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Catalog No.: 5000.51J
Effective: 10-14-05
Replaces: 06-15-03
TM
B6000
BOILER
MANAGEMENT
SYSTEM
SYSTEM CONTROL BOILER MONITOR
Installation and Operating Manual
Part No. 240564
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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. Page 2
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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. IMPORTANT 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 s
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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
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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
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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
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INSTALLATION 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
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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
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AIR TEMPERATURE SENSOR • INSTALLATION Fig. #9040 TYPICAL AIR TEMPERATURE SENSOR Air Temperature Sensor Installation Notes: • 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 sta
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WATER TEMPERATURE SENSOR • INSTALLATION The water sensor should be installed in the system supply. Multiple Boilers Single Boiler 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
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WATER TEMPERATURE SENSOR INSTALLATION (Domestic Hot Water Supply) HOT WATER BOILER SUPPLY OUTLET IMMERSION WELL WATER SENSOR INLET 1/2 NPT COLD WATER STORAGE TANK 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. Page 11
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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. For supply connections
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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 pico
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WIRING: WIRING: P Po ow wer Sour er Source to System Contr ce to System Control and Boiler Mod- ol and Boiler Mod- WIRING: WIRING: WIRING: P P Po o ow w wer Sour er Sour er Source to System Contr ce to System Contr ce to System Control and Boiler Mod- ol and Boiler Mod- ol and Boiler Mod- ules. ules. ules. ules. ules. NOTE: Tighten terminal strip clamping screws 20 lbs - In (2.26N.m) Breakage from over torquing is not covered under warranty. Dia. #9 Use copper conductors only. For supply c
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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 Indic
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IMPORTANT: The Boiler Monitor control board has a series of dip switches which iden- tify 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 5 678 8 OOOO O OOO 7 OOOO O OOO 6 OOOO O OOO 5 OOOO O OOO 4 OOOO O OOO 3 OOOO X X X X 2 O O X X O O X X 1 O X O X O X O X S
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BOILER MONITOR COMMUNICATIONS JUMPER W1 • Located in the upper left hand corner of the "LAST" Boiler Monitor board. • NOTE: The jumper indicates to the System Controller logic that the "Last" wired boiler has been communicated with over the RS485 BUSS Link. • Definition: The "LAST" wired boiler is physically wired with the greatest wire length from the "System Control" or is the last wired boiler for a single or multiple boiler installation. • On a single boiler make sure the W1 Jumper has been
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OPTIONAL BOILER MONITOR • Wiring • Contact Authorized Raypak representative for other wiring options 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). Dia. #2 Field Wiring - Single Boiler Dia. #7 Page 18
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Field Wiring - Multiple Boilers Dia. #7 Page 19
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INSTALLATION VERIFICATION PROCEDURE REGISTER Before proceeding any further, please verify that the user registration form has been completed and mailed (reference: Registration Card ). MECHANICAL INSTALLATION Verify installation has been completed (reference: Mechanical Installation ). AIR TEMPERATURE SENSOR Verify installation parameters have been met (reference: Air Temperature Sensor). WATER TEMPERATURE SENSOR Verify installation parameters have been met (reference: Water Temperature Sensor).
