Raypak Temp-Tracker Installation & Operating Instructions Manual
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Raypak Temp-Tracker Installation & Operating Instructions Manual

2 & 4-stage temperature controllers
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Installation & OPERATING
INSTRUCTIONS
2 & 4-Stage Temperature Controllers
For Raytherm™ & Hi Delta™
Boilers & Water Heaters
Catalog No. 5000.66D
Effective: 10-11-10
Replaces: 05-23-08
P/N 241177 Rev. 5

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Summary of Contents for Raypak Temp-Tracker

  • Page 1 INSTALLATION & OPERATING INSTRUCTIONS 2 & 4-Stage Temperature Controllers For Raytherm™ & Hi Delta™ Boilers & Water Heaters Catalog No. 5000.66D Effective: 10-11-10 Replaces: 05-23-08 P/N 241177 Rev. 5...
  • Page 2 Rev. 5 is a completely new edition of this manual. Please discard any previous revisions.

  • Page 3: Introduction

    Air Sensor Enclosure same size (105°C, stranded wire) as the ones on the unit or larger. Fig. 2: Temp-Tracker Controller Kit (shipped loose) INTRODUCTION USER INTERFACE The Temp-Tracker 2-stage and 4-stage temperature The Controller uses a Liquid Crystal Display (LCD) as controllers (Controller) are designed to be mounted on a method of supplying information.

  • Page 4: Sequence Of Operation

    DIP Switch Settings (DIP package located under cover on front of PCB) SWITCHES FACTORY (Default) Two-Stage (A) Heater Outlet Maximum: 200ºF (On) / 235ºF Heater (Off) 235ºF Heater (Off) (B) Heater Plant: Two Single-Stage (On) / One Two-Stage (Off) One Two-Stage (Off) Four-Stage (A) Heater Outlet Maximum: 200ºF (On) / 235ºF Heater (Off) 235ºF Heater (Off)
  • Page 5 MAIN SYSTEM PUMP SYSTEM SENSOR system. Consult the factory for piping arrangements (BY OTHERS) RAYPAK TEMPERATURE CONTOLLER not depicted here. SYSTEM RETURN MAXIMUM 4 TIMES THE PIPE DIAMETER OR 12”, WHICHEVER IS LESS. Fig. 9: Primary/Secondary Piping (Mode 2)
  • Page 6 SYSTEM ent, the control stages the heater to maintain the PUMP SYSTEM SENSOR (BY OTHERS) RAYPAK TEMPERATURE calculated outdoor reset target at the heater outlet CONTOLLER sensor. Once an indirect DWH override is present, the SYSTEM RETURN control stages the heater to maintain the heater target 2 at the heater outlet sensor.
  • Page 7 The control stages the heater to maintain the heater external sequence, such as the Raypak Temp- target at the heater outlet sensor. Tracker Mod+ Hybrid, to drive the staging rate...
  • Page 8 Code Descriptions Heater Differential (DIFF) A heat source must be operated with a differential in order to prevent short cycling. The heater differential is divided around the heater target temperature. The first-stage contact will close when the water tempera- ture at the operating sensor is 1/2 of the differential setting below the heater target temperature, and will open when the water temperature at the operating sensor is 1/2 of the differential setting above the...
  • Page 9 Low Volume, High Recovery Medium Volume, Medium Recovery Mass 2 Mass 3 High Volume Low Recovery Table A: Heater Mass Definitions NOTE: Always use a heater mass setting of 1 for Raypak equipment. If the Controller continues to stage too rapidly, contact Raypak.
  • Page 10 Heater Target Temperature (BOIL TARGET) The heater target temperature is determined from the mode of operation and type of demand applied. The Controller displays the temperature that it is currently trying to maintain at the operating sensor as BOIL TARGET in the view menu. The operating sensor for modes 2, 3, 5 and 7 is the system sensor.
  • Page 11 Pump Exercising Internal DHW Demand If the system pump has not operated at least once A sensor is required to be installed in the tank and con- every 70 hours, the control turns on the output for 10 nected to the Com and the Sys/D terminals (6 and 4). seconds.
  • Page 12 Reset Ratio Heater Design (BOIL DSGN) The controller uses the following four settings to calcu- The BOIL DSGN is the water temperature required to late the Reset Ration (RR): heat the zones when the outdoor air is as cold as the OUTDR DSGN temperature.
  • Page 13 0-10 VDC or 2-10 VDC. When the 2-10 VDC range is sequencing control, such as the Raypak Temp- selected, an input of 2 VDC corresponds to a heater Tracker Mod+ Hybrid. When in mode 8, the indirect target temperature of 50ºF (10ºC).

  • Page 14: Installation

    Fig. 20: Stage Actuation and Dead Bands BOILER OUTLET MAXIMUM CAUTION: The 120VAC connection must be TEMPERATURE applied to Terminal Block P3 (pins 1 and 2). Pin 3 must be connected to Ground. The external sequencer is able to operate the heater Electrical Connections to the temperature.

  • Page 15: Troubleshooting

    Heater Contacts Heater Sys/D or DHW Sensor The Stg 1, Stg 2, Stg 3 and Stg 4 terminals (15 through Either a System Sensor or DHW Sensor may be con- 22) are isolated outputs in the Controller. There is no nected to the Controller.
  • Page 16 5. After 13 seconds, Stage 4 is turned on. 6. After 16 seconds, the pump and stages 1 to 4 are shut off. The alarm contacts are closed for 10 sec- onds. 7. The control exits the test sequence and resumes normal operation.

  • Page 17: Electrical Wiring / Troubleshooting

    ELECTRICAL WIRING / TROUBLESHOOTING Pin # Label Function Pin # Label Function 24 VAC return power. Pump Contact – Not to exceed 5 amps. No power output. Enable/Disable - Hot 24 VAC - Incoming power for the Controller. Pump Contact – Not to exceed 5 Dem 1 Bring hot 24 VAC from the heater amps.

  • Page 18: Wiring Connections

    WIRING CONNECTIONS Factory-Mounted On Hi Delta 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: Controller Settings

    CONTROLLER Field Installation SETTINGS 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 Tables F through T describe the “View” and “Adjust” below.
  • Page 20 VIEW MENU MODE 2 (With Default Settings Shown) The View menu items display current operating tem- peratures and system status information. Use the Item button (see Fig. 5) to view items in this menu. Item Field Range Description BOILER TARGET - - - , 35 to 266°F The boiler target is the temperature the control is...
  • Page 21 ADJUST MENU MODE 2 (Page 1 of 2) (With Default Settings Shown) The Adjust menu items are the programmable settings used to operate the system. Press and hold all three buttons for one second to enter the Adjust menu, then select the desired item using the Item button.
  • Page 22 ADJUST MENU MODE 2 (Page 2 of 2) (With Default Settings Shown) Item Field Range Description Setting STAGE DELAY Select the minimum time delay between Au, 0:30 to stages. 9:55 min Note: This setting is only available when STAGE MODE is set to PId. DIFFERENTIAL Au, 2 to 42°F Select the boiler di erential.
  • Page 23 VIEW MENU MODE 3 (With Default Settings Shown) The View menu items display current operating tem- peratures and system status information. Use the Item button (see Fig. 5) to view items in this menu. Item Field Range Description - - - , TANK TARGET 35 to 266°F The temperature that the control is trying to maintain...
  • Page 24 ADJUST MENU MODE 3 (Page 1 of 2) (With Default Settings Shown) The Adjust menu items are the programmable settings used to operate the system. Press and hold all three buttons for one second to enter the Adjust menu, then select the desired item using the Item button.
  • Page 25 ADJUST MENU MODE 3 (Page 2 of 2) (With Default Settings Shown) Setting Item Field Range Description STAGE DELAY Select the minimum time delay between Au, 0:30 to stages. 9:55 min Note: This setting is only available when STAGE MODE is set to PId. PUMP DELAY OFF, 0:20 to Select the system pump purge time after...
  • Page 26 VIEW MENU MODE 5 (With Default Settings Shown) The View menu items display current operating tem- peratures and system status information. Use the Item button (see Fig. 5) to view items in this menu. Item Field Range Description OUTDOOR -60 to 190°F Current outdoor air temperature as measured by the (-51 to 88°C) outdoor sensor.
  • Page 27 ADJUST MENU MODE 5 (Page 1 of 3) (With Default Settings Shown) The Adjust menu items are the programmable settings used to operate the system. Press and hold all three buttons for one second to enter the Adjust menu, then select the desired item using the Item button.
  • Page 28 ADJUST MENU MODE 5 (Page 2 of 3) (With Default Settings Shown) Setting Item Field Range Description 120 to 230°F BOILER MAXIMUM (49 to 110°C), Select the maximum boiler target temperature. OFF, BOILER MINIMUM 80 to 180°F Select the minimum boiler target (27 to 82°C) temperature.
  • Page 29 ADJUST MENU MODE 5 (Page 3 of 3) (With Default Settings Shown) Setting Item Field Range Description MINIMUM ON TIME Select the minimum amount of time that the stage contact must remain on before it 0:10 to 5:00 min is allowed to turn o . Note: This setting is only available when STAGE MODE is set to P.
  • Page 30 VIEW MENU MODE 7 (With Default Settings Shown) The View menu items display current operating tem- peratures and system status information. Use the Item button (see Fig. 5) to view items in this menu. Item Field Range Description BOILER TARGET -- - , 35 to 266°F The boiler target is the temperature the control is...
  • Page 31 ADJUST MENU MODE 7 (Page 1 of 2) (With Default Settings Shown) The Adjust menu items are the programmable settings used to operate the system. Press and hold all three buttons for one second to enter the Adjust menu, then select the desired item using the Item button.
  • Page 32 ADJUST MENU MODE 7 (Page 2 of 2) (With Default Settings Shown) Setting Item Field Range Description STAGE DIFFERENTIAL Select the interstage temperature di erential 0 to 10°F between stages for proportional staging. (0 to 6°C) Note: This setting is only available when STAGE MODE is set to P.
  • Page 33 VIEW MENU MODE 8 (With Default Settings Shown) The View menu items display current operating tem- peratures and system status information. Use the Item button (see Fig. 5) to view items in this menu. Item Field Range Description BOILER OUTLET -20 to 266°F Current boiler outlet water temperature as measured (-29 to 130°C)
  • Page 34 ERROR MESSAGES ALL MODES The control was unable to read a piece of information from its EEPROM memory. The control will stop operation until all settings in the Adjust menu have been checked by the user or installer. To clear the error message, set Access Level DIP Switch A to Factory (on position), then check all Adjust menu items.

  • Page 35: Technical Data

    TECHNICAL DATA qUICK START SET-UP & PROGRAMMING TIPS (Controller only) 4-Stage Controller – PN 601880 1. Determine piping arrangement and mode number 2-Stage Controller – PN 601881 as depicted on pages 5 through 7. 2. Install system sensor and air sensor (for mode 5 Microprocessor PID control;...
  • Page 36 Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-9725 Litho in U.S.A.

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