Raypak 5000.72A Installation & Operating Instructions Manual Download Page 3

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WARNINGS

WARNING:

Improper installation, adjustment,

alteration, service, or maintenance can cause

property damage, personal injury or loss of life.

Refer to the user's information manual provided with

the heater. Installation and service must be

performed by a qualified installer, service agency, or

the gas supplier.

WARNING:

Risk of electrical shock. More than one

disconnect switch may be required to de-energize

the equipment before servicing.

WARNING:

When servicing or replacing any

components of the control system within this unit, be

certain that:

• The gas is off.

• All electrical power is disconnected.

Table Of Contents

WARNINGS...........................................................3

Introduction............................................................4

VERSA

Control Board.........................................4

VERSA

Display Board ........................................5

VERSA

PIM™ Module ........................................6

Quick Start Set-Up and Programming Tips...........8

Application & Modes .............................................9

Boiler Applications.................................................9

Hydronic Mode 1...................................................10

Hydronic Mode 2...................................................15

Hydronic Mode 3...................................................21

Water Heater Applications.....................................27

Pool Heater Applications.......................................32

VERSA IC

Control Menus ..................................36

Control Settings.....................................................41

Cold Water Protection (CWP) ...............................43

Heater Rotation.....................................................46

Sequence of Operation .........................................48

Wiring Connections – PIM™.................................50

Wiring Connections – VERSA IC

Control............55

Energy Management System Setup .....................56

Cascade Set-up and Operation ............................57

“Limp-Along” Operation of PIM™..........................62

Troubleshooting.....................................................63

Technical Data.......................................................66

Resetting VERSA

to Factory Defaults ................67

Resetting PIM™ to Accept New ID Card ..............67

Modbus Communication Values............................69

Table Of Figures....................................................76

List Of Tables ........................................................77

Summary of Contents for 5000.72A

Page 1: ...INSTALLATION OPERATING INSTRUCTIONS Catalog No 5000 72A Effective 11 01 14 Replaces 08 18 14 P N 241493 Rev 3 VERSA IC Integrated Boiler Control ...

Page 2: ...2 Rev 2 is a software revision J1214G Aug 2014 completely new edition of this manual ...

Page 3: ... disconnected Table Of Contents WARNINGS 3 Introduction 4 VERSA Control Board 4 VERSA Display Board 5 VERSA PIM Module 6 Quick Start Set Up and Programming Tips 8 Application Modes 9 Boiler Applications 9 Hydronic Mode 1 10 Hydronic Mode 2 15 Hydronic Mode 3 21 Water Heater Applications 27 Pool Heater Applications 32 VERSA IC Control Menus 36 Control Settings 41 Cold Water Protection CWP 43 Heater...

Page 4: ...RSA Control Board becomes inactive or if the communications between the VERSA Control Board and the PIM are terminated for any reason This limp along mode operation is outlined in more detail starting on page 62 The VERSA Control Board is ANSI Z21 23 certified as a controller In addition the VERSA IC control system allows cas cading control of multiple units up to 4 units total without the need fo...

Page 5: ...ter Protection o Mod Communication Connections o RS485 future usage o Modbus RS485 RTU ASCII VERSA Display Connection Ribbon Cable VERSA PIM Connection RJ45 Connection DIP Switches o 1 Access Level OFF Installer ON Advanced o 2 Cascading OFF Follower Slave ON Master o 3 Cold Water Protection OFF None ON CWS CWR o 4 Proportional Output Selection OFF 0 10 VDC ON 0 20mA requires 500 ohm resistor o 5 ...

Page 6: ...he PIM is designed for a range of boilers water heaters and pool heaters including ON OFF staged and modulating types The PIM is intended to provide safe lighting and supervision of the burners in a heater The PIM is also designed to connect to and receive commands from the VERSA Control Board for high er level functionality to include indirect DHW outdoor reset diagnostic messaging and other syst...

Page 7: ... and Setpoint Call present Icon When Displayed Pumps Menu View Test Boiler Pump Menu View Test and Boiler Pump is on System Pump Menu View Test and System Pump is on DHW Pump Menu View Test and DHW Pump is on Burner Menu View Test 1 Menu View Test and PIM 1 is on 2 Menu View Test and PIM 2 is on 3 Menu View Test and PIM 3 is on 4 Menu View Test and PIM 4 is on Burner Rate Menu View Test and PIM is...

Page 8: ...ing limp along operation VERSA IC Unit Type ID Card The VERSA IC Identification Card ID Card is a small circuit card that determines the operating parameters for each individual model by unlocking the correct pro gram within the VERSA Platform Ignition Module referred to simply as PIM throughout the rest of this manual It is permanently affixed to the chassis of the heater and MUST be present for ...

Page 9: ...er loop WH and P models do not require a mode selection as they are configured only for direct DHW or pool heating operation 8 Use the Application drawings and descriptions as a guide to set up the control 9 A change to a value will be made as soon as you push the ITEM button change the MENU screen or wait until the 180 second timer expires 10 Should any error be displayed check the Troubleshootin...

Page 10: ... 11 MODE 1 Hydronic Single Boiler CWP BOIL 3 Way MODE 1 Single Maximum distance not to exceed 4 pipe diameters or 12 whichever is less Maximum distance not to exceed 4 pipe diameters or 12 whichever is less A B AB GY MOD BK COM R 24VAC CWP Valve detail ...

Page 11: ...r S1 and Boiler Inlet Sensor S2 In order to enable MIX settings VERSA DIP 3 must be set to ON position Raypak s Cold Water protection system utilizes a proportional 3 way valve to bypass water from the boiler outlet to the inlet during opera tion when the system return water temperature is below the minimum acceptable level as defined in the Installation and Operating manual for the product being ...

Page 12: ...g 12 MODE 1 Hydronic Multi Boiler Fig 13 MODE 1 Hydronic Multi Boiler MIX TYPE BOIL Maximum distance not to exceed 4 pipe diameters or 12 whichever is less Maximum distance not to exceed 4 pipe diameters or 12 whichever is less ...

Page 13: ...ed 4 pipe diameters or 12 whichever is less GY MOD BK GND R 24VAC B A AB CWP Valve detail The cascade will be controlled by the System Sensor connected to the Master boiler S3a See System Sensor Installation on page 9 The VERSA IC of each boiler will provide Max Delta T control to cycle the burner to ensure that the Delta T is not exceeded between Boiler Outlet Sensors S1a b c d and Boiler Inlet S...

Page 14: ...dbus Rate EMS Rate PIM Identity is H Minimum Target Boiler Temperature Sys Purge 0 20 to 20 00 min 0 20 min Modbus Temp Rate PIM DIP Purge On Sets the length of the System Pump Purge Units F or C F Always Show Units Using Icons in Display When RESET from target screen is selected the following items will be available for adjustment Out Start 35 to 85 F 70 F PIM Identity is H Target Rset Outdoor Re...

Page 15: ...following settings will become available Mode Modbus Off Monitor Temp Rate Off Always Modbus Operating Mode Off Monitor Temp Control Rate Control Address 1 to 247 1 Modbus Off Modbus Slave Address Data Type RTU or ASCI RTU Modbus Off Modbus Data Type Baud Rate 2400 9600 19K2 57K6 115K 19K2 Modbus Off Communication Speed of Network Parity None Even Odd Even Modbus Off Error Detection of System Inte...

Page 16: ...p P1 runs during any call for burner operation and is delayed off as user defined in the BOILER menu after the burner has shut down The System Pump P2 runs whenever the system is enabled for heating and the outdoor air temperature is lower than the WWSD temperature setting if utilized Priority mode toggles the System Pump P2 off during an indirect call for heat The Indirect Pump P3 runs during an ...

Page 17: ...with Indirect DHW and CWP MIX TYPE BOIL MASTER Fig 17 MODE 2 Hydronic Multi Boiler with Indirect DHW on system Maximum distance not to exceed 4 pipe diameters or 12 whichever is less Maximum distance not to exceed 4 pipe diameters or 12 whichever is less ...

Page 18: ...connected in parallel from each cascade fol lower to allow these pumps to be functional during limp along operation During an indirect call for heat with or without priority selected the cascade firing rate is determined by the System Supply Sensor S3a temperature The VERSA IC will provide Max Delta T control to cycle the burner if the Max Delta T is exceeded between Boiler Outlet Sensors S1a b c ...

Page 19: ...the following items will be available for adjustment Out Start 35 to 85 F 70 F PIM Identity is H Target Rset Outdoor Reset Starting Temperature Out Design 60 to 45 F 10 F PIM Identity is H Target Rset Outdoor Reset Design Temperature Boil Start 35 to 150 F 70 F PIM Identity is H Target Rset Starting Boiler Target Temperature when Outdoor Temperature is at Outdoor Start Boil Design 70 to 200 F 180 ...

Page 20: ... will have the proper wiring and pipe configuration to control its own inlet temperature MIX TARGET 50 TO 140 F 120 F MIX DIP ON Inlet Target Temperature MIX LOCK ON OFF OFF MIX DIP ON The equipment will trigger a warning when MIX Target is not reached within 7 minutes MIX LOCK ON Alarm and lockout MIX LOCK OFF Alarm only MIX TRIM 5 TO 5 0 MIX DIP ON This adjustment is for various types and sizes ...

Page 21: ...and without CWP The Fig 20 MODE 3 Hydronic Single Boiler with Indirect DHW Maximum distance not to exceed 4 pipe diameters or 12 whichever is less CWP diagrams will show an individual 3 way valve at the boiler MIX Type BOIL The following piping con figurations can be used as fixed set point or set up to work in conjunction with an Outdoor Air Reset Sensor S4 to adjust the target water temperature ...

Page 22: ...operation see IND Sensor page 43 for further details To ensure proper operation during limp along mode connect an aqua stat across the indirect DHW override termi nals or install a jumper across the Indirect DHW override terminals and set PIM operator dial to be equal to DHW Target temperature to prevent an over temperature condition from occurring During an indirect call for heat the firing rate ...

Page 23: ... Ensure DIP switches 1 and 2 on the VERSA Control Board are in the ON position to make programming changes Prior to setting any DIP switches the heater must be turned off MODE 3 Cascade The following diagrams will show cascade systems up to 4 boilers maximum with and without CWP in con junction with an indirect DHW demand located on the system loop The CWP diagrams will show either an individual 3...

Page 24: ...t DHW on system with CWP MIX TYPE PLNT MASTER A B AB Fig 23 MODE 3 Boiler with Indirect DHW on system and CWP MIX TYPE BOIL Maximum distance not to exceed 4 pipe diameters or 12 whichever is less Maximum distance not to exceed 4 pipe diameters or 12 whichever is less ...

Page 25: ... during operation when the system return water tem perature is below the minimum acceptable level Item Range Default User Settings When is it Displayed Description BOILER 1 2 3 4 ON OFF OFF Cascade Followers present FT_Bus 1 2 3 4 are connected among all active units as defined in the Installation and Operating manual for the product being installed Priority mode toggles off the System Pump P2a wh...

Page 26: ...set Outdoor Reset Design Temperature Boil Start 35 to 150 F 70 F PIM Identity is H Target Rset Starting Boiler Target Temperature when Outdoor Temperature is at Outdoor Start Boil Design 70 to 200 F 180 F PIM Identity is H Target Rset Design Boiler Target Temperature when the Outdoor Temperature is at Outdoor Design Hottest Water on Coldest Day WWSD 40 to 100F 70F Target Rset PIM Identity is H The...

Page 27: ... Address Data Type RTU or ASCI RTU Modbus Off Modbus Data Type Baud Rate 2400 9600 19K2 57K6 115K 19K2 Modbus Off Communication Speed of Network Parity None Even Odd Even Modbus Off Error Detection of System Integrator needs this information Table D MODE 3 SETUP menu WH Direct DHW Applications This section covers single or multiple heater installa tions using WH model for use on direct Domestic Ho...

Page 28: ...28 Fig 26 WH Direct DHW single Heater with CWP VS Pump MIX TYPE 2 Fig 25 WH Direct DHW Single Heater ...

Page 29: ...upply Sensor S3 MUST BE installed in the stor age tank and functional for heater operation Ensure DIP switch 1 and 2 on the VERSA Control Board must be in the ON position to make programming MASTER Fig 28 WH Direct DHW Application Multiple Heaters with CWP VS Pump MASTER Fig 27 WH Direct DHW Application Multiple Heaters changes Prior to setting any DIP switches the heater must be turned off WH Cas...

Page 30: ...TUP ADJUST Menu Target EMS Modbus Not Visible EMS Temp Rate Modbus Temp Rate EMS Energy Management System Analog Target Temperature MODB Modbus TANK SETP 50 TO 150 F 125 F PIM Identity is WH WH Setpoint Temperature TANK DIFF 2 to 10 F 5 F PIM Identity is WH WH Differential Temperature Sys Purge OFF 0 20 to 20 00 min 0 20 min Modbus Temp Rate PIM DIP Purge On Sets the length of the System Pump Purg...

Page 31: ...eed of response MIX INV ON OFF OFF MIX DIP ON This option is related to the use of spring return actuators with a propor tional 2 or 3 way valve When communication with BMS is required user must enable Modbus port using the settings below by select ing other than OFF at Mode Modbus screen the following settings will become available Mode Modbus Off Monitor Temp Rate Off Always Modbus Operating Mod...

Page 32: ...VS Pump Fig 29 Pool Single condensing Heater application Maximum distance not to exceed 4 pipe diameters or 12 whichever is less Maximum distance not to exceed 4 pipe diameters or 12 whichever is less ality while achieving maximum system efficiency The piping configurations below are representative of con densing and non condensing heaters The CWP diagrams will show both a heater pump as well as a...

Page 33: ...during any call for heat The Heater Pump P1 is delayed off as user defined in the BOILER menu The System Pump output P2 is delayed off only when the heater is disabled by opening the con nection across the enable disable at the PIM MASTER Fig 31 Pool Multi Heaters Cascade Maximum distance not to exceed 4 pipe diameters or 12 whichever is less There is no mode to configure for Pool operation as thi...

Page 34: ... be connected in parallel from each cascade follower to allow the system pump to be functional during limp along operation if this output is used to operate the filtration pump Maximum distance not to exceed 4 pipe diameters or 12 whichever is less Each Follower boiler connects back to the Master boiler via a 2 wire connection for communication within the cas cade All sensors Supply S3a and Pool R...

Page 35: ... equipment will trigger a warning when MIX Target is not reached within 7 minutes MIX LOCK ON Alarm and lockout MIX LOCK OFF Alarm only MIX TRIM 5 TO 5 0 MIX DIP ON This adjustment is for various types and sizes of units as well as various actuator motor speeds and types supplied by Raypak MIX SPEED SLOW MED FAST MED MIX DIP ON This setting defines speed of response MIX INV ON OFF OFF MIX DIP ON T...

Page 36: ...ges to items in the SETUP menu The available menus are VIEW SETUP BOILER MONITOR and TOOLBOX The RESET button is used to reset the control when a hard lockout condition has occurred See specific heater I O for instructions regarding resetting the control User Interface Menus The following menus are available in the control by hit ting the MENU button on the membrane switch and then pushing the ITE...

Page 37: ... SUPPLY sensor has a fault IND SUPPLY 22 to 266 F PIM Identity is H MODE 3 Current temperature being supplied to the indirect the num ber field displays if the indirect DHW sensor fails Boil OUTLET 22 to 266 F Always Current boiler outlet temperature as communicated from the PIM the number field displays if the outlet sensor fails Boil INLET 22 to 266 F Always Current boiler inlet temperature as c...

Page 38: ...5 min waiting period has expired VENT WALL 22 TO 266 F N A Always model dependent Current Vent temperature LIMIT TEMP 22 TO 266 F N A Always Current Outlet Limit temperature EMS VDC 0 0 to 10 0 N A Always Current EMS signal in Volts DC FIRE RATE 0 100 N A Always PIM firing rate SPEEDX 1000 0 0 to 20 00 N A PIM Identity Modulating Blower speed in revolutions per minute rpm x 1000 OUTLET MAX 20 TO 4...

Page 39: ...r Temperature recorded Press UP DOWN buttons for 3 sec to clear this entry OUTDOOR LO 76 to 149 F MASTER MODBUS TEMP RATE EMS TEMP RATE PIM Identity is H TARGET RSET Captures the lowest Outdoor Temperature recorded Press UP DOWN buttons for 3 sec to clear this entry SYS HI 22 to 266 F MASTER MODBUS RATE EMS RATE PIM Identity is H or P Captures the highest System Supply Temperature recorded Press U...

Page 40: ...gged error present Alternate HISTORY 6 with lookup and display the most recent error information if less than 30 days old Press UP DOWN buttons for 3 sec to clear this entry HISTORY 7 Logged error present Alternate HISTORY 7 with lookup and display the most recent error information if less than 30 days old Press UP DOWN buttons for 3 sec to clear this entry HISTORY 8 Logged error present Alternate...

Page 41: ...tpoint operation This value is only available to set change when the PIM identity is H and the TARGET SETP The range of adjustments is from 50 F to the maximum value programmed into the PIM for instance XFyre 50 to 192 F XPak FT 50 to 192 F MVB XTherm 50 to 220 F The default value is 180 F Tank Setpoint TANK SETP This is the set point temperature for the storage tank It is only available to set ch...

Page 42: ...er to the spe cific product I O Manual for this information Minimum Target Boiler Temperature TARGET MIN This is the minimum target temperature that the boiler can be set to This value is only available to set change when the PIM identity is H The range of adjustments is from 50 F to 180 F Indirect Sensor Selection IND SENSOR This setting determines whether a DHW sensor or an aquastat will control...

Page 43: ...er operation MIX Lock The equipment will trigger a warning when MIX Target is not reached within 7 minutes MIX Lock defines whether the system will alarm and continue running or will alarm and lockout the unit MIX Lock ON will shut the unit down and provide an alarm if the inlet temperature is not achieved within 7 minutes requiring manual reset MIX Lock OFF will only pro vide an alarm contact clo...

Page 44: ...dbus Parity PARITY The choices are NONE EVEN and ODD The default is EVEN 1 stop bit is used for EVEN or ODD 2 stop bits are used for NONE Heater Mass BOIL MASS The heater mass setting 1 or 2 allows the installer to adjust the VERSA IC Control to the thermal mass of the system The heater mass setting automatically determines the preliminary PID modulation parame ters Boiler Pump Purge BOIL PURGE Th...

Page 45: ...of 1 00 OD 2 00 SYS This means that for each degree the outdoor temperature drops the water temperature will increase 2 degrees The VERSA control Reset Ratio allows for full cus tomization to match any buildings heat loss characteristics A heating curve that relies not only on Outdoor temper ature but also on the type of radiation will improve heat comfort The user can fine tune these adjustments ...

Page 46: ...ill force the cascade to achieve target differential by increasing the firing rate of the active unit until the system temperature is satisfied Once the system temperature is satisfied the active unit will cycle off This will in turn allow the rotation event to occur to ensure equalized runtime of the cascade members Target Differential Auto Manual The VERSA IC control system is configured as stan...

Page 47: ...the limit of the appliance This is done to prevent overshooting the temperature so as not to trip the manual reset high limit The manual differential is adjustable from 2 F to 42 F and is split equally above and below the target temperature Minimum Run Time The VERSA IC Control system attempts to maintain a minimum run time of 210 seconds for each heater This is accomplished several ways automatic...

Page 48: ...ill flash HOLD at 1 second intervals during this period of time Any CFH received from the system during this User Test will be ignored until the test is completed For Cascade configurations the USER TEST item is only available though the master unit To perform a user test at each individual follower go to each Boiler menu from the Master user interface and enable only the boiler to be tested When ...

Page 49: ...rns on the HSI and the HSI prov ing current is verified to be above the configured value b The configured heat up delay takes place to allow the HSI element to reach ignition tem perature c The gas valve output is energized for the trial for ignition time to light the burner d The HSI is de energized during the last sec ond of the trial for ignition period to sense for the burner flame e The flame...

Page 50: ...ately and the control will go into ignition lockout 34 Should a loss of flame occur on Hot Surface Ignition models during a heating cycle the gas valve is de energized within 0 8 seconds and the blower goes through a post purge After the flame recycle delay the control attempts to relight the burner multi try models allow 3 tries for ignition with inter purges If the burner relights normal Fig 34 ...

Page 51: ... 2 DHW Sensor Common 10K Thermistor J Curve Connector Pin Function Type Rating J2 3 System Supply Sensor 10K Thermistor J Curve J2 4 System Sensor Common 10K Thermistor J Curve J2 5 Outdoor Sensor 10K Thermistor J Curve J2 6 Outdoor Sensor Common 10K Thermistor J Curve J2 7 tN4 Communicat ions Communications Network Signal J2 8 0 10VDC Analog EMS Input 0 10 VDC or 4 20mA J2 9 Common Ground J3 1 Ft...

Page 52: ...0 5 Fan Power 18VDC 20 30AWG 2 0A J10 6 Fan Ground 20 30AWG 2 0A Connector Pin Function Type Rating J10 7 FUTURE J10 8 FUTURE J11 1 24VAC Power 30VAC 8A J11 2 24VAC Common 30VAC 8A J12 1 Gas Valve Common Isolated Relay 120 240VAC 8A J12 2 2 nd Stage Gas Valve 120 240VAC 5A J12 3 Gas Valve Return 120 240VAC 5A J12 4 2 nd Stage Gas Valve Return 120 240VAC 5A J12 5 Gas Valve MV PV 120 240VAC 8A J12 6...

Page 53: ...he event of losing the Master unit Follower units are made capable of operating the System and IND DHW pumps as required in limp along mode see page 62 The System pump outputs from each cas cade member must be connected in parallel to activate the system pump during limp along operation This configuration will allow the system to continue to oper ate during Master unit failure or lose of the Maste...

Page 54: ...MP SYSTEM PUMP DHW PUMP DHW PUMP 5A MAX 5A MAX DHW PUMP DHW PUMP 5A MAX 5A MAX TERMINAL BLOCK TERMINAL BLOCK TERMINAL BLOCK TERMINAL BLOCK 120VAC 120VAC RELAY RELAY 120VAC 120VAC RELAY RELAY DEDICATED DEDICATED AC POWER AC POWER A A B B COIL PUMP PUMP RELAY RELAY C C 1 1 R R 3 3 0 0 8 8 6 6 R R 1 1 4 4 2 2 1 1 R R 3 3 120VAC 1PH 240VAC 1PH A HOT HOT L1 B COMMON HOT L2 C GROUND GROUND ...

Page 55: ...to PIM CN4 1 External Valve Dry contact closure with call for burner CN4 2 External Valve CN4 3 Fan Damper Dry contact closure with call for burner CN4 4 Fan Damper CN4 5 Extra STATUS burner Dry contact closure with burner CN4 6 Extra Connecto r Pin Function Diagnostic Wiring CN5 1 Condensate Switch CN5 2 Vent Temp Limit CN5 3 Auto High Limit CN5 4 Low Water Cutoff CN5 5 Blocked Vent CN5 6 Low Gas...

Page 56: ...d set PIM operator dial to be equal to DHW Target temperature to prevent an over temperature con dition from occurring If a VERSA Control is not present the PIM shall activate the Indirect DHW pump whenever the Indirect DHW call is active The Boiler pump may also be activated based on the Indirect DHW piping configuration setting 3 Connect the indirect tank sensor to the terminals marked INDIRECT ...

Page 57: ...y responsible for supply water temperature control as well as managing minimum cycle times to prevent short cycling of the equipment Cascade Set up and Operation The VERSA IC system has the capability of control ling the operation of up to 4 heaters without the addition of an external sequencing controller In order to establish a cascade system one heater needs to have the VERSA IC Control DIP swi...

Page 58: ...us cables not exceed 200 feet Connect the Cascade Ft_bus wires to the PIM by pressing down on the slots with a small screwdriver and then inserting the wires into the holes See Fig 39 Fig 41 Ft_bus Wire Connection ...

Page 59: ...8 17 1 172 0 8 1 162 129 184 129 94 2 17 0 171 5 8 0 160 128 182 128 93 5 16 8 171 1 7 9 159 127 180 127 92 9 16 6 170 6 7 8 157 126 179 126 92 3 16 5 170 2 7 7 156 124 177 124 91 7 16 3 169 7 7 6 154 123 175 123 91 1 16 2 169 3 7 5 153 122 173 122 90 4 16 0 168 9 7 4 151 121 171 121 89 8 15 8 168 4 7 3 149 120 169 120 89 2 15 7 168 0 7 2 148 119 167 119 88 6 15 5 167 5 7 1 146 118 165 118 87 9 15...

Page 60: ...78 65 6 9 6 151 1 3 4 88 77 95 77 64 9 9 4 150 7 3 3 86 76 93 76 64 3 9 3 150 2 3 2 85 75 92 75 63 7 9 1 149 8 3 1 83 73 90 73 63 1 9 0 149 3 3 0 82 72 88 72 62 4 8 8 148 9 2 9 80 71 86 71 61 8 8 6 148 4 2 8 78 70 84 70 61 2 8 5 148 0 2 7 77 69 82 69 60 6 8 3 147 5 2 6 75 68 80 68 60 0 8 2 147 1 2 5 74 67 78 67 59 3 8 0 146 7 2 4 72 66 76 66 58 7 7 8 146 2 2 3 71 65 75 65 58 1 7 7 145 8 2 2 69 63 ...

Page 61: ... at each unit Cascade Follower Pump and Sensor Wiring 1 Once the Master has been identified additional boilers will be designated as Followers DIP switch 2 on each follower VERSA board must be set to the OFF Down position 2 For each follower boiler connect the boiler pump wires to the terminal block at the rear of each unit Connect to terminals 4 5 and 6 3 The System pump and DHW pump outputs may ...

Page 62: ... parameter settings to refine the firing rate for optimal setpoint control Full auto differential capabil ity is retained when enabled using DIP switch 1 on the PIM The PIM will respond to a DHW call signal on the field wiring terminals The DHW pump is activated and the temperature is controlled to the operating setpoint of the potentiometer The boiler pump will be activat ed whenever there is a C...

Page 63: ...proper gas valve closure Clean burner and electrodes Ignition Lockout Fault Red LED 3 Flashes Check the gas supply Check transformer Check igniters Check wiring Press reset button on PIM membrane switch Recycle power Ignition Proving Current Fault Red LED 4 Flashes Check HSI element for those models equipped with a hot surface igniter Replace as necessary Low Voltage Fault Red LED 5 Flashes Check ...

Page 64: ...eck gas pressure switch tubing IGNITION Ignition fault Reset ignition control Push either RESET button on membrane switch or reset button on PIM or recycle power LIMIT TRIP Boiler outlet temperature tripped the high limit Push reset button on high limit control if Manual Reset High Limit tripped Wait for water temperature to drop and auto reset high limit will reset Check pump operation Check bypa...

Page 65: ... 4 ERR 3 sec Communications with PIM 4 were established but then lost Confirm cabling and DIP switch settings CONDENSATE 3 sec Condensate switch has tripped Check for blockage of condensate drain Check condensate switch Check condensate switch wiring Check for heat exchanger leak which might overwhelm the capacity of the condensate drain causing this error VENT TEMP 1 sec Vent temperature switch h...

Page 66: ...alve Relays 5 0A max continuous Combustion Blower 5 0A max for standard J2 connection 15 0A max for heavy duty K5 relay terminals Hot Surface Igniter 5 0A max 120 240VAC Pump Relays 5 0A max continuous Alarm Relay 2 0A 30VDC or 30VAC max Operating Temperature 40 to 176 F 40 to 80 C Storage Temperature 40 to 185 F 40 to 85 C Flame Sensitivity 0 7 µA minimum Flame Failure Response or Reignition Time...

Page 67: ...reset test button 8 Remove power from the PIM control 9 Connect connector J6 to the PIM control 10 Power up the PIM control 11 If the reset was successful the green LED shows steady ON 12 If the red and yellow LEDs are ON and the green LED is OFF the reset was NOT successful 13 If the reset was not successful repeat steps 1 11 14 If reset was successful remove power and reset DIP switches for desi...

Page 68: ... for Modbus Modbus Communication Values The VERSA IC Control has a setting called Modbus that determines how it operates when a external con troller using the Modbus protocol is connected the available settings are 1 MODBUS OFF a Modbus messages are ignored 2 MODBUS MNTR Monitor Mode a The VERSA IC Control operates as usual however the Modbus connection allows for remote viewing and adjustment of ...

Page 69: ... R 8 6 1 S R p m u P W H D DHW Pump Runtime 9 6 1 S R Setback R S16 Only relevant if MODBUS MNTR 10 reserved Table V Modbus System Status Registers ITEM RANGE DEFAULT USER SETTINGS WHEN DISPLAYED DESCRIPTION MODBUS OFF MNTR TEMP RATE OFF Always ModBus Operating Mode Off Monitor Temp Control Rate Control ADDRESS 1 to 247 1 MODBUS ON ModBus slave address DATA TYPE RTU ASCI RTU MODBUS ON ModBus data ...

Page 70: ...on Status R S16 24 Boiler1 Runtime R S16 25 Boiler1 Cycles R S16 26 Boiler1 Pump R S16 27 Boiler1 Pump Runtime R S16 28 Boiler1 Error Code R S16 29 Boiler1 Error History 1 R S16 30 Boiler1 Error History 2 R S16 31 Boiler1 Error History 3 R S16 32 Boiler1 Error History 4 R S16 33 Boiler1 Error History 5 R S16 34 Boiler1 Error History 6 R S16 35 Boiler1 Error History 7 R S16 36 Boiler1 Error History...

Page 71: ...er2 Ignition Status R S16 53 Boiler2 Runtime R S16 54 Boiler2 Cycles R S16 55 Boiler2 Pump R S16 56 Boiler2 Pump Runtime R S16 57 Boiler2 Error Code R S16 58 Boiler2 Error History 1 R S16 59 Boiler2 Error History 2 R S16 60 Boiler2 Error History 3 R S16 61 Boiler2 Error History 4 R S16 62 Boiler2 Error History 5 R S16 63 Boiler2 Error History 6 R S16 64 Boiler2 Error History 7 R S16 65 Boiler2 Err...

Page 72: ...3 Ignition Status R S16 82 Boiler3 Runtime R S16 83 Boiler3 Cycles R S16 84 Boiler3 Pump R S16 85 Boiler3 Pump Runtime R S16 86 Boiler3 Error Code R S16 87 Boiler3 Error History 1 R S16 88 Boiler3 Error History 2 R S16 89 Boiler3 Error History 3 R S16 90 Boiler3 Error History 4 R S16 91 Boiler3 Error History 5 R S16 92 Boiler3 Error History 6 R S16 93 Boiler3 Error History 7 R S16 94 Boiler3 Error...

Page 73: ...ition Status R S16 111 Boiler4 Runtime R S16 112 Boiler4 Cycles R S16 113 Boiler4 Pump R S16 114 Boiler4 Pump Runtime R S16 115 Boiler4 Error Code R S16 116 Boiler4 Error History 1 R S16 117 Boiler4 Error History 2 R S16 118 Boiler4 Error History 3 R S16 119 Boiler4 Error History 4 R S16 120 Boiler4 Error History 5 R S16 121 Boiler4 Error History 6 R S16 122 Boiler4 Error History 7 R S16 123 Boile...

Page 74: ...esign R W S16 70 to 200 F 1005 DHW Exchange R W S16 OFF 70 to 200 F 1007 DHW Tank R W S16 OFF 50 to 180 F 1008 DHW Differential R W S16 2 to 10 F 1009 DHW Priority R W S16 0 no DHW priority 1 DHW priority 1 1010 DHW During UnOcc R W S16 0 No DHW during UnOcc 1 DHW during UnOcc 1011 WWSD During Occ R W S16 40 to 100 F 1012 WWSD During UnOcc R W S16 40 to 100 F 1013 Monitor Mode Tank MODBUS MNTR and...

Page 75: ...40 Internal fault 18 Vent Blocked 41 Delta T Max 19 Low Gas Pressure 42 HSI Proof 20 High Gas Pressure 43 Low Voltage 21 Extra 44 Blower Speed 22 Flow Switch 45 Safety Input 23 Air Pressure tN4 Errors 24 Option 1 46 Duplicate Master 25 Option 2 47 Device Error 26 Option 3 48 Device Lost Error Codes Register Parameter Read Write Format Note Register Address Pump Control Mode Parameters MODBUS TEMP ...

Page 76: ...le Boiler with Indirect DHW and CWP MIX TYPE BOIL 22 Fig 22 MODE 3 Hydronic Multi Boiler with Indirect DHW on system 23 Fig 23 MODE 3 Boiler with Indirect DHW on system and CWP MIX TYPE BOIL 24 Fig 24 MODE 3Hydronic Multi Boiler with Indirect DHW on system with CWP MIX TYPE PLNT 24 Fig 25 WH Direct DHW Single Heater 28 Fig 26 WH Direct DHW single Heater with CWP VS Pump MIX TYPE 2 28 Fig 27 WH Dir...

Page 77: ... 59 Table N 2 VERSA 0 10 VDC 4 20 mA operation 60 Table O LED Flash Codes on PIM 63 Table Q Error messages generated from the PIM but displayed on the VERSA IC Display 64 Table P Error messages generated from the VERSA IC Control Board 65 Table R VERSA IC Control Board Ratings 66 Table S PIM Ratings 66 Table T 10K Sensor resistance values 67 Table U Modbus Screens 69 Table V Modbus System Status R...

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Page 80: ...80 www raypak com Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 Fax 805 278 9725 Litho in U S A ...

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