Raypak RayTemp Hot Water Energy Management Control User's Manual
Contents
1. 27 WARRANTY si inite sa je tea times aie ak itn dik pa a a a ay a de AE ek eee rene 29 SERVICE RETURN AUTHORIZATION PROCEDURE 29 Section 1 GETTING STARTED THE BIG PICTURE This RayTemp control is designed to make recirculating domestic hot water heating systems energy efficient In a recirculating sys tem hot water is continuously pumped throughout the building This large loop has many branch es which extend to fixtures in the rooms It is essentially a giant radiator which has tremendous heat loss By lowering the tem perature 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 antici pation of demand So for the RECIRCULATION ad RETURN SENSOR NN N ko io N N NRECIRCULATION PUMP BY OTHERS OPTIONAL INTEGRAL PUMP 7 EXPANSION TANK BY OTHERS RAY TEMP CONTROLLER INSIDE BOILER Fig 8285 1 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 main taining the lowest temperature which will fully meet user needs This operation dramatically lessens costly heat loss lime2. ERASE MEMORY RESET PROGRAM ER ERASE RESET Press F4 or F5 to select which item will be reset or cleared then press CTRL E to confirm each action Set BAUD Rate will reconfigure the serial port according to the BA screen If the speed is differ ent then reset the BAUD rate on your LapTop garbage characters will appear Zero Run Meters set all run time meters to zero Erase History sets all 7 day and 365 day history to 30 Reset Program sets all program values to factory default values Erase All does all the above requires 30 seconds SECURITY PASSWORD PW TEXT Security Password This screen is used to prevent unauthorized access to the RayTemp either by modem or direct connection To use this feature select a password up to 40 characters and enter it on this screen Then all future communication with the control will be blocked until this password is entered A screen will appear asking for the password M ake a note of your password since you will not be able to access the control without it By default no pass word is required To disable password protection erase all text in this field FRONT PANEL MENU LOCK PM TEXT Front Panel Menu This option provides for limited access by the building care taker to a fixed set of screens from the front panel By default 13 of the most commonly used screens are accessible from the front panel They are identified in this screen by their two charac ter access code This
3. Fax Week Detailed graphs or the last 7 days 4 Fax Today Detailed graph for one day today 1 Far Yesterday Detailed graph for one day yesterday 1 Fax All Report and all graphs Kr EE blank No LO Noadivty o Sending Transmission in process This message may remain for up to 12 minutes depending on the action selected Data modem or fax modem has successfully completed the operation Failed data modem or fax modem did not reply or was unable to complete the action requested Failed Data modem or fax modem did not reply or was unable to complete the action required Sp ey a ee w Note The Pager Alarm action will always reply Failed because the modem does not connect with another modem In this screen no actions will retry in the event of transmission failure press plus again However when actual alarm conditions occur or when reports are scheduled for automatic transmission the RayTemp will retry Up to three attempts will be made per day at 10 minute intervals 28 WARRANTY The Raypak RayTemp Control is warranted to be free from defects in material and workmanship for a peri od of one year from the date of installation or fourteen months from date of shipment whichever occurs first THE FORGOING WARRANTY ISIN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES NOT EXPRESS LY SET FORTH HEREIN WHETHER EXPRESSED OR IM PLIED BY OPERATION OR LAW OR OTHERWISE INCLUDING BUT NOT LIMITED TO ANY IMPLIED WA
4. AUR MA a a ank se ae ske k 14 FIRST SCREEN AT POWER UP L ll L L L L L Y kk ak kk kk kk kk kk kk kek kk a n kk kn 17 MANUAL OVERRIDE l Ill Y Y FY Y Y FI aa aaa aa a aaa aa a aaa aaa aaa anko 17 VIEW SENSORS AND RELAYS imani Kia I pitati ee eee uad 17 TIME AND DATE sc kin ante tonal m ad epa a ae Cw YA dl e his bow a a ba 17 CELSIUS FAHRENHEIT SCALE ll Ill L FFF FF Lu ad 17 ERASE MEMORY RESET PROGRAM L L L L Lk kk ke eee ee 18 SECURITY PASSWORD G Models Only lt VFYY FY ud 18 FRONT PANEL MENU LOCK ll L L L L Lk FFY kk kk kk kk kk kk kak kk n kak knn ka 18 TIME SCHEDULE isis cee va anken oo a dye aou ai ard CAN EG ad dene dete ene Lae 19 SUPPLY TEMPERATURE cia tini dot a mo ad ank aa rd seam amwa adan 19 RETURN TEMPERATURE uei clad ken Dida Gade nek ba koka a 21 BRANCH TEMPERATURE av ll vann FF Y IL aa a aaa aa n aaa aaa aaa ankinn 22 RELAY SEQUENCING si iia sayo awa FY EA ana WR CNW ka koua pk O Gee ad 22 SENSOR OVERRIDE TEST ll lel lel LY aa nana aa nna sann nn 23 SAVINGS TEST SETUP ueu aeania kou klere owa ed GARW eed SE eda kana ko ok ann 24 SAVINGS TEST RESULTS ll ll ll eee ete sann nn 24 SENSOR CALIBRATION iii ll ll FY ll FY I FF aaa a aaa a a aaa a a 25 LOCATION TEXT ki iv tt a tan fo e fa a AEN Y fk ann kn a an a a an a af 26 DATA MODEM SETUP wi va von ie sak on va oui ae tie tie getan aiai hea ee ei azi 26 FAX MODEM SETUP AND TEST G Models Only
5. RayTemp unit Consult your Hayes compatible modem manual for more information about AT commands This text will appear on installation reports Edit text with SPACE BACKSP F4 and F5 26 FAX MODEM SETUP AND TEST FD TEXT Fax Dial O ut Use this screen to enter the phone number of the fax machine which is to receive fax alarm messages installation reports and or graphics Example ATDT5551212 Edit text with SPACE BACKSP F4 and F5 XX VALUE Fax Graph Max Temp This value sets the highest value of the Y axis tempera ture scale for all faxed graphs This item is unrelated to PC graphics Autoscaling is not support ed XN VALUE Fax Graph Min Temp This value sets the lowest value of the Y axis tempera ture scale for all faxed graphs This item is unrelated to PC graphics Autoscaling is not support ed XM VALUE Fax on Day of Month A complete installation report with graphics of logged data can be automatically faxed once a month to any group III fax machine This value sets the day of the month to transmit this data The report consists of seven pages The first two pages give all program values and performance data such as percent savings The next three and one half pages are detailed graphs for the last seven days The last one and one half pages are trend graphs for the last 12 months The default day of zero disables this function XW VALUE Fax on Day of Week Detailed graphs of logged data for the last seven days c
6. deposits and increases the life of the system The control is prepro grammed with typical settings making installation very simple However the program values can be adjusted to accommodate many types of water heating systems O utput 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 Demand for Hot Water in Percent o mid Peak Morning Demand 2am 4am 6am 8am 10am noon 2pm 4pm 6pm 8pm 10pm mid Hot Water Use Throughout the Day 3 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 oth ers you will need to provide Check the following list to verify that you received the following parts Included in the box Control 10 5 x 8 x 3 5 Cable Ties 15 black 40 F to 2219 rated Panel Cover Metal 4 x 7 5 Knockout Connectors 1 2 to romex M ounting Screws 3 4 Warranty Card Temperature Sensors Copper housing 10 K M anual Ohm at 25 C 24v Grounded Transformer Other parts you will need Cable twisted pair with shield stranded 18 Cable Ties AWG Belden type 8208 braid shield or 9552 2 twisted pairs foil shield Wire Nuts Thermal Insulation Tape Heat Conducting Paste Section 2 IN
7. feature provides a means of increasing temperature in oversized systems which show very little demand Example Set to 50 When demands of 50 or more are encountered the desired temperature will be at programmed maximum Below 50 the desired temperature will be proportional between maximum and min imum programmed values The range is from 10 to 100 percent Default Value 100 DA SELECT Demand for ASL Strategy This feature automatically adapts to manual changes in the optional secondary aquastat setting which may occur after installation This ensures continued savings even if the aquastat is lowered ASL is an acronym for Aquastat Set too Low The strategy works by lowering the setpoint temperature until the RayTemp has regained control For each 24 hour period that demand exceeds this DA percent the setpoint is lowered by 5 F Then for each 24 hour period that heater demand is less than one half of DA the setpoint is increased by 1 F until the original value is restored The default value is 70 The PERFORM ANCE DATA screen titled Temp Reduced by ASL Strategy will show a value other than zero if this strat egy is in effect Default Value 70 20 RETURN TEM PERATURE The return sensor is used to compensate for seasonal changes in loop heat loss The strategy may raise the supply branch temperature in cold weather to ensure that the last rooms on the loop have hot enough water even during low demand periods RO SELECT Retum Se
8. is the print quality 1 draft mode fast 2 medium 3 high resolution but slow Press Ctrl Enter to save your selection SIMULATED FRONT PANEL DISPLAY This Laptop selection from the menu bar opens up a window on the PC screen to receive for matted data and program information sent by a RayTemp control connected at the serial RS232 port From the main menu select LapTop and press enter Connect the cable to the RayTemp control and press F1 to begin communication The screen and keyboard will operate similar to the front panel but with enhanced features to take advantage of the larger screen This table shows the function keys for accessing all RayTemp display and programming features These keys apply to both the PC and LapTop display except as noted A screen saver clears the display after five minutes Press F1 thru F5 to restore the screen key Acton FL Press two keys for direct access to any screen 72 Selectnextscreen SSS Fa Select previous seen F increase program value SSS FS Decrease program waka SS SPACE Select next field in a screen BACK Select previous field in a screen SPACE Fe Activate full screen viewing PC le Restore LapTop window PC 11 READING LOGGED DATA Under the History Report menu item logged data can be retrieved from a RayTemp control saved to a disk file viewed graphically on screen or output to a printer To retrieve history con nect the Ra
9. line of text can be modified to select a custom set of screens in any order up to 13 screens If the first character on this line is a space then this menu system will be dis abled and all screens will be accessible from the front panel To gain access to all of the screens using only the front panel press both VALUE keys while in the PRODUCT IDENTIFICATION screen This enters a first character space as described above LK SELECT Keys Locked When Activated This option prevents changing of pro grammed values from the RayTemp front panel and keys WARNING This option cannot be deactivated from the control itself Deactivating this screen requires either 1 a connection to a PC running the PTT software or 2 returning the control to the manufacturer to have them reset this option TIME SCHEDULE TS TIME SCHEDULE This is a seven day time clock Each line is a program for starting a new period such as Night on a day such as M F and at a time such as 6 00 am Up to 20 lines can be displayed or programmed using the SPACE F4 and F5 keys Periods end automatically when a new one starts The day codes are M F Monday thru Friday S S Saturday and Sunday F S Friday thru Sunday and no days The recommended setting for intial programming is no days on all settings Changes can be made to accommodate individual schedules SUPPLY TEM PERATURE The RayTemp control strategy closely matches water temperature
10. temperatures which can be scheduled for any purpose They will become the maximum and minimum supply temperature if the Extra schedule is activated by the time clock Default Temp 140 F C7 SELECT Minimum Extra Temperature See C6 above Default Temp 130 F HL SELECT Supply High Limit If the recovery temperature or the return temperature is very low the RayTemp may need to take the supply temperature above the programmed maximum Regardless of any conditions the RayTemp will not take the supply or any branch temperature above this high limit value If the supply temperature exceeds this value by 10 F then alarm dial out will be activated Default Temp 140 F LL SELECT Supply Low Limit The RayTemp will not schedule the supply temperature lower than this value or programmed minimum If the supply temperature drops 10 F below this value then alarm dial out will be activated Default Temp 120 F DW SELECT Demand Windows in Minutes This value sets the time period of demand history to be used in calculating desired temperature The default value should yield a smooth pro file Decreasing this value will cause faster response to changing demand at the risk of instability Increasing this value will produce a very smooth desired temperature profile however the tem perature may not rise quickly enough during peak demand periods The range is from 10 to 90 minutes Default Value 40 DM SELECT Demand for Maximum Temperature This
11. to demand as hot water use varies throughout the day The setpoint is adjusted based on a demand profile which is recorded for the last seven days The RayTemp scans this profile and adjusts the setpoint in anticipation of demand This strategy is complemented with a seven day time clock which can provide fixed tem peratures during certain hours for special requirements such as laundry CO SELECT Maximum Regular Temperature During Regular periods the desired temper ature will be set between screen CO and C1 according to demand The time clock schedule deter mines when Regular takes effect Default Temp 140 F F C1 SELECT Minimum Regular Temperature The supply temperature will not be set below this value during Regular periods Default Temp 130 F C2 SELECT M aximum Peak Temperature C2 and C3 become the new maximum and min imum temperatures when the time clock schedule is in Peak mode Default Temp 140 F C3 SELECT Minimum Peak Temperature During peak periods the supply temperature will not be set below this value Default Temp 130 F C4 SELECT Maximum Laundry Temperature C4 and C5 will be the maximum and mini mum temperatures in effect if Laundry is activated by the seven day time clock For laundry needs C4 and C5 will usually be set to the same value Default Temp 140 F C5 SELECT Minimum Laundry Temperature See C4 above Default Temp 140 F C6 SELECT Maximum Extra Temperature C6 and C7 are an extra set of
12. Catalog No 5000 61B Effective 04 15 05 Replaces 09 01 02 INSTALLATION AND OPERATING INSTRUCTIONS RayTemp Hot Water Energy Management Control P N 241098 Section 1 GETTING STARTED i 9 3 eee eee eee eee EE bon n an 3 THE BIG PICTURE Lura a4 aa eta Gatien le ay 3 WHAT COMES WITH THE CONTROLL FFF ve e ess ve eee sena RAD 4 Section 2 INSTALLING THE CONTROL 000 cece nannan n ann kann n n n n n nna 4 ATTACHING THE TEMPERATURE SENSORS L LILI L L L L Lee eee eee ee e eee eee ennan 4 PROVIDING 24 VAC POWER TO CONTROL Y Y Y FFF FF FF FF YY ud 5 INSTALLATION LAYOUT aiii e kon RR RR AN weed ed DEAU REY ak 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 FFF RR FFR kek kk knn 11 SIMULATED FRONT PANEL DISPLAY FF Y Y aaa cee eee eee eee 11 READING LOGGED DATA Not All Models 12 USING YOUR PC AND MODEM TO CALL A CONTROL 12 Section 4 PROGRAMMING lt FF a n n nan n n n non non non minn non mn nn 14 QUICK REFERENGE furer wa lignet A UA aa aan ea ap a
13. P CONTROLLER N INSIDE BOILER RECIRCULATION PUMP RECIRCULATION BY OTHERS GE INSTALLATION LAYOUT NOTES PRESSURE RELIEF VALVE ms LUMB SWING CHECK VALVE IN GRAVITY CLOSED POSITION PUMP PIPE ALL RELIEF VALVES TO DRAIN OR AS LOCAL CODES REQUIRE UNION STALL COLD WATER BETWEEN HEATER OUTLET AND TANK ila 3 LOCATE TEE AS CLOSE AS POSSIBLE TO TANK GATE VALVE 5 SEE CHART MINIMUM PIPE SIZES FOR MINIMUM PIPE SIZES CHECK VALVE 6 SIZING BASED ON HEATER AND TANK BEING PLACED FIVE FEET APART IF DISTANCE IS GREATER THE PUMP MUST BE SIZED TO ACCOMMODATE INCREASE IN PIPING RELATED LOSSES BALL VALVE A PROVIDE FOR THERMAL EXPANSION OF HOT WATER IF A BACKFLOW TERMOMETER PREVENTER CHECK VALVE WATER METER OR PRESSURE REDUCING VALVE IS INSTALLED IN THE COLD WATER LINE Fig 8285 2 DIP SWITCH SETTINGS ON CIRCUIT BOARD CAUTION Incorrect DIP switch settings may damage the RayTemp M ake 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 SW 1 positions 6 thru 10 Relay 2 is set on SW 1 positions 1 thru 5 Relay 3 is set on SW2 positions 6 thru 10 Relay 4 is set on SW2 positions 1 t
14. RRANTIES OF MERCHANTABILITY OF FITNESS At its option Raypak will repair or replace any RayTemp Control which fails to conform to this warranty Repair or replacement shall be the sole remedy of the buyer under this warranty and Raypak shall not be liable for any installation removal or reinstallation costs or for any damage and or injury to building con tents products or persons by reason of the installation of the RayTemp Control or for incidental or conse quential losses damages or expenses including loss or profits directly or indirectly arising from this sale handling or use of the goods or from any other cause relating thereto whether such claims are for breach of warranty or negligence Any claim by buyer with reference to the Raypak RayTemp Control sold hereunder for any cause shall be deemed waived by buyer unless submitted to Raypak in writing within thirty 30 days from date buyer dis covered or should have discovered any claimed breach To obtain service under this warranty call or write RAY PAK INC 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 SERVICE RETURN AUTHORIZATION PROCEDURE Raypak will not accept a returned unit unless the buyer has received prior authorization to return the unit If a problem is suspected with the RayTemp control while under warranty the owner or operator should first call the installing dealer The dealer should contact Raypak at the above phone number for return authorization R
15. STALLING THE CONTROL The control should be mounted on a wall preferably at eye level with AC power as close as pos sible Consider the length of cable required for routing along walls along pipes and for connect ing the temperature sensors Notice on the bottom of the control that two of the five knockouts have been removed for rout ing 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 TEM PERATURE SENSORS To get an accurate reading of the water temperatures the sensors must be in good thermal con tact with the pipe Follow this procedure when connecting the temperature sensors Procedure for Connecting Temperature Sensors to Pipes Remove any existing insulation Clean the pipe surface using sandpaper Apply thermal conducting paste to the pipe surface Fasten the sensor tightly to the pipe using the black cable tie Attach 18 AWG shielded cable to the 6 in leads using wire nuts or electrical tape Fasten the cable to the pipe using a second black cable tie Replace the existing insulation or wrap thermal insulation tape around the pipe Overlap each turn and DO NOT STRETCH the tape 4 NOU BON 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 e
16. an be automatically faxed once a week to any Group III fax machine This value sets the day of the week to transmit this data o None Ne e auray ast 7 days on 3 1 2 pages ME Every Day Yesterday full size on 1 page 27 XH VALUE Fax on Hour of Day This option sets the time of day to transmit fax reports It works in conjunction with XW and XM above The RayTemp will attempt to fax the specified data on the specified day above and at this specified time M ilitary time is used with values of 0 to 23 12 is noon If the first attempt is not successful then the RayTemp will make two more attempts at 10 minute intervals Where multiple RayTemps are calling into one fax machine it s very important to set each control to a different day and or time otherwise some controls may always get a busy line MC MODEM TEST This screen provides for modem testing and manual fax transmission of reports and graphics The following table describes the options in this window These options are selected using the FIELD keys and activated by pressing the PLUS key The Status line in this window reports progress of the action as shown in the second table below Modem Setup command to modem See eee on ener we Pager Alarm Pager DiakO ut command to modem wa Fax Alarm Warning messege identifisocaton 1 NLR ma e kari Fax Year Trend graphs tor last 12 months 3 FaxManth Trend graph forthe 4 month period 1
17. ation will appear in installation reports Edit text with SPACE BACKSP F4 and F5 FN TEXT Disk File Name Accepts entry of a DOS file name into RayTemp memory The installation report and graphs will be saved in a file under this name seven characters maximum Edit text with SPACE BACKSP F4 and F5 Only needed when logging data to a connected LapTop DATA MODEM SETUP BA SELECT Communication Baud Rate For direct connect use 9600 Baud For modem use set at required 9600 Speed is activated only during power on reset or from ER ERASE RESET screen MS TEXT Modem Setup Accepts entry of AT command string into RayTemp memory If a modem is installed the RayTemp will transmit this command string to configure your modem Use the Hayes compatible modem manual for information about the AT commands This text will also appear on installation reports Edit text with SPACE BACKSP F4 and F5 Once set write down at command string SH TEXT Modem Disconnect Accepts entry of AT commands into RayTemp memory If a modem is installed the RayTemp will transmit this command to the modem to terminate the phone connection and prevent the modem from answering another call AD TEXT Pager Dial Out Accepts entry of AT commands into RayTemp memory If a modem is installed the RayTemp will transmit this command to the modem if an alarm condition exists For example commands can be selected to dial a pager and display a code to identify the calling
18. aypak pen I OU e amp O O PTT Software PTT Communication for Windows PC to 70 series control Direct Connect Communication Cable 5 424 Connects a 70 series control to a PC M odem Communication Cable 5 423 Connects a 70 series control to a modem Wiring pin assignments are provided below for building your own cables CAUTION Never plug a telephone line into the RJ 11 connector The control may be damaged RJ 11 Wire color codes RJ 11 Pin RayTemp PC Modem RJ 11 Pin DB 25 Pin RayTemp Modem Ground 6 7 Ground 10 INSTALLING PTT SOFTWARE ON YOUR PC This section provides instructions for installing PTT communication software First insert the PTT CD into your CD drive Double click on the folder Ptt258 then double click on Install The PTT communication software will then be installed on your C GBX subdirectory To run PTT type PTT then press enter from the C GBX subdirectory Within a few seconds the main menu software version I D and copyright notice will appear Use the arrow keys and enter key to select items from the menu bar at the top of the screen First check the default options by selecting the Options menu item There are several items that can be changed M ost PC s have several com munication ports Port 1 is usually for direct connections and port 2 is usually used for internet modems The second option sets the communication speed The default speed for RayTemp is 9600 Baud Next
19. ck at M aximum Supply SELECT Night Setback at M inimum Supply SELECT Morning Boost at M aximum Supply SELECT Morning Boost at M inimum Supply Screen codes in Boldface are described in detail on the pages listed 15 Screen Code and Description continued See page SELECT Supply High Limit ja SELECT Supply Low Limit SELECT Demand window in minutes SELECT Demand for maximum temperature SELECT Demand for ASL strategy SELECT of Room Sensors Installed SELECT Desired Daytime Room Temperature SELECT Desired Nighttime Room Temperature SELECT Recovery sensor installed SELECT Minimum recovery time SELECT Recovery sensor response SELECT Branch sensors installed SELECT Days to Acclimate Residents SELECT Day of M onth for Savings Test SELECT Old Maximum Supply Temperature SELECT of water heaters SELECT stages per heater SELECT Alternating Relay Sequencing SELECT Use 24Volt on off sensing SELECT Deadband also known as hysteresis SELECT Temperature Delay Between Stages ELECT Keys Locked ELECT Celsius Units SELECT Access Data Logger SELECT Fax Graph M ax Temp SELECT Fax Graph M in Temp SELECT Fax on Day Of Month SELECT Fax on Day of Week SELECT Fax on Hour of Day SELECT Operating M ode SELECT Communication BAUD Rate SELECT Network address number 16 FIRST SCREEN AT POWER UP FM PRODUCT IDENTIFICATION This screen displays the mode
20. dis agree 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 RT Relay Status verify that you can turn each water heater or stage on and 1 2 3 4 off You do this using the field and value keys If the heater ON OFF OFF OFF 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 per sist 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 program ming of the control has been completed explained in the next chapter Section 3 CONNECTING A COMPUTER This section explains how to connect your personal computer to the RayTemp Once connected you can view all of the front panel screens covered in the previous section You can also retrieve the recorded data and view color graphs of temperature and demand profiles PTT is the option al software tool for your personal computers that works with RayTemp controls It simulates the front panel and retrieves logged data PTT software and interface cables are available directly from Raypak The computer must be able to accept a serial RS 232 cable BUILDING OR BUYING INTERFACE CABLES The following cables are available from R
21. does not work with the RayTemp Once you see the Connect message in the TechTerm window press F1 and then F6 to begin communication 12 To end the modem session select the following screen in the LapTop window This screen is used to terminate the call The RayTemp will actually terminate the phone connection and prevent the MC Modem Control modem from answering the phone for about five minutes F4 to Hang Up The message CARRIER LOST will appear in the LapTop window Another call may then be placed to contact another RayTemp sharing the same phone line Always use this method to end a modem call to the RayTemp in shared phone line applications It s also a good idea to have an actual telephone connected to the line M ake sure a dial tone is present to verify that the call has been terminated 13 Section 4 PROGRAMMING QUICK REFERENCE This section describes all the programmable features of the control You make program changes from the front panel or by using a laptop For information on connection with a LapTop using PTT software refer to the previous section The following keys provide access to all RayTemp display and programming features These keys apply to the front panel or LapTop display as shown below A screen saver clears the display after five minutes on the LapTop Press F1 then F6 to restore the screen Front Panel Laptop Returns to first screen then press two keys for direct access to any screen as l
22. ed a value other than zero indicates that the RayTemp has reduced its set point temperature by this amount This was done to regain control because the existing aquastat setting was lowered SENSOR CALIBRATION The following screens allow you to introduce a fixed positive or negative offset to any tempera ture input You will not normally need to make any adjustments here since RayTemp sensors and electronics are very accurate The default values in these screens compensate for a small self heat ing affect on the thermistor sensor For small mass base thermistors the offset is 2 5 F For ther mistors mounted in housings or attached to a pipe with thermal paste the offset is 1 5 F You can check measurement accuracy of RayTemp using fixed resistors and the resistance tem perature chart published by Independent Energy Before doing this first set each offset below to zero T1 SELECT Supply Offset for sensors 1 thru 7 T8 SELECT Supply Offset for sensors 8 thru 15 Not used for this model 25 LOCATION TEXT DN TEXT Company Name Accepts entry of company name into RayTemp memory This information will appear in installation reports Edit with SPACE BACKSP F4 and F5 PN TEXT Property Name Accepts entry of site name into RayTemp memory This informa tion will appear in installation reports Edit with SPACE BACKSP F4 and F5 SL TEXT Site Location Accepts entry of city and state names into RayTemp memory This inform
23. equired information name of site location serial number reason for return An authoriza tion number will be issued Repaired or replacement equipment will be returned to you prepaid Warranty Card Please return this card within 30 days of installation to initiate your warranty and enable us to better serve you Control M odel _ 2 222 Date Purchased wy Control Serial Number __ _ _ 2 22222 Date Installed 2 22222 Water Heater M odel Numbers AaAaAaAaAaAaAaAaAaAEAEAE Water Heater Serial Number ____ 2 222222 O Company Name Contact Name LL Company Address eee City AAA State gt Zip Code Installation Location 44 Installation Address 2 2 22 City State Zip Code gt Type of Property Apt Condo gt Hotel Motel gt Other gt RayTemp Dealer __ _ 2 22222 Address yL City a ea ana aa State gt Zip Code __ _ _ _ _ _ _ o lt Registered Quality Management System www raypak com Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 800 872 9725
24. h you want includ ed in the printed report Press ESC to start printing USING YOUR PC PTT AND MODEM TO CALL A CONTROL If this is your first attempt at modem communication with a RayTemp control we recommend that you first try everything in your office using two phone lines Connect the RayTemp to an external modem and connect this modem to one line and your PC modem to another Next configure the RayTemps modem as described in the previous section M ake sure that the modem s auto answer AA light is on AIso buy a modem cable from RayTemp at least for your first installation This will prevent 80 of your possible problems To get on line with the RayTemp start the PTT software and select O ptions from the menu bar at the top of the screen Enter the port number usually 1 or 2 for the modem connected to your PC and make sure the speed is set to 9 600 Then press Ctrl Enter and select TechTerm from the menu bar A set of seven windows will appear Start entering the phone set up commands ATE1 ENTER Return should show OK If not re enter AT amp F ENTER Return should show OK AT amp DO zero ENTER Return should show ok For example to place a call dial ATDT5551212 and wait for a Connect message replace the 5551212 with your actual phone number If the screen is blank type ATE1 and try again Note The Modem section on the menu bar
25. hen the remaining heaters fire in rotation Since some designs require heater 1 to fire first this option meets this requirement while still providing limited rotation US SELECT Use 24volt on off sensing Do not use 22 DD SELECT Differential Increasing DD lengthens the heater burn cycle decreasing DD improves temperature stability For instance desired 140 deadband 1 heater turns off at 141 and on at 139 This deadband applies equally to all stages D1 SELECT Temperature Delay Between Stages In addition to differential setting This value causes successive output stages to come on according to the deviation to target tem perature D1 activates additional heaters or stages as demand increases For example with a set point of 140 F and a temperature delay of 1 F stage 1 will fire at 140 stage 2 at 138 stage 3 at 136 etc assuming 2 F deadband RL TEXT Relay Logic 1 12 The default value is NOTICE If you select minus and the RayTemp loses power or fails then the heater or pump will remain off Edit text with SPACE BACKSP F4 and F5 to return to a plus setting SENSOR OVERRIDE TEST ST SENSOR TEST This feature allows you to simulate any sensor temperature and observe the affect on desired temperature and relay sequencing Press SPACE or BKSP to select a sensor then override the actual sensor temperature by pressing F4 or F5 Each key stroke changes the tem perature by one degree F Pres
26. hru 5 These switches are factory set and should not need adjustment SW1 SW2 P N 901650 12345678910 12345678910 ort aaa lor MOn L stace 1 tLestace 2 L stAGE 3 stage 4a 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 2 STAGE STAGE SELECTOR FACTORY JUMPERED CONTROL STAGE 2 FACTORY JUMPERED CONTROL STAGE 1 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 cor rect 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 con nection 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 be
27. isted on the next screen WINDOW DOWN Select next screen WINDOW UP Select previous screen VALUE Increase program value WINDOW UP amp DOWN VALUE Decrease program value FIELD RIGHT SPACE Select next field in a screen FIELD LEFT BACKSPACE Select previous field in a screen F6 Activate full screen viewing PC with PTT only EL en 14 Screen code and description in sequence of appearance See page PRODUCT IDENTIFICATION Model type and version SENSO RS Displays temperature of each standard sensor OPTIONAL SENSORS Displays other sensors RELAY TEST On Off relay status and manual override SENSOR TEST Simulates sensor temperatures RUN TIME METERS Total on time for each heater or stage DETAIL LOG Shows history values for seven days TREND LOG Shows history values for one year CLOCK Display and set time and date TIME SCHEDULE Seven day 20 schedule time clock ERASE RESET Selective clear or restart MODEM TEST Terminate call or test modem or fax Company Name Property Name Site Location Disk File Name Modem Setup Modem Disconnect Pager Dial O ut Fax Dial O ut Security Password Front Panel M enu Relay Logic 1 12 SELECT Supply Sensor O ffset Not used for this model SELECT M aximum Supply Temperature SELECT M inimum Supply Temperature SELECT Outside Temperature for M aximum Supply SELECT Outside Temperature for M inimum Supply SELECT Night Setba
28. l number type of control copyright notice and software version number Press F2 to select the next screen in order or press two keys for direct access to any one of the following screens MANUAL OVERRIDE MO SELECT MODE Operating M ode selects one of three states of operation In Run mode all control functions are operational In Bypass mode control is returned to the mechanical con trols if provided In O ff mode all systems are shut off and remain off indefinitely In all three modes the RayTemp data logger and modem fax functions continue to operate VIEW SENSORS AND RELAYS SE SENSORS Displays the setpoint and current temperature reading from each primary tem perature sensor OS OPTIONAL SENSORS Displays current temperature reading from each optional temper ature sensor RT RELAY TEST Displays on off status of each relay output Press SPACE or BKSP to a select relay flashes Then press F4 to test on F5 to test off To return control to the RayTemp press SPACE or BKSP until no locations flash The RayTemp will automatically retake control if no man ual testing takes place for five minutes TIME AND DATE CK CLOCK Displays present time and date To set press SPACE F4 and F5 CELSIUS FAHRENHEIT SCALE CU SELECT For Celsius units select Yes and all process and program values will be displayed in the Celsius temperature scale The default setting of No selects the Fahrenheit scale 17
29. lectrical wires conduit motors spark igniters or other sources of high intermittent voltage or current EM I 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 1 CAUTION 1 CAUTION DO NOT connect power until DO NOT connect 120 VAC all wiring is complete to the RayTemp and checked 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 con trol software version and copyright notice sensor INPUTS o ooo UU DABGood an Bon Suppl Ret 24 vac stage Stove 2 Stoge 3 Stage 4 Sensor Connections OPTIONAL INTEGRAL PUMP A QD HOT TAP WATER RELIEF SUPPLY VE we I R asin Wan SN P NN as Da 7 D THERMOMETER iji pr y PUMP LOCATION ON MODELS WITHOUT TANKSTAT INTEGRAL PUMP SUPPLY AA SENSOR ol RETURN f SENSOR DRAIN RAY TEM
30. low Plug in the modem s power transformer and turn on the power switch Testing is covered in the next chapter RayTemp RJ11 to 9 pin Connector Y gt Je Dres 0 Active Phone Line From Wall CAUTION DO NOT connect a live phone line directly to the RayTemp control Doing so will damage the internal communication circuit 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 arrow 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 M inus decreases the selected number or selects the previous option Using the down WINDOW key select the SENSO RS SE Sensors screen and verify that each temperature sensor is measur Supply 136 4 ing the correct value It s best to use a reliable temperature Desired 135 0 reading device like a surface thermocouple or a digital Return 128 2 infrared thermometer Thermostats and mercury ther mometers are frequently inaccurate If the readings
31. nsor Installed Select YES if this sensor is connected otherwise select NO Default is YES R1 SELECT Minimum Retum Temperature If the return temperature drops below this value then the return sensor strategy will be activated Above this value the strategy will have no effect on desired temperature Default Temp 108 F R2 SELECT Retum Sensor Response This is a multiplier which increases the desired tem perature as the return temperature drops Example desired 130 return 100 RI above 102 R2 5 The desired temperature will be increased to 140 130 102 100 X 5 Default Value is 1 21 BRANCH TEM PERATURE NOT USED BO SELECT of Branch Sensors Installed Not used RELAY SEQUENCING HS SELECT of Heaters Enter 1 thru 4 for the number of heaters connected to relay out puts 1 thru 4 This allows the RayTemp to correctly sequence heaters and record demand SP SELECT Stages Per Heater Enter the number of stages in each heater from 1 to 4 SQ SELECT Firing O ptions Four options for stage sequencing are available Select number 1 2 3 or 4 as follows 1 No Lead Lag Stage 1 of heater 1 always fires first The remaining stages and heaters will fire in order as demand increases 24 Hour Rotation At midnight each day the firing order is rotated to the next heater This distributes the work load equally among all heaters Lead Lag amp Rotate With this option heater 1 always fires first t
32. reen press F4 or F5 to view savings analysis statistics as described below Average Energy Savings Displays the average energy savings in percent during the last 365 days This can be used to determine actual dollars savings and payback period This feature will not operate unless a day of month for savings test is selected A flip flop test then is activated which alternates between RayTemp mode and baseline mode which has higher energy con sumption Baseline Heater Run Time Displays average heater demand during Baseline mode for the last 365 days simulating a fixed setpoint control This is diagnostic information used in calculating savings RayTemp Heater Run Time Displays average heater demand for all heating days except base line days during the last 365 days This is diagnostic information used in calculating savings Days in Baseline M ode Shows the number of days during the last year that RayTemp was in base line mode simulating the preexisting fixed setpoint control Days in RayTemp Mode Shows the number of days during the last 365 days when there was demand for heat and baseline mode was not in effect 24 Total days in service displays the total operating days in modes RUN BYPASS and OFF When 24 VAC power is absent this value will not increase however the clock will still operate Number of power interruptions value is incremented each time 24 VAC power is removed or inter rupted ASL strategy temp reduc
33. s Shift F4 or Shift F5 to adjust the temperature by one tenth of a degree works with PTT You can change any or all sensors values and then look at other screens While in this mode all temperature values will be frozen at the values you select To restore the actual sensor values press SPACE or BKSP until Inactive appears The RayTemp will auto matically restore actual sensor values 30 minutes after exiting this screen 23 SAVINGS TEST SETUP S1 SELECT Day of Month for Savings Test Selecting a value other than 0 default acti vates the flip flop savings test This test will cause a simulation of conditions before the RayTemp was installed for 24 hours on the day specified every month The test will run only on the day of month selected AND on multiples of that day Examples Values 16 thru 28 will run test for that day only Value 14 will run test on day 14 and 28 Value 5 will run test on day 5 10 15 20 25 and 30 One day of testing may not yield accurate results while four or more days of testing will significantly cut into savings The recommended value is 14 2 test days S2 SELECT Old Maximum Supply Temperature Enter the supply temperature prior to installing the RayTemp if you wish to use the Acclimate feature or Savings Test feature above If the preexisting control operated at a fixed temperature enter that value here and also in the next screen SAVINGS TEST RESULTS PD PERFORMANCE DATA From this sc
34. yTemp serial cable between the RayTemp and your laptop PC Then select Retrieve The RayTemp will transmit logged data to your PC This takes about one minute at 9600 Baud A status window will be present while the data is being received The logged data consists of a report seven detailed daily graphs M onday thru Sunday and twelve monthly graphs January thru December A menu will appear from which you can view any of these graphs This data will be automatically saved to a disk file based on the file name in the report data PTT creates a unique name for each file by setting the last position of the file name prefix The codes are 0 thru 9 and then A thru Z For examples REDLIO N GIX will be saved as REDLIO NO GIX REDLIO N1 GIX REDLIO N2 GIX etc To view an existing history file select Display and select a file by pressing enter After the graphs are prepared a window will appear from which you can select any daily graph or monthly graph to view on the screen The Print option under History Report allows you to send site reports and graphs to any sup ported printer W hen this item is selected a directory of data files will appear Point to a file using the arrow keys then press enter to select the file A check mark will appear Place check marks next to all data file you wish printed then press Ctrl Enter to continue A second screen will appear for selecting graphs within a report Place a check mark press enter by each grap
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