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
o
o
o

Thermostat / Operating (if applicable) and Limit Control Compatible
Welded Relay Protection
Limited Recycle
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
o
o
o

Interrupted or Intermittent Duty Ignition
Technician Pump Priming Mode
Disable Function
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

R7184B

7505P 1515

15 sec

R7184P, R7184U I

602001

7505P 1530

15 sec

30 sec

R7184P, R7184U I

602001

7505P 152M

15 sec

2 min

R7184P, R7184U I

602001

1 Beckett snap-on alarm module required for direct replacement of this control.
2 Valve-on delay and motor-off delay timings on all models are programmable with Beckett snapon programming display. Other factory set timings are available. Contact Beckett for alternate
timings.

Page 1

Figure 1 - Getting to know the control

Reset Button
with Red Light

Green Light

Communication
Port 2
Communication
Port 1

Terminals
(if applicable)

Wiring
Connections

Optional Snap-on Display
Module: For programming
and diagnostics

Cad Cell
Connections

Optional Snap=on Alarm
Module: For adding isolated tow voltage alarm contacts to the base control.
See Alarm Module Instructions for specifications.

Page 2

Do Not UseThis Control in an Application
that is Not Within the Ratings Listedin This
Section. ImproperControlOperationMay
Result.

Insta|llation/Operation/

ProfessionalService
Required
Incorrect installation or misuse of
this control could result in severe

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 load amps (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)

Environmental Ratings:
+ 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

personal injury, death, or substantial 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 OilBurning 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.

and UL1998, and CSA C22.2 No. 199

Frozen Plumbingand
Water DamageHazard

Do Not Use This 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.

Page 3

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,

Fireor Explosion
Hazard
Can cause severe
property damage.
"

',
"

injury,

death,

" 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

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.

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 acceptable.
" Wiring:

Electrical Shock Hazard

personal
lectrical injury
shockor death.
can cause
',

',
,,

o Make connections to the control's terminals

severe

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
(Canada CSA C22.1).

as shown in Figures 2 through 9. Refer to
the label on the underside of the control for
wiring details.

Some Thermostats Are Polarity
Sensitive. Reversed polarity could cause erratic
cycling of the burner control.

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
runaway condition.
*

o Makesureall appliancewiring complieswith
all localcodesand ordinances.

controls

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).

fail and cause a

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

Typical

Boiler

Wiring:

Figure 2- 7505A (for replacement of R8184G)
• Intermittent ignition, no valve-on delay, no
motor-off delay

BOILER

CONTROL

vapor before starting or resetting the burner.

.. ,ooo,,oo,
w,,,o,w,,,
Result in Improper

Control Operation
',

GeniSys wiring label colors may not match the
wire colors of the burner or other manufacturers' controls.
The GeniSys Control should be wired according to the appliance manufacturer's instructions.

TR TW
JUMPER

TW Term!rials
Located on
opposite
side of
Contro]
(If appl cable}

Page4

Figure 3- 7505A(for replacement of R7184A)
e Interruptedignition,no valve-onor motor-offdelay
BOILER

Typical

Furnace

Wiring:

CONTROL

Figure 6- 7505A(for replacement of RSf84G)
e Intermittentignition,no valve-onor motor-offdelays

IGNITER
L2 _

SA ETYAND
ERATING

IGNITER

JUMPER

TW TR

TW
TR I nc_t_rl

opposite
side
Contro]

CAD CELL

(if appl

opposite
side
Co_t_ol

TW lelmmaEs
Located
on
of

TR TW
JUMPER

TR(_I
applicable)

cable)

Figure 4 - 7505B (for replacement of R7184B)
e Interrupted ignition, valve-on delay only (no motoroff delay)
BO&ER

Located

opposite
side of
TR
TW Terminals
Control

CONTROL

Figure 7- 7505A(for replacement of R7184A)
o Interruptedignition,no valve-onor motor-offdelay

L2
LI_

L2 _

SA ETYAND
RATING
THERMOSTAT

THERMOSTAT

TW
IGNITER

JUMPER

OIL

CAD CELL

TW Terminals
Located on
opposite
side of
Contro]

(If app]

cable)

JUMPER
_

TR TW
TW

Figure 5 - 7505P(for replacement of R7184P)
= Interruptedignition,valve-onand motor-offdelays

Located

__BOILER

TR
opposite
TW ]el s_de
minaEs
of
Control

Figure 8 - 7505B (for replacement of R7184B)
o Interrupted ignition, valve-on delay only (no
motor-off delay)

CONTROL

@
THERMOSTAT

TR TW

JUMPER

CAD CELL

_
--

TW ]el mma_s
Located on

opposite
s_de of
Control
(If applicable)

NOTE: To disable motor-off delay on a 7505P control,
jumperL1 and limittogetherand wire as shown in Fig.4.
Page 5

TW lerm_rlals
Located
on
opposite
side of
Contro_

Figure 9 - 7505P (for replacement of R7184P)
• Interrupted ignition,valve-on and motor-off delays

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.

Refer to the steps for "Starting
the System" and have the
system call for heat.

Burner must not start. Verify
that the green light is on
continuously and that the control
remains in Standby mode.

End the call for heat and
remove the cad cell jumper.

TR TW
JUMPER

OlLV

TR TW Tem_inals
Located on
CAD CELL

opposite
side of
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

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.

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.

After the 60 second recycle period,
the control will try to restart the
system.

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.

/ Checkout

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.

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.

o Simulate Flame Failure and Ignition
Failure

Monitor burner operation to ensure
that the burner ignites.

Operation
Fire Hazard

Qualified Technician only.
Reset and Service by
Page 6

o Standby

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.

/ j-I

f
delay

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

_.__

Ignition
I carryoverl

_(_71oto
r off

1. Standby: The burner is idle, waiting
for a call for heat.
2=

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").

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.

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 d recycle.
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.

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.

" 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.

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.

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.

4. Lockout:
The control has shut
down for one of the following safety
reasons:

Page 8

rialfor
ignition

prime

of Operation

- Burner 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.

•
o

Table

Do not allow oil to spray into a hot
combustion chamber while bleeding
air from the pump.
Install a gauge in the nozzle
discharge port tubing or fully open
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.
Ensure that the appliance is free of
oil and oil vapor before starting or
resetting the burner.
2 - Reset

Button

Initiate a call for heat.

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.

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.

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.

Operation

Pushing the reset button will:
Button Click
(press< t second)
Lockout

ResetfromSoftL0CK0Ut
GotoPumuPrimesee
Disablethe Burner:
Priming
the PumP"above/ Any time the burner is

Valve-onDelay,Trial
or Ignition,Ignition
Carryover

Yellowlight flashes
_oindicatecaclcel
resistance See "CadCe
ResistanceIndicator"for
table of resistancevalues

Run Ogniteris shut off]

Motor-OffDelay,
Standby

No action

Pump Prime

No action

Table

Button Hold
(press> t second)

3 = Status

running,press and hold
the resetbutton to disable
the burner The burnerwil
remainoff as long as the
buttonis nela

Button Hold
(press t5+ seconds)
ResetfromRestricted
(Hard)Lockout
Enables Pump Priming:
After the resetbutton has
beenheld for 15seconds,
the buttoncan thenbe
clickedduringthe next
ignitionsequenceto enter
Pump Prime mode.

ExitPump Prime modeand return to Standby

Lights

Light Color
Red

Restricted(Hard)Lockout

SoftLockout

Green

FlameSensedduringnormaloperation
(Couldbe straylight duringstandby)

Recycle

Yellow

Controlis in PumpPrime modeor
Resetbuttoncurrentlyheld for 15+
seconds.

Cad Cell resistance. See "Cad Cell Resistance
Indicator" on page 10 for a table of resistance
values.
Page 9

At the end of 4 minutes, the yellow
light will turn off and the control
will automatically return to standby
mode.

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.

m Resetting From Restricted or Hard
Lockout
Fire & Smoke
Hazard
control from restricted lockout
state, troubleshoot
the heating
Before
starting or resetting
the
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 resetting the burner.

m Cad 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

Flame UeteCti0.Ra.ge

Flashes
1

Normal (0 - 400 ohms)

Normal (400 - 800 ohms)

Normal (800 - 1600 ohms)

Limited (1600 ohms Lockout)

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 accumulation 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 according 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

Canada:

U.S.A.: RO. Box 1289" Elyria, Ohio 44036
www.beckettcorp.com
R.W. Beckett Canada, Ltd. • Unit #3,430 Laird Road.
Guelph, Ontario N1G 3X7

Form No. 61649 IR08
Printed in USA4-08

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