Instruction/ maintenance manual of the product LONMARK Y-200 Raypak
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INST ALLA TION & OPERA TING INSTR UCTIONS Catalog No. 5000.62H Effective: 09-28-09 Replaces: 1 1-25-08 P/N 241 125 Rev . 9 Y -200 Series Electr onic Boiler Sequencer & Outdoor R eset Contr ol .
2 is a registered trademark of Underwriters Laboratories Inc. ® Rev . 9 reflects the following: Changes to: C-UL Listed Mark on page 1..
3 IMPORT ANT SAFETY INSTRUCTIONS 4 INTRODUCTION 4 Concept of Operation 4 Y -200 Controller Configurations 5 Y -200 Options 5 INST ALLA TION 6 Mechanical Installation 6 Electrical Installation 6 Contro.
4 Y–200 SERIES ELECTRONIC BOILER CONTROL SAFETY INSTR UCTIONS Thank you for selecting the Raypak Y–200 Series Electronic Boiler Control. It is our sincere hope that you will enjoy its outstanding design, ease of use and energy-saving features.
5 Y -200 Controller Configur ation s Y -200 Options M odel No. D escription Y -241 4-St age Controller - Includes main controller assembly , air temperature sen- s or assembly (P/N 068634), water temperature assembly (P/N 068635) and one (1) stage contact board.
6 INST ALLA TION If the controller was not mounted on the boiler by the factory , care should be taken to select a suitable mounting location. The controller should be mounted on a solid and permanent base.
7 P ower to the Controller • Observe (follow proper) polarity . • Observe proper wire colors while making electrical connections. • Provide an external surge suppressor capable of maintaining system integrity . • Provide overload prot ection and a disconnect means for equipment serviceability as required by local and state code.
8 N otes: 1 . T ighten terminal strip clamping screws to 2.5 in- lbs. Breakage from over-torquing is not covered under warranty . 2 . Use stranded copper conductors only . For supply connections, use wires sized on the basis of 60°C (140°F) ampacity and rated a minimum 90°C (194°F).
9 Communication (RS485) Wiring R equir ed f or Optional Slav e Unit(s) Y -304 Slav e 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.
10 Wa ter T emperature Sensor Installation Hydronic Heating Applications • Hydronic installations may require outdoor reset function. See page 1 1, and screen 02. • Ensure shielded cable length does not exceed 300 feet. Use 18 AWG shielded wire for sensor con- nections.
11 Domestic Hot Wa ter Suppl y Applications • Outdoor reset function should be disabled. See screen 06 and 24. P ow er T est Check P ower Utilizing a V olt-ohm meter (VOM) monitor the following on the controller for proper voltage levels. Check at the T erminal Block (TB-1).
12 Installation V erification Procedur e R e gister J Before proceeding any further , please verify that the user registration form has been completed and mailed. Mechanical Installa tion J V erify that the mechanical installation has been completed in accordance with the instructions.
13 Control Scr eens T o access programming mode: Press and hold the " MODE" button for 4 seconds. When in Program mode, cursor is blinking on first settable parameter . U P/DOWN arrows change parameter . LEFT/RIGHT arrows move to next selectable parameter .
14 Manual Ov er ride 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. Boiler/Sta g e Off Dela y 15 0 to 600 seconds; sets the time interval between sequential boiler start-ups.
15 Circuit Boar d Layout Main Circuit Board d r a o B y r a i l i x u A d r a o B y a l e R e g a t S - 4 1 SW3 Reset Switch Manual Override Switch Manual Override Switch Fig.
16 K eypad Nor mal Mode M ove to next screen Not active except in special modes Move to previous screen Not active except in special modes T o access programming mode: Press and hold "MODE" button for 4 seconds.
17 Control Scr een Displays & Prog r amming 1 0 C N I K A P Y A R Y - S ER I E S V ER XX . X X X e r a w t f o s f o r e b m u n n o i s r e V n o i t a c i f i t n e d i t c u d o r P This is the initial screen displayed after system st art-up, provided that there are no faults.
18 Control Band: 3 0 D N A B L O R T N O C XX . X ° F *C Band is a range of temperature above and below the target temperature. Range: 1°F to 10°F (.5°C to 5.5°C) Default value is 3°F Screen number Fahrenheit or Celsius NO TE: The above settings are recommended at initial installation.
19 4 0 F F O T E S F F O Press "MODE" to select "OFF" or "ALL" or "FULL WEEK" "OFFSET" screen Screen number 4 0 L L A T E S F F O —— — X : H H M M + X X . X ° F There are six offset adjustment s allowed for each calendar day .
20 Holiday: SE T T I N G H O L I DA Y 0 5 H OL #X X X X — X X — X X Thirty two holidays are selectable (01-32) Month: 01 thru 12 Day: 01 thru 31 Ye ar: 01 to 99; Below 01 is Repeating Holiday (RH) setting RS T R A T I O X . X X : 1 0 6 XX X . X @ 7 0 X X X .
21 Fig. 10: System to Outdoor T emperature T yp ical Reset Ratio Setpoint at Design T emp: T emp@ T emp@ Radiation D esign C ond. 70°F 40°F 20°F 0°F - 20°F St a nding 190 105 0.3:1 0.6:1 0.8:1 1.1:1 Convection or Basebo ard 200 105 0. 3:1 0.5:1 0.
22 T he 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 r atio, wait several days and evaluate the comfort level before making another change.
23 Wa ter T emper a tur e: 8 0 P M E T R E T A W M AX : X XX . X M I N : X X X. X Displays the maximum water temperature for the boiler . Range is determined by s creen number 23. Factory default is 180°F (82.2°C) Maximum. S creen number Displays the minimum water temperature for the b oiler .
24 System Monitor : 1 1 R O T I N O M M E T S Y S M A S T E R P B SS S B S SS A A A S creen number This screen is only a display . T ot al # of stages available is set on screen 24.
25 Auxiliar y Delay: 3 1 Y A L E D X U A XX X SEC Screen number Auxiliar y 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.
26 Boiler/Stage Of f Delay: BO I L R / S T G O F F D L Y 1 5 C E S X X X C E S X X X Screen number Boiler T ur n-Of f Delay In a multiple boiler system: The boiler Turn-Of f Delay sets the amount of delay before each additional boiler is turned off. This delay starts when the preceding boil- er is turned off.
27 IN LE T O U T L E T D ELT A 1 7 X X X .X XXX . X X XX . X Screen number Current boiler inlet or system temperature* Current boiler outlet or system temperature* Boiler or System delta.
28 Pass wor d: 9 1 D R O W S S A P AAA Screen number Used by maintenance personnel to change settings. 0 2 P U — T E S T I N U MA S T ER P B S B S B S S S A A A Screen number In display mode shows AAA or current password. T o enter the password: 1. Push the mode key .
29 System T est: W A T E R TE M P L IM I TS 23 MA X : X X X . X M I N : X X X . X Screen number Maximum programmable setting is 235°F (1 12.7°C). Factory default value is 210°F(98.8°C). Minimum programmable setting is 40°F (4.4°C). Factory default value is 105°F (40.
30 Master Unit: 4 2 R E T S A M SN S : X R E L AY : X A U X : X Screen number 0, 1, 2 or 4 Number of temp. sensors. 1 thru 8 Number of staging contact s in use.
31 Slav e Unit: S ee Staging T able S L A VE S CON NE CT E D 2 5 #X X Screen number Number of slaves connected: 01 thru 04 6 2 S K R O W N O L OF F Screen number OFF ON F ACT O RY D EFA U L TS 27 NO Screen number Press MODE button to get into program mode.
32 8 2 S T L U A F E D R E S U T L U A F E D O N E N O N Screen number Press MODE button to get into program mode. Press UP or DOWN key to select “Setup Defaults”.
33 Alar m Call T elephone: A LA R M C A LL TE L E 3 0 X X XX X XX XXX X XX X XX Screen number Used to enter telephone number to be called when a fault occurs. 1 3 D I L L A C M R A L A X X XX X XX XXX X X Screen number Used to identify person or place to be called when a fault occurs.
34 Press MODE button to get into program mode. Go to screen number 25 and select the number of slaves you wish to use, 01 thru 04. S L A VE S CON N E CT E D 2 5 #X X Go to screen number 24 and select the number of sensors, relays and auxiliaries.
35 Press MODE button to get into program mode. Go to screen number 25 and display should read. S L A VE S CON NE CT E D 2 5 4 2 X X # E V A L S SN S : 0 R E L A Y : X A U X : X Go to screen number 20 and set up your unit operations. 0 2 P U - T E S T I N U SL A V E P B X X X XX X X X XX Ignore screen number 1 1 on the slave units.
36 Y -200 Master/Sla ve Diagr am.
37 Sensor R esistance at V arious T emperatures 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 T able M below .
38 Y -200 Illustrated P ar ts List Item No. Description Part No. 1-C PC Board As sy , Y -200 008846F 2-C Expansion Board As sy , 4-Stage 008847F 3-C Auxiliary B oard As sy 008848F 4-C T ransfor mer As.
39 L IMITED WARRANTY Y-200 Series SCOPE OF WARRANTY : R aypak, Inc. ("Raypak") warrants to the original owner the C ontrol Sys tem to be free from d ef ects in m ateria ls and workmanship under normal use and service for the a p pl ica ble warr an ty p eri od.
w w w.ray pak .co m Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A..
An important point after buying a device Raypak LONMARK Y-200 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Raypak LONMARK Y-200 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Raypak LONMARK Y-200 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Raypak LONMARK Y-200 you will learn all the available features of the product, as well as information on its operation. The information that you get Raypak LONMARK Y-200 will certainly help you make a decision on the purchase.
If you already are a holder of Raypak LONMARK Y-200, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Raypak LONMARK Y-200.
However, one of the most important roles played by the user manual is to help in solving problems with Raypak LONMARK Y-200. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Raypak LONMARK Y-200 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
