BECKETT Burner, Furnace Manual L0805069
User Manual: BECKETT BECKETT Burner, Furnace Manual BECKETT Burner, Furnace Owner's Manual, BECKETT Burner, Furnace installation guides
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iSys T"
lVlodel7505
Advanced Burner Control
Description /App|ications
The Beckett GeniSys TM Advanced Burner Control isa 120 Vac primary safety control
for residential and light commercial oil burners used in boiler, furnace, and water
heater applications having firing rates less than 20 GPH. The GeniSys is used with
a suitable cad cell flame sensor to control the oil burner motor, igniter, and optional
solenoid valve. It has 24 Vac thermostat terminals (if applicable) compatible with
both mechanical and many power stealing thermostats. It can provide interrupted or
intermittent duty ignition, and it has a 30 second lockout time on recycle.
Features
o Thermostat /Operating (if applicable) and Limit Control Compatible
o Welded Relay Protection
o Limited Recycle
o Limited Reset
o 3 Status Lights
o Valve-On Delay /Motor-Off Delay (Field programmable with Beckett add-on Display)
o 15 Second Lockout Time
o Interrupted or Intermittent Duty Ignition
o Technician Pump Priming Mode
o Disable Function
o Cad Cell Resistance Indicator
o Communication Ports (2)
Specifications
Electrical Ratings
Inputs:
o Voltage: 5Vdc+4%
o Current: 25 mA maximum display current
Environmental Ratings:
o Storage Ambient Temperature: -22°F to +150°F (-35°C to +65°C)
o Operating Ambient Temperature: -4°F to +150°F (-20°C to +65°C)
o Moisture: 5 to 85% RH, non-condensing and non-crystalizing
Table 1 =Models and Cross Reference Guide
7505A 0000 48245, 40200,
15 sec R7184A, R8184G 42230, 502001
7505B 1500 15 sec 15 sec R7184B
7505P 1515 15 sec 15 sec 15 sec R7184P, R7184U I 602001
7505P 1530 15 sec 15 sec 30 sec R7184P, R7184U I 602001
7505P 152M 15 sec 15 sec 2 min R7184P, R7184U I 602001
1
2
Beckett snap-on alarm module required for direct replacement of this control.
Valve-on delay and motor-off delay timings on all models are programmable with Beckett snap-
on programming display. Other factory set timings are available. Contact Beckett for alternate
timings.
Page 1
Figure 1 -Getting to know the control
Green Light
Reset Button
with Red Light
Communication
Port 2
Terminals
(if applicable)
Communication
Port 1
Wiring
Connections Optional Snap-on Display
Module: For programming
and diagnostics
Cad Cell
Connections
Optional Snap=on Alarm
Module: For adding isolat-
ed tow voltage alarm con-
tacts to the base control.
See Alarm Module Instruc-
tions for specifications.
Page 2
DoNot UseThis Con-
trol inanApplication
that is NotWithin the Ratings ListedinThis
Section.ImproperControlOperationMay
Result.
Electrical Ratings
inputs:
+ Voltage: 120 Vac nominal (102 to 132 Vac)
+ Current: 100 mA nominal (150 mA max at 132
Vac)
+ Frequency: 60 Hz
Outputs:
+ Motor: 120Vac, 10full loadamps(FLA),60 lockedrotor
amps(LRA)
*Note: Reduce motor FLA rating by igniter current
+ Igniter: 120 Vac, 3A@0.7 PF min
+ Solenoid Valve: 120 Vac, 1 A @ 0.7 PF min
+ Thermostat Anticipator Current: 0.1 A
(if applicable)
+ Thermostat Voltage: 24 Vac (if applicable)
EnvironmentalRatings:
+ Storage and Operating Ambient Temperature:
-40°F to +150°F (-40°0 to +65°0)
+ Moisture: 5 to 95% RH, non-condensing and
non-crystallizing
Approvals:
+ Underwriters Laboratory Recognition per UL372
and UL1998, and CSA C22.2 No. 199
Do Not UseThis Control
Above 19.9GPH
Most codes and standards require additional
safeguards and features for oil burner inputs
above 19.9 gph. Consult the appliance
manufacturer's instructions for control
selection.
Insta|llation/Operation/
ProfessionalService
Required
Incorrect installation or misuse of
this control could result in severe
personal injury, death, or sub-
stantial property damage from heavy smoke,
explosion or fire.
Please read and understand the manual supplied
with this control. This control 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 take precedence
over the general instructions provided in this
installation manual.
FrozenPlumbingand
Water DamageHazard
If the residence is unattended in severely cold
weather, burner primary control safety lockout,
heating system component failures, power
outages or other electrical system failures could
result in frozen plumbing and water damage
in a matter of hours. For protection, take
preventive actions such as having a security
system installed that operates during power
outages, senses low temperature and initiates
an effective action. Consult with your heating
contractor or a home security agency,
Page 3
Fireor Explosion
Hazard
Can cause severe injury, death, or
property damage.
" The control can malfunction if it gets wet,
leading to accumulation of oil or explosive oil
vapors.
', Never install where water can flood, drip or
condense on the control.
" Never use a control that has been wet
- replace it.
"Mounting:
Mount the control on a 4" x 4" junction box on
the burner, or inside the appliance cabinet.
in replacement applications, mount the
new control in the same location as the old
control. In some replacement applications, it
may be necessary to rotate the control on the
4" x 4" box for best fit.
o Mounting orientation: any orientation is ac-
ceptable.
" Wiring:
Electrical Shock Hazard o Makesureall appliancewiringcomplieswith
all localcodesand ordinances.
_lectrical shock can cause severepersonal injury or death.
', Disconnect ALL electrical power to the
appliance/burner circuit before installing or
servicing this control.
', Provide ground wiring to the appliance, burner
and metal control mounting box.
,, Perform all wiring in compliance with the
National Electrical Code ANSl/NFPA 70 Some Thermostats Are Polarity
(Canada CSA C22.1). Sensitive. Reversed polarity could cause erratic
cycling of the burner control.
o Make connections to the control's terminals
as shown in Figures 2 through 9. Refer to
the label on the underside of the control for
wiring details.
" Connect the wire from the RHor R terminal on
the thermostat to the TR terminal on the control
(if applicable).
', Connect the wire from the W terminal on the
thermostat to the TW terminal on the control (if
applicable).
Explosion,Fire,Scald,
and Burn Hazard
All heating appliances must have HIGH
LIMIT protection to interrupt electrical
power and shutdown the burner if
operating or safety controls fail and cause a
runaway condition.
* Followthe appliance manufacturer's wiring
diagrams and note all required safety controls.
" Typical safety controls include high
temperature or pressure limits, low water
cutoffs, pressure relief valves and blocked flue
sensing switches.
" Verify all limit and safety controls are installed
and functioning correctly, as specified by the
manufacturer, applicable safety standards,
codes and all authorities having jurisdiction.
" Ensure that the appliance is free of oil and oil
vapor before starting or resetting the burner.
Typical Boiler Wiring:
Figure 2- 7505A (for replacement of R8184G)
• Intermittent ignition, no valve-on delay, no
motor-off delay
LI BOILER CONTROL
.. ,ooo,,oo,w,,,o,w,,,
Result inImproper
Control Operation
', GeniSys wiring label colors may not match the
wire colors of the burner or other manufactur-
ers' controls.
" The GeniSys Control should be wired accord-
ing to the appliance manufacturer's instruc-
tions.
TR TW
JUMPER
TR TW Term!rials
Located on
opposite side of
Contro]
(If appl cable}
Page4
Figure 3- 7505A(for replacementof R7184A)
e Interruptedignition,novalve-onor motor-offdelay
BOILER CONTROL
L2 T
IGNITER
TR TW
JUMPER
TW
TR TW lelmmaEs
Located on
opposite side of
CAD CELL Contro]
(if appl cable)
Figure 4 - 7505B (for replacement of R7184B)
e Interrupted ignition, valve-on delay only (no motor-
off delay)
BO&ER CONTROL
LI_ @
L2
THERMOSTAT TR TW
JUMPER
OIL _TW
TR TW Terminals
Located on
opposite side of
CAD CELL _ Contro]
-- (If app] cable)
Figure 5 - 7505P(for replacement of R7184P)
= Interruptedignition,valve-onand motor-offdelays
__BOILER CONTROL
THERMOSTAT TR TW
JUMPER
TR TW ]el mma_s
Located on
opposite s_de of
CAD CELL _ Control
-- (If applicable)
NOTE: To disable motor-off delay on a 7505P control,
jumperL1and limittogetherand wire as shownin Fig.4.
Page 5
Typical Furnace Wiring:
Figure 6-7505A(for replacementof RSf84G)
e Intermittentignition,novalve-onor motor-offdelays
L2 _ SA ETYAND
ERATING
IGNITER
TR I nc_t_rl on
opposite side of TR TW
Co_t_ol JUMPER
_ TR(_Iapplicable)
TR TW Terminals
Located on
opposite side of
__ Control
Figure 7- 7505A(for replacement of R7184A)
o Interruptedignition,no valve-onor motor-offdelay
L2 _ SA ETYAND
RATING
THERMOSTAT
IGNITER
_ TR TW
JUMPER
TW
TR TW ]el minaEs
Located on
opposite s_de of
__ Control
Figure 8 - 7505B (for replacement of R7184B)
o Interrupted ignition, valve-on delay only (no
motor-off delay) @
TR TW lerm_rlals
Located on
opposite side of
Contro_
Figure 9 - 7505P (for replacement of R7184P)
• Interrupted ignition,valve-on and motor-off delays
TR TW
JUMPER
OlLV :@TR TW Tem_inals
Located on
opposite side of
CAD CELL Control
Note: Motor-off delay on a 7505P will be
disabled if the safety and operating limits as
shown in Figures 5 and 9 interrupt power to
the control terminal L1.
Connect thermostat leads (if applicable) to the
TR and TW terminals on the control or jumper
the TR and TW terminals on the control as
directed by the appliance wiring diagram.
Note: If the thermostat short cycles or operates
improperly, it may require an isolation relay for
proper operation. The Beckett A/C Ready Kit
(part no. 51950U) provides this function. Wiring
instructions are included with the A/C Ready Kit.
Startup /Checkout
5. End the call for heat. Verify that the
burner turns off before leaving the
installation site.
"Check Safety Features
o Safe Start Check
1. Place a jumper across the cad
cell terminals.
2. Refer to the steps for "Starting
the System" and have the
system call for heat.
3. Burner must not start. Verify
that the green light is on
continuously and that the control
remains in Standby mode.
4. End the call for heat and
remove the cad cell jumper.
o Simulate Flame Failure and Ignition
Failure
1. Refer to the steps for "Starting the
System" and have the system call
for heat.
2. After flame is established and the
burner igniter turns off, close the
hand valve in the oil supply line.
3. At flame loss, the control will
enter Recycle mode. Verify that
the green light is flashing. The
control will remain in Recycle for
60 seconds.
If the burner or control fails any of the
following tests, recheck control wiring. If
the burner or control still fails any tests,
replace the control.
• Starting the System
1.
2.
3.
Open the shut-off valves in the
supply line from the oil tank.
Close the disconnect switch to
supply power to the burner.
Adjust the thermostat or boiler
control to call for heat.
• If the pump has not been primed,
refer to "Priming the Pump" in
the "Operation" section of this
manual.
4. Monitor burner operation to ensure
that the burner ignites.
4. After the 60 second recycle period,
the control will try to restart the
system.
5. After the 15 second lockout time,
the control will lock out the burner
and the reset button will flash.
Verify that the burner motor and
igniter are off and that the burner
oil solenoid valve (if used) is not
energized.
Operation
Fire Hazard
Reset and Service by
Qualified Technician only.
Page 6
6. Open the hand valve in the oil line.
7. Click the reset button and verify
that the red light in the reset button
shuts off and that the burner lights.
8. End the call for heat.
Before leaving the installation, verify
that all thermostat and boiler/furnace
control wiring is correct. Consult heating
appliance manual for directions.
"Sequence of Operation
- Burner States
1. Standby: The burner is idle, waiting
for a call for heat.
2=
3=
Valve-On Delay: The igniter and
motor are on while the control delays
turning on the oil solenoid valve for
the programmed time.
Trial For Ignition: The oil solenoid
valve is energized. A flame should be
established within the factory set trial
for ignition time ("lockout time").
4. Lockout: The control has shut
down for one of the following safety
reasons:
a.The trial for ignition (lockout)
time expired without flame being
established.
b.The cad cell detected flame at the
end of the Valve On Delay state.
To reset the control from lockout click
the button 1-second.
NOTE: A recurrence of the above failure
modes or a failed welded relay check
could cause the control to enter a
Hard Lockout state that must be
reset only by a qualified service
technician.
5=
To reset from Hard Lockout, hold the
reset button for 15 seconds until the
yellow light turns on.
Ignition Carryover: Once flame is
established, the igniter remains on for
10 additional seconds to ensure flame
stability.
Page 8
o
d Standby / j-I prime I
@f€-_- e
rialfor _.__
delay _j ignition
eIgnition
I carryoverl
_(_71otor off O _' - e
6=
7=
8=
9=
Run: The flame is sustained until the
call for heat is satisfied. The burner
is then sent to Motor-Off Delay, if
applicable, or it is shut down and sent
to Standby.
Recycle: If the flame is lost while
the burner is firing, the control shuts
down the burner, enters a 60 second
recycle delay, and repeats the ignition
sequence. The control will continue
to Recycle each time the flame is
lost, until it reaches a pre-set time
allotment. The control will then go
into Hard Lockout instead drecycle.
This feature prevents excessive
accumulation of oil in the appliance
firing chamber.
Motor-Off Delay: If applicable, the oil
solenoid valve is turned off and the
control delays turning the motor off for
the set motor-off delay time before the
control returns to standby.
Pump Prime: The igniter and motor
are on with the oil solenoid valve
energized for 4 minutes. During
Pump Prime mode, the cad cell is
disregarded, allowing the technician
to prime the pump without having to
jumper the cad cell.
" Reset Button Operation
Table 2 explains what action the
control wilt take when the reset button
is pressed for different lengths of time
during the various burner operating
states.
"Priming the Pump
1, Prepare the burner for priming
by attaching a clear plastic hose
over the bleed port fitting and fully
opening the pump bleed port. Use a
suitable container to collect purged
oil.
Hot Gas Puff=Back
and Heavy Smoke
Hazard
Failure to bleed the pump properly could
result in unstable combustion, hot gas
puff-back and heavy smoke.
2,
3.
Initiate a call for heat.
After the burner starts, press and
hold the reset button for 15 seconds
until the yellow light turns on. This
indicates that the button has been
held long enough.
• Do not allow oil to spray into a hot 4.
combustion chamber while bleeding
air from the pump.
o Install a gauge in the nozzle
discharge port tubing or fully open 5.
the pump bleed valve to prevent
oil spray from accumulating in the
combustion chamber during the air
bleed procedure.
Ensure that all bubbles and froth are
purged from the oil supply system
before tightening the pump bleed
valve. 6.
Ensure that the appliance is free of
oil and oil vapor before starting or
resetting the burner.
Table 2-Reset Button Operation
Lockout
Valve-onDelay,Trial
orIgnition,Ignition
Carryover
Run Ogniteris shutoff]
Motor-OffDelay,
Standby
Button Click
(press< t second)
Release the reset button. The
yellow light will turn off and the
burner will start up again.
At burner start up, click the reset
button while the igniter is still on.
This will transition the control to a
dedicated Pump Prime mode, during
which the motor, igniter, and valve
are powered for four minutes. The
yellow light will be on.
Bleed the pump until all froth and
bubbles are purged. If desired,
terminate the call for heat or hold
the reset button for at least one
second to exit Pump Prime mode
and return to Standby.
Pushingthe reset button will:
Button Hold Button Hold
(press>tsecond) (press t5+ seconds)
ResetfromRestricted
ResetfromSoftL0CK0Ut (Hard)Lockout
GotoPumuPrimesee
PrimingthePumP"above/
Yellowlight flashes
_oindicatecaclcel
resistance See "CadCe
ResistanceIndicator"for
tableof resistancevalues
Noaction
Disablethe Burner:
Any timethe burner is
running,pressand hold
the resetbutton to disable
the burner Theburnerwil
remainoffas longas the
buttonis nela
EnablesPumpPriming:
After the resetbutton has
beenheldfor 15seconds,
the buttoncan thenbe
clickedduringthe next
ignitionsequenceto enter
PumpPrimemode.
PumpPrime Noaction ExitPump Primemodeand returnto Standby
Table 3 =Status Lights
o:
Light Color
Red Restricted(Hard)Lockout
Green FlameSensedduringnormaloperation
(Couldbe straylight duringstandby)
Yellow Controlis in PumpPrimemodeor
Resetbuttoncurrentlyheldfor 15+
seconds.
SoftLockout
Recycle
Cad Cell resistance. See "Cad Cell Resistance
Indicator" on page 10 for a table of resistance
values.
Page 9
7. At the end of 4 minutes, the yellow
light will turn off and the control
will automatically return to standby
mode.
8.
9.
If prime is not established during
the four minute pump prime mode,
return to step 5 to re-enter Pump
Prime mode. Repeat steps 5
through 7 until the pump is fully
primed and the oil is free of bubbles.
Terminate the call for heat, and
the control will resume normal
operation.
mCad Cell Resistance indicator
o During the burner Run state, click the
reset button (less than 1 second) to
check the cad cell resistance range.
The yellow light will flash 1 to 4 times,
depending on the amount of light
detected by the cad cell. See chart
below:
Ye,ow
Light FlameUeteCti0.Ra.ge
Flashes
1 Normal (0 - 400 ohms)
2 Normal (400 - 800 ohms)
3 Normal (800 - 1600 ohms)
Limited (1600 ohms -
4Lockout)
mResetting From Restricted or Hard
Lockout
Fire & Smoke
Hazard
Before starting or resetting the
control from restricted lockout
state, troubleshoot the heating
system for the root cause(s) of
the lockout.
Make necessary repairs or adjustment
to ensure a safe start condition.
Ensure that the appliance is free of oil
and oil vapors before starting or reset-
ting the burner.
If the control continues to lock out
without a satisfied call for heat,
or fails the motor relay check, the
control enters Hard (restricted)
Lockout in order to limit accumula-
tion of unburned oil in the combustion
chamber.
o To reset, hold the button down for 15
seconds until the red light turns off
and the yellow light turns on.
o Always verify the control functions
according to all specifications before
leaving the installation site.
o Replace the control if it does not
operate as specified.
" Disable Function
o Any time the burner is running, press
and hold the reset button to disable
the burner. The burner will remain off
as long as the button is held.
Page 10
Maintenance
Oil heating systems require annual service performed by a qualified, professional service
agency. The 7505 primary control should be inspected during this service routine ac-
cording to the following checklist:
[] NOTE: The 7505 control has no serviceable internal parts. Do not attempt to
remove cover.
[] Inspect the exterior of the control. Replace the control if there is any sign of impact
damage, water or corrosion.
[] Use a muttimeter to test the line voltage at control L1 and L2. It should be 102
- 132 Vac.
[] Inspect all external wiring for secure connections and verify insulation integrity.
[] Verify the control lockout and operation sequence, (Reference Startup/Checkout
section).
[] Observe a full operating cycle to prove the sequence and timings are correct.
[] Replace any control that does not meet listed specifications with an equivalent
replacement unit.
Page 11
U.S.A.: RO. Box 1289" Elyria, Ohio 44036
www.beckettcorp.com
Canada: R.W. Beckett Canada, Ltd. • Unit #3,430 Laird Road.
Guelph, Ontario N1G 3X7
Form No. 61649 IR08
Printed in USA4-08
