Raypak 240692 User Manual

Catalog No:  
Effective:  
Replaces:  
5000.54H  
06-19-07  
02-01-04  
ELECTRONIC BOILER  
SEQUENCER & OUTDOOR  
RESET CONTROLLER  
Installation and Operating Instructions  
PN 240692 Rev. 9  
TABLE OF CONTENTS  
Contents  
Basics  
Page  
4
Important Safety Instructions  
Introduction  
4
5
Concept of Operation  
Optional Configurations  
Control Features  
5
5
6
Installation and Mounting  
Mechanical Installation  
Electrical Installation  
Wiring: Power to Controller  
Air Temperature Sensor  
Water Temperature Sensor Installation  
Hydronic Installations  
Domestic Hot Water Installations  
Pool Heating Installations  
Field Wiring  
7
7
7
8
9
10  
10  
11  
12  
13  
14  
15  
16  
16  
18  
19  
19  
23  
24  
26  
27  
28  
29  
30  
Power Test  
Control Familiarization  
Sequence of Operation  
Manual Override  
Indicator Lights  
Control Functions  
Reset Ratio Chart  
Circuit Board  
Interior Jumper & Switches  
Optional Controls  
Replacement Parts List  
System Start-Up Settings  
Troubleshooting Guide  
Warranty  
BASICS  
Contents  
Item  
Quantity  
Y–Series Boiler Control, Installed on Boiler(s)  
Outdoor Temperature Sensor Assembly  
Water Temperature Sensor Assembly  
Optional Equipment  
As Ordered  
1
1
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.  
4
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 maximiz-  
ing 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 Y-  
Series 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  
Y-3B  
Y-4B  
BASIC UNIT, NO OPTIONS  
BASIC UNIT PLUS DIGITAL DISPLAY  
BASIC UNIT PLUS NIGHT SETBACK OPTION  
Y-5B  
BASIC UNIT PLUS NIGHT SETBACK AND DIGITAL DISPLAY OPTIONS  
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–Series, 2151 Eastman Avenue, Oxnard, CA 93030  
5
CONTROL FEATURES  
The Y-Series sequence panel includes:  
Standard Indicator Lights:  
Stages 1 to 8:  
Pump:  
Red, indicates which stages are turned on.  
Green, indicates that the pump circuit is energized.  
Call for Heat:  
Control On:  
Green, indicates that a call for heat signal is present.  
Green, indicates outdoor temperature is below the Outdoor Cutoff Temperature  
potentiometer setting and that the boiler will respond to a call for heat.  
Red, indicates one or more of the on-board settings is incorrect.  
Red, indicates that the Water or Outdoor Temperature Sensor has an out-of-range reading.  
Setting Error:  
Sensor Error:  
Adjustment Knobs:  
Reset Ratio:  
0.12:1 to 8:1; determines how much the micro-controller calculated Target  
Temperature will change for a given outdoor temperature change.  
Control Band:  
Pump Off Delay:  
1°F to 10°F; the temperature above or below the Target Temperature at which the boiler  
turns off and on.  
0 to 10 min.; determines when the pump shuts off after entering Outdoor Cutoff mode.  
.
Outdoor Cutoff  
Temperature:  
32°F to 200°F; a warm weather shutdown feature. When the outdoor temperature  
exceeds this setting, the boiler will not fire unless placed in manual override mode.  
Outdoor Cutoff  
Deadband:  
1°F to 10°F; the number of degrees below the Outdoor Cutoff (O/C)  
Temperature which causes the O/C to reset.  
Boiler On Delay:  
Stage On Delay:  
0 to 5 min.; sets the time interval between sequential boiler start ups.  
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 Test 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.  
6
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 INSTALLATION  
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  
120VACFEEDERCIRCUITS  
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.  
7
CHECKYOURPOWERSOURCE  
Using a volt-ohm meter, check the following voltages at the circuit breaker panel:  
BLACK  
CIRCUIT  
BREAKER  
VOLT-OHM  
METER  
WHITE  
GREEN  
GROUND  
A
B
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.  
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  
HOT  
120VAC  
WHT  
RTN  
SUPPLY  
GND  
BLK  
GRN  
WHT  
BLK  
SPG  
SINGLE POINT  
GROUND  
8
AIR TEMPERATURE SENSOR  
Red (connect)  
Black (connect)  
Fig. #9040  
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, 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.  
9
WATER TEMPERATURE SENSOR INSTALLATION  
HYDRONIC INSTALLATIONS  
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  
WATER TEMPERATURE SENSOR INSTALLATION  
DOMESTIC HOT WATER INSTALLATIONS  
Y-Series Controller  
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 about 77°F.  
2.  
3.  
4.  
Set switch #2 (Outdoor Reset) to ON - 70°F Defeat, on S3. (See pg.s 15 and 23-24.)  
Set the Outdoor Cutoff Temperature to 200°F. (See pg. 21.)  
Adjust the Set Point to desired domestic hot water temperature. Controller will track the Set Point  
Temperature. (See pg. 22.)  
NOTE: The Outdoor Air Temperature sensor can be used as a replacement for the Water Temperature Sensor. Both  
sensors are identical.  
11  
WATER TEMPERATURE SENSOR INSTALLATION  
POOL HEATING INSTALLATIONS  
Fig. # 9498  
Fig. # 9499  
1.  
2.  
Install the air temperature sensor across the air temperature sensor contacts (P2, pins 1 and 2; see the field  
wiring diagram on pg. 13).  
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.  
4.  
Set the Outdoor Cutoff Temperature to 200°F. (See pg. 21.)  
Adjust the setpoint to desired pool temperature. Thereafter, the controller will track the setpoint and fire  
heater stages as necessary.  
NOTE: The Outdoor Air Temperature sensor can be used as a replacement for the Water Temperature Sensor, as both  
sensors are indicated.  
12  
FIELD WIRING  
P5  
1
2
3
4
5
6
7
8
Stage 1  
Stage 2  
Stage 3  
Stage 4  
Single-Stage (On/Off) Boilers  
- All stage connections on the control  
board are connected at the {TH}  
(Thermostat) location on the  
boiler wiring diagram.  
1
2
3
4
5
6
7
8
Multiple-Stage Boilers  
Stage 5  
Stage 6  
Stage 7  
Stage 8  
- 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  
P6  
P4  
1
2
Pump Relay  
Pilot Duty Only  
2.5 Amp Max  
250V Max  
boiler wiring diagram.  
1
2
3
Thermostat  
(Jumpered) or  
Building Management System  
Utilize Shielded Cable  
P1  
P2  
Outdoor Air Temperature  
Sensor (see NOTE 4)  
Water Temperature  
Sensor  
1
2
3
4
Outdoor Temp  
Water Temp  
Notes:  
1. Tighten terminal strip clamping screws to 4 in-lbs. Breakage from over torquing is not covered under warranty.  
2. Use copper conductors only.  
3. For supply connections, use wires sized on the basis of 60°C (140°F) ampacity and rated a min. 90°C (194°F).  
4. The outdoor sensor must be connected, otherwise a sensor error will be displayed.  
13  
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.  
SYSTEM MODULE INSTALLATION  
Verify electrical power wiring connections.  
Verify electrical connection torque requirements.  
Verify Outdoor Air Temperature Sensor wiring.  
Verify Water Temperature Sensor wiring.  
Verify Power Test has been completed successfully.  
POWER TEST  
Utilizing a Volt-Ohm-Meter (VOM) monitor the following on the controller for proper voltage levels. Check at  
Terminal Block TB-1.  
POWER TEST TABLE  
From:  
To:  
Indication  
TB pin 1  
TB pin 1  
TB pin 2  
TB pin 2  
108 VAC to 132 VAC  
108 VAC to 132 VAC  
less than 1 VAC  
Single Point Ground  
Single Point Ground  
14  
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 pot (J2) shunt bar in the position that corresponds to the total  
number of stages to be controlled.  
2. First Stage Selector. Switch (S2); Place switches in the ON position corresponding to the first stage  
of each boiler in the system. Switch position #1 should always be in the ON position.  
3. Mode Selector. Switch (S3) determines the following:  
A. Switch #1, R/M  
OFF - Manual Lead-Lag selection  
ON - Automatic Lead-Lag selection  
B. Switch #2, 70°F OFF  
OFF - Outdoor Reset Enabled  
ON - 70°F Defeat Enabled, Outdoor Reset Disabled-used for domestic water installations.  
C. Switches #3 Master/Slave Option  
OFF - Designates the Y-Series as a Master Control (Normal)  
ON - Designates the unit as a slave (used for ganged Y-Series controls controlling 9 to 24 firing stages)  
D. Switch #4, No Min Set Point Switch  
OFF - Minimum allowable Set Point of 105°F to reduce potential of condensing the boiler.  
ON - Set Point can be reduced to 40°F for special applications (i.e. water source heat pumps, etc.)  
E. Switch #5 (reserved)  
F. Switch #6 (reserved)  
G. Switch #7 (reserved)  
H. Switch #8 (reserved)  
4. Lead-Lag Selector, Rotary switch (S4) selects the lead stage for stage sequencing. (Applies only in manual  
lead-lag mode when Mode Selector Switch (S3) Switch #1, is OFF) switch should point to first stage in multi  
stage applications.  
5. Output Over-Ride Switch (S5) provides Manual Override of the system control. Switches #1 through #8 turn  
on the corresponding relay and stage. Switch #9 turns on the pump circuit. The other stages are inter-  
locked with Switch #9 and will not fire unless the pump is on. Switch #10 is not used.  
6. System Test Switch (S1) is a momentary switch which will cause status indicators to blink five times  
then revert to normal indications. This tests the functions status of the micro-controller.  
Reinstall the panel above indicator lights that cover the Y-Series Electronic Boiler Control Circuit board.  
Refer to the CONTROL POTENTIOMETERS (KNOBS) section of this manual to set the initial system operating param-  
eters. Set knobs to default values and fine tune if necessary.  
15  
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 control band, the setpoint, the reset ratio and the outdoor air temperature. If outdoor is reset is  
disabled, the readings of the air sensor are not used in subsequent calculations. In either case, if the water temperature  
falls below the the calculated target temperature the Control sends a call for heat to the lead unit (stage).  
2. Upon a call for the heat the control closes the lead unit's thermostat (TH) circuit, which the energizes the lead unit's  
circulating pump. After the flow switch has confirmed adequate flow, the ignition sequence is initiated and the unit  
ignites at stage 1. The Control then sequences the units/stages in response to changes in the system to target differen  
tial temperature, time away from target temperature, and temperature rate-of-change parameter as determined by the  
P+I+D algorithems.  
3. Additional stages (and units) are activated or deactivated as required in order to maintain or restore target system  
water temperature. This Control uses "first on, last off" logic. As the system water temperature increases and begins to  
approach target temperature, the Control deactivates the stages and heaters in reverse order of firing until the first  
unit/stage fired is turned off. After the final stage of a given unit has been turned off, that unit's Economaster pump  
control will continue to power the unit's circulating pump until a user-adjustable time delay has elapsed, thereby  
extracting all available residual heat.  
4. The Control stores firing command and system response data in the last five memory registers of the microprocessor.  
On the next call for heat, the Control will modify the stored P+I+D data to optimize its own responses.  
5. When the outdoor temperature exceeds the outdoor cutoff temperature, the Control enters warm weather shut-down  
mode. The primary pump is turned off after a user-adjustable time delay, and the Control becomes dormant, until  
outdoor temperatures again fall below the outdoor cutoff temperature.  
MANUAL OVERRIDE  
Internal Switch (S5) Output Override can be used to manually override the Micro-controller control as long as the  
Electronic Boiler Control circuit board has 24 VAC power. See Output Over-Ride Switch (S5) above.  
16  
Y–SERIES ELECTRONIC BOILER CONTROL MODULE  
Night Setpoint  
Option  
Digital Display  
Option  
Panel with Clock & LCD  
Y-5 Configuration Shown  
17  
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
PUMPINDICATOR  
PUMP  
The Pump Indicator is illuminated whenever the pump circuit and pump relay are ener-  
gized.  
CALLFOR HEATINDICATOR  
CALL FOR HEAT  
The Call For Heat Indicator is illuminated whenever a call for heat signal is present. In  
most applications the thermostat connections on the control board (pg. 13) will be jumpered,  
which will generate a continuous call for heat signal. The thermostat leads may also be  
connected to a building management system which will produce the call for heat signal as  
required.  
CONTROL  
ON  
CONTROLON INDICATOR  
The Control On Indicator illuminates if all settings and system conditions are such that the  
control can function properly, and outdoor temperature cutoff temperature setting is less  
than or equal to the outdoor temperature.  
SETTING  
ERROR  
SETTINGERRORINDICATOR  
The Setting Error Indicator is illuminated if there is a potentiometer, switch setting or jumper  
placement error. Refer toTroubleshooting Guide "Setting Error LED Is On".  
SENSOR  
ERROR  
SENSORERRORINDICATOR  
The Sensor Error Indicator is illuminated if either temperature sensor is out of range.  
Steady on represents outdoor sensor failure, blinking represents water temperature sensor  
error. See "Sensor Error LED On" in the Troubleshooting Guide (pg. 29).  
18  
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 of 2:1 means that for every 2°F drop in  
outdoor temperature from 70°F, the Target Temperature will increase 1°F.  
For example:  
Assume a Reset Ratio setting of 2:1 and a Set Point of 120°F.  
When the outdoor temperature drops from 70°F to 20°F, the Target Temperature will in-  
crease from 120°F to 145°F. (With an outdoor to target ratio of 2:1, a 50°F outdoor tem-  
perature decrease results in a 25°F Target Temperature increase). See Reset Ratio Chart  
(pg. 20) for more information.  
The Reset Ratio is adjustable from 0.12:1 to 8.0:1.  
Recommended Initial Setting for Reset Ratio is 1:1.  
Suggested Settings  
Typical  
Reset Ratio Setpoint at Design Temp:  
Temp @  
Design Cond.  
Temp. @  
70°F  
40°F  
0.3:1  
0.3:1  
0.3:1  
0.9:1  
2.0:1  
2.0:1  
20°F  
0.6:1  
0.5:1  
0.6:1  
1.4:1  
3.3:1  
3.3:1  
0°F  
- 20°F  
1.1:1  
0.9:1  
1.1:1  
2.6:1  
6.0:1  
6.0:1  
RADIATION  
Standing  
190  
105  
105  
105  
105  
105  
105  
0.8:1  
0.7:1  
0.8:1  
2.0:1  
4.7:1  
4.7:1  
Convection or  
Baseboard  
200  
190  
140  
120  
120  
Fan Coil - Heating  
Fan Coil - Heat & Cool  
Radiant Floor  
Radiant Ceiling  
The selection of the correct ratio is dependent on the initial temperature Set Point and the desired system water temperature. If the building  
is too cold, move the ratio knob counter-clockwise one setting.After a change is made to the ratio, wait several days and evaluate the  
comfort level before making another change.  
19  
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  
BOILER TURN-ON DELAY  
In a multiple boiler system:  
The Boiler Turn-On Delay sets the time delay before each additional boiler is turned on in  
response to a call for heat. This delay starts when the preceding boiler is turned on.  
The Boiler Turn-On Delay range is from 0 to 5 min.  
Recommended Initial Setting for Boiler Turn-On Delay is 30 sec.  
STAGE TURN-ON DELAY  
The Stage Turn-On Delay sets the time delay before a new stage in a multistage boiler  
configuration is turned on. This delay starts when the stage or boiler preceding the next  
stage is turned on.  
The Stage Turn-On Delay range is from 0 to 60 sec.  
Recommended Initial Setting Stage for Turn-On Delay is 10 sec.  
CONTROL BAND  
The Control Band sets the maximum temperature above or below the Target Temperature  
(which is determined by the embedded micro-controller) between which the system tem-  
perature may deviate. This provides a control deadband that limits the boiler from short-  
cycling.  
The Control Band range is from 1°F to 10°F.  
Recommended Initial Setting for Control Band is 3°F.  
OUTDOOR CUTOFF DEADBAND  
The Outdoor Cutoff Deadband sets the number of degrees below the Outdoor Cutoff where  
the Outdoor Cutoff reset occurs.  
The Outdoor Cutoff Deadband range is from 1°F to 10°F.  
Recommended Initial Setting for Outdoor Cutoff Deadband is 3°F.  
OUTDOOR CUTOFF TEMPERATURE  
The Outdoor Cutoff sets the maximum outdoor temperature at which heat is desired. This  
control sets the outdoor temperature above which the boiler bank is disabled. If the out-  
door temperature increases beyond the Outdoor Cutoff setting, the Control ON LED turns  
off and if there is no call for heat, the pump turn-off delay starts turning off the pump. If  
the outdoor temperature falls below the Outdoor Cutoff minus the Outdoor Cutoff Deadband  
the boiler bank will again be enabled.  
The Outdoor Cutoff Temperature is from 32°F to 200°F.  
Recommended Initial Setting for Outdoor Cutoff Temperature is 65°F.  
21  
MAXIMUM WATER TEMPERATURE  
The Maximum Output Temperature is the system output high limit. This potentiometer  
sets the maximum value the Target Temperature is allowed to reach regardless of other  
operational settings or conditions.  
The Maximum Water Temperature range is from 70°F to 235°F.  
Recommended Initial Setting for Maximum Water Temperature is 180°F.  
SET POINT  
The Set Point is the system output temperature desired when the outdoor temperature is  
70°F. This potentiometer may be set to any temperature from 40°F to 220°F, and is the  
base-line setting for all operations. Note: Set Point cannot be below 105°F in normal  
operation unless the No Min Set Point switch is in the ON position. (See Mode Selector  
Switch). In domestic water supply applications, Set Point determines the water tem-  
perature maintained by the control.  
The Set Point range is from 40°F to 220°F.  
Recommended Initial Setting Set for Point is 120°F.  
CAUTION: Setting the Set Point below 105°F may cause the boiler to condense which  
will damage the boiler.  
22  
CIRCUIT BOARD  
S5 MANUAL BYPASS  
SWITCH  
S4 MANUAL LEAD/  
LAG  
J2 LAST STAGE  
SELECTOR  
JUMPER  
S3 MODE  
SELECTOR  
SELECTOR  
SWITCH  
MAINTENANCE  
PLUG TEST  
S1 SYSTEM  
TEST  
S2 FIRST STAGE  
SELECTOR I.D.  
23  
INTERIOR JUMPER & SWITCHES  
J-2  
The Last Stage Selector Jumper (J2) is comprised of an eight (8) position jumper block. Ashunt  
bar jumper is placed in the position corresponding to the last active stage or boiler number. See  
table below for examples of Jumper (J2) settings.  
Fig # 9242  
S-2  
The First Stage Selector (Stage #1 ID) (S2) Switch is an eight (8) position switch, each switch  
position corresponds to a Y-Series output stage. Turn ON the switch(s) that correspond(s) to  
the FIRST stage of EACH boiler. Turn OFF the switch(s) that correspond(s) to the second (or  
subsequent) stage(s), of EACH boiler.  
(Switch #1 should always be on.) See the table below for examples.  
Fig # 9245  
S-3  
The Mode Selector Switch (S3) is comprised of an eight (8) position dip switch with the  
following functions:  
AUTO  
Sw #1 - Manual/Auto Lead-lag Selection Off - Manual lead-lag selection  
On - Automatic lead-lag selection  
OD off  
Sw #2 - Outdoor Reset  
"OD off"  
Off - Outdoor Reset Enabled  
On - Outdoor Reset Disabled. Use this setting  
for applications like Domestic Hot Water  
where outdoor air sensing is not required.  
Note: The outdoor sensor must be connected in all modes, otherwise a sensor error will be  
displayed.  
Fig # 9246  
24  
SLAVE  
Sw #3 - Master/Slave  
Off - Designates the Y-Series as a Master Control  
(Normal)  
On - Designates the unit as a slave (used for  
ganged Y-Series' controlling 9 to 24 firing stages)  
DHW  
Sw #4 - Outdoor Reset  
Off - Minimum allowable Set Point of 105°F  
reduces potential of condensensing the boiler.  
On - Set Point can be reduced to 40°F for special  
applications (e.g. water source heat pumps, etc.)  
Sw #5 - 8 - Reserved  
Reserved for future use.  
S-4  
MANUAL LEAD-LAG  
The Lead-lag Selector Switch (S4) is a ten (10) position rotary switch. Switch positions  
0 and 9 are not used. In manual lead-lag selection, the Lead-lag Selector is used to select  
the lead boiler (stage). This is normally shipped from the factory set at position 1. If  
auto lead-lag is used, do not adjust this switch.  
Fig # 9244  
S-5  
OUTPUT OVERRIDE  
The Bypass Switches: Switch (S5) is a ten (10) position dip switch. Switch position  
10 is not used. The Bypass Switch enables the user to turn on any of the outputs  
regardless of the current settings and conditions. Switch position 9 will turn on the  
pump and the remaining eight switches will each override one of the output stages.  
The pump switch and the output stages switches are interlocked such that the output  
stages can only be turned on if the pump is on.  
Fig # 9243  
S-1  
SYSTEM TEST  
The System Test Switch (S1) is comprised of a single momentary push button switch.  
When depressed it should cause the Status Indicators to blink five times. This test  
sequence is an indication of the functioning status of the embedded micro-controller.  
The Status Indicators revert back to their original indications after the test sequence is  
completed.  
Fig # 9247  
25  
OPTIONAL CONTROLS  
Operational  
Override Switch  
Clock  
Alternate  
Setpoint Adjustment  
Digital Display  
Front Panel with Optional Alternate Setpoint  
OPTIONAL ALTERNATE SETPOINT OPERATION  
The Optional Alternate Setpoint can be used to establish an independent second set point for setback or  
temperature boost requirements.  
TRIPPERS  
The electro-mechanical timer consists of 84 small switches called "Trippers" and a 7-day mechanical  
clock. Each tripper represents a two-hour interval which determines set point selection as shown:  
Tripper Pushed In = Normal Setpoint Operation  
Tripper Pushed Out = Alternate Setpoint Operation  
OPERATION OVERRIDE SWITCH  
The Operation Override Switch is a three-position switch that determines if the trippers select the Setpoint,  
of if either the normal Setpoint or Alternate Setpoint is continuously selected. The Operation Override  
Switch can be set as follows  
I - Alternate Setpoint selected continuously  
L - Trippers determine selected set point  
O - Normal Setpoint select continuously  
NIGHT SETBACK OPTION:  
MECHANICAL CLOCK (7-DAY)  
Set to the appropriate local time.  
Note: Turn the numbered dial clockwise to set time.  
ALTERNATE SET POINT  
Works independently of normal Setpoint. See discussion of Setpoint for details. Set to appropriate  
setback or boost temperature. Turn the knob in the night setback option to the desired alternate setpoint.  
DIGITAL DISPLAY OPTION:  
LCD DISPLAY PANEL  
The optional LCD display will indicate all values plus calculated target temperature and actual air and  
water temperature.  
26  
REPLACEMENT PARTS LIST  
CALL OUT DESCRIPTION  
PART NO  
006039F  
006034F  
005764F  
006031F  
005657F  
N/A  
005654F  
005700F  
005701F  
005299B  
004821F  
006033F  
006032F  
1-C  
PC Board Standard  
PC Board w/ Night Set Back  
Programmed Eprom  
2-C  
Programmed Eprom W/ Night Set Back  
Transformer  
Door w/Window  
3-C  
1-S  
2-S  
3-S  
4-S  
5-S  
6-S  
1-N  
2-N  
Side Mount Bracket  
Air Temperature Sensor Complete  
Water Temperature Sensor Complete  
Air/Water Temperature Sensor  
Well Assembly  
Timer  
Alternate Setpoint Adjustment  
1-N  
2-N  
2-S  
3-C  
1-C  
5-S  
2-C  
3-S  
4-S  
6-S  
1-S  
5-S  
27  
SYSTEM START-UP SETTINGS  
SYSTEM SETTING ENTERED ON DATE:  
Front panel control potentiometers (knobs)  
Reset Ratio:  
______  
______  
______  
______  
Control Band:  
______  
______  
______  
______  
______  
______  
Default Value: 1:1  
Default Value: 3°F  
Pump off Delay:  
Outdoor Cutoff Deadband:  
Default Value: 3°F  
Default Value: 3 min.  
Boiler on Delay:  
Outdoor Cutoff Temp.:  
Default Value: 65°F  
Default Value: 30 sec.  
Stage on Delay:  
Max Water Temp.:  
Default Value: 10 sec.  
Default Value: 180°F  
Set Point:  
Default Value: 140°F  
Optional Alternate Set Point  
INTERIOR JUMPER & SWITCH SETTINGS:  
Output ON Switch (S2)  
Last Stage (J2)  
Mode Selector Switch (S3)  
Bypass Switch (S5)  
Lead-Lag Switch (S4)  
28  
TROUBLESHOOTING GUIDE  
In normal operating conditions, the Status Indications should be observed as follows:  
Control Enabled  
Sensor Error  
ON (lit)  
OFF  
Setting Error  
OFF  
If the outdoor sensor fails and all other operating conditions remain the same, the control will remain on but it will  
function as if the 70°F defeat mode is enabled. The following Status Indications should be observed:  
Control Enabled  
Sensor Error  
Setting Error  
ON (lit)  
ON (lit)  
OFF  
If a different LED status is observed other than those described above, use the following detailed descriptions as a  
guide:  
If Control Enabled LED is OFF  
Possible Causes:  
1. The output temperature sensor is out of range. The Sensor Error LED should be on. See below for details on the  
Sensor Error LED.  
2. There is a setting error. The Setting Error LED should be on. See below for details on the Setting Error LED.  
3. The outdoor temperature is higher than or equal to the outdoor cutoff setting less the outdoor cutoff deadband  
setting.  
Sensor Error LED is ON or blinking ON/OFF once per second  
Possible Causes:  
LED ON steady: Outdoor (air) sensor is out of range.  
LED blinking ON/OFF once per second: Output (water) sensor is out of range.  
1. Examine wiring, ensure continuity from Y-Series to sensor(s).  
2. Use a multimeter, measure resistance of sensor(s) compare with table below:  
SENSOR RESISTANCE AT VARIOUS TEMPERATURES  
TEMP  
Deg F  
40  
50  
60  
70  
80  
90  
100  
110  
120  
Resistance (K)  
26.11  
19.90  
15.31  
11.88  
9.30  
7.33  
5.83  
4.66  
3.76  
TEMP  
Deg F  
130  
140  
150  
160  
170  
180  
190  
200  
210  
Resistance (K)  
3.06  
2.48  
2.04  
1.69  
1.40  
1.17  
0.98  
0.83  
0.70  
3. If all okay, replace Y-Series Boiler Control Board.  
Setting Error LED is ON  
Possible Causes:  
1. The Maximum Output Temperature setting is less than the Minimum Output Temperature setting.  
2. The last stage selection is invalid. Either there is no stage selected or more than one stage is selected.  
3. The first output stage is not selected as a stage #1. The first output stage should be set as a stage #1 in all cases.  
4. In manual mode, the lead-lag selection is invalid (0 or 9).  
5. In manual mode, the lead-lag selection is higher than the last stage.  
6. In manual mode, the stage selected as the lead-lag is not set as a stage #1.  
29  
LIMITED WARRANTY  
B6000, Y-Series, E-4 & Accessories  
SCOPE OF WARRANTY  
Raypak, Inc. ("Raypak") warrants to the original owner the Control System to be free from defects in materials and workmanship under  
normal use and service for the applicable warranty period. In accordance with the terms of this Limited Warranty, RAYPAK will furnish  
a replacement or repair, at our option, any defective part which fails in normal use and service during the applicable warranty period. The  
replacement or repair will be warranted for only the unexpired portion of the original Warranty Period.  
APPLICABLE WARRANTY PERIOD  
The effective date of warranty coverage is the date of original installation, of the Control System, by a qualified electrician or by a  
RAYPAK authorized service technician. The Applicable Warranty Period is one (1) year from the effective date.  
WARRANTY EXCLUSIONS  
This Limited Warranty does not apply:  
1. ifthecontrolsystemisnotproperlyinstalledbyaqualifiedtechnicianinaccordancewithmanufacturer'sinstallation  
instructions, applicable codes, ordinances and good trade practices,  
2. to damage or malfunctions resulting from failure to properly install, operate or maintain the system in accordance  
withthemanufacturer'sinstructions;  
3. if the rating plate(s) or serial number(s) are altered, defaced or removed;  
4. if the System is modified in any way or used with any non-factory authorized accessories or components;  
5. to damage or failure from abuse, accident, act of nature, fire, flood, freezing or the like;  
6. to accessories, rubber or plastic parts, light bulbs or glass parts;  
7. if the System is moved from its original installation site; or if the original owner no longer owns the site or the System.  
LABOR AND SHIPPING COSTS  
This Limited Warranty does not cover labor costs for service, removal or reinstallation of any part nor shipping charges to or from  
RAYPAK'S designated repair center or to or from the installation site. All such costs are your responsibility.  
HOW TO MAKE A WARRANTY CLAIM  
Tomakeawarrantyclaim,promptlyship(postageprepaid)orcarrythedefectiveparttoadesignatedRAYPAKServiceDealerorService  
Station in the United States, supplying proof of purchase and date of installation and the model and serial numbers. If you cannot locate a  
dealer, contact RAYPAK'S Service Department at the address/telephone listed below. Raypak reserves the right at all times to inspect the  
claimed defect and verify warranty coverage at its factory.  
EXCLUSIVE WARRANTY - LIMITATION OF LIABILITY  
This is the only warranty given by RAYPAK. No one is authorized to make any other warranties on Raypak's behalf. ANY IMPLIED  
WARRANTIES, INCLUDING MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, SHALL NOT EXTEND  
BEYOND THE APPLICABLE WARRANTY PERIOD SPECIFIED ABOVE. RAYPAK'S SOLE LIABILITY WITH RESPECT  
TO ANY DEFECT SHALL BE AS SET FORTH IN THIS LIMITED WARRANTY. ANY CLAIMS FOR INCIDENTAL OR  
CONSEQUENTIAL DAMAGES (INCLUDING DAMAGE FROM WATER LEAKAGE) ARE EXCLUDED. Some states do not  
allow limitations on how long an implied warranty lasts, or for the exclusion of incidental or consequential damages, so the above limitation  
or exclusion may not apply to you.  
THIS LIMITED WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS  
WHICH VARY FROM STATE TO STATE.  
We suggest you immediately complete the information below and retain this Limited Warranty Certificate in case warranty service is  
needed.  
RAYPAK, INC. SERVICE DEPARTMENT  
2151 Eastman Avenue, Oxnard, California 93030  
Telephone: (805) 278-5300 FAX (805) 278-5468  
The following information must be provided when you write or call:  
________________________________________________  
Original Owner  
_______________________________________________  
Daytime Telephone Number  
__________________________________________________________________________________________________  
Complete Mailing Address  
________________________________________________  
City State Zip Code  
_______________________________________________  
Installation Site  
________________________________________________  
Model Number  
_______________________________________________  
Contractor/Installer  
________________________________________________  
Date of Installation  
_______________________________________________  
Serial Number  
Raypak, Inc., 2151 Eastman Ave, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468  
Litho in U.S.A.  
Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (800) 872-9725  
Raypak Canada Limited, 2805 Slough St., Mississauga, Ontario, Canada L4T 1G2 (905) 677-7999 Fax (905) 677-8036  
Litho in U.S.A.  

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