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COMMERCIAL PRODUCTS
GAS-FIRED
Fire, Explosion and Asphyxiation Hazards
Failure to follow these instructions exactly could lead to fi re or explosion and result in
death, severe personal injury or property damage.
1. Do not store or use gasoline or other fl ammable vapors and liquids in the vicinity of this or any other appliance.
2.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 buildi
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Contents General Information .................................................... 4 Hazard Defi nitions .........................................................................4 Professional Installer’s Responsibility ...........................................5 Pre-installation Checklist ........................................... 5 Indoor Installation ..........................................................................5 Combustion Air Supply ..............................................
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Section: General Information General Information Owner’s Responsibility Failure to follow these instructions, Hazard Defi nitions misuse, or incorrect adjustment of the burner could lead to equipment Indicates a hazardous malfunction and result in asphyxiation, situation which, if not explosion or fi re. avoided, will result in death or serious injury. Contact a professional, qualifi ed service agency for the installation, adjustment, and service of your gas burning system. Thereafter, hav
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Section: Pre-installation Checklist Professional Installer’s Responsibility Combustion Air Supply The burner requires combustion air and ventilation air Follow these instructions for reliable operation. Assure that the building and/or exactly combustion air openings comply with the latest edition of Failure to follow these instructions could the National Fuel Gas Code ANSI Z223.1 (NFPA 54). lead to equipment malfunction and result For appliance/burner units in confi ned spaces, the room i
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Section: Pre-installation Checklist Table 1 – Burner Specifi cations CG15 CG25 CG50 USA Canada USA Canada USA Canada † Input Firing Range : High Fire (Max.) 1,500 MBH 1,370 MBH 2,700 MBH ? MBH 5,000 MBH 4,000 MBH High Fire (Min.) 800 MBH 800 MBH 1,300 MBH 1,300 MBH 2,000 MBH 2,000 MBH Low Fire (Max.) 560 MBH 560 MBH 990 MBH 990 MBH 1,400 MBH 1,400 MBH Low Fire (Min.) 350 MBH 350 MBH 550 MBH 550 MBH 730 MBH 730 MBH Fuel: Natural Gas 0.6 Specifi c Gravity Typical 0.6 Specifi c Gravity Typ. 0.
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Section: Pre-installation Checklist Electrical Supply Test For Gas Pipe Leaks Check the nameplate on the burner to verify that the Leaking gas could result in asphyxiation, explosion, power connections available are correct for the burner. or fi re hazard. Refer to Figure 1. All power must be supplied through fused disconnect switches and comply with the latest The gas supply piping must be absolutely leak-free. edition of National Electric Code NFPA 70 (Canada CSA Pressure test the gas
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Section: Pre-installation Checklist Figure 3A - Maximum Capacity (at 3% O ) vs Furnace Pressure - CG15, 60Hz. 2 Figure 3B - Maximum Capacity (at 3% O ) vs Furnace Pressure - CG25, 60Hz. 2 Figure 3C - Maximum Capacity (at 3% O ) vs Furnace Pressure - CG50, 60Hz. 2 8
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Section: Pre-installation Checklist Figure 4 - Burner Dimensions DIM. A DIM. C DIM. B O.D. DIM. D DIM. G DIM. E DIM. H DIM. F Model Dim. A Dim. B Dim. C Dim. D Dim. E Dim. F Dim. G Dim. H O.D. Pipe Thread CG15 20.8 9.4 32.7 13.7 5.2 18.4 6.2 10.8 5.6 1-1/4 NPT CG25 20.9 9.3 33.2 13.4 6.8 17.8 6.7 12.6 6.9 2 NPT CG50 24.4 10.5 33.6 13.5 7.5 17.4 6.7 14.6 7.7 2-1/2 NPT NOTE: All dimensions are in inches. Figure 5 - Panel and Modulating Valve Dimensions 16.00 6.00 8.00 12.4 DIM. A FEMALE PIPE THREA
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Section: Mount the Burner & Connect Gas Piping Figure 6 - Custom Mounting Plate Mount the Burner Mount the burner to the appliance. The burner specifi ed for packaged equipment will have a fl ange welded for the required insertion. Follow the appliance manufacturer’s instructions for mounting. In the absence of instructions, or for retrofi ts, make sure that the air tube insertion dimension, measured along the side of the air tube from the welded fl ange to the end C of burner air tube, is cor
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Section: Connect Gas Piping to Furnace Pressure Drop curves of Figures 14A, 14B, Install a Drip Leg in Gas and 14C are correct for both propane and natural gas. Supply Piping That is also why a gas train adjusted for the burner’s natural gas requirements will be correctly adjusted for Foreign matter could lodge in gas valve its propane requirements. R. W. Beckett provides the cutoff seals, resulting in gas leak-through, same pressure regulating safety shutoff valve in the gas explosio
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Section: Connect Gas Piping Table 2A - Natural Gas Supply Piping Capacity 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 specifi c gravity. Pipe size (inches) IPS Pipe length (feet) 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 1100 2100 3300 5900 12000 30 152 285 590 800 1650 2700 4700 9700 40 130 245 500 760 1450 2300 410
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Section: Connect Gas Piping Figure 8A - UL Gas Train - High/Low and Low Fire Start LGPS TC TC HGPS U SSOV1 U 2PRSSOV MLTC MSC TP SK9982 SK9983 Figure 8B - UL Gas Train - Modulating LGPS TC TC HGPS U SSOV1 U MV MLTC SSOV2 MSC TP PRV SK9984 SK9985 When pressure reducing safety ABBREV. ITEM DESCRIPTION HGPS HIGH GAS PRESSURE SWITCH shutoff valves are used, the LGPS LOW GAS PRESSURE SWITCH distance from the fi nal shutoff valve (2PRSSOV in MSC MAIN SHUTOFF COCK Figure 8A) to the burner manifold mu
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Section: Wire the Burner & Sequence of Operation Wire the Burner Incorrect Wiring Will Result in Improper Control Install the burner and all wiring in accordance with the Operation National Electric Code ANSI/NFPA 70 (Canada CSA C22.1) and all applicable codes and requirements. Wire the burner in compliance with all instructions and diagrams provided by the appliance manufacturer. Fire or Explosion Hazard Verify operation of all controls in accordance with the Can cause severe injury, d
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Section: Sequence of Operation continuing to detect a fl ame, the burner will operate ○ For modulating control wiring (Figure 9B), the in the RUN mode until the load demand is satisfi ed burner starts at Low and is released to modulate or a limit opens. after the fl ame stabilization period. It can modulate between low and high as necessary to ○ For High/Low control wiring (Figure 9A), if meet load demand until the load is satisfi ed or a terminals RC1 and RC2 are jumpered, the limit opens,
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Section: Sequence of Operation Figure 9B - Typical Wiring Using Model RM7840L for Modulating Control (For Reference Only) 16
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Section: Prepare the Burner for Start-up 2. Gas Supply Piping Prepare the Burner for ○ Insure that the gas piping is properly sized and has Start-up been inspected by the gas utility, leak tested at all joints, and purged. ○ To protect the gas train and controls, insure that a Professional Installation drip leg or dirt pocket has been properly installed. and Service Required ○ Insure that the fuel gas being supplied is compatible with the burner specifi cation and is available at the Inc
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Section: Start the Burner plates, enclosures and guards are in place and Burner Start Procedure securely fastened. (Before proceeding, turn off and lock out electrical ○ When available, refer to the appliance power and close the main leak test cock to shut off manufacturer’s instructions and install the burner gas to the burner.) accordingly. 1. With the power and main gas supply to the burner 6. Test Instruments turned off, make sure gas has not accumulated in the boiler or fl ues. ○
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Section: Start the Burner 2. Push in on pin (G) to disengage the motor from the Figure 10A - Damper Motor with Cover damper shaft and cam stack. Rotate the damper shaft by hand to place the adjustment cams in a B position where their adjustment scale can be easily seen. Release pin (G) to secure the damper shaft and cam stack to the motor. 3. Using the wrench (C) supplied with the damper motor, adjust the blue low fi re cam (D) to the initial setting listed in Table 3. 4. Using the same w
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Section: Start the Burner Figure 12 - Modulation Assembly for Left Handed Optional Modulation Linkage Adjustment Gas Entry (Standard Construction) Instructions The optional modulation linkage assembly has been designed as an economic means to adjust the damper and the butterfl y valve to maintain air to gas ratios. When the optional Modulation linkage assembly is supplied with the burner, initial adjustments will be made at the factory. To ensure optimum operation, minor additional adjust
