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Raypak B6000 User's Manual

1. T 3 Fig 9458 Page 40 KN o Fig 4 9459 Page 41 SYSTEM CONTROL BOARD m BUZZER 28VDC RTS VG Fig 9460 Page 42 Replacement Parts List CALL OUT B6000 SYSTEM System Control Box Control P Board w Displa v Control PC Board wiDisplay Night setback NSB Control PE Board wDisplay MSB Modem Wo WIN Display Selector Panel Alarm Buzzer Piezo electric horn Alarm Reset switch Transformer 1211 74 17 VAC CT Transformer 1206 5 WAC C T Relay 5 YDE DPDIT Relay 20 VDC DPDT Fuse SN ZA Fuse 250v 14 601193 M8 6F1D Modem Temp Low Temp Sensor Fault Sensor Fault System Control W NSB amp Modem Max Temp Sensor Fault CP8 3 NMn System Control W NSB Modem amp Low Temp Max Temp Sensor Fault CP8 3 Special Features ERR CP10 0N 90E CP10 0NMn 9000 lt o ZY O OS O U5 Chip RAM with Lithium Battery 601192 601245 CP8 0 N 9343 System Control W NSB amp Low Tem Page 43 Replacement Parts List Page 44 B 1 Fig 9461 Located in place of ignition control on C2 boilers only BOILER MONITOR CONTROL BOX Page 45 Replacement Parts List CALL OUT B 6000 SYSTEM PART NO B 1 B 2 B 3 B 4 B 5 B 6 F1 amp F2 F3 K 1 K 2 K 3 K 4 K 7 K 8 K 6 K 5 K 1 K 2 K 3 K 4 K 5 K 6 K 7 K 8 U4 Boiler Monitor Control Box Control PC Board Power M
2. Q r A o L L L haat A Q d l o TO FROM TO Tile aTCM Te RwOSTAT RP RELAY 9 vscb QvAC COL Fusco o S Om D O 9 9 G BORER wOMTOR TERNAL W 3 dod c A bed L o i bt TOR K o oe XO 4 o E l l BOLIR MOPMRTOR H TERWMAL 78 3 Rat BOA PREP RELA TO FROM TO Flow Sw TOM TAT Y t USED 24vVAC CON fF vesc POWER SUPPLY L a i BELDEN 9042 SYSTEM CONTROL DAE PROTEC RON TN ey aa P x PS we ove 5 l ZS aaa dE j Nc W LAS mur vx wi LXX STSTEw CONTROL TERRA T5 2 d i j S T Page 19 INSTALLATION VERIFICATION PROCEDURE REGISTER Before proceeding any further please verify that the user registration form has been completed and mailed reference Registration Card MECHANICAL INSTALLATION Verify installation has been completed reference Mechanical Installation AIR TEMPERATURE SENSOR Verify installation parameters have been met reference Air Temperature Sensor WATER TEMPERATURE SENSOR Verify installation parameters have been met reference Water Temperature Sensor Verify System Control Boiler Monitor power wiring connections Verify Torque Requirements Verify Air Temperature Sensor wiring must be Belden 8132 9842 or equivalent Verify Water Temperature Sensor wiring must be Belden 8132 9842 or equivalent Verify Power Test has been co
3. B6000 SIMPLIFIED DIAGRAM OF TYPICAL PIPING PIPING LAYOUT MAY VARY PER SPECIFIC APPLICATION AIR TEMPERATURE SENSOR MUST BE INSTALLED ACROSS AIR TEMPERATURE SENSOR CONTACTS THE SENSOR IS NOT ACTIVATED AND CAN BE LEFT STORED IN B6000 ENCLOSURE Page 11 IMPORTANT Configuration Note lf your System Control Module is supplied with a single Field Wiring Teminal Strip use Alternate wiring See page 36 38 WIRING AIR AND WATER SENSORS TO THE SYSTEM CONTROL MODULE WATER SENSOR OUTDOOR SENSOR BELDEN 8132 OR BELDEN 9842 Page 12 WHT ORN TERMINAL TB WHT BLU NOTE Tighten terminal strip clamping screws 20 IS In 2 26N m Breakage from over torquing is not covered under warranty Use copper conductors only For supply connections use wires sized on the basis of 60 C Ampacity and rated Min 90 C 194 F BARE WIRE ast FM 7 wa f OMILLy COMMUNICATION RS 485 WIRING System Control Boiler Monitor e Use Belden 9842 Cable Or Equivalent See Note Polarity must be observed Make use of wire color coding to ensure proper polarity The shielding foil wrapper bare wire drain MUST be grounded Grounding is done at the System Control Module only DO NOT ground at Boiler Monitor mnm e Note Equivalent shielded cable must be suitable for RS 485 communication applications must have 100 140 ohm impedance and less than 30 picofarad per foot capacit
4. actual System Water temperature actual Target Temperature which is the desired system temperature Press MENU button Boiler Valve Firing Rates Indicates Boiler being monitored Provides valve firing position On multiple boiler installations press or to view position of other boiler firing rates INFORMATION ONLY Provides firing valve position for each boiler Multiple boilers press SELECT button to determine status of each boiler Press MENU button Page 23 Boiler Status Operating status of boiler Boiler Ok or Fault Indicator Pushing or buttons will show status of other boiler s in system READOUT Headout OK boiler operation normal FAULT indications MAX TEMP Target exceeds Max Temp Not a fault THERMOSTAT Operating aquastat Not a fault LWCO low water cutoff when supplied LO PRES WTR Low pressure water when supplied LO PRES GAS Low pressure gas when supplied HIGH PRES GAS High pressure gas HIGH LIMIT FLOW SWITCH Flow switch NO PILOT MANUAL OVERRIDE Boiler in emergency or manual operation e When a fault is indicated the red light to the right of the display flashes and the alarm buzzer sounds The light continues to flash after alarm is silenced and until the fault is corrected e When fault is corrected display will read OK
5. BOILER MONITOR CARD PICTORIAL BOILER MONITOR SELECT SWITCH SWITCH POSITION BOILER NUMBER ilz fs 4fs5 fe N OO OO O O O O X O O O GO O O 0 X c O O OO O 0 KK O xOOOOO Ox xX O OGO O 0 X X xX OD O O O Oj SWITCH X Closed BOILER MONITOR COMMUNICATIONS JUMPER W1 Located in the upper left hand corner of the LAST Boiler Monitor board NOTE The jumper indicates to the System Controller logic that the Last wired boiler has been communicated with over the RS485 BUSS Link Definition The LAST wired boiler is physically wired with the greatest wire length from the System Control or is the last wired boiler for a single or multiple boiler installation e On a single boiler make sure the W1 Jumper has been installed A 6 6 6 6 d aa O RAYPAK 8 eu way pve U4 B6000 BOILER MONITOR PART NO 01200 Wy Oo SUPPLY v rg 120 LES L W1 F2 EE Sa IE pn 1 Bt 2A es oE ES E et m gt DBB gp SP T now 4 we uu JUMPER BOILER MONITOR CAR PICTORIAL On boiler systems the jumper W1 MUST BE installed on the Last wired boiler This is located on the Boiler Monitor board in the upper left hand corner adjacent to the RS485 terminals On Multiple boiler systems the W1 jumper must be removed from all Boiler Monitor boards except on the Last wired boiler For normal boiler operation the dip switch settings can be utilized to define any of the boiler
6. e Should communication between the system control module and the boiler monitor module s be disrupted the display will show BOILER NOT ON LINE e Todisplay status of other boilers press the or buttons on multiple boiler installations Page 24 GREEN RED Manual Pump Low System Control Over On Water Display ride Cutoff OK X system operating nomaly LWCO X towwaterinvoier LOW PRES WATER Water Pressuretootow o LO PRESS GAS x usu HIGH PRESS GAS x as pressure on anton hgh THERMOSTAT OFF FLOW SWITCH NO PILOT BOILER NOT ON LINE X Communication lost EA x Light On PUMP light used only when Economaster programmed If a boiler should lose communication with the System Controller BOILER NOT ONLII Page 25 X HIGH LIMIT Boiler temp excess high limit X Primary Control Parameters System water temperature RESET RATIO Rise is the temperature rise in desired at outdoor Ratio of outdoor temperature system when all boilers are at full temperature of 70 to water system temperature rate DT of system Range 1 99 Range 40 200 Range 0 0 1 to 20 and None Default value is 20 F Default value 100 for constant water temperature for constant water temperature TAR T Set Point Default value is 1 0 1 LEAD LAG NIGHT SET BACK System water temperature desired at outdoor temperature of 70 NOTE S Def
7. NEUTRAL POWER TEST CHECK POWER Utilizing a Volt Ohm Meter VOM monitor the following on the System Control Module and Boiler Monitor s for proper voltage levels POWER TEST TABLE Module System Control System Control System Control System Control System Control System Control Module Boiler Monitor Boiler Monitor Boiler Monitor Boiler Monitor Boiler Monitor Boiler Monitor Boiler Monitor TB1 1 TB1 2 TB1 3 TB1 2 Test Points TB1 1 TB1 2 TB1 1 TB1 3 TB1 2 TB1 3 TB1 1 L TB1 2 L TB1 3 1 Test Points TB1 1 TB1 2 3 Nas LES l FROM BOILER j mE L L i SIS LOIUSlSOLElole1e1s oo o0 000006 SLSLOLSLSLSpoplojoye Indication 108 VAC to 132 VAC 108 VAC to 132 VAC LESS THAN 1 VAC 108 VAC to 132 VAC LESS THAN 1 VAC LESS THAN 0 5 VAC Indication 108 VAC to 132 VAC Coto 132 VAC HAN 1 VAC o to 132 VAC HAN 1 VAC HAN 0 5 VAC 2N HAN 0 5 VAC HAN 0 5 VAC HAN 0 5 VAC HAN 0 5 VAC IMPORTANT The Boiler Monitor control board has a series of dip switches which iden tify the boiler s SW2 It is required that the switches be set as shown in the switch position table shown below S CG One EREEREER O B RS 485 lT d Om EH U p RAYPAK e I unn roven E t ui B6000 BOILER MONITOR ui E3 PART NO 601200 Wy LFF Lamp F2 24 120 v 2 7 EEB TRANSFORMER 41 z B i EFF 24 V E VALVE e m L H we H ud L U Z
8. side e Install the sensor in a shaded area out of direct sunlight e Locate no higher than 2 3 way up side of building or between 2nd and 3rd floor if building is more than 3 stories tall e Shielded cable length not to exceed 4000 feet Do notlocate under an overhang near wall corners near drafts from stacks air moving devices windows doors or balconies e Assure cable length does not exceed 4000 ft Use larger gauge Belden 9842 cable if run is in excess of 100 ft Install in conduit with no other wiring Observe proper wire colors Sensor is polarity sensitive Page 9 WATER TEMPERATURE SENSOR N e INSTALLATION e The water sensor should be installed in the system supply Multiple Boilers oingle Boiler To System Control K NPT Immersion Well x aeina Supply Line TYPICAL WATER SENSOR IW Water Temperature Sensor Installation Notes Locate sensor in system piping within a minimum of three 3 ird or prior to the first take off connection on the downstream side of the System Supply Loop e Assure cable length does not exceed 4000 ft Use larger gauge Belden 9842 wire If run is in excess of 100 ft Install in conduit with no other wiring Observe proper wire colors Sensor is ploarity sensitive Page 10 WATER TEMPERATURE SENSOR INSTALLATION Domestic Hot Water Supply HOT WATER SUPPLY pat BOILER OUTLET ISS SS A IMMERSION WELL WATER SENSOR 1 2 NPT STORAGE
9. With Nite Set Back option only Possible Cause No Primary power Time display accidentally Re Programmed Nite set back turned off Clock times not set System ground not adequate Line noise Internal battery weak Prolonged power outage Boiler monitor has Manual Mode selected Inadequate grounds Line noise Power outages Power outages Internal battery weak Line noise System ground not adequate Primary power at boiler not connected Inadequate ground Line noise Power outage Power outage Power outage Page 48 Corrective Action Check power connections to units Check surge protection devices Check disconnects check grounds Check power switches Initialize system Program Nite set back feature Initialize system Initialize system and or contact authorized Raypak Representative for further instruc tions Select Automatic mode on Boiler Monitor Check primary power check wired ground Rework as necessary Initialize system Initialize system Initialize system Initialize system Initialize system Initialize system Initialize system Trouble Shooting Guide Continued Symptom Possible Cause Boiler not powered Corrective Action Check primary power Boiler x Not on Line Displayed Outdoor sensor not mounted Correct as necessary Check communication cable check surge ground Remove Replace R R as necessary Initializ
10. undershoot ALL BOILERS ON OFF Range 1 to 99 Default valve 20 F This Display Indicates The temperature above or below target at which the control will turn off or on all the boilers TARGET MIN MAX AND HI LIM Min Default 105 range 0 to 220 F Hi Lim shows the maximum obtainable water Max Default 180 range 0 to 220 F temperature Hi Lim Default 200 range 0 to 220 F Hi Lim can not be lower than the target XXX Max Note All of the values interact and are depedent upon each other Page 34 tandard Initialize LEAD LAG NIGHT SET BACK Initialize Y Yes P s N No Version of software This will initialize all previous selectable values to default values Should not be used unless operator wants to reprogram new values Should be used at Start up to clear the control memory This should be by passed if controls have been initialized as the first step Standard Utility Service LEAD LAG NIGHT SET BACK Utility Service Displays controller operating mode changes continously from 1 to 5 Displays Firing Rate of each Boiler Displays System Target Temperature Displays Actual System Temperature Information Only Displays the system operating conditions and t
11. Catalog No 5000 51J Effective 10 14 05 Replaces 06 15 03 B6000 BOILER MANAGEMENT SYSTEM SYSTEM CONTROL BOILER MONITOR Installation and Operating Manual UL UL ES G Part No 240564 U L is a registered trademark of UnderWriters Laboratories Inc amp C U L is a registered trademark of UnderWriters Laboratories Canada Inc Before operating this product please read these instructions completely Page 2 B6000 BOILER MANAGEMENT SYSTEM BMS Contents Equipment Quantity B6000 System Control 1 B6000 Boiler Monitor Installed on Boiler s As Ordered Outdoor Temperature Sensor Assy 064140 1 Water Temperature Sensor Assy 064139 1 Optional Equipment As Ordered Check packaging for damage or missing components IM PO RTANT NOTICE These instructions are intended for the use by qualified personnel only specifically trained and experienced in the installation of this type of equipment and related system components Installation and service personnel may be required by some states to be licensed If your state is such be sure your contractor bears the appropriate license Only qualified persons shall attempt to repair this equipment Repair must be according to these instructions WARNING Improper installation adjustment alteration service or maintenance may damage the equipment create a hazard resulting in asphyxiation explosion fire electric shock personal injury or property dam
12. DAMAGE FROM WATER LEAKAGE ARE EXCLUDED Some states do not allow limitations on how long an implied warranty lasts or for the exclusion of incidental or consequential damages so the above limitation or exclusion may not apply to you Nn 4 W THIS LIMITED WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE We suggest you immediately complete the information below and retain this Limited Warranty Certificate in case warranty service is needed RAYPAK INC SER VICE DEPARTMENT 2151 Eastman Avenue Oxnard California 93030 Telephone 805 278 5300 FAX 805 278 5468 The following information must be provided when you write or call Original Owner Daytime Telephone Number Complete Mailing Address City State Zip Code Installation Site Model Number Contractor Installer Date of Installation Serial Number Raypak Inc 2151 Eastman Ave Oxnard CA 93030 805 278 5300 FAX 805 278 5468 Litho in U S A Certified Quality System www raypak com Design and specifications subject to change without notice U This symbol on the nameplate means the product is listed by Underwriters L Laboratories Inc Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 FAX 800 872 9725 Litho in U S A
13. Q C d A A A A Q G M M MMM moo NO i i00 O Q Q Cc M ODO 0 COo 40 Q FP GQ M M G Thank you for selecting the Raypak B6000 Boiler Management System BMS It is our sincere hope that you will enjoy its power ease of use and energy saving features GETTING STARTED To learn about the B6000 BMS simply install it and start using it The following steps will outline the things you will need for installation and to prepare it for use FOREWORD The B6000 Boiler Management System is comprised of a Boiler Monitor for each boiler one System Control for each system an Outdoor Air Temperature Sensor and a Water Temperature Sensor The system is a microprocessor based energy manage ment hot water control system that controls single or multiple boiler installations used for hydronic heating and or domestic hot water supply The B6000 BMS is designed to provide the ultimate in personal comfort efficiency and operation The system requires minimal attention after initial setup The system control to boiler can be separated by up to 2000 feet It is capable of being monitored from a remote location with an optional modem package and a Personal Computer PC equipped with a modem The Raypak Boiler Management System minimizes boiler operator attendance and increases system reliability and cost effectiveness The System Control Module has Ascreen that displays the different operating characteristics of the system e Agreen light to the l
14. X 05 00 am Thursday 2 10 00 pm XX XX Thursday 1 XX XX 05 00 am Friday 2 10 00 pm XX XX Friday 1 OG XX 20GXX Saturday 2 XX XX XX XX Saturday 1 XX XX XNXX Sunday 2 XX XX XX XX Sunday The above example will set back temp weekends and 10 00 pm to 5 00 am weekdays Each day can have up to six 6 separate setbacks When notime is entered indicated by xx xx the setback time in effect from the previous time period will continue on to the next period which means when the night setback is ON the system water temperature for nighttime use will be maintained until the next OFF entry is reached Page 32 Boiler Valve Timing Boiler Valve Timing Information only us UP Boiler Number Displays in seconds real time opening and closing d DOWN of modulating gas valve from closed 096 to full open 10096 This display shows the time secs required for the gas valve to open and close If u display is from 12 to 26 and d is less than u and between 4 and 18 the gas valve requires no adjustment This timing is not operator changeable on the screen display Proportional Integral Derivative Operator Manual Action PIDOMA A Proportional Integral Derivative Operator Manual Action Pconst is the proportional ratio Wait is the time controller waits Dconst is the derivative ratio which causes the boiler to step u
15. age and will void the warranty CAUTION wore THAN ONE 1 SUPPLY SOURCE THIS CONTROL HAS THE POTENTIAL TO BE CONNECTED TO MORE THAN ONE 1 ELECTRICAL SUPPLY SOURCE TO REDUCE THE RISK OF ELECTRIC SHOCK DISCONNECT ALL CONNECTIONS BEFORE SERVICING CAUTION RISK OF ELECTRIC SHOCK MORE THAN ONE 1 DISCONNECT SWITCH MAY BE REQUIRED TO DE ENERGIZE THE EQUIPMENT BEFORE SERVICING PLEASE REGISTER Before proceeding any further please take a moment to complete the enclosed user registration form and mail to Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 Page 3 TABLE OF CONTENTS Contents Getting Started Foreword Installation and Mounting Mechanical Installation Electrical Installation Check Your Power Source Air Temperature Sensor Water Temperature Sensor Important Configuration Note Wiring Air and Water Sensors Communication RS485 Wiring Wiring Power Source to Control and Boiler Modules Power Test Boiler Monitor Select Switch Boiler Monitor Communications Jumper W1 Optional Boiler Monitor Control Field Wiring Single Boiler Field Wiring Multiple Boilers Installation Verification Procedure System Control Display Familiarization Power Up Boiler Monitor Power Up System Control Module Displays Important Start Alternate System Control Box System Control Board Pictorial Replacement Parts List Boiler Monitor Control Box System Settings Troubleshooting Guide Page 4 PAGE O CO CO N N Q
16. ance Install in conduit with no other wiring BELDEN 9842 NOTE Tighten terminal strip clamping screws 20 lbs In 6N m Breakage from over torguing is not covered under warranty Use copper conductors only Fon supply connections use wires sized on the basis of 60 C Ampacity and rated Min 90 C 194 F 9 L J BLU WHT BLU WHT WHT BLU WHT BLU L BARE WIRE DRAIN IX XO BOILER MONITOR dYSTEM CONTROL TERMINAL TB 3 10 TERMINAL TB2 i Vian ia ON RS 485 Communications Cable Schematic Page 13 WIRING Power Source to System Control and Boiler Mod ules NOTE Tighten terming D clamping screws 20 EER D He desl 2 26N m Breakage fromiover BOILER MONITOR r PR ina i J MI Tm OI UU is not covered T r Warranty Dia 9 x Observe proper Polarity Observe proper wire colors Provide external surge suppressor capable of maintaining system integrity _ Provide overload protection and disconnect means as required by code and for H equipment serviceability LU FYTERKUAI a PX AF 1 ke LAU SURGE PROTECTION Conduit can not be used as the ground Must be WIRED ground Very Important Grounding electrode conductor shall be used to connect the equipment grounding conductors the equipment enclosures and where the syste is grounded the grounded service conductor to the grounding electrode Page 14 SYSTEM CONTROL TERMINAL TB 1 GROUND HOT RETURN
17. ange lead boiler PRESS or button until desired boiler is displayed In the event of a fault in the designated lead boiler the next boiler numerically becomes the lead boiler Boiler being monitored is displayed If multiple boilers push or to select the desired boiler Page 29 LEAD LAG NIGHT SET BACK Automatic Lead Lag Lead Change Hours Designated lead boiler will change when remaining hours reaches O Range 0 225 hrs Default value is 100 hrs If set at 0 hours lead will not change Hours remaining will automatically total Enter the desired number of hours of lead boiler operation before change Hours re maining is automatically calculated Designated lead boiler will change as soon as remaining hours run out Set at 0 hours and lead will not change STANDARD BOILER PARAMETERS LEAD LAG NIGHT SET BACK Boiler Parameters Pump delay selectable from 0 to 20 gnition time sets the duration to monitor minutes Range 0 20 Default value 3 mins Ignition prior to lock out Range 15 100 Default value 30 secs PUSH SELECT PUMP DELAY Enter time desired for boiler pump operation if one is installed and wired to boiler moni tor If there is no pump or a continuous running pump ignore PUSH SELECT IGN TIME Display shows time of monitoring the ignition prior to main flame Default t
18. anual or Override Switch Transformer 120 8 5 VAC C T Transformer 120 24 VAC C T Transformer 120 24 VAC C2 Units only Ignition Control with Lockout Fuse AGC 2 250V 2A Fuse AGC3 250V 3A Relay 5 VDC SPDT Relay 24 VAC DPDT Relay 120 VAC SPDT Relay 24 VAC SPDT Relay Socket SPDT Relay Socket DPDT EPROM BVXx x Page 46 004795F 650745 064921 650495 650495 004818B 650896F 650523 650846F 650849F 650848F 650847F 650851F 650850F 601194 B6000 BOILER MANAGEMENT SYSTEM START UP DATA SYSTEM SETTINGS ENTERED ON DATE Temperature Scale F or C Standard oet Deg Ratio 1 Rise Deg System Water Temp Oc Reset Ratio Outdoor System Design Temp Diff Default Value 100 F 88 C Default Value 1 0 1 Default Value 20 F 7 C Select Set Optional Day Deg Nite Deg Ratio 1 Rise Deg System Temps Oc Reset Ratio System Design Temp Rise Default Value Default Value Default Value Default Value 100 F 38 C 90 F 32 C 1 0 1 20 F 7 C Universal otep Ao O C Deg O Cdb Deg C Band Deg Valve Opening Outdorr Cutoff Outdoor Cutoff Control Band Default Value Default Value Deadband Default Value 5 65 degs Default Value 4 Deg 3 Deg Lead of Boilers Indicates Lead Boiler Number of Boilers in system Select Set Optional Lead Change hrs Lead boiler will change after selected no of hours Universal Pump Delay Min Ign Time Sec Delay o
19. ature fire flood freezing or the like to accessories rubber or plastic parts light bulbs or glass parts 7 if the System is moved from its original installation site or if the original owner no longer owns the site or the System LABOR AND SHIPPING COSTS This Limited Warranty does not cover labor costs for service removal or reinstallation of any part nor shipping charges to or from RAYPAK S designated repair center or to or from the installation site All such costs are your responsibility HOW TOMAKEA WARRANTY CLAIM To make a warranty claim promptly ship postage prepaid or carry the defective part to a designated RAYPAK Service Dealer or Service Station in the United States supplying proof of purchase and date of installation and the model and serial numbers If you cannot locate a dealer contact RAYPAK S Service Department at the address telephone listed below Raypak reserves the right at all times to inspect the claimed defect and verify warranty coverage at its factory EXCLUSIVEWARRANTY LIMITATIONOFLIABILITY This is the only warranty given by R AY PAK No oneis authorized to make any other warranties on Raypak s behalf ANY IMPLIED WARRANTIES INCLUDING MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SHALL NOT EXTEND BEYOND THE APPLICABLE WARRANTY PERIOD SPECIFIED ABOVE RAYPAK SSOLELIABILITY WITH RESPECT TO ANY DEFECT SHALL BE AS SET FORTH IN THIS LIMITED WARRANTY ANY CLAIMS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING
20. ault value 100 Day This shadow box indicates the display 7 Default value 90 F Nite for Lead Lag Nite Setaback feature LEAD LAG NIGHT SET BACK Primary Control Parameters Day Value is used as the set point when setback is OFF Nite value when setback is ON Sets up boiler and system SET Sets desired water temperature 70 F minimum design Range 40 220 Day 40 220 Night Default value is 100 Day 90 F Nite To increase PUSH button to required temperature suggested setting is 110 F Page 26 PUSH SELECT RATIO Sets the desired change in system water temperature increases as the outdoor temperature decreases The reset ratio is expressed as follows 2 1 for every 2 degree change in outdoor temperature the sytem temperature will change 1 degree Temperature F e g Set 135 F Ratio Outdoor System 2 1 60 140 40 150 20 160 Typical Temp Temp RADIATION Design Cond 70 F 190 Standing 190 105 031 064 0 amp 4 Convection or Baseboard 200 105 0 3 1 0 5 1 0 7 1 Fan Coil Heating Fan Coil Heat amp Cool Radiant Floor Radiant Ceiling SUGGESTED GUIDELINES The selection of the correct ratio is dependent on the initial temperature and the desired system water temperature setpoint and the design temperature conditions The reset ratio and setpoint must be selected so that the controller wi
21. e system Refer to installation manual Outdoor Temp Sensor readings are high correctly mounting instructions Possible relocation for sensor Sensor reading 220 F Sensor wiring shorted Check sensor wiring for damage H R as necessary Initialize system Sensor reading 35 F Sensor wiring open R R as necessary Initialize system Low water cut off alarm Excessive circuit loading of pump contacts by user supplied system pump Low water level in boiler Check power Check pump contactor relay R R as necessary Replace F1 fusing Check main water supply Power lamp off on Boiler Monitor Fuse F1 blown Excessive circuit loading of pump contacts by user supplied system pump Circuit breaker tripped Replace F1 fusing Remove Relay K1 to isolate circuit loading H R as necessary Reset circuit breaker Excessive circuit loading of pump Pump not running contacts by user supplied system pump Pump going off on thermal over Replace F1 fusing Check pump Reset circuit breaker load circuit breaker tripped Off at flow switch Paddle damaged or missing Pump off on thermal overload Low limit settings Check paddle on flow switch Check pump contact or relay Replace F1 fusing Check and correct settings Off on High Limit Intermittent power or pump failure Meter amperage on pump R R as needed Page 49 LIMITED WARRANTY B6000 Y S
22. eft of the screen that indicates normal system operating conditions Ared light to the right of the screen that flashes when a fault occurs e Analarm buzzer with a silencing switch If the buzzer is silenced the red light will continue to flash until the diagnosed fault is corrected e Buttons which are used to monitor and program the selectable system features e On board relays designed to control primary system pumps combustion vent louvers and or other boiler accessories E3eOOQOD SYSTEM CONTROL ST Dukla Hakak CTA SYSTEM CLE bl TA CAN T NORMAL FAULT 2coog D Page 5 Each Boiler Monitor Module contains The boiler on off power switch The boiler manual override switch which allows the boiler to operate independently in the event of asystem control failure otandard indicator lights Power On green indicates the boiler is powered Manual Override red indicates boiler is in manual override mode Call for Heat amber indicates there is a call for heat Pump green indicates pump circuit is energized High Limit red indicates boiler is off on high limit Aqua Stat or Thermostat red indicates boiler is off on operating control may not appear on all models Flow red indicates boiler fault no flow Ignition red indicates ignition failure Pilot yellow or amber indicates pilot is lit Safety Fault red indicates fault in safety valve or safe
23. eries E 4 amp Accessories SCOPE OF WARRANTY Raypak Inc Raypak warrants to the original owner the Control System to be free from defects in materials and workmanship under normal use and service for the applicable warranty period In accordance with the terms of this Limited Warranty RAYPAK will furnish areplacement or repair at our option any defective part which fails in normal use and service during the applicable warranty period The replacement or repair will be warranted for only the unexpired portion of the original Warranty Period APPLICABLEWARRANTY PERIOD The effective date of warranty coverage is the date of original installation of the Control System by a qualified electrician or by a RAYPAK authorized service technician The Applicable Warranty Period is one 1 year from the effective date WARRANTY EXCLUSIONS This Limited Warranty does not apply 1 if the control system is not properly installed by a qualified technician in accordance with manufacture s installation instructions applicable codes ordinances and good trade practices 2 to damage or malfunctions resulting from failure to properly install operate or maintain the system in accordance with the manufacture s instructions 1f the rating plate s or serial number s are altered defaced or removed 1f the System is modified in any way or used with any non factory authorized accessories or components to damage or failure from abuse accident act of n
24. ff pump timing Ignition lockout timing Default Value 3 min Default value 15 seconds Select Set Option Time of Day AM or PM Day of Week Set back Off or On Default Value Monday Default Value Off Period 1 2 3 4 5 6 Set Back On Off On Off On Off On Off On Off On Thursday Friday Saturday Proportional Integral Derivative Pconst Wait Integral Derivative V Version of Software Page 47 Troubleshooting Guide The procedures outlined below assume that the initial installation turn on power up procedures have been completed and that the B6000 was operational This guide is a basic instruction to determine if an authorized Raypak representative should be contacted If you follow the instructions in this manual and have difficulty operating the B6000 locate the SYMPTOM in the left column below Check the corresponding POS SIBLE CAUSE and CORRECTIVE ACTION Column to locate and remedy the problem Symptom No Display Nite set back time display no longer correct Nite set back not working properly Time display does not maintain proper time System not working automatically Display shows incorrect number of boilers Scrambled control display Boiler does not function properly after power outage Boiler Not on Line displayed Outdoor and water temp readings Incorrect 35 F Displayed parameters do not make sense System Faults indicators do not make sense
25. g Power Switch to ON position The following indicator lights will be lit Power On The following indicator lights will be lit if the boiler is performing the valve calibration cycle Call for Heat Pump Pilot b Boiler will start provided there are no faults after the System Control module has been energized Version of Software Flashing N Y System Control Module a Energize the system control module The screen should show the System Temperature Display 1 b Press the MENU button until the screen shows the Initialize screen Press or button to change the cursor to Y Press Select button his will initialize the control memory to the default values Q O Page 22 DISPLAYS System Temperatures Indicates selectable item Program the System Control Module to meet the design conditions of the installation Return to System Temperature Display by pressing the MENU button until screen appears as below Current Outdoor Air Current System Target Temperature Mie d i Temperature Water Temperature System Design iea G Temperature aiae Selectable F or C Default is F INFORMATION ONLY This is the first screen displayed when system is energized After system is set up this display should be used F or C is selectable by pressing or Provides Outdoor temperature
26. he firing rate of each boiler up to total of 5 Page 35 IMPORTANT START l ALTERNATE If your system module s are supplied with a single Field Wiring Terminal Strip use this method for wiring WIRING AIR AND WATER SENSORS To The System Control Module RED ORN WHT WATER BLK WHT ORN SENSOR lt 2 3 ORN WHT e P WHT ORN S OUTDOOR SENSOR ae S U DEUM FIELD WIRING DRAIN pepe UR TO TERMINAL STRIP or BELDEN 9842 E GROUND SPG Dia 10 AIR WATER TEMPERATURE SENSOR SCHEMATIC Page 36 N L ALTERNATE Continued NN COMMUNICATION RS 485 WIRING From System Control Module To Boiler Module e Shielded communications cable Belden 9842 must be used Polarity must be observed Make use of wire color coding to ensure polarity e The shielding foil wrapper bare wire drain MUST be grounded Grounding is done at the System Control only DO NOT ground at boiler monitor e Note Equivalent shielded cable must be suitable for RS 485 communication applications must have 100 140 ohm impedance and less than 30 picofarad per foot capacitance e Install in conduit with no other wiring BELDEN 9842 piii AW T BLU WH OLY 7 YIII WHT BL s _WHT BLU 10 ORN WHT N ORN W XXX Co C BOILER MONITOR SHIEI TERMINAL TO SIN GROUI RS 485 Communic SY RS 485 Communications Cable Schematic WIRING Power Source to Control and Bo
27. iler Modules Observe Polarity very important Observe wire colors e Provide external surge suppressor capable of maintaining system integrity Provide overload protection and discon nect means as required by code and for equipment serviceability e Conduit can NOT be used as ground Must be WIRED Ground SINGLE POINT Page TO GROUND 2 7 O aaa 3 4 DISCONNECT 5 6 GROUND NEUTRAL HOT RETURN L LR DISCO POWER TEST CHECK POWER Utilizing a Volt Ohm Meter VOM monitor the following on the System Control and Boiler Monitor s for proper voltage levels Check at the Terminal Block TB SYSTEM CONTROL From TB pin 1 TB pin 1 TB pin 2 BOILER MONITOR S From TB pin 1 TB pin 2 SPG TB pin 2 To TB pin 2 SPG SPG SYSTEM CONTROL To TB pin 1 TB pin 2 SPG SPG POWER TEST TABLE INDICATION BOILER MONITOR S INDICATION From To 108 VAC to 132 VAC TB pin 1 TB pin 2 108 VAC to 132 VAC 108 VAC to 132 VAC TB pin 1 SPG 108 VAC to 132 VAC less than 1 VAC TB pin 2 SPG less than 1 VAC INDICATION Less than 0 5 VAC Less than 0 5 VAC Less than 0 5 VAC Less than 0 5 VAC T ALTERNATE Heturn to Boiler Monitor Select Switch NN See page 20 Page 39 Bis B 6 S 2 3 3 T 1
28. iming is 30 seconds Note On multiple boilers a time must be entered for each boiler Page 30 Night Setback OFF indicates the system is in the Normal or design operating mode ON indicated the system is operating in a programmed night setback mode LEAD LAG NIGHT SET BACK NOTE S This shadow box indicates the display for Lead Lag Nite Setaback feature Automatic Lead Lag Set Time of day Day of Week On or Off This screen shows the time and day of the week Default values Monday for the day and OFF for Setback Enter the current time PUSH SELECT Until day flashes Enter day of the week Setback status can be manually changed from OFF to ON or vice versa provided the setbacktimes have been cleared otherwise the timer will override the manually selected status of setback Push or to setback mode to on or off LEAD LAG NIGHT SET BACK Setback Times am or pm am or pm This screen shows the Setback ON and OFF times for each day There are six 6 ON and six 6 OFF times per day as indicated by the number on the left Page 31 Set Back Example Period SETBACK SETBACK ON OFF DAY 1 XX XX 05 00 am Monday 2 10 00 pm XX XX Monday 1 XX XX 05 00 am Tuesday 2 10 00 pm XX XX Tuesday 1 XX XX 05 00 am Wednesday 2 10 00 pm XX XX Wednesday 1 XX X
29. ll raise the system water temperature from the initial setpoint suggested 110 F to the maximum temperature required when the outdoor temperature drops from 70 F to the design temperature PUSH SELECT Design temperature rise of the system related to the boiler Default value 20 F Page 27 1 43 25 1 3 1 210 200 190 180 170 160 150 140 130 120 110 100 90 LL LU LLI Td O LU D LU Dr D 5 LU A LU LU Jo U gt U 80 70 50 60 40 30 l 140 130 120 110 100 90 80 70 60 50 40 30 20 10 0 10 20 30 40 45 OUTDOOR DESIGN TEMPERATURE DEGREE F Secondary Control Parameters Step O C O Cdb C Band is a range of Increment of firing Maximum outdoor Outdoor cutoff temperature above and valve opening temperature that heat is deadband is the below the target Range 1s 2s 5 100 desired set at 70 number of degrees temperature Default value 20 Range 35 to 199 below O C where Range 1 9 Default value is 65 O C reset occurs Default value is 3 F Range 1 9 Default value is 4 F Page 28 STEP Enter desired valve firing increments Recomme
30. mpleted successfully Verify RS485 Communications Cable must be Belden 9842 or equivalent Verify Boiler Monitor Select Switch SW2 settings Verify Installation Removal of Boiler Monitor Communications Jumper s W1 Verify Optional Boiler Monitor Control Wiring MODEM Optional Perform and or verify modem installation and hook up per Raypak Add On Options P N 240596 and B6000 BMS Optional Modem Software Documentation P N 240595 Page 20 SYSTEM CONTROL DISPLAY FAMILIARIZATION The System is set up by using the selector buttons and the displays on the System Control module There are ten or more displays Each display provides information regarding the system operating parameters and system component status Some displays provide information only such as current outdoor temperature system temperature etc Selectable data is identified by flashing characters The selector buttons are MENU which when pressed will change displays SELECT moves the cursor flashing character to the next selection in a display moves a value to a higher reading e g Display shows flashing boiler 1 Pushing will change display to boiler 2 moves a value to a lower position e g Display shows flashing boiler 2 Pushing will change display to boiler 1 EDITING B6000 DISPLAYS LOCATION The B6000 BMS has a forty 40 character screen that displays status and memory contents Selectable Parameters on the B6000 M
31. nded setting is between 5 and 20 for Modulating Boiler Or Enter 1S If Gas Valve is an On Off or Single Stage Or Enter 2S If Gas Valve is 2 Stage Firing Or Enter 2096 If the control boilers include modulating and 2 stage or single stage boilers under control of a single system control module O C Enter desired outdoor cutoff temperature usually 70 F depending on geographical loca tion When outdoor temperature exceeds desired setting target temperature will show O C Note Boiler will restart when outdoor temperature drops below O CF Tep O C db O Cdb Enter desired outdoor cutoff dead band which is the number of degrees below O C where O C resets usually 1F C Band Enter desired Control Band determines when boiler will fire below target temperature and shut off above target temperature usually 1 F NOTE The above settings are recommended at initial installation For maximum performance and system efficiency these settings should be modified as required to meet such parameters as system capacity location and usage NOTE Contact factory for recommended settings if this is a special application ie Heat pump applications Lead Boiler Select Indicates boiler designated as Lead Indicates number of boilers being used Used when there are multiple boilers Set number of boilers to match actual installation Readout lists lead boiler To ch
32. onitor Screen are as follows Selectable Parameters Range Value Change to Fahrenheit F or Celsius C Default After Initialization Maximum Water Temp 70 235 Degrees 180 Set 40 220 Degrees 100 Day Temperature 40 220 Degrees 100 Nite 40 220 Degrees 90 Hatio None 20 1 Numeric 1 0 1 Rise 1 99 Degrees 20 otep 1s 2s 5 100 Percentile 20 O C Outdoor Cutoff 35 199 Degrees 65 O Cdb O C dead band 1 9 Degrees 4 CBand Control Band 1 9 Degrees 3 Lead 1 8 Numeric 1 Change Hours 0 225 Numeric 100 Pump Delay 0 20 Minutes 3 Ign Time 15 100 Seconds 30 Indicates multiple entries When the B6000 BMS is equipped with a night setback feature WHEN INITIALIZED NITE SETBACK defaults to OFF Page 21 NOTE Nite setback feature must be set at the B6000 BMS Control Panel to ON This results in display change that shows NITE rather than DAY The BMS can change SETBACK TIMES up to six selections for each of the seven days WARNING WARNING WARNING WARNING WARNING WARNING When the initialize control selection is set to Y and SELECT button is pushed the B6000 BMS resets all of the SELECTABLE PARAMETERS on this screen to DEFAULT values Nite Setback NSB Lead Lag is set to OFF If option installed POWER UP Boiler Monitor a Energize by pushin
33. p until it acts on a temperature which tells the system how first to or down faster or slower over change Default value is 5 sec react to differing changes in water shoot or undershoot and finally onda temperature Default is 3 1 end up offset from desired tem perature Default is 1 3 Pconst Proportional ratio which causes the boiler to step up or down faster or slower WAIT Wait as time controller hesitates before acting on a temperature change Dconst Derivative ratio speeds or slows boiler response compensating for overshoot and undershoot Page 33 Proportional Integral Derivative Operator Manual Action PIDOMA B Proportional Integral Derivative Operator Manual Action Pconst is the proportional ratio Wait is the time controller waits Dconst is the derivative ratio which causes the boiler to step up until it acts on a temperature which tells the system how first to or down faster or slower over change Default value is 5 sec react to differing changes in water shoot or undershoot and finally onds temperature Default is 3 1 end up offset from desired tem perature Default is 1 3 Pconst Proportional ratio which causes the boiler to step up or down faster or slower WAIT Wait as time controller hesitates before acting on a temperature change Dconst Derivative ratio speeds or slows boiler response compensating for overshoot and
34. rews INSTALL CONDUIT AS APPROPRIATE NOTE Shielded cable Belden 8132 or 9842 or equivalent must be used to connect the sensors to the System Control Module DIMENSIONS AND WEIGHT system Control Module 19 1 2 lbs Boiler Monitor Module 21 1 4 Ibs 15 3 16 L 17 1 2 L 12 1 2 W 18 3 4 W 4 3 4 D 5 1 2 D ELECTRICAL CHARACTERISTICS Control Module 120 VAC 0 5A 60 Hz Boiler Monitor Module 120 VAC 2 0A 60 Hz ELECTRICAL INSTALLATION 115 VAC FEEDER CIRCUITS Install surge protection device s sized appropriately for your installation Install separate disconnect means for each load Pull in appropriately sized wire for equipment as defined by NEC and or local code All primary wiring willbe 125 of minimum rating lt is strongly recommended that the System Control Module and the Boiler Control Module be supplied from the same source power CHECK YOUR POWER SOURCE Using a volt ohm meter check the following voltages at the circuit breaker CB Neutral Return VOM x Hot ware GROUND BLACK EBEN oe AC 108 Volts AC Minimum 132 Volts MAX Hot to Ground AB 108 Volts AC Minimum 132 Volts MAX Hot to Neutral BC Must be less than 1 0 Volts AC Neutral to Ground Page 8 AIR TEMPERATURE SENSOR e INSTALLATION Fig 49040 TYPICAL AIR TEMPERATURE SENSOR Air Temperature Sensor Installation Notes Locate on coldest side of building usually North or West
35. s as 1 thru maximum independent of the Last wired boiler position Page 17 OPTIONAL BOILER MONITOR e Wiring e Contact Authorized Raypak representative for other wiring options NOTE Tighten terminal strip clamping screws 20 lbs In 2 26N m Breakage from over torquing is not covered under warranty Use copper conductors only For supply connections use wires sized on the basis of 60 C Ampacity and rated Min 90 C 194 F Field Wiring Single Boiler Dia 7 s mme na eee oree i BOILER MONITOR F CX X KX X cs Xv XX XX X X A X SX X s BOILER MONITOR BOILER MONITOR TERMINAL T8 3 TERMINAL TB 2 LG BELDEN MP d LL V T ORM WE CI pA ea A SENSOR o BK WHT BLU Fou o mS SENSOR wad BELDEN 38132 or BELDEN 9842 T 0 10 FLOW SWITCH THERMOSTAT PUMP RELAY IF USED 24VAC COIL F USFD L H N S dan BOILER MONITOR c sth MN o BZ iin 10 3 CX Aet XX r Pem L EXXX SYSTEM CONTROL EN M cy ORN Dia 2 TO ADDITIONAL SOLERS oe QF USED 4 bed ORN WHT m NA pe AL PROTECTION BH THERMOSTAT PUMP RELAY 24VAC COIL seu coma TG IF USED TERMINAL TB 1 x I Fo DISCONNECT Low Sh D TERMINAL TB 2 Field Wiring Multiple porera Dia 7 q F BOILER MONITOR 0 90 90 o F
36. ty circuit Main Gas green indicates modulating valve is energized Boiler identification dip switch lO O 9 999 99909 QQ Q B6000 A O B6000 A Illustrated Page 6 INSTALLATION AND MOUNTING The System Control module should be mounted on a permanent base not subject to vibrations moisture or dust It should be mounted with the display screen at a convenient height for reading and for access to the alarm silence button located on the top of the cabinet Dimensions amp Weight ee K N Boiler Monitor I 18 3 4 W o Ti Ii B 17 1 2 L ep 21 1 4 Ibs MECHANICAL INSTALLATION pu S L2 PYG on Install the B6000 System Control Module 2 poo eon m boiler s The B6000 System Control Modul B or MN EE facing downward Conduit holes are provk po ee Additional or larger conduit fittings that may EX the module Mount the B6000 System Control with 3 8 or 1 4 hardware in four 4 places A minimum of six 6 inches clearance on all sides is required and a minimum of eighteen 18 inches clearance from the front is required for service access The hinged side of the box is to the right and the clearance minimum 93 from bolt hole on the right side should be sufficient to open the cover Page 7 A sub panel containing the disconnect switches and surge suppressors is required at or near the equipment location s For accessibility remove the lower interior panel by removing the four 4 access sc

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