The Development Of Modern Primary Controls

Bulletins, GeniSys Controls, System Controls

Advances in electronics technology are making an exciting impact in our oilheat industry. These developments have enabled control manufacturers to put high performance features into residential primary controls. Residential controls are now being made available to you that have features that were previously found only with the expensive primary control unitsfor commercial or industrial applications. Features like valve-on delay (pre-purge), burner motor-off delay (post-purge), andinterrupted duty ignition are becoming universal. Preignition, limited reset and recycle, and alarms contacts are also helping to make today’s controls advanced and powerful tools.

This technical bulletin will discuss some of these important improvements and present a list of descriptive terms to help you become familiar with this new generation of controls. We will include a discussion of the Honeywell R7184 series control, themost recent entry into our marketplace. A handy R7184 quick reference guide for technicians that is included on page 4 will help you become knowledgeable with its operation and features.

IMPORTANT TECHNICAL ADVANCES

As the electronics industry constantly develops, many of its products and techniques have been applied to burner controls. Some of the developments that are key to us are the following:

  • Relays have become smaller and more reliable. It is now common to see several relays inside each control, so that the motor, ignitor, and valve may all be controlled by separate relays. Solid state relays are increasingly being used instead of the traditional electromechanical relays.
  • Microcontrollers (small computer chips designed specifically to control other electronics) have increased the ability to control the burner’s components separately and with more intelligence. A microcontroller’s software code can easily add control functions and make complex decisions, eliminating the need for large decision-making circuits. Circuits are now needed mostly to provide processor and 24 Volt power, convert sensor signals, and drive relays.
  • Timers have developed from being controlled by bimetal switches to being controlled by semiconductors. Now, many different timers can all be running at the same time. Timings are less affected by temperature, vibration, light, line voltage, etc. They can be accurate to within fractions of a second, instead of varying by 10% to over 50% for some traditional controls.
  • Flame sensing has progressed from stack mounted bimetal switches to cadmium sulfide sensors (cad cells) and ultraviolet sensors. These sensors can more quickly and accurately sense the flame, and they also have the ability to sense the varying brightness of a flame. Software programming can monitor the rise and fall of a cad cell resistance to better interpret its signal. For instance, the cad cell signal can be smoothed out to help prevent nuisance lockouts. The Honeywell R7184 can display the cad cell resistance (see the Quick Reference Guide on page 4), so you do not need to use an Ohmmeter.
    NOTE: For proper operation, it is important that the cad cell resistance is below 1600 Ohms.
  • LED indicators offer you an increasing amount of diagnostic information such as recycling, flame status, or different lockout modes. Indicators like these are making it easier than ever to know what was happening before you arrived at the installation.
  • Self checking and system checking to ensure a safe, proper starting and operation of the burner are now standard procedures in microcontroller-based controls.
  • Advanced features, both new and borrowed from more expensive controls, are being added to residential controls. In the near future, look for increased use of the reset button, special pump priming procedures, redundant safety features, brownout protection, advanced recycle methods, and other features that will make controls better and your job easier.

GLOSSARY OF CONTROL TERMS

You are probably familiar with the definition of most of the control-related terms below. However, you may not be aware of their benefits or importance to service technicians. As you read on, remember that many of these features were not readily available to us until recently.

1 BURNER MOTOR-OFF DELAY (POST-PURGE) is the time period after the fuel valve closes during which the burner motor continues to run. Don’t forget: post-purge controls typically need one wire to limit (commonly red) and one wire to constant L1 power (commonly black)!
2 DATA COMMUNICATION PORT is a small electrical port connected to the primary control’s computer chip. Comm. ports will enable the control to communicate with flame quality and other service instruments, home security systems, or data acquisition equipment, as they become available.
3 DIP SWITCHES (Dual Inline Package) are sets of switches that can be manually set to an open or closed position. DIP switches provide the serviceman with an easy way to select different control options (for instance, burner motor-off delay times).
4 DRY ALARM CONTACTS are isolated (non-powered) relay contacts that are closed when the burner is in safety lockout. Alarm or home security systems can use the alarm contacts to alert the homeowner or service company that the burner has locked out.
5 FLAME FAILURE RESPONSE TIME (FFRT) is the time it takes for a control to sense that the flame has been lost. The FFRT is one of the key safety timings of a control. If it is too short, you could have nuisance lockouts. If it is too long, the chamber could become flooded with fuel if the ignition fails.
6 IGNITION CARRYOVER is the period after a flame has first been sensed that the ignition source is left on (only applicable to controls that have interrupted duty ignition). Ignition carryover helps to ensure that the flame is strongly established before the ignition source is turned off.
7 INTERMITTENT DUTY IGNITION is the ignition method in which the ignition source is energized the entire time the burner is firing. In older, non-flame retention burners, intermittent ignition is usually required to sustain the stability of the flame.
8 INTERRUPTED DUTY IGNITION is the ignition method where the ignition source comes on only to light the flame. After the flame is established, the ignition is turned off and the flame keeps burning. Interrupted duty ignition saves on electrical energy and significantly increases the lifetime of the electrodes and the ignition source.
9 LED INDICATOR (Light Emitting Diode) is a small low power light that can be easily turned on and off by the primary control. The LED is a service tool that can be used to indicate that the burner sees light, is in a recycle or lockout mode, etc.
10 LIMITED RECYCLE means that the control will only recycle and try to restart the burner a limited number of times if the flame is repeatedly established and then lost. Limited recycle keeps the appliance from being excessively sooted due to repeated failing combustion.
11 LIMITED RESET (or RESTRICTED LOCKOUT) means that a simple press will only work a certain number of times to reset the control from lockout. After that, a special service reset procedure is required (for instance, holding the button longer). Limited reset prohibits those who are unqualified from repeatedly resetting the control and increasing burner system problems.
12 PREIGNITION is the term for energizing the ignition source before the motor / pump, to give the ignition source time to establish its arc. Pre-ignition decreases difficult ignitions that are due to delayed arc establishment.
13 RECYCLE is the waiting period after a burner has lost its flame before the control can try to restart the burner. The recycle (delay) period helps to ensure that the burner will safely try to restart the burner.
14 SAFETY LOCKOUT is the action a primary control takes to shut down the burner if no flame is detected within its safety lockout time (TFI). Safety lockout prohibits the burner from continuing to spray unburned fuel into the appliance.
15 SAFE START CHECK is an electronic procedure in which the control makes sure it is safe to start the burner when a call for heat is initiated. Safe start checks enable the control to ensure that the line voltage is sufficient, the cad cell is sensing darkness, and internal software is error free.
16 STANDBY is the period during which the burner is off, while the primary control waits for a call for heat. The R7184’s LED will turn on even in Standby if the cad cell senses light – helpful if you have stray light in the burner.
17 TRIAL FOR IGNITION (TFI) is the period during which the burner is attempting to ignite the fuel it is delivering to the nozzle. A shorter trial for ignition time (safety lockout time) keeps the appliance from being flooded with fuel if it does not light.
18 VALVE-ON DELAY (PREPURGE) is the time period during which the burner motor is running before the fuel valve is opened. Valve-on delay allows the burner to establish air flow and to bring the pump to full speed, helping to keep ignitions smooth and clean.

664849-2

CONTROLS OF THE FUTURE

As electronics and control technology continue to develop, our industry will continue to reap the benefits in the form of new controls and features. Controls will have more high performance features integrated into one package. They will be able to better diagnose the burner and communicate with service personnel.

Contact Us

Drop us a line with any comments or questions!

Burner Settings

(OEM Spec Guides)

Specifications for nozzles, air tube combinations, and other initial settings.

Tech Bulletins

Service bulletins and product updates.

Tutorials

Training videos and PowerPoint presentations.

Troubleshooting Guides

Solutions to common issues.

Find A Part

Look through exploded views to find the part you need.

Manuals & Guides

A library of product manuals and supplemental guides.

Product Warranty

View the limited warranty for all Beckett products.

Return Material Authorization

Submit a return material authorization (RMA) Request.

Warnings

(Proposition 65)

Frequently asked questions, and a list of affected products.

Classroom Training

Hands-on, practical installation, application, and operation training on Beckett’s latest products — in-person with the industry’s foremost authorities. Register today.

Online Training

Informative and technical training resources from the leading experts in the heating industry — now available online, on-demand, and FREE.

Product Instructional Videos

Our most popular product-related instructional / training videos for the most relevant and widely seen products and applications you’ll find in the field.

Find a Distributor

Beckett solutions are available through our network of distribution partners throughout the United States and Canada.

Find an Independent Representative

Beckett Independent Representatives provide Sales Support for our products throughout the United States and Canada.

Find an Export Representative

Beckett solutions are available for export outside of the United States and Canada through our network of Export Representatives.

Residential Heating Solutions from Beckett®

For over 80 years Beckett products have been the number one choice of homeowners and contractors for their furnaces, boilers, and water heaters. As North America's foremost brand of burners, Beckett continues to provide industry leading design, reliability, and support. All backed by a comprehensive warranty program that ensures you will have years of trouble-free operation.

RF Oil Burner

RF Oil Burner

NEW! Designed to meet the many challenges of today’s modern heating appliances and process equipment, the Beckett RF oil burner is designed to ...

Commercial Heating/Steam Solutions from Beckett®

As North America's leading brand of burners, you can have peace of mind in using a Beckett burner on your next commercial project. With the environment in mind, we have the most comprehensive lineup of biofuel rated burners in the industry. Supported by a broad network of trained technicians, choosing a Beckett burner for your next commercial project ensures your building will have years of trouble-free operation while reducing your equipment’s impact on the environment. A return on investment for future generations.

Road Maintenance Solutions from Beckett®

When the sun is blazing and you're responsible for keeping Americas roads maintained, you'll want a burner that's as hard working as you are. Beckett's lineup of DC burners provides mobile heat for all types of road maintenance equipment. With their ease of service and parts availability from coast to coast, you can ensure the job gets done when the heat is on.

Heated Pressure Washing Solutions from Beckett®

For over 30 years Beckett has served the pressure washer market in providing rugged yet reliable burners and components for the pressure washer industry. Our compact DC powered burners provide off-grid dependable operation in the wettest of environments. All backed by a comprehensive warranty program that ensures you will have years of trouble-free operation. So, when the "pressure" is on to get a job done, you can rely on Beckett to keep you in "hot water".

Agriculture / Greenhouse Solutions from Beckett®

With a wide range of capacities, Beckett has served the needs of the agricultural industry for over 20 years. Our proven experience in the combustion field allows us to work with appliance engineers to ensure the strictest of parameters are met when drying organic products. Beckett's modular burner platform provides the most flexibility in applications while offering the most comprehensive lineup of biofuel rated burners in the industry. This ensures efficient reliable heat for future generations.

Construction Solutions from Beckett®

When freezing temperatures hit your job sites and you need dependable heat, consider Beckett for the job. From the Arctic circle to Antarctica, Beckett has proven to be the burner of choice in the harshest most remote environments. Our robust, user-friendly design provide quick maintenance and dependable operation to ensure your site stays warm.

Food Processing Solutions from Beckett®

Beckett burners and components are used in food processing applications all over the world. From bakery ovens, coffee roasters, dehydrators, and industrial process lines, Beckett robust, reliable products reduce line down time and ensure an uninterrupted output.

R.W. Beckett

From tank to flame, Beckett delivers the most technically advanced product line in the industry — burners, igniters, controls, and accessories designed to meet the performance requirements of the industry while meeting the demands of biofuels to reduce emissions and meet carbon reduction goals. Explore all that Beckett has to offer below by selecting a brand, product category, or simply filtering through the entire product offering.

Westwood by Beckett

With the acquisition of Westwood Products in 2021, Beckett added depth and diversity to its already impressive catalog. In addition to the Tigerloop suite of Oil Dearaetors which has been transitioned to our Beckett branded offering, our Westwood by Beckett product offering includes fuel filters, electrodes, tank accessories, and many other HVAC service and repair items. The line includes B20 filters which, in conjunction with the Tigerloop Bio models, completes Beckett’s industry leading suite of B20 rated components from tank-to-flame and further positions as the market leader in the drive to alternative fuels.

Residential Heating Solutions from Beckett®

For over 80 years Beckett products have been the number one choice of homeowners and contractors for their furnaces, boilers, and water heaters. As North America's foremost brand of burners, Beckett continues to provide industry leading design, reliability, and support. All backed by a comprehensive warranty program that ensures you will have years of trouble-free operation.

Commercial Heating/Steam Solutions from Beckett®

As North America's leading brand of burners, you can have peace of mind in using a Beckett burner on your next commercial project. With the environment in mind, we have the most comprehensive lineup of biofuel rated burners in the industry. Supported by a broad network of trained technicians, choosing a Beckett burner for your next commercial project ensures your building will have years of trouble-free operation while reducing your equipment’s impact on the environment. A return on investment for future generations.

Road Maintenance Solutions from Beckett®

When the sun is blazing and you're responsible for keeping Americas roads maintained, you'll want a burner that's as hard working as you are. Beckett's lineup of DC burners provides mobile heat for all types of road maintenance equipment. With their ease of service and parts availability from coast to coast, you can ensure the job gets done when the heat is on.

Heated Pressure Washing Solutions from Beckett®

For over 30 years Beckett has served the pressure washer market in providing rugged yet reliable burners and components for the pressure washer industry. Our compact DC powered burners provide off-grid dependable operation in the wettest of environments. All backed by a comprehensive warranty program that ensures you will have years of trouble-free operation. So, when the "pressure" is on to get a job done, you can rely on Beckett to keep you in "hot water".

Agriculture / Greenhouse Solutions from Beckett®

With a wide range of capacities, Beckett has served the needs of the agricultural industry for over 20 years. Our proven experience in the combustion field allows us to work with appliance engineers to ensure the strictest of parameters are met when drying organic products. Beckett's modular burner platform provides the most flexibility in applications while offering the most comprehensive lineup of biofuel rated burners in the industry. This ensures efficient reliable heat for future generations.

Construction Solutions from Beckett®

When freezing temperatures hit your job sites and you need dependable heat, consider Beckett for the job. From the Arctic circle to Antarctica, Beckett has proven to be the burner of choice in the harshest most remote environments. Our robust, user-friendly design provide quick maintenance and dependable operation to ensure your site stays warm.

Food Processing Solutions from Beckett®

Beckett burners and components are used in food processing applications all over the world. From bakery ovens, coffee roasters, dehydrators, and industrial process lines, Beckett robust, reliable products reduce line down time and ensure an uninterrupted output.

Beckett Oil Burners

R.W. Beckett oil-fired burners were created with customer satisfaction and sustainability in mind. Our utilization of advanced components results in higher efficiency and reliability, all while reducing carbon emissions.

Our burners are suitable for a multitude of needs. They are certified for firing traditional heating oils, biodiesel blends (B20), and renewable diesel blends (R95). Truly versatile, our burners are available in AC and DC voltages and in capacities from 0.40 to 35.0 GPH. Applicable uses range from residential homes to commercial buildings, for both industrial and process installations, R.W. Beckett can meet your demands. After installation our proven burners provide years of reliable service with strong and accessible technical support.

Beckett Gas Burners

R.W. Beckett gas-fired burners were created with customer satisfaction and sustainability in mind. Our utilization of advanced components results in higher efficiency, reliability, and accessibility, all while reducing carbon emissions.

Available in capacities ranging from 250 to 5,000 MBH, our burners are suitable for a multitude of needs. Applicable uses range from residential homes to commercial, for both industrial and process installations, R.W. Beckett can meet your demands. Our burners are easy to install and service, engineered to provide years of reliable service, and backed by solid technical support and fast delivery.

Beckett GeniSys® Burner Primary Safety Controls

R.W. Beckett’s burner controls were created with customer satisfaction and safety in mind. Our entire suite of burner controls utilizes the most current technology to safely control the combustion process.

Available in both AC and DC voltages for off-grid applications, our controls are suitable for a multitude of needs. Our new GeniSys® model 7565 Advanced Burner Control is compatible with the myTechnician™ app for modernized accessibility. The app assists with diagnostics, troubleshooting, and more. With applicable uses of our controls ranging from residential homes to commercial buildings, to process applications R.W. Beckett can meet your demands. Our multitude of models offer both fixed and programmable options and serve as a direct replacement for many competitive combustion controls.

Beckett AquaSmart® Boiler Safety Controls

R.W. Beckett’s boiler controls were created with customer satisfaction and sustainability in mind. The boiler control was built using Beckett’s proprietary HeatManager® algorithm which saves fuel by minimizing operating temperature, reducing energy consumption without sacrificing homeowner comfort.

Applicable to both oil and gas-fired boilers, the control is convenient for any household. With our digital display and touch pad we have made for a more intuitive experience, allowing for flexible programming of temperature limits and other settings.

Beckett Powerlight® Igniters

R.W. Beckett igniters were created with customer satisfaction and reliability in mind. Providing an advanced option for oil-fired burners, our Powerlight® igniter also serves as a universal replacement for other manufacturers’ igniters.

Available in a variety of AC and DC voltages for off-grid applications, our product is suitable for a multitude of needs. Designed for various applications, our igniter can be found in residential homes, commercial property, and even high-moisture environments.

Beckett Tigerloop® Oil Dearators

R.W. Beckett’s oil deaerators were created with customer satisfaction and efficiency in mind. With over 30 years of fine-tuning, the Tigerloop® is the most advanced oil deaerator in the world.

With its unmatched performance, Tigerloop® can handle capacities up to 50 GPH and is compatible with different heating fuels, depending on the model. The standard model is compatible with #1 and #2 heating oil and B5 Bioheat, while the Bio model accepts biofuel blends up to B100. Catering to many needs, our oil deaerator is also a safe, economical, and environmentally friendly choice for all supply systems.

Beckett Oil Filters

Beckett branded Spin-on filters are epoxy coated, UL Listed or UL Recognized and rated from 10 to 15 microns. Commercial Spin-on filters are rated for 52 GPH, 20 PSI, and 30 Microns. The line includes a cast aluminum tops, Filter Life Indicator (FLi™) gauge and is suitable for #1 and #2 fuel oil and rated up to B100 bio-fuels.

Westwood by Beckett canister filters feature cast iron tops and epoxy coated canisters. Element options include Classic Felt, cellulose acetate, and Classic Yarn. UL Listed/Recognized canister filters exceed GPH and pressure ratings of most competitors.

Beckett Internet Connected Products

R.W Beckett’s internet connected products were created with customer satisfaction and accessibility in mind. With our modernized approach, these products can be remotely accessed through our mobile app or web browser.

Through the myTechnician™ mobile app, connected products come with multiple features including troubleshooting, product programming and diagnostics. With the BeckettLink® connected tank gauge system and Wi-Fi hub, end users and oil dealers can use the Beckett Dealer Dashboard to be alerted remotely if the tank drops below predetermined levels.

For your convenience, Tank Accessories has been divided into distinct categories to help you find the products you need. Please click the links below to see all the products in each of these categories.

Beckett Electrodes and Insulators

RW Beckett manufacturers hundreds of Westwood electrodes, flame rods and spark ignitors. Many are sold through distribution and additional items are available for OEM customers for special applications. RW Beckett can manufacture specialty electrodes to your specifications. The Auburn and Champion brands are also available.

All Categories

View All Products