Beckett 7590 User Manual

PARTS & ACCESSORIES

Model 7590

Gas Power Burner Control

Description / Applications

The Beckett GeniSys Gas Power Burner Control is a

safety control designed for use on gas power burners.

This control is intended for use in residential and light

commercial gas heating applications. Applications may

include boilers, furnaces, water heaters, space heating

and commercial cooking equipment. The 7590 provides

supervision of a separate 120 Vac igniter, a 120 Vac

combustion blower motor, a 24 Vac gas valve and 24

Vac connections for an air proving switch (on 7590C,

D). The control uses ame rectication principles to

prove the presence of the burner ame. Basic diagnostic

information is provided through 3 LEDs. Additional

diagnostic information and control setup will be available

through a separate diagnostic tool.

Contents

Features........................................................................................3

Specications .............................................................................. 4

Electrical Ratings .......................................................................... 4

Electrical Connections ................................................................... 4

Environmental Ratings .................................................................. 4

Approvals ...................................................................................... 4

Lockout Sequence Options ........................................................... 4

Timings ......................................................................................... 4

Control Cycling Rate ..................................................................... 4

Installation ....................................................................................6

Mounting ....................................................................................... 7

Transformer Sizing ........................................................................ 7

Spark Gap ..................................................................................... 7

Wiring ...........................................................................................7

Operation .....................................................................................8

7590T ............................................................................................ 8

Status & Diagnostics .................................................................. 8

Flame Signal Strength Indication .................................................. 9

Lockout .......................................................................................... 9

Reset from Lockout ....................................................................... 9

Lockout with Retry (Optional) ........................................................ 9

Stop/Hold Button ......................................................................... 10

Safety Check ............................................................................... 10

Check Safety Timings ................................................................. 10

Check for Normal Operation ....................................................... 10

Simplied Sequence of Operation ................................................11

Troubleshooting ........................................................................13

Troubleshooting Sequence ......................................................15

Limited Warranty Information ..................................................20

Hazard Denitions:

Indicates a hazardous situation that, if not avoided, will result in death or serious injury.

Indicates a hazardous situation that, if not avoided, could result in death or serious injury.

Indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.

Used to address practices not related to physical injury.

Safety instructions signs indicate specic safety-related

instructions or procedures.

Features

◦ For use in Natural Gas or LP gas applications.

◦ Controls 120 Vac spark igniter, motor/blower and 24 Vac gas valve, 50/60 HZ

◦ Provides proof of ame through ame rectication using a separate ame rod

◦ Checks combustion air proving switch contacts (24 Vac) on 7590C and 7590D

models to prove moving combustion air and guard against welded contacts.

◦ Field selectable for either lockout or recycle on loss of combustion air

◦ Field selectable relight or recycle operation on loss of ame (may be factory locked)

◦ Field selectable single or multiple trials for ignition on some models (may be locked)

◦ Field selectable ignition timing on some models (may be factory locked)

◦ Field selectable pre-purge timing (may be factory locked)

◦ The microprocessor is checked for proper operation prior to each ignition cycle

◦ Check for welded valve relays on each cycle

◦ Mounts on standard 4 x 4 junction box

◦ 3 status LEDs supply basic diagnostics, additional diagnostic information and eld

conguration will be available through a separate diagnostic tool

◦ An optional separate alarm module provides alarm contacts (dry contacts)

◦ A reset button is standard on all controls, non-volatile manual reset logic is available

on specic models (7590C).

◦ Communication Port to connect diagnostic tool and alarm module

Table 1 - Ignition Model Numbers

Feature

Model Line Model Description Part Number

output

120 volt Igniter

and blower motor

Standard 7590DYYYY X X X

Gas Power

Burner

The standard model 7590 is designed for use on applications below 400,000 BTUs. For applications above 400,000 BTUs, contact Beckett’s Engineering Group.

*Non-volatile lockout cannot be cleared by removing power from the control. The

control must be reset by pressing the Status/Reset button when the control is powered.

GeniSys Gas Power Burner Control Installation and Operation Manual

No Pressure Switch 7590TYYYY X X

Non-volatile Manual

Reset

7590CYYYY X X X X

output

24 volt gas valve

for

lockout*

Non-volatile

pressure switch

2 Pin- connector

Specications

Electrical Ratings

◦ Voltage: 120 volts 50/60 Hz (igniter,

motor) 24 volts (18-30 Vac) 50/60Hz

(gas valve and air proving switch)

◦ Current Draw (run): 0.2 Amps (control

only)

◦ Main Valve Rating: 2.0 Amps

◦ Motor Relay Rating: 7.4 Amps (120V)

◦ Igniter Relay Rating: 1.0 Amp (120V)

◦ Minimum Flame Current Required:

1.0 µA

◦ Flame Failure Response Time: 0.8

Seconds (Max.)

◦ Control is not polarity sensitive

◦ Heat Anticipator Setting: 0.2 amp + gas

valve current draw

Electrical Connections

◦ Two T-T screw terminals (on top) (see

Figure 1)

◦ 1/4” Quick Connects (6 total on bottom)

─ Igniter, L2

─ Motor, L2

─ L1, L2

◦ 3/16” Remote Sense quick connect

terminal (on bottom)

◦ 6-Pin (24V) connector (on bottom)

24 Volt Input, Gas Valve, Burner Ground

◦ 2-Pin (24 V) connector (on bottom)

Air Pressure Switch

◦ Micro-USB Communications Port (on

side of control) for diagnostic tool and alarm module (COM1).

◦ Additional Features

◦ 3 Diagnostic LEDs; Status (red), Flame

(yellow), MV (green)

◦ Alarm Contacts (optional module)

Environmental Ratings

◦ Operating Temperature Range: -40°F

to +175°F (-40°C to +79.4°C).

◦ Relative Humidity Operating Range 5%

- 95% (non-condensing).

Not intended for outdoor use unless mounted in appropriate enclosure.

Approvals

ETL listed per ANSI Z21.20 and CSA C22.2#199

Lockout Sequence Options

◦ Sequence is usually factory selected

◦ Lockout after single try for ignition

◦ Lockout with retrial every 1-8 hours

◦ Lockout after 3 trials for ignition

◦ Manual Reset logic: shutdown after

failure to light during trial for ignition

timing or after ame failure, (no relight

attempt), after 5 minute minimum waiting time, 1 retry attempt allowed,

then non-volatile lockout. Lockout

must be manually reset.

Timings

◦ All timings can be factory locked.

Timings below may be eld selectable

on some models.

◦ Ignition Timing: 4-15 seconds (4

seconds if Manual Reset)

◦ Pre-purge timing: 1-240 seconds

◦ Inter-purge timing: 90-300 seconds

Control Cycling Rate

The 7590 is designed for use in typical heating applications which cycle a few times per hour during the heating season. More rapid cycling of the control will shorten the useful life of the control. Controls in rapid cycling applications should be checked monthly for proper operation. All controls should be checked at least annually for proper operation.

Figure 1 - Getting to know the control

1/4” Terminal Connections

6-Pin 24 V Connector

Flame Sense

Com Port (COM 1)

Thermostat Terminals

Status/Reset LED Button

Flame LED

MV LED

Figure 2 - Gas Conversion Burner Hookup Drawing

Air Pressure Switch

Transformer

W W

Limit

(If Required)

LWCO

Y/W

Y BK

Igniter

Burner

Motor

Gas

Valve

(1/4” QC)

L2 (IGN)

Igniter

L2 (MTR)

Motor

Valve Common

Sense

(3/16” QC)

Flame Sensor

W/R

Valve

24V

24V GROUND

AP1

GeniSys Gas Power Burner Control Installation and Operation Manual

Air Pressure

Switch

AP2

Burner Ground

Com Port (COM 1)

on side of control

Thermal

Switch

Field Wiring

TT Terminals on top of control

Installation

Professional Service Required

Incorrect installation or misuse of this control could result in severe personal injury, death, or substantial

property damage from explosion or re.

Read and understand this manual. This

control must be installed, congured and put into operation only by a qualied

individual or service agency that is:

• Licensed or certied to install and

provide technical service to gas heating systems.

• Experienced with all applicable

codes, standards and ordinances.

• Responsible for the correct

installation and commissioning of this equipment.

The installation must strictly comply with all applicable codes and authorities having jurisdiction and the latest revision of the National Fire Protection Association Standard or CSA Standard for the installation of gas controls in the appropriate gas appliance.

Regulation by these authorities take precedence over the general instructions provided in this installation manual.

Fire or Explosion

Hazard

Can cause severe injury, death,

or property damage.

If You Smell Gas or Believe a Leak May Exist

• Turn off the manual gas valve to

the appliance.

• Leave the building.

• Do not try to light the appliance.

• Do not touch any electrical switch.

• Do not use a telephone within the

building.

• Leave the building before calling

the appropriate gas organization

Explosion, Fire, Scald, and Burn

Hazard

Can cause severe injury, death,

or property damage.

• The control can malfunction if it gets

wet, leading to an accumulation of explosive gas vapors.

• Never install where water can ood,

drip or condense on the control.

• Never use a control that has been

wet - replace it.

--------------------------------------

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 gas or gas vapors

have not accumulated in the appliance before starting or resetting the burner.

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 and burner.

• Perform wiring in compliance with

the National Electrical Code ANSI/ NFPA 70 (Canada CSA C22.1).

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