Raypak LONMARK Y-200 User's Manual
Contents
1. KEYI 7258 z gzz Rei Direct Prog Bes S 00000000 eee ke za TEETE 4 20 mA Coo000000 z201 a 240719 RS485 au S OR e J23 1A B EE PORT R13 O z5 Ban 2 10 V RO VIR loooa BEA ga Ther el kb B B Bris PORT 226 cq C18 C11 Ach Di 8 aD kal 74 CIRG Qi H ER ER EH R230 m FE c2 L2 Br22 E O IS v2 EEn R19 1 Bot m an REL O o aS pay Erz BR I uU10 BOARD S O 9 c7 Dan ET Ge R31 ut H R32 Zi 1g9lzis Le IO Q2 R308 B DI Brs3 J3 B mm U6 m O E e R R286 U12 B 28 CIA ni zZ D T HS R37 Ip 3 P N BLANK BOARD 601669 pee Di P N ASSEMBLY 6016708 O J4 ue C17 SS D3 MODEM MODULE J22 Bg e EE SE B Bro c18Q Bras nm ao lz Z7C16 R36 B C 0000090 J16 R49 Js ef e cz Ro d RESET PROG PORT KAY Le e O e DR BR u2 R45 pap BOARD Tpu GND Dos BAT1 U3 c22 R3 CH E el 2 Ba B 2 rome 1 R53 BR1225 Ss ES ESRRRBn ust 8 8 Se ie 500000000 olsa o JRG Lie x2 Si cll as ci P1 oooooooo hie CFH 3 o ppo EH O Ree R62 C24 Ha at KE og 8 ggss UR ROY g R56 ar Broa CH Brso D d Sg Olis LI D Bee SERVICE RESET R61 C23 ug L W k HWS HW2 HW4 Zi2aP re ee onWorks o og 1 U15 Ce Rev ME em R64 2 R65 D vare cone ___ AUX 3 E Bn vn sie 1 1 SE 1 m m m 12 L LONWORKS 1 nl C28 MODULE Reone SYSTEM rae ca eI R72 PUMP S RELAY AUX2 TO Ap v 00000000 p2 a Sie 1 EN ALARM ize LONWORKS SESCH Ifs EM RESET oo pity iq CONNECTION 1 m f No 2 ibaa 2 wigd aux 10 o000 ps D csp LH Engineering2. Manual Override Switch 4 Stage Relay Board Fig 8 Main Circuit Board o0000000 Circuit Board Layout 15 Auxiliary Board Manual Override Switch Keypad Normal Mode Move to next screen SC Push the MODE button to turn off the alarm horn MODE Not active except in special modes Not active except in special modes Move to previous screen Program Mode To access programming mode Press and hold MODE button for 4 seconds If no button is in rease selected parameter pressed while in PROGRAM mode for 30 seconds P screen returns to normal mode Pa MODE Move to previous programmable Move to next programmable parameter parameter Gs Decrease selected parameter When in PROGRAM mode cursor is blinking on first settable parameter If no button is pressed for 30 seconds screen returns to NORMAL mode Press MODE button to store change and return to NOR MAL mode Once programming is finished press the SW3 reset button on the motherboard to save the new programming Control Screen Displays amp Programming Initial Screen Screen number als liese Ile ttt ft feds ee els Pe feel ee ee eee Product identification Version number of software This is the initial screen displayed after system start up provided that there are no faults Primary Parameters Fahrenheit or Celsius Screen number itm iitr totaled sfetr fe fole wir Pe ofa ea eee Ly eee ee Cale
3. Recommended Initial Setting for outdoor cut off Temperature is 75 F 23 8 C Factory default is 75 F 23 8 C Note This function is disabled when the control is configured for a single sensor Outdoor Cut Off Deadband Screen number Fahrenheit or Celsius The Outdoor cut off deadband sets the number of degrees below the outdoor cut off where the outdoor cut off reset occurs The outdoor cut off deadband limit is 1 degree F to 10 degrees F Default is 3 degrees F Note This parameter can only be set in F but will display in C if C is chosen Note This function is disabled when the control is configured for a single sensor 23 System Monitor Screen number zlvls viele wll rfe ets ited ete pele tate Le Le le Lee Lele ls This screen is only a display Total of stages available is set on screen 24 Staging control is set on screen 20 SYSTEM PUMP MODULE Rule Always on before boiler Always off after last boiler off programmed delay or outdoor sensor reading is above cut off temperature setting P is relay 1 as supplied INDICATES BOILER 1st Stage Rule Always B before S S INDICATES BOILER STAGE 2nd Stage and Subsequent Stages Rule Must have B for that boiler ON and prior stages ON for that boiler A AUXILIARY RELAY MODULE Optional A1 User defined function e g powered louvers boiler pump draft fan A2 User defined function e g alarm light A3 User defined fu
4. System Monitor Screen 11 Preset PBSSSBSSSAAA Unit Set up Network 20 2 boilers 4 stages Note See Table J When ACTIVE initiates auto system test and displays all System Test 21 screens Default Not Active Set Password Changes the current user password Default AAA Min Default 105 F Water Temperature Sets Maximum and Minimum water tempterature limits 40 5 C Max Default Limits 23 allowed by the user in the Water Temperature Screen 210 F 98 8 C Displays the number of sensors utilized relays stages or Master Slave Unit 24 boilers and Aux contacts Default Master Slaves Conneted Default_ 00 LonWorks Default OFF Factory Defaults Default NO OY Biches oneal User Defaults 28 invoked Default None Terminal Password Default AAA Bee eg Alarm Call Tele 30 occurs None PT Alarm Call ID 31 occurs None Alarm Call Ret None Alarm Call Events None Default Interval 05 KP 06 KI 05 PID Settings 34 Configures PID operation KD 01 Table F Control Screens Continued Manual Override Internal switches have been provided on each of the stage modules that can be used to manually override the microcontroller See switch SW1 on each stage board page 15 14 Circuit Board Layout o o o o o o o o RS H SW3 Reset Switch
5. TANK WATER SENSOR gt lt 1 2 NPT NG Ka INLET Qu Gef OUTLET Y 200 RECIRCULATION wo Fig 7 Domestic Hot Water Supply e Outdoor reset function should be disabled See T screen 06 and 24 From To Indication TB pin 1 TB pin 2 108 VAC to 132 Power Test VAC TB pin 1 Single Point 108 VAC to 132 Check Power Ground VAC TBpin2 Single SCH Less than 0 6 VAC Utilizing a Volt ohm meter VOM monitor the following Groun on the controller for proper voltage levels Check at the Terminal Block TB 1 Table C Voltage Measurements 11 Installation Verification Procedure Register d Before proceeding any further please verify that the user registration form has been completed and mailed Mechanical Installation LI Verify that the mechanical installation has been completed in accordance with the instructions Outdoor Air Temperature Sensor LI Verify that all Outdoor Air Temperature Sensor installation parameters have been met Water Temperature Sensor LJ Verify that the Water Temperature Sensor installa tion parameters have been met Optional Equipment LJ Verify that optionally ordered equipment installa tion parameters have been met System Module Installation LJ Verify electrical power wiring connections Verify electrical connection torque requirements Verify Outdoor Air Temperature Sensor wiring Verify Water Temperature Sensor wiring m m m 1 Verify Power Test has been com
6. Off Delay range is from 0 to 600 sec onds Recommended Initial setting stage for Turn Off Delay is 10 seconds Factory default is 10 seconds Screen number ete jo telef slei ie os eee I ee ee ee ee NOTE PID mode is logic control microprocessor disables screens 3 14 and 15 for Standard This is the factory default screen Screen number s rjatwiolaieto ttt ft fee Standard mode is controlled by Screen 3 Control Band Screen 14 Time On Delay Screen 15 Time Off Delay 26 System Temperatures These screen parameters are only available if the inlet and outlet sensors have been installed and selected See screen 24 Screen number This screen is only a display iiwiefets elle fefefe frfa i Current boiler inlet or system Current boiler outlet or system Boiler or System delta temperature temperature NOTE 1 These values are currently reserved for viewing actual and delta temperatures 2 If the sensors are not selected or used dashes will be displayed Lead Change Time Auto or Manual Screen number alle Ileieisict les ie If manual lead Run time Lead boiler Last boiler change hours Displayed in manual For Manual Only Lead Change Hours Designated lead boiler will change when remaining hours reaches 0 Range 0 999 hours Default value is 100 hours If set at 0 hours lead will not change Hours remaining will automatically total Enter t
7. User Defaults 29 Modem Password 30 Alarm Call Telephone 31 Alarm Call ID 32 Alarm Call Retry 33 Alarm Call Events 34 PID Master Unit with Slaves Y 200 Master Slave Diagram Sensor Resistance Illustrated Parts List WARRANTY Y 200 SERIES ELECTRONIC BOILER CONTROL SAFETY INSTRUCTIONS NOTE These instructions are intended for use by qualified personnel who are specifically trained and experienced in the installation of this type of equipment and related system components Installation and service personnel may be required by some states to be licensed If your state requires certification be sure your contractor bears the appropriate license Only qualified persons shall attempt to repair this equipment Repair must be according to these instructions WARNING Improper installation adjustment alteration service or maintenance may damage the equipment create a hazard resulting in asphyxiation explosion fire electric shock personal injury or property damage and will void the warranty CAUTION MORE THAN ONE 1 SUPPLY SOURCE THIS APPLIANCE HAS PROVISIONS TO BE CONNECTED TO MORE THAN ONE 1 SUPPLY SOURCE TO REDUCE THE RISK OF ELECTRIC SHOCK DISCONNECT ALL SUCH CONNECTIONS BEFORE SERVICING CAUTION RISK OF ELECTRIC SHOCK MORE THAN ONE 1 DISCONNECT SWITCH MAY BE REQUIRED TO DE ENERGIZE THE EQUIPMENT BEFORE SERVICING Thank you for selecting the Raypak Y 200 Series Electronic Boiler Control It is our s
8. each calendar day Time in 24 hour 99 to 99 degrees of offset clock mode adds to or subtracts from the initial setpoint screen 02 to become active at selected time Screen number FULL WEEK screen lee eet Tell CC wlelel ola There are eight days of selectable offsets MON FRI Fahrenheit or Celsius TUE SAT WED SUN blank or THU HOL Holiday To set an offset select the day or choose ALL for all days Set the values in degrees A positive OFFSET will increase the Water Target Temperature A negative OFFSET will decrease it An offset value of 00 0 will return it to its original value 99 to 99 degrees of offset are available 19 Holiday Screen number ste ririiiwie fufofe fi fetai ols aye eee Ll ee els ele Thirty two holidays are Month Day Year selectable 01 32 01 thru 12 01 thru 31 01 to 99 Below 01 is Repeating Holiday RH setting NOTE Previous screen 04 is used for entering the offset value in degrees Reset Ratio Ratio of outdoor temperature to water system temperature Range 01 1 to 8 1 or None for constant water temperature then TARGET SETPOINT Default value is 1 00 1 Screen number pep be te Ct pe ot pepe fe el Default Default System temperature at 70 F 21 1 C System temperature at F 140 F 70 F 60 C 21 1 C This value is 200 F 10 F 93 3 C 12 2 C and the second number refers to the degree s
9. fan A2 User defined function i e alarm light A3 User defined function i e alarm bell NOTE Piezo electric alarm horn can be silenced by pressing the MODE switch Table K Definitions 28 System Test Screen number zlvls eieiei frels ttt eh ee ee A eee Ile ye or ACTIVE This display will cycle between turning all LCD segments on for four 4 seconds then off for four 4 seconds To stop this cycling push any button Self diagnostics are initiated at 0900 and 1900 hours NOTE 1 When system test is running this will not affect control or boiler operation 2 If system test is running it can be terminated by pushing any button Set Password BEIENEE Screen number In display mode shows AAA or current password To change the default password AAA to a new password 1 Push the mode key The cursor under the first A should start flashing 2 Change the first letter by using the up or down key to the desired letter 3 Use the right key to go to the next letter and change it with the up or down key 4 Do the same to the last letter then push the mode key when done Water Temperature Limits Screen number leist freme Ciel is Maximum programmable setting is 235 F 112 7 C Minimum programmable setting is 40 F 4 4 C Factory default value is 210 F 98 8 C Factory default value is 105 F 40 5 C NOTE This screen sets the maximum and minimum values allowable by the
10. user The values entered in user screen number 8 cannot exceed the maximum and minimum values programmed here 29 Master Unit Screen number mfafsfrje TTT e Sie eS ESA ES E BEA ES ee 0 1 20r4 1 thru 8 0 1 20r3 Number of temp sensors Number of staging contacts in Number of auxiliary boards use See screen 25 in use If SNS 0 This unit is a slave unit No sensors required or active If SNS 1 Water System Turn outdoor reset ratio to NONE on screen 06 If SNS 2 Water amp Outdoor Activates outdoor reset function on screens 6 9 and 10 If SNS 4 Water Outdoor Inlet Outlet Activates screen 17 This screen limits the programmable parameters available to the user The information provided is determined by boiler and control construction Stage Sensor Connections for Y 200 Master Slave Systems Master unit Slave 1 Slave 2 Total no Relay Relay Sansone Relay of stages boards boards boards Relay sensors boards sensors sensors As required for the installation See above section Table L Connections for Master Slave Systems NOTE The unit with sensors installed is identified NOTE The maximum is 4 sensors and 4 slave as the master unit controllers 30 Slave Unit See Staging Table Screen number s tjalviels lees ivietelelel fels Number of slaves connected 01 thru 04 A unit with no sensors attached to it defines itself as the SLAVE unit In program mode see page
11. 32 you identify which SLAVE unit you want it to be SLAVE units are numbered from 1 to 4 Connect the master unit to each slave unit in parallel using RS485 wiring as noted in the Communications RS485 Wiring section of this manual LonWorks Optional Screen number fefnjwjojn fjs ttt T fete OFF ON If ON the LonWorks network is active Factory Defaults Screen number Press MODE button to get into program mode Press UP arrow key to select YES Press MODE button to load Factory Defaults and to exit program mode NOTE If unit times out the factory defaults will not be set 31 User Defaults Screen number Program this screen when all other parameters have been entered visite leieicllviCGclsl Jefe Alix TL Lelelle elle TE Press MODE button to get into program mode Press UP or DOWN key to select Setup Defaults Screen number telefe faeetis jefe Press MODE button Open panel and press SW3 to complete programming Screen number visite folelelalulelris ie Alle ele le elle LTL If parameters have been changed and original user defaults are required Press UP or DOWN key to select Invoke Defaults Press MODE button to exit program mode Screen number Jyisteiel Clees Jele fete eT LL belle Display before and after programming user default setup Modem Password Press MODE button to get into program mode Enter password Press MODE but
12. CH CH N CH N N CH Table M Sensor Resistance at Various Temperatures 37 Y 200 Illustrated Parts List Item No 1 C 2 C 3 C 4 C 5 C 6 C 7 C 8 C 9 C 1 J 1 S 2 S 3 S 4 S 1 M 10 M Description Part No PC Board Assy Y 200 008846F Expansion Board Assy 4 Stage 008847F Auxiliary Board Ass 008848F Transformer Ass 008705F 008849F 008850F 010792 010791 009823 007155F 008828F 008829F 008845F 004821F 006744F Ribbon Cable Displa 011715F 38 LIMITED WARRANTY Y 200 Series 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 if the control system is not properly installed b
13. INSTALLATION amp OPERATING INSTRUCTIONS Y 200 Series Electronic Boiler Sequencer amp Outdoor Reset Control System Ly iil c US LONMARK 3 3 LISTED i q DIE Catalog No 5000 62H Effective 09 28 09 Replaces 11 25 08 P N 241125 Rev 9 el Dr us LISTED is a registered trademark of Underwriters Laboratories Inc Rev 9 reflects the following Changes to C UL Listed Mark on page 1 2 CONTENTS IMPORTANT SAFETY INSTRUCTIONS INTRODUCTION Concept of Operation Y 200 Controller Configurations Y 200 Options INSTALLATION Mechanical Installation Electrical Installation Controller Field Wiring Communication Field Wiring Air Temperature Sensor Installation Water Temperature Sensor Installation Power Test Installation Verification Procedure CONTROLLER FAMILIARIZATION Control Screens Circuit Board Layout Keypad Control Screen Displays amp Programming 01 Initial Screen 02 Primary Parameters 03 Control Band 04 Offset 05 Holiday 06 Reset Ratio 07 System Status 08 Water Temperature 09 Outdoor Cut Off Temperature 10 Outdoor Cut Off Deadband 11 System Monitor 12 System Temperatures 13 Auxiliary Delay 14 Boiler Stage On Delay 15 Boiler Stage Off Delay 16 PID 17 System Temperatures 18 Lead Change Time 19 Password 20 Setup 21 System Test 22 Set Password OO OO OO Om Oo E AL 23 Water Temperature Limits 24 Master Unit 25 Slave Unit 26 LonWorks 27 Factory Defaults 28
14. NAL Call for heat signal 24VAC not present on J6 connector WATER TEMP gt MAX System water temp gt Maximum allowed temp ILS gt OLS Inlet water temp gt Outlet water temp SYS IS OPEN System water sensor or cable connector is open SYS IS SHORT OLS IS OPEN OLS IS SHORT ILS IS OPEN ILS 1S SHORT OSS IS OPEN Outdoor air sensor or cable connector is open OSS IS SHORT Outdoor air sensor or cable connector is shorted Table I Error Indications 22 Water Temperature Screen number ls lisa frieme T fee Displays the maximum water temperature Displays the minimum water temperature for the boiler Range is determined by for the boiler Range is determined by screen number 23 Factory default is screen number 23 Factory default is 180 F 82 2 C Maximum 105 F 40 5 C Minimum Outdoor Cut Off Temperature Screen number efe jrjefojofan jelulrjolrir fee BERBER eRe eae Fahrenheit or Celsius The outdoor cut off 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 outdoor temperature increases beyond the outdoor cut off setting there is no call for heat and the pump turn off delay becomes active If the outdoor temperature falls below the outdoor cut off minus the outdoor cut off Deadband the boiler bank will again be enabled The Outdoor cut off Temperature is from 32 F to 200 F 0 C to 93 3 C
15. are should be taken to select a suitable mounting location The controller should be mounted on a solid and permanent base The unit should be readily accessible for maintenance and installation purposes and should be mounted so that the display is at a height and location convenient for viewing Mechanical Installation Install the controller within 30 feet of the boiler s It must be mounted vertically with the conduit holes fac ing downward The conduit holes are sized to accommodate standard 1 2 conduit fittings If addi tional or larger conduit fittings are required locate the conduit connections on the bottom of the module Slave units if present should be installed adjacent to the master unit Y 304 slave cable is approximately five feet long Mount the controller using the mounting bracket and appropriate hardware in four 4 places A minimum of eighteen 18 inches clearance from the front and six 6 inches clearance on all other sides is required for service access The hinged right side of the box should be installed with sufficient clearance minimum 3 from bolt hole on the right side to open the cover An electrical distribution sub panel containing appro priate disconnect switches and surge suppressors is required at or near the equipment location s Electrical Installation Requires 120 VAC Draws 0 5 amp 60 Hz 120 VAC Feeder Circuits Install a surge protection device sized appropriately for y
16. arm bell 3 diameter Shipped loose for field installation Y 301 Alarm bell 4 diameter Shipped loose for field installation Second 4 stage Expansion Board Converts Y 241 to Y 281 Ships Y 302 tgs i loose for field installation Auxiliary Relay Board Adds control functions for external equip Y 303 HA ment such as combustion air louvers Ships loose for field installation Slave Cable Connects slave units to the master controller Ships Y 304 GE i loose for field installation 4 20 mA 2 10 VDC Control Board Accepts 4 20 mA or 2 10 VDC input from external system such as a BMS to force a specific setpoint Y 305 8 j Ships loose for field installation Separate instruction manual see 5000 64 Inlet Outlet Sensors Provides a PAIR of sensors for the inlet and Y 306 outlet temp sensing ports Displays temp but does not affect control algorithm LonWorks Module Provides full communication between a Y 200 Y 307 series controller and a LonWorks enabled system Cannot have BOTH this AND a modem Shipped loose for field installation Separate instruction manual see 5000 63 Modem Module Provides full communication between a Y 200 Y 308 series controller and an external system Cannot have BOTH this AND a LonWorks Shipped loose for field installation Separate instruction manual see 5000 65 Table B Y 200 Options INSTALLATION If the controller was not mounted on the boiler by the factory c
17. aves as an energy wise boiler sequencer With the ability to control multiple firing stages and such features as a revolutionary selec table lead lag protocol the Y 200 redefines controllability in domestic water applications The controller is equipped with an energy saving warm weather shutdown capability When the outdoor temperature rises above an adjustable Outdoor Cut off Temperature the system automatically transitions to a dormant state This prevents the system from wasting energy trying to heat a building that is already at a comfortable temperature Once the outside temperature has fallen to the point that the system requires heat input to maintain the building temperature the Y 200 is reactivated and will hold the system temperature at the required point For replacement items see page 38 Y 200 Controller Configurations Model No Description Y 241 4 Stage Controller Includes main controller assembly air temperature sen sor assembly P N 068634 water temperature assembly P N 068635 and one 1 stage contact board Main controller includes one 1 mounted auxiliary contacts board Y 281 8 Stage Controller Includes main controller assembly air temperature sen sor assembly P N 068634 water temperature assembly P N 068635 and two 2 stage contact boards Main controller includes one 1 mounted auxiliary contacts board Table A Y 200 Controller Configurations Y 200 Options Y 300 Al
18. d are con nected at the TH Thermostat location on the boiler wiring diagram e Provide an external surge suppressor capable of maintaining system integrity e Provide overload protection and a disconnect means for equipment serviceability as required by local and state code e Conduit cannot be used as the ground There First st ti th trol board must be a WIRED ground irst stage connections on the control board are con nected at the TH Thermostat location on the boiler wiring diagram Second or third etc stage connec tions on the control board are connected at the locations shown on the boiler wiring diagram For Multiple Stage Boilers e Very Important A grounding electrode con ductor 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 J11 1 12 VAC 2 Y BL HOT BK COM W 120VAC SUPPLY G Fig 2 Wiring Diagram 7 Notes 1 3 Tighten terminal strip clamping screws to 2 5 in 4 For external building control or thermostat control remove wiring to J6 CHF connector and activate lbs Breakage from over torquing is not covered under warranty Use stranded copper conductors only For supply connections use
19. e shield at the slave unit end of the cable Note Equivalent shielded cable must be suitable for RS485 communication applications must have 100 140 ohm impedance and less than 30 pico farad per foot capacitance Must be installed in conduit that does not contain any other wiring Port J18 see Fig 4 is used for the interconnec tion between the master controller and slave units Master Slave interconnection should be wired from Master to Slave 1 Slave 1 to Slave 2 Slave 2 to Slave 3 and Slave 3 to Slave 4 W BL to slave BL W to slave O W to slave Shield Ground at Master Y 200 only Fig 4 Master RS485 Communications Cable Schematic Air Temperature Sensor Installation Fig 5 Typical Outdoor Air Temperature Sensor Locate the sensor on the coldest side of building usually the north side Install the sensor in a shaded area out of direct sunlight Locate no higher than 2 3 way up the side of the building or between the 2nd and 3rd floor if the building is more than 3 stories tall Do not locate under an overhang near wall cor ners near drafts from stacks air moving devices windows doors or balconies Shielded twisted pair 18 AWG must be used for sensor connections Polarity must be observed Cable length shall not exceed 300 feet and the shielding must be grounded Grounding is done at the Master Y 200 control ONLY Do Not ground the Slave units or Temperature Sensor encl
20. em The boiler Turn On Delay The Stage Turn On Delay sets the time delay before a sets the amount of delay before each additional boiler new stage in a multi stage boiler configuration is is turned on in response to a call for heat This delay turned on This delay starts when the stage or boiler starts when the preceding boiler is turned on preceding the next stage is turned on The Boiler Turn On Delay range is from 0 to 600 sec The Stage Turn On Delay range is from 0 to 600 sec onds Recommended Initial Setting for Boiler Turn On onds Delay is 30 seconds Recommended Initial setting stage for Turn On Delay Factory default is 30 seconds is 10 seconds Factory default is 10 seconds 25 Boiler Stage Off Delay Screen number etolijejalsisiz o Zeite telev tis eee eee eee EES Boiler Turn Off Delay In a multiple boiler system The boiler Turn Off Delay sets the amount of delay before each additional boiler is turned off This delay starts when the preceding boil er is turned off The Boiler Turn Off Delay range is from 0 to 600 sec onds Recommended Initial setting for Boiler Turn Off Delay is 30 seconds Factory default is 30 seconds Proportional Integral Derivative PID Stage Turn Off Delay The Stage Turn Off Delay sets the time delay before a stage in a multi stage boiler configuration is turned off This delay starts when the stage or boiler preceding the next stage is turned off The Stage Turn
21. he desired number of hours for the lead boiler operation before change Hours remaining are automatically calculated For Auto Only On multiple boiler systems and on each new firing cycle the lead boiler will change If a Last Boiler is select ed it will always be the last boiler to be called for during a heating cycle 27 Password Screen number Used by maintenance personnel to change settings In display mode shows AAA or current password To enter the password 1 Push the mode key The cursor under the first A should start flashing 2 Change the first letter by using the up or down key to the desired letter Use the right key to go to the next letter and change it with the up or down key Do the same to the last letter then push the mode key when done e If the password is valid the screen will allow the user to change to the first setup screen Setup Screen number ll stefi tt tt Gel eee ee eee ee ele ea SYSTEM PUMP MODULE Rule Always on before boiler Always off after last boiler off programmed delay P is relay 1 as supplied Not Programmable INDICATES BOILER NOTE B represents the boiler and stage one of that boiler Rule Always B before S Example A 4 Stage boiler BSSS INDICATES BOILER STAGE Rule Must have B for that boiler ON and prior stages ON for that boiler See example above AUXILIARY RELAY MODULE Optional A1 User defined function i e powered louvers boiler pump draft
22. incere hope that you will enjoy its outstanding design ease of use and energy saving features Please Register Before proceeding any further please take a moment to complete the enclosed user registration form and mail a copy to Raypak Inc Department Y 200 2151 Eastman Avenue Oxnard CA 93030 INTRODUCTION The Y 200 Series Electronic Boiler Control controller is a microprocessor based boiler management system designed to control either single or multiple stage fired boilers Ideally suited for use in hydronic heating and domestic hot water supply applications this controller has been engineered with the flexibility and raw power to tame the most demanding control situations Utilizing state of the art control algorithms the Y 200 Series minimizes operating costs by maximizing ener gy efficiency Concept of Operation The controller is an outdoor reset control that is perfect for managing hydronic heating systems Two tempera ture sensors are used to control system response One sensor is used to monitor the outdoor tempera ture the other sensor is used to regulate the temperature of the system water By varying the tem perature of the heating medium in response to changes in the outdoor temperature the Y 200 Series provides the ultimate in personal comfort and efficien cy of operation The controller is also well adapted to domestic hot water supply duty By disabling the outdoor reset func tion the Y 200 beh
23. is disabled in PID operation If the Control Band is adjusted during PID operation it disables the PID Control Band 03 function Lal ee a Offset 04 point at the date and time selected None for Domestic Hot Water Application ONLY or 0 01 1 to 8 1 determines how much the internally calculated Target Temperature will change for a given outdoor temperature Reset Ratio change System Status Maximum USER water temperatures 235 F 112 7 C and Water Temperature Minimum water temperatures 40 F 4 4 C Display Limits Only 32 to 200 F 0 to 93 3 C a warm weather shutdown feature Outdoor Cut off When the outdoor temperature exceeds this setting the Temperature boiler will not fire unless placed in manual override mode 01 to 10 F the number of degrees below the Outdoor Cut Outdoor Cut off off Temperature which causes the Outdoor Cut off Deadband 10 Temperature to reset Displays the Pump Boiler Stage and Auxiliary contact System Network Monitor Outdoor Water TAR status If flashing contacts are closed ON Displays the current Outdoor Air System Water and Target Temperature in degrees F or C AUX Dela 0 to 600 seconds sets the time interval between sequential boiler start ups 0 to 600 seconds Boiler Stage On Delay 14 sets time interval between stages turning on Table E Control Screens 13 NOTE Once programming is finished go to Screen 28 to program the USER DEFAULT SET_UP Then open the front pane
24. ish to use 01 thru 04 ES ale ele EE EE EAR es Screen number Go to screen number 24 and select the number of sensors relays and auxiliaries miatstrfete TTT Get ee le eee erie Screen number Go to screen number 20 and set up your Network master and slave operations Setup slave operations prior to Network Set up on Master Controller 34 Screen number AE lee oe ie Pee BE EE ee KE e ole el E Sele eee pee pe EISES lee ele Slave Unit Screen number Press MODE button to get into program mode Go to screen number 25 and display should read Go to screen number 24 and select the number of sensors relays and auxiliaries NOTE On slave unit select 0 for number of sensors screen number Select which slave number you wish it to be 01 through 04 EADIESZZKZRIREAEZKZR IWWER eee ie Pelee ares et eee ey Screen number Go to screen number 20 and set up your unit operations Ignore screen number 11 on the slave units 35 Y 200 Master Slave Diagram Outdoor Air Temperature Sensor 4 Four stage boilers 2 Y 281 controllers 2 Sensors System amp Ambient Water Temperature Sensor Shielded communicationis cable Belden 9842 8432 or Alpha 3492C must be used WBL BLAW OW Shield This port is used for the interconnection between the master controller and slave units J1 SYSTEM SENSORS SYSTEM OUTLET Op
25. l and press the SW3 reset button on the motherboard to save FACTORY DEFAULT Default value F Default 140 F 60 C Default 3 F No value when in PID Default OFF Default 00 00 RH Default value 200 F 10 F 93 3 C 12 2 C Max default value 180 F 82 2 C Min default value 105 F 40 5 C Changes Screen 23 Default value 75 F 23 8 C Default value 3 F This screen is DISPLAY only Default F 000 to 600 seconds determines when the pump shuts off 13 after entering Outdoor Cut off mode Default 180 seconds Default 10 seconds Disabled in PID 0 to 600 seconds sets the time interval between sequential boiler start ups 0 to 600 seconds Default 10 seconds Boiler Stage Off Dela 15 sets time interval between stages turning off Disabled in PID Selects either Standard or PID operation If PID is selected then PID amp Interval is programmable using screen Standard or PID 16 34 Default PID Displays the boiler inlet and outlet temperature in F or C Boiler Inlet Outlet Delta and the difference delta between them Requires 4 INLET OUTLET Optional 17 sensor installation option Y 306 Delta T Auto Lead Last 18 numbers and the mode either Auto or Manual hours Used to enter a password This allows Default AAA To Password 19 access to screens 20 through 34 change screen 22 Sets up the pump boiler and stage configuration for the Default
26. nction e g alarm bell Table J Definitions System Pump NO SCREEN The System Pump Relay works in conjunction with the OUTDOOR CUT OFF TEMPERATURE System Temperatures Screen number efe lvieiele tel Iesele Irlan fie Current outdoor air Current System Target temperature temperature Water Temperature System design temperature Displays 000 0 If system has reached Outdoor if no sensor is Cut off temp TAR OFF present 24 Auxiliary Delay Screen number alle eieiei tt tt fede ee ee RBS Auxiliary Delay When CFH signal is ON the relay contact of the A1 Auxiliary module stays closed When the CFH signal changes to OFF the contacts of the relay stay closed as long as the delay is set up The AUX contacts operate on a delay after CFH AUX turnoff range is 0 to 600 seconds The default value is 180 seconds NOTE If the Call for Heat CFH or Safety signal is removed from the Y 200 the pump delay will time out and open the auxiliary contact INSTALLERS NOTE If the end user requires the System Pump to be turned off if the CFH or Safety signal is removed it is recommended that the system pump be operated from the Aux 1 Relay to provide a delay on turn off Boiler Stage ON Delay NOTE Refer to screen number 16 standard Screen number ejo ifelals s rfe loef reich Col Asia Lellig Lili lite Boiler Turn On Delay Stage Turn On Delay In a multiple boiler syst
27. ndar Current time System water temperature desired at Month Day Year 24 hour clock outdoor temperature of 70 F 21 1 C Range 40 F to 220 F 4 4 C to 104 4 C Default Value 140 F 60 C 17 Control Band Screen number jefo wiriajo e efaj fel Control Band is a range of temperature above and Fahrenheit or Celsius below the target temperature Range 1 F to 10 F 5 C to 5 5 C Default value is 3 F Control Band Proportional Only The Control Band sets the maximum temperature above and below the Target Temperature which is determined by the embedded microcontroller between which the system temperature may deviate This provides a control dead band that prevents the boiler from short cycling in proportional mode NOTE The above settings are recommended at NOTE The Control Band is disabled when the unit initial installation For maximum performance and is operating in PID mode system efficiency these settings should be modified as required to meet such parameters as system capacity location and usage NOTE PID mode will be disabled if you adjust the control band 18 Offset Screen number zl Iesel jete feel Default OFF screen Press MODE to select OFF or ALL or FULL WEEK Screen number ALL means every day has the same parameters leese lei ttt ft lela Fahrenheit or Celsius There are six offset adjustments blank or allowed for
28. of change for the water temperature e g a ratio of 2 1 means for every 2 change in outdoor temperature the System Temperature will change 1 The reset temp cannot exceed the temp limits set on screen NOTE When the reset ratio selected is NONE 08 line 2 disappears Example Setpoint 135 F Temperature F Outdoor System NOTE The reset ratio can be modified by changing either the ratio value in line 1 or the system temperature value in line 2 NOTE Use reset ratio NONE when using this controller for domestic hot water or pool applications The Reset Parameter Sets the desired change in system Water temperature increases as the outdoor temperature decreases The reset ratio selector is used to determine the rate of change of the boiler s output water temperature rela tive to a change in the outdoor temperature The first Table G Outdoor to System Temperature Ratio number of the ratio refers to the outdoor temperature 20 225 220 210 200 190 180 170 160 150 140 130 120 110 100 90 SYSTEM TEMPERATURE F 80 70 60 50 40 I 30 140 130 120 110 100 90 80 70 60 50 40 30 20 10 10 20 30 40 45 OUTDOOR DESIGN TEMPERATURE F Fig 10 System to Outdoor Temperature Typical Reset Ratio Setpoint at Design Temp Tem
29. osure Must be installed with properly sized conduit that contains no other wiring The outdoor air temperature and water tempera ture sensor are identical and interchangeable Water Temperature Sensor Installation Hydronic Heating Applications 4 OR MORE STAGES OR 4 1 TURN DOWN OR HIGHER SYSTEM SUPPLY SYSTEM SUPPLY SYSTEM RETURN CONTROL SENSOR SENSOR PLACEMENT FOR SYSTEMS UTILIZING VFD PUMPS 1 2 NPT IMMERSION WELL Fig 6 Typical Water Sensor e Hydronic installations may require outdoor reset e Locate the water sensor as shown in Fig 6 function See page 11 and screen 02 NOTE When the system involves a variable speed pump it is recommended that the temperature sensor be installed in the tee connecting boiler outlet e Ensure shielded cable length does not exceed 300 feet Use 18 AWG shielded wire for sensor con nections SC SE E SC piping to the system This is to ensure the control con E in properly sized conduit with no can respond to the changing conditions of the system by placing the sensor as close to the blend location as possible and then provide an appropriate and measured response to maintain desired system delivery temperature NOTE Piping diagrams in this manual are not intended to replace an engineered piping system 10 Domestic Hot Water Supply Applications HOT sie NR gt SE a SCH Cp Sen a ji 0 STORAGE IMMERSION WELL cL
30. our installation at each module Install a separate disconnect means for each load Use appropriately sized wire for equipment as defined by NEC and or local code All primary wiring should be no less than 125 of minimum rating It is strongly recommended that the controller and the boiler s be supplied from the same power source Install conduit as appropriate NOTE Shielded 18 AWG gauge stranded wire must be used to connect the sensors to the controller The shielded cable should be protected by conduit whenever possible NOTE Minimum 18 AWG 105 C stranded wire must be used for all low voltage less than 30 volts external connections to the unit Solid conductors should not be used because they can cause excessive tension on contact points Install conduit as appropriate All high voltage wires must be the same size 105 C stranded wire as the ones on the unit or larger Check Your Power Source Using a Volt ohm meter check the following voltages at the terminal block inside the unit CIRCUIT BREAKER WHITE GREEN ID GROUND Fig 1 Volt ohm Meter AC 108 Volts AC Minimum 132 Volts MAX AB 108 Volts AC Minimum 132 Volts MAX BC Must be less than 6 Volts AC Power to the Controller Controller Field Wiring Observe follow propel polarity For Single Stage ON OFF Boilers e Observe proper wire colors while making electrical connections All stage connections on the control boar
31. p Temp Radiation Design Cond 70 F 40 F 20 F 0 F 20 F Nn Nya Convection or Baseboard Fan coil Heating Fan Coil Heat and Cool Radiant Floor Radiant Ceiling 120 105 2 0 1 3 3 1 4 7 1 6 0 1 Table H Suggested Guidelines 21 The selection of the correct ratio depends on the initial temperature Set Point set on screen 02 and the desired system water temperature If the building is too cold increase the ratio value After changing the ratio wait several days and evaluate the comfort level before making another change NOTE This information works the same in C not shown for clarity System Status Advanced Programming Feature Line 2 may be modified by inserting the building design characteristics into the formula The Reset Ratio will be modified to reflect those characteristics To show the status of other boilers in the system push either the LEFT or RIGHT button If the controller is in a fault condition the boiler number can be displayed automatically NOTE The alarm horn can be silenced by pushing the mode button Screen number zlvls eieiei elei fei eee el eee Ae oe If more than one ERROR all errors will be displayed in sequence ERROR Indications Message NO SAFETY SIGNAL Safety signal 24VAC not present on J7 connector NO CFH SIG
32. pleted successful ly 12 CONTROLLER FAMILIARIZATION This system is configured utilizing a LCD display 2 lines 20 characters each with keypad for data entry Open the front cover of the Control Box for access to the LCD display and keypad Open the control panel to gain access to the interface connections REFER TO THE TABLES ON THE FOLLOWING PAGES AND THE DISPLAY SCREENS FOR DETAILED CONFIGURATION INSTRUCTIONS NOTE Controller is shipped with factory defaults your system may require different program settings Control Screens To access programming mode Press and hold the MODE button for 4 seconds When in Program mode cursor is blinking on first settable parameter UP DOWN arrows change parameter LEFT RIGHT arrows move to next selectable parameter the new programming SCREEN DESCRIPTION Displays the product identification and version of software The present month day year and time in a 24 hour clock format setpoint temperature Temperature can be displayed in degrees Fahrenheit or Initial Screen 01 Calendar Time Initial Setpoint F or C 02 Celcius 40 to 220 F 4 4 to 104 4 C the system output temperature desired when the outdoor temperature is 70 F 21 1 C or in domestic hot water applications the desired Setpoint 02 water temperature 1 to 10 F the temperature above and below the Target Temperature at which the boiler turns off and on NOTE The Control Band
33. spect 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 FORTHIN 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 39 Ton ange Regis
34. tered Quality Management System www raypak com Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 Fax 805 278 5468 Litho in U S A
35. tional INLET J2 OUTLET J4 OUTDOOR OUTDOOR on ae Sr b 1 Sensor wires must be 18 AWG shielded cable CFH with ground wire attached at Y 200 ground plug as shown Do not ground at sensor J CFH E 2 1 2 1 7 8 NET 2 1 2 1 2 1 2 1 SAFETY JP SAFETIES RESET POWER Woy M 1 ma Lent J2 OUTLET BOARD J3 wer wt PROG PORT J4 OUTDOOR RELAY HOT BK oner ap COM GND A BOARD Fam pe E pr gcn e 5 GND D P2EFERAA SINGLE r H H POINT Porn 1 i GROUND b JT SAFETIES H H Slave Controller P 1 i LONWORKS D ALARM MODULE D RESET POWER e mp reem P 10 4 DI 1 H A d Ergo Si frai Jr Eight 18 AWG stranded wires per boiler to system controllers Provide one 120V 1 ph disconnect for both controllers SINGLE Sensor Resistance at Various Temperatures If a sensor error is suspected perform the following 1 Examine the wiring ensuring continuity from con troller to sensor s 2 Using a multimeter measure resistance of sen sor s and compare the value with the Table M below 3 If all okay replace main control board Temperature F Resistance K Ohms 1666 3 1193 1 863 6 631 7 466 7 348 0 262 0 199 0 153 6 119 4 93 5 73 8 58 6 46 9 37 7 30 5 24 9 20 5 16 9 10 ol El ol b i gt N CO CO Of CO Oo oO k N el N _ Q D
36. ton to exit program mode 32 Alarm Call Telephone Screen number Used to enter telephone number to be called when a fault occurs Alarm Call ID Screen number zl fafafa Teil Die CTT Ti Used to identify person or place to be called when a fault occurs Alarm Call Retry Screen number Used to set the number of times 00 to 20 you want the unit to keep calling out when a fault occurs Alarm Call Events Screen number alle ist ell Teil is Enable or disable system error indications Factory default Enable Press and hold MODE button to access system error indications 33 PID Proportional Integral Derivative Control Interval time in seconds that the PID updates KP Proportional control 01 30 Band in degrees above and below setpoint KI Integral control 01 99 Adjustable in 0 0 1 0 KD Derivative control 01 99 Adjustable in 0 0 10 0 PID Interval Screen number NOTE Refer to screen number 34 PID petro esite a h fsa Default Values Interval 05 KP 06 KI 05 KD 01 NOTE DO NOT change the default values unless directed to do so in consultation with factory technical support Changing of these parameters may create adverse operating conditions Master Unit with Slaves Refer to page 36 for the Master Slave diagram Screen number Press MODE button to get into program mode Go to screen number 25 and select the number of slaves you w
37. wires sized on the basis of 60 C 140 F ampacity and rated a minimum 90 C 194 F Install disconnect for each control unit SYSTEM SENSOR OUTLET SENSOR NEL cc SENSOR OUTDOOR SENSOR e Eee KEYPAD 1 J20 1 1 2 Sg E A J1 A 2 Rea SES 1 U2 5 Al des L CONTRO iSS 2 2 38 MODULE 1 joy_ OPTION as Gi 2 Ia E 9 2 J5 GND aie Y 2 9 7 J6 CFH B 2 S gt U7 SAFETY E LCD1 120VAC SUPPLY J19 J23 l MODEM 1 OPTION PROG PORT LONWORKS MODULE OPTION E LONWORKS CONNECTION J12 sa p JL Cie BE eg RELAY Fig 3 Wiring Diagram 8 HOT BK COM GN with 12 to 28 VAC 5 8 STAGE OPTION SYSTEM J PUMP ae NO 3 aAnNOuRWN D JO DF Gah Er S iwo owu be An Fs es Au en SI Communication RS485 Wiring Required for Optional Slave Unit s Y 304 Slave Cable Installation from System Control Module Y 304 slave cable or equivalent shielded commu nications cable Belden 9842 Belden 8132 or Alpha 3492C must be used Maximum cable length 100 ft Correct polarity must be observed Make use of wire color coding to ensure polarity The shielding foil wrapper bare wire drain MUST be grounded Grounding is done at the Master Y 200 Control only DO NOT ground th
38. y 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 ifthe 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 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 in
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