COMMERCIAL PRODUCTS GAS-FIRED Fire, Explosion and Asphyxiation Hazards Failure to follow these instructions exactly could lead to fire or explosion and result in death, severe personal injury or property damage. 1. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. 2. 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.
Contents General Information .................................................... 4 Hazard Definitions ......................................................................... 4 Professional Installer’s Responsibility ........................................... 5 Pre-installation Checklist ........................................... 5 Indoor Installation .......................................................................... 5 Combustion Air Supply ......................................................
Section: General Information General Information Hazard Definitions Indicates a hazardous situation which, if not avoided, will result in death or serious injury. Indicates a hazardous situation, which, if not avoided, could 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.
Section: Pre-installation Checklist Professional Installer’s Responsibility Follow these instructions exactly Failure to follow these instructions could lead to equipment malfunction and result in asphyxiation, explosion or fire. y Please read all instructions before proceeding. Follow all instructions completely.
Section: Pre-installation Checklist Table 1 – Burner Specifications CG15 USA Input Firing Range†: High Fire (Max.) High Fire (Min.) Low Fire (Max.) Low Fire (Min.) 1,500 MBH 800 MBH 560 MBH 350 MBH CG25 Canada 1,370 MBH 800 MBH 560 MBH 350 MBH USA 2,700 MBH 1,300 MBH 990 MBH 550 MBH CG50 Canada 2,300 MBH 1,300 MBH 990 MBH 550 MBH USA 5,000 MBH 2,000 MBH 1,400 MBH 730 MBH Canada 4,000 MBH 2,000 MBH 1,400 MBH 730 MBH Fuel: Natural Gas Propane (LP) 0.6 Specific Gravity Typical 1.
Section: Pre-installation Checklist Test For Gas Pipe Leaks Leaking gas could result in asphyxiation, explosion, or fire hazard. y The gas supply piping must be absolutely leak-free. y Pressure test the gas piping with air that is at least three times greater than the gas pressure being used. y Verify that there are no leaks before proceeding.
Section: Pre-installation Checklist Figure 3A - Maximum Capacity (at 3% O2) vs Furnace Pressure - CG15, 60Hz. Figure 3B - Maximum Capacity (at 3% O2) vs Furnace Pressure - CG25, 60Hz. Figure 3C - Maximum Capacity (at 3% O2) vs Furnace Pressure - CG50, 60Hz.
Section: Pre-installation Checklist Figure 4 - Burner Dimensions DIM. A DIM. C DIM. B O.D. DIM. D DIM. G DIM. E DIM. H DIM. F Model Dim. A Dim. B Dim. C Dim. D Dim. E Dim. F Dim. G Dim. H O.D. Pipe Thread CG15 20.8 9.4 32.7 13.7 5.2 18.4 6.2 10.8 5.6 1-1/4 NPT CG25 20.9 9.3 33.2 13.4 6.8 17.8 6.7 12.6 6.9 2 NPT CG50 24.4 10.5 33.6 13.5 7.5 17.4 6.7 14.6 7.7 2-1/2 NPT NOTE: All dimensions are in inches. Figure 5 - Panel and Modulating Valve Dimensions 16.
Section: Mount the Burner & Connect Gas Piping Mount the Burner Figure 6 - Custom Mounting Plate Mount the burner to the appliance. The burner specified for packaged equipment will have a flange welded for the required insertion. Follow the appliance manufacturer’s instructions for mounting. In the absence of instructions, or for retrofits, make sure that the air tube insertion dimension, measured along the side of the air tube from the welded flange to the end of burner air tube, is correct.
Section: Connect Gas Piping Install a Drip Leg in Gas Supply Piping Foreign matter could lodge in gas valve cutoff seals, resulting in gas leak-through, explosion or fire. Install a full-size drip leg or dirt pocket in the piping directly ahead of the main shutoff valve to capture foreign matter. Pressure Drop curves of Figures 14A, 14B, and 14C are correct for both propane and natural gas.
Section: Connect Gas Piping Table 2A - Natural Gas Supply Piping Capacity 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 specific gravity. Pipe size (inches) IPS Pipe length (feet) 0.75” 1.0” 1.25” 1.5” 2.0” 2.5” 3.0” 4.
Section: Connect Gas Piping Figure 8A - UL Gas Train - High/Low and Low Fire Start LGPS TC TC U MSC SSOV1 2PRSSOV LGPS TC HGPS U MLTC TC TP SK9982 HGPS TP MSC U SSOV1 MLTC 2PRSSOV U SK9983 Figure 8B - UL Gas Train - Modulating LGPS U MSC PRV TC TC SSOV1 U MLTC SSOV2 TC TC LGPS HGPS MV TP SK9984 HGPS TP MSC U PRV SSOV1 SSOV2 MLTC U MV SK9985 ABBREV.
Section: Wire the Burner & Sequence of Operation Wire the Burner Install the burner and all wiring in accordance with the National Electric Code ANSI/NFPA 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. Verify operation of all controls in accordance with the appliance manufacturer’s guidelines.
Section: Sequence of Operation in the RUN mode until the load demand is satisfied or a limit opens. ○ For High/Low control wiring (Figure 9A), if terminals RC1 and RC2 are jumpered, the burner operates in the Low-High-Off mode. The burner starts at Low and goes to High after the flame stabilization period. Flame is extinguished when the load is satisfied or a limit opens, and the burner is sent to post purge.
Section: Sequence of Operation Figure 9B - Typical Wiring Using Model RM7840L for Modulating Control (For Reference Only) 16
Section: Prepare the Burner for Start-up Prepare the Burner for Start-up Professional Installation and Service Required Incorrect installation and mishandling of startup could lead to equipment malfunction and result in asphyxiation, explosion or fire. y This burner must be installed and prepared for startup by a qualified service technician who is trained and experienced in commercial gas burner system installation and operation.
Section: Start the Burner ○ ○ ○ For propane-firing burners, insure that the propane restrictor has been correctly selected for your burner model (see Table 4) and properly installed (see Propane Restrictor Installation instructions). Before operating insure that all protective cover plates, enclosures and guards are in place and securely fastened. When available, refer to the appliance manufacturer’s instructions and install the burner accordingly. 6.
Section: Start the Burner 2. Push in on pin (G) to disengage the motor from the damper shaft and cam stack. Rotate the damper shaft by hand to place the adjustment cams in a position where their adjustment scale can be easily seen. Release pin (G) to secure the damper shaft and cam stack to the motor. Figure 10A - Damper Motor with Cover B 3. Using the wrench (C) supplied with the damper motor, adjust the blue low fire cam (D) to the initial setting listed in Table 3. 4.
Section: Start the Burner Optional Modulation Linkage Adjustment Instructions Figure 12 - Modulation Assembly for Left Handed Gas Entry (Standard Construction) The optional modulation linkage assembly has been designed as an economic means to adjust the damper and the butterfly valve to maintain air to gas ratios. When the optional Modulation linkage assembly is supplied with the burner, initial adjustments will be made at the factory.
Section: Start the Burner Table 3 - Initial Burner Settings for Both Propane & Natural Gas Furnace Pressure at High Fire High Fire Gas Pressure, inch WC High Fire Setting Low Fire Gas Pressure, inch WC Low Fire Damper Setting High Fire Gas Pressure, inch WC High Fire Setting Low Fire Gas Pressure, inch WC Low Fire Damper Setting High Fire Gas Pressure, inch WC High Fire Setting 9 2.7 25 1.0 9 2.9 26 1.1 9 3.2 27 1.3 10 3.7 31 0.9 9 3.4 32 1.0 9 3.7 34 1.1 9 3.9 37 1.
Section: Start the Burner Modulation Control Figure 13C - Manual Operation Operation in manual mode: Figure 13A - Display Meaning ○ Once in Manual Mode, the damper motor can be driven from high to low using the up/ down arrows. ○ To return to the automatic mode, press and hold exit button for ten seconds.
Section: Start the Burner B) At burner start-up - Note, as soon as the burner lights, be prepared to adjust the butterfly valve to set the low fire rate adjustment. 1. Monitor the flame through the observation port. If it appears to be too rich (yellow-orange flame), move the butterfly valve shaft slot setting toward a more vertical position. (This adjustment is made by turning the nut holding the spring-loaded swivel on the butterfly valve arm.
Section: Start the Burner Temperature Correction Estimating Rate Manifold to Furnace Pressure information can be used to estimate the burner’s firing rate when it is not possible to clock a meter for the rate. To estimate the burner’s firing rate: ○ Measure the furnace pressure over fire ○ Measure the manifold pressure (at the manifold pressure test connection).
Section: Start the Burner Figure 14A - Manifold to Furnace Pressure Drop vs Rate CG15 * 1800 1600 1400 Rate, MBH 1200 C G 15.4S C G 15.3S C G 15.2S C G 15.1S 1000 800 600 400 200 0 0 0 .5 1 1 .5 2 2 .5 3 3 .5 4 4 .5 P ressu re D ro p , In . W C Figure 14B - Manifold to Furnace Pressure Drop vs Rate CG25* 3500 3000 Rate, MBH 2500 C G 25.5S C G 25.4S C G 25.3S C G 25.2S C G 25.1S 2000 1500 1000 500 0 0 0 .5 1 1 .5 2 2 .5 3 3 .5 4 4 .5 P ressu re D ro p , In .
Section: Start the Burner Figure 14C - Manifold to Furnace Pressure Drop vs Rate CG50* 6000 5000 Rate, MBH 4000 C G 50.5S C G 50.4S C G 50.3S C G 50.2S C G 50.1S 3000 2000 1000 0 0 0 .5 1 1 .5 2 2 .5 3 3 .5 4 4 .5 P ressu re D ro p , In . W C * Charts represent both natural and propane gas. Check Operation and Safety Controls Testing by Qualified Technician Required.
Section: Start the Burner 6. High gas pressure switch – With the burner firing and a manometer attached to the test port nearest the high pressure switch, gradually increase the gas pressure until the high pressure switch opens and shuts the burner off. Note the pressure and manually reset the switch. The high gas pressure switch should be set at one and one half times the high fire manifold pressure (see nameplate data in Figure 1 or set switch as determined by testing). 7.
Section: Maintenance and Service Maintenance and Service Annual Professional Service Required Tampering with or making incorrect adjustments could lead to equipment malfunction and result in asphyxiation, explosion or fire. 6. Clean the inside surfaces of the burner housing scroll and especially the air intake area and airflow proving switch suction tube. 7. If the blower motor does not have permanently lubricated bearings, oil the motor. Clear any debris from the air vents on the motor body. 8.
Section: Maintenance and Service 6. Perform all maintenance and tests according to the burner control manufacturer’s instructions (limits, controllers, low water cutoff, relief valves, feed valves, etc.) Flame Safeguard Follow the control manufacturer’s instructions and verify that the control is functioning to specifications. See Page 14 or 16 for appropriate sequence of operation and Items 8 through 10 on Page 28 for control system checks.
Section: Maintenance and Service Figure 15B – Gas Gun Assembly Verify Alignment Verify burner model on adjustment scale 3/8” Verify burner model on head Verify O-ring is in place and lubricated* * Automotive chassis or bearing grease is satisfactory o-ring lubricant. - Disassembly of gas gun in not required for cleaning Burner Head Adjustment - There is an optimum gas orifice size and burner head setting for each firing rate of the burner.
Section: Maintenance and Service Propane Restrictor Description Installation The Beckett Propane Restrictor Conversion Kit allows for the conversion of CG15, CG25, and CG50 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 detailed in the burner manual. Note that Steps 1 and 2 on the reverse side refer to fully assembled burners.
Section: Maintenance and Service Use authorized replacement parts only. Restrictors are precisionmachined parts and O-rings are rated for fuel contact. Do not attempt to replicate or modify any parts. Refer to Table 4. The gun assembly is secured inside the air tube by a spring-loaded jacking screw. It is spring loaded in order to control the force it can impose on the gun assembly.
Section: Maintenance and Service For the Operator Inspect Heating System Regularly Lack of regular inspections and inadequate maintenance could lead to equipment malfunction and result in asphyxiation, explosion or fire. y (Always follow the appliance manufacturer’s recommended service instructions, when available.
Replacement Parts 1 2 7 6 3 5 4 8 9 12 10 11 20 15 13 18 14 16 21 26 24 34 19 17 25 Note 1: See Burner Configuration Table.
Item Description CG15 Part No. CG25 Part No. CG50 Part No.
Limited Warranty Information The R. W. BECKETT CORPORATION (“Beckett”) warrants to persons who purchase its “Products” from Beckett for resale, or for incorporation into a product for resale (“Customers”), that its equipment is free from defects in material and workmanship. To qualify for warranty benefits, products must be installed by a qualified service agency in full compliance with all codes and authorities having jurisdiction, and used within the tolerances of Beckett’s defined product specifications.