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Beckett AQUASMART 7600 manual

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Table of contents for the manual

  • Page 1

    P ARTS & AC CESSORIES Description / A pplica tions The Beckett AquaSmart™ is an advanced boiler control designed for use on residential and light commercial boiler systems. All models include the option of enabling Beckett HeatManager™ dynamic temperature reset that, when selected, provides up to 20% fuel consumption savings. The control in[...]

  • Page 2

    2 HeatManager™ dynamic temperature reset for additional energy savings — DOE 2012 Compliant — Meets NR CAN proposed 2012 requir ements Advanced microprocessor-based design Backlit LCD digital display with installer programming touch pad Quick access to system cycle history Onboard power disconnect switch (optional) High/Low limit and High/Low[...]

  • Page 3

    3 AquaSmart Boiler Control Manual Figure 1 - Getting to know the AquaSmart 7600 Series Control T emperature Ranges and Differentials High Limit Setting Range: 100 to 240°F (37 to 1 15°C) High Limit Differential Range: 5 to 45°F (2 to 25°C) Low Limit Setting Range: 100 to 220°F (37 to 104°C) Low Limit Differential Range: 10 to 45°F (5 to 25°[...]

  • Page 4

    4 Figure 2 - Basic Dimensions (inches) Mounting OEM Installation: When replacing an OEM-installed AquaSmart, consult the appliance manufacturer ’s wiring diagrams and instructions for additional information. Retro fi t Installation: The AquaSmart can be used to replace most standard boiler temperature controls. For a cross-reference of compatibl[...]

  • Page 5

    5 AquaSmart Boiler Control Manual AquaSmart Models and Cross-Reference Guide T able 1a - Direct Replacements Honeywell Beckett Replacement Notes L7148F (All) L8148E (All) 7600B Must con fi rm that 7600 V A rating is adequate to meet V A requirements of system. Make sure 7600 B1 output does not exceed 1.25A @ 24V AC (30 V A). 7600 outputs are not r[...]

  • Page 6

    6 Honeywell Beckett Replacement Notes L4081A/B L6081A/C 7600A or 7600B (Based on System V oltage Requirements) Remove switching relay , if used, from the system when replacing the L4081 or L6081. Make sure 7600 outputs do not exceed 7.4A @ 120 V AC. 7600 outputs are not rated for 240 V AC. L6006A (All) L6006C 1018 L6008A 1 192 L6008A 1242 7600A or [...]

  • Page 7

    7 AquaSmart Boiler Control Manual Compare the attached wires to available wiring diagrams on the control cover and to the devices to which they can be traced. If wiring diagrams have been lost they are available later in this manual. Label each wire accordingly , to ensure accurate reconnection. (Masking tape works well for labeling.) Remove each w[...]

  • Page 8

    8 Installing the 2-in-1 Sensor For proper operation, there must be a secure electrical bond between the green sensor wire from the sensor and the boiler metal vessel in direct contact with the boiler water . Failure to secure an electrical bond will result in the AquaSmart locking out and displaying, “LOCKOUT - LOW W A TER”. Explosion, Burn and[...]

  • Page 9

    9 AquaSmart Boiler Control Manual T est the Low W ater Cut-off (L WCO) Safety Function W ARNING! Avoid touching or shorting the live terminals during this test. T urn electric power ON to energize AquaSmart control. Perform the following tests to verify the L WCO function. For AquaSmart 7600A: Remove the green sensor lead from the ground screw . Th[...]

  • Page 10

    10 Immersion Well or 2-in-1 Sensor Mount the control by aligning the 7/8” diameter hole (found on back) around the mating feature of the immersion well or 2-in-1 sensor and press into place. Position the control upright and tighten down the #10 screw located on the left side of the control. T ighten so that control is securely in place ( Figure 9[...]

  • Page 11

    11 AquaSmart Boiler Control Manual Explosion Hazard. Can Cause Severe Injury , Death or Property Damage. Use this product only in systems with a pressure relief valve. Wiring the AquaSmart Control Consult the appliance wiring diagrams to check the manufacturer ’s speci fi cations. Refer to Figure 12 through Figure 17 for some typical wiring diag[...]

  • Page 12

    12 SK10030 P1 COLD WATER INLET EXP ANSION TA N K HEA TING ZONE AIR SEP ARA TOR AIR VENT Figure 12 - 7600A/B single-zone connections with or without a tankless coil W ater Flow: Control Wiring: 1. Set “DHWP OFF” (default, see programming section for instructions) 2. Set “C1 on TT” (default, see programming section for instructions) LOW VOL T[...]

  • Page 13

    13 AquaSmart Boiler Control Manual Figure 13 - 7600A/B multi-zone connections with or without a tankless coil W ater Flow: Control Wiring (Option 1): Circulator-On and -Off Delays on Zone 1 ONL Y 1. Set “DHWP OFF” (default, see programming section for instructions) 2. Set “C1 on TT” (default, see programming section for instructions) 3. Cir[...]

  • Page 14

    14 TR TW SK10032 6 5 4 3 2/N 1/H T T ZONE RELA Y ZONE 1 LOW VOL T AGE THERMOST A T LOW VOL T AGE THERMOST A T ZONE 2 ZONE RELA Y T T 1/H 2/N 3 4 NEUTRAL HOT 120 V AC BLACK WHITE P1 CIRCULA TOR 120 V AC P3* CIRCULA TOR 120 V AC 6 5 4 3 2/N 1/H T T ZONE RELA Y ZONE 3* LOW VOL T AGE THERMOST A T L2 L1 C1 C2 ZC ZR B1 B2 7600A : 120 V AC BURNER OR GAS I[...]

  • Page 15

    15 AquaSmart Boiler Control Manual Figure 14 - 7600A/B alternate multi-zone connections with or without a tankless coil W ater Flow: Control Wiring (Option 1): 7600B only 1. Set “DHWP OFF” (default, see programming section for instructions) 2. Set “C1 on TT” (default, see programming section for instructions) 3. Circulator-on delay will aff[...]

  • Page 16

    16 Figure 14 (continued) - 7600A/B alternate multi-zone connections with or without a tankless coil Control Wiring (Option 2): 7600A only 1. Set “DHWP OFF” (default, see programming section for instructions) 2. Set “C1 on TT” (default, see programming section for instructions) 3. Circulator-on delay will affect all zones. Circulator-of f de[...]

  • Page 17

    17 AquaSmart Boiler Control Manual SK10034 COLD WATER INLET EXP ANSION TA N K AIR SEP ARA TOR AIR VENT HEA TING ZONE 1 INDIRECT DHW DHW ZONE P2 P1 Figure 15 - 7600A/B single-zone connections with Indirect Domestic Hot Water (DHW) W ater Flow: Control Wiring: 1. Set “DHWP on ZR” (see programming section for instructions) 2. Set “C1 on TT” (d[...]

  • Page 18

    18 SK10035 COLD WATER INLET EXP ANSION TA N K AIR SEP ARA TOR AIR VENT HEA TING ZONE 1 INDIRECT DHW DHW ZONE P1 P2 P3 HEA TING ZONE 2 HEA TING ZONE 3* P4* Figure 16 - 7600A/B multi-zone connections with Indirect Domestic Hot Water (DHW) W ater Flow: CONTINUED ON NEXT P AGE ► * additional zones can be added by duplicating the plumbing and wiring o[...]

  • Page 19

    19 AquaSmart Boiler Control Manual Figure 16 (continued)- 7600A/B multi-zone connections with Indirect Domestic Hot Water (DHW) Control Wiring (Option 1): Circulator-On and -Off Delays on DHW Zone Only 1. Set “DHWP on TT” (see programming section for instructions) 2. Set “C1 on TT” (default, see programming section for instructions) 3. Circ[...]

  • Page 20

    20 L2 L1 C1 C2 ZC ZR B1 B2 TR TW SK10024 6 5 4 3 2/N 1/H T T ZONE RELA Y LOW VOL T AGE THERMOST A T ZONE 1 ZONE RELA Y T T 1/H 2/N 3 4 5 6 NEUTRAL HOT 120 V AC BLACK WHITE P1 CIRCULA TOR 120 V AC P3 CIRCULA TOR 120 V AC 4 3 2/N 1/H T T ZONE RELA Y ZONE 2 LOW VOL T AGE THERMOST A T LOW VOL T AGE THERMOST A T ZONE 3* ZONE RELA Y T T 1/H 2/N 3 4 5 6 C[...]

  • Page 21

    21 AquaSmart Boiler Control Manual Figure 16 (continued) - 7600A/B multi-zone connections with Indirect Domestic Hot Water (DHW) ◄ CONTINUED FROM PREVIOUS P AGE Control Wiring (Option 3): Utilizing a Zone Panel 1. Set “DHWP on TT” (see programming section for instructions). 2. Set “C1 on TT” (default, see programming section for instructi[...]

  • Page 22

    22 Figure 17 - 7600A/B alternate multi-zone connections with Indirect Domestic Hot Water (DHW) W ater Flow: SK10037 COLD WATER INLET EXP ANSION TA N K HEA TING ZONE 1 AIR SEP ARA TOR AIR VENT HEA TING ZONE 2 HEA TING ZONE 3* ZZ Z ZONE 1 24 V AC ZONE VA LV E ZONE 2 24 V AC ZONE VA LV E ZONE 3* 24 V AC ZONE VA LV E GENERAL CIRCULA TOR DHW ZONE INDIRE[...]

  • Page 23

    23 AquaSmart Boiler Control Manual Figure 17 (continued) - 7600A/B alternate multi-zone connections with Indirect Domestic Hot Water (DHW) Control Wiring (Option 1): 7600B only 1. Set “DHWP on ZR” (see programming section for instructions) 2. Set “C1 on BOTH” (see programming section for instructions) 3. Circulator-on delay will affect all [...]

  • Page 24

    24 ◄ CONTINUED FROM PREVIOUS P AGE Control Wiring (Option 2): 7600A only 1. Set “DHWP on ZR” (see programming section for instructions) 2. Set “C1 on BOTH” (see programming section for instructions) 3. Circulator-on delay will affect all zones. Circulator-of f delay will have no effect. 4. 24 V AC zone valves cannot be powered directly wi[...]

  • Page 25

    25 AquaSmart Boiler Control Manual T o ensure smooth appliance operation, the AquaSmart requires a separation between the High and Low limits no less than the greater differential plus 5°F . For example: If the HIGH LIMIT is set to 180°F , the HIGH DIFF to 20°F , and the LOW DIFF to 10°F , the control will not allow a LOW LIMIT above 155°F (18[...]

  • Page 26

    26 Press the “ENTER (RESET)” key . The control will ask you to con fi rm the setting with the following screen:   Press “ENTER (RESET)” if the value is correct, or “CANCEL (BACK)” if it is not. D. T emperature Low Limit Differential In any mode[...]

  • Page 27

    27 AquaSmart Boiler Control Manual Press the “ENTER (RESET)” key . The following screen will be displayed:   A B C D T o navigate the history menu, press “ ▲ ” or “ ▼ ” key to view additional data and cycles. Press the “ [...]

  • Page 28

    28 T o change the call for heat source that the circulator is activated from (see Figures 8 - 13 for examples), press the “ ▲ ” and “ ▼ ” keys until the following screen is displayed:   Press “ENTER (RESET) ” to toggle the circulator source between ON T[...]

  • Page 29

    29 AquaSmart Boiler Control Manual Press the “ ▲ ” and “ ▼ ” keys until the following screen is displayed:   Press “ENTER (RESET) ” . The following screen will be displayed:   Press “ENTER (R[...]

  • Page 30

    30 AquaSmar t Oper ation T able 4 – Typical operation with default settings (Circulator set “ON TT”) System Action AquaSmart Response T emperature falls below low limit Burner is turned on until the water temperature reaches the low limit plus the low differential. ZC is turned off until the water temperature reaches the low limit plus the lo[...]

  • Page 31

    31 AquaSmart Boiler Control Manual 75 50 100 125 150 175 200 225 250 275 300 75 50 100 125 150 175 200 225 250 275 300 How a Boiler Control Works Figure 19 - Cold Start Operation (Low Limit ► OFF) Figure 20 - Warm Start Operation (Low Limit ► ON) (T o maintain domestic hot water temperature) High T emperature Limit (Adjustable 100° to 240°F) [...]

  • Page 32

    32 T r oubleshooting Lockout The AquaSmart will lock out if any number of abnormal conditions are detected. Hea tMana ger T ec hnolog y The Beckett AquaSmart comes equipped with the Department of Energy (DOE) 2012 compliant Heat Manager load-matching energy saving algorithm. The Heat Manager saves fuel by dynamically changing the temperature high o[...]

  • Page 33

    33 AquaSmart Boiler Control Manual During Annual Maintenance or More Frequent Service Intervals, V erify the below items. Note: The 7600 control has no serviceable internal parts. DO NOT attempt to repair a malfunctioning control. The control is clean and all vents are free of dust, lint or foreign material. All wiring is tight, terminals are free [...]

  • Page 34

    34 Notes Section[...]

  • Page 35

    35 AquaSmart Boiler Control Manual SK10029 Mounting T empla te THIS END UP Use self-drilling screws supplied in the 7600RMU Remote Mount Kit -or- Drill 0.1 10” diameter holes[...]

  • Page 36

    Form No. 61738 Rev . 6, Printed in USA 6/1 1 CORPORA TION USA: P.O. Box 1289 ● Elyria, OH 44036 Canada: R.W. Beckett Canada, Ltd. ● Unit #3, 430 Laird Road ● Guelph, Ontario N1G 3X7 www.beckettcorp.com The R. W . BECKETT CORPORA TION (“Beckett”) warrants to persons who purchase its “Products” from Beckett for resale, or for incorporat[...]