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OWNER’S MANUAL AND INSTALLATION INSTRUCTIONS for

Beckett HeatManager

Form: 7512 rev 6



RESIDENTIAL HOT-WATER (BOILER) HEATING SYSTEM ECONOMIZER Description The Beckett HeatManager is a patented microprocessor-controlled fuel-saving device for residential hot-water (boiler) heating systems. The HeatManager reduces fuel consumption, wear on boiler parts and burner emissions by actively managing the burner, in conjunction with the aquastat, to properly match the boiler output to the required load.

Low Limit (if applicable): The low limit set point should be 150°F or lower for optimal fuel savings. If it is already below 150°F, do not readjust it. If it must be set above 150°F to provide adequate domestic hot water, constant power must be applied to ZC in the aquastat to override the triple-acting feature.

Startup / Checkout Applications The HeatManager is only for hot water heating systems that consistently operate above 150°F during the heating season. It can be used with any heating fuel (oil, gas, or propane) and will work equally well with cold-start and maintained boilers.

Installation Mounting: The HeatManager can be mounted either vertically or horizontally to an electric junction box or directly to the aquastat. Remove a knockout from the junction box or aquastat and mount the unit using the standard ½” electrical fitting and supplied lock nut. Wiring: For safety, power to the boiler must be turned off during installation. All wiring and connections must comply with Local and National Electrical Codes. The HeatManager is electrically installed in series between the boiler Aquastat and the burner. If there is a vent damper in the system, then the HeatManager is installed between the Aquastat and vent damper. Follow the typical wiring diagrams on the following pages. All unused wires must be individually insulated with tape or wire nuts. NOTE: Because the HeatManager can operate with different voltages for the power and control circuits, it has separate common wires for these circuits. It is necessary that these wires are connected to the proper commons or the unit will not function properly. See wiring diagrams on the reverse side of this sheet for details.

Temperature Sensor(s) Primary Heating Water Sensor: Attach the sensor to the boiler outflow/supply pipe as close to the boiler as possible using tie wire or tie wraps (see Fig. 1). Make sure that the sensor makes good thermal contact with the pipe. The sensor must be covered with pipe insulation (see Fig. 2). Route the sensor wire to the HeatManager and plug into ‘Heating Water Sensor’ jack. Do not wrap the sensor wire around the hot supply pipe. Secondary Domestic Water Temperature Sensor: This sensor is only used with systems that have a tankless coil in the boiler; it is not needed for systems with an indirect water heater. If needed, attach the sensor to the domestic hot water outflow pipe following the same procedure used for the heating water sensor and plug into ‘Domestic Water Sensor’ jack. If the domestic water sensor detects a demand for hot water, it will override the HeatManager ‘Economizing’ mode and allow the burner to fire.

Aquastat Settings High Limit: The high limit set point should be 180°F or higher. If it is already above 180°F, do not readjust it.

Set the HeatManager switch to ‘Off/Bypass’ and restore power to the boiler. Next, set the switch to ‘On’. HeatManager will go through a self-test. First all 4 lights will turn on verifying their proper functioning (they may flicker slightly), then the red light will flash indicating that sensor(s) were detected. After the sensor check, one of the green lights will activate to indicate the current operating mode. To verify that HeatManager is functioning properly, force a call for heat until boiler water temperature is at least 175°F then stop the call for heat. Only the ‘Standby’ LED should be lit. Wait a few minutes until the water temperature has dropped approx 5° and then force another call for heat. At this time the HeatManager should switch from ‘Standby’ to ‘Economizing’ (the Burner should not be running). After a further Temperature drop the HeatManager should go into the ‘Burner Enabled’ mode and the Burner should come on. If the above sequence does not function as described, re-check wiring and sensor installation.

Operating Modes / LED’s Standby: There is no call for heat from any of the thermostats. The burner is not running. Economizing: There has been a call for heat from a thermostat, but the HeatManager detects that there is available heat in the boiler that can be used without burning fuel. The burner is not running. Burner Enabled: The ‘Economizing’ period has ended and the HeatManager has allowed the burner to fire. The burner is running. Low Temperature Limit (Red Light on Steady): HeatManager has sensed that there is not enough available heat in the boiler to go into ‘Economizing’ mode. This will happen occasionally and does not indicate a problem. The burner is running. Check Sensor (Red Light Flashing): Indicates that a sensor is not operating properly and the HeatManager has taken itself out of the circuit. The sensor is either damaged or the sensor plug is not making good contact with the socket in the HeatManager. Note: Depending on the type of heating system, the circulator pump(s) may or may not be running when in any of the above modes.

Service and Troubleshooting After installation and checkout, the HeatManager requires no maintenance. 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 will function as it did prior to HeatManager installation, allowing service personnel to diagnose boiler problems.

R.W. Beckett Corporation, Elyria, Ohio USA

OWNER’S MANUAL AND INSTALLATION INSTRUCTIONS for

Beckett HeatManager

Form: 7512 rev 6



RESIDENTIAL HOT-WATER (BOILER) HEATING SYSTEM ECONOMIZER TEM PE RA TUR E S E N S O R W IR E

OUTFLOW PIPE CABLE PLUGS INTO JACK ON SENSOR THIS SIDE TOWARDS PIPE

TYRAPS

TA PE

IN S U L A T IO N

TA PE SIDE VIEW

O U TFLO W P IP E

SENSOR

Fig. 2

Fig. 1

WIRING NOTE: FOR 115V POWER USE BLK WIRE AND TAPE-OFF VIO FOR 220V POWER USE VIO WIRE AND TAPE-OFF BLK

=2

4V

BRN

TE NO ING WIR

BL

U=

24

= 115 /230V

V

INDIVIDUALLY TAPE OR WIRE-NUT NO TE IR IN G W

= 11 BR N

SE E

5/23 0V

NO TE IR IN G W SE E

24V CALL

MASTER BOILER SWITCH

BOILER AQUASTAT

D RE

MASTER BOILER SWITCH

YEL

YEL

D RE

WH T

INDIVIDUALLY TAPE OR WIRE-NUT

WH T

U BL

E SE

GRY = 24V

GRY = 24V

SE

INDIVIDUALLY TAPE OR WIRE-NUT

E OT GN IRIN EW

BOILER AQUASTAT

HOT CONNECTION BROKEN HERE

115/220V

POWER

POWER

CONNECTION BROKEN HERE

HOT

BURNER

TEMP. DROP

24V

HOT

BURNER

TEMP. DROP

EXISTING

EXISTING COMMON

COMMON

COMMON

TYPICAL 115/220V POWER & CONTROL -- BOILER BURNER CIRCUIT

TYPICAL 115/220V POWER / 24V CONTROL -- BOILER BURNER CIRCUIT (FOR 24V POWER & CONTROL THE BLUE WIRE WOULD BE CONNECTED TO THE 24V HOT, THE WHITE TO THE 24V COMMON. THE BLACK AND VIOLET WIRES ARE NOT USED AND SEPARATELY TAPED)

Beckett HeatManager with Honeywell R

71

84 A

R7184A,B,P,U "SERIES 5" Electronic Oil Primary When Aquastat Is Wired 24VAC

,B ,P ,U

TAPE OR WIRENUT INDIVIDUALLY

5

HeatManager

R

5 07 A1 84 71

BLUE Diagnostic Light

Data Port

Typical Honeywell L4006A Aqustat

1 Series Number Identification The Series number is the last number on the side label. (It is rotated 90° from the other numbers).

BROWN VIOLET

Red Reset Button EnviroCom Terminals Delay Time Dip Switch

NOTE: R7184 Controls prior to "Series 5" should be replaced with a "Series 5" control. The old control should be returned to Beckett for exchange.

Alarm Terminals

Thermostat Terminals

2

GREY BLACK

3/ T

Typical Honeywell R7184 SIDE VIEW

WHITE YELLOW

T Break Connection Here

R.W. Beckett Corporation, Elyria, Ohio USA

RED

CONSTANT 120 VAC

OWNER’S MANUAL AND INSTALLATION INSTRUCTIONS for

Beckett HeatManager

Form: 7512 rev 6



RESIDENTIAL HOT-WATER (BOILER) HEATING SYSTEM ECONOMIZER

TAPE OFF

TAPE OFF INDIVIDUALLY

INDIVIDUALLY

TAPE OFF INDIVIDUALLY

TM

HeatManager

BLUE

BLUE

BLUE

GREY

BROWN

GREY

VIOLET

VIOLET

VIOLET

120VAC

BLACK

L2

L1

T

TV

T

T

Z

T

TV

Z

WHITE G TYPICAL HONEYWELL L8124E

TYPICAL HONEYWELL L8124A,C

TO LINE VOLTAGE OIL BURNER RELAY OR GAS VALVE

TYPICAL HONEYWELL L8124G,L

C1 C2

C1

ZR

GREY

BLACK B2

B1

B2

C2

ZR

L1

L2

G

BROWN

WHITE

B1

YELLOW

B1

BLACK C1

RED

H

TO 24VAC GAS VALVE

N

N

G

TAPE OFF INDIVIDUALLY

TM

TM

HeatManager

GREY

H

WHITE

120VAC

TAPE OFF INDIVIDUALLY

TAPE OFF INDIVIDUALLY

BLUE

G

TO LINE VOLTAGE OIL BURNER RELAY OR GAS VALVE

G

120VAC

HeatManager

L2

RED

YELLOW

TM

L1

YELLOW

BROWN RED

B2 C2

HeatManager

BLUE

BLUE

BROWN

BROWN

VIOLET

VIOLET

VIOLET WHITE BLACK

G

L1

L2

T

TV

T

W

T

120 VAC

W

TP

Z

T

H N

Z TYPICAL

TYPICAL

TYPICAL HONEYWELL L8148J

HONEYWELL L8148E

HONEYWELL L8148A BROWN

C1 C2

GREY YELLOW

C1 C2 BLACK

C1 TO LINE VOLTAGE OIL BURNER RELAY OR GAS VALVE

TV

G

C2

B1 B2

B1

B2

L1

L2

YELLOW

WHITE

RED

BLACK B1

B2 B3

L1

L2

G

H

N

G

YELLOW RED

RED TO 24VAC GAS VALVE

GREY

H

N

120VAC

R.W. Beckett Corporation, Elyria, Ohio USA

TO 24VAC GAS VALVE

120VAC

WHITE

OWNER’S MANUAL AND INSTALLATION INSTRUCTIONS for

Beckett HeatManager

Form: 7512 rev 6



RESIDENTIAL HOT-WATER (BOILER) HEATING SYSTEM ECONOMIZER

Tape Off Individually

TM

HeatManager

Tape Off Individually

TM

HeatManager

Blue

Blue

Blue

Grey

Grey

Grey

Violet

Violet

Violet

White

White

White

Brown

Brown

Brown

Honeywell R8182E L1

Black

Tape Off Individually

TM

HeatManager

Honeywell R8182D

L2

120 H VAC N

L1

Black

T

T

120 H VAC N

T

Honeywell R8182F

L2

T

DIF

Reset Button

L1

L2 T

120 H VAC N

T

B

B Safety Switch

Black

B

B

Safety Switch

Safety Switch

Reset Button

Reset Button

Aquastat Switch Circuit Board Connection

L O

Circuit Board Connection

Yellow C1

Red

B2 C2

B1

F

H I

ZR

Yellow

C1

F

Circuit Board Connection

ZC

ZC Yellow Red

L O

H I

ZR

F

B1

F

C1

Red

B2 C2 F

B1

F Wire from bottom of HI Limit Setting

Yellow wire from bottom of HI Limit Setting

Yellow wire from bottom of Aquastat Switch

B2 C2

R8182 SERIES INSTRUCTIONS Remove the Yellow wire from the bottom of the Aquastat Switch. Connect the Yellow wire from the HeatManager to this terminal. Connect the Red wire from the HeatManager to the Yellow wire that was previously removed from the Aquastat.

TAPE OFF INDIVIDUALLY

TAPE OFF INDIVIDUALLY

TAPE OFF INDIVIDUALLY

TM

HeatManager

TM

HeatManager

BLUE

BLUE

BROWN

BROWN

BLUE GREY VIOLET

VIOLET

VIOLET WHITE BLACK

YELLOW

BLACK

WHITE

YELLOW

BLACK

OPERATING AQUASTAT

WHITE

L1

G

OPERATING AQUASTAT

T

L2

T

G

120 VAC

H N

R W BLACK WHITE ORANGE

RED

BLACK

G

WHITE

TYPICAL HONEYWELL

Y

R8184M,P

C

TYPICAL HONEYWELL L8151A

T

ORANGE GREY

T

RED

TYPICAL

B2

HONEYWELL

BROWN

R8184G,K,L,N CAD CELL EYE

F 120VAC

F F

CAD CELL EYE

C1 YELLOW

120VAC F

GREY

R.W. Beckett Corporation, Elyria, Ohio USA

TO LINE VOLTAGE OIL BURNER RELAY OR GAS VALVE

RED

C2

B1