Raypak B6000 Installation And Operating Manual
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Raypak B6000 Installation And Operating Manual

Boiler management system
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B6000
BOILER
MANAGEMENT
SYSTEM
SYSTEM CONTROL
Installation and Operating Manual
TM
Catalog No.: 5000.51J
Effective:
Replaces:
BOILER MONITOR
10-14-05
06-15-03
Part No. 240564

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  • Page 1 B6000 BOILER MANAGEMENT SYSTEM SYSTEM CONTROL Installation and Operating Manual Catalog No.: 5000.51J Effective: 10-14-05 Replaces: 06-15-03 BOILER MONITOR Part No. 240564...
  • Page 2 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. Page 2...

  • Page 3: Contents

    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. These instructions are intended for the use by qualified personnel only, Page 3...

  • Page 4: Table Of Contents

    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...

  • Page 5: Getting Started

    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.
  • Page 6 "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.

  • Page 7: B6000 System Control

    21-1/4 lbs. MECHANICAL INSTALLATION Install the B6000 System Control Module at a convenient place within 2000 feet of the boiler(s). The B6000 System Control Module must be mounted vertically with conduit holes facing downward. Conduit holes are provided to accommodate standard conduit fittings.

  • Page 8: Electrical Installation

    NEC and/or local code. All primary wiring will be 125% of minimum rating. It is strongly recommended that the System Control Module and the Boiler Control Module be supplied from the same source power. CHECK YOUR POWER SOURCE...

  • Page 9: Air Temperature Sensor

    AIR TEMPERATURE SENSOR • INSTALLATION Air Temperature Sensor Installation Notes: • Locate on coldest side of building, usually (North or West) side. • Install the sensor in a shaded area, out of direct sunlight. • 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.

  • Page 10: Water Temperature Sensor

    • INSTALLATION The water sensor should be installed in the system supply. Single Boiler TYPICAL WATER SENSOR Water Temperature Sensor Installation Notes: • Locate sensor in system piping within a minimum of three (3) feet or prior to the first take off connection, on the downstream side of the System Supply Loop.
  • Page 11 INLET OUTLET (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. IMMERSION WELL WATER SENSOR 1/2 NPT COLD...

  • Page 12: Important Configuration Note

    IMPORTANT Configuration Note: If 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 SYSTEM CONTROL...

  • Page 13: Communication (Rs485) Wiring

    • 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. • Note: Equivalent shielded cable must be suitable for RS 485 communication applications;...
  • Page 14 System Contr ce to System Contr ol and Boiler Mod- ol and Boiler Mod- ce to System Contr ce to System Control and Boiler Mod- ol and Boiler Mod- ol and Boiler Mod- Page 14 NOTE: Tighten terminal strip clamping screws 20 lbs - In (2.26N.m) Breakage from over...

  • Page 15: Power Test

    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...

  • Page 16: Boiler Monitor Select Switch

    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. BOILER MONITOR SELECT SWITCH SWITCH...

  • Page 17: Boiler Monitor Communications Jumper W1

    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. •...

  • Page 18: Optional Boiler Monitor Control

    OPTIONAL BOILER MONITOR • Wiring • 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...

  • Page 19: Field Wiring - Multiple Boilers

    Field Wiring - Multiple Boilers Dia. #7 Page 19...

  • Page 20: Installation Verification Procedure

    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...

  • Page 21: System Control/Display Familiarization

    "–" - 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 Monitor Screen are as follows: Selectable Parameters Change to Fahrenheit (F) or Celsius (C).

  • Page 22: Power Up - Boiler Monitor

    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.

  • Page 23: Displays

    INFORMATION ONLY - Provides firing valve position for each boiler. - Multiple boilers - press SELECT button to determine status of each boiler. Press MENU button * Indicates selectable item W a t e r [ T A R ] °...
  • Page 24 Should communication between the system control module and the boiler monitor module(s) be disrupted, the display will show "BOILER NOT ON-LINE". • To display status of other boilers press the (+) or (–) buttons on multiple boiler installations. B o i l e r *Boiler Pushing "+"...
  • Page 25 Pilot light failed to start BOILER NOT ON-LINE Communication lost x = Light On PUMP light used only when Economaster programmed. If a boiler should lose communication with the System Controller, BOILER NOT ONLIN Page 25 AMBER GREEN Manual Call...
  • Page 26 "Lead Lag, Nite Setaback" feature. D a y X X X – 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 27 – 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. Ratio Typical...
  • Page 28 Secondary Control Parameters S t e p X X % *Step *O/C Maximum outdoor Increment of firing valve opening. temperature that heat is Range 1s, 2s 5-100 desired, set at 70°, Default value 20%. Range 35° to 199°. Default value is 65. O / C O / C d b X X X...
  • Page 29 Used when there are multiple boilers. Set number (#) of boilers to match actual installation. Readout lists lead boiler. To change 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.
  • Page 30 Range 0-20. Default value 3 mins. 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.
  • Page 31 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. NOTE"S" This "shadow box" indicates the display for "Lead Lag, Nite Setaback" feature. * X X : X X P M Enter the current time.
  • Page 32 Set Back Example: Period 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 no time 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"...
  • Page 33 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 34 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 35 Displays Firing Rate of each Boiler Displays Actual System Temperature Information Only. Displays the system operating conditions and the firing rate of each boiler up to total of (5). LEAD LAG, NIGHT SET BACK Initialize I n i t i a l i z e ?

  • Page 36: Important (Start Alternate)

    IMPORTANT START "ALTERNATE" WIRING To The System Control Module WATER SENSOR OUTDOOR SENSOR AIR/WATER TEMPERATURE SENSOR SCHEMATIC If your system module(s) are supplied with a single Field Wiring Terminal Strip use this method for wiring. AIR AND WATER SENSORS BELDEN #8132 or BELDEN #9842 Page 36 BARE WIRE...
  • Page 37 Polarity must be observed. Make use of wire color coding to ensure polarity. • The shielding [foil wrapper - bare wire (drain)] MUST be grounded. Grounding is done at the (System Control) only. DO NOT ground at boiler monitor. • Note: Equivalent shielded cable must be suitable for RS 485 communication applications;...
  • Page 38 WIRING: Power Source to Control and Boiler Modules • Observe Polarity very important. • Observe wire colors • Provide external surge suppressor capable of maintaining system integrity. • Provide overload protection and discon- nect means as required by code and for equipment serviceability.
  • Page 39 "ALTERNATE" 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 INDICATION From: TB pin 1 TB pin 2 108 VAC to 132 VAC...
  • Page 40 Fig. # 9458 Page 40...
  • Page 41 Fig. # 9459 Page 41...

  • Page 42: System Control Board Pictorial

    SYSTEM CONTROL BOARD Fig. # 9460 Page 42...

  • Page 43: Replacement Parts List

    Replacement Parts List Part CP10.0_ _ _ 90FI CP10.0N _ _ 90EI CP10.0NMn 900D Page 43...
  • Page 44 Replacement Parts List Page 44...

  • Page 45: Boiler Monitor Control Box

    Fig. # 9461 Located in place of ignition control on C2 boilers only. BOILER MONITOR CONTROL BOX Page 45...
  • Page 46 K-1, K-2, K-3, K-4 K-7, K-8 K-1, K-2, K-3, K-4, K-5, K-6 K-7, K-8 B 6000 SYSTEM Boiler Monitor Control Box Control PC Board Power/Manual or Override Switch Transformer, 120/8.5 VAC C.T. Transformer, 120/24 VAC C.T. Transformer, 120/24 VAC (C2 Units only)

  • Page 47: System Settings

    B6000 BOILER MANAGEMENT SYSTEM START-UP DATA SYSTEM SETTINGS ENTERED ON DATE:_____________________________________ Set _____ Deg. System Water Temp. @ Oc Default Value 100°F (38°C) Day _____ Deg. Nite_____ Deg. System Temps @ Oc Default Value Default Value: 100°F (38°C) 90°F (32°C) Step _____ % O/C_____Deg.

  • Page 48: 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.
  • Page 49 "Not on Line" Displayed Outdoor Temp. Sensor readings are high. Sensor reading 220°F. Sensor reading - 35°F. Low water cut-off alarm. Power lamp off on Boiler Monitor. Pump not running. Off at flow switch. Off on High Limit. Possible Cause Boiler not powered.
  • Page 50 EXCLUSIVE WARRANTY - LIMITATION OF LIABILITY This is the only warranty given by RAYPAK. No one 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.
  • Page 51 Design and specifications subject to change without notice. This symbol on the nameplate means the product is listed by Underwriters Laboratories, Inc. ® ® Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 • (805) 278-5300 • FAX (800) 872-9725 Litho in U.S.A.

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