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® Before operating this product, please read these instructions completely. 2 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 Temperature Sensor Installation 10 Hydronic Installations 10 Domestic Hot Water Installations 11 Pool Heating Installations 12 Field Wiring 13 Power Test 14 Control Familiarization 15 Sequence of Operation 16 Manual Override 16 Indicator Lights 18 Control Functions 19 Reset Ratio Chart 19 Circuit Board 23 Interior Jumper & Switches 24 Optional Controls 26 Replacement Parts List 27 System Start-Up Settings 28 Troubleshooting Guide 29 Warranty 30 BASICS Contents Item Quantity Y–Series Boiler Control, Installed on Boiler(s) Outdoor Temperature Sensor Assembly Water Temperature Sensor Assembly Optional Equipment As Ordered 1 1 As Ordered Check packaging for damaged or missing components. IMPORTANT SAFETY INSTRUCTIONS IMPORTANT NOTICE: 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. 4 Thank you for selecting the Raypak Y–Series Electronic Boiler Control. It is our sincere hope that you will enjoy its outstanding design, ease of use and energy saving features. INTRODUCTION The Y-Series Electronic Boiler Control (controller) is a microprocessor-based energy 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, the Y-Series has been engineered with the flexibility and raw power to tame the most demanding control situations. Utilizing a state-of-the-art PID control algorithm, the Y-Series minimizes operating costs by maximizing energy efficiency. CONCEPT OF OPERATION This controller is an outdoor reset control that is perfect for managing hydronic heating systems. Two temperature sensors are used to control system response. One sensor is used to monitor the outdoor temperature, the other sensor is used to regulate the temperature of the system water. By varying the temperature of the heating medium in response to changes in the outdoor temperature, the Y-Series provides the ultimate in personal comfort and efficiency of operation. The Y-Series controller is also well adapted to domestic hot water supply duty. By disabling the outdoor reset function, the Y-Series behaves as an energy-wise boiler sequencer. With the ability to control up to eight firing stages, and such features as a revolutionary "First-On, First-Off" lead-lag protocol, the Y-Series redefines "controlability" 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 Cutoff 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- Series is reactivated and will hold the system temperature at the required point. The Y-Series can also be equipped with an optional clocked alternate setpoint package. The alternate setpoint allows control operation at an independent setpoint temperature and can be used either for night setback or preoccupancy boost. An electromechanical 7-day timer switches the control between regular and alternate setpoint modes and can be set at two hour activation intervals. See the section on the optional clocked alternate setpoint for details. OPTIONAL CONFIGURATIONS Y-2B BASIC UNIT, NO OPTIONS Y-3B BASIC UNIT PLUS DIGITAL DISPLAY Y-4B BASIC UNIT PLUS NIGHT SETBACK OPTION Y-5B BASIC UNIT PLUS NIGHT SETBACK AND DIGITAL DISPLAY OPTIONS PLEASE REGISTER Before proceeding any further, p...