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Catalog No: 5000.54H
Effective: 06-19-07
Replaces: 02-01-04
ELECTRONIC BOILER
SEQUENCER & OUTDOOR
RESET CONTROLLER
Installation and Operating Instructions
PN 240692 Rev. 9
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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. 2
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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 o
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BASICS Contents Item Quantity Y–Series Boiler Control, Installed on Boiler(s) As Ordered Outdoor Temperature 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 syst
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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 flexibili
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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 sett
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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 a
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CHECK YOUR POWER SOURCE Using a volt-ohm meter, check the following voltages at the circuit breaker panel: BLACK CIRCUIT VOLT-OHM BREAKER METER WHITE GREEN GROUND AB C 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 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. • Provid
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AIR TEMPERATURE SENSOR Red (connect) Fig. #9040 Black (connect) Red (spare) 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
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WATER TEMPERATURE SENSOR INSTALLATION 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. 10
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WATER TEMPERATURE SENSOR INSTALLATION DOMESTIC HOT WATER INSTALLATIONS Y-Series Controller Fig. # 9497.1 Air temperature sensor must be installed across air temperature sensor contacts. The sensor is not activated and can be left stored in controller enclosure. DOMESTIC HOT WATER APPLICATION SETUP PROCEDURE 1. Install a 10,000 Ohm, 1/8 Watt resistor between pins 1 and 2 on P2 connector (see pg. 13), in place of the Outdoor Air Temperature Sensor. The Outdoor Air Temperature will appear to be a
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WATER TEMPERATURE SENSOR INSTALLATION POOL HEATING INSTALLATIONS Fig. # 9498 Fig. # 9499 1. Install the air temperature sensor across the air temperature sensor contacts (P2, pins 1 and 2; see the field wiring diagram on pg. 13). 2. On the mode selector switch (S3), set switch #2 (Outdoor Reset) to ON to disable the outdoor reset function. (See pg.s 15 and 23). 3. Set the Outdoor Cutoff Temperature to 200°F. (See pg. 21.) 4. Adjust the setpoint to desired pool temperature. Thereafter, the cont
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FIELD WIRING P5 1 Stage 1 2 3 Single-Stage (On/Off) Boilers Stage 2 4 5 - All stage connections on the control Stage 3 6 board are connected at the {TH} 7 (Thermostat) location on the Stage 4 8 boiler wiring diagram. 1 Multiple-Stage Boilers Stage 5 2 3 - First stage connections on the Stage 6 4 control board are connected at 5 the {TH} (Thermostat) location Stage 7 6 on the boiler wiring diagram. 7 Stage 8 8 - Second (or third, etc.) stage connections on the control P6 board are connected at th
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INSTALLATION VERIFICATION PROCEDURE REGISTER 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. SYSTE
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CONTROL FAMILIARIZATION The System is configured using the circuit board jumpers and switches, and the front panel control potentiometers. Open the front cover of the Boiler Control Box for access to the front panel. Remove the front panel to gain access to the jumpers and switches on the Y-Series Electronic Boiler Control circuit board. Refer to the Interior Jumper and Switches section of this manual (pg. 24) for detailed configuration instructions. 1. Last Stage Selector. Install the jumper
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SEQUENCE OF OPERATION 1. When the reset is enabled, the Y-Series Control continously monitors outdoor temperature using the outdoor temperature sensor. When the outdoor temperature falls below the outdoor cutoff tempersture, the Control becomes active and closes the primary pump relay, energizing the primary system circulating pump. The Control then monitors the system supply water temperature. The microprocessor calculates an optimum target water temperature within selectable limits of the cont
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Y–SERIES ELECTRONIC BOILER CONTROL MODULE Night Setpoint Option Digital Display Option Panel with Clock & LCD Y-5 Configuration Shown 17
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INDICATOR LIGHTS STAGES 1 STAGE INDICATORS The pump driver and each of the output stages' drivers has its own LED indicator. Each of these LEDs is lit whenever the corresponding output relay is energized. 2 3 4 5 6 7 8 PUMP INDICATOR PUMP The Pump Indicator is illuminated whenever the pump circuit and pump relay are ener- gized. CALL FOR HEAT INDICATOR CALL FOR HEAT The Call For Heat Indicator is illuminated whenever a call for heat signal is present. In most applications the thermostat connec
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CONTROL FUNCTIONS RESET RATIO The Reset Ratio setting determines how much the Target Temperature will increase as the outdoor temperature drops. The Reset Ratio is expressed in the following manner: X:Y X - change in outdoor temperature Y - change in Target Temperature The first number in the ratio refers to the change in outdoor temperature in degrees Fahren- heit below outdoor cutoff while the second refers to the change in the computed Target Temperature in degrees Fahrenheit. A Reset Ratio
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RESET RATIO CHART PUMP TURN-OFF DELAY The Pump Turnoff Delay works in conjunction with the Outdoor Cutoff Temperature. The Pump Turnoff Delay sets the delay between the time when the Outdoor Cutoff Temperature is reached and the time when the pump is turned off. The Pump Turnoff Delay is adjustable from 0 to 10 min. Recommended Initial Setting for Pump Off Delay is 3 min 20
