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OIL BURNER MOUNTING
The burner is premounted at the factory. If field installation or replacement of Energy Kinetics supplied burner is
required, follow these instructions. Start by checking nozzle and electrode position per manufacturer's specifications prior
to assembly to unit. The EK3 Frontier boiler uses the Beckett CF500 burner. The CF500 burner will accept the Frontier
amulet, EK part number 10-0718. The amulet must be modified by trimming back the inside front edge. The inside front
edge has a lip designed to protect the head. The CF500 head requires that the inside lip be trimmed flush with the inside
diameter of the amulet. Test fit the amulet by inserting the amulet into the boiler opening. If the amulet doesn't easily
slide into the boiler, then gently sand the outside diameter of the amulet until it will fit into the boiler opening. Test fit the
amulet onto the burner head. The amulet for the Beckett CF500 burner has smooth interiors. If the amulet is a tight fit on
the burner head, then slightly moisten inside the amulet with water.
Place a 1/2" bead of retort cement onto the burner tube at the flange to air tube joint, and slide the (moistened)
amulet over the burner head and against the flange. Ensure proper seating of the amulet by pressing the amulet onto the
burner with a flat object. If needed, trim the front edge of the amulet to be recessed behind the front shroud of the burner
head. Leave the excess retort cement at the amulet to flange joint and the cement will provide an airtight seal of the air
tube flange to the boiler face. If needed, add extra retort cement to seal the air tube flange to the boiler face and to the
insulation inside the boiler door. The EK3 does run with some positive pressure in the combustion area and enough
retort cement must be used to provide a proper seal against that positive pressure.
Once the amulet has been seated and trimmed, and retort cement added, then install the burner into the boiler by
carefully inserting the air tube with amulet into the boiler opening while aligning the burner flange holes with the boiler
studs. Install flat washers and nuts onto the boiler studs and tighten all nuts evenly.
BECKETT CF500 OIL BURNER OPERATION
NOTICE: For reliable operation, set Air-Fuel mixture conservatively based on installation conditions. CO
and draft readings should be taken through 1/4" test port in front jacket opening just to right of burner. Sample tube must
extend at least eight (8) inches into front cover to obtain accurate readings. Smoke test and stack temperature should be
taken at flue outlet.
NOTICE: For accurate efficiency calculations, measure flue gas temperature in flue pipe. Overfire temperatures will
be higher than flue gas temperature measured in the flue pipe. Be sure to measure CO
stack temperature at the flue outlet. If using a digital flue gas analyzer, use a separate thermocouple inserted into the flue
outlet to measure flue temperature while drawing the gas sample from the over fire port.
Installation Conditions
Normal Conditions
Active Area (Washer, Dryer, Shop)
Outside Oil Tank
Note 1:
Note 2:
AFTER 15 MINUTES RUNNING, CHECK AND RECORD:
1.
DRAFT AT FLUE OUTLET ........................................
2.
DRAFT AT OVER FIRE
3.
DRAFT LOSS
4.
CO
2
5.
STACK TEMPERATURE .................................................
6.
SMOKE TEST
Draft over fire with a chimney should be -0.02" to +0.08" w.c.
If not, recheck chimney, chimney base and flue pipe for blockage or clean out door openings.
Draft Loss Definition: The draft loss through boiler is found by subtracting the overfire draft reading from the breech
draft reading. For example, if the breech draft is -0.04" w.c., and overfire draft is +0.02" w.c., then subtracting the two
readings gives a draft loss of 0.06" w.c., which is acceptable. If the draft loss exceeds 0.10" w.c., then the boiler may
need to be cleaned or there may be some other blockage that will need to be addressed.
DANGER:
1.
Verify proper operation of high limit aquastat:
a. With a Digital Manager:
i. Remove all heat and hot water calls (No input lights on left side of manager).
ii. Turn System switch off, then remove red sensor lead from the left side quick connect.
iii. Restore power. The 100
shortly, in less than a minute.
iv. At approximately 205
v. Turn off power and reconnect the red sensor lead.
DANGER:
2.
Verify proper operation of boiler pressure relief valve by following instructions on pressure relief valve,
which calls for a 'try lever test'. Make sure discharge pipe is properly placed to safely contain discharge and open
relief valve using the try lever.
EK3 Frontier Boiler Manual
For combinations of above, use lowest CO
When Air Box is used, CO
....................................
....................................
/O
.........................................................................
2
..............................................................
o
light will flash on the manager's temperature display, and the burner should start
o
o
F to 215
F, the high limit aquastat should shut off burner.
CO
Setting
2
12.5%
12.2%
12.0%
level or highest O
2
must be checked with air box cover in place.
2
10
Seventh Edition- October 2015
/O
in the over fire port and the
2
2
O
Setting
2
4.2%
4.6%
4.9%
level.
2
-0.02" to -0.12" w.c.
+0.08" to -0.02" w.c.
0.06" to 0.10" w.c.
See table above
o
o
350
to 450
F
Verify 0 smoke at breech
/O
2
2
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