Raypak Hot Water Energy Management Control User Manual
INSTALLATION AND OPERATING
INSTRUCTIONS
RayTemp™ Hot Water
Energy Management Control
Catalog No: 5000.61B
Effective: 04-15-05
Replaces: 09-01-02
P/N 241098
2
Section 1. GETTING STARTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
THE BIG PICTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
WHAT COMES WITH THE CONTROLL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Section 2. INSTALLING THE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
ATTACHING THE TEMPERATURE SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
PROVIDING 24 VAC POWER TO CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
INSTALLATION LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
”DIP” SWITCH SETTINGS ON CIRCUIT BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
CONNECTING THE OPTIONAL “ELSA” BRAND MODEM . . . . . . . . . . . . . . . . . . . . . . . .8
USING THE FRONT PANEL TO CHECK SENSORS AND RELAYS . . . . . . . . . . . . . . . . .9
Section 3. CONNECTING A COMPUTER (OR “LAPTOP”) . . . . . . . . . . . . . . . . . . . . .10
BUILDING OR BUYING INTERFACE CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
INSTALLING PTT SOFTWARE ON YOUR PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
SIMULATED FRONT PANEL DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
READING LOGGED DATA (Not All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
USING YOUR PC AND MODEM TO CALL A CONTROL . . . . . . . . . . . . . . . . . . . . . . . .12
Section 4. PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
FIRST SCREEN AT POWER-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
MANUAL OVERRIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
VIEW SENSORS AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
TIME AND DATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
CELSIUS / FAHRENHEIT SCALE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
ERASE MEMORY / RESET PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
SECURITY PASSWORD (“G” Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
FRONT PANEL MENU / LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
TIME SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
SUPPLY TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
RETURN TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
BRANCH TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
RELAY SEQUENCING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
SENSOR OVERRIDE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
SAVINGS TEST SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
SAVINGS TEST RESULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
SENSOR CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
LOCATION TEXT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
DATA MODEM SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
FAX MODEM SETUP AND TEST (“G” Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . .27
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
SERVICE/RETURN AUTHORIZATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . .29
3
THE BIG PICTURE
This RayTemp control is designed
to make recirculating domestic
hot water heating systems energy
efficient. In a recirculating system, hot water is continuously
pumped throughout the building.
This large loop has many branches which extend to fixtures in the
rooms. It is essentially a giant
radiator which has tremendous
heat loss. By lowering the temperature of this loop it is possible
to dramatically reduce this heat
loss. The trick is knowing when to
lower the temperature without
running out of hot water. With
RayTemp, water temperatures are
automatically scheduled in anticipation of demand. So for the
peak demand in the morning, the water is preheated to a higher temperature. The control does
this automatically by recording a seven day profile of demand, and then it uses this information to
establish setpoints. The control continually adjusts this setpoint to meet demand, always maintaining the lowest temperature which will fully meet user needs. This operation dramatically
lessens costly heat loss, lime deposits, and increases the life of the system. The control is preprogrammed with typical settings, making installation very simple. However, the program values can
be adjusted to accommodate many types of water heating systems. Output control is provided for
up to 4 stages of heat or four heaters. Two standard temperature sensors are connected to the
water heating systems at locations called “Supply”and “Return”.
Section 1. GETTING STARTED
Hot Water Use Throughout the Day
Fig # 8285.1
4
WHAT COMES WITH THE CONTROL
Before arriving at the job site to begin the installation, it’s important to first inspect the system and
determine what materials you will need. Some parts are included with the control while the others you will need to provide. Check the following list to verify that you received the following
parts.
1 Control, 10.5” x 8” x 3.5”
1 Panel Cover, Metal, 4” x 7.5”
4 Mounting Screws, 3/4”
2 Temperature Sensors, Copper housing,10 K
Ohm at 25°C
4 Cable Ties,15”, black, -40ºF to 221ºF rated
2 Knockout Connectors, 1/2” to romex
1 Warranty Card
1 Manual
1 24v Grounded Transformer
Cable, twisted pair with shield, stranded, 18
AWG. Belden type 8208 (braid shield) or 9552
(2 twisted pairs, foil shield)
Thermal Insulation Tape
Cable Ties
Wire Nuts
Heat Conducting Paste
Section 2. INSTALLING THE CONTROL
The control should be mounted on a wall, preferably at eye level with AC power as close as possible. Consider the length of cable required for routing along walls, along pipes, and for connecting the temperature sensors.
Notice on the bottom of the control that two of the five knockouts have been removed for routing of cables. If you want to use one or more of the other knockouts, these should be removed
before mounting the control onto the wall.
ATTACHING THE TEMPERATURE SENSORS
To get an accurate reading of the water temperatures, the sensors must be in good thermal contact with the pipe. Follow this procedure when connecting the temperature sensors.
Procedure for Connecting Temperature Sensors to Pipes:
1. Remove any existing insulation.
2. Clean the pipe surface using sandpaper.
3. Apply thermal conducting paste to the pipe surface.
4. Fasten the sensor tightly to the pipe using the black cable tie.
5. Attach 18 AWG shielded cable to the 6 in. leads using wire nuts or electrical tape.
6. Fasten the cable to the pipe using a second black cable tie.
7. Replace the existing insulation or wrap thermal insulation tape around the pipe.
Overlap each turn and DO NOT STRETCH the tape.
Included in the box
Other parts you will need
5
On the sensor end, roll the shielding and tape so it will not contact a conductor. On the control
end, the shield should be grounded. Do not ground both ends of the shielding.
Avoid routing wiring on or near other electrical wires, conduit, motors, spark igniters or other
sources of high, intermittent voltage or current. EMI (spikes) can disrupt information flow and
retention.
Procedure for Installing Supply Sensor in Tank:
1. Install sensor into dry well utilizing thermal conductive paste.
2. Install dry well into tank stat opening.
PROVIDING 24 VAC POWER TO THE CONTROL
!!! CAUTION !!!
DO NOT connect power until
all wiring is complete
and checked.
!!! CAUTION !!!
DO NOT connect 120 VAC
to the RayTemp!!!
Resulting damage will
void your warranty.
The RayTemp requires an external power transformer connected at terminals one and two.
Complete and check all wiring before connecting this transformer. The transformer must be rated
for 24 VAC at 16 VA or higher. When 24 VAC power is applied to the control the LCD display will
be blank for a few seconds. During this time the RayTemp is configuring any modem that may be
connected. After this the opening screen appears which identifies the model number, type of control, software version, and copyright notice.
Sensor Connections
6
Fig # 8285.2
INSTALLATION LAYOUT
7
”DIP” SWITCH SETTINGS ON CIRCUIT BOARD
CAUTION: Incorrect DIP switch settings may damage the RayTemp!!!
Make all adjustments with ALL power off.
The four relay outputs are factory set for normally closed dry contacts. These DIP switches are
located behind the terminal block, on the right side. The black dots in the diagram indicate where
to set the 20 switches for normally closed dry contacts. As shown, all four outputs will be the
same. Relay #1 is set on SW1 positions 6 thru 10. Relay #2 is set on SW1 positions 1 thru 5. Relay
#3 is set on SW2 positions 6 thru 10. Relay #4 is set on SW2 positions 1 thru 5.
DIP Switch Setting on Circuit Board
The RayTemp can control up to 4 stages:
• Four single-stage heaters
• Two two-stage heaters
• One four-stage heater
These switches are factory set and should not need adjustment.
Stage Connections on Heater
Remove factory jumpers for 3- and 4-stage connections.
CONNECTING THE OPTIONAL “ELSA” BRAND MODEM
Raypak recommends the ELSA Microlink 56k modem for data communication. This modem will
work with RayTemp and technical support will be provided if this modem is installed with the correct cables. Raypak will not be able to provide support if you use other modem brands or build
your own cables. In either case we strongly recommend that you test the RayTemp/modem connection in your office before installing the system. If possible, plan ahead, and have the phone
line/jack installed about two feet from the heater. Secure the ELSA modem and connect the phone
cable (that comes with the modem) from the wall jack to the ELSA modem jack labeled “Line”.
Connect the RayTemp cable 5-423 from the modem’s 8-pin connector to the RayTemp’s “Serial
to RJ11” adapter then connect the six-line data cable from the adapter to the RayTemp’s six-pin
“RJ11” port (see figure below). Plug in the modem’s power transformer and turn on the power
switch. Testing is covered in the next chapter.
8
CAUTION!
DO NOT connect a live phone line directly to the RayTemp control.
Doing so will damage the internal communication circuit!
RayTemp
RJ11 to 9-pin
Connector
MODEM
Active Phone Line
From Wall
9
USING THE FRONT PANEL TO CHECK SENSORS AND RELAYS
The RayTemp front panel features an alphanumeric LCD display of four rows by 20 lines. Six keys
are provided to select screens, fields, and make program changes. The up-arrow and down-arr ow
"WINDOW" keys are used to step thru each of the screens. The down-arrow screen selects the
next screen while the up-arrow key selects the previous screen. The left-arrow and right-arrow
"FIELD" keys move a flashing cursor to select different sections within a screen. The plus and
minus "VALUE" keys are used to make changes to a selected field or numeric value. Plus
increases the selected number or selects the next option. Minus decreases the selected number or
selects the previous option.
Using the down-“WINDOW” key select the “SENSORS”
screen and verify that each temperature sensor is measuring the correct value. It’s best to use a reliable temperature
reading device, like a surface thermocouple or a digital
infrared thermometer. Thermostats and mercury ther-
mometers are frequently inaccurate. If the readings disagree by more than two degrees there may be a problem with how the sensor is attached. Also
check for correct wiring at the terminal block.
Next select the “RELAY STATUS” screen and manually
verify that you can turn each water heater or stage on and
off. You do this using the field and value keys. If the heater
does not turn on it may be necessary to increase the
optional secondary mechanical aquastat setting a few
degrees. Use a multimeter to troubleshoot if problems persist. Return to the second screen titled “Master On/Off Mode” and put the control in “Bypass”.
The water heaters will now run using the optional secondary mechanical aquastats until programming of the control has been completed, explained in the next chapter.
SE-Sensors
Supply 136.4
Desired 135.0
Return 128.2
RT-Relay Status
#1 #2 #3 #4
ON OFF OFF OFF
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