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COMMERCIAL PRODUCTS
Fire, Explosion and Asphyxiation Hazards
Failure to follow these instructions exactly could lead to fi re or explosion and result in
death, severe personal injury or property damage.
1. Do not store or use gasoline or other fl ammable vapors and liquids in the vicinity of this or any other appliance.
2.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.
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Contents General Information .................................................... 3 Hazard Defi nitions: ........................................................................3 Owner’s Responsibility: .................................................................3 Professional Installer’s Responsibility: ..........................................4 Specifi cations ................................................................................4 Pre-installation Checklist ......................
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Section: General Information General Information To the Owner: Hazard Defi nitions: Thank you for purchasing a Beckett CG10 burner for use with your heating appliance. Please Indicates a hazardous pay attention to the Safety Warnings contained within this instruction manual. Keep this manual for situation which, if not your records and provide it to your qualifi ed service avoided, will result in death or serious injury. agency for use in professionally setting up and maintaining your bu
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Section: General Information Professional Installer’s Responsibility: Specifi cations Table 1 – Burner Specifi cations Follow these instructions Input fi ring range 300 to 1200 MBh exactly. Fuel Natural gas - 0.6 specifi c gravity typical Failure to follow these instructions could Gas train Standard: UL listed/CSD-1 Confi guration lead to equipment malfunction and result Options: IRI and FM in asphyxiation, explosion or fi re. Manifold pressure 1.0 to 4.6 inches W.C. typical Firing mode On/Off or O
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Section: Pre-installation Checklist Figure 1. Burner Nameplate General Model Information R.W. Beckett Serial Number, Construction and Setting Data Including Date Code R.W. Beckett Specifi cation Rating Information Number and Revision Approval Agency Symbols Boiler Manufacturer and Model, When Applicable Primary Group Additional Codes and Fuel Pre-installation Checklist Combustion air supply Indoor Installation Adequate Combustion and Protect against Dust and Ventilation Air Supply Moisture
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Section: Pre-installation Checklist ○ Flange mounting arrangement (Includes high- temperature gasket and /or fi ber rope for pressure Test For Gas Pipe Leaks fi ring). Leaking gas could result in asphyxiation, explosion, or fi re hazard. Verify fi ring input range The gas supply piping must be absolutely leak-free. Refer to appliance manufacturer’s instructions (if Pressure test the gas piping with air that is at least available) for the fi ring input range. Otherwise the three times greater
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Section: Pre-installation Checklist Flames are shaped by their Verify burner air tube assembly furnaces and by its fl ue locations. Increased height and width can decrease the length ○ The information in this section may be disregarded if requirement. When shaping is too severe fl ames the burner supplied by the appliance manufacturer is impinge on the walls. Impingement causes CO and a matched component. carbon deposits and may damage the wall. Maintaining ○ Maximum fi ring capacity de
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Section: Pre-installation Checklist Figure 5. Burner Dimensions Burner Model Airtube Dim. A Dim. B O.D. 10.1 - 10.3, 10.1S - 10.3S 51927 25.0” 11.7” 4.43” 10.4 - 10.6 51928 26.0” 12.7” 4.86” 10.4S - 10.6S 51961 25.7” 12.5” 4.61” 8
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Section: Mount the Burner & Connect Gas Piping Figure 6. Custom Mounting Plate 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 C of burner air tube, is corre
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Section: Connect Gas Piping Figure 7. Typical Gas Piping Layout ABBREV. ITEM DESCRIPTION HGPS HIGH GAS PRESSURE SWITCH LGPS LOW GAS PRESSURE SWITCH MSC MAIN SHUTOFF COCK MLTC MAIN LEAK TEST COCK PG PRESSURE GAUGE S STRAINER SSOV1 SAFETY SHUTOFF VALVE #1 TC TEST COCK U UNION 2PRV TWO POSITION REGULATING VALVE LGPS HGPS METER BURNER REGULATOR PG U U TC MLTC TC DRIP LEG MSC SSOV1 2PRV TC U S (IF USED) FACILITY PIPING GAS UTILITY PIPING GAS TRAIN BURNER Table 1. Gas supply piping capacity Schedule 4
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Section: Connect Gas Piping by natural gas appliances. It is safe and effective for Vent lines – Install vent lines to any gas valve component propane usage in this design application. that requires atmospheric air pressure to balance a diaphragm. Vent lines must be run to the outdoors, with Optional – Gas trains for IRI and FM are available and the termination point away from fresh air intakes and must be specifi ed when ordering a burner. windows. The terminal opening must be fi tted with
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Section: Wire the Burner Wire the Burner Electrical Shock Hazard Install the burner and all wiring in accordance with the Electrical shock can cause severe National Electric Code ANSI/NFPA 70 (Canada CSA personal injury or death. C22.1) and all applicable codes and requirements. Wire the burner in compliance with all instructions and diagrams provided by the appliance manufacturer. Disconnect electrical power before installing or Verify operation of all controls in accordance with the
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Section: Sequence of Operation & Prepare the Burner for Start-up Sequence of Operation Prepare the Burner for (Typical for RM7897A fl ame safeguard primary control) Start-up 1. Initiate – The primary control enters the INITIATE sequence when the control is fi rst powered on or power returns after an interruption. The initiate sequence is a ten second delay during which the Professional Installation control verifi es line voltage stability. & Service Required 2. Standby – The control enters S
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Section: Prepare the Burner for Start-up Start-up checklist ○ Set the breech damper to the required position for Verify the following before attempting to start system operation. the burner: ○ Fill the appliance with water (boilers). ○ Check all safety and operating controls for correct 1. General application, installation, wiring, and operation. ○ Insure that the maximum capacity of the appliance is ○ Carefully read and become familiar with the CG10 compatible with the specifi ed burner
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Section: Prepare the Burner for Start-up Figure 10. CG10 component familiarization Major Components Item Description 1 Jacking Screw 2 Ignition Transformer 3 Primary Control 4 Blower Motor 5 Air Flow Proving Switch 6 Electrode Cable* 7 UV Flame Detector (if used) 8 Shutter 9 Air Band 10 High Gas Pressure Switch 11 Manifold Pressure Test Connection 12 Gas Gun Assembly *Unplug form transformer when servicing CG10 Burner Manual 15
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Section: Start the Burner Start the Burner 4. In order to check the function of each component Professional Installation (i.e: fl ame safeguard sequence, airfl ow proving switch, ignition transformer, gas valves, safety and Service Required lockout timing, etc.), with the gas supply closed off, Incorrect installation and mishandling monitor a complete burner run sequence. Note that of start-up could lead to equipment the fl ame safeguard control will lock out since the malfunction and resu
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Section: Start the Burner Figure 11. Shutter and Band The shutter and band both control the amount of fl ow area available for air inlet to the burner. The greater their BAND INDICATOR MARK combined fl ow area, the higher the fi ring rate. The primary differences between the two are their ease of SHUTTER INDICATOR adjustment and their total airfl ow area. The shutter turns more easily and has a smaller net fl ow area. As a result we have found the shutter to be better suited for low rate
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Section: Start the Burner Estimating Rate Manifold to Furnace Pressure information can be used to estimate the burner’s fi ring rate when it is not possible to clock a meter for the rate. To estimate the burner’s fi ring rate: Measure the furnace pressure over fi re Measure the manifold pressure (at the manifold pressure test connection in Figure 10). Subtract the furnace pressure from the manifold pressure Compare the result to the data in Figure 12 or 13 as appropriate for your burner. Clo
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Section: Start the Burner Figure 12. Manifold to Furnace Pressure Drop vs. Rate - Stepped Spud Design 1400 1200 CG10.6S 1000 CG10.5S CG10.4S 800 CG10.3S CG10.2S 600 CG10.1S 400 200 0123456 Pressure Drop, In. WC Figure 13. Manifold to Furnace Pressure Drop vs. Rate - Swirl Vane Head Design 900 800 700 600 CG10.3 500 CG10.2 CG10.1 400 300 200 100 012345 Pressure Drop, In. WC CG10 Burner Manual 19 Rate, MBH Rate, MBH
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Section: Start the Burner 4. Airfl ow proving switch – With the burner fi ring at Check operation and safety controls its lowest rate, loosen the tubing connection to the airfl ow proving switch. A loss in air pressure at the Testing by Qualifi ed tubing should immediately cause the diaphragm in the switch to open and recycle or lockout the Technician Required. safeguard control. Failure to properly test and verify the correct 5. Low gas pressure switch – With the burner fi ring function of op
