Raypak TempTracker mod+ Hybrid Installation And Operation Instructions Manual

Raypak TempTracker mod+ Hybrid Installation And Operation Instructions Manual

Condensing and non-condensing hybrid control
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InstallatIon and operatIon InstructIons
condensInG and non-condensInG HYBrId control
now with optional
Bacnet Ms/tp
E
K
G
M
I
O
Comm
HYBRID
ENCLOSED
ENERGY
MANAGEMENT
EQUIPMENT
99RA
PWR
E
K
F
L
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M
H
N
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O
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L N
1 2
3 4
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11 12
11 12
the temptracker mod+ Hybrid is strictly an operating control. It cannot be used as a limit control. all
boilers must have all safety and limit controls required by code. It is the responsibility of the installer to verify
that all the safety and limits are working properly before the temptracker mod+ Hybrid is installed.
this control must be installed by a licensed electrician.
Cat.# 5000.69
04/15/11
F
L
OUTPUT RATINGS:
120VAC, 6A RESISTIVE
1A PILOT DUTY, 15A TOTAL
H
N
FOR ALL CIRCUITS
INPUT RATINGS:
J
P
115VAC 60Hz, 12VA MAX
Use Copper Conductors Only.
Power
CAUTION:
Risk of Electric Shock.
More than one disconnect switch may be required
to de-energize the equipment before servicing.
Ext A
Ext B
K
L
M
N
O
P
E
F
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H
I
J
CUR / VLT
CUR / VLT
CUR / VLT
CUR / VLT
CUR / VLT
CUR / VLT
GND
mA
VLT
GND
GND
mA
VLT
GND
GND
mA
VLT
GND
GND
mA
VLT
GND
mA
VLT
GND
GND
mA
VLT
13
14
15
16
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28
OUTPUT RATINGS:
120VAC, 6A RESISTIVE
1A PILOT DUTY, 15A TOTAL
FOR ALL CIRCUITS
INPUT RATINGS:
115VAC 60Hz , 30VA MAX
USE COPPER WIRE,
CLASS 1 WIRE ONLY.
ENCLOSED
ENERGY
CAUTION
: RISK OF ELECTRIC SHOCK
MANAGEMENT
More than one disconnect switch may be required
EQUIPMENT
99RA
to de-energize the equipment before servicing.
EXTENSION
MODULE
RS-485
WarnInG
HYBRID
SYSTEM
A
B
C
D
DO NOT APPLY ANY VOLTAGE
PROGRAM
RUN
TO INPUT TERMINALS
P/N 241382 REV.3

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Summary of Contents for Raypak TempTracker mod+ Hybrid

  • Page 1 11 12 WarnInG the temptracker mod+ Hybrid is strictly an operating control. It cannot be used as a limit control. all boilers must have all safety and limit controls required by code. It is the responsibility of the installer to verify that all the safety and limits are working properly before the temptracker mod+ Hybrid is installed.
  • Page 2: Table Of Contents

    HYBrId operating Menu ....28 temptracker mod+ Hybrid layout ... 6 Modulating and staging operating Menu .
  • Page 3: Hybrid Logic Overview

    When Hybrid is selected as the Boiler Type, the TempTracker mod+ Hybrid will operate each group based on the Target temperature switching set point.
  • Page 4: Modulating Logic Overview

    Hybrid will start calculating the Reaction Period. If after a full Reaction Time the control logic foresees the need for additional stages, the TempTracker mod+ Hybrid will energize the following stage. If that stage was another boiler, that boiler has to go through a full Purge Delay before starting to calculate the Reaction Time for that stage.
  • Page 5: Outdoor Reset Concept

    -20 Offset (OD):2.00 (SYS). This means that for each degree the outdoor temperature dropped the water temperature will increase 2 degrees. The TempTracker mod+ Hybrid has a full range of Reset Ratios to match any buildings heat loss characteristics. Outdoor Temperature A heating curve that relies not only on Outdoor temperature but also on the type of radiation will improve heat comfort.
  • Page 6: Temptracker Mod+ Hybrid Layout

    Sensor (#013398F) and System Sensor (#012187F), no with each boiler's limit circuit. Polarity is observed. Prove terminals must be connected for TempTracker mod+ Hybrid to operate boilers. System Output controls Four modulation/staging outputs can be Connect Extension panels to add pumps, valves, or other 4-20mA or Voltage.
  • Page 7: Temptracker Mod+ Extension Layout

    (cable provided with TempTracker mod+ Ext). 120VAC Power Six modulating outputs can be 4-20mA or voltage. Go to TempTracker mod+ Hybrid Startup Menu to determine the type of output for each stage. Complete TempTracker mod+ Extension Part Number 013179F...
  • Page 8: Features

    As a stand-alone, the TempTracker mod+ Hybrid is designed to control four stages. However, it has the capability of expanding its control to two extension panels each with six boiler stages. Thus, the TempTracker mod+ Hybrid can control a total of up to 16 boiler stages.
  • Page 9: Make Sure You Have The Right Control

    Setback/Shutdown Startup option). See "Shutdown/Tstat/Setback Mode" on page 26. • The Setback mode uses an external signal to switch the operation of the TempTracker mod+ Hybrid in and out of setback mode (only available when Setback is selected as the Setback/Shutdown Startup option).
  • Page 10: Installation

    • Select a location near the equipment to be controlled. • The surface should be flat and sufficiently wide and strong to hold the TempTracker mod+ Hybrid or the Extension. • Keep the control away from extreme heat, cold, or humidity. Ambient operating temperature is from 20 to 120°F.
  • Page 11: Install The Sensors

    Conduit note Immersion Sensor Determining the proper location of the Outdoor Sensor is very important. The TempTracker mod+ Hybrid will base the heat on the outdoor temperature information it receives from this location. If the sensor is in Well Locknut System Sensor the sun, or covered with ice, its reading will be different from the actual Outdoor temperature (OD).
  • Page 12: Wiring

    "Shutdown/Tstat/Setback Mode" on page 26. This will provide the user with an adjustable Day/Night Schedule. See "Day/Night Schedules" on page 37. • The Shutdown feature can be used whenever it is desirable to turn off the TempTracker mod+ Hybrid stage outputs from a remote location or another controller (i.e. EMS input).
  • Page 13: Wiring The Prove

    • A typical use of this feature is to check for pump flow or combustion air damper status before firing any boiler. • If the PROVE input is open on a call for heat, the TempTracker mod+ Hybrid will enable only the System Output.
  • Page 14: Wiring The Boilers

    Each boiler "A" or "B" has multiple stages Wiring to Modulating Boilers The TempTracker mod+ Hybrid can modulate any combination of current or voltage boiler signals. The Modulating Output Type must be set to match the boiler modulating signal before connecting any output wires to avoid damaging components.
  • Page 15: Wiring The 4-20Ma Modulating Boilers

    • The TempTracker mod+ Hybrid and the Extension sources excitation voltage for the 4-20mA signal. SYSTEM OUTPUT RATINGS: • Wire the (-) from the boiler modulating motor to the (GND) terminal on the TempTracker mod+ Hybrid. That is 120VAC, 6A RESISTIVE 1A PILOT DUTY, 15A TOTAL for boiler A, the modulating (GND) terminal will be 13.
  • Page 16: Connecting To The Extensions And 4-20Ma Ems Interface

    • The order in which the control, the extensions, and the interface are wired is not observed. • Set each Extension to a different letter (EXT-A or EXT-B). The TempTracker mod+ Hybrid will assign the stage letters based on the extension letter selected.
  • Page 17: Connecting To Bacnet Interface Module

    The module must be purchased separately. • The BACnet Interface Module comes with an RJ45 cable. • Both the TempTracker mod+ Hybrid and the BACnet Interface Module (#651735) are equipped with a RJ45 socket (RS485) to connect to communicate to each other.
  • Page 18: Hybrid Startup Menu

    Raypak, Inc. HYBrId startup Menu page 20 -------- SETTINGS ---- --- BOILER TYPE --- -- ARE YOU SURE? -- Season Winter Modulation System Target 140 Staging Yes <System Settings> Hybrid <Maintenance> BACK ▲ ▼ SAVE <System Startup> BACK ▲ ▼ SAVE page 21 page 20 BACK ▲ ▼ SELECT -EMS 4ma SETPOINT - --- SENSOR TYPE --- Reset -EMS 20ma SETPOINT- Reset [ ] 4-20mA EMS BACK ▲ ▼ SAVE BACK ▲ ▼ SAVE BACK ▲ ▼ SAVE reset...
  • Page 19: Modulating And Staging Startup Menu

    TempTracker mod+ Hybrid Installation and Operation Manual ModulatInG and staGInG startup Menu page 20 --- BOILER TYPE --- -- ARE YOU SURE? -- -------- SETTINGS ---- Modulation Season Winter Staging Yes System Target 140 Hybrid <System Settings> BACK ▲ ▼ SAVE <Maintenance> BACK ▲ ▼ SAVE <System Startup> page 20 BACK ▲ ▼ SELECT -- SENSOR TYPE -- Reset page 21 Reset - EMS INPUT MODE - -EMS 4ma SETPOINT -...
  • Page 20: Startup Settings

    To be able to change the TempTracker mod+ Hybrid settings the Program/Run Switch must be set to Program. The switch is located under the Enclosure Wiring Cover for security. PROGRAM...
  • Page 21: Ems 4Ma And 20Ma Set Points

    From 0ºF/ -18ºC to 200ºF/ 94ºC Default: 150ºF/ 66ºC Button: MENU/<System Startup>/../Sensor Type/Switch Setpoint SWITCH MODE = Outdoor Temperature ] • It is the set point at which the TempTracker mod+ Hybrid will switch between the Outdoor BACK ▲ ▼ SAVE Temp Condensing Boiler Group and Non-Condensing Boiler Group. • The Condensing Boiler group will be the lead group when the Target Temperature is below...
  • Page 22: Switch Delay

    • Select the number of condensing boilers. These boilers will occupy the first letters of the [ ] wiring stages on the TempTracker mod+ Hybrid starting with Stage-A. BACK ▲ ▼ SAVE • Then, select the number of non-condensing boilers later in the Startup menu. See "HYBRID Startup Menu"...
  • Page 23: Hybrid Modulating Boiler Settings

    Ignition %. See "Ignition %" on page 41. • The 1-10V Custom option gives the user the capability of adjusting the voltage level at which the boiler starts using the Ignition %. It shall be used on any Raypak 0-10V CONDENSING modulating boiler.
  • Page 24: Staging Mode

    • The 1-10V Custom option gives the user the capability of adjusting the voltage level BACK ▲ ▼ SAVE at which the boiler starts using the Ignition %. It shall be used on any Raypak 0-10V modulating boiler. The Ignition % will be the level at which the control will output 1VDC.
  • Page 25: Staging Boiler Settings

    2-Stage Button: MENU/<System Startup>/../Output Type 3-Stage • The TempTracker mod+ Hybrid can sequence any type of multi-stage boiler starting with a 4-Stage single On/Off and up to a four 4-stages. Just select the number of stages per boiler from this BACK ▲ ▼ SAVE...
  • Page 26: Indirect Domestic Hot Water Set Point

    (Available with any of the DHW Priority options) Adjustable from 140°F/60°C to 200°F/93°C Default: 180°F/82°C ] Button: MENU/<System Startup>/../Prove-Setpoint BACK ▲ ▼ SAVE • On a DHW call, the TempTracker mod+ Hybrid will raise the target temperature to the DHW Set Point until the DHW call expires. shutdown/tstat/setback Mode - SETBCK/SHUTDOWN - Shutdown Input, Tstate Input, Setback Input Default: Shutdown Input Shutdown/Disable Button: MENU/<System Startup>/../Setback\Shutdown...
  • Page 27: Bacnet Mode

    BACK ▲ ▼ SAVE When using the TempTracker mod+ Hybrid in a BACnet MS/TP network, the use of BACnet Interface Module is required (#651735). In addition, each of the Boiler Type and Sensor Type Startup menu option will offer a different list of BACnet variables. See "Boiler Type"...
  • Page 28: Hybrid Operating Menu

    BACK ▲ ▼ SAVE --- PURGE DELAY --- note 1.0 min ------- OFFSET ------ ] To be able to change the BACK ▲ ▼ SAVE TempTracker mod+ Hybrid settings [ ] the Program/Run Switch must BACK ▲ ▼ SAVE be set to Program. The switch is -- SYSTEM RUN-ON -- located under the Enclosure Wiring 10 min Cover for security. The Enclosure...
  • Page 29: Modulating And Staging Operating Menu

    TempTracker mod+ Hybrid Installation and Operation Manual ModulatInG and staGInG operatInG Menu ----- SEASON ----- Winter -------- SETTINGS ---- Season Winter Summer System Target 140 OD= F SYS= BACK ▲ ▼ SAVE <System Settings> <Maintenance> <A> <System Startup> 67% set point BACK ▲ ▼ SELECT STAGE ◄ ► MENU ----- SET POINT ----- [ BACK ▲ ▼ SAVE ----- SETTINGS 1 ---- ------- SETBACK ------- Setback - OUTDOOR CUTOFF - Purge Delay 1.0min...
  • Page 30: Setting The Control To Factory Defaults

    Raypak, Inc. settInG tHe control to FactorY deFaults To Reset the TempTracker mod+ Hybrid control to its original factory defaults, power down TOTAL CLEAR STARTED the control. Hold down the two right most buttons while powering the control back up until Release buttons the TOTAL CLEAR STARTED screen appears.
  • Page 31: Program Change Switch Setting

    Default: Winter Winter Button: MENU/Season Summer • The TempTracker mod+ Hybrid will turn all boiler relays off when it is in Summer setting. BACK ▲ ▼ SAVE However, an indirect DHW call will bring boilers back on when needed. The Message note Display Line will display Summer to show the status.
  • Page 32: Outdoor Cutoff Temperature

    Point2: System=170°F Oudoor=60°F Oudoor=0°F Outdoor Cutoff is turned ON and the Season is set to Winter, the TempTracker mod+ Hybrid Max Target will circulate at least 70°F water even in the hottest of weather.) In the OFF position, the Point2 system pump will always be off and all burner stages will be off.
  • Page 33: System Settings

    Adjustable from 0F°/0C° to 75F°/42C° Default: 10F°/6C° Button: MENU/<System Settings>/Setback • The Setback feature can be used to provide the TempTracker mod+ Hybrid with a lower PROGRAM temperature Set Point when less load is required. • The lower Set Point will appear on the main display indicating this condition.
  • Page 34: Lead Boiler Rotation

    • In these conditions, the system might require less output than the lowest lead Stage. When the TempTracker mod+ Hybrid brings on the Lead Stage, the Set Point is quickly exceeded, and the TempTracker mod+ Hybrid turns the Lead Stage off.
  • Page 35: Modulating Boiler Operating Settings

    That number will blink for the Soft-Off delay period. • If during the Soft-Off delay period the TempTracker mod+ Hybrid needed that stage to turn back on, the stage will be released from the Soft-Off delay and resume normal operation.
  • Page 36: Staging Boiler Operating Settings

    The temperature limits set on TempTracker mod+ Hybrid's Set Point for the reasons detailed below. the boilers must be higher than • The TempTracker mod+ Hybrid sensor is located in a common header some distance from the TempTracker mod+ Hybrid the boilers.
  • Page 37: Day / Night Schedule

    120VAC, 6A RESISTIVE 1A PILOT DUTY, 15A TOTAL Remember that the battery is the backup for the Time. If no power is supplied to the TempTracker mod+ Hybrid FOR ALL CIRCUITS and there was no battery or the battery had no power, time values will be lost and will need to be reset.
  • Page 38: Output Modulation Trim

    The TempTracker mod+ Hybrid display layout provides a variety of information that gives an immediate picture of the operation status. The display shows two boilers at a time. When extensions are present, the two middle buttons (◄ ►) scroll the screen to view additional boilers.
  • Page 39: Boiler Status

    C is the lead boiler in the lag Hybrid group or the lead boiler in Staging or Modulating Boiler Type. See "Lead Stages" on page 34. • C/E Extension panel is NOT communicating back to the TempTracker mod+ Hybrid. See "Connecting to the Extensions and 4-20mA EMS Interface" on page 16. • mON All boiler stages are set to ON.
  • Page 40: Display Messages

    Raypak, Inc. dIsplaY MessaGes The TempTracker mod+ Hybrid display layout reserved the second line for message indications. The following is a list of the most common Message Display Line information: • Boost To 170˚F The Boost has started 30 minutes before the Day Schedule setting and the Boost temperature is 170˚F.
  • Page 41: Mode

    35 • Raypak suggests that when Parallel is selected as the Modulation Mode to set the Modulation percent equal to or slightly higher than double the Ignition %. This way, the lag boiler will only start if the load is large enough for two boilers to run at the lowest...
  • Page 42: Copy Settings - Boiler A Only

    • S eason - Make sure that the Season is set to Winter. See "Season" on page 31 and "Display Messages" on page 40. • P rove - Even though, the system relay may be energized, the TempTracker mod+ Hybrid will not energize and stage relays unless the Prove is shorted.
  • Page 43 Day/Night Schedule and the Setback values. Then, reduce the Setback setting. See "Setback" on page 33. 82823 • B oiler Mode Settings - The TempTracker mod+ Hybrid will only control boilers their mode is set 59076 to Auto or Standby. Check if any boiler stage is set to Manual, Off, or Standby. See "Mode" on 42683 page 41.
  • Page 44: Hybrid - Outdoor Reset - Bacnet Variable List

    Raypak, Inc.
  • Page 45 TempTracker mod+ Hybrid Installation and Operation Manual...
  • Page 46: Modulation - Outdoor Reset - Bacnet Variable List 45 Staging - Outdoor Reset - Bacnet Variable List

    Raypak, Inc.
  • Page 47: Modulation - Set Point - Bacnet Variable List

    TempTracker mod+ Hybrid Installation and Operation Manual...
  • Page 48: Staging - Set Point - Bacnet Variable List

    Raypak, Inc.
  • Page 49: Bacnet Pics Statement

    Raypak, Inc. 2151 Eastman Ave., Oxnard, CA 93030 - (805)278-5300 product description TempTracker mod+ Hybrid control for hot water heating applications. (see http://www.raypak.com for more information) Bacnet standardized device profile (annex l) product device profile TempTracker mod+ Hybrid BACnet Control...
  • Page 50: Piping And Wiring Diagrams

    Reverse Return on the primary loop. The System output is controlling the System Pump. Raypak, Inc. is aware that each installation is unique. Thus, Raypak, Inc. is not responsible for any installation related to any electrical or plumbing diagram generated by Raypak, Inc. . The provided illustrations are to demonstrate...
  • Page 51: Hybrid Wiring Diagram

    TempTracker mod+ Hybrid Installation and Operation Manual HYBrId WIrInG dIaGraM two 4-20ma Modulating condensing Boilers HYBRID and two 4-stage non- SYSTEM OUTPUT RATINGS: condensing Boilers 120VAC, 6A RESISTIVE 1A PILOT DUTY, 15A TOTAL FOR ALL CIRCUITS INPUT RATINGS: 115VAC 60Hz , 30VA MAX USE COPPER WIRE, CLASS 1 WIRE ONLY.
  • Page 52: Modulating Piping Diagram

    Building Heating Loop system: The TempTracker mod+ Hybrid operates four modulating boilers. The boilers are piped in Reverse Return on the primary loop. The System output is controlling the System Pump. Raypak, Inc. is aware that each installation is unique. Thus, Raypak, Inc. is not responsible for any installation related to any electrical or plumbing diagram generated by Raypak, Inc.
  • Page 53: Modulating Wiring Diagram

    TempTracker mod+ Hybrid Installation and Operation Manual ModulatInG WIrInG dIaGraM Four 4-20ma Modulating Boilers HYBRID SYSTEM OUTPUT RATINGS: 120VAC, 6A RESISTIVE 1A PILOT DUTY, 15A TOTAL FOR ALL CIRCUITS INPUT RATINGS: 115VAC 60Hz , 30VA MAX USE COPPER WIRE, CLASS 1 WIRE ONLY.
  • Page 54: Staging Piping Diagram

    Building Heating Loop system: The TempTracker mod+ Hybrid operates two 2-stage Boilers. The boilers are piped in Reverse Return on the primary loop. The System output is controlling the System Pump. Raypak, Inc. is aware that each installation is unique. Thus, Raypak, Inc. is not responsible for any installation related to any electrical or plumbing diagram generated by Raypak, Inc.
  • Page 55: Staging Wiring Diagram

    TempTracker mod+ Hybrid Installation and Operation Manual staGInG WIrInG dIaGraM two 2-stage Boilers HYBRID SYSTEM OUTPUT RATINGS: 120VAC, 6A RESISTIVE 1A PILOT DUTY, 15A TOTAL FOR ALL CIRCUITS INPUT RATINGS: 115VAC 60Hz , 30VA MAX startup settInGs USE COPPER WIRE, CLASS 1 WIRE ONLY.
  • Page 56: Specifications

    ............2.5 pounds teMptracker Mod+ HYBrId specIFIcatIons Switch Between Boiler Groups Mode: .

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