Gas Burner Manual...Burner flange and air tube are hot when burner is in operation. Do not...
Transcript of Gas Burner Manual...Burner flange and air tube are hot when burner is in operation. Do not...
Operation On/Off & On/Off Low Fire StartAvailable Rates: 300 - 1200 MBH
Fire or Explosion Hazard
Can cause severe injury, death or property damage
If the information in these instructions is not followed exactly, a fire or explosion may result causing personal injury, death or property damage.
— Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
— WHAT TO DO IF YOU SMELL GAS• Do not try to light any appliance• Do not touch any electrical switch; do not use any phone in your building.• Immediately call your gas supplier from a neighbor’s phone. Follow the gas
supplier’s instructions.• If you cannot reach your gas supplier, call the fire department.• Installation and service must be performed by a qualified installer, service agency or the
gas supplier.
Gas Burner Manual
with GeniSys 7590 Control
2
General Information .................................................... 3TotheOwner:................................................................................3Owner’sResponsibility:.................................................................3ProfessionalInstaller’sResponsibility:..........................................4Specifications................................................................................4
Burner Configurations ................................................. 6Inspect/Prepare .............................................................. Installation Site ......................................................... 9
IndoorInstallation..........................................................................9InspectChimneyandVentSystem................................................9CombustionAirSupply................................................................11BuildingswithAdequateAirInfiltration.......................................11BuildingswithLessThanAdequateAirInfiltration......................11ClearancestoBurnerandAppliance...........................................11
Fuel Gas Supply ..........................................................11Prepare the Appliance ............................................... 14Mount the Burner ...................................................... 14Connect Gas Train Piping .......................................... 15
Propane Conversion ..................................................17PropaneRestrictorInstallation...................................................17
Wire the Burner .......................................................... 19Sequence of Operation ............................................. 23
Burner Start-up .......................................................... 24TestInstruments.........................................................................24BurnerStartProcedure..............................................................24VerifytheBurnerFiringRate.......................................................27EstimatingRate...........................................................................27ValidateSafetyControlOperation...............................................28
Combustion Air Adjustment Procedure ................... 28Maintenance and Service .......................................... 29
RequiredAnnualMaintenance...................................................30Replacement Parts ..................................................... 33Limited Warranty Information ................................... 36
Before Calling Beckett . . .
Beforecontactingusaboutyourburner,youmusthaveacompletelyfilledoutcopyoftheContractor Start-Up Form (Locatedinsideoflastpage).Thisinformationiscrucialfortroubleshootingandobtainingthecorrectreplacementpart.
Table of Contents
Figure1–BurnerDimensions..........................................................................................5Figure2–BurnerNameplate...........................................................................................5Figure3–BurnerConfigurationfor300to600MBHApplications..................................6Figure4–BurnerConfigurationfor600to1200MBHApplications................................7Figure5–GasGunAssembly-ComponentFamiliarization.............................................8Figure6–VentPipewithDraftRegulator........................................................................9Figure7–ChimneyDesign-AbovetheRoof................................................................10Figure8–TypicalGasPipingLayout...............................................................................12Figure9–MinimumCombustionChamberDims..........................................................15Figure10–GastrainconfigurationforOn/OffwithLowFireStart................................16Figure11–GastrainconfigurationforOn/Offoperation................................................16Figure12–GastrainconfigurationforOn/Offoperationunder399MBH.....................16Figure13–PropaneConversionMajorComponents.....................................................17Figure14–ComponentLocations..................................................................................18Figure15–GasGunAssemblyInstallation....................................................................18Figure16–7590Control...............................................................................................20Figure17–TypicalWiringSchematic,On/OffOperation................................................21Figure18–TypicalWiringSchematic,On/OffOperationwithtimer...............................22Figure19–ManifoldtoFurnacePressureDropvs.Rate-SteppedSpudDesign.........26Figure20–ManifoldtoFurnacePressureDropvs.Rate-SwirlVaneHeadDesign......26Figure21–ShutterandBand.........................................................................................29Figure22–ElectrodeandFlameRodSetting...............................................................31Figure23–GasGunAssembly-TopView.....................................................................32Figure24–BlowerWheelSpacing................................................................................32Figure25–CG10-24GasBurnerReplacementParts.....................................................33Figure26–CG10-24GasGunReplacementParts.........................................................34
Table1–BurnerSpecifications........................................................................................4Table2–AvailableModels...............................................................................................4Table3–LowRateBurnerConfiguration.........................................................................6Table4–HighRateBurnerConfiguration........................................................................7Table5–GasSupplyPipingCapacity.............................................................................13Table6–PropaneRestrictorsReplacementPartNos....................................................18Table7–OperatingSequence.......................................................................................23Table8–InitialBurnerSettings......................................................................................25
Figures & Tables
3Burner Manual — CG10-24
Section:GENERALINFORMATION
General InformationTo the Owner:
Thisequipmentmustbeinstalled,adjustedandstartedbyaqualifiedserviceagencythatislicensedandexperiencedwithallapplicablecodesandordinancesandresponsiblefortheinstallationandcommissioningoftheequipment.
Owner’s Responsibility:
Explosion, Fire, and Asphyxiation Hazard
Failure to follow these instructions, misuse, or incorrect adjustment of the burner could lead to equipment malfunction.
Contactaprofessional,qualifiedserviceagencyfortheinstallation,adjustmentandserviceofyourgasburningsystem.Thereafter,haveyourequipmentadjustedandinspectedatleastannuallytoensurereliableoperation.Thisworkrequirestechnicaltraining,tradeexperience,licensingorcertificationinsomestatesandtheproperuseofspecialcombustiontestinstruments.
Pleasecarefullyreadandcomplywiththefollowinginstructions:• Seethefrontcoverfor‘Whattodoifyousmellgas’.• Neverstoreorusegasolineorotherflammable
liquidsorvaporsnearthisburnerorappliance.• Neverattempttoburngarbageorrefusein
thisappliance.• Neverattempttolighttheburner/applianceby
throwingburningmaterialintotheappliance.• Neverattempttoburnanyfuelnotspecifiedand
approvedforuseinthisburner.• Neverrestricttheairinletopeningstotheburneror
thecombustionairventilationopeningsintheroom.
Thank you for purchasing a Beckett CG10 gas burnerforusewithyourheatingappliance.PleasepayattentiontotheSafetyWarningscontainedwithinthisinstructionmanual.Keepthismanualforyourrecordsandprovideittoyourqualifiedserviceagencyforuseinprofessionallysettingupandmaintainingyourburner.
YourCG10burnerwillprovideyearsofefficientoperationifitisprofessionallyinstalledandmaintainedbyaqualifiedservicetechnician.Ifatanytimetheburnerdoesnotappeartobeoperatingproperly,immediately contact your qualified service agencyforconsultation.
Gas equipment and their vent systems must be inspected annually by a qualified service agency to assure safe and reliable operation.
Frozen Plumbing and Water Damage Hazard
If the residence is unattended in severely cold weather, burner primary control safety lockout, heating system component failures, power outages or other electrical system failures could result in frozen plumbing and water damage in a matter of hours. For protection, take preventive actions such as having a security system installed that operates during power outages, senses low temperature and initiates an effective action. Consult with your heating contractor or a home security agency.
Contactaprofessional,qualifiedserviceagencytoreplaceanycomponentthathasbeenexposedtowater.
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.
Hazard Definitions:Indicatesahazardoussituationthat,ifnotavoided,willresultindeath or serious injury.
Indicatesahazardoussituationthat,ifnotavoided,couldresultindeath or serious injury.
Indicatesahazardoussituationthat,ifnotavoided,couldresultinminor or moderate injury.
Usedtoaddresspracticesnotrelatedtophysicalinjury.
Safetyinstructionssignsindicatespecificsafety-relatedinstructionsorprocedures.
Section:GENERALINFORMATION
4
Professional Installer’s Responsibility: Specifications
Concealeddamage–Ifyoudiscoverdamagetotheburner
orcontrolsduringunpacking,notifythecarrieratonceandfiletheappropriateclaimforms.Donotinstallaburnerorcontrolthathasbeendamaged.
Special Requirements:
WhencontactingBeckettforserviceinformation—Pleasehavetheburnerserialnumberandcontractorstart-upformavailablewhencallingorwriting.Youwillfindtheserialnumberonthelabellocatedontheleftrearoftheburner.
Fire Hazard: Overheating
Shouldover-heatingoccur:• Shutoffthemanualgascontrolto
theappliance.• DONOTshutoffpowertothe
equipment,allowtheblowerandpumpstocontinuerunning.
If any of these instructions are not clear,Call Beckett at 1-800-645-2876
for assistance.
Table 1 – Burner SpecificationsInputFiringRateAvailable* 300-1200MBH
FiringMode On-OfforOn/OffwithLowFireStart
Fuel Naturalgas-0.64specificgravityLPgas-1.53specificgravity
RequiredGasSupplyPressure(togastrain)
6”WCminimum(std)4.5”WCminimum(special)
InputVoltage** 120Vac+10%/-15%;60Hz
InputCurrent 5.3Amp
GasTrain 24VValvesHigh/Lowgaspressureswitch
LifeCycle Gasvalvesareratedfor100-000cycles(regardingvalveseatleakage).
ApplicationType Indoor,Stationary.Seenoticebelowforoutdooruse.
BurnerControl ProgrammablePre-purge
FlameDetection FlameRectification
Igniter Electronic-DirectSpark
Motor ThermallyProtected-ManualReset
CombustionAirProving DifferentialPressureSwitch
Weight 40lbs.
MountingOrientation Upto90°fromuprightwithmotorshafthorizontal
Dimensions 11.9”x16.0”x20.5”
AcceptableAmbientTemperatureRange -4°Fto+104°F
AcceptableAmbientHumidity 5%-95%RHnon-condensing
*Foraltitudeshigherthan2,000feet,deratetheburnercapacity4%foreach1,000feetabovesealevel.**Thisburnerisnotapprovedforusein50Hzapplications.
ThisburnerisULlistedforuseintheUSorCanadaperANSI/UL295&CSA/CGA3.4.Forusewithnaturalgasorpropane.
Table 2 – Available Models
Model No. Input Firing Rate (MBH)
CG10.1 300-378
CG10.2 379-476
CG10.3 477-600
CG10.4 601-756
CG10.5 757-952
CG10.6 953-1,200
CG10.1S 300-378
CG10.2S 379-476
CG10.3S 477-600
CG10.4S 601-756
CG10.5S 757-952
CG10.6S 953-1,200
Explosion, Fire, and Asphyxiation Hazard
Professional Service Required. • Pleasereadallinstructionsbeforeproceeding.
Followallinstructionscompletely.
• Thisequipmentmustbeinstalled,adjustedandstartedbyaqualifiedserviceagencythatislicensedandexperiencedwithallapplicablecodesandordinancesandresponsiblefortheinstallationandcommissioningoftheequipment.
• TheinstallationmustcomplywithalllocalcodesandordinanceshavingjurisdictionandthelatesteditionoftheNationalFuelGasCodeANSIZ223.1(NFPA54)andCAN1-B149.1inCanada.
• BurnermustbeusedwithinthelimitsofTable 1.
FOROUTDOORUSAGEitistheresponsibilityoftheOEM
equipmentmanufacturertoprotecttheburnersystemandcomponentsfromexposuretowaterintheend-useapplication.
5Burner Manual — CG10-24
Section:GENERALINFORMATION
BurnerModel
Dim.A
Dim.B* O.D.
Min. Max.
10.1-10.310.1S-10.3S 19.8” 1.88” 7.00” 4.43”
10.4-10.610.4S-10.6S 20.6” 3.00” 7.63” 4.61”
*Bisfactoryset(welded)dependingonapplication.
Figure 1 – Burner Dimensions
GeneralModelInformation
SerialNumber,IncludingDateCode
RatingInformation
ApprovalAgencySymbols
R.W.BeckettConstruction&SettingData
R.W.BeckettSpecificationNumberandRevision
BoilerManufacturerandModel,WhenApplicable
AdditionalCodes
Figure 2 – Burner Nameplate
A
B
16.0
7.7
6.17.9
11.9
1.5
1-1/4” NPT
O.D.
B Max.
B Min.
Section:BURNERCONFIGURATIONS
6
Burner ConfigurationsTheCG10burnerisofferedinconfigurationsthatallowittobecustomizedtothecapacityandfurnacesizeneedsofmanydifferentappliances.Twoblowerwheelsizesprovideairflowcapacitythroughtherange.Anairguideprovidesstaticpressureaugmentationatlowratesandaninletsleevemaximizesflowcapacityathighrates.Twoairtubeshroudsshapeandstabilizethebaseoftheflame.Twoburnerheadstylesareavailableforeachfiringrangetoprovidemixingcontrolandretaintheflame.SeeTable 3 andTable 4.
Figure 3 – Burner Configuration for 300 to 600 MBH Applications
ChassisFiring Rate
(MBH)BurnerHead
Blower Wheel Air Inlet Scroll Extension
CG10
300-37810.1
5.75”dia.x2.53”w,PartNo.21448
AirGuide,PartNo.189 None
10.1S
379-47610.2
10.2S
477-60010.3
10.3S
4” ID Shroud
CG10.1S - 10.3S
CG10.3
CG10.1 - CG10.2
Blower wheel
Air Guide
Table 3 – Low Rate Burner Configuration
7Burner Manual — CG10-24
Section:BURNERCONFIGURATIONS
Figure 4 – Burner Configuration for 600 to 1200 MBH Applications
CG10.4S - 10.6S
CG10.4 - 10.6
Blower wheel
Air Guide
ChassisFiring Rate
(MBH)BurnerHead
Blower Wheel Air Inlet Scroll Extension
CG10B
601-75610.4
6.31”dia.x2.42”w,PartNo.21339
AirGuide,PartNo.178
Installed
10.4S
757-95210.5
10.5S
CG10A 953-1,20010.6 InletSleeve,
PartNo.3233610.6S
4-1/2” ID Shroud
Inlet Sleeve
Scroll Extension
Table 4 – High Rate Burner Configuration
Section:BURNERCONFIGURATIONS
8
Spuds
Flame Rod
Air Diffuser
2 Wire Ties - secure wires in location shown below (see warning)
Electrical Shock and Explosion Hazard
Failure to secure wires away from contact with the blower wheel could result in electrical shock or explosion hazard.
Ignition Cable
Flame Rod Wire
Figure 5 – Gas Gun Assembly - Component Familiarization
9Burner Manual — CG10-24
Section:INSPECT/PREPARE INSTALLATIONSITE
Examinetheinstallationsiteforconditionsthatcouldadverselyaffectthehealthandsafetyofinstallationpersonnelandtheuseroftheapplianceorproperoperationoftheburnerandappliance,andcorrectanydefectsfound.
| Theareaaroundtheapplianceshouldbeunobstructedanddry.
| Wiringmustbeingoodconditionandmeetstate&localcoderequirements.
| Iftheburnerisreplacinganexistingoilburner,oldpipingandthetankmustbesecuredorremovedtopreventleakageorunintendeddeliveriesofoil.
| Localjurisdictionsmayrequireremovalofoiltanks.SeeNFPA-30flammableandcombustibleliquidscodeforapprovedprocedures.
Inspect Chimney and Vent System
1. Anyaccumulationofsootordebrisinchimneyoffsetsmustberemoved
2. Anyobstructionssuchasaprotrudingjointorapieceofbrokentilewedgedinthechimneymustberemoved.
3. Nootherapplianceconnectionshouldbemadetothesamefluepipe.
4. Thefluepipemusthaveanupwardpitchtowardthechimneyofatleast1/4”perfootoflength.Itshouldfittightlyandshouldnotprojectintothechimney,seeFigure 6.
Explosion, Fire, and Asphyxiation Hazard
Wet or dusty environments could lead to blocked air passages, corrosion damage to components, impaired combustion performance.
• Thisburnerisdesignedforclean,dryinstallations.
• Electricalcontrolsarenotprotectedagainstrainorsprayedliquids.
• Keeptheinstallationclearofdust,dirt,corrosivevapors,andmoisture.
• Protectivecoversandfrequentmaintenancemayberequired.
Inspect/Prepare Installation Site Indoor Installation
Barometric Draft Control
Flue Pipe Ell
Heating Unit1/4” per Foot
Minimum
Figure 6 – Vent Pipe with Draft Regulator
Fire, Smoke and Asphyxiation Hazard
• Carefullyinspectthechimney,chimneyliner&exhaustventsystem.
• Makesureitisproperlysizedandingoodworkingcondition.
• Followtheinstructionssuppliedbytheappliancemanufacturer.
• Ifadraftregulatorisrequired,itmustbeadouble-actingtype,agencyrecognizedforusewithgasventsystems.
• Thechimneyinstallationandventsizingmuststrictlycomplywithallapplicablecodes,authoritieshavingjurisdictionandthelatestrevisionoftheNationalFuelGasCode(ANSIZ223.1,orNFPA54)orCAN/CGAB/49Canada.Removeanyventdamperdevice.
• Regulationbytheseauthoritiestakeprecedenceoverthegeneralinstructionsprovidedinthisinstallationmanual.
Section:INSPECT/PREPARE INSTALLATIONSITE
10
ChimneyLiners
Thenewdesignsoffurnacesandboilersaremoreefficient.Oneresultofincreasedefficiencyislowerfluegastemperatures.Asfluegasesriseinthechimney,theycoolandcondensewhentheyreachthedewpoint.Thecondensationmixeswithsulphurinthefluegasescreatingsulfuricacid.Theacidattacksthechimneymortar,brickandclaylinerscausingcorrosion,deterioration,leaks,orblockageofthechimney.Eventuallytheblockagecouldpreventexhaustingthefluegases.Instead,thefluegasesventoutthebarometricdamperintothelivingspace.
Thereforeitisstronglyrecommendedthatanapprovedinsulatedstainlesssteelchimneylinerbeinstalled.Theinstallingcontractorissolelyresponsibleforinstallationoftheproperventsystem.
| Forthoseinstallationsnotrequiringachimney,suchasthrough-the-wallventedappliances,followtheinstructionsgivenbytheapplianceandpowerventer(ifused)manufacturers.
Minimum Clearence: 2 FT.
NOTE: Correctchimneydesignisshownbydottedlines.Incorrectchimneydesign,asshownbythesolidlines,mayresultindown-drafts.
Figure 7 – Chimney Design - Above the Roof
5. Anyleakagebetweenchimneytiles,aroundclean-outdoors,oraroundtheventpipeshouldbesealed.
6. Abarometricdraftcontrolisrequired,itshallbeadouble-actingtype,agencyrecognizedforusewithgasventsystems.
7. Thedesignandsizingoftheappliance’sventsystemshallcomplywiththerequirementsofNFPA54Chapters12and13.
8. Achimneyflueshallextendatleast3feetabovethehighestpointatwhichthechimneycomesincontactwiththeroof,andnotlessthan2feetabovethehighestroofsurfaceorstructurewithin10feethorizontallyofthechimney.RefertoFigure 7.
Somelocalcodesandgasutilitiesrequiretheinstallationof
athermalflueSafetyswitchonthedouble-actingdraftcontrol,ordrafthood.
Thethermalsafetyswitchsensesfluegasspillagecausedbyblockedflueexhaust,prolongeddown-draft,orinsufficientdraft.Thesafetyiswiredinserieswiththeburnercontrolcircuitandshutstheburneroff,whenthespillageofhotfluegasesisdetected.
11Burner Manual — CG10-24
Section:INSPECT/PREPARE INSTALLATIONSITE
Combustion Air Supply
Somelocalcodesandgasutilitiesrequiretheinstallation
ofaCOdetector,thisisstronglyrecommendedinallapplications.Consultwithyourheatingcontractororahomesecurityagency.
Carbon Monoxide Hazard
Do not block combustion air inlet. Failure to provide adequate air supply could seriously affect the burner performance and result in damage to the equipment and emission of poisonous carbon monoxide gas.
Buildings with Adequate Air Infiltration
Inmanycases,aburneroperatinginanunconfinedspaceofaconventionalframe,brickorstonebuildingwillreceiveadequateairsupplyfromleakageinthebuildingitself.Butiftheburnerislocatedinaconfinedspacesuchasafurnaceorboilerroom,thatspacemusthaveonepermanentopeningtowardthetopofthespaceandonenearthebottomofthespace.
Eachopeningmusthaveafreeareaofnotlessthanonesq.in.per1,000BTUperhourofthehighestinputratinglistedfortheappliance(refertoNFPA54&58).
Remembertotakethetotalinputofallair-usingappliancesintoconsiderationwhenfiguringtheopenings.Theopeningsmustconnectwiththeinsideofthebuilding,whichshouldhaveadequateinfiltrationfromtheoutside.
As an example:
Ifagasburnerwasfiringat350,000BTU/Hr,inanenclosedroominabuildingeachopeningintheenclosureshouldbe350sq.in.(350,000/1,000x1sq.in.=350sq.in.)A350sq.in.openingwouldtypicallybe12”x30”or19”x19”.
Buildings with Less Than Adequate Air Infiltration
Iftheburnerislocatedinatightlyconstructedbuildingwherethereisinadequateoutsideairinfiltration,outsidecombustionairmustbesuppliedbysomeothermeans.
Onemethodtoaccomplishthisisthroughapermanentopening(s)inanexteriorwall.Theopening,oropenings,musthaveatotalfreeareaofnotlessthanonesq.in.per5,000BTUperhour.Allappliancesmustbetakenintoconsideration.RefertoNFPA54&58.
Clearances to Burner and Appliance
| Providespacearoundburnerandapplianceforeasyserviceandmaintenance.
| Checkminimumclearancesagainstthoseshownbytheappliancemanufacturerandbyapplicablebuildingcodes.
| Therecommendedclearancearoundtheburneritselfis12”minimumforserviceaccess.
Fuel Gas Supply
Gassupplypipingmustbestructurallysupported
independentoftheburner.Theburnermanifoldandgasvalvearenotdesignedtosupportpipingloads.
Explosion, Fire, and Gas Leak Hazard
Provide Over-pressure Protection
TheNationalFuelGasCode,ANSIZ223.1(NFPA54)andASMECSD-1requirethatifgaspressureenteringthebuildingexceedstheratingofanygastraincomponentanoverpressureprotectiondevicemustbeinstalled.
Explosion and Fire Hazard
Never use an open flame for leak testing supply piping or equipment.
Never use Oxygen for leak testing or purging of fuel supply piping.
AtypicalgaspipinglayoutisshowninFigure 8onpage12.
Section:FUELGASSUPPLY
12
LGPS HGPS
S(IFUSED)DRIP LEG
BURNER
METER
MSC SSOV1 PRSSOV MLTC U TCU TCTCUPGREGULATOR
GAS UTILITY PIPING FACILITY PIPING GAS TRAIN BURNER
ABBREV.HGPSLGPSMSCMLTCPGSSSOV1TCUPRSSOV
ITEM DESCRIPTIONHIGHGASPRESSURESWITCHLOWGASPRESSURESWITCHMAINSHUTOFFCOCKMAINLEAKTESTCOCKPRESSUREGAUGESTRAINERSAFETYSHUTOFFVALVE#1TESTCOCKUNIONPRESSUREREGULATINGSAFETYSHUTOFFVALVE
Figure 8 – Typical Gas Piping Layout
Thegassupplysystemmustbesizedtodeliveratleasttheminimumrequiredpressuretothegastraininlet.
Contactyourlocalgasutilityforverificationofgaspressures,allowablepressuredrops,andanylocalpipingcoderequirements.
Ifusingcurrentfacilitypipingalreadyinplace,verifythefollowing:| Pipingdesignmeetsallapplicablecodes.| Pipingandcomponentsareinspectedandingood
workingcondition.| Pipingissizedcorrectlytosupplyrequiredgas
pressuretotheburnerandanyothergasappliancesinthefacility.
| AnynewbranchesinthesupplypipingmustbepressuretestedasoutlinedinANSIZ223.1/NFPA54.
Fornewfacilitypiping,followthepipesizingmethodsandtablesforpipesizingasoutlinedinANSIZ223.1/NFPA54.
Allgaspipinginstallationmustcomplywiththelatestedition
oftheNationalFuelGasCodeANSIZ223.1(NFPA54)andotherapplicablelocalcodes.
Explosion, Fire, and Gas Leak Hazard
• Donotdisassemblegasvalve.• Valvemustbeinstalledwiththegasflowinthe
samedirectionasthearrow.
Explosion, Fire, and Gas Leak Hazard
Do not use Teflon tape on gas piping. Damage to gas valve cutoff seals and valve bodies could cause gas leaks.• Piecesoftapecanbecutlooseduring
installationandlodgeingasvalvescausingcutoffsealproblems.
• Teflontape‘lubricates’pipethreads,allowingironpipestopenetratetoodeeplyintoaluminumvalvebodiescausingdistortionandleakage.
• Useonlypipesealantcompoundsthatareresistanttothegasbeingused.
Explosion, Fire, and Gas Leak Hazard
A Drip Leg is required in gas supply piping. Foreign matter could lodge in gas valve cutoff seals, resulting in gas leak-through, explosion or fire.Installafull-sizedriplegordirtpocketinthepipingdirectlyaheadofthemainshutoffvalvetocaptureforeignmatter.
NewfacilitypipingmustbepressuretestedinaccordancewithANSIZ223.1/NFPA54.
Aleaktestmustbeperformedonsupplypipingimmediatelyaftergasisturnedbackon.Anyleaksmustbefixedbeforecontinuingwiththeinstallation.
13Burner Manual — CG10-24
Section:FUELGASSUPPLY
Schedule40metallicpipewith0.50psiorlessinletpressureand0.30”W.C.pressuredrop
Maximumcapacityincubicfeetofgasperhour(CFH).Naturalgaswith0.60specificgravity.Pipesize(inches)IPS
Pipe Length (ft.) 0.75” 1.0” 1.25” 1.5” 2.0” 2.5” 3.0” 4.0”
10 278 520 1050 1600 3050 4800 8500 17500
20 190 350 730 1100 2100 3300 5900 12000
30 152 285 590 800 1650 2700 4700 9700
40 130 245 500 760 1450 2300 4100 8300
50 115 215 440 670 1270 2000 3600 7400
60 105 195 400 610 1150 1850 3250 6800
70 96 180 370 560 1050 1700 3000 6200
80 90 170 350 530 990 1600 2800 5800
90 84 160 320 490 930 1500 2600 5400
100 79 150 305 460 870 1400 2500 5100
125 72 130 275 410 780 1250 2200 4500
150 64 120 250 380 710 1130 2000 4100
175 59 110 225 350 650 1050 1850 3800
200 55 100 210 320 610 980 1700 3500
Forotherinletpressuresandpressuredrops,seeNFPA54forNaturalGaspipingorNFPA58forLPGasPiping.
Table 5 – Gas Supply Piping Capacity
Section:PREPARETHEAPPLIANCE
14
Prepare the Appliance
Breathing Hazard
Ceramic fiber or Fiberglass insulation
Ceramicfibermaterials,suchaschamberliners,maycontaincarcinogenicparticles(crystallinesilica)afterexposuretoheat.Airborneparticlesfromfiberglassorceramicfibercomponentshave
beenlistedaspotentiallycarcinogenicbytheStateofCalifornia.Takethefollowingprecautionswhenremoving,replacingandhandlingtheseitems.
Avoid breathing dust and avoid contact with skin or eyes.Wearlong-sleeved,loose-fittingclothing,glovesandeyeprotection.UseaNIOSHN95certifiedrespirator.Thisrespiratormeetsrequirementsforprotectionfromcrystallinesilica.ActualjobrequirementsforNIOSHregulationsmayrequireotheroradditionalprotection.Forinformation,refertotheNIOSHwebsite,http://www.cdc.gov/niosh/homepage.html.
Ceramic fiber removal:Topreventairbornedust,thoroughlywetceramicfiberwithwaterbeforehandling.Placeceramicfibermaterialsinaplasticbagandsealtodispose.
Avoid blowing, tearing, sawing or sprayingfiberglassorceramicfibermaterials.Ifsuchoperationsarenecessary,wearextraprotectiontopreventbreathingdust.
Wash work clothes separately from other laundry.Rinseclotheswasherthoroughlyafterwardstopreventcontaminationofotherclothing.
NIOSH First aid procedures:• Eyeexposure-irrigateeyesimmediately• Breathing-freshair
Asbestos Hazard
NEVER attempt to retrofit an appliance containing asbestos. Contact a professional to remove the asbestos prior to installation. If unsure call a qualified contractor to verify if asbestos is present.
Carbon Monoxide Hazard
Burnermountinggasketmustbeusedtosealagainstleakagefromtheappliance.Donotuseadamagedmountinggasket.Verifythatallboilersections,canopy,andaccessplatesordoorsarefullyequippedwithgasketsandsealedagainstanyleakage.
Mount the BurnerTheburnerspecifiedforpackagedequipmentwillhaveaflangetomatchtheapplianceboltpatternandweldedfortherequiredinsertion.Followtheappliancemanufacturer’sinstructionsformounting.
Carbon Monoxide Hazard
Protect the Air Tube from Overheating. Overheating could cause damage to the air tube and other combustion components leading to equipment malfunction and impaired combustion performance.• Theendoftheairtubemustnotextendinto
thecombustionchamberunprotectedunlessithasbeenfactory-testedandspecifiedbytheappliancemanufacturer.
• Theendoftheairtubeshouldbesetback¼”fromflushwiththerefractoryinsidewalltopreventdamagefromoverheating.
• Refertotheinstructionsoutlinedinthissectionformethodsofadditionalprotection.
Explosion, Fire, and Asphyxiation Hazard.
Adjustable flange shall not be used with portable equipment.
Forretrofitapplicationsandtoensurecorrectinstallation,verifythefollowing:
| Verifytheendoftheburnerairtubewillbesetback1/4”fromtheinteriorsurfaceofthecombustionchamberwhentheburnerismountedtotheappliance.SeeFigure 9.
| Ifthisdimensioncannotbeachieved,protecttheendoftheairtubebyinstallingasuitableceramicrefractorymaterialsuchasarefractorymillboardcapableofwithstandingatleast2300°F.
| Verifytheburnerflamesizeissuitablefortheappliancecombustionchamber.SeeFigure 9forminimumcombustionchamberdimensionsatthestatedfiringrateranges.
Dimensionsshownareforcastironsectionalboilers
withuptakesbetweensections.ForminimumdimensionsofotherfurnacetypesconsultR.W.BeckettCorporation.
| Verifythesuppliedgasketisinplaceontheburnerairtubeflangeandthenmounttheburnertotheapplianceusingapplianceorfieldsuppliedhardware.
15Burner Manual — CG10-24
Section:CONNECTGASTRAINPIPING
1/4”
‘A’‘L’ ‘W’
‘H’
Minimum CombustionChamber Dimensions (inches)
InputFiringRateinMBH
Length‘L’
Width‘W’
Height‘H’
BurnerHead
Centerlinetofloor‘A’
300-400 18 12 12 6
400-600 22 14 14 7
600-900 26 16 16 8
900-1200 30 18 18 9
Figure 9 – Minimum Combustion Chamber Dims. Connect Gas Train PipingTheCG10gasburnercomessuppliedwithstandardgastraincomponentsthatmeetUnderwritersLaboratory(UL)andCSD-1requirementsforgastrains.Thegastrainisnormallyshippedascomponentsandmustbeassembledandinstalledatthesite.
Thegastrainisusedforbothnaturalgasandpropane;forconvertingburner,seePropaneConversioninstructionsonpage17.
Verifythatthegastraincomponentsarenotdamagedandallpipingandfittingsarecleaninsideandout.
SeeFigure 10,Figure 11andFigure 12startingonpage16fortypicalcomponentlayout.
Vent lines–Installventlinestoanygasvalvecomponentthatrequiresatmosphericairpressuretobalanceadiaphragm.Ventlinesmustberuntotheoutdoors,withtheterminationpointawayfromfreshairintakesandwindows.Theterminalopeningmustbefittedwithawiremeshscreentoblockinsectsandothercontaminantsfromenteringtheventandmustbemountedinsuchapositionthatwater,ice,dirt,oranyotherforeignmattercannotinfiltrateandblocktheventpiping.Makesurethefinalassemblyisanchoredsecurely.
Explosion, Fire, and Asphyxiation Hazard.
Do not use Teflon tape on gas piping. Damage to gas valve cutoff seals and valve bodies could cause gas leaks.• Piecesoftapecanbecutlooseduring
installationandlodgeingasvalvescausingcutoffsealproblems.
• Teflontape‘lubricates’pipethreads,allowingironpipestopenetratetoodeeplyintoaluminumvalvebodiescausingdistortionandleakage.
• Useonlypipesealantcompoundsthatareresistanttothegasbeingused.
Explosion, Fire, and Asphyxiation Hazard.
The orientation of the gas valves may have an effect on operation and safety. Gas valves shall be mounted in accordance with their manufacturer’s instructions.
Section:CONNECTGASTRAINPIPING
16
TP
TCTCLGPS HGPS
SSOV1 PRSSOV MLTC UUMSC
Whenpressurereducingsafetyshutoffvalvesareused,thedistancefromthefinalshutoffvalve
(PRSSOV)totheburnermanifoldmustbekepttoaminimumforgoodlight-offreliability.R.W.Beckettrecommendsthefollowingmaximumlengths.Whentwoshut-offvalvesareused,thedistancebetweenvalvesshouldnotexceedthemax.lengthspecifiedbelow:
Pipe Size3/4”1”1-1/4”1-1/2”2”
Max. Length12”12”15”18”24”
IfaNormallyOpenVentValve(notshown)isused,thedistancebetweentheSSOVsmustbekepttoaminimumusingtheshortestpracticalnipples.
Key (Figure 10thruFigure 12)
Abbrev. Item Description
CGVHGPSLGPSMSCMLTCPRSSOVPRVSSOV1SSOV2TCTPU
CombinationGasValveHighGasPressureSwitchLowGasPressureSwitchMainShutoffCockMainLeakTestCockPressureRegulatingSafetyShutoffValveRegulatorSafetyShutoffValve#1SafetyShutoffValve#2TestCockTestPortUnion
TP
TCTCHGPS
PRV SSOV1 MLTC UUMSC
TP
TCTCLGPS HGPS
CGV MLTC UUMSC
LGPS
SSOV2
Max. Distance(see Notice below)
Max Distance (see Notice below)
Figure 10 – Gas train configuration for On/Off with Low Fire Start
Figure 11 – Gas train configuration for On/Off operation
Figure 12 – Gas train configuration for On/Off operation under 399 MBH
Max. Length(see Notice below) Burner Manifold
Max. Length(see Notice below) Burner Manifold
Max. Length(see Notice below) Burner Manifold
17Burner Manual — CG10-24
Section:PROPANECONVERSION
Propane Conversion
TheBeckettPropaneRestrictorConversionKitallowsfortheconversionofCG10burnersforusewithpropanegas.WiththeproperinstallationoftherestrictorandattachedO-ring,initialadjustmentsandsettingsforpropanewillbethesameastheinitialadjustmentsandsettingsfornaturalgas.
Propane(LP)–Whenthecorrectpropanerestrictorisaddedtoaburner’sgaspipeassemblyitchangestheburner’sgaspressuredropsothatthepropanepressuredropisequaltothenaturalgaspressuredropofthesameBTUfiringrate.ThatiswhytheManifoldtoFurnacePressureDropcurvesofFigure 19andFigure 20onpage26arecorrectforbothpropaneandnaturalgas.Thatisalsowhytheinitialburnersettings,Table 8onpage25,areappropriatefornaturalgas;orpropanewiththecorrectorifice.R.W.Beckettprovidesthesamepressureregulatingsafetyshutoffvalveinthegastrainforbothnaturalgasandpropane.Thevalveismarkedfornaturalgasduetoitsprimaryusageinapressurerangenormallyusedbynaturalgasappliances.Itissafeandeffectiveforpropaneusageinthisdesignapplication.
Propane Restrictor Installation
NotethatSteps1and2onthefollowingpagerefertofullyassembledburners.SkiptoStep3whenconvertingaburnerwithouttheairtubeassemblyinstalled.
RefertoFigure 13andFigure 14onpage18whenperformingthefollowingsteps.
1. Removethejackingscrew(B)fromtheairtube/manifoldassemblytofreetheinternalgastube(C).
HG
EF
C
B
A
Figure 13 – Propane Conversion Major Components
Explosion, Fire, and Asphyxiation Hazard
This conversion kit shall be installed by a qualified service agency in accordance with the manufacturer’s instructions and all applicable codes and requirements of the authority
having jurisdiction. (In Canada, in accordance with the requirements of the CAN/CGA-B149 Installation Code.) If the information in these instructions is not followed exactly, a fire, explosion, or production of carbon monoxide may result causing property damage, personal injury or loss of life. The qualified service agency is responsible for the proper installation of this kit. The installation is not proper and complete until the operation of the converted appliance is checked, as specified in the manufacturer’s instructions supplied with the kit.
2. Gentlyrocktheinternalgastube(C)toloosenthetubefromtheunion(F).
3. InspecttheO-ringsandinsurethattheyareproperlylubricated.(AsiliconO-ringlubricantisrecommended,butautomotivechassisorbearinggreaseisanacceptablesubstitute.)
4. ReferringtoFigure 13,placetherestrictor(E)withpre-attached,pre-lubricatedO-ring(G)intotheinternalgastube(C).Useyourhandtopresstherestrictorintothetube.TheO-ringwillholdtherestrictorinplace.
5. InsurethattheO-ring(H),attachedtotheoutsidediameterofinternalgastube,isproperlylubricatedandseatedagainsttheflangeontheinternalgastube.
6. Installtheinternalgastube(C)backintotheairtube(A)housing,refertoFigure 14.Fittheendofthetubeintotheunion(F)ontheairtube.
7. Re-installthejackingscrew(B).(Refertotheabovenoticeforinstallationdetails.)
8. FilloutandplacethesuppliedConversionDataPlate(PartNo.61712)adjacenttotheratingplate.
9. CompleteandattachthesuppliedAdjustmentDataTag(PartNo.61711).
Section:PROPANECONVERSION
18
Table 6 – Propane Restrictors Replacement Part Nos.
Burner ModelRestrictor
Kit
RestrictorInside
Diameter
O-RingPart
Number
CG10.1 3246700U 0.401 3226409U
CG10.2 3246701U 0.432 3226409U
CG10.3,CG10.2S 3246702U 0.470 3226409U
CG10.1S 3246703U 0.418 3226409U
CG10.3S,CG10.6S 3246705U 0.510 3226409U
CG10.4S 3246706U 0.459 3226409U
CG10.5S 3246707U 0.482 3226409U
CG10.4 3246723U 0.547 3226409U
CG10.5 3246724U 0.578 3226409U
CG10.6 3246725U 0.594 3226409U
Figure 15 – Gas Gun Assembly Installation
Major Component Key(ForFigure 13andFigure 14)
A AirTube E PropaneRestrictor
B JackingScrew F RestrictorO-ring
C InternalGasTube G GasTubeO-ring
D ExternalGasManifold
B
G
F
E
D
A
Figure 14 – Component Locations
C
19Burner Manual — CG10-24
Section:WIRETHEBURNER
Useauthorizedreplacementpartsonly.Restrictorsare
precision-machinedpartsandO-ringsareratedforfuelcontact.Donotattempttoreplicateormodifyanyparts.RefertoTable 6.
Thegunassemblyissecuredinsidetheairtubebyaspring-
loadedjackingscrew.Itisspringloadedinordertocontroltheforceitcanimposeonthegunassembly.Wheninstallingthejackingscrewlookinsidetheairtubetoverifythatthepointedtipofthejackingscrewpinisseatedintothesmallslotonthelocatingpadontopofthegun.Thereisalsoanexternalverificationofcorrectassembly:whenthescrewisfullytightened,thee-cliponthetopofthecenterpinshouldcomeflushwiththetopofthescrew.RefertoFigure 15.
Withthegasrestrictorinstalled,asshowninFigure 13,allburner
initialsettings(oradjustmentsandgasmanifoldpressure)forpropanewillbethesameasthenaturalgasinitialsettingsshownintheburnermanual,orprintedonthe“Mfr’sSettings”labelontheburnerhousing.Foracopyofthecurrentburnermanualgotowww.beckettcorp.com/product/cg10-gas-burner.Iffurthertechnicalassistanceisrequired,call800-645-2876,MondaythruFriday,8AMto5PMEST.
Wire the BurnerInstalltheburnerandallwiringinaccordancewiththeNationalElectricCodeANSI/NFPA70(CanadaCSAC22.1)andallapplicablecodesandrequirements.HighandLowgaspressureswitchesmustbeinstalledandwiredinaccordancewithmanufacturer’sinstructions.Wiretheburnerincompliancewithallinstructionsanddiagramsprovidedbytheappliancemanufacturer.Verifyoperationofallcontrolsinaccordancewiththeappliancemanufacturer’sguidelines.
SeeFigure 17andFigure 18fortypicalwiringdiagramsfortheCG10-24.
Maximumfusesizeforthe120Vac60Hzelectricalpowersupplytotheburneris20Amps.
Explosion, Fire, Scald, and Asphyxiation Hazard
All heating appliances must have HIGH LIMIT protection to interrupt electrical power and shutdown the burner if operating or safety controls fail and cause a runaway condition.
• Followtheappliancemanufacturer’swiringdiagramsandnoteallrequiredsafetycontrols.
• Typicalsafetycontrolsincludehightemperatureorpressurelimits,lowwatercutoffs,pressurereliefvalvesandblockedfluesensingswitches.
• Donottamperwith,orbypass,safetycontrols.Verifyalllimitandsafetycontrolsareinstalledandfunctioningcorrectly,asspecifiedbythemanufacturer,applicablesafetystandards,codesandallauthoritieshavingjurisdiction.
• Ifasafetycontrolisnotfunctioningproperly,shutoffallmainelectricalpowerandgassupplytotheburnerandcallaqualifiedserviceagencyimmediately.
Keep Service Access Covers Securely Installed
All covers must be securely in place to prevent electrical shock, protect against injury from moving parts and prevent damage from external elements.
Allcoversorserviceaccessplatesmustbeinplaceatalltimesexceptduringmaintenanceandservice.
Thisappliestoallcontrols,panels,enclosures,switches,andguardsoranycomponentwithacoveraspartofitsdesign.
Section:WIRETHEBURNER
20
Figure 16 – 7590 Control
Alarm Module:For adding isolated low voltage
alarm contacts to the base control. See Alarm Module
Instructions for specifications.
Communication Port 2
Reset Button with Red Light
Communication Port 1
Thermostat Terminals
Green LightYellow Light
Optional Component:
Electrical Shock Hazard
Electrical shock can cause severe personal injury or death.• Linevoltageneutralshallnotbeusedasa
substituteforground.• Disconnectelectricalpowerbeforeinstallingor
servicingtheburner.• Providegroundwiringtotheburner,metal
controlenclosuresandaccessories.Agoodgroundisrequiredtomaintainagoodflamesensing.
• Useagroundfaultinterruptifgroundingoftheburnercanbecompromised.
Explosion, Fire and Asphyxiation Hazard
Do not tamper with, or bypass, safety controls. 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.
Fire or Explosion Hazard
Can cause severe injury, death, or property damage.
• Thecontrolcanmalfunctionifitgetswet,leadingtoaccumulationofgas.
• Neverinstallwherewatercanflood,driporcondenseonthecontrol.
• Neveruseacontrolthathasbeenwet-replaceit.
Electromagnetic Interference
Operationofthisburnerinaresidentialareamaycauseinterference,inwhichcasetheuserwillberequiredtocorrecttheinterference.
21Burner Manual — CG10-24
Section:WIRETHEBURNER
Figure 17 – Typical Wiring Schematic, On/Off Operation
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T U
SED
.
Section:WIRETHEBURNER
22
Figure 18 – Typical Wiring Schematic, On/Off Operation with timer
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23Burner Manual — CG10-24
Section:SEQUENCEOFOPERATION
Sequence of Operation
Thisoperationsequenceistypicalforoperationwitha7590
control.ThisistheonlycontrolapprovedforuseontheCG10-24.
Donotstarttheburneryet.
(ReferenceTable 7)
| Callforheat,StatusLEDisturnedon.— Controlperformssafe-startcheck
— Ifsafe-startfails,controllocksout.
— Ifsafe-startpasses,controlchecksforpresenceofflame.
— Ifflameispresent,controlwillenterholdstateuntilflameisnolongerpresent.FlameLEDandStatusLEDwillflashuntilflameisnolongerpresent.
— Ifflameisnotpresent,controlwillcheckstatusofairprovingswitch.Ifswitchisclosed,(indicatingthepressureswitchisstuck)controlwillenterlockout.
| Iftheairprovingswitchisopen,themotorwillstart.Oncetheairprovingswitchcloses,pre-purgewillbegin(lastingtypically60seconds).Pre-purgeorignitiontimingswillnotstartuntiltheairprovingswitchcloses.
— Theairprovingswitchmustclosetoprovecombustionairispresent.Ifswitchfailstocloseduringthespecifiedperiod,thecontrolwillenterlockout.
Table 7 – Operating Sequence
LEDs
Call for Heat
FLAME
MV STATUS
Status LEDturns on
Motor Start
FLAME
MV STATUS
Status LEDON
Pre-purge
FLAME
MV STATUS
Status LEDFlashes
Ignition
FLAME
MV STATUS
Status, MVLEDs On
Run
FLAME
MV STATUS
Status, MV,Flame LEDs On
End Call for Heat
FLAME
MV STATUS
LEDs Off
Timers&Timings
Pre-purgeTimer
1-240Seconds
IgnitionTrialTimer
4-15Seconds
FlameCheck On On On On On
Motor/Blower BlowerStarts On On On Off
AirSwitchCheck On AirSwitchCloses On On On
Igniter On Off Off
GasValve On On Off
| Whenpre-purgeiscompleted,thecontrolturnsontheigniterandthegasvalve.MVLEDwillturnon.
— Sparkcontinuesuntilendofignitiontimingoruntilflameisproved.
| Onceflameisproved,TheFlameLEDisturnedonandthesparkisturnedoff.ThegasvalveandMVLEDremainenergized.
— Ifflameisnotproved,thecontrolwilllockoutorentertheinter-trialwaitingperiod.StatusLEDwillflashrapidlyforlockoutorslowlyforinter-trialwaiting.
— Ifmultipletriallogicisused,thecontrolwillcompletethetrialsforignition
— Whenflameisprovedthecontrolwillcontinueinrunmodeuntiltheendofthecallforheat.
| Whenthecallforheatisended,thegasvalve,MVLED,FlameLED,StatusLEDandmotorturnoff.
AdditionalinformationoncontroloperationisavailableintheGeniSys7590ControlManual(61981-001).
ForLowFireStarttheoperationsequenceisthesameforthe
7590Ccontrol,thedifferenceisthetimerwiredintothevalvecircuitwillenableLowFireStart.
Section:BURNERSTART-UP
24
Burner Start-up
Explosion, Fire, and Asphyxiation Hazard
Professional Installation & Service Required. Incorrect installation and set up could lead to equipment malfunction.
Asphyxiation Hazard
It is recommended that you measure the oxygen (O2) early in the test sequence because high levels of carbon monoxide (CO) can be created at very low or very high O2 levels. The typical operating range is between 3%-5% O2.
Thisburnermustbeinstalledandpreparedforstart-upbyaqualifiedservicetechnicianwhoistrainedandexperiencedingasburnersysteminstallationandoperation.
Donotattempttostarttheburnerunlessyouarefullyqualified.
Donotcontinuewiththisprocedurewithoutthepropertestinstruments.
Carefullyfollowthewiringdiagrams,controlinstructionsheets,controlsequenceofoperation,testproceduresandallappliancemanufacturer’sdirectionsthatpertaintothisinstallation.
Test Instruments
Thefollowingcalibratedtestequipmentisrequiredtoproperlyinstalltheappliance.Theyshouldbecalibratedandingoodworkingorder.
| Acombustionanalyzercapableofmeasuringoxygen(orcarbondioxide),carbonmonoxide,stacktemperature,ambienttemperature,andapplianceefficiency.
| Electricalmulti-metercapableofmeasuringvoltage,ohms,amps,andDCmicro-ampsformeasuringtheflamesignal.
| Calibratedmanometersandpressuregaugescapableofmeasuringallpressurerangesinthegassupplyandappliancedraft.ThiscouldtypicallyrangefromafewPSIto0.1”W.C.
Burner Start Procedure
(Before proceeding, turn off and lock out electrical power and close the main shut off cock to shut off gas to the burner.)
1. Withthepowerandmaingassupplytotheburnerturnedoff,makesuregashasnotaccumulatedintheboilerorflues.
2. Checktheinitialairsettings(shutter&band)forinputfiringrate.SeeTable 8onpage25forinitialairsettings.
3. Withthemainshutoffcockclosed.Setthelimitorcontrollertocallforheatthenapplypowertostarttheburner.
4. Verify Burner Safety Control Function–Inordertocheckthefunctionofeachcomponent(i.e.:7590sequence,airflowprovingswitch,ignitiontransformer,gasvalves,safetylockouttiming,etc.),withthemainshutoffcockclosed,monitoracompleteburnerrunsequence.Notethatthe7590Ccontrolwillentera5minutewaitingtimeafterfailingthetrialforignitionsincethefuelsupplyhasbeenclosedoff.Resetthecontrolbypressingandholdingtheresetbuttonwhilethecontrolispowered.
5. Verify Flame Sensor Function–If7590operationsequenceandfunctioniscorrect,turnoffpowerandremovesensorwirefrombottomof7590control.TurnonpowerandfuelandinitiateCallforHeat.Verifythatburnerfiresupandthegasvalvecloses.Aftercontrollocksout,flameshallgooff.
6. Turnpoweroffandreattachsensorwire.Turnpowerbackonandresetthecontrolusingresetbutton.InitiateCallforHeat.
7. Afteryouhaveobservedmainflameforabrieftime,presstheresetbuttononthecontrolfor1secondtoshutdownandre-starttheburner.Monitortheflameandsafetyshutoffvalvestoassurethatshutdowniscontrolledbythevalvesandthattheyoperateproperly.Withthistestpassed,youmaysafelyinitiateautomaticstart-upsonsubsequentcycles.
8. Whiletheburnerisfiring,examinetheventsystemforevidenceofleaks,obstructions,andforcorrectfunctionofthebarometricdraftcontrol.Leaktestallgaspipingfromtheburnertotheutilitysupplypiping.Ifleaksarefound,correctthemimmediately.
9. Low gas pressure switch–Withtheburnerfiringandamanometerattachedtoatestportnearthelowpressureswitch,graduallyclosethemainleaktestcocktoshutoffthegassupply.Notethepressureatwhichthelowgaspressureswitchopensandshutstheburneroff.Manuallyresettheswitch.Thelowgaspressureswitchshouldbesetathalfofthenormalsupplypressureintheline.
10.High gas pressure switch–Withtheburnerfiringandamanometerattachedtothetestportnearestthehighpressureswitch,graduallyincreasethegaspressureuntilthehighpressureswitchopensandshutstheburneroff.Notethepressureandmanuallyresettheswitch.Thehighgaspressureswitchshouldbesetatoneandonehalftimesthehighfiremanifoldpressure(seenameplatedatainFigure 1orsetswitchasdeterminedbytesting).
25Burner Manual — CG10-24
Section:BURNERSTART-UP
Table 8 – Initial Burner Settings
Furnace Pressure 0” W. C. .25” W. C. .50” W. C. 1.00” W. C. Fi
rin
g R
ate
MB
H
Bu
rner
Mo
del
Ru
nn
ing
Man
ifo
ld
Gas
Pre
ssu
re, I
n. W
C
Low
Fir
e S
tart
Gas
Pr
essu
re, I
n. W
C
Sh
utt
er S
etti
ng
Ban
d S
etti
ng
Ru
nn
ing
Man
ifo
ld
Gas
Pre
ssu
re, I
n. W
C
Low
Fir
e S
tart
Gas
Pr
essu
re, I
n. W
C
Sh
utt
er S
etti
ng
Ban
d S
etti
ng
Ru
nn
ing
Man
ifo
ld
Gas
Pre
ssu
re, I
n. W
C
Low
Fir
e S
tart
Gas
Pr
essu
re, I
n. W
C
Sh
utt
er S
etti
ng
Ban
d S
etti
ng
Ru
nn
ing
Man
ifo
ld
Gas
Pre
ssu
re, I
n. W
C
Low
Fir
e S
tart
Gas
Pr
essu
re, I
n. W
C
Sh
utt
er S
etti
ng
Ban
d S
etti
ng
Stepped Spud Head Configuration
300 CG10.1S 1.0 0.5 3 0 1.3 0.6 3 0 1.5 0.8 4 0 2.0 1.0 6 0
350 CG10.1S 1.4 0.7 4 0 1.6 0.8 4 0 1.9 0.9 5 0 2.4 1.2 7 0
400 CG10.2S 1.1 0.5 4 0 1.3 0.7 4 0 1.6 0.8 5 0 2.1 1.0 6 0
450 CG10.2S 1.4 0.7 5 0 1.7 0.8 6 0 1.9 1.0 7 0 2.4 1.2 9 0
500 CG10.3S 1.2 0.6 6 0 1.5 0.7 7 0 1.7 0.9 8 0 2.2 1.1 10 1
550 CG10.3S 1.3 0.7 8 0 1.6 0.8 9 0 1.8 0.9 10 0 2.3 1.2 - -
600 CG10.4S 2.5 1.3 5 0 2.8 1.4 6 0 3.0 1.5 7 0 3.5 1.8 9 0
700 CG10.4S 3.4 1.7 7 0 3.6 1.8 9 0 3.9 1.9 10 0 4.4 2.2 10 3
800 CG10.5S 3.1 1.6 10 0 3.4 1.7 10 1 3.6 1.8 10 1 4.1 2.1 10 3
900 CG10.5S 4.0 2.0 10 3 4.2 2.1 10 4 4.5 2.2 10 4 5.0 2.5 10 6
1000 CG10.6S 3.2 1.6 10 0 3.4 1.7 10 2 3.7 1.8 10 3 4.2 2.1 10 6
1100 CG10.6S 3.9 1.9 10 2 4.1 2.1 10 4 4.4 2.2 10 5 4.9 2.4 10 10
1200 CG10.6S 4.6 2.3 10 6 4.9 2.4 10 8 5.1 2.6 10 10 - - - -
Spinner Head Configuration
300 CG10.1 1.5 0.8 3 0 1.8 0.9 3 0 2.0 1.0 4 0 2.5 1.3 5 0
350 CG10.1 2.0 1.0 5 0 2.3 1.1 6 0 2.5 1.3 8 0 3.0 1.5 10 1
400 CG10.2 1.6 0.8 4 0 1.8 0.9 4 0 2.1 1.0 5 0 2.6 1.3 6 0
450 CG10.2 2.0 1.0 4 0 2.2 1.1 4 0 2.5 1.2 5 0 3.0 1.5 8 0
500 CG10.3 1.5 0.8 5 0 1.8 0.9 5 0 2.0 1.0 6 0 2.5 1.3 8 0
550 CG10.3 1.9 0.9 7 0 2.1 1.1 8 0 2.4 1.2 9 0 2.9 1.4 10 1
600 CG10.4 1.1 0.6 6 0 1.4 0.7 7 0 1.6 0.8 8 0 2.1 1.1 10 0
700 CG10.4 1.5 0.8 9 0 1.8 0.9 10 0 2.0 1.0 10 1 2.5 1.3 10 4
800 CG10.5 1.5 0.7 9 0 1.7 0.9 10 1 2.0 1.0 10 3 2.5 1.2 10 6
900 CG10.5 1.9 0.9 10 1 2.1 1.1 10 3 2.4 1.2 10 4 2.9 1.4 10 9
1000 CG10.6 1.8 0.9 10 2 2.1 1.0 10 4 2.3 1.2 10 5 2.8 1.4 10 9
1100 CG10.6 2.2 1.1 10 4 2.5 1.2 10 6 2.7 1.4 10 7 - - - -
1200 CG10.6 2.7 1.3 10 6 2.9 1.5 10 8 3.2 1.6 10 10 - - - -
InitialburnersettingsdonotaccountforvariationinfuelgasBTUcontentorvariationinfieldinstallationsetupsorconditions.Combustiontestequipmentmustbeusedbyaqualified
serviceagencyforpropersetup.
Section:BURNERSTART-UP
26
200
400
600
800
1000
1200
1400
0 1 2 3 4 5 6Pressure Drop, In. WC
Rat
e,M
BH
CG10.6SCG10.5SCG10.4SCG10.3SCG10.2SCG10.1S
0
200
400
600
800
1000
1200
1400
0 1 2 3 4 5
Rat
e,M
BH
Pressure Drop, In. WC
CG10.6CG10.5CG10.4CG10.3CG10.2CG10.1
Figure 19 – Manifold to Furnace Pressure Drop vs. Rate - Stepped Spud Design
Figure 20 – Manifold to Furnace Pressure Drop vs. Rate - Swirl Vane Head Design
27Burner Manual — CG10-24
Section:BURNERSTART-UP
Verify the Burner Firing Rate
The primary methodforverifyingtheburner’sfiringrateistoassurethattheburnerisoperatingwiththecorrectmanifoldpressureandthecorrectsetupforeithernaturalgasorpropane.
1. Turnoffelectricalpowertotheburnerandclosethemainshutoffcocksupplyinggastotheburner.
2. Removetheplugfromtheoutletpressuretapontheburnermanifoldendofthegasvalveandinstallahosebarbfittingandmanometer.
3. Turnonsystempowerandgassupplyandinitiateacallforheattolighttheburner.
4. Verifythevalvesregulatingpressure.Lettheburnercontinuetorunandadjustthegasvalvepressureregulatorinthefollowingstepstoobtainthecorrectmanifoldpressure.
5. ManifoldPressureistobeusedtosettheburnersfiringrate.SeeTable 8onpage25.
6. Removetheregulatorcoverscrewfromtheregulatoradjustmenttowerandturntheregulatoradjustscrewclockwisetoincreasepressureorcounterclockwisetodecreasepressure.Settheregulatortoproducethecorrectwatercolumnreadinginthemanometer.Checktheappliancebreechordraftsettingandadjustifnecessaryasitcanaffectthesetting.Replacetheregulatorcoverscrew.
7. Turnofftheburnerandturnoffallelectricalpowertothesystem.
8. Removethemanometerhoseandbarbfittingfromthegasvalveoutletpressuretap.
9. Replacetheoutletpressuretapplugandtighten(clockwise40–60in.-lbs.).
10.Turnonsystempowerandstarttheburner.
11.Checkforleaksatthegasvalveoutletpressuretapplugusingaleakdetectionsolutionorsoapsuds.Bubblesformingindicatealeak.SHUTOFFGASANDFIXALLLEAKSIMMEDIATELY.
If the burner is firing natural gasitmaybepossibletoverifythefiringrateby“clocking”thegasmeter:
1. Locatethegasmeterandexamineitsdisplaytobesurethatyoucandeterminea1cubicfootusageofgasandthatthemeteristemperaturecompensated.
2. Contactthegasutilitytofindtheheating valueofthegas.Itcanvaryfromabout950BTU/Ft3toabout1,100BTU/Ft3.
3. Examinethegaspipingtoknowofanyothergasappliancesconnectedtoit.Turnthemoffsothatonlythisburnerisusinggasfromthemeter.
4. Starttheburneranduseastopwatchtomeasurethenumberoftimed secondsittakesfortheburnertofire1cubicfootofgas.
5. CalculatethefiringrateinBTU/Hr.usingthefollowingequation:
Firing rate BTU/Hr. = Heating value (BTU/Ft3) x 3,600 ÷ Timed seconds
Forexample,iftheheatingvalueis1,050BTU/Ft3andyoutimed1cubicfootofgasat42secondsthenfiringrateBTU/Hr=1050x3,600÷42whichcalculatesto90,000BTU/Hr.
If the burner is firing LP gas,ameterisusuallynotavailable.ContactyourLPsupplierforrecommendations.
Estimating Rate
ManifoldtoFurnacePressureinformationcanbeusedtoestimatetheburner’sfiringratewhenitisnotpossibletoclockameterfortherate.
Toestimatetheburner’sfiringrate:
| Measurethefurnacepressureoverfire.
| Measurethemanifoldpressure(atthemanifoldpressuretestconnection).
| Subtractthefurnacepressurefromthemanifoldpressure.
| ComparetheresulttothedatainFigure 19andFigure 20onpage26asappropriateforyourburner.
Section:COMBUSTIONAIRADJUSTMENTPROCEDURE
28
Validate Safety Control Operation
Explosion, Fire, and Asphyxiation Hazard
Testing by Qualified Technician Required. Failure to properly test and verify the correct function of operation and safety
controls could lead to equipment malfunction.
Thetestingofoperatingandsafetycontrolsrequirestechnicaltrainingandexperiencewithpowergasburnersandappliances.
Carefullyfollowthemanufacturer’sinstructionssuppliedwiththeapplianceandthecontrols.
Verifythecorrectfunctionofalloperatingandsafetycontrolsusedintheinstallation.
Ifinstructionsarenotavailable,usethefollowingrecommendedproceduresandrecordallresultsinastart-uplog.
1. High limit/ Pressure Control–TochecktheHighLimit,raisethetemperatureorpressureoftheoperatingcontroltoahigherlevelandlowerthelimittoasettinglessthantheoperatingcontrol.Runtheburneruntilthehighlimitopensandshutstheburneroff.Adjustthecontrolsbacktothedesiredsettings.
2. Operating control–Runtheburneruntiltheoperatingcontrolshutsitoff.Ifnecessary,makeadjustmentstoensurethecontrolcyclestheburnerinthedesiredtemperatureorpressurerange.
3. Low water cutoff (LWCO)–Withtheburnerfiring,opentheblowdownvalveonthelowwatercutoff,ifapplicable.Asthewaterleveldrops,theLWCOswitchcontactsopenandshuttheburneroff.Whenthewaterlevelrises,theLWCOcontactscloseandrestarttheburner.MonitortheLWCOswitchoperationinrelationtothewaterlevelinthesight-glassforsynchronization.
4. Verify Flame Sensor Function–If7590operationsequenceandfunctioniscorrect,turnoffpowerandremovesensorwirefrombottomof7590control.TurnonpowerandfuelandinitiateCallforHeat.Verifythatburnerfiresupandthegasvalvecloses.Aftercontrollocksout,flameshallgooff.
Combustion Air Adjustment Procedure
CO Leakage, Asphyxiation
Failure to maintain proper stack temperature could result in flue gas condensing and cause chimney damage.
Alwaysusecalibratedtestinstrumentstosetcombustion
levels.Verifythattestinstrumentsarecalibratedandingoodworkingcondition.Ifnotalreadyprovided,drilltestaccessholesinthefluepipenearthebreech(orupstreamoftheboilerbreechdamper,ifapplicable)andinthefrontmountingplateareaforfireboxpressure.Becarefulnottodamageanywater-backedsurface.
1. Initiateacallforheat.
2. Adjustthedraft,over-fire,orbreechpressuretotheappliancemanufacturer’srecommendedlevelafterflamehasstabilized.
3. Measurethecarbonmonoxidelevelandadjustairsettings.Anoperatingrangeof0-50PPMisrecommendedfortheCG10burner.
4. Beforemakingthesetests,operatetheburnertoallowtheheatingsystemtemperaturetostabilizeornearlyreachsteady-statelevels.
5. MeasuretheO2orCO2atthe50PPMCOlevel.Itisrecommendedthatyoumeasuretheoxygen(O2)earlyinthetestsequencebecausehighlevelsofcarbonmonoxide(CO)canbecreatedatveryloworveryhighO2levels.Thetypicaloperatingrangeisbetween3%-5%.
6. OpentheairadjustmentuntiltheO2levelisincreasedbyatleast1%orto3%O2(whicheverishigher).ThisshouldreducetheCOlevelandprovideamarginofreserveairtoaccommodatevariableconditions.
7. SampletheCOlevelagain.Itshouldbeinthe0to50PPMrange.
8. Checkthedrafttoensureitstillmeetsspecifications.Ifamajorchangeindraftisrequired,repeattheabovesteps.
29Burner Manual — CG10-24
Section:COMBUSTIONAIRADJUSTMENTPROCEDURE
Theshutterandbandbothcontroltheamountofflowareaavailablefor
airinlettotheburner.Thegreatertheircombinedflowarea,thehigherthefiringrate.Theprimarydifferencesbetweenthetwoaretheireaseofadjustmentandtheirtotalairflowarea.Theshutterturnsmoreeasilyandhasasmallernetflowarea.Asaresultwehavefoundtheshuttertobebettersuitedforlowrateadjustments,andthebandbettersuitedforhighrateadjustments.Werecommendthatatlowratesthebandbeleftcompletelycloseduntiltheshutterhasbeenfullyopened,andthatforhigherratestheshutterisleftcompletelyopenasthebandisopened.
Air Band
Figure 21 – Shutter and Band
Band Indicator Mark
Shutter Indicator
Adjustment Scale(For Shutter and Band)
Tighten locking screws securely after adjustments
have been made
Shutter
9. Verifystacktemperaturemeetsappliancemanufacturer’srecommendations.Generallya325°Fstacktemperatureishighenoughtoavoidcorrosivecondensationintheventsystem,howeveralargecrosssectionflowareachimneyoraverytallchimneymayrequireahightemperature.SeeANSIZ223.1/NFPA54fordesignrequirements.
10.Performanyfinaladjustmentsandlocktheairsettingsecurely.Runtheburnerthroughseveralcyclestoverifypromptignitionandstableburneroperation.(seeFigure 21).
11.Recordthecombustionperformancereadings,burnersettingsandappliancedataonthestart-upforminthebackofthismanual.IftheburnerisfiringLPgasyoumustalsorecordset-upinformationonthepropaneconversionlabelandattachittotheappliance.
Maintenance and Service
Explosion, Fire, and Asphyxiation Hazard
Annual Professional Service Required. Tampering with or making incorrect adjustments could lead to equipment malfunction.
Donottamperwiththeburnerorcontrolsormakeanyadjustmentsunlessyouareatrainedandqualifiedservicetechnician.
Toensurecontinuedreliableoperation,aqualifiedservicetechnicianmustservicethisburnerannually.
Morefrequentserviceintervalsmayberequiredindustyor
adverseenvironments.
Operationandadjustmentoftheburnerrequirestechnicaltrainingandskillfuluseofcombustiontestinstrumentsandothertestequipment.
Electrical Shock and Explosion Hazard
Failure to turn off electric and gas supply could result in electrical shock, gas leakage, explosion, or fire hazards.
Turnmaingasvalvesandelectricpoweroffbeforeperforminganymaintenance.
Ifamaintenanceprocedurerequireselectricalpower,useextremecaution.
Fire Hazard
Removing the igniter from the factory-installed baseplate could cause serious death or injury.
Donotremoveigniterfromfactoryinstalledbaseplate.
Labelallwirespriortodisconnectingwhenservicingcontrols.Wiring
errorscancauseimproperanddangerousoperation.
Verify proper operation after servicing.
Explosion, Fire, Asphyxiation Hazard
Useauthorizedreplacementpartsonly.Donotattempttoreplicateormodifyanyparts.
Section:MAINTENANCEANDSERVICE
30
Required Annual Maintenance
Explosion, Fire, and Asphyxiation Hazard
Inspect Heating System Regularly. Lack of regular inspections and inadequate maintenance could lead to equipment malfunction.
(Alwaysfollowtheappliancemanufacturer’srecommendedserviceinstructions,whenavailable.)• Thefollowingchecklistisintendedtobeused
asaminimumreferenceguideonlyanddoesnotsupersedeorreplacetheheatingappliancemanufacturer’srecommendedserviceandmaintenanceinstructionsoranycoderequirements.
• Consulttheinstallationandserviceinstructionsprovidedbytheindividualcontrolorcomponentmanufacturerandcarefullyfollowtheirdirections.
• Maintenanceandtestingmayberequiredmorefrequentlyduetodustyorsevereoperatingconditions.
• Ifunusualorquestionableperformanceisobserved,shutthesystemdownandcontactyourqualifiedserviceagencyimmediately.
(The following should be performed by a qualified service technician only.)
| InspectandCleantheBurner
1. Inspectandcleanalldirtaccumulationfromthegastrain,burnerexterior,burnerairband/shutter,andsurroundingarea.
2. Removetheblowermotorandcleananyaccumulatedmatterfromtheblowerwheelandmotorendbell.
3. Checkwheelfordamageandthehubsetscrewfortightness.
4. Cleantheinsidesurfacesoftheburnerhousingscrollandespeciallytheairintakeareaandairflowprovingswitchsuctiontube.
5. Clearanydebrisfromtheairventsonthemotorbody.
6. Cleantheignitiontransformer,baseplate,andterminalbushing.Inspecttheignitionleadforsignsofdeteriorationandlooseterminals.
7. Removethegasgunassemblyandcleantheentireunit,payingspecialattentiontotheairdiffuser.
8. Inspecttheflamerodforoxidationordistortion.Cleanallsurfaces,settheprobeposition,andinsurethattheflamerodissecurelyfastened.RefertoFigure 22onpage31.
9. Inspecttheignitionelectrodeforanydamage.Cleanallsurfaces,settheproperelectrodegap,andmakesureitissecurelyfastened.SeeFigure 22.
10.Cleantheinsideoftheairtubeandinspectthecombustionendforanydeterioration.Checktherecessdimensionfromrefractory.
11. InspectgastubeO-ringconditionandreplaceifdamaged.Installgasgunassemblybackintotheburnerandtightenthegasgunsecurelyinplace.(AutomotivechassisorbearinggreaseissuitableforO-ringlubrication.)
12.Inspecttheconditionoftheappliancemountingplateandburnermountingflangegasketsandreplaceanydamagedmaterials.
13.Inspectallburnercontrolwiringandtheburnercontrolfordamagedinsulationandlooseterminals/connections.
14.Verifythatthesourcevoltagetotheburnerandcontrolpaneliswithin10%oftheburnerratingaslistedontheburnernameplate.
| Appliance –(Followappliancemanufacturer’sserviceprocedures.Thefollowingstepsareemphasizedbecausetheyrelatetoburneroperation)
1. Insurethatthefluepassages,flueventpipes,andchimneyfluesarecleanandunobstructed.
2. Checkbarometricdamperordrafthoodforproperoperation.
3. Checktheconditionofthecombustionchamberrefractory,thefront-plateinsulation,andallgasketsandseals.Repairorreplaceasnecessary.
4. Inspectboilersectionsandsystemloadpipingforpossibleleaks.Makeallnecessaryrepairs.
5. Checkalloperatingandsafetycontrolsontheboilerforproperinstallationandoperation.
6. Performallmaintenanceandtestsaccordingtotheburnercontrolmanufacturer’sinstructions(limits,controllers,lowwatercutoff,reliefvalves,feedvalves,etc.).
31Burner Manual — CG10-24
Section:MAINTENANCEANDSERVICE
| Gas supply piping:
1. Inspectallpipingforleakageandproperinstallation.
2. Performnecessaryrepairstocomplywithallcodes.
3. Checkinletpressuretothegasvalve.
| Installation area:
1. Insurethattherearenocombustiblematerials,flammableliquidsorvaporsinthevicinityoftheheatingappliance.
2. Verifythatthecombustionairsupplyisadequate.
| Adjust the burner for proper combustion:
1. Runtheburnerandperformacompletecombustiontestusingtheproperinstruments.Ifnecessaryrefertosectiontitled“BurnerStart-up”onpage24.Recordtheresultsforreference.
2. Visuallyinspecttheflame.Lookforchangesinshape,size,andcolor.
3. Monitorseveralburnerstart-upcycles.Verifypromptignitionandflamestability.
4. Calculatetheinputfiringrateandcomparetotheappliancespecifications.
5. Monitorthestacktemperature.Comparetostart-upandtrendlevel.
| 7590 GeniSys Primary Control:
FollowtheinstructionsinBeckettGeniSysModel7590manual(availableatwww.beckettcorp.comorbycalling1-800-645-2876).Verifythatthecontrolisfunctioningtospecifications.See“CheckforNormalOperation”section.
| Manual shutdown for long periods:
1. Closeallgasvalvesinthegassupplypipingsystem.
2. Turnoffallelectricalpowertotheburner.
3. Protecttheburnerandcontrolsfrommoistureanddirt.
Figure 22 – Electrode and Flame Rod Setting Note: Flame Rod crosses centerline of head assembly.
1/8”Gap
3/8”Gap
3/8”Gap
1/8”Gap
1/4”(InsulatorHeight)
90°
Bottom View Bottom View Side View
3/8”Gap
1/4”Gap
1/8”Gap
CG10.1 - 10.3 CG10.4 - 10.6 CG10.1S - 10.6S
Section:MAINTENANCEANDSERVICE
32
Verify alignment
Verify burner modelon adjustment scale
Verify O-ring is in placeand lubricated
Figure 23 – Gas Gun Assembly - Top View
CG10.1S - 10.6S
CG10.3 - 10.6
CG10.1 - 10.2
END BELL
MOTOREND BELL
MOTOR
0.020”
0.020”0.030” to 0.060”
CG10 CG10A & CG10B
Figure 24 – Blower Wheel Spacing
33Burner Manual — CG10-24
Section:REPLACEMENTPARTS
Replacement Parts
Figure 25 – CG10-24 Gas Burner Replacement Parts
8 7
SeeFigure 26
3
2
1
4 56
13
14
15
910
11
12
Item Description Beckett Part No.
1 JackingScrew 5193401U
2 AirTube SeeNote1
3LowGasPressureSwitch 52259-001U
HighGasPressureSwitch 52259-002U
4 ValveTimer 52402001U
5 WireAssembly-AirProvingSwitch 52268001U
6 WireAssembly-6pin 52401001U
7 PrimaryControl 7590C0001U
8 IgnitionTransformer 7474002U
9 AirProvingSwitchAssy 52264002U
10 Shutter 3215U
11 AirBand 5151503
12 24VTransformer 52310002U
13 AirInlet
AirGuide(300-600MBH) 189U
AirGuide(600-1,000MBH) 178U
InletSleeve 32336U
Item Description Beckett Part No.
14 BlowerWheel
CG10(300-600MBH) 21448U
CG10AorB(600-1,200MBH) 21339U
15 Motor120v 21341U
Note 1:Appliancemustbespecifiedtoorderanairtubewithweldedmountingflange.
Gas Valve Replacement Parts (not shown)Description Beckett Part No.
SolenoidGasValve24V,1”NPT 2193410U
SolenoidGasValve24V,3/4”NPT 2193411U
2StageGasSafetyValve24V,1”NPT 32990001U
RegulatorMaxitrol3/4”NPT 2192901CU
RegulatorMaxitrol1”NPT 2192902DU
Explosion, Fire, Asphyxiation Hazard
Useauthorizedreplacementpartsonly.Donotattempttoreplicateormodifyanyparts.
Section:REPLACEMENTPARTS
34
Item Description Beckett Part No.
1 HeadwithElectrode
10.1 101U
10.1S 101SU
10.2 102U
10.2S 102SU
10.3 103U
10.3S 103SU
10.4 104U
10.4S 104SU
10.5 105U
10.5S 105SU
10.6 106U
10.6S 106SU
2 SpringClamps(4-pack) 3236501U
3 ElectrodeSetwithCable
10.4-10.6 22225U
10.1-10.3 2191201U
10.1S-10.6S 2191205U
4 FlameRodwithCable 2191305U
5 O-ringSet(2-piece) 3226401U
6 PropaneRestrictor(LPOnly) SeeTable 6onpage18
Figure 26 – CG10-24 Gas Gun Replacement Parts
6
1
2
4
5
3
Contractor Start-Up Form
InstallationName:_____________________________________________ InstallationDate:_____________________
Installation Address:_________________________________________________________________________________
Start-UpCompany’sName_______________________________________Phone:____________________________
Name ofTechnician__________________________________________________________________________________
�� Appliance (Below information can be obtained from appliance name plate)
Manufacturer:______________________________________________________________________________
Type (circle one): [Boiler / Furnace / Other ] Model #:_______________ Serial #:____________________
InputMBH:_______________OriginalApplianceDesignedfor(circleone):[Oil / Natural Gas / Propane]
OutputMBH:______________
LimitsLimit Model No.
(Indicaten/aifnotrequiredbytheappliancemanuf.) Operation Verified
Temperature YES / NO
Pressure YES / NO
LWCO YES / NO
OtherLimits YES / NO / n/a
�� Burner
Fuel:[Natural Gas / Propane]Model#:________________Serial#:_________________________
CombustionHead:________PropaneOrificeSize(ifinstalled):________AirShutterSetting:____________
AirBandSetting:____________
�� Chimney/Smoke Pipe
ChimneyType:[Masonry / Metal Vent / Direct Vent]Location(circleone):[Inside / Outside]
ChimneyHeight:_____________FluePipeSize:______________FluePipeLength:________________Number
ofElbows:____________ConfirmDoubleActingDraftRegulatorInstalled:[Yes / No]
ThermalSafetySwitchInstalled[Yes / No]Voltage:[120V / 24V]
�� Gas Supply Piping
PipeDiameter:________LengthofPipefromBurnertoMeter:_________NumberofElbows:__________
GasPressuretoBurnerGasValveWhileBurnerisOperating____________InchesW.C.
�� Combustion Readings
O2:_________%CO:__________PPMCO2:_________%StackTemperature(325°FMIN.):__________°F
ManifoldGasPressure:______(InchesW.C.)DraftatBreech_____W.C.ClockedMeterInput_________MBH
AFTER COMPLETION AFFIX TO APPLICATION
USA:P.O.Box1289 Elyria,Ohio44036Canada:R.W.BeckettCanada,Ltd. Unit#3,430LairdRoad Guelph,OntarioN1G3X7
www.beckettcorp.com
PartNumber6104BCG10-24R04,PrintedintheU.S.A.08/17
TheR.W.BECKETTCORPORATION(“Beckett”)warrantstopersonswhopurchaseits“Products”fromBeckettforresale,orforincorporationintoaproductforresale(“Customers”),thatitsequipmentisfreefromdefectsinmaterialandworkmanship.Toqualifyforwarrantybenefits,productsmustbeinstalledbyaqualifiedserviceagencyinfullcompliancewithallcodesandauthoritieshavingjurisdiction,andusedwithinthetolerancesofBeckett’sdefinedproductspecifications.
Toreviewthecompletewarrantypolicyanddurationofcoverageforaspecificproduct,orobtainawrittencopyofwarrantyform61545,pleasechooseoneofthefollowingoptions:
1. Visitourwebsiteat:www.beckettcorp.com/warranty
2. Emailyourrequestto:[email protected]
3. Writeto:R.W.BeckettCorporation,P.O.Box1289,Elyria,OH44036
NOTE: Beckett is not responsible for any labor cost for removal and replacement of equipment.
THISWARRANTYISLIMITEDTOTHEPRECISETERMSSETFORTHABOVE,ANDPROVIDESEXCLUSIVEREMEDIESEXPRESSLYINLIEUOFALLOTHERREMEDIES,ANDINPARTICULARTHERESHALLBEEXCLUDEDTHEIMPLIEDWARRANTIESOFMERCHANTABILITYANDFITNESSFORAPARTICULARPURPOSE.INNOEVENTWILLBECKETTBELIABLEFORANYINCIDENTALORCONSEQUENTIALDAMAGEOFANYNATURE.Beckettneitherassumes,norauthorizesanypersontoassumeforBeckett,anyotherliabilityorobligationinconnectionwiththesaleofthisequipment.Beckett’sliabilityandCustomer’sexclusiveremedyislimitedtothecostoftheproduct.
Limited Warranty Information