2500/3500

CF 2500/
MODEL Oil
Burner

CF 3500
Instruction Manual
Low/High Operation
Firing rate: CF2500A 17.0 – 19.9 GPH
CF2500 17.0 – 25.0 GPH
CF3500A 17.0 – 35.0 GPH
Motor voltage: 208/230 — 60 Hz std.

Thank you for purchasing a Beckett

burner. With proper care and regular

maintenance, it will provide years of

trouble-free service. Please take a few

minutes to read the section entitled “To

the owner” inside this manual. Then, keep

the manual in a safe place where it can be

easily located if needed by your

professional service technician.

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 Instruction Manual – Model CF2500/CF3500 Oil Burner

Please . . . read this page first

Hazard definitions
The following will be used throughout this manual to bring attention to hazards and their risk factors, or to special information.
Denotes presence of a hazard which, if Denotes presence of a hazard which, if
ignored, will result in severe personal injury, ignored, could result in severe personal injury,
death or substantial property damage. death or substantial property damage.

Denotes presence of a hazard which, if Intended to bring special attention to

ignored, could result in minor personal injury information, but not related to personal injury
or property damage. or property damage.

To the owner — To the owner —

Installation and adjustment of the burner Never burn garbage or refuse in your heating
requires technical knowledge and the use of appliance or try to light the burner by tossing
combustion test instruments. Do not tamper burning material into the appliance. This
with the unit or controls. Call your qualified could result in severe personal injury, death
service technician. Incorrect operation of the or substantial property damage.
burner could result in severe personal injury,
death or substantial property damage. Never attempt to use crankcase or waste oil in
your heating appliance. This could damage
Have your equipment inspected and adjusted the fuel unit or heating equipment, resulting
at least annually by your qualified service in risk of severe personal injury, death or
technician to assure continued proper substantial property damage.
operation.
Never restrict air openings on the burner or to
Never attempt to use gasoline in your heating the room in which the appliance is located.
appliance or to store gasoline or combustible This could result in fire hazard or flue gas
materials near the heating equipment. This leakage, causing severe personal injury, death
could result in an explosion or fire, causing or substantial property damage.
severe personal injury, death or substantial
property damage.

To the installer — To the installer —

Read all instructions before proceeding. Concealed damage - If you discover damage
Follow all instructions completely. Failure to to the burner or controls during unpacking,
follow these instructions could result in notify the carrier at once and file the
equipment malfunction, causing severe appropriate claim.
personal injury, death or substantial property
damage. Contacting Beckett for service information
or parts - Please record the burner serial number
(and have available when calling or writing).
This equipment must be installed, adjusted You will find the serial number on the
and started only by a qualified service Underwriters Laboratories label, located on
technician – an individual or agency, licensed the left rear of the burner.
and experienced with all codes and
ordinances, who is responsible for the
installation and adjustment of the equipment. 50 Hz motors — The burner ratings, air
The installation must comply with all local settings and nozzle ratings are based on
codes and ordinances and with the National standard 60 hz motors (at 3450 rpm). Derate
Fire Protection Standard for Oil-Burning all ratings 20% when using 50 hz motors.
Equipment, NFPA 31 (or CSA B139-M91). Consult factory for specific application data.

High altitude installations — Accepted industry practice requires no derate of burner capacity up to 2,000 feet
above sea level. For altitudes higher than 2,000 feet, derate burner capacity 4% for each 1000 feet above sea level.

2 Form 6104 BCF-35-R0699

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 Instruction Manual – Model CF2500/CF3500 Oil Burner

Warranty Contents
Beckett warrants its equipment to those who
have purchased it for resale, including your
dealer. If you have any problems with your Please . . . read this page first ................ 2
equipment or its installation, you should
contact your dealer for assistance.
Pre-installation checklist........................... 4

Specifications
Mount the burner .......................................... 6
Fuels #1 or #2 Fuel Oil
Firing range CF2500A 17.0 - 19.9 GPH
Connect fuel line(s) ...................................... 8
CF2500 17.0 - 25.0 GPH
CF3500A 17.0 - 35.0 GPH
Motor 2 HP 3450 RPM Wire the burner ............................................ 10
208/230/60 hz/1-PH std.
13.4 amps @ 230 VAC Sequence of operation - typical ............ 11
Optional voltages:
(60 hz or 50 hz) – Prepare the burner for start-up ............. 11
• 208/230/480/3-PH
Ignition Trans. 120V/12,000V
Start the burner .......................................... 14
Housing Cast aluminum
Fuel unit 100 - 300 PSIG
Maintenance and service......................... 15
Oil nozzle 45° - 70° solid
Shipping wt. 106 lbs.
Dimensions See Figure 7 (Page 7) Replacement parts ................... Back cover
(See NOTICE on opposite page for 50 hz motor applications.)

Agency approvals

• Underwriters Laboratories has certified

Before you begin . . .
this burner to comply with ANSI
Standard 296 and has listed it for use
with No. 1 or No. 2 fuel oil as specified The following resources will give you additional information
in ASTM D396. State and local for your installation. We suggest that you consult these
approvals appear on the burner rating resources whenever possible. Pay particular attention to the
label. appliance manufacturer’s instructions.
• Certified by ULC.
Appliance manufacturer’s instructions — Always follow
• Approved by Commonwealth of the appliance manufacturer’s instructions for burner
Massachusetts - State Fire Marshall. installation, equipment and setup.
• Accepted by N.Y.C. M.E.A.
1–800–OIL–BURN — Beckett’s technical services hot-line.
• Other approvals may be available and
must be specified at time of order.
www.beckettcorp.com — Beckett’s website.

Form 6104 BCF-35-R0699 3

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 Instruction Manual – Model CF2500/CF3500 Oil Burner

Pre-installation checklist
❏ Combustion air supply ❏ Vent system
• The burner requires combustion air and ventilation air for • The flue gas venting system must be in good condition
reliable operation. Assure that the building and/or com- and must comply with all applicable codes.
bustion air openings comply with National Fire Protection
Standard for Oil-Burning Equipment, NFPA 31. For appli-
ance/burner units in confined spaces, the room must have
an air opening near the top of the room plus one near the ❏ Electrical supply
floor, each with a free area at least one square inch per • Verify that the power connections available are correct for
1,000 Btu/hr input of all fuel burning equipment in the
room. For other conditions, refer to NFPA 31 (CSA B1139- the burner. All power must be supplied through fused dis-
connect switches.
M91 in Canada).
• If there is a risk of the space being under negative pressure
or of exhaust fans or other devices depleting available air
for combustion and ventilation, the appliance/burner ❏ Verify burner components —
should be installed in an isolated room provided with out- • Burner box, Model CF2500A/CF2500/CF3500A
side combustion air.
• Air tube assembly (selected per following)
• Mounting flange kit
• Pedestal mounting assembly kit (recommended)
❏ Clearances • Oil nozzle, per Table 1 — Use only 45° to 70° solid pat-
tern nozzles unless otherwise shown by appliance manu-
• With the burner installed in the appliance, there must be facturer.
adequate space in front of and on the sides of the burner to The CF2500A, CF2500 and CF3500A are dual nozzle burn-
allow access and operation. Verify that the clearance di- ers. To select the nozzles, use half of the maximum firing
mensions comply with all local codes and with the appli- rate and select a nozzle under the 300 psig column (high
ance manufacturer's recommendations. fire rate). Select the corresponding nozzle from column 1
(Rated gph @ 100 psig). Two nozzles will be required.

❏ Fuel supply Table 1 – Nozzle capacities at various pressures

• The fuel supply piping and tank must provide #1 or #2 Rated Pressure - pounds per square inch
fuel oil at pressure or vacuum conditions suitable for the gph @
fuel unit (oil pump) on the burner. Refer to fuel unit litera-
ture in the literature envelope in the burner carton to verify 100 psig 125 150 175 200 250 300
allowable suction pressure. 5.00 5.59 6.13 6.61 7.07 7.50 8.66
The fuel unit is shipped without the by-pass 5.50 6.15 6.74 7.27 7.78 8.70 9.54
plug installed. You must install this plug on 6.00 6.71 7.33 7.94 8.48 9.49 10.40
two-pipe system. DO NOT install the by-pass
plug in the fuel unit if connected to a one- 6.50 7.26 7.96 8.60 9.20 10.30 11.25
pipe oil system. Failure to comply could cause 7.00 7.82 8.56 9.25 9.90 11.06 12.12
fuel unit seal failure, oil leakage and potential 7.50 8.38 9.19 9.91 10.60 11.85 13.00
fire and injury hazard.
8.00 8.94 9.80 10.58 11.31 12.65 13.85

When fuel supply is level with or higher than burner 8.50 9.50 10.45 11.27 12.06 13.40 14.70
fuel unit — 9.00 10.06 11.02 11.91 12.73 14.20 15.60
• When the fuel unit is not required to lift the oil, the instal- 9.50 10.60 11.70 12.60 13.50 15.00 16.45
lation is usually suitable for either a one-pipe or two-pipe
oil system. The oil pressure at the inlet of the fuel unit must 10.00 11.18 12.25 13.23 14.14 15.81 17.32
not exceed 3 psig. 10.50 11.74 12.85 13.90 14.85 16.60 18.18
• See Figure 8 for one-pipe fuel supply installations. See 11.00 12.30 13.47 14.56 15.55 17.39 19.05
Figure 9 for two-pipe fuel supply installations.
11.50 12.85 14.08 15.22 16.26 18.18 19.92
When fuel supply is below the burner fuel unit — 12.00 13.42 14.70 15.87 16.97 18.97 20.78
• Use a two-pipe oil system when the fuel unit must lift the
oil more than 2 feet. The return line provided by the two- 12.50 13.98 15.31 16.54 17.68 19.76 21.65
pipe system is needed to purge the air from the fuel lines 13.00 14.54 15.92 17.20 18.38 20.55 22.52
and minimize the likelihood of air-related problems dur- 13.50 15.10 16.53 17.85 19.09 21.34 23.38
ing operation.

4 Form 6104 BCF-35-R0699

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 Instruction Manual – Model CF2500/CF3500 Oil Burner

❏ Verify firing rate Figure 2 – Air tube mounting dimensions

• Refer to appliance manufacturer’s instructions (if avail- E Insertion depth

able) for firing rate and nozzle selection. Otherwise, the T G Air tube to inside of chamber
maximum recommended firing rate for the burner depends – 0.25" ± 0.125"
on the length of the firing chamber and the distance from 2° 1 T Air tube length
the burner center to the chamber floor. Verify that the cham- G
D Tube diameter
ber dimensions are at least as large as the minimum values
given in Figure 1. If the appliance dimensions are smaller
than recommended, reduce the firing rate accordingly.
D

❏ Verify air tube

• The information in this section may be disregarded if the F
air tube is supplied by the appliance manufacturer.
• The following tube arrangements are available:
Model CF2500A: Tube KP — 17.0 to 19.9 GPH E 3502
Model CF2500: Tube KP — 17.0 to 25.0 GPH
Model CF3500A: Tube KM — 17.0 to 35.0 GPH or
① Install the burner with a 2° pitch as shown.
Tube KR — 17.0 to 35.0 GPH
• Maximum firing capacity depends on the firebox pressure. A.T.C. Codes
Use Table 2 to verify the correct air tube type for the firing (A.T.C. = Air Tube Combination)
rate required. (Tube KR [CF3500A] is an optional air tube
CF2500A/
combination for maximum capacity rate. It requires a larger CF3500A
I.D. flange No. 51631.) CF2500
• See Figure 2 to verify the correct air tube length and air Tube KP Tube KM Tube KR
tube combination code. Dimensions Dimensions Dimensions
T D F T D F T D F
Figure 1 – Min. combustion chamber dimensions
All — 6 ½" 3¼" All — 8" 4 ½" All — 9 ¹⁵⁄₁₆" 5 ¹⁄₈"
6¾" CF 66 KP 8" CF 80 KM — —
— — 9 ¼" CF 92 KM — —
10¼" CF 102 KP 11 ½" CF 114 KM 11 ½" CF 114 KR
13¾" CF 136 KP 15" CF 150 KM 14" CF 140 KR
17¾" CF 176 KP 19" CF 190 KM 19" CF 190 KR

Table 2 – Air tube capacity vs. firebox pressure

Tube KP Tube KM/KR
Firebox No No
pressure reserve 10% reserve 10%
(In. W.C.) air turndown air turndown

L Maximum firing rate GPH

A
0.0 25.0 22.5 35.0 31.5
0.2 24.8 22.3 33.5 30.2
0.4 24.6 22.3 32.0 28.8
3501

0.6 24.5 22.1 30.2 27.2

Minimum dimensions
Firing rate 0.8 24.3 21.9 28.8 25.9
(all boilers)
A L 1.0 24.1 21.7 27.1 24.4
17 gph 10.5" 48.0" Note: 10% turndown indicates sufficient reserve air to reduce
22 gph 11.5" 58.0" the CO2 in the flue to 90% of its value.
27 gph 12.5" 66.0"
32 gph 12.5" 73.0" Note: The above ratings may vary 5% due to variations in actual job
35 gph 13.0" 77.0" conditions.

Form 6104 BCF-35-R0699 5

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 Instruction Manual – Model CF2500/CF3500 Oil Burner

Mount the burner Figure 4 – Nozzle and nozzle line assembly

❏ Mount flange(s) on air tube S Q

• This section does not apply to burners with welded flanges.

• Do not install air tube on burner.
• For non-pressure firing flange, refer to Figure 3: Install P
gasket (item a ) and flange (item d ). Ignore the next

0.713311"
paragraph.
• For pressure-firing flange, refer to Figure 3: Slide gasket Low fire High fire
(item a) onto the air tube, making sure the top of the air nozzle nozzle R
tube is up. Predrill holes in the pressure firing plate (item b) 3504
to match the appliance studs. Slide the pressure firing plate
(item b) and flange (item d) onto the air tube as shown.
Wrap ceramic fiber rope (item c) around the air tube and
press tightly into the inside diameter of the flange (item d).
• Slide the air tube (item e) into position in the appliance
front. Tighten the flange-mounting-stud nuts. Set the
insertion of the air tube so dimension G is ¹⁄₄" nominal.
• Pitch the air tube at 2° from horizontal as shown and secure
3505
the flange to the air tube. Remove the flange-mounting
stud nuts and remove the air tube from the appliance.

Figure 3 – Mount flange(s) on air tube

Critical dimensions —
S (Electrode spacing) = ³⁄₃₂" P (Nozzle center line to electrode tip) = ¹⁄₄"
2° Q (Nozzle to head) = ¹⁄₄" R (Nozzle face to electrode tip) = ¹⁄₈"
G

Failure to properly set and maintain the

electrode and nozzle spacing dimensions can
cause incorrect burner ignition or poor
combustion. This could result in severe
personal injury, death or substantial property
e damage.
c

a b d
3503 ❏ Install nozzle line assembly
• Insert the nozzle line assembly into the burner air tube as
❏ Mount air tube to burner in Figure 5.
• Remove the rear access door from the back of the burner • See Figures 5 and 6. Assemble the adjusting plate assem-
for improved access to the interior. bly per the instructions in the assembly packet.
• Attach the air tube to the burner with the bolts and acorn • Slide the secondary adjusting plate (item f) completely to
nuts provided. The acorn nuts must go on the outside of the left on the indicator adjusting plate (item e). Finger-
the burner, with the bolts inserted from the inside. tighten acorn nut c to secure the two plates together. Slide
both plates completely to the left on the primary adjusting
plate (item g) and finger-tighten acorn nut d.
❏ Install nozzle • Slide the completed adjusting plate assembly over the
• See Figure 4. Install the oil nozzle in the nozzle adapter. nozzle line end. Move the plate assembly and the nozzle
Use a ³⁄₄" open-end wrench to steady the nozzle adapter line so the plate assembly fits into position as shown in
and a ⁵⁄₈" open-end wrench to turn the nozzle. Tighten Figure 5.
securely but do not overtighten. • Install the spline nut (Figure 5, item b) on the end of the
• Check, and adjust if necessary, the critical dimensions P, nozzle line, leaving the nut loosely placed so the plates
Q, R and S shown in the drawing. Verify that the oil tube can be moved.
assembly and electrodes are in good condition, with no • Connect the high-voltage leads from the ignition trans-
cracks or damage. former to the electrodes.

6 Form 6104 BCF-35-R0699

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 Instruction Manual – Model CF2500/CF3500 Oil Burner

Figure 5 – Nozzle line assembly in burner Figure 6 – Adjusting plate assy.

Z Measure dimension Z from d d e f c g
front (flat) face of head to b
end of air tube, as shown. a
3508

Legend (Figures 5 and 6)

a Adjusting plate assembly
b Spline nut for securing nozzle line
c Bottom acorn nut
d Top acorn nut (for setting dim. Z
only)
e Indicator adjusting plate
f Secondary adjusting plate
3506 g Primary adjusting plate

❏ Set dimension Z rectly set, tighten acorn nut d. Verify

that the adjusting plate assembly is
• Replace the rear access door on the properly seated at the rear access
burner, making sure that the adjusting door, as shown in Figure 5.
plate assembly is now securely held in • Attach the oil line from the oil valve
place. to the nozzle line end. Tighten se-
• Loosen acorn nut d in Figure 5. Slide curely.
the nozzle line and plate assembly un- • Before proceeding, check dimen-
til dimension Z in Figure 5 is: sion Z once again. Loosen acorn nut
CF2500A/CF2500 1³⁄₄" ± ¹⁄₁₆" d if necessary to reposition the
CF3500A (tube KM) 2⁵⁄₈" ± ¹⁄₁₆" nozzle line. Once dimension Z is set,
CF3500A (tube KR) 3⁹⁄₁₆" ± ¹⁄₁₆" do not loosen acorn nut d again.
Measure dimension Z from the flat • When dimension Z (from end of air tube For the setting of acorn nut c, refer
3507 surface between (not on) the raised fins. to flat area of front face of head) is cor- to page 12.

Figure 7 – Burner installed in appliance front ❏ Insert burner

• Position the burner in the front of
the appliance and loosely tighten
the nuts on the mounting studs. The
H burner should be pitched downward
2° as shown in Figures 3 and 7.
• See Figure 7. Install the pedestal
support kit (recommended) by at-
taching the ³⁄₄" npt flange (item a)
K to the bottom of the burner using
J the (4) #10 screws provided. Cut and
1¾" thread (one end only) a ³⁄₄" pipe
D nipple (item b ) with length 14.5
inches less than dimension D in Fig-
a b ure 7. Thread the pipe into the
flange. Then slip the pipe end into
3509 c the floor flange (item c).
• Secure the burner to the appliance
by tightening the nuts on the burner
Legend flange mounting studs. Then secure
H Housing total length — 20" the pedestal support floor flange set
J Center to bottom of housing — 14¹⁄₂" K Overall housing height — 22³⁄₄" screw to the pipe.

Form 6104 BCF-35-R0699 7

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 Instruction Manual – Model CF2500/CF3500 Oil Burner

Connect fuel line(s)

• Install the oil lines using the following Figure 8a
guidelines. Failure to comply could lead One-pipe oil flow, one nozzle, low fire, “H” pump
to equipment damage and present a risk of
severe personal injury, death or substan-
200 psig g
tial property damage due to leakage of oil to
and potential fire hazard. d c c 300 psig
• Use only flare fittings at joints and con-
nections. Never use compression fittings.
200 psig b
• Install fittings only in accessible locations to a
to assure any leak will be detected. 300 psig
p
• Where joint sealing is needed, use only
pipe dope. Never use Teflon tape. Tape
strands can break free and damage the fuel c
unit.
• Never use a one-pipe oil system with a lift
in excess of 2 feet with an H fuel unit. On 3510
two-pipe oil systems, verify that the suc-
tion line vacuum does not exceed the fuel
unit manufacturer’s recommendation.

Figure 8b
One-pipe oil flow, two nozzles, high fire,“H” pump

❏ Fuel unit by-pass plug g

200 psig
to
The CF2500A, CF2500 and CF3500A burners d c c 300 psig
are shipped without the by-pass plug
installed. You must install this plug on two- 200 psig b
pipe systems. DO NOT install the by-pass plug to a
in the fuel unit if connected to a one-pipe oil 300 psig
p
system. Failure to comply could cause fuel
unit seal failure, oil leakage and potential fire
c
and injury hazard.
200 psig
to
❏ Oil supply/return lines 300 psig
3511

• Install the oil tank and oil lines in accordance with all
applicable codes.
• Size the oil supply and return lines using the guidelines Legend (see opposite page)
given in the fuel unit literature included in the literature
envelope. Oil line flow rate will equal the burner rate for
one-pipe systems. For two-pipe systems, refer to Table 3
for the fuel unit gearset capacity - the rate at which fuel is
recirculated when connected to a two-pipe system. Size
two-pipe oil lines based on this flow rate.
• Use continuous lengths of heavy-wall copper tubing, Table 3 - Fuel unit gearset capacities
routed under the floor where possible. Do not attach fuel
lines to the appliance or to floor joists if possible. This
reduces vibration and noise transmission problems Fuel unit Gearset capacity
• Install an oil filter sized to handle the fuel unit gearset flow model number (gallons per hour)
capacity (Table 3) for two-pipe systems. Size the filter
for the firing rate for one-pipe systems. Locate the filter H5PAN-C100H 79
immediately adjacent to the burner fuel unit.

8 Form 6104 BCF-35-R0699

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 Instruction Manual – Model CF2500/CF3500 Oil Burner

Figure 9a • Install two high-quality shutoff valves in accessible loca-

Two-pipe oil flow, one nozzle, low fire, “H” pump tions on the oil supply line. Locate one valve close to the
tank. Locate the other valve close to the burner, upstream
of the fuel filter.
200 psig g
to
d c c 300 psig
❏ Burner fuel flow
200 psig b
to
• One-pipe systems – See Figure 8 for the fuel flow paths
a
300 psig for high-fire and low-fire operation. Oil supply connects to
p
one of the fuel unit Inlet ports.
c Do not install by-pass plug in a one-pipe
system. Could cause unit seal failure, oil
k leakage and potential fire and injury hazard if
ignored.
3512

• Two-pipe systems – See Figure 9 for the fuel flow paths

for high-fire and low-fire operation. Oil supply connects to
one of the fuel unit Inlet ports. Oil return connects to the
fuel unit Return port.
Figure 9b By-pass plug must be installed in a two-pipe
Two-pipe oil flow, two nozzles, high fire, “H” pump system. Failure to comply could cause unit
seal failure, oil leakage and potential fire and
200 psig g injury hazard.
to
d c c 300 psig • Low-fire/high-fire operation – The fuel unit nozzle port
pressure is factory set at 300 psig.
200 psig b • At high fire, full pressure (300 psig) is applied at both
to a oil nozzles, causing full input.
300 psig
p • At low fire, full pressure (300 psig) is applied at one
nozzle, causing reduced input.
c

200 psig k
to
300 psig 3513

Legend (for Figures 8a, 8b, 9a and 9b)

a Return port
b Nozzle port
c Oil valves
d Nozzle & adapter
g Inlet port
k Return line to oil tank
p Air bleed valve

Form 6104 BCF-35-R0699 9

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 Instruction Manual – Model CF2500/CF3500 Oil Burner

Wire the burner

Do not by-pass any safety control. By-passing a safety control could result in severe personal injury, death or
substantial property damage.

Install the burner and all wiring in accordance with the burner, with R8184 oil primary, for reference purposes only.
National Electrical Code and all applicable local codes or The CF2500/CF3500A burner is available with many different
requirements. wiring configurations. Refer to the wiring diagram shipped
with the burner for the actual wiring applying to your burner.
Wire the burner in compliance with all instructions provided
by the appliance manufacturer. Verify operation of all controls When firing over 20 GPH, the CF2500 and CF3500A will be
in accordance with the appliance manufacturer's guidelines. supplied with a flame safeguard control. An airflow switch
and low-fire start switch may also be supplied. Consult local,
See Figure 10 for a typical wiring diagram for a CF2500A state and federal codes for burner requirements above 20 GPH.

Figure 10 – CF2500A Typical wiring H N G Power supply

120v/60 hz
Legend
FD
FD Fused disconnect, by others

LM Limit controls, by others

OP Operating controls, by others

Field wiring
LM OP
PR Oil primary control, R8184 typical
Factory wiring
CC Flame sensor, cad cell typical
BK = black OR = orange WH = white
TM Optional delay timer
BK BL = blue BR = brown/red
TR Ignition transformer
Motor M1 wiring 14 ga All other wiring 16 ga
PR
M1 Burner motor

S1 Primary oil valve T

S2 High-fire valve

S3 Redundant oil valve

T
DM Damper motor and end switch

∗ H/L Insert high/low-fire control here TR

BL (Note 1) WH
LFHS Low-fire hold switch BL

T–T 24-volt thermostat/limit terminals S3

TM
F-F Cad cell flame sensor terminals OR OR S1 WH
OR T
Note 1 — Indicates alternate wiring for in-
terrupted ignition controls — connect DM
transformer to blue primary lead. For in-
LFHS H/L
termittent duty — connect transformer to
orange primary lead only. F W
CC S2
DM
R B
M1
F
BR WH
Electrical shock hazard - can cause
injury or death. Disconnect power before
installing or servicing. Provide ground WH
wiring to the burner in accordance with WH
the National Electrical Code. 3514

10 Form 6104 BCF-35-R0699

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 Instruction Manual – Model CF2500/CF3500 Oil Burner

Sequence of operation — typical

1. On call for heat from the appliance operating controls (and high fire. The damper motor end switch is set to operate
the circuit from T to T of the R8184 closed), power is before the damper has reached full open to assure a smooth
applied to the R8184 black wire (BK). transition to high fire.

2. The R8184 applies 120 volts to the orange wire (OR), acti- 7. If a high/low-fire control is installed at H/L, this control
vating the burner motor (M1) and the ignition transformer will cycle the firing rate automatically during an operat-
(TR). The oil pump is operated by the burner motor, so oil ing cycle.
pressure is delivered to the oil valve inlets.
8. At the start of the cycle, the R8184 begins checking for
3. Power is applied to the oil valve circuit. If optional timer, flame signal between F and F. Flame must be established
(TM), is installed, oil flow will be delayed for the timer within 15 seconds of initiation. If no flame is sensed after
duration, thus providing a prepurge period. When the timer 15 seconds, the R8184 will terminate all power to the
times out, oil valves S1 and S3 are activated, allowing oil blower and oil circuits, shutting the burner down. The con-
to flow to the low-fire nozzle. trol will electrically lock out.

4. With the low-fire hold switch (LFHS) in the “IN” position, • To reset the control after lockout, wait 2 to 3 minutes
the burner will remain at low fire. after lockout to give the internal switch time to cool.

5. When the low-fire hold switch is moved to the “OUT” Then push the reset button on the primary control, al-
position, the damper motor (DM) will be activated. This lowing the burner to operate in normal sequence.
will begin opening the air damper.
• Troubleshoot the reason for flame sense failure.
6. When the damper motor end switch is tripped, high-fire oil
valve (S2) is activated, providing pressure at the high-fire 9. When the call for heat signal terminates (at the black wire
oil nozzle. With both nozzles firing, the burner is now at of the R8184), the R8184 terminates power to all circuits,
closing the oil valves and stopping the burner motor.

Prepare the burner for start-up

Start-up checklist – Verify the following before attempting to start burner.

❏ Combustion air supply and venting have been inspected ❏ Fuel supply line is correctly installed, the oil tank is
and verified to be free of obstructions and installed in sufficiently filled, and shutoff valves are open.
accordance with all applicable codes.
❏ Burner is securely mounted in appliance, with pressure
❏ Oil nozzles have been selected correctly and securely firing plate and gasket installed for pressurized chamber
installed in the nozzle adapter. application.
❏ Fuel unit by-pass plug is installed for two-pipe oil systems. ❏ Appliance has been filled with water (boilers) and controls
(Do not install by-pass plug for one-pipe systems.) have been operationally checked.
❏ Fuel connection to nozzle line assembly is secure. ❏ Burner has been installed in accordance with appliance
manufacturer’s instructions (when available).
❏ Dimension Z has been set per this instruction manual. See
Set dimension Z on page 7. ❏ Also refer to appliance manufacturer’s instructions (when
available) for start-up procedures.

Form 6104 BCF-35-R0699 11

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 Instruction Manual – Model CF2500/CF3500 Oil Burner

Prepare the burner for start-up - continued

❏ Z dimension Figure 11 – Adjusting plate initial setting, typical

• Should be set per these instructions (see page 7). The top d e f h b c g
acorn nut (Figure 11, item d) should never be loosened
once the Z dimension is initially set. 3515

❏ Adjusting plate assembly (Figure 11)

• Make sure spline nut (item b) and bottom acorn nut (item
c) are loose.

❏ Initial head position (Figure 11) Legend

• The indicator plate assembly (item e) markings correspond b Spline nut for securing nozzle line f Secondary adjusting
to head position settings. c Bottom acorn nut (for head adjust- plate
• Slide the secondary adjusting plate (item f) toward the rear ments g Primary adjusting
of the burner until the number on the indicator plate corre- d Top acorn nut (for setting dim. Z only plate
sponds to the initial head setting given in Table 4 for the — do not loosen after setting Z) h Copper oil line from
desired firing rate (high-fire). e Indicator adjusting plate oil valve to nozzle line
• Figure 11 shows a typical example, with a head setting of
5.
• When the head position has been set, tighten the bottom ❏ Prepare the fuel unit for air venting
acorn nut (item c) and the spline nut (item b).
• To vent air from one-pipe oil systems, attach a clear hose to
the vent plug on the fuel unit. Provide a container to catch
❏ Initial air settings (Figure 12) the oil. Loosen the vent plug.
• Vent the air as described under Start the burner, page 14.
• Loosen the screw holding the air adjusting plate (item m).
Set the air to the desired low-fire rate. (The numbers on this
plate correspond to the approximate firing rate settings Table 4 – Initial indicator adjustment plate
given in Table 5.) settings (head position)
• Rotate the air adjusting plate until the lower edge of the
pointer is opposite the number from Table 5 corresponding Approximate Firing rate, gph
to the desired low-fire rate. head settings Tube “KP” Tube “KM”/“KR”
• This initial setting should be adequate for starting the
burner at low fire. Once the burner is in operation, the air 0 -- --
setting will be adjusted for best performance as discussed
later in this manual. 1 -- 17.00
• The damper moves to high-fire position as the damper rod
(item d) rotates the damper linkage arm (item f). You will 2 -- 17.50
adjust the setting of the damper linkage arm when setting 3 17.00 18.00
the high-fire air as discussed on page 14 in Start the
burner. 4 17.50 18.50
• Follow the procedures given later in this manual for fine
tuning the air settings. 5 18.00 19.00

6 18.50 20.00
❏ Set appliance limit controls 7 19.00 21.00

• Set the appliance limit controls in accordance with the 8 20.00 28.00
appliance manufacturer's recommendations.
• Move the low-fire hold switch (not shown) to the “IN” 9 21.00 32.00
position. This will hold the burner in low fire during initial 10 25.00 35.00
start-up.

12 Form 6104 BCF-35-R0699

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 Instruction Manual – Model CF2500/CF3500 Oil Burner

Figure 12 – Air damper and damper motor assembly

a a

b b

OPEN CLOSE
CLOSE c

h
7 8 9 10 1
6 11
e 4
5 2

3
2
f
0 1
g
k
m

3516 3517

Table 5 – Initial air adjusting plate settings

(damper position) Legend (Figure 12)

Approximate Firing rate, gph a Damper motor – do not adjust internal cam
adjusting plate
settings Tube “KP” Tube “KM”/“KR” b Arm assembly
0 -- -- c Ball joint assembly – do not adjust position of ball
1 8.00 8.00 joint

2 9.00 9.00 d Damper rod

3 11.00 11.00
e Damper rod guide
4 12.00 12.00
5 15.00 15.00 f Damper linkage arm - sets high-fire air position

6 17.00 17.00 g Damper

7 18.00 19.00
h Damper label - position indicator for air adjusting plate
8 19.00 22.00
9 20.00 25.00 k Damper indicator - permanently attached to damper

10 22.00 29.00 m Air adjusting plate - sets low-fire air position

10.5 25.00 35.00

Form 6104 BCF-35-R0699 13

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 Instruction Manual – Model CF2500/CF3500 Oil Burner

Start the burner

Do not proceed unless all prior steps in this ❏ Place the end of the tube in a container to catch the
manual have been completed. Failure to oil. Then loosen the fuel unit air vent valve.
comply could result in severe personal injury,
death or substantial property damage. ❏ Tighten the air vent valve after all air has been purged.
❏ IF burner stops during venting —
Do not attempt to start the burner when excess • The burner primary control will lockout if flame
oil has accumulated, when the appliance is is not established within its time limit.
full of vapor or when the combustion chamber This is typically 15 seconds for R8184 primary
is very hot. Do not attempt to reestablish flame controls, but may be less for other flame
with the burner running if the flame should be supervisory controls.
extinguished during start-up, venting or • The burner may lockout several times during the
adjustment. Allow the unit to cool off and all period needed to purge all the air. Reset the
vapors to dissipate before attempting another primary control each time in order to continue
start. Failure to comply with these guidelines purging.
could cause an explosion or fire, resulting in • If the burner is equipped with an R8184 primary,
severe personal injury, death or substantial you will need to wait about 2 minutes after each
property damage. lockout to allow time for the reset switch to cool.
• Squeeze off the air bleed tubing or close the air
Damper motor and motor arm assembly - Do vent valve when the pump stops running to prevent
not attempt to adjust the cam setting in the air from flowing back into the oil line.
damper motor. It is factory preset. Do not move If the fuel unit air vent valve is completely
the ball joint assembly further out on the open, assuring no flow of oil to the burner oil
motor arm assembly. This would change the nozzle, you can temporarily jumper the F-F
timing of damper opening versus fuel rate. terminals of an R8184 primary during the
The damper linkage arm screw must be purge period to allow enough time for all air
tightened securely to assure the damper will to purge. Never leave the burner unattended
provide sufficient air at high fire. Failure to when doing this. Remove the jumper when
comply could cause unreliable combustion purging is completed. This procedure should
or flame failures, leading to possible severe only be used by a qualified burner technician,
personal injury, death or substantial property experienced in burner operation and
damage. control. Improper application of this method
can cause combustion chamber explosion, fire
hazard or fuel leakage, resulting in severe
personal injury, death or substantial property
damage.
❏ Start burner and vent air from oil line ❏ IF burner stops after flame established —
1. Move the low-fire hold switch to the “IN” position (to • Additional venting is probably required. Repeat
hold burner in low fire when started). the air venting procedure.
2. Verify that the air adjusting plate (Figure 12, item m) has 9. Once flame is steady, proceed to Set high-fire air.
been set to the initial low-fire air position as described on
page 12 under Initial air settings.
3. Loosen the screw on the damper linkage arm (Figure 12, ❏ Set high-fire air
item f) and allow the damper indicator (Figure 12, item k) 1. Allow the burner to run at low fire until the appliance has
to rest on the air adjusting plate (Figure 12, item m). warmed sufficiently.
4. Open the oil shutoff valves in the oil supply (and return) 2. Visually check the flame. The flame should not be dark
line(s) to the burner. orange or smoky. If the flame appears to be smoking, in-
5. Set the thermostat (or operating control) to call for heat. crease the amount of air by readjusting the damper indi-
cator to a higher number.
6. Close the line switch to the burner. The burner motor
should start immediately. 3. Once the appliance has warmed, the high-fire setting can
be checked and adjusted.
7. If the burner motor does not start, reset the motor overload
switch (if so equipped) and press the reset switch of the 4. Locate the approximate air adjusting plate setting for high
burner primary control. fire in Table 5, page 13.
8. Vent the fuel unit as soon as the burner motor starts 5. Place the low-fire hold switch in the “OUT” position.
rotating. To vent — The damper motor will begin to rotate.
a. At the same time, loosen the screw securing the air
❏ Attach a clear plastic tube to the air bleed valve (Figure adjusting plate (Figure 12, item m) as the damper be-
8a, 8b, 9a or 9b as applies, item p). gins to move.

14 Form 6104 BCF-35-R0699

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 Instruction Manual – Model CF2500/CF3500 Oil Burner

b. Slowly rotate the air adjusting plate (increase the ❏ Set low-fire air
amount of air) as the damper drives to high-fire.
c. Lock down air adjusting plate at the high-fire air set- 1. Loosen the air adjusting plate (Figure 12, item m) screw
ting found in Table 5 for the high-fire rate. and set the air adjusting plate at the low-fire air setting
found in Table 5, page 13. The damper should stay at the
6. Use combustion test instruments to adjust the burner. high-fire setting. The damper linkage will prevent move-
a. Adjust the air until a trace of smoke is achieved with ment of the damper plate.
CO2 level as high as possible (lowest possible O2).
Example: 13.5% CO2 (2.5% O2) with a trace of smoke. 2. Move the low-fire hold switch from the “OUT” to the
b. Increase the air to reduce CO2 by 2 percentage points “IN” position.
at a zero smoke level. (Increase O2 by 3 percentage a. The damper will return to the low-fire air setting.
points at a zero smoke level.) 3. Check the smoke and CO2 (O2) levels.
Example: Reduce CO2 from 13.5% to 11.5%, with zero a. Pull a smoke sample from the flue.
smoke (or increase O2 from 2.5% to 5.5%). b. The sample should be clean (zero smoke level).
c. A margin of reserve air has been added to accommo- c. Check the CO2 (O2) level:
date variable conditions. CO2 should be at 11 to 12% (O2 at 5.9 to 4.5%).
7. Check the breech draft pressure against the appliance If the CO2 is less than 11% (O2 more than 5.9%), decrease
manufacturer’s recommended setting (typically + 0.1" the air and check the smoke level.
W.C.).
4. Operate the burner from low fire to high fire and back to
8. If the breech pressure is higher or lower than recommended verify operation.
level, adjust the appliance breech damper to achieve the
specified setting. Recheck the smoke and CO2 levels. 5. Turn the burner off. Wait one or two minutes (for chamber
Adjust burner air if necessary. to clear) and then turn on again to verify starting charac-
teristics.
9. Once all settings are complete and satisfactory, rotate the
damper linkage arm (Figure 12, item f) until it touches 6. Perform limit circuit performance test specified by appli-
the damper rod (Figure 12, item d) and tighten the damper ance manufacturer to verify operation of burner/appli-
linkage arm screw securely. ance combination.

Maintenance and service

The burner must be serviced at least annually by a qualified service technician to assure continued reliable
operation. Operation and adjustment of the burner requires technical knowledge and the use of combustion test
instruments. Do not tamper with the burner or controls. Failure to comply could result in failure of the burner or
system, resulting in severe personal injury, death or substantial property damage.

Annual service ❏ Inspect combustion air and vent systems.

— by qualified service technician ❏ Replace oil filter.
❏ Oil motor (if not permanently lubricated).
Have the burner inspected, tested and started at least annually
by a qualified service technician. This annual test/inspection
should include at least the following: Monthly maintenance
— by owner
❏ Replace oil nozzles.
❏ Clean burner and blower wheel (if needed to remove lint ❏ Observe combustion air openings and vent system for
or debris). integrity. Openings must be clean and free of any obstruc-
❏ Test ignition and combustion at low and high fire and tions.
verify air damper settings. ❏ Check the oil lines and fittings to verify there are no leaks.
❏ Test oil supply line vacuum - verify that it is within al- ❏ Observe burner ignition and performance to verify smooth
lowable range indicated in fuel unit literature. operation.
❏ Check pump pressure to nozzles at low and high fire. ❏ Shut the system down if you observe abnormal or ques-
❏ Inspect fuel system (including tank, lines and all connec- tionable operation. Call a qualified service agency for
tions). professional inspection and service.

Form 6104 BCF-35-R0699 15

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Instruction Manual – Model CF2500/CF3500 Oil Burner

Replacement parts
1 2 4 5 3 11 19 25
20

12
LOW FIRE START VALVE 21
OUT IN LOW FIRE HOLD

15
16 22

7 6 8

7 8 9 10
6 11
5 12
4

3
2
01
9 10 13
23
3518

14 17 18 24

Item Part name Description Part number Item Part name Description Part number

1 Air tube Specify burner model and tube length 9 Damper linkage arm All models 5984BK
(See Figure 2, page 5 for codes)
10 Damper spring All models 4339
2 Flange kit Adjustable flange See Figure 13
Adjusting plate assem-
Damper motor assem- All models 11 bly
All models 51478
3 bly
51229
12 Knurled nut All models 3666
4 Electrode assembly All models 51212
13 Fuel pump H pump (standard) 21529
9 ¼" long 5990092
14 Pedestal kit All models 51193
10 ½" long 5990104
5 Ignition leads 12 ¾" long 5990126
15 Oil valve Box mounted 7201

16 ¼" long 5990162 16 Damper door All models 16703GY

20 ¼" long 5990202 17 Damper indicator All models 5985BK

6 Nozzle line assembly Specify burner model and air tube length 18 Coupling Specify pump used

7 Head assembly CF2500/CF3500A 51475P 19 Sight glass All models 31346

8 Fuel lines Specify length 20 Rear cover assembly CF2500/CF3500A 51204

21 Control Specify
22 Transformer 12,000 volt 51214
Figure 13 23 Motor Specify burner model
Adjustable mounting plates for CF2500/CF3500A
24 Blower wheel CF2500/CF3500A 21528
25 Motor relay Specify relay used

Kit #51631 Kit #51630

16" Diameter 16" Diameter
(Use only with
KR air tube)
Kit #51498
13.92" Diameter

U.S.A.: P. O. Box 1289 • Elyria, Ohio 44036 • 800-645-2876 • 440-327-1060 • FAX 440-327-1064
Canada: R. W. Beckett Canada, Ltd. • 430 Laird Road • Guelph, Ontario, N1G 3X7 • 800-665-6972 • FAX 519-763-5656

Form 6104 BCF-35-R0699