Raypak B6000 User Manual

CatalogNo.: 5000.51J  
Effective:  
Replaces:  
10-14-05  
06-15-03  
TM  
B6000  
BOILER  
MANAGEMENT  
SYSTEM  
SYSTEMCONTROL  
BOILERMONITOR  
Installation and Operating Manual  
Part No. 240564  
B6000 BOILER MANAGEMENT SYSTEM (BMS)  
Contents  
Equipment  
Quantity  
B6000 System Control  
1
B6000 Boiler Monitor, Installed on Boiler(s)  
Outdoor Temperature Sensor Assy. (064140)  
Water Temperature Sensor Assy. (064139)  
Optional Equipment  
As Ordered  
1
1
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 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.  
Page 3  
TABLE OF CONTENTS  
PAGE  
3
Contents  
Getting Started  
5
Foreword  
5
Installation and Mounting  
Mechanical Installation  
7
7
Electrical Installation  
8
Check Your Power Source  
Air Temperature Sensor  
8
9
Water Temperature Sensor  
Important Configuration Note  
Wiring - Air and Water Sensors  
Communication (RS485) Wiring  
Wiring: Power Source to Control and Boiler Modules  
Power Test  
10  
12  
12  
13  
14  
15  
16  
17  
18  
18  
19  
20  
21  
22  
23  
23  
35  
39  
40  
42  
44  
46  
47  
Boiler Monitor Select Switch  
Boiler Monitor Communications Jumper W1  
Optional Boiler Monitor Control  
Field Wiring - Single Boiler  
Field Wiring - Multiple Boilers  
Installation Verification Procedure  
System Control/Display Familiarization  
Power Up - Boiler Monitor  
Power Up - System Control Module  
Displays  
Important (Start Alternate)  
System Control Box  
System Control Board Pictorial  
Replacement Parts List  
Boiler Monitor Control Box  
System Settings  
Troubleshooting Guide  
Page 4  
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.  
Page 5  
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  
Page 6  
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  
18-3/4" W  
5-1/2" D  
17-1/2" L  
21-1/4 lbs.  
MECHANICAL INSTALLATION  
Install the B6000 System Control Module
boiler(s). The B6000 System Control Modul
facing downward. Conduit holes are provid
Additional or larger conduit fittings that may
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.  
Page 7  
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  
17 1/2 L  
21 1/4 lbs  
15 3/16 L  
12 1/2 W  
4 3/4 D  
18 3/4 W  
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  
CB  
Neutral (Return)  
VOM  
Hot  
WHITE  
GROUND  
BLACK  
GREEN  
A
B
C
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  
Page 8  
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 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.  
Page 9  
WATER TEMPERATURE SENSOR  
• INSTALLATION  
The water sensor  
should be installed  
in the system supply.  
Multiple Boilers  
Single Boiler  
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.  
Page 10  
WATER TEMPERATURE SENSOR INSTALLATION (Domestic Hot Water Supply)  
HOT  
WATER  
SUPPLY  
BOILER  
OUTLET  
IMMERSION WELL  
WATER SENSOR  
1/2 NPT  
INLET  
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  
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 use  
wiressizedonthebasisof60°C  
Ampacity and rated Min. 90°C  
(194°F).  
Page 12  
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  
wiressizedonthebasisof60°C  
Ampacity and rated Min. 90°C  
(194°F).  
BOILER MONITOR  
TERMINAL TB 3  
SYSTEM CONTROL  
TERMINAL TB2  
RS 485 Communications Cable Schematic  
Page 13  
WIRING: Power Source to System Control and Boiler Mod-  
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 connections use  
wiressizedonthebasisof60°C  
Ampacity and rated Min. 90°C  
(194°F).  
• 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.  
Page 14  
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  
System Control  
System Control  
System Control  
System Control  
TB1-1- TB1-3  
TB1-2- TB1-3  
TB1-1 - I  
108 VAC to 132 VAC  
LESS THAN 1 VAC  
108 VAC to 132 VAC  
LESS THAN 1 VAC  
LESS THAN 0.5 VAC  
TB1-2 - I  
TB1-3 - I  
Module  
Test Points  
Indication  
Boiler Monitor  
Boiler Monitor  
Boiler Monitor  
Boiler Monitor  
Boiler Monitor  
Boiler Monitor  
TB1-1- TB1-2  
TB1-1- TB1-3  
108 VAC to 132 VAC  
108 VAC to 132 VAC  
HAN 1 VAC  
C to 132 VAC  
HAN 1 VAC  
HAN 0.5 VAC  
FROM: BOILER
Boiler Monitor  
TB1 - 1  
on  
HAN 0.5 VAC  
HAN 0.5 VAC  
HAN 0.5 VAC  
HAN 0.5 VAC  
TB1 - 2  
TB1 - 3  
TB1 - 2  
Pa
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  
1
2
3
4
5
6
7
8
8
7
6
5
4
3
2
1
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
X
O
O
O
O
O
O
X
O
O
O
O
O
O
X
X
O
O
O
O
O
X
O
O
O
O
O
X
O
X
O
O
O
O
O
X
X
O
O
O
O
O
O
X
X
X
O
O
O
SWITCH  
O = Open  
X = Closed  
Page 16  
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 installed.  
BOILER MONITOR CARD PICTORIAL  
On boiler systems the jumper (W1) MUST BE installed on the "Last" wired boiler. This  
is located on the Boiler Monitor board in the upper left hand corner, adjacent to the  
RS485 terminals.  
On Multiple boiler systems the W1 jumper must be removed from all Boiler Monitor  
boards except on the "Last" wired boiler.  
For normal boiler operation the dip switch settings can be utilized to define any of the  
boilers as #1 thru # (maximum), independent of the "Last" wired boiler position.  
Page 17  
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  
wiressizedonthebasisof60°C  
Ampacity and rated Min. 90°C  
(194°F).  
Dia. #2  
Field Wiring - Single Boiler  
Dia. #7  
Page 18  
Field Wiring - Multiple Boilers  
Dia. #7  
Page 19  
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).  
Verify System Control/Boiler Monitor power wiring connections.  
Verify Torque Requirements.  
Verify Air Temperature Sensor wiring, must be Belden #8132, #9842 or equivalent.  
Verify Water Temperature Sensor wiring, must be Belden #8132, #9842 or equivalent.  
Verify Power Test has been completed successfully.  
Verify RS485 Communications Cable, must be Belden #9842 or equivalent.  
Verify Boiler Monitor Select Switch (SW2) settings.  
Verify Installation/Removal of Boiler Monitor Communications Jumper(s) [W1].  
Verify Optional Boiler Monitor Control Wiring.  
MODEM (Optional)  
Perform and/or verify modem installation and hook-up per Raypak Add/On Options  
P/N 240596 and B6000 BMS Optional Modem Software Documentation P/N 240595.  
Page 20  
SYSTEM CONTROL/DISPLAY FAMILIARIZATION  
The System is set up by using the selector buttons and the displays on the System Control  
module.  
There are ten or more displays. Each display provides information regarding the system  
operating parameters and system component status. Some displays provide information  
only, such as current outdoor temperature, system temperature, etc..  
Selectable data is identified by flashing characters.  
The selector buttons are:  
"MENU" - which when pressed will change displays.  
"SELECT" - moves the cursor - flashing character - to the next selection in a display.  
"+" - moves a value to a higher reading (e.g. Display shows flashing boiler #1. Pushing  
"+" will change display to boiler #2).  
"–" - moves a value to a lower position (e.g. Display shows flashing boiler #2. Pushing  
"–" will change display to boiler #1).  
EDITING B6000 DISPLAYS LOCATION  
The B6000 BMS has a forty (40) character screen that displays status and memory contents.  
Selectable Parameters on the B6000 Monitor Screen are as follows:  
Selectable Parameters  
Range  
Value  
Change to Fahrenheit (F) or Celsius (C).  
Default (After Initialization)  
Maximum Water Temp  
Set  
Day Temperature  
Nite  
Ratio  
° Rise  
70 - 235  
40 - 220  
40 - 220  
40 - 220  
None - 20:1  
1 - 99  
1s,2s, 5 - 100  
35 - 199  
1 - 9  
Degrees…………180  
Degrees…………100  
Degrees…………100  
Degrees………… 90  
Numeric…………1.0:1  
Degrees………… 20  
Percentile……… 20  
Degrees………… 65  
Step  
O/C (Outdoor Cutoff)  
O/Cdb (O/C dead band)  
CBand (Control Band)  
Lead  
Degrees…………  
Degrees…………  
Numeric…………  
4
3
1
1 - 9  
1 - 8  
Change Hours  
Pump Delay *  
Ign Time*  
0 - 225  
0 - 20  
15 - 100  
Numeric…………100  
Minutes…………  
Seconds………… 30  
3
*Indicates multiple entries  
When the B6000 BMS is equipped with a night setback feature, [ WHEN INITIALIZED],  
NITE SETBACK defaults to OFF.  
Page 21  
NOTE: NitesetbackfeaturemustbesetattheB6000BMSControlPanelto"ON". Thisresults  
indisplaychangethatshowsNITEratherthanDAY. TheBMScanchange "SETBACKTIMES"  
up to six selections for each of the seven days.  
WARNING WARNING WARNING WARNING WARNING WARNING  
When the initialize control selection is set to "Y" and "SELECT" button is pushed, the B6000  
BMS resets all of the SELECTABLE PARAMETERS on this screen to DEFAULT values.  
Nite Setback (NSB), Lead Lag is set to "OFF" (If option installed).  
POWER-UP  
Boiler Monitor  
a. Energize by pushing Power Switch to "ON" position. The following indicator lights will  
be  
lit: - Power On  
The following indicator lights will be lit if the boiler is performing the valve calibration cycle.  
- Call for Heat  
- Pump  
- Pilot  
b. Boiler will start provided there are no "faults" after the System Control module has  
been energized.  
V X . X X X X  
I n i t i a l i z e ?  
N
Version # of Software  
Flashing (N,Y)  
System Control Module  
a. Energize the system control module.  
- The screen should show the System Temperature (Display #1)  
b. Press the "MENU" button until the screen shows the Initialize screen .  
c. Press "+" or "–" button to change the cursor to "Y".  
d. Press "Select" button.  
- This will initialize the control memory to the default values.  
Page 22  
DISPLAYS  
System Temperatures  
* Indicates selectable item  
Program the System Control Module to meet the design conditions of the installation.  
Return to System Temperature Display by pressing the "MENU" button until screen appears  
as below.  
O u t d o o r  
X X X ° F  
W a t e r [ T A R ]  
X X X  
[ X X X ]  
X
Displays "H"  
if over Hi Limit,  
"M" if over MAX  
CurrentOutdoorAir  
Temperature  
CurrentSystem  
WaterTemperature  
TargetTemperature  
System Design  
Temperature  
Selectable °F or °C  
Default is °F  
INFORMATION ONLY  
This is the first screen displayed when system is energized. After system is set up this  
display should be used. °F or °C is selectable by pressing "+" or "–".  
Provides:  
- Outdoor temperature – actual  
- System Water temperature – actual  
- Target Temperature, which is the desired system temperature.  
Press MENU button  
Boiler Valve  
Firing Rates  
V a l v e  
# X :  
P o s i t i o n  
X X X %  
Indicates Boiler being monitored  
Provides valve firing position  
On multiple boiler installations press "+" or "–"  
to view position of other boiler firing rates.  
INFORMATION ONLY  
- Provides firing valve position for each boiler.  
- Multiple boilers - press SELECT button to determine status of each boiler.  
Press MENU button  
Page23  
Boiler Status  
S T A T U S :  
- -  
B o i l e r  
O K - -  
# X  
Operating status of boiler  
Ok or Fault Indicator  
*Boiler  
Pushing "+" or "-" buttons will show  
status of other boiler(s) in system  
READOUT  
Readout  
OK - boiler operation  
normal  
FAULT indications: MAX TEMP - Target exceeds Max Temp -Not a fault-  
THERMOSTAT - Operating aquastat - Not a fault -  
LWCO - low water cutoff - when supplied  
LO PRES WTR - Low pressure water - when supplied  
LO PRES GAS - Low pressure gas - when supplied  
HIGH PRES GAS -High pressure gas  
HIGH LIMIT -  
FLOW SWITCH - Flow switch  
NO PILOT -  
MANUAL OVERRIDE - Boiler in emergency or manual operation  
• When a fault is indicated, the red light, to the right of the display, flashes and the alarm  
buzzer sounds. The light continues to flash after alarm is silenced and until the fault is  
corrected.  
• When fault is corrected display will read "OK"  
• Should communication between the system control module and the boiler monitor  
module(s) be disrupted, the display will show "BOILER NOT ON-LINE".  
• To display status of other boilers press the (+) or (–) buttons on multiple boiler installations.  
Page 24  
GREEN RED AMBER GREEN RED  
Power Manual  
Call  
for  
Heat  
x
Pump  
On  
Low  
Water  
Cutoff  
System Control  
Display  
On  
Over-  
ride  
OK  
x
x
System operating normally  
LWCO  
Low water in boiler  
LOW PRES WATER  
Water Pressure too low  
LO PRESS GAS  
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
Gas pressure below setting  
HIGH PRESS GAS  
Gas pressure on manifold too high  
HIGH LIMIT  
Boiler temp excess high limit  
THERMOSTAT OFF  
Boiler off on aquastat  
FLOW SWITCH  
Flow through boiler insufficient  
NO PILOT  
x
x
x
x
x
Pilot light failed to start  
BOILER NOT ON-LINE  
Communication lost  
x
x = Light On  
PUMP light used only when Economaster programmed.  
If a boiler should lose communication with the System Controller, BOILER NOT ONLIN  
Page 25  
Primary Control Parameters  
S e t  
R a t i o  
° R i s e  
*System water temperature  
desired at outdoor  
temperature of 70°.  
Range 40 - 200  
*RESET RATIO  
* Rise is the temperature rise in  
Ratio of outdoor temperature  
to water system temperature.  
Range: 0.0:1 to 20: and "None"  
for constant water temperature  
for constant water temperature  
system when all boilers are at full  
rate. (ÐT of system) Range 1 -99  
Default value is 20°F  
Default value 100°.  
(TAR T - Set Point). Default value is 1.0:1.  
LEAD LAG, NIGHT SET BACK  
* System water temperature desired  
at outdoor temperature of 70°.  
Default value 100° (Day).  
NOTE"S"  
Default value 90°F (Nite).  
This "shadow box" indicates the display  
for "Lead Lag, Nite Setaback" feature.  
LEAD LAG, NIGHT SET BACK  
Primary Control Parameters  
D a y  
X X X  
N i t e  
X X  
R a t i o  
X . X : X  
° R i s e  
X X  
Day Value is used as the set point  
when setback is OFF; Nite value,  
when setback is ON.  
– Sets up boiler and system,  
SET – Sets desired water temperature @ 70°F - minimum design  
Range 40 -220 (Day), 40 - 220 (Night)  
Default value is 100° (Day); 90°F (Nite)  
To increase PUSH [+] button to required temperature - suggested setting is 110°F.  
Page 26  
PUSH SELECT  
RATIO – Sets the desired change in system water temperature increases as the outdoor  
temperature decreases. The reset ratio is expressed as follows:  
2:1 for every 2 degree change in outdoor temperature the sytem temperature will change  
1 degree.  
Temperature °F  
e.g: Set = 135°F  
Ratio  
2:1  
Outdoor  
System  
60  
40  
20  
140  
150  
160  
Suggested Guidelines  
Typical  
Reset Ratio Setpoint at Design Temp:  
Temp@  
Temp@  
RADIATION  
Design Cond  
70°F  
105  
105  
105  
105  
105  
105  
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  
Standing  
Convection or  
Baseboard  
190  
200  
190  
140  
120  
120  
0.8:1  
0.7:1  
0.8:1  
2.0:1  
4.7:1  
4.7:1  
Fan Coil - Heating  
Fan Coil - Heat & Cool  
Radiant Floor  
Radiant Ceiling  
SUGGESTED GUIDELINES  
The selection of the correct ratio is dependent on the initial temperature and the desired system  
water temperature setpoint and the design temperature conditions.  
The reset ratio and setpoint must be selected so that the controller will raise the system water  
temperaturefromtheinitialsetpointsuggested110°Ftothemaximumtemperaturerequired  
when the outdoor temperature drops from 70°F to the design temperature.  
PUSH SELECT  
Design temperature rise of the system related to the boiler. Default value 20°F.  
Page 27  
Secondary Control Parameters  
S t e p  
O / C O / C d b  
C b a n d  
X X % X X X  
X
° F X  
*O/Cdb,  
*C Band is a range of  
*Step  
*O/C  
Outdoor cutoff  
temperature above and  
below the target  
temperature.  
Range 1-9  
Default value is 3°F.  
Increment of firing  
valve opening.  
Range 1s, 2s 5-100  
Defaultvalue20%.  
Maximum outdoor  
temperature that heat is  
desired, set at 70°,  
Range 35° to 199°.  
Default value is 65.  
deadband is the  
number of degrees  
below O/C where  
O/C reset occurs.  
Range 1-9  
Default value is 4°F.  
Page 28  
*STEP  
Enter desired valve firing increments. Recommended setting is between 5% and 20% for  
Modulating Boiler.  
Or  
Enter 1S If Gas Valve is an On-Off or Single Stage  
Or  
Enter 2S If Gas Valve is 2 Stage Firing  
Or  
Enter 20% If the control boilers include modulating and 2 stage or single stage boilers under  
control of a single system control module.  
*O/C  
Enter desired outdoor cutoff temperature, usually 70°F, depending on geographical loca-  
tion.  
When outdoor temperature exceeds desired setting, target temperature will show "O/C".  
Note: Boiler will restart when outdoor temperature drops below O/CF Tep - O/C db.  
*O/Cdb  
Enter desired outdoor cutoff dead band, which is the number of degrees below O/C where  
O/C resets, usually 1F.  
*C Band  
Enter desired Control Band, determines when boiler will fire below target temperature and  
shut off above target temperature, usually 1°F.  
NOTE: The above settings are recommended at initial installation. For maximum  
performance and system efficiency these settings should be modified, as required, to meet  
such parameters as system capacity, location and usage.  
NOTE: Contact factory for recommended settings if this is a special application ie. Heat  
pump applications.  
Lead Boiler Select  
L e a d  
X
#
o f  
B o i l e r s  
X
*Indicates boiler  
designated as "Lead".  
*Indicates number of boilers being used.  
Used when there are multiple boilers. Set number (#) of boilers to match actual installation.  
Readout lists lead boiler. To change lead boiler PRESS [+] or [–] button until desired boiler  
is displayed. In the event of a fault in the designated lead boiler the next boiler, numerically,  
becomes the lead boiler.  
Boiler being monitored is displayed. If multiple boilers, push [+] or [–] to select the desired  
boiler.  
Page 29  
LEAD LAG, NIGHT SET BACK  
Automatic Lead Lag  
L e a d  
H o u r s  
C h a n g e  
h r s .  
X X X  
X X X  
R e m a i n i n g  
*Lead Change Hours  
Designated lead boiler will change when remaining hours reaches 0.  
Range 0-225 hrs. Default value is 100 hrs.  
If set at 0 hours lead will not change.  
Hours remaining will automatically total.  
Enter the desired number of hours of lead boiler operation before change. Hours re-  
maining is automatically calculated. Designated lead boiler will change as soon as  
remaining hours run out. Set at 0 hours and lead will not change.  
STANDARD  
BOILER PARAMETERS  
LEAD LAG, NIGHT SET BACK  
Boiler Parameters  
P u m p  
# X :  
D e l a y  
X X m i n  
I G N T i m e  
X X X s e c  
*Pump delay selectable from 0 to 20  
minutes. Range 0-20. Default value 3 mins.  
*Ignition time sets the duration to monitor  
Ignition prior to lock out. Range 15-100.  
Default value 30 secs.  
PUSH SELECT  
PUMP DELAY  
Enter time desired for boiler pump operation, if one is installed and wired to boiler moni-  
tor. If there is no pump or a continuous running pump, ignore.  
PUSH SELECT  
IGN TIME  
Display shows time of monitoring the ignition prior to main flame. Default timing is 30  
seconds.  
Note: On multiple boilers, a time must be entered for each boiler.  
Page 30  
Night Setback  
"OFF" indicates the system is in the Normal or design operating mode. "ON" indicated  
the system is operating in a programmed night setback mode.  
LEAD LAG, NIGHT SET BACK  
NOTE"S"  
This "shadow box" indicates the display  
for "Lead Lag, Nite Setaback" feature.  
Automatic Lead Lag  
* X X : X X P M  
** M o n d a y  
S e t b a c k : *** O F F  
*Set Time of day  
** Day of Week  
*** On or Off  
This screen shows the time and day of the week. Default values:  
Monday for the day, and "OFF" for Setback.  
Enter the current time.  
PUSH SELECT Until day flashes.  
Enter day of the week.  
Setback status can be manually changed from "OFF" to "ON", or vice versa, provided the  
setbacktimeshavebeencleared,otherwisethetimerwilloverridethemanuallyselectedstatus  
of setback. Push [+] or [–] to setback mode to "on" or "off".  
LEAD LAG, NIGHT SET BACK  
Setback Times  
S e t b a c k :  
1 : * X X : X X  
* M o n d a y  
X X : X X  
-
am or pm  
am or pm  
This screen shows the Setback "ON" and "OFF" times for each day.  
There are six (6) "ON" and six (6) "OFF" times per day, as indicated  
by the number on the left.  
Page 31  
Set Back Example:  
Period  
SETBACK  
"ON"  
SETBACK  
"OFF"  
DAY  
1
2
xx:xx  
10:00 pm  
05:00 am  
xx:xx  
Monday  
Monday  
1
2
xx:xx  
10:00 pm  
05:00 am  
xx:xx  
Tuesday  
Tuesday  
1
2
xx:xx  
10:00 pm  
05:00 am  
xx:xx  
Wednesday  
Wednesday  
1
2
xx:xx  
10:00 pm  
05:00 am  
xx:xx  
Thursday  
Thursday  
1
2
xx:xx  
10:00 pm  
05:00 am  
xx:xx  
Friday  
Friday  
1
2
xx:xx  
xx:xx  
xx:xx  
xx:xx  
Saturday  
Saturday  
1
2
xx:xx  
xx:xx  
xx:xx  
xx:xx  
Sunday  
Sunday  
The above example will set back temp weekends and 10:00 pm to 5:00 am weekdays. Each  
day can have up to six (6) separate setbacks.  
When no time is entered (indicated by xx:xx) the setback time in effect from the previous time  
period will continue on to the next period, which means, when the night setback is "ON" the  
system water temperature for nighttime use will be maintained until the next "OFF" entry is  
reached.  
Page 32  
Boiler Valve Timing  
Boiler Valve Timing  
Information only  
V a l v e  
X X u  
T i m i n g  
# X :  
X X d  
s e c .  
u= UP  
Boiler Number  
Displays in seconds real time opening and closing  
d = DOWN  
of modulating gas valve from closed (0%) to full open (100%)  
This display shows the time (secs) required for the gas valve to open and close. If "u"  
display is from 12 to 26 and "d" is less than "u" and between 4 and 18 the gas valve  
requires no adjustment. This timing is not operator changeable on the screen display.  
Proportional Integral  
Derivative Operator  
Manual Action (PIDOMA)  
A.Proportional Integral Derivative  
OperatorManualAction  
A P c o n s t  
W a i t  
X
D c o n s t  
X /  
X
X /  
X
*Pconst is the proportional ratio  
which causes the boiler to step up  
or down, faster or slower (over-  
shoot or undershoot) and finally  
end up offset from desired tem-  
perature. Default is 1/3.  
*Wait is the time controller waits *Dconst is the derivative ratio  
until it acts on a temperature which tells the system how first to  
change. Default value is 5 sec- react to differing changes in water  
onds.  
temperature. Default is 3/1.  
*Pconst  
Proportional ratio which causes the boiler to step up or down, faster or slower.  
*WAIT  
Wait as time controller hesitates before acting on a temperature change.  
*Dconst  
Derivative ratio speeds or slows boiler response compensating for overshoot and undershoot.  
Page 33  
Proportional Integral  
Derivative Operator  
Manual Action (PIDOMA)  
B.Proportional Integral Derivative  
OperatorManualAction  
B P c o n s t  
W a i t  
X
D c o n s t  
X /  
X
X /  
X
*Pconst is the proportional ratio  
which causes the boiler to step up  
or down, faster or slower (over-  
shoot or undershoot) and finally  
end up offset from desired tem-  
perature. Default is 1/3.  
*Dconst is the derivative ratio  
which tells the system how first to  
react to differing changes in water  
temperature. Default is 3/1.  
*Wait is the time controller waits  
until it acts on a temperature  
change. Default value is 5 sec-  
onds.  
*Pconst  
Proportional ratio which causes the boiler to step up or down, faster or slower.  
*WAIT  
Wait as time controller hesitates before acting on a temperature change.  
*Dconst  
Derivative ratio speeds or slows boiler response compensating for overshoot and undershoot.  
ALL BOILERS ON/OFF  
A l l  
X X  
B o i l e r s  
a b o v e / X X  
o n / o f f  
b e l o w  
Range 1 to 99. Default valve 20° F.  
This Display Indicates:  
The temperature above or below target at which the control will turn off or on all the boilers.  
TARGET MIN/MAX AND HI LIM  
T a r g e t M i n / M a x :  
X X X / X X X  
H i L i m  
X X X  
Min Default 105, range 0 to 220°F  
Max Default 180, range 0 to 220°F  
Hi Lim Default 200, range 0 to 220°F  
Hi Lim shows the maximum obtainable water  
temperature.  
Hi Lim can not be lower than the target XXX/  
Max.  
Note: All of the values interact and are  
depedent upon each other.  
Page34  
tandard  
Initialize  
LEAD LAG, NIGHT SET BACK  
Initialize  
Y - Yes  
N - No  
V X . X X X X  
I n i t i a l i z e ?  
Y
Version # of software.  
* This will initialize all previous selectable values to default values. Should not be  
used unless operator wants to reprogram new values. Should be used at Start-up  
to clear the control memory.  
This should be by-passed, if controls have been initialized as the first step.  
Standard  
Utility Service  
LEAD LAG, NIGHT SET BACK  
Utility Service  
T e m p :  
X X X  
( X X X ) m : x  
X X X % X X X % X X X % X X X % X X X %  
Displays controller operating mode,  
changes continously from 1 to 5.  
Displays System Target Temperature  
Displays Firing Rate of each Boiler  
Displays Actual System Temperature  
Information Only.  
Displays the system operating conditions and the firing rate of each boiler up to total of (5).  
Page35  
IMPORTANT  
START "ALTERNATE"  
If your system module(s) are supplied with a single  
Field Wiring Terminal Strip use this method for wiring.  
WIRING  
-
AIR AND WATER SENSORS  
To The System Control Module  
WATER  
SENSOR  
OUTDOOR  
SENSOR  
BAREWIRE  
(SHIELD/  
DRAIN)  
FIELD WIRING  
TERMINAL STRIP  
BELDEN #8132  
or BELDEN #9842  
TO:  
SINGLEPOINT  
GROUND  
(SPG)  
Dia. #10  
AIR/WATER TEMPERATURE SENSOR SCHEMATIC  
Page36  
"ALTERNATE"  
Continued  
COMMUNICATION (RS 485) WIRING  
From: System Control Module  
To:  
Boiler Module  
• Shielded communications cable - Belden #9842 must be used.  
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 (System Control) 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.  
RS 485 Communica
P
WIRING: Power Source to Control and Boiler Modules  
• Observe Polarity very important.  
• Observe wire colors  
• Provide external surge suppressor  
capable of maintaining system integrity.  
• Provide overload protection and discon-  
nect means as required by code and for  
equipment serviceability.  
• Conduit can NOT be used as ground.  
* Must be "WIRED" Ground.  
Page3
"ALTERNATE"  
POWER TEST  
CHECK POWER  
Utilizing a Volt-Ohm-Meter (VOM) monitor the following on the "System Control" and "Boiler  
Monitor(s)" for proper voltage levels. Check at the Terminal Block (TB).  
POWER TEST TABLE  
BOILER MONITOR(S)  
INDICATION  
SYSTEM CONTROL  
INDICATION  
From:  
To:  
From:  
To:  
TB pin 1  
TB pin 2  
108 VAC to 132 VAC  
108 VAC to 132 VAC  
less than 1 VAC  
TB pin 1  
TB pin 2  
108 VAC to 132 VAC  
108 VAC to 132 VAC  
less than 1 VAC  
TB pin 1  
TB pin 2  
SPG  
SPG  
TB pin 1  
TB pin 2  
BOILER  
SPG  
SPG  
SYSTEM  
MONITOR(S) CONTROL  
INDICATION  
From:  
To:  
TB pin 1  
TB pin 1  
Less than 0.5 VAC  
Less than 0.5 VAC  
Less than 0.5 VAC  
Less than 0.5 VAC  
TB pin 2  
SPG  
TB pin 2  
SPG  
TB pin 2  
SPG  
END – – – – – – – –  
"ALTERNATE"  
Return to: "Boiler Monitor Select Switch"  
(See page 20.)  
Page39  
Fig. # 9458  
Page 40  
Fig. # 9459  
Page 41  
SYSTEM CONTROL BOARD  
Fig. # 9460  
Page42  
Replacement Parts List  
CP10.0_ _ _  
CP10.0N _ _  
CP10.0NMn  
New  
Part  
#
90FI  
90EI  
900D  
Page43  
Replacement Parts List  
Page44  
Fig. # 9461  
Located in place of  
ignition control on  
C2 boilers only.  
BOILER MONITOR CONTROL BOX  
Page 45  
Replacement Parts List  
CALL OUT  
B 6000 SYSTEM  
Boiler Monitor Control Box  
Control PC Board  
PART NO.  
B-1  
004795F  
650745  
B-2  
Power/Manual or Override Switch  
Transformer, 120/8.5 VAC C.T.  
Transformer, 120/24 VAC C.T.  
Transformer, 120/24 VAC (C2 Units only)  
Ignition Control with Lockout  
Fuse, AGC 2, 250V, 2A  
B-3  
064921  
B-4  
650495  
B-5  
650495  
B-6  
F1 & F2  
F3  
004818B  
650896F  
650523  
Fuse, AGC3, 250V, 3A  
K-1, K-2, K-3, K-4  
K-7, K-8  
K-6  
Relay, 5 VDC, SPDT  
650846F  
650849F  
650848F  
650847F  
Relay, 24 VAC, DPDT  
Relay, 120 VAC, SPDT  
K-5  
Relay, 24 VAC, SPDT  
K-1, K-2, K-3,  
K-4, K-5, K-6  
Relay, Socket SPDT  
Relay, Socket DPDT  
EPROM BVx.x  
650851F  
650850F  
601194  
K-7, K-8  
U4  
Page 46  
B6000 BOILER MANAGEMENT SYSTEM START-UP DATA  
SYSTEM SETTINGS ENTERED ON DATE:_____________________________________  
Temperature Scale °F or °C  
Standard  
Set _____ Deg.  
Ratio  
_____ : 1 Rise _____ Deg.  
System Water Temp. @ Oc  
Default Value 100°F (38°C)  
Reset Ratio-Outdoor:  
Default Value: 1.0:1  
Select Set Optional  
Ratio _____:1  
Reset Ratio  
System Design Temp. Diff.  
Default Value: 20°F (7°C)  
Day _____ Deg.  
Nite_____ Deg.  
Rise _____ Deg.  
System Design Temp. Rise  
Default Value:  
System Temps @ Oc  
Default Value  
100°F (38°C)  
Default Value:  
90°F (32°C)  
Default Value:  
1 .0:1  
20°F (7°C)  
Universal  
Step _____ %  
Valve Opening  
Default Value:  
5%  
O/C_____Deg.  
Outdorr Cutoff  
Default Value:  
65 degs.  
O/Cdb _____Deg.  
Outdoor Cutoff  
Deadband  
Default Value: 4 Deg  
# of Boilers  
C Band  
_____ Deg.  
Control Band  
Default Value:  
3 Deg.  
Lead  
_____  
_____  
Indicates Lead Boiler  
Number of Boilers in system.  
Select Set Optional  
Lead Change hrs. _____  
Lead boiler will change after selected no. of hours.  
Universal  
Ign Time _____ Sec.  
Pump Delay _____ Min.  
Delay off pump timing.  
Default Value: 3 min.  
Ignition lockout timing.  
Default value: 15 seconds.  
Select Set Option  
____________  
Time of Day  
__________  
AM or PM  
____________________ _______________  
Day of Week  
Set-back- Off or On  
Default Value: Off  
Default Value: Monday  
Period  
1
2
3
4
5
6
Set-Back  
Monday  
Tuesday  
On  
Off  
On  
Off  
On  
Off  
On  
Off  
On  
Off  
On  
Off  
___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___  
___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___  
Wednesday ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___  
Thursday  
Friday  
Saturday  
Sunday  
___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___  
___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___  
___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___  
___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___  
Proportional Integral Derivative  
____________________  
____________________  
____________________  
Pconst  
Wait (Integral)  
Derivative  
V___________________  
Version # of Software  
Page 47  
Troubleshooting Guide  
If you follow the instructions in this manual and have  
difficultyoperatingtheB6000, locatetheSYMPTOM in  
the left column below. Check the corresponding POS-  
SIBLECAUSEand CORRECTIVEACTIONColumnto  
locate and remedy the problem.  
The procedures outlined below assume that the initial  
installation / turn on / power up procedures have been  
completed and that the B6000 was operational. This  
guide is a basic instruction to determine if an authorized  
Raypak representative should be contacted.  
Symptom  
Possible Cause  
Corrective Action  
No Display.  
No Primary power.  
Check power connections to units.  
Check surge protection devices.  
Check disconnects, check  
grounds.  
Check power switches.  
* Nite set-back time display no  
longer correct.  
Time display accidentally  
Re-Programmed.  
Initialize system.  
Program Nite set-back feature.  
* Nite set-back not working  
properly.  
Nite set-back turned off.  
Clock times not set.  
Initialize system.  
* Time display does not maintain  
proper time.  
System ground not adequate.  
Line noise.  
Internal battery weak.  
Prolonged power outage.  
Initialize system and / or  
contact authorized Raypak  
Representative for further instruc-  
tions.  
System not working automatically.  
Boiler monitor has Manual Mode  
selected  
Select Automatic mode on Boiler  
Monitor.  
Display shows incorrect number of  
boilers.  
Inadequate grounds.  
Line noise  
Check primary power - check  
wired ground.  
Power outages.  
Rework as necessary.  
Initialize system.  
Scrambled control display.  
Power outages.  
Initialize system.  
Initialize system.  
Boiler does not function properly  
after power outage.  
Internal battery weak.  
Line noise.  
System ground not adequate.  
Boiler "Not on Line" displayed.  
Primary power at boiler not  
connected.  
Initialize system.  
Initialize system.  
Outdoor and water temp.  
readings Incorrect (-35°F).  
Inadequate ground  
Line noise.  
Power outage.  
Displayed parameters  
do not make sense.  
Power outage.  
Power outage.  
Initialize system.  
Initialize system.  
System Faults indicators do not  
make sense.  
* With Nite Set-Back option only.  
Page 48  
Trouble Shooting Guide-Continued  
Possible Cause  
Corrective Action  
Symptom  
Boiler not powered.  
Check primary power.  
Boiler # x  
Correct as necessary.  
"Not on Line" Displayed  
Check communication cable,  
check (surge) ground Remove /  
Replace (R/R) as necessary.  
Initialize system.  
Outdoor sensor not mounted  
correctly.  
Refer to installation manual  
mounting instructions. Possible  
relocation for sensor.  
Outdoor Temp. Sensor readings  
are high.  
Sensor wiring shorted  
Sensor wiring open.  
Check sensor wiring for damage.  
R/R as necessary.  
Initialize system.  
Sensor reading 220°F.  
R/R as necessary  
Initialize system.  
Sensor reading - 35°F.  
Low water cut-off alarm.  
Excessive circuit loading of pump  
contacts by user supplied system  
pump.  
Check power.  
Check pump contactor / relay  
R/R as necessary.  
Low water level in boiler  
Replace F1 fusing.  
Check main water supply  
Fuse F1 blown.  
Replace F1 fusing.  
Remove Relay-K1 to isolate circuit  
loading.  
R/R as necessary.  
Reset circuit breaker.  
Power lamp off on Boiler Monitor.  
Excessive circuit loading of pump  
contacts by user supplied system  
pump.  
Circuit breaker tripped.  
Excessive circuit loading of pump  
contacts by user supplied system  
pump.  
Replace F1 fusing.  
Pump not running.  
Pump going off on thermal over-  
load circuit breaker tripped  
Check pump.  
Reset circuit breaker  
Paddle damaged or missing.  
Pump off on thermal overload.  
Check paddle on flow switch.  
Check pump, contact or relay.  
Replace F1 fusing.  
Off at flow switch.  
Off on High Limit.  
Low limit settings.  
Intermittent power or pump  
failure.  
Check and correct settings.  
Meter amperage on pump.  
R/R as needed.  
Page49  
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  
furnishareplacementorrepair, atouroption, anydefectivepartwhichfailsinnormaluseandserviceduringtheapplicablewarrantyperiod.  
The replacement or repair will be warranted for only the unexpired portion of the original Warranty Period.  
APPLICABLEWARRANTYPERIOD  
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.  
WARRANTYEXCLUSIONS  
This Limited Warranty does not apply:  
1. if the control system is not properly installed by a qualified technician in accordance with manufacture's installation  
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  
with the manufacture's instructions;  
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.  
HOWTOMAKEAWARRANTYCLAIM  
To make a warranty claim, promptly ship (postage prepaid) or carry the defective part to a designated RAYPAK Service Dealer or  
Service 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.  
EXCLUSIVEWARRANTY-LIMITATIONOFLIABILITY  
ThisistheonlywarrantygivenbyRAYPAK. NooneisauthorizedtomakeanyotherwarrantiesonRaypak'sbehalf. ANYIMPLIED  
WARRANTIES,INCLUDINGMERCHANTABILITYORFITNESSFORAPARTICULARPURPOSE,SHALLNOTEXTEND  
BEYONDTHEAPPLICABLEWARRANTYPERIODSPECIFIEDABOVE. RAYPAK'SSOLELIABILITYWITHRESPECTTO  
ANY DEFECT SHALL BE AS SET FORTH IN THIS LIMITED WARRANTY. ANY CLAIMS FOR INCIDENTAL OR  
CONSEQUENTIALDAMAGES(INCLUDINGDAMAGEFROMWATERLEAKAGE)AREEXCLUDED.Somestatesdonotallow  
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.SERVICEDEPARTMENT  
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:  
________________________________________________  
OriginalOwner  
_______________________________________________  
Daytime Telephone Number  
__________________________________________________________________________________________________  
Complete Mailing Address  
________________________________________________  
City State Zip Code  
_______________________________________________  
Installation Site  
________________________________________________  
Model Number  
_______________________________________________  
Contractor/Installer  
________________________________________________  
Date of Installation  
_______________________________________________  
SerialNumber  
Raypak, Inc., 2151 Eastman Ave, Oxnard, CA 93030 (805) 278-5300 FAX (805) 278-5468  
Litho in U.S.A.  
Design and specifications subject to change without notice.  
This symbol on the nameplate means the product is listed by Underwriters  
Laboratories, Inc. ®  
U
®
L
Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 • (805) 278-5300 • FAX (800) 872-9725  
Litho in U.S.A.  

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