Beckett AF User manual

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
provided in this manual regarding your
responsibilities in caring for your heating
equipment.
Contact a professional, qualified service agency
for installation, start-up or service work.
• Save this manual for future reference.
To the Professional, Qualified Installer or
Service Agency:
*Pleaseread and carefullyfollow all instructions
provided in this manual before installing,
starting, or servicing this burner or heating
system,
The Installation must be made in accordance
with all stateand local codes havingjurisdiction,

Table of Contents
Hazard Definitions and Owner's Information ........................................................................................ 3
General Information .........................................................................................................................................4
Table 1 Burner Specification ................................................................................................................................ 4
Notice Special Requirements .............................................................................................................................. 5
Table 2 Air Tube Combination (ATC) Codes ......................................................................................... 5
lnspectlPrepare Installation Site .................................................................................................................6
Inspect Chimney or Direct Vent System .............................................................................................................. 6
Combustion Air Supply ........................................................................................................................................ 7
Clearances to burner and appliance ................................................................................................................... 7
Combustion chamber - Burner Retrofitting .......................................................................................................... 7
Prepare the Burner ...........................................................................................................................................8
Low Firing Rate Baffle ......................................................................................................................................... 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 BurnedSet Combustion ..............................................................................................................18
Startup/checkout ............................................................................................................................................... 19
Set Combustion with Instruments ...................................................................................................................... 19
Perform Regular Maintenance ...................................................................................................................2o
Parts Diagram ...................................................................................................................................................22
Beckett Limited Warranty Information ...................................................................................................24
Page 2 6104BAFG R04

General information
Hazard Definitions
indicates a hazardous situ-
ation, 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.
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.
Intended to bring special attention to
information, but not related to personal injury or property
damage.
Owner's Responsibility
Incorrect installation, adjustment,
and use of this burner could result in
severe personal injury, death, or sub-
stantial property damage from fire,
carbon monoxide poisoning, soot or explosion.
Contact a professional, qualified service agency for the
installation, adjustment and service of your oil heating
system. This work requires technical training, trade ex-
perience, licensing or certification 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 flammable
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 specified 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.
This manual contains information that applies to both AF and AFG burners. These burners may
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 Airflow Design Standard inlet bell Special airguide
ULAir Tube Combinations "F" Series ONLY "F" or "M" Series
Igniter Gaskets Baseplate/Barrier Optional, as specified Required, always specified
Low Firing Rate Baffle Not required Required, per specification
Figure 1. Burner label location
Generalm0del
Information
Serial number,-
including date code
Rating Information-
Approvalagency--
symbols
Primary group --
and fuel oH
Model" AFG"
Series0il Burner
SERIAL NUMBER
000405-62736
IIIIIIlllilllHIIIIIIIlU
0.O0-3.00GPH,lo0V/S0HZ5O0
USTED@.
OIL BURNER NO. R-I00001
R,W,Beckett Corp.
_/o0,o_o
Uode_nt_eUSA
Fo_u_ w_hGrip1 _ 2
kppr_o_ulyi,19O0
MP1192 NB_O01 O00
MFR'SSE]-rlNGS
ATC: _O0XN
RIO0_: 0,75-LO0GPH
sic Ptl:
NOZZLE: 1.0X80B0tVN
P_P PO0: 1001,9
BJBS001 R00
000405-62736
4 ULTESTsoot
5 ULTOOTSP[C
6 ULTO0TSPEC
7ULIEST SPEC
8 ULTEST SPO0
9 ULTF3,_r SPZC
Sto_en _0m_
NOPr_l BEC-O041
A_pted N.Y.C._Ek 21_-83-E
6104BAFG R04
-- R.W.Beckett
manufacturer's settings
-- R.W,BeckeKspecification
numberand revision
--Con be cu_
individual specification
--State and local approvals
"'--........ /" SK9890 Page 3

Genera| information
To the Owner:
Thank you for purchasing aBeckett burner
for use with your heating appliance. Please pay at-
tention to the Safety Warnings contained within this
instruction manual. Keep this manual for your records
and provide it to your qualified service agency for use
in professionally setting up and maintaining your oil
burner.
Your Beckett burner will provide years of efficient op-
eration if it is professionally installed and maintained
by a qualified service technician. If at any time the
burner does not appear to be operating properly, im-
mediatel_L contact ouv_QU_Lgualifiedservice
for consultation.
We recommend annual inspection/service of your
oil heating system by a qualified 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 pre-
vent condensation of moisture on the inside surface
of the tank.
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,
flame impingement, appliance sooting, hot gas
puff=back, and asphyxiation or fire hazards.
Maintain the design to its original configuration.
Only use parts specified 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
• Void manufacturer's warranties
• Seriously impact burner performance
• Greatly increase your liability risk
Impaired Burner Perfor=
mance and Fire Hazard.
Do NOT operate the burner beyond specifica-
tions outlined in the following Table.
•For applications beyond these limits, consult
Beckett Technical Service at 1-800-645-2876.
•NOTE: Some packaged appliances with burners
may be agency listed as a unit to operate beyond
these limits. Consult the appliance manufac-
turer's specifications and agency approvals for
verification.
Table 1 - Burner Specifications
Capacity 'F' Head (AF &AFG)
(Note 1) Firing rate range: .............. 0.40 - 3.00 GPH
Input: .......................56,000- 420,000Btu
'LI' Head(AFG Only)
Firing raterange:..................0.40 - 1.10GPH
Input: .....................56,000- 154,000Btu/h
'L2'Head(AFG Only)
Firing raterange:................. 0.50 - 1.00GPH
Input: ......................70,000- 140,000Btu/h
'VI' Head(AFG Only)
Firing raterange:................. 0.75 - 2.75GPH
Input: ....................105,000-385,000Btu/h
Certifications/ULlistedtocomply withANSI/UL296andCSA-B140.0
Approvals
Fuels U.S No.1orNo.2 heating oil only (ASTM D396)
CanadaNo.1stoveoilorNo.2 furnaceoilonly
Electrical
j CAUT|ON
DO NOT USE GASOLINE, CRANKCASE OIL,
OR ANY OIL CONTAINING GASOLINE.
Power supply:............ 120 volts AC, 60 Hz single phase
Operating load: .......... Amps max
Motor: ......................... 1/7 hp, 3450 rpm, NEMA48M frame
PSC rotation CCW when facing
shaft end
Ignition: ...................... Continuous duty solid-state igniter
Fuel pump Outlet pressure: .................................. Note 2
Air tube ATC code: ................................... See Table 2
Dimensions Height (maximum) ....................... 12.5 inches
(with cover) Width (maximum) .......................... 15 inches
Depth ......................................... 9.25 inches
Air tube diameter ....................... 4.00 inches
Ambient +320 F.(0 C.) Minimum
Operating +1150 F. (+46 C.) Maximum
Temperature (See above Warning)
Moisture 5% to 95% RH, non-condensing and non-crystallizing
Note 1:Approval agency listed rating for these bumers is 0.40 to 3.O0
gph. However, the firing rate range is limited by the specific
air tube combination being used. Refer to Table 2.
Note 2. See appliance manufacturer's burner specifications for rec-
ommended pump discharge pressure.
Page 4 6104BAFG R04

Genera| Specifications
Table 2- Air Tube Combination (ATC) codes
Firing Head Static Ven- ATC Codes for usable air tube lengths
Rate plate turi ('A' in inches; See Figure 3.)
(gph) size
(rnin- (inches) 4-1/2 55-3/8 6-5/8 7 7-1/4 910-1/2 13 16
max)
0.50-0.75 F0 3-3/8U None AF44XR AF53XR AF65XR AF72XR AFg0XR AF104XR AF130XR A160XR
0.75-1.25 F3 2-3/4U None AF44XN AF53XN AF65XN AF72XN AFg0XN 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 AFg0YB AF104YB AF130YB AF160YB
1.10-2.00 F12 2-3/4U None AF44XO AF53XO AF65XO AF72XO AFg0XO AF104XO AF130XO AF160XO
1.65-2.50 F22 2-3/4U None AF44XP AF53XP AF56XP AF72XP AFg0XP 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 AFGg0MB
0.50-1.00 L2 2-3/4U 8hole AFG50MP AFG70MP AFGg0MP
0.75-2.75 Vl 2-3/4U 8hole AFG50MD AFG70MD AFGg0MD
0.40-0.75 F0 3-1/2U None AF44WG AF53WG AF65WG AF72WG AF90WG AF104WG AF130WG A160WG
Notice Special Requirements
• THE INSTALLATION OF A BURNER SHALL BE
IN ACCORDANCE WITH THE REGULATIONS
OF AUTHORITIES HAVING JURISDICTION.
• For recommended installation practices in the
U.S. refer to the latest edition of NFPA 31. (CSA-
B139 and CSA-B140 in Canada.
• Concealed damage -- If you discover damage to
the burner or controls during unpacking, notify the
carrier at once and file the appropriate claim.
• When contacting Beckett for service information
-- Please record the burner serial number (and
have available when calling or writing). You will
find the serial number on the silver label located
on the left rear of the burner. Refer to Figure 1.
Professional Service
Required
Incorrect installation, adjustment,
and use of this burner could result
in severe personal injury, death, or
substantial property damage from
fire, carbon monoxide poisoning, soot or explo-
sion.
Please read and understand the manual supplied with
this equipment. This equipment must be installed, ad-
justed and put into operation only by a qualified individu-
al or service agency that is:
• Licensed or certified to install and provide tech-
nical service to oil heating systems.
• Experienced with all applicable codes, standards
and ordinances.
• Responsible for the correct installation and com-
mission of this equipment.
• Skilled in the adjustment of oil burners using
combustion test instruments.
The installation must strictly comply with all applicable
codes, authorities having jurisdiction and the latest revi-
sion 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 R04 Page 5

Ilnspect/Prepare installation Site
inspect Chimney or Direct Vent System
Fire, Smoke & Asphyxia-
tion Hazard
• Carefully inspect the chimney or exhaust vent
system.
• Make sure it is properly sized and in good work-
ing condition.
• Follow the instructions supplied by the appliance
manufacturer.
• The installation must strictly comply with all ap-
plicable codes, authorities having jurisdiction and
the latest revision of the National Fire Protection
Association Standard NFPA 31 for the installa-
tion of chimneys and vent sizing, (or CSA-B139
and CSA-B140 in Canada).
•Regulation by these authorities take precedence
over the general instructions provided in this in-
stallation manual.
1. Starting with minimum gph firing rate, the mini-
mum size recommended is 6" flue pipe with 8"X
8" inside chimney, unless specified otherwise by
the appliance manufacturer.
2. A chimney flue 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 Fig-
ure 2.
3. Any accumulation of soot or debris in chimney
offsets should be removed
4. Any obstructions such as a protruding joint or a
piece of broken tile wedged in the chimney should
be removed.
5. No other appliance connection should be made to
the same flue pipe.
6. The flue pipe should have an upward pitch toward
the chimney of at least 1/4" per foot of length. It
should fit tightly and should not project into the
chimney.
7. Any leakage between tiles, around clean-out
doors, or around the vent pipe should be sealed.
INSULATED STAINLESS STEEL CHIMNEY LINERS
The new designs of high efficiency oil furnaces
and boilers in conjunction with flame retention oil
burners are more efficient. One result of increased
efficiency is lower flue gas temperatures. As
flue 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 flue
gases creating sulphuric acid. The acid will attack
the chimney mortar, brick and clay liners caus-
ing corrosion, deterioration and blockage of the
chimney. Eventually the blockage could prevent
exhausting the flue gases. Instead, the flue gases
could vent out the barometric damper into the liv-
ing space.
Therefore, it is strongly recommended that an ap-
proved insulated stainless steel liner be installed.
For those installations not requiring a chimney,
such as through-the-wall vented appliances, fol-
low the instructions given by the appliance and
power venter (if used) manufacturers.
Figure 2= Chimney Design - Above the Roof
MJN_MUM
CLEARENCE
2 FT
ZWIND \
ADJACENI
HI©H
BUILD}NO NOTE: Correct
chimney design is
shown by dotted
lines. Incorrect
chimney design,
as shown by the
solid lines, may
result in down-
drafts.
Page 6 6104BAFG R04

Combustion air supply
Adequate Combustion
and Ventilation Air Supply
Required
Failure to provide adequate air supply could
seriously affect the burner performance and re=
suit in damage to the equipment, asphyxiation,
explosion or fire hazards.
• The burner cannot properly burn the fuel if it is not
supplied with a reliable combustion air source.
• Follow the guidelines in the latest editions of the
NFPA 31 and CSA-B139 regarding providing ad-
equate air for combustion and ventilation.
Appliance located in confined sj:)ace
The confined space should have two (2) permanent
openings: one near the top of the enclosure and
one near the bottom of the enclosure. Each open-
ing 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 build-
ing interior, which should have adequate infiltration
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 re-
quired for combustion air. if there is any possibility
of the equipment room developing negative pres-
sure (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.
Direct air sup_p/Ivand sidewall venting.
• Some AFG burners are equipped with combus-
tion air boots to allow use of outside air for com-
bustion.
• When sidewall venting appliances, carefully fol-
low appliance and power venter instructions for
installation and wiring.
Follow the Outside Air Kit
instructions Exactly
Failure to comply could result in impaired corn=
bustion, appliance soot=up, puffback of smoke,
and fire or asphyxiation hazards.
• Do not attempt to install outside air piping to
the burner without using the outside air kit and
instructions.
Inspect/Prepare installation Site
Outside air kit a_%lications
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
easy service and maintenance.
• Check minimum clearances against those shown
by the appliance manufacturer and by applicable
building codes.
Protect Steel Combustion
Chamber From Burnout
Failure to comply could result in damage to the
heating equipment and result in fire or asphyxi-
ation hazards.
• When retrofitting appliances that have unlined
stainless steel combustion chambers, protect
the chamber by lining the inside surfaces with a
ceramic fiber blanket, such as a wet-pac or other
suitable refractory material.
• Some steel chambers may not require liners
because the appliance was designed and tested
for use with flame retention burners. Refer to the
manufacturer's instructions.
Combustion chamber = Burner retrofit=
ting
Verify that the appliance combustion chamber pro-
vides at least the minimum dimensions given in
Table 3.
Table 3. Chamber Dimensions
Chamber Dimensions (inches)
Firing Rate Round
(GPH) i.D.
0.50 8
0.75 9
1.00 10
1.25 11
1.50 12
2.00 14
2.50 16
3.00 18
Rectangular Height Floorto
nozzle
Width Length
7 8 12 5-6
8 9 12 5-6
9 10 12.5 5-6
10 11 12.5 5-6
11 12 13 6-7
12 15 13.5 6-7
13 17 14 7-8
14 18 15 7-8
6104BAFG R04 Page 7

Inspect/Prepare |nstallation Site
Prepare the Burner
Low Firing Rate Baffle
The AFG Low Firing Rate Baffle (LFRB) reduces
the air flow and pressure. The LFRB is sometimes
used for firing rates under 1.00 gph as listed in
Table 4. Refer to the appliance manufacturer's in-
structions. Do not omit the LFRB when specified.
Omitting the baffle when specified or installing the
baffle when not specified could result in impaired
burner performance.
Burner fuel unit
• Verify that the burner fuel unit is compatible with
the oil supply system. For more details, refer to
the pump manufacturer's instructions provided
with the burner.
Attach air tube (if not already installed)
If using a flange and gasket, slide them onto the air
tube. Then attach the air tube to the burner chassis
using the four sheet metal screws provided. Refer
to Figure 4 for details.
Nozzle and Pump Pressure
Correct Nozzle and Flow
Rate Required
incorrect nozzles and flow rates
could result in impaired combus=
tion, under-firing, over-firing, soot-
ing, puff-back of hot gases, smoke
and potential fire or asphyxiation hazards.
Use only nozzles having the brand, flow rate (gph), spray
angle and pattern specified by the appliance manufac-
turer.
Follow the appliance manufacturer's specifications for
the required pump outlet pressure for the nozzle, since
this affects the flow rate.
• Nozzle manufacturers calibrate nozzle flow rates
at 100 psig.
• When pump pressures are higher than 100 psig,
the actual nozzle flow rate will be greater than
the gph stamped on the nozzle body. (Example:
A 1.00 gph nozzle at 140 psig = 1.18 gph)
Securely tighten the nozzle (90 torque inch pounds). For
typical nozzle flow rates at various pressures refer to
Table 5.
Table 4. AFG Reduced Firing Rates (with
LFRB)
Burner head type Low Firing Rate Baffle installed
F0 up to0.65gph
F3or L1 up to0.85gph
F4or F6 up to0.90gph
V1 up to1.00gph
Table 5. Nozzle Flow Rate by Size
Nozzle flow rate U. S. gallons per hour of No. 2 fuel oil when
pump pressure (psig) is:
125 140 psi 150 psi 175 psi 200 psi
psi
Nozzle
size
(rated at
100 psig)
0.40 0.45 0.47 0.49 0.53 0.56
0.50 0.56 0.59 0.61 0.66 0.71
0.60 0.67 0.71 0.74 0.79 0.85
0.65 0.73 0.77 0.80 0.86 0.92
0.75 0.84 0.89 0.92 0.99 1.06
0.85 0.95 1.01 1.04 1.13 1.20
0.90 1.01 1.07 1.10 1.19 1.27
1.00 1.12 1.18 1.23 1.32 1.41
1.10 1.23 1.30 1.35 1.46 1.56
1.20 1.34 1.42 1.47 1.59 1.70
1.25 1.39 1.48 1.53 1.65 1.77
1.35 1.51 1.60 1.65 1.79 1.91
1.50 1.68 1.77 1.84 1.98 2.12
1.65 1.84 1.95 2.02 2.18 2.33
1.75 1.96 2.07 2.14 2.32 2.48
2.00 2.24 2.37 2.45 2.65 2.83
2.25 2.52 2.66 2.76 2.98
2.50 2.80 2.96
Install burner nozzle (if not already in-
stalled)
1. Remove the plastic plug protecting the nozzle
adapter threads
2. Place a 3/4" open-end wrench on the nozzle
adapter. Insert the nozzle into the adapter and fin-
ger tighten. Finish tightening with a 5/8" open-end
wrench. Use care to avoid bending the burner head
support legs or electrodes. If you remove the head
to replace the nozzle (type '%1"/"L2" or "Vl" heads),
carefully reconnect the head to the nozzle adapter,
making sure that the head support makes contact
with the nozzle adapter shoulder. Refer to Figure
5or6.
Page 8 6104BAFG R04

3. If the nozzle is already installed, remove the noz-
zle line assembly to verify that the nozzle size and
spray pattern are correct for the application (per ap-
pliance manufacturer's information). Verify that the
electrode tip settings comply with Figure 3.
4. If the nozzle is not installed, obtain a nozzle from
the manufacturer, having the capacity and spray
angle specified in the appliance manufacturer's in-
formation. For conversions or upgrades, when in-
formation is not available for the application:
• Refer to Table 6 to select the mid-range nozzle
spray angle for the head type being used.
• Fire the burner and make sure the combustion
is acceptable and the flame is not impinging on
chamber surfaces.
• If a shorter flame is needed, select a wider spray
angle. If a longer flame is needed, select a nar-
rower spray angle.
• Either hollow or solid spray patterns may be used.
If combustion results are not satisfactory with the
selected spray pattern, try the other pattern.
6. Nozzle Spray Angles
Recommended nozzle spray angles
"F" head 70 ° or 80 ° nozzle
"LI" & "L2" head 45 °, 60 °, or 70° nozzle
"Vl" head 45 °, 60 °, or 70° nozzle
Table
Check/adjust electrodes
Check the electrode tip settings. Adjust if neces-
sary to comply with the dimensions shown in Fig-
ure 3. To adjust, loosen the electrode clamp screw
and slide/rotate electrodes as necessary. Securely
tighten the clamp screw when finished.
Servicing nozzle line assembly
1. Turn off power to burner before proceeding.
2. Disconnect oil connector tube from nozzle line.
3. Loosen the two screws securing igniter retain-
ing clips and rotate both clips to release igniter
baseplate. Then tilt igniter back on its hinge.
4. Remove splined nut.
5. "F" head air tube. - Remove nozzle line as-
sembly from burner, being careful not to
damage the electrodes or insulators while
handling. To ease removal of long assemblies
(over 9 inches), rotate assembly 180° from
installed position after pulling partially out of
tube.
6. "LI", "L2", and "Vl" head air tubes.- Slide
nozzle line assembly forward (further into air
tube) so the head clears the venturi opening.
Then rotate the nozzle line assembly 90 ° so
the nozzle line end points up. Pull the nozzle
line assembly toward you and remove assem-
bly from burner.
To replace the nozzle assembly, reverse the
above steps.
R04
.
6104BAFG
Prepare the Burner
Figure 3. - Electrode Tip Adjustment
Standard Dimensions for F, LI, and Vl Heads.
5/32" Gap -,,,,
_'_ 5/16' Above _"
/_ Ce_nter
Spacing
The Dimensions shown below are for use with L2 heads
and M series air tube combinations ending with an 'N' suf-
fix (example: AFG70MDAQN)
5132"Gap _
Spacing
Mount burner on appliance
Mounting options
1. Bolt the burner to the appliance using the fac-
tory-mounted flange or an adjustable flange.
Mounting dimensions
1. When using the Beckett universal adjustable
flange, mount the air tube at a 2 ° downward
pitch unless otherwise specified by the appli-
ance manufacturer.
2. Verify that the air tube installed on the burner
provides the correct insertion depth. See Fig-
ure 7.
3. The end of the air tube should normally be %"
back from the inside wall of the combustion
chamber. Never allow the leading edge of the
head assembly to extend into the chamber, un-
less otherwise specified by the heating appli-
ance manufacturer. Carefully measure the in-
sertion depth when using an adjustable flange.
Verify the insertion depth when using a welded
flange.
Page 9

Prepare the Burner
Figure 4. Check/Adjust 'Z' Dimension for 'F' Heads
Z (WTH
HEAT SHIELD
H EA]
SH}ELD
F HEAD-
(NO S/'_ELD) --4
1-1/8" /
ELECrROD
NSUI ATOR
ELECTRO[
TIPS
F
NOZZLE
--EUECTRODE
RODS
Adjust the 'Z' dimen-
sion to the required ADAPTER
specification.
Incorrect Adjustments could cause combus-
tion problems, carbon deposition from flame
impingement, heavy smoke generation and
fire hazard.
• Make all adjustments exactly as outlined in
the following information.
A}R TUBE
STAT}C PLATE
NOZZLE
SPLINED NUT
90 °
Q
ELBOW
CONNECTOR TUBE
ESCUTCHEON PLATE
Check/Adjust 'Z' Dimension-'F' heads
e
e
e
e
e
The important 'Z' dimension is the distance from the face of the nozzle
to the flat face of the head (or heat shield, if applicable). This dis-
tance for F heads is 1-½" (1-X" if the air tube has a heat shield). The
"Z" dimension is factory set for burners shipped with the air tube in-
stalled. Even if factory set, verify that the "Z" dimension has not been
changed.
Use the following procedure to adjust the "Z" dimension, if it is not
correct:
Turn off power to the burner.
Disconnect the oil connector tube from the nozzle line
See above figure. Loosen the splined nut from the nozzle line.
Loosen the hex head screw securing the escutcheon plate to the
burner housing.
Place the end of a ruler at the face of the nozzle and, using a
straight edge across the head, measure the distance to the face of
the head. A Beckett T501 gauge may also be used.
Slide the nozzle line forward or back until this dimension for F
heads is 1-½" (1-_" to the face of the heat shield, if applicable).
Tighten the hex head screw to secure the escutcheon plate to the
burner chassis. Then tighten the splined nut and attach the oil con-
nector tube.
Recheck the "Z" dimension periodically when servicing to ensure the
escutcheon plate has not been moved. You will need to reset the "Z"
dimension if you replace the air tube or nozzle line assembly. The
Beckett Z gauge (part number Z-2000) is available to permit checking
the F head "Z" dimension without removing the burner from the appli-
ance.
Burner Dimensions
ForusablelengthA (inches)
Dimension (inches) F Head L1 L2 V1
Head Head Head
H (nozzle to head), +1/32 N/A 1/4 7/32 1/4
L (Total tube length) A+1/2 A+1/2 A+1/2 A+1/2
R (electrode length), + 1/4 A+2-1/4 A+1-1/8 A+1-1/8 A+1-1/8
S (adapter to static plate), + (Note 1) 1-3/8 1-3/8 1-3/8
1/16
Q (nozzle line length), A+ 15/16 A+ 3/16 A+ 3/16 A+ 3/16
Z (F head-no heat shield) 1-1/8 N/A N/A N/A
(F head-with heat shield) 1-3/8 N/A N/A N/A
Z (L1 head w/straight N/A 1-3/8 N/A N/A
shroud) (LI/L2/V1 head N/A 1-3/4 1-3/4 1-3/4
w/conic shroud)
Note 1:1-3/8 for dimension A less than 4"; 1-5/8 for dimension A from 4"
through 4-1/2 " 2-13/32 for dimension A greater than 4-1/2".
Page 10 6104BAFG R04

Prepare the Burner
burners shipped with the air tube installed. Even if factory set, verify
Figure 5. Check/Adjust 'Z' Dimension - L1 & that the"Z" dimension has not been changed.
L2 Heads
indicator
Head
--- Z _
___
Z
Leading edge of head (straight shroud)
____ m ____ Bo_c_k of heod t....... face
port
Leading edge of head (conic shroud)
L1/L2heads(seeTable7 andFigure3fordimensions)
1. See figure above. The important "Z" dimension is the distance from
the leading edge of the head to the end of the air tube. This distance
for L1 & L2 heads is 1-_" if the tube has a straight shroud or 1-¾" if
the air tube has a conic shroud. The "Z" dimension is factory set for
2. Usethe followingproceduretoadjustthe "Z"dimension,if it is not
correct:
• Turnoffpowertothe burner.
,Disconnectthe oilconnectortubefromthenozzleline.
• Referto figure. Loosen the splinednut from the nozzle line.
Loosenthe hexheadscrewsecuringtheescutcheonplatetothe
burnerhousing.
,Placethe endof aruleratthe leadingedgeofthe headand, us-
inga straightedgeacrossthe end of the airtube, measurethe
distanceto the endof thetube.A BeckettT501gauge mayalso
beused.
,Slidethe nozzlelineforwardor backuntilthisdimensionis1-_"
for L1&L2headsifthetubehasa straightshroud,or 1-¾"if the
airtubehasa conicshroud.
• Tightenthe hex headscrewto securethe escutcheonplate to
the burnerchassis.Thentightenthe splinednut andattachthe
oilconnectortube.
3. Recheckthe "Z"dimensionperiodicallywhen servicingto ensure
the escutcheonplatehas not beenmoved.You will needto reset
the"Z"dimensionif you replacethe air tubeor nozzleline assem-
bly.
Figure 6.
Heads
SK9460B
Check/Adjust 'Z' Dimension - Vl
Spllned nut
_Leading edge of head
Back of head to nozzle face
_. Nozzl_
He_° lu pport
Vl heads(seeTablebelowandFigureabovefordimensions)
See figure above. The important "Z" dimension is the distance from
the leading edge of the head to the end of the air tube. This distance
for V1 heads is 1-¾". The "Z" dimension is factory set for burners
shipped with the air tube installed. Even if factory set, verify that the
"Z" dimension has not been changed.
2. Use the followingprocedureto adjustthe "Z"dimension,if it is not
correct:
• Turnoffpowertothe burner.
,Disconnectthe oilconnectortubefromthenozzleline.
• See figure above. Loosen the splinednut from the nozzle line.
Loosenthe hex headscrewsecuringthe headadjustingplate to
theburnerhousing.
,Loosentheacorn nut.Movethe headadjustingplateuntilthe "0"
linesupwith the referenceindicatoron the housing,andretighten
thehexheadscrew.Placetheendof aruleratthe leadingedgeof
theheadand,usingastraightedgeacrosstheendoftheair tube,
measurethedistancetotheendofthetube.A BeckettT501gauge
mayalsobeused.
,Slidethenozzlelineforwardor backuntilthisdimensionis 1-¾"for
V1heads.Tightenthe acornnut.
,Tightenthe hexheadscrewto securethe headadjustingplateto
the burnerchassis.Thentightenthe splinednutand attachthe oil
connectortube.
3. Recheckthe"Z"dimensionperiodicallywhenservicingtoensurethe
escutcheonplatehasnot beenmoved.Youwill needto resetthe "Z"
dimensionifyoureplacethe airtubeor nozzlelineassembly.
Set
1.
head position adjusting plate (Vl head only)
After setting "Z" dimension, loosen head adjusting plate hex head
screw and nozzle line splined nut. Move the nozzle line assembly until
the burner reference indicator lines up with the head adjusting plate
setting number given in Table shown below.
2. Tighten the hex head screw and splined nut. (DO NOT loosen the
acorn nut when setting head position.) Refer to the manufacturer's in-
structions for OEM settings.
3. The position of the head affects air flow volume and pattern. For most
applications, the burner will perform satisfactorily with the air adjust-
ment plate setting of Table shown below.
4. If combustion results indicate the need for change, adjust the head po-
sition adjusting plate forward or back one position at a time to optimize
combustion.
Table for initial adjusting plate settings for Vl
Head Vl Adjusting AFG with Vl
Plate Setting Head
Burner Firing
Rates
0 0.75-1.00
1 1.00-1.50
2 1.50-1.75
3 1.75-2.00
4 2.00-2.25
5 2.25-2.50
6 2.50-2.75
6104BAFG R04 Page 11

Mount burner on app|iance
Figure 7. -Mounting Burner in Appliance
Ifspace between burner
air tube and opening
exceeds 1/2 inch, pack _/_/_
burner opening with ce- _/4"
ramic fiber refractory• __
---q_
..... i ..... i_ ....
Tilt down 2° 4"
Installing the Oil Tank and Supply System
Oil Leak and Fire Hazard
Instafl the oil tank following applicable stan=
dards in the U.S. by referring to the latest
edition of NFPA 31 or CSA=B139 & CSA-B140
in Canada, and all authorities having jurisdic=
tion.
_t_CAILITIION Do Not Use Teflon Tape
Damage to the pump could cause impaired
burner operation, off leakage and appliance
soot=up.
• Never use Teflon tape on fuel oil fittings.
• Tape fragments can lodge in fuel line compo-
nents and fuel unit, damaging the equipment
and preventing proper operation.
•Use oil-resistant pipe sealant compounds.
Note: to determine the proper fuel line size, refer
to the fuel pump manufacturer's instructions pro-
vided with the burner. Refer to Figure 8 or Figure 9
for typical installation layouts.
Fuel Line Valves and Filter
Install two high quality, oil duty rated, fusible
handle design shutoff valves in accessible loca-
tions on the oil supply line. Locate one close to the
tank and the other close to the burner, upstream of
the filter for service access.
Install a generous capacity filter inside the building
between the fuel tank shutoff valve and the burner,
locating both the filter and the valve close to the
burner for ease of servicing. Filter should be rated
for 50 microns or less.
Figure 8. - Inside Tank Gravity Feed System
A,R
VENT 1-1/4" MiNiMUM
FiLL
PiPE
OIL
TANK
FUEL
HANDLE
SHUT OFF
VALVES
FUEL
FILTER
F OIL
SAFETY
VALVE
......L_ ¸
Figure 9. - Outside Buried Tank-Lift System
, FUEL
AIR /FILTER
VENT FUEL /
1-1/4" :' L PUMP /FUSIBLE
i
i
i
-/ RETURN 3 "-4_
LiNE
To further protect the fuel supply sys-
tem and reduce nozzle orifice plugging with firing rates
below 0.75 gph, a dual filtration system can be installed.
This typically consists of a 50 micron primary filter,
located near the fuel tank and a secondary filter rated for
at least 10 microns located near the burner.
Fuel suAp_Lyl level with or above burner -
Do Not Install By-pass Plug
with 1-Pipe System
Failure to comply could cause immediate pump
seal failure, pressurized oil leakage and the
potential for a fire and injury hazard.
• The burner is shipped without the by-pass plug
installed.
•Install the by-pass plug in two-pipe oil supply
systems ONLY.
Page 12 6104BAFG R04

CAUTION Oil Supply Pressure
Control Required
Damage to the filter or pump seals could cause
oil leakage and a fire hazard.
• The oil supply inlet pressure to the burner can=
not exceed 3 psig.
• Insure that a pressure limiting device is installed
in accordance with the latest edition of NFPA 31.
• Do NOT install valves in the return line.
(NFPA 31, Chapter 8.)
• Gravit_ Eeed Systems: Always install an anti-
siphon valve in the oil supply line or a solenoid
valve (RWB Part # 2182602U)in the pump/noz-
zle discharge tubing to provide backup oil flow
cut-off protection.
The burner may be equipped with a single-stage
fuel unit for these installations. Connect the fuel
supply to the burner with a single supply line if you
want a one-pipe system (making sure the bypass
plug is NOT installed in the fuel unit.) Manual bleed-
ing of the fuel unit is required on initial start-up. If
connecting a two-pipe fuel supply, install the fuel
unit bypass plug.
Fuel sup_p__!ylbelow the level of the burner -
When the fuel supply is more than eight feet below
the level of the burner, a two-pipe fuel supply sys-
tem is required. Depending on the fuel line diam-
eter and horizontal and vertical length, the instal-
lation may also require a two-stage pump. Consult
the fuel unit manufacturer's literature, included with
the burner, for lift and vacuum capability.
Fuel line installation =
•Continuous lengths of heavy wall copper tubing
are recommended. Always use flare fittings.
Never use compression fittings.
• Always install fittings in accessible locations.
Proper routing of fuel lines is required to prevent
air cavitation and vibration.
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 instafled that operates during
power outages, senses low temperature and
initiates an effective action. Consult with your
heating contractor or a home security agency.
Wire burner
Wire burner
Burner packaged with appliance
Electrical Shock Hazard
Electrical shock can cause severe
personal injury or death.
•Disconnect electrical power before installing or
servicing the burner.
•Provide ground wiring to the burner, metal con-
trol enclosures and accessories. (This may also
be required to aid proper control system opera-
tion.)
•Perform all wiring in compliance with the Na-
tional Electrical Code ANSI/NFPA 70 (Canada
CSA C22.1 )
• Refer to appliance manufacturer's wiring diagram
for electrical connections.
Burner installed at jobsite
• Refer to Figures 11a and 11b, for typical burner
wiring, showing cad cell primary controls. Burner
wiring may vary, depending on primary control
actually used.
• Refer to the appliance manufacturer's wiring dia-
gram prior to connecting the burner wiring. All wir-
ing must be in accordance with the latest revision
of National Electric Code NFPA 70 and all local
codes and regulations. In Canada, all wiring is
to be in accordance with the Canadian Electrical
Code, Part 1.
The 7505 primary control with valve-on delay (pre-
purge) and burner motor=off delay (postpurge) re-
quires a constant 120 volts AC power source sup-
plied to the BLACK wire on the control. The RED
wire goes to the appliance limit circuit. Please note
that other control manufacturers may use different
wire colors for power and limit connections.
Special wiring required with covered
burners
The mounting plate is not a conduit connec-
tion point. Pass conduit and attached connector
through the opening in the mounting plate and at-
tach it directly to the burner=mounted 4x4 electrical
box.
If attaching a burner cover to a previously installed
burner, attach the mounting plate and then slide the
conduit into the "J" shaped conduit slot.
6104BAFG R04 Page 13

Burner Controls
GeniSys Model 7505 Centre|
Fire or Explosion Hazard
Can cause severe injury, death, or
property damage.
•The control can malfunction if it gets wet,
leading to accumulation of oil or explosive oil
vapors.
• Never install where water can flood, drip or
condense on the control.
•Never use a control that has been wet - replace it.
Features
" Thermostat /Operating and Limit Control Compatible
Welded Relay Protection
Limited Recycle
Limited Reset
3 Status Lights
Valve-On Delay /Motor-Off Delay (Field
programmable with 52067 GeniSys Display)
15 Second Lockout Time
Interrupted or Intermittent Duty ignition
Technician Pump Priming Mode
Disable Function
" Cad Cell Resistance Indicator
Communication Ports
Figure 10.
Wiring
Explosion, Fire, Scald,
and Burn Hazard
All heating appliances must have
HIGH LIMIT protection to interrupt
electrical power and shutdown the
burner if operating or safety controls
fail and cause a runaway condition.
• Follow the appliance manufacturer's wiring
diagrams and note all required safety controls.
• Typical safety controls include high temperature
or pressure limits, low water cutoffs, pressure
relief valves and blocked flue sensing switches.
• Verify all limit and safety controls are installed
and functioning correctly, as specified by the
manufacturer, applicable safety standards,
codes and all authorities having jurisdiction.
• Ensure that the appliance is free of oil and oil
vapor before starting or resetting the burner.
Operation
incorrect Wiring Will Re=
suit in improper Control
• GeniSys wiring label colors may not match the
wire colors of the burner or other manufacturers'
controls.
• The GeniSys Control should be wired according
to the appliance manufacturer's instructions.
Wiring
Connections
Yellow Light
Green Light Reset Button
with Red Light
Cad Ceil
Connections
Communication Port 2
Communication Port 1
Display Module:
For programming and
diagnostics
Alarm Module:
For adding isolated
low voltage alarm
contacts to the base
control. See Alarm
Module Instructions for
specifications.
Page 14 6104BAFG R04

Burner Contro|s
Typical Burner Sequence of Operation for GeniSys 7505 Control.
Refer to the appliance manufacturer's wiring diagram for actual specifications.
o lo
_Pump
Standby prime
Trial for
Valve-on delay ignition Lockout
o
Ignition carryover i
° !-1 ! i Recycle
]
]
]
i
=
=
=
=
Standby: The burner is idle, waiting for a call for 5.
heat.
Valve=On Delay: The igniter and motor are on while
the control delays turning on the oil solenoid valve
for the programmed time.
Trial For Ignition: The oil solenoid valve is
energized. Aflame should be established within the
factory set trial for ignition time ("lockout time").
Lockout: The control has shut the burner down for
one of the following safety reasons:
• The trial for ignition (lockout) time expired without
flame being established.
• The cad cell detected flame at the end of the
Valve-On Delay.
• The Recycle mode 30-second time budget expired
(see "Recycle" section for complete explanation of
recycle time budget).
Click the reset button to reset the control from
lockout. If the control locks out three times without
completing a successful call for heat, or if the
control fails the welded relay check, the control
enters Restricted (Hard) Lockout and must be
reset by a technician. Hold the reset button for 15
seconds until the yellow light turns on, to reset from
Restricted Lockout.
=
=
=
=
Ignition Carryover: Once flame is established,
the igniter remains on for 10 additional seconds to
ensure flame stability.
Run: The flame is sustained until the call for heat
is satisfied. The burner is then sent to Motor-Off
Delay, if applicable, or it is shut down and sent to
Standby.
Recycle: If the flame is lost while the burner is
firing, the control shuts down the burner, enters a 60
second recycle delay, and then repeats the ignition
sequence. The control will continue to Recycle
each time the flame is lost until the accumulated
oil-flow-without-flame time reaches 30 seconds, at
which point the control will go into lockout instead
of recycle if the flame is lost again during run. This
feature prevents excessive accumulation of oil in
the appliance firing chamber.
Motor=Off Delay: If applicable, the oil solenoid
valve is turned off and the control delays turning
the motor off for the set motor-off delay time before
the control returns to standby.
Pump Prime: The igniter and motor are on with the
oil solenoid valve energized for 4 minutes. During
Pump Prime mode, the cad cell is disregarded,
allowing the technician to prime the pump without
6104BAFG R04 Page 15

Burner Contro|s
Figure 11a. = Interrupted ignition, valve-on delay
only (no motor-off delay) Figure 11b. = Interrupted ignition, valve-on delay
and motor-off delay
L1.
L2 SAFETY AND
OPERATING
LIMITS
IGNITER
THERMOSTAT
CAD CELL
L1 -LIMIT
JUMPER
TR_TW
TR-TW TERMINALS
LOCATED ON OPPOSITE
SIDE OF CONTROL
L1
L2
THERMOSTAT
OIL M_ f TR
TR-TW TERMINALS
LOCATED ON OPPOSITE
SIDE OF CONTROL
CAD CELL
Reset Button Operation
Table 2explains what action the control will take when the reset button is pressed for different lengths of time
during the various burner operating states.
Lockout
Valve-on Delay,Trial for
Ignition,Ignition Carryover
Table 2 -Reset Button 0 _eration
Pushing the reset button will:
--- Button Click Button Hold Button Hold
(press < 1 second) (press > 1 second) (press 15+ seconds)
Reset from Restricted (Hard)
Resetfrom Soft Lockout Lockout
Run(igniter is shut off)
Motor-Off Delay,
Standby
PumpPrime
Go to Pump Prime (see
"Primingthe Pump" above)
Yellow lightflashes to indicate
cad cel resistance. See "Cad
Cell Resistance Indicator"for
table of resistance values.
No action
Disable the Burner:
Any time the burner is running,
press and hold the reset button
to disable the burner. The
burner will remain off as long
as the button is held.
Enables Pump Priming:
After the reset button has been
held for 15 seconds, the button
can then be clickedduring the
next ignitionsequence to enter
Pump Prime mode.
No action Exit PumpPrime modeand return to Standby
Table 3 =Status Lights
Red
Green
Yellow
Restricted (Hard) Lockout
Flame Sensed during normal operation (Could
be stray light during standby)
Control is in Pump Prime mode or
Reset button currently held for 15+ seconds.
Soft Lockout
Recycle
Cad Cell resistance. See "Cad Cell Resistance
Indicator" on page 8 for a table of resistance values.
Page 16 6104BAFG R04

Burner Contro|s
Typical Burner Wiring & Burner Sequence of Operation for R7184P Control.
Refer to the appliance manufacturer's wiring diagram for actual specifications.
120 VAC BURNER
START WIRE
FROM APPLIANCE
(FROM LIMIT CIRCUIT)
120 VAC
FROM
APPLIANCE
EQUIPMENT
GROUND
LI (HOT)
[ L'2 (NEUTRAL)
r
w_GROUND
SCREW I
JG RED
BLACK
WHITE
WHITE
WHITE
WHITE
VIOLET
BLUE /
WHITE STRIPE
ORANGE
YELLOW
YELLOW
LIMIT
R7184
L1 SERIES
PRIMARY
CONTROL
L2
A O-----
VALVE
AO---
IGNITION
MOTOR T O--
CAD CELL T C)--
CAD CELL
TO REMOTE
LOW VOLTAGE
AC ALARM
_ _ CIRCUIT
(IF USED)
24 VAC
THERMOSTAT
BURNER JUNCTION BOX
SK9359D
..... =120 VAC FIELD WIRING
120 MAC FACTORY WIRING
- LOW VOLTAGE FIELD WIRING
- LOW VOLTAGE FACTORY WIRING WIRENUT =WIRE WITH 1/4"
QUICK CONNECT
RECEPTACLE
Figure 10. - Typical Burner Wiring
1. STANDBY. The burner is idle, waiting for a call for
heat. When a call for heat is initiated, there is a 3-
10 second delay while the control performs a safe
start check.
2. VALVE-ON DELAY. The ignition and motor are
turned on for a 15 second valve-on delay.
3. TRIAL FOR IGNITION (TFI). The fuel valve is
opened. A flame should be established within the
15 second lockout time.
4. LOCKOUT. If flame is not sensed by the end of
the TFI, the control shuts down on safety lockout
and must be manually reset. If the control locks out
three times in a row, the control enters restricted
lockout.
5. IGNITION CARRYOVER. Once flame is estab-
lished, the ignition remains on for 10 seconds to
ensure flame stability before turning off. If the con-
trol is wired for intermittent duty ignition, the ignition
unit stays on the entire time the motor is running.
6. RUN. The burner runs until the call for heat is sati-
fled. The burner is then sent to burner motor off
delay, if applicable, or it is shut down and sent to
standby.
7. RECYCLE. If the flame is lost while the burner is
firing, the control shuts down the burner, enters a 60
second recycle delay, and then repeats the above
ignition sequence. If flame is lost three times in a
row, the control locks out to prevent cycling with
repetitious flame loss due to poor combustion.
8. BURNER MOTOR-OFF DELAY. The fuel valve
is closed and the burner motor is kept on for the
selected motor-off delay time before the control re-
turns the burn.er to standby.
STANDBY I
_LOCKOUT I
I
I61351
Control System Features
Feature Interrupted Limited reset, Diagnostic LED, Valve-on Burner motor Alarm Con=
ignition Limited recycle cad cell indicator delay off delay facts
R7184A YES YES YES i i i
R7184B YES YES YES YES -- --
R7184P YES YES YES YES YES Optional
6104BAFG R04 Page 17

Wire burner
Some Thermostats Are Polar=
ity Sensitive. Reversed polarity
could cause erratic cycling of the burner control.
•Connect the wire from the RHor R terminal on the
thermostat to the TR terminal on the control.
•Connect the wire from the W terminal on the
thermostat to the TW terminal on the control.
o Make connections to the control's terminals as shown
in Figures 11a and 11b. Refer to the label on the un-
derside of the control for wiring details.
o Note: Motor-off delay on a 7505P will be disabled if
the safety and operating limits as shown in Figures
11a and 11b interrupt power to the control terminal
L1.
o Connect thermostat leads to the TR and TW
terminals on the control or jumper the TR and
TW terminals on the control, as directed by the
appliance wiring diagram.
• Thermostat anticipator Current: 0.1 amp
• Thermostat voltage: 24 volts AC
Note that if the thermostat short cycles or operates
improperly, it may require an isolation relay for proper
operation. The Beckett A/C Ready Kit (part no. 51950U)
provides this function. Wiring instructions are included
with the A/C Ready Kit.
Start up burner/set combustion
Hot Gas Puff-Back and
Heavy Smoke Hazard
Failure to prime the pump properly could result
in unstable combustion, hot gas puff=back and
heavy smoke.
•Do not allow oil to spray into a hot combustion
chamber while bleeding air from the pump.
• Install a gauge in the nozzle discharge port
tubing or fully open the pump bleed valve to
prevent oil spray from accumulating in the com-
bustion chamber during the air bleed procedure.
•Ensure that all bubbles and froth are purged
from the oil supply system before tightening the
pump bleed valve.
•Ensure that the appliance is free of oil and oil
vapor before starting or resetting the burner.
3. Set the thermostat substantially above room tem-
perature.
4. Close the line voltage switch to start the burner.
If the burner does not start immediately you may
have to reset the burner primary control.
5. Initiate a call for heat.
6. After the burner starts, press and hold the reset
button for 15 seconds until the yellow light turns on.
This indicates that the button has been held long
enough.
7. Release the reset button. The yellow light will turn
off and the burner will start up again.
8. At burner start up, click the reset button while the
igniter is still on. This will transition the control to a
dedicated Pump Prime mode, during which the mo-
tor, igniter, and valve are powered for four minutes.
The yellow light will be on.
9. Bleed the pump until all froth and bubbles are
purged. If desired, terminate the call for heat or
hold the reset button for at least one second to exit
Pump Prime mode and return to Standby.
10.At the end of 4 minutes, the yellow light will turn off
and the control will automatically return to standby
mode.
11. If prime is not established during the four minute
pump prime mode, return to step 8 to re-enter Pump
Prime mode. Repeat steps 8 through 10 until the
pump is fully primed and the oil is free of bubbles.
12. Terminate the call for heat, and the control will re-
sume normal operation.
Cad Cell Resistance indicator
o During the burner Run state, click the reset button
(less than 1 second) to check the cad cell resistance
range. The yellow light will flash 1 to 4 times, de-
pending on the amount of light detected by the cad
cell. See chart below:
1 Normal(0-400ohms) l
2 N°rma!4°°-8°°°hms
3 Norma I (800- 1600 ohms) I
4 Limited (1600 ohms -Lockout) 1
Resetting From Restricted Lockout
o If the control locks out three times without a satisfied
call for heat, or fails the motor relay check, the Lock-
out becomes restricted in order to limit accumulation
of unburned oil in the combustion chamber.
o To reset, hold the button down for 15 seconds until
the red light turns off and the yellow light turns on.
o Always verify the control functions according to all
specifications before leaving the installation site.
.
2.
Open the shutoff valves in the oil supply line to the
burner.
Close air band and partially open air shutter. This
is an initial air setting for the pump bleeding pro-
cedure only. Additional adjustments must be made
with instruments.
o Replace the control if it does not operate as speci-
fied.
Page 18 6104BAFG R04

Startup /Checkout
Explosion and Fire Hazard
Failure to follow these instructions
could lead to equipment maifunc=
tion and result in heavy smoke
emission, soot=up, hot gas puff=
back, fire and asphyxiation hazards.
•Do not attempt to start the burner when excess
oil has accumulated in the appliance, the ap-
pliance is full of vapor, or when the combustion
chamber is very hot.
•Do not attempt to re-establish flame with the
burner running if the flame becomes extin-
guished during start-up, venting, or adjustment.
•Vapor-Filled _Ap_pliance: Allow the unit to cool
off and all vapors to dissipate before attempting
another start.
•Oil-Flooded A liance: Shut off the electrical
power and the oil supply to the burner and then
clear all accumulated oil before continuing.
• if the condition still appears unsafe, contact the
Fire Department. Carefully follow their directions.
•Keep a fire extinguisher nearby and ready for
use.
If the burner or control fails any of the following tests,
recheck control wiring. If the burner or control still fails
any tests, replace the control.
Startup/Checkout
4. After the 60 second recycle period, the control
will try to restart the system.
5. After the 15 second lockout time, the control
will lock out the burner and the reset button will
flash. Verify that the burner motor and igniter
are off and that the burner oil solenoid valve (if
used) is not energized.
6. Open the hand valve in the oil line.
7. Click the reset button and verify that the red light
in the reset button shuts off and that the burner
lights.
8. End the call for heat.
o Before leaving the installation, verify that all thermo-
stat and boiler/furnace control wiring is correct. Con-
sult heating appliance manual for directions.
Set combustion with instruments
CAUTION OIL-BURNING EQUIPMENT
SHALL BE CONNECTED TO
FLUES HAVING SUFFICIENT DRAFT AT ALL TIMES
TO ENSURE SAFE AND PROPER OPERATION OF
THE BURNER.
1. Allow the burner to run for approximately 5 to 10
minutes.
- Check Safety Features
o Safe Start Check
1. Place a jumper across the cad cell terminals.
2. Refer to the steps for "Start up burner/set
combustion" and have the system call for heat.
3. Burner must not start. Verify that the green light
is on continuously and that the control remains
in Standby mode.
4. End the call for heat and remove the cad cell
jumper.
o Simulate Flame Failure and Ignition Failure
1. Refer to the steps for "Start up burner/set
combustion" and have the system call for heat.
2. After flame is established and the burner igniter
turns off, close the hand valve in the oil supply
line.
3. At flame loss, the control will enter Recycle
mode. Verify that the green light is flashing. The
control will remain in Recycle for 60 seconds.
.
.
Set the stack or over-fire draft to the level specified
by the appliance manufacturer.
Natural Draft Applications; typically over-fire
draft is -0.01" or -0.02" w.c.
Direct Venting; typically may not require draft
adjustment.
High Efficiency/Positive Pressure Appliances;
also vary from traditional appliances (see manu-
facturer's recommendations).
Follow these four steps to properly adjust the burn-
er:
Step 1: Adjust the air shutter/band until a trace of
smoke is achieved.
Step 2:
Step 3:
At the trace of smoke level, measure the
CO2 (or 02) . This is the vital reference
point for further adjustments. Example:
13.5% CO2 (2.6% 02)
Increase the air to reduce the CO2 by
1.5 to 2 percentage points. (02 will be in-
creased by approximately 2.0 to 2.7 per-
centage points.) Example: Reduce CO2
from 13.5% to 11.5% (2.6% to 5.3% 02).
6104BAFG R04 Page 19

Perform regu|ar maintenance
Step 4:
o
Recheck smoke level. It should be Zero.
This procedure provides a margin of
reserve air to accommodate variable
conditions.
If the draft level has changed, recheck
the smoke and CO2 levels and readjust
the burner if necessary
4. Once combustion is set, tighten all fasteners on air
band, air shutter and head adjusting plate or es-
cutcheon plate.
.Burner equipped with cover - Reinstall the cover
and repeat Steps 2 and 4. If CO2 increases (02
decreases), remove the cover and adjust the air
setting so the CO2 (02) with cover on meets re-
quirements of Step 3.
.Start and stop the burner several times to ensure
satisfactory operation. Test the primary control and
all other appliance safety controls to verify that they
function according to the manufacturer's specifica-
tions.
Perform regular maintenance
Annual Professional Ser-
vice Required
Tampering with or making incorrect
adjustments could lead to equip-
ment malfunction and result in
asphyxiation, explosion or fire.
•DO NOT TAMPER WITH THE UNIT OR CON-
TROLS - CALL YOUR QUALIFIED SERVICE
TECHNICIAN OR SERVICEMAN.
• To ensure continued reliable operation, a quali-
fied 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.
CI Replace the oil supply line filter. The line filter car-
tridge must be replaced to avoid contamination of
the fuel unit and nozzle.
CI Inspect the oil supply system. All fittings should
be leak-tight. The supply lines should be free of
water, sludge and other restrictions.
CI Remove and clean the pump strainer if applica-
ble.
CI Verify the nozzle is the one originally specified by
the appliance manufacturer and replace the noz-
zle with one having the exact specifications from
the same manufacturer.
CI Clean and inspect the electrodes for damage, re-
placing any that are cracked or chipped.
CI Check electrode tip settings. Replace electrodes
if tips are rounded.
CI Inspect the igniter spring contacts. Clean or re-
place if corroded.
CI Clean the cad cell grid surface, if necessary.
CI Make sure Low Firing Rate Baffle is in place if
required for the burner application. Omitting the
baffle can result in unacceptable burner combus-
tion.
CI Inspect all gaskets. Replace any that are dam-
aged or would fail to seal adequately.
CI Inspect the combustion head and air tube. Re-
move any carbon or foreign matter. Replace all
damaged units with exact parts.
CI Clean the blower wheel, air inlet, air guide, burner
housing and static plate of any lint or foreign ma-
terial.
CI If motor is not permanently lubricated, oil motor
with a few drops of SAE 20 nondetergent oil at
each oil hole. DO NOT over oil motor. Excessive
oiling can cause motor failure.
CI Check motor current. The amp draw should not
exceed the nameplate rating.
CI Check all wiring for secure connections or insula-
tion breaks.
CI Check the pump pressure and cutoff function.
CI Check primary control safety lockout timing.
CI Check ignition system for proper operation.
CI Inspect the vent system and chimney for soot ac-
cumulation or other restriction.
CI Clean all flue passages and flue pipe. Replace
corroded or damaged pipes.
CI Clean the appliance thoroughly according to the
manufacturer's recommendations.
CI Check the burner performance. Refer to the sec-
tion "Set combustion with test instruments".
CI It is good practice to make a record of the service
performed and the combustion test results.
Shutting the Burner Off
CAUTION IF THE BURNER IS SHUT DOWN
FOR AN EXTENDED PERIOD OF
TIME, ALWAYS KEEP THE VALVE SHUT OFF.
Turn off all electric power to the burner.
Note: There could be more than one disconnect
switch.
Page 20 6104BAFG R04