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INSTALLATION & OPERATING
INSTRUCTIONS
Y-200 Series
Electronic Boiler Sequencer & Outdoor
Reset Control System
Catalog No. 5000.62H Effective: 09-28-09 Replaces: 11-25-08 P/N 241125 Rev. 9
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is a registered trademark of Underwriters Laboratories Inc. ® Rev. 9 reflects the following: Changes to: C-UL Listed Mark on page 1. 2
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CONTENTS IMPORTANT SAFETY 23 Water Temperature Limits 29 INSTRUCTIONS 4 24 Master Unit 30 INTRODUCTION 4 25 Slave Unit 31 Concept of Operation 4 26 LonWorks 31 Y-200 Controller Configurations 5 27 Factory Defaults 31 Y-200 Options 5 28 User Defaults 32 INSTALLATION 6 29 Modem Password 32 Mechanical Installation 6 30 Alarm Call Telephone 33 Electrical Installation 6 31 Alarm Call ID 33 Controller Field Wiring 8 32 Alarm Call Retry 33 Communication Field Wiring 9 33 Alarm Call Events 33 Air Temper
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Y–200 SERIES ELECTRONIC INTRODUCTION BOILER CONTROL The Y-200 Series Electronic Boiler Control (controller) is a microprocessor-based boiler management system SAFETY INSTRUCTIONS 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 NOTE: These instructions are intended for use by has been engineered with the flexibility and raw power qualified personnel who are specifically traine
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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 control
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NOTE: Shielded 18 (AWG) gauge stranded wire INSTALLATION must be used to connect the sensors to the controller. The shielded cable should be protected by If the controller was not mounted on the boiler by the conduit whenever possible. factory, care should be taken to select a suitable mounting location. The controller should be mounted on a solid and permanent base. The unit should be NOTE: Minimum 18 AWG, 105°C, stranded wire readily accessible for maintenance and installation must be used for
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Power to the Controller Controller Field Wiring • Observe (follow proper) polarity. For Single-Stage (ON/OFF) Boilers • Observe proper wire colors while making electrical connections. All stage connections on the control board are con- • Provide an external surge suppressor capable of nected at the {TH} (Thermostat) location on the boiler maintaining system integrity. wiring diagram. • Provide overload protection and a disconnect means for equipment serviceability as required by For Multiple-Sta
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Notes: 4. For external building control or thermostat control, remove wiring to J6 (CHF) connector and activate 1. Tighten terminal strip clamping screws to 2.5 in- with 12 to 28 VAC. 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). 3. Install disconnect for each control unit. Fig. 3: Wiring Diagram 8
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Communication (RS485) Wiring Air Temperature Sensor Required for Optional Slave Installation 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-20
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Water Temperature Sensor Installation Hydronic Heating Applications 4 OR MORE STAGES OR 4:1 TURN DOWN OR HIGHER 5’ MAX 5’ MAX 12” MAX Fig. 6: Typical Water Sensor • Locate the water sensor as shown in Fig. 6. • Hydronic installations may require outdoor reset function. See page 11, and screen 02. NOTE: When the system involves a variable-speed • Ensure shielded cable length does not exceed 300 pump, it is recommended that the temperature feet. Use 18 AWG shielded wire for sensor con- sensor be i
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Domestic Hot Water Supply Applications Fig. 7: Domestic Hot Water Supply • Outdoor reset function should be disabled. See From To Indication screen 06 and 24. 108 VAC to 132 TB pin 1 TB pin 2 VAC Power Test Single Point 108 VAC to 132 TB pin 1 Ground VAC Check Power Single Point TB pin 2 Less than 0.6 VAC Ground Utilizing a Volt-ohm meter (VOM) monitor the following on the controller for proper voltage levels. Check at the Table C: Voltage Measurements Terminal Block (TB-1). 11
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Installation Verification CONTROLLER Procedure FAMILIARIZATION Register This system is configured utilizing a LCD display (2 lines, 20 characters each) with keypad for data entry. Before proceeding any further, please verify that Open the front cover of the Control Box for access to the user registration form has been completed and the LCD display and keypad. Open the control panel to mailed. gain access to the interface connections. REFER TO THE TABLES ON THE FOLLOWING Mechanical Installation
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Control Screens NOTE: Once programming is finished, go to Screen 28 to program the USER DEFAULT SET_UP. Then open the front panel and press To access programming mode: Press and hold the the SW3 reset button on the motherboard to save "MODE" button for 4 seconds. When in Program the new programming. mode, cursor is blinking on first settable parameter. UP/DOWN arrows change parameter. LEFT/RIGHT arrows move to next selectable parameter. SCREEN DESCRIPTION FACTORY DEFAULT Initial Screen 01 Dis
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0 to 600 seconds; sets the time interval between sequential boiler start-ups. 0 to 600 seconds; Default = 10 seconds. Boiler/Stage Off Delay 15 sets time interval between stages turning off. Disabled in PID. Selects either Standard or PID operation. If PID is selected then PID & 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 differenc
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Circuit Board Layout SW3 Reset Switch Main Circuit Board Manual Override Switch 1 Manual Override Switch 4-Stage Relay Board Auxiliary Board Fig. 8: Circuit Board Layout 15
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Keypad Normal Mode Move to next screen Push the "MODE" button to turn off the alarm horn 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 Increase selected parameter pressed while in PROGRAM mode for 30 seconds, screen returns to normal mode Move to next programmable Move to previous programmable parameter parameter Decrease selected parameter When in
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Control Screen Displays & Programming Screen number Initial Screen: R A Y P A K I N C 0 1 Y - S ER I E S V ER XX . X X X Product identification Version number of software This is the initial screen displayed after system start-up, provided that there are no faults. Fahrenheit or Celsius Screen number Primary Parameters: IN I T I A L S E T P O I N T ° F 0 2 M M - D D - YY H H M M X XX . X ° Calendar: Current time: System water temperature desired at Month-Day-Year 24 hour clock outdoor temperatur
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Control Band: Screen number C O N T R O L B A N D 0 3 XX . X ° F Fahrenheit or Celsius Control Band is a range of temperature above and *C Band is a range of temperature above and below below the target temperature. 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 tempera
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Screen number Offset: "OFFSET" screen O F F S E T O F F 0 4 Default "OFF" screen Press "MODE" to select "OFF" or "ALL" or "FULL WEEK" Screen number "ALL" means every day has the same parameters. O F F S E T A L L 0 4 —— — X : H H M M + X X . X ° F Fahrenheit or Celsius There are six offset adjustments +, blank or – allowed for 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
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Holiday: Screen number SE T T I N G H O L I D A Y 0 5 H OL # X X X X — X X — X X 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 Screen number constant water temperature (then TARGET=SETPOINT). Default value is 1.00:1. RS T R A
