Raypak 240692 Installation And Operating Instructions Manual Download Page 1 | Manualshive

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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

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Summary of Contents for 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: ...nstallation 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 2 ...

Page 3: ...emperature Sensor 9 Water Temperature Sensor Installation 10 Hydronic Installations 10 Domestic Hot Water Installations 11 Pool Heating Installations 12 Field Wiring 13 Power Test 14 Control Familiarization 15 Sequence of Operation 16 Manual Override 16 Indicator Lights 18 Control Functions 19 Reset Ratio Chart 19 Circuit Board 23 Interior Jumper Switches 24 Optional Controls 26 Replacement Parts ...

Page 4: ...ur 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 damag...

Page 5: ...l up to eight firing stages and such features as a revolutionary First On First Off lead lag protocol the Y Series redefines controlability in domestic water applications The controller is equipped with an energy saving warm weather shutdown capability When the outdoor temperature rises above an adjustable Outdoor Cutoff Temperature the system automatically transitions to a dormant state This prev...

Page 6: ...erride mode Outdoor Cutoff 1 F to 10 F the number of degrees below the Outdoor Cutoff O C Deadband Temperature which causes the O C to reset Boiler On Delay 0 to 5 min sets the time interval between sequential boiler start ups Stage On Delay 0 to 60 sec determines the time delay between stages turning on Max Water Temp 70 F to 235 F the maximum value that the Target Temperature is allowed to reach...

Page 7: ...ss 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 faste...

Page 8: ...cal 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 Very Important A grounding electrode conductor shall be used to connect the equipment grounding conductors the equipment encl...

Page 9: ...ee stories tall Do not locate under an overhang near wall corners near drafts from stacks air moving devices windows doors or balconies Shielded cable length run is not to exceed 300 feet Install with properly sized conduit that contains no other wiring Observe proper wire colors The outdoor air temperature and water temperature sensors are identical and interchangeable Both are equipped with dual...

Page 10: ...ensor 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 10 ...

Page 11: ...The Outdoor Air Temperature will appear to be about 77 F 2 Set switch 2 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 Temper...

Page 12: ...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 WATER TEMPERATURE SENSOR INSTALLATION POOL HEATI...

Page 13: ...tdoor Air Temperature Sensor see NOTE 4 Water Temperature Sensor P5 Stage 1 Stage 2 Stage 3 Stage 4 1 2 3 4 5 6 7 8 Stage 5 Stage 6 Stage 7 Stage 8 Pump Relay Pilot Duty Only 2 5 Amp Max 250V Max Thermostat Jumpered or Building Management System Outdoor Temp Water Temp 1 2 3 P1 1 2 P4 P6 1 2 3 4 5 6 7 8 P2 1 2 3 4 Notes 1 Tighten terminal strip clamping screws to 4 in lbs Breakage from over torqui...

Page 14: ...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 controlle...

Page 15: ...lave 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 E Switch 5 reserved F Switch 6 reserved G Switch 7 reserved H Switch 8 reserved 4 Lead Lag Selector Rotary switch...

Page 16: ...emperature 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 ...

Page 17: ...17 Panel with Clock LCD Y 5 Configuration Shown Y SERIES ELECTRONIC BOILER CONTROL MODULE Night Setpoint Option Digital Display Option ...

Page 18: ... may also be connected to a building management system which will produce the call for heat signal as required CONTROLONINDICATOR The Control On Indicator illuminates if all settings and system conditions are such that the control can function properly and outdoor temperature cutoff temperature setting is less than or equal to the outdoor temperature SETTINGERRORINDICATOR The Setting Error Indicat...

Page 19: ...ratio of 2 1 a 50 F 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 19 Suggested Settings The selection of the correct ratio is dependent on the initial temperature Set Point and the desired system water temperature If th...

Page 20: ...ith 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 ...

Page 21: ...ate This provides a control deadband that limits the boiler from short 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 fo...

Page 22: ...ature 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 b...

Page 23: ...CIRCUIT BOARD 23 S5 MANUAL BYPASS SWITCH S4 MANUAL LEAD LAG SELECTOR SWITCH S2 FIRST STAGE SELECTOR I D MAINTENANCE PLUG TEST J2 LAST STAGE SELECTOR JUMPER S1 SYSTEM TEST S3 MODE SELECTOR ...

Page 24: ...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 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...

Page 25: ...itch and the output stages switches are interlocked such that the output stages can only be turned on if the pump is on SYSTEMTEST 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...

Page 26: ... 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 MECHANICAL CLOCK 7 DAY Set to the appropriate local time Note Turn the numbered dial clockwise to set time ALTERNATE ...

Page 27: ...ammed 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 PART NO 006039F 006034F 005764F 006031F 005657F N A 005654F 005700F 005701F 005299B 004821F 006033F 006032F REPLACEMENT PARTS LIST ...

Page 28: ..._____ Default Value 3 min Default Value 3 F Boiler on Delay ______ Outdoor Cutoff Temp ______ Default Value 30 sec Default Value 65 F Stage on Delay ______ Max Water Temp ______ Default Value 10 sec Default Value 180 F Set Point ______ Default Value 140 F Optional Alternate Set Point ______ INTERIOR JUMPER SWITCH SETTINGS Last Stage J2 Output ON Switch S2 Mode Selector Switch S3 Lead Lag Switch S4...

Page 29: ...or 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...

Page 30: ...tedRAYPAKServiceDealerorService 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 Raypak reserves the right at all times to inspect the claimed defect and verify warranty coverage at its factory EXCLUSIVE WARRANTY LIMITATION OF LIA...

Page 31: ...pak 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 www raypak com ...

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