Installation and Operation Instructions SEQUENCING MODULATING CONTROLS for Hydronic Heating Systems SYSTEM OUTPUT RATINGS: 120VAC, 6A RESISTIVE 1A PILOT DUTY, 15A TOTAL FOR ALL CIRCUITS A INPUT RATINGS: B 115VAC 60Hz , 30VA MAX USE COPPER WIRE, CLASS 1 WIRE ONLY. ---- C ---- D ENCLOSED ENERGY MANAGEMENT EQUIPMENT CAUTION: RISK OF ELECTRIC SHOCK More than one disconnect switch may be required to de-energize the equipment before servicing.
Raypak, Inc. Contents TempTracker mod+ Layout . . . . . . 3 TempTracker mod+ Overview . . . . . 4 Reset Ratio/Outdoor Reset . . . . . . . . . . 5 Make Sure You Have the Right Control . . . Initial Setup . . . . . . . . . . . . . . . . Selecting the System Features . . . . . . . Installation . . . . . . . . . . . . . . . . Mounting the Enclosure . . . . . . . . . . . Install the Sensors . . . . . . . . . . . . . .
TempTracker mod+ & TempTracker mod+ Extension Installation Manual TempTracker mod+ Layout Program Switch to restrict access to function changes. This switch is covered with Wiring Enclosure. The digital display shows the system status, set point, lead stage , and status of each stage. To view and adjust settings, press the appropriate buttons. Buttons function is presented on Bottom Row of display. LED indicates the associated relay status.
Raypak, Inc. TempTracker mod+ Overview Sequences up to 4 Fully Modulating Stages. The TempTracker mod+ is the perfect control whenever multiple fully modulating stages are required for hydronic heating applications. The TempTracker mod+ controls the on/off and the modulation of each stage to maintain precise system set point control. PID Type Logic The TempTracker mod+’s control algorithms allow it to look at the rate of change in the system.
TempTracker mod+ & TempTracker mod+ Extension Installation Manual 5 Understanding Operation Concept In Outdoor Reset, the TempTracker mod+ controls a hot water heating system to provide a building with comfortable and even heat levels. The TempTracker mod+ varies the temperature of the circulating heating water in response to changes in the outdoor temperature. The heating water temperature is controlled through the modulation of stages.
Raypak, Inc. Make Sure You Have the Right Control If you need the TempTracker mod+ to do additional tasks that either are not listed or do not know how to configure them, contact your local Raypak representative. Initial Setup Setting an Initial Program will ease the configuration of the TempTracker mod+ and will give the opportunity to utilize many of the energy saving features and give more comfortable heat when needed.
TempTracker mod+ & TempTracker mod+ Extension Installation Manual 7 System Run-On • This feature lets the TempTracker mod+ run the SYS relay for a longer period after the boilers have been turned off. When this relay is used to control a pump, it helps in dissipating the excess heat from the boilers combustion chamber. Installation Each of the TempTracker mod+ or TempTracker mod+ Extension consists of three primary enclosure components.
Raypak, Inc. Install the Sensors Immersion Heating System Sensor Immersion Well 3/8" ID 1/2" NPT Common Supply Pipe Heating/Storage Tank System Sensor (HSS) Installation Locating HSS • Put the Heating System sensor approximately 10' feet past the last boiler on the common supply header but before any major takeoffs. • The sensor must be located where it sees the output of all the boiler stages.
M PROGRAM DO NOT APPLY ANY VOLTAGE TO INPUT TERMINALS RUN A B C D Dmod+ Extension C B A PWRmod+SYS TempTracker & TempTracker Installation Manual CUR / VLT CUR / VLT CUR / VLT CUR / VLT L N Wiring GND - 3 4 5 6 7 8 9 10 11 12 1 2 mA + VLT GND + - mA mA VLT GND - + + + VLT GND - + mA + VLT T + 9 SYSTEM TEMP OUTDOOR TEMP T O PROVE /DHW O SHUTDOW /TSTAT /SETBACK O O 25 26 27 28 29 30 31 32 13 14 15 16 17 18 19 20 21 22 23 24 SYS PWR L N WARNING Neutral 120VAC Shutd
O PROGRAM 10 Wiring the System Prove (Terminals 29, 30) OUTDOOR TEMP SYSTEM TEMP PROVE /DHW SHUTDOWN /TSTAT /SETBACK GND - 3 4 5 6 7 8 9 10 11 12 1 2 OUTDOOR TEMP SYSTEM TEMP PROVE /DHW SHUTDOWN /TSTAT /SETBACK • The Prove feature is provided to check system component operation. T O T O T O O O T O O O • A typical use of this feature is 25 to 26 check for flow before firing any boiler.
MANAGEMENT EQUIPMENT LISTED 99RA CAUTION: RISK OF ELECTRIC SHOCK More than one disconnect switch may be required to de-energize the equipment before servicing.
Raypak, Inc. ----------- SETTINGS -----------Season Winter Set Point 140 F BACK SELECT (START) to continue Reset Ratio -------- SYSTEM STARTUP ------ START ------------- WARNING -----------THESE SETTINGS CHANGE PRIMARY SYSTEM FUNCTIONS. BACK CONTINUE SAVE F ] SAVE ------------ SET POINT ---------- 140 Reset Ratio F --------- RESET RATIO 1.00 OD=4.00 1.00 OD=3.00 1.00 OD=2.00 1.00 OD=1.50 1.00 OD=1.25 1.00 OD=1.00 1.25 OD=1.00 1.
TempTracker mod+ & TempTracker mod+ Extension Installation Manual ---------------- GAIN -------------- ----------- SETTINGS -----------Season Winter Set Point 70 F BACK SELECT SYSTEM SETTINGS1 [ BACK ] [ +0 F BACK SELECT -------------- SETBACK ----------- [ 10 F BACK ] SAVE ] [ ------ CONFIGURATION 2 -----A=4-20ma B=0-10v C=0-5v D=2-10v [ BACK EXIT -------- STAGE A TRIM -------Output Trim +0.
S CLASS 1 WIRE ONLY. -------- SYSTEM -----140DSTARTUP F [ ] (START) BACK SAVE to continue Raypak, Inc.
[ ] CHANGE SETTINGS PRIMARY THESE FUNCTIONS. -----EMS 20ma SETPOINT----BACKSYSTEM SAVE CHANGE PRIMARY SYSTEM FUNCTIONS. BACK CONTINUE BACK CONTINUE TempTracker mod+ & TempTracker mod+ Extension Installation Manual 15 220 F --------- RESET RATIO ---------BACK SAVE -------- SYSTEM STARTUP -----[ ] -------ARE YOU SURE? ------1.00 OD=4.00 Sys Disabled No 1.00 OD=3.00 Sys BACK SAVE -------ARE YOU SURE? ------ steel and cast iron boilers or boilers with low turndown ratios. (START) Yes 1.00 OD=2.
BACK SAVE Raypak, Inc. Sensor Fault ----SETBACK/SHUTDOWN Setback Input Shutdown or TStat Input 16 BACK SAVE -------------- BOOST MODE --------All Off, All On Default: All On Shutdown/Disable 30 Minutes Tstat/Enable Disabled Button: MENU//..../Sensor Fault Setback The Sensor Fault will determine the operating status of all output stages that are set to Auto BACK SAVE BACK a sensor reads Short orSAVE when Open.
D ENCLOSED ENERGY MANAGEMENT TempTracker mod+ & TempTracker mod+ Extension Installation Manual EQUIPMENT CAUTION: RISK OF ELECTRIC SHOCK LISTED 99RA Operating Settings Program Change Settings PROGRAM To be able to change the TempTracker mod+ settings the Program/Run Switch must be set to D C BThe Enclosure A Program. The switch is located under the Enclosure PWR Wiring CoverSYS for security. Wiring Cover can be securely closed using a lock.
Raypak, Inc.
---------- SETTINGS 1 --------- Gain +0 BACK SELECT ----------SETTINGS -----------Lead Rotation Last-On Season Winter Purge Delay 1.
Delay ] SAVE 7min Season Winter Parallel 10 sec [ ] Set Point 70 F Day/Night Schedules [ ] All Off BACK SAVE Adjustable 1min to 60min Default: 10min BACK NEXT SAVE Button: MENU///Standby Time • The Standby Delay Time only applies to Boilers in Standby Mode. TRIM --BACK OUTDOOR SENSOR --------CONFIGURATION 2SELECT -----BACK EXIT A=4-20ma B=0-10v • A boiler can be set to be a Standby boiler using the Stage Menu.
SAVE --- DAY/NIGHT SCHEDULES --Set Time **:** Day Schedule **:** Night& Schedule **:** mod+ TempTracker mod+ BACK Shut /T BACK -- OUTDOOR SENSOR TRIM ----TempTracker SAVE --------- PURGE DELAY --------- Extension Installation Manual 21 --- SYSTEM SENSOR TRIM ---- [ ] ALERT SETBACK INPUT min • The amount of Setback selected is subtracted from the Set Point when a Setback Input Signal is received or the1.0 Night Time [ ] BACK SELECT schedule setting started.
SetPoint Point Set Reset F Parallel Day/Night All BACK Off 22 Raypak, BACK BACK BACK Inc.
FOR ALL CIRCUITS INPUT RATINGS: 115VAC 60Hz , 30VA MAX USE COPPER WIRE, Extension TempTracker mod+ & TempTracker mod+ CLASS 1 WIRE ONLY.
Raypak, Inc. [ BACK Configuration Button: MENU// • This menu option provides a consolidated view of the Startup and Stage settings. Display +0 F ] SAVE ------ CONFIGURATION 1 -----v1.00c Reset F Parallel Day/Night Schedules All Off BACK NEXT The TempTracker mod+ display layout provides a variety of information that gives an immediate picture of the operation status. The display shows four boilers at a time.
TempTracker mod+ & TempTracker mod+ Extension Installation Manual Boiler Stage SettingsOD=35 SYS=98 F F Button: STAGE/ The Stage menu offers the capability of adjusting each of the boiler's operation individually. A 95% B 50% C --- D --- 25 ------- STAGE A MODE -------Auto Standby Manual Off On BACK SAVE • In most installations, all active Boiler adjustments are the same, but each can be STAGE MENU configured differently if desired.
Raypak, Inc. Troubleshooting Sensor INPUTS Display shows Sensor OPEN or SHORT When OPEN, Check the sensor is connected and the wires are continuous to the TempTracker mod+. Finally follow the procedure for Incorrect Temperature or Pressure Display. When SHORT Remove the wires from the sensor terminals. The display should change to read OPEN. If it does not, the TempTracker mod+ may be damaged. Display shows an Incorrect Temperature Remove the wires from the sensor terminals.
TempTracker mod+ & TempTracker mod+ Extension Installation Manual Boilers are Short-Cycling • Lag Delay - Increase the Lag Delay only if all boilers tend to short-cycle. • Last Stage Hold - Increase the Last Stage Hold only if the lead boiler tends to short-cycle. System is Overshooting or Undershooting • Gain - If the system is overshooting reduce the Gain. • Gain - If the system is undershooting increase the Gain.
Raypak, Inc. Multiple Modulating Boilers Direct Heating Piping Diagram Outdoor Sensor SYSTEM OUTPUT RATINGS: 120VAC, 6A RESISTIVE 1A PILOT DUTY, 15A TOTAL FOR ALL CIRCUITS A INPUT RATINGS: 115VAC 60Hz , 30VA MAX B USE COPPER WIRE, CLASS 1 WIRE ONLY. C ---- ---- D CAUTION: RISK OF ELECTRIC SHOCK More than one disconnect switch may be required to de-energize the equipment before servicing.
TempTracker mod+ & TempTracker mod+ Extension Installation Manual Multiple Modulating Boilers Direct Heating Wiring Diagram SYSTEM OUTPUT RATINGS: 120VAC, 6A RESISTIVE 1A PILOT DUTY, 15A TOTAL FOR ALL CIRCUITS A INPUT RATINGS: 115VAC 60Hz , 30VA MAX B USE COPPER WIRE, CLASS 1 WIRE ONLY. C ---- ---- D CAUTION: RISK OF ELECTRIC SHOCK More than one disconnect switch may be required to de-energize the equipment before servicing.
Raypak, Inc. Multiple Modulating Boilers Heating with Buffer Tank Piping Diagram Outdoor Sensor SYSTEM OUTPUT RATINGS: 120VAC, 6A RESISTIVE 1A PILOT DUTY, 15A TOTAL FOR ALL CIRCUITS A INPUT RATINGS: 115VAC 60Hz , 30VA MAX B USE COPPER WIRE, CLASS 1 WIRE ONLY. C ---- ---- D CAUTION: RISK OF ELECTRIC SHOCK More than one disconnect switch may be required to de-energize the equipment before servicing.
TempTracker mod+ & TempTracker mod+ Extension Installation Manual Multiple Modulating Boilers Heating with Buffer Tank Wiring Diagram SYSTEM OUTPUT RATINGS: 120VAC, 6A RESISTIVE 1A PILOT DUTY, 15A TOTAL FOR ALL CIRCUITS A INPUT RATINGS: 115VAC 60Hz , 30VA MAX B USE COPPER WIRE, CLASS 1 WIRE ONLY. C ---- ---- D CAUTION: RISK OF ELECTRIC SHOCK More than one disconnect switch may be required to de-energize the equipment before servicing.
Specifications Voltage Input: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 VAC 60 Hz Power Consumption: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 VA Max Operating Temperature: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .