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Raychem HWAT

Pentair Raychem HWAT System Installation And Operation Manual

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HWAT System
INSTALLATION AND OPERATION MANUAL FOR HOT WATER TEMPERATURE MAINTENANCE SYSTEMS FOR THERMALLY INSULATED PIPES
THERMAL MANAGEMENT SOLUTIONS WWW.THERMAL.PENTAIR.COM
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Important Safeguards and Warnings
WARNING: FIRE AND SHOCK HAZARD
Raychem HWAT Systems must be installed correctly to ensure proper operation and to prevent shock and fire. Read these important warnings and carefully follow all the installation instructions.
• To minimize the danger of fire from sustained electrical arcing if the heating cable is damaged or improperly installed, and to comply with Pentair Thermal Management requirements, agency certifi­cations, and national electrical codes, ground-fault equipment protection must be used on each heating cable branch circuit. Arcing may not be stopped by conventional circuit breakers.
• Approvals and performance are based on the use of Pentair Thermal Management parts only. Do not sub­stitute parts or use vinyl electrical tape.
• Bus wires will short if they contact each other. Keep bus wires separated.
• Connection kits and heating cable ends must be kept dry before and during installation.
• The black heating cable core is conductive and can short. They must be properly insulated and kept dry.
• Damaged bus wires can overheat or short. Do not break bus wire strands when preparing the cable for connection.
• Damaged heating cable can cause electrical arc­ing or fire. Do not use metal attachments such as pipe straps or tie wire. Use only Pentair Thermal Management approved tapes and cable ties to secure the cable to the pipe.
• Do not attempt to repair or energize damaged cable. Remove damaged cable at once and replace with a new length using the Raychem RayClic-S splice kit. Replace damaged connection kits.
• Use only fire-resistant insulation which is compatible with the application and the maximum exposure temperature of the system to be traced.
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Table of Contents
1
General Information 1
1.1 Use of the Manual 1
1.2 Safety Guidelines 2
1.3 Typical HWAT System 2
1.4 Electrical Codes 3
1.5 Approvals 3
1.6 Warranty 4
1.7 Trade Coordination 4
1.8 General Installation Notes 5
1.9 Tools Required 6
2
Heating Cable Verification and Selection 7
2.1 Heating Cable 7
3
Heating Cable Installation 8
3.1 Heating Cable Storage 8
3.2 Pre-Installation Checks 8
3.3 Installation 8
4
Heating Cable Components 14
4.1 General Connection Kit Information 14
5
Control and Monitoring 16
5.1 HWAT-ECO and ACCS-30 Controllers 16
6
Thermal Insulation 17
6.1 Insulating the System 17
6.2 Insulation Installation 17
7
Power Supply and Electrical Protection 20
7.1 Voltage Rating 20
7.2 Circuit Breaker Sizing 20
7.3 Electrical Loading 20
7.4 Ground-Fault Protection 21
8
Commissioning and Preventive Maintenance 22
8.1 Tests 22
8.2 Preventative Maintenance 24
9
Test Procedures 25
9.1 System Tests 25
9.2 Fault Location Tests 31
9.3 Cable and Connection Continuity
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10
Test Procedures 34
11
Troubleshooting Guide 38
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1.1 Use of the Manual
This installation and operation manual is for Raychem HWAT Hot Water Temperature Maintenance systems installed on thermally insulated pipes only.
This manual details how to install and operate an HWAT system. The HWAT System includes the HWAT-R2 heating cables, RayClic connection kits, and the HWAT-ECO or ACS-30 controllers. It is important to review this manual and the following documents with the installing contractor:
• HWAT System Product Selection & Design Guide (H57538)
• HWAT-ECO Data Sheet (H57339)
• ACS-30 Mulitpoint Commercial heat-tracing Control System Data Sheet (H58261)
• HWAT Heating Cable Data Sheet (H57512)
• RayClic Connection System Data Sheet (H57545)
• HWAT-ECO Installation and Operation Manual (H57340)
• ACS-30 Programming Guide (H58692)
For additional information, contact:
Pentair Thermal Management
7433 Harwin Drive Houston, TX 77036 USA Tel: +1.800.545.6258 Tel: +1.650.216.1526 Fax: +1.800.527.5703 Fax: +1.650.474.7711 thermal.info@pentair.com
www.thermal.pentair.com
Important: For the Pentair Thermal Management warranty and agency approvals to apply, the instruc­tions that are included in this manual and product packages must be followed.
1
General Information1 General Information
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1.2 Safety Guidelines
The safety and reliability of any heat-tracing system depends on the quality of the products selected, and on proper design, installation, and maintenance. Incorrect design, handling, installation, or mainte­nance of any of the system components can cause underheating or overheating of the pipe, or dam­age to the heating cable system, and may result in system failure, electric shock, or fire. The guide­lines and instructions contained in this guide are important. Follow them carefully to minimize these risks and to ensure that the HWAT System performs reliably.
Pay special attention to the following:
• Instructions marked
Important
• Warnings marked
WARNING
1.3 Typical HWAT System
A typical HWAT System is shown is Figure 1. The heating cable is cut to length in the field and is attached to the pipe with glass tape. A power con­nection kit connects the heating cable bus wires to power in a junction box. RayClic tees and splices accommodate pipe branches to connect two or three heating cables together. An end seal kit is used to terminate the end of the heating cable. A controller is used to set the maintain temperature and improve energy savings.
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General Information
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Splice
To power distribution panel
Note: Partial pipe insulation
shown here for clarity. All pipes must be fully insulated
End seal
Tee
Thermal
insulation
Heating cable
Pipe temperature sensor
Temperature sensor
Heating cable
Insulation
Glass tape
Power connection
Controller
To BMS
ETL
label
180°
Figure 1: Typical HWAT heating cable system
1.4 Electrical Codes
Section 427 of the National Electrical Code (NEC), and Part 1, Section 62 of the Canadian Electrical Code (CEC), in particular, govern the installation of electrical heat-tracing systems used on hot water pipes. All installations must be in compliance with this and any other applicable national or local codes.
1.5 Approvals
HWAT-R2 heating cable and RayClic connection kits, are UL Listed and CSA certified for use in non-haz­ardous locations. The HWAT-ECO controller is c-UL­us Listed and the ACS-30 controller is c-CSA-us cer­tified (ACS-UIT) and c-UL-us Listed (ACS-PCM2-5) to
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General Information
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US and Canadian standards for us in non-hazardous locations. Refer to the specific product data sheets for details.
1.6 Warranty
Pentair Thermal Management standard limited war­ranty applies to all products.
An extension of the limited warranty period to ten (10) years from the date of installation is available if a properly completed on-line warranty form is completed within (30) days from the date of installa­tion. The extension is valid for the HWAT-R2 heating
cable, RayClic connection kits and accessories, but not the HWAT-ECO or ACS-30 controllers. You can access the complete warranty on www.thermal.pentair.com.
1.7 Trade Coordination
Installation of an HWAT System can involve or impact the work of numerous trades. Therefore, effective and early coordination between trades is a critical aspect of all HWAT System Installations. The instal­lation of the heating cable and connections must be properly scheduled, along with the scheduling of the risers and insulation installation.
This guide will assist the installer throughout the installation process and must be reviewed by all affected trades before installation of the HWAT System begins. In a fast-track job, the HWAT System must be considered a critical path item: the pipe, heating cable, insulation, and wallboard must all be installed in the proper order, since the heating cable cannot be installed later. If, for example, the walls go up before the heating cable commissioning tests have been completed, it may be necessary to remove the walls in order to repair a damaged or improperly installed system.
Ensuring that the installation of the HWAT System is included in the overall construction schedule will help ensure a successful and trouble-free installation.
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General Information
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1.8 General Installation Notes
Read and observe the instructions in this guide to insure that the HWAT System is installed successfully.
• Accidental damage to the system can be minimized during construction by installing thermal insulation on the pipe immediately after the pipe has been traced and the heating cable has been tested.
• Read all installation documentation to familiarize yourself with the system components.
• Read and follow all warnings and recommenda­tions. All involved trades should review this entire guide and assess the recommendations applicable to their scope of work.
• All heat-traced pipes and equipment must be ther­mally insulated. Insulation is an important part of the HWAT System. For an effective system, the fiberglass insulation must be a specific thickness for each specific pipe size as detailed in Table 2 on page17.
• Do not install the HWAT System below the mini­mum installation temperature.
– The minimum installation temperature for HWAT
heating cables is 0°F (–18°C)
– The minimum installation temperature for HWAT-
ECO is 40°F (5°C).
• Ensure that your water heater temperature is set at your desired pipe maintain temperature.
• Do not energize cable when it is coiled or on the reel.
• Never use metal tie wire or pipe straps to secure heating cables to pipes.
Important: Exceeding 185°F (85°C) for HWAT-R2 will decrease the power output of the heating cables over time.
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General Information
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1.9 Tools Required
For installing cable and connection kits:
• Utility knife
• Diagonal cutters
• Cable cutters
• Tape measure
• Screwdriver
• Heat gun or propane torch
For testing the heating cable:
• Megohmmeter 2500 Vdc
• Multimeter (voltage, resistance and capacitance)
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General Information
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2
Heating Cable Verification and
Selection
2.1 Heating Cable
The HWAT System includes HWAT-R2 heating cable designed to maintain the piping at specific tempera­ture settings with the use of the HWAT-ECO or ACS­30 controllers. Figure 2 shows the construction of the heating cable.
Nickel-plated copper bus wires
Self-regulating conductive core
Polymer-coated aluminum wrap
Tinned-copper braid
Modified polyolefin outer jacket
Modified polyolefin inner jacket
Figure 2: HWAT-R2 heating cable
The minimum control setpoint for HWAT-R2 is 105°F (40°C). The maximum control setpoint for HWAT-R2 is 140°F (60°C).
2 Heating Cable Verification and
Selection
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3
Heating Cable Installation
3.1 Heating Cable Storage
• Store the heating cable in a clean, dry location. Temperature range: 0°F (–18°C) to 140°F (60°C).
• Protect the heating cable from mechanical damage.
3.2 Pre-Installation Checks
Check materials received:
• Review the heating cable design and compare the list of materials to the catalog numbers of the heating cables and connection kits received to confirm that the proper materials are on site. The heating cable type is printed on its jacket.
• The HWAT System is limited to 208 V or 240 V ser­vice when using the HWAT-ECO controller. When using the ACS-30 controller the voltage range is 208–277 V. Ensure that the service voltage avail­able is correct.
• Inspect the heating cable and connection kits to ensure there is no in-transit damage.
• Verify that the heating cable jackets are not dam­aged by conducting the insulation resistance test (refer to Section 9) on each reel of cable. Do not power the heating cable when it’s on the reel.
Check piping to be traced:
• Make sure all mechanical pipe testing (i.e. hydro­static testing/purging) is complete and the system has been cleared by the client for tracing.
• Walk the system and plan the routing of the heat­ing cable on the pipe.
• Inspect the piping and remove any burrs, rough surfaces or sharp edges.
3.3 Installation
• Pay out the heating cable, loosely stringing it along the pipe, making sure that the cable is always next to the pipe when crossing obstacles.
• Install HWAT heating cable in straight runs along the pipe. Spiraling the heating cable is not
necessary.
3 Heating Cable Installation
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3
Heating Cable Installation
• If the cable is on the wrong side of an obstacle such as a crossing pipe or I-beam, you will need to reinstall it or cut and splice it.
• When installing the heating cable, the cable must not be compressed or pinched between two objects. Wall and floor penetrations and pipe hangers are particular areas of concern.
Figure 3: Protecting the heating cable in floor penetrations
• Run insulation through the pipe hanger ensuring that the pipe is not resting on the heater.
Figure 4: Pipe hanger with heating cable
• When making floor or wall penetrations, make sure the hole is large enough to accommodate the pipe and the thermal insulation. When sealing around pipes at floor penetrations, avoid damag­ing or cutting the heating cable, or pinching it between the pipe and the concrete.
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3
Heating Cable Installation
• The heating cable must not be embedded directly in the sealing material; the pipe should have ther­mal insulation over it (if allowed by local codes) or the heating cable should be run through the pen­etration in a tube or conduit. If the conduit must be sealed, use a pliable fire-resistant material (Dow Corning Fire Stop, 3M Fire Barrier, or T&B Flame­Safe) that can be removed if necessary.
Figure 5: Multiple pipe floor penetration
• On vertical piping groups, run the heating cable along the inside of the pipe close to other pipes so it will not be damaged if the pipe hits the side of the floor penetration. Run the heating cable over the outside of the pipe support. Do not clamp the heating cable to the pipe with the pipe support.
• In high-rise construction it may be necessary to install the HWAT System 10 or 12 floors at a time to fit into the construction schedule. If so, the end of the heating cable should be sealed with a RayClic-E end seal and placed in an accessible location. This allows testing of one part of the heating cable at a time, and allows splicing it to another section when the system is complete.
Paying out the cable:
• Use a reel holder that pays out smoothly with little tension. If the heating cable snags, stop pulling.
• Keep the heating cable strung loosely but close to the pipe being traced to avoid interference with supports and equipment.
• Meter marks on the heating cable can be used to determine cable length.
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3
Heating Cable Installation
• Protect all heating cable ends from moisture, con­tamination and mechanical damage.
Figure 6: HWAT cable layout
When paying out the heating cable, AVOID:
• Sharp edges
• Excessive pulling force or jerking
• Kinking and crushing
• Walking on it, or running over it with equipment
WARNING: Fire and shock hazard. Do not install damaged cable. Connection kits and cable ends must be kept dry before and during installation.
Positioning heating cables
If possible, position the heating cable on the lower section of the pipe, at the 4 or 8 o’clock positions, as shown below, to protect it from damage.
Figure 7: Cable positioning
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3
Heating Cable Installation
Attaching the heating cable
Starting from the end opposite the reel, tape the heating cable to the pipe every 2 feet. Work back to the reel. Leave extra heating cable at the power con­nection, at all sides of splices and tees to allow for future servicing. See Table 1 on page15.
• Install heating cable connection kits immediately after attaching the heating cable. If immediate installation is not possible, protect the heating cable ends from moisture.
Bending the cable
When positioning the heating cable on the pipe, do not bend tighter than 1/2” radius. The heating cable does not bend easily in the flat plane. Do not force such a bend, as the heating cable will be damaged.
1/2"
Figure 8: Bending technique
Crossing the cable
HWAT heating cables are self-regulating and may be overlapped whenever necessary without overheating or burning out.
Cutting the cable
Cut the heating cable to the desired length after it is attached to the pipe. HWAT can be cut to length without affecting the heat output per foot.
Attachment tapes
To ensure that the heating cable is in full contact with the pipe, use tape to attach the heating cable to the pipe every 2 ft (.6 m). Use Raychem GT-66 attachment tape. One roll will handle approximately 50 ft (15 m) of cable.
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3
Heating Cable Installation
Figure 9: Attaching the heating cable
To ensure sufficient heat transfer AT-180 aluminum tape must be used to install the heating cable on plastic pipes as shown in Figure 10.
WARNING: Do not use metal attachments such as pipe straps or tie wire. Do not use vinyl-based electrical or duct tape. Use only Pentair Thermal Management approved tapes.
Raychem HWAT heating cable
Continuous AT-180 alluminum tape over heating cable
Rigid plastic pipe
Thermal insulation
Figure 10: Installed on plastic pipe with aluminum tape
Raychem GT-66 glass tape
2 ft.
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4
Heating Cable Components
4.1 General Connection Kit Information
Raychem RayClic connection kits must be used with HWAT-R2 heating cable. A complete circuit requires a power connection and an end seal. Splices and tees and other connection kits are used as needed. Use the HWAT System Design Guide (H57510) to select appropriate connection kits. Installation instructions are included with every connection kit. Steps for preparing the heating cable and installing connection kits must be followed. HWAT connection kit locations should be noted on “As Built” drawings. Connection kit locations should be marked on the outside of the insulation cladding with the labels provided in the kits.
RayClic-PT
powered
tee
RayClic-PC
powered connection
RayClic-S
splice
RayClic-X
cross tee
RayClic-T
tee
RayClic-PS
powered
splice
RayClic-LE
lighted end seal
RayClic-E
end seal
Alternate
lighted end seal
Alternate
connection kits
HWAT heating cable
Figure 11: RayClic connection system
Connection Kit Installation
• When practical, mount the connection kits on top of the pipe. All heating cable connections must be mounted above grade level.
• Leave excess cable to serve as a service loop at all connection kits (power, splice, cross or tee) for future maintenance, as detailed in Table 1. The additional heating cable will easily pay for itself in time savings if it becomes necessary to check or replace a connection kit after installation. Splices and tees should have a service loop on each of the heating cables entering the connection kit.
4 Heating Cable Components
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4
Heating Cable Components
TABLE 1: SERVICE LOOPS FOR EACH CONNECTION KIT
RayClic-PC 1 2.0 ft (0.6 m) 2 ft (0.6 m) RayClic-S 2 1.0 ft (0.3 m) 2 ft (0.6 m) RayClic-T 3 1.0 ft (0.3 m) 3 ft (0.9 m) RayClic-X 4 1.0 ft (0.3 m) 4 ft (1.2 m) RayClic-PS 2 1.5 ft (0.5 m) 3 ft (0.9 m) RayClic-PT 3 1.3 ft (0.4 m) 4 ft (1.2 m) RayClic-E 1 NA NA RayClic-LE 1 2.0 ft (0.6 m) 2.0 ft (0.6m)
Connection # of cable Cable length/ Total cable length kit name connections/kit connection (Service loop)
• All power connection kits must be installed in accessible locations. Access to splices, tee kits and end seals is recommended for future modifi­cation or maintenance but is not required.
• Locate junction boxes for easy access but not where they may be exposed to mechanical abuse.
• Heating cables must be installed over, not under, pipe straps used to secure components.
WARNING: The black heating cable core is elec­trically conductive and can short. It must be proper­ly insulated and kept dry. Damaged bus wires can overheat or short.
WARNING: Fire and shock hazard. Raychem brand specified components must be used. Do not substitute parts or use vinyl electrical tape.
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5
Control and Monitoring
5.1 HWAT-ECO and ACS-30 Controllers
The Raychem HWAT-ECO controller is designed for use only with HWAT-R2 heating cables and must be used to ensure proper water temperature.
Refer to the HWAT-ECO Installation and Operation Manual (H57340) for the installation and operation instructions of the controller.
Figure 12: HWAT-ECO controller
The ACS-30 Control System is also approved for use with HWAT-R2 heating cable. Refer to the ACS-30 Programming Guide (H58692) for the installation and operating instructions of the control system.
Heat-tracing system
ACCS-UIT2
(Optional)
RMM2
COMMON ALARM
POWER CONTROL
MODULE ACCS-PCM-5
COMMON ALARM
POWER CONTROL
MODULE ACCS-PCM-5
ACCS-PCM2-5 ACCS-PCM2-5
Figure 13: ACS-30 Control System
5 Control and Monitoring
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6
Thermal Insulation
6.1 Insulating the System
Pipes must be insulated with the correct thermal insulation to maintain the desired pipe tempera­tures. For pipes 1 1/4 inches and smaller, use insu­lation that is oversized by 1/4 inch to allow room for insulating over the heating cables. The thermal insulation schedule is shown in Table 2.
TABLE 2: FIBERGLASS INSULATION SCHEDULE
1/2 3/4 1/2 3/4 1 1 1 1 1/4 1 1 1/4 1 1/2 1 1/2 1 1/2 1 1/2 1 1/2 2 2 2 2 1/2 2 1/2 2 1/2 3 3 3
Copper pipe IPS insulation Insulation size (in) size (in) thickness (in)
Important: For pipes 3 inches and larger, the thickness of insulation can be equal to the pipe diam­eter with one run of heating cable or 1/3 the pipe diameter with two runs of heating cable.
6.2 Insulation Installation
• Before insulating the pipe, visually inspect the
heating cable and connection kits to ensure they are properly installed and there are no signs of damage. Damaged cable or connection kits must be replaced.
• Check that the insulation type and thickness com-
plies with the insulation schedule detailed in Table
2.
• Insulate the pipes immediately after the heating
cable is installed and has passed all tests to mini­mize damage to the cable.
• Insulate the pipe at floor and wall penetrations.
Failure to do so will cause cold spots in the water system and could lead to damage to the heating cable. If local codes do not allow this, the heating cable should be run through a conduit or channel before the firestop is installed. Use a fire-resistant
6 Thermal Insulation
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6
Thermal Insulation
sealing compound such as Dow Corning Fire Stop, 3M Fire Barrier, or T&B Flame-Safe.
• Do not use staples to close the insulation. Use tape or the adhesive-lined edge of the insulation to ensure that the seam remains sealed. Staples can damage the HWAT heating cable.
Figure 14: Sealing the insulation seam
• When installing splice, tee and end seal kits under­neath the thermal insulation, mark the location of splices, tees, and end seals on the outside of the insulation, with labels provided in the kits, while installing the insulation. Use large diameter insu­lation or sheets to cover splices, tees, or service loops.
Figure 15: Installing Connection kits above insulation.
• All power connection kits must be mounted above the thermal insulation.
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6
Thermal Insulation
• Splice and Tee connection kits may be installed above the insulation using the optional SB-04 mounting bracket. The pipe and heating cable ser­vice loops must be fully insulated as shown above.
Figure 16: Installing connection kits below insulation.
• Make sure that all heat-traced piping, fittings, wall penetrations, and branch piping are insulated. Correct temperature maintenance requires proper­ly installed and dry thermal insulation. Uninsulated sections of pipe can result in cold spots.
• After installing insulation, electrical codes require that you install “Electric Traced” labels along the piping at suitable intervals (10-foot intervals rec­ommended) on alternate sides.
WARNING: Use only fire-resistant insulation,
such as fiberglass.
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7
Power Supply and Electrical
Protection
7.1 Voltage Rating
Verify that the supply voltage is either 208 or 240 volts as specified by the HWAT System design.
7.2 Circuit Breaker Sizing
Circuit breakers must be sized using the cable lengths shown in Table 3. Do not exceed the maxi­mum circuit length shown for each breaker size. When using the HWAT-ECO controller install circuit breakers that incorporate 30-mA ground-fault circuit protection, or provide equivalent levels of ground­fault protection. Ground-fault protection is integrat­ed into the ACS-30 control system so no additional protection is required.
TABLE 3: MAXIMUM CIRCUIT LENGTH IN FEET METERS
15 Amp 250 (75) 20 Amp 330 (100) 30 Amp 500 (150)
Breaker Size HWAT-R2
7.3 Electrical Loading
Over-current devices are selected according to the heating cable type, supply voltage, and circuit length to allow for start-up. The design specifies the size and type of over-current device. Piping systems are seldom installed exactly as the drawings show. If changes are made, make sure that all circuit lengths comply with Table 3.
7 Power Supply and Electrical
Protection
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7
Power Supply and Electrical
Protection
7.4 Ground-Fault Protection
If the heating cable is improperly installed, or physi­cally damaged to the point that water contacts the bus wires, sustained arcing or fire could result. If arcing does occur, the fault current may be too low to trip conventional circuit breakers. Pentair Thermal Management, the U.S. National Electrical Code, and the Canadian Electrical Code require both ground-fault protection of equipment and a ground­ed metallic covering on all heating cables. All HWAT heating cables meet the metallic covering require­ments. Ground-fault protection must be provided by the installer.
WARNING: To minimize the danger of fire from sustained electrical arcing if the heating cable is damaged or improperly installed, and to comply with Pentair Thermal Management requirements, agency certifications, and national electrical codes, ground­fault equipment protection must be used on each heating cable branch circuit. Arcing may not be stopped by conventional circuit breakers.
WARNING: Disconnect all power before making connections to the heating cable.
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8
Commissioning and Preventive
Maintenance
Pentair Thermal Management requires a series of commissioning tests be performed on the HWAT System. These tests are also recommended at regu­lar intervals for preventive maintenance. Results must be recorded and maintained for the life of the system, utilizing the “Installation and Inspection Record” (refer to Section 11). Submit this manual with initial commissioning test results to the owner.
Ensure that your water heater and mixing valve temperature are set at your desired pipe maintain temperature.
Important: Exceeding185°F (85°C) for HWAT-R2 will decrease the power output of the heating cables over time.
8.1 Tests
A brief description of each test is found below. Detailed test procedures are found in Section 9.
Visual inspection
Visually inspect the pipe, insulation, and connec­tions to the heating cable for physical damage. Check that no moisture is present, electrical con­nections are tight and grounded, insulation is dry and sealed, and control and monitoring systems are operational and properly set. Damaged heating cable must be replaced. Once the heating cable is installed any repairs to pipes should be done very carefully. The heater must be shielded from exces­sive heat. Temperatures greater than 185°F will permanently damage the affected section of heater. Damage due to excessive external heat may or may not effect the operation of the entire circuit. A torch must not be used on the pipe, pipe hangers, or riser clamps after the heating cable has been installed on the pipe because this can cause permanent dam­age to the heating cable (even if it does not appear to be burned). Use a saw, not a torch, to cut riser clamps. If use of a torch is unavoidable, cut the fiberglass tape that holds the HWAT cable to the pipe on either side of the area to be heated, and pull the cable away from the pipe. Make sure you do not cut the HWAT cable. Shield the cable from the flame.
8 Commissioning and Preventive
Maintenance
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8
Commissioning and Preventive
Maintenance
Charred or damaged cable must be replaced to avoid the risk of arcing or fire.
Figure 17: Shielding the cable from the flame
Circuit length verification (capacitance test)
The installed circuit length is verified through a capacitance measurement of the HWAT heating cable. Compare the calculated installed length against the system design. If the calculated length is shorter than the system design, confirm all con­nections are secure and the grounding braid is continuous.
Insulation Resistance
Insulation Resistance (IR) testing is used to verify the integrity of the heating cable inner and outer jackets. IR testing is analogous to pressure testing a pipe and detects if a hole exists in the jacket.
Power check
The power check is used to verify that the system is generating the correct power output. This test can be used in commissioning to confirm that the circuit is functioning correctly. For on-going maintenance, compare the power output to previous readings.
The heating cable power output per foot is calculated by dividing the total wattage by the total length of a circuit. The current, voltage, operation temperature and length must be known. Circuit length can be determined from “as built” drawings, meter marks on the cable or with the capacitance test. The watts per foot can be compared to the heating cable out-
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8
Commissioning and Preventive
Maintenance
put in Section 9 for an indication of heating cable performance:
Ground-fault test
Test all ground-fault breakers per manufacturer’s instructions.
Cable and Connection Continuity
Cable and connection continuity test verifies all the electrical connections are made properly. Pentair recommends conducing this test as the cable is installed to identify any potential problems imme­diately. This test can also be conducted after the entire cable run is installed but before end seals are applied.
8.2 Preventative Maintenance
Recommended maintenance for HWAT Systems consists of performing the system tests for commis­sioning, and on a regular basis. Procedures for these tests are described in Section 9. Systems should be checked each year. If the HWAT System fails any of the tests, refer to Section 10 for trouble shooting assistance. Make the necessary repairs and replace any damaged cable immediately. De-energize all cir­cuits that may be affected by maintenance. Protect the heating cable from mechanical or thermal dam­age during maintenance work.
Maintenance records
The “Installation and Inspection Record,” (refer to Section 11) should be filled out during all mainte­nance and repairwork and kept for future reference.
Repairs
Use only HWAT heating cable, HWAT-ECO or ACS-30 controller, and RayClic connection kits when replac­ing any damaged heating cable system. Repair the thermal insulation to original condition or replace with new insulation, if damaged. Retest the system after all repairs or replacements.
WARNING: Damage to cables or components can cause sustained electrical arcing or fire. Do not attempt to repair damaged heating cable. Do not energize cables that have been damaged by fire. Replace damaged cable at once by removing the entire damaged section and splicing in a new length using the appropriate RayClic splice kits.
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9
Test Procedures
9.1 System Tests
The following tests must be done after installing the RayClic connection kits, but before the thermal insulation is applied to the pipe:
1. Visual inspection
2. Insulation resistance test
After the thermal insulation has been installed on the pipe, the following tests must be performed:
1. Visual inspection
2. Insulation resistance test
3. Circuit length verification (capacitance test)
4. Power test
5. Temperature test
All test procedures are described in this manual. It is the installer’s responsibility to perform these tests or have an electrician perform them. Record the results in the Installation and Inspection Record in Section 11.
1. Visual inspection test
• Check inside all power, splice and tee kits for proper installation, overheating, corrosion, mois­ture, or loose connections.
• Check the electrical connections to ensure that ground and bus wires are insulated over their full length.
• Check for damaged, missing or wet thermal insulation.
• Check that end seals, splices, and tees are prop­erly labeled on insulation cladding.
• Check HWAT-ECO or ACS-30 controller for proper setpoint and operation. Refer to the HWAT-ECO Installation and Operation Manual or ACS-30 Programming Guide for details.
2. Insulation Resistance test
Frequency
Insulation resistance testing is required during the installation process, and as part of regularly sched­uled maintenance, as follows:
9 Test Procedures
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9
Test Procedures
• Before installing the cable
• Before installing components
• Before installing the thermal insulation
• After installing the thermal insulation
• Prior to initial start-up (commissioning)
• As part of the regular system inspection
• After any maintenance or repair work
Procedure
Insulation resistance testing (using a megohm­meter) should be conducted at three voltages; 500, 1000, and 2500 Vdc. Potential problems may not be detected if testing is done only at 500 and 1000 volts. First measure the resistance between the heating cable bus wires and the braid (Test A), then measure the insulation resistance between the braid and the metal pipe (Test B). Do not allow test leads to touch junction box, which can cause inaccurate readings.
Important: System tests and regular maintenance procedures require that insulation resistance testing be performed. Test directly from the HWAT-ECO, ACS­30 or the junction box closest to the RayClic-PC.
WARNING: Fire hazard in hazardous locations. Insulation resistance test can produce sparks. Be sure there are no flammable vapors in the area before performing this test.
Insulation resistance criteria
A clean, dry, properly installed circuit should measure thousands of megohms, regardless of the heating cable length or measuring voltage (500–2500Vdc). The following criteria are provided to assist in determining the acceptability of an installa­tion where optimum conditions may not apply.
• All insulation resistance values should be greater
than 1000 megohms. If the reading is lower, con­sult Section 10, Troubleshooting Guide.
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Test Procedures
Important: Insulation resistance values for Test A and B for any particular circuit should not vary more than 25 percent as a function of measuring voltage. Greater variances may indicate a problem with your heat-tracing system, confirm proper installation and/ or contact Pentair Thermal Management for assis­tance.
Figure 18: Insulation resistance test
Test A
L2
L1
Test B
Attach to pipe
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Test Procedures
Insulation Resistance test procedure
1. De-energize the circuit.
2. Disconnect the HWAT-ECO or ACS-30 controller if installed.
3. Disconnect bus wires from terminal block.
4. Set test voltage at 0 Vdc.
5. Connect the negative (—) lead to the heating cable metallic braid or RayClic green wire.
6. Connect the positive (+) lead to both heating cable bus wires or RayClic black wires.
7. Turn on the megohmmeter and set the voltage to 500 Vdc; apply the voltage for 1 minute. Meter needle should stop moving. Rapid deflection indi­cates a short. Record the insulation resistance value in the Inspection Record.
8. Repeat Steps 4–7 at 1000 and 2500 Vdc.
9. Turn off the megohmmeter.
10. If the megohmmeter does not self-discharge, discharge phase connection to ground with a suitable grounding rod. Disconnect the megohmmeter.
11. Repeat this test between braid and pipe.
12. Reconnect bus wires to terminal block.
13. Reconnect the HWAT-ECO controller.
3. Circuit length verification (capacitance test)
Connect the capacitance meter negative lead to both bus wires and the positive lead to the braid wire. Set the meter to the 200nF range. Multiply this reading by the Capacitance factor for the correct heating cable shown below to determine the total circuit length.
Length (ft or m) = Capacitance (nF) x Capacitance factor (ft or m/nf)
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Test Procedures
TABLE 4: CAPACITANCE FACTORS
HWAT-R2 5.8 1.8
Heating Cable Capacitance Factor ft/nF m/nF
Compare the calculated circuit length to the design drawings and circuit breaker sizing tables.
Figure 19: Capacitance test
4. Power check
The power output of self-regulating heating cable is temperature-sensitive and requires the following special procedure to determine its value:
Important: Run hot water through the piping sys­tem before powering the HWAT-R2 heating cable. This will ensure the system is at a uniform pipe tempera­ture. Dot not power the system when the pipe temper­ature is below 50F(10C).
1. Power the heating cable and allow it to stabilize
for 2 hours, then measure current and voltage at the junction box. If a controller is used, refer to details below.
2. Measure the pipe temperature under the thermal
insulation at several locations.
3. Calculate the power of the heating cable by mul-
tiplying the current by the input voltage and divid­ing by the actual circuit length.
Power (w/ft or m) =
Volts (Vac) x Current (A)
Length (ft or m)
The power calculated should be similar to the value generated by:
Rated Power (w/ft or m) = Volts (Vac) x Rated Current
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Test Procedures
TABLE 5: RATED CURRENT A/FT OR M
HWAT-R2 140˚F (60˚C) .017 (.056)
Heating Pipe Rated Current Cable Temperature (A/ft or m)
5. Temperature test
When testing an HWAT System for temperatures it is important to test in an appropriate sequence. Testing should start at the point of use closest to the water heater and progress out.
Testing should be done after a minimum of 4 hours of no water usage. This will ensure that the tem­peratures indicated are not due to flow conditions. It is a good idea to turn off all cold water valves to eliminate the possibility of introducing cold water to the hot side via a cross connection.
The following example illustrates a typical tempera­ture test sequence for an HWAT System.
2
3
1
5
4
9
8
7
10
6
11
Figure 20: Typical temperature test sequence
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Test Procedures
9.2 Fault Location Tests
There are three methods used for finding a fault within a section of heating cable:
1. Ratio method
2. Conductance method
3. Capacitance method
1. Ratio method
The ratio method uses resistance measurements taken at each end of the heating cable to approxi­mate the location of a bus wire short. A shorted heating cable could result in a tripped circuit break­er. If the resistance can be read on a standard ohm meter this method can also be used to find a fault from a bus wire to the ground braid. This type of short would trip a GFPD and show a failed reading. Measure the bus-to-bus heating cable resistance at each end (measurement A and measurement B) of the suspected section.
A B
A
B
A B
Braid
Figure 21: Cable resistance measurement test
The approximate location of the fault, expressed as a percentage of the heating cable length from the front end, is:
Fault location:
D =
A
x 100
(A + B)
Example: A = 1.2 ohms B = 1.8 ohms
Fault location: D = 1.2 / (1.2 + 1.8) x 100 = 40%
The fault is located 40% into the circuit as mea­sured from the front end.
To locate a low resistance ground fault, measure between bus and braid.
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Test Procedures
A B
A
B
Braid
Figure 22: Low resistance ground-fault test
The approximate location of the fault, expressed as a percentage of the heating cable length from the front end is:
Fault location:
D =
A
x 100
(A + B)
Example: A = 1.2 ohms B = 1.8 ohms
Fault location: D = 1.2 / (1.2 + 1.8) x 100 = 40%
The fault is located 40% into the circuit as mea­sured from the front end
2. Conductance method
The conductance method uses the core resistance of the heating cable to approximate the location of a fault when the heating cable has been severed and the bus wires have not been shorted together. A sev­ered cable may result in a cold section of pipe and may not trip the circuit breaker.
Measure the bus-to-bus heating cable resistance at each end (measurement A and measurement B) of the suspect section. Since self-regulating cables are a parallel resistance, the ratio calculations must be made using the conductance of the cable.
A B
Figure 23: Cable resistance measurement
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Test Procedures
The approximate location of the fault, expressed as a percentage of the heating cable length from the front end, is:
Fault location:
D =
1/ A
x 100
(1/A + 1/B)
Example: A = 100 ohms B = 25 ohms
Fault location: D = (1/100) / (1/100 + 1/25) x 100 = 20%
The fault is located 20% from the front end of the circuit.
3. Capacitance method
This method uses capacitance measurement (nF) as described in "3. Circuit length verification (capaci­tance test)" on page28, to approximate the loca­tion of a fault where the heating cable has been sev­ered, or a connection kit has not been connected.
Record the capacitance reading from one end of the heating cable. The capacitance reading should be measured between both bus wires twisted together (positive lead) and the braid (negative lead). Multiply the measured capacitance with the heating cable’s capacitance factor as listed in the following example:
Example: HWAT-R2 = 16.2 nF
Capacitance factor = 5.8 ft/nF
Fault location = 42.2 nF x 5.8 ft/nF = 245 ft (75 m) from reading location
As an alternative, capacitance values from each end. The ratio of one capacitance value taken from one end (A) divided by the sum of both A and B (A + B) and then multiplied by 100 yields the distance from the first end, expressed as a percentage of the total heating cable circuit length. See Table 4 on page29, for capacitance factors.
Fault location:
C =
A
x 100
(A + B)
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Test Procedures
9.3 Cable and Connection Continuity Test:
To complete a continuity test it is best to start the installation with a power connection kit. A com­pleted power connection kit allows for easier testing. The bus wires and braid can be temporarily con­nected together at the power connection end (Figure
24) and resistance can be tested at the other end as each additional component is added to the system.
Procedure:
1. De-energize the circuit
2. Disconnect cable bus wires and ground wire
3. Temporarily connect cable bus wires and ground wire together with a wire nut (Figure 24)
Figure 24:
4. Go to the end of the heating cable run and mea­sure resistance using an ohm meter.
5. A resistance reading should be taken for each bus wire to braid and then bus wire to bus wire. Braid to A should equal Braid to B, A to B will be slightly higher. (Figure 25)
Figure 25:
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Test Procedures
6. If a higher reading is measured on one of the tests all connections are not completed and there is not continuity for one or both of the bus wires.
7. If resistance values of braid to A and braid to B are not within 20% of each other inspect all connec­tion kits (splice, tee, and cross) between the power connection and the cable end that is being tested.
8. If resistance values of braid to A and braid to B are within 20% of each other the cable continuity is intact. Continue with system installation.
9. Repeat test procedures for all branch lines to verify entire heat tracing circuit.
10. After entire circuit passes continuity test, remove
wire nut on power connection kit and connect to heat trace controller.
Note: Readings can be taken at a previously installed RayClic power, splice, tee or cross con­nection by using the test ports available inside the component (see figure 26). Testing at a RayClic will only confirm continuity to the previous components; it will not verify continuity to the cable end seal.
Figure 26:
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Troubleshooting Guide
Symptom Probable Causes
Corrective Action
Low water temperature
Insulation is wet, or missing.
HWAT-ECO controller lowered the pipe setpoint temperature because water heater is cold.
Ambient too low.
Improper voltage applied.
Improper insulation thickness used.
HWAT-ECO or ACS-30 was set incorrectly.
Cold water is being introduced into the hot water system.
Tripped circuit breaker
Remove wet insulation and replace with dry insulation, and secure it with proper weatherproofing.
Verify the HWAT-ECO water heater setting, water heater temperature, and sensor placement; and correct as required.
Set the HWAT-ECO or ACS-30 to the appropriate ambient temperature.
Refer to the HWAT-ECO Installation and Operation Manual (H57340) to set the HWAT-ECO to the correct voltage (208 or 240 Vac)
Contact your Pentair Thermal Management representative to confirm the design and modify as recommended.
Refer to the HWAT-ECO Installation and Operation Manual (H57340) or ACS-30 Programming Guide (H58692) for the correct settings.
Verify that the plumbing fixtures and valves are operating properly.
See "Circuit breaker trips" section of this Troubleshooting Guide.
Symptom Probable Causes
Corrective Action
Low or no power output Low or no input voltage applied.
The circuit is shorter than the design shows, due to splices or tees not being connected, or the heating cable having been severed.
Improper component connection causing a high-resistance connection.
HWAT-ECO or ACS-30 set wrong or incorrectly wired.
The heating cable has been exposed to excessive temperature, moisture or chemicals.
Repair the electrical supply lines and equipment.
Check the routing and length of heating cable (use “as built” drawings to reference actual pipe layout). Connect all splices or tees. Locate and replace any damaged heating cables. Then recheck the power output.
Examine RayClic connection kits for proper installation. Check for loose wiring connections and rewire if necessary.
Refer to the HWAT-ECO Installation and Operation Manual (H57340) or ACS-30 Programming Guide (H58692) for the correct settings.
Check the pipe temperature. Verify heater selection. Check the power output of the heating cable per the design vs. actual. Reduce pipe temperature if possible or contact your Pentair Thermal Management representative to confirm design.
Replace damaged heating cable. Check the pipe temperature. Check the power output of heating cable.
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Troubleshooting Guide
Corrective Action
Remove wet insulation and replace with dry insulation, and secure it with proper weatherproofing.
Verify the HWAT-ECO water heater setting, water heater temperature, and sensor placement; and correct as required.
Set the HWAT-ECO or ACS-30 to the appropriate ambient temperature.
Refer to the HWAT-ECO Installation and Operation Manual (H57340) to set the HWAT-ECO to the correct voltage (208 or 240 Vac)
Contact your Pentair Thermal Management representative to confirm the design and modify as recommended.
Refer to the HWAT-ECO Installation and Operation Manual (H57340) or ACS-30 Programming Guide (H58692) for the correct settings.
Verify that the plumbing fixtures and valves are operating properly.
See "Circuit breaker trips" section of this Troubleshooting Guide.
Corrective Action
Repair the electrical supply lines and equipment.
Check the routing and length of heating cable (use “as built” drawings to reference actual pipe layout). Connect all splices or tees. Locate and replace any damaged heating cables. Then recheck the power output.
Examine RayClic connection kits for proper installation. Check for loose wiring connections and rewire if necessary.
Refer to the HWAT-ECO Installation and Operation Manual (H57340) or ACS-30 Programming Guide (H58692) for the correct settings.
Check the pipe temperature. Verify heater selection. Check the power output of the heating cable per the design vs. actual. Reduce pipe temperature if possible or contact your Pentair Thermal Management representative to confirm design.
Replace damaged heating cable. Check the pipe temperature. Check the power output of heating cable.
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Troubleshooting Guide
Symptom Probable Causes
Corrective Action
Low or inconsistent insulation resistance
Nicks or cuts in the heating cable.
Short between the braid and heating cable core or the braid and pipe.
Arcing due to damaged heating-cable insulation.
Moisture present in the components.
Test leads touching the junction box.
If heating cable is not yet insulated, visually inspect the entire length for damage, especially at elbows and flanges and around valves. If the system is insulated, remove the connection kits one-by-one to isolate the damaged the section.
Replace damaged heating-cable sections.
If moisture is present, dry out the connections and retest. Be sure all conduit entries are sealed, and that condensate in conduit cannot enter power connection boxes. If heating-cable core or bus wires are exposed to large quantities of water, replace the heating cable. (Drying the heating cable is not sufficient, as the power output of the heating cable can be significantly reduced.)
Clear the test leads from junction box and restart.
Symptom Probable Causes
Corrective Action
Circuit breaker trips
Circuit breaker is undersized.
Connections and/or splices are shorting out.
Physical damage to heating cable is causing a direct short.
Bus wires are shorted at the end.
Circuit lengths too long
Nick or cut exists in heating cable or power feed wire with moisture present or moisture in connections.
GFPD is undersized (5 mA used instead of 30 mA) or miswired.
Recheck the design for startup temperature and current loads. Do not exceed the maximum circuit length for heating cable used. Replace the circuit breaker, if defective or improperly sized.
Visually inspect the RayClic connection systems. Replace if necessary.
Check for damage around the valves and any area where there may have been maintenance work. Replace damaged sections of heating cable.
Check the end seal to ensure that bus wires are not shorted. If a dead short is found, the heating cable may have been permanently damaged by excessive current and may need to be replaced.
Separate the circuit into multiple circuits that do not exceed max circuit lengths.
Replace the heating cable, as necessary. Dry out and reseal the connections and splices. Using a megohmmeter, retest insulation resistance.
Replace undersized GFPD with 30 mA GFPD. Check the GFPD wiring instructions.
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Troubleshooting Guide
Corrective Action
If heating cable is not yet insulated, visually inspect the entire length for damage, especially at elbows and flanges and around valves. If the system is insulated, remove the connection kits one-by-one to isolate the damaged the section.
Replace damaged heating-cable sections.
If moisture is present, dry out the connections and retest. Be sure all conduit entries are sealed, and that condensate in conduit cannot enter power connection boxes. If heating-cable core or bus wires are exposed to large quantities of water, replace the heating cable. (Drying the heating cable is not sufficient, as the power output of the heating cable can be significantly reduced.)
Clear the test leads from junction box and restart.
Corrective Action
Recheck the design for startup temperature and current loads. Do not exceed the maximum circuit length for heating cable used. Replace the circuit breaker, if defective or improperly sized.
Visually inspect the RayClic connection systems. Replace if necessary.
Check for damage around the valves and any area where there may have been maintenance work. Replace damaged sections of heating cable.
Check the end seal to ensure that bus wires are not shorted. If a dead
short is found, the heating cable may have been permanently damaged
by excessive current and may need to be replaced.
Separate the circuit into multiple circuits that do not exceed max circuit lengths.
Replace the heating cable, as necessary. Dry out and reseal the connections and splices. Using a megohmmeter, retest insulation resistance.
Replace undersized GFPD with 30 mA GFPD. Check the GFPD wiring instructions.
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11
Troubleshooting Guide
Pentair Thermal Management Industrial Heat-Tracing Installation and Inspection Record
Test Date:_________ Facility: (Circuit Number) Commission Inspection date: Inspected by (Name): Panel and Circuit Breaker Number: Water heater/mixing valve temperature setting (°F) Designed circuit length (ft):
Capacitance test
nF: Cap factor (Table 4): nF X Cap Factor= (ft/m) HWAT-ECO setting: Heating cable type: Voltage: Ambient Temp: Set point: Maintain Power factor
Test Date: Visual Inspection
Confirm 30-mA ground-fault device (proper rating/function) Confirm all electrical connections in the RayClic and HWAT-ECO are tight
and wires secure. Visual inspection inside connection boxes for overheating, corrosion,
moisture, loose connections and other problems. Proper electrical connection, ground, and bus wires insulated over full length. Correct thermal insulation used for each pipe size (Reference Table 2) Damaged or missing thermal insulation for the entire hot water piping system. Covered end seals, splices, and tees properly labeled on insulation. Check HWAT-ECO for moisture, corrosion, setpoint, switch operation
Insulation resistance test
Bus to braid (Test A) 500 Vdc 1000 Vdc 2500 Vdc Braid to pipe (Test B) 500 Vdc 1000 Vdc
2500 Vdc
Power and temperature check
Panel voltage (V) Circuit voltage (V) Circuit end (V) Circuit amps after 2 hours (A) Pipe temperature (°F)
megohm megohm megohm megohm
11 Troubleshooting Guide
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Troubleshooting Guide
Test Date:_________
megohm megohm megohm megohm
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Page 48
WWW.THERMAL.PENTAIR.COM
NORTH AMERICA
Tel: +1.800.545.6258 Fax: +1.800.527.5703 Tel: +1.650.216.1526 Fax: +1.650.474.7711 thermal.info@pentair.com
EUROPE, MIDDLE EAST, AFRICA
Tel: +32.16.213.511 Fax: +32.16.213.603 thermal.info@pentair.com
ASIA PACIFIC
Tel: +86.21.2412.1688 Fax: +86.21.5426.2917 cn.thermal.info@pentair.com
LATIN AMERICA
Tel: +1.713.868.4800 Fax: +1.713.868.2333 thermal.info@pentair.com
Pentair, RayClic, and HWAT are owned by Pentair or its global affili­ates. All other trademarks are the property of their respective owners. Pentair reserves the right to change specifications without prior notice.
© 2004–2016 Pentair. P000000272
THERMAL MANAGEMENT SOLUTIONS Raychem-IM-H57548-HWATsystem-EN 16/08
Page 49
HWAT-ECO
INSTALLATION AND OPERATION MANUAL FOR HOT WATER TEMPERATURE MAINTENANCE SYSTEM ELECTRONIC CONTROLLER
THERMAL MANAGEMENT SOLUTIONS WWW.THERMAL.PENTAIR.COM
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Important Safeguards and Warnings
WARNING: FIRE AND SHOCK HAZARD
Raychem HWAT Systems must be installed correctly to ensure proper operation and to prevent shock and fire. Read these important warn­ings and carefully follow all the installation instructions.
• To minimize the danger of fire from sustained electrical arcing if the heating cable is damaged or improperly installed, and to comply with Pentair Thermal Management requirements, agency certifica­tions, and national electrical codes, ground-fault equipment protec­tion must be used on each heating cable branch circuit. Arcing may not be stopped by conventional circuit breakers.
• Approvals and performance are based on the use of Pentair Thermal Management parts only. Do not substitute parts or use vinyl electrical tape.
• Bus wires will short if they contact each other. Keep bus wires separated.
• Connection kits and heating cable ends must be kept dry before and during installation.
• The black heating cable core is conductive and can short. They must be properly insulated and kept dry.
• Damaged bus wires can overheat or short. Do not break bus wire strands when preparing the cable for connection.
• Damaged heating cable can cause electrical arcing or fire. Do not use metal attachments such as pipe straps or tie wire. Use only Pentair Thermal Management approved tapes and cable ties to secure the cable to the pipe.
• Do not attempt to repair or energize damaged cable. Remove damaged cable at once and replace with a new length using the Raychem RayClic-S splice kit. Replace damaged connection kits.
• Use only fire-resistant insulation which is compatible with the application and the maximum exposure temperature of the system to be traced.
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EN-RaychemHWATECOcontroller-IM-H57340 03/13
Table of Contents
1
General Information 1
1.1 Use of the Manual 1
1.2 Features 1
1.3 Technical Data 3
1.4 Care and Maintenance 7
1.5 HWAT Heating Cables 7
2
Installation 9
2.1 Installing the Controller 9
2.2 Wiring the Controller 13
3
Programming the Controller 26
3.1 Programming Overview 26
3.2 Initializing the Controller 27
3.3 Advanced Programming 33
4
Error/Alarms and Troubleshooting 45
5
Pre-Defined Programs 50
6
Heat-Up Cycle Graphs 52
7
Cool-Down Graph 54
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EN-RaychemHWATECOcontroller-IM-H57340 03/13
A
F
B
C
D
E
Item Qty Description
A 1 HWAT-ECO controller B 1 Temperature sensor with 13 ft (4 m) cable C 2 Mounting screws D 2 Mounting washers E 1 Aluminum tape F 1 Manual
HWAT-ECO
INSTALLATION AND OPERATION MANUAL FOR
HOT WATER TEMPERATURE MAINTENANCE SYSTEM
ELECTRONIC CONTROLLER
THERMAL MANAGEMENT SOLUTIONS WWW.THERMAL.PENTAIR.COM
Figure 1: Kit contents
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EN-RaychemHWATECOcontroller-IM-H57340 03/13
Power supply (green LED)
Power to heating cable (green LED)
Heat-up cycle (green LED) - increased risk of scalding
Pipe Temperature alarm (requires installed sensor) (green LED)
Alarm (red LED)
Escape, backspace; NO; or display maintain temperature setpoint
Arrow keys: to change menu selection or position the cursor
Confirm selection, new value or YES
6.5"
(165 mm)
2 ea - 1/2" conduit
entries
To water heater sensor To HWAT-ECO network/alarm entries
3.4"
(85 mm)
A B C D E
F G H
A
B
C
D
E
F
G
H
Figure 2: HWAT-ECO controller
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EN-RaychemHWATECOcontroller-IM-H57340 03/13
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General Information
1
EN-RaychemHWATECOcontroller-IM-H57340 03/13
1.1 Use of the Manual
This manual covers the installation and operation of the HWAT-ECO controller and must be used with the following additional documents:
• HWAT System Product and Selection Design Guide (H57538)
• HWAT System Installation and Operation Manual (H57548)
Important: For the Pentair Thermal Management warranty and agency approvals to apply, the instruc­tions included in this manual and product packages must be followed.
1.2 Features
The Raychem HWAT-ECO controller is designed for operation with HWAT-Y2 and HWAT-R2 self­regulating heating cables. The HWAT-ECO controller provides the following features:
• Flexible temperature control of hot water tem-
perature maintenance systems.
• Integrated function that lowers the maintain tem-
perature during low use hours to save energy.
• Heat-Up cycle function that increases the water
temperature in a stagnant pipe.
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General Information
2
EN-RaychemHWATECOcontroller-IM-H57340 03/13
• Building Management System (BMS) interface that receives a DC voltage to set the maintain temperature.
• Alarm relay to signal power, temperature, or communication problems.
• Pipe temperature monitoring, low temperature alarm and high temperature cut-out.
• Master/slave function that allows one HWAT-ECO to control up to eight additional HWAT-ECO controllers.
• 9 pre-defined programs that can be customized by the user.
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General Information
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EN-RaychemHWATECOcontroller-IM-H57340 03/13
1.3 Technical Data
Use Only for HWAT-Y2 and
HWAT-R2 heating cables
Maintain temperature setpoint
105˚F (40˚C) to 140˚F (60˚C)
Hot water piping ambient temperature
60˚F (15˚C) to 80˚F (25˚C)
Controller ambient temperature
40˚F (5˚C) to 105˚F (40˚C) ambient
Switching capacity 24 A 208/240 Vac max.
Operating voltage 208/240 (±10%), 60 Hz
Internal power consumption
2.5 W
Circuit protection (not provided with HWAT-ECO controller)
Max. 30 A with 30 mA ground-fault protection
Power terminal block 16–10 AWG (1.5–4 mm2)
Use copper conductors only
Internal temperature alarm
150˚F (65˚C)
BMS control voltage 0–10 Vdc
BMS cable maximum length
328 ft (100 m)
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General Information
4
EN-RaychemHWATECOcontroller-IM-H57340 03/13
Alarm contacts Max. 24 Vdc or 24 Vac, 1A,
SPST, voltage free, NO/NC
Alarm events • Loss of power
• Controller reinitialized
• Internal controller temperature too high
• Lost date and time settings
• Internal failure
• Pipe temperature too high (optional)
• Pipe heater tempera­ture too low (optional)
• Network error
Power correction factor To increase or decrease
your actual pipe maintain temperature or adjust for plastic pipe.
Pipe temperature sensor Thermistor with 13 ft
(4m) lead provided. A PT100 RTD may be option­ally used. Max length is 328 ft (100 m)
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General Information
5
EN-RaychemHWATECOcontroller-IM-H57340 03/13
Electromagnetic Complies to EN 5014-1
Compatibility (EMC) for emission and 60730-1 for immunity
Real time clock Leap year correction
Clock accuracy ±10 minutes per year
Enclosure rating NEMA 12 (IP54) – indoor
use only
Enclosure material ABS
Mounting Wall mount with two
screws or optional DIN rail
Conduit entries 2 ea – 1/2 in conduit entries
Cable gland 3-hole grommet
Maximum cable size:
• 2-wire: 20 AWG (0.5 mm2)
• 4-wire: 24 AWG (0.2 mm2)
Default programs 9 pre-defined programs
that can be customized by user
Program settings 48 1/2-hour time blocks
of the following program settings: Off, Economy, Maintain and Heat-Up cycle
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EN-RaychemHWATECOcontroller-IM-H57340 03/13
Password 4-digit password protection
Master/slave Master is selectable in the
controller, up to 8 slaves can be connected
Master/slave cable 2-wire, min. 24 AWG
(0.2 mm2) twisted pair and insulation of 300 V, Max length cable is 100 m
Parameters in memory All parameters are stored
in nonvolatile memory, except time and date
Clock backup time Rechargable Lithium bat-
tery. Battery will retain time and date for up to 30 days when power is lost
Approvals
80BJ
Type 12
Energy Management Equipment
(for use with HWAT-R2 and HWAT-Y2 heating cables only.)
Weight 2 lbs (1 kg)
Size 6.5 in x 3.4 in x 2.8 in
(165 mm x 85 mm x 71 mm)
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1.4 Care and Maintenance
To clean the HWAT-ECO use a damp cloth. Do not use solvents. Do not pour water directly on the device. Do not use a water hose or high pressure cleaner.
Important: In case of questions or product failure, please contact your Pentair Thermal Management rep­resentative, or call Pentair Thermal Management at 800-545-6258.
1.5 HWAT Heating Cables
Maintain temperature
Depending on the ambient temperature and voltage, HWAT-Y2 is designed to maintain temperatures up to 125˚F (52˚C), and HWAT-R2 is designed to maintain temperatures up to 140˚F (60˚C).
Installing the heating cables
Install the HWAT heating cable system as instructed in the HWAT System Installation and Operation Manual (H57548). The controller must be installed by a professional electrical installer familiar with elec­trical safety codes and practices.
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Ground-fault protection
WARNING: To minimize the danger of fire from sustained electrical arcing if the heating cable is damaged or improperly installed, and to comply with the requirements of approvals agencies, Pentair Thermal Management and national electrical codes, ground-fault equipment protection must be used on each heating cable branch circuit. Arcing may not be stopped by conventional circuit protection. The HWAT-ECO does not include ground-fault protection.
Pre-Installation testing
Prior to installing the HWAT-ECO controller, perform the insulation resistance (Megger) test and circuit length verification (Capacitance) test on the heating cable as detailed in the HWAT System Installation and Operation Manual (H57548).
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2.1 Installing the Controller
Install the controller in an indoor, dry, clean, acces­sible location. If using the optional pipe temperature sensor, make sure you install the controller within 328 ft (100 m) of where you want to monitor the pipe temperature.
Opening the controller
WARNING: To prevent shock, always switch off the power supply (circuit breaker) before opening the controller.
The HWAT-ECO has a removable front cover. Both the cover and the box have electronic parts and are connected to each other by a 14-pin connector. First unscrew the four screws in the cover. Carefully pull the cover straight out, not sideways!
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Figure 3: Opening the controller
Wall mounting the controller
Mount the controller using either of the options below:
1. You can mount the controller to the wall using the two supplied screws and sealing rings in the two holes located inside the bottom part of the controller.
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5.9" (148 mm)
1.7"
(43 mm)
TEMP BMS
B A
Figure 4: Hole locations for mounting with screws
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2. Optionally you can mount the controller using DIN 35 Rail mounting.
Optional Din Rail Mount
(Rail not provided)
Mounting
Removing
Press tab to remove box
Figure 5: Mounting with DIN 35 Rail
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2.2 Wiring the Controller
The diagram below shows the arrangement of the terminal blocks for power, alarm, pipe temperature sensor, BMS and network.
Ground
HWAT-ECO
General Arrangement
Power
terminal block
Sensor, BMS,
and network
terminal block
Alarm
terminal block
Ø
1Ø2
HWAT Line
Ø
1Ø2
TEMP BMS
B A
Figure 6: General arrangement for terminal blocks
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The diagram below shows the connection of a single controller (without optional water heater sensor, BMS, network and alarm connections).
Important: Tighten the terminal screws to 6 inch-
lbs. (0.68 N-m)
Ø
Ø
G
1/2"
Conduits
HWAT
heating
cable
RayClic-PC
Max. 30 A
ground fault
circuit breaker
208-240 Vac
Ground
Incoming power 208/240 Vac Max
Wiring diagram
for HWAT-ECO
To
HWAT
heating
cable
TEMP BMS
B A
Figure 7: Connecting a single controller (w/o sensor, BMS, network and alarm connections)
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For controlling multiple HWAT circuits with the same programming parameters (i.e. voltage, maintain temperature, ambient temperature, economy tem­perature), connect the heating cable output relay to an external contactor coil(s).
N
ø
1
HWAT-ECO internal switch
ø3ø
2
HWAT heating cable
HWAT heating cable
Braid/pipe
Two-pole with 30-mA ground-fault trip (208/240 Vac)
Two-pole with 30-mA ground-fault trip (208/240 Vac)
Three-pole main CB
HWAT-ECO internal relay
Power connection
Panel energized light
*Contactor coil
(208 or 240 V)
Heating cable
End seal
Three-pole main contactor
Ground Line voltage 208 V or 240 V
Install contactor manufacturer’s recommended snubber circuit across the coil
*
Figure 8: Multiple HWAT circuits connection
Pipe temperature sensor (optional usage)
Installation of the pipe temperature sensor is option­al. If installed, the HWAT-ECO provides low tempera­ture alarm and high temperature cut-out.
The temperature sensor should be connected to a single or master controller only. Connect both wires
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of the temperature sensor to the TEMP terminal in the controller (PL4). The sensor wires do not have a special polarity. To connect a wire, use a screw­driver to push down the orange tab on the side of the terminal. Put the wire into the hole and release the orange tab.
PL4PL3
PL5
Standard temperature sensor
PT100 sensor (2 wire)
short
for
PT100
TEMP BMS
B A
PL4PL3
PL5
TEMP BMS
B A
Alarm,
Sensor,
and BMS
terminals
PL6
Alarm contact
TEMP BMS
B A
Figure 9: TEMP terminal location and sensor wiring
Optionally, PT100 RTDs from the water heater can be used. To install a PT100 sensor first connect a jumper between the terminals indicated in Figure 9, then connect the two wires from the RTD. If you are using a three wire sensor, remove the compensation lead and only connect the two measurement wires.
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The pipe temperature sensor must be placed on 1-inch diameter pipes or larger, installed opposite from the HWAT heating cable to accurately measure the pipe temperature.
The temperature sensor cable is 13 ft 3 in (4 m) in length, however the user can extend the cable up to 328 ft (100 m) by splicing a length of 300 volt, 18 AWG (0.75mm2) cable.
Cold water in
mixing
valve
Tempered water out
Hot water out
Hot water in
HWAT-Y2
HWAT-R2
Water heater
A
B
Temperature sensor
Insulation
180°
Heating cable
Figure 10: Positioning temperature sensor (optional)
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Alarm wiring (optional)
The alarm contact (24 Vac, 24 Vdc, 1A) inside the con­troller can be used to switch an external device. The contact is closed during operation and open during an alarm or during loss of power. In a network, all alarm contacts should be connected in series.
Alarm,
Sensor,
and BMS
terminals
PL6
Alarm contact
TEMP BMS
B A
NC O NO
Figure 11: Connecting the alarm contact
The alarm terminal (PL6) is located in the upper right corner of the controller and has the text “alarm contact” next to it. To connect a wire, use a screw­driver to push down the orange tab on the side of the terminal. Put the wire into the hole and release the orange tab. The wires used for the alarm contact should be rated for 300 V. See “Chapter 4, Error/
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Alarms and Troubleshooting” for more information about alarm conditions.
The alarm contact is designed as a fail safe mode and can be wired for normally open (NO) or normally closed (NC) operation. The following table summa­rizes the relay positions in the different controller states:
Position NC NO
Power Off Open Closed
Power On Closed Open
Alarm Mode Open Closed
Network
The Master/slave function allows one HWAT-ECO to control up to eight additional HWAT-ECO controllers. Connect all HWAT-ECO controllers to each other in parallel using the A and B inputs on terminal (PL3). This means that several controllers will have two wires in one hole. The wire should be a twisted pair and be rated for 300 V. The total maximum length of this cable between all controllers is 328 ft (100 m). Be careful not to mix A and B connections. To connect a wire, use a screwdriver to push down the orange tab on the side of the terminal. Put the wire into the hole and release the orange tab.
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MASTER
TEMP BMS
B A
TEMP BMS
B A
SLAVE 1
OPTIONAL BMS
WATER HEATER SENSOR
NETWORK WIRE
TO SLAVE 2
Figure 12: Networking controllers together
The diagram below shows the connection of multiple controllers (with optional RS-485 connections).
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HWAT
heating
cable
L
L
208/240V
HWAT
heating
cable
Master Slave 1 Slave 2
RS-485 RS-485
Sensor
BMS
Alarm
L
L
208/240V
L
L
208/240V
HWAT
heating
cable
Figure 13: Connecting multiple controllers (with RS-485)
When multiple controllers are networked and you are using BMS and Alarm functions, you must use a 4-wire conductor.
max. 20 AWG
(0.5 mm
2
)
max. 24 AWG
(0.2 mm2)
Figure 14: Combine alarm and BMS wire in 4-wire cable
Important: For master/slave combination with
alarm function, the alarms are connected in series by a RS485 wire. Since the cable gland grommet has only 3 holes, you must combine the alarm wire and the BMS wire in a 4-wire cable.
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Building Management System (BMS) (optional)
See Table 5 on page 39.
The BMS input of the HWAT-ECO is a 0 to 10-Vdc input. If the controller is programmed to have a BMS connection, the BMS controls the temperature set­point. Using 300-V rated cable, connect the BMS sig­nal wire to terminal (PL5). Connect the ground wire to the “–” and the 0-10 V output to the “+” terminal.
Alarm,
Sensor,
and BMS
terminals
0-10v
ground
BMS
PL3 PL5PL4
PL6
Alarm contact
TEMP BMS
B A
Figure 15: Connecting the BMS
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Figure 16 shows the connection of a single controller (with optional sensor, BMS and alarm connections).
Master
HWAT
heating
cable
Sensor
BMS
Alarm
L
L
208/240V
RayClic-PC
Figure 16: Single controller connection (with sensor, BMS, and alarm connections)
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Closing the controller
Position the cover in front of the wall-mounted box. The separation sheet inside the controller will help guide the cover and the connector. Push the cover onto the box. Note that the connector pins will offer some resistance. Put the screws in place and tighten to 10 inch-lbs (1.13 N-m).
Figure 17: Closing the controller
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Power supply (green LED)
Power to heating cable (green LED)
Heat-up cycle (green LED) - increased risk of scalding
Pipe temperature alarm (requires installed sensor) (green LED)
Alarm (red LED)
Escape, backspace; NO; or display maintain temperature setpoint
Arrow keys: to change menu selection or position the cursor
Confirm selection, new value or YES
02-11-2012 09:30 Maintain *
A B C D E
F G H
A
B
C
D
E
F
G
H
Figure 18: Controller display
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3.1 Programming Overview
Display functions
Quickstart Any key to start
The display has two lines with 16 characters each. The display shows the following text on start up:
The HWAT-ECO has six buttons:
Up/Down/Left/Right arrows
Escape (ESC) button
Enter button
You can program the HWAT-ECO by simply executing the Quickstart program which is suitable for normal operations. In addition, advanced programming can be used to modify initial settings, set additional fea­tures such as BMS and Network Master, reinitialize the entire controller, or customize the pre-defined programs.
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3.2 Initializing the Controller
The first time you power up the controller, you must execute the Quickstart program to set the initial set­tings. Once initialized continue to power the control­ler for at least 6 hours to charge the internal battery.
TABLE 1:
QUICKSTART MENU
Time and date Year
Month Day Hour Minutes
Select Year Select Month Select Day Select Hour Select Minutes
Cable type HWAT-R2
“Press Enter for this cable type.”
HWAT-Y2
“Press Enter for this cable type.”
Voltage select 208 Vac
“Press Enter for this voltage type.”
240 Vac
“Press Enter for this voltage type.”
Units English
“Press Enter for this unit type.”
Metric
“Press Enter for this unit type.”
Ambient temp. Maintain temp. Economy temp.
“Enter ambient temp.” “Enter maintain temp. setpoint” “Enter economy temp. setpoint”
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TABLE 1:
QUICKSTART MENU
Default program Constant
Apartments Family home Prison Hospital Nursing home Hotel Sports center Convales. home
“Scroll to program and press Enter.”
During the Quickstart you can press the ESC button to go back to a previous menu. On startup the dis­play will show the following text:
Quickstart Any key to start
Press a key to start, and the following menus appear:
Time and Date
Use the up/down arrows to select the year and press Enter. Then, select and enter the month, day, hour, and minutes. The time and date is contained in vola­tile memory, and is maintained during power out­ages by an internal rechargeable battery. Power the HWAT-ECO for at least 6 hours to charge the battery.
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Cable type
Use the up/down arrows to select HWAT-Y2 or HWAT-R2 cable used in your installation. Press Enter.
Voltage
Use the up/down arrows to select 208 V or 240 V (applied voltage to the cable). Press Enter.
Units
Use the up/down arrows to select English or Metric units. Press Enter.
Ambient temperature
The ambient temperature is the air temperature surrounding the hot water piping where the heating cable is installed. Use the up/down arrow keys to select from 60˚F (15˚C) to 80˚F (25˚C). Press Enter.
If your design requires that the ambient temperature is significantly different from one location to another, you will need an HWAT-ECO controller for each ambi­ent condition.
Maintain temperature
The maintain temperature setpoint is the water tem­perature that you set for normal use. Use the up/ down arrow keys to select the temperature.
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The minimum temperature is 105˚F (40˚C) or the economy temperature, whichever is higher. The maximum temperature depends on cable type, volt­age and ambient temperature. The programmed maintain temperature will display if you press the ESC button once the system is in operation.
TABLE 2:
MAXIMUM MAINTAIN TEMPERATURE 208VOLT
Ambient temperature
Heating cable
60˚F (15˚C)
70˚F (20˚C)
80˚F (25˚C)
HWAT-Y2
120˚F (49˚C) 125˚F (52˚C) 125˚F (52˚C)
HWAT-R2 140˚F (60˚C) 140˚F (60˚C) 140˚F (60˚C)
TABLE 3:
MAXIMUM MAINTAIN TEMPERATURE 240VOLT
Ambient temperature
Heating cable
60˚F (15˚C)
70˚F (20˚C)
80˚F (25˚C)
HWAT-Y2 120˚F (49˚C) 125˚F (52˚C) 125˚F (52˚C)
HWAT-R2 140˚F (60˚C) 140˚F (60˚C) 140˚F (60˚C)
Economy temperature
The economy temperature setpoint is the water tem­perature for periods during which hot water is not usually used (at night) or when a lot of hot water is used (peak period). Use the up/down arrows to select
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the temperature. The minimum temperature is 105˚F (40˚C) and the maximum temperature is the selected maintain temperature.
Default programs
The HWAT-ECO has 9 pre-defined programs. (See “Chapter 5, Pre-Defined Programs” for more infor­mation.) Use the up/down arrows to select a pre­defined program. Press Enter. HWAT-ECO takes a few seconds to copy the pre-defined program to the internal memory. During this time a row of dots will show in the display.
Pipe temperature
This function also ensures that the delivered water temperature is not lower than the desired maintain temperature.
Completing initialization
The controller will start automatically when you finish selecting your Quickstart options. Additional settings are available in the Setup menu for advanced installations. See section 3.3 on page 33 for more information.
Press Enter to start the controller. If you press the ESC button, you can retrace all menu items to check the settings. After starting the controller the display shows date, time, temperature setting and a “*” to
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indicate that the controller is unlocked. If you wish to lock (password protect) the controller, see section
3.3.2.6 for instructions.
Displaying Maintain Temperature Setpoint
After finishing the Quickstart, the display will show the date, time, temperature mode and a star to indi­cate that the controller is unlocked.
02-11-2013 Maintain
09:13
While in operating mode, press ESC to view a bar graph that shows the maintain temperature setpoint. To enter the programming menu, press any other key. The controller will exit the menu automatically after five seconds of key inactivity.
Figure 19: Bar graph
Displaying Pipe Temperature
When the optional pipe temperature sensor is con­nected, the controller will display date and time as above and alternate between temperature mode and pipe temperature.
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02-11-2013 Pipe T: 110°F
09:13
*
3.3 Advanced Programming
Advanced programming options are also available. Table 4 and the remainder of this section outline the advanced programming options that include modify­ing initial settings, setting additional features such as BMS and Network Master, reinitializing the entire controller, or customizing the pre-defined programs.
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TABLE 4:
ADVANCED PROGRAMMING MENU
1 Time and Date
1 Year 2 Month 3 Day 4 Hour 5 Minutes
Select Year Select Month Select Day Select Hour Select Minutes
2 Setup
(enter pass­word if Lock is ON)
1 Main Temp “Enter maintain temp. setpoint”
2 Economy Temp “Enter economy temp. setpoint”
3 Ambient Temp “Enter ambient temp.”
4 Power Correction Selectable
5 Lock Lock/unlock Setup and Timer
menus
6 BMS Select Yes/No
7 Network Master Select Yes/No
8 Reinitialize Select Yes/No
9 Short heater Select Yes/No
10 LTA (Low Temp Alarm)
1. Set Status
2. Set Temperature
3. Set Alarm Filter Time
4. Set Deadband
Select Yes/No Enabled or Disabled 95°F (35°C) min 5-30 Minutes 4-18°F (2-10°C)
11 HTC (High Tem. Cut Out)
1. Set Status
2. Set Temperature
3. Set Alarm Filter Time
4. Set Deadband
Enabled or Disabled Maximum 205°F 10-30 Minutes 4-18°F (2-10°C)
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TABLE 4:
ADVANCED PROGRAMMING MENU
3 Timer
(enter pass­word if Lock is ON)
1 Default program Constant
Apartments Family home Prison Hospital Nursing home Hotel Sports Center Convalesc. home
2. Edit program Monday Tuesday Wednesday Thursday Friday Saturday Sunday
Edit timer for Monday Edit timer for Tuesday Edit timer for Wednesday Edit timer for Thursday Edit timer for Friday Edit timer for Saturday Edit timer for Sunday
4 Holiday On
Off xxDays off
5 Info Show firmware version number + Cable type + Sensor temp.
Time and Date
Use the up/down arrows to select the year and press Enter. Then select and set the month, day, hour and minutes.
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Setup
When Lock is on (no star in the lower right corner) enter a password to access the setup menu. The controller locks again after 60 seconds of inactivity.
When Lock is off the following menus are directly accessible.
1. Maintain temperature
The maintain temperature setpoint is the water tem­perature that you set for normal use. Use the up/ down arrows to select the temperature. The mini­mum temperature is 105˚F (40˚C) or the economy temperature, whichever is higher. The maximum temperature depends on cable type, pipe diameter, insulation thickness and ambient temperature.
2. Economy temperature
The economy temperature setpoint is the water temperature for periods during which hot water is not usually used (at night) or when a lot of hot water is used (peak period). Use the up/down arrows to select the temperature. The minimum temperature is 105˚F (40˚C) and the maximum temperature is the selected maintain temperature. Press Enter.
3. Ambient temperature
The ambient temperature is the air temperature surrounding the pipes where the heating cable is
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installed. Use the up/down arrows to select from 60˚F (15˚C) to 80˚F (25˚C). Press Enter to confirm.
If your design requires that the ambient temperature is significantly different from one location to another, you will need an HWAT-ECO controller for each ambient condition.
4. Power correction
The power correction factor can be selected to increase or decrease your actual pipe maintain tem­perature or to adjust for using HWAT heating cables on rigid plastic pipes.
The power correction factor can be adjusted from 0.6 to 1.40, increasing or decreasing the percent time the heating cable is powered during the duty cycle.
For installation on rigid plastic pipe set the power factor at:
HWAT-Y2: 1.20 HWAT-R2: 1.25
5. Lock (password)
Use the up/down arrows to select Lock On/Off and press Enter. If you select ‘On’, you must enter a password using the left/right and up/down arrow buttons to select a 4-digit password. Press Enter.
You will need to remember your 4-digit password whenever you wish to unlock the controller for
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reprogramming. Once you unlock and reprogram, you will need to relock by entering your password.
If Lock is On, the Setup and Timer menus are pro­tected by the password. After you enter the pass­word, the controller remains unlocked until five minutes of key inactivity or until you select Lock ‘On’ again.
6. Building Management System (BMS)
You can activate the Building Management System option using this menu. When set to “Yes” the control­ler responds only to the voltage applied to the BMS terminal. For voltages ≤ 4 Vdc: heating cable is OFF. For voltages between 4.1 Vdc and 6.4 Vdc: maintain temperatures are set as indicated in Table 5. For voltages > 6.4 Vdc: 100% power is applied to the heating cable. See "Building Management System (BMS) (optional)" on page 22 for installation infor­mation. If Water heater is ON, it overrules the BMS temperature setting if necessary.
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TABLE 5: BMS VOLTAGE INPUT
Temp °F (°C)
HWAT-Y2
HWAT-R2
U-BMS/U-GLT (VOLT)
>147 (>64) X >6.4 147 (64) X 6.4 140 (60) X 6 131 (55) X X 5.5 122 (50) X X 5 113 (45) X X
4.5
106 (41) X X
4.1
Off X X
0
7. Network Master
In large installations where more than one HWAT­ECO controllers are connected to each other, you must select one controller as the Master. This con­troller should be fully programmed and all slave controllers will use the Master settings.
The master controller sends commands to all slave controllers to switch them ON or OFF. The master program is used for all controllers as follows: Slave controllers on the same phase (max. three control­lers) will have a delayed ON and OFF. This way the start-up current of the cable will never occur at the same moment for these controllers (A, B and C). Slave controllers connected to a different phase will switch at the same time (1, 2 and 3).
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After selecting “Master: Yes”, the slave controllers will initialize and show:
:Slave: “x y” x= phase number (1 to 3) y= slave identification (A, B and C)
The master controller is always 1 A, the slave con­trollers will get their number and identification auto­matically. Always check afterwards if all controllers have unique id-numbers, if not, check the RS485 cables and repeat this procedure.
8. Reinitialize
To Reinitialize all settings back to the factory set­tings (except time and date), set the “Reinitialize” menu to “Yes.”
9. Short Heater
This feature allows you to activate a low current alarm:
Yes: Allows low current such as when used as a demonstration, or to control a contactor. In this mode there is no low current alarm.
No: Generates low current alarm when measured current is less that 300 mA.
10. LTA (Low Pipe Temperature Alarm)
When the optional pipe temperature sensor option is installed, the HWAT-ECO controller monitors the temperature of the hot water distribution pipes
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where the sensor is installed and can generate a low pipe temperature alarm.
1. Set Status: Enabled or Disabled
2. Set temperature: – Minimum: 95°F (35°C) – Maximum: < Maintain (or Economy)
3. Set Alarm filter time: 5–30 minutes
4. Set deadband: 4–18°F (2–10°C), 9°F
(5°C default)
11. HTC (High Temperature Cut-Out)
When the optional pipe temperature sensor option is installed, the HWAT-ECO controller monitors the temperature of the hot water distribution pipes where the sensor is installed and a high temperature cut-out can be set.
High Temperature Cut-out:
Minimum: > set point Maximum: 205°F (96°C) Alarm filter: 5–30 minutes (default 10) Dead band: > 5°F (3°C) default 0°F(6°C)
Timer
The Timer feature lets you re-program any of the pre-defined programs to suit your personnel requirements. Reprogramming is done graphically in 1/2 hour time blocks. A block can be set to Heat-Up
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cycle, Maintain temperature, Economy temperature, or Off. See “Chapter 6, Heat-Up Cycle Graphs” for more information.
Edit pre-defined programs
To edit a program, switch Lock to Off. If password protected, you will need to enter the password to unlock the controller. After you enter the password, the controller remains unlocked until five minutes of key inactivity or the Lock ‘On’ is selected again
Select temperature
Use the up/down arrows to select the temperature:
= Maintain temperature= Heat-up cycle
= Economy temperature = Off
Figure 20: Timer block options
Select time block
Use the left/right arrows to select the time block. Timer programming example from 00:00 to 08:00:
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.......... 04:00 – 04:30: Off
00:00 – 00:30: Heat-up cycle 04:30 – 05:00: Economy 00:30 – 01:00: Heat-up cycle 05:00 – 05:30: Economy 01:00 – 01:30: Heat-up cycle 05:30 – 06:00: Economy 01:30 – 02:00: Heat-up cycle 06:00 – 06:30: Economy 02:00 – 02:30: Off 06:30 – 07:00: Maintain 02:30 – 03:00: Off 07:00 – 07:30: Maintain 03:00 – 03:30: Off 07:30 – 08:00: Maintain
03:30 – 04:00: Off ...........
Figure 21: Timer programming example
Heat-Up cycle
The HWAT-ECO can be programmed to power HWAT-Y2 or HWAT-R2 at full power for any selected number of hours. When hot water is not being used and the pipes are stagnant, the HWAT-ECO can raise the temperature of the water in the stagnant pipes. To determine the amount of time that is required to reach a desired temperature, refer to “Chapter 6, Heat-Up Cycle Graphs.” You must know the pro­grammed maintain temperature, pipe sizes, system voltage and the type of heating cable to determine the amount of time that is required to reach a desired temperature. If the desired temperature can be reached in a timeframe that is less than when the pipes will be flowing again, the Heat-Up cycle can be programmed for the number of hours that are required and the desired temperature will be reached. To determine the amount of time that is
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required to return back to the maintain temperature after the Heat-Up cycle is complete and the heating cable is off, refer to “Chapter 7, Cool-Down Graph.”
Holiday
This menu is used to set the controller to Off, timed­off, or to resume your timer program.
On: The controller uses the normal operation the timer program.
Off: The controller will not power the system until you select “Use timer”.
xx Days off: You can select a number of days. The controller automatically returns to timer mode when the selected number of days have passed.
Info
The display shows the firmware version number, selected cable type and the current sensor tempera­ture. Press Enter twice to update the sensor tem­perature on the display.
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Error/Alarms and
Troubleshooting
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EN-RaychemHWATECOcontroller-IM-H57340 03/13
Please ensure that the unit is correctly connected to the power supply and the heating cable is connected to the HWAT-ECO unit.
Error code Definitions
Cause/reasons
Remedy
Error 1: Internal temperature
alarm;
Temperature is too high. (> 65°C)
Turn off power and allow the controller to cool and then re-energize. The controller will lock out after three occur­rences. If this does not restore the controller, replace the HWAT-ECO.
Error 2: Pipe Sensor failure
(Only when tempera­ture alarm “enabled” selected)
• Sensor or sensor cable defect
• Low temp alarm or High temperature cut-out selected and sensor is not installed.
Connect sensor to HWAT-ECO or turn off temperature alarm.
Check sensor connections; replace sensor, check tempera­ture sensor mounting
Error 3: Network failure
Two or more HWAT­ECO’s are set as Master
Reinitialize MASTER (see "Setup" on page 36)
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Error code Definitions
Cause/reasons
Remedy
Error 4: Internal Error Controller needs to be replaced.
Contact Pentair Thermal Management representative
Error 5: No/Low current alarm Ensure that the heating circuit
is connected to power output of the HWAT-ECO.
If controlling a contactor, ensure that the Short Heater Alarm is enabled.
Error 6: Configuration Error Refer to "Short Heater" menu.
• If heating cable is longer that 15 ft. (4.5 m) then, Short heater = No
• If heating cable is shorter than 15 ft. (4.5 m) then, Short heater = Yes
Error 7: Pipe temperature too
high
(Only when HTC is enabled)
• Boiler temperature is too high.
• Pipe temperature too hot
• Verify High Temperature Cut-out (HTC) is set correctly.
• Correct boiler or mixing valve setting.
• Verify HWAT-ECO programming.
• Verify that pipe insulation schedule is correct.
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