Beckett CG10 User manual

Fire, Explosion and Asphyxiation Hazards
Failure to follow these instructions exactly could lead to fire or explosion and result in
death, severe personal injury or property damage.
1. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appli=
ance.
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.
• Immediately call your gas supplier from a telephone outside the building.
• Follow the gas supplier's instructions.
• Call the fire department if you cannot contact your supplier.
3. Installation and service must be performed by a qualified installer, service agency, or the gas supplier.
61 04 BCGIO RoB 11

Table of Contents
General information (Please...read this page first)
Hazard Definitions ............................................................................................................................................................. 3
To the Owner ..................................................................................................................................................................... 3
To the Installer................................................................................................................................................................... 4
Burner Specifications ......................................................................................................................................................... 4
Figure 1-Burner nameplate ............................................................................................................................................. 5
Pro=installation checklist .................................................................................................................................................. 5=8
Combustion air supply ....................................................................................................................................................... 5
Indoor Installation .............................................................................................................................................................. 5
Clearances ........................................................................................................................................................................ 6
Fuet gas supply ................................................................................................................................................................. 6
Flue vent system ............................................................................................................................................................... 6
Etectrical supply ................................................................................................................................................................. 6
Figure 1-Burner nameplate ............................................................................................................................................. 6
Verify burner components .................................................................................................................................................. 6
Verify firing input range ...................................................................................................................................................... 6
Figure 2 - Minimum combustion chamber dimensions ..................................................................................................... 6
Verify burner air tube assembly ......................................................................................................................................... 7
Figure 3 - Maximum capacity vs furnace pressure, Step spud ......................................................................................... 7
Figure 4 - Maximum capacity vs furnace pressure, Swirler head ..................................................................................... 8
Figure 5 - Burner dimensions ........................................................................................................................................... 8
Mount the burner .................................................................................................................................................................. 9
Figure 6 -Custom mounting prate .................................................................................................................................... 9
Connect gas piping ......................................................................................................................................................... 9=11
Figure 7- Typical gas piping layout ................................................................................................................................ 10
Table 1-Gas suppty piping capacity .............................................................................................................................. 10
Gas trains 9
Figure 8 - UL gas train configuration .............................................................................................................................. 11
Wire the burner .............................................................................................................................................................. 11=12
Figure 9- Typical burner wiring ...................................................................................................................................... 12
Sequence of operation ....................................................................................................................................................... 12
Prepare the burner for start=up .................................................................................................................................... 13=14
Start-up checklist ............................................................................................................................................................. 13
General ........................................................................................................................................................................ 13
Gas supply piping ............................................................................................................................................................ 13
Electrical 11
Boiler or appliance ........................................................................................................................................................... 13
Burner ........................................................................................................................................................................ 13
Figure 10 - CG10 Component familiarization ................................................................................................................. 14
Test instruments .............................................................................................................................................................. 14
Start the Burner ............................................................................................................................................................. 15=20
Burner start procedure ..................................................................................................................................................... 15
Verify input firing rate ....................................................................................................................................................... 15
Figure 11-Shutter and band tocation............................................................................................................................. 16
Table 2- Initial burner settings ......................................................................................................................................... 16
Figure 12 -Manifold to furnace pressure drop vs rate, Stepped spud ........................................................................... 18
Figure 13 - Manifold to furnace pressure drop vs rate, Swirl vane head ........................................................................ 18
Check operation and safety controls ............................................................................................................................... 19
Use test instruments to set combustion ........................................................................................................................... 20
Recommended combustion test sequence ..................................................................................................................... 20
Maintenance and Service .............................................................................................................................................. 21=23
Annual maintenance ........................................................................................................................................................ 21
Figure 14 -Gas Gun assembly installation ..................................................................................................................... 22
Figure 15A- Gas Gun assembly .................................................................................................................................... 23
Figure 15B - Gas Gun assembly ................................................................................................................................... 23
For the operator .................................................................................................................................................................. 24
Table 3 - Periodic inspection checklist ............................................................................................................................ 24
Replacement Parts ............................................................................................................................................................. 25
Burner Configurations .................................................................................................................................................. 26=27
Low Rate Burner Configuration; 300 to 800 MBH Applications ....................................................................................... 26
High Rate Burner Configuration; 600 to 1200 MBH Applications .................................................................................... 26
Burner Configuration Table .............................................................................................................................................. 27
Warranty Information ......................................................................................................................................... Back Cover
_-- 6104 BCG10 R08

Genera| information
Hazard Definitions:
indicates an imminently
hazardous situation,
which, if not avoided, will result in death,
serious injury, or property damage.
indicates apotentially
hazardous situation,
which, if not avoided, could result in death,
severe personal injury, and/or substantial
property damage.
indicates apotentially
hazardous situation,
which, if not avoided, may result in
personal injury or property damage.
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 j
intended to bring special attention to information, but not
related to personal injury or property damage.
To the Owner:
Thank you for purchasing a Beckett CGIO 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 burn-
er.
Your CG10 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-
mediately_ contact ou_!oML_qualifiedservice
for consultation.
We recommend annual inspection/service of your
gas heating system by a qualified service agency.
Owner's Responsibility
Failure to follow these instructions,
misuse, or incorrect adjustment of
the burner could lead to equipment
malfunction and result in asphyxia-
tion, explosion or fire.
Contact a professional, qualified service agency for the
installation, adjustment and service of your gas burning
system. Thereafter, have your equipment adjusted and
inspected at least annually to ensure reliable operation.
This work requires technical training, trade experience,
licensing or certification in some states and the proper
use of special combustion test instruments.
Please carefully read and comply with the following in-
structions:
* See the front cover for 'What to do if you smell
gas'.
* 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.
6104 BCGIO R08 :3

Genera| nform; ion (cont.)
Professional lnstaller's Responsibility
Follow these instructions
exactly.
Failure to follow these instructions
could lead to equipment
malfunction and result in
asphyxiation, explosion or fire.
•Please read all instructions before proceeding. Follow
all instructions completely.
•This equipment must be installed, adjusted and
started by a qualified service agency that is licensed
and experienced with all applicable codes and
ordinances and responsible for the installation and
commissioning of the equipment.
•The installation must comply with all local codes and
ordinances having jurisdiction and the latest edition
of the National Fuel Gas Code ANSi Z223.1 (NFPA
54) and CAN1-B149.1 in Canada.
General Specifications
Table 1 = Burner Specifications
Fuel
Flame safeguard
Ignition
Natural gas - 0.6 specific gravity typical
RM7895A Standard (Options available)
Direct spark main flame
iNOTICE ]
Concealed damage - If you discover damage to the
burner or controls during unpacking, notify the carrier at
once and file the appropriate claim forms.
High altitude installations -Accepted industry practice
requires no derate of burner capacity up to 2000 feet
above sea level. For altitudes higher than 2000 feet, de-
rate the burner capacity 2% for each 1000 feet above the
2000 feet.
50 Hz motors - The burner ratings, air settings and other
adjustments are based on 60 hz motors at 3450 rpm.
Derate firing capacity 20% when using 50 hz motors.
Consult factory for specific application data.
Special Requirements:
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.
Agency Approvals
Underwriters Laboritories
Certified by C-UL
Accepted by N.Y.C.M.E.A.
Other approvals may be available and must be speci-
fied at time of order.
4 61 04 BCGIO RoB

Figure 1. Burner Nameplate
General Model information ..........
Serial Number,
Including Date Code ........................
Rating Information .............
Approval Agency
Symbols
Primary Group ...........
and Fuel
%_es (}as !u_x_
................................................_ _£_...............................................
050214--00000
i !
=_ M@rs_ Gfsi_?$@d_ 4,8a
(;#i}_ 21GK
IRIe
f, ;::1,
r :::tk,.... i j.
21_/ g_di: ,!:3 ',
; ::;X: ....6;: .........
/B,_: t
C0t04IIRO0
05[214-00000
@ I
R.W. Beckett
Construction and Setting Data
R.W. Beckett Specification
....... Number and Revision
Boiler Manufacturer and Model,
,_............When Applicable
................................Additional Codes
Pre-instal|ation checklist
I3 Combustion air supply
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 and emission
of poisonous carbon monoxide gas.
• The burner cannot properly burn the fuel if it is not
supplied with a reliable combustion air source.
• Follow the guidelines in the latest edition of National
Fuel Gas Code ANSI Z223.1 (NFPA 54) and CANI-
B149.1 regarding providing adequate air for com-
bustion and ventilation.
• For appliance/burner units in confined spaces, the
room must have an air opening near the top of the
room, plus one near the floor, each with a free area
at least one square inch per 1000 Btu/hr input for all
fuel-burning equipment in the room.
g Indoor Installation
Protect against Dust and
Moisture
Wet or dusty environments could lead to blocked
air passages, corrosion damage to components,
impaired combustion performance and result in
asphyxiation, explosion or fire.
• This burner is designed for clean, dry installations.
• Electrical controls are not protected against rain or
sprayed liquids.
• Keep the installation clear of dust, dirt, corrosive va-
pors, and moisture.
• Protective covers and more frequent maintenance
may be required.
If there is risk of the space being under negative pres-
sure, or of exhaust fans or other devices depleting avail-
able air for combustion and ventilation, the appliance/
burner should be installed in an isolated room provided
with outside combustion air.
61 04 BCGIO RoB

Test For Gas Pipe Leaks
Leaking gas could result in asphyxiation, explo-
sion, or fire hazard.
• The gas supply piping must be absolutely leak-free.
• Pressure test the gas piping with air that is at least
three times greater than the gas pressure being
used.
• Verify that there are no leaks before proceeding.
OClearances
With the burner installed in the appliance, there must be
adequate space in front of and on the sides of the burner
to allow access and operation. Verify that the clearance
dimensions comply with local codes and with the appli-
ance manufacturer's recommendations.
OFuel gas supply
Verify that the gas supply piping complies with all appli-
cable local codes and the latest edition of the National
Fuel Gas Code ANSI Z223.1 (NFPA 54).
Insure that the supply gas pipe size is capable of provid-
ing at least the minimum pressure required to the burner
gas train inlet at the burner's full capacity rating. Refer
to Table 1.
OFlue vent system
The flue gas vent system must be in good condition and
must comply with National Fuel Gas Code ANSI Z223.1
(NFPA 54) and all other applicable codes having jurisdic-
tion for vent construction, capacity, and sizing.
OElectrical supply
Check the nameplate on the burner to verify that the
power connections available are correct for the burner.
Refer to Figure 1. All power must be supplied through
fused disconnect switches and comply with the latest
edition of National Electric Code NFPA 70 (Canada CSA
C22.1) and all other local or applicable codes.
OVerify burner components
• Burner model can be checked from burner carton or
rating label on burner
• Flange mounting arrangement (Includes high-tem-
perature gasket and/or fiber rope for pressure fir-
ing)
OVerify firing input range
Refer to appliance manufacturer's instructions (if avail-
able) for the firing input range. Otherwise the maximum
recommended firing range for the burner depends on the
length and width of the firing chamber and the distance
from the burner center to the chamber floor. Verify that
the chamber dimensions are at least as large as the min-
imum values given in Figure 2. If the appliance dimen-
sions are smaller, reduce the firing rate accordingly.
iNOTICE I
Dimensions shown are for cast iron sectional boilers with
uptakes between sections. For minimum dimensions of
other furnace types consult R.W. Beckett Corporation.
Figure 2. Minimum Combustion Chamber Dimensions
300-400
600-900
18 12 12
26 16 16
6
6 61 04 BCG10 R08

0Verify burner air tube assembly
•The information in this section may be disregard-
ed if the burner supplied by the appliance manu-
facturer is a matched component.
Maximum firing capacity depends on the furnace
pressure. Use the charts shown in Figure 3 and
Figure 4, to verify the correct burner configura-
tion for the input rate.
• Refer to Figure 5 to verify the air tube assembly
length and mounting insertion dimensions.
iNOTICE 1
The volume of the furnace also influences the combus-
tion process. R. W. Beckett Corp. recommends at least
1 cubic foot of furnace volume for each 150,000 BTU/Hr
of firing rate.
NOTICE I
Flames are shaped by their furnaces and by its flue Io=
cations. Increased height and width can decrease the
length requirement. When shaping is too severe flames
impinge on the walls. Impingement causes CO and car-
bon deposits and may damage the wall. Maintaining
these minimum dimensions should prevent impingement,
but smaller furnaces may be acceptable depending upon
the results of applications testing. We recommend fac-
tory testing of all new burner/furnace combinations by
the furnace manufacturer and/or R. W. Beckett Corp.
Figure 3. Maximum Capacity (at 3% 0 2) vs Furnace Pressure - Step Spud Configuration
1400
"r 1300
1200
>:, 1100
=_
o 1000
Q,. 900
O
E 800
E 700
=_
× 600 q
500
400
-----.-.__,.,__._.
.= = = = = =
==== = _ .==,=_ =
i
0 0.2 0.4 0.6 0.8
Furnace Pressure, In. W.C.
_CGI0.6S
_-CGI0.5S
-_- CGI0.4S
-4- ,CGI0.3S
-_<-,CG 10.2S
+CGI0.1S
6104 BCGIO R08 7

Figure 4. Maximum Capacity (at 3% 0 2) vs Furnace Pressure -Swirler Head Configuration
8OO
Z
G_ 700
o 600
O
E 500
E
× 400
300
[J,_
i
0.2 0.4 0.6 0.8
Furnace Pressure, In. WC
_CG10.3
-_-CG10.2
" _" CG10.1
Figure 5. Burner Dimensions
&l
10.4S - 10.6S 51961
I-1/4 NPT.........
.......................................................................25.0" .............................11.7"
25.7" __125"
8 61 04 BOG10 R08

U urner
Mount the burner to the appliance. The burner
specified for packaged equipment will have a
flange welded for the required insertion. Follow
the appliance manufacturer's instructions for
mounting.
Figure 6. Custom Mounting Plate
In the absence of instructions, or for retrofits,
make sure that the air tube insertion dimension,
measured along the side of the air tube from the
welded flange to the end of burner air tube, is
correct.
Protect the Air Tube
from Overheating
Overheating could cause damage to the air tube
and other combustion components leading to
equipment malfunction and impaired combus-
tion performance.
• The end of the air tube must not extend into the
combustion chamber unprotected unless it has been
factory-tested and specified by the appliance manu-
facturer.
• The end of the air tube should be set back ¼" from
flush with the refractory inside wall to prevent dam-
age from overheating.
• Refer to the instructions outlined in this section for
methods of additional protection.
If this dimension cannot be achieved, protect the
end of the air tube by installing a suitable ceramic
refractory material such as a refractory mill board
capable of withstanding at least 2300 degrees F.
The entry hole diameter in the appliance should
be 1" larger than the air tube to facilitate ease of
installation and provide adequate protection.
Referring to Figure 6, if the front plate opening
(C) in the boiler is larger than the burner flange
bolt circle, then a custom mounting plate (A) of at
least 1/4" thickness must be used with a suitable
high=temperature refractory material anchored
on the fire=side. A suitable high=temperature gas=
ket (B) must be used for an effective seal.
Attach the plate and gasket to the boiler and
tighten the mounting nuts or bolts securely.
Verify that the air tube is ¼" back from flush (see
Figure 2), and there is nothing blocking the flame
zone that could cause flame impingement.
Key:
A Burner mouning flange
B Gasket
C Appliance mounting plate
Connect as pi in
All gas piping installation must comply with the latest edi-
tion of the National Fuel Gas Code ANSI Z223.1 (NFPA
54) and other applicable local codes.
The gas supply system must be sized to deliver at least
the minimum required pressure to the gas train inlet.
Contact your local gas utility for verification of gas pres-
sures, allowable pressure drops, and any local piping
code requirements. Refer to Figure 7 for an illustration of
a gas piping layout and refer to Table 1 for pipe sizing.
Do Not Use Teflon
Tape on Gas Piping
Damage to gas valve cutoff seals and valve
bodies could cause gas leaks and result in
asphyxiation, explosion or fire.
•Pieces of tape can be cut loose during installation
and lodge in gas valves causing cutoff seal prob-
lems.
•Teflon tape 'lubricates' pipe threads, allowing iron
pipes to penetrate too deeply into aluminum valve
bodies causing distortion and leakage.
•Use only pipe sealant compounds that are resistant
to the gas being used.
6104 BCGIO RoB 9

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
SSOVl SAFETY SHUTOFF VALVE #1
TO TEST COCK
U UNION
2PRV TWO POSITION REGULATING VALVE
LGPS HGPS
DRiPLEG S
(IF USED)
Table 1. Gas supply piping capacity
30
5O
70
9O
125
175
152
115
96
84
72
59
285
215
180
160
130
110
590
44O
370
320
275
225
800
670
560
490
410
350
1650
1270
1050
930
780
65O
2700
2000
1700
1500
1250
1050
47O0
3600
3000
2600
2200
1850
97O0
74O0
6200
54OO
4500
3800
Install a Drip Leg in
Gas Supply Piping
Foreign matter could lodge in gas
valve cutoff seals, resulting in gas
leak-through, explosion or fire.
Install a full-size drip leg or dirt pocket in the piping di-
rectly ahead of the main shutoff valve to capture foreign
matter.
Gas Trains
Standard-An Underwriters Laboratories (UL)listed gas
train is standard for the CGI0 gas burner. This configu-
ration also meets CSD-1 requirements. See Figure 8 for
typical component layout.
Optional - Gas trains for IRI and FM are available and
must be specified when ordering a burner.
Verify - Verify that the train components are not dam-
aged and all piping and fittings are clean inside and out.
The gas train is normally shipped as components and
must be assembled and installed at the site.
Vent lines - Install vent lines to any gas valve compo-
nent that requires atmospheric air pressure to balance
a diaphragm. Vent lines must be run to the outdoors,
with the termination point away from fresh air intakes and
windows. The terminal opening must be fitted with a wire
mesh screen to block insects and other contaminants
from entering the vent and must be mounted in such a
position that water, ice, dirt, or any other foreign matter
cannot infiltrate and block the vent piping. Make sure the
final assembly is anchored securely.
11O61 04 BCG10 RoB

Figure 8. UL gas train configuration
LGPS HGPS
MSC U SOVI TC PRSSOV TC M_C U TC
LGPS HGPS
MSC U SOV_ TC PRSSOV TC
MLTC MAIN L_K TEST COCK I U UNION
j NOTICE ]
When pressure reducing safety shutoff
valves are used, the distance from the
final shutoff valve (PRSSOV in fig. 8)
to the burner manifold must be kept to
a minimum for good light-off reliability.
R.W. Beckett recommends the following
maximum lengths:
Pipe Size Max. Length
1" 12"
1-1/4" 15"
1-1/2" 18"
2" 24"
re rner
Install the burner and all wiring in accordance with the
National Electric Code ANSI/NFPA 70 (Canada CSA
C22.1) and all applicable codes and requirements. Wire
the burner in compliance with all instructions and dia-
grams provided by the appliance manufacturer. Verify
operation of all controls in accordance with the appliance
manufacturer's guidelines.
See Figure 9 for a typical wiring diagram, with the
RM7895A flame safeguard control, for reference purpos-
es only. Check the literature that was packaged with the
burner for the primary control manufacturer's instructions
and the exact wiring diagram for your specific burner.
Do Not Bypass Safety
Controls
Tampering with, or bypassing safety con=
trois could lead to equipment malfunction
and result in asphyxiation, explosion or
fire.
• Safety controls are designed and installed to pro-
vide protection.
• Do NOT tamper with or bypass any safety control.
• Ifa safety control is not functioning properly, shut off
all main electrical power and gas supply to the burn-
er and call a qualified service agency immediately.
Electrical Shock
Hazard
Electrical shock can cause severe
personal injury or death.
• Disconnect electrical power before installing or ser-
vicing the burner.
• Provide ground wiring to the burner, metal control
enclosures and accessories. (This may also be re-
quired to aid proper control system operation.)
• Perform all wiring in compliance with the Nation-
al Electrical Code ANSI/NFPA 70 (Canada CSA
C22.1)
Keep Service Access
Covers Securely
Installed
These covers must be securely in place to
prevent electrical shock, damage from ex=
ternal elements, and protect against injury
from moving parts.
All covers or service access plates must be in place
at all times except during maintenance and service.
This applies to all controls, panels, enclosures,
switches, and guards or any component with a cov-
er as part of its design.
61 04 BCG10 RoB I I

Figure 9. Typical wiring using Model RM7897A (for reference only)
AiR
PROVING
SWITCH
FLAME ROD
SEE NOTE I
LINE VOLTAGE SE3VICE t20V 60Hz
_ FROM FUSED DISCONNECT
SUPPLIED BY INSTALLER
HIGH GAS LOW GAS ._.k
PRESSURE PRESSURE LW.C.O. HIGH OPERATING LIMIT CONTROL
w m m W_RED BY _NS'TALLER
_* SUPPLiEDBY CUSTOMER
FIBLD WiRiNG TIE.-N
Key:
TRANS o_GN_T!ON T_AINSFORMER
GV1 _©N_'@FFGAS VALVE
GV2 _HIGH LOW VALVE
LWC©. -LOW WATER CU%OP_
WkeColor:
A-, WH{TE
B BLACK
C _BLUE
D_ORANGE
E _BROWNfRED
G -BROWN
H-REDfWHt_ E
L_B_CKfRED
Notes:
. FOR UV RUN WHTE W!RE TO G TER#,.t_NAL
AND BLUE W_RE TO F TERM NAL
FOR FLAME ROD RUN W_RE TO F, G
iS A CHASSIS GROUND,
2, "- CLiP AND RB'_,IOVE JUMPER JR1
G_O
TERM_N_AL
Sequence of peration ..
(typical for RM7895A flame safeguard primary control)
1. Initiate - The primary control enters the INITI- 5.
ATE sequence when the control is first powered
on or power returns after an interruption. The
initiate sequence is a ten second delay during
which the control verifies line voltage stability.
.
.
.
Standby - The control enters STANDBY until
the limits, operating limit control, burner switch,
and all microcomputer-monitored circuits are in
the correct state.
Load demand - Operating limit control contacts
close on drop in temperature (or pressure) and
initiates the start sequence.
Prepurge - The control will signal the PRE-
PURGE sequence when the airflow interlock
and all switches are in the correct state. The Pre-
purge sequence is the amount of time the blower
motor runs prior to the ignition start sequence.
Timing for the Prepurge sequence is determined
by a card mounted inside the control module
(typically 30 seconds).
Trial for ignition (TFI) - After the Prepurge se-
quence has timed out, the ignition and main gas
valves will be energized. Because the burner
has direct spark ignition for the main flame, the
flame must be established and detected by the
control within 4 seconds or lockout will occur.
.Run - With a flame established and the control
continuing to detect a flame, the burner will op-
erate in the RUN mode until the load demand is
satisfied or a limit opens.
7. Load Satisfied -The burner switches to idle un-
til the next call for operation.
jNOTICE ]
This operation sequence is typical and for reference
only. The primary control could vary, depending on the
customer specification and code requirements. For the
specific operating sequence that applies to your instal-
lation, consult the appliance manufacturer's directions,
wiring instructions, and control manufacturer's literature
supplied with your burner.
112 6104 BCGIO RoB

pare rner for start-up
Professional
installation &Service
Required
/ncorrect installation and mis-
handling of start-up could lead to
equipment malfunction and result
in asphyxiation, explosion or fire.
*This burner must be installed and prepared for start-
up by a qualified service technician who is trained
and experienced in commercial gas burner system
installation and operation.
*Do not attempt to start the burner unless you are fully
qualified.
* Carefully follow the wiring diagrams, control instruc-
tion sheets, flame safeguard sequence of operation,
test procedures and all appliance manufacturer's di-
rections that pertain to this installation.
* If any of these items are not clear or are unavailable,
call Beckett at 1-800-645-2876 for assistance.
CI
CI
Insure that the fuel gas being supplied is compat-
ible with the burner specification and is available
at the correct regulated pressure. (See burner
name plate and specification sheets).
Insure that the vent lines for the diaphragm valves
have been run to the outside and properly termi-
nated.
3. Electrical
E3
E3
Insure that all wiring has been completed and
complies with the National Electric Code NFPA
70 and local requirements.
Refer to Figure 1 and verify that the electrical
supply to the burner matches the voltage specifi-
cation on the label.
4. Boiler or Appliance
CI Insure that the flue passages and combustion
area have been thoroughly cleaned and are in
good condition.
Start=up checklist -Verify the following before
attempting to start the burner
1. General
E3 Carefully read and become familiar with the
CGI0 Manual, Flame Safeguard Control Instruc-
tions, sequence of operation, pertinent wiring
diagrams, gas system layout, insurance require-
ments, other controls and valve literature perti-
nent to the installation.
CI Follow the appliance manufacturer's start-up pro-
cedures (when available).
CI Inspect the combustion air supply and exhaust
venting and verify that they are free of obstruc-
tions and installed and sized in accordance with
all applicable codes.
CI Notify appropriate personnel to schedule start-
up (gas utility, owner, operators, subcontractors,
etc.).
2. Gas Supply Piping
CI Insure that the gas piping is properly sized and
has been inspected by the gas utility, leak tested
at all joints, and purged.
CI To protect the gas train and controls, insure that
a drip leg or dirt pocket has been properly in-
stalled.
CI
CI
CI
CI
Set the breech damper to the required position
for system operation.
Fill the appliance with water (boilers).
Check all safety and operating controls for correct
application, installation, wiring, and operation.
Insure that the maximum capacity of the appli-
ance is compatible with the specified burner input
firing rate.
5. Burner - See Figure 10 for familiarization
CI
CI
Insure that the gas burner model and capacity
meet the requirements for the installation.
Insure that the gas train meets operating speci-
fications, all safety codes and insurance require-
ments.
CI
CI
Refer to Table 2 and Figure 11 to insure that the
burner air shutter and band are positioned for ini-
tial start-up preliminary settings.
Insure that the burner is securely mounted in the
appliance with the pressure firing plate and all
gaskets in place for pressurized chamber appli-
cations.
CI Before operating insure that all protective cover
plates, enclosures and guards are in place and
securely fastened.
6104 BCG10 R08 113

CI When available, refer to the appliance manufac-
turer's instructions and install the burner accord-
ingly.
6. Test instruments
CI The following calibrated test equipment is re-
quired to properly install the appliance. Whether
these are included in one kit or are individual test
components, they should be calibrated and in
good working order.
CI A combustion analyzer capable of measuring
oxygen (or carbon dioxide), carbon monoxide,
CI
CI
stack temperature, ambient temperature, and ap-
pliance efficiency.
Electrical multi-meter capable of measuring volt-
age, ohms, amps, and DC micro-ammeter for
measuring the flame signal. These could be
included in one meter or separate meters, but
should be calibrated and accurate.
Calibrated manometers and gauges capable of
measuring all pressure ranges in the gas supply
and appliance draft. This could typically range
from a few psi to 0.01" W. C.
Figure 10. CGIO component familiarization
REMOVE THESE SCREWS
TO OPEN TRANSFORMER
MAJOR COMPONENTS
1_JACKING SCREW
2_ IGNITION TRANSFORMER
3. PRIMARY CONTROL
z_ BLOWER MOTOR
5 A_R FLOW PROWNG SWITCH
6 ELECTRODE CABLE*
7 UV FLAME DETECTOR (iF USED}
8 SHU_ER
9. AiR BAND
10 H_GH GAS PRESSURE SW_TCH
11_ MAN_FOLD PRESSURE TEST CONNECTION
12. GAS GUN ASSEMBLY
_tJNPLUGFROM_RANSF'ORMER WHEN SERVICI_4G
114 6104 BCGIO RoB

Start the Burner
Professional Installation
and Service Required
Incorrect installation and mis=
handling of start-up could lead to
equipment malfunction and result
in asphyxiation, explosion or fire.
•This burner must be installed and prepared for start-
up by a qualified service technician who is trained
and experienced in commercial gas burner system
installation and operation.
• Do not attempt to start the burner unless you are fully
qualified.
• Do not continue with this procedure until all items in
the 'Prepare the Burner for Start-up' section have
been verified.
• Carefully follow the wiring diagrams, control instruc-
tion sheets, flame safeguard sequence of operation,
test procedures and all appliance manufacturer's di-
rections that pertain to this installation.
• If any of these items are not clear or are unavailable,
call Beckett at 1-800-645-2876 for assistance.
Burner start procedure:
(Before proceeding, turn off and lock out
electrical power and close the main leak test
cock to shut off gas to the burner.)
1. With the power and main gas supply to the burn-
er turned off, make sure gas has not accumu-
lated in the boiler or flues.
.
.
Check the initial air settings (shutter & band) for
input firing rate. Check the manufacturer's set-
tings either on the nameplate shown in Figure
1 or listed in Table 2. If adjustment is necessary
refer to Figure 11 and loosen the adjustment
screws then twist the shutter and/or air band un-
til the indicators point to the values shown on the
nameplate or listed in Table 2.
With the main gas supply valve closed. Set the
limit or controller to call for heat then apply pow-
er to start the burner. Reset the high and low gas
pressure switches if necessary.
.
.
In order to check the function of each component
(i.e: flame safeguard sequence, airflow proving
switch, ignition transformer, gas valves, safety
lockout timing, etc.), with the gas supply closed
off, monitor a complete burner run sequence.
Note that the flame safeguard control will lock
out since the fuel supply has been closed off.
If component operation sequence and function
is correct, reset the flame safeguard and initi-
ate a new cycle. Monitor the start-up cycle and
manually open the main leak test cock as soon
as the flame safeguard powers the safety shut-
off valves. If the boiler room is quiet you may
be able to hear the valve open, if not you can
generally place your hand on the valve and feel
it open. After you have observed main flame
for a brief time, trip any of the switches in the
limit string to shut the burner down. Monitor the
flame and safety shutoff valves to assure that
shutdown is controlled by the valves and that
they operate properly. With this test passed you
may safely initiate automatic start-ups on subse-
quent cycles.
Verify input firing rate:
.Clock the meter for CFH and calculate the input
firing rate. Compare the calculated rate to the
specified input for the boiler found on the speci-
fication sheets and on the rating plates for the
burner and boiler. Do not exceed the specified
maximum input for the boiler.
.Attach a manometer to the manifold test port,
clock the meter, and adjust the regulated pres-
sure until the specified input level is achieved.
Refer to Table 2.
3. Be sure to set the breech or furnace pressure to
the correct value, since this will have an effect on
the manifold pressure.
61 04 BCGIO ROB 115

Figure 11. Shutter and Band
SHUTTER
(for low rate adjustments)
adjust this with band fully
CLOSED AIR BAND
(for high rate adjustments)
adjust this with shutter fully
OPEN
O= Tighten locking screws securely after adjustments have been made
Table 2. initial burner settings
NOTICE ]
The shutter and band both control the amount of flow
area available for air inlet to the burner. The greater their
combined flow area, the higher the firing rate. The pri-
mary differences between the two are their ease of ad-
justment and their total airflow area. The shutter turns
more easily and has a smaller net flow area. As a result
we have found the shutter to be better suited for low rate
adjustments, and the band better suited for high rate ad-
justments. We recommend that at low rates the band
be left completely closed until the shutter has been fully
opened, and that for higher rates the shutter is left com-
pletely open as the band is opened.
300 CG 10.1S 1.0 0.5 3 0 1.3 0.6 3 0 1.5 0.8 4 0 2.0 1.0 6 0
400 CG10.2S 1.1 0.5 4 0 1.3 0.7 4 0 1.6 0.8 5 0 2.1 1.0 6 0
500 CG10.3S 1.2 0.6 6 0 1.5 0.7 7 0 1.7 0.9 8 0 2.2 1.1 10 1
800 CG10.5S 3.1 1.6 8 0 3.4 1.7 9 0 3.6 .8 10 1 4.1 2.1 10 3
1000 CG 10.6S 3.2 1.6 10 0 3.4 1.7 10 2 3.7 1.8 10 3 4.2 2.1 10 6
1200 CG10.6S 4.6 2.3 10 6 4.9 2.4 10 8 5.1 2.6 10 10
300 CG10.1 1.5 0.8 3 0 1.8 0.9 3 0 2.0 .0 4 0 2.5 1.3 5 0
400 CG10.2 1.6 0.8 4 0 1.8 0.9 4 0 2.1 .0 5 0 2.6 1.3 6 0
500 CG10.3 1.5 0.8 5 0 1.8 0.9 5 0 2.0 .0 6 0 2.5 1.3 8 0
Notice: The settings in this chart are for reference only. The actual conditions at the installation may require further adjustment by the fully qualified
and experienced start-up technician.
I 6 6104 BOG10 RoB

Estimating Rate
Manifold to Furnace Pressure information can be used to estimate the burner's firing rate when it is not possible to clock
a meter for the rate.
To estimate the burner's firing rate:
• Measure the furnace pressure over fire
• 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.
NOTICE i
Clocking agas meter
Before you clock the meter you must make sure that the burner is operating at a steady rate, and that it is the only
thing that is using gas that would flow through the meter.
Uncorrected flow rate
• Locate the dial that moves the fastest and determine how many cubic feet are represented by one revolution of
its dial.
• Use your watch for timing and observe how many cubic feet are used in one minute.
• Multiply by 60
Example: The dial is a one cubic foot dial, and goes around 7 ½ times in one minute. That gives 7.5 cubic feet per
minute. Multiply by 60 to get 450 cubic feet per hour (CFH) as your uncorrected flow rate.
Pressure correction
Gas is compressible, the higher the pressure on it, the smaller the number of cubic feet it occupies. To correct for
that you will need to know the gas pressure at the meter.
• Ifthere's a gauge at the meter, read it while the gas is flowing. (If not, measure the gas pressure in the line down-
stream of the meter before any valves or regulators, with no gas flowing.)
• Convert the gas pressure to PSI if you measure it in any other units. (1 PSI = 27.7 inches water column)
• Add 14.7 to the meter pressure, divide their sum by 14.7, and multiply that result times the uncorrected flow rate
to obtain the pressure corrected flow rate.
Example: The meter in the example above is operating at 14" WC.
14 /27.7 = .5 PSI at the gauge; 14.7 + .5 =15.2; 15.2 /14.7 = 1.034 correction factor;
1.034 x 450 = 465 CFH corrected for pressure
Temperature correction
Gas volume also changes with the temperature of the gas. Most gas meters are temperature compensated, and say so
on the face of the index and don't require temperature correction. The temperature we correct to is 60° F. That's close
to the temperature of the ground, so usually it's not necessary to correct for temperature from underground lines.
• Measure the gas temperature at the meter.
• Add 460 to the gas temperature and divide 520 by the result to obtain the correction factor.
• Multiply the pressure corrected flow rate times the temperature correction factor.
Example: The meter in the example is connected to an above ground line on a hot day and shows 100° F gas tem-
perature. 460 + 100 = 560; 520 /560 = .929; 465 x .929 = 432 CFH corrected for pressure and temperature. This
figure is often called SCFH (for standard cubic feet per hour).
BTU's and iViBH
The BTU content of natural gas varies from one location to another, and even from day to day at a fixed location. For
firing estimates it is usually assumed to be 1000 BTU's per standard cubic foot.
To calculate BTU/Hr firing rates multiply SCFH times 1000.
Example: 432 SCFH x 1000 = 432,000 BTU/Hr.
MBH stands for thousands of BTU's per hour. Since 1 cubic foot of natural gas contains 1000 BTU, 1 MBH equals 1
SCFH of gas flow.
Example: 432 SCFH = 432 MBH
61 04 BCG10 FIOIB 11"2'

Figure 12. Manifold to Furnace Pressure Drop vs. Rate -Stepped Spud Design
-r-
m
n,,
1400
1200
1000
800
600
4OO
200
q
t
I
f
I
1
I I I
234
Pressure Drop, In. WC
I
5
--÷ - CG 10.6S
-43--CG10.5S
--_-- CG10.4S
-'4 -CG10.3S
_-A -CG10.2S
+CG10.1S
I
6
Figure 13. Manifold to Furnace Pressure Drop vs. Rate - Swirl Vane Head Design
900
800
700
600
m
500
400
n,,
300
200
100
0
I
J
I o
S
I
1
I I
2 3
Pressure Drop, In. WC
I
4
I
5
_CG10.3
oI _CG10.2
=CG10.1
118 6104 BCGIO R08

Check operation and safety controls:
Testing by Qualified
Technician Required.
Failure to properly test and verify the correct
function of operation and safety controls
could lead to equipment malfunction and
result in asphyxiation, explosion or fire.
•The testing of operation and safety controls requires
technical training and experience with commercial
gas burning systems.
• Carefully follow the manufacturer's instructions sup-
plied with the controls.
• Verify the correct function of all operation and safety
controls used in the installation.
• If instructions are not available, use the following
recommended procedures and record all results in
a start-up log.
• Refer to Figure 7 and Figure 10 for typical test points
and component locations.
.
.
.
.
High limit - To check the High Limit, raise the
temperature or pressure of the operating control
to a higher level and lower the limit to a setting
less than the operating control. Run the burner
until the high limit opens and shuts the burner
off. Adjust the controls back to the desired set-
tings.
Operating control - Run the burner until the
operating control shuts it off. If necessary, make
adjustments to ensure the control cycles the
burner in the desired temperature or pressure
range.
Low water cutoff (LWCO) - With the burner fir-
ing, open the blow down valve on the low water
cutoff, if applicable. As the water level drops, the
LWCO switch contacts open and shut the burner
off. When the water level rises, the LWCO con-
tacts close and restart the burner. Monitor the
LWCO switch operation in relation to the water
level in the sight-glass for synchronization.
Airflow proving switch - With the burner firing
at its lowest rate, loosen the tubing connection
to the airflow proving switch. A loss in air pres-
sure at the tubing should immediately cause the
diaphragm in the switch to open and recycle or
lockout the safeguard control.
.
.
.
.
.
10.
Low gas pressure switch -With the burner
firing and a manometer attached to a test port
near the low pressure switch, gradually close the
main leak test cock to shut off the gas supply.
Note the pressure at which the low gas pressure
switch opens and shuts the burner off. Manually
reset the switch. The low gas pressure switch
should be set at half of the normal supply pres-
sure in the line.
High gas pressure switch - With the burner fir-
ing and a manometer attached to the test port
nearest the high pressure switch, gradually in-
crease 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 set at one and
one half times the high fire manifold pressure
(see nameplate data in Figure 1 or set switch as
determined by testing).
Leak=test valve - With the burner firing and ma-
nometer attached to the leak4est valve port, turn
the burner electrical switch off and observe that
the gas pressure does not increase after several
minutes. This proves total closure of the main
gas valve.
Flame safeguard safety lockout - Simulate a
flame failure by turning the main gas supply off.
The control should shut the burner off on safety
within the safety lockout time.
Flame sensor circuit (flame rod) - With the
burner power switch turned off, refer to the wir-
ing diagram supplied with the control and locate
the sensor connection terminals. Place DC volt-
meter probes in the flame amplifier test jacks.
With the burner firing, the flame signal should be
steady and at least 1.25 VDC.
Flame sensor circuit (UV scanner) - With the
burner power switch turned off, refer to the wir-
ing diagram supplied with the control and locate
the sensor connection terminals. Place DC volt-
meter probes in the flame amplifier test jacks.
With the burner firing, the flame signal should be
steady and at least 1.25 VDC.
61 04 BCGIO RoB I 9

Use test instruments to set combustion:
iNOTICE i
Always use calibrated test instruments to set combus-
tion levels. Verify that test instruments are calibrated and
in good working condition. If not already provided, drill
test access holes in the flue pipe near the breech (or
upstream of the boiler breech damper, if applicable) and
in the front mounting plate area for firebox pressure. Be
careful not to damage any water-backed surface.
Verify that all boiler sections, canopy, and access plates or
doors are fully equipped with gaskets and sealed against
any leakage, which could affect the combustion test re-
sults. Before making these tests, operate the burner for
several minutes to allow the heating system temperature
to stabilize or nearly reach steady-state levels. Record
all results in the start-up log for future reference.
CI Draft - Set the breech or furnace pressure to the
level specified by the appliance manufacturer.
Typical example: +0.10" W. C.
C3
C3
C3
Oxygen - It is recommended that you measure
the oxygen (02) early in the test sequence be-
cause high levels of carbon monoxide can be cre-
ated at very low or even very high 02 levels. The
typical operating range is between 2.5% - 4.5 %.
The equivalent carbon dioxide (CO2) operating
range is 9% - 10.5%.
Carbon monoxide (CO) -An operating range of
0 -50 PPM is recommended for the CGI0 burner.
The maximum carbon monoxide (CO)level per-
mitted in the flue gas by the UL 795 Standard is
400 PPM (.04%).
Stack Temperature - The stack temperature
should be within the range specified by the appli-
ance manufacturer. It is influenced by input firing
rate, flame shape, excess air ratio, and cleanli-
ness of boiler flue passages. This temperature,
combined with the ambient temperature, and
02% (or CO2) is used in calculating the appli-
ance efficiency.
Recommended combustion test sequence:
.
.
.
.
Adjust the draft or breech pressure to the appli-
ance manufacturer's recommended level. provide a margin of reserve air to accommodate variable conditions.
Measure the carbon monoxide level and adjust
air settings, if necessary, to regulate it to about
50 PPM for a starting point.
Measure the 02 or CO2 at the 50 PPM CO level.
For this discussion, assume the 02 is 1.5% (11%
CO2).
Open the air adjustment until the 02 level ts in-
creased by at least 1% or to 3% 02 (whichever
is higher). This should reduce the CO level and
5. Sample the CO level again. It should be in the 0
to 20 PPM range.
6. Check the draft to ensure it still meets specifi-
cations. If a major change in draft is required,
repeat the above steps.
.Perform any final adjustments and lock the air
settings securely. Run the burner through sev-
eral cycles to verify prompt ignition and stable
burner operation.
_-O 6104 BCGIO R08