Raypak 240692 Operating instructions
Contents
1. Operational Override Switch O1 O 2 Om Clock Os Os O 4 ORR Q 9 6 6 Alternate ow 9 on ne Setpoint Adjustment 1 Sks e E pump CALL FOR HEAT sabe me o Digital Display ELECTRONIC he m e BOILER CONTROL O Front Panel with Optional Alternate Setpoint OPTIONAL ALTERNATE SETPOINT OPERATION The Optional Alternate Setpoint can be used to establish an independent second set point for setback or temperature boost requirements TRIPPERS The electro mechanical timer consists of 84 small switches called Trippers and a 7 day mechanical clock Each tripper represents a two hour interval which determines set point selection as shown Tripper Pushed In Normal Setpoint Operation Tripper Pushed Out Alternate Setpoint Operation OPERATION OVERRIDE SWITCH The Operation Override Switch is a three position switch that determines if the trippers select the Setpoint of if either the normal Setpoint or Alternate Setpoint is continuously selected The Operation Override Switch can be set as follows I Alternate Setpoint selected continuously L Trippers determine selected set point O Normal Setpoint select continuously NIGHT SETBACK OPTION MECHANICAL CLOCK 7 DAY Set to the appropriate local time Note Turn the numbered dial clockwise to set time ALTERNATE SET POINT Works inde2. Fa F m Me Me Me E 1 52 GE GA 5 56 m7 8 rasa Fig 9242 1 The First Stage Selector Stage 1 ID S2 Switch is an eight 8 position switch each switch position corresponds to a Y Series output stage Turn ON the switch s that correspond s to the FIRST stage of EACH boiler Turn OFF the switch s that correspond s to the second or subsequent stage s of EACH boiler Switch 1 should always be on See the table below for examples 52 STAGE 1 10 E Number of Boilers Stage Number LastStage Fig 9245 Switch in ON Position Switch in Position The Mode Selector Switch S3 is comprised of an eight 8 position dip switch with the following functions AUTO Sw 1 Manual Auto Lead lag Selection Off Manual lead lag selection On Automatic lead lag selection OD off Sw 2 Outdoor Reset Off Outdoor Reset Enabled OD off On Outdoor Reset Disabled Use this setting for applications like Domestic Hot Water where outdoor air sensing is not required Note The outdoor sensor must be connected in all modes otherwise a sensor error will be Fig 9246 displayed 24 SLAVE Sw 3 Master Slave Off Designates the Y Series as a Master Control Normal On Designates the unit as a slave used for ganged Y Series controlling 9 to 24 firing stages DHW Sw 4 Outdoor Reset Off Minimum allowable Set Point of 105 F re
3. Green indicates that the pump circuit is energized Call for Heat Green indicates that a call for heat signal is present Control On Green indicates outdoor temperature is below the Outdoor Cutoff Temperature potentiometer setting and that the boiler will respond to a call for heat Setting Error Red indicates one or more of the on board settings is incorrect Sensor Error Red indicates that the Water or Outdoor Temperature Sensor has an out of range reading e Adjustment Knobs Reset Ratio Control Band Pump Off Delay Outdoor Cutoff Temperature Outdoor Cutoff Deadband Boiler On Delay Stage On Delay Max Water Temp Set Point 0 12 1 to 8 1 determines how much the micro controller calculated Target Temperature will change for a given outdoor temperature change 1 to 10 F the temperature above or below the Target Temperature at which the boiler turns off and on 0 to 10 min determines when the pump shuts off after entering Outdoor Cutoff mode 32 F to 200 F a warm weather shutdown feature When the outdoor temperature exceeds this setting the boiler will not fire unless placed in manual override mode 1 F to 10 F the number of degrees below the Outdoor Cutoff O C Temperature which causes the O C to reset 0 to 5 min sets the time interval between sequential boiler start ups 0 to 60 sec determines the time delay between stages turning on 70 to 235 F the maximum value
4. Series Electronic Boiler Control controller is a microprocessor based energy management system designed to control either single or multiple stage fired boilers Ideally suited for use in hydronic heating and domestic hot water supply applications the Y Series has been engineered with the flexibility and raw power to tame the most demanding control situations Utilizing a state of the art PID control algorithm the Y Series minimizes operating costs by maximiz ing energy efficiency CONCEPT OF OPERATION This controller is an outdoor reset control that is perfect for managing hydronic heating systems Two temperature sensors are used to control system response One sensor is used to monitor the outdoor temperature the other sensor is used to regulate the temperature of the system water By varying the temperature of the heating medium in response to changes in the outdoor temperature the Y Series provides the ultimate in personal comfort and efficiency of operation The Y Series controller is also well adapted to domestic hot water supply duty By disabling the outdoor reset function the Y Series behaves as an energy wise boiler sequencer With the ability to control up to eight firing stages and such features as a revolutionary First On First Off lead lag protocol the Y Series redefines controllability in domestic water applications The controller is equipped with an energy saving warm weather shutdown capability When the outdoor tempera
5. 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 ifthe control system is not properly installed by a qualified technician in accordance with manufacturer 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 manufacturer s instructions if the rating plate s or serial number s are altered defaced or removed if 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 nature fire flood freezing or the like to accessories rubber or plastic parts light bulbs or glass parts 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 TO MAKE A WARRANTY CLAIM make a warranty claim promptly ship postage prepaid or carry the defective part to a designated RAYPAK Service Dealer or Service Station in the Un
6. outdoor tem perature decrease results in a 25 F Target Temperature increase See Reset Ratio Chart pg 20 for more information The Reset Ratio is adjustable from 0 12 1 to 8 0 1 Recommended Initial Setting for Reset Ratio is 1 1 Suggested Settings Typical Reset Ratio Setpoint at Design Temp ke mns NET eee peo Standing Convection or Baseboard Fan Coil Heating Fan Coil Heat amp Cool Radiant Floor Radiant Ceiling The selection of the correct ratio is dependent on the initial temperature Set Point and the desired system water temperature If the building is too cold move the ratio knob counter clockwise one setting After a change is made to the ratio wait several days and evaluate the comfort level before making another change 19 RESET RATIO CHART 1 1 25 1 3 1 5 1 225 220 1 1 2 1 210 180 170 160 2 1 150 SEL 140 3 1 130 120 110 100 90 SYSTEM TEMPERATURE DEGREE F 80 70 60 50 40 30 140 130 120 110 100 90 80 70 60 50 40 30 20 10 0 10 20 30 40 45 OUTDOOR DESIGN TEMPERATURE DEGREE F 4 9 6 3 7 2 1 O pump 10 OFF DELAY PUMP TURN OFF DELAY The
7. outdoor temperature cutoff temperature setting is less than or equal to the outdoor temperature SETTINGERROR INDICATOR The Setting Error Indicator is illuminated if there is a potentiometer switch setting or jumper placement error Refer toTroubleshooting Guide Setting Error LED Is On SENSOR ERROR INDICATOR The Sensor Error Indicator is illuminated if either temperature sensor is out of range Steady on represents outdoor sensor failure blinking represents water temperature sensor error See Sensor Error LED On in the Troubleshooting Guide pg 29 18 CONTROL FUNCTIONS 1 1 RESET RATIO 2 1 The Reset Ratio setting determines how much the Target Temperature will increase as the outdoor temperature drops The Reset Ratio is expressed in the following manner X Y X change in outdoor temperature Y change in Target Temperature 2 1 12 1 8 1 The first number in the ratio refers to the change in outdoor temperature in degrees Fahren RESET RATIO heit below outdoor cutoff while the second refers to the change in the computed Target Temperature in degrees Fahrenheit A Reset Ratio of 2 1 means that for every 2 F drop in outdoor temperature from 70 F the Target Temperature will increase 1 F For example Assume a Reset Ratio setting of 2 1 and a Set Point of 120 F When the outdoor temperature drops from 70 F to 20 F the Target Temperature will in crease from 120 F to 145 F With an outdoor to target ratio of 2 1 a 50 F
8. wire conductors can cause excessive tension on contact points ELECTRICAL INSTALLATION ELECTRICAL CHARACTERISTICS 120 VAC 60 Hz 0 5A 120 VAC FEEDER CIRCUITS Install a surge protection device sized appropriately for your installation at each module Install a separate disconnect means for each load Use appropriately sized wire for equipment as defined by NEC and or local code All primary wiring should be 125 of minimum rating Itis strongly recommended that the Y Series Electronic Control Module and the boiler s be supplied from the same power source CHECK YOUR POWER SOURCE Using a volt ohm meter check the following voltages at the circuit breaker panel CIRCUIT BREAKER WHITE GREEN GROUND AC 108 Volts AC Minimum 132 Volts MAX AB 108 Volts AC Minimum 132 Volts MAX BC Must be less than 1 0 Volts AC WIRING POWER SOURCE TO CONTROLLER e Observe polarity e Observe proper wire colors while making electrical connections e Provide an external surge suppressor capable of maintaining system integrity e Provide overload protection and a disconnect means for equipment serviceability as required by local and state code e Conduit cannot be used as the ground There must be a WIRED ground e Very Important A grounding electrode conductor shall be used to connect the equipment grounding conductors the equipment enclosures and where the system is grounded the grounded service conductor to the g
9. 0 is not used 6 System Test Switch S1 is a momentary switch which will cause status indicators to blink five times then revert to normal indications This tests the functions status of the micro controller Reinstall the panel above indicator lights that cover the Y Series Electronic Boiler Control Circuit board Refer to the CONTROL POTENTIOMETERS KNOBS section of this manual to set the initial system operating param eters Set knobs to default values and fine tune if necessary SEQUENCE OF OPERATION 1 When the reset is enabled the Y Series Control continously monitors outdoor temperature using the outdoor temperature sensor When the outdoor temperature falls below the outdoor cutoff tempersture the Control becomes active and closes the primary pump relay energizing the primary system circulating pump The Control then monitors the system supply water temperature The microprocessor calculates an optimum target water temperature within selectable limits of the control band the setpoint the reset ratio and the outdoor air temperature If outdoor is reset is disabled the readings of the air sensor are not used in subsequent calculations In either case if the water temperature falls below the the calculated target temperature the Control sends a call for heat to the lead unit stage 2 Upon a call for the heat the control closes the lead unit s thermostat TH circuit which the energizes the lead unit s circulating pump After the
10. Catalog No 5000 54H Effective 06 19 07 Replaces 02 01 04 ELECTRONIC BOILER SEQUENCER amp OUTDOOR RESET CONTROLLER Installation and Operating Instructions BS DIG PN 240692 Rev 9 Y SERIES ELECTRONIC BOILER CONTROL Installation and Operating Instructions is a registered trademark of Underwriters Laboratories Inc UL is a registered trademark of Underwriters Laboratories Canada Inc Before operating this product please read these instructions completely TABLE OF CONTENTS Contents Basics Important Safety Instructions Introduction Concept of Operation Optional Configurations Control Features Installation and Mounting Mechanical Installation Electrical Installation Wiring Power to Controller Air Temperature Sensor Water Temperature Sensor Installation Hydronic Installations Domestic Hot Water Installations Pool Heating Installations Field Wiring Power Test Control Familiarization Sequence of Operation Manual Override Indicator Lights Control Functions Reset Ratio Chart Circuit Board Interior Jumper amp Switches Optional Controls Replacement Parts List System Start Up Settings Troubleshooting Guide Warranty Page O uui MH A NNN rd lt lt R amp coc FTA An amp BASICS Contents Quantity Y Series Boiler Control Installed on Boiler s As Ordered O
11. Pump Turnoff Delay works in conjunction with the Outdoor Cutoff Temperature The Pump Turnoff Delay sets the delay between the time when the Outdoor Cutoff Temperature is reached and the time when the pump is turned off The Pump Turnoff Delay is adjustable from 0 to 10 min Recommended Initial Setting for Pump Off Delay is 3 min 20 2 3 1 4 30 sec 0 5 BOILER ON DELAY 30 20 40 10 50 0 stage 60 ON DELAY T ourpoon 19 CUTOFF DEADBAND 120 80 160 65 32 200 OUTDOOR CUTOFF TEMP BOILER TURN ON DELAY In a multiple boiler system The Boiler Turn On Delay sets the time delay before each additional boiler is turned on in response to a call for heat This delay starts when the preceding boiler is turned on The Boiler Turn On Delay range is from 0 to 5 min Recommended Initial Setting for Boiler Turn On Delay is 30 sec STAGE TURN ON DELAY The Stage Turn On Delay sets the time delay before a new stage in a multistage boiler configuration is turned on This delay starts when the stage or boiler preceding the next stage is turned on The Stage Turn On Delay range is from 0 to 60 sec Recommended Initial Setting Stage for Turn On Delay is 10 sec CONTROL BAND The Control Band sets the maximum temperature above or below the Target Temperature which is determined by the embedded micro controller between which the system tem perature may deviate This provides a control deadband that limits the boiler from s
12. SERIES FROM M CONTROLLER PUMP amp N NY ISOLATION VALVES FILTER SYSTEM N j X WATER hm p SENSOR M Fig 4 9498 10 PRIMARY LOOP 4 POOL O 12 MAX OR MINIMUM POSSIBLE b o HEATER Q FROM 1 N PUMP amp ORAE ee er SYSTEM STANDARD QN FRONT MOUNTED PUMP 1287 1826 VALVE A IS THE EXTERNAL BYPASS VALVE NECESSARY FOR SIZES VALVE B IS THE BALANCING VALVE 2100 4001 VALVE C AR ATION VALVES BYPASS SUPPLIED BY RAYPAK Fig 9499 1 Install the air temperature sensor across the air temperature sensor contacts P2 pins 1 and 2 see field wiring diagram on pg 13 2 On the mode selector switch S3 set switch 2 Outdoor Reset to ON to disable the outdoor reset function See pg s 15 and 23 3 Set the Outdoor Cutoff Temperature to 200 F See pg 21 4 Adjust the setpoint to desired pool temperature Thereafter the controller will track the setpoint and fire heater stages as necessary NOTE The Outdoor Air Temperature sensor can be used as a replacement for the Water Temperature Sensor as both sensors are indicated 12 FIELD WIRING Notes Outdoor Air Temperature Water Temperature Single Stage On Off Boilers stage connections on the control board are connected at the TH Thermostat location on the boiler wiring diagram Multiple Stage Boilers First stage connections on the control b
13. allation purposes and should be mounted so that the indicating lights are at a height and location convenient for viewing MECHANICAL INSTALLATION Install the control within 10 feet of the boiler s The control must be mounted vertically with the conduit holes facing downward The conduit holes are sized to accommodate standard conduit fittings If additional or larger conduit fittings are required the holes should be located on the bottom of the module Mount the control using the mounting bracket and appropriate 3 8 or 1 4 hardware in four 4 places A minimum of eighteen 18 inches clearance from the front and six 6 inches clearance on all other sides is required for service access The hinged right side of the box should be installed with sufficient clearance minimum 3 from the bolt holes on the right side to open the cover An electrical distribution sub panel containing appropriate disconnect switches and surge suppressors is required at or near the equipment location s To access the control board remove the interior front panel by unscrewing the four 4 decal panel fasteners INSTALL CONDUIT AS APPROPRIATE NOTE 1 Shielded 18 gauge cable must be used to connect the sensors to the Boiler Control Module The shielded cable should be protected by conduit whenever possible NOTE 2 18 AWG Stranded wire must be used for all connections to printed circuit board PCB Solid conductors should not be used because solid
14. duces potential of condensensing the boiler On Set Point can be reduced to 40 F for special applications e g water source heat pumps etc Sw 5 8 Reserved Reserved for future use Fig 9244 Fig 9243 Fig 9247 MANUAL LEAD LAG The Lead lag Selector Switch S4 is a ten 10 position rotary switch Switch positions 0 and 9 are not used In manual lead lag selection the Lead lag Selector is used to select the lead boiler stage This is normally shipped from the factory set at position 1 If auto lead lag is used do not adjust this switch OUTPUT OVERRIDE The Bypass Switches Switch S5 is a ten 10 position dip switch Switch position 10 is not used The Bypass Switch enables the user to turn on any of the outputs regardless of the current settings and conditions Switch position 9 will turn on the pump and the remaining eight switches will each override one of the output stages The pump switch and the output stages switches are interlocked such that the output stages can only be turned on if the pump is on SYSTEM TEST The System Test Switch S1 is comprised of a single momentary push button switch When depressed it should cause the Status Indicators to blink five times This test sequence is an indication of the functioning status of the embedded micro controller The Status Indicators revert back to their original indications after the test sequence is completed 25 OPTIONAL CONTROLS
15. e below SENSOR RESISTANCE AT VARIOUS TEMPERATURES 10 733 Es 3 Ifall okay replace Y Series Boiler Control Board Setting Error LED is ON Possible Causes The Maximum Output Temperature setting is less than the Minimum Output Temperature setting The last stage selection is invalid Either there is no stage selected or more than one stage is selected The first output stage is not selected as a stage 1 The first output stage should be set as a stage 1 in all cases In manual mode the lead lag selection is invalid 0 or 9 In manual mode the lead lag selection is higher than the last stage In manual mode the stage selected as the lead lag is not set as a stage 1 Ox o ds 29 LIMITED WARRANTY B6000 Y Series 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 a replacement 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 APPLICABLE WARRANTY PERIOD The effective date of warranty coverage is the date of original installation of the Control System by
16. erature Sensor installation parameters have been met WATER TEMPERATURE SENSOR Verify that the Water Temperature Sensor installation parameters have been met SYSTEM MODULE INSTALLATION Verify electrical power wiring connections Verify electrical connection torque requirements Verify Outdoor Air Temperature Sensor wiring Verify Water Temperature Sensor wiring Verify Power Test has been completed successfully POWER TEST Utilizing a Volt Ohm Meter VOM monitor the following on the controller for proper voltage levels Check at Terminal Block TB 1 POWER TEST TABLE From Indication TB pin 1 TB pin 2 108 VAC to 132 VAC TB pin 1 Single Point Ground 108 VAC to 132 VAC TB pin 2 Single Point Ground less than 1 VAC 14 CONTROL FAMILIARIZATION The System is configured using the circuit board jumpers and switches and the front panel control potentiometers Open the front cover of the Boiler Control Box for access to the front panel Remove the front panel to gain access to the jumpers and switches on the Y Series Electronic Boiler Control circuit board Refer to the Interior Jumper and Switches section of this manual pg 24 for detailed configuration instructions 1 Last Stage Selector Install the jumper pot 72 shunt bar in the position that corresponds to the total number of stages to be controlled 2 First Stage Selector Switch S2 Place switche
17. etting for Maximum Water Temperature is 180 F SET POINT The Set Point is the system output temperature desired when the outdoor temperature is 70 F This potentiometer may be set to any temperature from 40 F to 220 F and is the base line setting for all operations Note Set Point cannot be below 105 F in normal operation unless the No Min Set Point switch is in the ON position See Mode Selector Switch In domestic water supply applications Set Point determines the water tem perature maintained by the control The Set Point range is from 40 F to 220 F Recommended Initial Setting Set for Point is 120 F CAUTION Setting the Set Point below 105 F may cause the boiler to condense which will damage the boiler 22 CIRCUIT BOARD S5 MANUAL BYPASS S4 MANUAL LEAD J2 LAST STAGE S3 MODE SWITCH LAG SELECTOR SELECTOR SELECTOR JUMPER SWIT 212 72 ER 3 Br b 4 r DOC E n 7 5 g f i X Q DO u di OAID ees 71 TUU Le t p MAINTENANCE S1 SYSTEM S2 FIRST STAGE PLUG TEST TEST SELECTOR I D 23 INTERIOR JUMPER amp SWITCHES J 2 The Last Stage Selector Jumper J2 is comprised of an eight 8 position jumper block A shunt bar jumper is placed in the position corresponding to the last active stage or boiler number See table below for examples of Jumper J2 settings nm D O D I Ca NJ D mo E a
18. flow switch has confirmed adequate flow the ignition sequence is initiated and the unit ignites at stage 1 The Control then sequences the units stages in response to changes in the system to target differen tial temperature time away from target temperature and temperature rate of change parameter as determined by the P I D algorithems 3 Additional stages and units are activated or deactivated as required in order to maintain or restore target system water temperature This Control uses first on last off logic As the system water temperature increases and begins to approach target temperature the Control deactivates the stages and heaters in reverse order of firing until the first unit stage fired is turned off After the final stage of a given unit has been turned off that unit s Economaster pump control will continue to power the unit s circulating pump until a user adjustable time delay has elapsed thereby extracting all available residual heat 4 The Control stores firing command and system response data in the last five memory registers of the microprocessor On the next call for heat the Control will modify the stored P I D data to optimize its own responses 5 When the outdoor temperature exceeds the outdoor cutoff temperature the Control enters warm weather shut down mode The primary pump is turned off after a user adjustable time delay and the Control becomes dormant until outdoor temperatures again fall below the outdoor c
19. hort cycling The Control Band range is from 1 F to 10 F Recommended Initial Setting for Control Band is 3 F OUTDOOR CUTOFF DEADBAND The Outdoor Cutoff Deadband sets the number of degrees below the Outdoor Cutoff where the Outdoor Cutoff reset occurs The Outdoor Cutoff Deadband range is from 1 F to 10 F Recommended Initial Setting for Outdoor Cutoff Deadband is 3 F OUTDOOR CUTOFF TEMPERATURE The Outdoor Cutoff sets the maximum outdoor temperature at which heat is desired This control sets the outdoor temperature above which the boiler bank is disabled If the out door temperature increases beyond the Outdoor Cutoff setting the Control ON LED turns off and if there is no call for heat the pump turn off delay starts turning off the pump If the outdoor temperature falls below the Outdoor Cutoff minus the Outdoor Cutoff Deadband the boiler bank will again be enabled The Outdoor Cutoff Temperature is from 32 F to 200 F Recommended Initial Setting for Outdoor Cutoff Temperature is 65 F 21 155 165 180 105 205 70 255 MAX WATER TEMP 120 140 100 160 80 180 60 200 40 220 SET POINT MAXIMUM WATER TEMPERATURE The Maximum Output Temperature is the system output high limit This potentiometer sets the maximum value the Target Temperature is allowed to reach regardless of other operational settings or conditions The Maximum Water Temperature range is from 70 F to 235 F Recommended Initial S
20. ited 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 EXCLUSIVE WARRANTY LIMITATION OF LIABILITY This is the only warranty given by RAYPAK Noone is 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 S SOLE LIABILITY WITH RESPECT TO ANY DEFECT SHALL BE AS SET FORTH IN THIS LIMITED WARRANTY ANY CLAIMS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING 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 RU 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 SERVICE DEPARTMENT 2151 Eastman Avenue Oxnard California 93030 Telephone 805 278 5300 FAX 805 278 5468 The following information must be pr
21. nal Alternate Set Point INTERIOR JUMPER amp SWITCH SETTINGS Output ON Switch S2 Lead Lag Switch S4 TROUBLESHOOTING GUIDE In normal operating conditions the Status Indications should be observed as follows Control Enabled ON lit Sensor Error OFF Setting Error OFF If the outdoor sensor fails and all other operating conditions remain the same the control will remain on but it will function as if the 70 F defeat mode is enabled The following Status Indications should be observed Control Enabled ON lit Sensor Error ON lit Setting Error OFF If a different LED status is observed other than those described above use the following detailed descriptions as a guide If Control Enabled LED is OFF Possible Causes 1 The output temperature sensor is out of range The Sensor Error LED should be on See below for details on the Sensor Error LED 2 There is a setting error The Setting Error LED should be on See below for details on the Setting Error LED 3 The outdoor temperature is higher than or equal to the outdoor cutoff setting less the outdoor cutoff deadband setting Sensor Error LED is ON or blinking ON OFF once per second Possible Causes LED ON steady Outdoor air sensor is out of range LED blinking ON OFF once per second Output water sensor is out of range 1 Examine wiring ensure continuity from Y Series to sensor s 2 Usea multimeter measure resistance of sensor s compare with tabl
22. oard are connected at the TH Thermostat location on the boiler wiring diagram Second or third etc stage connections on the control board are connected at the locations shown on the boiler wiring diagram Utilize Shielded Cable Sensor see NOTE 4 q Sensor Stage 1 Stage 2 Stage 3 Stage 4 Stage 5 Stage 6 Stage 7 Stage 8 Pump Relay lt _ Pilot Duty Only 2 5 Amp Max 250V Max Thermostat Jumpered or Aan 00000000 00000000 A Building Management System 2 Outdoor Temp _ AU 9 Water Temp lt lt Nw JA o 0 0 i 1 Tighten terminal strip clamping screws to 4 in lbs Breakage from over torquing is not covered under warranty 2 Use copper conductors only 4 The outdoor sensor must be connected otherwise a sensor error will be displayed 13 For supply connections use wires sized on the basis of 60 C 140 F ampacity and rated a min 90 194 N INSTALLATION VERIFICATION PROCEDURE REGISTER Before proceeding any further please verify that the user registration form has been completed and mailed MECHANICAL INSTALLATION Verify that the mechanical installation has been completed in accordance with the instructions OUTDOOR AIR TEMPERATURE SENSOR Verify that all Outdoor Air Temp
23. ovided 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 Registered Quality System www raypak com Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 Fax 800 872 9725 Raypak Canada Limited 2805 Slough St Mississauga Ontario Canada L4T 1G2 905 677 7999 Fax 905 677 8036 Litho in U S A
24. pendently of normal Setpoint See discussion of Setpoint for details Set to appropriate setback or boost temperature Turn the knob in the night setback option to the desired alternate setpoint DIGITAL DISPLAY OPTION LCD DISPLAY PANEL The optional LCD display will indicate all values plus calculated target temperature and actual air and water temperature 26 REPLACEMENT PARTS LIST CALL OUT DESCRIPTION PART NO 1 C PC Board Standard 006039F PC Board w Night Set Back 006034F 2 C Programmed Eprom 005764F Programmed Eprom W Night Set Back 006031F 3 C Transformer 005657F Door w Window N A Side Mount Bracket 005654F Air Temperature Sensor Complete 005700F Water Temperature Sensor Complete 005701F Air Water Temperature Sensor 005299B Well Assembly 004821F Timer 006033F Alternate Setpoint Adjustment 006032F U 77 27 SYSTEM START UP SETTINGS SYSTEM SETTING ENTERED ON DATE Front panel control potentiometers knobs Reset Ratio Default Value 1 1 Pump off Delay Default Value 3 min Boiler on Delay Default Value 30 sec Stage on Delay Default Value 10 sec Last Stage J2 Mode Selector Switch S3 Bypass Switch S5 Control Band Default Value 3 F Outdoor Cutoff Deadband Default Value 3 F Outdoor Cutoff Temp Default Value 65 F Max Water Temp Default Value 180 F Set Point Default Value 140 F Optio
25. rounding electrode SPG SINGLE POINT GROUND AIR TEMPERATURE SENSOR Red connect Red spare Black connect IUD OUTDOOR AIR TEMPERATURE SENSOR Outdoor Air Temperature Sensor Installation Notes Locate the sensor on the coldest side of building usually the North or West side e Install the sensor in a shaded area out of direct sunlight e Locate no higher than 2 3 up the side of the building or between the 2nd and 3rd floor if the building is more than three stories tall e Do not locate under an overhang near wall corners near drafts from stacks air moving devices windows doors or balconies e Shielded cable length run is not to exceed 300 feet e Install with properly sized conduit that contains no other wiring e Observe proper wire colors outdoor air temperature and water temperature sensors are identical and interchangeable Both are equipped with dual sensing elements Connect only one red wire and the black wire to the sensor connecting points The second element is an installed spare WATER TEMPERATURE SENSOR INSTALLATION HYDRONIC INSTALLATIONS SYSTEM SUPPLY SYSTEM SUPPLY CITY WATER INLET CITY WATER INLET i SYSTEM RETURN MN CONTROL SENSOR 1 2 NPT IMMERSION WELL WATER SENSOR Fig 9496 TYPICAL WATER SENSOR e water sensor should be installed in the system supply Locate the water temperature sensor in the system piping j
26. s in the ON position corresponding to the first stage of each boiler in the system Switch position 1 should always be in the ON position 3 Mode Selector Switch S3 determines the following A Switch 1 R M OFF Manual Lead Lag selection ON Automatic Lead Lag selection B Switch 2 70 F OFF OFF Outdoor Reset Enabled ON 70 F Defeat Enabled Outdoor Reset Disabled used for domestic water installations C Switches 3 Master Slave Option OFF Designates the Y Series as a Master Control Normal ON Designates the unit as a slave used for ganged Y Series controls controlling 9 to 24 firing stages D Switch 4 No Min Set Point Switch OFF Minimum allowable Set Point of 105 F to reduce potential of condensing the boiler ON Set Point can be reduced to 40 F for special applications i e water source heat pumps etc Switch 5 reserved Switch 6 reserved Switch 7 reserved Switch 8 reserved gi iom qm 4 Lead Lag Selector Rotary switch S4 selects the lead stage for stage sequencing Applies only in manual lead lag mode when Mode Selector Switch S3 Switch 1 is OFF switch should point to first stage in multi stage applications 5 Output Over Ride Switch S5 provides Manual Override of the system control Switches 1 through 8 turn on the corresponding relay and stage Switch 9 turns on the pump circuit The other stages are inter locked with Switch 9 and will not fire unless the pump is on Switch 1
27. that the Target Temperature is allowed to reach 40 to 220 the system output temperature desired when the outdoor temperature is 70 or in domestic water applications the desired water temperature Logic Test Button Jumper and Switches System Test Button S Last Stage Jumper J2 First Stage 1 Selector Mode Selector S3 Bypass Switches 55 1 initiates micro self test which causes the status indicator lights to blink 5 times indicating the micro controller is functioning properly selects the last active stage used for boiler control S2 designates the first stage of each boiler in a multi boiler system Switch position 1 should always be on switch 1 selects either Manual or Auto Lead Lag Mode Switch 2 provides an Outdoor Reset defeat Switch 3 configures the Y Series for Master Slave ganged operation Switch 4 allows the Set Point to be set below 105 F allows user to turn on any stage s regardless of current settings and conditions if and only if the pump relay is already activated INSTALLATION AND MOUNTING If the Y Series Electronic Boiler Control was not mounted on the boiler by the factory care should be taken to select a suitable mounting location The control should be mounted on a solid and permanent base The control enclosure is NEMA 3R rated rainproof and sleet resistant and can be mounted outdoors if required The unit should be readily accessible for maintenance and inst
28. ture rises above an adjustable Outdoor Cutoff Temperature the system automatically transitions to a dormant state This prevents the system from wasting energy trying to heat a building that is already at a comfortable temperature Once the outside temperature has fallen to the point that the system requires heat input to maintain the building temperature the Y Series is reactivated and will hold the system temperature at the required point The Y Series can also be equipped with an optional clocked alternate setpoint package The alternate setpoint allows control operation at an independent setpoint temperature and can be used either for night setback or preoccupancy boost An electromechanical 7 day timer switches the control between regular and alternate setpoint modes and can be set at two hour activation intervals See the section on the optional clocked alternate setpoint for details OPTIONAL CONFIGURATIONS Y 2B BASIC UNIT NO OPTIONS Y 3B BASIC UNIT PLUS DIGITAL DISPLAY Y 4B BASIC UNIT PLUS NIGHT SETBACK OPTION Y 5B BASIC UNIT PLUS NIGHT SETBACK AND DIGITAL DISPLAY OPTIONS PLEASE REGISTER Before proceeding any further please take a moment to complete the enclosed user registration form and mail a copy to Raypak Inc Department Y Series 2151 Eastman Avenue Oxnard CA 93030 CONTROL FEATURES The Y Series sequence panel includes e Standard Indicator Lights Stages 1 to 8 Red indicates which stages are turned on Pump
29. ust prior to the first boiler connections on the upstream side of the System Supply Loop e Cable length must not exceed 300 feet e Install in shielded conduit with no other wiring e Observe wire colors 10 WATER TEMPERATURE SENSOR INSTALLATION DOMESTIC HOT WATER INSTALLATIONS HOT ws WATER SUPPLY STORAGE IMMERSION WELL TANK WATER SENSOR 1 2 NPT INLET 54 OUTLET i Y Series Controller RECIRCULATION Fig 9497 1 Air temperature sensor must be installed across air temperature sensor contacts The sensor is not activated and can be left stored in controller enclosure DOMESTIC HOT WATER APPLICATION SETUP PROCEDURE 1 Install a 10 000 Ohm 1 8 Watt resistor between pins 1 and 2 on P2 connector see pg 13 in place of the Outdoor Air Temperature Sensor The Outdoor Air Temperature will appear to be about 77 F 2 Set switch 42 Outdoor Reset to ON 70 F Defeat on S3 See pg s 15 and 23 24 3 Set the Outdoor Cutoff Temperature to 200 F See pg 21 4 Adjust the Set Point to desired domestic hot water temperature Controller will track the Set Point Temperature See pg 22 NOTE The Outdoor Air Temperature sensor can be used as a replacement for the Water Temperature Sensor Both sensors are identical WATER TEMPERATURE SENSOR INSTALLATION POOL HEATING INSTALLATIONS PRIMARY LOOP TO BALANCING VALVE POOL 4 E T ON BYPASS SYS Y
30. utdoor Temperature Sensor Assembly 1 Water Temperature Sensor Assembly 1 Optional Equipment As Ordered Check packaging for damaged or missing components IMPORTANT SAFETY INSTRUCTIONS IMPORTANT NOTICE These instructions are intended for use by qualified personnel who are 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 requires certification 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 damage and will void the warranty CAUTION MORE THAN ONE 1 SUPPLY SOURCE THIS APPLIANCE HAS PROVISIONS TO BE CONNECTED TO MORE THAN ONE 1 SUPPLY SOURCE TO REDUCE THE RISK OF ELECTRIC SHOCK DISCONNECT ALL SUCH CONNECTIONS BEFORE SERVICING CAUTION RISK OF ELECTRIC SHOCK MORE THAN ONE 1 DISCONNECT SWITCH MAY BE REQUIRED TO DE ENERGIZE THE EQUIPMENT BEFORE SERVICING Thank you for selecting the Raypak Y Series Electronic Boiler Control It is our sincere hope that you will enjoy its outstanding design ease of use and energy saving features INTRODUCTION The Y
31. utoff temperature MANUAL OVERRIDE Internal Switch S5 Output Override can be used to manually override the Micro controller control as long as the Electronic Boiler Control circuit board has 24 VAC power See Output Over Ride Switch S5 above 16 Y SERIES ELECTRONIC BOILER CONTROL MODULE Night Setpoint Option CALL FOR HEAT ELECTRONIC BOILER CONTROL Digital Display Option Panel with Clock amp LCD Y 5 Configuration Shown 17 f STAGES O 1 2 Q 3 Q 4 5 Oe Q 7 038 PUMP CALL FOR HEAT CONTROL ON SETTING ERROR SENSOR ERROR INDICATOR LIGHTS STAGE INDICATORS The pump driver and each of the output stages drivers has its own LED indicator Each of these LEDS is lit whenever the corresponding output relay is energized PUMPINDICATOR The Pump Indicator is illuminated whenever the pump circuit and pump relay are ener gized CALLFOR HEATINDICATOR The Call For Heat Indicator is illuminated whenever a call for heat signal is present In most applications the thermostat connections on the control board pg 13 will be jumpered which will generate a continuous call for heat signal The thermostat leads may also be connected to a building management system which will produce the call for heat signal as required CONTROLON INDICATOR The Control On Indicator illuminates if all settings and system conditions are such that the control can function properly and
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