Raypak Raytemp Installation Manual

INSTALLATION & OPERATING

INSTRUCTIONS

RayTemp™ Hot Water

Energy Management

Control

For Raytherm™ & Hi Delta™

Hot Water Supply Boilers &

Water Heaters

Catalog No. 5000.61E Effective: 09-08-10 Replaces: 02-06-08 P/N 241098 Rev. 6

Rev 6 includes the following:
Changes to: Fig. 1 on page 6, Fig. 4 on page 8, “20 characters” was “20 lines” on page 10, screen code

index on pages 14-15
Additions: Warnings and notes on page 3, General Safety information on page 4, contact number for Pro­Temp Controls on page 12
Deletions: None

2

CONTENTS

WARNINGS 4
GENERAL SAFETY 5

Time/Temperature Relationships in
Scalds 5

GETTING STARTED . . . . . . . . . . . . 6

The Big Picture . . . . . . . . . . . . . . . . . . . . . .6

What Comes with the Control . . . . . . . . . . .6

INSTALLING THE CONTROL . . . . . . 7

Attaching the Temperature Sensors . . . . . . .7

Providing 24 VAC Power to the Control . . . .7

Installation Layout . . . . . . . . . . . . . . . . . . . 8

“DIP” Switch Settings on Circuit Board . . . . .9

Connecting the Optional “ELSA” Brand

Modem . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Using the Front Panel to Check Sensors and

Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

CONNECTING A COMPUTER . . . . .10

Building or Buying Interface Cables . . . . . . 11

Installing PTT Software on Your PC . . . . . . 11

Simulated Front Panel Display . . . . . . . . . .11

Reading Logged Data (Not All Models). . . .12

Using Your PC, PTT and Modem to Call a

Control . . . . . . . . . . . . . . . . . . . . . . . . . . .12

PROGRAMMING . . . . . . . . . . . . . . .13

Quick Reference . . . . . . . . . . . . . . . . . . . . 13

First Screen at Power-up . . . . . . . . . . . . . .16

Manual Override . . . . . . . . . . . . . . . . . . . . .16

View Sensors and Relays . . . . . . . . . . . . . .16

Time and Date . . . . . . . . . . . . . . . . . . . . . .16

Celsius / Fahrenheit Scale. . . . . . . . . . . . . .16

Erase Memory / Reset Program . . . . . . . . .16

Security Password (“G” Models Only). . . . .16

Front Panel Menu / Lock . . . . . . . . . . . . . . 16

Time Schedule . . . . . . . . . . . . . . . . . . . . . .17

Supply Temperature . . . . . . . . . . . . . . . . . .17

Return Temperature . . . . . . . . . . . . . . . . . .18

Branch Temperature . . . . . . . . . . . . . . . . . .18

Relay Sequencing (4-Stage Control) . . . . . 18

Relay Sequencing (2-Stage Control) . . . . . 18

Sensor Override Test . . . . . . . . . . . . . . . . .19

Savings Test Setup . . . . . . . . . . . . . . . . . . .19

Savings Test Results . . . . . . . . . . . . . . . . . 19

Sensor Calibration . . . . . . . . . . . . . . . . . . .20

Location Text . . . . . . . . . . . . . . . . . . . . . . .20

Data Modem Setup . . . . . . . . . . . . . . . . . . 20

Fax Modem Setup and Test (“G” Models

Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

WARRANTY . . . . . . . . . . . . . . . . . . 23

Service/Return Authorization Procedure . . 23

3

WARNINGS

Pay Attention to These Terms

DANGER:

WARNING:

CAUTION:

NOTE:

NOTE: Minimum 18 AWG, 105°C, stranded wire

must be used for all low voltage (less than 30 volts)
external connections to the unit. Solid conductors
should not be used because they can cause exces­sive tension on contact points. Install conduit as
appropriate. All high voltage wires must be the same
size (105°C, stranded wire) as the ones on the unit
or larger.

Indicates the presence of immediate hazards which will cause severe person­al injury, death or substantial property damage if ignored.

Indicates the presence of hazards or unsafe practices which could cause
severe personal injury, death or substantial property damage if ignored.

Indicates the presence of hazards or unsafe practices which could cause
minor personal injury or product or property damage if ignored.

Indicates special instructions on installation, operation, or maintenance which
are important but not related to personal injury hazards.

NOTE: Piping diagrams in this manual are not
intended to replace an engineered piping system.

4

GENERAL SAFETY

Water temperature over 125°F can
cause instant severe burns or death
from scalds.

Children, disabled, and elderly are
at highest risk of being scalded.

See instruction manual before set­ting temperature at water heater.

Feel water before bathing or show­ering.

Temperature limiting valves are
available, see manual.

Water

Temp.

Time to Produce

Serious Burn

120°F More than 5 minutes

125°F 1-1/2 to 2 minutes

130°F About 30 seconds

135°F About 10 seconds

140°F Less than 5 seconds

145°F Less than 3 seconds

150°F About 1-1/2 seconds

155°F About 1 second

Table co urtesy of The Shriners Burn Institute

To meet commercial hot water use needs, the high
limit safety control on this water heater is adjustable up
to 210°F. However, water temperatures over 125°F
can cause instant severe burns or death from scalds.
When supplying general purpose hot water, the rec­ommended initial setting for the temperature control is
125°F.

Safety and energy conservation are factors to be con­sidered when setting the water temperature on the
thermostat. The most energy-efficient operation will
result when the temperature setting is the lowest that
satisfies the needs of the application.

Water temperature over 125°F can cause instant
severe burns or death from scalds. Children, disabled
and elderly are at highest risk of being scalded.

• Feel water before bathing or showering.

• Temperature limiting valves are available.

NOTE: When this water heater is supplying general
purpose hot water for use by individuals, a thermo­statically controlled mixing valve for reducing point of
use water temperature is recommended to reduce
the risk of scald injury. Contact a licensed plumber or
the local plumbing authority for further information.

Maximum water temperatures occur just after the
heater’s burner(s) have shut off. To determine the
water temperature being delivered, turn on a hot water
faucet and place a thermometer in the hot water
stream and read the thermometer.

Time/Temperature
Relationships in Scalds

The following chart details the relationship of water
temperature and time with regard to scald injury and
may be used as a guide in determining the safest
water temperature for your applications.

Table A: Time to Produce Serious Burn

5

GETTING STARTED

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.”

Fig. 2: Hot Water Use Throughout the Day

What Comes with the Control

Before beginning 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.

Included in the box:

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

Other parts you will need:

Fig. 1: Typical Installation

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

6

INSTALLING THE
CONTROL

he control should be mounted on a wall, preferably at

T
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.

n the sensor end, roll the shielding and tape so it will

O
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,

onduit, motors, spark igniters or other sources of

c
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.

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.

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. Afterwards, the opening screen
appears, which identifies the model number, type of
control, software version, and copyright notice.

2-Stage Control

4-Stage Control

Fig. 3: Stages and Sensor Connections

7

Installation Layout

Fig. 4: Installation Layout

8