Adjusting Beckett Fuel Pump Pressure: A Step-By-Step Guide

Adjusting the pressure on a Beckett fuel pump is not a simple task and should not be attempted by a novice. It is critical to understand the relationship between pump pressure and nozzle size, as well as the potential consequences of overfiring or underfiring a boiler. Incorrect adjustments can lead to serious issues, including the destruction of the boiler over time. To adjust the pressure, one must have a clear understanding of the system and access to the right tools, such as a combustion analyzer, smoke tester, and pressure gauge. It is highly recommended to seek the assistance of a trained technician or professional with the necessary expertise and equipment to safely and effectively adjust the pressure on a Beckett fuel pump.

Check the nozzle size and pump pressure relationship

The relationship between the pump pressure and nozzle size is critical. If a boiler is designed to run at 1 gallon per hour and you install a 1-gallon-per-hour nozzle, the nozzle is rated to deliver one gallon per hour at 100 pounds of pressure, and 100 pounds ONLY. If you raise the oil pump pressure to 200 pounds, a 1-gallon-per-hour nozzle will not deliver twice as much oil, but roughly a third more - exceeding the boiler's capacity to handle that big a flame and potentially destroying the boiler over time.

Conversely, you CAN underfire a boiler, but not beyond the limits of the burner's design. Typically, the lowering of the firing rate by using a smaller nozzle is a good way to begin this process; which, in many cases, is perfectly okay to do. All the burner guys generally agree that higher pump pressure results in a finer oil "mist," which results in a cleaner burn.

However, you must use a "nozzle firing rate chart" to determine what a 1-gallon-per-hour nozzle will do at 140 pounds in BTU firing rate, always being sure the added pressure from the 100-pound "standard" upon which all nozzle firing rates and imprints are based.

The way to measure the actual pressure is to look at the oil pump decal, see which port is designed for a gauge, and attach one to determine the actual pressure. Then, use the firing rate conversion chart to determine the REAL firing rate once you change the pressure on whatever nozzle rating you have.

One last but critical caveat: Without combustion test apparatus, YOU CANNOT determine the results of your tweaks and will create a dangerous situation. Smoke and CO are your enemies. Excess air is as well. Without a combustion analyzer, you are embarking on a disaster on all fronts.

When considering proper nozzle selection, remember these points:

• Always use the appliance manufacturer’s nozzle specifications.
• Follow the burner manufacturer’s recommendations when retrofitting a new burner to an old appliance.
• You must set up the combustion with properly maintained test instruments. Smoke, CO2, or O₂, drafts, and pump pressure.
• Once the CO2 has been determined at a trace of smoke, add enough extra air to reduce the CO2 by one and one-half percent.

Use a combustion test apparatus to avoid dangerous situations

Adjusting the pressure on a Beckett fuel pump is not a simple task and should not be performed by a novice. It is critical to understand the relationship between pump pressure and nozzle size, as an incorrect adjustment can lead to a dangerous situation. Without a combustion test apparatus, you cannot determine the results of your adjustments, and you risk creating a hazardous environment with high levels of smoke and CO.

To avoid such dangerous situations, it is essential to use a combustion test apparatus, such as a combustion analyzer and a smoke tester, to ensure that any adjustments made to the Beckett fuel pump pressure do not result in an overly rich or poor mixture. Here is a step-by-step guide on how to use a combustion test apparatus to adjust the pressure on a Beckett fuel pump safely:

• Understand the Basics: Before making any adjustments, familiarize yourself with the Beckett fuel pump's design and components. The Beckett CleanCut fuel unit, for example, uses a solenoid valve to control oil flow, offering improved reliability and faster actuator speed compared to traditional cone valve and diaphragm systems.
• Prepare the Necessary Tools: Gather all the required tools and equipment, including a combustion test apparatus (combustion analyzer and smoke tester), pressure gauge, and any other specialized tools recommended by Beckett, such as the pump testing manifold model #P115-10.
• Consult the Manual: Refer to the Beckett fuel pump's manual or instructional videos to understand the specific steps for your model. The Beckett website offers a range of resources, including product manuals, troubleshooting guides, and training videos, which can be extremely helpful.
• Determine the Correct Pressure: Refer to the pump's decal to identify the port designed for a pressure gauge. Attach the pressure gauge to this port to determine the actual pressure. This step is crucial as it provides a baseline for your adjustments.
• Adjust the Pressure: If adjustments are necessary, refer to the nozzle firing rate chart to determine the correct pressure for your specific nozzle. The relationship between pump pressure and nozzle size is critical, as an incorrect pressure can lead to an overly rich or poor mixture, affecting combustion.
• Perform a Combustion Test: Using the combustion test apparatus, perform a combustion test to ensure a safe and efficient burn. This typically involves a smoke test, draft, and CO2 testing. Adjust the air shutter concurrently with pump pressure adjustments to maintain the appropriate air-fuel mixture.
• Fine-Tune as Needed: Based on the results of the combustion test, make fine adjustments to the pump pressure and air shutter until you achieve optimal combustion. It is crucial to have both the combustion analyzer and smoke tester in hand during these adjustments to ensure a safe and efficient burn.
• Retest and Verify: After making adjustments, retest the combustion and verify that the CO2 levels have been reduced by 1 to 2 percentage points and that the smoke test reads zero. This ensures that you have built in a margin to accommodate variables during the heating season.
• Seek Professional Help: If you are unsure about any aspect of the process or the results of your adjustments, do not hesitate to consult a licensed technician or seek professional assistance.

Remember, adjusting the pressure on a Beckett fuel pump is a complex task that requires a good understanding of combustion and the fuel pump's specific design. Always prioritize safety, and when in doubt, leave it to a trained professional.

Check the oil pump decal to determine the port for a gauge

To check the oil pump decal to determine the port for a gauge, follow these steps:

First, it is important to understand the relationship between pump pressure and nozzle size. If a boiler is designed to run at a certain capacity, installing a nozzle with a different capacity can affect the performance of the boiler. For example, if a boiler is designed to run at 1.00 GPH and you install a 1.00 GPM nozzle, the nozzle is rated to deliver one gallon per hour at 100 PSI. If you raise the oil pump pressure, the nozzle will not deliver twice as much oil but will instead deliver roughly a third more, which can exceed the boiler's capacity and potentially destroy it over time.

To measure the actual pressure, locate the oil pump decal and identify which port is designed for a gauge. Attach a gauge to this port to determine the current pressure. Then, use a firing rate conversion chart to determine the real firing rate once you change the pressure on the nozzle.

It is critical to have a combustion test apparatus to safely adjust the pressure. Without one, you will be unable to determine the results of your adjustments, creating a dangerous situation with potential smoke and CO buildup.

Once you have determined the correct port and attached a gauge, you can proceed with further adjustments, but it is recommended to have a professional perform these adjustments to ensure safety and avoid potential issues.

Use a combustion analyzer to adjust the air shutter

A combustion analyzer is a crucial tool for adjusting the air shutter on a Beckett fuel pump. This device allows you to evaluate the combustion process and ensure the furnace is operating efficiently and safely. By understanding the key parameters involved in combustion, you can fine-tune the fuel-to-air ratio and achieve optimal performance.

To begin, locate the certified combustion test access fitting on the exhaust flue, typically one to two feet above the furnace or boiler. Insert the probe from your combustion analyzer into this access fitting to measure the efficiency of the exhaust flue in removing flue gases and converting fuel and air into heat.

The combustion analyzer will provide various readings, including ambient CO, CO air-free, oxygen levels, carbon dioxide (CO2), ambient temperature, stack temperature, dew point, and draft. These values give you insights into the efficiency of combustion and the amount of CO generated.

Pay close attention to the CO levels as an imbalance in combustion can lead to the creation of carbon monoxide, a toxic and odorless gas. By optimizing the fuel-to-air ratio, you can minimize the risk of CO poisoning for occupants.

Now, let's discuss the specific steps to adjust the air shutter using the combustion analyzer:

• Loosen the screws or adjust the sliding metal piece: Depending on your Beckett fuel pump model, you may need to loosen the screws near the air shutter or adjust a sliding metal piece at the end of the venturi tube to control the airflow.
• Light the burner: With the combustion analyzer in place, ignite the burner to start the combustion process.
• Monitor the flame color: Observe the color of the flame. A proper air-to-fuel mixture will result in a blue flame with minimal yellow tips. If the flame is predominantly yellow or orange, there is too much air, while a weak blue flame indicates insufficient air.
• Adjust the air shutter: Based on the flame color, adjust the air shutter accordingly. If there is too much air, close the air shutter slightly to reduce the airflow. If there is too little air, open the air shutter to allow more air into the combustion process.
• Repeat for all burners: If your Beckett fuel pump has multiple burners, repeat the above steps for each burner to ensure consistent performance across all of them.
• Tighten the screws: Once you are satisfied with the adjustments and the flame color is optimal, tighten the screws to secure the air shutter in place.

Remember, always refer to the owner's manual of your Beckett fuel pump for specific instructions tailored to your model. Additionally, ensure that you have the necessary qualifications and training to perform these adjustments safely and effectively.

Check the pump strainer and clean the filter

To check the pump strainer and clean the filter of your Beckett fuel pump, follow these steps:

Removing the Strainer

• Turn off the Beckett fuel pump and disconnect the power supply to prevent electrical shock or equipment damage.
• Remove the pump cover by loosening the four cover screws.

Cleaning the Strainer

• Pull out the strainer.
• Clean the pump strainer using a brush and clean fuel oil or kerosene.

Reinstalling the Strainer

• Remove the old cover gasket and replace it with a new one.
• Install the cover and tighten the four cover screws evenly, using the same torque for each.

If you are using the inlet into the side of the fuel unit, it is not necessary to remove the cover to check the strainer. Simply remove the inlet line and fitting to view the strainer through the inlet opening. If the strainer is clean at the inlet opening, it will be clean throughout. To replace the strainer and cover gasket, use part number 51843U.

Frequently asked questions