installation & operating instructionsmasterhydronicsinc.com/.../2014/...control-5000.72.pdf ·...

INSTALLATION & OPERATINGINSTRUCTIONS

Catalog No. 5000.72 Effective: 01-04-13 Replaces: NEW P/N 241493 Rev. 1

VERSA IC™ Control

3

Table of Contents

WARNINGS ..............................................................3

Introduction ...............................................................4

VERSA Control Board ..............................................4

VERSA Display Board ..............................................5

VERSA PIM™ Module...............................................6

Application & Modes .................................................9

Boiler Applications ...................................................10

Water Heater Applications .......................................22

Control Menus .........................................................26

Control Settings .......................................................31

Sequence of Operation ...........................................37

Wiring Connections – PIM™ ...................................39

Wiring Connections – VERSA IC™ Control ............42

Energy Management System Setup .......................43

Cascade Set-up and Operation ...............................44

Stand-alone Operation of PIM™ .............................46

Troubleshooting .......................................................47

Technical Data .........................................................50

Quick Start Set-Up and Programming Tips .............51

Resetting PIM™ to Accept New ID Card ................52

Modbus Communication Values ..............................52

WARNINGS

WARNING: Improper installation, adjustment,alteration, service, or maintenance can causeproperty damage, personal injury or loss of life.Refer to the user's information manual provided withthe heater. Installation and service must beperformed by a qualified installer, service agency, orthe gas supplier.

WARNING: Risk of electrical shock. More than onedisconnect switch may be required to de-energizethe equipment before servicing.

WARNING: When servicing or replacing anycomponents of the control system within this unit, becertain that:• The gas is off.• All electrical power is disconnected.

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Introduction

The Raypak VERSA IC is an appliance integrated con-trol system consisting of the following components:

• VERSA IC Control Board• VERSA Display Board• VERSA IC Platform Ignition Module (PIM) in HSI,

DSI or Supervised Pilot Ignition• ID Card• Water Sensors (up to 6)• Vent Sensor• Outdoor Air Sensor

The VERSA IC control system provides integratedfunctions of automatic ignition control, thermostat con-trol, high temperature limit control, diagnosticenumeration, safety interlock, domestic hot water(DHW) override and several options for externalheater control for Raypak commercial boilers, waterheaters and pool heaters. The VERSA IC control sys-tem controls the heater pump, system pump andindirect DHW pump simultaneously as needed.

VERSA Control Board

The VERSA Control Board provides high level func-tionality for the VERSA IC control system. It has fieldinterlock connections, cascading heater connectionsand VERSA Display Board connections. The VERSAIC control system allows “limp along” operation via thePIM if the VERSA Control Board becomes inactive orif the communications between the VERSA ControlBoard and the PIM are terminated for any reason.This “limp along” mode operation is outlined in moredetail starting on page 46. The VERSA Control Boardis ANSI Z21.23 certified.

In addition, the VERSA IC control system allows cas-cading control of multiple units up to 4 units totalwithout the need for an external sequencer. TheVERSA IC control system is Modbus ready for easyexternal communication and control.

Fig. 1: Water Sensor

Fig. 2: Outdoor Air Sensor

RaypakVERSA#013935F

Designed and assembled in Canada158033

ON1 2 3 4 5 6 7 8

Condensate Switch

Vent Temp Limit

Auto High Limit

Low WaterBlocked Vent

Low Gas Press

High Gas Press

(Extra)

CN5

Water Flow Switch

Blower Air Switch

Factory Option 3

Factory Option 2

Factory Option 1

CN8

LED OutDiagnosticsPower OnCall For HeatBurner OnService

CN6

1049-01

PIM 2Ft_Bus

A

B

PIM 3Ft_Bus

A

B

PIM 4Ft_Bus

A

B

GND

CN2

F6018C

Fan /Damper

CN4

R

Com

S6

RS485-A

RS485-B

Mod +

GND

GND

GND

ModBus-A

ModBus-B

CN1

CWS/CWR

Remote LCD

CN7

S7

Extra

ExternalValve

Power: 24 V (ac) ± 10% 50/60 Hz 5.2 VA 215 mARelays: 240 V (ac) 5 A

Fig. 3: VERSA Control Board

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The VERSA Control Board includes connections for:

• LED Indicator Lights (model specific)o Green – POWER ONo Amber – CALL FOR HEATo Blue – BURNER ONo Red – SERVICE REQUIRED

• Diagnostic Inputso Condensate Switcho Vent Temperature Limito Auto High Limito Low Water Cutoffo Blocked Vento Low Gas Pressureo High Gas Pressureo Extra – (future usage)o Water Flow Switcho Blower Air Switch (model specific)o Factory Option 1 – Factory Defined

(3 second delay)o Factory Option 2 – Factory Defined

(10 second delay)o Factory Option 3 – Factory Defined

(90 second delay)• Cascade Communication Connections (Ft_bus

Communication)o PIM 2 – A & Bo PIM 3 – A & Bo PIM 4 – A & B

• External Device Triggers (dry contact)o External Valveo Fan/Dampero Extra

• Auxiliary Sensor Inputso Aux 1 – IND Supply Sensor (S6)o Aux 2 – CWS/CWR (future usage)

• 0-10vdc Output (CWS/CWR)o Mod+/-

• Communication Connectionso RS485 (future usage)o Modbus RS485 (RTU/ASCII)

• VERSA IC Display Connection (Ribbon Cable)• PIM Connection (RJ45 Connection)• Dip Switches

o #1 – Access Level• OFF – Installer• ON - Advanced

o #2 – Cascading• OFF – Follower/Slave• ON – Master

o #3 – Cold Water Protection• OFF – None• ON – CWS/CWR

o #4 – Proportional Output Selection• OFF – 0-10 VDC• ON – 0-20mA (requires 500 ohm resistor)

o #5 – Remote Display (RS485)• OFF – • ON –

o #6 – Heater Rotation• OFF – No Rotation• ON – Enable Rotation

o #7 – TBDo #8 – TBD

Fig. 4: VERSA IC Control DIP Switches

VERSA Display Board

The VERSA Display Board is the board with the LCDdisplay viewable from outside of the heater. All opera-tion and settings of the VERSA IC control areaccomplished through the use of the 5 buttons of theuser interface. These buttons are labeled as follows:

• MENU – Scroll through available menus• ITEM – Scroll items within the selected menu• UP – Increase values in the Adjust menu• DOWN – Decrease values in the Adjust menu• RESET – Clear lockout

Fig. 5: VERSA IC Display Board

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The display uses a Liquid Crystal Display (LCD) as themethod for supplying information. Use the LCD tosetup and monitor the operation of your heater.

If the membrane switch remains inactive for 180 sec-onds (3 minutes), the screen will revert to the VIEWmenu – Boil INLET unless some error/fault exists –then the fault will be displayed. Touching any buttonresets this timer (the timer can be seen in the bottomright corner of the display) to keep the current view.

Fig. 6: Display

The VERSA Control Board has 2 access levels:Installer and Advanced. Most settings are hidden inthe Installer mode. The Advanced mode can beaccessed by changing the VERSA dip switch #1 fromthe “OFF” position (Installer) to the “ON” position(Advanced).

The default menu displayed is the VIEW menu. Ifthere is an unresolved (active) error, then the defaultmenu is the TOOLBOX menu. The default item will bethe active error message. After 60 seconds of keypadinactivity, the VERSA IC display will return to thedefault menu and display the default item.

VERSA PIM™ Module

The PIM™ (Platform Ignition Module) is available inDSI (Direct Spark Ignition), HSI (Proven Hot SurfaceIgnition), or IID (Intermittent Ignition Device -Supervised Pilot) (Future) versions depending onRaypak model type.

The PIM integrates the functions of Automatic IgnitionControl with temperature regulating and control func-tions. The PIM is designed for a range of boilers, waterheaters and pool heaters including ON/OFF, stagedand modulating types. The PIM is intended to providesafe lighting and supervision of the burners in a heater.

The PIM is also designed to connect to and receivecommands from the VERSA Control Board for higherlevel functionality to include indirect DHW, outdoorreset, diagnostic messaging, and other system capa-bilities. Communication is accomplished using aproprietary protocol on the Ft_bus.

The PIM is CSA certified to the ANSI Z21.20 Standardfor Thermostats and Automatic Gas Ignition Systemsand Components and CAN/CSA C22.2 No. 199-M99.The VERSA PIM also complies with the UL372Primary Safety Controls for Gas and Oil FireAppliances (Harmonized version); UL 1998 Softwarein Programmable Components, 2nd edition and UL353 Limit Controls.

The PIM provides standard support for 10k ohm @77°F NTC curve J Thermistor probes. The Inlet, Outlet,Hi-Limit, and Vent (model dependent) sensors aredirectly processed by the PIM. The optional System,

WARNING: Return the VERSA control dipswitch #1 to the “OFF” (Installer) position afterheaters are fully set up and commissioned to preventinadvertent changes to program settings by unau-thorized personnel.

J5

J6

J7

J8

J9

J10

J11

J12

J14

RESET

POWER

ALARM/TEST

FAULT

FS GND

J4

L115ABLOWEROPTION

BLOWER

1 9 1 10

OPERATORSETPOINT

FIELD OPTIONSSEE MANUAL

J15 REMOTE LED

FC-

FC+

T3

J2 J1

F1

P2

J3

Fig. 7: VERSA DSI PIM Module

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Icon When Displayed

VIEW Menu = View

SETUP Menu = Setup

BOILER Menu = Boiler View Menu of Boiler 1,2, 3 or 4

BOILER 1 Menu = Boiler View Menu of Boiler 1




MONITOR Menu = Monitor

M Single boiler orMaster Boiler in Cascade

Menu = View, Solid if Installer AccessLevelFlashes at 1Hz if OEM Access Level

Menu = Toolbox

WWSD Warm Weather Shutdown is active

Menu = View, Flashes at 1 Hz if one ofthe connected PIMs is in LockoutMenu = View, Solid if there is a knownactive error on one of the connectedPIMs

Calls Menu = View/Test

Heat Menu = View/Test and Heat Call present

DHW Menu = View/Test and DHW Call present

Pool Menu = View/Test and Pool Call present

Tank Menu = View/Test and Tank Call present

Setpoint Menu = View/Test and Setpoint Callpresent

Icon When Displayed

Pumps Menu = View/Test

BoilerPump Menu = View/Test and Boiler Pump is on

SystemPump Menu = View/Test and System Pump is on

DHWPump Menu = View/Test and DHW Pump is on

Burner Menu = View/Test

1 Menu = View/Test and PIM 1 is on




(BurnerRate) %

Menu = View/Test and PIM is modulat-ing. Displays current plant firing rate.

(tN4) Menu = View and tN4 communicationis present

ModBus Menu = View and ModBus communi-cation is present

°CWhenever the item displayed in thenumber field is a temperature andUNITS = degC

°FWhenever the item displayed in thenumber field is a temperature andUNITS = degF

min Whenever the item displayed in thenumber field is in minutes

hr Whenever the item displayed in thenumber field is in hours

sec Whenever the item displayed in thenumber field is in seconds

µA Whenever the item displayed in thenumber field is in micro-amps

% Whenever the item displayed in thenumber field is in percent

RPM Whenever the item displayed in thenumber field is in RPM

Table A: VERSA Display Symbol Descriptions

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PIM Dip Switches

There is an 8-position dip switch on each PIM that canbe field configurable during commissioning. The UPposition is “ON” and the DOWN position of each dipswitch is “OFF”. The items in BOLD below representfactory defaults settings.

Dip Switch #1 – Operator DifferentialON = Manual DifferentialOFF = Auto Differential

Dip Switch #2 – Analog Input TypeON = Direct DriveOFF = Target Temperature

Dip Switch #3 – Pump Post PurgeON = Pump Post Purge ActiveOFF = Pump Post Purge Inactive

Dip Switch #4 – Pump Exercise EnableON = Pump Exercise ActiveOFF = Pump Exercise Inactive

Dip Switch #5 – EMS/DemandsON = EMS Analog Input OnlyOFF = VERSA IC Demands Only

Dip Switch #6 – EMS Signal TypeON = 4-20mA*OFF = 0-10vdc

Dip Switch #7 – Freeze ProtectionON = Freeze Protection ActiveOFF = Freeze Protection Inactive

Dip Switch #8 – Commission TestON = Commission Test ActiveOFF = Commission Test Inactive

*NOTE: 4-20mA operation requires the use of anexternal 500Ω, 1/2W resistor.

PIM Operator Set Point Dial

The PIM has a set point dial that is used to determinethe operator set point during standalone operation ofthe VERSA IC Control System. The default position ofthe operator set point dial is the maximum set pointwhich is defined by the PIM parameters defined by theID card. The dial can be adjusted down to a userdefined level between the minimum setting of 70°F orthe maximum allowed by the ID card. This function isonly active during standalone operation.

VERSA IC Identification Card

The VERSA IC Identification Card (ID Card) is a smallcircuit card that determines the operating parametersfor each individual model by unlocking the correct pro-gram within the VERSA PIM module (referred tosimply as PIM throughout the rest of this manual). It ispermanently affixed to the chassis of the heater andMUST be present for the heater to operate.

If a PIM needs to be reconfigured for another ID Card(such as during service or replacement), its internal IDCard settings must be cleared before using on anoth-er heater. To clear these settings, follow the procedureon page 52 – Resetting the PIM to Accept a New IDCard.

Applications & Modes

The VERSA IC Control system is designed for a widerange of applications. The installer/design engineershould refer to the following drawings for configura-tions currently supported by the VERSA IC ControlSystem to determine which most closely resemblesthe intended/installed system configuration. Refer tothe section(s) of this manual for instructions outliningthe piping layout, sensor locations and settings forbest operation of the specific configuration shown.

Hot water heating systems all have unique levels ofoperating diversity that must be accounted for in thesystem design. The system should always includeadequate system flow in excess of the connected boil-er flow for proper operation. Where the system flowmay drop below the connected boiler flow, abuffer/decoupler may be needed. Failure to design foradequate flow (i.e. bypasses, 3 way control valves,flow limiting balance devices, buffer tanks, etc.) willresult in boiler short cycling and may reduce boiler life.Always contact your local Raypak representative forsystem design assistance to avoid these issues.

WARNING: In the event of ID Card failure, replace-ment must be performed by a qualified technicianand must be replaced with an ID Card of the samenumber.

Fig. 8: VERSA PIM ID Card

Outdoor, and DHW tank sensors are also connected tothe PIM but are passed through to the VERSA ControlBoard which is required to provide those additionalfunctions. Auxiliary sensors connect direct to theVERSA Control Board for other enhanced functionsdepending on the mode selected. Refer to the I&OManual for the product being installed for detailedwiring information.

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H - Hydronic HeatingApplications

All Hydronic applications can be configured with orwithout outdoor air reset functionality. The followingare the various system configurations discussed in fur-ther detail later in this manual.

Single Boiler – See Page 10

Multi-boiler Cascade – See Page 12

Single Boiler with Indirect DHW onSystem Loop – See Page 14

Multi-boiler Cascade with IndirectDHW on System Loop – See Page 16

Single Boiler with Indirect DHW onBoiler Loop – See Page 18

Multi-boiler Cascade with IndirectDHW on Boiler Loop – See Page 20

WH - Direct DHW Applications

When a unit is ordered as a “WH” configuration theonly application available is direct Domestic HotWater. Systems can be configured for Single unit or upto 4 heater Cascade systems as highlighted below.

Single Heater – See Page 22

Multi-heater Cascade – See Page 24

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Single Boiler Hydronic Heating - Mode 1

This section covers a single boiler used for hydronic heating. Primary/secondary piping is the only method sup-ported by Raypak to ensure proper boiler and system functionality while achieving maximum system efficiency.

The piping configuration shown above can be used as fixed set point or set up to work in conjunction with anOutdoor Air Reset Sensor (S4) to adjust the target water temperature as the outdoor air temperature changes.The boiler firing rate will be controlled by the System Supply Sensor (S3). The VERSA IC™ will provide MaxDelta T (Differential Temperature) control and will cycle the burner in the event the Max Delta T is exceededbetween Boiler Outlet Sensor (S1) and Boiler Inlet Sensor (S2). The Boiler Pump (P1) runs during any call forburner operation and is delayed “off” as user defined in the SETUP menu after the burner has shut down. TheSystem Pump (P2) runs whenever the system is enabled for heating and the outdoor air temperature is lowerthan the WWSD temperature setting (if utilized). The System Pump is delayed “off” as user defined in the SETUPmenu. MODE 1 is used for this configuration. See SETUP menu items in Table B. This configuration supportsBMS 0-10vdc input for temperature or rate control and can be configured for connectivity to BMS via the onboardModbus port covered later in this manual.

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Item Range Default Access Level When is it Displayed Description

BOILER 1 ON <> OFF ON Installer Ft_Bus 1 is connected or “NO PIM™1” Error

Selects whether PIM™ 1 is operational

TARGET RSET <> SETP EMS MODB

SETP

Installer PIM™ Identity is H EMS=TEMP/RATE MODBUS=TEMP/RATE

RSET = Outdoor Reset SETP = Setpoint EMS = Energy Management System (Analog Target Temperature) MODB = ModBus

MODE 1, 2, 3 1 Installer PIM™ Identity is H

Piping and application configuration (see pages 12-20 for descriptions of applications and modes)

SETPOINT 50 to PIM™ Value 180°F Installer PIM™ Identity is H TARGET = SETP

Target setpoint boiler temperature while a heat demand is present for setpoint operation

OUT START 35 TO 85°F 70°F Advanced PIM™ Identity is H TARGET = RSET

Outdoor reset starting temperature

OUT DESIGN -60 to 45°F 10°F Installer PIM™ Identity is H TARGET = RSET

Outdoor reset design temperature

Boil START 35 to 150°F 70°F Advanced PIM™ Identity is H TARGET = RSET

Starting boiler target temperature when the outdoor temperature is at outdoor start

Boil DESIGN 70 to 200°F 180°F Installer PIM™ Identity is H TARGET = RSET

Design boiler target temperature when the outdoor temperature is at outdoor design

Boil MASS 1 <> 2 <> 3 1 Installer Always Thermal mass of boiler – 1 = low mass boiler and 3 = high mass boiler

TARGET MAX 100°F to PIM™ Operating Limit

PIM™ value**

Installer PIM™ Identity is H Maximum target boiler temperature

TARGET MIN 50 TO 180°F 50°F Installer PIM™ Identity is H

Minimum target boiler temperature

TARGET DIFF 2 to 42°F 10°F Installer PIM™ Identity is H PIM™ DIP = Manual Diff

Differential for target boiler temperature

BOIL PURGE OFF, 0:20 TO 10:00 min 0:20 min Advanced PIM™ DIP = Purge On Sets the length of the boiler pump purge

SYS PURGE OFF, 0:20 TO 20:00 min 0:20 min Advanced PIM™ DIP = Purge On Sets the length of the system pump purge

tN4 CYCLE Au, 5 to 30 min Au Advanced PIM™ Identity is H tN4 Bus Detected

Cycle length which all tN4 devices synchronize to

tN4 SCHD OFF, <> Mb1 OFF Installer PIM™ Identity is H tN4 Schedule #1

Selects if control will follow Master Schedule #1

WWSD 40 - 100°F, OFF 70°F Installer TARGET = RSET PIM™ Identity is H

The system warm weather shut down temperature

UNITS °F <> °C °F Installer Always Show units using icons in display

MODE Modbus

OFF <> MNTR <> TEMP <> RATE

OFF Advanced Always ModBus Operating Mode: Off, Monitor, Temp Control, Rate Control

ADDRESS 1 to 247 1 Advanced Always ModBus slave address DATA TYPE RTU <> ASCI RTU Advanced Always ModBus data type BAUD RATE 2400 <> 9600 <> 19K2

<> 57K6 <> 115K 19K2 Advanced Always Modbus baud rate

PARITY NONE <> EVEN <> ODD EVEN Advanced Always Modbus parity ** Check the Installation & Operating Manual for each specific product.

Table B: Mode 1 Setup Menu

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Multi-Boiler Cascade Hydronic Heating - Mode 1

This section covers a cascade of boilers (up to 4 boilers maximum) in a hydronic heating system. Reverse/returnpiping is shown and is recommended to ensure balanced flow through each of the connected boilers.Primary/secondary piping is the only method supported by Raypak to ensure proper boiler and system function-ality while achieving maximum system efficiency.

The piping configuration shown can be used with a fixed set point or in conjunction with an Outdoor Air ResetSensor (S4a) to adjust the target water temperature as the outdoor air temperature changes. The system will becontrolled by the System Supply Sensor (S3a). The system will provide Max Delta T control to cycle the burn-er to ensure that the Delta T is not exceeded (between Boiler Outlet Sensors (S1a-b-c-d) and Boiler Inlet Sensors(S2a-b-c-d)). The Boiler Pumps (P1a-b-c-d) run during any call for that pumps associated boilers burner and isdelayed “off” as user defined in the SETUP menu after the associated boilers burner has shut down. The SystemPump (P2a) runs whenever the system is enabled for heating and the outdoor air temperature is lower than theWWSD temperature setting (if utilized). The System Pump is delayed “off” as user defined in the SETUP menu.

Each Follower boiler connects back to the Master boiler via a two wire connection for communication within thecascade. All sensors (Supply (S3a) and Outdoor Air (S4a)) connect to the Master boiler. Each boiler in the cas-cade connects to and controls its own respective Boiler Pump (P1a-b-c-d). The System Pump (P2a) gets itsenable signal from the Master boiler. It is important to remember to enable a boiler to be a follower in the cas-cade by turning dip switch #2 on the VERSA Control Board to the “OFF” position for each of the followers. Oncethe followers have been configured correctly you must then enable the followers within the SETUP menu of theMaster boiler by turning them from “OFF” to “ON”. MODE 1 is used for this configuration. See SETUP menuitems in Table C. This configuration supports BMS 0-10vdc input for temperature control (rate not supported)and can be configured for connectivity to BMS via the onboard Modbus port covered later in this manual.

To enable Follower boilers, scroll to the SETUP menu and, using the item button, scroll to the individual boilersand toggle from “OFF” to “ON” to allow them to operate when commanded by the Master to run.

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BOILER 2 ON <> OFF OFF Installer Ft_Bus 2 is connected or “NO PIM™2” Error







SETP Installer PIM™ Identity is H EMS=TEMP/RATE MODBUS=TEMP/RATE


MODE 1, 2, 3 1 Installer PIM™ Identity is H TARGET = RSET or SETP




OUT START

35 to 85°F 70°F Advanced PIM™ Identity is H TARGET = RSET


OUT DESIGN

-60 to 45°F 10°F Installer PIM™ Identity is H TARGET = RSET




Boil DESIGN

70 to 200°F 180°F Installer PIM™ Identity is H TARGET = RSET


Boil MASS 1 <> 2 <> 3 1 Installer Always Thermal mass of boiler – 1 = low mass boiler and 3 = high mass boiler TARGET MAX

100°F to PIM™ Operating Limit

PIM™ value**

Installer MODBUS RATE EMS RATE PIM™ Identity is H Ft_Bus 1 is connected

Maximum target boiler temperature

TARGET MIN

50 to 180°F OFF Installer MODBUS RATE EMS RATE PIM™ Identity is H Ft_Bus 1 is connected


TARGET DIFF

2 to 42°F 10°F Installer MODBUS RATE EMS RATE PIM™ Identity is H PIM™ DIP = Manual Diff


BOIL PURGE

OFF, 0:20 to 10:00 min

0:20 min

Advanced MODBUS RATE PIM™ DIP = Purge On

Sets the length of the boiler pump purge

SYS PURGE

OFF, 0:20 to 20:00 min

0:20 min

Advanced MODBUS TEMP/RATE PIM™ DIP = Purge On

Sets the length of the system pump purge







UNITS °F <> °C °F Installer Always Show units using icons in display MODE Modbus



ADDRESS 1 to 247 1 Advanced MODBUS OFF ModBus slave address DATA TYPE

RTU <> ASCI RTU Advanced MODBUS OFF ModBus data type

BAUD RATE

2400 <> 9600 <> 19K2 <> 57K6 <> 115K

19K2 Advanced MODBUS OFF

PARITY NONE <> EVEN <> ODD

EVEN Advanced MODBUS OFF

** Check the Installation & Operating Manual for each specific product.

Table C: Mode 1 Cascade Setup Menu

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Single Boiler with Indirect DHW on SystemLoop – Mode 2

This section covers a single boiler used for hydronic heating in conjunction with an indirect DHW demand locat-ed on the system loop. Primary/secondary piping is the only method supported by Raypak to ensure properboiler and system functionality while achieving maximum system efficiency.

The piping configuration shown can be used as fixed set point or set up to work in conjunction with an OutdoorAir Reset Sensor (S4) to adjust the target water temperature as the outdoor air temperature changes. The sys-tem can also be set to operate the indirect DHW call with or without priority. The boiler firing rate will be controlledby the System Supply Sensor (S3). The Indirect Sensor (S5) determines the indirect call/tank setpoint. TheVERSA IC™ control system also allows for a thermostat controller (tank-stat) to be mounted in the indirect tankand provide a call for indirect operation via contact closure in lieu of the tank sensor. The thermostat wiring con-nection is at the PIM™ J1 terminal block at terminals 8 and 10. When using an indirect DHW sensor to controltank temperature contact closure is required across the indirect override connections for proper operation (seeIND Sensor, page 32 for further details).

The VERSA IC™ will provide Max Delta T (Differential Temperature) control and will cycle the burner in the eventthe Max Delta T is exceeded between Boiler Outlet Sensor (S1) and Boiler Inlet Sensor (S2). The Boiler Pump(P1) runs during any call for burner operation and is delayed “off” as user defined in the SETUP menu after theburner has shut down. The System Pump (P2) runs whenever the system is enabled for heating and the outdoorair temperature is lower than the WWSD temperature setting (if utilized). Priority mode toggles the System Pump(P2) off during an indirect call-for-heat. The Indirect Pump (P3) runs during an indirect call-for-heat with no “off”delay. The System Pump is delayed “off” as user defined in the SETUP menu.

Mode 2 is used for this configuration. Ensure dip switch #1 on the VERSA Control Board is in the ON positionto make programming changes.

15




















TARGET MAX 100°F to PIM™ Operating Limit

PIM™ value**

Installer PIM™ Identity is H Ft_Bus 1 is connected


TARGET MIN 50 TO 180°F 50°F Installer PIM™ Identity is H Ft_Bus 1 is connected


TARGET DIFF 2 to 42°F Auto Installer PIM™ Identity is H PIM™ DIP = Manual Diff


IND SENSOR OFF <> ON OFF Installer MODE = 2 or 3 DHW SENSOR = OFF

Selects whether a DHW sensor is used in lieu of tankstat

IND SETP OFF, 50 TO 180°F 140°F Installer MODE = 2 or 3 DHW SENS = ON

Target indirect DHW temperature when a DHW sensor is selected

IND DIFF 2 to 10°F 6°F Advanced MODE = 2 or 3 DHW SENS = ON

Differential for the target indirect DHW tank temperature

IND SUPPLY OFF, 70 to 200°F 180°F Advanced MODE = 2 or 3 DHW SENS = OFF

Target boiler temperature for the DHW heat exchanger during indirect DHW operation

IND PRIORITY OFF <> ON OFF Advanced PIM™ Identity is H MODE = 2

Selects whether or not indirect DHW priority is active during indirect DHW operation

PRI OVR Au, 0:10 to 2:00 hr 1:00 hr Advanced PIM™ Identity is H tN4 Bus Detected OR DHW PRIORITY = ON

Sets the length of the priority override time

BOIL PURGE OFF, 0:20 TO 10:00 min 0:20 min Advanced MODBUS RATE PIM™ DIP = Purge On


SYS PURGE OFF, 0:20 TO 20:00 min 0:20 min Advanced MODBUS TEMP/RATE PIM™ DIP = Purge On











ADDRESS 1 to 247 1 Advanced MODBUS OFF ModBus slave address DATA TYPE RTU <> ASCI RTU Advanced MODBUS OFF ModBus data type BAUD RATE 2400 <> 9600 <> 19K2 <>

57K6 <> 115K 19K2 Advanced MODBUS OFF

PARITY NONE <> EVEN <> ODD EVEN Advanced MODBUS OFF ** Check the Installation & Operating Manual for each specific product.

Table D: Mode 2 Setup Menu

16

Multi-boiler Cascade with Indirect on the SystemLoop – Mode 2

This section covers a cascade of up to 4 boilers used for hydronic heating in conjunction with an indirect DHWdemand located on the system loop. Reverse/return piping is shown and is recommended to ensure balancedflow through each of the connected boilers. Primary/secondary piping is the only method supported by Raypakto ensure proper boiler and system functionality while achieving maximum system efficiency.

The piping configuration shown can be used as fixed set point or set up to work in conjunction with an OutdoorAir Reset Sensor (S4a) to adjust the target water temperature as the outdoor air temperature changes. The sys-tem can also be set to operate the indirect DHW call with or without priority. The system temperature will becontrolled by the System Supply Sensor (S3a) during a call for hydronic heat or an indirect call. The IndirectDHW Sensor (S5a) determines the indirect call based on the user defined set point. The VERSA IC™ controlsystem also allows for a thermostat controller (tank-stat) to be mounted in the indirect tank and provide a call forindirect operation via contact closure in lieu of the tank sensor. The thermostat wiring connection is at the MasterPIM™ J1 terminal block at terminals 8 and 10. When using an indirect DHW sensor to control tank temperaturecontact closure is required across the indirect override connections for proper operation (see IND Sensor, page32 for further details).

During an indirect call-for-heat with or without priority selected, the cascade firing rate is determined by theSystem Supply Sensor (S3a) temperature. The system will provide Max Delta T control to cycle the burner inthe event the Max Delta T is exceeded between Boiler Outlet Sensors (S1a-b-c-d) and Boiler Inlet Sensors(S2a-b-c-d). Priority mode toggles off the System Pump (P2a) when an indirect call-for-heat is present. BoilerPumps (P1a-b-c-d) run in conjunction with their associated burner during all heat calls regardless of priority. TheIndirect DHW pump (P3a) runs during an indirect call-for-heat with no “off” delay. The Boiler Pumps (P1a-b-c-d)and System Pump (P2a) delay “off” as user defined in the ADJUST menu. The System Pump (P2a) runs when-ever the system is enabled for heating and the outdoor air temperature is lower than the WWSD temperaturesetting (if utilized) unless an indirect call-for-heat is present with priority.

Mode 2 is used for this configuration. Ensure dip switch #1 on the Master VERSA Control Board is in the ONposition to make programming changes. It is important to remember to enable a boiler to be a follower in thecascade by turning dip switch #2 on the VERSA Control Board to the "OFF" position for each of the followers.To enable Follower boilers, scroll to the SETUP menu and, using the item button, scroll to the individual boilersand toggle from OFF to ON to allow them to operate when commanded by the Master to run.

17

























Boil MASS 1 <> 2 <> 3 1 Installer Always Thermal mass of boiler – 1 = low mass boiler and 3 = high mass boiler TARGET MAX 100°F to PIM™

Operating Limit PIM™ value**

Installer MODBUS RATE EMS RATE PIM™ Identity is H Ft_Bus 1 is connected


TARGET MIN 50 TO 180°F OFF Installer MODBUS RATE EMS RATE PIM™ Identity is H Ft_Bus 1 is connected


TARGET DIFF

2 to 42°F 10°F Installer PIM™ Identity is H PIM™ DIP = Manual Diff


IND SENSOR OFF <> ON OFF Installer PIM™ Identity is H MODE = 2 or 3

Selects whether a DHW sensor is used

IND SETP OFF, 50 TO 180°F 140°F Installer PIM™ Identity is H MODE = 2 or 3 DHW SENS = ON


IND DIFF 2 to 10°F 6°F Advanced PIM™ Identity is H MODE = 2 or 3 DHW SENS = ON


IND SUPPLY OFF, 70 to 200°F 180°F Advanced PIM™ Identity is H MODE = 2 or 3 DHW SENS = OFF


IND PRIORITY

OFF <> ON OFF Advanced PIM™ Identity is H MODE = 2

Selects whether or not indirect DHW priority is active during indirect DHW operation



BOIL PURGE OFF, 0:20 TO 10:00 min 0:20 min Advanced PIM™ DIP = Purge On Sets the length of the boiler pump purge SYS PURGE OFF, 0:20 TO 20:00 min 0:20 min Advanced PIM™ DIP = Purge On Sets the length of the system pump purge tN4 CYCLE Au, 5 to 30 min Au Advanced tN4 Bus Detected Cycle length which all tN4 devices synchronize to tN4 SCHD OFF, <> Mb1 OFF Installer PIM™ Identity is H

tN4 Schedule #1 Selects if control will follow Master Schedule #1






ADDRESS 1 to 247 1 Advanced MODBUS OFF ModBus slave address DATA TYPE RTU <> ASCI RTU Advanced MODBUS OFF ModBus data type BAUD RATE 2400 <> 9600 <> 19K2

<> 57K6 <> 115K 19K2 Advanced MODBUS OFF

PARITY NONE <> EVEN <> ODD EVEN Advanced MODBUS OFF ** Check the Installation & Operating Manual for each specific product.

Table E: Mode 2 Cascade Setup Menu

18

Single Boiler with Indirect DHW on Boiler Loop –Mode 3

This section covers a single boiler used for hydronic heating in conjunction with an indirect DHW demand locat-ed on the boiler loop. Primary/secondary piping is the only method supported by Raypak to ensure proper boilerand system functionality while achieving maximum system efficiency.

The piping configuration shown can be used as fixed set point or set up to work in conjunction with an OutdoorAir Reset Sensor (S4) to adjust the target water temperature as the outdoor air temperature changes. The sys-tem will operate the indirect DHW call with priority function only. The system will be controlled by the SystemSupply Sensor (S3) whenever the indirect call-for-heat is not active. The Indirect Sensor (S5) determines theindirect call/tank set point. The VERSA IC™ control system also allows for a thermostat controller (tank-stat) tobe mounted in the indirect tank and provide a call for indirect operation via contact closure in lieu of the tank sen-sor. The thermostat controller wiring connection is at the PIM™ J1 terminal block at terminals 8 and 10. Whenusing an indirect DHW sensor to control tank temperature contact closure is required across the indirect over-ride connections for proper operation (see IND Sensor, page 32 for further details). During an indirectcall-for-heat the firing rate is determined by the Indirect Setpoint or Max Target at the water temperature to theIndirect System Sensor (S6). The VERSA IC™ will provide Max Delta T (Differential Temperature) control andwill cycle the burner in the event the Max Delta T is exceeded between Boiler Outlet Sensor (S1) and Boiler InletSensor (S2). The Boiler Pump (P1) runs during any call for burner operation and is delayed “off” as user definedin the SETUP menu after the burner has shut down. The System Pump (P2) runs whenever the system isenabled for heating and the outdoor air temperature is lower than the WWSD temperature setting (if utilized). Anindirect DHW call-for-heat will toggle the System Pump (P2) off until the indirect call-for-heat is satisfied or thepriority timer has elapsed allowing the system to return to heating mode. The Indirect DHW Pump (P3) runs dur-ing an indirect call-for-heat with no “off” delay. The System Pump is delayed “off” as user defined in the SETUPmenu.

Mode 3 is used for this configuration. Ensure dip switch #1 on the VERSA Control Board is in the ON positionto make programming changes.

19




TARGET RSET <> SETP

EMS

MODB

SETP Installer PIM™ Identity is H

EMS=TEMP/RATE

MODBUS=TEMP/RATE

RSET = Outdoor Reset SETP = Setpoint

EMS = Energy Management System (Analog Target Temperature)

MODB = ModBus MODE 1, 2, 3 3 Installer PIM™ Identity is H

TARGET = RSET or SETP Piping and application configuration (see pages 12-20 for descriptions of applications and modes)





OUT DESIGN








TARGET MAX


PIM™ value**



TARGET MIN

50 TO 180°F 50°F Installer PIM™ Identity is H Ft_Bus 1 is connected


TARGET DIFF

2 to 42°F Auto Installer PIM™ Identity is H PIM™ DIP = Manual Diff


IND SENSOR

OFF <> ON OFF Installer MODE = 2 or 3 DHW SENSOR = OFF






IND SUPPLY OFF, 70 to 200°F 180°F Advanced MODE = 2 or 3 DHW SENS = OFF




BOIL PURGE

OFF, 0:20 TO 10:00 min

0:20 min Advanced MODBUS RATE PIM™ DIP = Purge On


SYS PURGE OFF, 0:20 TO 20:00 min

0:20 min Advanced MODBUS TEMP/RATE PIM™ DIP = Purge On











ADDRESS 1 to 247 1 Advanced MODBUS OFF ModBus slave address DATA TYPE RTU <> ASCI RTU Advanced MODBUS OFF ModBus data type BAUD RATE 2400 <> 9600 <>

19K2 <> 57K6 <> 115K





Table F: Mode 3 Setup Menu

20

Multi-boiler Cascade with Indirect DHW on BoilerLoop – Mode 3

This section covers a cascade of up to 4 boilers used for hydronic heating in conjunction with an indirect DHWdemand located on the boiler loop. Reverse/return piping is shown and is recommended to ensure balanced flowthrough each of the connected boilers. Primary/secondary piping is the only method supported by Raypak toensure proper boiler and system functionality while achieving maximum system efficiency.

The piping configuration shown can be used as fixed set point or set up to work in conjunction with an OutdoorAir Reset Sensor (S4a) to adjust the target water temperature as the outdoor air temperature changes. The sys-tem will operate the indirect DHW call with priority only. The cascade firing rate will be controlled by the SystemSupply Sensor (S3a) whenever the indirect call-for-heat is not active. The Indirect Sensor (S5) determines theindirect call/tank set point. When using an indirect DHW sensor to control tank temperature contact closure isrequired across the indirect override connections for proper operation. During an indirect call-for-heat the firingrate is determined by the Indirect Setpoint or Max Target at the water temperature to the Indirect System Sensor(S6). The system will provide Max Delta T control to cycle the burner in the event the Max Delta T is exceededbetween Boiler Outlet Sensors (S1a-b-c-d) and Boiler Inlet Sensors (S2a-b-c-d). Priority mode toggles off theSystem Pump (P2a) when an indirect call-for-heat is present. Boiler Pumps (P1a-b-c-d) run in conjunction withtheir associated burner during all heat calls regardless of priority. The Indirect DHW Pump (P3a) runs during anindirect call-for-heat with no “off” delay. The Boiler Pumps (P1a-b-c-d) and System Pump (P2a) delay “off” asuser defined in the ADJUST menu. The System Pump (P2a) runs whenever the system is enabled for heatingand the outdoor air temperature is lower than the WWSD temperature setting (if utilized) unless an indirect call-for-heat is present with priority.

Mode 3 is used for this configuration. Ensure dip switch #1 on the Master VERSA Control Board is in the ONposition to make programming changes. It is important to remember to enable a boiler to be a follower in thecascade by turning dip switch #2 on the VERSA Control Board to the "OFF" position for each of the followers.To enable Follower boilers, scroll to the SETUP menu and, using the item button, scroll to the individual boilersand toggle from OFF to ON to allow them to operate when commanded by the Master to run.

21

















OUT START 35 to 85°F 70°F Advanced PIM™ Identity is H TARGET = RSET


OUT DESIGN








TARGET MAX


PIM™ value**



TARGET MIN

50 to 180°F 50°F Installer PIM™ Identity is H Ft_Bus 1 is connected


TARGET DIFF

2 to 42°F Auto Installer PIM™ Identity is H PIM™ DIP = Manual Diff


IND SENSOR

OFF <> ON OFF Installer MODE = 2 or 3 DHW SENSOR = OFF






IND SUPPLY

OFF, 70 to 200°F 180°F Advanced MODE = 2 or 3 DHW SENS = OFF




BOIL PURGE

OFF, 0:20 to 10:00 min 0:20 min Advanced MODBUS RATE PIM™ DIP = Purge On


SYS PURGE OFF, 0:20 to 20:00 min 0:20 min Advanced MODBUS TEMP/RATE PIM™ DIP = Purge On











ADDRESS 1 to 247 1 Advanced MODBUS OFF ModBus slave address DATA TYPE RTU <> ASCI RTU Advanced MODBUS OFF ModBus data type BAUD RATE 2400 <> 9600 <> 19K2

<> 57K6 <> 115K 19K2 Advanced MODBUS OFF




Table G: Mode 3 Cascade Setup Menu

22

WH – Direct DHW Applications – Single Heater

This section covers a single WH model for use on direct Domestic Hot Water heating systems used in conjunc-tion with a storage tank. The piping configuration above is representative of a condensing heater and shows themakeup water on the supply side of the heater. Piping for noncondensing heaters have the cold water connec-tion between the heater outlet and the storage tank to prevent condensation in the heater.

The tank temperature will be controlled by the Supply Sensor (S3). The VERSA IC™ will provide Max Delta T(Differential Temperature) control and will cycle the burner in the event the Max Delta T is exceeded betweenHeater Outlet Sensor (S1) and Heater Inlet Sensor (S2). The Heater Pump (P1) runs during any call for burneroperation and is delayed “off” as user defined in the SETUP menu after the burner has shut down. The SystemPump output (P2) is enabled to run whenever the heater is enabled for operation. The Heater Pump (P1) runsduring any call-for-heat. The Heater Pump (P1) is delayed “off” as user defined in the ADJUST menu. TheSystem Pump output (P2) is delayed “off” only when the heater is disabled by opening the connection acrossthe enable/disable at the PIM™.

There is no mode to configure for WH operation as this is the only mode available when built as a WH modelunit. The Supply Sensor (S3) must be installed in the storage tank and functional for heater operation.

23




TARGET EMS MODB

Installer EMS=TEMP/RATE MODBUS=TEMP/RATE

EMS = Energy Management System (Analog Target Temperature) MODB = ModBus

TANK SETP

OFF, 50 to PIM™ value 125°F Installer PIM™ Identity is WH Tank setpoint temperature

TANK DIFF 2 to 10°F 5°F Installer MODBUS TEMP/RATE EMS TEMP/RATE PIM™ Identity is WH

Tank differential temperature

BOIL PURGE



SYS PURGE

OFF, 0:20 to 20:00 min 0:20 min Advanced MODBUS TEMP/RATE PIM™ DIP = Purge On







BAUD RATE

2400 <> 9600 <> 19K2 <> 57K6 <> 115K




Table H: Direct DHW Setup Menu

24

WH – Direct DHW Applications – Multi-heaterCascade

This section covers a cascade of up to 4 WH models for use on direct Domestic Hot Water heating systems usedin conjunction with a storage tank. The piping configuration above is representative of a cascade of condensingheaters and shows the makeup water on the supply side of the heaters. Piping for noncondensing heaters havethe cold water connection between the heater outlet and the storage tank to prevent condensation in the heater.

The tank temperature will be controlled by the Supply Sensor (S3). The VERSA IC™ control system will pro-vide Max Delta T control to cycle the burner in the event the Max Delta T is exceeded between Heater OutletSensors (S1a-b-c-d) and Heater Inlet Sensors (S2a-b-c-d). The Heater Pumps (P1a-b-c-d) run during any callfor the associated heaters burner operation and is delayed “off” as user defined in the SETUP menu after theassociated heater burner has shut down. The System Pump output (P2a) is enabled to run whenever the heateris enabled for operation. The System Pump output (P2a) is delayed “off” only when the heater is disabled byopening the connection across the enable/disable at the PIM™.

There is no mode to configure for WH operation as this is the only mode available when built as a WH modelunit. Ensure dip switch #1 on the VERSA Control Board is in the ON position to make programming changes. Itis important to remember to enable a heater to be a follower in the cascade by turning dip switch #2 on theVERSA Control Board to the "OFF" position for each of the followers. To enable Follower heaters, scroll to theSETUP menu and, using the item button, scroll to the individual heaters and toggle from OFF to ON to allowthem to operate when commanded by the Master to run.

25










TARGET EMS MODB

Installer EMS=TEMP/RATE MODBUS=TEMP/RATE

EMS = Energy Management System (Analog Target Temperature) MODB = ModBus

TANK SETP

OFF, 50ºF to PIM™ Value

125°F Installer PIM™ Identity is WH Tank setpoint temperature

TANK DIFF 2 to 10°F 5°F Installer MODBUS TEMP/RATE EMS TEMP/RATE PIM™ Identity is WH

Tank differential temperature

BOIL PURGE



SYS PURGE

OFF, 0:20 to 20:00 min 0:20 min Advanced MODBUS TEMP/RATE PIM™ DIP = Purge On







BAUD RATE

2400 <> 9600 <> 19K2 <> 57K6 <> 115K




Table I: Direct DHW Cascade Setup Menu

26

VERSA IC™ Control MenusThe user interface consists of several Menu options.

Press the MENU button to scroll through the different menus in the interface. Press the ITEM button to select aspecific menu to scroll through available items within a selected menu. The UP and DOWN buttons allow for set-ting changes to items in the SETUP menu. The available menus are VIEW, SETUP, BOILER, MONITOR andTOOLBOX. The RESET button is used to reset the control when a hard lockout condition has occurred. Seespecific heater I&O for instructions regarding resetting the control.

User Interface Menus

The following menus are available in the control by hitting the MENU button on the membrane switch and thenpushing the ITEM button to scroll through the menus. Some menus are model specific and not available on allequipment types.

27

VIEW Menu

The “VIEW” icon is turned on. BOILER and 1 segment are turned on if BOILER 2, 3 or 4 are set to ON.

Item Range Access When is it Displayed Description OUTDOOR ---, -76 to 149°F Installer MASTER

MODBUS TEMP/RATE EMS TEMP/RATE PIM™ Identity is H TARGET = RSET

Local or tN4 remote outdoor air temperature, the number field displays “----“ if the OUTDOOR sensor has a fault.

Boil TARGET ---, -22 to 266°F Installer MASTER MODBUS RATE EMS RATE

Current target water temperature, the number field displays “----“ when there is no current target.

SUPPLY ---, -22 to 266°F Installer MASTER Current system supply temperature, the number field displays “----“ if the SUPPLY sensor has a fault.

DHW SUPPLY ---, -22 to 266°F Installer MASTER MODBUS TEMP/RATE EMS TEMP/RATE PIM™ Identity is H Mode = 3

Current system DHW Supply temperature, the number field displays “----“ if the DHW sensor has a fault.

Boil OUTLET ---. -22 to 266°F Installer Always Current boiler outlet temperature as communicated from the PIM™, the number field displays “----“ if the outlet sensor fails.

Boil INLET ---, -22 to 266°F Installer Always Current boiler inlet temperature as communicated from the PIM™, the number field displays “----“ if the inlet sensor fails.

Boil T 0 to 252°F Installer Always Current temperature difference between the boiler outlet and boiler inlet, the number field displays “----“ if the inlet and/or outlet sensor fails.

INDIR DHW ---, -22 to 266°F Installer MASTER MODBUS TEMP/RATE EMS TEMP/RATE PIM™ Identity is H MODE = 2 or 3 DHW SENSOR = ON

Current temperature being supplied to the indirect, the number field displays “----“ if the indirect DHW sensor fails.

TANK DHW ---, -22 to 266°F Installer MASTER MODBUS TEMP/RATE EMS TEMP/RATE PIM™ Identity is WH

Current tank temperature, the number field displays “----“ if the tank sensor fails.

POOL ---, -22 to 266°F Installer MASTER MODBUS TEMP/RATE EMS TEMP/RATE PIM™ Identity is P

Current pool temperature, the number field displays “----“ if the pool sensor fails.

MOD RATE 1 0 to 100% Installer MASTER MODBUS RATE EMS RATE BOILER 1 = ON

Target firing rate for Boiler 1







STATUS Installer Always Shows the operational status of Boiler 1

Table J: View Menu

28

BOILER View Menu

The “BOILER 1” icon is turned on. Boiler 1, 2, 3 or 4 are displayed for their respective boilers.

Item Range Access Level When is it Displayed Description

IGNITION IDLE, PREP, IGN, BURN, POST, HARD, SOFT

Advanced Always IDLE=no CFH; PREP=pre-purge or inter-purge between trials for ignition; IGN=trial for ignition; BURN=burner operating; POST=post purge; HARD=a hard lockout fault has occurred requiring manual reset (Ignition Lockout or manual high limit); and SOFT=a soft lockout fault has occurred which interrupts the heating cycle (any safety other than ignition or manual high limit). The CFH will resume after the soft lockout fault has been corrected and a 15 min. waiting period has expired.

VENT WALL ---, 22 TO 266°F Advanced Always, model dependent Current Vent temperature LIMIT TEMP ---, 22 TO 266°F Advanced Always Current Outlet -Limit temperature AUX TEMP ---, 22 TO 266°F Advanced Aux sensor present Auxiliary temperature sensor FLOW RATE Advanced Flow meter present Flow rate in liters per min (lpm) EMS Vdc 0.0 to 10.0 Advanced Always Current EMS signal in Volts DC FIRE RATE 0 – 100% Advanced Always PIM™ firing rate SPEEDX 1000 0.0 to 20.00 Advanced PIM™ Identity Modulating Blower speed in revolutions per minute (rpm) x 1000 HIGH LIMIT Model dependent Advanced Always High Limit setting H L OFFSET Model dependent Advanced Always High Limit offset for max setpoint OPERATOR 70 to 210°F Advanced Always Operator Limit Potentiometer setting AUTO DIFF 2 to 42°F Advanced PIM™ Differential DIP set to Auto Current auto differential PUMP PREP 5 sec Advanced Always Duration of Pump Prepurge BLOW PREP Model dependent Advanced Always Duration of Blower Prepurge BLOW PREP Model dependent Advanced PIM™ Identity Modulating Blower % during Prepurge BLOW POST Model dependent Advanced Always Duration of Blower Postpurge BLOW POST Model dependent Advanced PIM™ Identity Modulating Blower % during Postpurge MIN RATE 0 – 50% Advanced PIM™ Identity Modulating Minimum modulation rate (%) during operation START RATE 0 – 50% Advanced PIM™ Identity Modulating Start modulation rate (%) during ignition MAX RATE 100% Advanced PIM™ Identity Modulating Maximum modulation rate (%) during operation FLAME CUR 0 - 25 Advanced Always Flame current in micro-amps ( A) MASS LO, Always IDENTITY H, WH, P Always Identifies the unit as boiler, water heater or pool heater IGN TYPE 1STG, 2STG, MOD Advanced Always PIM™ Board type ID CARD 0 – 255 Advanced Always Identifies Raypak Identity Card PIM™ ID 0 – 255 Advanced Always Identifies Raypak PIM™ PCB SW ID 0 - 65535 Advanced Always PIM™ Software identification number

Table K: BOILER View Menu

29

MONITOR Menu

The “MONITOR” icon is turned on.

Item Range Access Level When is it Displayed Description RUN TIME Burner

0 to 9999 hr Installer Always Burner runtime (hours). Press UP & DOWN buttons for 3 sec to clear

CYCLES Burner

0 to 9999 Installer Always Number of boiler cycles. Press UP & DOWN buttons for 3 sec to clear

RUN TIME Pumps – Boiler

0 to 9999 hr Installer Always Boiler pump runtime (hours). Press UP & DOWN buttons for 3 sec to clear

RUN TIME PUMPS – System

0 to 9999 hr Installer Always System pump runtime (hours). Press UP & DOWN buttons for 3 sec to clear

RUN TIME PUMPS – DHW

0 to 9999 hr Installer MODBUS TEMP/RATE EMS TEMP/RATE PIM™ Identity is H MODE = 2 or 3

DHW pump runtime (hours). Press UP & DOWN buttons for 3 sec to clear

OUTLET HI -22to 266°F Installer Always Captures the highest Boiler Outlet Temperature recorded. Press UP & DOWN buttons for 3 sec to clear

OUTLET LO -22to 266°F Installer Always Captures the lowest Boiler Outlet Temperature recorded. Press UP & DOWN buttons for 3 sec to clear

INLET HI -22to 266°F Installer Always Captures the highest Boiler Inlet Temperature recorded. Press UP & DOWN buttons for 3 sec to clear

INLET LO -22to 266°F Installer Always Captures the lowest Boiler Inlet Temperature recorded. Press UP & DOWN buttons for 3 sec to clear

DELTA HI -22to 266°F Installer Always Captures the highest Delta T Temperature recorded. Press UP & DOWN buttons for 3 sec to clear

OUTDOOR HI -76 to 149°F Installer MASTER MODBUS TEMP/RATE EMS TEMP/RATE PIM™ Identity is H TARGET = RSET

Captures the highest Outdoor Temperature recorded. Press UP & DOWN buttons for 3 sec to clear

OUTDOOR LO -76 to 149°F Installer MASTER MODBUS TEMP/RATE EMS TEMP/RATE PIM™ Identity is H TARGET = RSET

Captures the lowest Outdoor Temperature recorded. Press UP & DOWN buttons for 3 sec to clear

SYS HI -22to 266°F Installer MASTER MODBUS RATE EMS RATE PIM™ Identity is H or P

Captures the highest System Supply Temperature recorded. Press UP & DOWN buttons for 3 sec to clear

SYS LO -22to 266°F Installer MASTER MODBUS RATE EMS RATE PIM™ Identity is H or P

Captures the lowest System Supply Temperature recorded. Press UP & DOWN buttons for 3 sec to clear

DHW HI -22to 266°F Installer MASTER MODBUS TEMP/RATE EMS TEMP/RATE PIM™ Identity is H MODE = 2 or 3 DHW SENS = ON

Captures the highest indirect DHW Temperature recorded. Press UP & DOWN buttons for 3 sec to clear

DHW LO -22to 266°F Installer MASTER MODBUS TEMP/RATE EMS TEMP/RATE PIM™ Identity is H MODE = 2 or 3 DHW SENS = ON

Captures the lowest indirect DHW Temperature recorded. Press UP & DOWN buttons for 3 sec to clear

TANK HI -22to 266°F Installer MASTER MODBUS TEMP/RATE EMS TEMP/RATE PIM™ Identity is WH

Captures the highest Tank Temperature recorded. Press UP & DOWN buttons for 3 sec to clear

TANK LO -22to 266°F Installer MASTER MODBUS TEMP/RATE EMS TEMP/RATE PIM™ Identity is WH

Captures the lowest Tank Temperature recorded. Press UP & DOWN buttons for 3 sec to clear

POOL HI -22to 266°F Installer MASTER MODBUS TEMP/RATE EMS TEMP/RATE PIM™ Identity is P

Captures the highest Pool Temperature recorded. Press UP & DOWN buttons for 3 sec to clear

POOL LO -22to 266°F Installer MASTER MODBUS TEMP/RATE EMS TEMP/RATE PIM™ Identity is P

Captures the lowest Pool Temperature recorded. Press UP & DOWN buttons for 3 sec to clear

Table L: MONITOR Menu

30

TOOLBOX Menu

The “TOOLBOX” icon is turned on.

Item Range Default Access Level

When is it Displayed

Description

Lookup Active Error Installer Active Error Present

Lookup and display the active error information

USER TEST OFF <> ON OFF Advanced Advanced Select ON to start the function, setting returns to OFF after running the test.

MAX HEAT OFF <> ON OFF Advanced Advanced Select ON to start the function, the setting will time out to OFF after 24 hrs or can be set to OFF again by the user

P/N 104901 (JXX <> XXA)

Installer Always Software number of VERSA IC™ Control. The number field alternate Jxx <> xxA when the item is entered

DEFAULTS ---- Advanced Always Press UP & DOWN for 3 seconds to show CLR and load factory defaults to all settings

tN4 DEVICE 1 to 24 Advanced Always Show the number of devices on the boiler bus

HISTORY-1 <-> Advanced Logged error present

Alternate “HISTORY 1” with lookup and display the most recent error information if less than 24 days old. Press UP & DOWN buttons for 3 sec to clear



















HISTORY-11<-> Advanced Logged error present










Table M: TOOLBOX Menu

31

Control Settings

Boiler System (BOILER 1,2,3,4)

These settings inform the control how many units arepart of a cascaded system. Each heater in the cas-cade must have this setting adjusted to “ON” to berecognized. In addition, dip switch #2 on the MASTERheater VERSA Control Board should be set to “ON”(Master) while the same dip switch for the remainingheaters should be set to “OFF” (Follower/Slave).Connections between the additional heaters must bemade between the respective heater PIM™ and theMaster heater VERSA Control Board (see WiringConnections on pages 39-41 for details).

Target Configuration (TARGET)

This setting is used to define if the control will operatebased on Outdoor Air Reset (RSET), setpoint control(SETP), or an Energy Management System throughthe ModBus communication protocol (MODB). Thedefault setting is SETP.

Differential Settings

A heat source must be operated with a differential inorder to prevent short cycling. The heater differential isdivided around the heater target temperature.

1. Target Differential (TARGET DIFF)Target Differential is split equally above and belowthe target set point (SETPOINT). For example, inthe case of a 180°F set point with a 10°F differen-tial, the control will energize the boiler when thecontrolled temperature drops to 175°F and thenwill shut the boiler off at 185°F. The TargetDifferential defaults to 10°F with a range of 2°F to42°F. This value is only available to set/changewhen the PIM™ identity is “H” and the PIM™ dipswitch #1 (Operator Differential) is set to ON(Manual Differential).

2. Tank Differential (TANK DIFF)Tank Differential is subtractive to the set point. Forexample, in the case of a TANK SETP set point of130°F with a 6°F differential, the control will ener-

gize the heater when the tank temperature dropsto 124°F and then will shut the heater off at 130°F.The Tank Differential defaults to 5°F with a rangeof 2°F to 10°F. This value is only available toset/change when the PIM™ identity is “WH”.

3. Pool Differential (POOL DIFF)Pool Differential is subtractive to the set point. Forexample, in the case of a POOL SETP set point of80°F with a 2°F differential, the control will ener-gize the heater when the pool temperature dropsto 78°F and then will shut the heater off at 80°F.The Pool Differential defaults to 2°F with a rangeof 1°F to 5°F. This value is only available toset/change when the PIM™ identity is “P”.

4. Indirect Differential (IND DIFF)Indirect Differential is the differential for the indi-rect DHW tank temperature. It is subtractive to theset point. For example, in the case of an INDSETP set point of 130°F with a 6°F differential, thecontrol will energize the heater when the tank tem-perature drops to 124°F and then will shut theheater off at 130°F. The Indirect Differentialdefaults to 6°F with a range of 2°F to 10°F. Thisvalue is only available to set/change when thePIM™ identity is “H” and MODE = 2 or 3 and DHWSENS = ON.

Heater Mass (BOIL MASS)

The heater mass setting (1, 2 or 3) allows the installerto adjust the VERSA IC™ Control to the thermal massof the system. The heater mass setting automaticallydetermines the minimum “on time” and minimum “offtime” of the heater, and the PID modulation parame-ters. A higher thermal mass setting provides slowermodulation, while a lower thermal mass providesfaster modulation.

NOTE: During service or if it is determined that aheater should NOT be operational, this value can beset to OFF to disable a heater so the system will notuse it or calculate it in the system operation.

NOTE: Always start with a heater mass setting of 1.If the Control responds too rapidly, look to increasethe BOIL MASS setting.

Heater Mass Definitions

Mass = 1 Low Volume, High Recovery

Mass = 2 Medium Volume, Medium Recovery

Mass = 3 High Volume, Low Recovery

32

Boiler Pump Purge (BOIL PURGE)

The VERSA IC™ Control continues to operate theboiler pump after the burner shuts down for the timeselected. When BOIL PURGE is set to OFF, there isno boiler pump post purge. The default timing is 20sec, but can be adjusted from 20 sec to 10 minutes.

System Pump Purge (SYS PURGE)

The VERSA IC™ Control continues to operate the sys-tem pump after the system is shut down, either byremoving the enable closure or by warm weather shutdown (when used). When SYS PURGE is set to OFF,there is no system pump post purge. The default tim-ing is 20 sec, but can be adjusted from 20 sec to 20minutes.

Tank Setpoint (TANK SETP)

This is the set point temperature for the storage tank.It is only available to set/change when the PIM™ iden-tity is “WH”. A range of 50°F to 150°F or 160°F (modeldependent) is available with a default of 125°F. Fortemperatures in excess of this range, use an H modelboiler configured in Mode 1 for process application.

Pool Setpoint (POOL SETP)

This is the set point temperature for the pool. Thisvalue is only available to set/change when the PIM™identity is “P”. A range of 50°F to 104°F is availablewith a default of 80°F.

Pool Maximum Supply(SUPPLY MAX)

This is the maximum supply temperature to the pool.This value is only available to set/change when thePIM™ identity is “P”. The heater will shut down if thetemperature exceeds this maximum value. The rangeof adjustment is 100°F to 110°F.

Mode Selection (MODE)

This MODE selection determines the operational char-acteristics of the system. MODE = 1 relates tohydronic heating or process heating applications.Mode = 2 relates to conventional heating with an indi-rect heating need located in the system loop piping.Mode = 3 relates to conventional heating with an indi-rect heating needs located within the boiler looppiping. Refer to the Application diagrams and descrip-tions on pages 10-25 for more details of how yourspecific system should be configured.

Setpoint Temperature (SETPOINT)

This is the target setpoint heater temperature when acall-for-heat is present while operating in setpointoperation. This value is only available to set/changewhen the PIM™ identity is “H” and the TARGET =SETP. The range of adjustments is from 50°F to themaximum value programmed into the PIM™. Thedefault value is 180°F.

Maximum Target Boiler Temperature(TARGET MAX)

This is the maximum target temperature that the boil-er can be set to. This value is only available toset/change when the PIM™ identity is “H”. The rangeof adjustments is from 100°F to the PIM™ value.Refer to the specific product I&O Manual for this infor-mation.

Minimum Target Boiler Temperature(TARGET MIN)

This is the minimum target temperature that the boilercan be set to. This value is only available toset/change when the PIM™ identity is “H”. The rangeof adjustments is from 50°F to 180°F.

Indirect Sensor Selection(IND SENSOR)

This setting determines whether a DHW sensor or anaquastat will control the indirect DHW tank tempera-ture for pool heating. This value is only available forset/change when the PIM™ identity is “H”, the MODE= 2 or 3 and the DHW SENSOR = OFF. The settingcan be “ON” or “OFF”. The default value is “OFF.”Contact closure is required for operation across theIND Override at the PIM™ J1 terminal block at termi-nals 8 and 10 when using the IND Sensor option.

CAUTION: When using the IND Sensor it is recom-mended that the operator setpoint dial on the PIM beset for 140°F max or an aquastat be installed on thedischarge pipe of the indirect tank to act as a sec-ondary limit during stand alone operation to preventan over-temperature condition from occurring.

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Target Indirect DHW Temperature(IND SETP)

This is the target indirect DHW water temperature set-ting when a DHW sensor is selected. This value isonly available for set/change when the PIM™ identityis “H”, the MODE = 2 or 3 and the DHW SENSOR =ON. The range of settings is 50°F to 180°F. Thedefault value is 140°F.

Target Boiler Temperature for DHWHeat Exchanger (IND SUPPLY)

This is the target boiler temperature for the DHW heatexchanger during indirect DHW operation. This valueis only available to set/change when the PIM™ identi-ty is “H”, the MODE = 2 or 3 and the DHW SENSOR =OFF. The range of settings is 70°F to PIM™ value.The default value is 180°F. This setting is only avail-able when using an aquastat in the indirect tank in lieuof a 10k Ohm sensor. When using a sensor this settingis defaulted to the Target Max setting.

Selection of Indirect Priority(IND PRIORITY)

This selects whether or not indirect DHW priority isactive during indirect DHW operation. This value isonly available to set/change when the PIM™ identity is“H”, the MODE = 2. The setting can be “ON” or “OFF”.The default value is “OFF”. Mode 3 requires priorityfunctionality due to the piping configuration.

Priority Override Time (PRI OVR)

This selects the length of time for the priority override.This value is only available for set/change when thePIM™ identity is “H” and the tN4 bus is detected ORDHW PRIORITY = ON. The settings can be “Au” orfrom 10 sec to 2.0 hours. The default value is“1:00 hr”. This will maintain the priority override untilthe call-for-heat in this system is satisfied. When in setpoint “Au” is not selectable.

Temperature Units of Measure(°F or °C)

This selects the units of measure to show on the dis-play. The choices are degrees Fahrenheit (°F) anddegrees Celsius (°C). The default is degreesFahrenheit (°F).

Modbus Operating Mode Selection(MODBUS)

This allows the system integrator to select the Modbusoperating mode. The choices are “OFF”, monitor(MNTR), temperature control (TEMP) and rate control(RATE). The default setting is “OFF”.

Modbus Component Address(ADDRESS)

This assigns a slave address to components on theModbus communication network. The range of adjust-ments is 1 to 247. The default value is 1.

Modbus Data Type (DATA TYPE)

This assigns the Modbus data type. The optionsinclude “RTU” and “ASCI”. The default is “RTU”.

Modbus Communication Baud Rate(BAUD RATE)

This assigns the communication speed for the Modbuscommunication network. The choices include: 2400,9600, 19K2, 57K6 and 115K. The default value is19K2.

Modbus Parity (PARITY)

The choices are “NONE”, “EVEN” and “ODD”. Thedefault is “EVEN”. 1 stop bit is used for “EVEN” or“ODD”. 2 stop bits are used for “NONE”

Tank Operation - UnoccupiedPeriods (TANK UNOCC)

This value determines whether a tank call-for-heat willbe addressed during unoccupied or sleep periods.This value is only available to set/change when thePIM™ identity is “WH” and the network is operatingunder tN4 Schedule #1. The choices are “ON” or“OFF”. The default value is “ON” meaning that a tankCFH will be honored at anytime.

Pool Operation - Unoccupied Periods(POOL UNOCC)

This value determines whether a pool call-for-heat willbe addressed during unoccupied or sleep periods.This value is only available to set/change when thePIM™ identity is “P” and the network is operatingunder tN4 Schedule #1. The choices are “ON” or“OFF”. The default value is “ON” meaning that a poolCFH will be honored at any time.

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Indirect Operation - Unoccupied Periods (IND UNOCC)

This value determines whether a DHW call-for-heatwill be addressed during unoccupied or sleep periods.This value is only available to set/change when thePIM™ identity is “H”, the mode = 2 or 3 and the net-work is operating under tN4 Schedule #1. The choicesare “ON” or “OFF”. The default value is “ON” meaningthat a DHW CFH will be honored at anytime.

WWSD Operation - Unoccupied Periods (WWSD UNOCC)

This value determines the WWSD temperature settingduring Master Schedule #1 Unocc/Sleep periods. Thisvalue is only available to set/change when the PIM™identity is “H” and the network is operating under tN4Schedule #1. The range of values is from 40°F to100°F. The default value is 70°F.

tN4 Schedule Selection (tN4 SCHD)

This selects if the control will follow Master Schedule#1. This value is only available to set/change whenthe PIM™ identity is “H”. The choices are “OFF” and“Mb1”. The default value is “OFF”.

tN4 Cycle Length (tN4 CYCLE)

This selects the cycle length which all tN4 devices syn-chronize to. This value is only available to set/changewhen the PIM™ identity is “H” and the tN4 bus hasbeen detected. The choices are “Au” and 5 to 30 min-

Additional Operational Features

Outdoor Reset Operation

When a building is being heated, heat escapesthrough the walls, doors, and windows to the colderoutside air. The colder the outside temperature, themore heat escapes. If you can input heat into the build-ing at the same rate that it is lost out of the building,then the building temperatures will remain constant.The Reset Ratio is an adjustment that lets you achievethis equilibrium between heat input and heat loss.

The VERSA control can change the System Set Pointbased on outdoor temperature (Outdoor Reset). TheVERSA control varies the temperature of the circulat-ing heating water in response to changes in the

outdoor temperature. The heating water temperatureis controlled through the modulation and/or sequenc-ing of the cascade.

The VERSA control can also control the system circu-lating pump with an adjustable Outdoor Cutoff(WWSD). When the outdoor temperature is above theWWSD Cutoff, the pump is turned off and no heatingwater is circulated through the system. When the out-door temperature drops below the Outdoor Cutoff, thesystem pump relay is activated and the heating watercirculates through the system. The temperature of theheating water is controlled by the Reset Ratio, WaterOffset, and changes with the outdoor temperature.

Reset Ratio/Outdoor Reset

The starting point for most systems is the 1.00(OD):1.00 (SYS) (Outdoor Temperature: HeatingWater Temperature) ratio. This means that for everydegree the outdoor temperature drops, the tempera-ture of the heating water will increase one degree.With the VERSA, both ends of the slope areadjustable. It is factory set at 70°F water temperature(Boil START) at 70°F outdoor air (OUT START), and180°F water temperature (Boil DESIGN) at 10°F out-door air (OUT DESIGN). Each building has differentheat loss characteristics. A very well insulated buildingwill not lose much heat to the outside air, and mayneed a Reset Ratio of 2.00 (OD):1.00 (SYS) (Outdoor:Water). This means the outdoor temperature wouldhave to drop 2 degrees to increase the water temper-ature 1 degree. On the other hand, a poorly insulatedbuilding may need a Reset Ratio of 1.00 (OD):2.00(SYS). This means that for each degree the outdoortemperature dropped the water temperature willincrease 2 degrees. The VERSA control Reset Ratioallows for full customization to match any buildingsheat loss characteristics.

A heating curve that relies not only on Outdoor temper-ature but also on the type of radiation will improve heatcomfort. The user can fine tune these adjustmentsbased on the specific building need.

Reset Ratio

The control uses the four following settings to deter-mine the reset ratio:

Outdoor Starting Temperature (OUT START)This is the outdoor temperature at which the controlstarts to calculate a reset when Outdoor Reset isactive. This value is only available for set/changewhen the PIM™ identity is “H” and the TARGET =

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RSET. The range of adjustment is 35°F to 85°F. Thedefault value is 70°F. See Figure 9 for Outdoor Resetcurve information.

Outdoor Design Temperature (OUT DESIGN)This is the outdoor temperature that is typically thecoldest temperature of the year where the building islocated. This temperature is used when doing heatloss calculations for the building. This value is onlyavailable for set/change when the PIM™ identity is “H”and the TARGET = RSET. The range of adjustment is-60°F to 45°F. The default value is 10°F. See Figure 9for Outdoor Reset curve information.

Boiler Design temperature (Boil DESIGN)This is the water temperature required to heat the sys-tem when the outdoor air temperature is as cold as theOUT DESIGN temperature. This value is only avail-able for set/change when the PIM™ identity is “H” andthe TARGET = RSET. The range of adjustment is 70°Fto TARGET MAX. The default value is 180°F. SeeFigure 9 for Outdoor Reset curve information.

Boiler Start Temperature (Boil START)This is the starting boiler target temperature that thesystem requires when the outdoor air temperatureequals the OUT START temperature setting. The BoilSTART is typically set to the desired building tempera-ture. This value is only available for set/change whenthe PIM™ identity is “H” and the TARGET = RSET.The range of adjustment is TARGET MIN to 150°F.The default value is 70°F. See Figure 9 for OutdoorReset curve information.

Warm Weather Shut Down (WWSD)

When the outdoor air temperature rises above theWWSD setting, the VERSA IC™ Control turns on the

WWSD segment in the display. When the Control is inWarm Weather Shut Down, the Control does not oper-ate the heating system to satisfy any heating demand– however, any water heating or indirect heating loadwill override the WWSD function until such call-for-heat is satisfied. This value is only available toset/change when the PIM™ identity is “H” and theTARGET = SETP. The range of adjustments is from40°F to 100°F or OFF. The default value is 70°F.

Reset Ratio

The VERSA control uses the following four settings asshown to calculate the Reset Ratio (RR):

For example, when using the default values, the RR is:

RR = (70 - 10) / (180 - 70) = 0.55

Pump Exercise

This feature (when enabled via dip switch #4 on thePIM™ being set to ON) will cycle the pumps for 10seconds every 72 hours, even with no heat demand, tohelp extend the life of the pumps. During this opera-tion, the word “EXERCISE” will display on the VERSAIC™ Display.

Freeze Protection

This feature (when enabled via dip switch #7 on thePIM™ being set to ON) will cycle the boiler pump on ifeither the inlet or outlet heater sensors drops below45°F. The pump will continue to operate until the tem-perature rises above 50°F at both sensors. If thetemperature continues to drop below 38°F as noted oneither sensor, the heater will enable a heating cycle tooperate at minimum firing rate to raise the water tem-perature in the boiler to avoid freezing. The heatingcycle will terminate when both the Inlet and Outlet tem-peratures rise above 42°F.

Should the heater be in a soft lockout condition, theFreeze Protection operation will over-ride all soft lock-out timers to operate – however, it will NOT override ahard lockout.

Freeze protection is functional with the VERSA IC™Control operator, but will also function in Stand-alonemode should the VERSA IC™ Control not be function-ing as long as the PIM™ dip switch #7 is enabled asnoted above.

135°F

Decreasing Outdoor Temperature

70°F -10°F

180°F

Fig. 9: Outdoor Air Reset Curve

RESET RATIO (RR) =BOILER DESIGN — BOILER START

OUTDOOR START — OUTDOOR DESIGN

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Target Differential – Auto/Manual

The VERSA IC™ control system is configured as stan-dard with an “Auto Differential” feature. This functionserves as part of how the controller attempts toachieve a minimum ON time to ensure maximum sys-tem and boiler operating efficiency. The VERSA IC™will automatically adjust the target differential duringeach cycle as needed to prevent short cycling of theburner while also trying to maintain the system supplytemperature as close to target as is possible. The usercan select via dip switch #1 on the PIM™ to disablethe auto differential function and set a fixed differential.Typically a manual differential is suggested whenoperating at elevated temperatures near the limit ofthe appliance. This is done to prevent overshooting thetemperature so as not to trip the manual reset highlimit. The manual differential is adjustable from 2°F to42°F and is split equally above and below the targettemperature.

Minimum Run Time

The VERSA IC™ Control system attempts to maintaina minimum run time of 210 seconds for each heater.This is accomplished several ways automatically bythe control system. One method is by automaticallyadjusting the differential used around the target tem-perature and another is by extending the OFF time ofthe burner to achieve longer ON times. However,should the temperature exceed the full differentialabove the target temperature, the heater will shutdown. Conversely, if the system temperature exceedsthe full differential below the target temperature, theheater will fire to achieve the set point.

Outdoor Sensor Fault Operation

If the Outdoor Sensor is open (OPN) or shorted (SHT),the alarm will signify the fault, but the boiler will contin-ue operation and set the TARGET temperature basedon an outdoor temperature of 32°F.

System Sensor Fault Operation

If the System Sensor is not functioning, the heater willalarm to signify the fault but will still operate to achievetarget based on the Outlet Sensor. The boiler pumpwill be enabled to run continuously during this fault toensure water flow is moving past the active outlet sen-sor.

Field Test

Whenever the heater is IDLE or in lockout, pressingand holding the test/reset button on the PIM™ (or the

reset button on the heater membrane switch – if pres-ent) for a period of 5 seconds shall initiate a field testmode. The PIM™ will light the amber Alarm/Test LEDindicator and sequentially turn on the pump outputs fora minimum of 10 seconds each. Pressing and holdingthe test button (or reset button) for at least one secondwill cancel the field test and the PIM™ Alarm/Test LEDshall be turned off.

User Test

This test is accessible from the TOOLBOX menu onthe VERSA IC™ Display. “USER TEST” is displayedon the first line of the display and “OFF” is shown onthe 2nd line. “USER TEST” remains on the first line ofthe display throughout this testing mode. Only the 2ndline of the display changes to show the state of opera-tion. When this functionality is enabled (push the UPbutton on the membrane switch), the system begins asystem wide test of the heater. “STRT” appears on thedisplay, then the system pump is enabled (and the dis-play shows “SYS”).

After approx. 10 seconds, the DHW pump is enabled(and the system pump disabled) and the displayshows “DHW”. After approx. 10 seconds, the boilerpump is enabled along with the system pump (the dis-play shows “PMP1”). After approx. 10 seconds, thedisplay will show “Boil 1” which initiates a CFH for thisUser Test.

If the heater is enabled to run, the heater will gothrough a normal trial for ignition and light. If ignition issuccessful, the display will show “MIN1” and theheater will operate at minimum firing rate. Pushingthe UP button on the membrane switch will hold the fir-ing rate at this level as long as desired and the displaywill flash “HOLD” at 1 second intervals during this peri-od of time.

Pressing the UP button again will step the program toramp up the firing rate to maximum input and “MAX1”will display. Pressing the UP button again will hold thisfiring rate for as long as desired and the display willflash “HOLD” at 1 second intervals during this periodof time.

NOTE: If the heater outlet temperature approachesthe PIM™ Hi-Limit value, the heater will ramp downthe firing rate to keep the temperature in a safe oper-ating range.

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Any CFH received from the system during this UserTest will be ignored until the test is completed.

Commission Test Mode

When the PIM™ dip switch #8 is turned to the ONposition, a Commission Test Mode is activated. ThePIM™ lights the amber Alarm/Test LED. This modeactivates certain functions to assist initial commissiontesting of the system. The configured high limit tem-perature is overridden to match the setpointpotentiometer position. The high limit can then beadjusted by the potentiometer to assist commissiontesting and verification. The operating setpoint is auto-matically set to 20°F above the high limit (stand alonemode), or it can be controlled by the VERSA IC™Control.

Max Heat Function

This function sets the target temperature equal toBoiler Maximum value whenever any demand is pres-ent. In addition, the DHW priority is disabled andWWSD is disabled. The Max Heat function will beaborted if 24 hours has elapsed since it was initiatedor if the user sets MAX HEAT = OFF in the TOOLBOXmenu.

Max Delta T Control

The VERSA IC™ system is capable of controlling theoperation of the heaters so that a maximum value ofDelta T is not exceeded in an attempt to protect theheaters from flashing to steam or damaging the heatexchanger due to scale which can form at high tem-peratures.

If the Maximum Delta T value is exceeded, the heaterwill shutdown (pumps will continue to operate), thealarm light will turn on and the display will show“DELTA T ERR”. Once the Delta T drops below halfthe maximum value, the alarm light will turn off and theheater will return to IDLE state until a CFH is present.

NumberField Output Action

SYS System Pump relay turns on.

DHW DHW Pump relay turns on.

PMP 1 System and Boiler Pump relays turn on.

Boil 1 Ignite Boiler Burner.

Min 1 Hold Boiler at Min Fire.

Max 1 Ramp Boiler to Max Fire and hold.

Sequence of Operation

1. Upon initial application of 24VAC power, the PIM™resets with all outputs in the “OFF” state.

2. The PIM™ and VERSA IC™ Control perform aprocessor and memory self-test to ensure properoperation.

3. The PIM™ confirms the presence of a valid IDCard which matches the configuration stored inmemory at the factory. If a valid ID Card is NOTpresent, the PIM™ generates a diagnostic faultand will shut down waiting for this fault to beaddressed.

4. The PIM™ reads the dip switch settings and con-figures itself for the desired operation.

5. The PIM™ scans the Ft_bus communications forthe VERSA IC™ Control and if found, systemoperation is controlled by the VERSA IC™Control.

6. Non-volatile memory is checked for any activelockout conditions. If any exist, they must beaddressed before the PIM™ will allow a new trialfor ignition to start.

7. The PIM™ continually monitors the flame status toensure that no flame is present during Standby. Ifan erroneous flame is detected, the PIM™ gener-ates a False Flame error fault.

8. The PIM™ verifies that the vent sensor (somemodels) is below the vent limit temperature beforeburner operation. If the vent temperature isexceeded, the PIM™ performs a Post-purge andproceeds to a hard lockout.

9. A Call-for-heat is initiated by the presence of anyone or more of the 4 sources below:a. A heat demand (contact closure) on the TH

field wiring terminalsb. A voltage greater than 0.5vdc on the analog 0-

10vdc EMS signal inputc. A heat demand present on the DHW field

wiring terminalsd. A heat demand from the VERSA IC™ control

based on the DHW sensor temperature

10. The PIM™ initiates a trial for ignition counter to theprogrammed number of trials for ignition (1 or mul-tiple) and proceeds to Pump Purge mode.

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11. The VERSA IC™ Control will turn on the system,boiler and/or DHW pump as necessary to addressthe call-for-heat. This is dependent on the Modeof operation selected. The pumps will proceedthrough their purge period before the control willmove into a Trial for Ignition (TFI).

12. The VERSA Control Board and PIM™ check thesafety circuit and will stop from going into a trial forignition if any of the safety devices is in anerror/fault condition.

13. If no fault condition is found, the air pressureswitch (if equipped) is verified to be in the openposition before the blower is energized.

14. The blower(s) are energized and set to pre-purgespeed (if modulating).

15. The air pressure switch is verified to close within60 seconds to prove air flow.

16. Once the air pressure switch closes (or the blowerspeed is acknowledged as operating at the pre-purge speed by the tachometer output), the blowerproceeds to pre-purge for the specified duration.

17. The voltage level of the 24VAC supply input isconfirmed to be above 18.0VAC – if not, a LowVoltage fault will be recorded and the heater willgo into a soft lockout condition until the voltagerises above 18.0VAC consistently.

18. If all checks have passed, the system proceeds toignition.

19. The PIM™ re-initializes the ignition counter to theconfigured number of trials (typically 1 or 3).

20. The Hi Limit sensor is confirmed to read below theHi Limit setpoint.

21. The blower light-off RPM speed (modulating blow-ers only) is verified.

22. The gas valve relay contacts are verified open – ifclosed, a fault code will be issued and the heaterwill post-purge and go into a hard lockout condi-tion.

23. On heaters equipped with a Hot Surface Igniter: a. The control turns on the HSI and the HSI prov-

ing current is verified to be above theconfigured value.

b. The configured heat-up delay takes place toallow the HSI element to reach ignition tem-perature.

c. The gas valve output is energized for the trial-for-ignition time to light the burner.

d. The HSI is de-energized during the last sec-ond of the trial-for-ignition period to sense forthe burner flame.

e. The flame sense is checked for successfullighting of the burner. If a valid flame is detect-ed, the main gas valve, operating pumps andblower relay remain energized and the PIM™proceeds to the Heating mode.

24. On heaters equipped with a Direct Spark Igniter:a. The DSI igniter (high voltage spark output) is

energized.b. The gas valve output is energized for the trial-

for-ignition time to light the burner.c. The flame sense is checked for successful

lighting of the burner. If a valid flame is detect-ed, the sparking is terminated, the main gasvalve, operating pumps and blower relayremain energized and the PIM™ proceeds tothe Heating mode.

25. If flame is not detected during the trial-for-ignitionperiod, the gas valve output is disabled immedi-ately and the blower goes to a post-purge.

26. On single trial-for-ignition models, the PIM™enters ignition lockout and the LED on the PIM™indicates the fault code for ignition lockout. TheVERSA IC™ Display should also state IgnitionLockout.

27. On multi-trial-for-ignition models, the control goesthrough an interpurge delay before additional igni-tion attempts are started. If no flame is detectedafter the final trial-for-ignition, the PIM™ entersignition lockout and the LED on the PIM™ indi-cates the fault code for ignition lockout. TheVERSA IC™ Display should also state IgnitionLockout.

NOTE: On CSD-1 controls, recovery from ignitionlockout requires a manual reset by either pushingthe RESET button on the membrane switch (if theheater is so equipped) or pushing the reset button onthe PIM (located next to the LEDs) on lockout con-trols. Recovery from ignition lockout on auto resetcontrols can be accomplished by recycling the call-for-heat, removing 24VAC (turning the power off tothe heater) from the PIM for a minimum of 5 secondsor the control will automatically reset and start a newheating cycle if the call-for-heat is still active and theconfigured reset time has elapsed.

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28. During heating the flame status, air pressureswitch, LWCO, water pressure switch and othersafety switches are continually monitored for prop-er state.

29. The boiler operating temperature is monitoredagainst the target temperature to determine theproper firing rate or staging level.

30. The PIM™ remains in heating mode until the stag-ing reaches 0% or the firing rate drops below theconfigured minimum value for the heater.

31. When the call-for-heat is satisfied the gasvalves(s) are immediately disabled and a blowerpost-purge is completed and the controls proceedto IDLE mode.

32. The pumps complete a purge period as set in theADJUST menu.

33. Should a loss of flame occur on Direct SparkIgnition models during a heating cycle, the controlwill energize the high voltage spark igniter within0.8 seconds for the configured trial-for-ignitionperiod in an effort to relight the burner (multi-trymodels allow 3 tries for ignition with inter-purges).If the burner relights, normal operation is resumed.If the burner does not relight, the gas valve is de-energized immediately and the control will go intoignition lockout.

34. Should a loss of flame occur on Hot SurfaceIgnition models during a heating cycle, the gasvalve is de-energized within 0.8 seconds and theblower goes through a post-purge. After the flamerecycle delay, the control attempts to relight theburner (multi-try models allow 3 tries for ignitionwith inter-purges). If the burner relights, normaloperation is resumed. If the burner does notrelight, the gas valve is de-energized immediatelyand the control will go into ignition lockout.

Fig. 10: PIM™ Connections – DSI Control

Wiring Connections -PIM™

The following information relates to the wiring connec-tions on the PIM™, VERSA IC™ Control and VERSAIC™ Display boards. Refer to each product specificI&O manual for specific connections for specific mod-els.

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Connector Pin # Function Type & Rating J1 1 Alarm

Contacts 0-30VAC, 2.0A Max – Dry contact

J1 2 Alarm Contacts

0-30VAC, 2.0A Max – Dry contact

J1 3 N/A 0-30VAC, 2.0A Max

J1 4 24VAC Out (R)

18-30VAC, 2.0A Max

J1 5 Remote Reset

0-30VAC, 2.0A Max

J1 6 N/A 0-30VAC, 2.0A Max

J1 7 24VAC Out (R)

18-30VAC, 2.0A Max

J1 8 DHW Call (DHW)

0-30VAC, 2.0A Max

J1 9 Heat Call (TH)

0-30VAC, 2.0A Max

J1 10 24VAC Out (R)

18-30VAC, 2.0A Max

J2 1 DHW Sensor

10K Thermister – J Curve

J2 2 DHW Sensor Common


Connector Pin # Function Type & Rating J2 3 System

Supply Sensor


J2 4 System Sensor Common


J2 5 Outdoor Sensor


J2 6 Outdoor Sensor Common


J2 7 tN4 Communications

Communications Network Signal

J2 8 0-10VDC Analog EMS Input

0-10 VDC or 4-20mA

J2 9 Common Ground

J3 1 Ft_bus B 22AWG Twisted Pair

J3 2 Ft_bus A 22AWG Twisted Pair

J4 1 PIM™ to VERSA IC™ Control

RJ45

PIM™ Low-Voltage Field Wiring Connections (30VAC Max)

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PIM™ Factory Low-Voltage Wiring Connections

Connector Pin # Function Type & Rating

J5 1 Ft_bus B (PIM™ to PIM™)

20-30AWG, 2.0A

J5 2 Ft_bus A (PIM™ to PIM™)

20-30AWG, 2.0A

J6 1 ID Card 20-30AWG, 2.0A



J7 1 Hi-Limit Sensor 10K Thermister – J Curve

J7 2 Hi-Limit Sensor Common


J7 3 Outlet Sensor Common


J7 4 Outlet Sensor 10K Thermister – J Curve

J8 1 NOT USED J8 2 Air Pressure

Switch (model specific)

20-30AWG, 2.0A

J8 3 NOT USED J8 4 Air Pressure

Switch (model specific) Return

20-30AWG, 2.0A

J8 5 Safety loop 20-30AWG, 2.0A

J8 6 Safety loop 20-30AWG, 2.0A

J9 1 Inlet Sensor 10K Thermister – J Curve

J9 2 Vent Sensor 10K Thermister – J Curve

J9 3 Inlet Sensor Common


J9 4 Vent Sensor Common


J10 1 FUTURE J10 2 PWM Out

(Modulation %) 20-30AWG, 2.0A

J10 3 FUTURE J10 4 Tachometer Input 20-30AWG,

2.0A J10 5 Fan Power

(18VDC) 20-30AWG, 2.0A

J10 6 Fan Ground 20-30AWG, 2.0A

Connector Pin # Function Type & Rating

J10 7 FUTURE J10 8 FUTURE

J11 1 24VAC Power 30VAC, 8A J11 2 24VAC Common 30VAC, 8A

J12 1 Gas Valve Common (Isolated Relay)

120/240VAC, 8A

J12 2 2nd Stage Gas Valve

120/240VAC, 5A

J12 3 Gas Valve Return 120/240VAC, 5A

J12 4 2nd Stage Gas Valve Return

120/240VAC, 5A

J12 5 Gas Valve (MV/PV)

120/240VAC, 8A

J12 6 Valve Power (Isolated Contact)

120/240VAC, 8A

J13 1 Blower Output (L1)

120/240VAC, 5A

J13 2 Blower Output (L2)

120/240VAC, 5A

J13 3 Blower Ground 120/240VAC, 8A

J13 4 L1 Supply Input 120/240VAC, 8A

K5 Relay F1 & F2 Terminals 120/240VAC, 15A

J14 1 DHW Pump 120/240VAC, 5A

J14 2 Boiler Pump 120/240VAC, 5A

J14 3 L1s – System Pump Supply

120/240VAC, 8A

J14 4 System Pump 120/240VAC, 5A

J14 5 L1 Supply Power 120/240VAC, 8A

J14 6 NOT USED J14 7 L2 (Neutral) 120/240VAC,

8A J14 8 Pumps Ground 120/240VAC,

8A

HV Spark Output (T3 Coil)

25kV

GND Burner Ground S1 Hot Surface Igniter 5.0A Max S1/FS Hot Surface Igniter 5.0A Max FS Flame Sense Rod P2 FC+ Flame Current

Measurement

P2 FC- Flame Current Measurement

42

** CAN BE MODIFIED TO ACCEPT 4-20mA CONSULT VERSA IC MANUAL

ALARM

Wiring Connections – VERSA IC™ Control

Fig. 11: VERSA IC™ Control Connections

Connector Pin # Function Field Wiring CN1 1 Aux 2 CWS/CWR (S7) CN1 2 Aux 1 S6 – IND Sensor CN1 3 Common Aux 1 & 2

Common CN1 4 Mod + CN1 5 Mod - CWS/CWR

CN1 6 RS485 Ground CN1 7 RS485-A CN1 8 RS485-B

FUTURE

CN1 9 Modbus Ground

CN1 10 ModBus-A CN1 11 ModBus-B

ModBus Communication link

CN2 1 PIM™2 Ft-Bus A

CN2 2 PIM™2 Ft-Bus B





CN2 7 Ground

Cascade Connections from Master VERSA IC™ Control to Follower/Slave PIM™s

CN3 Communication Cable to PIM™

CN4 1 External Valve

CN4 2 External Valve

Dry contact closure with call for burner

CN4 3 Fan/Damper

CN4 4 Fan/Damper


CN4 5 Extra

CN4 6 Extra


Connector Pin # Function Diagnostic Wiring

CN5 1 Condensate Switch

CN5 2 Vent Temp Limit

CN5 3 Auto High Limit CN5 4 Low Water

Cutoff

CN5 5 Blocked Vent CN5 6 Low Gas

Pressure

CN5 7 High Gas Pressure

CN5 8 Extra CN6

Communication cable to Diagnostic LEDs (model specific)

Green – Power On; Amber – Call for Heat; Blue – Burner ON; Red - Service

CN7

Communication cable to VERSA IC™ Display Board

CN8 1 Flow Switch

CN8 2 Air Press Switch

CN8 3 Factory Option #1



43

Wiring the Thermostat

Connect the Enable/Disable terminals to the PIM™(shown in Fig. 11). Alternately, any dry contact closure(including a remote thermostat) across these terminalswill enable the unit to run. Caution should be used toensure neither of the terminals becomes connected toground.

Wiring the Outdoor Sensor

1. There is no connection required if an outdoor sen-sor is not used in this installation.

2. If using an Outdoor Sensor, connect the sensorwires to the terminals marked OUTDOOR SEN-SOR (see wiring diagram). Caution should beused to ensure neither of these terminalsbecomes connected to ground.

3. Use a minimum 18 AWG wire for runs of up to 150feet.

4. Mount the outdoor sensor on an exterior surface ofthe building, preferably on the north side of thebuilding in an area that will not be affected bydirect sunlight and that will be exposed to varyingweather conditions.

Wiring the Indirect Sensor

1. There is no indirect sensor connection required ifan indirect water heater is not used in the installa-tion.

2. When the Indirect DHW call-for-heat is active, thePIM™ communicates this to the VERSA IC™Control. The VERSA IC™ Control calculates theoptimal operation and sends the firing rate andpump output requests to the PIM™ so it can acti-vate the Indirect DHW pump and Boiler pump ifneeded. If an optional Indirect DHW sensor is con-nected to J2-1 and J2-2, the PIM™ will pass thissignal to the VERSA IC™ Control. This allows theVERSA IC™ Control to optimize the Indirect DHWdemand to maintain the Indirect DHW setpoint.The Indirect DHW thermostat must be closed forproper operation when using the Indirect DHWsensor. It is recommended that a tankstat be usedas a limiting device in conjunction with a tank sen-sor and wired to the Indirect DHW connections atthe PIM. If a VERSA IC™ Control is not presentthe PIM™ shall activate the Indirect DHW pumpwhenever the Indirect DHW call is active. TheBoiler pump may also be activated based on theIndirect DHW piping configuration setting.

3. Connect the indirect tank sensor to the terminalsmarked INDIRECT DHW SENSOR (see wiringdiagram). Caution should be used to ensure nei-ther of these terminals becomes connected toground.

Energy MangementSystem Setup

Temperature or Rate Control usingan external 0–10VDC or 4-20mAcontrol signal

1. A signal from an energy management system canbe used to control either the setpoint temperatureor the firing rate of the heater.

2. To enable this remote control function, set dipswitch #5 on the PIM™ to the UP position. Dipswitch #5 Toggles between an EMS (UP) signal ora demand signal from the VERSA IC™ Control(DOWN). Using dip switch #2 on the PIM™, selectbetween Direct Drive (UP) or Target Temperature(DOWN) setpoint.

3. For use of a 4-20mA signal, dip switch #6 must bein the ON (UP) position and a 500 OHM 1/2 wattresistor wired in parallel across the input wires.

4. Connect an Energy Management system or otherauxiliary control signal to the terminals marked0-10V (+/-) on the PIM™ (see Fig. 11). Cautionshould be used to ensure that the +0-10V connec-tion does not create a short to ground.

• Temperature Control: Remote target tempera-ture can be used in both single boilerapplications as well as to provide target temper-ature to a multi-boiler cascade. Whenconfigured to allow an energy management sys-tem to provide a target temperature input to theVERSA IC™ Control, the control requires both acontact closure across the enable/disable con-nection as well as a DC voltage input to allowthe boiler to fire. The minimum voltage requiredto operate the burner is 1.0vdc and equates to atarget temperature equal to the TARGET MINsetting in the SETUP menu of the VERSA IC™Control. An input voltage of 10vdc equates to atarget temperature equal to the TARGET MAXsetting in the SETUP menu. The VERSA IC™Control will determine the firing rate required toachieve the designated target temperature pro-vided from the EMS.

44

• Rate Control: Firing rate control will not workwith a multi-boiler cascade arrangement.Multi-boiler systems require each boiler to bedriven individually when wanting to provide firingrate control from an EMS or multi-boilersequencer such as our RaypakTempTrackerMOD+ Hybrid. When configured toallow an energy management system to providea burner firing rate input to the VERSA IC™Control, the control requires both a contact clo-sure at the enable/disable connection as well asa DC voltage input to allow the boiler to fire. Theminimum voltage required to fire the burner is1.0vdc which also equates to low fire. A voltageof 10vdc equates to a call for full fire. To turn offthe burner the EMS will need to open the contactacross the enable/disable. Reducing the voltageinput signal below .88vdc will also shut off theactive burner call. When operating in responseto a firing rate input from an EMS the VERSAIC™ Control does not provide temperature con-trol of the system, however will still provide MaxDelta T functionality as well as Manual HighLimit operation. The EMS system is now fullyresponsible for supply water temperature controlas well as managing minimum cycle times toprevent short cycling of the equipment.

Cascade Set-up and Operation

The VERSA IC™ system has the capability of control-ling the operation of up to 4 heaters without theaddition of any external sequencing controller. In orderto establish a cascade system, the first heater needsto have the VERSA IC™ Control dip switch #2 set tothe ON position to be recognized as the Master heaterin the system. The remaining heaters need to havetheir VERSA IC™ Control dip switch #2 set to the OFFposition to be recognized as Followers/Slaves on thesystem. In addition, communication wire needs to runfrom the J3 connections on each heater PIM™ (mini-mum 22AWG twisted pair wire) to the CN2 terminalson the VERSA IC™ Control on the Master heater.Once the field wiring is installed as per the instructionsbelow it is important to remember to enable each ofthe Follower boilers within the SETUP menu on theMaster boiler. Once enabled within the VERSA IC™control system it is now possible to view the individualboiler data at the Master boiler as well as now possi-ble for the Master boiler to begin using the Followersto answer any heat requests from the system.

Wiring the Cascade SystemCommunication Bus

Designate the primary boiler as the master boiler/boil-er1 by leaving dip switch #2 on the VERSA IC™Control board in the ON position. All other VERSAIC™ Controls require dip switch #2 to be toggled OFF,designating them as followers. Follower VERSA IC™Controls are ignored by their corresponding PIM™Modules. Use standard 22 AWG wire to connect themaster VERSA IC™ Control to the PIM™ on the fol-lowers. A total of 3 followers can be connected to theVERSA IC™ Control on the master. For systemsrequiring more than 4 connected boilers, an externalsequencer such as the Raypak TempTrackerMOD+Hybrid can be used.

It is recommended that the shortest length cable pos-sible be used to reach between the boilers. Do not rununprotected cables across the floor or where they willbecome wet or damaged. Do not run communicationcables parallel with, or close to or against, high voltage(120 volt or greater) wiring. Raypak recommends thatthe total maximum length of each set of communica-tion bus cables not exceed 200 feet.

Route the Cascade Ft_bus wires out the back of thecabinets and connect as shown in Fig. 13. Connectthe Cascade Ft_bus wires to the PIM™ by pressingdown on the slots with a small screwdriver and theninserting the wires into the holes. See Fig. 12.

Fig. 12: Ft_bus Wire Connection

45

VERSAMASTER

Fig. 13: Cascade System Wiring

Cascade System Pump and Sensor Wiring

1. On the boiler designated as the Master, connectthe system pump wiring to the terminal block at therear of the unit. The output is rated for pilot dutyonly (2A maximum).

2. Connect the boiler pump wires to the terminalblock at the rear of their unit. Connect to terminals4, 5, and 6.

3. Connect the system supply sensor to terminals 3and 4 on the J2 connector located on the MasterPIM™.

4. Connect the Outdoor Sensor (if used) to terminals5 and 6 on the J2 connector located on the MasterPIM™.

5. Connect the Enable/Disable wiring to terminals 9and 10 on the J1 connector located on the MasterPIM™. This connection must be provided throughdry contacts closure.

Cascade Follower Pump and Sensor Wiring

1. Once the primary boiler has been identified, addi-tional boilers will be designated as follower boilers.Ensure dip switch #2 on each follower VERSAIC™ Control is set to the OFF/Down position.

2. For each follower boiler, connect the boiler pumpwires to the terminal block at the rear of each unit.Connect to terminals 4, 5, and 6.

3. The System and DHW pump outputs are not usedon the Cascade Follower.

Alarm Connection

An alarm bell or light may be connected to the alarmcontacts on the boiler PIM™. The Alarm Contacts are3A rated dry contacts on a normally-open relay thatcloses during fault or lockout conditions, and the max-imum voltage across the contacts is 30 VAC or30 VDC.

Connections are made at J1 pins 1 and 2 on the boil-er PIM™. In a cascade system, the alarm output of themaster boiler will be active if either the master boiler orfollower(s) have a lockout condition. The alarm outputof the follower boilers will only energize if a lockoutcondition occurs on that specific boiler.

NOTE: This dry contacts closure can come from aroom thermostat or a remote relay. No power of anykind should be applied to either of these terminals.

46

Stand-alone Operationof PIM™

The VERSA IC™ PIM™ is fully capable of stand-aloneoperation of the heater should anything happen to theVERSA IC™ Control board or the communicationsbetween the PIM™ and VERSA IC™ Control board.

The potentiometer on the PIM™ (see Figure 14) isused to control the Operating Setpoint. This is the tar-get outlet temperature used in the firing ratecalculations. The maximum target setpoint will be lim-ited to the high-limit setting less the operatorsafeguard, regardless of the potentiometer position.

The PIM™ calculates the required firing rate or stagedemand using a PID-based algorithm. This algorithmuses the heater inlet and outlet sensor inputs and thetarget setpoint from the operator potentiometer setting.The algorithm uses the boiler mass and other param-eter settings to refine the firing rate for optimal setpointcontrol. Full auto-differential capability is retainedwhen enabled using the dip switch #1 on the PIM™.

The PIM™ will respond to a DHW call signal on thefield wiring terminals. The DHW pump is activated andthe temperature is controlled to the operating setpointof the potentiometer. The boiler pump may also beactivated based on the DHW piping configuration anddip switch setting.

Limitations During PIM™Stand-alone Operation

1. Diagnostic information is limited to the alarm relayand red LED flash codes on the PIM™.

2. System Sensor operation is NOT supported.

3. DHW Sensor operation is NOT supported.

4. Outdoor Sensor and Outdoor Reset functions areNOT supported.

5. tN4 networking support is disabled.

6. Pump purge timings are controlled by parametersettings factory determined and are non-adjustable.

NOTE: The PIM reverts to Stand-alone operationmode whenever communication with the VERSAIC™ Control Board is lost for more than 30 secondsor if the VERSA IC™ Control is not found on thecommunications bus during power up.

POTENTIOMETER

Fig. 14: PIM™ Potentiometer Location

47

Troubleshooting

Before troubleshooting the system, ensure that:

• All mechanical and electrical connections aresecure and tight

• All system wiring is correct• A system ground is properly connected to the

heater (The igniter, flame sensor and ignitionmodule must share a common ground with theburner. Nuisance shutdowns are often causedby a poor or erratic ground.)

• The system is powered and the thermostat iscalling for heat

If the VERSA IC™ Display is showing an error/faultcode, troubleshoot as noted in Tables O and P.

The PIM™ is equipped with an onboard buss type fuse(T8AL250VP) to protect the 24VAC circuits and the24VAC relay outputs to the gas valves. ONLY use atype GMA fuse (8 Amp max) as a replacement forproper operation.

Fault codes are displayed on the VERSA IC™ Display.Many of these fault codes are also displayed by aflashing red LED on the PIM™ module. The numberof flashes indicates the fault – see Table N below forexplanation of the flash codes and troubleshootingrecommendations.

The PIM™ is equipped with an Alarm LED which flash-es in response to a noted error/fault. Table N belowoutlines the flash codes and recommended trou-bleshooting tasks to address each fault.

Error Mode LED Flash Code on PIM™ Recommended Troubleshooting Normal Operation Red LED OFF ID Card Fault Red LED Steady ON, Green Power

LED OFF Check that the proper ID Card is securely connected. Perform a power and system reset.

Internal Control Fault Red LED Steady ON Perform a power and system reset. If the fault remains, replace the PIM™.

Airflow Fault Red LED – 1 Flash Check blower operation and air flow switch. False Flame Error Red LED – 2 Flashes Check for proper gas valve closure. Clean burner and electrodes. Ignition Lockout Fault Red LED – 3 Flashes Check the gas supply. Check transformer. Check igniters. Check wiring.

Press reset button on PIM™/membrane switch. Recycle power. Ignition Proving Current Fault Red LED – 4 Flashes Check HSI element (for those models equipped with a hot surface

igniter). Replace as necessary. Low Voltage Fault Red LED – 5 Flashes Check the 24VAC input voltage – the voltage must be above 18.0VAC for

proper operation. Replace transformer as necessary. Vent Temperature Fault Red LED – 6 Flashes Check for a blocked flue. Check the vent sensor and wiring. Check vent

connections and vent system. If damage is observed, contact a qualified installer to have the vent system properly inspected and repaired as necessary.

Hi-Limit Fault Red LED – 7 Flashes Check for proper water flow. Check hi-limit setting and outlet sensor. Sensor Fault Red LED – 8 Flashes Check the VERSA IC™ Control for fault identification. Check sensor and

wiring. Low Gas Pressure Fault Red LED – 9 Flashes Check gas pressure. Verify proper low gas pressure switch operation and

setting. Check wiring. Water Pressure Fault Red LED – 10 Flashes Check system piping for leaks. Check water pressure switch (if

equipped) and connections. Blower Speed Fault Red LED – 11 Flashes Verify the tachometer signal and the connections at terminals J5 on the

PIM™. LWCO Fault Red LED – 12 Flashes Check the LWCO switch. Checking wiring connections. Check for

proper pump operation. Check isolation valves to ensure that they are fully open for proper operation.

Hi-Temperature Delta Fault Red LED – 13 Flashes Check pump operation. Confirm proper water flow across heat exchangers (Delta T).

Ft_bus Communications Fault Red LED – 14 Flashes Verify that the VERSA IC™ Control is connected and operating properly. Check the cable between the PIM™ and the VERSA IC™ Control.

General limit circuit fault Red LED – 15 Flashes Check the VERSA IC™ for fault indication and troubleshooting information.

Table N: LED Flash Codes on PIM™

48

Error Message Description Recommended Troubleshooting OUTLET SEN Heater outlet sensor fault Check outlet sensor

Check outlet sensor wiring LIMIT SEN High limit sensor fault Check limit sensor

Check limit sensor wiring INLET SEN Heater inlet sensor fault Check inlet sensor

Check inlet sensor wiring VENT SEN Vent sensor fault Check vent sensor

Check vent sensor wiring INTERLOCK Factory installed jumper in place if not shipped with

water pressure switch Check louver end switch & wiring Check combustion air damper end switch & wiring Check extractor & wiring

WATER PRESS Water pressure switch fault (if equipped) – Raypak factory installed jumper in place if not shipped with water pressure switch

Verify wiring at J4 terminals 6 & 7 Check heater pump Check isolation valves

AIR PRESS Air pressure switch fault (if equipped) – Raypak factory installed jumper in place if not shipped with air pressure switch

Verify wiring at J9 terminals 2 & 4 Check blower(s) Check air pressure switch tubing

GAS PRESS Gas pressure switch fault (if equipped) – Raypak factory installed jumper in place if not shipped with high pressure switch and/or low gas pressure switch

Verify wiring at J9 terminals 1 & 3 Check gas pressure switches Check gas pressure Check gas pressure switch tubing

IGNITION Ignition fault Reset ignition control – Push either RESET button on membrane switch or reset button on PIM™ or recycle power

LIMIT TRIP Boiler outlet temperature tripped the high limit

Push reset button on high limit control if Manual Reset High Limit tripped Wait for water temperature to drop and auto reset high limit will reset Check pump operation Check bypass (if equipped) for too much water flow

FLAME Flame detected without call for heat Shut off gas supply Recycle power Check gas valve leakage

ID CARD Invalid/missing ID Card Connect ID Card mounted in heater Contact the factory if “Invalid ID Card” is noted

IGN CTRL Internal PIM™ control fault Recycle power – if error continues to occur, replace PIM™ DELTA T Threshold Delta T temperature exceeded Check pump operation

Check Delta T setting Check bypass (if equipped) for too much water flow

LO HSI CUR Low HSI current at PIM™ control Check HSI current Replace HSI Replace PIM™ control

LOW 24VAC Low 24VAC power at PIM™ control Check power supply Check transformer

BLOW SPEED Blower speed (rpm) out of range Check power supply Check blower wiring to PIM™ Check blower type

SAFETY INPUT Additional factory installed safety fault – see Product I&O manual for specific information relating to this

Verify wiring at J9 – terminals 5 & 6

Table O: Error messages generated from the PIM™ but displayed on the VERSA IC™ Display

49

Error Message Timeout Description Troubleshooting CTRL SETUP 3 sec EEPROM setup block read error at power up. Factory

defaults are reloaded. Operation stops until all adjustments are checked.

Check all SETUP items

SUPPLY ERR 3 sec System supply sensor is shorted or has an open circuit. The control will cease operation.

Check supply sensor Check supply sensor wiring

DHWSUP ERR 3 sec Plant sensor is shorted or has an open circuit. The control will cease operation.

Check Aux1 sensor Check Aux 1 sensor wiring

OUTDOOR ERR 3 sec Outdoor air sensor is shorted or has an open circuit. The control will continue to operate assuming an outdoor temperature of 32°F

Check outdoor air sensor Check outdoor air sensor wiring

DHW ERR 3 sec Indirect DHW sensor is shorted or has an open circuit. The control will cease operation for indirect DHW, but will continue to operate as required for system heating.

Check DHW sensor Check DHW sensor wiring

TANK ERR 3 sec Tank sensor is shorted or has an open circuit. The control will cease operation.

Check tank sensor Check tank sensor wiring

POOL ERR 3 sec Pool sensor is shorted or has an open circuit. The control will cease operation.

Check pool sensor Check pool sensor wiring

DEV LOST 3 sec Device xx on heater bus is lost, if device is on the tN4 bus, the zone is displayed as well.

Check wiring between VERSA IC™ control board and all PIM™s on the network Check communication wiring for BMS system

DEV ERR 3 sec More than 1 master detected on tN4 bus. tN4 device at displayed address (B:xx) has an error

Check dip switches on cascaded heaters to make sure only 1 unit is set to Master while the others are set to Followers/Slave. Check communication wiring at heater with noted address

MIX MOD 3 sec A mixing module has been connected to the heater bus. Use the functionality provided for in the VERSA IC™ control board and disable the mixing module from heater control

PIM 1 ERR 3 sec Communications with PIM™1 were established but then lost.

Check cabling and dip switch settings for Master/Follower configuration.


Confirm cabling and dip switch settings.





CONDENSATE 3 sec Condensate switch has tripped Check for blockage of condensate drain Check condensate switch Check condensate switch wiring Check for heat exchanger leak which might overwhelm the capacity of the condensate drain causing this error

VENT TEMP 1 sec Vent temperature switch has tripped Check vent temperature switch Check vent temperature switch wiring Check PVC/CPVC/Polypropylene vent for any damage due to excessive temperatures Check vent for leaks near vent temperature switch

AUTO LIMIT 3 sec Automatic high limit has tripped Check the automatic high limit switch Check the automatic high limit switch wiring Check for proper pump operation Check bypass (if equipped) for too much water flow

LOW WATER 1 sec Low water cut-off has tripped Push reset button on LWCO control Check LWCO probe & wiring

VENT BLOCK 3 sec Blocked vent switch has tripped Check venting Check vent pressure switch & wiring Check vent pressure switch tubing

LOW GAS 1 sec Low gas pressure switch has tripped Push reset button on low gas pressure switch Verify proper gas pressure Open manual gas valves fully Clean out drip leg

HIGH GAS 1 sec High gas pressure switch has tripped Push reset button on high gas pressure switch Verify proper gas pressures

EXTRA 1 sec Extra limit switch has tripped – see product I&O manual for more detail if this limit is used and how to troubleshoot it.

See product specific I&O manual troubleshooting section

WATER FLOW 3 sec Water flow switch has tripped Check heater pump operation Purge air from system Replace flow switch as necessary

BLOWER 10 sec Blower air pressure switch has tripped Check air filter Check blower Check air pressure switch hose Check wiring

OPTION 1 3 sec Factory option #1 switch has tripped. This switch uses a 3 sec delay on initial CFH before reporting the fault

Check wiring diagram to determine what is connected here


Check wiring diagram to determine what is connected here


Check wiring diagram to determine what is connected here Check field interlocks such as combustion air damper proving switch

Table P: Error messages generated from the VERSA IC™ Control Board

50

Technical Data

VERSA IC™ Control Board Ratings

PIM™ Ratings

Enclosure Bare board with stand-offs

Power Supply 24 VAC +/- 10%, 60Hz

Control Load TBD

Safety/Fan/Extra Relays 240VAC, 5A

Modulating Output 0-10vdc, 3K min. load impedance / 0-20mA

Demands Connect to 24VAC return to initiate demand

Ambient Conditions Inside enclosure use ONLY; 32°F to 122°F (0°C to 60°C), <90% relative humiditynon-condensing

Input Power 18-30 VAC 50/60Hz (Class 2 transformer)

Input Current Drain 400mA @ 24VAC with gas and blower relays energized

Gas Valve Relays 5.0A max (continuous)

Combustion Blower 5.0A max for standard (J2) connection15.0A max for heavy duty (K5 relay) terminals

Hot Surface Igniter 5.0A max, 120/240VAC

Pump Relays 5.0A max (continuous)

Alarm Relay 2.0A, 30VDC or 30VAC max

Operating Temperature -40°F to +176°F (-40°C to +80°C)

Storage Temperature -40°F to +185°F (-40°C to +85°C)

Flame Sensitivity 0.7 µA minimum

Flame Failure Response orReignition Time 0.8 seconds minimum

Flame Detector Self-CheckRate Once per second minimum

Flame Failure Lockout Time Varies by model

Spark Rate Remote sense – 50/60Hz; Local sense – 25/30Hz

Moisture Resistance Conformal coated to operate non-condensing to 95% relative humidity

51

10K Sensor Resistance Values

Temperature (°F) Resistance (Ω)

32 32550

41 25340

50 19870

59 15700

68 12490

77 10000

86 8059

95 6535

104 5330

113 4372

122 3605

131 2989

140 2490

149 2084

158 1753

167 1481

176 1256

185 1070

194 915

203 786

212 667

Quick Start Set-up &Programming Tips

1. Determine the piping arrangement for your partic-ular application by referencing the Applicationdrawings and descriptions on pages 10 to 25.

2. Install System Sensor, Outdoor Sensor, IndirectSensor and DHW Sensor as necessary as depict-ed in the appropriate Application drawing.

3. Wire the sensors to the VERSA IC™ system asdescribed on the wiring diagram of the respectivemodel (see model I&O wiring diagrams). Sensorwires should be routed to the heater in separateconduit.

4. Ensure that the entire system is ready for opera-tion.

a. Water piping properly filled and purged of air?b. Gas pipe properly installed and purged?c. Electrical connections properly installed?d. For cascading systems:

i. Are communication wires properlyinstalled between Follower/Slave PIM™sand the Master VERSA IC™ Control?

ii. Are the dip switches properly set forMaster/Slave operation?

e. Vent properly installed and terminated?f. Sensor wires properly routed in separate con-

duit?g. External interlocks properly installed and

wired to VERSA IC™ Control (louver interlock,extractor, external gas valve, etc.)?

5. Turn on system electricity to allow programmingthe VERSA IC™ Control.

6. For H models go to the ADJUST menu and set theheater MODE as indicated on the Applicationdrawing – 1, 2 or 3. (Mode 1 is for stand-alone orcascade heaters with no DHW or Indirect needs;Mode 2 includes DHW or Indirect needs in the sys-tem loop; and Mode 3 includes DHW or Indirectneeds in the boiler loop). WH models do notrequire a mode selection as they are configuredonly for direct DHW operation.

7. Use the Application drawings and descriptions asa guide to set up the control.

52

Modbus CommunicationValues

The VERSA IC™ Control has a setting called Modbusthat determines how it operates when modbus is con-nected, as follows:

1. MODBUS = OFF

a. Modbus messages are ignored.

2. MODBUS = MNTR (Monitor Mode)

a. The VERSA IC™ Control operates as usual,however the modbus connection allows forremote viewing and adjustment of selectedVERSA IC™ Control parameters.

3. MODBUS = TEMP (Temperature Control Mode)

a. The VERSA IC™ Control operates as a slaveto a Modbus master control.

i. DHW and System Pumps are turned onand off according to the pump operationsent by the Modbus master control.

ii. Boiler pumps are operated as per usualby the VERSA IC™ Control.

iii. The boiler system is operated at the targettemperature sent by the Modbus mastercontrol.

1. A non-zero target temperature istaken to be a call-for-heat.

4. MODBUS = RATE (Rate Control Mode)

a. The VERSA IC™ Control operates as a slaveto a Modbus master control.

i. Operates as a single boiler only (no cas-cade)

ii. Pumps are turned on and off according tothe pump operation sent by the Modbusmaster control

8. A change to a value will be made as soon as youpush the ITEM button, change the MENU screenor wait until the 180 second timer expires.

9. Should any error be displayed, check theTroubleshooting Section to identify the source ofthe error and recommended troubleshootingideas.

Resetting PIM™ toAccept New ID Card

Should it be necessary to move a PIM™ control toanother dissimilar model heater, the PIM™ has to bereset to allow the new ID Card to unlock the appropri-ate program parameters and to load them into thePIM™ memory.

Follow these steps for a hard reset of the PIM™ toclear program parameters:

1. Remove power from the PIM™ control.

2. Set all dip switches on the PIM™ to their OFFposition.

3. Unplug the current ID Card from connector J12 onthe PIM™ control.

4. Press and hold the reset/test button (located nextto the LEDs on the right side of the PIM™ board)while powering the controller for 5 seconds.

5. The red diagnostic LED will flash indicating a suc-cessful reset. The PIM™ board’s memory is nowclear of any ID Card parameters.

6. Release the reset/test button.

7. Remove power from the PIM™ control.

8. Connect the new ID Card to connector J12 on thePIM™ control.

9. Power up the PIM™ control.

10. If the reset was successful, the green LED showssteady ON.

11. If the red and yellow LEDs are ON and the greenLED is OFF, the reset was NOT successful.

12. Repeat this procedure again.

13. If reset was successful, remove power and resetdip switches for desired operation and return theunit to operation.

WARNING: DO NOT swap a PIM from 1 heater toanother heater without resetting the PIM as outlinedbelow.

53

Register Parameter Read/Write Format Note Register AddressSystem Status Registers

MODBUS R S16 "0 = Off, 1 = Monitor, 2 = Temp, 3 = Rate"

0

System SupplyTemperature

161SR

OutdoorTemperature

261SR

361SRerutarepmeT WHD

Aux 1Temperature

461SR

Aux 2Temperature

561SR

661SRpmuP metsySSystem PumpRuntime

761SR

861SRpmuP WHDDHW PumpRuntime

961SR

Setback R S16 Only relevant if MODBUS = MNTR

10

reserved

Table R: Modbus System Status Registers

ITEM RANGE DEFAULT ACCESS LEVEL

WHEN DISPLAYED DESCRIPTION

MODBUS OFF – MNTR – TEMP – RATE


ADDRESS 1 to 247 1 Advanced MODBUS ON ModBus slave address

DATA TYPE RTU <> ASCI RTU Advanced MODBUS ON ModBus data type

BAUD RATE

2400 <> 9600 <> 19K2 <> 57K6 <> 115K 19K2 Advanced MODBUS ON

PARITY NONE - EVEN - ODD EVEN Advanced MODBUS ON Even/Odd=1 stop bit, None=2 stop bits

Table Q: Modbus Screens

iii. The boiler is operated at the target ratesent by the Modbus master control

1. A non-zero target rate is taken to be acall-for-heat

2. Target rates of 1 - 100 will translate toboiler outputs of (min mod) - (maxmod)

To enable Modbus with the VERSA IC™ Control, youmust first turn dip switch #1 on the VERSA Control

Board to the “ON” position to access the Advancedmenus. The lock icon on the upper right hand cornerof the VIEW menu will disappear when configured cor-rectly. From the VIEW menu press the MENU buttononce to reach the SETUP menu. Using the ITEM but-ton scroll to the Modbus MODE screen and selecteither MNTR, TEMP or RATE for the functionalitydesired. From there press the ITEM button to move tothe ADDRESS screen, DATA TYPE screen, BAUDRATE screen and then PARITY screen to completesetup for Modbus.

54

Register Parameter Read/Write Format Note Register AddressBoiler 1 StatusRegisters

Boiler1 detected R S16 "0 = boiler not detected, 1 = boiler detected"

16

Boiler1 On/Off R/W S16 "0 = offline, 1 =online"

1028

Boiler1 Outlet temperature

7161SR

Boiler1 Inlet temperature

8161SR

Boiler1 Vent temperature

9161SR

Boiler1 High Limit temperature

0261SR

Boiler1 Operator temperature

1261SR

Boiler1 ModRate

2261SR

Boiler1 Mix Rate R S16 not available in initial release

23

Boiler1 IgnitionStatus

4261SR

5261SRemitnuR 1relioB6261SRselcyC 1relioB7261SRpmuP 1relioB

Boiler1 PumpRuntime

8261SR

Boiler1 ErrorCode

9261SR

Boiler1 ErrorHistory 1

0361SR


1361SR


2361SR


3361SR


4361SR


5361SR


6361SR


7361SR


8361SR


9361SR


0461SR


1461SR


2461SR


3461SR


4461SR

reserved

Table S: Boiler 1 Status Registers

55


= SUBDOM.MNTR or TEMP


45


1029


6461SR


7461SR


8461SR


9461SR


0561SR

Boiler2 ModRate

1561SR


52


3561SR


Boiler2 PumpRuntime

7561SR

Boiler2 ErrorCode

8561SR


9561SR


0661SR


1661SR


2661SR


3661SR


4661SR


5661SR


6661SR


7661SR


8661SR


9661SR


0761SR


1761SR


2761SR


3761SR

reserved

Table T: Boiler 2 Status Registers

56


= SUBDOM.MNTR or TEMP


74


1030


5761SR


6761SR


7761SR


8761SR


9761SR

Boiler3 ModRate

0861SR


81


2861SR


Boiler3 PumpRuntime

6861SR

Boiler3 ErrorCode

7861SR


8861SR


9861SR


0961SR


1961SR


2961SR


3961SR


4961SR


5961SR


6961SR


7961SR


8961SR


9961SR


00161SR


10161SR


20161SR

reserved

Table U: Boiler 3 Status Registers

57


MODBUS = MNTR or TEMP


103


1031


40161SR


50161SR


60161SR


70161SR


80161SR

Boiler4 ModRate

90161SR


110


11161SR


Boiler4 PumpRuntime

51161SR

Boiler4 ErrorCode

61161SR


71161SR


81161SR


91161SR


02161SR


12161SR


22161SR


32161SR


42161SR


52161SR


62161SR


72161SR


82161SR


92161SR


03161SR


13161SR

reserved

Table V: Boiler 4 Status Registers

58

Register Parameter Read/Write Format Note Register AddressMonitor Mode Parameter Registers

MODBUS = MNTR

1161SRllaC HC2161SRllaC WHD

Target temperature R S16 degF 13

Target rate R S16 Plant target output (%)

14

Auto Diff R S16 " 0 = off, 1 = on" 15

ManualDifferential

R/W S16 5 to 50F (only relevant when auto diff is off)

1006

Monitor ModeSpace Heating

MODBUS = MNTR and Space Heating Mode

Target Mode R/W S16 " 0 = Reset, 1 = Setpoint"

1000

Setpoint Target R/W S16 70 to 200F 1001Outdoor Start R/W S16 35 to 85F 1002Outdoor Design R/W S16 -60 to 45F 1003Boil Start R/W S16 35 to 150F 1004Boil Design R/W S16 70 to 200F 1005DHW Exchange R/W S16 70 to 200F 1007DHW Tank R/W S16 70 to 190F 1008DHW Differential R/W S16 2 to 10F 1009DHW Priority R/W S16 "0 = no DHW

priority, 1 = DHW priority"

1010

DHW DuringUnOcc

R/W S16 "0 = No DHWduring UnOcc, 1= DHW duringUnOcc "

1011

WWSD DuringOcc

R/W S16 40 to 100F 1012

WWSD DuringUnOcc

R/W S16 40 to 100F 1013

Monitor ModeTank

MODBUS = MNTR and Tank Mode

Tank Setpoint R/W S16 50 to 180F 1014Tank Differential R/W S16 2 to 10F 1015Tank DuringUnOcc

R/W S16 "0 = No heating during UnOcc, 1= heating duringUnOcc"

1016

Monitor ModePool

MODBUS = MNTR and Pool Mode

Pool Setpoint R/W S16 50 to 180F 1017Pool Differential R/W S16 2 to 10F 1018Pool SupplyMax

R/W S16 100 to 140F 1019

Pool DuringUnOcc

R/W S16 "0 = No heating during UnOcc, 1= heating duringUnOcc"

1020

reserved

Table W: Modbus Monitor Modes

59

Register Parameter Read/Write Format Note Register AddressPump Control Mode Parameters

MODBUS = TEMP or RATE

120161SW/RpmuP metsyS220161SW/RpmuP WHD

Boiler Pump R/W S16 Only relevant when "MODBUS= RATE"

1023

reservedTemperature Control Mode Parameters

MODBUS = TEMP

Target temperature R/W S16 70 to 200F 1024

Auto Diff R S16 " 0 = off, 1 = on" 132

ManualDifferential

R/W S16 5 to 50F (only relevant when auto diff is off)

1025

reservedRate Control Mode Parameters

MODBUS = RATE

Target ModRate

R/W S16 0 - 100% 1026

Target Mix Rate R/W S16 0 - 100% (not available in initial release)

1027

reserved

Table X: Modbus Control Mode Parameters

Table Y: Modbus Error Table

Code Description Code Description0 No Error PIM Jumpers

VERSA Errors 26 LWCO (Jumper)1 EEPROM 27 Water Pressure (Jumper)2 Outdoor Sensor 28 Air Pressure (Jumper)3 Supply Sensor 29 Gas Pressure (Jumper)4 Plant Sensor PIM Sensors5 Mix Sensor 30 Boiler Outlet Sensor6 DHW Sensor 31 Boiler Inlet Sensor7 Tank Sensor 32 Vent Sensor8 Pool Sensor 33 High Limit Sensor9 No PIM1 PIM Ignition

10 No PIM2 34 Ignition Failure11 No PIM3 PIM Errors12 No PIM4 35 Vent Hi-Limit13 Condensate 36 Boiler Hi-Limit14 Vent Temperature 37 False Flame15 Auto Hi-Limit 38 OEM ID Card16 Low Water 39 Internal fault17 Vent Blocked 40 Delta T Max18 Low Gas Pressure 41 HSI Proof19 High Gas Pressure 42 Low Voltage20 Extra 43 Blower Speed21 Flow Switch 44 Safety Input22 Air Pressure tN4 Errors23 Option 1 45 Duplicate Master24 Option 2 46 Device Error25 Option 3 47 Device Lost

Error Codes

60

www.raypak.com Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-9725

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