Operation On/Off Rate: 80 to 250 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.
Contents General Information..................................................... 3 To the Owner:................................................................................. 3 Owner’s Responsibility:.................................................................. 3 Professional Installer’s Responsibility:........................................... 4 Specifications................................................................................. 4 Inspect/Prepare Installation Site .................
Section: GENERAL INFORMATION General Information To the Owner: This equipment must be installed, adjusted and started by a qualified service agency that is licensed and experienced with all applicable codes and ordinances and responsible for the installation and commissioning of the equipment. Thank you for purchasing a Beckett CG4 burner for use with your heating appliance. Please pay attention to the Safety Warnings contained within this instruction manual.
Section: GENERAL INFORMATION Professional Installer’s Responsibility: Professional Service Required Failure to follow these instructions could lead to equipment malfunction and result in asphyxiation, explosion or fire. yy Please read all instructions before proceeding. Follow all instructions completely.
Section: GENERAL INFORMATION Figure 1 – Burner Dimensions 15.8” 9.5” 8.0” 7.6” 13.1” 8.3” 14.4” 10.3” 6.0” Figure 2 – Burner Nameplate 1.13 Your burner will have labels that are specific to its construction. This is for reference only. General Model Information Serial Number SERIAL NUMBER 140121-08157 CG4001 Rev.A 00 2.50 R.W. Beckett Specification Number and Revision Model “CG4” Gas ConversionBurner Brûleur de conversion Approvals / Certifications ######### Conforms to ANSI Std Z21.
Section: INSPECT/PREPARE INSTALLATION SITE Inspect/Prepare Installation Site Indoor Installation Explosion, Fire, Asphyxiation Hazard Wet or dusty environments could lead to blocked air passages, corrosion damage to components, impaired combustion performance and result in asphyxiation, explosion or fire. yy This burner is designed for clean, dry installations. yy Electrical controls are not protected against rain or sprayed liquids.
Section: INSPECT/PREPARE INSTALLATION SITE 5. Any leakage between tiles, around clean-out doors, or around the vent pipe should be sealed. 6. A Draft regulator is required, it shall be a doubleacting type, agency recognized for use with gas vent systems. 7. The design and sizing of the appliance’s vent system shall comply with the requirements of NFPA 54 Chapters 12 and 13. 8.
Section: INSPECT/PREPARE INSTALLATION SITE Combustion Air Supply Some local codes and gas utilities require the installation of a CO detector, this is strongly recommended in all applications. 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. One method to accomplish this is through a permanent opening(s) in an exterior wall.
Section: INSPECT/PREPARE INSTALLATION SITE Fuel Gas Supply Explosion, Fire, and Gas Leak Hazard Explosion, Fire, Asphyxiation Hazard Leaking gas could result in asphyxiation, explosion, or fire hazard. A Drip Leg is required in Gas Supply Piping. Foreign matter could lodge in gas valve cutoff seals, resulting in gas leakthrough, explosion or fire.
Section: INSPECT/PREPARE INSTALLATION SITE Table 4 – Minimum Combustion Chamber Dims. Chamber Dimensions (Inches) Rectangular Firing Rate MBH Width (W) Height (H) Horizontal Cylinder I. D. Length (L) Floor to Tube (A) 80 8 8 9 13 4 105 9 9 10 13.5 4.5 140 10.5 10.5 12 14 5.3 175 11.5 11.5 13 14.5 5.8 210 13 13 14.5 15 6.5 250 15 15 16 16 7.5 L H A W Table 5 – Firing Rates and Configurations Fuel Orifices Firing Rate BTU/Hr. Natural Gas Orifice Dia.
Section: INSPECT/PREPARE INSTALLATION SITE ○○ ○○ ○○ ○○ ○○ ○○ ○○ The burner’s firing rate is the input rating. If it is given in GPH of oil, multiply by 140,000 to get BTU/ Hr for gas or by 140 to get MBH. The burner’s firing rate must be no more than 5% higher than the appliance’s stated input rate (based on industry tolerance) and no more than 10% lower than the appliance’s stated input rate (based on the potential for low stack temperature condensation hazards).
Section: PREPARE THE APPLIANCE Fire and Asphyxiation Hazard Failure to comply with manufacturer’s instructions could result in damage to the stainless steel combustion chamber which can result in fire or asphyxiation hazards. If retrofitting a CG4 to a stainless steel combustion chamber, check the appliance manufacturers instructions to determine if a lining is required and comply with their recommendations. Assemble the Burner Gather the Necessary Parts 1.
Section: ASSEMBLE THE BURNER Pieces of tape can be cut loose during installation and lodge in gas valves causing cutoff seal problems. Teflon tape lubricates pipe threads, allowing iron pipes to penetrate too deeply into aluminum valve bodies causing distortion and leakage. Use only pipe sealant compounds that are resistant to the gas being used. Verify that the gas valve is not damaged and that all piping and fittings are de-burred and clean inside and out. Install the Valve and Manifold to the Burner 1.
Section: ASSEMBLE THE BURNER Figure 7 – Installation of air band, shutter, and air provings switch Slotted Air Band Air Proving Switch Blank Air Band Shutter Figure 8 – Air Tube Installation #10-24 x 1/2” Button Socket Head Screws (Qty: 2) #8 x 7/16” Hex Washer Head Screws (Qty: 2) Air Tube Gas Connection on Top 1/4-20 x 5/8” Hex Head Screws (Qty:4) 14
Section: ASSEMBLE THE BURNER Figure 9 – Gas Manifold Manifold (Factory Assembled) 3/4” Pipe Nipple (Installer Provided) Union Flow Arrow Points This Way Figure 10 – Gas Manifold Installation #10-24 x 1-1/4” Button Socket Head Screws (Qty: 4) O-Ring (Lubricate Before Installing) Fuel Orifice (If Used) CG4 Burner Manual 15
Section: MOUNT THE BURNER Mount the Burner Connect Gas Piping 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. Install the test cock tee, its plug, and the union (provided with the burner) into the supply piping and connect them to the burner valve and manifold (Figure 12).
Section: WIRE THE BURNER Wire the Burner Electrical Shock Hazard 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. Electrical shock can cause severe personal injury or death.
Section: SEQUENCE OF OPERATION Sequence of Operation ○○ If the air proving switch is open, the motor will start. Once the air proving switch closes, pre-purge will begin (lasting 30 seconds). Pre-purge or ignition timings will not start until the air proving switch closes. ── The air proving switch must close to prove combustion air is present. If switch fails to close during the specified period, the control will enter lockout.
Section: PREPARE THE BURNER FOR START-UP Prepare the Burner for Start-up Asphyxiation, Explosion/ Fire Professional Installation & Service Required. Incorrect installation and mishandling of start-up could lead to equipment malfunction. This burner must be installed and prepared for startup by a qualified service technician who is trained and experienced in gas burner system installation and operation. Do not attempt to start the burner unless you are fully qualified.
Section: START THE BURNER Call for Heat. Verify that burner fires up and the gas valve closes. After control locks out, flame shall go off. 6. Turn power off and reattach sensor wire. Turn power back on. Control should reset. Initiate Call for Heat. 7. After you have observed main flame for a brief time, press the reset button on the control for 1 second to shut down and re-start the burner.
Section: START THE BURNER 4. Start the burner and use a stopwatch to measure the number of timed seconds it takes for the burner to fire 1 cubic foot of gas. 5. Calculate the firing rate in BTU/Hr. using the following equation: Firing rate BTU/Hr. = Heating value (BTU/Ft3) x 3,600 ÷ Timed seconds For example, if the heating value is 1,050 BTU/Ft3 and you timed 1 cubic foot of gas at 42 seconds then firing rate BTU/Hr = 1050 x 3,600 ÷ 42 which calculates to 90,000 BTU/Hr.
Section: START THE BURNER Use Test Instruments to Set Combustion Always use calibrated test instruments to set combustion levels. Verify that test instruments are calibrated and in good working condition. If not already provided, drill test access holes in the flue pipe near the breech (or upstream of the boiler breech damper, if applicable) and in the front mounting plate area for firebox pressure. Be careful not to damage any water-backed surface.
Section: MAINTENANCE AND SERVICE Maintenance and Service Explosion, Fire and Asphyxiation Hazard Annual Professional Service Required. Tampering with or making incorrect adjustments could lead to equipment malfunction and result in asphyxiation, explosion or fire. Do not tamper with the burner or controls or make any adjustments unless you are a trained and qualified service technician. To ensure continued reliable operation, a qualified service technician must service this burner annually.
Section: MAINTENANCE AND SERVICE 8. Inspect the flame rod for oxidation or distortion. Clean all surfaces, set the probe position, and insure that the flame rod is securely fastened. Refer to Figure 17. 9. Inspect the ignition electrode for any damage. Clean all surfaces, set the proper electrode gap, and make sure it is securely fastened. 10. Clean the inside of the air tube and inspect the combustion end for any deterioration. Referring to Figure 11 on Page 16, check the recess dimension from refractory.
Section: MAINTENANCE AND SERVICE Figure 16 – Blower wheel assembly Use a Feeler Gauge to set the gap to 0.030 ±1/64 inch 6. Referring to the illustration to the left, slide the new blower wheel onto the shaft. ○○ Use a feeler gauge to set the wheel-to-motor gap, 0.030 ±1/64 inch. ○○ Slide blower wheel toward motor until it contacts feeler gauge. ○○ Rotate the blower wheel until the setscrew is centered on the flat of the motor shaft. Tighten the set screw 45 to 80 in.-lbs. to secure the wheel.
Section: REPLACEMENT PARTS Replacement Parts Figure 18 – Replacement Parts 21 22 18 20 17 19 = Complete Assembly 16 15 13 14 1 2 12 See Inset 11 10 3 9 8 4 5 7 6 Item Description Explosion, Fire, Asphyxiation Hazard Use authorized replacement parts only. Do not attempt to replicate or modify any parts.
Contractor Start-Up Form Installation Name:_________________________________________ Installation Date:___________________ Installation Address:_________________________________________________________________________ Start-Up Company’s Name_________________________________ Phone:__________________________ Name of Technician_________________________________________________________________________ ■■ Appliance (Below information can be obtained from appliance name plate) Manufacturer:___________________
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.
