Catalog No: Effective: Replaces: 5000.54H 06-19-07 02-01-04 ELECTRONIC BOILER SEQUENCER & OUTDOOR RESET CONTROLLER Installation and Operating Instructions PN 240692 Rev.
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.
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 Rese
BASICS Contents Item Quantity Y–Series Boiler Control, Installed on Boiler(s) Outdoor Temperature Sensor Assembly Water Temperature Sensor Assembly Optional Equipment As Ordered 1 1 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.
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.
CONTROL FEATURES The Y-Series sequence panel includes: • Standard Indicator Lights: Stages 1 to 8: Pump: Call for Heat: Control On: Setting Error: Sensor Error: • Red, indicates which stages are turned on. Green, indicates that the pump circuit is energized. Green, indicates that a call for heat signal is present. Green, indicates outdoor temperature is below the Outdoor Cutoff Temperature potentiometer setting and that the boiler will respond to a call for heat.
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.
CHECK YOUR POWER SOURCE Using a volt-ohm meter, check the following voltages at the circuit breaker panel: BLACK CIRCUIT BREAKER VOLT-OHM METER WHITE GREEN GROUND 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 • Observe polarity. • Observe proper wire colors while making electrical connections. • Provide an external surge suppressor capable of maintaining system integrity.
AIR TEMPERATURE SENSOR Red (spare) Red (connect) Black (connect) Fig. #9040 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. • 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.
WATER TEMPERATURE SENSOR INSTALLATION HYDRONIC INSTALLATIONS Fig. #9496 TYPICAL WATER SENSOR • 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. • Install in shielded conduit with no other wiring. • Observe wire colors.
WATER TEMPERATURE SENSOR INSTALLATION DOMESTIC HOT WATER INSTALLATIONS Y-Series Controller 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.
WATER TEMPERATURE SENSOR INSTALLATION POOL HEATING INSTALLATIONS Fig. # 9498 Fig. # 9499 1. Install the air temperature sensor across the air temperature sensor contacts (P2, pins 1 and 2; see the 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.
FIELD WIRING P5 1 2 3 4 5 6 7 8 Stage 1 Single-Stage (On/Off) Boilers Stage 2 - All stage connections on the control board are connected at the {TH} (Thermostat) location on the boiler wiring diagram. Stage 3 Stage 4 Multiple-Stage Boilers 1 2 3 4 5 6 7 8 Stage 5 - First stage connections on the control board are connected at the {TH} (Thermostat) location on the boiler wiring diagram. Stage 6 Stage 7 Stage 8 - Second (or third, etc.
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.
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.
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.
Y–SERIES ELECTRONIC BOILER CONTROL MODULE Night Setpoint Option Digital Display Option Panel with Clock & LCD Y-5 Configuration Shown 17
STAGES 1 2 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. 3 4 5 6 7 8 PUMP PUMP INDICATOR The Pump Indicator is illuminated whenever the pump circuit and pump relay are energized. CALL FOR HEAT CALL FOR HEAT INDICATOR The Call For Heat Indicator is illuminated whenever a call for heat signal is present.
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: X:Y X - change in outdoor temperature Y - change in Target Temperature The first number in the ratio refers to the change in outdoor temperature in degrees Fahrenheit below outdoor cutoff while the second refers to the change in the computed Target Temperature in degrees Fahrenheit.
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.
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.
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 Setting 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.
CIRCUIT BOARD S5 MANUAL BYPASS SWITCH S4 MANUAL LEAD/ LAG SELECTOR SWITCH MAINTENANCE PLUG TEST J2 LAST STAGE SELECTOR JUMPER S1 SYSTEM TEST 23 S3 MODE SELECTOR S2 FIRST STAGE SELECTOR I.D.
INTERIOR JUMPER & 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. Fig # 9242 S-2 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.
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 reduces 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.
OPTIONAL CONTROLS Operational Override Switch Clock Alternate Setpoint Adjustment Digital Display 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.
REPLACEMENT PARTS LIST CALL OUT DESCRIPTION 1-C PC Board Standard PC Board w/ Night Set Back 2-C Programmed Eprom Programmed Eprom W/ Night Set Back 3-C Transformer 1-S Door w/Window 2-S Side Mount Bracket 3-S Air Temperature Sensor Complete 4-S Water Temperature Sensor Complete 5-S Air/Water Temperature Sensor 6-S Well Assembly 1-N Timer 2-N Alternate Setpoint Adjustment 2-N PART NO 006039F 006034F 005764F 006031F 005657F N/A 005654F 005700F 005701F 005299B 004821F 006033F 006032F 1-N 2-S 3-C 1-C 5-S
SYSTEM START-UP SETTINGS SYSTEM SETTING ENTERED ON DATE: Front panel control potentiometers (knobs) Reset Ratio: ______ Control Band: Default Value: 1:1 Pump off Delay: Default Value: 3°F ______ Outdoor Cutoff Deadband: Default Value: 3 min. Boiler on Delay: ______ Default Value: 3°F ______ Outdoor Cutoff Temp.: Default Value: 30 sec. Stage on Delay: ______ ______ Default Value: 65°F ______ Max Water Temp.: Default Value: 10 sec.
TROUBLESHOOTING GUIDE In normal operating conditions, the Status Indications should be observed as follows: Control Enabled Sensor Error Setting Error ON (lit) OFF 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.
LIMITED WARRANTY B6000, Y-Series, E-4 & 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.
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.
