beckett PF20322 Clean Cut Fuel Pump Instructions

: June 17, 2024
: beckett

Table of Contents

beckett PF20322 Clean Cut Fuel Pump
PRODUCT INFORMATION
Disassembly
Before Installation
Installation Tips
CONTACT
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beckett PF20322 Clean Cut Fuel Pump

PRODUCT INFORMATION

WARNING Professional Service Required

Incorrect installation, adjustment, or misuse of this product could result in severe personal injury, death, or substantial property damage from fire, carbon monoxide poisoning, soot or explosion.
The pump must be installed, adjusted, and put into operation only by a qualified individual or service agency that is:

Licensed or certified to install and provide technical service to oil heating systems.
Experienced with all applicable codes, standards, and ordinances.
Responsible for the correct installation and commission of this equipment.
Skilled in the adjustment of oil burners using combustion test instruments.

The installation must strictly comply with all applicable codes, authorities having jurisdiction, and the latest revision of the National Fire Protection Association Standard for the installation of Oil-burning Equipment, NFPA 31 (or CSA-B139 and CSA-B140 in Canada). Regulation by these authorities may require requirements and instructions to those provided in this installation manual. These instructions cover only the replacement of a failed pump or the upgrade of an existing pump. For instructions on how to install a new appliance, fuel tank, or burner see the applicable installation manuals.

WARNING Oil Leak & Fire Hazard

Not adhering to the following may fail the valve seals and cause the pump to leak oil.
Never exceed 3 psig on the Pump Inlet or Return Ports. (see NFPA 31-25, 8.6.3).
Approved fuels – USA: ASTM D396 for #1 or #2 heating oil, ASTM D396 for B6-B20 biodiesel blends. Canada: #1 Stove oil or #2 Furnace oil only.
Never place any fuel line restriction that may increase the pressure at the Pump Return Port.
If a vacuum safety valve is used on the inlet line it must be equipped with an accumulator and pressure relief to the tank.
Dangerous thermal expansion of oil trapped by an inlet line check valve can create extreme pressures that damage fuel unit seals, line fittings, inlet filters, gauges, and other components.
Do not use Teflon tape or compression fittings.

Disassembly

Disconnect the power to the burner and the oil supply system. Note the burner air settings.
Make sure the coil voltage on the pump matches the replacement part.
Unplug the cord set from the coil.
Remove the existing pump and properly dispose (See Figure 1).
Remove all fuel lines: Supply line, output to the nozzle, and return line if used.
Remove the mounting screws. Most are 3/8” hex heads.
Inspect the plastic coupling shaft that drives the pump (See Figure 2). Replace if the “D” Shaped holes are rounded or the internal splines are worn. $beckett-PF20322-Clean-Cut-Fuel-Pump-FIG-1 $2$$

Beckett CleanCut Pumps

Note: The PF204[XX] CleanCut Pump with a double gear set is referred to as a “ Two Stage” on the pump label. This pump is used to provide extra lift for long oil supply run lengths. This should not be confused with a “High Fire/Low Fire pump” which can be described as a “2-stage”.

Maximum Allowable Vacuum Inches hg

| PF203[XX]| PF204[XX]
Single Pipe System| 6”| 12”
Two Pipe System| 12”| 17”

Oil Supply Vacuum Test: To verify the operating vacuum is appropriate for the fuel pump.

With no power and oil to the burner remove fittings to the pump.
Install a vacuum gauge in an unused inlet port on the pump, or install a tee with a gauge in the inlet line and reconnect the oil supply line.
Power the burner and check the gauge, letting the gauge stabilize.
The table below shows the maximum allowable vacuum for the pump.
- Note: Vacuum levels above the maximum limits can cause poor combustion performance.

Replacement Parts

Beckett Part No.| Description| Where Used
21807U| Cordset – 13” Non-Delay| All CleanCut® Pumps
21887U| Cordset – 13” w/ PD Timer| All CC Pumps – 4 Sec Time Delay
3713824U| Solenoid Coil 120VAC| PF20322
3713798U| Solenoid Coil 240VAC| PF20332
3713823U| Solenoid Coil 12VDC / 24VAC| PF20372
071N0805U| Solenoid Coil 120VAC| PF20323
071N0806U| Solenoid Coil 240VAC| PF20333
071N0807U| Solenoid Coil 12VC| PF20363
21877U| Valve Stem| All PFx03x2 Pumps
SP105281U| Cleancut® Strainer Kit| All 1-stage CleanCut Pumps
SPG33172BU| Strainer cover gasket (6)| PF203x2 Pumps
SPG33129BU| Strainer cover O-Ring (6)| PF203x3 Pumps
Couplings

Before Installation

Configure Pump Before Installation:

1-Pipe Operation: Remove the hex plug from the desired inlet port with either a 5/8” hex or 1/4” Allen wrench and discard. Connect inlet piping to the 1/4” NPT fitting using the appropriate pipe sealant. DO NOT USE TEFLON TAPE OR COMPRESSION FITTINGS.
2-Pipe Operation: The return port is only used for 2–pipe operation. For a 2-pipe operation, a bypass plug will need to be installed.
- a). CleanCut (Figure 3) — PF203[X]2, PF20422: Remove the return port 5/8” hex plug and discard. The port is located at the bottom of the pump. Install bypass plug set screw (1/16” – 27 NPT) with a 5/32” Allen wrench in the return port and tighten. Connect return piping to the return port (1/4” NPT) using the appropriate pipe sealant. Make sure no valves are placed in the return line. The return line can now be attached. DO NOT USE TEFLON TAPE or COMPRESSION FITTINGS.
- b). CleanCut (Figure 4) Page 3 — PF203[X]3: Remove the bypass plug access port (Item b) with a 5/32” Allen wrench, located below the nozzle port. Do Not discard. Install the bypass plug, which has the slotted screw head, and tighten it. Reinstall the access port making sure the O-ring is retained at the base of the plug and tighten. Remove the return port (Item g) located at the bottom of the pump with a 1/4” Allen wrench and discard. Connect return piping to the return port (1/4” NPT) using the appropriate pipe sealant. Make sure no valves are placed in the return line. The return line can now be attached. DO NOT USE TEFLON TAPE or COMPRESSION FITTINGS.
- a — Nozzle Port
- b — Return Port, remove plug for bypass plug installation, and install return turn fuel line fitting here.
- c — Pressure Adjustment (Slotted Screw)
- a— Nozzle Port 3/16” Flare Fitting
- b— By-pass Port Plug: 5/32” Allen wrench
- c — Solenoid.
- d— Pressure Regulation 5/32” Allen wrench
- e— Inlet Port 1/4” NPT, 1/4” Allen wrench
- f— Bleeder Valve 3/8” hex
- g— Return Port 1/4” NPT, 1/4” Allen wrench
- h— Inlet Port 1/4” NPT, 1/4” Allen wrench
- i— O-Ring
- j— Bypass plug with screwdriver slot
- The Beckett CleanCut pump can be oriented in any position up to 90° from the horizontal ground plane (as shown above).
- It must not be oriented upside down, or with the shaft pointing up or down.

Reassembly:

Fuel lines are assumed to be flare fittings or NPT pipe fittings. If in good condition, reconnect fuel lines using the existing fittings and pipes. Use pipe sealant on appropriate fittings. The use of pipe thread sealant compatible with both fuel oil and biodiesel fuel is required.

Install the coupling to the motor shaft. Apply a light coat of grease to the pump end of the coupling.
Align with the mounting holes and mount the pump using the bolts removed from the burner. See Figure 5 for the appropriate pump mounting orientation, about the horizontal plane.
To install a CleanCut fuel unit on a housing that has two top shutter mounting holes, make sure the screw is installed in the hole on the left that is closest to the front of the burner (air tube side).
When upgrading to a CleanCut, on housing that has only one air shutter locking screw, please see the installation tips section and Figure 6 for guidance on the removal of the lower tab, and use of the bottom screw for locking the shutter.
Optional Cord Set Installation:
- a). Route the new cord set through in the housing where the previous cord was located.
- b). Attach the violet and white wires of the cord set to the terminal location previously used on the control.
- c). Re-attach the control to the 4×4 junction box taking care not to pinch the wires in the 4×4.
- d). Close the igniter taking care not to pinch any wires.
- e). Connect the new cord set to the pump.

Installation Tips

If upgrading to a CleanCut pump and the shutter screw interferes with the solenoid on the fuel unit, see Figure 6 and follow these steps:
- a). Remove existing fuel unit and solenoid valves, if applicable, and appropriately dispose of them.
- b). Note the air setting of the shutter, then remove the air shutter, and set the shutter aside to be reinstalled later.
- c). Remove the shutter tab by using a pair of side cutter pliers and file sharp edges flush with the burner surface. This will permit the shutter to be locked securely.
- d). Install the air shutter using the screw located below the pump. Adjust the shutter to the original air setting and tighten the screw securely. Check combustion performance with test instruments. See the appliance manual or burner manual for guidance.
On older burners, do not install the top shutter screw, it will interfere with the solenoid on the fuel unit.
To install a CleanCut fuel unit on a housing that has two top shutter mounting screw holes, make sure the screw is installed in the hole on the left that is closest to the front of the burner (air tube side).
Other Mounting Installations: The CleanCut Pump with a standard cord set or a PD Timer can be installed on the Carlin EZ-1, Wayne ’M’, Wayne ’E’, Wayne ’HS’, Ducane ’DM’, Aero, and other 3450 RPM burners.
Ducane ’DR’: A 5/16” diameter hole will have to be drilled into the housing through the wire cavity.
Weil-McLain ’QB’: The valve coil blocks the air shutter screw. Allow enough slack in the cord set to pivot the valve coil away from the housing.

Bleeding The Pump

Open all fuel valves and check for line leaks. Tighten fittings and/or flare as needed to stop leaks. DO NOT use compression fittings.
One-pipe system requires a manual bleeding process. Two-pipe systems “bleed” automatically – but the bleeding process can be accelerated with a manual process.
Note: All fuel lines must be airtight with no leaks or burner performance will be impacted. With poor combustion, rumbles and pulsations may occur.
For accelerated bleeding oil systems:
- a). Place a hose on the bleed port, and position a catch-can underneath.
- b). Open the 3/8” hex head on the port and turn counter clockwise (CCW) 1/2 to 1 full turn, and allow the oil to flow in the catch-can.
- c). Apply power to the burner. The oil will begin flowing into the catch can.
- d). Allow the oil to flow for 15 seconds in the can until there are no foam or air bubbles present. If signs of air remain, make sure all air is purged from the oil filter cartridge.
- e). Tighten the 3/8” hex bleed port clockwise (CW). Re-check the system for leaks.

Adjusting The Pump Pressure

Install a pressure gauge, deadheading the nozzle port on the port.
Set the pump pressure to the required settings, which are located in the appliance manufacturer’s instructions. If unavailable, consult the Beckett Spec Guide at www.beckettcorp.com. The new pump is factory set at 100 psi, unless noted otherwise.
Turn the adjustment screw CW with a slotted screwdriver or 5/32” Allen wrench to increase the pump pressure. See Figure 3 (Item c) page 2 and Figure 4 (Item e) page 3.
Cycle the burner and confirm the following:
- a). The pump output pressure is maintained at a level where it was set to in step 1 above when the pump’s coil is energized.
- b). The pump pressure decreases when the burner control removes power from the pump’s valve coil. With the nozzle port deadheaded, the pressure will only drop to approximately 20% of the operating pressure.
- c). Remove power from the burner.
- d). Remove the Pressure Gauge. Connect the copper line to the nozzle port of the pump and tighten it with a 7/16” hex wrench.
Turn the power on to the burner and check all fuel lines and fittings for leaks.
Check burner combustion performance with proper test equipment. See the burner operating manual for testing guidelines.

CONTACT

www.beckettcorp.com.
USA: R.W. Beckett Corporation, 1-800-645-2876
Canada: R.W. Beckett Canada Ltd, 1-800-665-6972
Printed in the USA 06/20 Part No. 62168 R01 This document and all information contained herein are the sole property of the R.W.
Beckett Corporation cannot be reproduced or transmitted in whole or part without express written permission of the R.W. Beckett Corporation.