Raypak B6000 User Manual

B6000

BOILER MANAGEMENT SYSTEM

Catalog No.: 5000.51J Effective: 10-14-05 Replaces: 06-15-03

SYSTEM CONTROL BOILER MONITOR

Installation and Operating Manual

Part No. 240564

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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B6000 BOILER MANAGEMENT SYSTEM (BMS)

Contents

Equipment Quantity

B6000 System Control 1 B6000 Boiler Monitor, Installed on Boiler(s) As Ordered Outdoor Temperature Sensor Assy. (064140) 1 Water Temperature Sensor Assy. (064139) 1 Optional Equipment As Ordered

Check packaging for damage or missing components.

IMPORT ANT NOTICE: These instructions are intended for the use by qualified personnel only,

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 is such, 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 CONTROL HAS THE POTENTIAL TO BE

CONNECTED TO MORE THAN ONE (1) ELECTRICAL SUPPLY SOURCE. TO REDUCE THE RISK OF ELECTRIC SHOCK, DISCONNECT ALL CONNECTIONS BEFORE SERVICING.

CAUTION: RISK OF ELECTRIC SHOCK. MORE THAN ONE (1) DISCONNECT SWITCH MAY BE

REQUIRED TO DE-ENERGIZE THE EQUIPMENT BEFORE SERVICING.

PLEASE REGISTER Before proceeding any further, please take a moment to complete the enclosed user registration form and

mail to Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030.

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TABLE OF CONTENTS

PAGE Contents 3 Getting Started 5 Foreword 5 Installation and Mounting 7 Mechanical Installation 7 Electrical Installation 8 Check Your Power Source 8 Air Temperature Sensor 9 Water Temperature Sensor 10 Important Configuration Note 12 Wiring - Air and Water Sensors 12 Communication (RS485) Wiring 13 Wiring: Power Source to Control and Boiler Modules 14 Power Test 15 Boiler Monitor Select Switch 16 Boiler Monitor Communications Jumper W1 17 Optional Boiler Monitor Control 18 Field Wiring - Single Boiler 18 Field Wiring - Multiple Boilers 19 Installation Verification Procedure 20 System Control/Display Familiarization 21 Power Up - Boiler Monitor 22 Power Up - System Control Module 23 Displays 23 Important (Start Alternate) 35 System Control Box 39 System Control Board Pictorial 40 Replacement Parts List 42 Boiler Monitor Control Box 44 System Settings 46 Troubleshooting Guide 47

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Thank you for selecting the Raypak B6000 Boiler Management System (BMS). It is our sincere hope that you will enjoy its power, ease of use and energy saving features.

GETTING STARTED

To learn about the B6000 BMS, simply install it and start using it. The following steps will outline the things you will need for installation and to prepare it for use.

FOREWORD

The B6000 Boiler Management System is comprised of a Boiler Monitor for each boiler, one System Control for each system, an Outdoor Air Temperature Sensor and a Water Temperature Sensor. The system is a microprocessor-based energy manage-

ment hot water control system that controls single or multiple boiler installations used for hydronic heating and/or domestic hot water supply.

The B6000 BMS is designed to provide the ultimate in personal comfort, efficiency and operation. The system requires minimal attention after initial setup. The system control to boiler can be separated by up to 2000 feet. It is capable of being monitored from a remote location, with an optional modem package and a Personal Computer (PC) equipped with a modem. The Raypak Boiler Management System minimizes boiler operator attendance and increases system reliability and cost effectiveness.

The System Control Module has

• A screen that displays the different operating characteristics of the system.

• A green light, to the left of the screen, that indicates normal system operating conditions.

• A red light, to the right of the screen, that flashes when a fault occurs.

• An alarm buzzer with a silencing switch. If the buzzer is silenced the red light will continue to flash until the diagnosed fault is corrected.

• Buttons which are used to monitor and program the selectable system features.

• On board relays designed to control primary system pumps, combustion vent louvers and/or other boiler accessories.

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Each Boiler Monitor Module contains

• The boiler on-off power switch.

• The boiler manual override switch, which allows the boiler to operate independently in the event of asystem control failure.

• Standard indicator lights: "Power On" - green, indicates the boiler is powered. "Manual Override" - red, indicates boiler is in manual override mode. "Call for Heat" - amber, indicates there is a call for heat. "Pump" - green, indicates pump circuit is energized. "High Limit" - red, indicates boiler is off on high limit. "Aqua Stat" or "Thermostat" - red, indicates boiler is off on operating control (may not appear on all models). "Flow" - red, indicates boiler fault - no flow. "Ignition" - red, indicates ignition failure. "Pilot" - yellow or amber, indicates pilot is lit. "Safety Fault" - red, indicates fault in safety valve or safety circuit. "Main Gas" - green, indicates modulating valve is energized.

• Boiler identification dip switch.

B6000/A Illustrated

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INST ALLA TION AND MOUNTING

The System Control module should be mounted on a permanent base not subject to vibrations, moisture or dust. It should be mounted with the display screen at a convenient height for reading and for access to the alarm silence button located on the top of the cabinet.

Dimensions & Weight

Boiler Monitor System Control 18-3/4" W 12-1/2" W 5-1/2" D 4-3/4" D 17-1/2" L 15-3/16" L 21-1/4 lbs. 20 lbs.

MECHANICAL INSTALLATION

Install the B6000 System Control Module at a convenient place within 2000 feet of the boiler(s). The B6000 System Control Module must be mounted vertically with conduit holes facing downward. Conduit holes are provided to accommodate standard conduit fittings. Additional or larger conduit fittings that may be required should be located on the bottom of the module.

Mount the B6000 System Control with 3/8" or 1/4" hardware in four (4) places. A minimum of six (6) inches clearance on all sides is required and a minimum of eighteen

(18) inches clearance from the front is required for service access. The hinged side of the box is to the right and the clearance (minimum 3" from bolt hole on the right side) should be sufficient to open the cover.

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A sub-panel containing the disconnect switches and surge suppressors is required at or near the equipment location(s). For accessibility remove the lower interior panel, by removing the four (4) access screws.

INSTALL CONDUIT AS APPROPRIATE. NOTE: Shielded cable, Belden #8132 or #9842 or equivalent, must be used to connect the

sensors to the System Control Module.

DIMENSIONS AND WEIGHT

System Control Module 19 1/2 lbs Boiler Monitor Module 21 1/4 lbs

15 3/16 L 17 1/2 L 12 1/2 W 18 3/4 W 4 3/4 D 5 1/2 D

ELECTRICAL CHARACTERISTICS

Control Module - 120 VAC, 0.5A; 60 Hz Boiler Monitor Module - 120 VAC, 2.0A; 60 Hz

ELECTRICAL INSTALLATION

115 VAC FEEDER CIRCUITS

Install surge protection device(s) sized appropriately for your installation. Install separate disconnect means for each load. Pull in appropriately sized wire for equipment as defined by NEC and/or local code. All primary wiring will be 125% of minimum rating. It is strongly recommended that the System Control Module and the Boiler Control Module be supplied from the same source power.

CHECK YOUR POWER SOURCE

Using a volt-ohm meter, check the following voltages at the circuit breaker

Hot

BLACK

WHITE

GROUND

Neutral (Return)

GREEN

VOM

PIDOMA

AC = 108 Volts AC Minimum, 132 Volts MAX

Hot to Ground

AB = 108 Volts AC Minimum, 132 Volts MAX

Hot to Neutral

BC = Must be less than 1.0 Volts AC

Neutral to Ground

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AIR TEMPERATURE SENSOR

• INSTALLATION

TYPICAL AIR TEMPERATURE SENSOR

Air Temperature Sensor Installation Notes:

Fig. #9040

• Locate on coldest side of building, usually (North or West) side.

• Install the sensor in a shaded area, out of direct sunlight.

• Locate no higher than 2/3 way up side of building or between 2nd and 3rd floor if building

is more than 3 stories tall.

• Shielded cable length not to exceed 4000 feet.

• Do not locate under an overhang, near wall corners, near drafts from stacks, air

moving devices, windows, doors, or balconies.

• Assure cable length does not exceed 4000 ft. Use larger gauge (Belden #9842)

cable if run is in excess of 100 ft.

• Install in conduit with no other wiring.

• Observe proper wire colors. Sensor is polarity sensitive.

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WATER TEMPERATURE SENSOR

• INSTALLATION

The water sensor should be installed in the system supply.

Return

Single Boiler

Supply

Multiple Boilers

Water Sensor

TYPICAL WATER SENSOR

Water Temperature Sensor Installation Notes:

• Locate sensor in system piping within a minimum of three (3) feet or prior to the first take off connection, on the downstream side of the System Supply Loop.

• Assure cable length does not exceed 4000 ft. Use larger gauge (Belden #9842) wire if run is in excess of 100 ft.

• Install in conduit with no other wiring.

• Observe proper wire colors. Sensor is ploarity sensitive.

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WATER TEMPERATURE SENSOR INSTALLATION (Domestic Hot Water Supply)

HOT WATER SUPPLY

STORAGE

TANK

IMMERSION WELL WATER SENSOR 1/2 NPT

COLD WATER

OUTLET

INLET

BOILER

INLET

OUTLET

B6000

SIMPLIFIED DIAGRAM OF TYPICAL PIPING

(PIPING LAYOUT MAY VARY PER SPECIFIC APPLICATION)

AIR TEMPERATURE SENSOR MUST BE INSTALLED ACROSS AIR TEMPERATURE SENSOR CONTACTS. THE SENSOR IS NOT ACTIVATED AND CAN BE LEFT STORED IN B6000 ENCLOSURE.

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IMPORTANT

Configuration Note:

If your System Control Module is supplied with a single Field Wiring

Teminal Strip use "Alternate" wiring. (See page 36-38)

WIRING - AIR AND WATER SENSORS

TO THE SYSTEM CONTROL MODULE

WATER SENSOR

OUTDOOR SENSOR

SYSTEM CONTROL

TERMINAL TB 2

BELDEN #8132 OR BELDEN #9842

NOTE: Tighten terminal strip clamping screws 20 lbs - In (2.26N.m) Breakage from over torquing is not covered under warranty.

Use copper conductors only.

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For supply connections use wires sized on the basis of 60°C Ampacity and rated Min. 90°C (194°F).

COMMUNICATION (RS 485) WIRING

System Control Boiler Monitor

• Use Belden #9842 Cable Or Equivalent (See Note). Polarity must be observed. Make

use of wire color coding to ensure proper polarity.

• The shielding foil wrapper - bare wire (drain) - MUST be grounded.

Grounding is done at the System Control Module only. DO NOT ground at Boiler Monitor.

•

Note: Equivalent shielded cable must be suitable for RS 485 communication applications; must have 100-140 ohm impedance; and less than 30 picofarad per foot capacitance.

• Install in conduit with no other wiring.

BELDEN #9842

NOTE: Tighten terminal strip clamping screws 20 lbs - In (2.26N.m) Breakage from over torquing is not covered under warranty.

Use copper conductors only. For supply connections use

wires sized on the basis of 60°C Ampacity and rated Min. 90°C (194°F).

BOILER MONITOR SYSTEM CONTROL TERMINAL TB 3 TERMINAL TB2

RS 485 Communications Cable Schematic

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WIRING:WIRING:

WIRING:

WIRING:WIRING: ules.ules.

ules.

ules.ules.

P P

er Sourer Sour

er Sour

er Sourer Sour

ce to System Contrce to System Contr

ce to System Contr

ce to System Contrce to System Contr

ol and Boiler Mod-ol and Boiler Mod-

ol and Boiler Mod-

ol and Boiler Mod-ol and Boiler Mod-

NOTE: Tighten terminal strip clamping screws 20 lbs - In (2.26N.m) Breakage from over torquing is not covered under warranty.

Dia. #9

• Observe proper Polarity.

• Observe proper wire colors.

• Provide external surge suppressor capable of maintaining system integrity.

• Provide overload protection and disconnect means as required by code and for equipment serviceability.

• Conduit can not be used as the ground. (Must be "WIRED" ground).

• Very Important: 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.

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Use copper conductors only. For supply connections use

wires sized on the basis of 60°C Ampacity and rated Min. 90°C (194°F).

POWER TEST

CHECK POWER Utilizing a Volt-Ohm-Meter (VOM) monitor the following on the "System Control Module"

and "Boiler Monitor(s)" for proper voltage levels.

POWER TEST TABLE Module Test Points Indication

System Control TB1-1- TB1-2 108 VAC to 132 VAC System Control TB1-1- TB1-3 108 VAC to 132 VAC System Control TB1-2- TB1-3 LESS THAN 1 VAC System Control TB1-1 - I 108 VAC to 132 VAC System Control TB1-2 - I LESS THAN 1 VAC System Control TB1-3 - I LESS THAN 0.5 VAC

Module Test Points Indication Boiler Monitor TB1-1- TB1-2 108 VAC to 132 VAC

Boiler Monitor TB1-1- TB1-3 108 VAC to 132 VAC Boiler Monitor TB2-2- TB2-3 LESS THAN 1 VAC Boiler Monitor TB1 -1 - I 108 VAC to 132 VAC Boiler Monitor TB2 -2 - I LESS THAN 1 VAC Boiler Monitor TB3 -3 - I LESS THAN 0.5 VAC

FROM: BOILER MONITOR to SYSTEM CONTROL

Boiler Monitor System Control Indication TB1 - 1 TB1 - 1 LESS THAN 0.5 VAC TB1 - 2 TB1 - 2 LESS THAN 0.5 VAC TB1 - 3 TB1 - 3 LESS THAN 0.5 VAC TB1 - 2 TB1 - 3 LESS THAN 0.5 VAC

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IMPORTANT: The Boiler Monitor control board has a series of dip switches which identify the boiler(s) (SW2). It is required that the switches be set as shown in the switch position table shown below.

BOILER MONITOR CARD PICTORIAL

BOILER MONITOR SELECT SWITCH

SWITCH POSITION

BOILER NUMBER SWITCH 1234 5678 8 OOOO OOOO 7 OOOO OOOO 6 OOOO OOOO 5 OOOO OOOO 4 OOOO OOOO 3 OOOO XXXX 2 O O X X O O X X 1 O X O X O X O X

SWITCH O = Open X = Closed

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