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  5. Installation & Operating Instructions Manual

Raypak Temp-Tracker Installation & Operating Instructions Manual

Manual is about: 2 & 4 stage for Raytherm & Hi Delta boilers & water heaters

Summary of 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

    3 contents introduction........................................................ 3 user interface..................................................... 3 sequence of operation......................................4 installation ......................................................... 14 troubleshooti...

  • Page 4

    4 item the abbreviated name of the selected item will be dis- played in the item field of the display. To view the next available item in a menu, press and release the item button. The display will return to the first item in the selected menu (see fig. 5). Adjust to make an adjustment to a setting ...

  • Page 5

    5 primary/secondary piping in primary/secondary applications, the heater outlet temperature is typically higher than the system loop temperature. Therefore, the controller uses an addi- tional sensor (called the system sensor) to measure the temperature in the system. The operating sensor in primary...

  • Page 6

    6 domestic hot water operation, uni-temp 80 piping (mode 3) mode 3 is designed for dedicated dhw operation using unitemp 80 piping. The controller operates the heater to maintain a tank temperature at the system sensor. Mode 3 requires the use of three water sensors. The inlet water sensor is locate...

  • Page 7

    7 external target temperature input and override with primary piping mode 6 (mode = 6) (not supported) mode 6 is designed for a 0-10vdc or a 4-20 ma exter- nal input signal and override operation using primary piping. The external input signal creates an internal cfh and changes the heater target ac...

  • Page 8

    8 auto differential auto differential is only available when using pid stag- ing. If auto differential is selected, the control automatical- ly determines the best differential as the load changes, thereby improving efficiency. During light loads, the dif- ferential is increased to allow longer on a...

  • Page 9

    9 proportional, integral & derivative (pid) pid staging allows the controller to determine when the next stage is required to turn on or off. The controller automatically determines the settings that are manually selected in the proportional mode. After each stage is turned on in the firing sequence...

  • Page 10

    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 ...

  • Page 11

    11 pump exercising if the system pump has not operated at least once every 70 hours, the control turns on the output for 10 seconds. This minimizes the possibility of the pump seizing during a long period of inactivity. Setpoint operation a setpoint is a fixed water temperature target that the heate...

  • Page 12

    12 reset ratio the controller uses the following four settings to calcu- late the reset ration (rr): for example, using the mode 5 default values, the rr would be .56:1. Heater start (boil start) the boil start temperature is the theoretical supply water temperature that the system requires when the...

  • Page 13

    13 2-10 vdc or 4-20 ma external input signal the external input signal can be selected to be either 0-10 vdc or 2-10 vdc. When the 2-10 vdc range is selected, an input of 2 vdc corresponds to a heater target temperature of 50ºf (10ºc). An input voltage of 10 vdc corresponds to a heater target temper...

  • Page 14

    14 boiler outlet maximum temperature the external sequencer is able to operate the heater temperature. However, the boil out max setting lim- its the highest temperature at the heater outlet sensor. Should the heater outlet setting exceed the boil out max setting, the stage contacts are opened to sh...

  • Page 15

    15 heater contacts the stg 1, stg 2, stg 3 and stg 4 terminals (15 through 22) are isolated outputs in the controller. There is no power available on these terminals from the controller. These terminals are to be used as a switch to either make or break the heater circuit. When the controller requir...

  • Page 16

    16 connecting the controller apply power to the controller. The operation of the controller on power up is described in the sequence of operation section, starting on page 4 of this manu- al. Testing the controller’s outputs the controller has a built-in test routine, which is used to test the main ...

  • Page 17

    17 electrical wiring / troubleshooting table e: control pin-outs pin # label function 1 cd 24 vac return power. 2 dem 1 enable/disable - hot 24 vac - incoming power for the controller. Bring hot 24 vac from the heater transformer. 3 dem 2 indirect dhw override – hot 24 vac – incoming power for the d...

  • Page 18

    18 wiring connections to udb p4 fig. 24: wiring diagram (factory mounted) 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 c...

  • Page 19

    19 controller settings tables f through t describe the “view” and “adjust” menus. They also show 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 ...

  • Page 20

    20 mode 2 (with default settings shown) view menu 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 - - - , 35 to 266°f (2 to 130°c), off boiler target the boiler targe...

  • Page 21

    21 mode 2 (with default settings shown) adjust menu (page 1 of 2) 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. Finally, use the ▲ or ▼ butt...

  • Page 22

    22 mode 2 (with default settings shown) adjust menu (page 2 of 2) item field range description setting au, 0:30 to 9:55 min stage delay select the minimum time delay between 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 ...

  • Page 23

    23 mode 3 (with default settings shown) view menu 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 - - - , 35 to 266°f (2 to 130°c), off tank target the temperature th...

  • Page 24

    24 mode 3 (with default settings shown) adjust menu (page 1 of 2) 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. Finally, use the ▲ or ▼ butt...

  • Page 25

    25 mode 3 (with default settings shown) adjust menu (page 2 of 2) item field range description setting au, 0:30 to 9:55 min stage delay select the minimum time delay between stages. Note: this setting is only available when stage mode is set to pid. 2 to 42°f (1 to 23°c) stage differential select th...

  • Page 26

    26 mode 5 (with default settings shown) view menu 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 -60 to 190°f (-51 to 88°c) outdoor current outdoor air temperature a...

  • Page 27

    27 mode 5 (with default settings shown) adjust menu (page 1 of 3) 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. Finally, use the ▲ or ▼ butt...

  • Page 28

    28 mode 5 (with default settings shown) adjust menu (page 2 of 3) item field range description setting 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 s e l e c t th e m i n i m u m b o i l e r t a r g et tempe...

  • Page 29

    29 mode 5 (with default settings shown) adjust menu (page 3 of 3) item field range description setting 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 se...

  • Page 30

    30 mode 7 (with default settings shown) view menu 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 - - - , 35 to 266°f (2 to 130°c), off boiler target the boiler targe...

  • Page 31

    31 mode 7 (with default settings shown) adjust menu (page 1 of 2) 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. Finally, use the ▲ or ▼ butt...

  • Page 32

    32 mode 7 (with default settings shown) adjust menu (page 2 of 2) item field range description setting 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 mode is set to p. 0:1...

  • Page 33

    33 mode 8 (with default settings shown) view menu 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 -20 to 266°f (-29 to 130°c) boiler outlet current boiler outlet wate...

  • Page 34

    34 error messages table u: error messages e01 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 f...

  • Page 35

    35 technical data (controller only) 4-stage controller – pn 601880 2-stage controller – pn 601881 controller microprocessor pid control; this is not a safety (limit) control enclosure enclosure d, black noryl plastic dimensions 4-3/4” h x 2-7/8” w x 1-7/8” d (120 x 74 x 48 mm) approvals csa c us, me...

  • Page 36: Www.Raypak.Com

    36 www.Raypak.Com raypak, inc., 2151 eastman avenue, oxnard, ca 93030 (805) 278-5300 fax (805) 278-9725 litho in u.S.A..