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Summary of Contents for Raypak 240692
- Page 1 ELECTRONIC BOILER SEQUENCER & OUTDOOR RESET CONTROLLER Installation and Operating Instructions Catalog No: 5000.54H Effective: 06-19-07 Replaces: 02-01-04 PN 240692 Rev. 9...
- Page 2 Y–SERIES ELECTRONIC BOILER CONTROL Installation and Operating Instructions is a registered trademark of Underwriters Laboratories Inc.® is a registered trademark of Underwriters Laboratories-Canada Inc. ® Before operating this product, please read these instructions completely.
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Page 3: Table Of Contents
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... -
Page 4: Basics
BASICS Item Y–Series Boiler Control, Installed on Boiler(s) Outdoor Temperature Sensor Assembly Water Temperature Sensor Assembly Optional Equipment Check packaging for damaged or missing components. IMPORTANT SAFETY INSTRUCTIONS IMPORTANT NOTICE: specifically trained and experienced in the installation of this type of equipment and related system components. -
Page 5: Introduction
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-Series Electronic Boiler Control (controller) is a microprocessor-based energy management system designed to control either single or multiple stage-fired boilers. -
Page 6: Control Features
0.12:1 to 8:1; determines how much the micro-controller calculated Target Temperature will change for a given outdoor temperature change. Control Band: 1°F to 10°F; the temperature above or below the Target Temperature at which the boiler turns off and on. Pump Off Delay: 0 to 10 min.;... -
Page 7: Installation And Mounting
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. -
Page 8: Check Your Power Source
CHECK YOUR POWER SOURCE Using a volt-ohm meter, check the following voltages at the circuit breaker panel: BLACK CIRCUIT BREAKER WHITE GREEN A B C 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 •... -
Page 9: Outdoor Air Temperature Sensor
AIR TEMPERATURE SENSOR Red (spare) 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. • Install the sensor in a shaded area, out of direct sunlight. •... -
Page 10: Water Temperature Sensor Installation
• The water sensor should be installed in the system supply. • Locate the water temperature sensor in the system piping just prior to the first boiler connections, on the upstream side of the System Supply Loop. • Cable length must not exceed 300 feet. -
Page 11: Domestic Hot Water Installations
WATER TEMPERATURE SENSOR INSTALLATION DOMESTIC HOT WATER INSTALLATIONS 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 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. -
Page 12: Pool Heating Installations
WATER TEMPERATURE SENSOR INSTALLATION POOL HEATING INSTALLATIONS Install the air temperature sensor across the air temperature sensor contacts (P2, pins 1 and 2; see the field wiring diagram on pg. 13). 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). -
Page 13: Field Wiring
Multiple-Stage Boilers - First stage connections on the control board 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. -
Page 14: Installation Verification Procedure
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 Temperature Sensor installation parameters have been met. WATER TEMPERATURE SENSOR Verify that the Water Temperature Sensor installation parameters have been met. -
Page 15: 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. -
Page 16: Sequence Of Operation
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. - Page 17 Y–SERIES ELECTRONIC BOILER CONTROL MODULE Night Setpoint Option Digital Display Option Panel with Clock & LCD Y-5 Configuration Shown...
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Page 18: Indicator Lights
INDICATOR LIGHTS STAGES 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. PUMP INDICATOR PUMP The Pump Indicator is illuminated whenever the pump circuit and pump relay are ener- gized. -
Page 19: Control Functions
CONTROL FUNCTIONS RESET RATIO 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: The first number in the ratio refers to the change in outdoor temperature in degrees Fahren- heit below outdoor cutoff while the second refers to the change in the computed Target Temperature in degrees Fahrenheit. -
Page 20: Reset Ratio Chart
RESET RATIO CHART PUMP TURN-OFF DELAY The 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. - Page 21 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.
- Page 22 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.
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Page 23: Circuit Board
CIRCUIT BOARD S5 MANUAL BYPASS S4 MANUAL LEAD/ J2 LAST STAGE S3 MODE SWITCH SELECTOR SELECTOR SELECTOR JUMPER SWITCH MAINTENANCE S1 SYSTEM S2 FIRST STAGE PLUG TEST TEST SELECTOR I.D. -
Page 24: Interior Jumper & Switches
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. -
Page 25: Output Override
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. -
Page 26: Optional Controls
OPTIONAL CONTROLS Operational Override Switch Clock Alternate Setpoint Adjustment Digital Display 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. -
Page 27: Replacement Parts List
REPLACEMENT PARTS LIST CALL OUT DESCRIPTION PC Board Standard PC Board w/ Night Set Back Programmed Eprom Programmed Eprom W/ Night Set Back Transformer Door w/Window Side Mount Bracket Air Temperature Sensor Complete Water Temperature Sensor Complete Air/Water Temperature Sensor Well Assembly Timer Alternate Setpoint Adjustment... -
Page 28: System Start-Up Settings
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) -
Page 29: Troubleshooting Guide
Res is tance (K) 3.06 If all Okay, Replace Y-Series Boiler Control Board 3. If all okay, replace Y-Series Boiler Control Board. Setting Error LED is ON Possible Causes: 1. The Maximum Output Temperature setting is less than the Minimum Output Temperature setting. -
Page 30: Warranty
HOW TO MAKE A 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. - Page 31 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.
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