Raypak 240692 User Manual
ELECTRONIC BOILER
SEQUENCER & OUTDOOR
RESET CONTROLLER
Catalog No: 5000.54H
Effective: 06-19-07
Replaces: 02-01-04
Installation and Operating Instructions
PN 240692 Rev . 9
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.
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TABLE OF CONTENTS
Contents Page
Basics 4
Important Safety Instructions 4
Introduction 5
Concept of Operation 5
Optional Configurations 5
Control Features 6
Installation and Mounting 7
Mechanical Installation 7
Electrical Installation 7
Wiring: Power to Controller 8
Air Temperature 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 List 27
System Start-Up Settings 28
Troubleshooting Guide 29
Warranty 30
BASICS
Contents
Item Quantity
Y–Series Boiler Control, Installed on Boiler(s) As Ordered
Outdoor T emperature Sensor Assembly 1
Water Temperature Sensor Assembly 1
Optional Equipment 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. Installation and service personnel may be required by some states to be licensed. If your
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 damage, and will void the warranty .
CAUTION: MORE THAN ONE (1) SUPPLY SOURCE. THIS APPLIANCE HAS PROVISIONS
TO BE CONNECTED TO MORE THAN ONE (1) SUPPLY SOURCE. TO REDUCE THE RISK
OF ELECTRIC SHOCK, DISCONNECT ALL SUCH CONNECTIONS BEFORE SERVICING.
CAUTION: RISK OF ELECTRIC SHOCK. MORE THAN ONE (1) DISCONNECT SWITCH
MAY BE REQUIRED TO DE-ENERGIZE THE EQUIPMENT BEFORE SERVICING.
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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. Ideally suited for use in hydronic heating and domestic hot water
supply applications, the Y-Series has been engineered with the flexibility and raw power to tame the most demanding
control situations. Utilizing a state-of-the-art PID control algorithm, the Y-Series minimizes operating costs by maximizing energy efficiency.
CONCEPT OF OPERATION
This controller is an outdoor reset control that is perfect for managing hydronic heating systems. Two temperature
sensors are used to control system response. One sensor is used to monitor the outdoor temperature, the other sensor is
used to regulate the temperature of the system water. By varying the temperature of the heating medium in response to
changes in the outdoor temperature, the Y-Series provides the ultimate in personal comfort and efficiency of operation.
The Y-Series controller is also well adapted to domestic hot water supply duty. By disabling the outdoor reset function, the
Y-Series behaves as an energy-wise boiler sequencer. With the ability to control 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
prevents the system from wasting energy trying to heat a building that is already at a comfortable temperature. Once the
outside temperature has fallen to the point that the system requires heat input to maintain the building temperature, the YSeries is reactivated and will hold the system temperature at the required point.
The Y-Series can also be equipped with an optional clocked alternate setpoint package. The alternate setpoint allows
control operation at an independent setpoint temperature and can be used either for night setback or preoccupancy boost.
An electromechanical 7-day timer switches the control between regular and alternate setpoint modes and can be set at two
hour activation intervals. See the section on the optional clocked alternate setpoint for details.
OPTIONAL CONFIGURATIONS
Y-2B BASIC UNIT, NO OPTIONS
Y-3B BASIC UNIT PLUS DIGITAL DISPLAY
Y-4B BASIC UNIT PLUS NIGHT SETBACK OPTION
Y-5B BASIC UNIT PLUS NIGHT SETBACK AND DIGITAL DISPLAY OPTIONS
PLEASE REGISTER
Before proceeding any further, please t ake a moment to complete the enclosed user registration form and mail a
copy to Raypak, Inc., Department Y–Series, 2151 Eastman Avenue, Oxnard, CA 93030
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CONTROL FEATURES
The Y-Series sequence panel includes:
• Standard Indicator Lights:
Stages 1 to 8: Red, indicates which stages are turned on.
Pump: Green, indicates that the pump circuit is energized.
Call for Heat: Green, indicates that a call for heat signal is present.
Control On: Green, indicates outdoor temperature is below the Outdoor Cutoff Temperature
potentiometer setting and that the boiler will respond to a call for heat.
Setting Error: Red, indicates one or more of the on-board settings is incorrect.
Sensor Error: Red, indicates that the Water or Outdoor Temperature Sensor has an out-of-range reading.
• Adjustment Knobs:
Reset Ratio: 0.12:1 to 8:1; determines how much the micro-controller calculated T arget
Temperature will change for a given outdoor temperature change.
Control Band: 1°F to 10°F; the temperature above or below the Target Temperature at which the boiler
turns off and on.
Pump Off Delay: 0 to 10 min.; determines when the pump shuts off after entering Outdoor Cutoff mode.
. Outdoor Cutoff 32°F to 200°F; a warm weather shutdown feature. When the outdoor temperature
Temperature: exceeds this setting, the boiler will not fire unless placed in manual override 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.
Set Point: 40°F to 220°F; the system output temperature desired when the outdoor temperature is
70°F or, in domestic water applications, the desired water temperature.
• Logic T est Button, Jumper and Switches:
System Test Button (S1): initiates micro self test which causes the status indicator lights to blink 5 times
indicating the micro-controller is functioning properly.
Last Stage Jumper (J2): selects the last active stage used for boiler control.
First Stage #1 Selector (S2): designates the first stage of each boiler in a multi-boiler system. Switch
position #1 should always be on.
Mode Selector (S3): switch #1 selects either Manual or Auto Lead-Lag Mode. Switch #2 provides an
Outdoor Reset defeat. Switch #3 configures the Y–Series for Master/Slave ganged
operation. Switch #4 allows the Set Point to be set below 105°F.
Bypass Switches (S5): allows user to turn on any stage(s) regardless of current settings and
conditions if, and only if, the pump relay is already activated.
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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. The unit should be readily
accessible for maintenance and installation purposes, and should be mounted so that the indicating lights are at a height
and location convenient for viewing.
MECHANICAL INSTALLA TION
Install the control within 10 feet of the boiler(s). The control must be mounted vertically with the conduit holes facing
downward. The conduit holes are sized to accommodate standard conduit fittings. If additional or larger conduit fittings
are required, the holes should be located on the bottom of the module.
Mount the control using the mounting bracket and appropriate 3/8” or 1/4” hardware in four (4) places.
A minimum of eighteen (18) inches clearance from the front, and six (6) inches clearance on all other sides is required for
service access. 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 fasteners.
INSTALL CONDUIT AS APPROPRIATE.
NOTE #1 : Shielded 18 gauge cable must be used to connect the sensors to the Boiler Control Module. The shielded
cable should be protected by conduit whenever possible.
NOTE #2 : 18 AWG - Stranded wire must be used for all connections to printed circuit board (PCB). Solid conductors
should not be used because solid wire conductors can cause excessive tension on contact pointS.
ELECTRICAL INSTALLATION
ELECTRICAL CHARACTERISTICS: 120 VAC, 60 Hz, 0.5A
120 V AC FEEDER CIRCUITS
Install a surge protection device sized appropriately for your installation at each module.
Install a separate disconnect means for each load. Use appropriately sized wire for equipment as defined by NEC and/or
local code. All primary wiring should be 125% of minimum rating.
It is strongly recommended that the Y-Series Electronic Control Module and the boiler(s) be supplied from the same power
source.
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CHECK YOUR POWER SOURCE
Using a volt-ohm meter, check the following voltages at the circuit breaker panel:
BLACK
CIRCUIT
BREAKER
WHITE
GREEN
GROUND
ABC
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
VOLT-OHM
METER
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.
• 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 enclosures, and where the system is grounded, the grounded service
conductor to the grounding electrode.
GRN
WHT
BLK
120VAC
SUPPLY
HOT
RTN
GND
GRN
SPG
SINGLE POINT
GROUND
WHT
BLK
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AIR TEMPERA TURE 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.
• 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 sensing elements. Connect only one red wire and the black wire to the sensor connecting points. The
second element is an installed spare.
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W A TER TEMPERATURE SENSOR INST ALLA TION
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.
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