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Beckett CG10 manual

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Table of contents for the manual

  • Page 1

    COMMERCIAL PRODUCT S Fire, Explosion and Asphyxiation Hazards Failure to follow these instructions exactly could lead to fi re or explosion and result in death, severe personal injury or property damage. Do not store or use gasoline or other fl ammable vapors and liquids in the vicinity of this or any other appliance. What to do if you smell gas:[...]

  • Page 2

    2 Contents General Information .................................................... 3 Hazard De fi nitions: ........................................................................ 3 Owner ’s Responsibility: ................................................................. 3 Professional Installer ’s Responsibility: ...........................[...]

  • Page 3

    3 CG10 Burner Manual Hazard De fi nitions: Gener al Inf or ma tion Indicates a hazardous situation which, if not avoided, will result in death or serious injury . Used with the safety alert symbol, indicates a hazardous situation, which, if not avoided, may result in minor or moderate injury . Indicates a hazardous situation, which, if not avoided[...]

  • Page 4

    4 Professional Installer ’ s Responsibility: Section: General Information Follow these instructions exactly . Failure to follow these instructions could lead to equipment malfunction and result in asphyxiation, explosion or fi re. Please read all instructions before proceeding. Follow all instructions completely . This equipment must be installe[...]

  • Page 5

    5 CG10 Burner Manual Figure 1. Burner Nameplate Pr e-installa tion Chec klist If there is risk of the space being under negative pressure, or of exhaust fans or other devices depleting available air for combustion and ventilation, the appliance/burner should be installed in an isolated room provided with outside combustion air . Indoor Installation[...]

  • Page 6

    6 Flange mounting arrangement (Includes high- temperature gasket and /or fi ber rope for pressure fi ring). V erify fi ring input range Refer to appliance manufacturer ’s instructions (if available) for the fi ring input range. Otherwise the maximum recommended fi ring range for the burner depends on the length and width of the fi ring cham[...]

  • Page 7

    7 CG10 Burner Manual 400 500 600 700 800 900 1000 1100 1200 1300 1400 0 0.2 0.4 0.6 0.8 1 Furnace Pressure, In. W.C. Maximum Capacity, MBH CG10.6S CG10.5S CG10.4S CG10.3S CG10.2S CG10.1S V erify burner air tube assembly The information in this section may be disregarded if the burner supplied by the appliance manufacturer is a matched component. Ma[...]

  • Page 8

    8 Figure 5. Burner Dimensions Burner Model Airtube Dim. A Dim. B O.D. 10.1 - 10.3, 10.1S - 10.3S 51927 25.0” 1 1.7” 4.43” 10.4 - 10.6 51928 26.0” 12.7” 4.86” 10.4S - 10.6S 51961 25.7” 12.5” 4.61” Section: Pre-installation Checklist[...]

  • Page 9

    9 CG10 Burner Manual Mount the burner to the appliance. The burner speci fi ed for packaged equipment will have a fl ange welded for the required insertion. Follow the appliance manufacturer ’s instructions for mounting. In the absence of instructions, or for retro fi ts, make sure that the air tube insertion dimension, measured along the side[...]

  • Page 10

    10 Figure 7. T ypical Gas Piping Layout Schedule 40 metallic pipe with 0.50 psi or less inlet pressure and 0.30” W .C. pressure drop Maximum capacity in cubic feet of gas per hour (CFH). Natural gas with 0.60 speci fi c gravity . Pipe size (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 16[...]

  • Page 11

    11 CG10 Burner Manual Figure 8. UL gas train con fi guration MSC U PRSSOV SSOV1 ML TC U BURNER C6097B HGPS TP C6097A LGPS TC TC MSC SSOV1 PRSSOV ML TC U U TP TC TC HGPS LGPS ABBREV . HGPS LGPS MSC ML TC PRSSOV SSOV1 TC TP U ITEM DESCRIPTION HIGH GAS PRESSURE SWITCH LOW GAS PRESSURE SWITCH MAIN SHUTOFF COCK MAIN LEAK TEST COCK PRESSURE REGULA TING [...]

  • Page 12

    12 W ir e the Bur ner Install the burner and all wiring in accordance with the National Electric Code ANSI/NFP A 70 (Canada CSA C22.1) and all applicable codes and requirements. Wire the burner in compliance with all instructions and diagrams provided by the appliance manufacturer . V erify operation of all controls in accordance with the appliance[...]

  • Page 13

    13 CG10 Burner Manual Initiate – The primary control enters the INITIA TE sequence when the control is fi rst powered on or power returns after an interruption. The initiate sequence is a ten second delay during which the control veri fi es line voltage stability . Standby – The control enters ST ANDBY until the limits, operating limit contro[...]

  • Page 14

    14 Start-up checklist V erify the following before attempting to start the burner: 1. General Carefully read and become familiar with the CG10 Manual, Flame Safeguard Control Instructions, sequence of operation, pertinent wiring diagrams, gas system layout, insurance requirements, other controls and valve literature pertinent to the installation. F[...]

  • Page 15

    15 CG10 Burner Manual Section: Prepare the Burner for Start-up Figure 10. CG10 component familiarization Major Components Item Description 1 Jacking Screw 2 Ignition T ransformer 3 Primary Control 4 Blower Motor 5 Air Flow Proving Switch 6 Electrode Cable* 7 UV Flame Detector (if used) 8 Shutter 9 Air Band 10 High Gas Pressure Switch 1 1 Manifold P[...]

  • Page 16

    16 Star t the Bur ner Burner start procedure (Before proceeding, turn off and lock out electrical power and close the main leak test cock to shut off gas to the burner .) With the power and main gas supply to the burner turned off, make sure gas has not accumulated in the boiler or fl ues. Check the initial air settings (shutter & band) for in[...]

  • Page 17

    17 CG10 Burner Manual Figure 1 1. Shutter and Band T able 2. Initial burner settings Furnace Pressure 0” W .C. 0.25” W .C. 0.50” W .C. 1.00” W .C. Firing Rate MBH Burner Model Running Manifold Gas Press. in WC Low Fire Start Gas Press. in WC Shutter Setting Band Setting Running Manifold Gas Press. in WC Low Fire Start Gas Press. in WC Shutt[...]

  • Page 18

    18 Estimating Ra te Manifold to Furnace Pressure information can be used to estimate the burner ’s fi ring rate when it is not possible to clock a meter for the rate. T o estimate the burner ’s fi ring rate: Measure the furnace pressure over fi re Measure the manifold pressure (at the manifold pressure test connection in Figure 10). Subtract[...]

  • Page 19

    19 CG10 Burner Manual 200 400 600 800 1000 1200 1400 0123456 Pressure Drop, In. WC Rate, MBH CG10.6S CG10.5S CG10.4S CG10.3S CG10.2S CG10.1S 100 200 300 400 500 600 700 800 900 012345 Pressure Drop, In. WC Rate, MBH CG10.3 CG10.2 CG10.1 Figure 12. Manifold to Furnace Pressure Drop vs. Rate - Stepped Spud Design Figure 13. Manifold to Furnace Pressu[...]

  • Page 20

    20 High limit – T o check the High Limit, raise the temperature or pressure of the operating control to a higher level and lower the limit to a setting less than the operating control. Run the burner until the high limit opens and shuts the burner off. Adjust the controls back to the desired settings. Operating control – Run the burner until th[...]

  • Page 21

    21 CG10 Burner Manual V erify that all boiler sections, canopy , and access plates or doors are fully equipped with gaskets and sealed against any leakage, which could affect the combustion test results. Before making these tests, operate the burner for several minutes to allow the heating system temperature to stabilize or nearly reach steady-stat[...]

  • Page 22

    22 Burner: Run the burner and perform a complete combustion test using the proper instruments before proceeding. If necessary refer to the section labeled Start the Burner . Record the results for reference. ○ 1. Annual maintenance (The following should be performed by a quali fi ed service technician only.) Maintenance and Ser vice Inspect and [...]

  • Page 23

    23 CG10 Burner Manual Adjust the burner for proper combustion: Follow the guidelines under “Start the Burner” to set the combustion levels using test instruments. Flame safeguard : Follow the control manufacturer ’s instructions and verify that the control is functioning to speci fi cations. See Page 13 for typical sequence of operation and [...]

  • Page 24

    24 Figure 14A – Gas Gun Assembly Figure 14B – Gas Gun Assembly Burner Head Adjustment - There is an optimum gas ori fi ce size and burner head setting for each fi ring rate of the CG10 burner . The gas ori fi ce size sets the gas fl ow velocity; the head setting establishes the air fl ow velocity . When those velocities are properly matche[...]

  • Page 25

    25 CG10 Burner Manual Propane Restrictor Description The Beckett Propane Restrictor Conversion Kit allows for the conversion of CG10 burners for use with propane gas. With the proper installation of the restrictor and attached O-ring, adjustments and settings for propane use will be the same as the adjustments and settings for natural gas use as de[...]

  • Page 26

    26 Refer to Figures 15 and 16 when performing the following steps. Remove the jacking screw ( B ) from the air tube/ manifold assembly to free the internal gas tube ( C ). Gently rock the internal gas tube ( C ) to loosen the tube from the union ( F ). Inspect the O-rings and insure that they are properly lubricated. (A silicon O-ring lubricant is [...]

  • Page 27

    27 CG10 Burner Manual T est/Inspection Frequency Comments Inspect area surrounding heating plant Daily Keep area clean and free of clutter Inspect gas supply system for leaks Daily Use visual and electronic leak detection Inspect appliance & piping for water leaks Daily Keep burner and controls dry at all times Inspect gauges, indicators, monit[...]

  • Page 28

    28 R eplacement P ar ts For best performance specify genuine Beckett replacement parts. Item Description Part # 1 Ignition T ransformer 7503U 2 Control Subbase See Note 1 3 Primary Control See Note 1 4 Suction Line 32359U 5 Shutter 3215U 6 High Gas Pressure Switch 2190903U 7 Air Band 3819A 8 Motor - 120v - 220v 21341U 21654U 9 Blower Wheel - CG10 -[...]

  • Page 29

    29 CG10 Burner Manual Bur ner Con fi gur a tions The CG10 burner is offered in con fi gurations that allow it to be customized to the capacity and furnace size needs of many different appliances. T wo blower wheel sizes provide air fl ow capacity through the range. An air guide provides static pressure augmentation at low rates and an inlet slee[...]

  • Page 30

    30 Section: Burner Con fi gurations The table below shows proven combinations of the components and the nominal fi ring rate ranges they serve. These combinations may vary and may be used outside of the nominal listed ranges based on results of speci fi c applications tests conducted for OEM appliance manufacturers. Burner Model Air T ube Shroud[...]

  • Page 31

    31 CG10 Burner Manual[...]

  • Page 32

    USA: P .O. Box 1289 ● Elyria, Ohio 44036 Canada: R.W . Beckett Canada, Ltd. ● Unit #3, 430 Laird Road ● Guelph, Ontario N1G 3X7 www .beckettcorp.com Part Number 6104 BCG10 R13, Printed in the U.S.A. 05/10 The R. W . BECKETT CORPORA TION (“Beckett”) warrants to persons who purchase its “Products” from Beckett for resale, or for incorpo[...]