Beckett CG10-24 Gas Burner User manual

Brand: Beckett

Model: CG10-24 Gas Burner

Type: User manual

Operation On/Off & On/Off Low Fire Start

Available 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



General Information .................................................... 3

TotheOwner:................................................................................ 3

Owner’sResponsibility:................................................................. 3

ProfessionalInstaller’sResponsibility:.......................................... 4

Specications................................................................................ 4

Burner Conﬁgurations ................................................. 6

Inspect/Prepare ..............................................................

Installation Site ......................................................... 9

IndoorInstallation.......................................................................... 9

InspectChimneyandVentSystem................................................ 9

CombustionAirSupply................................................................ 11

BuildingswithAdequateAirInltration....................................... 11

BuildingswithLessThanAdequateAirInltration...................... 11

ClearancestoBurnerandAppliance........................................... 11

Fuel Gas Supply ..........................................................11

Prepare the Appliance ............................................... 14

Mount the Burner ...................................................... 14

Connect Gas Train Piping .......................................... 15

Propane Conversion ..................................................17

PropaneRestrictorInstallation...................................................17

Wire the Burner .......................................................... 19

Sequence of Operation ............................................. 23

Burner Start-up .......................................................... 24

TestInstruments.........................................................................24

BurnerStartProcedure..............................................................24

VerifytheBurnerFiringRate.......................................................27

EstimatingRate...........................................................................27

ValidateSafetyControlOperation...............................................28

Combustion Air Adjustment Procedure ................... 28

Maintenance and Service .......................................... 29

RequiredAnnualMaintenance...................................................30

Replacement Parts ..................................................... 33

Limited Warranty Information ................................... 36

Before Calling Beckett . . .

Beforecontactingusaboutyourburner,youmusthaveacompletelylledoutcopyofthe

Contractor Start-Up Form

(Locatedinsideoflastpage).Thisinformationiscrucialfortroubleshootingandobtainingthecorrectreplacementpart.

Table of Contents

Figure1–BurnerDimensions..........................................................................................5

Figure2–BurnerNameplate...........................................................................................5

Figure3–BurnerCongurationfor300to600MBHApplications..................................6

Figure4–BurnerCongurationfor600to1200MBHApplications................................7

Figure5–GasGunAssembly-ComponentFamiliarization.............................................8

Figure6–VentPipewithDraftRegulator........................................................................9

Figure7–ChimneyDesign-AbovetheRoof................................................................10

Figure8–TypicalGasPipingLayout...............................................................................12

Figure9–MinimumCombustionChamberDims..........................................................15

Figure10–GastraincongurationforOn/OffwithLowFireStart................................16

Figure11–GastraincongurationforOn/Offoperation................................................16

Figure12–GastraincongurationforOn/Offoperationunder399MBH.....................16

Figure13–PropaneConversionMajorComponents..................................................... 17

Figure14–ComponentLocations..................................................................................18

Figure15–GasGunAssemblyInstallation....................................................................18

Figure16–7590Control...............................................................................................20

Figure17–TypicalWiringSchematic,On/OffOperation................................................21

Figure18–TypicalWiringSchematic,On/OffOperationwithtimer...............................22

Figure19–ManifoldtoFurnacePressureDropvs.Rate-SteppedSpudDesign.........26

Figure20–ManifoldtoFurnacePressureDropvs.Rate-SwirlVaneHeadDesign......26

Figure21–ShutterandBand.........................................................................................29

Figure22–ElectrodeandFlameRodSetting...............................................................31

Figure23–GasGunAssembly-TopView.....................................................................32

Figure24–BlowerWheelSpacing................................................................................32

Figure25–CG10-24GasBurnerReplacementParts.....................................................33

Figure26–CG10-24GasGunReplacementParts.........................................................34

Table1–BurnerSpecications........................................................................................4

Table2–AvailableModels...............................................................................................4

Table3–LowRateBurnerConguration.........................................................................6

Table4–HighRateBurnerConguration........................................................................7

Table5–GasSupplyPipingCapacity.............................................................................13

Table6–PropaneRestrictorsReplacementPartNos....................................................18

Table7–OperatingSequence.......................................................................................23

Table8–InitialBurnerSettings......................................................................................25

Figures & Tables

Burner Manual — CG10-24

Section:GENERALINFORMATION

General Information

To the Owner:

Thisequipmentmustbeinstalled,adjustedandstarted

byaqualiedserviceagencythatislicensedand

experiencedwithallapplicablecodesandordinances

andresponsiblefortheinstallationandcommissioning

oftheequipment.

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.

Contactaprofessional,qualiedserviceagencyfor

theinstallation,adjustmentandserviceofyourgas

burningsystem.Thereafter,haveyourequipment

adjustedandinspectedatleastannuallytoensure

reliableoperation.Thisworkrequirestechnical

training,tradeexperience,licensingorcertication

insomestatesandtheproperuseofspecial

combustiontestinstruments.

Pleasecarefullyreadandcomplywiththe

followinginstructions:

•

Seethefrontcoverfor‘Whattodoifyousmellgas’.

•

Neverstoreorusegasolineorotherammable

liquidsorvaporsnearthisburnerorappliance.

•

Neverattempttoburngarbageorrefusein

thisappliance.

•

Neverattempttolighttheburner/applianceby

throwingburningmaterialintotheappliance.

•

Neverattempttoburnanyfuelnotspeciedand

approvedforuseinthisburner.

•

Neverrestricttheairinletopeningstotheburneror

thecombustionairventilationopeningsintheroom.

Thank you for purchasing a Beckett CG10 gas

burner

forusewithyourheatingappliance.Please

payattentiontotheSafetyWarningscontainedwithin

thisinstructionmanual.Keepthismanualforyour

recordsandprovideittoyourqualiedserviceagency

foruseinprofessionallysettingupandmaintaining

yourburner.

YourCG10burnerwillprovideyearsofefcient

operationifitisprofessionallyinstalledandmaintained

byaqualiedservicetechnician.Ifatanytimethe

burnerdoesnotappeartobeoperatingproperly,

immediately contact your qualiﬁed service agency

forconsultation.

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.

Contactaprofessional,qualied

serviceagencytoreplaceany

componentthathasbeenexposedtowater.

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:

Indicatesahazardoussituation

that,ifnotavoided,willresultin

death or serious injury.

Indicatesahazardoussituation

that,ifnotavoided,couldresult

indeath or serious injury.

Indicatesahazardoussituation

that,ifnotavoided,couldresult

inminor or moderate injury.

Usedtoaddresspracticesnot

relatedtophysicalinjury.

Safetyinstructionssigns

indicatespecicsafety-related

instructionsorprocedures.

Section:GENERALINFORMATION

Professional Installer’s Responsibility: Speciﬁcations

Concealeddamage–Ifyou

discoverdamagetotheburner

orcontrolsduringunpacking,notifythecarrierat

onceandletheappropriateclaimforms.Donot

installaburnerorcontrolthathasbeendamaged.

Special Requirements:

WhencontactingBeckettforserviceinformation—

Pleasehavetheburnerserialnumberandcontractor

start-upformavailablewhencallingorwriting.You

willndtheserialnumberonthelabellocatedonthe

leftrearoftheburner.

Fire Hazard: Overheating

Shouldover-heatingoccur:

•

Shutoffthemanualgascontrolto

theappliance.

•

DONOTshutoffpowertothe

equipment,allowtheblowerandpumps

tocontinuerunning.

If any of these instructions are not clear,

Call Beckett at 1-800-645-2876

for assistance.

Table 1 – Burner Speciﬁcations

InputFiringRateAvailable* 300-1200MBH

FiringMode On-OfforOn/OffwithLowFireStart

Fuel

Naturalgas-0.64specicgravity

LPgas-1.53specicgravity

RequiredGasSupply

Pressure(togastrain)

6”WCminimum(std)

4.5”WCminimum(special)

InputVoltage** 120Vac+10%/-15%;60Hz

InputCurrent 5.3Amp

GasTrain

24VValvesHigh/Lowgaspressure

switch

LifeCycle

Gasvalvesareratedfor100-000

cycles(regardingvalveseatleakage).

ApplicationType

Indoor,Stationary.Seenoticebelow

foroutdooruse.

BurnerControl ProgrammablePre-purge

FlameDetection FlameRectication

Igniter Electronic-DirectSpark

Motor ThermallyProtected-ManualReset

CombustionAirProving DifferentialPressureSwitch

Weight 40lbs.

MountingOrientation

Upto90°fromuprightwithmotor

shafthorizontal

Dimensions 11.9”x16.0”x20.5”

AcceptableAmbient

TemperatureRange

-4°Fto+104°F

AcceptableAmbient

Humidity

5%-95%RHnon-condensing

*Foraltitudeshigherthan2,000feet,deratetheburnercapacity4%

foreach1,000feetabovesealevel.

**Thisburnerisnotapprovedforusein50Hzapplications.

ThisburnerisULlistedforuse

intheUSorCanadaperANSI/UL

295&CSA/CGA3.4.Forusewith

naturalgasorpropane.

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

Explosion, Fire, and

Asphyxiation Hazard

Professional Service Required.

•

Pleasereadallinstructionsbeforeproceeding.

Followallinstructionscompletely.

•

Thisequipmentmustbeinstalled,adjusted

andstartedbyaqualiedserviceagencythat

islicensedandexperiencedwithallapplicable

codesandordinancesandresponsibleforthe

installationandcommissioningoftheequipment.

•

Theinstallationmustcomplywithalllocalcodes

andordinanceshavingjurisdictionandthelatest

editionoftheNationalFuelGasCodeANSI

Z223.1(NFPA54)andCAN1-B149.1inCanada.

•

Burnermustbeusedwithinthelimitsof

Table 1

FOROUTDOORUSAGEitisthe

responsibilityoftheOEM

equipmentmanufacturertoprotecttheburner

systemandcomponentsfromexposuretowaterin

theend-useapplication.

Burner Manual — CG10-24

Section:GENERALINFORMATION

Burner

Model

Dim.

O.D.

Min. Max.

10.1-10.3

10.1S-10.3S

19.8” 1.88” 7.00” 4.43”

10.4-10.6

10.4S-10.6S

20.6” 3.00” 7.63” 4.61”

*Bisfactoryset(welded)dependingonapplication.

Figure 1 – Burner Dimensions

GeneralModelInformation

SerialNumber,IncludingDate

Code

RatingInformation

ApprovalAgencySymbols

R.W.BeckettConstruction&

SettingData

R.W.BeckettSpecication

NumberandRevision

BoilerManufacturerand

Model,WhenApplicable

AdditionalCodes

Figure 2 – Burner Nameplate

16.0

7. 7

6.1

7. 9

11.9

1.5

1-1/4” NPT

O.D.

B Max.

B Min.

Section:BURNERCONFIGURATIONS

Burner Configurations

TheCG10burnerisofferedincongurationsthatallowittobecustomizedtothecapacityandfurnacesizeneedsof

manydifferentappliances.Twoblowerwheelsizesprovideairowcapacitythroughtherange.Anairguideprovides

staticpressureaugmentationatlowratesandaninletsleevemaximizesowcapacityathighrates.Twoairtube

shroudsshapeandstabilizethebaseoftheame.Twoburnerheadstylesareavailableforeachringrangeto

providemixingcontrolandretaintheame.See

Table 3

and

Table 4

Figure 3 – Burner Conﬁguration for 300 to 600 MBH Applications

Chassis

Firing Rate

(MBH)

Burner

Head

Blower Wheel Air Inlet Scroll Extension

CG10

300-378

10.1

5.75”dia.x2.53”w,

PartNo.21448

AirGuide,

PartNo.189

None

10.1S

379-476

10.2

10.2S

477-600

10.3

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

Burner Manual — CG10-24

Section:BURNERCONFIGURATIONS

Figure 4 – Burner Conﬁguration for 600 to 1200 MBH Applications

CG10.4S - 10.6S

CG10.4 - 10.6

Blower wheel

Air Guide

Chassis

Firing Rate

(MBH)

Burner

Head

Blower Wheel Air Inlet Scroll Extension

CG10B

601-756

10.4

6.31”dia.x2.42”w,

PartNo.21339

AirGuide,

PartNo.178

Installed

10.4S

757-952

10.5

10.5S

CG10A 953-1,200

10.6

InletSleeve,

PartNo.32336

10.6S

4-1/2” ID Shroud

Inlet Sleeve

Scroll Extension

Table 4 – High Rate Burner Conﬁguration

Section:BURNERCONFIGURATIONS

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

Burner Manual — CG10-24

Section:INSPECT/PREPARE  INSTALLATIONSITE

Examinetheinstallationsiteforconditionsthatcould

adverselyaffectthehealthandsafetyofinstallation

personnelandtheuseroftheapplianceorproper

operationoftheburnerandappliance,andcorrectany

defectsfound.

|

Theareaaroundtheapplianceshouldbe

unobstructedanddry.

|

Wiringmustbeingoodconditionandmeetstate&

localcoderequirements.

|

Iftheburnerisreplacinganexistingoilburner,old

pipingandthetankmustbesecuredorremovedto

preventleakageorunintendeddeliveriesofoil.

|

Localjurisdictionsmayrequireremovalofoiltanks.

SeeNFPA-30ammableandcombustibleliquids

codeforapprovedprocedures.

Inspect Chimney and Vent System

1.  Anyaccumulationofsootordebrisinchimney

offsetsmustberemoved

2. Anyobstructionssuchasaprotrudingjointora

pieceofbrokentilewedgedinthechimneymust

beremoved.

3. Nootherapplianceconnectionshouldbemadeto

thesameuepipe.

4. Theuepipemusthaveanupwardpitchtowardthe

chimneyofatleast1/4”perfootoflength.Itshould

ttightlyandshouldnotprojectintothechimney,

see

Figure 6

Explosion, Fire, and

Asphyxiation Hazard

Wet or dusty environments could lead

to blocked air passages, corrosion

damage to components, impaired

combustion performance.

•

Thisburnerisdesignedforclean,

dryinstallations.

•

Electricalcontrolsarenotprotectedagainstrain

orsprayedliquids.

•

Keeptheinstallationclearofdust,dirt,corrosive

vapors,andmoisture.

•

Protectivecoversandfrequentmaintenancemay

berequired.

Inspect/Prepare

Installation Site

Indoor Installation

Barometric Draft Control

Flue Pipe Ell

Heating Unit

1/4” per Foot

Minimum

Figure 6 – Vent Pipe with Draft Regulator

Fire, Smoke and

Asphyxiation Hazard

•

Carefullyinspectthechimney,chimney

liner&exhaustventsystem.

•

Makesureitisproperlysizedandin

goodworkingcondition.

•

Followtheinstructionssuppliedbythe

appliancemanufacturer.

•

Ifadraftregulatorisrequired,itmustbe

adouble-actingtype,agencyrecognized

forusewithgasventsystems.

•

Thechimneyinstallationandvent

sizingmuststrictlycomplywithall

applicablecodes,authoritieshaving

jurisdictionandthelatestrevisionofthe

NationalFuelGasCode(ANSIZ223.1,

o r  N F P A 5 4 )  o r  C A N / C G A  B / 4 9  C a n a d a . 

Removeanyventdamperdevice.

•

Regulationbytheseauthorities

takeprecedenceoverthegeneral

instructionsprovidedinthisinstallation

manual.

Section:INSPECT/PREPARE  INSTALLATIONSITE

ChimneyLiners

Thenewdesignsoffurnacesandboilersaremore

efcient.Oneresultofincreasedefciencyislowerue

gastemperatures.Asuegasesriseinthechimney,

theycoolandcondensewhentheyreachthedew

point.Thecondensationmixeswithsulphurinthe

uegasescreatingsulfuricacid.Theacidattacksthe

chimneymortar,brickandclaylinerscausingcorrosion,

deterioration,leaks,orblockageofthechimney.

Eventuallytheblockagecouldpreventexhausting

theuegases.Instead,theuegasesventoutthe

barometricdamperintothelivingspace.

Thereforeitisstronglyrecommendedthatanapproved

insulatedstainlesssteelchimneylinerbeinstalled.The

installingcontractorissolelyresponsibleforinstallation

oftheproperventsystem.

|

Forthoseinstallationsnotrequiringachimney,such

asthrough-the-wallventedappliances,followthe

instructionsgivenbytheapplianceandpowerventer

(ifused)manufacturers.

Minimum Clearence: 2 FT.

NOTE: Correctchimneydesignisshownbydottedlines.Incorrectchimneydesign,asshownbythesolid

lines,mayresultindown-drafts.

Figure 7 – Chimney Design - Above the Roof

5. Anyleakagebetweenchimneytiles,around

clean-outdoors,oraroundtheventpipeshould

besealed.

6. Abarometricdraftcontrolisrequired,itshallbea

double-acting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. Achimneyueshallextendatleast3feetabove

thehighestpointatwhichthechimneycomes

incontactwiththeroof,andnotlessthan2feet

abovethehighestroofsurfaceorstructurewithin

10feethorizontallyofthechimney.Referto

Figure 7

Somelocalcodesandgas

utilitiesrequiretheinstallationof

athermalueSafetyswitchonthedouble-acting

draftcontrol,ordrafthood.

Thethermalsafetyswitchsensesuegasspillage

causedbyblockedueexhaust,prolongeddown-draft,

orinsufcientdraft.Thesafetyiswiredinserieswith

theburnercontrolcircuitandshutstheburneroff,when

thespillageofhotuegasesisdetected.

Burner Manual — CG10-24

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.Consultwithyourheatingcontractoror

ahomesecurityagency.

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

Inmanycases,aburneroperatinginanunconned

spaceofaconventionalframe,brickorstonebuilding

willreceiveadequateairsupplyfromleakageinthe

buildingitself.Butiftheburnerislocatedinaconned

spacesuchasafurnaceorboilerroom,thatspacemust

haveonepermanentopeningtowardthetopofthe

spaceandonenearthebottomofthespace.

Eachopeningmusthaveafreeareaofnotlessthanone

sq.in.per1,000BTUperhourofthehighestinputrating

listedfortheappliance(refertoNFPA54&58).

Remembertotakethetotalinputofallair-using

appliancesintoconsiderationwhenguringthe

openings.Theopeningsmustconnectwiththeinside

ofthebuilding,whichshouldhaveadequateinltration

fromtheoutside.

As an example:

Ifagasburnerwasringat350,000BTU/Hr,inan

enclosedroominabuildingeachopeninginthe

enclosureshouldbe350sq.in.(350,000/1,000x1sq.

in.=350sq.in.)A350sq.in.openingwouldtypically

be12”x30”or19”x19”.

Buildings with Less Than Adequate Air

Inﬁltration

Iftheburnerislocatedinatightlyconstructedbuilding

wherethereisinadequateoutsideairinltration,outside

combustionairmustbesuppliedbysomeothermeans.

Onemethodtoaccomplishthisisthroughapermanent

opening(s)inanexteriorwall.Theopening,oropenings,

musthaveatotalfreeareaofnotlessthanonesq.in.

per5,000BTUperhour.Allappliancesmustbetaken

intoconsideration.RefertoNFPA54&58.

Clearances to Burner and Appliance

|

Providespacearoundburnerandapplianceforeasy

serviceandmaintenance.

|

Checkminimumclearancesagainstthoseshown

bytheappliancemanufacturerandbyapplicable

buildingcodes.

|

Therecommendedclearancearoundtheburner

itselfis12”minimumforserviceaccess.

Fuel Gas Supply

Gassupplypipingmustbe

structurallysupported

independentoftheburner.Theburnermanifoldand

g a s  v a l v e  a r e  n o t  d e s i g n e d  t o  s u p p o r t  p i p i n g  l o a d s . 

Explosion, Fire, and Gas

Leak Hazard

Provide Over-pressure Protection

TheNationalFuelGasCode,ANSIZ223.1(NFPA

54)andASMECSD-1requirethatifgaspressure

enteringthebuildingexceedstheratingofanygas

traincomponentanoverpressureprotectiondevice

mustbeinstalled.

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.

Atypicalgaspipinglayoutisshownin

Figure 8

onpage12.



Section:FUELGASSUPPLY

LGPS

HGPS

(IFUSED)

DRIP LEG

BURNER

METER

MSC

SSOV1

PRSSOV

MLTC

U TCTC

UPGREGULATOR

GAS UTILITY PIPING

FACILITY PIPING

GAS TRAIN

BURNER

ABBREV.

HGPS

LGPS

MSC

MLTC

SSOV1

PRSSOV

ITEM DESCRIPTION

HIGHGASPRESSURESWITCH

LOWGASPRESSURESWITCH

MAINSHUTOFFCOCK

MAINLEAKTESTCOCK

PRESSUREGAUGE

STRAINER

SAFETYSHUTOFFVALVE#1

TESTCOCK

UNION

PRESSUREREGULATINGSAFETY

SHUTOFFVALVE

Figure 8 – Typical Gas Piping Layout

Thegassupplysystemmustbesizedtodeliveratleast

theminimumrequiredpressuretothegastraininlet.

Contactyourlocalgasutilityforvericationofgas

pressures,allowablepressuredrops,andanylocalpiping

coderequirements.

Ifusingcurrentfacilitypipingalreadyinplace,verify

thefollowing:

|

Pipingdesignmeetsallapplicablecodes.

|

Pipingandcomponentsareinspectedandingood

workingcondition.

|

Pipingissizedcorrectlytosupplyrequiredgas

pressuretotheburnerandanyothergasappliances

inthefacility.

|

Anynewbranchesinthesupplypipingmust

bepressuretestedasoutlinedinANSIZ223.1/

NFPA54.

Fornewfacilitypiping,followthepipesizingmethods

andtablesforpipesizingasoutlinedinANSIZ223.1/

NFPA54.

Allgaspipinginstallationmust

complywiththelatestedition

oftheNationalFuelGasCodeANSIZ223.1(NFPA

54)andotherapplicablelocalcodes.

Explosion, Fire, and Gas

Leak Hazard

•

Donotdisassemblegasvalve.

•

Valvemustbeinstalledwiththegasowinthe

samedirectionasthearrow.

Explosion, Fire, and Gas

Leak Hazard

Do not use Teﬂon tape on gas piping. Damage

to gas valve cutoff seals and valve bodies could

cause gas leaks.

•

Piecesoftapecanbecutlooseduring

installationandlodgeingasvalvescausingcutoff

sealproblems.

•

Teon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.

Explosion, Fire, and Gas

Leak Hazard

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.

Installafull-sizedriplegordirtpocketinthepiping

directlyaheadofthemainshutoffvalvetocapture

foreignmatter.

Newfacilitypipingmustbepressuretestedin

accordancewithANSIZ223.1/NFPA54.

Aleaktestmustbeperformedonsupplypiping

immediatelyaftergasisturnedbackon.Anyleaksmust

bexedbeforecontinuingwiththeinstallation.

Burner Manual — CG10-24

Section:FUELGASSUPPLY

Schedule40metallicpipewith0.50psiorlessinletpressureand0.30”W.C.pressuredrop

Maximumcapacityincubicfeetofgasperhour(CFH).Naturalgaswith0.60specicgravity.Pipesize(inches)IPS

Pipe Length (ft.) 0.75” 1.0” 1.25” 1.5” 2.0” 2.5” 3.0” 4.0”

10 278 520 1050 1600 3050 4800 8500 17500

20 190 350 730 110 0 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 74 0 0

60 105 195 400 610 115 0 1850 3250 680 0

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 510 0

125 72 130 275 410 780 1250 2200 4500

150 64 120 250 380 710 113 0 2000 4100

175 59 110 225 350 650 1050 1850 3800

200 55 100 210 320 610 980 1700 3500

Forotherinletpressuresandpressuredrops,seeNFPA54forNaturalGaspipingorNFPA58forLPGasPiping.

Table 5 – Gas Supply Piping Capacity

Section:PREPARETHEAPPLIANCE

Prepare the Appliance

Breathing Hazard

Ceramic ﬁber or Fiberglass insulation

Ceramicbermaterials,suchaschamber

liners,maycontaincarcinogenicparticles

(crystallinesilica)afterexposureto

heat.Airborneparticlesfromberglass

orceramicbercomponentshave

beenlistedaspotentiallycarcinogenicbytheState

ofCalifornia.Takethefollowingprecautionswhen

removing,replacingandhandlingtheseitems.

Avoid breathing dust and avoid contact with skin

or eyes.Wearlong-sleeved,loose-ttingclothing,

glovesandeyeprotection.UseaNIOSHN95certied

respirator.Thisrespiratormeetsrequirements

forprotectionfromcrystallinesilica.Actualjob

requirementsforNIOSHregulationsmayrequire

otheroradditionalprotection.Forinformation,refer

totheNIOSHwebsite,http://www.cdc.gov/niosh/

homepage.html.

Ceramic ﬁber removal:Topreventairbornedust,

thoroughlywetceramicberwithwaterbefore

handling.Placeceramicbermaterialsinaplasticbag

andsealtodispose.

Avoid blowing, tearing, sawing or spraying

berglassorceramicbermaterials.Ifsuchoperations

arenecessary,wearextraprotectiontoprevent

breathingdust.

Wash work clothes separately from other laundry.

Rinseclotheswasherthoroughlyafterwardstoprevent

contaminationofotherclothing.

NIOSH First aid procedures:

•

Eyeexposure-irrigateeyesimmediately

•

Breathing-freshair

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.

Carbon Monoxide

Hazard

Burnermountinggasketmustbeusedtosealagainst

leakagefromtheappliance.Donotuseadamaged

mountinggasket.Verifythatallboilersections,canopy,

andaccessplatesordoorsarefullyequippedwith

gasketsandsealedagainstanyleakage.

Mount the Burner

Theburnerspeciedforpackagedequipmentwill

haveaangetomatchtheapplianceboltpatternand

weldedfortherequiredinsertion.Followtheappliance

manufacturer’sinstructionsformounting.

Carbon Monoxide

Hazard

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.

•

Theendoftheairtubemustnotextendinto

thecombustionchamberunprotectedunless

ithasbeenfactory-testedandspeciedbythe

appliancemanufacturer.

•

Theendoftheairtubeshouldbesetback¼”

fromushwiththerefractoryinsidewallto

preventdamagefromoverheating.

•

Refertotheinstructionsoutlinedinthissection

formethodsofadditionalprotection.

Explosion, Fire, and

Asphyxiation Hazard.

Adjustable ﬂange shall not be used with portable

equipment.

Forretrotapplicationsandtoensurecorrectinstallation,

verifythefollowing:

|

Verifytheendoftheburnerairtubewillbesetback

1/4”fromtheinteriorsurfaceofthecombustion

chamberwhentheburnerismountedtothe

appliance.See

Figure 9

|

Ifthisdimensioncannotbeachieved,protectthe

endoftheairtubebyinstallingasuitableceramic

refractorymaterialsuchasarefractorymillboard

capableofwithstandingatleast2300°F.

|

Verifytheburneramesizeissuitableforthe

appliancecombustionchamber.See

Figure 9

for

minimumcombustionchamberdimensionsatthe

statedringrateranges.

Dimensionsshownarefor

castironsectionalboilers

withuptakesbetweensections.Forminimum

dimensionsofotherfurnacetypesconsultR.W.

BeckettCorporation.

|

Verifythesuppliedgasketisinplaceontheburner

airtubeangeandthenmounttheburnertothe

applianceusingapplianceoreldsuppliedhardware.

Burner Manual — CG10-24

Section:CONNECTGASTRAINPIPING

1/4”

‘A’

‘ L’ ‘W’

‘H’

Minimum Combustion

Chamber Dimensions (inches)

Input

FiringRate

inMBH

Length

‘ L’

Width

‘W’

Height

‘H’

Burner

Head

Centerline

tooor‘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 Piping

TheCG10gasburnercomessuppliedwithstandardgas

traincomponentsthatmeetUnderwritersLaboratory

(UL)andCSD-1requirementsforgastrains.Thegas

trainisnormallyshippedascomponentsandmustbe

assembledandinstalledatthesite.

Thegastrainisusedforbothnaturalgasandpropane;

forconvertingburner,seePropaneConversion

instructionsonpage17.

Verifythatthegastraincomponentsarenotdamaged

andallpipingandttingsarecleaninsideandout.

See

Figure 10

,

Figure 11

and

Figure 12

startingonpage

16fortypicalcomponentlayout.

Vent lines–

Installventlinestoanygasvalvecomponent

thatrequiresatmosphericairpressuretobalancea

diaphragm.Ventlinesmustberuntotheoutdoors,with

theterminationpointawayfromfreshairintakesand

windows.Theterminalopeningmustbettedwithawire

meshscreentoblockinsectsandothercontaminants

fromenteringtheventandmustbemountedinsucha

positionthatwater,ice,dirt,oranyotherforeignmatter

cannotinltrateandblocktheventpiping.Makesurethe

nalassemblyisanchoredsecurely.

Explosion, Fire, and

Asphyxiation Hazard.

Do not use Teﬂon tape on gas piping. Damage

to gas valve cutoff seals and valve bodies could

cause gas leaks.

•

Piecesoftapecanbecutlooseduring

installationandlodgeingasvalvescausingcutoff

sealproblems.

•

Teon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.

Explosion, Fire, and

Asphyxiation Hazard.

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:CONNECTGASTRAINPIPING

TCTC

LGPS HGPS

SSOV1 PRSSOV MLTC UUMSC

Whenpressurereducingsafetyshutoffvalvesare

used,thedistancefromthenalshutoffvalve

(PRSSOV)totheburnermanifoldmustbekepttoaminimumforgoodlight-off

reliability.R.W.Beckettrecommendsthefollowingmaximumlengths.When

twoshut-offvalvesareused,thedistancebetweenvalvesshouldnotexceed

themax.lengthspeciedbelow:

Pipe Size

3/4”

1”

1-1/4”

1-1/2”

2”

Max. Length

12”

15”

18”

24”

IfaNormallyOpenVentValve(notshown)isused,thedistancebetweenthe

SSOVsmustbekepttoaminimumusingtheshortestpracticalnipples.

Key (Figure 10thruFigure 12)

Abbrev. Item Description

CGV

HGPS

LGPS

MSC

MLTC

PRSSOV

PRV

SSOV1

SSOV2

CombinationGasValve

HighGasPressureSwitch

LowGasPressureSwitch

MainShutoffCock

MainLeakTestCock

PressureRegulatingSafetyShutoffValve

Regulator

SafetyShutoffValve#1

SafetyShutoffValve#2

TestCock

TestPort

Union

TCTC

HGPS

PRV SSOV1 MLTC

UUMSC

TCTC

LGPS HGPS

CGV

MLTC U

UMSC

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

Max. Length

(see Notice below)

Burner Manifold

Max. Length

(see Notice below)

Burner Manifold

Burner Manual — CG10-24

Section:PROPANECONVERSION

Propane Conversion

TheBeckettPropaneRestrictorConversionKitallowsfor

theconversionofCG10burnersforusewithpropane

gas.Withtheproperinstallationoftherestrictorand

attachedO-ring,initialadjustmentsandsettingsfor

propanewillbethesameastheinitialadjustmentsand

settingsfornaturalgas.

Propane(LP)–Whenthecorrectpropanerestrictor

isaddedtoaburner’sgaspipeassemblyitchanges

theburner’sgaspressuredropsothatthepropane

pressuredropisequaltothenaturalgaspressuredrop

ofthesameBTUringrate.ThatiswhytheManifoldto

FurnacePressureDropcurvesof

Figure 19

and

Figure

onpage26arecorrectforbothpropaneand

naturalgas.Thatisalsowhytheinitialburnersettings,

Table 8

onpage25,areappropriatefornaturalgas;

orpropanewiththecorrectorice.R.W.Beckett

providesthesamepressureregulatingsafetyshutoff

valveinthegastrainforbothnaturalgasandpropane.

Thevalveismarkedfornaturalgasduetoitsprimary

usageinapressurerangenormallyusedbynaturalgas

appliances.Itissafeandeffectiveforpropaneusagein

thisdesignapplication.

Propane Restrictor Installation

NotethatSteps1and2onthefollowingpagereferto

fullyassembledburners.SkiptoStep3whenconverting

aburnerwithouttheairtubeassemblyinstalled.

Referto

Figure 13

and

Figure 14

onpage18when

performingthefollowingsteps.

1.  Removethejackingscrew(B)fromtheairtube/

manifoldassemblytofreetheinternalgastube(C).

Figure 13 – Propane Conversion Major Components

Explosion, Fire, and

Asphyxiation Hazard

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. Gentlyrocktheinternalgastube(C)toloosenthetube

fromtheunion(F).

3. InspecttheO-ringsandinsurethattheyareproperly

lubricated.(AsiliconO-ringlubricantisrecommended,

butautomotivechassisorbearinggreaseisan

acceptablesubstitute.)

4. Referringto

Figure 13

,placetherestrictor(E)with

pre-attached,pre-lubricatedO-ring(G)intotheinternal

gastube(C).Useyourhandtopresstherestrictorinto

thetube.TheO-ringwillholdtherestrictorinplace.

5. InsurethattheO-ring(H),attachedtotheoutside

diameterofinternalgastube,isproperlylubricated

andseatedagainsttheangeontheinternalgastube.

6. Installtheinternalgastube(C)backintotheairtube

(A)housing,referto

Figure 14

.Fittheendofthetube

intotheunion(F)ontheairtube.

7.  Re-installthejackingscrew(B).(Refertotheabove

noticeforinstallationdetails.)

8. FilloutandplacethesuppliedConversionDataPlate

(PartNo.61712)adjacenttotheratingplate.

9. CompleteandattachthesuppliedAdjustmentData

Tag(PartNo.61711).

Section:PROPANECONVERSION

Table 6 – Propane Restrictors Replacement Part Nos.

Burner Model

Restrictor

Kit

Restrictor

Inside

Diameter

O-Ring

Part

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

(ForFigure 13andFigure 14)

A AirTube E PropaneRestrictor

B JackingScrew F RestrictorO-ring

C InternalGasTube G GasTubeO-ring

D ExternalGasManifold

Figure 14 – Component Locations

Burner Manual — CG10-24

Section:WIRETHEBURNER

Useauthorizedreplacement

partsonly.Restrictorsare

precision-machinedpartsandO-ringsareratedfor

fuelcontact.Donotattempttoreplicateormodify

anyparts.Referto

Table 6

.

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.

Wheninstallingthejackingscrewlookinsidetheair

tubetoverifythatthepointedtipofthejacking

screwpinisseatedintothesmallslotonthe

locatingpadontopofthegun.Thereisalsoan

externalvericationofcorrectassembly:whenthe

screwisfullytightened,thee-cliponthetopofthe

centerpinshouldcomeushwiththetopofthe

screw.Referto

Figure 15

Withthegasrestrictorinstalled,

asshownin

Figure 13

,allburner

initialsettings(oradjustmentsandgasmanifold

pressure)forpropanewillbethesameasthenatural

gasinitialsettingsshownintheburnermanual,or

printedonthe“Mfr’sSettings”labelontheburner

housing.Foracopyofthecurrentburnermanualgo

to

www.beckettcorp.com/product/cg10-gas-burner

.If

furthertechnicalassistanceisrequired,call800-645-

2876,MondaythruFriday,8AMto5PMEST.

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.High

andLowgaspressureswitchesmustbeinstalledand

wiredinaccordancewithmanufacturer’sinstructions.

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.

See

Figure 17

and

Figure 18

fortypicalwiringdiagramsfor

theCG10-24.

Maximumfusesizeforthe120

Vac60Hzelectricalpowersupply

totheburneris20Amps.

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.

•

Followtheappliancemanufacturer’swiring

diagramsandnoteallrequiredsafetycontrols.

•

Typicalsafetycontrolsincludehightemperature

orpressurelimits,lowwatercutoffs,pressure

reliefvalvesandblockeduesensingswitches.

•

Donottamperwith,orbypass,safetycontrols.

Verifyalllimitandsafetycontrolsareinstalled

andfunctioningcorrectly,asspeciedbythe

manufacturer,applicablesafetystandards,codes

andallauthoritieshavingjurisdiction.

•

Ifasafetycontrolisnotfunctioningproperly,

shutoffallmainelectricalpowerandgas

supplytotheburnerandcallaqualiedservice

agencyimmediately.

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.

Allcoversorserviceaccessplatesmustbeinplaceatall

timesexceptduringmaintenanceandservice.

Thisappliestoallcontrols,panels,enclosures,switches,

andguardsoranycomponentwithacoveraspartof

itsdesign.

Section:WIRETHEBURNER

Figure 16 – 7590 Control

Alarm Module:

For adding isolated low voltage

alarm contacts to the base

control. See Alarm Module

Instructions for specications.

Communication Port 2

Reset Button with Red Light

Communication Port 1

Thermostat Terminals

Green Light

Yellow Light

Optional Component:

Electrical Shock Hazard

Electrical shock can cause severe personal

injury or death.

•

Linevoltageneutralshallnotbeusedasa

substituteforground.

•

Disconnectelectricalpowerbeforeinstallingor

servicingtheburner.

•

Providegroundwiringtotheburner,metal

controlenclosuresandaccessories.A

goodgroundisrequiredtomaintainagood

amesensing.

•

Useagroundfaultinterruptifgroundingofthe

burnercanbecompromised.

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.

•

Thecontrolcanmalfunctionifitgetswet,leading

toaccumulationofgas.

•

Neverinstallwherewatercanood,dripor

condenseonthecontrol.

•

Neveruseacontrolthathasbeenwet-replaceit.

Electromagnetic

Interference

Operationofthisburnerinaresidentialareamay

causeinterference,inwhichcasetheuserwillbe

requiredtocorrecttheinterference.

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Beckett CG10-24 Gas Burner User manual

Beckett CG10-24 Gas Burner User manual

Beckett CG10-24 Gas Burner User manual

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