Burner Start-Up Prep; Test Instruments; Burner Start/Check Procedure - Beckett CG15 Manual

Burner Start-up Prep

Explosion, Fire, and Asphyxiation
Hazard
Professional Installation & Service
Required. Incorrect installation and set up
could lead to equipment malfunction.
Asphyxiation Hazard
It is recommended that you measure the oxygen
(O2) early in the test sequence because high levels
of carbon monoxide (CO) can be created at very low
or very high O2 levels. The typical operating range is
between 3%-5% O2.
Do not attempt to start the burner unless you are
fully qualified.
Do not continue with this procedure without the proper

test instruments.

Carefully follow control instruction sheets, control
sequence of operation, test procedures and all appliance
manufacturer's directions that pertain to this installation.
Complete contractor start up form in back of manual.
Test Instruments
The following calibrated test equipment is required to
properly install the appliance. They should be calibrated
and in good working order.
• A combustion analyzer capable of measuring
oxygen (or carbon dioxide), carbon monoxide,
stack temperature, ambient temperature, and
appliance efficiency.
• Electrical multi-meter capable of measuring voltage,
ohms, amps, and DC micro-amps for measuring the
flame signal.
• Calibrated manometers and pressure gauges
capable of measuring all pressure ranges in the gas
supply and appliance draft. This could typically range
from a few PSI to 0.1" W.C.

Burner Start/Check Procedure

(Before proceeding, turn off and lock out electrical
power and close the main shut off cock to shut off
gas to the burner.)
22 — Section: Start Up And Operation
1. With the power and main gas supply to the burner
turned off, make sure gas has not accumulated in the
boiler or flues.
2. Check the initial air settings for input firing rate. See
Table 4 for initial air settings.
3. With the main shutoff cock closed, set the limit or
controller to call for heat then apply power to start the
burner.
4. Verify Burner Safety Control Function – In order to
check the function of each component (i.e.: 7800 Series
sequence, airflow proving switch, ignition transformer,
gas valves, safety lockout timing, etc.), with the main
shutoff cock closed, monitor a complete burner run
sequence. Reset the control by pressing and holding
the reset button while the control is powered.
5. Verify Flame Sensor Function – If 7800 Series
operation sequence and function is correct, turn off
power and remove sensor wire from terminal 'F' on
control. Turn on power and fuel then initiate Call for
Heat. Verify that burner lights off and the gas valve
closes. After control locks out, flame shall go off. It
may require several cycles to purge the line.
6. Turn power off and reattach sensor wire. Turn power
back on and reset the control using reset button.
Initiate Call for Heat.
7. After you have observed main flame for a brief time,
press the reset button on the control for 1 second to
shut down and re-start the burner. Monitor the flame
and safety shutoff valves to assure that shutdown is
controlled by the valves and that they operate properly.
With this test passed, you may safely initiate automatic
start-ups on subsequent cycles.
8. While the burner is firing, examine the vent system for
evidence of leaks, obstructions, and for correct function
of the barometric draft control. Leak test all gas piping
from the burner to the utility supply piping. If leaks are
found, correct them immediately.
9. Low gas pressure switch – With the burner firing
and a manometer attached to a test port near the low
pressure switch, gradually close the main leak test
cock to shut off the gas supply. Note the pressure at
which the low gas pressure switch opens and shuts
the burner off. Manually reset the switch. The low gas
pressure switch should be set at half of the normal
supply pressure in the line.
10. High gas pressure switch – With the burner firing and
a manometer attached to the test port nearest the high
pressure switch, gradually increase the gas pressure
until the high pressure switch opens and shuts the
burner off. Note the pressure and manually reset the
switch. The high gas pressure switch should be set at
one and one half times the high fire manifold pressure.
CG15, CG25, CG50 Burner Manual, Form No. 6104BCG50