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RESIDENTIAL BURNERS
Potential for Fire, Smoke and Asphyxiation Hazards
To the Homeowner or Equipment Owner:
Please read and carefully follow all instructionsprovided in this manual regarding yourresponsibilities in caring for your heatingequipment.
Contact a professional, quali ed service agency forinstallation, start-up or service work.
Save this manual for future reference.
Incorrect installation, adjustment, or misuse of this burner could result in death, severe personal injury, or substantial property damage.
To the Professional, Quali ed Installer or Service Agency:
Please read and carefully follow all instructions providedin this manual before installing, starting, or servicing thisburner or heating system.
The Installation must be made in accordance with all stateand local codes having jurisdiction.
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Section: General Information
Do NOT Alter the OriginalBurner Design
Tampering with or altering the burner design couldseriously impair performance, resulting in loss ofstatic pressure, damage to the system components,reduced air volume, heavy smoke, ameimpingement, appliance sooting, hot gas puff-back,and asphyxiation or re hazards.
Maintain the design to its original con guration.Only use parts speci ed for AF or AFG Burners.Do NOT remove the air guide from the AFG chassis.Do NOT use M Series air tube combinations on AFBurners.
Never try to convert an AF to an AFG or vice versa Any design alteration will:
Void UL Listing
Void manufacturers warranties
Seriously impact burner performance
Greatly increase your liability risk
Impaired Burner Performanceand Fire Hazard.
Do NOT operate the burner beyond speci cationsoutlined in the following Table.
For applications beyond these limits, consult BeckettTechnical Service at 1-800-645-2876.
NOTE: Some packaged appliances with burnersmay be agency listed as a unit to operate beyondthese limits. Consult the appliance manufacturersspeci cations and agency approvals for veri cation.
Table 1 Burner Speci cations
Capacity(Note 1)
F Head (AF & AFG)Firing rate range: 0.40 3.00 GPHInput: 56,000 420,000 Btu
L1 Head (AFG Only)Firing rate range: 0.40 - 1.10 GPHInput: 56,000 154,000 Btu/h
L2 Head (AFG Only)
Firing rate range: 0.50 - 1.00 GPHInput: 70,000 140,000 Btu/h
V1 Head (AFG Only)Firing rate range: 0.75 - 2.75 GPHInput: 105,000 385,000 Btu/h
Certications/Approvals
UL listed to comply with ANSI/UL296 and CSA-B140.0
Fuels USA: No. 1 or No. 2 heating oil only (ASTM D396)Canada: No. 1 stove oil or No. 2 furnace oil only
DO NOT USE GASOLINE, CRANKCASEOIL, OR ANY OIL CONTAINING GASOLINE.
Electrical Power supply: 120 volts AC, 60 Hz single phaseOperating load: 5.8 Amps maxMotor: 1/7 hp, 3450 rpm, NEMA 48M frame PSCrotation CCW when facing shaft endIgnition: Continuous duty solid-state igniter
Fuel pump Outlet pressure: Note 2
Air tube ATC code: See Table 2
Dimensions(with cover)
Height (maximum): 12.5 inchesWidth (maximum): 15 inchesDepth: 9.25 inches Air tube diameter: 4.00 inches
Ambient Operat-ing Temperature
+32o F. (0 C.) Minimum+115o F. (+46 C.) Maximum(See above Warning)
Moisture 5% to 95% RH, non-condensing and non-crystallizing
Note 1: Approval agency listed rating for these burners is 0.40 to 3.00gph. However, the ring rate range is limited by the speci c air tubecombination being used. Refer to Table 2 .Note 2: See appliance manufacturers burner speci cations forrecommended pump discharge pressure.
If the residence is unattended in severely coldweather, burner primary control safety lockout,heating system component failures, power outagesor other electrical system failures could result infrozen plumbing and water damage in a matter ofhours. For protection, take preventive actions suchas having a security system installed that operatesduring power outages, senses low temperatureand initiates an effective action. Consult with yourheating contractor or a home security agency.
Frozen Plumbing andWater Damage Hazard
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Table 2 Air Tube Combination (ATC) codes
FiringRate (gph)(min-max)
HeadStatic
plate size(inches)
Venturi
ATC Codes for usable air tube lengths(A in inches; See Figure 3.)
4-1/2 5 5-3/8 6-5/8 7 7-1/4 9 10-1/2 13 16
0.50-0.75 F0 3-3/8U None AF44XR - AF53XR AF65XR - AF72XR AF90XR AF104XR AF130XR A160XR
0.75-1.25 F3 2-3/4U None AF44XN - AF53XN AF65XN - AF72XN AF90XN AF104XN AF130XN AF160XN
0.85-1.35 F4 2-3/4U None AF44WH - AF53WH AF65WH - AF72WH AF90WH AF104WH AF130WH AF160WH
0.85-1.65 F6 2-3/4U None AF44YB - AF53YB AF65YB - AF72YB AF90YB AF104YB AF130YB AF160YB
1.10-2.00 F12 2-3/4U None AF44XO - AF53XO AF65XO - AF72XO AF90XO AF104XO AF130XO AF160XO
1.65-2.50 F22 2-3/4U None AF44XP - AF53XP AF56XP - AF72XP AF90XP AF104XP AF130XP AF160XP
2.50-3.00 F31 None None AF44XS - AF53XS AF65XS - AF72XS AF90XS AF104XS AF130XS AF160XS
0.50-1.10 L1 3-3/8U 8hole - AFG50MB - - AFG70MB - AFG90MB - - -
0.50-1.00 L2 2-3/4U 8hole AFG50MP - - AFG70MP - AFG90MP - - -
0.75-2.75 V1 2-3/4U 8hole - AFG50MD - - AFG70MD - AFG90MD - - -
0.40-0.75 F0 3-1/2U None AF44WG - AF53WG AF65WG - AF72WG AF90WG AF104WG AF130WG A160WG
Section: General Information
Please read and understand the manual supplied withthis equipment. This equipment must be installed,adjusted and put into operation only by a quali edindividual or service agency that is:
Licensed or certi ed to install and provide technicalservice to oil heating systems.
Experienced with all applicable codes, standardsand ordinances.
Responsible for the correct installation andcommission of this equipment.
Skilled in the adjustment of oil burners usingcombustion test instruments.
The installation must strictly comply with all applicablecodes, authorities having jurisdiction and the latestrevision of the National Fire Protection AssociationStandard for the installation of Oil-burning Equipment,NFPA 31 (or CSA-B139 and CSA-B140 in Canada).Regulation by these authorities take precedence overthe general instructions provided in this installationmanual.
Incorrect installation, adjustment, anduse of this burner could result in severe personal injury, death, or substantial property damage from re, carbonmonoxide poisoning, soot or explosion.
Professional ServiceRequired
Special Requirements
THE INSTALLATION OF A BURNER SHALL BE IN ACCORDANCE WITH THE REGULATIONS OF AUTHORITIES HAVING JURISDICTION.For recommended installation practices in the U.S.refer to the latest edition of NFPA 31. (CSA-B139and CSA-B140 in Canada.Concealed damage If you discover damage tothe burner or controls during unpacking, notify thecarrier at once and le the appropriate claim.When contacting Beckett for service information Please record the burner serial number (and haveavailable when calling or writing). You will nd theserial number on the silver label located on the leftrear of the burner. Refer to Figure 1 .
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Carefully inspect the chimney or exhaust ventsystem.
Make sure it is properly sized and in good workingcondition.
Follow the instructions supplied by the appliancemanufacturer.
The installation must strictly comply with allapplicable codes, authorities having jurisdiction andthe latest revision of the National Fire Protection
Association Standard NFPA 31 for the installation ofchimneys and vent sizing, (or CSA-B139 and CSA-B140 in Canada).
Regulation by these authorities take precedenceover the general instructions provided in thisinstallation manual.
Fire, Smoke & AsphyxiationHazard
piece of broken tile wedged in the chimney shouldbe removed.
No other appliance connection should be made tothe same ue pipe.
The ue pipe should have an upward pitch towardthe chimney of at least 1/4 per foot of length. Itshould t tightly and should not project into thechimney.
Any leakage between tiles, around clean-out doors,or around the vent pipe should be sealed.
Insulated stainless steel chimney liners
The new designs of high ef ciency oil furnaces andboilers in conjunction with ame retention oil burnersare more ef cient. One result of increased ef ciency is
lower
ue gas temperatures. As
ue gases rise in thechimney, they will cool and condense when they reachthe dew point. The condensation will mix with the sulphurin the ue gases creating sulphuric acid. The acid willattack the chimney mortar, brick and clay liners causingcorrosion, deterioration and blockage of the chimney.Eventually the blockage could prevent exhausting theue gases. Instead, the ue gases could vent out thebarometric damper into the living space.
Therefore, it is strongly recommended that an approvedinsulated stainless steel liner be installed.
For those installations not requiring a chimney, suchas through-the-wall vented appliances, follow theinstructions given by the appliance and power venter(if used) manufacturers.
5.
6.
7.
Inspect Chimney or Direct Vent System
Starting with minimum gph ring rate, the minimumsize recommended is 6 ue pipe with 8 X 8inside chimney, unless speci ed otherwise by theappliance manufacturer.
A chimney ue shall extend at least 3 feet abovethe highest point at which the chimney comes incontact with the roof, and not less than 2 feet abovethe highest roof surface or structure within 10 feethorizontally of the chimney. Refer to Figure 2 .
Any accumulation of soot or debris in chimneyoffsets should be removed
Any obstructions such as a protruding joint or a
1.
2.
3.
4.
Section: Inspect/Prepare Installation Site
Figure 2 Chimney Design - Above the Roof
NOTE: Correct chimney design is shown by dotted lines. Incorrect chimney design, as shown by the solid lines, mayresult in down-drafts.
Inspect/Prepare Installation Site
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Combustion air supply
Do not attempt to install outside air piping tothe burner without using the outside air kit andinstructions.
Failure to comply could result in impaired combustion,appliance soot-up, puffback of smoke, and re orasphyxiation hazards.
Follow the Outside Air KitInstructions Exactly
Appliance located in con ned space
The con ned space should have two (2) permanentopenings: one near the top of the enclosure and one
near the bottom of the enclosure. Each opening shallhave a free area of not less than (1) one square inchper 1,000 BTUs per hour of the total input rating of allappliances within the enclosure. The openings shallhave free access to the building interior, which shouldhave adequate in ltration from the outside.
Exhaust fans and other air-using devices
Size air openings large enough to allow for all air-using devices in addition to the minimum area requiredfor combustion air. If there is any possibility of theequipment room developing negative pressure (becauseof exhaust fans or clothes dryers, for example), eitherpipe combustion air directly to the burner or provide asealed enclosure for the burner and supply it with its owncombustion air supply.
Direct air supply and sidewall venting
Some AFG burners are equipped with combustionair boots to allow use of outside air for combustion.When sidewall venting appliances, carefullyfollow appliance and power venter instructions forinstallation and wiring.
Outside air kit applications
Refer to separate instruction sheet supplied with AF/AFGoutside air kit for installation. This optional kit allowscombustion air to be piped directly to the burner (Beckettpart number 51747).
Clearances to burner and applianceProvide space around burner and appliance for easyservice and maintenance.Check minimum clearances against those shownby the appliance manufacturer and by applicablebuilding codes.
Combustion chamber Burner retro ttingVerify that the appliance combustion chamber providesat least the minimum dimensions given in Table 3 .
Chamber Dimensions (inches)
FiringRate
(GPH)
RoundI.D.
Rectangular Height
Floorto
nozzleWidth Length
0.50 8 7 8 12 5-60.75 9 8 9 12 5-6
1.00 10 9 10 12.5 5-61.25 11 10 11 12.5 5-6
1.50 12 11 12 13 6-7
2.00 14 12 15 13.5 6-72.50 16 13 17 14 7-8
3.00 18 14 18 15 7-8
Table 3. Chamber Dimensions
Section: Inspect/Prepare Installation Site
The burner cannot properly burn the fuel if it is notsupplied with a reliable combustion air source.
Follow the guidelines in the latest editions of theNFPA 31 and CSA-B139 regarding providingadequate air for combustion and ventilation.
Failure to provide adequate air supply couldseriously affect the burner performance and result indamage to the equipment, asphyxiation, explosion or re hazards.
Adequate Combustionand Ventilation Air SupplyRequired
When retro tting appliances that have unlinedstainless steel combustion chambers, protect thechamber by lining the inside surfaces with a ceramicber blanket, such as a wet-pac or other suitablerefractory material.
Some steel chambers may not require linersbecause the appliance was designed and testedfor use with ame retention burners. Refer to themanufacturers instructions.
Failure to comply could result in damage to theheating equipment and result in re or asphyxiation
hazards.
Protect Steel CombustionChamber From Burnout
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Table 4. AFG Reduced Firing Rates (with LFRB)
Burner head type Low Firing Rate Baf e installedF0 up to 0.65 gph
F3 or L1 up to 0.85 gph
F4 or F6 up to 0.90 gph
V1 up to 1.00 gph
Prepare the Burner
Low Firing Rate Baf eThe AFG Low Firing Rate Baf e (LFRB) reduces theair ow and pressure. The LFRB is sometimes used forring rates under 1.00 gph as listed in Table 4 . Referto the appliance manufacturers instructions. Do not
omit the LFRB when speci
ed. Omitting the baf
e whenspeci ed or installing the baf e when not speci ed couldresult in impaired burner performance.
Burner fuel unitVerify that the burner fuel unit is compatible with theoil supply system. For more details, refer to the pumpmanufacturers instructions provided with the burner.
Attach air tube (if not already installed)If using a ange and gasket, slide them onto the air tube.Then attach the air tube to the burner chassis using the
four sheet metal screws provided. Refer to Figure 4 fordetails.
Nozzle and Pump Pressure
Install burner nozzle (if not already installed)Remove the plastic plug protecting the nozzleadapter threads
Place a 3/4 open-end wrench on the nozzleadapter. Insert the nozzle into the adapter andnger tighten. Finish tightening with a 5/8 open-endwrench. Use care to avoid bending the burner headsupport legs or electrodes. If you remove the headto replace the nozzle (type L1/L2 or V1 heads),carefully reconnect the head to the nozzle adapter,making sure that the head support makes contact withthe nozzle adapter shoulder. Refer to Figure 5 or 6 .
1.
2.
Section: Prepare the Burner
Use only nozzles having the brand, ow rate (gph),spray angle and pattern speci ed by the appliancemanufacturer.
Follow the appliance manufacturers speci cations forthe required pump outlet pressure for the nozzle, sincethis affects the ow rate.
Nozzle manufacturers calibrate nozzle ow rates at100 psig.
When pump pressures are higher than 100 psig, theactual nozzle ow rate will be greater than the gphstamped on the nozzle body. (Example: A 1.00 gphnozzle at 140 psig = 1.18 gph)
Securely tighten the nozzle (90 torque inch pounds). Fortypical nozzle ow rates at various pressures refer toTable 5 .
Incorrect nozzles and ow rates couldresult in impaired combustion, under- ring, over- ring, sooting, puff-back ofhot gases, smoke and potential re orasphyxiation hazards.
Correct Nozzle and FlowRate Required
Table 5. Nozzle Flow Rate by Size
Nozzle ow rate U. S. gallons per hour of No. 2 fueloil when pump pressure (psig) is:
Nozzlesize
(rated at100 psig)
125 psi 140 psi 150 psi 175 psi 200 psi
0.40 0.45 0.47 0.49 0.53 0.560.50 0.56 0.59 0.61 0.66 0.71
0.60 0.67 0.71 0.74 0.79 0.850.65 0.73 0.77 0.80 0.86 0.920.75 0.84 0.89 0.92 0.99 1.06
0.85 0.95 1.01 1.04 1.13 1.200.90 1.01 1.07 1.10 1.19 1.27
1.00 1.12 1.18 1.23 1.32 1.41
1.10 1.23 1.30 1.35 1.46 1.561.20 1.34 1.42 1.47 1.59 1.70
1.25 1.39 1.48 1.53 1.65 1.771.35 1.51 1.60 1.65 1.79 1.91
1.50 1.68 1.77 1.84 1.98 2.121.65 1.84 1.95 2.02 2.18 2.331.75 1.96 2.07 2.14 2.32 2.48
2.00 2.24 2.37 2.45 2.65 2.83
2.25 2.52 2.66 2.76 2.98 -2.50 2.80 2.96 - - -
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Figure 4. Check/Adjust Z Dimension for F Heads
Section: Mount Burner on Appliance
Make all adjustments exactly as outlined in thefollowing information.
Incorrect Adjustments could cause combustion problems, carbon deposition from ameimpingement, heavy smoke generation and rehazard.
Adjust the Z dimensionto the requiredspeci cation.
Check/Adjust Z Dimension - F headsThe important Z dimension is the distance from the faceof the nozzle to the at face of the head (or heat shield, ifapplicable). This distance for F heads is 1- (1- if theair tube has a heat shield). The Z dimension is factoryset for burners shipped with the air tube installed. Evenif factory set, verify that the Z dimension has not beenchanged.
Use the following procedure to adjust the Z dimension, ifit is not correct:
1.
2.
Turn off power to the burner.Disconnect the oil connector tube from the nozzle lineSee above gure. Loosen the splined nut from thenozzle line. Loosen the hex head screw securing theescutcheon plate to the burner housing.Place the end of a ruler at the face of the nozzle and,using a straight edge across the head, measure thedistance to the face of the head. A Beckett T501 gaugemay also be used.Slide the nozzle line forward or back until thisdimension for F heads is 1- (1- to the face of theheat shield, if applicable).Tighten the hex head screw to secure the escutcheonplate to the burner chassis. Then tighten the splinednut and attach the oil connector tube.
Recheck the Z dimension periodically when servicing toensure the escutcheon plate has not been moved. Youwill need to reset the Z dimension if you replace the airtube or nozzle line assembly. The Beckett Z gauge (partnumber Z-2000) is available to permit checking the Fhead Z dimension without removing the burner from theappliance.
3.
1-3/8
1-1/8
Burner Dimensions
For usable length A (inches)Dimension (inches) F Head L1 Head L2 Head V1 Head
H(nozzle to head), +1/32 N/A 1/4 7/32 1/4
L(Total tube length) A+1/2 A+1/2 A+1/2 A+1/2
R(electrode length), + 1/4 A+2-1/4 A+1-1/8 A+1-1/8 A+1-1/8
S(adapter to static plate), + 1/16
(Note 1) 1-3/8 1-3/8 1-3/8
Q(nozzle line length), A+ 15/16 A+ 3/16 A+ 3/16 A+ 3/16
Z(F head-no heat shield)
(F head-with heat shield)(L1 head w/straight shroud)
(L1/L2/V1 head w/conic shroud)
1-1/81-3/8N/AN/A
N/AN/A
1-3/81-3/4
N/AN/AN/A
1-3/4
N/AN/AN/A
1-3/4
Note 1: 1-3/8 for dimension A less than 4; 1-5/8 for dimension A from 4 through 4-1/2 ,2-13/32 for dimension A greater than 4-1/2.
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V1 Adjusting PlateSetting
AFG with V1 HeadBurner Firing Rates
0 0.75-1.00
1 1.00-1.50
2 1.50-1.75
3 1.75-2.00
4 2.00-2.25
5 2.25-2.50
6 2.50-2.75
Table for initial adjusting plate settings for V1 Head Set head position adjusting plate (V1 head only)
After setting Z dimension, loosen head adjusting plate hexhead screw and nozzle line splined nut. Move the nozzle lineassembly until the burner reference indicator lines up withthe head adjusting plate setting number given in Table shownbelow.
Tighten the hex head screw and splined nut. (DO NOT loosenthe acorn nut when setting head position.) Refer to themanufacturers instructions for OEM settings.
The position of the head affects air ow volume and pattern.For most applications, the burner will perform satisfactorilywith the air adjustment plate setting of Table shown below.
If combustion results indicate the need for change, adjust thehead position adjusting plate forward or back one position at atime to optimize combustion.
1.
2.
3.
4.
Section: Mount Burner on Appliance
Figure 6. Check/Adjust Z Dimension - V1 Heads
V1 heads (see Table below and Figure above for dimensions)
See gure above. The important Z dimension is the distancefrom the leading edge of the head to the end of the air tube.This distance for V1 heads is 1-. The Z dimension isfactory set for burners shipped with the air tube installed.Even if factory set, verify that the Z dimension has not beenchanged.
1.
Use the following procedure to adjust the Z dimension, if itis not correct:
2.
Turn off power to the burner.Disconnect the oil connector tube from the nozzle line.See gure above. Loosen the splined nut from thenozzle line. Loosen the hex head screw securing thehead adjusting plate to the burner housing.Loosen the acorn nut. Move the head adjusting plateuntil the 0 lines up with the reference indicator onthe housing, and retighten the hex head screw. Placethe end of a ruler at the leading edge of the head and,using a straight edge across the end of the air tube,measure the distance to the end of the tube. A BeckettT501 gauge may also be used.Slide the nozzle line forward or back until this dimensionis 1- for V1 heads. Tighten the acorn nut.Tighten the hex head screw to secure the headadjusting plate to the burner chassis. Then tighten thesplined nut and attach the oil connector tube.
Recheck the Z dimension periodically when servicing toensure the escutcheon plate has not been moved. You willneed to reset the Z dimension if you replace the air tubeor nozzle line assembly.
3.
Figure 5. Check/Adjust Z Dimension - L1 & L2 Heads
L1/L2 heads (see Table 7 and Figure 3 for dimensions)
See gure above. The important Z dimension is thedistance from the leading edge of the head to the end of theair tube. This distance for L1 & L2 heads is 1-3/8 if the tubehas a straight shroud or 1-3/4 if the air tube has a conicshroud. The Z dimension is factory set for burners shippedwith the air tube installed. Even if factory set, verify that theZ dimension has not been changed.
1.
Use the following procedure to adjust the Z dimension, if itis not correct:
Turn off power to the burner.Disconnect the oil connector tube from the nozzle line.Refer to gure. Loosen the splined nut from thenozzle line. Loosen the hex head screw securing theescutcheon plate to the burner housing.Place the end of a ruler at the leading edge of the headand, using a straight edge across the end of the airtube, measure the distance to the end of the tube. ABeckett T501 gauge may also be used.Slide the nozzle line forward or back until this dimensionis 1-3/8 for L1 & L2 heads if the tube has a straightshroud, or 1-3/4 if the air tube has a conic shroud.Tighten the hex head screw to secure the escutcheonplate to the burner chassis. Then tighten the splined nutand attach the oil connector tube.
Recheck the Z dimension periodically when servicing toensure the escutcheon plate has not been moved. You willneed to reset the Z dimension if you replace the air tubeor nozzle line assembly.
2.
3.
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Installing the Oil Tank and Supply System
Fuel supply level with or above burner
Figure 7. Mounting Burner in Appliance
SK8745
Tilt down 2
If space between burnerair tube and opening
exceeds 1/2 inch, packburner opening with
ceramic fiber refractory.
Figure 8. Inside Tank Gravity Feed System
Figure 9. Outside Buried Tank-Lift System
Note: to determine the proper fuel line size, refer to thefuel pump manufacturers instructions provided withthe burner. Refer to Figure 8 or Figure 9 for typicalinstallation layouts.
Fuel Line Valves and Filter
Install two high quality, oil duty rated, fusible handledesign shutoff valves in accessible locations on the oilsupply line. Locate one close to the tank and the otherclose to the burner, upstream of the lter for serviceaccess.
Install a generous capacity lter inside the buildingbetween the fuel tank shutoff valve and the burner,locating both the lter and the valve close to the burnerfor ease of servicing. Filter should be rated for 50microns or less.
Section: Mount Burner on Appliance
Oil Leak and Fire Hazard
Install the oil tank following applicable standardsin the U.S. by referring to the latest edition of NFPA31 or CSA-B139 & CSA-B140 in Canada, and allauthorities having jurisdiction.
Never use Te on tape on fuel oil ttings.
Tape fragments can lodge in fuel line componentsand fuel unit, damaging the equipment andpreventing proper operation.
Use oil-resistant pipe sealant compounds.
Damage to the pump could cause impaired burneroperation, oil leakage and appliance soot-up.
Do Not Use Te on Tape
To further protect the fuel supplysystem and reduce nozzle ori ce
plugging with ring rates below 0.75 gph, a dual ltrationsystem can be installed. This typically consists of a 50micron primary lter, located near the fuel tank and asecondary lter rated for at least 10 microns locatednear the burner.
The burner is shipped without the by-pass pluginstalled.
Install the by-pass plug in two-pipe oil supplysystems ONLY.
Failure to comply could cause Immediate pump sealfailure, pressurized oil leakage and the potential for a re and injury hazard.
Do Not Install By-pass Plugwith 1-Pipe System
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The burner may be equipped with a single-stage fuelunit for these installations. Connect the fuel supply to theburner with a single supply line if you want a one-pipesystem (making sure the bypass plug is NOT installed inthe fuel unit.) Manual bleeding of the fuel unit is requiredon initial start-up. If connecting a two-pipe fuel supply,install the fuel unit bypass plug.
Fuel supply below the level of the burner
When the fuel supply is more than eight feet belowthe level of the burner, a two-pipe fuel supply systemis required. Depending on the fuel line diameter andhorizontal and vertical length, the installation mayalso require a two-stage pump. Consult the fuel unitmanufacturers literature, included with the burner, for lift
and vacuum capability.
Fuel line installation
Continuous lengths of heavy wall copper tubing arerecommended. Always use are ttings. Neveruse compression ttings.
Always install ttings in accessible locations.Proper routing of fuel lines is required to prevent aircavitation and vibration.
Wire burner Burner packaged with appliance
Refer to appliance manufacturers wiring diagram forelectrical connections.
Burner installed at jobsiteRefer to Figures 11a and 11b , for typical burnerwiring, showing cad cell primary controls. Burnerwiring may vary, depending on primary controlactually used.Refer to the appliance manufacturers wiringdiagram prior to connecting the burner wiring. Allwiring must be in accordance with the latest revisionof National Electric Code NFPA 70 and all localcodes and regulations. In Canada, all wiring is to be
in accordance with the Canadian Electrical Code,Part 1.
The 7505 primary control with valve-on delay (pre-time) and burner motor-off delay (post-time) requiresa constant 120 volts AC power source supplied to theBLACK wire on the control. The RED wire goes to theappliance limit circuit. Please note that other controlmanufacturers may use different wire colors for powerand limit connections.
Special wiring required with covered burners
The mounting plate is not a conduit connection point.Pass conduit and attached connector through theopening in the mounting plate and attach it directly to theburner-mounted 4x4 electrical box.
If attaching a burner cover to a previously installedburner, attach the mounting plate and then slide theconduit into the J shaped conduit slot.
Section: Wire Burner
The oil supply inlet pressure to the burner cannotexceed 3 psig .
Insure that a pressure limiting device is installed inaccordance with the latest edition of NFPA 31.
Do NOT install valves in the return line. (NFPA 31,Chapter 8.)
Gravity Feed Systems: Always install an anti-siphonvalve in the oil supply line or a solenoid valve (RWBPart # 2182602U) in the pump/nozzle dischargetubing to provide backup oil ow cut-off protection.
Damage to the lter or pump seals could cause oilleakage and a re hazard.
Oil Supply PressureControl Required
Disconnect electrical power before installing orservicing the burner.
Provide ground wiring to the burner, metal controlenclosures and accessories. (This may also berequired to aid proper control system operation.)
Perform all wiring in compliance with the NationalElectrical Code ANSI/NFPA 70 (Canada CSA C22.1)
Electrical shock can cause severe personal injury or death.
Electrical Shock Hazard
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Burner ControlsGeniSys Model 7505 Control
Wiring
Figure 10 - 7505 Control
FeaturesThermostat / Operating and Limit ControlCompatibleWelded Relay ProtectionLimited RecycleLimited Reset3 Status LightsValve-On Delay / Motor-Off Delay (Fieldprogrammable with 52067 GeniSys Display)15 Second Lockout TimeInterrupted or Intermittent Duty IgnitionTechnician Pump Priming ModeDisable FunctionCommunication Ports
Section: Burner Controls
The control can malfunction if it gets wet, leading toaccumulation of oil or explosive oil vapors.
Never install where water can ood, drip orcondense on the control.
Never use a control that has been wet - replace it.
Can cause severe injury, death, or property
damage.
Fire or Explosion Hazard
Follow the appliance manufacturers wiring diagramsand note all required safety controls.
Typical safety controls include high temperature orpressure limits, low water cutoffs, pressure reliefvalves and blocked ue sensing switches.
Verify all limit and safety controls are installedand functioning correctly, as speci ed by themanufacturer, applicable safety standards, codesand all authorities having jurisdiction.
Ensure that the appliance is free of oil and oil vapor
before starting or resetting the burner.
All heating appliances must have HIGHLIMIT protection to interrupt electrical power and shutdown the burner if operatingor safety controls fail and cause a runawaycondition.
Explosion, Fire, Scald, andBurn Hazard
Incorrect Wiring WillResult in Improper ControlOperation
GeniSys wiring label colors may not match the wirecolors of the burner or other manufacturers controls.
The GeniSys Control should be wired according tothe appliance manufacturers instructions.
Display Module:Permanent device for programmingand diagnostics
Alarm Module:For adding isolated low voltage alarmcontacts to the base control. See AlarmModule Instructions for speci cations.
Contractors Tool:Hand-held device forprogramming and diagnostics
Cad CellConnections
WiringConnections
Communication Port 2
Reset Button with Red Light
Communication Port 1
Thermostat Terminals
Green Light
Yellow Light
Optional Components :
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the igniter remains on for 10 additional secondsto ensure ame stability.
Run : The ame is sustained until the call forheat is satis ed. The burner is then sent toMotor-Off Delay, if applicable, or it is shut down
and sent to Standby.Recycle : If the ame is lost while the burner isring, the control shuts down the burner, entersa 60 second recycle delay, and repeats theignition sequence. The control will continueto Recycle each time the ame is lost, untilit reaches a pre-set time allotment. Thecontrol will then go into Hard Lockout insteadof recycle. This feature prevents excessiveaccumulation of oil in the appliance ringchamber.
Motor-Off Delay : If applicable, the oil solenoidvalve is turned off and the control delaysturning the motor off for the set motor-off delaytime before the control returns to standby.Pump Prime: The igniter and motor are on withthe oil solenoid valve energized for 4 minutes.During Pump Prime mode, the cad cell isdisregarded, allowing the technician to primethe pump without having to jumper the cad cell.
6.
7.
8.
9.
Typical Burner Sequence of Operation for GeniSys 7505 Control.Refer to the appliance manufacturers wiring diagram for actual speci cations.
Standby : The burner is idle, waiting for a call forheat.
Valve-On Delay : The igniter and motor areon while the control delays turning on the oilsolenoid valve for the programmed time.
Trial For Ignition : The oil solenoid valve isenergized. A ame should be established withinthe factory set trial for ignition time (lockouttime).Lockout : The control has shut down for one ofthe following safety reasons:
The trial for ignition (lockout) time expiredwithout ame being established.
The cad cell detected ame at the end of theValve On Delay state.
To reset the control from lockout click the button1-second.
NOTE: A recurrence of the above failure modes or afailed welded relay check could cause the control toenter a Hard Lockout state that must be reset onlyby a quali ed service technician.To reset from Hard Lockout, hold the reset button for15 seconds until the yellow light turns on.
Ignition Carryover : Once ame is established,
1.
2.
3.
4.
a.
b.
5.
2
1
3
5
68
4
7
Standby
Motor-off delay
Valve-on delayTrial for ignition
Ignition carryover
Run
Lockout
Recycle
9Pumpprime
Section: Burner Controls
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Figure 11a. Interrupted ignition, valve-on delayonly (no motor-off delay)
Figure 11b. Interrupted ignition, valve-on delay andmotor-off delay
SAFETY ANDOPERATING
LIMITS
LIMIT
L1
L2 (VLV)
VALVE
L2
MOTOR
L2 (MTR)
L2 (IGN)
IGNITER
CADCELL
MOTOR
IGNITER
W
R
8 0
7 0 6 0
5 0
5 0
7 0
8 0
6 0
OIL VALVE
CAD CELL
THERMOSTAT
TR
TW
TR-TW
JUMPER
TR-TW TERMINALS
LOCATED ON OPPOSITE
SIDE OF CONTROL
L1
L2SAFETY ANDOPERATING
LIMITS
LIMIT
L1
L2 (VLV)
VALVE
L2
MOTOR
L2 (MTR)
L2 (IGN)
IGNITER
CADCELL
MOTOR
IGNITER
W
R
8 0
7 0 6 0
5 0
5 0
7 0
8 0
6 0
OIL VALVE
CAD CELL
THERMOSTAT
TR
TW
TR-TW
JUMPER
TR-TW TERMINALS
LOCATED ON OPPOSITE
SIDE OF CONTROL
L1
L2
LIMIT L1 - LIMIT
JUMPER
Table 2 - Reset Button Operation
If the burner is in thebelow state:
Pushing the reset button will:
Button Click(press < 1 second)
Button Hold(press > 1 second)
Button Hold(press 15+ seconds)
Lockout Reset from Soft LockoutReset from Restricted (Hard)
LockoutValve-on Delay, Trial forIgnition, Ignition Carryover
Go to Pump Prime (seePriming the Pump above)
Disable the Burner: Any time the burner is running,press and hold the reset buttonto disable the burner. Theburner will remain off as longas the button is held.
Enables Pump Priming: After the reset button has beenheld for 15 seconds, the buttoncan then be clicked during thenext ignition sequence to enterPump Prime mode.
Run (igniter is shut off) No action
Motor-Off Delay,Standby
No action
Pump Prime No action Exit Pump Prime mode and return to Standby
Table 3 - Status LightsLight Color On Continuously Flashing
Red Restricted (Hard) Lockout Soft Lockout
GreenFlame Sensed during normal operation (Couldbe stray light during standby) Recycle
YellowControl is in Pump Prime mode or Reset button currently held for 15+ seconds. N/A
Reset Button OperationTable 2 explains what action the control will take when the reset button is pressed for different lengths of time duringthe various burner operating states.
Section: Burner Controls
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RECYCLE. If the ame is lost while the burner is ring, the control shuts down the burner, entersa 60 second recycle delay, and then repeats theabove ignition sequence. If ame is lost threetimes in a row, the control locks out to preventcycling with repetitious ame loss due to poorcombustion.
BURNER MOTOR-OFF DELAY. The fuel valveis closed and the burner motor is kept on for theselected motor-off delay time before the controlreturns the burner to standby.
7.
8.
Figure 10 - Typical Burner Wiring & Burner Sequence of Operation for R7184P Control.Refer to the appliance manufacturers wiring diagram for actual speci cations.
STANDBY. The burner is idle, waiting for a call forheat. When a call for heat is initiated, there is a 3-10 second delay while the control performs a safestart check.
VALVE-ON DELAY. The ignition and motor areturned on for a 15 second valve-on delay.
TRIAL FOR IGNITION (TFI). The fuel valve isopened. A ame should be established within the
15 second lockout time.LOCKOUT. If ame is not sensed by the end ofthe TFI, the control shuts down on safety lockoutand must be manually reset. If the control locks outthree times in a row, the control enters restrictedlockout.
IGNITION CARRYOVER. Once ame isestablished, the ignition remains on for 10 secondsto ensure ame stability before turning off. If thecontrol is wired for intermittent duty ignition, theignition unit stays on the entire time the motor isrunning.
RUN. The burner runs until the call for heat issati ed. The burner is then sent to burner motor offdelay, if applicable, or it is shut down and sent tostandby.
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2.
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5.
6.
Feature InterruptedignitionLimited reset,
Limited recycleValve-on
delayBurner motor off
delayAlarm
Contacts
R7184A YES YES
R7184B YES YES YES
R7184P YES YES YES YES Optional
Control System Features
Section: Burner Controls
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Make connections to the controls terminals asshown in Figures 11a and 11b . Refer to the labelon the underside of the control for wiring details.Note: Motor-off delay on a 7505P will be disabled ifthe safety and operating limits as shown in Figures11a and 11b interrupt power to the control terminalL1.Connect thermostat leads to the TR and TWterminals on the control or jumper the TR and TWterminals on the control, as directed by the appliancewiring diagram.
- Thermostat anticipator Current: 0.1 amp - Thermostat voltage: 24 volts AC
Note that if the thermostat short cycles or operatesimproperly, it may require an isolation relay for properoperation. The Beckett A/C Ready Kit (part no. 51950U)provides this function. Wiring instructions are includedwith the A/C Ready Kit.
Start Up Burner/SetCombustion
Some Thermostats Are PolaritySensitive. Reversed polarity
could cause erratic cycling of the burner control.Connect the wire from the R H or R terminal on thethermostat to the TR terminal on the control. Connectthe wire from the W terminal on the thermostat to the TWterminal on the control.
Open the shutoff valves in the oil supply line to theburner.
Close air band and partially open air shutter. This isan initial air setting for the pump bleeding procedureonly. Additional adjustments must be made withinstruments.
1.
2.
Set the thermostat substantially above room temperature.
Close the line voltage switch to start the burner. Ifthe burner does not start immediately you may haveto reset the burner primary control.
Initiate a call for heat.
After the burner starts, press and hold the resetbutton for 15 seconds until the yellow light turns on.This indicates that the button has been held longenough.
Release the reset button. The yellow light will turnoff and the burner will start up again.
At burner start up, click the reset button while theigniter is still on. This will transition the controlto a dedicated Pump Prime mode, during whichthe motor, igniter, and valve are powered for fourminutes. The yellow light will be on.
Bleed the pump until all froth and bubbles arepurged. If desired, terminate the call for heat orhold the reset button for at least one second to exit
Pump Prime mode and return to Standby. At the end of 4 minutes, the yellow light will turn offand the control will automatically return to standbymode.
If prime is not established during the four minutepump prime mode, return to step 8 to re-enterPump Prime mode. Repeat steps 8 through 10until the pump is fully primed and the oil is free ofbubbles.
Terminate the call for heat, and the control willresume normal operation.
Cad Cell Resistance MeasurementIf the Beckett 7505 control is equipped with theGeniSys Display Module, part 52067U, the cad cellresistance can be selected and read on the LCDscreen. Also, the GeniSys Contractor Tool, part52082U, can be used for this purpose.If these are not available, the cad cell leads canbe unplugged from the control and the resistancemeasured with a meter in the conventional way.Conduct these tests with ame present.
Flame Detection Range
Normal = 0 to 1600 ohms
Limited = 1600 ohms to lockout
Resetting From Restricted or Hard LockoutIf the control continues to lockout without a satis edcall for heat, or fails the motor relay check, thecontrol enters Hard (restricted) Lockout in order tolimit accumulation of unburned oil in the combustionchamber.To reset, hold the button down for 15 seconds untilthe red light turns off and the yellow light turns on.
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4.
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9.
10.
11.
12.
Section: Start-up Burner/Set Combustion
Wire Burner
Do not allow oil to spray into a hot combustionchamber while bleeding air from the pump.
Install a gauge in the nozzle discharge port tubingor fully open the pump bleed valve to prevent oilspray from accumulating in the combustion chamberduring the air bleed procedure.
Ensure that all bubbles and froth are purged fromthe oil supply system before tightening the pumpbleed valve.
Ensure that the appliance is free of oil and oil vaporbefore starting or resetting the burner.
Failure to prime the pump properly could result inunstable combustion, hot gas puff-back and heavysmoke.
Hot Gas Puff-Back andHeavy Smoke Hazard
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Always verify the control functions according to allspeci cations before leaving the installation site.Replace the control if it does not operate asspeci ed.
Startup / Checkout
If the burner or control fails any of the following tests,recheck control wiring. If the burner or control still failsany tests, replace the control.
Check Safety FeaturesSafe Start Check
Place a jumper across the cad cell terminals.
Refer to the steps for Start up burner/setcombustion and have the system call for heat.
Burner must not start. Verify that the green lightis on continuously and that the control remains in
Standby mode.End the call for heat and remove the cad cell
jumper.
Simulate Flame Failure and Ignition Failure
Refer to the steps for Start up burner/setcombustion and have the system call for heat.
After ame is established and the burner igniterturns off, close the hand valve in the oil supplyline.
At ame loss, the control will enter Recycle
1.
2.
3.
4.
1.
2.
3.
mode. Verify that the green light is ashing. Thecontrol will remain in Recycle for 60 seconds.
After the 60 second recycle period, the controlwill try to restart the system.
After the 15 second lockout time, the control willlock out the burner and the reset button will ash.Verify that the burner motor and igniter are offand that the burner oil solenoid valve (if used) isnot energized.Open the hand valve in the oil line.
Click the reset button and verify that the red lightin the reset button shuts off and that the burnerlights.
End the call for heat.
Before leaving the installation, verify that allthermostat and boiler/furnace control wiring iscorrect. Consult heating appliance manual fordirections.
Set combustion with instruments
4.
5.
6.
7.
8.
Allow the burner to run for approximately 5 to 10minutes.
Set the stack or over- re draft to the level speci edby the appliance manufacturer.
Natural Draft Applications; typically over- redraft is -0.01 or -0.02 w.c.
Direct Venting ; typically may not require draftadjustment.
High Ef ciency/Positive Pressure Appliancesalso vary from traditional appliances (seemanufacturers recommendations).
Follow these four steps to properly adjust theburner:
Step 1: Adjust the air shutter/band until a trace ofsmoke is achieved.
Step 2: At the trace of smoke level, measure theCO 2 (or O 2) . This is the vital referencepoint for further adjustments. Example:13.5% CO 2 (2.6% O 2)
Step 3: Increase the air to reduce the CO 2 by 1.5 to2 percentage points. (O 2 will be increasedby approximately 2.0 to 2.7 percentagepoints.) Example: Reduce CO 2 from13.5% to 11.5% (2.6% to 5.3% O 2).
1.
2.
3.
Section: Start-up Burner/Set Combustion
Do not attempt to start the burner when excess oilhas accumulated in the appliance, the appliance isfull of vapor, or when the combustion chamber isvery hot.
Do not attempt to re-establish ame with the burnerrunning if the ame becomes extinguished during
start-up, venting, or adjustment.Vapor-Filled Appliance: Allow the unit to cool offand all vapors to dissipate before attempting anotherstart.
Oil-Flooded Appliance: Shut off the electricalpower and the oil supply to the burner and then clearall accumulated oil before continuing.
If the condition still appears unsafe, contact the FireDepartment. Carefully follow their directions.
Keep a re extinguisher nearby and ready for use.
Failure to follow these instructions couldlead to equipment malfunction and resultin heavy smoke emission, soot-up, hotgas puff-back, re and asphyxiationhazards.
Explosion and Fire Hazard
Oil-Burning Equipmentshall be connected to ues
having suf cient draft at all times to ensuresafe and proper operation of the burner.
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Step 4: Recheck smoke level. It should be Zero.
This procedure provides a margin ofreserve air to accommodate variableconditions.
If the draft level has changed, recheck thesmoke and CO 2 levels and readjust theburner if necessary.
Once combustion is set, tighten all fasteners onair band, air shutter and head adjusting plate orescutcheon plate.
Burner equipped with cover - Reinstall the coverand repeat Steps 2 and 4. If CO 2 increases (O 2 decreases), remove the cover and adjust theair setting so the CO 2 (O 2) with cover on meetsrequirements of Step 3.
Start and stop the burner several times to ensuresatisfactory operation. Test the primary controland all other appliance safety controls to verifythat they function according to the manufacturersspeci cations.
Perform Regular Maintenance
4.
5.
6.
replacing any that are cracked or chipped.
Check electrode tip settings. Replace electrodes iftips are rounded.
Inspect the igniter spring contacts. Clean or replaceif corroded.
Clean the cad cell grid surface, if necessary.
Make sure Low Firing Rate Baf e is in placeif required for the burner application. Omittingthe baf e can result in unacceptable burnercombustion.
Inspect all gaskets. Replace any that are damagedor would fail to seal adequately.
Inspect the combustion head and air tube. Removeany carbon or foreign matter. Replace all damagedunits with exact parts.
Clean the blower wheel, air inlet, air guide, burnerhousing and static plate of any lint or foreign
material.If motor is not permanently lubricated, oil motor witha few drops of SAE 20 nondetergent oil at each oilhole. DO NOT over oil motor. Excessive oiling cancause motor failure.
Check motor current. The amp draw should notexceed the nameplate rating.
Check all wiring for secure connections or insulationbreaks.
Check the pump pressure and cutoff function.
Check primary control safety lockout timing.
Check ignition system for proper operation.
Inspect the vent system and chimney for sootaccumulation or other restriction.
Clean all ue passages and ue pipe. Replacecorroded or damaged pipes.
Clean the appliance thoroughly according to themanufacturers recommendations.
Check the burner performance. Refer to the sectionSet combustion with test instruments.
It is good practice to make a record of the serviceperformed and the combustion test results.
Shutting the Burner Off
Replace the oil supply line lter. The line ltercartridge must be replaced to avoid contaminationof the fuel unit and nozzle.
Inspect the oil supply system. All ttings should beleak-tight. The supply lines should be free of water,sludge and other restrictions.
Remove and clean the pump strainer if applicable.
Verify the nozzle is the one originally speci ed bythe appliance manufacturer and replace the nozzlewith one having the exact speci cations from thesame manufacturer.
Clean and inspect the electrodes for damage,
Section: Perform Regular Maintenance
DO NOT TAMPER WITH THE UNIT ORCONTROLS - CALL YOUR SERVICE PERSONNEL.To ensure continued reliable operation, a quali edservice technician must service this burner annually.
More frequent service intervals may be required industy or adverse environments.
Operation and adjustment of the burner requirestechnical training and skillful use of combustion testinstruments and other test equipment.
Tampering with or making incorrectadjustments could lead to equipmentmalfunction and result in asphyxiation,explosion or re.
Annual ProfessionalService Required
Always keep the fuel oil supplyvalve shut-off if the burner(s)
is shut down for an extended period of time.
Turn off all electric power to the burner.Note: There could be more than one disconnect switch.
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#
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USA: P.O. Box 1289 Elyria, Ohio 44036Canada: R.W. Beckett Canada, Ltd. Unit #3, 430 Laird Road Guelph, Ontario N1G 3X7
www.beckettcorp.com
The R. W. BECKETT CORPORATION (Beckett) warrants to persons who purchase its Products fromBeckett for resale, or for incorporation into a product for resale (Customers), that its equipment is freefrom defects in material and workmanship. To qualify for warranty bene ts, products must be installed by aquali ed service agency in full compliance with all codes and authorities having jurisdiction, and used within
the tolerances of Becketts de
ned product speci
cations.To review the complete warranty policy and duration of coverage for a speci c product, or obtain a writtencopy of warranty form 61545, please choose one of the following options:
Visit our website at: www.beckettcorp.com/warranty
Email your request to: rwb-customer-service@beckettcorp.com
Write to: R. W. Beckett Corporation, P. O. Box 1289, Elyria, OH 44036
NOTE: Beckett is not responsible for any labor cost for removal and replacement of equipment.
THIS WARRANTY IS LIMITED TO THE PRECISE TERMS SET FORTH ABOVE, AND PROVIDESEXCLUSIVE REMEDIES EXPRESSLY IN LIEU OF ALL OTHER REMEDIES, AND IN PARTICULARTHERE SHALL BE EXCLUDED THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESSFOR A PARTICULAR PURPOSE. IN NO EVENT WILL BECKETT BE LIABLE FOR ANY INCIDENTAL ORCONSEQUENTIAL DAMAGE OF ANY NATURE. Beckett neither assumes, nor authorizes any person toassume for Beckett, any other liability or obligation in connection with the sale of this equipment. Beckettsliability and Customers exclusive remedy is limited to the cost of the product.
1.
2.
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Limited Warranty Information
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