Beckett CG25 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 smefl 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.
6104 BOGS0 RoB 11

Table of Contents
Please...read this page first
Hazard Definitions ............................................................................................................................................................. 3
To the Owner ..................................................................................................................................................................... 3
To the Installer ................................................................................................................................................................... 3
Warranty 3
Pre-instatlation checklist ......................................................................................................................................................... 4
Indoor Installation .............................................................................................................................................................. 4
Combustion air supply ....................................................................................................................................................... 4
Clearances ........................................................................................................................................................................ 4
Fuel gas supply ................................................................................................................................................................. 4
Flue vent system ............................................................................................................................................................... 5
Electrical supply ................................................................................................................................................................. 5
Figure 1- Burner nameplate ............................................................................................................................................. 5
Verify burner components .................................................................................................................................................. 5
Verify firing input range ...................................................................................................................................................... 5
Figure 2 - Minimum combustion chamber dimensions ..................................................................................................... 5
Verify burner air tube assembly ......................................................................................................................................... 6
Figure 3 - Maximum capacity vs furnace pressure, Step spud ......................................................................................... 6
Figure 4 - Maximum capacity vs furnace pressure, Swirler head ..................................................................................... 6
Figure 5 - Burner dimensions ........................................................................................................................................... 7
Mount the burner .................................................................................................................................................................... 7
Figure 6 - Custom mounting plate .................................................................................................................................... 8
Connect gas piping ................................................................................................................................................................. 8
Figure 7 - Typical gas piping layout .................................................................................................................................. 8
Table 1 - Gas supply piping capacity ................................................................................................................................ 9
Gas trains 9
Figure 8 - UL gas train configuration ................................................................................................................................ 9
Wire the burner ..................................................................................................................................................................... 10
Figure 9- Typical burner wiring ...................................................................................................................................... 10
Sequence of operation .......................................................................................................................................................... 11
Prepare the burner for start-up ............................................................................................................................................. 11
Start-up checklist ............................................................................................................................................................. 11
General ........................................................................................................................................................................ 11
Gas supply piping ............................................................................................................................................................ 11
Electrical 11
Boiler or appliance ........................................................................................................................................................... 12
Burner ........................................................................................................................................................................ 12
Figure 10 - CG10 Component familiarization ................................................................................................................. 12
Test instruments .............................................................................................................................................................. 12
Start the Burner .................................................................................................................................................................... 13
Burner start procedure ..................................................................................................................................................... 14
Figure 11- Shutter and band location ............................................................................................................................. 14
Table 2 - Initial burner settings ......................................................................................................................................... 15
Verify input firing rate ....................................................................................................................................................... 15
Figure 12 - Manifold to furnace pressure drop vs rate, Stepped spud ............................................................................ 15
Figure 13 - Manifold to furnace pressure drop vs rate, Swirl vane head ........................................................................ 16
Check operation and safety controls ............................................................................................................................... 17
Use test instruments to set combustion ........................................................................................................................... 18
Recommended combustion test sequence ..................................................................................................................... 18
Maintenance and Service
Annual maintenance ........................................................................................................................................................ 19
Figure 14A- Gas Gun assembly .................................................................................................................................... 20
Figure 14B - Gas Gun assembly ................................................................................................................................... 20
Figure 15 - Gas Gun assembly installation ..................................................................................................................... 21
For the operator .................................................................................................................................................................... 22
Table 3 - Periodic inspection checklist ............................................................................................................................ 22
Replacement Parts
Burner exploded view ...................................................................................................................................................... 23
Burner Configurations ........................................................................................................................................................... 24
Low Rate Burner Configuration; 300 to 800 MBH Applications ....................................................................................... 24
High Rate Burner Configuration; 600 to 1200 MBH Applications .................................................................................... 24
Burner Configuration Table .............................................................................................................................................. 25
2 6104 BCGSO R08

hera| rrn ion
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.
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 burner for use
with your heating appliance. Please pay attention to
the Safety Warnings contained within this instruction
manual. Keep this manual for your records and pro-
vide it to your qualified service agency for use in pro-
fessionally setting up and maintaining your burner.
Your burner will provide years of efficient operation if
it is professionally installed and maintained by a quali-
fied service technician. If at any time the burner does
not appear to be operating properly, immediately__
contact ov_o_M_Lqualifiedservice_ for consulta-
tion.
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 liq-
uids or vapors near this burner or appliance.
• Never attempt to burn garbage or refuse in this ap-
pliance.
• Never attempt to light the burner/appliance by throw-
ing burning material into the appliance.
• Never attempt to burn any fuel not specified and ap-
proved for use in this burner.
• Never restrict the air inlet openings to the burner
or the combustion air ventilation openings in the
room.
61 04 BCGSO RoB 3

General nforrn ion
Professional Ir|staller's Responsibility Pre-installation checklist
Follow these instructions
exactly.
Failure to follow these instructions
could lead to equipment malfunc-
tion and result in asphyxiation,
explosion or fire.
• Please read all instructions before proceeding. Follow
all instructions completely.
• This equipment must be installed, adjusted and start-
ed by a qualified service agency that is licensed and
experienced with all applicable codes and ordinances
and responsible for the installation and commission-
ing 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.
Concealed damage - If you discover damage to the burn-
er or controls during unpacking, notify the carrier at once
and file the appropriate claim forms.
High altitude installations- Accepted industry practice re-
quires no derate of burner capacity up to 2000 feet above
sea level. For altitudes higher than 2000 feet, derate 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. De=
rate firing capacity 20% when using 50 hz motors. Con-
sult factory for specific application data.
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.
[3 Combustion air supply
The burner requires combustion air and ventilation air for
reliable operation. Assure that the building and/or com=
bustion air openings comply with the latest edition of the
National Fuel Gas Code ANSI Z223.1 (NFPA 54). For ap-
pliance/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. For Canadian installations, refer to latest edi-
tion of CAN1- B149.1 standard.
If there is risk of the space being under negative pressure,
or of exhaust fans or other devices depleting available
air for combustion and ventilation, the appliance/burner
should be installed in an isolated room provided with out-
side combustion air.
[3 Clearances
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.
[3 Fuel 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.
46104 BCGSO RoB

Table1 = Burner Specifications
CG25 ICGS0
input firing range:High Fire (Max.) 1500 MBH 2700 MBH 5000 MBH
High Fire (Min.) 800 MBH 1300 MBH 2000 MBH
Low Fire (Max.) 560 MBH 990 MBH 1400 MBH
Low Fire (Min.) 350 MBH 550 MBH 730 MBH
Fuel: i Natural gas z 0.6 Specific gravity typical
Gas Train: Standard U.L. Listed /CSD-1 configuration
Options IRI, FM
Gas Train inlet Pressure:
Minimum &5!' WC*
Maximum 10 PSi 10 PSi 10 PSi
Manifold pressure:
Highest High Fire 3.7" WC 3.5" WC 3.5" WC
Lowest High Fire 2.7" WC 2.5" WC 2.5" WC
HighiLow HighiL0w
Modulation Modulation Modulation
Standard Flame Safeguard:
Low Fire Start RM7895A
High /Low RM7895C RM7895C RM7895C
Modulation RM7895C RM7840L RM7840L
Flame Detector: Standard
Optional UV -
Airflow Proving Switch: Standard Standard Standard
Gas pressure switches: i Standard high and low
ignition: Direct ignition of Main Flame
1i2HP
3450 RPM 3450 RPM
Standard Voltage 120 volt, i phl 60 Hz 120 vo!t, ! phl 60 HZ 208!230v, 1 ph, 60 Hz
Current Draw 6.4 Amps @! 20 volt AC !0.4 Amps @!20 vo!t AC 1&4 Amps @230 volt AC
OptionalVo!tages 208/230V ! ph 60Hz 208/230v i ph 60Hz 208!230V, 3Phi60Hz
208/230VI 3 ph; 60 Hz 2081230V, 3 ph, 60 Hz 460V, 3 ph, 60 Hz
460V, 3 phl 60 Hz 460V, 3 phl 60 Hz
575v, 3 phl 60 HZ 575v, 3 ph 60Hz
Weight: 125 lbs. 145 lbs. 165 Ibs.
Dimensions: Refer to Figures 4 & 5.
*See manufacturer's nameplate settings for specific minimum gas pressure requirements.
Figure 1. Burner label location
Generalmodel information _ _._,_ CC50
}.................._ _.:_!_....................
Serial number,including date code _ 4. 0
I HWii
Rating information _*_ i_:_c:_::_"_-_'__',
Approval agency symbols _.
Primary group and fuel _ ::" ;
,: ,)4 1
M 1:
:¢* :'":_'_ R.W. Beckett construction
and setting data
(i!i'i_/4 i:_t_: _ R.W. Beckett specification number
..........................................*;............ and revision
,c : _ Boiler manufacturer and model
(when applicable)
Additional codes
61 04 BCGSO 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.
[3 Flue 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.
Figure 2. Minimum Combustion Chamber Dimensions
[3 Electrical supply
Check the nameplate on the burner to verify that the pow-
er connections available are correct for the burner. Refer
to Figure 1.All power must be supplied through fused dis-
connect switches and comply with the latest edition of Na-
tional Electric Code NFPA 70 (Canada CSA C22.1) and
all other local or applicable codes.
[3 Verify burner components
Burner model can be checked from burner carton or
rating label on burner
Flange mounting arrangement (Includes high-
temperature gasket and/or fiber rope for pressure
firing)
[3 Verify 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 minimum
values given in Figure 2. If the appliance dimensions are
smaller, reduce the firing rate accordingly.
Minimum Inside Dimensions (inches)
Burner Wdth Height Length Burner Head
Model 'W! 'H' 'L' at Min Centerline to
H & W* floor 'A'
CG15.1S 15 16 42 7
CG15.2S 16 17 45 8
CGIS.3S 17 18 47 8
CGIS.4S 18 19 50 9
CGS0.1S 21 23 55 10
CGS0.2S 22 24 58 11
CGS0.3S 24 26 62 12
CGS0.4S 25 27 65 12
CGS0.SS 27 29 70 13
j NOTICE ]
Dimensions shown are for cast iron sectional boilers with
uptakes between sections. For minimum dimensions of
other furnace types consult R.W. Beckett Corporation.
Flames are shaped by their furnaces and by its flue lo-
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.
NOTICE j
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.
[3
e
Verify burner air tube assembly
The information in this section may be disregarded
ifthe burner supplied by the appliance manufacturer
is a matched component.
Maximum firing capacity depends on the furnace
pressure. Use the charts shown in Figure 3A, Fig-
ure 3B, and Figure 3C, to verify the correct burner
configuration for the input rate.
Refer to Figures 4 & 5 to verify the air tube assem-
bly length and mounting insertion dimensions.
6 61 04 80G50 RoB

Figure 3A. Maximum Capacity (at 3% 02) vs Furnace Pressure -CG15
1500
1400
1300
"3"
m- 1200
¢,t-'
1100
lOOO
9OO
L
L =
m A
4, = A i
t
0 0.2 0.4 0.6 0.8
Furnace Pressure, In. WC
CG 15.4S
_CG15.3S
= A -CG15.2S
_:: _ CG15.1S
Figure 3B. Maximum Capacity (at 3% 02) vs Furnace Pressure -CG25
26OO
2500
2400
2300
I
m 2200
2100
2000
1900
1800
1700
-÷
0 0.2 0.4 0.6 0.8
Furnace Pressure, In. WC
--'._-- CG25.5S
_CG25.4S
_ CG25.39
_':: _ CG25.2S
--_¢: - CG25.1S
Figure 3C. Maximum Capacity (at 3% 02) vs Furnace Pressure =CGSO
5OOO
4500
-1-
4000
35OO
3OOO
_CG50.59
_ 6G50.4S
A = CGS0 3S
-""_:- CG50,28
- CGS0,1S
0 0.2 0.4 0.6 0.8
Furnace Pressure, In. WC
61 04 BOGS0 R08 7

Figure 4. Burner Dimensions
F
E
_I_ LL HPL I tI_Li_U
_i)l_£t',_S_©_S ARE bi_!N_:HE$
Figure 5. Panel and Modulating Valve Dimensions
THREAD
15 6104 BOGS0 R08

U urneF Figure 6. Custom Mounting Plate
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.
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.
_! _______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________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 com-
bustion chamber unprotected unless it has been fac-
tory-tested and specified by the appliance manufac-
turer.
•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 instal-
lation 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-temper-
ature refractory material anchored on the fire-side. A
suitable high-temperature gasket (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 ipin!
NOTICE 1
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. Con-
tact your local gas utility for verification of gas pressures,
allowable pressure drops, and any local piping code re-
quirements. 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 bod-
ies could cause gas leaks and result in asphyxi-
ation, explosion or fire.
• Pieces of tape can be cut loose during installation and
lodge in gas valves causing cutoff seal problems.
• 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.
61 04 80G50 RoB 9

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.
OGas 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 Figures 8A
and 8B 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 damaged
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.
Figure 7. Typical Gas Piping Layout
REGULATOR PG DRIPLEG
ABBREV, ITEM DESCRIPTION
HGPS HIGH GAS PRESSURE SWITCH
LGPS LOW GAS PRESSURE SWITCH
MSC MAIN SHUTOFF COCK
MLTC MAIN LEAK TEST COCK
PG PRESSURE GAUGE
S STRAINER
SSOV1 SAFETY SHUTOFF VALVE #1
TC TEST COCK
U UNION
2PRV TWO POSITION REGULATING VALVE
LGPS HGPS
s
(IF USED)
Table 1. Gas supply piping capacity
Schedule 40 metallic pipe with 0:50 psi or less inlet pressure and 0:30" w.c: pressure drOp
Maximum capacity in cubic feet of gas per hour (CFH). Natural gas with 0:60 specific gravity. Pipe size (inches) IPS
-F;Tr;e:ien;i777
(feet)
10
20
30 152
13o
11550
60 lO5
70 96
0175"
278 520
90"350
285
245
215
!95
180
1050
730
590
500
44O
400 610
370 560
::::::::::::::: :77777:-77-T::7===========================
1;5" 2.5' 3!0;' 4:0'
1600 3050 4800 8500 17500
1100 2100 x 3300 " 5900 " t2000
800
760
67O
1650 2700
1450" 2300
1270 2000
,1150 i850
1050 1700
4700 9700
00 8300
3600 7400
3250 "i 6800
3000 6200
80
90
1oo
125
15o
175
2oo
90' i70 350
84 160 320
79 !50 " 305
72 130 275
64 "120 250
59 110 225
55 i00 210
530 990 1600
490 930 1500
460 ' 870 ,1400 2500
410 780 1250 2200
380 710 ,1130" 2000
350 650 1050 1850
320 _ 6i0 980
2800 5800
2600 5400
5100
4500
4,1oo
3800
1700 3500
11O 61 04 BCGSO RoB

Figure 8A. UL gas train -High/Low and Low Fire Start
LGP_ HGPS
MSC U8SOV_ TC 2PRV TC MLTC U
LGPS HGPS
MSC U
TC
Figure 8B. UL gas train =Modulating
• i ;i!ili!i!iiiii!iliiiiiiiiii ili!i
_ U PRV _OV_ TC _0_ TC M_YC: U M'V TC
ABBREV. ITEM DESCRIPTION
HGPS HIGH GAS PRESSURE SWITCH
LGPS LOW GAS PRESSURE SWITCH
MSC MAIN SHUTOFF COCK
MLTC MAIN LEAK TEST COCK
PG PRESSURE GAUGE
S STRAINER
SSOV1 SAFETY SHUTOFF VALVE #1
SSOV2 SAFETY SHUTOFF VALVE #2
TC TEST COCK
U UNION
2PRV TWO POSITION REGULATING VALVE
j NOTICE i
When pressure reducing safety shutoff valves are used,
the distance from the final shutoff valve (2PRV 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 Maximum 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
diagrams provided by the appliance manufacturer. Verify
operation of all controls in accordance with the appliance
manufacturer's guidelines.
Do Not Bypass Safety
Controls
Tampering with, or bypassing safety controls
could lead to equipment malfunction and result
in asphyxiation, explosion or fire.
• Safety controls are designed and installed to provide
protection.
• Do NOT tamper with or bypass any safety control.
• If a safety control is not functioning properly, shut off
all main electrical power and gas supply to the burner
and call a qualified service agency immediately.
iNOTICE j
See Figures 9A & 9B for typical wiring diagrams, with the
flame safeguard control, for reference purposes 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.
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 National
Electrical Code ANSI/NFPA 70 (Canada CSA C22.1)
Keep Service Access
Covers Securely installed
These covers must be securely in place to pre-
vent electrical shock, damage from external ele-
ments, 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 cover
as part of its design.
61 04 BCGSO RoB 11 11

Sequence of Operation
- (typica| for RM7895C flame safeguard primary control)
.Initiate-The primary control enters the INITIATE
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.
3. 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 Prepurge
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.
6. Flame Stabilization - The burner will operate in
low fire for 10 seconds before initiating high fire.
.Run - With a flame established and the control
continuing to detect a flame, the burner will oper-
ate in the RUN mode until the load demand is
satisfied or a limit opens.
.Load Satisfied - The burner switches to idle un-
til the next call for operation.
I I
This operation sequence is typical and for reference only.
The primary control could vary, depending on the cus-
tomer specification and code requirements. For the spe-
cific operating sequence that applies to your installation,
consult the appliance manufacturer's directions, wiring in-
structions, and control manufacturer's literature supplied
with your burner.
Figure 9A. Typical wiring using Model RM7897C for High/Low Control (for reference only)
G_4@
i|
|
|
I
|
$ _,_
L£G_ND:
Ii _OVl_}# if717Sl_.f _
@ _ _ _'_ & _04:_ ¸
I 2 6104 80G50 RoB

Figure 9B. Typical wiring using Model RM7840L for Modulating Control (for reference only)
++7+++L
Prepare burner for start-up
,
Professional Installation
and Service Required
Incorrect installation and mishan-
dling of start-up could lead to equip-
ment 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.
• 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.
Start-up check|ist -Verify the following be-
fore attempting to start the burner.
General
CI Carefully read and become familiar with the
manual, flame safeguard control instructions, se-
quence of operation, pertinent wiring diagrams,
gas system layout, insurance requirements, other
controls and valve literature pertinent to the instal-
lation.
[El 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
[El Insure that the gas piping is properly sized and
has been inspected by the gas utility, leak tested
at all joints, and purged.
[El To protect the gas train and controls, insure that a
drip leg or dirt pocket has been properly installed.
61 04 BCGSO !:tO8 113

=
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.
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 sup-
ply to the burner matches the voltage specifica-
tion 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.
CI Set the breech damper to the required position for
system operation.
CI Fill the appliance with water (boilers).
CI Check all safety and operating controls for correct
application, installation, wiring, and operation.
CI 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 Insure that the gas burner model and capacity
meet the requirements for the installation.
CI Insure that the gas train meets operating specifi-
cations, all safety codes and insurance require-
ments.
CI Refer to Table 2 and Figures 11A and 11B to in-
sure that the burner air damper is positioned for
initial start-up preliminary settings.
CI Insure that the burner is securely mounted in the
appliance with the pressure firing plate and all
gaskets in place for pressurized chamber applica-
tions.
CI Before operating insure that all protective cover
plates, enclosures and guards are in place and
securely fastened.
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 required
to properly install the appliance. Whether these
are included in one kit or are individual test com-
ponents, they should be calibrated and in good
working order.
CI A combustion analyzer capable of measuring oxy-
gen (or carbon dioxide), carbon monoxide, stack
temperature, ambient temperature, and appliance
efficiency.
CI 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.
CI 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.
Having several manometers or U tubes with the
correct range can simplify the testing and set up
procedures.
114, 6104 BOG50 R08

Start the Burner
Professional installation
and Service Required
Incorrect installation and mishan=
dling of start=up could lead to equip=
ment 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.
[:3 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 burner
turned off, make sure gas has not accumulated in
the boiler or flues.
.Check the initial air settings for the input firing
rate. Check the manufacturer's settings either on
the nameplate shown in Figure 1 or listed in Ta-
ble 2. If adjustment is necessary refer to Figures
11A& 11B and set the damper motor cam so that
the indicator points 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 power
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.
Figure 10. Component Famifiarization (CG50 shown, CG15 & CG25 similar.)
Major Components:
1. Damper Motor
2. Primary Control
3. Blower Motor
4. Ignition Transformer
5. Gas Gun Assembly
6. Air Flow Proving Switch
7. High Gas Pressure Switch
8. Test Connection
9. UV Scanner
61 04 BOG50 R08 115

.If component operation sequence and function is
correct, reset the flame safeguard and initiate a
new cycle. Monitor the start-up cycle and manu-
ally open the main leak test cock as soon as the
flame safeguard powers the safety shutoff 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 con-
trolled by the valves and that they operate prop-
erly. With this test passed you may safely initiate
automatic start-ups on subsequent cycles.
Initial air settings
The following steps outline the procedure for initially set-
ting the damper. Refer to Figures 11Aand 11B and Table
2 for this procedure.
1. Remove the cover screw (A) then the cover (B)
and place to one side.
.Using the wrench (C) supplied with the damper
motor, adjust the blue Low fire cam (D) to the ini-
tial setting listed in Table 2. The appliance manu=
facturer's literature will provide furnace pressure
data.
3. Using the same wrench, adjust the red High fire
cam (H) to the initial setting listed in Table 2.
4. Ensure the damper plate is in the correct posi-
tion. The cam notch (E) should align with the Low
fire setting on the damper motor scale (F).
.If the damper plate is not in the correct position,
disengage the motor by pushing in on the motor
pin (G), then rotating the damper plate until the
cam notch and motor scale setting are aligned.
Re-engage the pin.
.On High/Low units only, use a small straight edge
screw driver, turn the white adjustment screw, lo-
cated in the orange transition cam, either clock-
wise or counterclockwise until the cam indicator
is half way between the high and low settings on
the scale.
NOTICE
Figure 11A. Damper Motor with Cover
B
A
Figure 11B. Damper Motor
CG
1
FE
D H
Legend (Figures 11A& 11B)
A
B
C
D
E
F
G
H
J
Cover screw
Cover
Wrench
Low fire cam (blue)
Cam notch
Damper motor scale
Disengaging pin
High fire cam (red)
Transition cam (orange)
The damper plate is attached by screws to its shaft, and bears against a flat on the shaft for alignment. The shaft is
secured to the damper motor by a sleeve coupling with two setscrews bearing against the damper shaft and two more
against the motor shaft. The motor shaft has a flat matching the one on the damper shaft. The flats on the damper
shaft and the motor shaft should be aligned so that the position indicator in the damper motor reads accurately. The
best way to align the flats is to tighten the setscrews that bear against the flats on the shafts first, and then tighten the
ones that bear against the round surface of the shafts afterward.
The test for proper alignment is to disengage the damper motor from its shaft using the disengaging pin (Item G in Figure 11B) and
rotate the damper plate to its full closed position. The position indicator should point to 0° within +/- 5° tolerance.
116 6104 BCGSO RoB

Optional Modulation Linkage Adjustment
instructions
The optional modulation linkage assembly has been de-
signed as an economic means to adjust the damper and
the butterfly valve to maintain air to gas ratios. When the
optional Modulation linkage assembly is supplied with the
burner, initial adjustments will be made at the factory. To
ensure optimum operation, minor additional adjustments
must be made after the burner is fired on a boiler.
The following adjustment will be pre-set at the factory, but
may require minor adjustment at start-up:
• The damper motor high fire and low fire cams will
be preset
• The linkage between the damper and the butterfly
valve will be preset as illustrated in the manual.
• The butterfly valve shaft will be set to a nominal po-
sition.
Figure 12A. Modulation Assembly
RIGHT HANDED GAS, ENTRY
Opt_ona! Censtructien
_CGS0 SHOWN oCG25 AND CGt5 ARE SIMILAR
!utterly Va|ve Sha_
Figure 12B. Modulation Assembly
LEFT HANDED GAS ENTRY
Sta_da_ Construction
*CG_ SHOWN oC@25 AND CG15 ARE 8_MtLAR
'Valve Shaft
OAdjustment Procedure:
Referring to the appliance manufacturer's literature, insure
that all preliminary adjustments and calibrations required
for the burner and appliance have been performed.
A) Prior to starting the burner
1. Verify that the damper motor high fire and low fire
cam settings match the nameplate (Figure 1) or
Table 2.
2. Examine the linkage for signs of damage.
3. Referring to the illustrations in Figures 12A or
12B, verify that the linkage is installed as shown.
4. Prior to adjusting the burner, have available all
the necessary test equipment.
• A manometer to check pressures downstream
of the gas pressure regulator; at the manifold
pressure test connection and in the furnace
• A draft gauge to check breeching pressure
• A flue gas analyzer that can measure 02 (or
CO2) and CO.
61 04 BOGS0 RoB 11"2'

5. Adjustthegaspressureregulatortoabout½"WC 6. Topreventtheburnerfrommodulatingto high
higherthantheanticipatedhighfiregaspressure fire,setthe modulationcontrollerto themanual
(seeTable2). controlmode.If necessary,refertothemanual
suppliedwiththemodulationcontroller.
iVlodulation Control
Figure 13A. Display Meaning
ACTUAL VALUE
(CURRENT OPERATION
SET
BURNER RELEASED WHEN LIT
DAMPER OPENING
DAMPER CLOSING (MODULATE UP)
(MODULATE DOWN INCREASE VALUE
Figure 13C. Manual Operation
Operation in manual mode:
Once in Manual Mode, the
damper motor can be driven from
high to low using the up/down
arrows.
• To return to the automatic mode,
press and hold exit button for ten
seconds.
Modulation of the burner's firing rate is accomplished
by driving the damper motor in small increments to
either increase or decrease rate in response to boiler
demand. A pressure transducer (for steam boilers)
or temperature sensor (for water boilers) senses
boiler demand and communicates it to the controller.
Display and programming functions for the Siemens
RWF40 controller are shown in Figure 13Awith the
controller in the basic display mode.
Figure 13B. Manual Mode
Putting in manual mode:
- Press and hold exit button for
10 seconds.
The damper motor can be driven from low to high or
high to low by pressing the up and down arrows as
shown in Figure 13C. Pressing EXIT for 10 seconds
returns the controller to the automatic mode.
Figure 13D. Operation Set Point
Setting operation set point:
• From the original display, press
program button once. (user
level)
• Set point 1 is displayed
• Use up/down arrows to change
setting.
• When finished, press exit
Manual operation light will
uliminate. The operating set point can be changed as shown
in Figure 13D. Pressing the PGM button accesses
the User Level of the software, where this change
is made. The up and down arrow buttons raise and
lower the operating set point. Pressing EXIT returns
the control to the Basic Display level and saves your
changes.
The damper motor can be manually operated for
set-up and service of the burner by placing the con-
troller in the manual mode, as shown in Figure 13B.
Press and hold the EXIT button for 10 seconds to
enter the manual mode. The manual operation light
will illuminate.
Programming functions within the software are used
to match its settings to the connected hardware, and
to adjust the control's response to unusual job site
requirements if necessary. A manual for the control-
ler is provided with the burner to allow programming
at that level.
118 6104 BCGSO R08

B) At burner start=up - Note, as soon as the burner
lights, be prepared to adjust the butterfly valve to
set the low fire rate adjustment.
.Monitor the flame through the observation port.
If it appears to be too rich (yellow-orange flame),
move the butterfly valve shaft slot setting toward a
more vertical position. (This adjustment is made
by turning the nut holding the spring-loaded swiv-
el on the butterfly valve arm. If insufficient ad-
justment is available by this method the butterfly
valve shaft can be repositioned in the arm. Care
must be taken to make only small changes.)
.Use a flue gas analyzer to check the flue gas rat=
ings for 02 and CO. Your target should be 4% 02
and CO should be well below 50PPM. (Note that
the CO is usually near 0 at 4% 02.)
3. If the 02 and CO levels are not on target, turn the
low fire adjustment nut as required to meet the
target listed in Step 2.
.Check the low fire rate. Either clock the meter
or compare the manifold pressure drop to factory
standards. Adjust the low fire cam setting in the
damper motor (if necessary refer to the Initial Air
Setting procedure described previously) and the
butterfly valve shaft slot position as described in
Step 1. Refer to Step 2 and double check the 02
and CO readings.
5. When low fire is set, use the modulation control-
ler to manually step the burner up to its high fire
rate.
.Check flue gas 02 and CO. Your target should
be 3% 02. CO should be well below 50PPM, and
is usually near 0 for that 02. Adjust the regulated
gas pressure as required to meet the target.
.Check the high fire rate and adjust the high fire
cam setting and regulated gas pressure as re=
quired to meet the target. (If necessary, refer to
the Initial Air Setting procedure described previ-
ously.)
.Using the modulation controller, manually step
the burner back down to low fire and verify the
02 and CO ratings. If the high fire adjustments
were significant they may have affected the low
fire settings as well. Refer to Step 4 in this pro-
cedure to make adjustments as necessary.
.Using the modulation controller, manually step
the burner through its range, stopping at several
points to check 02 and CO measurements.
10. After you are satisfied with the modulation link-
age adjustments secure all linkage fasteners and
continue the start-up procedure.
It is acceptable for a burner with linkage control of the fuel
to show 2% variation in 02 through the range as long as
02 stays above the target points. If the 02 drops below
the target points it may lead to a CO problem. Moving the
damper arm position on the damper shaft changes mid-
range 02.Loosening the clamping screws and moving
the swivel end of the arm downward increases midrange
02 , upward decreases it. This change will affect the low
fire 02 setting, and you'll need to re-set it.
Verify input firing rate:
.Clock the meter, correct for pressure and term-
perature to get SCFH and calculate the input fir-
ing rate. Compare the calculated rate to the spec-
ified input for the boiler found on the specification
sheets and on the rating plates for the burner and
boiler. Do not exceed the specified maximum in-
put 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.
6104 BCGS0 ROB 119

Table 2. Initial burner settings
...............................................................................................L;ur ceP=ssu eat,,0hF, e ...........
O"W.C. 0.25" W.C. 0.50" W.C. 1.00" W.C.
8
E
C_3
800 468 CG15.1S 0.9 9 2.7 25 1.0 9 2.9 26 1.1 9 3.2 27 1.3 10 3.7 31
" I I I i I II I Ii I I I I I I I I
900 468 CG15.1S 0:9 9 314 32 110 9 3.7 34 1.1 9 3.9 37 112 10 414 43
950 548 CG15.2S 0.9 12 2.6
i I II
1050 548 CG15.2S 0.9 12 '312
1150 641 CG15.3S 0.9 16 2.8
'i250 " 64i CG15.3S 0.9 16 3.3
1300 750 CG15.4S 0.9 20 2.7
IIII
1400 750 CG15.4S 019 20 31i
i350 "669 cc25._s o.7 "2.7j
1450 669 CG25.!sI0.ZI!T 3.1
i
i550 774 CG25.2S 017 20 2.7 i
2000 896
'2100 i037
2300 1037
12400 i2oo
2500 1200
30 0.9 13 2.9 33 1.0 13 3.1 36 1.2 14 3.6 42
o:9 i3 314' 'i:o' 3.7 58 1.1 i4 4!2 84
42 0.9 17 3.1 49 1.0 17 3.3 56 1.2 19 3.8 74
52 _ 0:9 u 17 316 68 I i10 I i7 318 85 . I .
51 1.0 21 2.9 66 1.0 22 3.2 80
I I I I
66 1:0 21 3.3 100
38 0.7 i7 3.0 38 0.8 i7 3.2 39 '&9 317 4i
41 0.7 17 3.4 41 0.8 17 3.6 42 0.9 18 4.1 41
017 20 219 018 21 I 3.2 I 43 I 0.9 I 23 I 3.7 " 46
1700 774 CG25.2S 0.7 20 3.2
I I I
1800 896 CG25.3S 0:7 23 '217
CG25.3S 0.7 23 3.3
cG25.4s 017 27 ' 2.8
CG25.4S 0.7 27 3.4
I li
CG25.5S 0.6 30 2.5
CG25.5S 0.6 30 3.0
48 0.7 20 3.4
54 0.7 23 2.9
66 0.7 23 3.6 68 0.8 24 3.8 70
I I i
66 0.7 27 3.1 71'018 28 3.3 76
84 0.7 27 3.6 93 0.8 28 3.9 102
'0i7 30 2!8 ioo 08 31 310 ii5
100 0.7 30 3.2 115
49 0.8 21 3.7 51 0.9 23 4.2 56
55 .... '
0.8 24 3.2 56 0.9 26 3.7 60
0.9 26 4.3 78
I I
0.9 30 3.8 90
mmm mmmmmmmmm mmmm
CG50.1S
CG50AS
CG50.2S
cG5oi2s
CG50.3S
CG50.3S
CG50.4S
CG5&4S
CG50.5S
CG5O15S
CG50.5S
Gas pressures are as measured at the manifold test connection.
Notice: The settings in this chart are for reference only. The actual conditions at the installation may require further adjust-
merit by the fully qualified and experienced start=up technician.
20 6104 80G50 R08