Beckett CG50 manual

COMMERCIAL PRODUCT S 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[...]

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3 CG15, CG25, CG50 Burner Manual Contents General Information .................................................... 4 Hazard De fi nitions ......................................................................... 4 Professional Installer ’s Responsibility ........................................... 5 Pre-installation Checklist ...................[...]

4 Hazard De fi nitions Gener al Inf or ma tion Indicates a hazardous situation which, if not avoided, will 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 . Indicates a hazardous situation, which, if not avoided, could result in de[...]

5 CG15, CG25, CG50 Burner Manual Pr e-installa tion Chec klist Indoor Installation 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 (NFP A 54). For appliance/burner unit[...]

6 CG15 CG25 CG50 Input Firing Range † : High Fire (Max.) High Fire (Min.) Low Fire (Max.) Low Fire (Min.) USA Canada USA Canada USA Canada 1,500 MBH 800 MBH 560 MBH 350 MBH 1,370 MBH 800 MBH 560 MBH 350 MBH 2,700 MBH 1,300 MBH 990 MBH 550 MBH ? MBH 1,300 MBH 990 MBH 550 MBH 5,000 MBH 2,000 MBH 1,400 MBH 730 MBH 4,000 MBH 2,000 MBH 1,400 MBH 730 M[...]

7 CG15, CG25, CG50 Burner Manual 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 NFP A 70 (Canada CSA C22.1) and all other local[...]

8 Figure 3A - Maximum Capacity (at 3% O 2 ) vs Furnace Pressure - CG15, 60Hz. Figure 3B - Maximum Capacity (at 3% O 2 ) vs Furnace Pressure - CG25, 60Hz. Figure 3C - Maximum Capacity (at 3% O 2 ) vs Furnace Pressure - CG50, 60Hz. Section: Pre-installation Checklist[...]

9 CG15, CG25, CG50 Burner Manual Figure 4 - Burner Dimensions Figure 5 - Panel and Modulating V alve Dimensions 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/[...]

10 Mount the burner to the appliance. The burner speci fi 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 retro fi ts, make sure that the air tube insertion dimension, measured along the side of the air tube f[...]

11 CG15, CG25, CG50 Burner Manual Figure 7 - T ypical Gas Piping Layout Gas T rains to Furnace 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 prov[...]

12 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 fi c gravity . Pipe size (inches) IPS Pipe length (feet) 0.75” 1.0” 1.25” 1.5” 2.0” 2.5” 3.0” 4.0” 10 278 520 1050 1600 3050 4800 8500 17500 20 190 350 7[...]

13 CG15, CG25, CG50 Burner Manual Figure 8A - UL Gas Train - High/Low and Low Fire Start Figure 8B - UL Gas T rain - Modulating ABBREV . HGPS LGPS MSC ML TC MV SSOV1 SSOV2 TC TP U 2PRSSOV ITEM DESCRIPTION HIGH GAS PRESSURE SWITCH LOW GAS PRESSURE SWITCH MAIN SHUTOFF COCK MAIN LEAK TEST COCK MODULA TION V AL VE SAFETY SHUT OFF V AL VE #1 SAFETY SHUT[...]

14 W ir e the Bur ner Install the burner and all wiring in accordance with the National Electric Code ANSI/NFP A 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 . V erify operation of all controls in accordance with the appliance[...]

15 CG15, CG25, CG50 Burner Manual Figure 9A - T ypical Wiring Using Model RM7897C for High/Low Control (For Reference Only) continuing to detect a fl ame, the burner will operate in the RUN mode until the load demand is satis fi ed or a limit opens. For High/Low control wiring ( Figure 9A ), if terminals RC1 and RC2 are jumpered, the burner opera[...]

16 Figure 9B - T ypical Wiring Using Model RM7840L for Modulating Control (For Reference Only) Section: Sequence of Operation[...]

17 CG15, CG25, CG50 Burner Manual Pr epar e the Bur ner f or Star t-up Start-up Checklist V erify the following before attempting to start the burner . 1. General Carefully read and become familiar with the manual, fl ame safeguard control instructions, sequence of operation, pertinent wiring diagrams, gas system layout, insurance requirements, ot[...]

18 Star t the Bur ner Initial Air Settings If your burner was built for a speci fi c OEM (Original Equipment Manufacturer) application, the “Mfr ’s Settings” label (see Figure 1 ) will indicate the application and the initial air settings made at Beckett. Please verify those settings using the following procedure. If your burner was not buil[...]

19 CG15, CG25, CG50 Burner Manual Figure 10A - Damper Motor with Cover Figure 10B - Damper Motor with Cover Removed Push in on pin ( G ) to disengage the motor from the damper shaft and cam stack. Rotate the damper shaft by hand to place the adjustment cams in a position where their adjustment scale can be easily seen. Release pin ( G ) to secure t[...]

20 Optional Modulation Linkage Adjustment Instructions The optional modulation linkage assembly has been designed as an economic means to adjust the damper and the butter fl y valve to maintain air to gas ratios. When the optional Modulation linkage assembly is supplied with the burner , initial adjustments will be made at the factory . T o ensure[...]

21 CG15, CG25, CG50 Burner Manual T able 3 - Initial Burner Settings for Both Propane & Natural Gas Furnace Pressure at High Fire 0” W .C. 0.25” W .C. 0.50” W .C. 1.00” W .C. High Fire Rate MBH Low Fire Rate MBH Burner Model Low Fire Gas Pressure, inch WC Low Fire Damper Setting High Fire Gas Pressure, inch WC High Fire Damper Setting L[...]

22 Figure 13A - Display Meaning Modulation Control Modulation of the burner ’s fi ring rate is accomplished by driving the damper motor in small increments to either increase or decrease rate in response to boiler demand. A pressure transducer (for steam boilers) or temperature sensor (for water boilers) senses boiler demand and communicates it [...]

23 CG15, CG25, CG50 Burner Manual V erify Input Firing Rate Clock the meter , correct for pressure and termperature to get SCFH and calculate the input fi ring rate. Compare the calculated rate to the speci fi ed input for the boiler found on the speci fi cation sheets and on the rating plates for the burner and boiler . Do not exceed the speci [...]

24 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. T o estimate the burner ’s fi ring rate: Measure the furnace pressure over fi re Measure the manifold pressure (at the manifold pressure test connection). Subtract the furnace p[...]

25 CG15, CG25, CG50 Burner Manual Figure 14A - Manifold to Furnace Pressure Drop vs Rate CG15 * Figure 14B - Manifold to Furnace Pressure Drop vs Rate CG25* 0 200 400 600 800 1000 1200 1400 1600 1800 0 0 .5 1 1 .5 2 2 .5 3 3 .5 4 4 .5 Pressure Drop, In. WC Rate, MBH C G 15. 4S C G 15. 3S C G 15. 2S C G 15. 1S 0 500 1000 1500 2000 2500 3000 3500 0 0[...]

26 Check Operation and Safety Controls Figure 14C - Manifold to Furnace Pressure Drop vs Rate CG50* 0 1000 2000 3000 4000 5000 6000 0 0 .5 1 1 .5 2 2 .5 3 3 .5 4 4 .5 Pressure Drop, In. WC Rate, MBH C G 50. 5S C G 50. 4S C G 50. 3S C G 50. 2S C G 50. 1S * Charts represent both natural and propane gas. T esting by Quali fi ed T echnician Required. [...]

27 CG15, CG25, CG50 Burner Manual High gas pressure switch – With the burner fi ring and a manometer attached to the test port nearest the high pressure switch, gradually increase the gas pressure until the high pressure switch opens and shuts the burner off. Note the pressure and manually reset the switch. The high gas pressure switch should be[...]

28 Maintenance and Ser vice Annual Maintenance (The following should be performed by a quali fi ed service technician only .) Burner: Run the burner and perform a complete combustion test using the proper instruments before proceeding. If necessary refer to the section labeled Start the Burner . Record the results for reference. Inspect and clean [...]

29 CG15, CG25, CG50 Burner Manual Check barometric damper or draft hood for proper operation. Inspect boiler sections and system load piping for possible leaks. Make all necessary repairs. Check all operating and safety controls on the boiler for proper installation and operation. Perform all maintenance and tests according to the burner control ma[...]

30 Burner Head Adjustment - There is an optimum gas ori fi ce size and burner head setting for each fi ring rate of the burner . The gas ori fi ce size sets the gas fl ow velocity; the head setting establishes the air fl ow velocity . When those velocities are properly matched the burner provides its best performance and stability . The gas or[...]

31 CG15, CG25, CG50 Burner Manual Propane Restrictor Description The Beckett Propane Restrictor Conversion Kit allows for the conversion of CG15, CG25, and CG50 burners for use with propane gas. With the proper installation of the restrictor and attached O-ring, adjustments and settings for propane use will be the same as the adjustments and settin[...]

32 T able 4 - Propane Restrictors Replacement Part Numbers Burner Model Restrictor Part Number Restrictor Inside Diameter O-Ring Part Number CG15.1S 3246709U 0.532 3226401U CG15.2S 3246710U 0.576 3226401U CG15.3S 324671 1U 0.623 3226401U CG15.4S 3246712U 0.677 3226401U CG25.1S 3246713U 0.712 3226402U CG25.2S 3246714U 0.742 3226402U CG25.3S 3246715U[...]

33 CG15, CG25, CG50 Burner Manual For the Operator T est/Inspection Frequency Comments Inspect area surrounding heating plant Daily Keep area clean and free of clutter Inspect gas supply system for leaks Daily Use visual and electronic leak detection Inspect appliance & piping for water leaks Daily Keep burner and controls dry at all times Insp[...]

34 R eplacement P ar ts For best performance specify genuine Beckett replacement parts. Note 1: See Burner Con fi guration T able. 1 2 8 3 4 5 12 13 14 7 6 19 18 17 16 15 21 24 25 20 23 22 11 9 10 26 27[...]

35 CG15, CG25, CG50 Burner Manual Item Description CG15 Part No. CG25 Part No. CG50 Part No. 1 Timer (if used) 21295U 21295U 21295U 2 Air Proving Switch 22181U 22181U 22182U 3 Ignition Transformer 7503U 7503U 7503U 4 Spring Latch (Dzus Fastener) 32444U 32444U 32444U 5 Sight Glass** 31346U 31346U 31346U 6 Rear Access Door* For UV For Flame Rod 52013[...]

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 BCF50 R13, Printed in the U.S.A. 06/10 The R. W . BECKETT CORPORA TION (“Beckett”) warrants to persons who purchase its “Products” from Beckett for resale, or for incorpo[...]