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  3. CG10-24 Gas Burner
CG10-24 Gas Burner

Beckett CG10-24 Gas Burner User manual

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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
2
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
3
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
4
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.
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.
5
Burner Manual — CG10-24
Section:GENERALINFORMATION
Burner
Model
Dim.
A
Dim.
B*
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
(blankifnotapplicable)
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
A
B
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
6
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
7
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
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
9
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
10
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.
11
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
12
LGPS
HGPS
S
(IFUSED)
DRIP LEG
BURNER
METER
MSC
SSOV1
PRSSOV
MLTC
U
TC
U TCTC
UPGREGULATOR
GAS UTILITY PIPING
FACILITY PIPING
GAS TRAIN
BURNER
ABBREV.
HGPS
LGPS
MSC
MLTC
PG
S
SSOV1
TC
U
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.
13
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
14
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.
15
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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
16
TP
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”
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
TC
TP
U
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
TP
TCTC
HGPS
PRV SSOV1 MLTC
UUMSC
TP
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
17
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
20
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).
H
G
E
F
C
B
A
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
18
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
B
G
F
E
D
A
Figure 14 – Component Locations
C
19
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
20
Figure 16 – 7590 Control
Communication Port 2
Reset Button with Red Light
Communication Port 1
Thermostat Terminals
Green Light
Yellow Light
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.
Alarm Module:
For adding isolated low voltage
alarm contacts to the base
control. See Alarm Module
Instructions for specications.
Optional Component:
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