Beckett Welding System 7514 User Manual

INSTALLATION INSTRUCTIONS for  
Form 7514 rev. 0  
HeatManager2.5 model 7514  
LIGHT COMMERCIAL HYDRONIC HEATING SYSTEM ECONOMIZER  
Description  
The HeatManager™2.5 is  
a
patented microprocessor-  
Wiring  
controlled fuel-saving device for commercial and residential  
hydronic heating systems. It reduces fuel consumption, wear  
on boiler parts and burner emissions by actively managing the  
burner, in conjunction with the boiler aquastat, to properly  
match the boiler output to the required load.  
All wiring and connections must comply with Local and National  
Electrical Codes. The unit should be wired as shown in the  
wiring diagram (Fig. 1a or Fig. 1b) on the reverse side.  
NOTE: All unused leads should be trimmed and individually  
taped.  
Operation  
Sensors  
After installation, setting the toggle switch on the unit to the  
‘ON’ position activates the device. The LCD display indicates  
the various ‘modes’ of the device, and sensed temperatures.  
The possible messages and their explanation are:  
Insert the sensor connector into the ‘Heating Water Sensor’ jack  
in the side of the unit. Attach the sensor to the boiler outflow  
pipe using Ty-Wraps® (see Fig. 2) or another secure method.  
Make sure that the sensor makes good thermal contact with the  
pipe. Cover the sensor with a small piece of pipe insulation (not  
provided) and secure in place (see Fig. 3).  
‘STANDBY MODE’ - The boiler is operating under its own  
internal aquastat, which has turned the burner off. This occurs  
for a period of time after the burner has shut down.  
For boilers which also supply domestic hot water, install a  
second sensor in the ‘Domestic Water Sensor’ jack and attach  
the sensor end to the domestic hot water outflow-pipe at the  
storage tank, if present, or at the boiler domestic water coil  
outlet-pipe, if no storage tank is used. Follow the same  
procedure to attach the sensor as used above for the ‘Heating  
Water Sensor’. This sensor should not be used if the boiler does  
not supply heat for domestic hot water.  
‘ECONOMIZER MODE’ - The boiler aquastat has requested  
the burner to come on but the HeatManager™ has sensed that  
there is available heat which can be used without burning fuel.  
The burner will remain off and useful heat will be delivered  
from the boiler’s existing supply of hot water.  
‘HEATING MODE’ – The burner is allowed to fire.  
If any of the sensor leads are too short, they can be extended by  
using standard ‘modular telephone’ wire and connectors (see  
Fig. 4).  
‘HEATING LOW LIMIT’ - The unit has switched the burner on  
due to an increase in load. This condition may occur  
occasionally. If this message appears frequently, the boiler  
aquastat is set at too low a temperature. It should be  
increased in 2º F increments until the condition stops.  
Checkout  
Recheck wiring one last time and make sure that the  
temperature sensor(s) is plugged into the proper jack(s). The  
During normal operation, one of the above messages will be  
alternated with the message(s) below.  
sensor(s) are only detected during power-up.  
Set the  
HEATMANAGER™ switch to ‘Off/Bypass’ and restore power to  
the boiler. Reset the switch to ‘On’. After a brief check of the  
electronics, the sensor(s) will be detected and the green  
‘HEAT TEMP = ‘ - The measured value of the boiler outflow  
water temperature is displayed in degrees F.  
‘Power/Normal’ indicator should light continuously.  
It is  
important to verify recognition of the sensors by viewing the  
temperature reading(s), on the display. If the installed sensor(s)  
are not detected, the HEATMANAGER™ will not function  
properly. If the green indicator is blinking or if the display does  
not verify the installed sensor(s), turn The HEATMANAGER™  
‘Off’ and check the sensor installation. After the sensor-check,  
depending upon the temperature of the boiler water at power-up,  
the HEATMANAGER™ will go into one of its various modes. If  
the HEATMANAGER™ goes into the ‘Standby Mode’; note the  
aquastat setting and force a burner call by temporarily setting the  
aquastat higher and verifying the change of mode of the  
HEATMANAGER™. Make sure to return the aquastat to its’  
original setting. This indicates the unit is operating normally. If  
the HeatManager™ does not come out of ‘STANDBY MODE’  
when the boiler’s aquastat is calling for the burner to run, the unit  
is probably wired incorrectly; see the WIRING NOTE.  
‘DOM. TEMP = ‘ - The measured value of the domestic hot  
water outflow temperature is displayed in degrees F. *  
* Note: This message will only appear if the boiler supplies  
domestic hot water and the optional second sensor is installed  
(see Sensor Section of these instructions).  
In the event that a sensor fails, the HEATMANAGER™ will  
return full control of the burner to the boiler aquastat, the  
‘Power/Normal’ indicator will blink, and the following message  
will be display:  
‘SENSOR FAILURE ‘  
If this message appears, see the instructions under Service  
and Troubleshooting or call your installer for service.  
Service and Troubleshooting  
Installation  
After installation, the HeatManager™ requires no maintenance  
and will provide years of trouble free operation. The unit may be  
disconnected at any time by putting the switch to the  
‘OFF/BYPASS’ position. In this position, the unit has no effect  
on the system and the boiler functions as it was prior to the  
IntelliCon installation. This allows service personnel to diagnose  
any boiler problems without the unit intervening.  
The HEATMANAGER™ unit is electrically installed in series  
with the boiler aquastat as shown in the wiring diagram (Fig. 1a  
or Fig.1b on the reverse side of this page). Check the shipping  
box label for correct model. The HEATMANAGER™ can be  
used with 24, 115 and 220 Volts AC (see Fig. 1a or Fig. 1b for  
wiring details) for power and control.  
For safety, power to the boiler should be shut off during  
installation.  
If at any time the ‘SENSOR FAILURE’ message appears on the  
front panel display, a sensor is not operating and the unit  
automatically returns full control to the Boiler’s aquastat. To  
correct this, leave the power switch in the ‘ON’ position and  
unplug each sensor from the unit (one at a time) and reconnect  
them. If the error message remains, a sensor is defective and  
must be replaced. Since it is improbable for two sensors to fail  
at the same time, a new sensor should be swapped with the  
existing sensor(s), one at a time, to determine which sensor has  
failed.  
To ensure maximum savings, it is recommended that the  
Aquastat be set to a minimum of 170˚F.  
Positioning  
The unit can be mounted in any position. For readability of the  
display, the vertical position is preferred. Depending on the  
boiler’s configuration, the unit can be mounted on an electric  
junction box or directly on an external aquastat. Remove a  
knockout from the junction box or aquastat and mount the unit  
using the standard ½’ electrical fitting on the case, and the  
supplied lock-nut.  
Here again, the power switch must be left in the ‘ON’ position  
while changing the sensors.  
NOTE: Installer, please leave these instructions with the unit for  
future reference.  
R.W. Beckett Corporation, Elyria, Ohio USA  
 

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