AF130XS AF160XS

0.50-1.10 L1 3-3/8U 8hole - AFG50MB - - AFG70MB - AFG90MB - - -

0.50-1.00 L2 2-3/4U 8hole AFG50MP - - AFG70MP - AFG90MP - - -

0.75-2.75 V1 2-3/4U 8hole - AFG50MD - - AFG70MD - AFG90MD - - -

0.40-0.75 F0 3-1/2U None AF44WG - AF53WG AF65WG - AF72WG AF90WG AF104WG AF130WG A160WG

Head Static

plate

size

(inches) 4-1/2 5 5-3/8 6-5/8 7 7-1/4 9 10-1/2 13 16

Ven-

turi

ATC Codes for usable air tube lengths

(‘A’ in inches; See Figure 3.)

Notice Special Requirements

THE INSTALLATION OF A BURNER SHALL BE

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IN ACCORDANCE WITH THE REGULATIONS
OF AUTHORITIES HAVING JURISDICTION.
For recommended installation practices in the

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U.S. refer to the latest edition of NFPA 31. (CSA­B139 and CSA-B140 in Canada.
Concealed damage — If you discover damage to

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the burner or controls during unpacking, notify the
carrier at once and fi le the appropriate claim.
When contacting Beckett for service information

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— Please record the burner serial number (and
have available when calling or writing). You will
fi nd the serial number on the silver label located
on the left rear of the burner. Refer to Figure 1.

WARNING

!

Professional Service

Required

Incorrect installation, adjustment,

and use of this burner could result
in severe personal injury, death, or

substantial property damage from
fi re, carbon monoxide poisoning, soot or explo­sion.

Please read and understand the manual supplied with

this equipment. This equipment must be installed, ad­justed and put into operation only by a qualifi ed individu-
al or service agency that is:

Licensed or certifi ed to install and provide tech-

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nical service to oil heating systems.
Experienced with all applicable codes, standards

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and ordinances.
Responsible for the correct installation and com-

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mission of this equipment.
Skilled in the adjustment of oil burners using

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combustion test instruments.

The installation must strictly comply with all applicable

codes, authorities having jurisdiction and the latest revi­sion of the National Fire Protection Association Standard
for the installation of Oil-burning Equipment, NFPA 31
(or CSA-B139 and CSA-B140 in Canada).

Regulation by these authorities take precedence over

the general instructions provided in this installation

6104BAFG R06 Page 5

Inspect/Prepare Installation Site

Inspect Chimney or Direct Vent System

WARNING

!

Carefully inspect the chimney or exhaust vent

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system.
Make sure it is properly sized and in good work-

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ing condition.
Follow the instructions supplied by the appliance

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manufacturer.
The installation must strictly comply with all ap-

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plicable codes, authorities having jurisdiction and
the latest revision of the National Fire Protection
Association Standard NFPA 31 for the installa­tion of chimneys and vent sizing, (or CSA-B139
and CSA-B140 in Canada).
Regulation by these authorities take precedence

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over the general instructions provided in this in­stallation manual.

Starting with minimum gph fi ring rate, the mini-

1.
mum size recommended is 6” fl ue pipe with 8” X
8” inside chimney, unless specifi ed otherwise by
the appliance manufacturer.
A chimney fl ue shall extend at least 3 feet above

2.
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 2.
Any accumulation of soot or debris in chimney

3.
offsets should be removed
Any obstructions such as a protruding joint or a

4.
piece of broken tile wedged in the chimney should
be removed.

Fire, Smoke & Asphyxia-

tion Hazard

No other appliance connection should be made to

5.
the same fl ue pipe.
The fl ue pipe should have an upward pitch toward

6.
the chimney of at least 1/4” per foot of length. It
should fi t tightly and should not project into the
chimney.
Any leakage between tiles, around clean-out

7.
doors, or around the vent pipe should be sealed.

INSULATED STAINLESS STEEL CHIMNEY LINERS

The new designs of high effi ciency oil furnaces

and boilers in conjunction with fl ame retention oil
burners are more effi cient. One result of increased
effi ciency is lower fl ue gas temperatures. As
fl ue gases rise in the chimney, they will cool and
condense when they reach the dew point. The
condensation will mix with the sulphur in the fl ue
gases creating sulphuric acid. The acid will attack
the chimney mortar, brick and clay liners caus­ing corrosion, deterioration and blockage of the
chimney. Eventually the blockage could prevent
exhausting the fl ue gases. Instead, the fl ue gases
could vent out the barometric damper into the liv­ing space.

Therefore, it is strongly recommended that an ap-

proved insulated stainless steel liner be installed.

For those installations not requiring a chimney,

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

Figure 2 – Chimney Design - Above the Roof

NOTE: Correct

chimney design is
shown by dotted
lines. Incorrect
chimney design,
as shown by the
solid lines, may
result in down­drafts.

Page 6 6104BAFG R06

Combustion air supply

WARNING

!

Adequate Combustion

and Ventilation Air Supply
Required

Failure to provide adequate air supply could

seriously affect the burner performance and re­sult in damage to the equipment, asphyxiation,
explosion or fi re hazards.

The burner cannot properly burn the fuel if it is not

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supplied with a reliable combustion air source.
Follow the guidelines in the latest editions of the

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NFPA 31 and CSA-B139 regarding providing ad­equate air for combustion and ventilation.

Appliance located in confi ned space
The confi ned space should have two (2) permanent

openings: one near the top of the enclosure and
one near the bottom of the enclosure. Each open­ing shall have a free area of not less than (1) one
square inch per 1,000 BTU’s per hour of the total
input rating of all appliances within the enclosure.
The openings shall have free access to the build­ing interior, which should have adequate infi ltration
from the outside.

Exhaust fans and other air-using devices
Size air openings large enough to allow for all air-

using devices in addition to the minimum area re­quired for combustion air. If there is any possibility
of the equipment room developing negative pres­sure (because of exhaust fans or clothes dryers, for
example), either pipe combustion air directly to the
burner or provide a sealed enclosure for the burner
and supply it with its own combustion air supply.

Inspect/Prepare Installation Site

Outside air kit applications
Refer to separate instruction sheet supplied with

AF/AFG outside air kit for installation. This optional
kit allows combustion air to be piped directly to the
burner (Beckett part number 51747).

Clearances to burner and appliance

Provide space around burner and appliance for

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easy service and maintenance.
Check minimum clearances against those shown

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by the appliance manufacturer and by applicable
building codes.

WARNING

!

Failure to comply could result in damage to the

heating equipment and result in fi re or asphyxi-
ation hazards.

When retrofi tting appliances that have unlined

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stainless steel combustion chambers, protect
the chamber by lining the inside surfaces with a
ceramic fi ber blanket, such as a wet-pac or other
suitable refractory material.
Some steel chambers may not require liners

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because the appliance was designed and tested
for use with fl ame retention burners. Refer to the
manufacturer’s instructions.

Combustion chamber — Burner retrof t­ting

Verify that the appliance combustion chamber pro-

vides at least the minimum dimensions given in
Table 3.

Protect Steel Combustion

Chamber From Burnout

Direct air supply and sidewall venting

Some AFG burners are equipped with combus-

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tion air boots to allow use of outside air for com­bustion.

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When sidewall venting appliances, carefully fol­low appliance and power venter instructions for
installation and wiring.

WARNING

!

Follow the Outside Air Kit
Instructions Exactly

Failure to comply could result in impaired com-

bustion, appliance soot-up, puffback of smoke,
and fi re or asphyxiation hazards.

Do not attempt to install outside air piping to

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the burner without using the outside air kit and
instructions.

6104BAFG R06 Page 7

Table 3. Chamber Dimensions

Chamber Dimensions (inches)

Firing Rate

(GPH)

0.50 8 7 8 12 5-6

0.75 9 8 9 12 5-6

1.00 10 9 10 12.5 5-6

1.25 11 10 11 12.5 5-6

1.50 12 11 12 13 6-7

2.00 14 12 15 13.5 6-7

2.50 16 13 17 14 7-8

3.00 18 14 18 15 7-8

Round

I.D.

Rectangular Height Floor to

Width Length

nozzle