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INSTALLATION INSTRUCTIONS for Form 7514 rev. 0
HeatManager
™
2.5 model 7514
LIGHT COMMERCIAL HYDRONIC HEATING SYSTEM ECONOMIZER
R.W. Beckett Corporation, Elyria, Ohio USA
Description
The HeatManager™2.5 is a patented microprocessor-
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.
Operation
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:
‘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.
‘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.
‘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.
During normal operation, one of the above messages will be
alternated with the message(s) below.
‘HEAT TEMP = ‘ - The measured value of the boiler outflow
water temperature is displayed in degrees F.
‘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.
Installation
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.
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.
Wiring
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.
Sensors
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).
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.
If any of the sensor leads are too short, they can be extended by
using standard ‘modular telephone’ wire and connectors (see
Fig. 4).
Checkout
Recheck wiring one last time and make sure that the
temperature sensor(s) is plugged into the proper jack(s). The
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
‘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.
Service and Troubleshooting
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.
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.
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.