Weil-McLain UO-3 CV User manual

Oil Fired Water Boiler
Beckett Model NX Burners
Potential for Fire, Smoke and Asphyxiation Hazards
To the Homeowner or Equipment Owner:
Please read and carefully follow all instructions provided
in this manual regarding your responsibilities in caring for
your heating equipment.
Contact a professional, qualified service agency for
installation, start-up or service work.
Save this manual for future reference.
Incorrect installation, adjustment, or misuse of this burner could result in death, severe personal
injury, or substantial property damage.
To the Professional, Qualified Installer or Service
Agency:
Please read and carefully follow all instructions provided
in this manual before installing, starting, or servicing this
burner or heating system.
The Installation must be made in accordance with all
state and local codes having jurisdiction.
WARNING
Weil-McLain Part No. 550-141-996/510
Instruction Manual

2

3
Weil-McLain Ultra Oil NX Burner Manual
To the Owner:
Thank you for purchasing a Beckett
burner for use with your heating appliance.
Please pay attention to the Safety Warnings
contained within this instruction manual. Keep
this manual for your records and provide it
to your qualified service agency for use in
professionally setting up and maintaining your
oil burner.
Your Beckett burner will provide years of
efficient operation if it is professionally
installed and maintained by a qualified service
technician. If at any time the burner does not
appear to be operating properly, immediately
contact your qualified service agency for
consultation.
We recommend annual inspection/service
of your oil heating system by a qualified
service agency.
Daily – Check the room in which your burner/
appliance is installed. Make sure:
Air ventilation openings are clean and
unobstructed
Nothing is blocking burner inlet air
openings
No combustible materials are stored near
the heating appliance
There are no signs of oil or water leaking
around the burner or appliance
Weekly
Check your oil tank level. Always keep
your oil tank full, especially during the
summer, in order to prevent condensation
of moisture on the inside surface of the
tank.
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Remainder of manual to be used ONLY BY
QUALIFIED SERVICE TECHNICIANS
▼▼
Weil-McLain Burner Specifications ...........................5
NX Burner Specifications for Weil-McLain Ultra Oil Boilers ..........5
General Information ....................................................6
Notice Special Requirements........................................................6
Inspect/Prepare Installation Site................................6
Clearances to Burner and Appliance.............................................6
Inspect Chimney or Direct Vent System........................................6
Combustion Air Supply Information...............................................7
Safety Shutoff for Direct Vent System...........................................8
Direct/Sidewall Venting Application ..............................................8
Mounting dimensions ....................................................................8
Installing the Oil Tank and Supply System ....................................9
Fuel Line Valves and Filter ...........................................................9
Fuel supply level with or above burner..........................................9
Wiring Connections Diagram ..................................................... 10
Burner Control...........................................................12
Sequence of Operation - GeniSys 7505 .................................... 12
Start the Burner and Set Combustion.....................15
Start-up and Initial Settings ........................................................ 15
Set Combustion with Test Instruments....................................... 15
Cover Installation ....................................................................... 17
Trained Service Technician’s Regular Maintenance17
Removing Nozzle Line for Service ............................................ 18
(Reference the Replacement Parts Diagram.) ........................... 18
Nozzle Installation ..................................................................... 18
Check/Adjust Electrodes ............................................................ 19
Check Retention Head Alignment and Cad Cell Sighting .......... 20
Check/Adjust “Zero” Calibration ................................................. 20
Blower Wheel Replacement....................................................... 20
Shutting the Burner Off .............................................................. 20
Replacement Parts....................................................22
Contents
General Information ....................................................4
Hazard Definitions ........................................................................4

4
General Information
Section: General Information
Hazard Definitions
Within the boundaries of the hazard warning, there will
be information presented describing consequences if the
warning is not heeded and instructions on how to avoid
the hazard.
Indicates a hazardous situation,
which, if not avoided, will result
in death or serious injury.
Indicates a hazardous situation,
which, if not avoided, could
result in death or serious injury.
Indicates a hazardous situation,
which, if not avoided, could
result in minor or moderate injury.
Intended to bring special attention
to information, but not related to
personal injury or property damage.
Owner’s Responsibility
Incorrect installation, adjustment, and
use of this burner could result in severe
personal injury, death, or substantial
property damage from fire, carbon
monoxide poisoning, soot or explosion.
Contact a professional, qualified service agency for the
installation, adjustment and service of your oil heating
system. This work requires technical training, trade
experience, licensing or certification in some states and
the proper use of special combustion test instruments.
Please carefully read and comply with the following
instructions:
Never store or use gasoline or other flammable
liquids or vapors near this burner or appliance.
Never attempt to burn garbage or refuse in this
appliance.
Never attempt to light the burner/appliance by
throwing burning material into the appliance.
Never attempt to burn any fuel not specified and
approved for use in this burner.
Never restrict the air inlet openings to the burner or
the combustion air ventilation openings in the room.
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Please read and understand the manual supplied with
this equipment. This equipment must be installed,
adjusted and put into operation only by a qualified
individual or service agency that is:
Licensed or certified to install and provide technical
service to oil heating systems.
Experienced with all applicable codes, standards
and ordinances.
Responsible for the correct installation and
commission of this equipment.
Skilled in the adjustment of oil burners using
combustion test instruments.
The installation must strictly comply with all applicable
codes, authorities having jurisdiction and the latest
revision of the National Fire Protection Association
Standard for the installation of Oil-burning Equipment,
NFPA 31 (or CSA-B139 and CSA-B140 in Canada).
Regulation by these authorities take precedence over the
general instructions provided in this installation manual.
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Incorrect installation, adjustment, and
use of this burner could result in severe
personal injury, death, or substantial
property damage from fire, carbon
monoxide poisoning, soot or explosion.
Professional Service
Required
Frozen Plumbing and
Water Damage Hazard
If the residence is unattended in severely cold weather,
burner primary 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
preventive actions such as having a security system
installed that operates during power outages, senses low
temperature and initiates an effective action. Consult with
your heating contractor or a home security agency.

5
Weil-McLain Ultra Oil NX Burner Manual
Figure 1. Burner label location
NX Burner Specifications for Weil-McLain
Ultra Oil Boilers
The table below provides burner specifications and
starting air settings for NX burners applied to Weil-
McLain Model UO boilers. Follow all instructions in this
burner manual, the boiler manual and the fuel pump
literature to install, setup and service the burner.
Weil-McLain Burner
Specifications
Boiler
Model Burner Spec
Firing
Rate
(GPH)
Air Tube
Combination Insertion Primary Nozzle Alternate Nozzle
Fuel Pump
Pressure
(psig)
Head/Air
Adjustment
Plate Setting
UO-3 CV WL6403
(See Note1) 0.80 NX70LC 1-3/4” 0.65 X 60°A Delavan
0.65 X 70°B
Hago 150 1.75
UO-3 CV WL6403 1.00 NX70LC 1-3/4” 0.75 X 60°B
Hago
0.75 X 60°B
Delavan 175 2.50
UO-4 CV WL6404 1.20 NX90LB 3-1/2” 1.00 X 70°B
Hago
1.00 X 70°B
Delavan 140 4.00
UO-5 CV WL6405 1.40 NX90LD 3-1/2” 1.10 X 70°B
Hago
1.10 X 70°B
Delavan 160 1.50
UO-3 DV WL6503
(See Notes1 & 2) 0.80 NX70LC 1-3/4” 0.65 X 60°A Delavan
0.65 X 70°B
Hago 150 1.75
UO-3 DV WL6503
(See Note 2) 1.00 NX70LC 1-3/4” 0.75 X 60°B Hago
0.75 X 60°B
Delavan 175 2.50
UO-4 DV WL6504
(See Note 2) 1.20 NX90LB 3-1/2” 0.85 X 60°W Delavan
0.85 X 60°W
Hago 190 4.00
UO-5 DV WL6505
(See Note 2) 1.40 NX90LD 3-1/2” 1.10 X 70°B Hago
1.10 X 70°B
Delavan 160 1.50
1) Shipped as 1.0 GPH Burner Configuration. The 0.80 GPH input uses same burner as 1.0 GPH input. Replace
nozzle, adjust pump pressure and Head/Air setting as shown above and install 14”x16” blanket on combustion
chamber floor. (See Maintenance Section for Nozzle Replacement details.)
2) Direct Vent Boilers require that a combustion chamber blanket be installed (blanket supplied with burner).
Table 1. Burner Configurations - Verify that burner specification number (on burner carton) and configuration agrees
with information below.
Fozen Plumbing and Water Damage
Hazard.
Unoccupied residences in severly cold weather could
experience frozen plumbing in just a few hours if the
heating system fails for any reason. Consult your
HVAC contractor for effective preventive protection,
such as electronic monitoring systems with 24/7 dial-up
The remainder of this manual
contains Information to be used
ONLY by a qualified Service Technician.
Section: Weil-McLain Burner Specifications

6
Certifications/approvals
Underwriters Laboratories has certified this burner
to comply with ANSI/UL 296 and CSA-B139. Low
sulfur #1 and #2 fuel oils reduce heat exchanger
deposits with all burners compared to the standard
fuels. Reduced deposits extend the service
interval for cleaning and improve the efficiency of
the appliance over time. Low sulfur fuels reduce
particulate and oxides of nitrogen emissions as
well. The Oilheat Manufacturers’Association
recommends these fuels as the preferred fuels for
this burner.
Notice Special Requirements
THE INSTALLATION OF A BURNER SHALL BE IN
ACCORDANCE WITH THE REGULATIONS OF
AUTHORITIES HAVING JURISDICTION.
For recommended installation practices in the U.S.
refer to the latest edition of NFPA 31. (CSA-B139
and CSA-B140 in Canada.
Concealed damage — If you discover damage to
the burner or controls during unpacking, notify the
carrier at once and file the appropriate claim.
When contacting Beckett for service information
— Please record the burner serial number (and have
available when calling or writing). You will find the
serial number on the silver label located on the left
rear of the burner. Refer to Figure 1.
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Starting with minimum gph firing rate, the minimum
size recommended is 6” flue pipe with 8” X 8”
inside chimney, unless specified otherwise by the
appliance manufacturer.
A chimney flue shall extend at least 3 feet above
the highest point at which the chimney comes in
contact with the roof, and not less than 2 feet above
the highest roof surface or structure within 10 feet
horizontally of the chimney. Refer to Figure 2.
1.
2.
Table 3. – Air Tube Combinations (ATC)
Firing rate
(gph) Head ATC codes for usable air tube lengths:
(min-max) 5” 7” 9”
0.40-1.35 9-Slot NX50LB NX70LB NX90LB
0.40-1.35 6-Slot NX50LC NX70LC NX90LC
1.10-1.75 9-Slot NX50LD NX70LD NX90LD
1.10-1.75 6-Slot NX50LF NX70LF NX90LF
Inspect/Prepare
Installation Site
Clearances to Burner and Appliance
Provide space around burner and appliance for ease
of service and maintenance. Check the minimum
clearances against those shown by the appliance
manufacturer and by applicable building codes.
Inspect Chimney or Direct Vent System
General Information
Table 2. – Burner Specifications
Capacity
LB & LC
Firing rate: 0.40 – 1.35 GPH
Input: 56,000 – 189,000 Btu
Capacity
LD & LF
Firing rate: 1.10 - 1.75 GPH
Input: 154,000 – 245,000 Btu/h
Fuels
U. S. No. 1 or No. 2 heating oil only (ASTM D396)
Canada No. 1 stove oil or No. 2 furnace oil only
Electrical Power supply: 120 VAC, 60 Hz, single phase
Operating load: 5.8 Amps max
Motor: 1/7 hp, 3450 rpm, NEMA 48M frame
PSC rotation CCW when facing shaft end
Ignition: Continuous duty solid-state igniter
Fuel pump Outlet pressure - See Note 1
Air tube ATC code - See Table 3
Dimensions
(with cover)
Height (maximum): 12-1/2 inches
Width (maximum): .15 inches
Depth: 9-1/4 inches
Air tube diameter: 3-1/4 inches
*Note 1. See appliance manufacturer’s burner specifications for recom-
mended outlet pressure.
DO NOT USE GASOLINE, CRANKCASE
OIL, OR ANY OIL CONTAINING GASOLINE.
Carefully inspect the chimney or exhaust vent
system.
Make sure it is properly sized and in good working
condition.
Follow the instructions supplied by the appliance
manufacturer.
The installation must strictly comply with all
applicable codes, authorities having jurisdiction and
the latest revision of the National Fire Protection
Association Standard NFPA 31 for the installation of
chimneys and vent sizing, (or CSA-B139 and CSA-
B140 in Canada).
Regulation by these authorities take precedence
over the general instructions provided in this
installation manual.
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Fire, Smoke & Asphyxiation
Hazard
Section: General Information & Inspect/Prepare Installation SIte

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Weil-McLain Ultra Oil NX Burner Manual
Any accumulation of soot or debris in chimney
offsets should be removed
Any obstructions such as a protruding joint or a
piece of broken tile wedged in the chimney should
be removed.
No other appliance connection should be made to
the same flue pipe.
The flue pipe should have an upward pitch toward
the chimney of at least 1/4” per foot of length. It
should fit tightly and should not project into the
chimney.
Any leakage between tiles, around clean-out doors,
or around the vent pipe should be sealed.
Insulated Stainless Steel Chimney Liners
The new designs of high efficiency oil furnaces and
boilers in conjunction with flame retention oil burners
are more efficient. One result of increased efficiency is
lower flue gas temperatures. As flue gases rise in the
chimney, they will cool and condense when they reach
the dew point. The condensation will mix with the sulphur
in the flue gases creating sulphuric acid. The acid will
attack the chimney mortar, brick and clay liners causing
corrosion, deterioration and blockage of the chimney.
Eventually the blockage could prevent exhausting the
flue gases. Instead, the flue gases could vent out the
barometric damper into the living space.
Therefore, it is strongly recommended that an approved
insulated stainless steel liner be installed.
3.
4.
5.
6.
7.
For those installations not requiring a chimney, such
as through-the-wall vented appliances, follow the
instructions given by the appliance and power venter (if
used) manufacturers.
Combustion Air Supply Information
Figure 2 – Chimney Design - Above the Roof
See NFPA Standard 31 for complete details. Appliances
located in confined spaces: All confined spaces should
have two (2) permanent openings; one near the top of
the enclosure and one near the bottom of the enclosure.
Each opening must have a free area of not less than
one (1) square inch per 1,000 BTU’s per hour of the total
input rating of all appliances within the enclosure. The
openings should have free access to the building interior,
which should have adequate infiltration from the outside.
The burner cannot properly burn the fuel if it is not
supplied with a reliable combustion air source.
Follow the guidelines in the latest editions of the
NFPA 31 and CSA-B139 regarding providing
adequate air for combustion and ventilation.
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Failure to provide adequate air supply could
seriously affect the burner performance and result in
damage to the equipment, asphyxiation, explosion or
fire hazards.
Adequate Combustion
and Ventilation Air Supply
Required
NOTE: Correct chimney design is shown by dotted lines. Incorrect chimney design, as shown by
the solid lines, may result in down-drafts.
Section: Inspect/Prepare Installation SIte

8
Exhaust fans and other air-using devices: Size air
openings large enough to supply all air-using devices
in addition to the minimum size required for combustion
air. If there is any possibility of the equipment room
developing a negative pressure due to exhaust fans,
clothes dryers, etc., either pipe combustion air directly to
the burner or provide a sealed enclosure for the burner
and supply it with its own combustion air supply.
Safety Shutoff for Direct Vent System
The direct vent blocked flue safety shut off system, refer
to Figure 3, shuts down the burner if the exhaust flue is
blocked and/or if the air inlet is blocked. It recognizes
a blocked flue by sensing excessive pressure in the
combustion chamber. It recognizes a blocked inlet by
sensing excessive vacuum in the air inlet adapter.
This system meets the requirements for a blocked flue or
blocked combustion air inlet per CSA Standard B140.0.
It is designed to interrupt the cad cell circuit and allow
the control to shut down the burner.
Direct/Sidewall Venting Application
For direct vent installations, follow instructions provided
with appliance and direct vent system. Outside
combustion air is required for direct venting.
When installing an NX outside air adapter (Beckett Part
Number 52018U), refer to the instruction sheet supplied
with the adapter. This kit allows combustion air to be
Figure 3. Pressure Switch Installation
piped directly to the burner. The NX outside air adapter
kit may also be used for chimney vent applications that
require outside combustion air.
Mounting dimensions
When using the Beckett universal adjustable flange,
mount the air tube at a 2° downward pitch unless
otherwise specified by the appliance manufacturer.
Verify that the air tube installed on the burner
provides the correct insertion depth. See Figure 4.
1.
2.
Figure 4. – Mounting Burner in Appliance
SK8745
Tilt down 2°
If space between burner
air tube and opening
exceeds 1/2 inch, pack
burner opening with
ceramic fiber refractory.
Connect Outside Air Duct
to NX Adapter
The outside air adapter must be installed by strictly
following the kit installation instructions.
DO NOT attempt to install outside air piping without
using the outside air adapter and instructions
provided.
Abundant fresh air is required for proper combustion.
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Failure to install adapter properly could
result in impaired combustion, appliance
soot-up, puffback of smoke, and fire or
asphyxiation hazards.
Do not attempt to install outside air piping to
the burner without using the outside air kit and
instructions.
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Failure to comply could result in impaired
combustion, appliance soot-up, puffback of smoke,
and fire or asphyxiation hazards.
Follow the Outside Air Kit
Instructions Exactly
Section: Inspect/Prepare Installation SIte

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Weil-McLain Ultra Oil NX Burner Manual
The end of the air tube should normally be ¼” back
from the inside wall of the combustion chamber.
Never allow the leading edge of the head assembly
to extend into the chamber, unless otherwise
specified by the heating appliance manufacturer.
Carefully measure the insertion depth when using
an adjustable flange. Verify the insertion depth
when using a welded flange.
Installing the Oil Tank and Supply System
3.
Note: to determine the proper fuel line size, refer to
the fuel pump manufacturer’s instructions provided
with the burner. Refer to Figure 5 or Figure 6 for typical
installation layouts.
Fuel Line Valves and Filter
Install two high quality, oil duty rated, fusible handle
design shutoff valves in accessible locations on the oil
supply line. Locate one close to the tank and the other
close to the burner, upstream of the filter for service
access.
Install a generous capacity filter inside the building
between the fuel tank shutoff valve and the burner,
locating both the filter and the valve close to the burner
for ease of servicing. Filter should be rated for 50
microns or less.
Fuel supply level with or above burner
Figure 5. – Inside Tank Gravity Feed System
The burner may be equipped with a single-stage fuel
unit for these installations. Connect the fuel supply to the
burner with a single supply line if you want a one-pipe
system (making sure the bypass plug is NOT installed in
the fuel unit.) Manual bleeding of the fuel unit is required
on initial start-up. If connecting a two-pipe fuel supply,
install the fuel unit bypass plug.
Oil Leak and Fire Hazard
Install the oil tank following applicable standards
in the U.S. by referring to the latest edition of NFPA
31 or CSA-B139 & CSA-B140 in Canada, and all
authorities having jurisdiction.
Never use Teflon tape on fuel oil fittings.
Tape fragments can lodge in fuel line components
and fuel unit, damaging the equipment and
preventing proper operation.
Use oil-resistant pipe sealant compounds.
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Damage to the pump could cause impaired burner
operation, oil leakage and appliance soot-up.
Do Not Use Teflon Tape
The burner is shipped without the by-pass plug installed.
Install the by-pass plug in two-pipe oil supply systems ONLY.
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Failure to comply could cause immediate pump seal
failure, pressurized oil leakage and the potential for a
fire and injury hazard.
Do Not Install By-pass Plug
with 1-Pipe System
The oil supply inlet pressure to the burner cannot
exceed 3 psig.
Insure that a pressure limiting device is installed in
accordance with the latest edition of NFPA 31.
Do NOT install valves in the return line.
Gravity Feed Systems: Always install an anit-siphon
valve in the oil supply line or a solenoid valve (RWB
Part # 2182602U) in the pump/nozzle discharge
tubing to provide backup oil flow cut-off protection.
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Damage to the filter or pump seals could cause oil
leakage and a fire hazard.
Oil Supply Pressure
Control Required
Section: Inspect/Prepare Installation SIte

10
Fuel supply below the level of the burner
When the fuel supply is more than eight feet below
the level of the burner, a two-pipe fuel supply system
is required. Depending on the fuel line diameter and
horizontal and vertical length, the installation may
also require a two-stage pump. Consult the fuel unit
manufacturer’s literature, included with the burner, for lift
and vacuum capability.
Fuel line installation
Continuous lengths of heavy wall copper tubing are
recommended. Always use flare fittings. Never use
compression fittings.
Always install fittings in accessible locations. Proper
routing of fuel lines is required to prevent air cavitation
and vibration.
Wiring Connections Diagram
Figure 6. – Outside Buried Tank-Lift System
Figure 7. – Burner Connections.
Power Cord
Burner packaged with appliance - Refer to
appliance manufacturer’s wiring diagram for
electrical connections.
Burner installed at jobsite - Refer to Figures 7a
and 7b, for typical burner wiring, showing cad
cell primary controls. Burner wiring may vary,
depending on primary control actually used. Refer
to the appliance manufacturer’s wiring diagram
prior to connecting the burner wiring. All wiring
must be in accordance with the latest revision of
national Electric Code NFPA 70 and all local codes
and regulations. In Canada, all wiring is to be in
accordance with the Canadian Electrical Code, Part 1.
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To further protect the fuel supply
system and reduce nozzle orifice
plugging with firing rates below 0.75 gph, a dual filtration
system can be installed. This typically consists of a 50
micron primary filter, located near the fuel tank and a
secondary filter rated for at least 10 microns located
near the burner.
NOTICE
Disconnect electrical power before installing or
servicing the burner.
Provide ground wiring to the burner, metal control
enclosures and accessories. (This may also be
required to aid proper control system operation.)
Perform all wiring in compliance with the National
Electrical Code ANSI/NFPA 70 (Canada CSA C22.1)
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Electrical shock can cause severe personal
injury or death.
Electrical Shock Hazard
Incorrect Wiring Will
Result in Improper Control
Operation
GeniSys wiring label colors may not match the wire
colors of the burner or other manufacturers’ controls.
The GeniSys Control should be wired according to
the appliance manufacturer’s instructions.
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Section: Inspect/Prepare Installation SIte

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Weil-McLain Ultra Oil NX Burner Manual
Figure 7a. – GeniSys 7505 Control interrupted
ignition, valve-on delay only (no motor-off delay)
Figure 7b. – GeniSys 7505 Control Interrupted
ignition, valve-on delay and motor-off delay
SAFETYAND
OPERATING
LIMITS
LIMIT
L1
L2 (VLV)
VALVE
L2
MOTOR
L2 (MTR)
L2 (IGN)
IGNITER
CAD
CELL
MOTOR
IGNITER
W
R
80
70
60
50
50
70
80
60
OIL VALVE
CAD CELL
THERMOSTAT
TR
TW
TR-TW
JUMPER
TR-TW TERMINALS
LOCATED ON OPPOSITE
SIDE OF CONTROL
L1
L2
SAFETYAND
OPERATING
LIMITS
LIMIT
L1
L2 (VLV)
VALVE
L2
MOTOR
L2 (MTR)
L2 (IGN)
IGNITER
CAD
CELL
MOTOR
IGNITER
W
R
80
70
60
50
50
70
80
60
OIL VALVE
CAD CELL
THERMOSTAT
TR
TW
TR-TW
JUMPER
TR-TW TERMINALS
LOCATED ON OPPOSITE
SIDE OF CONTROL
L1
L2
LIMIT
Refer to the appliance manufacturer’s wiring diagram
prior to connecting the burner wiring. All wiring must be
in accordance with the latest revision of National Electric
Code NFPA 70 and all local codes and regulations.
The 7505 primary control with
valve-on delay (pre-time) and
burner motor-off delay (post-time) requires a constant
120 volts AC power source supplied to the BLACK wire
on the control. The RED wire goes to the appliance limit
circuit. Please note that other control manufacturers may
use different wire colors for power and limit connections.
Make connections to the control’s terminals as
shown in Figures 7a and 7b. Refer to the label on
the underside of the control for wiring details.
Motor-off delay on a 7505P will be
disabled if the safety and operating
limits as shown in Figures 7a and 7b interrupt power to
the control terminal L1.
Connect thermostat leads to the TR and TW
terminals on the control or jumper the TR and TW
terminals on the control, as directed by the appliance
wiring diagram.
- Thermostat anticipator Current: 0.1 amp
- Thermostat voltage: 24 volts AC
If the thermostat short cycles or
operates improperly, it may require
an isolation relay for proper operation. The Beckett
A/C Ready Kit (part no. 51950U) provides this function.
Wiring instructions are included with the A/C Ready Kit.
○
○
L1 - LIMIT
Follow the appliance manufacturer’s wiring diagrams
and note all required safety controls.
Typical safety controls include high temperature or
pressure limits, low water cutoffs, pressure relief
valves and blocked flue sensing switches.
Verify all limit and safety controls are installed
and functioning correctly, as specified by the
manufacturer, applicable safety standards, codes
and all authorities having jurisdiction.
Ensure that the appliance is free of oil and oil vapor
before starting or resetting the burner.
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All heating appliances must have HIGH
LIMIT protection to interrupt electrical
power and shutdown the burner if
operating or safety controls fail and
cause a runaway condition.
Explosion, Fire, Scald, and
Burn Hazard
Section: Inspect/Prepare Installation SIte

12
Sequence of Operation - GeniSys 7505
Refer to the appliance manufacturer’s wiring diagram for
actual specifications.
Standby: The burner is idle, waiting for a call for
heat.
Valve-On Delay: The igniter and motor are on while
the control delays turning on the oil solenoid valve
for the programmed time.
Trial For Ignition: The oil solenoid valve is
energized. A flame should be established within the
factory set trial for ignition time (lockout time).
Lockout: The control has shut down for one of the
following safety reasons:
The trial for ignition (lockout) time expired
without flame being established.
The cad cell detected flame at the end of the
Valve On Delay state.
To reset the control from lockout click the button
1-second.
NOTE: A recurrence of the above failure
modes or a failed welded relay check
could cause the control to enter a Hard
Lockout state that must be reset only
by a qualified service technician.
To reset from Hard Lockout, hold the
reset button for 15 seconds until the
yellow light turns on.
Ignition Carryover: Once flame is
established, the igniter remains on for 10
additional seconds to ensure flame stability.
Run: The flame is sustained until the call for
heat is satisfied. The burner is then sent to
Motor-Off Delay, if applicable, or it is shut
down and sent to Standby.
Recycle: If the flame is lost while the
burner is firing, the control shuts down the
burner, enters a 60 second recycle delay,
1.
2.
3.
4.
a.
b.
5.
6.
7.
and repeats the ignition sequence. The control will
continue to Recycle each time the flame is lost, until
it reaches a pre-set time allotment. The control will
then go into Hard Lockout instead of recycle. This
feature prevents excessive accumulation of oil in
the appliance firing chamber.
Motor-Off Delay: If applicable, the oil solenoid
valve is turned off and the control delays turning the
motor off for the set motor-off delay time before the
control returns to standby.
Pump Prime: The igniter and motor are on with the
oil solenoid valve energized for 4 minutes. During
Pump Prime mode, the cad cell is disregarded,
allowing the technician to prime the pump without
having to jumper the cad cell.
Cad Cell Resistance Indicator: If the Beckett
7505 control is equipped with the GeniSys Display
Module, part 52067U, the cad cell resistance can
be selected and read on the LCD screen. Also, the
GeniSys Contractor Tool, part 52082U, can be used
for this purpose.
If these are not available, the cad cell leads can
be unplugged from the control and the resistance
measured with a meter in the conventional way.
Conduct these tests with flame present.
Flame Detection Range
Normal = 0 to 1600 ohms
Limited = 1600 ohms to lockout
8.
9.
10.
2
1
3
5
6
8
4
7
Standby
Motor-off delay
Valve-on delay Trial for
ignition
Ignition carryover
Run
Lockout
Recycle
9Pump
prime
Burner Control
The control can malfunction if it gets wet, leading to
accumulation of oil or explosive oil vapors.
Never install where water can flood, drip or
condense on the control.
Never use a control that has been wet - replace it.
y
y
y
Can cause severe injury, death, or property damage.
Fire or Explosion Hazard
Section: Burner Control

13
Weil-McLain Ultra Oil NX Burner Manual
Table 5 - Status Lights
Light Color On Continuously Flashing
Red Restricted (Hard) Lockout Soft Lockout
Green Flame Sensed during normal operation
(Could be stray light during standby) Recycle
Yellow Control is in Pump Prime mode or
Reset button currently held for 15+ seconds. N/A
Table 4 - Reset Button Operation
If the burner is in the
below state:
Pushing the reset button will:
Button Click
(press < 1 second) Button Hold (press > 1 second) Button Hold (press 15+ seconds)
Lockout Reset from Soft Lockout Reset from Restricted (Hard)
Lockout
Valve-on Delay, Trial for
Ignition, Ignition Carryover
Go to Pump Prime (see “Priming
the Pump” above)
Disable the Burner:
Any time the burner is running,
press and hold the reset but-
ton to disable the burner. The
burner will remain off as long as
the button is held.
Enables Pump Priming:
After the reset button has been
held for 15 seconds, the button
can then be clicked during the
next ignition sequence to enter
Pump Prime mode.
Run (igniter is shut off) No action
Motor-Off Delay, Standby No action
Pump Prime No action Exit Pump Prime mode and return to Standby
Reset Button Operation
The table below explains what action the control will take when the reset button is pressed for different lengths of time during the
various burner operating states.
Figure 8. GeniSys Model 7505 Control
Section: Burner Control
Display Module:
Permanent device for programming
and diagnostics
Alarm Module:
For adding isolated low voltage alarm
contacts to the base control. See Alarm
Module Instructions for specifications.
Contractor’s Tool:
Hand-held device for
programming and diagnostics
Cad Cell
Connections
Wiring
Connections
Communication Port 2
Reset Button with Red Light
Communication Port 1
Thermostat Terminals
Green Light
Yellow Light
Optional Components:

14
firing, the control shuts down the burner, enters
a 60 second recycle delay, and then repeats the
above ignition sequence. If flame is lost three times
in a row, the control locks out to prevent cycling
with repetitious flame loss due to poor combustion.
BURNER MOTOR-OFF DELAY. The fuel valve
is closed and the burner motor is kept on for the
selected motor-off delay time before the control
returns the burner to standby.
8.
Figure 9. Typical Burner Wiring & Burner Sequence of Operation for R7184P Control.
Refer to the appliance manufacturer’s wiring diagram for actual specifications.
STANDBY. The burner is idle, waiting for a call for
heat. When a call for heat is initiated, there is a 3-10
second delay while the control performs a safe start
check.
VALVE-ON DELAY. The ignition and motor are turned
on for a 15 second valve-on delay.
TRIAL FOR IGNITION (TFI). The fuel valve is
opened. A flame should be established within the 15
second lockout time.
LOCKOUT. If flame is not sensed by the end of the
TFI, the control shuts down on safety lockout and
must be manually reset. If the control locks out three
times in a row, the control enters restricted lockout.
IGNITION CARRYOVER. Once flame is established,
the ignition remains on for 10 seconds to ensure flame
stability before turning off. If the control is wired for
intermittent duty ignition, the ignition unit stays on the
entire time the motor is running.
RUN. The burner runs until the call for heat is satified.
The burner is then sent to burner motor off delay, if
applicable, or it is shut down and sent to standby.
RECYCLE. If the flame is lost while the burner is
1.
2.
3.
4.
5.
6.
7.
Feature Interrupted
ignition Limited reset, Limited recycle Diagnostic LED, cad cell indicator Valve-on delay Burner motor off delay Alarm Contacts
R7184A YES YES YES — — —
R7184B YES YES YES YES — —
R7184P YES YES YES YES YES Optional
Control System Features
SK9359
61351
Section: Burner Control

15
Weil-McLain Ultra Oil NX Burner Manual
Start the Burner and Set
Combustion
Start-up and Initial Settings
Open the shutoff valves in the oil supply line to the
burner.
Referencing Figure 9, verify and/or set the Head/Air
Adjustment Pointer to the value specified by the
Appliance Manufacturer. Refer to Table 1. (This
is an initial air setting for the pump bleeding
procedure only.) Calibrated test instruments must
be used for the final head/air adjustment.
Adjust the thermostat or temperature controller
to call for heat. (Note: return controller(s) to
the original settings upon completion of burner
installation or service.)
Close the line voltage switch to start the burner. If
the burner does not start within the 3 to 10 second
safety start check timing, you may have to reset the
safety switch on the burner primary control.
Bleed the air from the fuel pump as soon as the
burner motor begins rotating.
Prepare for combustion tests by drilling a 1/4 ”
sampling hole in the flue pipe between the
appliance and the barometric draft regulator. Seal
this hole when testing is complete. (See appliance
manufacturer’s instructions for location.)
Check/Adjust the Zero Calibration for the Head/Air
Adjustment Mechanism. Refer to Figure 9.
Slightly loosen the zero setting locking nut.
Turn the adjustment screw until the reading is
set to zero. (Mid-point of pointer should line up
with zero.
Turn the adjustment screw counterclockwise
to adjust the plate with the pointer to the zero
position.
1.
2.
3.
4.
5.
6.
7.
a.
b.
c.
Slide the nozzle line assembly forward until the
retention head engages the fixed stops in the
retention ring at the end of the air tube. Refer to
Figure 10.
Tighten the zero setting locking nut.
The rear door must be closed. The adjustment
screw may now be turned clockwise to adjust
the head/air setting.
Turn the adjusting screw to a setting 1/2 number
lower than the proper setpoint as indicated
in Table 1. Then turn the adjusting screw
counterclockwise to the proper setting.
Tighten the locking nut after the head/air setting
has been adjusted.
Set Combustion with Test Instruments
d.
e.
f.
g.
h.
Pointer
Zero Setting
Locking Nut
Adjustment
Screw Am52000
Figure 9. Head/air Adjustment Plate Assembly
Do not attempt to start the burner when excess oil
has accumulated in the appliance, the appliance is
full of vapor, or when the combustion chamber is
very hot.
Do not attempt to re-establish flame with the burner
running if the flame becomes extinguished during
start-up, venting, or adjustment.
Vapor-Filled Appliance: Allow the unit to cool off
and all vapors to dissipate before attempting another
start.
Oil-Flooded Appliance: Shut off the electrical
power and the oil supply to the burner and then clear
all accumulated oil before continuing.
If the condition still appears unsafe, contact the Fire
Department. Carefully follow their directions.
Keep a fire extinguisher nearby and ready for use.
y
y
y
y
y
y
Failure to follow these instructions could
lead to equipment malfunction and result
in heavy smoke emission, soot-up, hot
gas puff-back, fire and asphyxiation
hazards.
Explosion and Fire Hazard
Oil-Burning Equipment
shall be connected to flues
having sufficient draft at all times to assure
safe and proper operation of the burner.
Section: Start the Burner and Set Combustion

16
Allow the burner to run for approximately 5 to 10
minutes.
1. Step 2: At the trace of smoke level, measure the
CO2(or O2) . This is the vital reference
point for further adjustments. Example:
13.5% CO2(2.6% O2)
Step 3: Increase the air to reduce the CO2by 1.5 to
2 percentage points. (O2will be increased
by approximately 2.0 to 2.7 percentage
points.) Example: Reduce CO2from
13.5% to 11.5% (2.6% to 5.3% O2).
Step 4: Recheck smoke level. It should be Zero.
This procedure provides a margin of
reserve air to accommodate variable
conditions.
If the draft level has changed, recheck the
smoke and CO2levels and readjust
burner, if necessary.
Step 5: Once the combustion has been set, tighten
the lower acorn nut and splined nut on the
air adjustment assembly. See Figure 9.
Chimney Vent Systems: Install the burner cover
and repeat Steps 2 and 4 above. If CO2increases
(O2decreases), remove the cover and adjust the
air setting so the CO2(O2) with the cover installed
meets the requirements of Step 3.
Direct Vent Systems with outside air ducted to
burner: Install the burner cover.
Start and stop the burner several times to ensure
satisfactory operation. Test the primary control
and all other appliance safety controls to verify
that they function according to the manufacturer’s
specifications.
4.
5.
6.
Figure 10. – Nozzle Line/Head/Air Tube Assembly (Low firing rate shown.)
Retention Head
Retention Head
Head Support Legs
Head Support Legs
Electrode Tips
Electrode Tips
Electrode Clamp
Electrode Clamp
Electrode Bracket
Electrode Bracket
Electrode Insulator
Electrode Insulator
Electrode Extension Rods
Electrode Extension Rods
Nozzle Adapter
Nozzle Adapter
Nozzle
Nozzle
Stops in Retention Ring
Stops in Retention Ring
Retention Ring
Retention Ring
Throttle Ring
Throttle Ring
Throttle Cup
Throttle Cup
Nozzle Line
Nozzle Line
Bulkhead Fitting
Bulkhead Fitting
SK9666A
SK9666A
Throttle Cup Hub
Throttle Cup Hub
Set the stack or over-fire draft to the level specified
by the appliance manufacturer.
Natural Draft Applications; typically over-fire
draft is -0.01” or -0.02” w.c.
Direct Venting; typically may not require draft
adjustment.
High Efficiency/Positive Pressure Appliances;
also vary from traditional appliances (see
manufacturer’s recommendations).
Follow these five steps to properly adjust the
burner:
Step 1: Adjust the head/air until a trace of smoke
is achieved. This can be accomplished
by turning the screw on the head/air
adjustment plate assembly to increase air
(CCW) or decrease air (CW).
2.
○
○
○
3.
The NX burner has a reduced
diameter air tube, precision-
designed air throttle cup and combustion head
for improved performance. This design provides
very accurate control of the air/fuel ratio, but the
light reaching the cad cell through small holes in
these components is limited. Because of this, the
average cad cell resistance may be higher than
conventional burners with larger openings.
Section: Start the Burner and Set Combustion

17
Weil-McLain Ultra Oil NX Burner Manual
Cover Installation
Install the four cover mounting thumb screws in the
cover mounting plate.
Install the cover over the mounting plate while
aligning the side slots with the installed cover
mounting screws.
1.
2.
The following guidelines are provided for routine
maintenance.
Replace the oil supply line filter. The line filter
cartridge must be replaced to avoid contamination of
the fuel pump and nozzle.
Inspect the oil supply system. All fittings should be
tight and leak-free. The supply lines should be free
of water, sludge and other restrictions.
Remove and clean the pump strainer if applicable.
Replace the used nozzle with a new nozzle
that conforms to the appliance manufacturer’s
specifications.
Clean and inspect the electrodes for damage,
replacing any that are cracked or chipped.
Check electrode tip settings. Replace electrodes if
tips are rounded.
Inspect the igniter spring contacts.
Clean the cad cell lens surface, if necessary.
Make sure Low Firing Rate Baffle is in place if
required for the burner application. Omitting the
baffle can result in unacceptable burner combustion.
Inspect all gaskets. Replace any that are damaged
or would fail to seal adequately.
Clean the blower wheel, air inlet, air guide, retention
head, throttle cup and throttle ring of any lint or
foreign material.
Use a clean soft cloth with a degreaser to clean
any accumulated soot or oil stains from the
throttle cup sight windows.
○
○
○
○
○
○
○
○
○
○
○
○
Check motor current. The amp draw should not
exceed the nameplate rating.
Check all wiring for secure connections or insulation
breaks.
○
○
Trained Service Technician’s
Regular Maintenance
Figure 11. – Burner Cover
SK9804A
DO NOT TAMPER WITH THE UNIT OR CONTROLS
- CALL YOUR QUALIFIED SERVICE TECHNICIAN
OR SERVICEMAN.
To ensure continued reliable operation, a qualified
service technician must service this burner annually.
More frequent service intervals may be required in
dusty or adverse environments.
Operation and adjustment of the burner requires
technical training and skillful use of combustion test
instruments and other test equipment.
y
y
y
y
Tampering with or making incorrect
adjustments could lead to equipment
malfunction and result in asphyxiation,
explosion or fire.
Annual Professional
Service Required
Use a clean soft cloth and degreaser, on an annual
basis, to remove any build-up or dark stains from the
windows.
If damaged, replace the nozzle line assembly with
an assembly that has a windowed throttle cup.
y
y
If a window is punctured, significantly
scratched or removed from the throttle cup,
the burner performance could be impaired,
resulting in safety lockout, appliance soot-
up, equipment damage, hot gas puff-back
and asphyxiation hazard.
Do Not Puncture, Scratch,
or Remove Flame Sighting
Windows
Section: Trained Service Technician’s Regular Maintenance

18
Check the pump pressure and cutoff function.
Check primary control safety lockout timing.
Check ignition system for proper operation.
Inspect and clear the vent system and chimney of
any soot accumulation or other restriction.
Clean all flue passages and flue pipe. Replace
corroded or damaged pipes.
Clean the appliance thoroughly according to the
manufacturer’s recommendations.
Check the burner performance. Refer to the section
“Set combustion with test instruments”.
It is good practice to keep a record of the service
performed and the combustion test results.
Removing Nozzle Line for Service
(Reference the Replacement Parts Diagram.)
○
○
○
○
○
○
○
○
Before proceeding, turn off the main power switch
to the burner.
Remove the burner cover by loosening the four
thumb screws (two on each side of burner).
Disconnect the copper connector tube assembly
from the nozzle line bulkhead fitting.
Loosen the two screws securing the igniter
retaining clips and rotate both clips to release the
igniter baseplate. The igniter should pop up and be
supported by the prop spring.
1.
2.
3.
4.
Use only nozzles having the brand, flow rate (gph),
spray angle and pattern specified by the appliance
manufacturer or Beckett Residential Burner OEM Spec
Guide, Part #6711.
Follow the appliance manufacturer’s specifications for
the required pump outlet pressure for the nozzle, since
this affects the flow rate.
Nozzle manufacturers calibrate nozzle flow rates at
100 psig.
This burner utilizes pressures higher than 100 psig,
so the actual nozzle flow rate will be greater than the
gph stamped on the nozzle body. (Example: A 1.00
gph nozzle @ 140 psig = 1.18 gph)
For typical nozzle flow rates at various pressures see
accompanying chart.
y
y
Incorrect nozzles and flow rates could
result in impaired combustion, under-
firing, over-firing, sooting, puff-back of
hot gases, smoke and potential fire or
asphyxiation hazards.
Correct Nozzle and Flow
Rate Required
Loosen the two screws securing the rear door.
Swing the door to the right and down.
Loosen the splined nut.
Remove the nozzle line electrode and head
assembly from the burner by drawing it straight
back and out the rear door opening. The
adjustment mechanism is still attached. Be careful
not to damage the electrodes or insulators while
handling.
To replace the nozzle assembly, reverse the above
procedure.
Nozzle Installation
5.
6.
7.
8.
Disconnect electrical power before installing or servicing
the burner.
Provide ground wiring to the burner, metal control
enclosures and accessories. (This may also be required
to aid proper control system operation.)
Perform all wiring in compliance with the National
Electrical Code ANSI/NFPA 70 (Canada CSA C22.1)
Electrical shock can cause severe personal
injury or death.
Electrical Shock Hazard
Use care when handling, removing and installing oil
nozzles.
Carefully follow the guidelines provided in this
section.
y
y
Adamaged nozzle could cause impaired combustion,
sooting, puffback of hot gases, smoke, oil leakage
and potential fire or asphyxiation hazards.
Protect Nozzle from
Damage
Section: Trained Service Technician’s Regular Maintenance

19
Weil-McLain Ultra Oil NX Burner Manual
Perform the following steps when replacing a nozzle.
Remove the nozzle line assembly to gain access to
the nozzle.
Use a 3/4” open-end wrench to hold the nozzle
adapter. DO NOT attempt to remove or replace
the nozzle without securing the adapter, as nozzle
alignment could be seriously affected.
Do not squeeze the electrodes when handling the
nozzle line assembly. Excessive force could change
the electrode tip settings or damage the ceramic
electrode insulators.
Use a 5/8” open-end wrench to carefully remove the
existing nozzle.
Inspect the nozzle adapter before installing the
new nozzle. If it is grooved or scratched on the
sealing surface, replace the nozzle line assembly.
If the surface is damaged, oil could leak at the
nozzle to adapter joint, causing serious combustion
problems.
Protect the nozzle orifice and strainer when
installing. If the orifice gets dirt in it or is scratched,
the nozzle will not function properly.
1.
2.
3.
4.
5.
6.
5/32” GAP
1/4” above
nozzle center
3/32” Nozzle-to-tip
Spacing
SK9664
Nozzle flow rate U. S. gallons per hour of No. 2 fuel oil when
pump pressure (psig) is:
Nozzle
size
(rated at
100 psig)
125
psi
140 psi
(factory
std.)
150
psi
175 psi 200
psi
0.40 0.45 0.47 0.49 0.53 0.56
0.50 0.56 0.59 0.61 0.66 0.71
0.60 0.67 0.71 0.74 0.79 0.85
0.65 0.73 0.77 0.80 0.86 0.92
0.75 0.84 0.89 0.92 0.99 1.06
0.85 0.95 1.01 1.04 1.13 1.20
0.90 1.01 1.07 1.10 1.19 1.27
1.00 1.12 1.18 1.23 1.32 1.41
1.10 1.23 1.30 1.35 1.46 1.56
1.20 1.34 1.42 1.47 1.59 1.70
1.25 1.39 1.48 1.53 1.65 1.77
1.35 1.51 1.60 1.65 1.79 -
1.50 1.68 1.77 1.84 - -
1.65 1.84 - - - -
1.75 - - - - -
Table 6 - Nozzle Flow Rate by Size
Figure 12. – Electrode tip gap and spacing
To install a new nozzle, place a 3/4” open-end
wrench on the nozzle adapter. Insert the nozzle
into the adapter and secure finger tight. Finish
tightening with a 5/8” open-end wrench. Use care
to avoid bending the burner head support legs or
electrodes.
Do not over-torque the nozzle when installing. This
will cause deep grooves in the nozzle adapter,
preventing a seal when a new nozzle is installed.
Carefully check and realign the electrode tips after
replacing a nozzle, ensuring the electrode settings
comply with Figure 12.
If the head was removed when replacing the
nozzle, carefully reconnect the head to the nozzle
adapter. Make sure to align the key in the support
leg with the keyway in the nozzle adapter and
to butt the head support to the nozzle adapter
shoulder, see Figure 10.
Check/Adjust Electrodes
Check the electrode tip settings, as shown in Figure 12.
If necessary, adjust by loosening the electrode clamp
screw (Figure 10) and slide/rotate the electrodes as
necessary. When the adjustment is complete, securely
tighten the clamp screw.
Note that if the throttle cup is moved be sure to
reposition it with no gap between the nozzle adapter and
hub.
7.
8.
9.
10.
Section: Trained Service Technician’s Regular Maintenance

20
Check Retention Head Alignment and Cad
Cell Sighting
(Refer to Figure 13.)
The cad cell sighting holes in the throttle cup and the
retention head must be aligned to allow the cad cell
to detect the flame. Make sure the stamped key in the
retention head collar lines up with the keyway in the
nozzle adapter when mounting the retention head. Note
that in specific applications, the retention head may not
have a sighting hole.
Check/Adjust “Zero” Calibration
On burners with factory-installed air tubes, the zero
calibration has been factory set. Make sure the retention
head (Figure 10) is securely against the stops in the
retention ring when the adjustment plate pointer is at “0”
(Figure 9).
If the zero calibration has not been set, perform the
following procedure:
Install the nozzle line, with the adjustment plate
assembly attached, into the burner.
Install and tighten the rear door to hold the air
adjustment plate assembly in position.
Slightly loosen the upper acorn nut, the splined nut,
and the lower acorn nut.
1.
2.
3.
Turn the air adjustment screw clockwise to adjust
the plate with the pointer to the zero position.
Referring to Figure 10, slide the nozzle line
assembly forward until the retention head engages
the fixed stops in the retention ring at the end of the
air tube.
Tighten the upper acorn nut securely.
The rear door must be kept tightly closed. The
adjustment screw may now be turned to adjust the
head/air setting.
Turn the adjusting screw to a setting ½ number
lower than the proper set point as indicated in Table
1. Then turn the adjusting screw counterclockwise
to the proper setting.
Tighten the splined nut and lower acorn nut after
the head/air setting has been adjusted.
Blower Wheel Replacement
For installation or replacement of a blower wheel, insure
that there is a space between the blower wheel and the
motor face of 0.115”. Refer to Figure 14.
Shutting the Burner Off
Turn off all electric power to the burner.
Note: There could be more than one disconnect switch.
4.
5.
6.
7.
8.
9.
If the burner is shut down
for an extended period of
time, always keep the valve shut off.
Section: Trained Service Technician’s Regular Maintenance