R02 01/09
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Table of Contents
Hazard Def nitions and Owner’s Information........................................................................................3
Information To Be Used Only By Qualif ed Service Technicians
General Information.........................................................................................................................................4
Table 1 Burner Specification................................................................................................................................4
Notice Special Requirements..............................................................................................................................5
Table 2 Air Tube Combination (ATC) Codes ………………………………………………………….. .....................5
Inspect/Prepare Installation Site.................................................................................................................6
Inspect Chimney or Direct Vent System..............................................................................................................6
Combustion Air Supply........................................................................................................................................7
Clearances to burner and appliance ...................................................................................................................7
Combustion chamber - Burner Retrofitting..........................................................................................................7
Prepare the Burner...........................................................................................................................................8
Low Firing Rate Baffle.........................................................................................................................................8
Burner Fuel Unit ..................................................................................................................................................8
Attach Air Tube....................................................................................................................................................8
Nozzle and Pump Pressure.................................................................................................................................8
Install Burner Nozzle ...........................................................................................................................................8
Check/Adjust Electrodes .....................................................................................................................................9
Servicing nozzle line assembly...........................................................................................................................9
Check/Adjust ‘Z’ Dimension - F Heads .............................................................................................................10
Check/Adjust ‘Z’ Dimension - L & V Heads ....................................................................................................... 11
Mount burner on appliance...........................................................................................................................9
Mounting Options ................................................................................................................................................9
Mounting Dimensions..........................................................................................................................................9
Installing the Oil Tank & Supply System............................................................................................................12
Fuel Line Valves & Filter....................................................................................................................................12
Wire Burner .......................................................................................................................................................13
Burner Packaged with Appliance.......................................................................................................................13
Burner Installed at Job Site ...............................................................................................................................13
Special Wiring Required with Covered Burners ................................................................................................13
Burner Control .................................................................................................................................................14
GeniSys Model 7505 Control ............................................................................................................................14
Wiring ................................................................................................................................................................14
Typical Burner Sequence of Operation for GeniSys 7505 Control....................................................................15
Typical Burner Sequence of Operation for R7184P Control..............................................................................17
Start-up Burner/Set Combustion..............................................................................................................18
Startup/checkout ...............................................................................................................................................19
Set Combustion with Instruments......................................................................................................................19
Perform Regular Maintenance...................................................................................................................20
Parts Diagram...................................................................................................................................................22
Beckett Limited Warranty Information ...................................................................................................24
Page 2
6104BAFG R06
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General Information
Hazard Definitions
WARNING
Owner’s Responsibility
Indicates a hazardous situ-
ation, which, if not avoided,
will result in death or serious injury.
!
!
DANGER
Incorrect installation, adjustment,
and use of this burner could result in
severe personal injury, death, or sub-
stantial property damage from fire,
Indicates a hazardous
!
carbon monoxide poisoning, soot or explosion.
WARNING
situation, which, if not
avoided, could result in death or serious
injury.
Contact a professional, qualified service agency for the
installation, adjustment and service of your oil heating
system. This work requires technical training, trade ex-
perience, licensing or certification in some states and the
proper use of special combustion test instruments.
Indicates a hazardous
situation, which, if not
avoided, could result in minor or moderate
injury.
!
CAUTION
Please carefully read and comply with the following
instructions:
y Never store or use gasoline or other flammable
liquids or vapors near this burner or appliance.
y Never attempt to burn garbage or refuse in this
appliance.
y Never attempt to light the burner/appliance by
throwing burning material into the appliance.
y Never attempt to burn any fuel not specified and
approved for use in this burner.
Within the boundaries of the hazard warning, there will
be information presented describing consequences if the
warning is not heeded and instructions on how to avoid
the hazard.
NOTICE
Intended to bring special attention to
information, but not related to personal injury or property
damage.
y Never restrict the air inlet openings to the burner
or the combustion air ventilation openings in the
room.
NOTICE
This manual contains information that applies to both AF and AFG burners. These burners may
appear to be basically identical, but there are differences in design and performance. Please review the comparison
chart below:
Feature
AF
AFG
Static Pressure Capability
Blower Wheel Design
Conventional - Low range
Standard strip
Enhanced - Medium range
Special tablock
Inlet Airflow Design
Standard inlet bell
“F” Series ONLY
Optional, as specified
Not required
Special airguide
UL Air Tube Combinations
Igniter Gaskets Baseplate/Barrier
Low Firing Rate Baffle
“F” or “M” Series
Required, always specified
Required, per specification
Figure 1. Burner label location
6104BAFG R06
Page 3
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General Information
Impaired Burner Perfor-
mance and Fire Hazard.
Do NOT operate the burner beyond specif ca-
tions outlined in the following Table.
To the Owner:
!
WARNING
Thank you for purchasing a Beckett burner
for use with your heating appliance. Please pay at-
tention to the Safety Warnings contained within this
instruction manual. Keep this manual for your records
and provide it to your qualified service agency for use
in professionally setting up and maintaining your oil
burner.
y For applications beyond these limits, consult
Beckett Technical Service at 1-800-645-2876.
y NOTE: Some packaged appliances with burners
may be agency listed as a unit to operate beyond
these limits. Consult the appliance manufac-
turer’s specifications and agency approvals for
verification.
Your Beckett burner will provide years of efficient op-
eration if it is professionally installed and maintained
by a qualified service technician. If at any time the
burner does not appear to be operating properly, im-
mediately contact your quali f ed service agency
for consultation.
Table 1 – Burner Specif cations
‘F’ Head (AF & AFG)
(Note 1) Firing rate range: ..............0.40 – 3.00 GPH
Capacity
Input: ....................... 56,000 – 420,000 Btu
We recommend annual inspection/service of your
oil heating system by a qualif ed service agency.
‘L1’ Head (AFG Only)
Firing rate range: ..................0.40 - 1.10 GPH
Input: ..................... 56,000 – 154,000 Btu/h
Daily – Check the room in which your burner/appli-
ance is installed. Make sure:
• Air ventilation openings are clean and unobstruct-
ed
• Nothing is blocking burner inlet air openings
• No combustible materials are stored near the heat-
ing appliance
• There are no signs of oil or water leaking around
the burner or appliance
‘L2’ Head (AFG Only)
Firing rate range: .................0.50 - 1.00 GPH
Input: ...................... 70,000 – 140,000 Btu/h
‘V1’ Head (AFG Only)
Firing rate range: .................0.75 - 2.75 GPH
Input: .................... 105,000 – 385,000 Btu/h
Certifications/ UL listed to comply with ANSI/UL296 and CSA-B140.0
Approvals
Fuels
U. S No. 1 or No. 2 heating oil only (ASTM D396)
Canada No. 1 stove oil or No. 2 furnace oil only
Weekly
• Check your oil tank level. Always keep your oil tank
full, especially during the summer, in order to pre-
vent condensation of moisture on the inside surface
of the tank.
CAUTION
!
DO NOT USE GASOLINE, CRANKCASE OIL,
OR ANY OIL CONTAINING GASOLINE.
Electrical
Power supply:............ 120 volts AC, 60 Hz single phase
Operating load: .......... Amps max
Do NOT Alter the Original
Burner Design
WARNING
Motor: .........................1/7 hp, 3450 rpm, NEMA 48M frame
PSC rotation CCW when facing
!
shaft end
Tampering with or altering the burner design
could seriously impair performance, resulting
in loss of static pressure, damage to the system
components, reduced air volume, heavy smoke,
flame impingement, appliance sooting, hot gas
puff-back, and asphyxiation or fire hazards.
Maintain the design to its original configuration.
Only use parts specified for AF or AFG Burners
Do NOT remove the air guide from the AFG chassis.
Do NOT use ‘M’ Series air tube combinations on AF Burn-
ers.
Ignition: ......................Continuous duty solid-state igniter
Fuel pump
Air tube
Outlet pressure: ..................................Note 2
ATC code: ...................................See Table 2
Dimensions
(with cover)
Height (maximum) ....................... 12.5 inches
Width (maximum) .......................... 15 inches
Depth ......................................... 9.25 inches
Air tube diameter ....................... 4.00 inches
o
Ambient
Operating
+32 F. (0 C.) Minimum
o
+115 F. (+46 C.) Maximum
Temperature (See above Warning)
Never try to convert an AF to an AFG or vice versa
Any design alteration will:
Moisture 5% to 95% RH, non-condensing and non-crystallizing
Note 1: Approval agency listed rating for these burners is 0.40 to 3.00
y Void UL Listing
gph. However, the firing rate range is limited by the specific
air tube combination being used. Refer to Table 2.
Note 2. See appliance manufacturer’s burner specifications for rec-
ommended pump discharge pressure.
y Void manufacturer’s warranties
y Seriously impact burner performance
y Greatly increase your liability risk
Page 4
6104BAFG R06
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General Specifications
Table 2 – Air Tube Combination (ATC) codes
Firing
Rate
(gph)
Head
Static
plate
size
Ven-
turi
ATC Codes for usable air tube lengths
(‘A’ in inches; See Figure 3.)
(min-
max)
(inches)
4-1/2
5
5-3/8
6-5/8
7
7-1/4
9
10-1/2
13
16
0.50-0.75
0.75-1.25
0.85-1.35
0.85-1.65
1.10-2.00
1.65-2.50
2.50-3.00
0.50-1.10
0.50-1.00
0.75-2.75
0.40-0.75
F0
F3
3-3/8U
2-3/4U
2-3/4U
2-3/4U
2-3/4U
2-3/4U
None
None
None
AF44XR
AF44XN
-
AF53XR
AF53XN
AF65XR
AF65XN
-
AF72XR
AF72XN
AF72WH
AF72YB
AF72XO
AF72XP
AF72XS
-
AF90XR
AF90XN
AF90WH
AF90YB
AF104XR
AF104XN
AF130XR
AF130XN
A160XR
-
-
AF160XN
F4
None AF44WH
-
AF53WH AF65WH
-
AF104WH AF130WH AF160WH
F6
None
None
None
None
8hole
8hole
8hole
AF44YB
AF44XO
AF44XP
AF44XS
-
-
AF53YB
AF65YB
-
AF104YB
AF130YB
AF160YB
F12
F22
F31
L1
-
AF53XO
AF65XO
-
AF90XO
AF90XP
AF104XO
AF130XO
AF160XO
-
AF53XP
AF56XP
-
AF104XP
AF130XP
AF160XP
-
AF53XS
AF65XS
-
AF90XS
AF104XS
AF130XS
AF160XS
3-3/8U
2-3/4U
2-3/4U
3-1/2U
AFG50MB
AFG50MP
AFG50MD
-
-
-
-
-
-
-
AFG70MB
AFG70MP
AFG70MD
-
AFG90MB
AFG90MP
AFG90MD
AF90WG
-
-
-
-
-
-
-
L2
-
-
V1
F0
-
-
-
None AF44WG
AF53WG AF65WG
AF72WG
AF104WG AF130WG
A160WG
Notice Special Requirements
Professional Service
Required
Incorrect installation, adjustment,
and use of this burner could result
in severe personal injury, death, or
substantial property damage from
WARNING
y THE INSTALLATION OF A BURNER SHALL BE
IN ACCORDANCE WITH THE REGULATIONS
OF AUTHORITIES HAVING JURISDICTION.
y For recommended installation practices in the
U.S. refer to the latest edition of NFPA 31. (CSA-
B139 and CSA-B140 in Canada.
!
fire, carbon monoxide poisoning, soot or explo-
y
Concealed damage — If you discover damage to
the burner or controls during unpacking, notify the sion.
carrier at once and file the appropriate claim.
When contacting Beckett for service information
— Please record the burner serial number (and
have available when calling or writing). You will
find the serial number on the silver label located
on the left rear of the burner. Refer to Figure 1.
Please read and understand the manual supplied with
this equipment. This equipment must be installed, ad-
justed and put into operation only by a qualified individu-
al or service agency that is:
y
y Licensed or certified to install and provide tech-
nical service to oil heating systems.
y Experienced with all applicable codes, standards
and ordinances.
y Responsible for the correct installation and com-
mission of this equipment.
y Skilled in the adjustment of oil burners using
combustion test instruments.
The installation must strictly comply with all applicable
codes, authorities having jurisdiction and the latest revi-
sion of the National Fire Protection Association Standard
for the installation of Oil-burning Equipment, NFPA 31
(or CSA-B139 and CSA-B140 in Canada).
Regulation by these authorities take precedence over
the general instructions provided in this installation
6104BAFG R06
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Inspect/Prepare Installation Site
Inspect Chimney or Direct Vent System
5. No other appliance connection should be made to
the same flue pipe.
6. The flue pipe should have an upward pitch toward
the chimney of at least 1/4” per foot of length. It
should fit tightly and should not project into the
chimney.
7. Any leakage between tiles, around clean-out
doors, or around the vent pipe should be sealed.
Fire, Smoke & Asphyxia-
tion Hazard
y Carefully inspect the chimney or exhaust vent
system.
y Make sure it is properly sized and in good work-
ing condition.
WARNING
!
y Follow the instructions supplied by the appliance
manufacturer.
INSULATED STAINLESS STEEL CHIMNEY LINERS
y The installation must strictly comply with all ap-
plicable codes, authorities having jurisdiction and
the latest revision of the National Fire Protection
Association Standard NFPA 31 for the installa-
tion of chimneys and vent sizing, (or CSA-B139
and CSA-B140 in Canada).
y Regulation by these authorities take precedence
over the general instructions provided in this in-
stallation manual.
The new designs of high efficiency oil furnaces
and boilers in conjunction with flame retention oil
burners are more efficient. One result of increased
efficiency is lower flue gas temperatures. As
flue gases rise in the chimney, they will cool and
condense when they reach the dew point. The
condensation will mix with the sulphur in the flue
gases creating sulphuric acid. The acid will attack
the chimney mortar, brick and clay liners caus-
ing corrosion, deterioration and blockage of the
chimney. Eventually the blockage could prevent
exhausting the flue gases. Instead, the flue gases
could vent out the barometric damper into the liv-
ing space.
1. Starting with minimum gph firing rate, the mini-
mum size recommended is 6” flue pipe with 8” X
8” inside chimney, unless specified otherwise by
the appliance manufacturer.
2. A chimney flue 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 Fig-
ure 2.
Therefore, it is strongly recommended that an ap-
proved insulated stainless steel liner be installed.
y For those installations not requiring a chimney,
such as through-the-wall vented appliances, fol-
low the instructions given by the appliance and
power venter (if used) manufacturers.
3. Any accumulation of soot or debris in chimney
offsets should be removed
4. Any obstructions such as a protruding joint or a
piece of broken tile wedged in the chimney should
be removed.
Figure 2 – Chimney Design - Above the Roof
NOTE: Correct
chimney design is
shown by dotted
lines. Incorrect
chimney design,
as shown by the
solid lines, may
result in down-
drafts.
Page 6
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Inspect/Prepare Installation Site
Combustion air supply
Adequate Combustion
Outside air kit applications
Refer to separate instruction sheet supplied with
AF/AFG outside air kit for installation. This optional
kit allows combustion air to be piped directly to the
burner (Beckett part number 51747).
WARNING
and Ventilation Air Supply
Required
!
Failure to provide adequate air supply could
seriously affect the burner performance and re-
sult in damage to the equipment, asphyxiation,
explosion or fire hazards.
Clearances to burner and appliance
y Provide space around burner and appliance for
easy service and maintenance.
y Check minimum clearances against those shown
by the appliance manufacturer and by applicable
building codes.
y The burner cannot properly burn the fuel if it is not
supplied with a reliable combustion air source.
y Follow the guidelines in the latest editions of the
NFPA 31 and CSA-B139 regarding providing ad-
equate air for combustion and ventilation.
Protect Steel Combustion
Chamber From Burnout
WARNING
!
Appliance located in confined space
Failure to comply could result in damage to the
heating equipment and result in fire or asphyxi-
ation hazards.
The confined space should have two (2) permanent
openings: one near the top of the enclosure and
one near the bottom of the enclosure. Each open-
ing shall have a free area of not less than (1) one
square inch per 1,000 BTU’s per hour of the total
input rating of all appliances within the enclosure.
The openings shall have free access to the build-
ing interior, which should have adequate infiltration
from the outside.
y When retrofitting appliances that have unlined
stainless steel combustion chambers, protect
the chamber by lining the inside surfaces with a
ceramic fiber blanket, such as a wet-pac or other
suitable refractory material.
y Some steel chambers may not require liners
because the appliance was designed and tested
for use with flame retention burners. Refer to the
manufacturer’s instructions.
Exhaust fans and other air-using devices
Size air openings large enough to allow for all air-
using devices in addition to the minimum area re-
quired for combustion air. If there is any possibility
of the equipment room developing negative pres-
sure (because of exhaust fans or clothes dryers, for
example), either pipe combustion air directly to the
burner or provide a sealed enclosure for the burner
and supply it with its own combustion air supply.
Combustion chamber — Burner retrof t-
ting
Verify that the appliance combustion chamber pro-
vides at least the minimum dimensions given in
Table 3.
Direct air supply and sidewall venting
y Some AFG burners are equipped with combus-
tion air boots to allow use of outside air for com-
bustion.
Table 3. Chamber Dimensions
Chamber Dimensions (inches)
y When sidewall venting appliances, carefully fol-
low appliance and power venter instructions for
installation and wiring.
Firing Rate Round
Rectangular
Width Length
Height Floor to
nozzle
(GPH)
I.D.
0.50
0.75
1.00
1.25
1.50
2.00
2.50
3.00
8
7
8
12
12
5-6
5-6
5-6
5-6
6-7
6-7
7-8
7-8
9
8
9
10
11
12
14
16
18
9
10
11
12
15
17
18
12.5
12.5
13
Follow the Outside Air Kit
Instructions Exactly
WARNING
!
10
11
12
13
14
Failure to comply could result in impaired com-
bustion, appliance soot-up, puffback of smoke,
and fire or asphyxiation hazards.
13.5
14
y Do not attempt to install outside air piping to
the burner without using the outside air kit and
instructions.
15
6104BAFG R06
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Inspect/Prepare Installation Site
Prepare the Burner
Table 4. AFG Reduced Firing Rates (with
LFRB)
Low Firing Rate Baff e
Burner head type
Low Firing Rate Baffle installed
up to 0.65 gph
The AFG Low Firing Rate Baffle (LFRB) reduces
the air flow and pressure. The LFRB is sometimes
used for firing rates under 1.00 gph as listed in
Table 4. Refer to the appliance manufacturer’s in-
structions. Do not omit the LFRB when specified.
Omitting the baffle when specified or installing the
baffle when not specified could result in impaired
burner performance.
F0
F3 or L1
F4 or F6
V1
up to 0.85 gph
up to 0.90 gph
up to 1.00 gph
Table 5. Nozzle Flow Rate by Size
Nozzle f ow rate U. S. gallons per hour of No. 2 fuel oil when
pump pressure (psig) is:
Burner fuel unit
Nozzle
size
(rated at
100 psig)
125
psi
140 psi
150 psi
175 psi
200 psi
y Verify that the burner fuel unit is compatible with
the oil supply system. For more details, refer to
the pump manufacturer’s instructions provided
with the burner.
0.40
0.50
0.60
0.65
0.75
0.85
0.90
1.00
1.10
1.20
1.25
1.35
1.50
1.65
1.75
2.00
0.45
0.56
0.67
0.73
0.84
0.95
1.01
1.12
1.23
1.34
1.39
1.51
1.68
1.84
1.96
2.24
0.47
0.59
0.71
0.77
0.89
1.01
1.07
1.18
1.30
1.42
1.48
1.60
1.77
1.95
2.07
2.37
0.49
0.61
0.74
0.80
0.92
1.04
1.10
1.23
1.35
1.47
1.53
1.65
1.84
2.02
2.14
2.45
0.53
0.66
0.79
0.86
0.99
1.13
1.19
1.32
1.46
1.59
1.65
1.79
1.98
2.18
2.32
2.65
0.56
0.71
0.85
0.92
1.06
1.20
1.27
1.41
1.56
1.70
1.77
1.91
2.12
2.33
2.48
2.83
Attach air tube (if not already installed)
If using a flange and gasket, slide them onto the air
tube. Then attach the air tube to the burner chassis
using the four sheet metal screws provided. Refer
to Figure 4 for details.
Nozzle and Pump Pressure
Correct Nozzle and Flow
WARNING
!
Rate Required
Incorrect nozzles and flow rates
could result in impaired combus-
tion, under-firing, over-firing, soot-
ing, puff-back of hot gases, smoke
and potential fire or asphyxiation hazards.
2.25
2.50
2.52
2.80
2.66
2.96
2.76
-
2.98
-
-
-
Use only nozzles having the brand, flow rate (gph), spray
angle and pattern specified by the appliance manufac-
turer.
Follow the appliance manufacturer’s specifications for
the required pump outlet pressure for the nozzle, since
this affects the flow rate.
Install burner nozzle (if not already in-
stalled)
1. Remove the plastic plug protecting the nozzle
adapter threads
y Nozzle manufacturers calibrate nozzle flow rates
at 100 psig.
2. Place a 3/4” open-end wrench on the nozzle
adapter. Insert the nozzle into the adapter and fin-
ger tighten. Finish tightening with a 5/8” open-end
wrench. Use care to avoid bending the burner head
support legs or electrodes. If you remove the head
to replace the nozzle (type “L1”/“L2” or “V1” heads),
carefully reconnect the head to the nozzle adapter,
making sure that the head support makes contact
with the nozzle adapter shoulder. Refer to Figure
5 or 6.
y When pump pressures are higher than 100 psig,
the actual nozzle flow rate will be greater than
the gph stamped on the nozzle body. (Example:
A 1.00 gph nozzle at 140 psig = 1.18 gph)
Securely tighten the nozzle (90 torque inch pounds). For
typical nozzle flow rates at various pressures refer to
Table 5.
Page 8
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Prepare the Burner
3. If the nozzle is already installed, remove the noz-
zle line assembly to verify that the nozzle size and
spray pattern are correct for the application (per ap-
pliance manufacturer’s information). Verify that the
electrode tip settings comply with Figure 3.
4. If the nozzle is not installed, obtain a nozzle from
the manufacturer, having the capacity and spray
angle specified in the appliance manufacturer’s in-
formation. For conversions or upgrades, when in-
formation is not available for the application:
y Refer to Table 6 to select the mid-range nozzle
spray angle for the head type being used.
Figure 3. – Electrode Tip Adjustment
Standard Dimensions for F, L1, and V1 Heads.
y Fire the burner and make sure the combustion
is acceptable and the flame is not impinging on
chamber surfaces.
y If a shorter flame is needed, select a wider spray
angle. If a longer flame is needed, select a nar-
rower spray angle.
The Dimensions shown below are for use with L2 heads
and M series air tube combinations ending with an ‘N’ suf-
fix (example: AFG70MDAQN)
y Either hollow or solid spray patterns may be used.
If combustion results are not satisfactory with the
selected spray pattern, try the other pattern.
Table 6. Nozzle Spray Angles
Recommended nozzle spray angles
“F” head
“L1” & “L2” head
“V1” head
70° or 80° nozzle
45°, 60°, or 70° nozzle
45°, 60°, or 70° nozzle
Mount burner on appliance
Check/adjust electrodes
Check the electrode tip settings. Adjust if neces-
sary to comply with the dimensions shown in Fig-
ure 3. To adjust, loosen the electrode clamp screw
and slide/rotate electrodes as necessary. Securely
tighten the clamp screw when finished.
Mounting options
1. Bolt the burner to the appliance using the fac-
tory-mounted flange or an adjustable flange.
Mounting dimensions
Servicing nozzle line assembly
1. Turn off power to burner before proceeding.
2. Disconnect oil connector tube from nozzle line.
3. Loosen the two screws securing igniter retain-
ing clips and rotate both clips to release igniter
baseplate. Then tilt igniter back on its hinge.
4. Remove splined nut.
1. When using the Beckett universal adjustable
flange, mount the air tube at a 2° downward
pitch unless otherwise specified by the appli-
ance manufacturer.
2. Verify that the air tube installed on the burner
provides the correct insertion depth. See Fig-
ure 7.
5. “F” head air tube. - Remove nozzle line as-
sembly from burner, being careful not to
damage the electrodes or insulators while
handling. To ease removal of long assemblies
(over 9 inches), rotate assembly 180° from
installed position after pulling partially out of
tube.
6. “L1”, “L2”, and “V1” head air tubes. - Slide
nozzle line assembly forward (further into air
tube) so the head clears the venturi opening.
Then rotate the nozzle line assembly 90° so
the nozzle line end points up. Pull the nozzle
line assembly toward you and remove assem-
bly from burner.
3. The end of the air tube should normally be ¼”
back from the inside wall of the combustion
chamber. Never allow the leading edge of the
head assembly to extend into the chamber, un-
less otherwise specified by the heating appli-
ance manufacturer. Carefully measure the in-
sertion depth when using an adjustable flange.
Verify the insertion depth when using a welded
flange.
7. To replace the nozzle assembly, reverse the
above steps.
6104BAFG R06
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Prepare the Burner
Figure 4. Check/Adjust ‘Z’ Dimension for ‘F’ Heads
1-1/8”
1-3/8”
Adjust the ‘Z’ dimen-
sion to the required
specif cation.
Incorrect Adjustments could cause combus-
tion problems, carbon deposition from flame
impingement, heavy smoke generation and
fire hazard.
WARNING
!
y Make all adjustments exactly as outlined in
the following information.
Check/Adjust ‘Z’ Dimension - ‘F’ heads
Burner Dimensions
1. The important ‘Z’ dimension is the distance from the face of the nozzle
to the flat face of the head (or heat shield, if applicable). This dis-
tance for F heads is 1-⅛” (1-⅜” if the air tube has a heat shield). The
“Z” dimension is factory set for burners shipped with the air tube in-
stalled. Even if factory set, verify that the “Z” dimension has not been
changed.
For usable length A (inches)
F Head
L1
L2
V1
Dimension (inches)
Head
Head
Head
1/4
7/32
1/4
N/A
H (nozzle to head), +1/32
L (Total tube length)
2. Use the following procedure to adjust the “Z” dimension, if it is not
correct:
A+1/2
A+1/2
A+1/2
A+1/2
A+2-1/4
(Note 1)
A+1-1/8 A+1-1/8 A+1-1/8
R (electrode length), + 1/4
y
y
y
Turn off power to the burner.
Disconnect the oil connector tube from the nozzle line
See above figure. Loosen the splined nut from the nozzle line.
Loosen the hex head screw securing the escutcheon plate to the
burner housing.
1-3/8
1-3/8
1-3/8
S (adapter to static plate), +
1/16
A+ 15/16
A+ 3/16
A+ 3/16
A+ 3/16
Q (nozzle line length),
y
Place the end of a ruler at the face of the nozzle and, using a
straight edge across the head, measure the distance to the face of
the head. A Beckett T501 gauge may also be used.
Slide the nozzle line forward or back until this dimension for F
heads is 1-⅛” (1-⅜” to the face of the heat shield, if applicable).
Tighten the hex head screw to secure the escutcheon plate to the
burner chassis. Then tighten the splined nut and attach the oil con-
nector tube.
1-1/8
1-3/8
N/A
N/A
N/A
N/A
N/A
N/A
Z (F head-no heat shield)
(F head-with heat shield)
N/A
N/A
1-3/8
1-3/4
N/A
1-3/4
N/A
1-3/4
Z (L1 head w/straight
shroud) (L1/L2/V1 head
w/conic shroud)
y
y
Note 1: 1-3/8 for dimension A less than 4”; 1-5/8 for dimension A from 4”
through 4-1/2 “, 2-13/32 for dimension A greater than 4-1/2”.
3. Recheck the “Z” dimension periodically when servicing to ensure the
escutcheon plate has not been moved. You will need to reset the “Z”
dimension if you replace the air tube or nozzle line assembly. The
Beckett Z gauge (part number Z-2000) is available to permit checking
the F head “Z” dimension without removing the burner from the appli-
ance.
Page 10
6104BAFG R06
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Prepare the Burner
burners shipped with the air tube installed. Even if factory set, verify
that the “Z” dimension has not been changed.
2. Use the following procedure to adjust the “Z” dimension, if it is not
correct:
Figure 5. Check/Adjust ‘Z’ Dimension - L1 &
L2 Heads
y
y
y
Turn off power to the burner.
Disconnect the oil connector tube from the nozzle line.
Refer to figure. Loosen the splined nut from the nozzle line.
Loosen the hex head screw securing the escutcheon plate to the
burner housing.
y
Place the end of a ruler at the leading edge of the head and, us-
ing a straight edge across the end of the air tube, measure the
distance to the end of the tube. A Beckett T501 gauge may also
be used.
y
y
Slide the nozzle line forward or back until this dimension is 1-⅜”
for L1 & L2 heads if the tube has a straight shroud, or 1-¾” if the
air tube has a conic shroud.
Tighten the hex head screw to secure the escutcheon plate to
the burner chassis. Then tighten the splined nut and attach the
oil connector tube.
L1/L2 heads (see Table 7 and Figure 3 for dimensions)
1. See figure above. The important “Z” dimension is the distance from
the leading edge of the head to the end of the air tube. This distance
for L1 & L2 heads is 1-⅜” if the tube has a straight shroud or 1-¾” if
the air tube has a conic shroud. The “Z” dimension is factory set for
3. Recheck the “Z” dimension periodically when servicing to ensure
the escutcheon plate has not been moved. You will need to reset
the “Z” dimension if you replace the air tube or nozzle line assem-
bly.
2. Use the following procedure to adjust the “Z” dimension, if it is not
correct:
Figure 6. Check/Adjust ‘Z’ Dimension - V1
Heads
y
y
y
Turn off power to the burner.
Disconnect the oil connector tube from the nozzle line.
See figure above. Loosen the splined nut from the nozzle line.
Loosen the hex head screw securing the head adjusting plate to
the burner housing.
y
Loosen the acorn nut. Move the head adjusting plate until the “0”
lines up with the reference indicator on the housing, and retighten
the hex head screw. Place the end of a ruler at the leading edge of
the head and, using a straight edge across the end of the air tube,
measure the distance to the end of the tube. A Beckett T501 gauge
may also be used.
y
y
Slide the nozzle line forward or back until this dimension is 1-¾” for
V1 heads. Tighten the acorn nut.
Tighten the hex head screw to secure the head adjusting plate to
the burner chassis. Then tighten the splined nut and attach the oil
connector tube.
V1 heads (see Table below and Figure above for dimensions)
1. See figure above. The important “Z” dimension is the distance from
the leading edge of the head to the end of the air tube. This distance
for V1 heads is 1-¾”. The “Z” dimension is factory set for burners
shipped with the air tube installed. Even if factory set, verify that the
“Z” dimension has not been changed.
3. Recheck the “Z” dimension periodically when servicing to ensure the
escutcheon plate has not been moved. You will need to reset the “Z”
dimension if you replace the air tube or nozzle line assembly.
Table for initial adjusting plate settings for V1
Head
Set head position adjusting plate (V1 head only)
V1 Adjusting
Plate Setting
AFG with V1
Head
1. After setting “Z” dimension, loosen head adjusting plate hex head
screw and nozzle line splined nut. Move the nozzle line assembly until
the burner reference indicator lines up with the head adjusting plate
setting number given in Table shown below.
Burner Firing
Rates
2. Tighten the hex head screw and splined nut. (DO NOT loosen the
acorn nut when setting head position.) Refer to the manufacturer’s in-
structions for OEM settings.
3. The position of the head affects air flow volume and pattern. For most
applications, the burner will perform satisfactorily with the air adjust-
ment plate setting of Table shown below.
4. If combustion results indicate the need for change, adjust the head po-
sition adjusting plate forward or back one position at a time to optimize
combustion.
0
1
2
3
4
5
6
0.75-1.00
1.00-1.50
1.50-1.75
1.75-2.00
2.00-2.25
2.25-2.50
2.50-2.75
6104BAFG R06
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Mount burner on appliance
Figure 8. – Inside Tank Gravity Feed System
Figure 7. – Mounting Burner in Appliance
If space between burner
air tube and opening
exceeds 1/2 inch, pack
burner opening with ce-
ramic fiber refractory.
Tilt down 2o
SK8745
Installing the Oil Tank and Supply System
Oil Leak and Fire Hazard
WARNING
!
Figure 9. – Outside Buried Tank-Lift System
Install the oil tank following applicable stan-
dards in the U.S. by referring to the latest
edition of NFPA 31 or CSA-B139 & CSA-B140
in Canada, and all authorities having jurisdic-
tion.
Do Not Use Tef on Tape
CAUTION
!
Damage to the pump could cause impaired
burner operation, oil leakage and appliance
soot-up.
y Never use Teflon tape on fuel oil fittings.
y Tape fragments can lodge in fuel line compo-
nents and fuel unit, damaging the equipment
and preventing proper operation.
NOTICE
To further protect the fuel supply sys-
tem and reduce nozzle orifice plugging with firing rates
below 0.75 gph, a dual filtration system can be installed.
This typically consists of a 50 micron primary filter,
located near the fuel tank and a secondary filter rated for
at least 10 microns located near the burner.
y Use oil-resistant pipe sealant compounds.
Note: to determine the proper fuel line size, refer
to the fuel pump manufacturer’s instructions pro-
vided with the burner. Refer to Figure 8 or Figure 9
for typical installation layouts.
Fuel supply level with or above burner –
Fuel Line Valves and Filter
Do Not Install By-pass Plug
with 1-Pipe System
WARNING
Install two high quality, oil duty rated, fusible
handle design shutoff valves in accessible loca-
tions on the oil supply line. Locate one close to the
tank and the other close to the burner, upstream of
the filter for service access.
!
Failure to comply could cause Immediate pump
seal failure, pressurized oil leakage and the
potential for a fire and injury hazard.
Install a generous capacity filter inside the building
between the fuel tank shutoff valve and the burner,
locating both the filter and the valve close to the
burner for ease of servicing. Filter should be rated
for 50 microns or less.
y The burner is shipped without the by-pass plug
installed.
y Install the by-pass plug in two-pipe oil supply
systems ONLY.
Page 12
6104BAFG R06
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Wire burner
Wire burner
Oil Supply Pressure
Control Required
CAUTION
!
Burner packaged with appliance
Damage to the filter or pump seals could cause
oil leakage and a fire hazard.
WARNING
y The oil supply inlet pressure to the burner can-
not exceed 3 psig.
y Insure that a pressure limiting device is installed
in accordance with the latest edition of NFPA 31.
y Do NOT install valves in the return line.
(NFPA 31, Chapter 8.)
y Gravity Feed Systems: Always install an anti-
siphon valve in the oil supply line or a solenoid
valve (RWB Part # 2182602U) in the pump/noz-
zle discharge tubing to provide backup oil flow
cut-off protection.
Electrical Shock Hazard
!
Electrical shock can cause severe
personal injury or death.
y Disconnect electrical power before installing or
servicing the burner.
y Provide ground wiring to the burner, metal con-
trol enclosures and accessories. (This may also
be required to aid proper control system opera-
tion.)
y Perform all wiring in compliance with the Na-
tional Electrical Code ANSI/NFPA 70 (Canada
CSA C22.1)
The burner may be equipped with a single-stage
fuel unit for these installations. Connect the fuel
supply to the burner with a single supply line if you
want a one-pipe system (making sure the bypass
plug is NOT installed in the fuel unit.) Manual bleed-
ing of the fuel unit is required on initial start-up. If
connecting a two-pipe fuel supply, install the fuel
unit bypass plug.
y Refer to appliance manufacturer’s wiring diagram
for electrical connections.
Burner installed at jobsite
y Refer to Figures 11a and 11b, for typical burner
wiring, showing cad cell primary controls. Burner
wiring may vary, depending on primary control
actually used.
y Refer to the appliance manufacturer’s wiring dia-
gram prior to connecting the burner wiring. All wir-
ing must be in accordance with the latest revision
of National Electric Code NFPA 70 and all local
codes and regulations. In Canada, all wiring is
to be in accordance with the Canadian Electrical
Code, Part 1.
Fuel supply below the level of the burner –
When the fuel supply is more than eight feet below
the level of the burner, a two-pipe fuel supply sys-
tem is required. Depending on the fuel line diam-
eter and horizontal and vertical length, the instal-
lation may also require a two-stage pump. Consult
the fuel unit manufacturer’s literature, included with
the burner, for lift and vacuum capability.
Fuel line installation –
y Continuous lengths of heavy wall copper tubing
are recommended. Always use f are f ttings.
Never use compression f ttings.
The 7505 primary control with valve-on delay (pre-
time) and burner motor-off delay (post-time) re-
quires a constant 120 volts AC power source sup-
plied to the BLACK wire on the control. The RED
wire goes to the appliance limit circuit. Please note
that other control manufacturers may use different
wire colors for power and limit connections.
y Always install fittings in accessible locations.
Proper routing of fuel lines is required to prevent
air cavitation and vibration.
Frozen Plumbing and
Water Damage Hazard
Special wiring required with covered
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.
burners
The mounting plate is not a conduit connec-
tion point. Pass conduit and attached connector
through the opening in the mounting plate and at-
tach it directly to the burner-mounted 4x4 electrical
box.
If attaching a burner cover to a previously installed
burner, attach the mounting plate and then slide the
conduit into the “J” shaped conduit slot.
6104BAFG R06
Page 13
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Burner Controls
GeniSys Model 7505 Control
Wiring
Explosion, Fire, Scald,
and Burn Hazard
Fire or Explosion 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.
Can cause severe injury, death, or
property damage.
y The control can malfunction if it gets wet,
leading to accumulation of oil or explosive oil
vapors.
y Never install where water can flood, drip or
condense on the control.
y Follow the appliance manufacturer’s wiring
diagrams and note all required safety controls.
y Typical safety controls include high temperature
or pressure limits, low water cutoffs, pressure
relief valves and blocked flue sensing switches.
y Verify all limit and safety controls are installed
and functioning correctly, as specified by the
manufacturer, applicable safety standards,
codes and all authorities having jurisdiction.
y Ensure that the appliance is free of oil and oil
vapor before starting or resetting the burner.
y
Never use a control that has been wet - replace it.
Features
• Thermostat / Operating and Limit Control Compatible
• Welded Relay Protection
• Limited Recycle
• Limited Reset
• 3 Status Lights
• Valve-On Delay / Motor-Off Delay (Field
programmable with 52067 GeniSys Display)
• 15 Second Lockout Time
• Interrupted or Intermittent Duty Ignition
• Technician Pump Priming Mode
• Disable Function
Incorrect Wiring Will Re-
sult in Improper Control
Operation
y GeniSys wiring label colors may not match the
wire colors of the burner or other manufacturers’
controls.
y The GeniSys Control should be wired according
to the appliance manufacturer’s instructions.
• Cad Cell Resistance Indicator
• Communication Ports
Figure 10.
Yellow Light
Green Light
Reset Button
with Red Light
Wiring
Connections
Communication Port 2
Communication Port 1
Cad Cell
Connections
Thermostat Terminals
Alarm Module:
For adding isolated
low voltage alarm
contacts to the base
control. See Alarm
Module Instructions for
specifications.
Display Module:
For programming and
diagnostics
Page 14
6104BAFG R06
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Burner Controls
Typical Burner Sequence of Operation for GeniSys 7505 Control.
Refer to the appliance manufacturer’s wiring diagram for actual specifications.
9
1
3
5
6
Pump
prime
Standby
4
2
Trial for
ignition
Lockout
Valve-on delay
Ignition carryover
7
8
Recycle
Run
Motor-off delay
6. Run: The flame is sustained until the call for heat
is satisfied. The burner is then sent to Motor-Off
Delay, if applicable, or it is shut down and sent to
Standby.
1. Standby: The burner is idle, waiting for a call for
heat.
2. Valve-On Delay: The igniter and motor are on while
the control delays turning on the oil solenoid valve
for the programmed time.
7. Recycle: If the flame is lost while the burner is
firing, the control shuts down the burner, enters a
60 second recycle delay, and repeats the ignition
sequence. The control will continue to Recycle
each time the flame is lost, until it reaches a pre-set
time allotment. The control will then go into Hard
Lockout instead of recycle. This feature prevents
excessive accumulation of oil in the appliance firing
chamber.
3. Trial For Ignition : The oil solenoid valve is
energized. A flame should be established within the
factory set trial for ignition time (lockout time).
4. Lockout: The control has shut down for one of the
following safety reasons:
a. The trial for ignition (lockout) time expired without
flame being established.
b. The cad cell detected flame at the end of the
Valve On Delay state.
8. Motor-Off Delay: If applicable, the oil solenoid
valve is turned off and the control delays turning the
motor off for the set motor-off delay time before the
control returns to standby.
To reset the control from lockout click the button 1-
second.
9. Pump Prime: The igniter and motor are on with the
oil solenoid valve energized for 4 minutes. During
Pump Prime mode, the cad cell is disregarded,
allowing the technician to prime the pump without
having to jumper the cad cell.
NOTE: A recurrence of the above failure modes or a
failed welded relay check could cause the control to
enter a Hard Lockout state that must be reset only
by a qualified service technician.
To reset from Hard Lockout, hold the reset button for
15 seconds until the yellow light turns on.
5. Ignition Carryover: Once flame is established,
the igniter remains on for 10 additional seconds to
ensure flame stability.
6104BAFG R06
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Burner Controls
Figure 1 1a. – Interrupted ignition, valve-on delay
only (no motor-off delay)
Figure 1 1b. – Interrupted ignition, valve-on delay
and motor-off delay
L1
L2
W
R
L1
L2
W
R
SAFETY AND
OPERATING
LIMITS
SAFETY AND
OPERATING
LIMITS
THERMOSTAT
THERMOSTAT
IGNITER
MOTOR
IGNITER
MOTOR
IGNITER
L2 (IGN)
IGNITER
L2 (IGN)
MOTOR
L2 (MTR)
MOTOR
L2 (MTR)
L1
LIMIT
L1 - LIMIT
JUMPER
LIMIT
L2
L2
TR
TW
VALVE
TR
VALVE
OIL VALVE
OIL VALVE
L2 (VLV)
L2 (VLV)
TW
TR-TW TERMINALS
LOCATED ON OPPOSITE
SIDE OF CONTROL
TR-TW TERMINALS
LOCATED ON OPPOSITE
SIDE OF CONTROL
CAD
CELL
CAD
CELL
CAD CELL
CAD CELL
Reset Button Operation
Table 2 explains what action the control will take when the reset button is pressed for different lengths of time
during the various burner operating states.
Table 2 - Reset Button Operation
Pushing the reset button will:
If the burner is in the
Button Click
Button Hold
Button Hold
(press 15+ seconds)
below state:
(press < 1 second)
(press > 1 second)
Reset from Restricted (Hard)
Lockout
Lockout
Valve-on Delay, Trial for
Reset from Soft Lockout
Go to Pump Prime (see
Disable the Burner:
Enables Pump Priming:
Ignition, Ignition Carryover “Priming the Pump” above)
Any time the burner is running, After the reset button has been
press and hold the reset button held for 15 seconds, the button
Yellow light flashes to indicate
to disable the burner. The
burner will remain off as long
as the button is held.
can then be clicked during the
next ignition sequence to enter
Pump Prime mode.
cad cell resistance. See “Cad
Cell Resistance Indicator” for
Run (igniter is shut off)
table of resistance values.
Motor-Off Delay,
Standby
No action
Pump Prime
No action
Exit Pump Prime mode and return to Standby
Table 3 - Status Lights
Light Color
On Continuously
Flashing
Red
Restricted (Hard) Lockout
Soft Lockout
Green
Flame Sensed during normal operation (Could Recycle
be stray light during standby)
Yellow
Control is in Pump Prime mode or
Cad Cell resistance. See “Cad Cell Resistance
Reset button currently held for 15+ seconds.
Indicator” on page 18 for a table of resistance
values.
Page 16
610
4
B
A
F
G
R
06
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Burner Controls
Typical Burner Wiring & Burner Sequence of Operation for R7184P Control.
Refer to the appliance manufacturer’s wiring diagram for actual specifications.
Figure 10. – Typical Burner Wiring
7. RECYCLE. If the flame is lost while the burner is
1. STANDBY. The burner is idle, waiting for a call for
heat. When a call for heat is initiated, there is a 3-
10 second delay while the control performs a safe
start check.
2. VALVE-ON DELAY. The ignition and motor are
turned on for a 15 second valve-on delay.
3. TRIAL FOR IGNITION (TFI). The fuel valve is
opened. A flame should be established within the
15 second lockout time.
4. LOCKOUT. If flame is not sensed by the end of
the TFI, the control shuts down on safety lockout
and must be manually reset. If the control locks out
three times in a row, the control enters restricted
lockout.
firing, the control shuts down the burner, enters a 60
second recycle delay, and then repeats the above
ignition sequence. If flame is lost three times in a
row, the control locks out to prevent cycling with
repetitious flame loss due to poor combustion.
8. BURNER MOT OR-OFF DELAY. The fuel valve
is closed and the burner motor is kept on for the
selected motor-off delay time before the control re-
turns the burner to standby.
5. IGNITION CARRYOVER. Once flame is estab-
lished, the ignition remains on for 10 seconds to
ensure flame stability before turning off. If the con-
trol is wired for intermittent duty ignition, the ignition
unit stays on the entire time the motor is running.
6. RUN. The burner runs until the call for heat is sati-
fied. The burner is then sent to burner motor off
delay, if applicable, or it is shut down and sent to
standby.
61351
Control System Features
Feature Interrupted
ignition
Limited reset,
Limited recycle
Diagnostic LED,
cad cell indicator
Valve-on
delay
Burner motor Alarm Con-
off delay
tacts
R7184A
R7184B
R7184P
YES
YES
YES
YES
YES
YES
YES
YES
YES
—
—
—
YES
YES
—
—
YES
Optional
6104BAFG R06
Page 17
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Wire burner
3. Set the thermostat substantially above room tem-
perature.
4. Close the line voltage switch to start the burner.
If the burner does not start immediately you may
Some Thermostats Are Polar-
ity Sensitive. Reversed polarity
could cause erratic cycling of the burner control.
NOTICE
y Connect the wire from the RH or R terminal on the
thermostat to the TR terminal on the control.
y Connect the wire from the W terminal on the
thermostat to the TW terminal on the control.
have to reset the burner primary control.
5. Initiate a call for heat.
6. After the burner starts, press and hold the reset
button for 15 seconds until the yellow light turns on.
This indicates that the button has been held long
enough.
○ Make connections to the control’s terminals as shown
in Figures 11a and 11b. Refer to the label on the un-
derside of the control for wiring details.
7. Release the reset button. The yellow light will turn
off and the burner will start up again.
8. At burner start up, click the reset button while the
igniter is still on. This will transition the control to a
dedicated Pump Prime mode, during which the mo-
tor, igniter, and valve are powered for four minutes.
The yellow light will be on.
9. Bleed the pump until all froth and bubbles are
purged. If desired, terminate the call for heat or
hold the reset button for at least one second to exit
Pump Prime mode and return to Standby.
10. At the end of 4 minutes, the yellow light will turn off
and the control will automatically return to standby
mode.
11. If prime is not established during the four minute
pump prime mode, return to step 8 to re-enter Pump
Prime mode. Repeat steps 8 through 10 until the
pump is fully primed and the oil is free of bubbles.
12. Terminate the call for heat, and the control will re-
sume normal operation.
○ Note: Motor-off delay on a 7505P will be disabled if
the safety and operating limits as shown in Figures
11a and 11b interrupt power to the control terminal
L1.
○ Connect thermostat leads to the TR and TW
terminals on the control or jumper the TR and
TW terminals on the control, as directed by the
appliance wiring diagram.
▪ Thermostat anticipator Current: 0.1 amp
▪ Thermostat voltage: 24 volts AC
Note that if the thermostat short cycles or operates
improperly, it may require an isolation relay for proper
operation. The Beckett A/C Ready Kit (part no. 51950U)
provides this function. Wiring instructions are included
with the A/C Ready Kit.
▪ Cad Cell Resistance Indicator
○ During the burner Run state, click the reset button
(less than 1 second) to check the cad cell resistance
range. The yellow light will flash 1 to 4 times, de-
pending on the amount of light detected by the cad
cell. See chart below:
Start up burner/set combustion
Yellow Light Flashes
Flame Detection Range
Normal (0 - 400 ohms)
Hot Gas Puff-Back and
Heavy Smoke Hazard
Failure to prime the pump properly could result
in unstable combustion, hot gas puff-back and
heavy smoke.
1
2
3
4
Normal (400 - 800 ohms)
Normal (800 - 1600 ohms)
Limited (1600 ohms - Lockout)
y Do not allow oil to spray into a hot combustion
chamber while bleeding air from the pump.
y Install a gauge in the nozzle discharge port
tubing or fully open the pump bleed valve to
prevent oil spray from accumulating in the com-
bustion chamber during the air bleed procedure.
y Ensure that all bubbles and froth are purged
from the oil supply system before tightening the
pump bleed valve.
▪ Resetting From Restricted or Hard Lockout
○ If the control continues to lockout without a satisfied
call for heat, or fails the motor relay check, the control
enters Hard (restricted) Lockout in order to limit accu-
mulation of unburned oil in the combustion chamber.
○ To reset, hold the button down for 15 seconds until
the red light turns off and the yellow light turns on.
y Ensure that the appliance is free of oil and oil
vapor before starting or resetting the burner.
○ Always verify the control functions according to all
specifications before leaving the installation site.
○ Replace the control if it does not operate as speci-
fied.
1. Open the shutoff valves in the oil supply line to the
burner.
2. Close air band and partially open air shutter. This
is an initial air setting for the pump bleeding pro-
cedure only. Additional adjustments must be made
with instruments.
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Startup/Checkout
4. After the 60 second recycle period, the control
will try to restart the system.
Startup / Checkout
Explosion and Fire Hazard
WARNING
5. After the 15 second lockout time, the control
will lock out the burner and the reset button will
flash. Verify that the burner motor and igniter
are off and that the burner oil solenoid valve (if
used) is not energized.
!
Failure to follow these instructions
could lead to equipment malfunc-
tion and result in heavy smoke
emission, soot-up, hot gas puff-
back, fire and asphyxiation hazards.
6. Open the hand valve in the oil line.
y Do not attempt to start the burner when excess
oil has accumulated in the appliance, the ap-
pliance is full of vapor, or when the combustion
chamber is very hot.
y Do not attempt to re-establish flame with the
burner running if the flame becomes extin-
guished during start-up, venting, or adjustment.
y Vapor-Filled Appliance: Allow the unit to cool
off and all vapors to dissipate before attempting
another start.
7. Click the reset button and verify that the red light
in the reset button shuts off and that the burner
lights.
8. End the call for heat.
○ Before leaving the installation, verify that all thermo-
stat and boiler/furnace control wiring is correct. Con-
sult heating appliance manual for directions.
y Oil-Flooded Appliance: Shut off the electrical
power and the oil supply to the burner and then
clear all accumulated oil before continuing.
y If the condition still appears unsafe, contact the
Fire Department. Carefully follow their directions.
y Keep a fire extinguisher nearby and ready for
use.
Set combustion with instruments
OIL-BURNING EQUIPMENT
CAUTION
!
SHALL BE CONNECTED TO
FLUES HAVING SUFFICIENT DRAFT AT ALL TIMES
TO ENSURE SAFE AND PROPER OPERATION OF
THE BURNER.
If the burner or control fails any of the following tests,
recheck control wiring. If the burner or control still fails
any tests, replace the control.
1. Allow the burner to run for approximately 5 to 10
minutes.
2. Set the stack or over-fire draft to the level specified
▪ Check Safety Features
by the appliance manufacturer.
○ Safe Start Check
y Natural Draft Applications; typically over-fire
draft is -0.01” or -0.02” w.c.
1. Place a jumper across the cad cell terminals.
y Direct Venting; typically may not require draft
2. Refer to the steps for “Start up burner/set
combustion” and have the system call for heat.
adjustment.
y High Eff ciency/Positive Pressure Appliances;
also vary from traditional appliances (see manu-
facturer’s recommendations).
3. Burner must not start. Verify that the green light
is on continuously and that the control remains
in Standby mode.
3. Follow these four steps to properly adjust the burn-
er:
4. End the call for heat and remove the cad cell
jumper.
Step 1: Adjust the air shutter/band until a trace of
○ Simulate Flame Failure and Ignition Failure
smoke is achieved.
1. Refer to the steps for “Start up burner/set
combustion” and have the system call for heat.
Step 2: At the trace of smoke level, measure the
CO (or O ) . This is the vital reference
2
2
point for further adjustments. Example:
2. After flame is established and the burner igniter
turns off, close the hand valve in the oil supply
line.
13.5% CO (2.6% O )
2
2
Step 3: Increase the air to reduce the CO by
2
1.5 to 2 percentage points. (O will be in-
creased by approximately 2.0 to 2.7 per-
2
3. At flame loss, the control will enter Recycle
mode. Verify that the green light is flashing. The
control will remain in Recycle for 60 seconds.
centage points.) Example: Reduce CO
2
from 13.5% to 11.5% (2.6% to 5.3% O ).
2
6104BAFG R06
Page 19
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Perform regular maintenance
Step 4: Recheck smoke level. It should be Zero.
ˆ Verify the nozzle is the one originally specified by
the appliance manufacturer and replace the noz-
zle with one having the exact specifications from
the same manufacturer.
•
This procedure provides a margin of
reserve air to accommodate variable
conditions.
• If the draft level has changed, recheck
ˆ Clean and inspect the electrodes for damage, re-
placing any that are cracked or chipped.
ˆ Check electrode tip settings. Replace electrodes
if tips are rounded.
the smoke and CO levels and readjust
2
the burner if necessary
4. Once combustion is set, tighten all fasteners on air
band, air shutter and head adjusting plate or es-
cutcheon plate.
ˆ Inspect the igniter spring contacts. Clean or re-
place if corroded.
ˆ Clean the cad cell grid surface, if necessary.
ˆ Make sure Low Firing Rate Baffle is in place if
required for the burner application. Omitting the
baffle can result in unacceptable burner combus-
tion.
5. Burner equipped with cover - Reinstall the cover
and repeat Steps 2 and 4. If CO increases (O
2
2
decreases), remove the cover and adjust the air
setting so the CO (O ) with cover on meets re-
quirements of Step 3.
ˆ Inspect all gaskets. Replace any that are dam-
aged or would fail to seal adequately.
2
2
ˆ Inspect the combustion head and air tube. Re-
move any carbon or foreign matter. Replace all
damaged units with exact parts.
ˆ Clean the blower wheel, air inlet, air guide, burner
housing and static plate of any lint or foreign ma-
terial.
6. Start and stop the burner several times to ensure
satisfactory operation. Test the primary control and
all other appliance safety controls to verify that they
function according to the manufacturer’s specifica-
tions.
ˆ If motor is not permanently lubricated, oil motor
with a few drops of SAE 20 nondetergent oil at
each oil hole. DO NOT over oil motor. Excessive
oiling can cause motor failure.
Perform regular maintenance
ˆ Check motor current. The amp draw should not
exceed the nameplate rating.
ˆ Check all wiring for secure connections or insula-
tion breaks.
ˆ Check the pump pressure and cutoff function.
ˆ Check primary control safety lockout timing.
ˆ Check ignition system for proper operation.
ˆ Inspect the vent system and chimney for soot ac-
cumulation or other restriction.
Annual Professional Ser-
vice Required
WARNING
!
Tampering with or making incorrect
adjustments could lead to equip-
ment malfunction and result in
asphyxiation, explosion or fire.
y DO NOT TAMPER WITH THE UNIT OR CON-
TROLS - CALL YOUR QUALIFIED SERVICE
TECHNICIAN OR SERVICEMAN.
ˆ Clean all flue passages and flue pipe. Replace
corroded or damaged pipes.
y To ensure continued reliable operation, a quali-
fied service technician must service this burner
annually.
y More frequent service intervals may be required
in dusty or adverse environments.
y Operation and adjustment of the burner requires
technical training and skillful use of combustion
test instruments and other test equipment.
ˆ Clean the appliance thoroughly according to the
manufacturer’s recommendations.
ˆ Check the burner performance. Refer to the sec-
tion “Set combustion with test instruments”.
ˆ It is good practice to make a record of the service
performed and the combustion test results.
Shutting the Burner Off
IF THE BURNER IS SHUT DOWN
FOR AN EXTENDED PERIOD OF
TIME, ALWAYS KEEP THE VALVE SHUT OFF.
CAUTION
!
ˆ Replace the oil supply line filter. The line filter car-
tridge must be replaced to avoid contamination of
the fuel unit and nozzle.
ˆ Inspect the oil supply system. All fittings should
be leak-tight. The supply lines should be free of
water, sludge and other restrictions.
ˆ Remove and clean the pump strainer if applica-
ble.
Turn off all electric power to the burner.
Note: There could be more than one disconnect
switch.
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6104BAFG R06
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Perform regular maintenance
Replace the blower wheel:
1. Turn off all power to the burner before servic-
ing.
2. Disconnect the burner motor wires.
3. Remove the bolts securing the motor to the
burner housing.
Figure 12. Blower wheel assembly
4. Remove the motor and blower wheel.
5. Remove the existing blower wheel.
6. Referring to the figure below, slide the new
blower wheel onto the shaft.
y Use a feeler gauge to set the wheel-to-motor
gap, as shown below. (AF = 0.125 +1/64 inch,
AFG = 0.030 +1/64 inch)
Use a Feeler Gauge to set
the gap to;
AF = 0.125 +1/64 inch
AFG = 0.030 +1/64 inch
y Slide blower wheel toward motor until it con-
tacts feeler gauge.
y Rotate the blower wheel until the setscrew is
centered on the flat of the motor shaft. Tighten
the setscrew to secure the wheel.
SK9190
7. DO NOT use a motor that has endshield open-
ings outside the blower wheel circumference
(represented by the dashed line).
8. Install the motor on the burner housing. Tighten
screws. Reconnect wires.
9. Restore power, start the burner and perform
combustion tests. Refer to the section “Set
combustion with test instruments”.
6104BAFG R06
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21
23
24
6
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For best performance specify genuine
Beckett
replacement parts
#
1
2
3
4
Part No.
Description
#
16
Part No.
51771U
51304
5880
Description
Burner Housing Assembly
Air Band - Specify # of slots
Air Shutter - Specify # of slots
Valve Cordset
Igniter & Base Plate
Igniter Gasket Kit
Low Firing Rate Baffle
Cad Cell Detector
Specify*
Specify*
21807U
17 & 18
19
20
7006U
Not Shown 21887U
PD Timer Delay Cordset
CleanCut Pump
21
22
5
6
7
8
2184404U
5394
Copper Oil Line - 8”
Splined Nut
5940
Electrode Kit - M Head up to 9”
3666
Specify *
Welded Flange
3811
Gasket Only
3493
Escutcheon (F & L1/L2 heads)
23
24
25
26
27
Specify *
Specify *
5685
Retention Head Assembly
Nozzle Line Electrode & Head Assembly
Pedestal Kit
9
2139
2454
Hole Plug
Coupling
10
11
2182602U
32395U
Solenoid Valve Kit (delay)
Cover
31231U (AFG)
31841U (AF)
Air Guide (AFG)
Air Inlet Bell (AF)
12
13
2999U (AFG)
2459U (AF)
Blower Wheel (AFG)
Blower Wheel (AF)
21805U
4189
PSC Motor
Mounting Screws
* Contact your Beckett Representative for part num-
ber and pricing.
** Contact your Beckett Representative for available
pre and post time settings.
14
15
5770
Electrical Box
7505P
Replaces R7184P - Pre and Post-
time**
6104BAFG R06
Page 23
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Limited
WARRANTY
For Residential, Commercial and Specialty Burners
The R. W. BECKETT CORPORATION (“Beckett”) warrants to persons who purchase its Beckett burners from Beckett for resale or for
incorporation into a product for resale (“Customers”) that its equipment is free from defects in material and workmanship under normal use and
service for 60 months from the date of manufacture for Residential Burners and 18 months from the date of manufacture for Commercial and
Specialty Burners. Residential burner models include: AF, AFG, AFII, NX, SF, SR and SMG. Commercial burner models include: CF375,
CF500, CF800, CF1400, CF2300A, CF2500, CF3500A, CG10, CG15, CG25 and CG50. Specialty burner models include: ADC, ADCP, ARV,
SDC and SM. The provisions of this warranty are extended to individual major burner components as follows:
a) 60 months from date of manufacture for all Beckett-branded major components, except for 12 Vdc components.
b) 18 months from date of manufacture for all non-Beckett-branded major components and Beckett branded 12 Vdc components.
Note: Normal service items found to be defective upon receipt by the customer are covered by this warranty.
THIS WARRANTY DOES NOT EXTEND TO EQUIPMENT SUBJECTED TO MISUSE, NEGLECT, OR ACCIDENT: NOR DOES THIS WARRANTY APPLY
UNLESS THE PRODUCT COVERED BY IT IS PROPERLY INSTALLED BY A QUALIFIED, COMPETENT TECHNICIAN, WHO IS LICENSED WHERE
STATE AND LOCAL CODES REQUIRE, AND WHO IS EXPERIENCED IN MAKING SUCH INSTALLATIONS, IN ACCORDANCE WITH THE LATEST
EDITION OF NFPA NO. 31 OF THE NATIONAL FIRE PROTECTION ASSOCIATION, THE LATEST EDITION OF THE NATIONAL FUEL GAS CODE (NFPA
NO. 54) AND IN ACCORDANCE WITH ALL APPLICABLE LOCAL, STATE AND NATIONAL CODES HAVING JURISDICTIONAL AUTHORITY.
Equipment, which is defective in material or workmanship and within the warranty period, may be returned for credit as follows:
Beckett Burners, Beckett-branded major components and non-Beckett-branded major components that came as original equipment on a Beckett burner
or were sold as a replacement part by Beckett should be returned, freight prepaid, to Beckett’s home office. Credit will be issued to the customer unless
the returned equipment is determined by Beckett to be out of warranty or damaged by user, in which case the equipment will be scrapped.
Note: Beckett is not responsible for any labor cost for removal and replacement of equipment.
THIS WARRANTY IS LIMITED TO THE PRECISE TERMS SET FORTH ABOVE, AND PROVIDES EXCLUSIVE REMEDIES EXPRESSLY IN LIEU OF ALL OTHER
REMEDIES, AND IN PARTICULAR THERE SHALL BE EXCLUDED THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE. IN NO EVENT WILL BECKETT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGE OF ANY NATURE. Beckett neither assumes nor
authorizes any person to assume for Beckett any other liability or obligation in connection with the sale of this equipment, Beckett’s liability and Customer’s
exclusive remedy being limited to credit as set forth above.
R.W. BECKETT CORPORATION
P.O. Box 1289 Elyria, Ohio 44036
Form No. 61545 R72905
The Oilheat Manufacturers’ Association supports the use of low sulfur fuels as defined by ASTM D396, Grades No. 1 Low Sulfur
and No. 2 Low Sulfur, as the preferred heating fuel for the following reasons:
• Low sulfur fuels reduce deposits on heat exchanger surfaces, extending the service interval between cleanings.
• The reduced deposits increase the efficiency of the appliance.
• Low sulfur fuels reduce particulate emissions.
• Low sulfur fuels reduce oxides of nitrogen emissions.
R.W. BECKETT CORPORATION
U.S.A.: P.O. Box 1289 · Elyria, Ohio 44036
Canada: R.W. Beckett Canada, Ltd. · Unit #3, 430 Laird Road · Guelph, Ontario N1G 3X7
Form Number 6104 BAFG R06
Printed in U.S.A.
01/14/09
© 2008 R.W. Beckett Corporation
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