Beckett 7505 User Manual

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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.

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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

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

Motor-off

delay time

Replaces

Honeywell:

R7184P, R7184U

Replaces

48245, 40200,

42230, 50200

Carlin:

60200

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.

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Fire or Explosion

LIMIT

L2 (VLV)

VALVE

MOTOR

L2 (MTR)

L2 (IGN)

IGNITER

CAD CELL

MOTOR

IGNITER

LIMIT

CAD CELL

THERMOSTAT

BOILER CONTROL

TR-TW

JUMPER

TR-TW TERMINALS

LOCATED ON OPPOSITE

SIDE OF CONTROL

B2 B1

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

L2 (VLV)

VALVE

MOTOR

L2 (MTR)

L2 (IGN)

IGNITER

CAD CELL

MOTOR

IGNITER

LIMIT

CAD CELL

THERMOSTAT

TR-TW

JUMPER

TR-TW TERMINALS

LOCATED ON OPPOSITE

SIDE OF CONTROL

BOILER CONTROL

B2 B1

LIMIT

L2 (VLV)

VALVE

MOTOR

L2 (MTR)

L2 (IGN)

IGNITER

CAD CELL

MOTOR

IGNITER

B2 B1

LIMIT

OIL VALVE

CAD CELL

THERMOSTAT

BOILER CONTROL

TR-TW

JUMPER

TR-TW TERMINALS

LOCATED ON OPPOSITE

SIDE OF CONTROL

LIMIT

L2 (VLV)

VALVE

MOTOR

L2 (MTR)

L2 (IGN)

IGNITER

CAD CELL

MOTOR

IGNITER

OIL VALVE

CAD CELL

THERMOSTAT

TR-TW

JUMPER

TR-TW TERMINALS

LOCATED ON OPPOSITE

SIDE OF CONTROL

BOILER CONTROL

B2 B1

SAFETY AND

OPERATING

LIMITS

LIMIT

L2 (VLV)

VALVE

MOTOR

L2 (MTR)

L2 (IGN)

IGNITER

CAD CELL

MOTOR

IGNITER

CAD CELL

THERMOSTAT

TR-TW

JUMPER

TR-TW TERMINALS

LOCATED ON OPPOSITE

SIDE OF CONTROL

LIMIT

SAFETY AND

OPERATING

LIMITS

LIMIT

L2 (VLV)

VALVE

MOTOR

L2 (MTR)

L2 (IGN)

IGNITER

CAD CELL

MOTOR

IGNITER

CAD CELL

THERMOSTAT

TR-TW

JUMPER

TR-TW TERMINALS

LOCATED ON OPPOSITE

SIDE OF CONTROL

LIMIT

SAFETY AND

OPERATING

LIMITS

LIMIT

L2 (VLV)

VALVE

MOTOR

L2 (MTR)

L2 (IGN)

IGNITER

CAD CELL

MOTOR

IGNITER

OIL VALVE

CAD CELL

THERMOSTAT

TR-TW

JUMPER

TR-TW TERMINALS

LOCATED ON OPPOSITE

SIDE OF CONTROL

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

L2 (VLV)

VALVE

MOTOR

L2 (MTR)

L2 (IGN)

IGNITER

CAD CELL

MOTOR

IGNITER

OIL VALVE

CAD CELL

THERMOSTAT

TR-TW

JUMPER

TR-TW TERMINALS

LOCATED ON OPPOSITE

SIDE OF CONTROL

● 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

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.

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

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.

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.

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

for a call for heat.

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 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

established, the igniter remains on for 10 additional seconds to ensure ame

stability.

Page 7

Standby

Valve-on

delay

Motor-off

delay

Run: The ame is sustained until the

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

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

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 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.

Trial for ignition

Ignition

carryover

Run

Pump prime

Lockout

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.

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

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

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)

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