Beckett AFG Burner User Manual
Contents
1. Table 4 AFG Reduced Firing Rates with LFRB Fo Fort Vi Burner fuel unit e Verify that the burner fuel unit is compatible with the oil supply system For more details refer to Connect fuel lines later in this manual Nozzle and Pump Pressure AWARNING Correct Nozzle and Flow Rate Required Incorrect nozzles and flow rates could result in impaired combus tion under firing over firing soot ing puff back of hot gases smoke and potential fire or asphyxiation hazards Use only nozzles having the brand flow rate gph spray angle and pattern specified by the appliance manufac turer Follow the appliance manufacturer s specifications for the required pump outlet pressure for the nozzle since this affects the flow rate e Nozzle manufacturers calibrate nozzle flow rates at 100 psig When pump pressures are higher than 100 psig the actual nozzle flow rate will be greater than the gph stamped on the nozzle body Example A 1 00 gph nozzle at 140 psig 1 18 gph Securely tighten the nozzle 90 torque inch pounds For typical nozzle flow rates at various pressures refer to Ta ble 5 RWB 6104 BAFG R02 Table 5 Nozzle Flow Rate by Size Nozzle flow rate U S gallons per hour of No 2 fuel oil when pump pressure psig is 175 psi size rated at 100 psig Attach air tube if not already installed If using a flange and gasket slide them onto the air tube Then attach the air tube to2. start check 2 VALVE ON DELAY The ignition and motor are turned on for a 15 second valve on delay 3 TRIAL FOR IGNITION TFI The fuel valve is opened A flame should be established within the 15 second lockout time 4 LOCKOUT If flame is not sensed by the end of the TFI the control shuts down on safety lockout and must be manually reset If the control locks out three times in a row the control enters restricted lockout 5 IGNITION CARRYOVER Once flame is estab lished the ignition remains on for 10 seconds to ensure flame stability before turning off If the con trol is wired for intermittent duty ignition the ignition unit stays on the entire time the motor is running 6 RUN The burner runs until the call for heat is sati fied The burner is then sent to burner motor off delay if applicable or it is shut down and sent to standby Control System Features 7 RECYCLE If the flame is lost while the burner is firing the control shuts down the burner enters a 60 second recycle delay and then repeats the above ignition sequence If flame is lost three times in a row the control locks out to prevent cycling with repetitious flame loss due to poor combustion 8 BURNER MOTOR OFF DELAY The fuel valve is closed and the burner motor is kept on for the selected motor off delay time before the control re turns the burner to standby MOTOR OFF DELAY Interrupted Limited reset Diagnostic LED Valve on Burner moto
3. are unique to AF burn ers replace parts numbered 6 and 14 Refer to parts list below for part numbers SK9462 PartNo Description 14 2999U AFG Blower Wheel AFG 2459U AF Blower Wheel AF 3616 Gasket Only i Contact your Beckett Representative for part num ber and pricing 15 16 17 18 19 20 Page 15 Limited WARRANTY For Residential Commercial and Specialty Burners The R W BECKETT CORPORATION Beckett warrants to persons who purchase its Beckett burners from Beckett for resale or for incorporation into a product for resale Customers that its equipment is free from defects in material and workmanship under normal use and service for 60 months from the date of manufacture for Residential Burners and 18 months from the date of manufacture for Commercial and Specialty Burners Residential burner models include AF AFG AFII NX SF SR and SMG Commercial burner models include CF375 CF500 CF800 CF1400 CF2300A CF2500 CF3500A CG10 CG15 CG25 and CG50 Specialty burner models include ADC ADCP ARV SDC and SM The provisions of this warranty are extended to individual major burner components as follows a 60 months from date of manufacture for all Beckett branded major components except for 12 Vde components b 18 months from date of manufacture for all non Beckett branded major components and Beckett branded 12 Vde components Note Normal service items found to be defective upon r
4. for the installation of Oil burning Equipment NFPA 31 or CSA B139 and B140 in Canada Regulation by these authorities take precedence over the general instructions provided in this installation manual E _ _ _ _ _ _ _ _ _ _ _ _ _ ATC Codes for usable air tube lengths A in inches See Figure 3 Bias 2a0_ F22 2am None araxe arsoxe arame arrow arwxr arioxe arson aFvaox Page 4 RWB 6104 BAFG R02 Notice Special Requirements For recommended installation practice in Canada refer to the latest version of CSA Standard B139 amp B140 Concealed damage If you discover damage to the burner or controls during unpacking notify the carrier at once and file the appropriate claim When contacting Beckett for service information Please record the burner serial number and have available when calling or writing You will find the serial number on the silver label located on the left rear of the burner Refer to Figure 1 Inspect Prepare Installation Site Chimney or vent e Inspect the chimney or vent making sure it is properly sized and in good condition for use For those installations not requiring a chimney such as through the wall vented appliances fol low the instructions given by the appliance and power venter if used manufacturers Adequate Comb
5. manufacturer Natural Draft Applications typically over fire draft is 0 01 or 0 02 w c Direct Venting typically may not require draft adjustment High Efficiency Positive Pressure Appliances also vary from traditional appliances see manu facturer s recommendations Follow these four steps to properly adjust the burn er Step 1 Adjust the air shutter band until a trace of smoke is achieved At the trace of smoke level measure the CO2 or O2 This is the vital reference point for further adjustments Example 13 5 CO2 2 6 O2 Increase the air to reduce the CO2 by 1 5 to 2 percentage points O2 will be in creased by approximately 2 0 to 2 7 per centage points Example Reduce CO2 from 13 5 to 11 5 2 6 to 5 3 O2 Step 4 Recheck smoke level It should be Zero e This procedure provides a margin of reserve air to accommodate variable conditions e If the draft level has changed recheck the smoke and CO2 levels and readjust the burner if necessary Once combustion is set tighten all fasteners on air band air shutter and head adjusting plate or es cutcheon plate Burner equipped with cover Reinstall the cover and repeat Steps 2 and 4 above If CO2 increases O2 decreases remove the cover and adjust the air setting so the CO2 O2 with cover on meets requirements of Step 3 Start and stop the burner several times to ensure satisfactory operation Test the primary control and all other appliance safe
6. oil flow cut off protection The burner may be equipped with a single stage fuel unit for these installations Connect the fuel supply to the burner with a single supply line if you want a one pipe system making sure the bypass plug is NOT installed in the fuel unit Manual bleed ing of the fuel unit is required on initial start up If connecting a two pipe fuel supply install the fuel unit bypass plug RWB 6104 BAFG R02 Fuel supply below the level of the burner When the fuel supply is more than eight feet below the level of the burner a two pipe fuel supply sys tem is required Depending on the fuel line diam eter and horizontal and vertical length the instal lation may also require a two stage pump Consult the fuel unit manufacturer s literature for lift and vacuum capability Fuel line installation Continuous lengths of heavy wall copper tubing are recommended Always use flare fittings Never use compression fittings Always install fittings in accessible locations Proper routing of fuel lines is required to prevent air cavitation and vibration Do Not Use Teflon Tape Damage to the pump could cause impaired burn er operation oil leakage and appliance soot up Never use Teflon tape on fuel oil fittings Tape fragments can lodge in fuel line components and fuel unit damaging the equipment and pre venting proper operation Use oil resistant pipe sealant compounds Fuel line valve and fi
7. shroud 1 See figure above The important Z dimension is the distance from the leading edge of the head to the end of the air tube This distance for L1 amp L2 heads is 1 if the tube has a straight shroud or 1 4 if the air tube has a conic shroud The Z dimension is factory set for heck Adjust Z Dimension V1 Heads Z Leading edge of head j t Back of head to nozzle foce Hex head screw a indicator Heod Nozzle Adopter Acorn nut Head Support Splined nut Figure 5 VT Head V1 heads see Table below and Figure above for dimensions 1 See figure above The important Z dimension is the distance from the leading edge of the head to the end of the air tube This distance for V1 heads is 1 4 The Z dimension is factory set for burners shipped with the air tube installed Even if factory set verify that the Z dimension has not been changed Set head position adjusting plate V1 head only 1 After setting Z dimension loosen head adjusting plate hex head screw and nozzle line splined nut Move the nozzle line assembly until the burner reference indicator lines up with the head adjusting plate setting number given in Table shown below Tighten the hex head screw and splined nut DO NOT loosen the acorn nut when setting head position Refer to the man
8. the burner chassis using the four sheet metal screws provided Refer to Figure 3 for details Install burner nozzle if not already in stalled 1 Remove the plastic plug protecting the nozzle adapter threads 2 Place a open end wrench on the nozzle adapter Insert the nozzle into the adapter and finger tighten Finish tightening with a open end wrench Use care to avoid bending the burner head support legs or electrodes If you remove the head to replace the nozzle type L1 L2 or V1 heads carefully reconnect the head to the nozzle adapter making sure that the head support makes contact with the nozzle adapter shoulder Refer to Figure 4 or 5 Table 6 Nozzle Spray Angles Recommended nozzle spray angles 70 or 80 nozzle 45 60 or 70 nozzle L1 amp L2 head V1 head 45 60 or 70 nozzle RWB 6104 BAFG R02 3 If the nozzle is already installed remove the noz zle line assembly to verify that the nozzle size and spray pattern are correct for the application per ap pliance manufacturer s information Verify that the electrode tip settings comply with Figure 2 4 If the nozzle is not installed obtain a nozzle from the manufacturer having the capacity and spray angle specified in the appliance manufacturer s in formation For conversions or upgrades when in formation is not available for the application e Refer to Table 6 to select the mid range no
9. Beckett AF AFG oil Burner Manual To the Homeowner or Equipment Owner e Please read and carefully follow all instructions provided in this manual regarding your responsi bilities in caring for your heating equipment e Contact a professional qualified service agency for installation start up or service work e Save this manual for future reference Type M Air Tube Combination AFG Models only Yh Type L1 Head Type V1 Head Potential for Fire Smoke and Asphyxiation Hazards Incorrect installation adjustment or misuse of this burner could result in death severe personal injury or substantial property damage To the Professional Qualified Installer or Service Agency Please read and carefully follow all instructions provided in this manual before installing starting or servicing this burner or heating system The Installation must be made in accordance with all state and local codes having jurisdiction RWB 6104 BAFG R02 Page 1 Table of Contents Hazard Definitions and Owner s Information 00 0 0ccccccccccccccccccceccececcecceecceseeeseeteeseetsesersnteessenres 3 Information To Be Used Only By Qualified Service Technicians General InforMatiON sinnene dan aed a R ARE aiid iiaiai 3 Table 1 B rner Specification irinna A A EA EA EA N E ai 4 Table 2 Air Tube Combination ATC Codes 0 0 0 0 cecececeeee etre rete reenter terete eet ea E AEEA EENE eeteeiieeeeneen
10. IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN NO EVENT WILL BECKETT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGE OF ANY NATURE Beckett neither assumes nor authorizes any person to assume for Beckett any other liability or obligation in connection with the sale of this equipment Beckett s liability and Customer s exclusive remedy being limited to credit as set forth above R W BEGKETT CORPORATION P O Box 1289 Elyria Ohio 44036 Form No 61545 R72905 The Oilheat Manufacturers Association supports the use of low sulfur fuels as defined by ASTM D396 Grades No 1 Low Sulfur and No 2 Low Sulfur as the preferred heating fuel for the following reasons e Low sulfur fuels reduce deposits on heat exchanger surfaces extending the service interval between cleanings e The reduced deposits increase the efficiency of the appliance e Low sulfur fuels reduce particulate emissions e Low sulfur fuels reduce oxides of nitrogen emissions R W BECKETT CORPORATION U S A P O Box 1289 Elyria Ohio 44036 www beckettcorp com Canada R W Beckett Canada Ltd Unit 3 430 Laird Road Guelph Ontario N1G 3X7 Form Number 6104 BAFG R02 0 45558 08184 2 Printed in U S A 2006 R W Beckett Corporation 4 15 06 Page 16 RWB 6104 BAFG R02
11. P specification AR TUBE Q Incorrect Adjustments could cause combus static PLATE tion problems carbon deposition from flame impingement heavy smoke generation and fire hazard SPLINED NYT e Make all adjustments exactly as outlined in Figure 3 F Head the following information a 90 ELBOW NOZZLE LINE CONNECTOR TUBE ESCUTCHEON PLATE Check Adjust Z Dimension F heads Burner Dimensions 1 The important Z dimension is the distance from the face of the nozzle to the flat face of the head or heat shield if applicable This dis For usable E A inches tance for F heads is 1 1 if the air tube has a heat shield The Di h F Head Z dimension is factory set for burners shipped with the air tube in m a eT stalled Even if factory set verify that the Z dimension has not been changed H nozzle to head 1 52 HH 2 K following procedure to adjust the Z dimension if it is not L Total tube emeen _ Turn off power to the burner R electrode length 1 4 length 1 4 A 1 1 8 1 8 Disconnect the oil connector tube from the nozzle line l S adapter to static plate Note 1 1 3 8 1 3 8 EA 3 8 See above figure Loosen the splined nut from the nozzle line ee Loosen the hex head screw securing the escutcheon plate to the Place the end of a ruler at the face of the nozzle and using a Z goeree head no heat shield 1 1 8 N A N A Eaa straight edge across t
12. aaaanaaAaadaa anaa Aana 8 Check Adjust Z Dimension L amp V Heads eceeececcneeeee et nneee eerie eee e eine ee eeen EENE NNE OET 9 Servicing nozzle line assembly cecceeeeecee cee ee eee eeeete cece aaeaeeeeeeeeeeeee tga caaaeaeeeeeeeeeeeedseececccceeeeeseeeeeteseeneecaeees 10 Mount burner on appliance eee cece ee cee eeeeeeneeeeeceeecacensceeeaeeeeseaceeeneaeeeecensacesensaeassnsasetanseetaeeses 10 Mounting OPlONS ccc ccssececex covsetedvvessiincevves van ai E EE E E TOE R E N 10 Mounting Dimensi ns sreroisarsiceirrook k rionn atenen E E EAEE AEAEE EEEO sesnandeesedidedscerdigedeesdandeeeeentanedeeendeed 10 Connect Fuel LINES scrisese nerna EE A R a E E ad R DEAE a raa aait 10 Wire BNR ccs seicxs seceded sce encase shad ees an en an o i 11 Burner Packaged with Appliance ccccceccecceeeeeeeeeeeeececaeeeeeeeeeeeee cee saaaaecaeeeeeeeeeeeseccccacaeseeeeseeeesesseeseesiaeeees 11 Burner Installed at JOD Site seicssecsdissstesidbasissecanthede a N E dis danas EE edie aaron 11 Special Wiring Required with Covered Burners c cceccecceeceeeeeeeeeeeceeceneaecaeeeeeeeeeeeeececccacaeseeeeeeeeeeetenssenanees 11 Start up Burner Set Combustion 0 0 0 ccc cscs ssnssesesesesesesesesesescseecansnsnesesesanensasscasaceeeeeseneneees 13 Set Combustion with Test Instrument ccccccecceeeeeeceeeceeeeee cee eee eens eae caeaeaaaneeceeeeeeeeescaceaaeaeeeeeeeeeseeeeeseenaeees 13 Perform Regular Maintena
13. ance limit circuit Please note that other control manufacturers may use different wire colors for power and limit connections Special wiring required with covered burners The mounting plate is not a conduit connec tion point Pass conduit and attached connector through the opening in the mounting plate and at tach it directly to the burner mounted 4x4 electrical box If attaching a burner cover to a previously installed burner attach the mounting plate and then slide the conduit into the J shaped conduit slot Page 11 Typical Burner Wiring amp Burner Sequence of Operation for R7184P Control Refer to the appliance manufacturer s wiring diagram for actual specifications EQUIPMENT 120 VAC BURNER START WIRE FROM APPLIANCE FROM LIMIT CIRCUIT L1 HOT FROM APPLIANCE IGNITION BURNER MOTOR R7184 SERIES PRIMARY CONTROL TO REMOTE LOW VOLTAGE VALVE AC ALARM CIRCUIT IF USED IGNITION WHITE STRIPE ORANGE MOTOR YELLOW CAD CELL 24 VAC BURNER JUNCTION BOX YELLOW lt CAD CELL THERMOSTAT 20 VAC FIELD WIRING SK9359D 20 VAC FACTORY WIRING LOW VOLTAGE FIELD WIRING LOW VOLTAGE FACTORY WIRING WIRE WITH 1 4 QUICK CONNECT RECEPTACLE A WIRENUT Figure 7 Typical Burner Wiring 1 STANDBY The burner is idle waiting for a call for heat When a call for heat is initiated there is a 3 10 second delay while the control performs a safe
14. anees 4 Notice Special REQUIFEMOENIS ssiri dedi veces sdeevadndgdaxaayecs giv evens de a ids saan tose a ai a as dua aa A DiE dade es 5 Inspect Prepare Installation Site ccc cee cece eeeeececeeseeneaeeneceaeeeeeeeeaeeeeneneeneneneesansneasanenetees 5 GHIA OVS E E E eee cc oso ea eee seg E eee ee ence oe GH 5 Combustion Air SUPPI yssir neiaa aan eereritnn ad av aa a S N een Gina a res a aN N 5 Clearances to burner and appliance ccceccecceceeeeeeeeeeececeaeeaeceeeeeeeeeeeseceaaaaecaeeeeeeeeeeeeesecqcecieeeeeeeeeeteteeesnseeas 6 Combustion chamber Burner Retrofitting sics ssisesscvyicene ev vicseerieieiccticteyeetegeveaaeanvediied E EE EE TER 6 Prepare the BUNE sisi ice tania ca ah iitr a aa a aae iiie iia 6 Low Firing Rate Battle seereis smeer reei naei sienai S TAONE EAEEREN SES ARAON NEEE EEan edr EES ATAOE TENES EE 6 Burner Fuel UNit erreusera a A aaa Aaa AN AN a AA AARE AAEREN 6 Nozzle and PUMP PreSSure cccceeeeeeeceeccec cee eeeeeee eee eecaaeaaeceeeeeeeeeeeccesaaaecaeeeseeeeeeeeeseedeccaecaeeeeeseeereteteeesnceeaeees 6 Attach Air TU De ices vacicgsssivesviccucs iobezes fanveed siecuteed a a a dese tanedieadens aa edges aaa ana erence ed anata 7 Install Burmer NOZZIC sensin aaa sees sda vessancdetehssaavagnatgyanceds cadsaadeves sagan aaa a E AEEA A EEEE 7 Check Adjust El6ctrod ecrire EEE E EEEE EE O E E ERE 7 Check Adjust Z Dimension F HeadS saessseesresessrrneserresaeernnaarinnnanttananatnnnaadatanaaaatiannakaa
15. bly to extend into the chamber un Figure 6 Mounting Burner in Appliance If space between burner air tube and opening exceeds 1 2 inch pack burner opening with ce ramic fiber refractory Tilt down 2 Page 10 less otherwise specified by the heating appli ance manufacturer Carefully measure the in sertion depth when using an adjustable flange Verify the insertion depth when using a welded flange Connect fuel lines Carefully follow the fuel unit manufacturer s litera ture and the latest edition of NFPA 31 for oil supply system specifications Fuel supply level with or above burner Do Not Install By pass Plug AMARNING vith 1 Pipe System Failure to comply could cause Immediate pump seal failure pressurized oil leakage and the po tential for a fire and injury hazard e The burner is shipped without the by pass plug installed e Install the by pass plug in two pipe oil supply sys tems ONLY Oil Supply Pressure Control Required Damage to the filter or pump seals could cause oil leakage and a fire hazard e The oil supply inlet pressure to the burner cannot exceed 3 psig e Insure that a pressure limiting device is installed in accordance with the latest edition of NFPA 31 e Gravity Feed Systems Always install an anit siphon valve in the oil supply line or a solenoid valve RWB Part 2182602U in the pump noz zle discharge tubing to provide backup
16. cribing conse quences if the warning is not heeded and instruc tions on how to avoid the hazard Intended to bring special attention to information but not related to personal injury or property damage Owner s Responsibility Incorrect installation adjustment and use of this burner could result in severe personal injury death or sub stantial property damage from fire carbon monoxide poisoning soot or explosion Contact a professional qualified service agency for the installation adjustment and service of your oil heating system This work requires technical training trade ex perience licensing or certification in some states and the proper use of special combustion test instruments Please carefully read and comply with the following in structions e Never store or use gasoline or other flammable liquids or vapors near this burner or appliance e Never attempt to burn garbage or refuse in this appliance e Never attempt to light the burner appliance by throwing burning material into the appliance e Never attempt to burn any fuel not specified and approved for use in this burner e Never restrict the air inlet openings to the burner or the combustion air ventilation openings in the room _ _ _ _ TT RWB 6104 BAFG R02 General Information To the Owner Thank you for purchasing a Beckett burner for use with your heating appliance Please pay at tention to the Safety Warnings contai
17. eceipt by the customer are covered by this warranty THIS WARRANTY DOES NOT EXTEND TO EQUIPMENT SUBJECTED TO MISUSE NEGLECT OR ACCIDENT NOR DOES THIS WARRANTY APPLY UNLESS THE PRODUCT COVERED BY IT IS PROPERLY INSTALLED BY A QUALIFIED COMPETENT TECHNICIAN WHO IS LICENSED WHERE STATE AND LOCAL CODES REQUIRE AND WHO IS EXPERIENCED IN MAKING SUCH INSTALLATIONS IN ACCORDANCE WITH THE LATEST EDITION OF NFPA NO 31 OF THE NATIONAL FIRE PROTECTION ASSOCIATION THE LATEST EDITION OF THE NATIONAL FUEL GAS CODE NFPA NO 54 AND IN ACCORDANCE WITH ALL APPLICABLE LOCAL STATE AND NATIONAL CODES HAVING JURISDICTIONAL AUTHORITY Equipment which is defective in material or workmanship and within the warranty period may be returned for credit as follows Beckett Burners Beckett branded major components and non Beckett branded major components that came as original equipment on a Beckett burner or were sold as a replacement part by Beckett should be returned freight prepaid to Beckett s home office Credit will be issued to the customer unless the returned equipment is determined by Beckett to be out of warranty or damaged by user in which case the equipment will be scrapped Note Beckett is not responsible for any labor cost for removal and replacement of equipment THIS WARRANTY IS LIMITED TO THE PRECISE TERMS SET FORTH ABOVE AND PROVIDES EXCLUSIVE REMEDIES EXPRESSLY IN LIEU OF ALL OTHER REMEDIES AND IN PARTICULAR THERE SHALL BE EXCLUDED THE
18. he head measure the distance to the face of F head with heat shield 1 3 8 N A N A N A the head A Beckett T501 gauge may also be used Slide the nozzle line forward or back until this dimension for F Z L1 head w straightshroud N A 1 3 8 heads is 1 14 1 6 to the face of the heat shield if applicable L1 L2 V1 head wiconic N A 1 3 4 14 13H Tighten the hex head screw to secure the escutcheon plate to the shroud burner chassis Then tighten the splined nut and attach the oil con nector tube Note 1 1 3 8 for dimension A less than 4 1 5 8 for dimension A from 4 3 Recheck the Z dimension periodically when servicing to ensure the through 4 1 2 2 13 32 for dimension A greater than 4 1 2 escutcheon plate has not been moved You will need to reset the Z dimension if you replace the air tube or nozzle line assembly The Beckett Z gauge part number Z 2000 is available to permit checking the F head Z dimension without removing the burner from the appli ance Page 8 RWB 6104 BAFG R02 Check Adjust Z Dimension L1 amp L2 Heads Leading edge of head straight shroud h Back of heod to nozzle foce Hex head screw Reference indicator Head n Nozzle Adapter Heod Support Splined nut Figure 4 L1 amp L2 Heads L1 L2 heads see Table 7 and Figure 3 for dimensions f Leading edge of heod conic
19. imensions Height maximum s s s 12 5 inches with cover Width MaxiMUM ossee 15 inches Depth ween 9 25 inches Air tube diameter 4 00 inches Note 1 Approval agency listed rating for these burners is 0 40 to 3 00 gph However the fring rate range is limited by the specifi air tube combination being used Refer to Table 2 Note 2 See appliance manufacturer s burner speciftations for rec ommended pump discharge pressure Table 2 Air Tube Combination ATC codes Static Ven plate turi size AWARNING Professional Service Required Incorrect installation adjustment and use of this burner could result in severe personal injury death or substantial property damage from fire carbon monoxide poisoning soot or explo sion Please read and understand the manual supplied with this equipment This equipment must be installed adjust ed and put into operation only by a qualified individual or service agency that is e Licensed or certified to install and provide techni cal service to oil heating systems e Experienced with all applicable codes standards and ordinances e Responsible for the correct installation and com mission of this equipment e Skilled in the adjustment of oil burners using com bustion test instruments The installation must strictly comply with all applicable codes authorities having jurisdiction and the latest revi sion of the National Fire Protection Association Standard
20. ke sure Low Firing Rate Baffle is in place if required for the burner application Omitting the baffle can result in unacceptable burner combus tion Inspect all gaskets Replace any that are dam aged or would fail to seal adequately Inspect the compustion head and air tube Re move any carbon or foreign matter Replace all damaged units with exact parts Clean the blower wheel air inlet air guide burner housing and static plate of any lint or foreign ma terial If motor is not permanently lubricated oil motor with a few drops of SAE 20 nondetergent oil at each oil hole DO NOT over oil motor Excessive oiling can cause motor failure Check motor current The amp draw should not exceed the nameplate rating by more than 10 QO QO QO O000 Q Check all wiring for secure connections or insula tion breaks Check the pump pressure and cutoff function Check primary control safety lockout timing Check ignition system for proper operation Inspect the vent system and chimney for soot ac cumulation or other restriction Clean the appliance thoroughly according to the manufacturer s recommendations Check the burner performance Refer to the sec tion Set combustion with test instruments It is good practice to make a record of the service performed and the combustion test results Replace the blower wheel 1 2 3 4 5 6 7 8 9 Turn off all power to the burner before servic ing Discon
21. l configuration Only use parts specified for AF or AFG Burners Do NOT remove the air guide from the AFG chassis Do NOT use M Series air tube combinations on AF Burn ers Never try to convert and AF to and AFG or vice versa Any design alteration will e Void UL Listing e Void manufacturer s warranties e Seriously impact burner performance e Greatly increase your liability risk ES Page 3 General Specifications Table 1 Burner Specifications Capacity F Head AF amp AFG Note 1 Firing rate range ue 0 40 3 00 GPH APUN erinrar 56 000 420 000 Btu L1 Head AFG Only Firing rate range 8 0 40 1 10 GPH Aput iiir 56 000 154 000 Btu h L2 Head AFG Only Firing rate range 0 0 50 1 00 GPH pU aici 70 000 140 000 Btu h V1 Head AFG Only Firing rate range n 0 75 2 75 GPH puti eniran 105 000 385 000 Btu h Certifications UL certified to comply with ANSI UL296 amp Approvals tested to CSA B140 0 Fuels U S No 1 or No 2 heating oil only ASTM D396 Canada No 1 stove oil or No 2 furnace oil only Electrical Power supply 006 120 volts AC 60 Hz single phase Operating load ote 5 8 Amps max Motor ww 1 7 hp 3450 rom NEMA 48M frame PSC rotation CCW when facing shaft end Ignition Continuous duty solid state igniter Fuel pump Outlet pressure oe Note 2 Air tube AUG COUE niiina See Table 2 D
22. ld ing interior which should have adequate infiltration from the outside Exhaust fans and other air using devices Size air openings large enough to allow for all air using devices in addition to the minimum area re quired for combustion air If there is any possibility of the equipment room developing negative pres sure because of exhaust fans or clothes dryers for example either pipe combustion air directly to the burner or provide a sealed enclosure for the burner and supply it with its own combustion air supply Direct air supply and sidewall venting e Some AFG burners are equipped with combus tion air boots to allow use of outside air for com bustion When sidewall venting appliances carefully fol low appliance and power venter instructions for installation and wiring AAWARNING Follow the Outside Air Kit Instructions Exactly Failure to comply could result in impaired com bustion appliance soot up puffback of smoke and fire or asphyxiation hazards Do not attempt to install outside air piping to the burner without using the outside air kit and in structions R W Beckett manufacturer s settings R W Beckett specification number and revision SK9475 Page 5 Outside air kit applications Refer to separate instruction sheet supplied with AF AFG outside air kit for installation This optional kit allows combustion air to be piped directly to the burner Beckett part number 51747 Clea
23. lter Install two high quality fusible handle design shut off valves in accessible locations on the oil supply line to comply with the NFPA 31 Standard Locate one close to the tank and the other close to the burner upstream of the filter Install a generous capacity filter inside the build ing between the fuel tank shutoff valve and the burner locating both the filter and the valve close to the burner for ease of servicing Filter should be rated for 50 microns or less RWB 6104 BAFG R02 Wire burner Burner packaged with appliance AWARNING Electrical Shock Hazard Electrical shock can cause severe personal injury or death Disconnect electrical power before installing or servicing the burner Provide ground wiring to the burner metal control enclosures and accessories This may also be required to aid proper control system operation Perform all wiring in compliance with the Nation al Electrical Code ANSI NFPA 70 Canada CSA C22 1 Refer to appliance manufacturer s wiring diagram for electrical connections Burner installed at jobsite Refer to Figure 7 for typical burner wiring show ing cad cell primary controls Burner wiring may vary depending on primary control actually used The R7184 primary control with valve on delay prepurge and burner motor off delay postpurge requires a constant 120 volts AC power source sup plied to the BLACK wire on the control The RED wire goes to the appli
24. moved You will need to reset the Z dimension if you replace the air tube or nozzle line assem bly Use the following procedure to adjust the Z dimension if it is not correct Turn off power to the burner Disconnect the oil connector tube from the nozzle line See figure above Loosen the splined nut from the nozzle line Loosen the hex head screw securing the head adjusting plate to the burner housing Loosen the acorn nut Move the head adjusting plate until the 0 lines up with the reference indicator on the housing and retighten the hex head screw Place the end of a ruler at the leading edge of the head and using a straight edge across the end of the air tube measure the distance to the end of the tube A Beckett T501 gauge may also be used Slide the nozzle line forward or back until this dimension is 1 7 for V1 heads Tighten the acorn nut Tighten the hex head screw to secure the head adjusting plate to the burner chassis Then tighten the splined nut and attach the oil connector tube 3 Recheck the Z dimension periodically when servicing to ensure the escutcheon plate has not been moved You will need to reset the Z dimension if you replace the air tube or nozzle line assembly Table for initial adjusting plate settings for V1 H ead AFG with V1 Head Burner Firing Rates o f oo V1 Adjusting Plate Setting Page 9 Servicing nozzle line assembly 1 Turn off power to burner before p
25. nce 0 0 cece cece cece ee eeeeeeeeeceeeeeeceneacaesneacaseneeeassneeeeeaeeeeeeateeeeeneaseesneneees 14 Pants Diagram esses acct cscs cetacean A ete 15 Beckett Limited Warranty Information 0 20 cece eee eeeeeeeeeeeneneeeeeteteeeeeeneteeeneneeteseneneees 16 This manual contains information that applies to both AF and AFG burners These burners may appear to be basically identical but there are differences in design and performance Please review the comparison chart below Static Pressure Capability Conventional Low range Enhanced Medium range Blower Wheel Design Standard strip Special tablock Inlet Airflow Design Standard inlet bell Special airguide Igniter Gaskets Baseplate Barrier Optional as specified Required always specified Low Firing Rate Baffle Not required Required per specification UL Air Tube Combinations F Series ONLY Page 2 RWB 6104 BAFG R02 Hazard Definitions Indicates an imminently haz A DANGER ardous situation which if not avoided will result in death serious injury or property damage Indicates a potentially ee hazardous situation which if not avoided could result in death severe personal injury and or substantial property damage EEE Indicates a potentially haz ACAUTION ardous 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 des
26. nect the burner motor wires Remove the bolts securing the motor to the burner housing Remove the motor and blower wheel Remove the existing blower wheel Referring to the figure below slide the new blower wheel onto the shaft Use a feeler gauge to set the wheel to motor gap as shown below AF 0 125 1 64 inch AFG 0 030 1 64 inch Slide blower wheel toward motor until it con tacts feeler gauge Rotate the blower wheel until the setscrew is centered on the flat of the motor shaft Tighten the setscrew to secure the wheel DO NOT use a motor that has endshield open ings outside the blower wheel circumference represented by the dashed line Install the motor on the burner housing Tighten screws Reconnect wires Restore power start the burner and perform combustion tests Refer to the section Set combustion with test instruments Figure 8 Blower wheel assembly Use a Feeler Gauge to set the gap to AF 0 125 1 64 inch AFG 0 030 1 64 inch SK9190 RWB 6104 BAFG R02 Professional Maintenance For best performance specify genuine Beckett replacement parts PartNo Description Co Samers C e oae C o Yi 10 26 Square O e ae C fon o henning Pae Vine O m Sa a 31231U AFG Air Guide AFG 31841 AF Air Inlet Bell AF Pe frenn oeancut Pump P w Wouning scons Pe eon feco C fren ro Tereon 21805U PSC Motor 4189 Mounting Screws RWB 6104 BAFG R02 Parts that
27. ned within this instruction manual Keep this manual for your records and provide it to your qualified service agency for use in professionally setting up and maintaining your oil burner Your Beckett burner will provide years of efficient op eration if it is professionally installed and maintained by a qualified service technician If at any time the burner does not appear to be operating properly im mediately contact your qualified service agency for consultation We recommend annual inspection service of your oil heating system by a qualified service agency Daily Check the room in which your burner appli ance is installed Make sure e Air ventilation openings are clean and unobstruct ed e Nothing is blocking burner inlet air openings e No combustible materials are stored near the heat ing appliance e There are no signs of oil or water leaking around the burner or appliance Weekly e Check your oil tank level Always keep your oil tank full especially during the summer in order to pre vent condensation of moisture on the inside surface of the tank Do NOT Alter the Original A WARNING Burner Design Tampering with or altering the burner design could seriously impair performance resulting in loss of static pressure damage to the system components reduced air volume heavy smoke flame impingement appliance sooting hot gas puff back and asphyxiation or fire hazards Maintain the design to its origina
28. r Alarm Con ignition Limited a ee cell indicator aa off ET E menaf ws vw Page 12 RWB 6104 BAFG R02 Start up burner set combustion A WARNING Explosion and Fire Hazard Failure to follow these instructions could lead to equipment malfunc tion and result in heavy smoke emission soot up hot gas puff back fire and asphyxiation hazards Do not attempt to start the burner when excess oil has accumulated in the appliance the appliance is full of vapor or when the combustion chamber is very hot Do not attempt to re establish flame with the burner running if the flame becomes extinguished during start up venting or adjustment Vapor Filled Appliance Allow the unit to cool off and all vapors to dissipate before attempting an other start Oil Flooded Appliance Shut off the electrical power and the oil supply to the burner and then clear all accumulated oil before continuing If the condition still appears unsafe contact the Fire Department Carefully follow their directions Keep a fire extinguisher nearby and ready for use Open the shutoff valves in the oil supply line to the burner Close air band and partially open air shutter This is an initial air setting for the pump bleeding pro cedure only Additional adjustments must be made with instruments Set the thermostat substantially above room tem perature Close the line voltage switch to start the burner If the burner does not start immediately yo
29. rances to burner and appliance e Provide space around burner and appliance for easy service and maintenance e Check minimum clearances against those shown by the appliance manufacturer and by applicable building codes Combustion chamber Burner retrofit ting Verify that the appliance combustion chamber pro vides at least the minimum dimensions given in Table 3 Failure to comply could result in damage to the heating equipment and result in fire or asphyxi ation hazards Protect Steel Combustion Chamber From Burnout e When retrofitting appliances that have unlined stainless steel combustion chambers protect the chamber by lining the inside surfaces with a ce ramic fiber blanket such as a wet pac or other suitable refractory material e Some steel chambers may not require liners be cause the appliance was designed and tested for use with flame retention burners Refer to the manufacturer s instructions Table 3 Chamber Dimensions Chamber Dimensions inches Rectangular I D Firing Page 6 Prepare the Burner Low Firing Rate Baffle The AFG Low Firing Rate Baffle LFRB reduces the air flow and pressure The LFRB is sometimes used for firing rates under 1 00 gph as listed in Table 4 Refer to the appliance manufacturer s in structions Do not omit the LFRB when specified Omitting the baffle when specified or installing the baffle when not specified could result in impaired burner performance
30. roceeding 2 Disconnect oil connector tube from nozzle line 3 Loosen the two screws securing igniter retain ing clips and rotate both clips to release igniter baseplate Then tilt igniter back on its hinge Remove splined nut F head air tube Remove nozzle line assem bly from burner being careful not to damage the electrodes or insulators while handling To ease removal of long assemblies over 9 inches ro tate assembly 180 from installed position after pulling partially out of tube 6 L1 L2 and V1 head airtubes Slide nozzle line assembly forward further into air tube so the head clears the venturi opening Then rotate the nozzle line assembly 90 so the nozzle line end points up Pull the nozzle line assembly toward you and remove assembly from burner 7 To replace the nozzle assembly reverse the above steps as Mount burner on appliance Mounting options 1 Bolt the burner to the appliance using the fac tory mounted flange or an adjustable flange Mounting dimensions 1 When using the Beckett universal adjustable flange mount the air tube at a 2 downward pitch unless otherwise specified by the appli ance manufacturer 2 Verify that the air tube installed on the burner provides the correct insertion depth See Fig ure 6 3 The end of the air tube should normally be back from the inside wall of the combustion chamber Never allow the leading edge of the head assem
31. ty controls to verify that they function according to the manufacturer s specifica tions Step 2 Step 3 Page 13 Perform regular maintenance A WARNING Annual Professional Ser vice Required QUQ 0 2 U Page 14 Tampering with or making incorrect adjustments could lead to equip ment malfunction and result in asphyxiation explosion or fire Do not tamper with the burner or controls or make any adjustments unless you are a trained and qualified service technician To ensure continued reliable operation a quali fied service technician must service this burner annually More frequent service intervals may be required in dusty or adverse environments Operation and adjustment of the burner requires technical training and skillful use of combustion test instruments and other test equipment Replace the oil supply line filter The line filter car tridge must be replaced to avoid contamination of the fuel unit and nozzle Inspect the oil supply system All fittings should be leak tight The supply lines should be free of water sludge and other restrictions Remove and clean the pump strainer if applica ble Replace the nozzle with an equivalent nozzle Clean and inspect the electrodes for damage re placing any that are cracked or chipped Check electrode tip settings Replace electrodes if tips are rounded Inspect the igniter spring contacts Clean the cad cell grid surface if necessary Ma
32. u may have to reset the safety switch of the burner pri mary control Bleed air from fuel unit as soon as burner motor starts rotating To bleed the fuel unit attach a clear plastic hose over the vent fitting Loosen the fitting and catch the oil in an empty container Tighten the fitting when all air has been purged from the oil supply system If the burner locks out on safety during bleeding reset the safety switch and complete the bleed ing procedure Note Electronic safety switches can be reset immediately others may require a three to five minute wait If burner stops after flame is established addi tional bleeding is probably required Repeat the bleeding procedure until the pump is primed and a flame is established when the vent fitting is closed RWB 6104 BAFG R02 6 For R7184 primary controls see Technician s Quick Reference Guide part number 61351 for special pump priming sequence Prepare for combustion tests by drilling a sam pling hole in the flue pipe between the appliance and the barometric draft regulator Initial air adjustment Using a smoke tester ad just the air shutter and air band if necessary to obtain a clean flame Now the additional combus tion tests with instruments can be made Set combustion with instruments 1 2 3 4 5 6 Allow the burner to run for approximately 5 to 10 minutes Set the stack or over fire draft to the level specified by the appliance
33. ufacturer s in structions for OEM settings The position of the head affects air flow volume and pattern For most applications the burner will perform satisfactorily with the air adjust ment plate setting of Table shown below If combustion results indicate the need for change adjust the head po sition adjusting plate forward or back one position at a time to optimize combustion RWB 6104 BAFG R02 burners shipped with the air tube installed Even if factory set verify that the Z dimension has not been changed 2 Use the following procedure to adjust the Z dimension if it is not correct Turn off power to the burner Disconnect the oil connector tube from the nozzle line Refer to figure Loosen the splined nut from the nozzle line Loosen the hex head screw securing the escutcheon plate to the burner housing Place the end of a ruler at the leading edge of the head and us ing a straight edge across the end of the air tube measure the distance to the end of the tube A Beckett T501 gauge may also be used Slide the nozzle line forward or back until this dimension is 1 for L1 amp L2 heads if the tube has a straight shroud or 1 if the air tube has a conic shroud Tighten the hex head screw to secure the escutcheon plate to the burner chassis Then tighten the splined nut and attach the oil connector tube Recheck the Z dimension periodically when servicing to ensure the escutcheon plate has not been
34. ustion A WARNING and Ventilation Air Supply Required Failure to provide adequate air supply could se riously affect the burner performance and result in damage to the equipment asphyxiation ex plosion or fire hazards The burner cannot properly burn the fuel if it is not supplied with a reliable combustion air source Follow the guidelines in the latest editions of the NFPA 31 and CSA B139 regarding providing ad equate air for combustion and ventilation Figure 1 Burner label location MFR S SETTINGS 34 ron FRG FN 0 75 1 35 PH She A ae oem BJB3001 R00 000405 62736 Model AFG Series Oil Burner General model Information Serial number including date code Rating Information SERAL NUMBER 000405 62736 050 300 GPH 120 001 5 Approval agency symbols OL BURNER NO Pi 100001 in ba SA For we 1 or 2 TRE Primary grou and fuel oi WP 1192 BB R00 RWB 6104 BAFG R02 Can be customized by individual specification State and local approvals Combustion air supply See NFPA 31 Standard for complete details Appliance located in confined space The confined space should have two 2 permanent openings one near the top of the enclosure and one near the bottom of the enclosure Each open ing shall have a free area of not less than 1 one square inch per 1 000 BTU s per hour of the total input rating of all appliances within the enclosure The openings shall have free access to the bui
35. zzle spray angle for the head type being used e Fire the burner and make sure the combustion is acceptable and the flame is not impinging on chamber surfaces e Ifa shorter flame is needed select a wider spray angle If a longer flame is needed select a nar rower spray angle e Either hollow or solid spray patterns may be used If combustion results are not satisfactory with the selected spray pattern try the other pattern Check adjust electrodes Check the electrode tip settings Adjust if neces sary to comply with the dimensions shown in Fig ure 2 To adjust loosen the electrode clamp screw and slide rotate electrodes as necessary Securely tighten the clamp screw when finished Figure 2 Electrode Tip Adjustment Standard Dimensions for F L1 and V1 Heads 5 16 Above Center cme 1 16 Nozzle to ti hs ore Spacing 5 32 Gap The Dimensions shown below are for use with L2 heads and M series air tube combinations ending with an N suf fix example AFG70MDAQN 5 32 Gap 1 4 Above Center R K9461 1 8 Nozzle to tip Spacing Page 7 Check Adjust Z Dimension for F Heads ELECTRODE RODS Z NO HEAT SHIELD ELECTRODE WITH INSULATOR HEAT ae uaa ELECTRODE TIPS HEAT F HEAD SHIELD NOZZLE F HEAD Adjust the Z dimen nozzle sion to the required
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