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.


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


Professional Service Required. • Pleasereadallinstructionsbeforeproceeding.

Followallinstructionscompletely.

• Thisequipmentmustbeinstalled,adjustedandstartedbyaqualifiedserviceagencythatislicensedandexperiencedwithallapplicablecodesandordinancesandresponsiblefortheinstallationandcommissioningoftheequipment.

• TheinstallationmustcomplywithalllocalcodesandordinanceshavingjurisdictionandthelatesteditionoftheNationalFuelGasCodeANSIZ223.1(NFPA54)andCAN1-B149.1inCanada.

• BurnermustbeusedwithinthelimitsofTable 1.

FOROUTDOORUSAGEitistheresponsibilityoftheOEM

equipmentmanufacturertoprotecttheburnersystemandcomponentsfromexposuretowaterintheend-useapplication.



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



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


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


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.


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.


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.



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.


• Donotdisassemblegasvalve.• Valvemustbeinstalledwiththegasflowinthe

samedirectionasthearrow.


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.


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.


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.


Burnermountinggasketmustbeusedtosealagainstleakagefromtheappliance.Donotuseadamagedmountinggasket.Verifythatallboilersections,canopy,andaccessplatesordoorsarefullyequippedwithgasketsandsealedagainstanyleakage.

Mount the BurnerTheburnerspecifiedforpackagedequipmentwillhaveaflangetomatchtheapplianceboltpatternandweldedfortherequiredinsertion.Followtheappliancemanufacturer’sinstructionsformounting.


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.


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.


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.


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




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


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


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.


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.



Figure 17 – Typical Wiring Schematic, On/Off Operation

CO

NFI

DEN

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L: D

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.


22

Figure 18 – Typical Wiring Schematic, On/Off Operation with timer

No

tes:

|

L1pow

ersha

llbe

runthroug

hthelim

itsfo

rhigh

gas,low

gas,LWCO,h

ighlim

it,and

op

eratingco

ntrol.

|

Solidline

s(-

)=fa

ctorw

iring

Dashe

dlines

(----)=fieldwiring

T-T

TER

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ALS

ON

TO

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ON

TRO

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FIEL

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PER

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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


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).



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

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Pr

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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

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C

Low

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e S

tart

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Pr

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re, I

n. W

C

Sh

utt

er S

etti

ng

Ban

d S

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ng

Ru

nn

ing

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ld

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Pre

ssu

re, I

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C

Low

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e S

tart

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Pr

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re, I

n. W

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Sh

utt

er S

etti

ng

Ban

d S

etti

ng

Ru

nn

ing

Man

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ld

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Pre

ssu

re, I

n. W

C

Low

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Pr

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Sh

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Ban

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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.


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



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


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.


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


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


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.).



| 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


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


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


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


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

gas burner manual...burner flange and air tube are hot when burner is in operation. do not...

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