INSTALLATION & OPERATING INSTRUCTIONS Y-305 4-20 mA / 2-10 VDC Input Control Module Used with Y-200 Series Electronic Boiler Sequencer & Outdoor Reset Control System This manual should be maintained in legible condition and kept adjacent to the heater or in another safe place for future reference. Catalog No. 5000.64B Effective: 09-19-08 Replaces: 03-25-08 P/N 241224 Rev. 3 Introduction 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. The Raypak Y-200 Series Controller, equipped with the Y-305 4-20 mA / 2-10 VDC Module, provides the ultimate in temperature setpoint control for Raypak boiler applications. The Y-305 4-20 mA / 2-10 VDC Module provides a conversion, from either a milliamp or a voltage input from an outside control source, to a setpoint temperature reading on the Y-200 series controller LCD panel. Installation The Module is provided in a kit which includes the necessary hardware to install the board onto the Y-200 control board. This manual should be used in conjunction with the Y-200 Series Installation & Operating Manual (Catalog No. 5000.62, P/N 241125). 1. Verify that the control signal is within the 4-20 mA / 2-10 VDC parameter. 2. Turn off the power to the Y-200. Important Safety Instructions 3. Open the front cover of the Y-200 to access the display/keypad door. 4. Open the display/keypad door to access the Y-200 Control Board (P/N 601670). 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. Some states may require that installation and service personnel be licensed. Only qualified persons shall attempt to repair this equipment. Repair must be done according to the instructions provided. 5. Secure the nylon standoff (P/N 550767) onto the Y-200 Control Board as shown in Fig. 1. 6. Plug the Y-305 4-20 mA / 2-10 VDC Module into the Y-200 Control Board at the J20 expansion port (10-pin plug), securing Module with nylon standoff. 7. Attach 4-20 mA / 2-10 VDC signal wires to 2-pin plug connector (P/N 650935). 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 void the warranty. 8. Plug 2-pin connector into either the J1 or J2 connection of Module (J1 for 4-20 mA operation, J2 for 2-10 VDC operation). CAUTION: This appliance has provisions to be connected to more than one (1) supply source. To reduce the risk of electric shock, disconnect all connections before servicing. CAUTION: Risk of electric shock: More than one (1) disconnect switch may be required to de-energize the equipment before servicing. Rev. 3 reflects the following: Changes to: The text in paragraph one of the Introduction section on page 2; steps 5 and 6 of the Installation section on page 2; Fig. 1 on page 3; steps 1 and 2 of the 4-20 mA Mode section on page 4; steps 1 and 2 of the 2-10 VDC Mode section on page 4. 2 Hole for nylon stand-off Y-305 4-20 mA /2-10 VDC Module (P/N 601740) Nylon stand-off (P/N 550767) 2-pin plug connector (P/N 650935) Y-200 Control Board (P/N 601670) Fig. 1: Components 3 Start-up LED1 NOTE: The Y-305 4-20 mA / 2-10 VDC Module can be set up for 4-20 mA mode or 2-10 VDC mode, not both. SW1 4-20 mA Mode 1. Set the SW1-2 dip switch (4-20 mA) to the ON position, and the SW1-1 dip switch (2-10 VDC) to the OFF position. 2. Restore power to the Y-200. Module set to 2-10 VDC mode 3. Green LED1 indicates Module is in 4-20 mA mode. Fig. 3: Module Set to 2-10 VDC Mode 4. Green LED1 flashing once per second indicates a weak (less than 4 mA) signal. 5. Green LED1 flashing two times per second indicates an overload (over 20 mA) signal. LED1 SW1 Pin Interface Pin Functions 1 5 VDC 2 4-20 mA selector switch 3 2-10 VDC selector switch 4 4-20 mA LED drive 5 N/C 6 N/C 7 2-10 VDC output 8 4-20 mA output 9 2-10 VDC LED drive 10 GND Table A: Interface Pin Functions Module set to 4-20 mA mode Fig. 2: Module Set to 4-20 mA Mode Pin 10 Pin 1 2-10 VDC Mode 1. Set the SW1-1 dip switch (2-10 VDC) to the ON position, and the SW1-2 dip switch (4-20 mA) to the OFF position. 2. Restore power to the Y-200. 3. Red LED1 indicates Module is in 2-10 VDC mode. 4. Red LED1 flashing once per second indicates a weak (less than 2 VDC) signal. Fig. 4: Pin Locations 5. Red LED1 flashing two times per second indicates an overload (over 10 VDC) signal. 4 Module Adjustment POT1 NOTE: The instructions below use a 140 °F setpoint temperature. 4-20 mA Module 1. Set the input device signal to 12 mA. POT2 2. Remove 2-pin connector from J1 connector on Module. 3. Verify 12 mA input signal at 2-pin plug connector using a calibrated digital volt meter (DVM). Fig. 5: Pot Locations 4. Plug 2-pin connector back into the J1 connector. 5. Set Y-200 display to screen #2. (Refer to Y-200 Installation & Operating Manual, Catalog No. 5000.62.) 6. If necessary, adjust POT1 to achieve a 140 °F setpoint temperature on Y-200 display. (POT1: Clockwise adjustment increases temperature; counter-clockwise adjustment decreases temperature.) mA Input Volt Input Setpoint Temp. (°F) 4 2 60 5 2.5 70 6 3 80 7 3.5 90 8 4 100 2-10 VDC Module 9 4.5 110 1. Set the input device signal to 6 VDC. 10 5 120 11 5.5 130 12 6 140 3. Verify 6 VDC input signal at 2-pin connector using a calibrated digital volt meter (DVM). 13 6.5 150 14 7 160 4. Plug 2-pin connector back into the J2 connector. 15 7.5 170 16 8 180 17 8.5 190 18 9 200 19 9.5 210 20 10 220 2. Remove 2-pin connector from J2 connector on Module. 5. Set Y-200 display to screen #2. (Refer to Y-200 Installation & Operating Manual, Catalog No. 5000.62.) 6. If necessary, adjust POT2 to achieve a 140 °F setpoint temperature on Y-200 display. (POT2: Counterclockwise adjustment increases temperature; clockwise adjustment decreases temperature.) Table B: Input vs. Setpoint Temperature 5 LIMITED WARRANTY Y-305 4-20 mA / 2-10 VDC Module for Y-200 Series Electronic Boiler Sequencer & Outdoor Reset Control System 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 by a qualified technician in accordance with manufacturer'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 manufacturer'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. if the 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 a Raypak 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 the Raypak Service Department at the address/telephone listed below. Raypak reserves the right at all times to inspect 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 behalf of Raypak. 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 FORTH IN 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 Ow ner Model N umber Mailing A ddr ess Serial Number Date of Installation City State Installation Site Zip Code Daytime Telephone N umber Contr actor/Installer 6 7 www.raypak.com Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.