Page 2 - Y–SERIES ELECTRONIC BOILER CONTROL; Installation and Operating Instructions
Y–SERIES ELECTRONIC BOILER CONTROL Installation and Operating Instructions is a registered trademark of Underwriters Laboratories Inc.® is a registered trademark of Underwriters Laboratories-Canada Inc. ® Before operating this product, please read these instructions completely. 2
Page 3 - TABLE OF CONTENTS
TABLE OF CONTENTS Contents Page Basics 4 Important Safety Instructions 4 Introduction 5 Concept of Operation 5 Optional Configurations 5 Control Features 6 Installation and Mounting 7 Mechanical Installation 7 Electrical Installation 7 Wiring: Power to Controller 8 Air Temperature Sensor 9 Water Tem...
Page 4 - BASICS; Contents; IMPORTANT SAFETY INSTRUCTIONS; MORE THAN ONE (1) SUPPLY SOURCE. THIS APPLIANCE HAS PROVISIONS
BASICS Contents Item Quantity Y–Series Boiler Control, Installed on Boiler(s) As Ordered Outdoor Temperature Sensor Assembly 1 Water Temperature Sensor Assembly 1 Optional Equipment As Ordered Check packaging for damaged or missing components. IMPORTANT SAFETY INSTRUCTIONS IMPORTANT NOTICE: These in...
Page 5 - INTRODUCTION; CONCEPT OF OPERATION
Thank you for selecting the Raypak Y–Series Electronic Boiler Control. It is our sincere hope that you will enjoy itsoutstanding design, ease of use and energy saving features. INTRODUCTION The Y-Series Electronic Boiler Control (controller) is a microprocessor-based energy management system designe...
Page 6 - CONTROL FEATURES; Standard Indicator Lights:
CONTROL FEATURES The Y-Series sequence panel includes: • Standard Indicator Lights: Stages 1 to 8: Red, indicates which stages are turned on. Pump: Green, indicates that the pump circuit is energized. Call for Heat: Green, indicates that a call for heat signal is present. Control On: Green, indicate...
Page 7 - INSTALLATION AND MOUNTING; MECHANICAL INSTALLATION; INSTALL CONDUIT AS APPROPRIATE.; ELECTRICAL INSTALLATION
7 INSTALLATION AND MOUNTING If the Y–Series Electronic Boiler Control was not mounted on the boiler by the factory, care should be taken to select asuitable mounting location. The control should be mounted on a solid and permanent base. The control enclosure isNEMA 3R rated, rainproof and sleet resi...
Page 8 - CHECK YOUR POWER SOURCE; WIRING: POWER SOURCE TO CONTROLLER
CIRCUIT BREAKER WHITE GROUND BLACK GREEN A B C VOLT-OHM METER CHECK YOUR POWER SOURCE Using a volt-ohm meter, check the following voltages at the circuit breaker panel: AC = 108 Volts AC Minimum, 132 Volts MAXAB = 108 Volts AC Minimum, 132 Volts MAXBC = Must be less than 1.0 Volts AC WIRING: POWER S...
Page 10 - WATER TEMPERATURE SENSOR INSTALLATION; HYDRONIC INSTALLATIONS
WATER TEMPERATURE SENSOR INSTALLATION HYDRONIC INSTALLATIONS Fig. #9496 TYPICAL WATER SENSOR • The water sensor should be installed in the system supply. • Locate the water temperature sensor in the system piping just prior to the first boiler connections, on theupstream side of the System Supply Lo...
Page 11 - DOMESTIC HOT WATER APPLICATION SETUP PROCEDURE; DOMESTIC HOT WATER INSTALLATIONS
Air temperature sensor must be installed across air temperature sensor contacts. The sensor is not activated and can beleft stored in controller enclosure. 11 DOMESTIC HOT WATER APPLICATION SETUP PROCEDURE 1. Install a 10,000 Ohm, 1/8 Watt resistor between pins 1 and 2 on P2 connector (see pg. 13), ...
Page 12 - POOL HEATING INSTALLATIONS
12 1. Install the air temperature sensor across the air temperature sensor contacts (P2, pins 1 and 2; see the fieldwiring diagram on pg. 13). 2. On the mode selector switch (S3), set switch #2 (Outdoor Reset) to ON to disable the outdoor reset function.(See pg.s 15 and 23). 3. Set the Outdoor Cutof...
Page 13 - FIELD WIRING; Multiple-Stage Boilers
FIELD WIRING Single-Stage (On/Off) Boilers - All stage connections on the control board are connected at the {TH}(Thermostat) location on theboiler wiring diagram. Multiple-Stage Boilers - First stage connections on the control board are connected atthe {TH} (Thermostat) locationon the boiler wiring...
Page 15 - CONTROL FAMILIARIZATION
CONTROL FAMILIARIZATION The System is configured using the circuit board jumpers and switches, and the front panel control potentiometers. Open the front cover of the Boiler Control Box for access to the front panel. Remove the front panel to gain access to thejumpers and switches on the Y-Series El...
Page 17 - Y–SERIES ELECTRONIC BOILER CONTROL MODULE
17 Panel with Clock & LCD Y-5 Configuration Shown Y–SERIES ELECTRONIC BOILER CONTROL MODULE Night Setpoint Option Digital Display Option
Page 18 - INDICATOR LIGHTS
PUMP CALL FOR HEAT CONTROLON SETTINGERROR SENSORERROR INDICATOR LIGHTS STAGE INDICATORSThe pump driver and each of the output stages' drivers has its own LED indicator. Each ofthese LEDs is lit whenever the corresponding output relay is energized. PUMP INDICATORThe Pump Indicator is illuminated when...
Page 19 - Suggested Settings; RADIATION; CONTROL FUNCTIONS
RESET RATIOThe Reset Ratio setting determines how much the Target Temperature will increase as theoutdoor temperature drops. The Reset Ratio is expressed in the following manner: X:Y X - change in outdoor temperatureY - change in Target Temperature The first number in the ratio refers to the change ...
Page 20 - RESET RATIO CHART
RESET RATIO CHART 20 PUMP TURN-OFF DELAYThe Pump Turnoff Delay works in conjunction with the Outdoor Cutoff Temperature. The Pump Turnoff Delay sets the delay between the time when the Outdoor CutoffTemperature is reached and the time when the pump is turned off.The Pump Turnoff Delay is adjustable ...
Page 23 - CIRCUIT BOARD
CIRCUIT BOARD 23 S5 MANUAL BYPASS SWITCH S4 MANUAL LEAD/ LAG SELECTOR SWITCH S2 FIRST STAGE SELECTOR I.D. MAINTENANCE PLUG TEST J2 LAST STAGE SELECTOR JUMPER S1 SYSTEM TEST S3 MODE SELECTOR
Page 24 - INTERIOR JUMPER & SWITCHES; AUTO
INTERIOR JUMPER & SWITCHES 24 Fig # 9242 Fig # 9245 Fig # 9246 S-3 J-2 The Last Stage Selector Jumper (J2) is comprised of an eight (8) position jumper block. A shuntbar jumper is placed in the position corresponding to the last active stage or boiler number. Seetable below for examples of Jumpe...
Page 26 - OPTIONAL CONTROLS
26 Operational Override Switch Clock Alternate Setpoint Adjustment Digital Display OPTIONAL ALTERNATE SETPOINT OPERATIONThe Optional Alternate Setpoint can be used to establish an independent second set point for setback ortemperature boost requirements. TRIPPERSThe electro-mechanical timer consists...
Page 27 - REPLACEMENT PARTS LIST
3-C 1-C 2-C 1-S 5-S 4-S 6-S 3-S 5-S 2-S 2-N 1-N 27 CALL OUT 1-C 2-C 3-C 1-S2-S3-S4-S5-S6-S 1-N2-N DESCRIPTION PC Board StandardPC Board w/ Night Set BackProgrammed EpromProgrammed Eprom W/ Night Set BackTransformerDoor w/WindowSide Mount BracketAir Temperature Sensor CompleteWater Temperature Sensor...
Page 28 - SYSTEM START-UP SETTINGS
SYSTEM START-UP SETTINGS SYSTEM SETTING ENTERED ON DATE: Front panel control potentiometers (knobs) Reset Ratio: ______ Control Band: ______ Default Value: 1:1 Default Value: 3°F Pump off Delay: ______ Outdoor Cutoff Deadband: ______ Default Value: 3 min. Default Value: 3°F Boiler on Delay: ______ O...
Page 29 - TROUBLESHOOTING GUIDE
T EM P De g F 40 50 60 70 80 90 100 110 120 Re s is t a n c e (K) 26.11 19.90 15.31 11.88 9.30 7.33 5.83 4.66 3.76 T EM P De g F 130 140 150 160 170 180 190 200 210 Re s is t a n c e (K) 3.06 2.48 2.04 1.69 1.40 1.17 0.98 0.83 0.70 If a ll Oka y , Re p la c e Y-Se rie s Bo ile r Co n t ro l Bo a rd ...
