Beckett CG15 Manuel utilisateur

COMMERCIAL PRODUCTS

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.

fDo not store or use gasoline or other ﬂammable vapors and liquids in the vicinity of this or any other appliance.

fWhat to do if you smell gas:

- Do not try to light any appliance.

- Do not touch any electrical switch.

- Do not use any phone in your building.

Immediately call your gas supplier from a telephone outside the building.

- Follow the gas supplier’s instructions.

- Call the ﬁre department if you cannot contact your supplier.

fInstallation and service must be performed by a qualiﬁed installer, service agency, or the gas supplier.

2— CG15, CG25, CG50 Burner Manual, Form No. 6104BCG50

Table of Contents

General Information .................................................4

Hazard Deﬁnitions ........................................................................................... 4

Owner’s Responsibility:................................................................................... 4

Professional Installer’s Responsibility ............................................................. 5

Speciﬁcations............................................................6

Inspect & Prepare Installation Site ..........................8

Indoor Installation............................................................................................ 8

Inspect Chimney and Vent System.................................................................. 8

Chimney Liners ............................................................................................... 9

Flue Pipe and Barometric Draft Control......................................................... 10

Combustion Air Supply.................................................................................. 12

Buildings with Adequate Air Inﬁltration ......................................................... 12

Buildings with Less Than Adequate Air Inﬁltration ........................................ 12

Minimum Burner and Appliance Clearance................................................... 12

Fuel Gas Supply............................................................................................. 12

Installation Instructions..........................................15

Mount the Burner.......................................................................................... 15

Assemble Gas Train ....................................................................................... 16

Vent lines ................................................................................................ 16

Converting the Burner for use with Propane Gas

.................................................. 18

Installing the Propane Restrictor ................................................................... 19

Wire the Burner............................................................................................. 20

Start Up and Operation ..........................................21

RM7897C & RM7840L Flame Safeguard Controls Sequence ...................... 21

Burner Start-up Prep ..................................................................................... 22

Test Instruments ..................................................................................... 22

Burner Start/Check Procedure ...................................................................... 22

Estimating Rate............................................................................................. 25

Clocking the Gas Meter................................................................................. 25

Combustion Adjustment Procedure .............................................................. 26

Damper Terminals Explained ......................................................................... 26

Adjusting the Damper ................................................................................... 27

Low Fire (Blue):....................................................................................... 27

High Fire (Red): ....................................................................................... 27

Transition (Orange) .................................................................................. 27

Check Operation & Safety Controls............................................................... 27

Full Modulation.............................................................................................. 30

Wiring for Full Modulation ............................................................................. 31

Damper Motor Components ......................................................................... 31

Modulation Adjustment Instructions ............................................................. 32

To Set Firing Rate: ......................................................................................... 33

Maintenance and Service.......................................34

For the Operator............................................................................................ 34

Required Annual Maintenance ..................................................................... 35

Inspect and Clean the Burner ................................................................. 35

Troubleshooting......................................................38

Reading the Control.......................................................................................38

Failure Did Not Light...................................................................................... 38

Main Flame Establishment Period (MFEP) Fail ............................................. 39

Replacement Parts ..................................................40

Contractor Start-Up Form ......................................43

Limited Warranty Information................................44

CG15, CG25, CG50 Burner Manual, Form No. 6104BCG50 — 3

Figures & Tables

Figure 1 — Burner Label Information...............................................................................................................6

Figure 2 — Burner Dimensions........................................................................................................................7

Figure 3 — Panel and Modulating Valve Dimensions .......................................................................................7

Figure 4 — Chimney Design - Above the Roof.................................................................................................9

Figure 5 — Venting Single Appliance with Power Gas Burner........................................................................10

Figure 6 — Venting Multiple Appliances with Power Gas Burners................................................................. 11

Figure 7 — Typical Gas Piping Layout.............................................................................................................13

Figure 8 — Minimum Combustion Chamber Dimensions .............................................................................16

Figure 9 — UL Gas Train: Lo/Hi/Off or Lo/Hi/Lo, CG15 & CG25 (1 million to 2.5 million BTU)........................17

Figure 10 — UL Gas Train: Lo/Hi/Off or Lo/Hi/Lo (1 million to 5 million BTU) .................................................17

Figure 11 — UL Gas Train On/Off Full Modulation (1 million to 5 million BTU) ...............................................17

Figure 12 — Propane Conversion Major Components ...................................................................................18

Figure 13 — Component Locations................................................................................................................18

Figure 14 — Gas Gun Installation...................................................................................................................19

Figure 15 — Manifold to Furnace Pressure Drop vs Rate CG15 * .................................................................24

Figure 16 — Manifold to Furnace Pressure Drop vs Rate CG25* ..................................................................24

Figure 17 — Manifold to Furnace Pressure Drop vs Rate CG50* ..................................................................25

Figure 18 — Typical Gas Meter Layout...........................................................................................................25

Figure 19 — Damper Actuator Terminals ........................................................................................................26

Figure 20 — Beckett Damper Actuator Familiarization ...................................................................................28

Figure 21 — Damper Actuator Cams & Scale ................................................................................................29

Figure 22 — Burner with Siemens SQM40 Actuator .....................................................................................30

Figure 23 — Terminal Strip WIring..................................................................................................................31

Figure 24 — Damper Cam Adjustment ..........................................................................................................31

Figure 25 — Damper Cam Position Scale ......................................................................................................31

Figure 26 — Damper Cam Adjustment ..........................................................................................................32

Figure 27 — Firing Rate Control on Wiring Box..............................................................................................32

Figure 28 — Firing Rate Control on 12 x 16 Panel..........................................................................................32

Figure 29 — Modulation Linkage ...................................................................................................................33

Figure 30 — Gas Gun Assembly ....................................................................................................................37

Figure 31 — Typical Gas Train Layout..............................................................................................................39

Table 1 — Burner Speciﬁcations ......................................................................................................................6

Table 2 — Gas Supply Piping Capacity...........................................................................................................14

Table 3 — Propane Restrictors Replacement Part Numbers..........................................................................19

Table 4 — Initial Burner Settings for Both Propane & Natural Gas .................................................................23

Table 5 — Periodic Inspection Sheet..............................................................................................................34

Table 6 — Two fast and two slow blinks (From the RM7895/RM7897 Manuals) ...........................................38

Table 7 — Fault Code 28 (From the 7800 SERIES Relay Module Fault Codes Literature)..............................38

Table 8 — Fault Code 19 (From the 7800 SERIES Relay Module Fault Codes Literature)..............................38

4— Section: General Information CG15, CG25, CG50 Burner Manual, Form No. 6104BCG50

■General Information Owner’s Responsibility:

Thank you for purchasing this Beckett product

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 provide it to your qualiﬁed service

agency for use in professionally setting up and

maintaining your system.

If at any time the product does not appear to be

operating properly, immediately contact your

qualiﬁed service agency for consultation.

Hazard Deﬁnitions

Indicates a hazardous situation

that, if not avoided, will result

in death or serious injury.

Indicates a hazardous

situation that, if not avoided,

could result in death or

serious injury.

Indicates a hazardous

situation that, if not avoided,

could result in minor or

moderate injury.

Used to address practices not

related to physical injury.

Safety instructions signs

indicate speciﬁc safety-related

instructions or procedures.

Follow these instructions exactly.

Failure to follow these instructions, misuse, or incorrect

adjustment of the burner could lead to equipment

malfunction and result in asphyxiation, 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

instructions:

fSee the front cover for ‘What to do if you smell gas’.

fNever store or use gasoline or other ﬂammable liquids

or vapors near this burner or appliance.

fNever attempt to burn garbage or refuse in this

appliance.

fNever attempt to light the burner/appliance by throwing

burning material into the appliance.

fNever attempt to burn any fuel not speciﬁed and

approved for use in this burner.

fNever restrict the air inlet openings to the burner or the

combustion air ventilation openings in the room.

Frozen Plumbing and Water Damage Hazard

If the facility is unattended in severely cold weather,

burner primary control safety lockout, heating system

component failures, power outages or other electrical

system failures could result in frozen plumbing and

water damage in a matter of hours. For protection, take

preventive actions such as having a security system

installed that operates during power outages, senses low

temperature and initiates an effective action. Consult with

your heating contractor or security agency.

Burn Hazard, Hot Surface

Burner ﬂange and air tube are hot

when burner is in operation. Do

not service this area during or

immediately after operation. Allow

area to cool.

Contact a professional, qualiﬁed service agency to

replace any component that has been exposed to water.

CG15, CG25, CG50 Burner Manual, Form No. 6104BCG50 Section: General Information — 5

Professional Installer’s Responsibility

If any of these instructions are not clear,

Call Beckett at 1-800-645-2876

for assistance.

This burner is UL listed for use

in the US or Canada per ANSI/UL

295 & CSA/CGA 3.4. For use with

natural gas or propane.

Explosion, Fire, and Asphyxiation Hazard

Professional Service Required.

fPlease read all instructions before proceeding. Follow all

instructions completely.

fThis equipment must be installed, adjusted and started

by a qualiﬁed service agency that is licensed and

experienced with all applicable codes and ordinances

and responsible for the installation and commissioning

of the equipment.

fThe 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.

fBurner must be used within the limits of Table 1.

Fire Hazard: Overheating

Should over-heating occur:

fShut off the manual gas control to the

appliance.

fDO NOT shut off power to the equipment,

allow the blower and pumps to continue

running.

Special Requirements:

When contacting Beckett for service information — Please

have the burner serial number and contractor start-up form

available when calling or writing. You will ﬁnd the serial

number on the label located on the left rear of the burner.

Concealed damage – If you discover damage to the burner

or controls during unpacking, notify the carrier at once and

ﬁle the appropriate claim forms. Do not install a burner or

control that has been damaged.

FOR OUTDOOR USAGE it is the responsibility of the OEM

equipment manufacturer to protect the burner system

and components from exposure to water in the end-use

application.

6 — Section: Specications CG15, CG25, CG50 Burner Manual, Form No. 6104BCG50

Burner Model CG15 CG25 CG50

Input Firing Range†:

High Fire (Max.)

High Fire (Min.)

Low Fire (Max.)

Low Fire (Min.)

USA Canada USA Canada USA Canada

1,500 MBH

800 MBH

560 MBH

350 MBH

1,370 MBH

800 MBH

560 MBH

350 MBH

2,700 MBH

1,300 MBH

990 MBH

550 MBH

2,300 MBH

1,300 MBH

990 MBH

550 MBH

5,000 MBH

2,000 MBH

1,400 MBH

730 MBH

4,000 MBH

2,000 MBH

1,400 MBH

730 MBH

Fuel:

Natural Gas

Propane (LP)

0.6 Speciﬁc Gravity Typical

1.53 Speciﬁc Gravity Typical

0.6 Speciﬁc Gravity Typ.

1.53 Speciﬁc Gravity Typ.

0.6 Speciﬁc Gravity Typ.

1.53 Speciﬁc Gravity Typ.

Gas Train:

Standard

Options

UL Listed / CSD-1 conﬁguration

IRI, FM

UL Listed / CSD-1 conﬁguration

IRI, FM

UL Listed / CSD-1 conﬁguration

IRI, FM

Gas Train Inlet Pressure Range:

Minimum

Maximum

3.7” WC*

0.5 PSI Typical

(1, 5, & 10 available)

3.5” WC*

0.5 PSI Typical

(1, 5, & 10 available)

3.5” WC*

0.5 PSI Typical

(1, 5, & 10 available)

Manifold to Furnace

Pressure Drop:**

Highest High Fire

Lowest High Fire

3.7” WC

2.7” WC

3.5” WC

2.5” WC

3.5” WC

2.5” WC

Firing Modes Available: Low Fire Start

High/Low

Modulation

High/Low

Modulation

High/Low

Modulation

Standard Flame Safeguard:

Low Fire Start

High / Low

Modulation

RM7897A

RM7897C

RM7840L

RM7897C

RM7840L

Flame Detector:

Standard UV UV UV

Proof of Combustion Air: Standard Standard Standard

Gas Pressure Switches: Standard High and Low Standard High and Low Standard High and Low

Ignition: Direct Ignition of Main Flame Direct Ignition of Main Flame Direct Ignition of Main Flame

Motor:

RPM

Standard Voltage

Motor FLA

Optional Voltages

1/2HP

3450 RPM

120 volt, 1 ph, 60 Hz

6.4 Amps @120 volt AC

208/230v, 1 ph, 60 Hz

208/230v, 3 ph, 60 Hz

460v, 3 ph, 60 Hz

575v, 3 ph, 60 Hz

3/4 HP

3450 RPM

120 volt, 1 ph, 60 Hz

10.4 Amps @120 volt AC

208/230v, 1 ph, 60 Hz

208/230v, 3 ph, 60 Hz

460v, 3 ph, 60 Hz

575v, 3 ph, 60 Hz

2 HP

3450 RPM

208/230v, 1 ph, 60 Hz

13.4 Amps @230 volt AC

208/230v, 3 ph, 60 Hz

460v, 3 ph, 60 Hz

575v, 3 ph, 60 Hz

Weight: 125 lbs. 145 lbs. 165 lbs.

Dimensions: Refer to Figures 2 and 3.

*See manufacturer’s nameplate settings for speciﬁc minimum gas pressure requirements.

** See Figures 14A, 14B, & 14C.

† Canada High Fire rate is reduced to accomodate 25% reserve air.

†† More otions available not shown on table

Table 1 — Burner Specications

■Specifications

Table 1

gives typical burner speciﬁcations; there are

more options available that are not shown. Speciﬁc

conﬁgurations for each burner model (i.e. 15.1, 15.2,

etc.) are used to achieve different ﬁring rates within the

range listed under Input Firing Rate. Refer to the burner

label to ﬁnd speciﬁc information about your burner.

Figure 1

outlines how to read the label.

Figure 2

and

Figure 3

give the physical dimensions of

the burner for installation.

Figure 1 — Burner Label Information

Model

Serial Number & Date Code

Rating Information

Approvals

Allowed Fuels

Setting Data

R.W. Beckett Speciﬁcation

Number & Revision

Boiler Manufacturer &

Model (when applicable)

Additional Codes

CG15, CG25, CG50 Burner Manual, Form No. 6104BCG50 Section: Specications — 7

16.00

DIM. A

6.00

12.63

DIM. B

Female pipe thread

2.9

Model Dim. A Dim. B Dim. C Dim. D Dim. E Dim. F Dim. G Dim. H O.D. Male Pipe Thread

CG15 20.8 9.4 32.7 13.7 5.2 18.4 6.2 10.8 5.6 1-1/4 NPT

CG25 20.9 9.3 33.2 13.4 6.8 1 7. 8 6.7 12.6 6.9 2 NPT

CG50 24.4 10.5 33.6 13.5 7. 5 1 7. 4 6.7 14.6 7. 7 2-1/2 NPT

NOTE: All dimensions are in inches.

Figure 3 — Panel and Modulating Valve Dimensions

Model Dim. A Dim. B Dim. C Female Pipe

Thread

CG15 5.12 11.75 2.85 1-1/4 NPT

CG25 5.12 11.75 3.35 2 NPT

CG50 5.81 13.25 3.38 2-1/2 NPT

NOTE: All dimensions are in inches.

Figure 2 — Burner Dimensions

DIM. C

DIM. D

DIM. G

DIM. H

DIM. F

DIM. E

DIM. A

DIM. B

O.D.

Male pipe thread

DIM.

8 — Section: Inspect & Prepare Installation Site CG15, CG25, CG50 Burner Manual, Form No. 6104BCG50

■Inspect & Prepare Installation Site

Indoor Installation

Examine the installation site for conditions that could

adversely affect the health and safety of installation

personnel and the user of the appliance or proper

operation of the burner and appliance, and correct any

defects found.

• The area around the appliance should be

unobstructed and dry.

• Wiring must be in good condition and meet state

and local code requirements.

• If the burner is replacing an existing oil burner, the

old piping and the tank must be secured or removed

to prevent leakage or unintended deliveries of oil.

• Local jurisdictions may require removal of oil tanks.

See NFPA-30 ﬂammable and combustible liquids

code for approved procedures.

Inspect Chimney and Vent System

1. Any accumulation of soot or debris in chimney

offsets must be removed

2. Any obstructions such as a protruding joint or a

piece of broken tile wedged in the chimney must

be removed.

3. The ﬂue pipe must have an upward pitch toward the

chimney of at least 1/4” per foot of length. It should

ﬁt tightly and should not project into the chimney.

4. Any leakage between chimney tiles, around clean-

out doors, or around the vent pipe should be sealed.

5. A barometric draft control is required. It shall be a

double-acting type, agency recognized for use with

gas vent systems.

6. The design and sizing of the appliance’s vent system

shall comply with the requirements of NFPA 54

Chapters 12 and 13.

7. A chimney ﬂue shall extend at least 3 feet above

the highest point at which the chimney comes in

contact with the roof, and not less than 2 feet above

the highest roof surface or structure within 10 feet

horizontally of the chimney. Refer to

Figure 4

Some local codes and gas utilities require the installation

of a thermal ﬂue Safety switch on the double-acting draft

control or draft hood. The thermal safety switch senses

ﬂue gas spillage caused by blocked ﬂue exhaust, prolonged

down-draft, or insufﬁcient draft. The safety is wired in

series with the burner control circuit and shuts the burner

off, when the spillage of hot ﬂue gases is detected.

Explosion, Fire, and Asphyxiation Hazard

Wet or dusty environments could lead to blocked air

passages, corrosion damage to components, impaired

combustion performance.

fThis burner is designed for clean, dry installations.

fThis burner is not intended for outdoor use or

applications subject to any liquid.

fKeep the installation clear of dust, dirt, corrosive vapors,

and moisture.

fProtective covers and frequent maintenance may be

required.

fCarefully inspect the chimney, chimney liner & exhaust

vent system. Make sure it is properly sized and in good

working condition.

fFollow the instructions supplied by the appliance

manufacturer to which this burner is applied.

fIf a draft regulator is required, it must be a double-acting

type, agency recognized for use with gas vent systems.

fThe chimney installation and vent sizing

must strictly comply with all applicable codes,

authorities having jurisdiction and the latest

revision of the National Fuel Gas Code (ANSI

Z223.1, or NFPA54) or CAN/CGA B/49 Canada.

Remove any vent damper device.

Regulation by these

authorities take precedence over the general instructions

provided in this installation manual.

CG15, CG25, CG50 Burner Manual, Form No. 6104BCG50 Section: Inspect & Prepare Installation Site — 9

Chimney Liners

Explosion, Fire, and Asphyxiation Hazard

The new designs of furnaces and boilers are more

efﬁcient. One result of increased efﬁciency is lower

ﬂue gas temperatures. As ﬂue gases rise in the

chimney, they cool and condense when they reach

the dew point. The condensation mixes with sulphur

in the ﬂue gases creating sulfuric acid. The acid

attacks the chimney mortar, brick and clay liners

causing corrosion, deterioration, leaks, or blockage of

the chimney. Eventually the blockage could prevent

exhausting the ﬂue gases. Instead, the ﬂue gases

vent out the barometric damper into the living space.

Approved insulated stainless steel chimney liner

should be installed, the installing contractor is solely

responsible for installation of the proper vent system.

For those installations not requiring a chimney, such

as through-the-wall vented appliances, follow the

instructions given by the appliance and power venter (if

used) manufacturers.

Minimum Clearence: 2 FT.

Figure 4 — Chimney Design - Above the Roof

Note: Correct chimney design is shown by dotted lines. Incorrect chimney

design, as shown by the solid lines, may result in down-drafts.

10 — Section: Inspect & Prepare Installation Site CG15, CG25, CG50 Burner Manual, Form No. 6104BCG50

Flue Pipe and Barometric Draft Control

The ﬂue pipe should be same size as the breech

connection on the appliance (see

Figure 5

and

Figure 6

). For modern units this should cause no

problem in sizing the ﬂue pipe.

The ﬂue pipe must have an upward pitch toward the

chimney of at least 1/4” per foot of length. It should ﬁt

tightly and should not project into the chimney.

Figure 5 — Venting Single Appliance with Power Gas Burner

Not

Recommended

Poor location for Draft Regulator,

due to combustion noise

Barometric Draft Control

Flue Pipe (90° or 45°)

Chimney

Chimney Liner

Barometric

Draft Control

Barometric

Draft Control

BEST

Heating Unit

Not

Recommended

Draft Regulator should not be

installed in a bullheaded tee.

Not

Recommended

Must maintain boiler ﬂue pipe size

to chimney for single appliances.

Not

Recommended

No square breeching.

Barometric

Draft Control

A barometric draft control is required. It shall be a

double-acting type, agency recognized for use with gas

vent systems.

Please reference appliance instruction for chimney size.

Chimney liners may be required by local code.

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