INSTALLATION & OPERATING INSTRUCTIONS Y-200 Series Electronic Boiler Sequencer & Outdoor Reset Control System Catalog No. 5000.62H Effective: 09-28-09 Replaces: 11-25-08 P/N 241125 Rev.
is a registered trademark of Underwriters Laboratories Inc. ® Rev. 9 reflects the following: Changes to: C-UL Listed Mark on page 1.
CONTENTS IMPORTANT SAFETY INSTRUCTIONS INTRODUCTION Concept of Operation Y-200 Controller Configurations Y-200 Options INSTALLATION Mechanical Installation Electrical Installation Controller Field Wiring Communication Field Wiring Air Temperature Sensor Installation Water Temperature Sensor Installation Power Test Installation Verification Procedure CONTROLLER FAMILIARIZATION Control Screens Circuit Board Layout Keypad Control Screen Displays & Programming 01 Initial Screen 02 Primary Parameters 03 Control
INTRODUCTION Y–200 SERIES ELECTRONIC BOILER CONTROL The Y-200 Series Electronic Boiler Control (controller) is a microprocessor-based boiler 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, this controller has been engineered with the flexibility and raw power to tame the most demanding control situations.
Y-200 Controller Configurations Model No. Y-241 Y-281 Description 4-Stage Controller - Includes main controller assembly, air temperature sensor assembly (P/N 068634), water temperature assembly (P/N 068635) and one (1) stage contact board. Main controller includes one (1) mounted auxiliary contacts board. 8-Stage Controller - Includes main controller assembly, air temperature sensor assembly (P/N 068634), water temperature assembly (P/N 068635) and two (2) stage contact boards.
INSTALLATION NOTE: Shielded 18 (AWG) gauge stranded wire must be used to connect the sensors to the controller. The shielded cable should be protected by conduit whenever possible. If the controller was not mounted on the boiler by the factory, care should be taken to select a suitable mounting location. The controller should be mounted on a solid and permanent base.
Controller Field Wiring Power to the Controller • • • • • • Observe (follow proper) polarity. Observe proper wire colors while making electrical connections. Provide an external surge suppressor capable of maintaining system integrity. Provide overload protection and a disconnect means for equipment serviceability as required by local and state code. Conduit cannot be used as the ground. (There must be a “WIRED” ground.
4. For external building control or thermostat control, remove wiring to J6 (CHF) connector and activate with 12 to 28 VAC. Notes: 1. Tighten terminal strip clamping screws to 2.5 inlbs. Breakage from over-torquing is not covered under warranty. 2. Use stranded copper conductors only. For supply connections, use wires sized on the basis of 60°C (140°F) ampacity and rated a minimum 90°C (194°F). 3. Install disconnect for each control unit. Fig.
Communication (RS485) Wiring Required for Optional Slave Unit(s) Air Temperature Sensor Installation Y-304 Slave Cable Installation from System Control Module • • • • • • Y-304 slave cable or equivalent shielded communications cable (Belden #9842, Belden #8132 or Alpha 3492C) must be used. Maximum cable length 100 ft. Correct polarity must be observed. Make use of wire color coding to ensure polarity. The shielding [foil wrapper-bare wire (drain)] MUST be grounded.
Water Temperature Sensor Installation Hydronic Heating Applications 4 OR MORE STAGES OR 4:1 TURN DOWN OR HIGHER 5’ MAX 5’ MAX 12” MAX • • • Fig. 6: Typical Water Sensor • Hydronic installations may require outdoor reset function. See page 11, and screen 02. Locate the water sensor as shown in Fig. 6. NOTE: When the system involves a variable-speed pump, it is recommended that the temperature sensor be installed in the tee connecting boiler outlet piping to the system.
Domestic Hot Water Supply Applications Fig. 7: Domestic Hot Water Supply • Outdoor reset function should be disabled. See screen 06 and 24. From TB pin 1 Power Test TB pin 1 Check Power TB pin 2 Utilizing a Volt-ohm meter (VOM) monitor the following on the controller for proper voltage levels. Check at the Terminal Block (TB-1). To TB pin 2 Single Point Ground Single Point Ground Indication 108 VAC to 132 VAC 108 VAC to 132 VAC Less than 0.
CONTROLLER FAMILIARIZATION Installation Verification Procedure Register This system is configured utilizing a LCD display (2 lines, 20 characters each) with keypad for data entry. Open the front cover of the Control Box for access to the LCD display and keypad. Open the control panel to gain access to the interface connections. J Before proceeding any further, please verify that the user registration form has been completed and mailed.
Control Screens NOTE: Once programming is finished, go to Screen 28 to program the USER DEFAULT SET_UP. Then open the front panel and press the SW3 reset button on the motherboard to save the new programming. To access programming mode: Press and hold the "MODE" button for 4 seconds. When in Program mode, cursor is blinking on first settable parameter. UP/DOWN arrows change parameter. LEFT/RIGHT arrows move to next selectable parameter.
0 to 600 seconds; sets the time interval between sequential boiler start-ups. 0 to 600 seconds; Default = 10 seconds. sets time interval between stages turning off. Disabled in PID. Selects either Standard or PID operation. If PID is selected then PID & Interval is programmable using screen 34. Default = PID Displays the boiler inlet and outlet temperature in °F or °C INLET / OUTLET = and the difference (delta) between them. (Requires 4sensor installation, option Y-306.
Circuit Board Layout SW3 Reset Switch Main Circuit Board Manual Override Switch 1 Manual Override Switch 4-Stage Relay Board Fig.
Keypad Normal Mode Move to next screen Push the "MODE" button to turn off the alarm horn Not active except in special modes Not active except in special modes Move to previous screen Program Mode To access programming mode: Press and hold "MODE" button for 4 seconds.
Control Screen Displays & Programming Initial Screen: Screen number R A Y P A K Y - S E R I I E N S C 0 V Product identification E R X X . X X 1 X Version number of software This is the initial screen displayed after system start-up, provided that there are no faults.
Control Band: C O N T Screen number R O L X X B A N D . X ° F Control is a range of temperature above and *C BandBand is a range of temperature above and below below the temperature. target temperature. the target Range: 1°F to 10°F (.5°C to 5.
Offset: Screen number "OFFSET" screen O F F S E T O F F 0 4 Default "OFF" screen Press "MODE" to select "OFF" or "ALL" or "FULL WEEK" Screen number "ALL" means every day has the same parameters. O F F — — — S E T A L L X : H H M M + X X . X 0 4 ° F Fahrenheit or Celsius There are six offset adjustments +, blank or – allowed for each calendar day. Time in 24-hour -99 to 99 degrees of offset. clock mode.
Holiday: Screen number S E T T I N H O L # X X G Thirty two holidays are selectable (01-32) H O L I D A Y X X — X X — X Month: 01 thru 12 Day: 01 thru 31 0 5 X Year: 01 to 99; Below 01 is Repeating Holiday (RH) setting NOTE: Previous screen (04) is used for entering the offset value in degrees. Reset Ratio: Ratio of outdoor temperature to water system temperature. Range: . 01:1 to 8:1 or "None" for constant water temperature (then TARGET=SETPOINT). Default value is 1.
Fig. 10: System to Outdoor Temperature Radiation Typical Temp@ Temp@ Design Cond. 70°F Reset Ratio Setpoint at Design Temp: 40°F 20°F 0°F -20°F Standing 190 105 0.3:1 0.6:1 0.8:1 1.1:1 Convection or Baseboard 200 105 0.3:1 0.5:1 0.7:1 0.9:1 Fan coil Heating 190 105 0.3:1 0.6:1 0.8:1 1.1:1 Fan Coil Heat and Cool 140 105 0.9:1 1.4:1 2.0:1 2.6:1 Radiant Floor 120 105 2.0:1 3.3:1 4.7:1 6.0:1 Radiant Ceiling 120 105 2.0:1 3.3:1 4.7:1 6.
Advanced Programming Feature The selection of the correct ratio depends on the initial temperature Set Point set on screen 02 and the desired system water temperature. If the building is too cold, increase the ratio value. After changing the ratio, wait several days and evaluate the comfort level before making another change. Line 2 may be modified by inserting the building design characteristics into the formula. The Reset Ratio will be modified to reflect those characteristics.
Water Temperature: W A T E R M A X : X X Screen number T E M X . X P M I N : X X Outdoor Cut-Off Temperature: U T D T E M P O O R X 8 . X Displays the minimum water temperature for the boiler. Range is determined by screen number 23. Factory default is 105°F (40.5°C) Minimum. Displays the maximum water temperature for the boiler. Range is determined by screen number 23. Factory default is 180°F (82.2°C) Maximum. O X 0 Screen number C U T O F F X X .
System Monitor: Screen number S Y S T E M M A S T E R M O N I T O R P B S S S B S S S A 1 1 A A This screen is only a display. Total # of stages available is set on screen 24. Staging control is set on screen 20. P= SYSTEM PUMP MODULE Rule: Always on before boiler. Always off after last boiler off + programmed delay, or outdoor sensor reading is above cut off temperature setting. P is relay #1 as supplied.
Auxiliary Delay: A U X Screen number D E L A Y X X X 1 S E 3 C Auxiliary Delay When CFH signal is "ON" the relay contact of the A1 Auxiliary module stays closed. When the CFH signal changes to "OFF", the contacts of the relay stay closed as long as the delay is set up. The AUX contacts operate on a delay after CFH. AUX turnoff range is 0 to 600 seconds. The default value is 180 seconds.
Boiler/Stage Off Delay: B O I X X X L Screen number R / S S E C T G O F F X X D X L Y S E 1 5 C Boiler Turn-Off Delay Stage Turn-Off Delay The Boiler Turn-Off Delay range is from 0 to 600 seconds. The Stage Turn-Off Delay range is from 0 to 600 seconds. The Stage Turn-Off Delay sets the time delay before a stage in a multi-stage boiler configuration is turned off. This delay starts when the stage or boiler preceding the next stage is turned off.
System Temperatures: These screen parameters are only available if the inlet and outlet sensors have been installed and selected. See screen 24. Screen number This screen is only a display. I N L E T X X X . O X Current boiler inlet or system temperature* U T L E T D E L T A X X X . X X X X . X Current boiler outlet or system temperature* 1 7 Boiler or System delta.* NOTE: 1. These values are currently reserved for viewing actual and delta temperatures. 2.
Password: P Screen number A S S W O R D 1 A A 9 A Used by maintenance personnel to change settings. In display mode shows AAA or current password. To enter the password: 1.Push the mode key. The cursor under the first A should start flashing. 2.Change the first letter by using the up or down key to the desired letter. Use the right key to go to the next letter and change it with the up or down key. Do the same to the last letter then push the mode key when done.
System Test: S Y S T Screen number E M N O T T E S T A C T 2 I V 1 E or ACTIVE This display will cycle between turning all LCD segments on for four (4) seconds then off for four (4) seconds. To stop this cycling push any button. Self-diagnostics are initiated at 0900 and 1900 hours. NOTE: 1) When system test is running, this will not affect control or boiler operation. 2) If system test is running, it can be terminated by pushing any button.
Master Unit: Screen number M A S T E S N S : X R 2 R 0, 1, 2 or 4 Number of temp. sensors. E L A Y : X A 1 thru 8 Number of staging contacts in use. See screen 25. U X : 4 X 0, 1, 2 or 3 Number of auxiliary boards in use. If SNS:0 This unit is a slave unit (No sensors required or active) If SNS:1 Water (System) - Turn outdoor reset ratio to "NONE" on screen 06.
Slave Unit: See Staging Table S L A V Screen number E S # C X O N N E C T E D 2 5 X Number of slaves connected: 01 thru 04 A unit with no sensors attached to it defines itself as the SLAVE unit. In program mode (see page 32) you identify which SLAVE unit you want it to be. SLAVE units are numbered from 1 to 4. Connect the master unit to each slave unit in parallel using RS485 wiring as noted in the Communications (RS485) Wiring section of this manual.
User Defaults: Screen number Program this screen when all other parameters have been entered. S U S E R E T U P D E D E F A U L F A U L T S T S 2 8 Press MODE button to get into program mode. Press UP or DOWN key to select “Setup Defaults”. Screen number F U S E R I N I S D H E E F A U L T S 2 8 D Press MODE button. Open panel and press SW3 to complete programming.
Alarm Call Telephone: A L A R M X X X X X X Screen number C A L L X X X X X T E L E X X X X 3 0 X Used to enter telephone number to be called when a fault occurs. Alarm Call ID: Screen number A L A R M X X X X X X C A L L X X X X I X D 3 1 X Used to identify person or place to be called when a fault occurs. Alarm Call Retry: A L X X A R Screen number M S Y C A L L R E T R Y S T E M I D L E . 3 . 2 .
PID Proportional - Integral - Derivative Control Interval - time in seconds that the PID updates KP - Proportional control (01 - 30) - Band in degrees above and below setpoint KI - Integral control (01 - 99) - Adjustable in % 0.0 - 1.0 KD - Derivative control (01 - 99) - Adjustable in % 0.0 - 10.
Screen number N E T W O R K S E T S L A V E : 1 R : X - U P X X X X X X 2 0 X X Screen number N E T W O R K S E T S L A V E : 2 R : X - U P X X X X X E T X X X X M O N X X X X C B 0 9 X X X X X C 5 0 3 X X X X Slave Unit: L A V E S C O N N E C T E A V E S N S : 0 R E X 1 1 X X 2 NOTE: On slave unit select 0 for number of sensors. Select which slave number you wish it to be, 01 through 04.
Y-200 Master/Slave Diagram 36
Sensor Resistance at Various Temperatures If a sensor error is suspected, perform the following: 1. Examine the wiring, ensuring continuity from controller to sensor(s). 2. Using a multimeter, measure resistance of sensor(s) and compare the value with the Table M below. 3. If all okay, replace main control board. Temperature (°F) Resistance (K Ohms) -10 1193.1 -20 1666.3 0 863.6 10 631.7 20 466.7 30 348.0 40 262.0 50 199.0 60 153.6 70 119.4 80 93.5 90 73.8 100 58.6 110 46.
Y-200 Illustrated Parts List Item No. 1-C 2-C 3-C 4-C 5-C 6-C 7-C 8-C 9-C 1-J 1-S 2-S 3-S 4-S 1-M 10-M Description PC Board Assy, Y-200 Expansion Board Assy, 4-Stage Auxiliary Board Assy Transformer Assy LCD Display Assy Control Keypad Modem Module Lon Works Module 4-20 MA/2-10 VDC Module Wire Bonding Connector Air Temp Sensor Assy Water Temp Sensor Assy Air/Water Temp Sensor Well Assy Retainer and Screw Ribbon Cable Display 38 Part No.
LIMITED WARRANTY Y-200 Series 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 (805) 278-5468 Litho in U.S.A.
