Raypak Water Heater Hot Water Energy Management Control User Guide

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  
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  
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, lime 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. 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”.  
Hot Water Use Throughout the Day  
3
 
WHAT COMES WITH THE CONTROL  
Before arriving at the job site to begin the installation, its 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  
1 Control, 10.5” x 8” x 3.5”  
1 Panel Cover, Metal, 4” x 7.5”  
4 Mounting Screws, 3/ 4”  
4 Cable Ties,15”, black, -40ºF to 221ºF rated  
2 Knockout Connectors, 1/ 2” to romex  
1 Warranty Card  
2 Temperature Sensors, Copper housing,10 K 1 Manual  
Ohm at 25°C 1 24v Grounded Transformer  
Other parts you will need  
Cable, twisted pair with shield, stranded, 18  
AWG. Belden type 8208 (braid shield) or 9552  
(2 twisted pairs, foil shield)  
Cable Ties  
Wire Nuts  
Thermal Insulation Tape  
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 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 TEMPERATURE 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:  
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.  
4
 
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 120 VAC  
to the RayTemp!!!  
!!! CAUTION !!!  
DO NOT connect power until  
all wiring is complete  
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 Connections  
5
 
INSTALLATION LAYOUT  
Fig # 8285.2  
6
 
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.  
These switches are factory set and should not need adjustment.  
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  
Stage Connections on Heater  
Remove factory jumpers for 3- and 4-stage connections.  
7
 
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 modems 8-pin connector to the RayTemps Serial  
to RJ11” adapter then connect the six-line data cable from the adapter to the RayTemps six-pin  
RJ11” port (see figure below). Plug in the modems power transformer and turn on the power  
switch. Testing is covered in the next chapter.  
RayTemp  
RJ11 to 9-pin  
Connector  
MODEM  
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!  
8
 
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. 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 measur-  
SE-Sensors  
Supply  
Desired  
Return  
136.4  
135.0  
128.2  
ing the correct value. Its 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 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  
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 per-  
RT-Relay Status  
#1  
#2  
#3  
#4  
ON OFF OFF OFF  
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.  
9
 
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 Raypak:  
Description  
Part #  
PTT Software  
Communication for Windows PC to 70 series control  
PTT  
Direct Connect Communication Cable  
Connects a 70 series control to a PC  
5-424  
5-423  
Modem Communication Cable  
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.  
RayTemp to PC/ Modem Pin Assignments  
RJ-11 Pin  
(RayTemp)  
DB-9 Pin  
(PC/ Modem)  
RJ-11 Wire color codes:  
White = 1  
Ground  
Program  
Receive  
Transmit  
6
2
5
4
5
4
3
2
Ground  
Program  
Transmit  
Receive  
Black = 2  
Red = 3  
Green = 4  
Yellow = 5  
Blue = 6  
RayTemp to Modem Pin Assignments  
RJ-11 Wire color codes:  
White = 1  
RJ-11 Pin  
(RayTemp)  
DB-25 Pin  
(Modem)  
Black = 2  
Red = 3  
Green = 4  
Yellow = 5  
Blue = 6  
Ground  
Receive  
Transmit  
6
5
4
7
3
2
Ground  
Transmit  
Receive  
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. Most PCs 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 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  
F1  
Action  
Press two keys for direct access to any screen  
Select next screen  
F2  
F3  
Select previous screen  
F4  
Increase program value  
Decrease program value  
Select next field in a screen  
Select previous field in a screen  
F5  
SPACE  
BACK  
SPACE  
F6  
Activate full-screen viewing (PC)  
Restore LapTop window (PC)  
SHIFT  
F6  
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 RayTemp 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 (Monday 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 REDLION.GIX will be saved as REDLION0.GIX, REDLION1.GIX,  
REDLION2.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. When 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 graph 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. Make sure that the modems auto answer  
AA” light is on. Also, 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 “Options” 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&F” ENTER” Return should show OK.  
AT&D0” (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 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  
modem from answering the phone for about five minutes.  
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  
MC-Modem Control  
F4 to Hang-Up  
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. Make 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  
Key  
Laptop  
or PC Key  
Screen Selected  
Returns to first screen, then press two  
keys for direct access to any screen as  
listed on the next screen  
WINDOW  
F1  
UP & DOWN  
WINDOW DOWN  
WINDOW UP  
VALUE+  
F2  
F3  
Select next screen  
Select previous screen  
Increase program value  
Decrease program value  
Select next field in a screen  
F4  
VALUE-  
F5  
FIELD RIGHT  
FIELD LEFT  
SPACE  
BACKSPACE Select previous field in a screen  
Activate full-screen viewing (PC with  
F6  
PTT only)  
SHIFT F6  
14  
 
Screen code and description, in sequence of appearance  
See page  
FM  
SE  
OS  
RT  
ST  
PRODUCT IDENTIFICATION - Model, type, and version  
SENSORS - 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  
17  
17  
17  
17  
23  
RM  
RUN TIME METERS - Total on-time for each heater or stage  
DL  
TL  
CK  
TS  
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  
17  
19  
18  
28  
ER  
MC MODEM TEST - Terminate call or test modem or fax  
PD  
PERFORMANCE DATA - Savings Analysis  
24  
DN  
PN  
SL  
TEXT - Company Name  
TEXT - Property Name  
TEXT - Site Location  
TEXT - Disk File Name  
26  
26  
26  
26  
FN  
MS  
SH  
AD  
FD  
PW  
PM  
RL  
TEXT - Modem Setup  
26  
26  
26  
27  
18  
18  
23  
TEXT - Modem Disconnect  
TEXT - Pager Dial-Out  
TEXT - Fax Dial-Out  
TEXT - Security Password  
TEXT - Front Panel Menu  
TEXT - Relay Logic (1-12)  
T1  
T8  
SELECT - Supply Sensor Offset  
Not used for this model  
25  
C0  
C1  
C2  
C3  
C4  
C5  
C6  
C7  
SELECT - Maximum Supply Temperature  
SELECT - Minimum Supply Temperature  
19  
19  
19  
19  
19  
19  
20  
20  
SELECT - Outside Temperature for Maximum Supply  
SELECT - Outside Temperature for Minimum Supply  
SELECT - Night Setback at Maximum Supply  
SELECT - Night Setback at Minimum Supply  
SELECT - Morning Boost at Maximum Supply  
SELECT - Morning Boost at Minimum Supply  
Screen codes in Boldface are described in detail on the pages listed.  
15  
 
Screen Code and Description - continued  
See page  
HL  
LL  
SELECT - Supply High Limit  
SELECT - Supply Low Limit  
20  
20  
DW SELECT - Demand window in minutes  
DM SELECT - Demand % for maximum temperature  
20  
20  
20  
DA  
SELECT - Demand % for ASL strategy  
R0  
R1  
R2  
E0  
E1  
E2  
B0  
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  
21  
21  
21  
22  
S0  
S1  
S2  
SELECT - Days to Acclimate Residents  
SELECT - Day of Month for Savings Test  
SELECT - Old Maximum Supply Temperature  
19  
24  
24  
HS  
SP  
SQ  
US  
DD  
D1  
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  
22  
22  
22  
22  
23  
23  
LK  
CU  
SELECT - +- Keys Locked  
SELECT - Celsius Units  
18  
17  
LG  
SELECT - Access Data Logger #  
SELECT - Fax Graph Max Temp  
SELECT - Fax Graph Min Temp  
SELECT - Fax on Day Of Month  
XX  
XN  
XM  
27  
27  
27  
27  
27  
XW SELECT - Fax on Day of Week  
XH SELECT - Fax on Hour of Day  
MO SELECT - Operating Mode  
17  
26  
BA  
SELECT - Communication BAUD Rate  
SELECT - Network address number  
NI  
16  
 
FIRST SCREEN AT POWER-UP  
FM PRODUCT IDENTIFICATION. This screen displays the model 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 Mode 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 Off 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  
 
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. Make 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 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.  
18  
 
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 TEMPERATURE  
The RayTemp control strategy closely matches water temperature 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.  
C0 SELECT - Maximum Regular Temperature During Regular periods the desired temper-  
ature will be set between (screen) C0 and C1 according to demand. The time clock schedule deter-  
mines when Regular takes effect. Default Temp 140°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 - Maximum 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.  
19  
 
C6 SELECT - Maximum Extra Temperature C6 and C7 are an extra set of 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 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  
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 PERFORMANCE  
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 TEMPERATURE  
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.  
R0 SELECT - Return Sensor Installed Select YES if this sensor is connected, otherwise select  
NO. Default is YES.  
R1 SELECT - Minimum Return 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 - Return Sensor Response This is a multiplier which increases the desired tem-  
perature as the return temperature drops. Example: desired = 130, return = 100, R1 (above) = 102,  
R2 = 5. The desired temperature will be increased to 140 = 130 + (102-100) X 5. Default Value  
is 1.  
21  
 
BRANCH TEMPERATURE - NOT USED  
B0 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 Options  
Four options for stage sequencing are available. Select number 1, 2,  
3, or 4 as follows:  
#1  
#2  
#3  
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 & Rotate: With this option, heater #1 always fires  
first, then 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.  
flue  
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. Press 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 screen 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 Mode 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 reduced 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  
information 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 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-Out 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  
can be automatically faxed, once a week, to any Group III fax machine. This value sets the day of  
the week to transmit this data.  
Value  
Transmit  
None  
Day Graphs  
0
1
2
3
4
5
6
7
8
None  
Monday  
Tuesday  
Wednesday  
Thursday  
Friday  
Last 7 days on 3 1/ 2 pages  
Last 7 days on 3 1/ 2 pages  
Last 7 days on 3 1/ 2 pages  
Last 7 days on 3 1/ 2 pages  
Last 7 days on 3 1/ 2 pages  
Last 7 days on 3 1/ 2 pages  
Last 7 days on 3 1/ 2 pages  
Yesterday full size on 1 page  
Saturday  
Sunday  
Every Day  
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. Military 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.  
Option  
Setup  
Transmit  
Function Pages  
"Modem Setup" command to modem  
"Modem Disconnect" command to modem  
"Pager Dial-Out" command to modem  
Warning message, identifies location  
Report Installation report  
N/ A  
Disconnect  
Pager Alarm  
Fax Alarm  
Fax  
N/ A  
N/ A  
1
2
3
1
4
1
1
7
Fax Year  
Trend graphs for last 12 months  
Trend graph for the 4 month period  
Detailed graphs for the last 7 days  
Detailed graph for one day, today  
Detailed graph for one day, yesterday  
Report and all graphs  
Fax Month  
Fax Week  
Fax Today  
Fax Yesterday  
Fax All  
Status  
Description  
(blank)  
No Activity  
Sending  
Transmission in process. This message may remain for up to 12  
minutes depending on the action selected  
OK  
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  
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 IS IN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES NOT EXPRESS-  
LY SET FORTH HEREIN, WHETHER EXPRESSED OR IMPLIED BY OPERATION OR LAW OR OTHERWISE,  
INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES 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:  
RAYPAK, 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. Required 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 Model: ___________________________________ Date Purchased: __________________________________  
Control Serial Number: _____________________________ Date Installed: ____________________________________  
Water Heater Model Number:_______________________ Water Heater Serial Number: ________________________  
Company Name: __________________________________ Contact Name: ____________________________________  
Company Address: ________________________________ City: _________________ State:_____ Zip Code:________  
Installation Location: _________________________________________________________________________________  
Installation Address: _______________________________ City: _________________ State:_____ Zip Code:________  
Type of Property: Apt/ Condo_______ Hotel/ Motel_______ Other ________  
RayTemp Dealer: __________________________________ Address: _________________________________________  
City: _____________________ State: ______ Zip Code: ______________  
29  
 
Raypak Inc., 2151 Eastman Avenue, Oxnard, CA 93030 • (805) 278-5300 • (800) 872-9725  
 

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