Beckett 7505 User Manual

Page 1
GeniSys
Model 7505
Advanced Burner Control
Description / Applications
The Beckett GeniSysTM Advanced Burner Control is a 120 Vac primary safety control for residential and light commercial oil burners used in boiler, furnace, and water
heater applications having ring rates less than 20 GPH. The GeniSys is used with a suitable cad cell ame 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.
Page 2
Features
Thermostat / Operating (if applicable) and Limit Control Compatible
Welded Relay Protection
Limited Recycle
Limited Reset
3 Status Lights
Valve-On Delay / Motor-Off Delay (Field programmable with Beckett add-on Display)
15 Second Lockout Time
Interrupted or Intermittent Duty Ignition
Technician Pump Priming Mode
Disable Function
Cad Cell Resistance Indicator
Communication Ports (2)
Specications
Electrical Ratings
Inputs:
Voltage: 5 Vdc +4%
Current: 25 mA maximum display current
Environmental Ratings:
Storage Ambient Temperature: -22°F to +150°F (-35°C to +65°C)
Operating Ambient Temperature: -4°F to +150°F (-20°C to +65°C)
Moisture: 5 to 85% RH, non-condensing and non-crystalizing
Table 1 - Models and Cross Reference Guide
Beckett GeniSys
Control Part No.
7505A 0000
7505B 1500 15 sec 15 sec - R7184B -
7505P 1515
7505P 1530
7505P 152M
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 snap-
on programming display. Other factory set timings are available. Contact Beckett for alternate timings.
Page 1
TM
Lockout
Time
15 sec - - R7184A, R8184G
15 sec 15 sec 15 sec
15 sec 15 sec 30 sec
15 sec 15 sec 2 min
Valve-on
delay time
2
Motor-off
delay time
2
Replaces
Honeywell:
R7184P, R7184U
R7184P, R7184U
R7184P, R7184U
Replaces
48245, 40200,
42230, 50200
1
1
1
Carlin:
60200
60200
60200
1
1
1
1
Page 3
Figure 1 – Getting to know the control
Wiring
Connections
Yellow
Light
Green Light
Thermostat
Terminals
(if applicable)
Reset Button with Red Light
Communication Port 2
Communication
Port 1
Optional Snap-on Display
Module: For programming
and diagnostics
Cad Cell Connections
Optional Snap-on Alarm
Module: For adding isolat-
ed low voltage alarm con­tacts to the base control. See Alarm Module Instruc-
tions for specications.
Page 2
Page 4
Do Not Use This Con-
trol in an Application
that is Not Within the Ratings Listed in This Section. Improper Control Operation May 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:
*Note: Reduce motor FLA rating by igniter current
120 Vac, 10 full load amps (FLA), 60 locked rotor
amps (LRA)
Igniter: 120 Vac, 3 A @ 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°C to +65°C) Moisture: 5 to 95% RH, non-condensing and
non-crystallizing
Installation/Operation/ Maintenance
Professional Service
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 re.
Please read and understand the manual supplied
with this control. This control must be installed, adjusted and put into operation only by a qualied
individual or service agency that is:
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).
Licensed or certied 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.
Approvals:
Underwriters Laboratory Recognition per UL372
and UL1998, and CSA C22.2 No. 199
Do Not Use This Control
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
Above 19.9 GPH
Regulation by these authorities take precedence
over the general instructions provided in this
installation manual.
Frozen Plumbing and
Water Damage Hazard
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 5
Fire or Explosion
LIMIT
L1
L2 (VLV)
VALVE
L2
MOTOR
L2 (MTR)
L2 (IGN)
IGNITER
CAD CELL
MOTOR
IGNITER
W
R
80
70
60
50
50
70
80
60
LIMIT
CAD CELL
THERMOSTAT
BOILER CONTROL
TR
TW
TR-TW
JUMPER
TR-TW TERMINALS
LOCATED ON OPPOSITE
SIDE OF CONTROL
B2 B1
T
T
L1
L2
L1
L2
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 ood, drip or
condense on the control. Never use a control that has been wet
- replace it.
Electrical Shock Hazard
Electrical shock can cause severe
personal 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 ANSI/NFPA 70 (Canada CSA C22.1).
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.
Follow the 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 ue sensing switches.
Verify all limit and safety controls are installed
and functioning correctly, as specied 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.
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.
Incorrect Wiring Will Result in Improper
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 t.
Mounting orientation: any orientation is ac-
ceptable.
Wiring:
Make sure all appliance wiring complies with
all local codes and ordinances.
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.
NOTICE
Some Thermostats Are Polarity Sensitive. Reversed polarity could cause erratic cycling of the burner control.
Connect the wire from the RH or 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).
Typical Boiler Wiring:
Figure 2 – 7505A (for replacement of R8184G)
● Intermittent ignition, no valve-on delay, no
motor-off delay
TR-TW Terminals
Located on
opposite side of
Control
(If applicable)
Page 4
Page 6
Figure 3 – 7505A (for replacement of R7184A)
LIMIT
L1
L2 (VLV)
VALVE
L2
MOTOR
L2 (MTR)
L2 (IGN)
IGNITER
CAD CELL
MOTOR
IGNITER
W
R
80
70
60
50
50
70
80
60
LIMIT
CAD CELL
THERMOSTAT
TR
TW
TR-TW
JUMPER
TR-TW TERMINALS
LOCATED ON OPPOSITE
SIDE OF CONTROL
BOILER CONTROL
B2 B1
T
T
L1
L2
L1
L2
LIMIT
L1
L2 (VLV)
VALVE
L2
MOTOR
L2 (MTR)
L2 (IGN)
IGNITER
CAD CELL
MOTOR
IGNITER
B2 B1
T
T
W
R
80
70
60
50
50
70
80
60
LIMIT
OIL VALVE
CAD CELL
THERMOSTAT
BOILER CONTROL
TR
TW
TR-TW
JUMPER
TR-TW TERMINALS
LOCATED ON OPPOSITE
SIDE OF CONTROL
L1
L2
L1
L2
LIMIT
L1
L2 (VLV)
VALVE
L2
MOTOR
L2 (MTR)
L2 (IGN)
IGNITER
CAD CELL
MOTOR
IGNITER
W
R
80
70
60
50
50
70
80
60
OIL VALVE
CAD CELL
THERMOSTAT
TR
TW
TR-TW
JUMPER
TR-TW TERMINALS
LOCATED ON OPPOSITE
SIDE OF CONTROL
BOILER CONTROL
B2 B1
T
T
L1
L2
L1
L2
SAFETY AND
OPERATING
LIMITS
LIMIT
L1
L2 (VLV)
VALVE
L2
MOTOR
L2 (MTR)
L2 (IGN)
IGNITER
CAD CELL
MOTOR
IGNITER
W
R
80
70
60
50
50
70
80
60
CAD CELL
THERMOSTAT
TR
TW
TR-TW
JUMPER
TR-TW TERMINALS
LOCATED ON OPPOSITE
SIDE OF CONTROL
L1
L2
LIMIT
SAFETY AND
OPERATING
LIMITS
LIMIT
L1
L2 (VLV)
VALVE
L2
MOTOR
L2 (MTR)
L2 (IGN)
IGNITER
CAD CELL
MOTOR
IGNITER
W
R
80
70
60
50
50
70
80
60
CAD CELL
THERMOSTAT
TR
TW
TR-TW
JUMPER
TR-TW TERMINALS
LOCATED ON OPPOSITE
SIDE OF CONTROL
L1
L2
LIMIT
SAFETY AND
OPERATING
LIMITS
LIMIT
L1
L2 (VLV)
VALVE
L2
MOTOR
L2 (MTR)
L2 (IGN)
IGNITER
CAD CELL
MOTOR
IGNITER
W
R
80
70
60
50
50
70
80
60
OIL VALVE
CAD CELL
THERMOSTAT
TR
TW
TR-TW
JUMPER
TR-TW TERMINALS
LOCATED ON OPPOSITE
SIDE OF CONTROL
L1
L2
LIMIT
● Interrupted ignition, no valve-on or motor-off delay
TR-TW Terminals
Located on
opposite side of
Control
(If applicable)
Figure 4 – 7505B (for replacement of R7184B)
● Interrupted ignition, valve-on delay only (no motor­off delay)
Typical Furnace Wiring:
Figure 6 – 7505A (for replacement of R8184G)
● Intermittent ignition, no valve-on or motor-off delays
TR-TW Terminals
Located on
opposite side of
Control
(If applicable)
TR-TW Terminals
Located on
opposite side of
Control
Figure 7 – 7505A (for replacement of R7184A)
● Interrupted ignition, no valve-on or motor-off delay
Figure 5 – 7505P (for replacement of R7184P)
● Interrupted ignition, valve-on and motor-off delays
NOTE: To disable motor-off delay on a 7505P control,
jumper L1 and limit together and wire as shown in Fig. 4.
Page 5
TR-TW Terminals
opposite side of
TR-TW Terminals
opposite side of
Located on
Control
(If applicable)
Located on
Control
(If applicable)
TR-TW Terminals
Located on
opposite side of
Control
Figure 8 – 7505B (for replacement of R7184B)
● Interrupted ignition, valve-on delay only (no motor-off delay)
TR-TW Terminals
Located on
opposite side of
Control
Page 7
Figure 9 – 7505P (for replacement of R7184P)
SAFETY AND OPERATING
LIMITS
LIMIT
L1
L2 (VLV)
VALVE
L2
MOTOR
L2 (MTR)
L2 (IGN)
IGNITER
CAD CELL
MOTOR
IGNITER
W
R
80
70
60
50
50
70
80
60
OIL VALVE
CAD CELL
THERMOSTAT
TR
TW
TR-TW
JUMPER
TR-TW TERMINALS
LOCATED ON OPPOSITE
SIDE OF CONTROL
L1
L2
● Interrupted ignition, valve-on and motor-off delays
TR-TW Terminals
Located on
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 / Checkout
End the call for heat. Verify that the
5. burner turns off before leaving the installation site.
Check Safety Features
Safe Start Check
Place a jumper across the cad
1.
cell terminals.
Refer to the steps for “Starting
2.
the System” and have the system call for heat.
Burner must not start. Verify
3.
that the green light is on continuously and that the control remains in Standby mode.
End the call for heat and
4.
remove the cad cell jumper.
Simulate Flame Failure and Ignition
Failure
Refer to the steps for “Starting the
1. System” and have the system call for heat.
After ame is established and the
2.
burner igniter turns off, close the
hand valve in the oil supply line.
At ame loss, the control will
3. enter Recycle mode. Verify that
the green light is ashing. 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
Open the shut-off valves in the
1. supply line from the oil tank.
Close the disconnect switch to
2. supply power to the burner.
Adjust the thermostat or boiler
3. control to call for heat.
If the pump has not been primed,
refer to “Priming the Pump” in the “Operation” section of this manual.
Monitor burner operation to ensure
4. that the burner ignites.
After the 60 second recycle period,
4. the control will try to restart the system.
After the 15 second lockout time,
5. the control will lock out the burner
and the reset button will ash.
Verify that the burner motor and igniter are off and that the burner oil solenoid valve (if used) is not energized.
Operation
Reset and Service by
Qualied Technician only.
Fire Hazard
Page 6
Page 8
Open the hand valve in the oil line.
6.
Click the reset button and verify
7. that the red light in the reset button shuts off and that the burner lights.
End the call for heat.
8.
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
Standby: The burner is idle, waiting
1.
for a call for heat.
Valve-On Delay: The igniter and
2.
motor are on while the control delays turning on the oil solenoid valve for the programmed time.
Trial For Ignition: The oil solenoid
3.
valve is energized. A ame 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 ame being
established.
b. The cad cell detected ame 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 qualied service
technician.
To reset from Hard Lockout, hold the
reset button for 15 seconds until the yellow light turns on.
Ignition Carryover: Once ame is
5.
established, the igniter remains on for 10 additional seconds to ensure ame
stability.
Page 7
1
Standby
2
Valve-on
delay
8
Motor-off
delay
Run: The ame is sustained until the
6.
call for heat is satised. The burner is then sent to Motor-Off Delay, if applicable, or it is shut down and sent
to Standby.
Recycle: If the ame is lost while
7.
the burner is ring, 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 ame is lost, until it reaches a pre-set time
allotment. The control will then go into Hard Lockout instead of recycle. This feature prevents excessive accumulation of oil in the appliance
ring chamber.
Motor-Off Delay: If applicable, the oil
8.
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
9.
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 will take when the reset button is pressed for different lengths of time during the various burner operating states.
Priming the Pump
Prepare the burner for priming
1. by attaching a clear plastic hose
over the bleed port tting and fully
opening the pump bleed port. Use a suitable container to collect purged oil.
3
Trial for ignition
5
Ignition
carryover
6
Run
9
Pump prime
4
Lockout
7
Recycle
Page 9
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.
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.
Table 2 - Reset Button Operation
Initiate a call for heat.
2.
After the burner starts, press and
3. 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
4. yellow light will turn off and the burner will start up again.
At burner start up, click the reset
5. 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
6.
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.
If the burner is in the
below state:
Lockout Reset from Soft Lockout
Valve-on Delay, Trial
for Ignition, Ignition
Carryover
Run (igniter is shut off)
Motor-Off Delay, Standby
Pump Prime No action Exit Pump Prime mode and return to Standby
Table 3 - Status Lights
Light Color On Continuously Flashing
Red Restricted (Hard) Lockout Soft Lockout
Green Flame Sensed during normal operation
(Could be stray light during standby)
Yellow Control is in Pump Prime mode or
Reset button currently held for 15+
seconds.
Button Click
(press < 1 second)
Go to Pump Prime (see “Priming the Pump” above)
Yellow light ashes
to indicate cad cell
resistance. See “Cad Cell Resistance Indicator” for table of resistance values.
No action
Pushing the reset button will:
Button Hold
(press > 1 second)
Disable the Burner: 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.
Recycle
Cad Cell resistance. See “Cad Cell Resistance Indicator” on page 10 for a table of resistance values.
Button Hold
(press 15+ seconds)
Reset from Restricted
(Hard) Lockout
Enables Pump Priming:
After the reset button has been held for 15 seconds, the button can then be clicked during the next
ignition sequence to enter Pump Prime mode.
Page 8
Page 10
At the end of 4 minutes, the yellow
7. light will turn off and the control will automatically return to standby mode.
If prime is not established during
8.
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
9. the control will resume normal operation.
Cad Cell Resistance Indicator
During the burner Run state, click the
reset button (less than 1 second) to check the cad cell resistance range.
The yellow light will ash 1 to 4 times,
depending on the amount of light detected by the cad cell. See chart below:
Yellow
Light
Flashes
1 Normal (0 - 400 ohms)
2 Normal (400 - 800 ohms)
3 Normal (800 - 1600 ohms)
4
Flame Detection Range
Limited (1600 ohms ­Lockout)
Resetting 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 reset­ting the burner.
If the control continues to lock out
without a satised 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.
To reset, hold the button down for 15
seconds until the red light turns off and the yellow light turns on.
Always verify the control functions
according to all specications before
leaving the installation site.
Replace the control if it does not
operate as specied.
Disable Function
Page 9
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 11
Maintenance
Oil heating systems require annual service performed by a qualied, 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 multimeter 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 specications with an equivalent
replacement unit.
Page 10
Page 12
CORPO RATION
Canada: R.W. Beckett Canada, Ltd. ● Unit #3, 430 Laird Road ● Guelph, Ontario N1G 3X7
USA: P.O. Box 1289 ● Elyria, OH 44036
www.beckettcorp.com
Form No. 61649 R09
Printed in USA 4-08
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