Raypak Temp-Tracker Installation & Operating Instructions Manual Download Page 1

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INSTALLATION & OPERATING

INSTRUCTIONS

Catalog No. 5000.66D

Effective: 10-11-10

Replaces: 05-23-08

P/N 241177 Rev. 5

For Raytherm™ & Hi Delta™

Boilers & Water Heaters

2 & 4-Stage Temperature Controllers

Summary of Contents for Temp-Tracker

Page 1: ...INSTALLATION OPERATING INSTRUCTIONS Catalog No 5000 66D Effective 10 11 10 Replaces 05 23 08 P N 241177 Rev 5 For Raytherm Hi Delta Boilers Water Heaters 2 4 Stage Temperature Controllers ...

Page 2: ...2 Rev 5 is a completely new edition of this manual Please discard any previous revisions ...

Page 3: ...ptional 1 Well Assembly USER INTERFACE The Controller uses a Liquid Crystal Display LCD as a method of supplying information Use the LCD to setup and monitor the operation of your system The Controller uses three push buttons Item for selecting and adjusting the settings see Fig 3 As you program your Controller record your settings in the actual settings columns of the Adjust menu in tables G H fo...

Page 4: ...is powered up it turns on all seg ments in the display for two seconds Next the software version is displayed for two seconds Finally the Controller enters into the normal operating mode Display Backlight The control s display has a backlight that is perma nently on while the control is powered Fig 7 Display Fig 8 Symbol Description the View menu the View segment is displayed To select the Adjust ...

Page 5: ...oncept drawings they are not intended to describe a complete system nor any particular system Consult the factory for piping arrangements not depicted here RAYPAK TEMPERATURE CONTOLLER SYSTEM RETURN SYSTEM SUPPLY ALTERNATE SENSOR LOCATION 4 OR MORE STAGES SYSTEM SENSOR MAIN SYSTEM PUMP BY OTHERS OPTIONAL INTEGRAL PUMP BOIL OUT SENSOR BOIL IN SENSOR PUMP LOCATION ON MODELS WITHOUT INTEGRAL PUMP MAX...

Page 6: ... using Primary Secondary Piping The CFH is available to provide outdoor reset for hydronic heat ing systems The override can be used to heat an indirect domestic hot water tank Once a CFH is present the control stages the heater to maintain the calculated outdoor reset target at the heater system sensor Once an indirect DHW override is present the control stages the heater to maintain the heater t...

Page 7: ...erride is present the control stages the heater to maintain the heater target at the heater system sensor If both an external input signal and an indirect DHW override are present at the same time the control operates at the higher of the two tar gets 500 Ω GND HOT GND HOT 0 20 mA INPUT 0 20 mA INPUT 500 Ω Fig 13 500 Ω Resistor for 4 20 mA Operation NOTE To convert a 0 20 mA input signal to 0 10 V...

Page 8: ...d settings that determine when the next stage is required to turn on These manual settings are based on temperature and time The interstage differential sets the temperature drop at which the next stage turns on However in order for a stage to fire both the interstage delay on and minimum off times must first elapse Fig 17 Proportional Staging Code Descriptions Heater Differential DIFF A heat sour...

Page 9: ...Mass 2 Medium Volume Medium Recovery Mass 3 High Volume Low Recovery NOTE Always use a heater mass setting of 1 for Raypak equipment If the Controller continues to stage too rapidly contact Raypak Table A Heater Mass Definitions Interstage Differential STG DIFF The interstage differential is the temperature drop at which the next stage will turn on Once a stage turns on the next stage cannot turn ...

Page 10: ...DLY is set to OFF there is no purging When Pump DLY is set to ON the system pump runs continuously When on is selected and the control is configured for outdoor reset the system pump contin ues to run even during Warm Weather Shut Down Mode 5 Heater Minimum BOIL MIN The BOIL MIN is the lowest water temperature that the Controller is allowed to use as a heater target temper ature e g 120 ºF During ...

Page 11: ...talled in the tank and con nected to the Com and the Sys D terminals 6 and 4 A CFH for DHW is generated when the temperature at the DHW sensor drops 1 2 of the tank differential set ting below the desired DHW tank temperature The TANK TARGET setting is used to set the desired DHW tank temperature Once a CFH is generated the Dem segment turns on in the LCD The Controller then operates the heater st...

Page 12: ...the Controller is in Warm Weather Shut Down the Dem 1 segment is displayed if there is a heat demand However the Controller does not operate the heating system to satisfy this demand External Temperature Target Input When Mode 7 is selected the controller allows for an external control to operate the heater temperature through an input signal generated by a Building Management System BMS or Energy...

Page 13: ... such as the Raypak Temp Tracker Mod Hybrid When in mode 8 the indirect DHW override is disabled Direct Drive Input Signal An external heater sequencer provides a positive 0 10 VDC input signal to the controller V input terminal 10 The negative VDC signal is applied to the Com input terminal 9 The heater remains off while the direct drive input signal is between 0 0 to 0 5 VDC The Stage 1 con tact...

Page 14: ...in decals describing the various connections See Fig 25 for proper wiring Electrical Connections to the Controller The installer should test to confirm that no voltage is present at any of the wires during installation Powered Input Connections System Pump Contact The Pump terminals 13 and 14 on the controller to pins 4 and 5 on P3 are an isolated output in the con troller There is no power availa...

Page 15: ...he two wires from the sensor to the Com common sensor and the Sys D demand DHW sensor termi nals 4 and 6 TROUBLESHOOTING Field Testing the Power Supply Verify that all exposed wires and bare terminals are not in contact with other wires or grounded surfaces Turn on the power and measure the voltage between the 1 and 2 terminals on the P3 terminal block using an AC voltmeter The reading should be 1...

Page 16: ...onds Stage 2 is turned on 4 After 10 seconds Stage 3 is turned on Fig 22 Testing the Controller s Outputs Sensor Resistance Temperature F Resistance Ω 50 490 813 40 336 606 30 234 196 20 165 180 10 118 018 0 85 362 10 62 465 20 46 218 30 34 558 40 26 099 50 19 900 60 15 311 70 11 883 77 10 000 80 9 299 90 7 334 100 5 828 110 4 665 120 3 760 130 3 050 140 2 490 150 2 045 160 1 689 170 1 403 180 1 1...

Page 17: ...eturn power Pin Label Function 13 Pmp Pump Contact Not to exceed 5 amps No power output 14 Pmp Pump Contact Not to exceed 5 amps No power output 15 Stg 1 Stage 1 Odd numbered pin on the stage connection plug 16 Stg 1 Stage 1 Even numbered pin on the stage connection plug 17 Stg 2 Stage 2 Odd numbered pin on the stage connection plug 18 Stg 2 Stage 2 Even numbered pin on the stage connection plug 1...

Page 18: ...ta heaters the multi stage Temp Tracker can be ordered factory mounted The controller is already powerd by the heater the inlet and outlet sensors are installed in the inlet outlet header and the controller alarm is connected to the UDB diagnostic board The heater stage connections are also wired ...

Page 19: ...ow the default settings as well as any possible adjustment ranges 120V Fig 25 Wiring Diagram Field Installation Field Installation Field wiring must be connected to the terminal block on the back side of the controller mounting bracket Follow the wiring diagram as specified in Fig 25 below ...

Page 20: ...30 C BOILER OUTLET Current boiler outlet water temperature as measured by the boiler outlet sensor Note When MODE is set to 2 this item is only visible in the Factory access level 20to 266 F 29 to 130 C BOILER INLET Current boiler inlet water temperature as measured by the boiler inlet sensor Note This item is only available when a boiler inlet sensor is installed 0 to 252 F 0 to 140 C BOILER DELT...

Page 21: ...resent OFF 70 to 230 F 21 to 110 C BOILER TARGET 2 Select the boiler target temperature while a setpoint demand is present 120 to 235 F 49 to 113 C BOILER OUTLET MAXIMUM Select the maximum boiler outlet temperature Exceeding this temperature shuts off the burners 120 to 235 F 49 to 113 C OFF BOILER MAXIMUM Select the maximum boiler target temperature OFF 80 to 180 F 27 to 82 C BOILER MINIMUM Selec...

Page 22: ...on Note This setting is only available when STAGE MODE is set to P 0 10 to 4 00 min INTERSTAGE OFF DELAY Select the amount of time that must pass once a stage has been turned off in order to allow the next stage to turn off Note This setting is only available when STAGE MODE is set to P 0 10 to 5 00 min MINIMUM ON TIME Select the minimum amount of time that the stage contact must remain on before ...

Page 23: ...LET Current boiler inlet water temperature as measured by the boiler inlet sensor Note This item is only available when a boiler inlet sensor is installed 0 to 252 F 0 to 140 C BOILER DELTA T Currenttemperaturedifferencebetweentheboileroutlet sensor and the boiler inlet sensor Note This item is only available when a boiler inlet sensor is installed 20to 266 F 29 to 130 C TANK Currentdomestichotwat...

Page 24: ... the dedicated domestic hot water tank target temperature Au 2 to 42 F 1 to 23 C TANK DIFFERENTIAL Selectthededicateddomestichotwatertank differential The DHW sensor temperature must fall below this setting before the burners will turn on 120 to 225 F 49 to 107 C BOILER OUTLET MAXIMUM Select the maximum boiler outlet temperature Exceeding this temperature shuts off the burners 0 00 to 3 00 min 1 s...

Page 25: ...4 00 min INTERSTAGE OFF DELAY Select the amount of time that must pass once a stage has been turned off in order to allow the next stage to turn off Note This setting is only available when STAGE MODE is set to P 0 10 to 5 00 min MINIMUM ON TIME Select the minimum amount of time that the stage contact must remain on before it is allowed to turn off Note This setting is only available when STAGE MO...

Page 26: ...vailable when MODE is set to 5 20to 266 F 29 to 130 C BOILER OUTLET Current boiler outlet water temperature as measured by the boiler outlet sensor Note When MODE is set to 5 this item is only visible in the Factory access level 20to 266 F 29 to 130 C BOILER INLET Current boiler inlet water temperature as measured by the boiler inlet sensor Note This item is only available when a boiler inlet sens...

Page 27: ...ng temperature used in the reset ratio for the heating system Typically set to the desired building temperature 60 to 32 F 51 to 0 C OUTDOOR DESIGN Select the outdoor design temperature used in the reset ratio for the heating system Set to the coldest annual outdoor temperature in the local area 35 to 150 F 2 to 66 C BOILER START Select the starting water temperature used in the reset ratio calcul...

Page 28: ...tween stages Note This setting is only available when STAGE MODE is set to PId Au 2 to 42 F 1 to 23 C DIFFERENTIAL Select the boiler differential Note The automatic setting is only available when STAGE MODE is set to Pld staging 0 to 10 F 0 to 6 C STAGE DIFFERENTIAL Select the interstage temperature differential between stages for proportional staging Note This setting is only available when STAGE...

Page 29: ...the stage contact must remain off before it is allowed to turn back on Note This setting is only available when STAGE MODE is set to P OFF 0 20 to 9 55 min On PUMP DELAY Select the system pump purge time after shutting off the burner 35 to 100 F 2 to 38 C OFF WARM WEATHER SHUT DOWN Select the heating system warm weather shut down for outdoor reset operation Heat demands are ignored once the outdoo...

Page 30: ...30 C BOILER OUTLET Current boiler outlet water temperature as measured by the boiler outlet sensor Note When MODE is set to 7 this item is only visible in the Factory access level 20to 266 F 29 to 130 C BOILER INLET Current boiler inlet water temperature as measured by the boiler inlet sensor Note This item is only available when a boiler inlet sensor is installed 0 to 252 F 0 to 140 C BOILER DELT...

Page 31: ...emperature Exceeding this temperature shuts off the burners 120 to 230 F 49 to 110 C OFF BOILER MAXIMUM Select the maximum boiler target temperature OFF 80 to 180 F 27 to 82 C BOILER MINIMUM Select the minimum boiler target temperature 0 00 to 3 00 min 1 second increments FIRE DELAY Select the amount of time required for combustion pre purging ignition and the flame to be established Note This set...

Page 32: ...n STAGE MODE is set to P 0 10 to 5 00 min MINIMUM ON TIME Select the minimum amount of time that the stage contact must remain on before it is allowed to turn off Note This setting is only available when STAGE MODE is set to P 0 10 to 5 00 min MINIMUM OFF TIME Select the minimum amount of time that the stage contact must remain off before it is allowed to turn back on Note This setting is only ava...

Page 33: ...a boiler inlet sensor is installed 0 to 999 BOILER ON HOURS The total number of running hours of the boiler since this item was last cleared Clear the numbers of hours while viewing this item by pressing and holding the and buttons together Table S View Menu Mode 8 ADJUST MENU The Adjust menu items are the programmable settings used to operate the system Press and hold all three buttons for one se...

Page 34: ...sed on the boiler outlet sensor If the boiler outlet sensor is not available and the boiler inlet sensor is present and operational the control will operate using the boiler inlet sensor Otherwise the control will not operate the burner Test the boiler supply sensor and related wiring The error message will clear once the error condition is corrected and a button is pressed BOILER SUPPLY SENSOR OP...

Page 35: ...sensor for mode 5 only as positioned in the mode arrangements located on page 6 3 Wire the sensors to the Controller as described in Fig 25 on page 19 4 Ensure that entire system is ready to start a Water piping properly filled and purged b Gas pipe properly installed and purged c Electrical connections properly installed in conduit d Vent properly installed and terminated e Sensor wires properly ...

Page 36: ...36 www raypak com Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 Fax 805 278 9725 Litho in U S A ...

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