Raypak VERSA IC Installation & Operating Instructions Manual Download Page 10

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Fig. 10: MODE 1, Hydronic Single Boiler

Fig. 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

(+ MOD)

(COM)

(+ 24VAC)

CWP Valve detail

Summary of Contents for VERSA IC

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 Application...

Page 4: ...SA 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...

Page 5: ...er 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...

Page 6: ...e 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 he...

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 Pum...

Page 8: ...ng 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...

Page 9: ...r 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 con...

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...

Page 11: ...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...

Page 12: ...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 diamete...

Page 13: ...d 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 Instal...

Page 14: ...bus 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 Alw...

Page 15: ...ollowing 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...

Page 16: ...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 an...

Page 17: ...ith 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 n...

Page 18: ...onnected 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...

Page 19: ...he 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...

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 wi...

Page 21: ...nd 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 th...

Page 22: ...peration 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 In...

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 d...

Page 24: ...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 Maxim...

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 Fol...

Page 26: ...et 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 18...

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...

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: ...pply 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...

Page 30: ...UP 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 Setpoin...

Page 31: ...ed 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...

Page 32: ...S 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...

Page 33: ...uring 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...

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...

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...

Page 36: ...es 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...

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...

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 Al...

Page 39: ...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 Tempera...

Page 40: ...ged 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 pres...

Page 41: ...point 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 instanc...

Page 42: ...r 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 availabl...

Page 43: ...r 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...

Page 44: ...bus 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...

Page 45: ...f 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...

Page 46: ...ll 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...

Page 47: ...he 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...

Page 48: ...ll 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 TE...

Page 49: ...ns 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 val...

Page 50: ...tely 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...

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...

Page 52: ...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 Comm...

Page 53: ...e 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...

Page 54: ...P 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...

Page 55: ...o 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 contac...

Page 56: ...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 whe...

Page 57: ...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...

Page 58: ...s 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 Wir...

Page 59: ...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...

Page 60: ...8 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...

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 t...

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 s...

Page 63: ...roper 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 switc...

Page 64: ...ck 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 tr...

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...

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 continuou...

Page 67: ...set 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...

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...

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 DESCR...

Page 70: ...n 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 Histor...

Page 71: ...r2 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 Er...

Page 72: ...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 Erro...

Page 73: ...tion 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 Er...

Page 74: ...sign 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 prior...

Page 75: ...0 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...

Page 76: ...e 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...

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 generat...

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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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