Raypak Y-200 User Manual

INSTALLATION & OPERATING

INSTRUCTIONS

Y-200 Series

Electronic Boiler Sequencer & Outdoor Reset Control System

Catalog No. 5000.62H Effective: 09-28-09 Replaces: 11-25-08 P/N 241125 Rev. 9

is a registered trademark of Underwriters Laboratories Inc. ®

Rev. 9 reflects the following: Changes to: C-UL Listed Mark on page 1.

CONTENTS

IMPORTANT SAFETY INSTRUCTIONS 4 INTRODUCTION 4

Concept of Operation 4 Y-200 Controller Configurations 5 Y-200 Options 5

INSTALLATION 6

Mechanical Installation 6 Electrical Installation 6 Controller Field Wiring 8 Communication Field Wiring 9 Air Temperature Sensor Installation 9 Water Temperature Sensor Installation 10 Power Test 11 Installation Verification Procedure 12

CONTROLLER FAMILIARIZATION 12

Control Screens 13 Circuit Board Layout 15 Keypad 16 Control Screen Displays & Programming 17

01 Initial Screen 17 02 Primary Parameters 17 03 Control Band 18 04 Offset 19 05 Holiday 20 06 Reset Ratio 20 07 System Status 22 08 Water Temperature 23 09 Outdoor Cut-Off Temperature 23 10 Outdoor Cut-Off Deadband 23 11 System Monitor 24 12 System Temperatures 24 13 Auxiliary Delay 25 14 Boiler/Stage On Delay 25 15 Boiler/Stage Off Delay 26 16 PID 26 17 System Temperatures 27 18 Lead Change Time 27 19 Password 28 20 Setup 28 21 System Test 29 22 Set Password 29

23 Water Temperature Limits 29 24 Master Unit 30 25 Slave Unit 31 26 LonWorks 31 27 Factory Defaults 31 28 User Defaults 32 29 Modem Password 32 30 Alarm Call Telephone 33 31 Alarm Call ID 33 32 Alarm Call Retry 33 33 Alarm Call Events 33

34 PID 34 Master Unit with Slaves 34 Y-200 Master/Slave Diagram 36 Sensor Resistance 37 Illustrated Parts List 38

WARRANTY 39

Y–200 SERIES ELECTRONIC BOILER CONTROL

SAFETY INSTRUCTIONS

OTE: 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.

Thank you for selecting the Raypak Y–200 Series Electronic Boiler Control. It is our sincere hope that you will enjoy its outstanding design, ease of use and energy-saving features.

Please Register

Before proceeding any further, please take a moment to complete the enclosed user registration form and mail a copy to: Raypak, Inc., Department Y–200, 2151 Eastman Avenue, Oxnard, CA 93030.

INTRODUCTION

The Y-200 Series Electronic Boiler Control (controller) is a microprocessor-based boiler 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, this controller has been engineered with the flexibility and raw power to tame the most demanding control situations. Utilizing state-of-the-art control algorithms, the Y-200 Series minimizes operating costs by maximizing energy efficiency.

Concept of Operation

The 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-200 Series provides the ultimate in personal comfort and efficiency of operation.

The controller is also well adapted to domestic hot water supply duty. By disabling the outdoor reset function, the Y-200 behaves as an energy-wise boiler sequencer. With the ability to control multiple firing stages, and such features as a revolutionary selectable lead-lag protocol, the Y-200 redefines "controllability" 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 Y-200 is reactivated and will hold the system temperature at the required point.

For replacement items, see page 38.

Y-200 Controller Configurations

Model No. Description Y-241 4-Stage Controller - Includes main controller assembly, air temperature sen-

or assembly (P/N 068634), water temperature assembly (P/N 068635) and one (1) stage contact board. Main controller includes one (1) mounted auxiliary contacts board.

Y-281 8-Stage Controller - Includes main controller assembly, air temperature sen-

sor assembly (P/N 068634), water temperature assembly (P/N 068635) and two (2) stage contact boards. Main controller includes one (1) mounted auxiliary contacts board.

Table A: Y-200 Controller Configurations

Y-200 Options

Option No. Description

Y-300 Alarm bell, 3” diameter. Shipped loose for field installation.

Y-301 Alarm bell, 4” diameter. Shipped loose for field installation.

Y-302

Y-303

Y-304

Y-305

Y-306

Y-307

Y-308

Second 4-stage Expansion Board. Converts Y-241 to Y-281. Ships

loose for field installation.

Auxiliary Relay Board. Adds control functions for external equipment such as combustion air louvers. Ships loose for field installation.

Slave Cable. Connects slave units to the master controller. Ships loose for field installation.

4-20 mA/2-10 VDC Control Board. Accepts 4-20 mA or 2-10 VDC input from external system such as a BMS to force a specific setpoint. Ships loose for field installation. Separate instruction manual; see

5000.64.

Inlet/Outlet Sensors. Provides a PAIR of sensors for the inlet and outlet temp. sensing ports. Displays temp. but does not affect control algorithm.

LonWorks Module. Provides full communication between a Y-200 series controller and a LonWorks-enabled system. Cannot have BOTH this AND a modem. Shipped loose for field installation. Separate instruction manual; see 5000.63.

Modem Module. Provides full communication between a Y-200 series controller and an external system. Cannot have BOTH this AND a LonWorks. Shipped loose for field installation. Separate instruction manual; see 5000.65.

Table B: Y-200 Options

INSTALLATION

CIRCUIT

BREAKER

HITE

GROUND

BLACK

GREEN

AB C

VOLT-OHM

METER

If the controller was not mounted on the boiler by the factory, care should be taken to select a suitable mounting location. The controller should be mounted on a solid and permanent base. The unit should be readily accessible for maintenance and installation purposes, and should be mounted so that the display is at a height and location convenient for viewing.

Mechanical Installation

Install the controller within 30 feet of the boiler(s). It must be mounted vertically with the conduit holes facing downward. The conduit holes are sized to accommodate standard 1/2" conduit fittings. If additional or larger conduit fittings are required, locate the conduit connections on the bottom of the module.

Slave units, if present, should be installed adjacent to the master unit. (Y-304 slave cable is approximately five feet long.)

Mount the controller using the mounting bracket and appropriate hardware in four (4) places.

NOTE: Shielded 18 (AWG) gauge stranded wire must be used to connect the sensors to the controller. The shielded cable should be protected by conduit whenever possible.

OTE: Minimum 18 AWG, 105°C, stranded wire

must be used for all low voltage (less than 30 volts) external connections to the unit. Solid conductors should not be used because they can cause excessive tension on contact points. Install conduit as appropriate. All high voltage wires must be the same size (105°C, stranded wire) as the ones on the unit or larger.

Check Your Power Source

Using a Volt-ohm meter, check the following voltages at the terminal block inside the unit:

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 bolt hole 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).

Electrical Installation

Requires: 120 VAC, Draws 0.5 amp; 60 Hz.

120 VAC 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 no less than 125% of minimum rating.

It is strongly recommended that the controller and the boiler(s) be supplied from the same power source. Install conduit as appropriate.

Fig. 1: Volt-ohm Meter

AC = 108 Volts AC Minimum, 132 Volts MAX AB = 108 Volts AC Minimum, 132 Volts MAX BC = Must be less than .6 Volts AC

Power to the Controller

Controller Field Wiring

• Observe (follow proper) 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

• 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.

be a “WIRED” ground.)

For Single-Stage (ON/OFF) Boilers

ll stage connections on the control board are con-

A nected at the {TH} (Thermostat) location on the boiler wiring diagram.

For Multiple-Stage Boilers

First stage connections on the control board are connected at the {TH} (Thermostat) location on the boiler wiring diagram. Second (or third, etc.) stage connections on the control board are connected at the locations shown on the boiler wiring diagram.

Fig. 2: Wiring Diagram

otes:

. Tighten terminal strip clamping screws to 2.5 in-

lbs. Breakage from over-torquing is not covered under warranty.

. Use stranded copper conductors only. For supply

connections, use wires sized on the basis of 60°C (140°F) ampacity and rated a minimum 90°C (194°F).

3. Install disconnect for each control unit.

. For external building control or thermostat control,

remove wiring to J6 (CHF) connector and activate with 12 to 28 VAC.

Fig. 3: Wiring Diagram

Communication (RS485) Wiring Required for Optional Slave Unit(s)

Y-304 Slave Cable Installation from System Control Module

• Y-304 slave cable or equivalent shielded communications cable (Belden #9842, Belden #8132 or Alpha 3492C) must be used. Maximum cable length 100 ft. Correct polarity must be observed. Make use of wire color coding to ensure polarity.

• The shielding [foil wrapper-bare wire (drain)] MUST be grounded. Grounding is done at the Master Y-200 Control only. DO NOT ground the shield at the slave unit end of the cable.

• Note: Equivalent shielded cable must be suitable for RS485 communication applications; must have 100-140 ohm impedance and less than 30 picofarad per foot capacitance.

Air Temperature Sensor Installation

Fig. 5: Typical Outdoor Air Temperature Sensor

• Locate the sensor on the coldest side of building, usually the north side.

• Must be installed in conduit that does not contain any other wiring.

• Port J18 (see Fig. 4) is used for the interconnection between the master controller and slave units.

• Master/Slave interconnection should be wired from Master to Slave #1, Slave #1 to Slave #2, Slave #2 to Slave #3, and Slave #3 to Slave #4.

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

• Locate no higher than 2/3 way up the side of the building, or between the 2nd and 3rd floor if the building is more than 3 stories tall.

• Do not locate under an overhang, near wall corners, near drafts from stacks, air moving devices, windows, doors, or balconies.

• Shielded twisted pair (18 AWG) must be used for sensor connections. Polarity must be observed. Cable length shall not exceed 300 feet, and the shielding must be grounded.

• Grounding is done at the Master Y-200 control ONLY. Do Not ground the Slave units or Temperature Sensor enclosure.

• Must be installed with properly-sized conduit that contains no other wiring.

• The outdoor air temperature and water temperature sensor are identical and interchangeable.

Fig. 4: Master RS485 Communications Cable

Schematic

Water Temperature Sensor

12” M

5’ MAX

OR MORE STAGES OR

4:1 TURN DOWN OR HIGHER

Installation

Hydronic Heating Applications

• Hydronic installations may require outdoor reset function. See page 11, and screen 02.

• Ensure shielded cable length does not exceed 300 feet. Use 18 AWG shielded wire for sensor connections.

• Must be installed in properly-sized conduit with no other wiring.

NOTE: Piping diagrams in this manual are not intended to replace an engineered piping system.

Fig. 6: Typical Water Sensor

• Locate the water sensor as shown in Fig. 6.

NOTE: When the system involves a variable-speed pump, it is recommended that the temperature sensor be installed in the tee connecting boiler outlet piping to the system. This is to ensure the control can respond to the changing conditions of the system by placing the sensor as close to the blend location as possible and then provide an appropriate and measured response to maintain desired system delivery temperature.

Domestic Hot Water Supply Applications

Fig. 7: Domestic Hot Water Supply

• Outdoor reset function should be disabled. See screen 06 and 24.

Power Test

Check Power

Utilizing a Volt-ohm meter (VOM) monitor the following on the controller for proper voltage levels. Check at the Terminal Block (TB-1).

From To Indication

TB pin 1 TB pin 2

TB pin 1

TB pin 2

Table C: Voltage Measurements

Single Point

Ground

Single Point

Ground

108 VAC to 132

VAC

108 VAC to 132

VAC

Less than 0.6 VAC

Installation Verification Procedure

CONTROLLER FAMILIARIZATION

Before proceeding any further, please verify that the user registration form has been completed and mailed.

Mechanical Installation

Verify that the mechanical installation has been completed in accordance with the instructions.

Outdoor Air Temperature Sensor

Verify that all Outdoor Air Temperature Sensor installation parameters have been met.

Water Temperature Sensor

Verify that the Water Temperature Sensor installation parameters have been met.

Optional Equipment

his system is configured utilizing a LCD display (2

T lines, 20 characters each) with keypad for data entry. Open the front cover of the Control Box for access to the LCD display and keypad. Open the control panel to gain access to the interface connections.

REFER TO THE TABLES ON THE FOLLOWING PAGES AND THE DISPLAY SCREENS FOR DETAILED CONFIGURATION INSTRUCTIONS.

NOTE: Controller is shipped with factory defaults. your system may require different program settings.

J Verify that optionally ordered equipment installa-

tion parameters have been met.

System Module Installation

Verify electrical power wiring connections.

J Verify electrical connection torque requirements.

J Verify Outdoor Air Temperature Sensor wiring.

J Verify Water Temperature Sensor wiring.

J Verify Power Test has been completed successful-

ly.

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