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Beckett 7600 Boiler User Manual

1. ZONE 1 ZONE 2 LOW VOLTAGE LOW VOLTAGE THERMOSTAT THERMOSTAT ZONE 1 ZONE 2 24 VAC 24 VAC ZONE VALVE ZONE VALVE Honewell Taco V8043F 550 e amp 1D uu BET ete SK10038 AquaSmare DHW LIMIT CONTROL FIELD MFR T SUPPLIED SERVICE 40 VA SWITCH TRANSFORMER S NEUTRAL WHITE 9 250 24 VAC GAS 120 VAC IGNITION SYSTEM a BLACK HOT N gt z 4 G 99 GENERAL CIRCULATOR CIRCULATOR 120 VAC CONTINUED ON NEXT PAGE gt AquaSmart Boiler Control Manual 23 Additional zones be added by duplicating the Figure 17 continued 7600A B alternate multi zone plumbing and wiring of zone 3 adding additional connections with Indirect Domestic Hot Water DHW transformers as needed lt CONTINUED FROM PREVIOUS PAGE 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 off delay will have no effect 4 24 VAC zone valves cannot be powered directly with the 7600
2. INDIRECT DHW HEATING ZONE 1 SK10034 BOILER EXPANSION TANK pM Control Wiring 1 Set DHWP on ZR see programming section for instructions 2 Set C1 on TT default see programming section for instructions 3 Circulator on and off delay will only affect zone 1 SK10023 AquaSmart WHITE OF ZONE RED 1 OF LOW VOLTAGE THERMOSTAT CIRCULATOR NG E 120 VAC 2 NEUTRAL WHITE v 120 VAC 120 VAC BURNER OR SLACKS a GAS IGNITION SYSTEM HOT FIELD MER CIRCULATOR 7600B SUPPLIED 120 VAC 24 VAC GAS SERVICE IGNITION SYSTEM SWITCH DHW LIMIT CONTROL E 2 OY 2G G AquaSmart Boiler Control Manual 17 Figure 16 7600A B multi zone connections additional zones can be added by duplicating with Indirect Domestic Hot Water DHW the plumbing and wiring of zone 3 Water Flow Ur Gr Gr SK10035 INDIRECT DHW HEATING HEATING HEATING ZONE ZONE ZONE 1 2 3 BOILER EXPANSION TANK CONTINUED ON NEXT PAGE gt Figure 16 continued 76
3. 8 2 in 1 Installation Instructions seen 9 Test the Low Water Cut off LWCO Safety Function 9 Installing the AquaSmart Control ssssseee 10 Immersion Well or 2 in 1 Sensor 10 Appliance Surface cro E UR aie RERO UIS 10 Wiri 10 Wiring the AquaSmart Control 11 Programming Basic Functions 25 A Temperature High Limit sse 25 B Temperature Low Dimitte Er e TRE 25 C Temperature High Limit 25 D Temperature Low Limit 26 Programming Additional Options 26 A Changing the Heat Manager 5 26 B Viewing the Boiler Cycle 26 C Changing the Circulator 5 27 D Changing Domestic Hot Water Priority DHWP Setting 28 E Selecting Fahrenheit or Celsius Temperature Display 28 F Changing Low Water Cut Off LWCO Setting 28 AquaSmart Operation 30 Control Checkout Procedure 30 How a Boiler Control Works ssssseeeen 31 Display Boiler Status 32 Troubleshooti
4. Follow all applicable safety codes rules and guidelines for installing an immersion well Improper installation For proper operation there can result in the Boiler overheating 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 WATER Figure 5 Overall Dimensions amp Specifications 1 1 8 T Part No Lead Length Insulation Depth Insertion Depth Specifications 76002N1S01 8 1 4 1 1 2 1 5 8 Storage Temperature Range 40 to 250 F 76002N1S02 6 1 4 3 1 2 1 5 8 Operating Temperature Range 32 to 250 F 76002N1S05 5 4 3 4 1 5 8 Maximum Pressure 250 PSIG 76002N1S06 8 1 4 1 1 2 7 8 Installation Torque Range Screw in 185 200 in Ibs 2 in 1 Installation Instructions This is very important for successful control operation 1 Remove the existing immersion well Clean the threads in the boiler port tapping Follow all applicable safety codes rules and guidelines for removing installing immersion wells 2 Apply pipe sealant to the 2 in 1 sensor threads and install it securely into the port BECKETT RECOMMENDS ONLY TO USE TEFLON TAPE OR RECTORSEAL NO 5 PIPE SEALANT 3 Tighten with 1 1 8 open end or b
5. 29 AquaSmart Operation Table 4 Typical operation with default settings Circulator set ON TT System Action AquaSmart Response Burner is turned on until the water temperature reaches the low Temperature falls below low limit limit plus the low differential ZC is turned off until the water temperature reaches the low limit plus the low differential Burner is turned on as long as the water temperature is below Thermostat call for heat the high limit Circulator is turned on after circulator on delay if the low limit is satisfied Thermostat is satisfied Burner is turned off Circulator is turned off after circulator off delay ZR call for heat Burner is turned on as long as the water temperature is below the high limit ZR is satisfied Burner is turned off Temperature reaches high limit Burner is turned off until the water temperature falls below the high limit minus the high differential Circulator is inactive for 3 days Circulator is turned on for 2 seconds to help prevent seizure Burner Circulator and ZC are turned off until the control is AquaSmart locks out reset The lockout condition may reset automatically or require a manual reset See lockout section for more information B1 has been energized for 1 hour or AquaSmart has been locked out for 1 hour Circulator and ZC are turned on to help prevent system freeze up by circulating the bo
6. Set C1 on ZR see programming section for instructions 3 Circulator on delay will affect all zones Circulator off delay will have no effect CIRCULATOR 120 VAC V 90009 2G EN G E LOW VOLTAGE THERMOSTAT CIRCULATOR 120 VAC AquaSmare 8010032 25 eye 2G G A LOW VOLTAGE THERMOSTAT CIRCULATOR 120 VAC 7600A 120 VAC BURNER OR GAS IGNITION SYSTEM 7600B 24 VAC GAS IGNITION SYSTEM 6 69 9 fe o9 NEUTRAL WHITE D G ZONE 1 120 VAC a LOW VOLTAGE pier aupg PACK THERMOSTAT SUPPLIED SERVICE SWITCH Additional zones can be added by duplicating the Figure 14 7600A B alternate multi zone connections plumbing and wiring of zone 3 adding additional with or without a tankless coil transformers as needed Water Flow AIR SEPARATOR GENERAL N CIRCULATOR ZONE 3 24 VAC ZONE VALVE HEATING HEATING HEATING ZONE ZONE ZONE 1 2 3 SK10033 BOILER EXPANSION TANK Control Wiring Option 1 7600B only 1 Set DHWP OF
7. m High Temperature Limit Low Temperature Limit Adjustable 100 to 240 F Adjustable 100 to 220 F Shuts burner off at HIGH LIMIT set point Starts the burner at LOW LIMIT set point Example Shown 5 Example Shown Low Limit 140 s High Limit 200 Differential 10 Differential 20 During the OFF cycle with no call for During a call for heat the burner will be heat the burner is turned on at 140 to shut off at 200 and be turned back on at maintain the boiler water temperature 180 200 20 The circulator will and is shut off at 150 140 10 continue to operate until the call for heat is satisfied TEMPERATURE F AquaSmart Boiler Control Manual 31 Display Boiler Status Mode A STANDBY UTR IBUF amp B ECONGMZING HIGH LIMIT 155 LOCKOUT SENSOR ERROR NOTE When economizing the display will toggle between screens A and B every 5 seconds KEY D Current operating temperature mode of boiler STANDBY will be displayed if neither the burner nor circulator are energized CIRCULATING will be displayed if the circulator is energized but the burner is not HEATING WTR will be displayed if a non priority heat call has caused the burner to be energized HEATING DHW will be displayed if a priority heat call has caused the burner to be energized FREEZE RES will be displayed if the burner has been running for 1 hour or the AquaSmart has been locked out fo
8. BACK if it is not B Temperature Low Limit 1 In any mode or screen other than an OPTION sub menu press the LOW LIMIT key 2 The following screen will be displayed LGU LIT THOF CHANGE AND ENTER The temperature displayed is the current setting Use the A and keys to select the desired setting Tap the button to increase or decrease the temperature by 1 or hold it to increase or decrease the temperature by 5 at a time The control will not allow you to select out of range values For cold start operation turn the low limit off by pressing the down arrow key repeatedly until OFF is displayed IMPORTANT To prevent flue gas condensation and reduce fatigue caused by thermal cycling on conventional non condensing boilers the LOW LIMIT set point should be 150 F or above NOTE Appliance manufacturer s temperature requirements supersede this recommendation 3 Press the ENTER RESET key 4 The control will ask you to confirm the setting with the following screen LGW ISGF ENTER GR CANCEL Press ENTER RESET if the value is correct or CANCEL BACK if it is not C Temperature High Limit Differential 1 In any mode or screen other than an OPTION sub menu press the HIGH DIFF key 2 The following screen will be displayed HIGH DIFF 10 CHANGE AND ENTER The temperature displayed is the current setting Use the and Y keys to selec
9. THERE SHALL BE EXCLUDED THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FORA PARTICULAR PURPOSE IN NO EVENT WILL BECKETT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGE OF ANY NATURE Beckett neither assumes nor authorizes any person to assume for Beckett any other liability or obligation in connection with the sale of this equipment Beckett s liability and Customer s exclusive remedy is limited to the cost of the product Beckett CORPORATION USA P O Box 1289 Elyria OH 44036 Canada R W Beckett Canada Ltd e Unit 43 430 Laird Road Guelph Ontario N1G 3X7 www beckettcorp com Form No 61738 Rev 6 Printed in USA 6 11
10. Water Flow _ AIR SEPARATOR VY DHW ZONE ZONE 2 ZONE 3 24 VAC 24 VAC N ZONE VALVE ZONE VALVE SK10037 INDIRECT DHW HEATING HEATING HEATING ZONE ZONE ZONE BOILER EXPANSION TANK kH A gpk GENERAL CIRCULATOR CONTINUED ON NEXT PAGE gt Additional zones can be added by duplicating the Figure 17 continued 7600A B alternate multi zone plumbing and wiring of zone 3 adding additional connections with Indirect Domestic Hot Water DHW transformers as needed lt CONTINUED FROM PREVIOUS PAGE 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 zones Circulator off delay will have no effect 4 Up to two 24 VAC zone valves can be powered with the 7600B Add an additional transformer as shown for every two or less valves over the original two 5 Ensure there are no jumpers between the terminals of the zone valves ZONE 3 LOW VOLTAGE THERMOSTAT DHW ZONE ZONE 3 24 VAC 24 VAC ZONE VALVE ZONE VALVE Honeywell Honewell V8043F V8043E V8044E TR m OAM UD
11. in Immersion Well Sensor must butt against end Temperature Sensor ae Brass Fitting m Copper Well Tube pd M SK10016 Sensor connects to Beckett AquaSmart AquaSmart Boiler Control Manual Installing the 2 in 1 Sensor Do not use in steam WARNING Explosion A WARNING applications For use in Burn and Scald Hazards hot water boilers or water heaters only Do Excessive water temperatures could cause explosion not use outside of the intended use and burns scalding pressure relief flooding and fitting leaks specifications The 2 in 1 Sensor shall only be installed by a trained professional Leak Burn and Scald The sensor must be installed in the proper location WARNING Hazards for correct low water cut off EWCO operation in accordance with the Boiler Manufacturer s Incompatible thread sealants could severely damage instructions the sensor threads The 2 in 1 sensor body is installed directly into the DO NOT use any anaerobic fast setting sealants such as but not limited to Loctite Leak Lock Permatex or Gasoila Call RWB Technical Services at 1 800 645 2876 to Make Sure the plumbing Tor Comes te hot walter hag confirm if unsure anti scald valve protection Carefully follow the outlined procedures for temperature sensor installation to ensure accurate water temperature sensing and effective control operation
12. temperature sensing and effective control operation Make sure the plumbing for domestic hot water has anti scald valve protection 1 Make sure the immersion well is clean inside has no leaks is of proper length and is otherwise suitable for receiving the new control and temperature sensor 2 Replace questionable wells with new ones and use pipe sealant to seal the threads 3 Grasp the sensor lead just behind the sensor probe and carefully insert it into the well until it comes to rest at the very end of the well The sensor is designed with radial splines to provide a snug fit in most standard wells 4 The thermal time constant of the sensor is 40 seconds Consider using thermal grease if faster response in desired 5 Surface mounting may require additional lead length to reach the control receptacle Use the extension cable part no 52120 found in the 7600RMU Remote Mount Kit to extend the lead by 48 6 Install the strain relief part no 3266201 as shown capturing the cable against the hex Crimp the strain relief opposite side of the cable This anchors the sensor securely inside the immersion well 7 Plug the temperature sensor lead terminal into the receptacle on the control base See Figure 10 Note The sensor is not tested and approved for being mounted to the outside of a pipe It is for use in immersion wells only Figure 4b Strain Relief Figure 4a Installation of Temperature Sensor
13. to verify the LWCO function For AquaSmart 7600A Remove the green sensor lead from the ground screw The sensor should cause the AquaSmart display to indicate LOCKOUT LOW WATER If it does not replace the sensor For AquaSmart 7600B Remove the green sensor lead from the ground screw and remove both the B1 and B2 24 Vac leads from their terminals The sensor should cause the AquaSmart display to indicate LOCKOUT LOW WATER If it does not replace the sensor Attach wires and tighten terminal screws securely when testing is complete Figure 8 Sensor Water Detection Method AquaSmart Boiler Control 2 IN 1 SENSOR ol Ground Screw Water Not Present Ground Wire Pipe Clamp Water Inlet The AquaSmart 2 in 1 Sensor uses the conduction method to detect whether water is present in the boiler This is done by using the water in the boiler itself to conduct a signal and complete an electrical circuit It is necessary that the ground wire from the sensor be bonded to the boiler wall not the jacket unless the jacket is bonded to the boiler wall When water is not present there is no conduction and the circuit is incomplete For the AquaSmart we recommend that a grounding pipe clamp be mounted to the water inlet pipe and that a ground wire be bonded from the pipe clamp to the green terminal inside the AquaSmart control The 2 in 1 sensor green groun
14. 0 VAC Requirements Not a suitable replacement if SPDT switch action is required only break on rise available on 7600 L6006A All 7600A or 7600B To use with a millivolt system an appropriate voltage relay with isolated gold plated contacts must be added to switch the millivolt circuit L6006C 1018 Based on System Make sure 7600 outputs do not exceed 7 4A 120 VAC 7600 outputs are not rated for 240 VAC L6008A 1192 Voltage 7600 will require an additional wire L2 for operation Short Tw Tr terminals C1 C2 ZC and ZR are unused L6008A 1242 Requirements Set low limit on 7600 to OFF Available operating limit and or differential ranges may not be equivalent Compare the settings to the AquaSmart ranges before replacing L8124B 1039 L8148J 1009 7600A or 7600B Based on System Voltage Requirements Carlin Beckett Replacement To use with a millivolt system an appropriate voltage relay with isolated gold plated contacts must be added to switch the millivolt circuit 7600 outputs are not rated for 240 VAC Notes Requirements p Make sure 7600 outputs do not exceed 7 4A 90200A Volta l Set low limit on 7600 to OFF tag Available operating limit and differential ranges are not equivalent Compare the settings to the AquaSmart ranges before replacing Requirements 90000 All 7600A or 7600B Requires the addition of a manual reset high limit 90200E Based on System Make sure 7600
15. 00 multi zone connections Additional zones can be added by duplicating with Indirect Domestic Hot Water DHW the plumbing and wiring of zone 3 lt CONTINUED FROM PREVIOUS PAGE 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 Circulator on and off delays will only affect DHW zone CIRCULATOR 120 VAC 3 oO 9 LOW VOLTAGE N THERMOSTAT CIRCULATOR 120 VAC AguaSmart w y LIMIT CONTROL Oct oF D ZR B1 2G A G LOW VOLTAGE THERMOSTAT CIRCULATOR 120 VAC 1 7600 120 VAC BURNER OR 2 GAS IGNITION SYSTEM CIRCULATOR 7600B 120 VAC 24 VAC GAS IGNITION SYSTEM EO i NEUTRAL WHITE ZW fS gt G AA AJ Don Een LOW VOLTAGE BLACK THERMOSTAT 120 VAC HOT FIELD MFR SUPPLIED SERVICE SWITCH CONTINUED ON NEXT PAGE gt AquaSmart Boiler Control Manual 19 Figure 16 continued 7600A B multi zone connections Additional zones can be added by duplicating with Indirect Domestic Hot Water DHW the plum
16. 00B is operated with a vent damper it will not function without one even if the jumper plug is replaced Water Flow Symbols Key Figures 12 through 17 Air Vent Air Separator Expansion Tank Isolation Valve Pressure Regulator Zone Valve Check Valve Circulator Aquasmart Boiler Control Manual Figure 12 7600A B single zone connections with or without a tankless coil Water Flow AIR SEPARATOR HEATING ZONE BOILER X EXPANSION TANK SK10030 AN EORR Control Wiring 1 Set DHWP OFF default see programming section for instructions 2 Set C1 on TT default see programming section for instructions E SK10019 AguaSmart WHITE Sa RED LOW VOLTAGE THERMOSTAT C2 ZC ZR NEUTRAL WHITE 120 VAC lt 7600A HOT 9 BLACK 120 VAC BURNER OR FIELD MFR GAS IGNITION SYSTEM SUPPLIED 7600B SERVICE 24 VAC GAS SWITCH Q pi IGNITION SYSTEM CIRCULATOR 120 VAC Figure 13 7600 multi zone connections Additional zones can be added by duplicating with or without a tankless coil the plumbing and wiring of zone 3 Water Flow AIR PARATOR Y Y 2 HEATIN
17. 7600 B1 output does not exceed 1 25A 24VAC 30 VA L8148E All 1600 7600 outputs are not rated for 240 VAC B2 Tw and Tr terminals replace TV T and Z respectively L8124 lt A All L8124C All 7600A 7600 outputs are not rated for 240 VAC L7124A C All L7148A All 7600A The 7600 has no Honeywell EnviraCOM Communications port L7224AICIU All The diagnostic LED lights are replaced by the 7600 s display L7248AI C All 7600 outputs are not rated for 240 VAC L8148A All 7600A B1 terminal on 7600 utilizes a 1 4 quick connect Set low limit on 7600 to OFF L8124E 1016 7600B 7600 outputs are not rated for 240 VAC L8148E 1265 B2 Tw and terminals replace TV T and Z respectively L8124M All 7600A For replacement with the 7600 Turn low limit off so the circulator is controlled directly by the thermostat and ZC is constantly powered L8151A 7600A 7600 outputs are not rated for 240 VAC Remote mount sensor cable needed Part No 52120 Beckett 3100 7600B Not a suitable replacement if Low Water Cutoff LWCO functionality of the 3100 is used 3150 7600A Not a suitable replacement if Low Water Cutoff LWCO functionality of the 3150 is used Beckett Carlin Replacement Notes Make sure 7600 outputs do not exceed 7 4A 90524A 7600A Available operating limit and differential ranges are not equivalent Compare the settings to the AquaSmart ranges before replacing T
18. A Add an additional transformer as shown for every two or less valves 5 Ensure there are no jumpers between the terminals of the zone valves ZONE 3 LOW VOLTAGE THERMOSTAT DHW ZONE ZONE 3 24 VAC 24 VAC ZONE VALVE ZONE VALVE Honeywell Honewell A V8043F V8043E V8044E TR TH D OUY MTR Ts RNR ZONE 1 ZONE 2 LOW VOLTAGE LOW VOLTAGE THERMOSTAT THERMOSTAT ZONE 1 ZONE 2 24 VAC 24 VAC ZONE VALVE ZONE VALVE Honewell Taco lt 9 AquaSmaret g HF I 2 L SK10047 DHW LIMIT NEUTRAL WHITE 120 VAC si BURNER OR 120 VAC GAS IGNITION BLACK SVETEM 2 509 9 I CONTROL FIELD MFR 3 T Lo T SUPPLIED SERVICE 40 VA SWITCH TRANSFORMER G 40 VA NA TRANSFORMER GENERAL CIRCULATOR CIRCULATOR 120 VAC Programming Basic Functions Electrical Shock Hazard Can cause severe injury death or equipment damage Live line voltage wires and connections will be exposed while programming the AquaSmart Take care to touch only the AquaSmart keypad w
19. AquaSmart Model 7600 Advanced Microprocessor Boiler Control r x WARNING tric Sh Discon Hazar AY race et d Description Applications 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 2096 fuel consumption savings The control includes a backlit LCD digital display with touch pad to easily program temperature limits differentials and other advanced options The AquaSmart also has memory storage of system history for help with diagnostics and troubleshooting Table of Contents Features eerte 2 Technical Specifications 3 Electrical Ratings cene reor TO HORE s 3 Temperature Ranges and 3 Environmental Ratings cce esed e rot t Pee eda 3 Approvals SRM 3 Installation ER i ERR Sunes scenes 4 MOUNN Genas iet o on a aes 4 AquaSmart Models and Cross Reference Guide 5 Removing the Control to be Replaced 7 Installing the Temperature Sensor 7 Installing the 2 in 1 Sensor sa 8 2 in 1 Sensor Technical Specifications
20. CHANGE AND ENTER Press the A and Y keys to select the desired setting and press the ENTER RESET key DELAS ON 8 12 ENTER OR CANCEL Press ENTER RESET if the value is correct or CANCEL BACK if it is not AquaSmart Boiler Control Manual c To change the call for heat source that the circulator is activated from see Figures 8 13 for examples press the and Y keys until the following screen is displayed CIRE GN TT ENTER TO CHANGE Press ENTER RESET to toggle the circulator source between ON TT ON ZR and ON BOTH 4 Press CANCEL BACK to exit D Changing Domestic Hot Water Priority DHWP Setting The Domestic Hot Water Priority function temporarily overrides the HeatManager Dynamic Temperature Reset functionality when there is a call for domestic hot water This ensures that hot water will be produced when needed It also temporarily turns off either the C1 or ZC outputs depending on the DHWP and circulator source settings to give priority to the DHWP zone when it calls for heat See Figures 8 13 for examples of how to use these settings for maximum benefit 1 In any mode other than an OPT ON sub menu press the OPTION key The following screen appears HEAT MANAGR MENU ENTER TO HEU 2 Press the A and Y keys until the following screen is displayed MORE OPTIONS ENTER TO 3 Press ENTER RESET The following screen w
21. CONTINUED FROM PREVIOUS PAGE 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 off delay will have no effect 4 24 VAC zone valves cannot be powered directly with the 7600A Add an additional transformer for every two or less valves 5 Ensure there are no jumpers between the terminals of the zone valves ZONE 1 ZONE 2 ZONE 3 LOW VOLTAGE LOW VOLTAGE LOW VOLTAGE THERMOSTAT THERMOSTAT THERMOSTAT ZONE 1 ZONE 2 ZONE 3 24 VAC 24 VAC 24 VAC ZONE VALVE ZONE VALVE ZONE VALVE Taco Honeywell Honeywell 550 V8043E V8044E V8043F Ne 1 Y OmV AguaSmart 5 ami SK10046 C2 ZC ZR Bi 40 V TRANSFORMER zz 120 VAC NEUTRAL WHITE BURNER OR 40 VA 120 VAC GAS IGNITION o BLACK GENERAL SYSTEM TRANSFORMER EIELD MFR Q CIRCULATOR SUPPLIED CIRCULATOR SERVICE 120 VAC SWITCH Figure 15 7600 single zone connections with Indirect Domestic Hot Water DHW Water Flow AIR PARATOR Gr
22. F 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 off delay will have no effect 4 Up to two 24 VAC zone valves can be powered with the 7600B Add an additional transformer as shown for every two or less valves over the original two 5 Ensure there are no jumpers between the terminals of the zone valves ZONE 1 ZONE 2 ZONE 3 LOW VOLTAGE LOW VOLTAGE LOW VOLTAGE THERMOSTAT THERMOSTAT THERMOSTAT ZONE 1 ZONE 2 ZONE 3 24 VAC 24 VAC 24 VAC ZONE VALVE ZONE VALVE ZONE VALVE E Taco Honeywell Honeywell 550 V8043E V8044E V8043F 1 Y OUI R AguaSmart 2 Q d 2 ZC ZR 40 VA TRANSFORMER x NEUTRAL WHITE 24 VAC GAS TAVE IGNITION SYSTEM QA o BLACK Q GENERAL CIRCULATOR SUPPLIED CIRCULATOR SERVICE 120 VAC SWITCH CONTINUED ON NEXT PAGE gt AquaSmart Boiler Control Manual 15 Additional zones be added by duplicating the Figure 14 continued 7600A B alternate multi zone connections plumbing and wiring of zone 3 adding additional with or without a tankless coil transformers as needed lt
23. G HEATING E HEATING P3 SK10031 ZONE ZONE ZONE 1 2 3 BOILER EXPANSION TANK Control Wiring Option 1 Circulator On and Off Delays on Zone 1 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 and off delays will only affect zone 1 b CIRCULATOR 120 VAC AquaSmart v WHITE OF ZONE RED 1 OF LOW VOLTAGE THERMOSTAT ISX 81D LOW VOLTAGE THERMOSTAT CIRCULATOR 120 VAC pi 7600A 120 VAC BURNER OR CIRCULATOR GAS IGNITION SYSTEM TM 120 VAC 7600B 24 VAC GAS IGNITION SYSTEM 3 MOS ZONE NEUTRAL WHITE C 120 VAC P mU LOW VOLTAGE HOT gigi pjyeg BLACK THERMOSTAT SUPPLIED SERVICE SWITCH CONTINUED ON NEXT PAGE gt AquaSmart Boiler Control Manual Figure 13 continued 7600A B multi zone connections Additional zones can be added by duplicating with or without a tankless coil the plumbing and wiring of zone 3 lt CONTINUED FROM PREVIOUS PAGE Control Wiring Option 2 Circulator On Delay on All Zones 1 Set DHWP OFF default see programming section for instructions 2
24. anual to control how the AquaSmart will return from a LOCKOUT LOW WATER condition when the boiler water returns to a sufficient level In AUTO the AquaSmart returns automatically In MAN manual the ENTER RESET button must be held for 5 seconds 1 In any mode other than an OPTION sub menu press the OPTION key The following screen appears HEAT MANAGR MENU ENTER TO VIEW 28 2 Press the and Y keys until the following screen is displayed MORE OPTIONS ENTER TO VIEW 3 Press ENTER RESET The following screen will be displayed LUCO MENU ENTER TO VIEW 4 Press ENTER RESET The following screen will be displayed DELAY OFF 2 00 ENTER TO CHANGE 5 Use the A and Y keys to scroll between the DELAY OFF DELAY ON and RESET functions or press ENTER RESET to change Use the A and Y keys to change the setting 6 If DELAY OFF is displayed Press ENTER RESET again the following screen appears DELAY GFF 0 00 ENTER OR CANCEL 7 Press ENTER RESET to accept the settings or press CANCEL BACK to go to the previous screen 8 The same steps are used to change the DELAY ON time setting 9 If the RESET function has been selected press ENTER RESET to change between MAN and AUTO Press CANCEL BACK to go to the previous screen 10 Press CANCEL BACK to exit LWCO menu AquaSmart Boiler Control Manual
25. bing and wiring of zone 3 lt CONTINUED FROM PREVIOUS PAGE Control Wiring Option 2 Circulator On Delay on All Zones 1 Set DHWP OFF default see programming section for instructions 2 Set C1 on ZR see programming section for instructions 3 Circulator on delay will affect all zones Circulator off delay will CIRCULATOR have no effect 4 DHW zone will not have priority over heating zones pe A 909 3000 G AZ ZONE 3 LOW VOLTAGE THERMOSTAT CIRCULATO 120 VAC Q o 2 2G G LOW VOLTAGE THERMOSTAT CIRCULAT 120 VAC AguaSmart 7 o R 2 9 9 eG Q Ba ZONE 7 LOW VOLTAGE THERMOSTAT 7600A 120 VAC BURNER OR GAS IGNITION SYSTEM 7600B 24 VAC GAS IGNITION SYSTEM DHW LIMIT CONTROL Oe E NEUTRAL WHITE 120 VAC HOT BLACK SUPPLIED SERVICE SWITCH 90 3000 G I BAK Wh CONTINUED ON NEXT PAGE gt Figure 16 continued 7600A B multi zone connections Additional zones can be added by duplicating with Indirect Domestic Hot Water DHW the plumbing and wiring of zone 3 l
26. d wire shall also be bonded to the green terminal in the AquaSmart control AquaSmart Boiler Control Manual Installing the AquaSmart Control Refer back to Figure 3 for appropriate mounting method Immersion Well or 2 in 1 Sensor 1 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 Tighten so that control is securely in place Figure 9 2 Plug the temperature sensor lead terminal into the receptacle on the control base See Figure 10 Appliance Surface 1 Use the AquaSmart mounting template to locate the mounting holes in a desired location on mounting surface The template can be found in the back of this manual 2 Use 3 8 x 3 4 self drilling screws 110 hole diameter if pre drilling included in the installation kit Run screws into mounting surface leaving a 1 4 space between bottom of screw head and mounting surface 3 Open the cover of the AquaSmart control to expose key hole locations in plastic case Align key holes over mounting screws and secure in place 4 Plug the temperature sensor lead terminal into the receptacle on the control base See Figure 10 5 If necessary use the 48 cable extension to connect sensor to control base Refer back to Figure 3 Wiring Electrical S
27. dditional wire L2 for operation Short TW TR terminals C1 C2 ZC and ZR are unused L4006H 1004 Volta d Set low limit on 7600 to OFF L4008A All tag Available operating limit and or differential ranges may not be equivalent Compare the settings to the AquaSmart ranges before replacing L4080B D Requirements To use with a millivolt system an appropriate voltage relay with isolated gold plated contacts must be added to switch the millivolt circuit Requires the addition of a manual reset high limit L4006E All 7600A or 7600B Make sure 7600 outputs do not exceed 7 4A 120 VAC 7600 outputs are not rated for 240 VAC L4008E All Based on System 7600 will require an additional wire L2 for operation Short TW TR terminals C1 C2 ZC and ZR are unused Voltage Set low limit on 7600 to OFF L4080F G Requirements Available operating limit and or differential ranges may not be equivalent Compare the settings to the AquaSmart ranges before replacing To use with a millivolt system an appropriate voltage relay with isolated gold plated contacts must be added to switch the millivolt circuit AquaSmart Boiler Control Manual 5 Table 1b continued from previous page Beckett Honeywell Replacement Notes 7600A or 7600B L4081A B Based on System Remove switching relay if used from the system when replacing the L4081 or L6081 L6081A C Voltage Make sure 7600 outputs do not exceed 7 4A 120 VAC 7600 outputs are not rated for 24
28. eleased HeatManager Technology 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 operating limit to the minimum temperature necessary to meet the heating demand The qualified service technician can adjust the HeatManager algorithm to maximize comfort or energy savings The HeatManager algorithm is designed to operate the boiler at its lowest possible temperature while still meeting the heating demand By dynamically changing the boiler temperature it is designed to reduce the energy used by the system without sacrificing comfort The default HIGH efficiency setting should work best for most systems However there are many system factors that may have an effect on its ability to react to changes quickly enough and supply adequate heat such as amount of connected radiation boiler size system design temperatures etc The efficiency setting adjusts how aggressively the HeatManager algorithm attempts to reduce the boiler operating temperature If a loss of comfort is experienced decreasing the efficiency setting will help regain comfort at the expense of fuel savings see section A of Programming Additional Options for instructions on changing the efficiency setting 32 Final Checklist Before Leaving the Installation Site Verify All wiring has be
29. en done correctly in a workmanlike way is secure and meets all applicable codes AquaSmart control temperature settings differentials and optional functions are correctly set The control program is functioning properly by observing at least one complete cycle At shutdown the temperature and pressure level match the recommended settings The pressure relief valve operation and boiler water feed system works properly by bleeding some water and observing the refill cycle The low water cutoff operation by lowering the water level until it shuts the burner off The boiler passages and vent system are clear of obstructions and operating to the appliance manufacturer s specifications and all required clearance dimensions to combustible materials are met With combustion test instruments the burner is set to manufacturer s specifications After the system has run through a complete cycle that all fittings are free of leaks A record has been made of all service work and all temperature control settings and optional functions Attach a label or tag to the boiler for future reference The AquaSmart Installation Manual is left at a suitable location near the boiler for future reference and the equipment owner is informed of this The control door is attached and securely closed Accessories Service During Annual Maintenance or More Freq
30. es o 2in 1 Sensor o 36 Ground Wire o Pipe Clamp for grounding o Installation Instructions AquaSmart Boiler Control Manual Notes Section 34 AquaSmart Boiler Control Manual 35 Limited Warranty Information The W BECKETT CORPORATION Beckett warrants to persons who purchase its Products from Beckett for resale or for incorporation into a product for resale Customers that its equipment is free from defects in material and workmanship To qualify for warranty benefits products must be installed by a qualified service agency in full compliance with all codes and authorities having jurisdiction and used within the tolerances of Beckett s defined product specifications To review the complete warranty policy and duration of coverage for a specific product or obtain a written copy of warranty form 61545 please choose one of the following options 1 Visit our website at www beckettcorp com warranty 2 Email your request to rwb customer service beckettcorp com 3 Write to R W Beckett Corporation P O Box 1289 Elyria OH 44036 NOTE Beckett is not responsible for any labor cost for removal and replacement of equipment THIS WARRANTY IS LIMITED TO THE PRECISE TERMS SET FORTH ABOVE AND PROVIDES EXCLUSIVE REMEDIES EXPRESSLY IN LIEU OF ALL OTHER REMEDIES AND IN PARTICULAR
31. he diagnostic LED lights are replaced by the 7600 s display Beckett White Rodgers Replacement Notes 11C15 11 7600A Make sure 7600 outputs do not exceed 7 4A 120 VAC 7600 outputs are not rated for 240 8B48A 217 7600A 11C30 3 7600A Make sure 7600 outputs do not exceed 7 4A 120 VAC 7600 outputs are not rated for 240 11B54 4 Available operating limit and differential ranges are not equivalent Compare the settings to the AquaSmart ranges before replacing 8F48A 351 8B43A 601 10005 Not a suitable replacement if SPDT switch action is required only break on rise available on 7600 MORIE 1600 Make sure 7600 outputs do not exceed 7 4A 120 VAC 7600 outputs are not rated for 240 VAC Burn Scald Explosion and Equipment Malfunction Hazard Replacement of the following controls must be done only by a qualified service agency or technician who is trained and experienced in the use of boiler controls Carefully follow these guidelines and the directions provided by the manufacturer of the control being replaced Note Beckett assumes no liability for incorrect installation or replacement Table 1b Functional Replacement Advanced Wiring Needed Table continued on next page Beckett Honeywell Replacement L4006A 7600A or 7600B Make sure 7600 outputs do not exceed 7 4A 120 VAC 7600 outputs are not rated for 240 VAC L4006G 1022 Based on System 7600 will require an a
32. hile programming the control WARNING Fire Explosion and Burn Hazards Can cause severe injury death or equipment damage Do not set the operating limits of the control outside of those listed by the appliance manufacturer Figure 18 AquaSmart Keypad Beckett ZA QU SIT arti v LOW CANCEL ENTER DIFF OPTION BACK RESET To 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 180 F 20 F the greater of the two differentials 5 F 155 F A Temperature High Limit 1 In any mode or screen other than an OPTION sub menu press the HIGH LIMIT key 2 The following screen will be displayed HIGH LUT 1805 CHANGE AND ENTER The temperature displayed is the current setting Use the A and V keys to select the desired setting Tap the button to increase or decrease the temperature by 1 or hold it to increase or decrease the temperature by 5 at a time The control will not allow you to select out of range values 3 Press the ENTER RESET key 4 The control will ask you to confirm the setting with the following screen HIGH LIMIT 1560F ENTER OR CANCEL Press ENTER RESET if the value is correct or CANCEL
33. hock Fire A WARNING Explosion and Burn Hazards This control must be installed adjusted and put into operation only by a trained licensed qualified professional or service agency in accordance with the latest revision of the National Electric Code ANSI NFPA 70 Canada CSA C22 1 state local codes and authorities having jurisdiction Follow the appliance manufacturer s wiring diagrams and note all safety controls Typical safety controls include high temperature or pressure limits low water cutoffs anti scald valves pressure relief valves and water feed valves Verify all limits and safety controls are installed and functioning correctly as specified by the appliance manufacturer applicable safety standards codes and all authorities having jurisdiction Provide ground wiring to the appliance burner and controls Figure 9 Mounting Clamp and Screw for Immersion Well For clarity the printed circuit board is not shown Electrical Shock Hazard WARNING Can Cause Severe Injury Death or Equipment Damage Disconnect power before wiring to prevent electrical shock or equipment damage All wiring must comply with local electrical codes and ordinances The limits given in the specifications section must not be exceeded when applying this control Terminals on the AquaSmart are approved for copper wire only Refer to the label on the inside of the AquaSmart door or to Technical Specificati
34. iler water to all zones If DHWP is set on T T and there is a T T call for heat ZC is held Priority call for heat off for up to 20 minutes to give the DHW zone priority If DHWP is set on ZR and there is a ZR call for heat C1 is held off for up to 20 minutes to give the DHW zone priority Control Checkout Procedure These procedures are typical for the default configuration of the control 1 Wire and configure the AquaSmart as required by the application 2 NOTE Do not apply a thermostat call for heat to the AquaSmart at this time Allow the burner to heat the water to above the low limit plus the low limit differential The display should read HEATING WTR on the LCD display B1 should be energized and C1 and ZC should be off 3 When the water is sufficiently heated the burner will turn off and the display should read STANDBY Now ZC should be energized and B1 and C1 should be off 4 Apply a call for heat from the thermostat The burner and circulator should now also turn on B1 C1 and ZC should now all be energized Allow the AquaSmart to heat the water to the high limit During this step the display should read HEATING WTR or HEATING DHW 5 Once the high limit is reached the burner should turn off C1 and ZC should now be energized and B1 should be off The display should now read CIRCULATING 6 Setthe thermostat back so that it is no longer calling for heat The circulator shou
35. ill be displayed LUCO MENU ENTER TO MEW 4 Press the A and Y keys until the following screen is displayed DHUP OFF ENTER TO CHANGE 5 Press ENTER RESET to toggle between OFF ON TT and ON ZR settings See wiring diagrams in Figures 11 thru 13 for proper wiring with DHWP on 6 Press CANCEL BACK to exit E Selecting Fahrenheit or Celsius Temperature Display 1 In any mode other than an OPTION sub menu press the OPTION key The following screen appears HEAT MANAGR MENU ENTER TO VIEW 2 Press the A and Y keys until the following screen is displayed NORE OPTIONS ENTER TO HIEW 3 Press ENTER RESET The following screen will be displayed LUCO MENU ENTER TO LIEU 4 Press the A and Y keys until the following screen is displayed DEG F C F ENTER TO CHANGE 5 Press ENTER RESET to toggle between F and C 6 Press CANCEL BACK to exit F Changing Low Water Cut Off LWCO Setting The Low Water Cut off function is active when the 2 in 1 sensor is used with the AquaSmart control to prevent the burner from firing without sufficient water present in the boiler The DELAY OFF time can be selected to delay the response of the control to a low water condition The DELAY ON time can be selected to delay the response of the control when the boiler water returns to a sufficient level The RESET function can be set to AUTO or MAN m
36. ire Explosion and Burn Hazards This control must be installed adjusted and put into operation only by a trained licensed qualified professional or service agency in accordance with the National Electric Code ANSI NFPA 70 Canada CSA C22 1 state local codes and authorities having jurisdiction The installer must carefully read and follow the installation and service instructions contained in this manual and make them available to the equipment owner so they can be kept for future reference This product is not suitable for temperature control of pools spas or Jacuzzis This product is not to be used as a step or a shelf Figure 1 Getting to know the AquaSmart 7600 Series Control Il Electrical Shock Hazard The AquaSmart control should only be operated with the door attached and securely closed Communication Port VARRO Y EIS H Tw Tr Terminals m ai v Sensor Mount oar owe omon f E 4 co Sensor Jack Touch Pad An B Rotate door until grooves Pull door up are aligned a Door Removal Technical Specifications ED Do Not Use This Control in Temperature Ranges and Differentials CAUTION an Application that is Not High Limit Setting Range 100 to 240 F 37 to 115 C Within the Ratings Listed in This Section High Limit Differential Range 5 to 45 F 2 to 25 C x Low Limit Setting Range 100 to 220 F 37 to 104 C I
37. ld turn off now ZC should be energized and B1 and C1 should be off The display should now read STANDBY CAUTION Do not leave the installation site if the AquaSmart operation did not match the descriptions in any of the above steps Make all necessary adjustments until the correct operation is verified The above procedure helps to verify that the high and low limits are working properly and that the thermostat is wired correctly to the control 30 How a Boiler Control Works Figure 19 Cold Start Operation Low Limit OFF High Temperature Differential Adjustable 5 to 45 F Starts the burner when temperature drops to the HIGH LIMIT DIFFERENTIAL setting High Temperature Limit Adjustable 100 to 240 F Shuts burner off at HIGH LIMIT set point Example Shown High Limit 200 Differential 20 During a call for heat the burner will be shut off at 200 and be turned back on at 180 200 20 The circulator will continue to operate until the call for heat is satisfied TEMPERATURE F Figure 20 Warm Start Operation Low Limit ON To maintain domestic hot water temperature High Temperature Differential Low Diff ow Temperature Differentia Adjustable 5 to 45 F Adjustable 10 to 45 F Starts the burner when temperature drops to the Shuts burner off when temperature rises to HIGH LIMIT DIFFERENTIAL setting the LOW LIMIT DIFFERENTIAL setting
38. moving the Control to be Replaced Electrical shock hazard Disconnect all electrical power to the appliance circuit before replacing the control There may be more than one disconnect switch 1 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 2 Label each wire accordingly to ensure accurate reconnection Masking tape works well for labeling 3 Remove each wire from the old control Make sure each label is intact 4 Loosen the control mounting arrangement and remove the control from the system 5 Make note of the temperature settings for high limit low limit and differentials This will provide important reference data for the new control adjustment Please note that differentials may be used differently in other manufacturer s controls See Figure 19 amp 16 toward end of manual for a description of how the AquaSmart s differentials work Consult the manual of the control being replaced for information regarding its differentials Installing the Temperature Sensor This is very important for successful control operation Burn and Scald Hazard Excessive water temperatures could cause explosion burns scalding pressure relief flooding and fitting leaks e Carefully follow the outlined procedures for temperature sensor installation to ensure accurate water
39. mproper Control Operation May Result Low Limit Differential Range 10 to 45 F 5 to 25 C Factory Range Stops available consult factory Electrical Ratings Environmental Ratings Input Voltage 120 Vac 50 60 Hz Input Current 0 1A B1 C1 ZC o Storage Temperature 40 to 150 F 40 to 65 C MAX Input Current 20A Reduce to 15A if optional o Operating Temperature 4 to 150 F 20 to 65 power disconnect switch is used 7600B at 50 Hz 4 to 140 F 20 to 60 C 24 Vac Thermostat Anticipator Current 0 1 Amp o Maximum Sensing Element Temperature 250 F 121 C Burner Current Rating B1 o Relative Humidity 5 to 85 RH non condensing and 7600A oil 7 4 A at 120 Vac FLA 44 4 A inrush LRA non crystallizing 7600B gas 1 25 A at 24 Vac 30 VA total load Circulator Current Rating C1 7 4 A at 120 Vac FLA Approvals 44 4 A inrush LRA UL US Underwriters Laboratories Listed to UL353 Zone Control Current Rating ZC 7 4 A at 120 Vac UL1998 for U S and Canada FLA 44 4 A inrush LRA LISTED CSA C22 2 No 24 AquaSmart Boiler Control Manual 3 Figure 2 Basic Dimensions inches SK10013 o 75 4 350 nstal lation Figure 3 Mounting Options Sensor Immersion Well Mounting Mounting OEM Installation When replacing an OEM installed AquaSmart consult the appliance manufacturer s wi
40. ng eere 32 EE E 32 HeatManager 32 Final Checklist 33 A CCOSSOMIGS irre 33 P 33 Mounting Template eene 35 Limited Warranty Information 36 Features o HeatManager dynamic temperature reset for additional energy savings DOE 2012 Compliant Meets NR CAN proposed 2012 requirements 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 differential adjustments 24Vac Thermostat compatible Circulator control 120Vac Zone Control 120Vac programmable priority override for domestic hot water Temperature sensor mounts in standard immersion wells Compatible retrofit for most standard boiler temperature controls Programmable circulator on and off delays Helps prevent freeze up by energizing circulator and ZC if an error condition is detected Periodically exercises circulator pump to help prevent sieze up Cold start compatible 6 pin vent damper receptacle on 7500B for easy wiring to most vent dampers WARNING Electrical Shock F
41. ome instead of letting it sit in the boiler The circulator on delay holds the C1 output off for the set time at the start of a call for heat This helps the boiler to heat up more quickly and spend less time in the condensing range if applicable Both circulator delays are selectable from 0 to 4 minutes and 15 seconds 1 In any mode other than an OPTION sub menu press the OPTION key The following screen will be displayed HEAT MANAGR MENU ENTER TO HEU Press the and Y keys until the following screen is displayed CIRCULATOR MENU ENTER TO MEW Press ENTER RESET The following screen will be displayed a DELAY GFF 010 ENTER TO CHANGE To change the circulator off delay after a call for heat ends press ENTER RESET The following screen will be displayed GELAY OFF 010 CHANGE AND ENTER The time displayed is the current setting in minutes seconds Press the A and V keys to select the desired setting a press ENTER RESET DELAY GFF 0 10 ENTER OR CANCEL Press ENTER RESET if the value is correct or CANCEL BACK if it is not To change the circulator on delay when a call for heat begins press the A and Y keys until the following screen is displayed GELAY ON 010 ENTER TO CHANGE The time displayed is the current setting in minutes seconds Press ENTER RESET The following screen will be displayed DELAY ON 0 10
42. ons in this manual for Electrical ratings and maximum load information Use manufacturer instructions when wiring controlled equipment or refer to typical hookups in Figure 12 through Figure 17 More than one service switch may be needed to disconnect all power to the AquaSmart The optional power disconnect switch interrupts power to the AquaSmart control Depending on system wiring some terminals and connections most notably ZR and the input to the optional power disconnect switch may still be live 10 Explosion Hazard A WARNING Cause Severe Injury Death or Property Damage Use this product only in systems with a pressure relief valve Wiring the AquaSmart Control o Consult the appliance wiring diagrams to check the manufacturer s specifications o Refer to Figure 12 through Figure 17 for some typical wiring diagrams o Verify the wires are still labeled correctly and make connections to the appropriate terminals on the control wiring terminal strip o Provide disconnect means and overload protection as required on power supply o Connect control conduit bracket to earth ground using the supplied grounding screw o B1 terminal is a 1 4 in tab terminal quick connect Some Thermostats Are CAUTION Polarity Sensitive Reversed polarity could cause erratic cycling of the boiler control Connect the red thermostat wire from the RH or R terminal of the thermostat to the Tr te
43. outputs do not exceed 7 4A 90200EL Voltage Set low limit on 7600 to OFF 90300B Requirements Available operating limit and differential ranges are not equivalent Compare the settings to the AquaSmart ranges before replacing 7600A or 7600B Not a suitable replacement if SPDT switch action is required only break on rise available on 7600 90200D Based on System Make sure 7600 outputs do not exceed 7 4A Voltage Set low limit on 7600 to OFF Requirements Available operating limit and differential ranges are not equivalent Compare the settings to the AquaSmart ranges before replacing White Beckett Notes Rodgers Replacement 11B06 1 11019 1 7600A or 76006 Make sure 7600 outputs do not exceed 7 4A 120 VAC 7600 outputs are not rated for 240 VAC 11B18 101 Based on System 7600 will require an additional wire L2 for operation Short Tw Tr terminals C1 C2 ZC and ZR are unused 11B30 104 Voltage 9 Set low limit on 7600 to OFF 11B02 1 Requirements 1145 33 41B06 46 7600A or 7600B Make sure 7600 outputs do not exceed 7 4A 120 VAC 7600 outputs are not rated for 240 11B95 31 Based on System 7600 will require an additional wire L2 for operation Short Tw Tr terminals C1 C2 ZC and ZR are unused 41B18 153 Voltage Set low limit on 7600 to OFF Requirements Available operating limit and or differential ranges are not equivalent Compare the settings to the AquaSmart ranges before replacing 7600 7600 Not a
44. ox wrench Pipe wrenches pliers and adjustable wrenches will damage round off the hex 4 Securely install the AquaSmart control to the sensor Plug the 2 in 1 Sensor RJ connector phone jack style into the receptacle Item a Figure 6 on the control 5 Route the 36 green wire through the AquaSmart bottom rectangular slot Item c Figure 6 Securely install the fork connector of the 36 ground wire and the ground wire from the 2 in 1 sensor under the ground screw at the bottom of the control Item b Figure 6 6 Thoroughly clean the pipe surface and securely tighten the pipe clamp on the water inlet pipe to the boiler as close to the boiler as possible 7 Route the 36 green ground wire to the pipe clamp then cut to proper length if necessary 8 Strip the wire and insert the stripped end into hole on the pipe clamp item d Figure 7 Tighten retaining screw against the wire making sure that you have good contact 9 Complete control wiring and fill the appliance with water to the pressure required according to appliance manufacturer s instructions Make sure all air is purged from the system and there are no leaks Turn on power to the appliance and observe one call for heat cycle with shut off at set temperature Test the Low Water Cut off LWCO Safety Function WARNING Avoid touching or shorting the live terminals during this test Turn electric power ON to energize AquaSmart control Perform the following tests
45. r 1 hour E Current boiler water temperature measurement F Adjusted high limit when economizing G Lockout reason see Lockout section under Troubleshooting Troubleshooting Lockout The AquaSmart will lock out if any number of abnormal conditions are detected Frozen Plumbing and caution Water Damage Hazard If the residence is unattended in severely cold weather boiler control safety lockout heating system component failures power outages or other electrical system failures could result in frozen plumbing and water damage in a matter of hours For protection take preventative actions such as having a security system installed that operates during power outages senses low temperature and initiates an effective action Consult your qualified service technician or a home security agency 1 SENSOR ERR The sensor has either detected an internal error or is not communicating properly with the AquaSmart The AquaSmart will not reset from this condition until it can detect a properly working sensor 2 SELF CHECK An internal safety check such as the check on the B1 relay contacts has failed Hold ENTER RESET key for 5 seconds to reset from this condition If the error occurs again replace the control 3 CANCEL The CANCEL BACK key was held for 5 seconds or longer which temporarily suspends the control s operation The control will resume normal operation once the CANCEL BACK button is r
46. ring diagrams and instructions for additional information Retrofit Installation The AquaSmart can be used to replace most standard boiler temperature controls For a cross reference of compatible replacements refer to Table 1 Y i There are two basic methods for mounting the AquaSmart to the boiler as outlined in Figure 3 Surface Mounting 1 Sensor Immersion Well Mounting This is the Position the strain relief over the hex most common method If the existing well is not capturing the sensor cable and crimp to secure suitable for any reason a standard design aftermarket immersion well with the proper dimensions can be purchased from a HVAC distributor The AquaSmart can then be mounted in the typical way SK10017 2 Surface Mounting This is sometimes required and is part of the AquaSmart base design The base has adequate clearance built in to accommodate the temperature sensor lead exiting the back of the control A remote mounting kit Pt No 7600RMU that includes a 48 extension cable Sensor Lead a 48 and mounting screws can be purchased separately extension cable can be for applications where needed 5 WALL PANEL AquaSmart Models and Cross Reference Guide Table 1a Direct Replacements Beckett Honeywell Replacement Notes Must confirm that 7600 VA rating is adequate to meet VA requirements of system L7148F All Make sure
47. rminal on the control Connect the white thermostat wire from the W terminal of the thermostat to the Tw terminal on the control Figure 11 TR B2 amp Vent Damper Connections Observe proper polarity when wiring L1 L2 If polarity is reversed a NOTICE call for heat on the ZR input may not be recognized 7600B only TERMINALS TR Z or NOTICE hot and B2 TV or ground offer a 24 volt supply for operating other 24 VAC equipment on the boiler IMPORTANT TO PREVENT DAMAGE TO THE CONTROL DO NOT OVERLOAD THE TRANSFORMER The AquaSmart is equipped with a 30VA transformer Make sure that the total load including the burner circuit and TR amp B2 connections do not exceed 30VA See Figure 11 How to calculate VA Add all AMP ratings of 24VAC components in this circuit and multiply sum by 24 volts Example 4 4 2 2 1 2A x 24V 28 8 VA When powering multiple circulators NOTICE from the C1 and C2 terminals take extra care not to exceed the output s reading If the sum of the full load amps of all the circulators exceeds the output s rating use the C1 and C2 terminals to power the coil of a multiple pole contactor the contacts of which can be wired to switch L1 to each circulator To wire a vent damper to the 7600B first remove jumper plug from 6 position receptacle and then connect 6 pin connector of the vent damper to the receptacle See Figure 11 Once the 76
48. s until the following screen is displayed HISTORY MENU ENTER TO HEU 3 Press the ENTER RESET key The following screen will be displayed EE I EHS OFF gt 30 05 IHOF 4 To navigate the history menu press A or V key to view additional data and cycles 5 Press the Y key to view the other data screen for the most recent cycle The following screen will be displayed i START gt LL END SENSOR ERR 6 Press CANCEL BACK to exit Key for steps B3 amp B5 A Current cycle data being displayed 1 being the most recent cycle B Burner on time in minutes seconds C Burner off time in minutes seconds D Average water temperature over burner off on cycle E Cycle start reason LL burner turned on to maintain low limit TT burner turned on to satisfy a thermostat call for heat ZR 7 burner turned on to satisfy a ZR call for heat F Cycle end reason the call for heat from T T or ZR was satisfied HL the boiler water temperature reached the high operating limit LL the boiler water temperature reached the low limit plus low differential Lockout reasons see Lockout Troubleshooting section for more details SENSOR ERR SELF CHECK CANCEL C Changing the Circulator Settings The circulator off delay keeps the C1 output energized for the set time after a call for heat ends This helps to increase the efficiency of the system by transferring more heat into the h
49. suitable replacement if SPDT switch action is required only break on rise available on 7600 1131 102 Based on System 7600 outputs are not rated for 240 VAC Voltage 7600 will require an additional wire L2 for operation Short Tw Tr terminals C1 C2 ZC and ZR are unused 1127 2 Requirements Set low limit on 7600 to OFF 11 79 2 3 Not a suitable replacement if SPDT switch action is required only break on rise available on 7600 7600A or 7600B 7600 outputs are not rated for 240 VAC 1127 9 Based on System 7600 will require an additional wire L2 for operation Short Tw Tr terminals C1 C2 ZC and ZR are unused Voltage Set low limit on 7600 to OFF Requirements Available operating limit and or differential ranges may not be equivalent Compare the settings to the AquaSmart ranges before replacing Requires the addition of a manual reset high limit rai ed Make sure 7600 outputs do not exceed 7 4A 120 VAC 7600 outputs are not rated for 240 11B27 9 y 7600 will require an additional wire L2 for operation Short Tw Tr terminals C1 C2 ZC and ZR are unused Voltage Fed Requirements Set low limit on 7600 to OFF q Available operating limit and or differential ranges are not equivalent Compare the settings to the AquaSmart ranges before replacing 7600A or 7600B 8J48A 209 ak i To use with a millivolt system an appropriate voltage relay with isolated gold plated contacts must be added to switch the millivolt circuit Re
50. t CONTINUED FROM PREVIOUS PAGE 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 instructions 3 Circulator on and off delay will only effect DHW zone 4 Acall for heat on TT from the DHW zone will change boiler set point to the high limit All other zones will heat to the reset temperature determined by the HeatManager 5 Ensure that the zone panel and AquaSmart are powered from the same service switch ZONE 1 ZONE 3 LOW ZONE 2 LOW VOLTAGE LOW VOLTAGE THERMOSTAT _ VOLTAGE THERMOSTAT THERMOSTAT SK10036 AguaSmart LIMIT CONTROL 2 Q ZR B1 M z NEUTRAL WHITE 120 VAC 7600A a o BLACK 120 VAC BURNER OR HOT GAS IGNITION SYSTEM SUPPLIED CIRCULATOR 7600B SERVICE 120 VAC 24 VAC GAS SWITCH IGNITION SYSTEM P2 Q CIRCULATOR 120 VAC CIRCULATOR CIRCULATOR 120 VAC 120 VAC AquaSmart Boiler Control Manual 21 Additional zones can be added by duplicating the Figure 17 7600A B alternate multi zone connections plumbing and wiring of zone 3 adding additional with Indirect Domestic Hot Water DHW transformers as needed
51. t the desired setting Tap the button to increase or decrease the temperature by 1 or hold it to increase or decrease the temperature by 5 at a time The control will not allow you to select out of range values AquaSmart Boiler Control Manual 25 3 Press the ENTER RESET key 4 The control will ask you to confirm the setting with the following screen HIGH DIFF ENTER GR CANCEL Press ENTER RESET if the value is correct or CANCEL if it is not D Temperature Low Limit Differential 1 In any mode or screen other than an OPTION sub menu press the LOW DIFF key 2 The following screen will be displayed LOW DIFF TOF CHANGE AND ENTER The temperature displayed is the current setting Use the A and keys to select the desired setting Tap the button to increase or decrease the temperature by 1 or hold it to increase or decrease the temperature by 5 at a time The control will not allow you to select out of range values Press the ENTER RESET key The control will ask you to confirm the setting with the following screen LOL DIFF ENTER GR CANCEL Press ENTER RESET if the value is correct or CANCEL if it is not Programming Additional Options Note Some additional menus may be visible that are not included in the following pages Those menus are non functional and reserved for future use Elec
52. trical Shock Hazard Can cause severe injury death or equipment damage Live line voltage wires and connections will be exposed while programming the AquaSmart Take care to touch only the AquaSmart keypad while programming the control WARNING Fire Explosion and Burn Hazards Can cause severe injury death or equipment damage Do not set the operating limits of the control outside of those listed by the appliance manufacturer A Changing the Heat Manager Settings 1 In any mode or screen other than an OPTION sub menu press the OPTION key 2 The following screen will be displayed HEAT MANAGR MENU ENTER TO Press ENTER RESET key 3 The following screen will be displayed ECONGHZER ON ENTER CHANGE a To toggle the fuel economizer on or off Press ENTER RESET key To Adjust the Heat Manager efficiency setting Press the A or Y keys until the following screen is displayed EFFICIENCY MED ENTER CHANGE Press ENTER RESET to toggle the comfort setting between H MED and LOW See HeatManager Technology section for an explanation of the efficiency settings 4 Press CANCEL BACK to exit a B Viewing the Boiler Cycle History 1 In any mode or screen other than an OPTION sub menu press the OPTION key 2 The following screen will be displayed HEAT MANAGR MENU ENTER TO VIEW Press the A or Y key
53. uent Service Intervals Verify 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 from corrosion and insulation is intact There is no physical damage to the case or display There is no evidence of water damage on the control or terminals The control is securely mounted to the well or other mounting support The sensor is in its place with no evidence of tampering The sensor lead on remote mounted units is in good condition and securely anchored in the immersion well with the strain relief The control temperatures differentials and optional functions are set correctly and working to established specifications Consult the service tag or label on the boiler A record of service and any adjustments are made to the service label or tag The control door is attached and securely closed AquaSmart Remote Mount Unit Pack 7600RMU Includes o Cable Assembly with Coupler o Mounting Template o Self drilling Screws Qty 3 o Cable Ty wrap AquaSmart Temperature Sensor Unit Pack 7600TSU Includes o Temperature Sensor o Cable Ty wrap o Joint Compound o Installation Instructions AquaSmart 2 in 1 Sensor Unit Pack 76002N1S01U Includ

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