Raypak TempTracker mod+ Manuel utilisateur

INSTALLATION AND OPERATION INSTRUCTIONS

SEQUENCING MODULATING CONTROLS

for Hydronic Heating Systems

This manual attempted to be complete and accurate at the time of publication. Additional upgrades and new features may change

TempTracker mod+ functions. Upgrades to this manual may occur at any time. Contact the factory for further details.

WARNING

The TempTracker mod+ is strictly an operating control. It CANNOT be used as a limit control. All boilers must

have all safety and limit controls required by code. It is the responsibility of the installer to verify that all the

safety and limits are working properly before the TempTracker mod+ is installed.

This control must be installed by a licensed electrician.

P/N 241297 REV.2

Cat.# 5000.67 08/31/09

--------

SYSTEM

RUNPROGRAM

DO NOT APPLYANY VOLTAGE

TO INPUT TERMINALS

345678910 11 12 13 15

14 17

16 18 20

19 21 24

23 29

25 27

26 28 32

30 31

OORS-485

GND VLT

SYS ABCD

PWR

CUR / VLT

GND VLT

TEMP

OUTDOOR

TEMP

SYSTEM

EXTENSION

MODULE

CUR / VLT

PROVE

/DHW SHUTDOWN

/SETBACK

FOR ALL CIRCUITS

120VAC, 6A RESISTIVE

OUTPUT RATINGS:

1A PILOT DUTY, 15A TOTAL

115VAC 60Hz , 30VA MAX

INPUT RATINGS:

USE COPPER WIRE,

CLASS 1 WIRE ONLY.

CAUTION

: RISK OF ELECTRIC SHOCK

More than one disconnect switch may be required

to de-energize the equipment before servicing.

ENCLOSED

ENERGY

MANAGEMENT

EQUIPMENT

99RA

/TSTAT

2 Raypak, Inc.

TEMPTRACKER MOD+ LAYOUT. . . . . . 3

TEMPTRACKER MOD+ OVERVIEW . . . . 4

Reset Ratio/Outdoor Reset . . . . . . . . . .5

Make Sure You Have the Right Control . . 6

INITIAL SETUP . . . . . . . . . . . . . . . 6

Selecting the System Features. . . . . . . 6

INSTALLATION . . . . . . . . . . . . . . . 7

Mounting the Enclosure . . . . . . . . . . 7

Install the Sensors . . . . . . . . . . . . . 8

Heating/Storage Tank System Sensor (HSS)

Installation . . . . . . . . . . . . . . . . . . .8

Outdoor Sensor Installation . . . . . . . . . .8

Wiring. . . . . . . . . . . . . . . . . . . . 9

Wiring the Power (Terminals 1, 2) . . . . . . .9

Wiring the Sensors. . . . . . . . . . . . . . .9

Wiring the Shutdown, Tstat, or Setback (Terminals

31, 32) . . . . . . . . . . . . . . . . . . . . .9

Wiring the System Prove (Terminals 29, 30) 10

Wiring for Domestic Hot Water Priority (Terminals

29, 30) . . . . . . . . . . . . . . . . . . . . 10

Wiring the System Output (Terminals 3, 4). . 10

Wiring the Boilers . . . . . . . . . . . . . . 10

Wiring to Modulating Motors . . . . . . . . . 11

Connecting to the TempTracker mod+ Extension

Panels . . . . . . . . . . . . . . . . . . . . 11

MENU SEQUENCE . . . . . . . . . . . . .12

Startup Settings . . . . . . . . . . . . . .14

Program Change Settings . . . . . . . . . . 14

Startup Sequence . . . . . . . . . . . . . . 14

Sensor Type . . . . . . . . . . . . . . . . . 14

EMS Input Mode . . . . . . . . . . . . . . . 14

(Available In Set point Only) . . . . . . . . . 14

Selecting the Output Type . . . . . . . . . . 14

Modulating Mode. . . . . . . . . . . . . . . 14

Prove/Domestic Hot Water (DHW). . . . . . 15

Domestic Hot Water Set Point . . . . . . . . 15

Shutdown/Tstat/Setback Mode. . . . . . . . 15

Boost Mode . . . . . . . . . . . . . . . . . 15

(Not Available with Setback) . . . . . . . . . 15

Sensor Fault . . . . . . . . . . . . . . . . . 16

Setting the Control to Factory Defaults. . .16

Program Change Settings . . . . . . . . . . 17

Season . . . . . . . . . . . . . . . . . . . . 17

Set Point . . . . . . . . . . . . . . . . . . . 17

Reset Ratio. . . . . . . . . . . . . . . . . . 17

Outdoor Cutoff Temperature . . . . . . . . . 18

Offset. . . . . . . . . . . . . . . . . . . . . 18

Minimum Water Temp . . . . . . . . . . . . 18

Maximum Water Temp . . . . . . . . . . . . 18

System Settings . . . . . . . . . . . . . .19

Gain . . . . . . . . . . . . . . . . . . . . . 19

Lead Boiler Rotation . . . . . . . . . . . . . 19

Purge Delay . . . . . . . . . . . . . . . . . 19

Lag Delay . . . . . . . . . . . . . . . . . . 20

Standby Time. . . . . . . . . . . . . . . . . 20

System Run-On . . . . . . . . . . . . . . . 20

Setback. . . . . . . . . . . . . . . . . . . . 20

Last Stage Hold . . . . . . . . . . . . . . . 21

Day/Night Schedules. . . . . . . . . . . . . 21

Set Time . . . . . . . . . . . . . . . . . . . 22

History . . . . . . . . . . . . . . . . . . .22

Maintenance . . . . . . . . . . . . . . . .23

System & Outdoor Sensor Trim . . . . . . . 23

Soft-Off Delay . . . . . . . . . . . . . . . . 23

Output Trim. . . . . . . . . . . . . . . . . . 23

Conguration . . . . . . . . . . . . . . . . . 24

Display . . . . . . . . . . . . . . . . . . . . 24

Boiler Stage Settings. . . . . . . . . . . .25

Mode . . . . . . . . . . . . . . . . . . . . . 25

TROUBLESHOOTING. . . . . . . . . . . .26

SPECIFICATIONS . . . . . . . . . . . . . .32

TempTracker mod+ Specications . . . . .32

TempTracker mod+ Extension Specications32

Contents

TempTracker mod+ & TempTracker mod+ Extension Installation Manual 3

--------

SYSTEM

RUNPROGRAM

DO NOT APPLY ANY VOLTAGE

TO INPUT TERMINALS

345678910 11 12 13 15

14 17

16 18 20

19 21 24

23 29

25 27

26 28 32

30 31

OORS-485

GND VLT

SYS ABCD

PWR

CUR / VLT

GND VLT

TEMP

OUTDOOR

TEMP

SYSTEM

EXTENSION

MODULE

CUR / VLT

PROVE

/DHW SHUTDOWN

/SETBACK

FOR ALL CIRCUITS

120VAC, 6A RESISTIVE

OUTPUT RATINGS:

1A PILOT DUTY, 15A TOTAL

115VAC 60Hz , 30VAMAX

INPUT RATINGS:

USE COPPER WIRE,

CLASS 1 WIRE ONLY.

CAUTION

: RISK OF ELECTRIC SHOCK

More than one disconnect switch may be required

to de-energize the equipment before servicing.

ENCLOSED

ENERGY

MANAGEMENT

EQUIPMENT

99RA

/TSTAT

The digital display shows the system status, set point,

lead stage <in brackets>, and status of each stage.

To view and adjust settings, press the appropriate buttons.

LED indicates the

associated relay status. Buttons function is presented on

Bottom Row of display.

Program Switch to restrict access to

function changes. This switch is

covered with Wiring Enclosure.

120VAC Power Four N.O. Boiler startup relay

outputs. Each is wired in series

with each boiler's limit circuit.

System Output controls

pumps, valves, or other

system components.

Four modulation outputs can be 4-20mA,

0-5V, 0-10V, 1-5V, or 2-10V. Go to

Startup Menu to determine the type of

output for each stage.

When connecting Outdoor and System

Sensors, no Polarity is observed.

Prove terminals must be connected

for TempTracker mod+ to operate boilers.

Connect Extension panels to

add additional stages using

a 6 pin phone line only (cable

provided with TempTracker

mod+ Extension).

TEMPTRACKER MOD+ LAYOUT

4 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. If the system temperature is changing

quickly, the TempTracker mod+ will react quickly to adjust the modulating stages’ output. If the system temperature changes slowly,

the TempTracker mod+ will make slow and gradual output adjustments. Therefore, the TempTracker mod+ adapts to specic system

requirements and minimizes uctuations around the set point.

CONTROLS 4-20MA MODULATING MOTORS OR 0-5 V, 0-10 V, 1-5V, 2-10V MODULATING MOTORS

The TempTracker mod+ is designed to accurately control the output from 25% to 100% of modulation for each of these different types

of motors. One TempTracker mod+ can even control a variety of the above different motors.

ONLY ONE SENSOR

When Set Point sensor type is selected, the TempTracker mod+ requires only one sensor located in the common output header of all

stages. However, when Reset is selected, an additional Outdoor Sensor is required for Outdoor Reset Ratio input.

DIGITAL DISPLAY OF ALL SYSTEM SETTINGS

The TempTracker mod+’s alphanumeric digital display names each system parameter in simple English and shows its precise value. The

easy to follow menu system allows users to quickly make changes to any system setting without having to learn any specialized codes

or keyboard commands.

AUTOMATIC ROTATION AMONG STAGES

Rotating the rst stage to be activated on a call for output promotes even wear on each stage. The TempTracker mod+ has three modes

of rotation: Manual, Last On, or Time. The Time rotates the lead stage every selected time period from every hour to every 60 days.

OUTDOOR RESET

The TempTracker mod+ has a hydronic outdoor temperature reset function. This allows the TempTracker mod+ to change the set point

based on outdoor temperature. Furthermore, additional settings have been added to ne tune this operation, like Offset, Minimum, and

Maximum Water Temperature and night setback schedule.

STANDBY BOILERS

Each of the TempTracker mod+ stages can be congured as a Standby boiler with an adjustable Standby delay. A boiler can be used as

a backup during extended large demand periods.

SYSTEM OUTPUT

In Set Point or Outdoor Reset modes, the System Output will activate whenever the outdoor temperature is below the Outdoor Cutoff

setting. A System Prove input checks the status of components activated by the System output before stages can be activated.

PARALLEL MODULATION

The TempTracker mod+ uses parallel modulation that can modulate several boilers together as a one large boiler. This mode is useful

for boilers with lower water content, which are usually more efcient at lower ring points.

ADD UP TO 16 BOILER STAGE (OPTIONAL)

As a stand-alone, the TempTracker mod+ is designed to control four modulating boilers. However, it has the capability of expanding its

control to two extension panels each with six boiler stages. Thus, the TempTracker mod+ can control a total of up to 16 boiler stages.

TempTracker mod+ & TempTracker mod+ Extension Installation Manual 5

UNDERSTANDING OPERATION CONCEPT

The TempTracker mod+ has multiple operating modes that satisfy most hydronic systems.

It can change the System Set Point based on outdoor temperature (Outdoor Reset) or it can

modulate its stages to achieve an adjustable xed Set Point.

In Outdoor Reset, the TempTracker mod+ controls a hot water heating system to provide a

building withcomfortableandevenheat levels. TheTempTracker mod+ variesthe 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.

The TempTracker mod+ also controls the system circulating pump with an adjustable Outdoor

Cutoff. When the outdoor temperature is above Outdoor Cutoff, the pump is off and no heating

water is circulated through the system.When the outdoor temperature drops below the Outdoor

Cutoff, the system pump relay is activated and the heating water circulates through the system.

Thetemperatureof theheating wateris controlledby theResetRatio,WaterOffset,and changes

with Outdoor temperature.

RESET RATIO/OUTDOOR RESET

When a building is being heated, heat escapes through the walls, doors, and windows to

the colder outside air. The colder the outside temperature, the more heat escapes. If you

can input heat into the building at the same rate that it is lost out of the building, then

the building temperatures will remain constant. The Reset Ratio is an adjustment that

lets you achieve this equilibrium between heat input and heat loss.

The starting point for most systems is the 1.00 (OD):1.00 (SYS) (Outdoor Air

Temperature : Heating Water Temperature) ratio. This means that for every degree

the outdoor temperature drops, the temperature of the heating water will increase one

degree. The starting point of the curves is adjustable, but comes factory selected at

70°F Outdoor Temp. and 100°F Water Temp. For example with a 1.00 (OD):1.00 (SYS)

ratio, if the outdoor temperature is 40°F, this means the temperature has fallen 30°from

the starting point of 70°F. Therefore, the heating water temperature will increase 30°to

130°F.

Each building has different heat loss characteristics. A very well insulated building will

not lose much heat to the outside air, and may need a Reset Ratio of 2.00 (OD):1.00

(SYS) (Outdoor:Water). This means the outdoor temperature would have to drop

2 degrees to increase the water temperature 1 degree. On the other hand, a poorly

insulated building with insufcient radiation may need a Reset Ratio of 1.00 (OD):2.00

(SYS). This means that for each degree the outdoor temperature dropped the water

temperature will increase 2 degrees. The TempTracker mod+ has a full range of Reset

Ratios to match any buildings heat loss characteristics.

A heating curve that relies not only on Outdoor temperature but also on type of radiation

will improve heat comfort. The following are suggested initial settings for different

types of radiation based on average building insulation and heat loss. The contractor

can ne tune these adjustments based on the specic building need.

Type of Radiation in Building Reset Ratio Offset

Radiators (Steel & Cast Iron) 1.00 (OD) : 1.00 (SYS) 0˚F

Baseboard (Finned copper tube& Cast Iron) 1.00 (OD) : 1.00 (SYS) 0˚F

Radiant (High Mass/Concrete) 4.00 (OD) : 1.00 (SYS) -10˚F

Radiant (Low Mass/Joists) 2.00 (OD) : 1.00 (SYS) -10˚F

Fan Coils & Air Handlers 1.00 (OD) : 1.00 (SYS) 20˚F

Outdoor Temperature

Water Temperature

70 405060

130

120

110

100

Outdoor Temperature

Water Temperature

70 405060

110

100

Outdoor Temperature

Water Temperature

70 405060

150

140

130

120

1:4

With a 0° Offset, the

Reset curves begin at

100° Water Temperature.

With a -20° Offset, the

Reset curves begin at

80° Water Temperature.

With a +20° Offset, the

Reset curves begin at

120° Water Temperature.

1:4

1:4 1:1

1:1

4:1

100

+20 Offset

-20 Offset

Outdoor Temperature

Water Temperature

70 405060

130

120

110

100

1:4 1:1

4:1

Colder

Warmer

Outdoor Temperature (in °F)

70 60 50 40 20

30 0 -10

10 -20

100

120

110

130

140

150

160

180

170

190

200

210

220 1:3 1:2 1:1.5

1:1.25

1:1

1.25:1

1.5:1

2:1

3:1

4:1

Water Temperature (in °F)

Reset Ratio Curves

Reset Ratio is Presented as

Outdoor Temp. : Water Temp.Ratio

1:4

WARNING

When controlling a non condensing

boiler directly without the use of a

mixing valve, minimum boiler water

temperature must be set to boiler

manufacturer specications. In that

case, system temperature must not go

below such temperature.

6 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 congure them, contact your

local Raypak representative.

INITIAL SETUP

Setting an Initial Program will ease the conguration of the TempTracker mod+ and will give the opportunity to utilize many of the

energy saving features and give more comfortable heat when needed.

The program should consist of the following:

• Selecting the features that your system can utilize,

• Installation: Install the Control, switches and sensors,

• Setting the System Startup,

• Setting the System Settings,

• Setting the Stages

• Adjusting Reset Ratio and Water Offset (In Reset Mode Only)

SELECTING THE SYSTEM FEATURES

The TempTracker mod+ has been designed with Hydronic building heating as the primary purpose. With this in mind, many of the

TempTracker mod+ features can be utilized to ease, enhance and improve your system performance. Some of these features are listed

in this section.

OUTDOOR RESET OR SET POINT

• The TempTracker mod+ can control the System Temperature either by adjusting the calculated temperature according to the Outdoor

Temperature (Outdoor Reset) or by maintaining an adjustable Set Point. The earlier relies on an Outdoor Sensor (supplied with the

control) and achieves better fuel savings in addition to better comfort.

NUMBER OF STAGES

• The TempTracker mod+ can be congured to control up to 4 modulating boilers. It can control up to 16 boiler stages using a maximum

of two TempTracker mod+ Extension Panels

MODULATION MODE

• The TempTracker mod+ stages boilers using parallel modulation. Parallel modulation can modulate several boilers together as a

one large boiler. This is useful for boilers which are more efcient at lower ring points.

MODULATING SIGNAL

• The TempTracker mod+ is designed to accurately control the output from 25% to 100% of modulation for each of these different

types of equipment. One TempTracker mod+ can even control a variety of the above different modulation equipment.

AUTOMATIC ROTATION AMONG BOILERS

• Rotating the rst burner to be activated on a call for output promotes even wear on all burners. The TempTracker mod+ has three

modes of rotation: Manual, Last-ON, or Time automatically rotating every selected time period from every hour to every 60 days.

STANDBY BOILER

• Any boiler can be congured as a Standby boiler. It withholds a specic boiler from being included in the Lead Rotation. However,

the Standby boiler will be red only as a backup when all other stages combined cannot satisfy the demand and after an adjustable

delay period.

SETBACK OR DAY/NIGHT SCHEDULING

Two Setback modes are available for the TempTracker mod+:

• The Day/Night Scheduling provides an adjustable time-based schedule for the Setback.

• The Setback mode uses an external signal to switch the operation of the TempTracker mod+ in and out of setback mode.

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.

• TheEnclosureDisplayModule: contains the display, buttons, LEDs and electric wiring terminals. It has two screws to hold it to

the base. A program conguration switch, used to adjust TempTracker mod+ settings, is placed above the terminals. This switch

is enclosed with the enclosure wiring cover for security. Wiring terminals are of the plug-in type to ease installation and removal.

• TheEnclosureBase: contains the holes to mount and hold the control against the wall or any at surface. All other enclosure

components mount on the base. The bottom section of the Enclosure Base contains the wiring chamber with knockouts on the

bottom to easy installation.

• TheEnclosureWiringCover: seals the wires from the external environment. It has two screws to hold it the base and a hole to

secure a lock on the wiring enclosure. A plastic web that separates the wiring chamber into high and low volt sections has been

provided.

MOUNTING THE ENCLOSURE

• Select a location near the equipment to be controlled.

• The surface should be at, and be sufciently wide and strong to hold the

TempTracker mod+ or the TempTracker mod+ Extension.

• Keep the control away from extreme heat, cold, or humidity. Ambient

control operating temperature is from 20 to 120°F.

• Remove the Enclosure Wiring Cover from the control enclosure by

removing the two bottom screws.

• Remove the Enclosure Display Module by removing the middle screws.

• Screw the Enclosure Base to the surface through the upper and lower

mounting holes on the back of the enclosure.

• Replace the Enclosure Display Module and replace the middle screws.

• Do not replace the enclosure wiring cover until all wiring is done.

Mounting Holes

Display Mounting Screws Wiring Cover

Mounting Screws

Enclosure Display Module

Enclosure Wiring Cover Enclosure Base

Hole for optional lock

(not supplied)

8 Raypak, Inc.

INSTALL THE SENSORS

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. If a

boiler is piped so that the sensor does not see its output, the TempTracker mod+

will not sequence the boilers correctly.

• Only use a Standard Brass Tube sensor.

• The sensor wires can be extended up to 500' using a shielded 2-conductor cable

(Belden #8760 or equivalent). Do not ground the shield at the sensor but at the

panel using one of the terminals marked with an “O”.

• Do not run sensor wires in conduit with line voltage wiring.

• Install a 3/8"ID 1/2"NPT immersion well.

• Insert the sensor probe of the supplied sensor into the well.

Immersion Well

3/8" ID 1/2" NPT

Heating System

Sensor

Common Supply Pipe

Sensor Probe

Immersion Heating System Sensor

Shield

Common Supply Pipe

Sensor Probe

Strap-On Heating System Sensor

Shield

Pipe Insulation

Connect

To control

ALERT

If the System Sensor can not sense

the correct heating system water

temperature supplied to the building,

the TempTracker mod+ will not provide

comfortable heat levels. Be sure the

System Sensor is located on a main

supply pipe which can not easily be

isolated from the system.

OUTDOOR SENSOR INSTALLATION

• Only use the Raypak sensor included with the unit.

• Locate the sensor in the shade on the north side of the building. The sensor

should never be in direct sunlight.

• Be sure the location is away from doors, windows, exhaust fans, vents, or other

possible heat sources.

• The sensor should be mounted approximately 10' feet above ground level.

• Adhere the Outdoor Label provided to the back of the sensor base.

• Use the Enclosure Base bottom knockout for the conduit. Use the locknut to

hold the conduit and enclosure base together. Screw the cover to the base.

• If screws are used to afx the enclosure to the wall, make sure to seal around the

sensor and wall except from the bottom.

• The sensor wires can be extended up to 500' using shielded 2-conductor cable

(#18/2). Do not ground the shield at the sensor but at the control using the

terminal marked with an “O”.

• Do not run sensor wires in conduit with line voltage wiring.

WARNING

The TempTracker mod+ is an operating control only. All boilers

must have all safety and limit controls required by code. It is the

responsibility of the installer to verify that all the safety and limits

are working properly before the TempTracker mod+ is installed.

ALERT

Determining the proper location for the Outdoor Sensor is very important. The TempTracker mod+ will base

the heat on the outdoor temperature information it receives from this location. If the sensor is in the sun, or

covered with ice, its reading will be different from the actual Outdoor temperature (OD).

System Sensor

In Well

Shield

Not connected

Well Locknut

Sensor in Well

Well

Sensor 2-Conductor

Shielded Cable

System

Strap-On

Sensor

Shield

Not connected

Plastic

Tie-Wraps

Around Pipe

Outdoor

Sensor

snap-in

location

Shield

not connected

Conduit

Outdoor Label

on back of Sensor

Outdoor Sensor

Strap-On Sensor

Immersion Sensor

Mounting

screws

location

Seal around

sensor and wall

Outdoor

drip-hole

TempTracker mod+ & TempTracker mod+ Extension Installation Manual 9

WIRING

WIRING THE POWER (TERMINALS 1, 2)

• Bring the 120VAC 60Hz power wires through the bottom Knockout of the enclosure.

• Class 1 voltages must enter the enclosure through a different opening from any Class 2 voltage wiring.

• Connect the hot line to terminal marked L.

• Connect the neutral line to the terminal marked N.

• Raypak recommends installing a surge suppressor on the power source to the TempTracker mod+.

WARNING

Class 1 voltages must enter the enclosure through a different opening from any Class 2 voltage wiring.

Raypak recommends installing a surge suppressor on the power source to the TempTracker mod+.

Mini-MOD

SYSTEM

Full Modulation Sequencing Control

RUNPROGRAM DO NOT APPLY ANY VOLTAGE

TO INPUT TERMINALS

345678910 11 12 13 15

14 17

16 18 22

19 21 24

23 29

25 27

26 28 32

30 31

OORS-485

GND VLT

SYS ABCD

PWR

CUR / VLT

GND VLT

TEMP

OUTDOOR

TEMP

SYSTEM

EXTENSION

MODULE

CUR / VLT

------

Line

Neutral

120VAC

Power Source

Outdoor Sensor

Sensor Shiled

25 27

26 28 32

30 31

TEMP

OUTDOOR

TEMP

SYSTEM

System Sensor

Sensor Shiled

Shutdown,

T-Stat, or

Setback Signal

345678910 11 12

SYS ABCD

System Pump

or Pump Starter

Boiler Enable

Output

Boiler

Boiler 4-20mA

Modulation Output

4-20mA

Burner

Motor

Boiler Voltage

Modulation Output

Voltage

Burner

Motor

GND V+

PROVE

/DHW

SHUTDOWN

/SETBACK

PROVE

/DHW

25 27

26 28 32

30 31

TEMP

OUTDOOR

TEMP

SYSTEM

Prove Signal

PROVE

/DHW

25 27

26 28 32

30 31

TEMP

OUTDOOR

TEMP

SYSTEM

DHW Signal

PROVE

/DHW

FOR ALL CIRCUITS

120VAC, 6A RESISTIVE

OUTPUT RATINGS:

1A PILOT DUTY, 15A TOTAL

115VAC 60Hz , 30VA MAX

INPUT RATINGS:

USE COPPER WIRE,

CLASS 1 WIRE ONLY.

ENCLOSED

ENERGY

MANAGEMENT

EQUIPMENT

LISTED

99RA

CAUTION: RISK OF ELECTRIC SHOCK

More than one disconnect switch may be required

to de-energize the equipment before servicing.

/TSTAT

SHUTDOWN

/SETBACK

/TSTAT

SHUTDOWN

/SETBACK

/TSTAT SHUTDOWN

/SETBACK

/TSTAT

WIRING THE SENSORS WARNING

Connect the shield at the control terminal end and cut the shield wire at the sensor end.

Mini-MOD

SYSTEM

Full Modulation Sequencing Control

RUNPROGRAM DO NOT APPLY ANY VOLTAGE

TO INPUT TERMINALS

345678910 11 12 13 15

14 17

16 18 22

19 21 24

23 29

25 27

26 28 32

30 31

OORS-485

GND VLT

SYS ABCD

PWR

CUR / VLT

GND VLT

TEMP

OUTDOOR

TEMP

SYSTEM

EXTENSION

MODULE

CUR / VLT

------

Line

Neutral

120VAC

Power Source

Outdoor Sensor

Sensor Shiled

30 31

TEMP

OUTDOOR

TEMP

SYSTEM

System Sensor

Sensor Shiled

Shutdown,

T-Stat, or

Setback Signal

345678910 11 12

SYS ABCD

System Pump

or Pump Starter

Boiler Enable

Output

Boiler

Boiler 4-20mA

Modulation Output

4-20mA

Burner

Motor

Boiler Voltage

Modulation Output

Voltage

Burner

Motor

GND V+

PROVE

/DHW

SHUTDOWN

/SETBACK

PROVE

/DHW

25 27

26 28 32

30 31

TEMP

OUTDOOR

TEMP

SYSTEM

Prove Signal

PROVE

/DHW

25 27

26 28 32

30 31

TEMP

OUTDOOR

TEMP

SYSTEM

DHW Signal

PROVE

/DHW

FOR ALL CIRCUITS

120VAC, 6A RESISTIVE

OUTPUT RATINGS:

1A PILOT DUTY, 15A TOTAL

115VAC 60Hz , 30VA MAX

INPUT RATINGS:

USE COPPER WIRE,

CLASS 1 WIRE ONLY.

ENCLOSED

ENERGY

MANAGEMENT

EQUIPMENT

LISTED

99RA

CAUTION: RISK OF ELECTRIC SHOCK

More than one disconnect switch may be required

to de-energize the equipment before servicing.

/TSTAT

SHUTDOWN

/SETBACK

/TSTAT

SHUTDOWN

/SETBACK

/TSTAT SHUTDOWN

/SETBACK

/TSTAT

SYSTEM SENSOR WIRING (TERMINALS 27, 28)

• A TempTracker mod+ must be connected to a temperature sensor located in the common header.

• The TempTracker mod+ is designed to be connected to a temperature sensor for immersion in a 3/8ID well.

• Temperature sensor wires can be extended up to 500’ by splicing shielded 2-conductor cable (Belden #8760 or

equivalent).

• Temperature sensors have no polarity. Connect the two wires from the sensor to the TempTracker mod+ terminals

marked SYSTEM TEMP 27, 28.

• Connect the sensor shield to the circled terminal 28 with one of the sensor wires.

OUTDOOR SENSOR WIRING (TERMINALS 25, 26)

• The TempTracker mod+ will vary the system Set Point when Outdoor Reset is selected based on outdoor

temperature.

• Whether in Set Point or Outdoor Reset modes, the outdoor sensor can be used as an Outdoor Cutoff. The

TempTracker mod+ will disable all Boilers when the outdoor temperature is above the adjustable Outdoor Cutoff

temperature. This feature will automatically be activated when an outdoor sensor is connected.

• For an outdoor sensor use a Raypak outdoor sensor.

• The sensor wires can be extended up to 500’ using shielded 2-conductor cable (Belden #8760 or equivalent).

• Temperature sensors have no polarity. Connect the wires from the outdoor sensor to the TempTracker mod+

terminals marked OUTDOOR TEMP - 25, 26.

• Connect the shield to the circled terminal 26 with one of the sensor wires.

Mini-MOD

SYSTEM

Full Modulation Sequencing Control

RUNPROGRAM DO NOT APPLY ANY VOLTAGE

TO INPUT TERMINALS

345678910 11 12 13 15

14 17

16 18 22

19 21 24

23 29

25 27

26 28

30 31

RS-485

GND VLT

SYS ABCD

PWR

CUR / VLT

GND VLT

TEMP

OUTDOOR

TEMP

SYSTEM

EXTENSION

MODULE

CUR / VLT

------

Line

Neutral

120VAC

Power Source

Outdoor Sensor

Sensor Shiled

25 27

26 28 32

30 31

TEMP

OUTDOOR

TEMP

SYSTEM

System Sensor

Sensor Shiled

Shutdown,

T-Stat, or

Setback Signal

345678910 11 12

SYS ABCD

System Pump

or Pump Starter

Boiler Enable

Output

Boiler

Boiler 4-20mA

Modulation Output

4-20mA

Burner

Motor

Boiler Voltage

Modulation Output

Voltage

Burner

Motor

GND V+

PROVE

/DHW

SHUTDOWN

/SETBACK

PROVE

/DHW

25 27

26 28 32

30 31

TEMP

OUTDOOR

TEMP

SYSTEM

Prove Signal

PROVE

/DHW

25 27

26 28 32

30 31

TEMP

OUTDOOR

TEMP

SYSTEM

DHW Signal

PROVE

/DHW

FOR ALL CIRCUITS

120VAC, 6A RESISTIVE

OUTPUT RATINGS:

1A PILOT DUTY, 15A TOTAL

115VAC 60Hz , 30VA MAX

INPUT RATINGS:

USE COPPER WIRE,

CLASS 1 WIRE ONLY.

ENCLOSED

ENERGY

MANAGEMENT

EQUIPMENT

LISTED

99RA

CAUTION: RISK OF ELECTRIC SHOCK

More than one disconnect switch may be required

to de-energize the equipment before servicing.

/TSTAT

SHUTDOWN

/SETBACK

/TSTAT

SHUTDOWN

/SETBACK

/TSTAT SHUTDOWN

/SETBACK

/TSTAT

WIRING THE SHUTDOWN, TSTAT, OR SETBACK (TERMINALS 31, 32)

• The Shutdown will be available when selected as the Shutdown/Tstat/Setback mode from the Startup menu. See

page 15. This will provide the user with a customizable Day/Night Schedule. See page 21.

• The Shutdown feature can be used whenever it is desirable to turn off the TempTracker mod+ stage outputs from

a remote location or another controller (i.e. EMS input).

• The Tstat option, when selected from the Shutdown/Tstat/Setback startup menu, provide the capability of

controlling the operation of the TempTracker mod+ based on a thermostat input. See page 15. This will provide

the user with a customizable Day/Night Schedule. See page 21.

• The thermostat will provide the TempTracker mod+ with a call for heat by shorting terminals 31 and 32.

• When the Shutdown input is enabled by closing the dry contact, or when the Tstat input is disabled by opening the

dry-contact, all active boilers will immediately modulate down to low for the Soft-Off period, then turn off.

• The System Output relay will remain active until the System Run-On Delay expires and then it will turn off.

Mini-MOD

SYSTEM

Full Modulation Sequencing Control

RUNPROGRAM DO NOT APPLY ANY VOLTAGE

TO INPUT TERMINALS

345678910 11 12 13 15

14 17

16 18 22

19 21 24

23 29

25 27

26 28

30 31

OORS-485

GND VLT

SYS ABCD

PWR

CUR / VLT

GND VLT

TEMP

OUTDOOR

TEMP

SYSTEM

EXTENSION

MODULE

CUR / VLT

------

Line

Neutral

120VAC

Power Source

Outdoor Sensor

Sensor Shiled

25 27

26 28 32

30 31

TEMP

OUTDOOR

TEMP

SYSTEM

System Sensor

Sensor Shiled

Shutdown,

T-Stat, or

Setback Signal

345678910 11 12

SYS ABCD

System Pump

or Pump Starter

Boiler Enable

Output

Boiler

Boiler 4-20mA

Modulation Output

4-20mA

Burner

Motor

Boiler Voltage

Modulation Output

Voltage

Burner

Motor

GND V+

PROVE

/DHW

SHUTDOWN

/SETBACK

PROVE

/DHW

25 27

26 28 32

30 31

TEMP

OUTDOOR

TEMP

SYSTEM

Prove Signal

PROVE

/DHW

25 27

26 28 32

30 31

TEMP

OUTDOOR

TEMP

SYSTEM

DHW Signal

PROVE

/DHW

FOR ALL CIRCUITS

120VAC, 6A RESISTIVE

OUTPUT RATINGS:

1A PILOT DUTY, 15A TOTAL

115VAC 60Hz , 30VA MAX

INPUT RATINGS:

USE COPPER WIRE,

CLASS 1 WIRE ONLY.

ENCLOSED

ENERGY

MANAGEMENT

EQUIPMENT

LISTED

99RA

CAUTION: RISK OF ELECTRIC SHOCK

More than one disconnect switch may be required

to de-energize the equipment before servicing.

/TSTAT

SHUTDOWN

/SETBACK

/TSTAT

SHUTDOWN

/SETBACK

/TSTAT SHUTDOWN

/SETBACK

/TSTAT

• When Setback is selected in the Startup, a BMS/EMS or external clock can provide a Setback signal using these input terminals.

• The signal must be a dry contact only. No voltage can be placed across the SHUTDOWN/SETBACK terminals.

• Bring the two wires from the dry contact to the terminals marked SHUTDOWN/SETBACK- 31,32.

10 Raypak, Inc.

WIRING THE SYSTEM PROVE (TERMINALS 29, 30)

• The Prove feature is provided to check system component operation.

• A typical use of this feature is to check for ow before ring any boiler.

• If the PROVE input is open on a call, the TempTracker mod+ will enable only the System Output. All Boiler

outputs will be off when the PROVE input is open.

• A factory-installed jumper provides the Prove signal. Do not remove the jumper unless it will be replaced by a

System Prove signal or use the terminals for DHW call.

• The Prove signal must be a dry contact only. No voltage can be placed across the PROVE - 29, 30 terminals.

• Bring the two wires from the dry contact to the terminals marked PROVE - 29, 30.

WARNING

The PROVE input can not be used as a safety limit. All equipment must have its own

certied limit and safety controls as required by local codes. If Prove is selected in the

startup menu, no boiler stage will start unless Prove terminals are shorted. DO NOT

remove the PROVE jumper supplied unless replacing it with a Prove signal.

Mini-MOD

SYSTEM

Full Modulation Sequencing Control

RUNPROGRAM DO NOT APPLY ANY VOLTAGE

TO INPUT TERMINALS

345678910 11 12 13 15

14 17

16 18 22

19 21 24

23 29

25 27

26 28 32

30 31

OORS-485

GND VLT

SYS ABCD

PWR

CUR / VLT

GND VLT

TEMP

OUTDOOR

TEMP

SYSTEM

EXTENSION

MODULE

CUR / VLT

------

Line

Neutral

120VAC

Power Source

Outdoor Sensor

Sensor Shiled

25 27

26 28 32

30 31

TEMP

OUTDOOR

TEMP

SYSTEM

System Sensor

Sensor Shiled

Shutdown,

T-Stat, or

Setback Signal

345678910 11 12

SYS ABCD

System Pump

or Pump Starter

Boiler Enable

Output

Boiler

Boiler 4-20mA

Modulation Output

4-20mA

Burner

Motor

Boiler Voltage

Modulation Output

Voltage

Burner

Motor

GND V+

PROVE

/DHW

SHUTDOWN

/SETBACK

PROVE

/DHW

25 27

26 28

30 31

TEMP

OUTDOOR

TEMP

SYSTEM

Prove Signal

PROVE

/DHW

25 27

26 28 32

30 31

TEMP

OUTDOOR

TEMP

SYSTEM

DHW Signal

PROVE

/DHW

FOR ALL CIRCUITS

120VAC, 6A RESISTIVE

OUTPUT RATINGS:

1A PILOT DUTY, 15A TOTAL

115VAC 60Hz , 30VA MAX

INPUT RATINGS:

USE COPPER WIRE,

CLASS 1 WIRE ONLY.

ENCLOSED

ENERGY

MANAGEMENT

EQUIPMENT

LISTED

99RA

CAUTION: RISK OF ELECTRIC SHOCK

More than one disconnect switch may be required

to de-energize the equipment before servicing.

/TSTAT

SHUTDOWN

/SETBACK

/TSTAT

SHUTDOWN

/SETBACK

/TSTAT

SHUTDOWN

/SETBACK

/TSTAT

Mini-MOD

SYSTEM

Full Modulation Sequencing Control

RUNPROGRAM DO NOT APPLY ANY VOLTAGE

TO INPUT TERMINALS

345678910 11 12 13 15

14 17

16 18 22

19 21 24

23 29

25 27

26 28 32

30 31

OORS-485

GND VLT

SYS ABCD

PWR

CUR / VLT

GND VLT

TEMP

OUTDOOR

TEMP

SYSTEM

EXTENSION

MODULE

CUR / VLT

------

Line

Neutral

120VAC

Power Source

Outdoor Sensor

Sensor Shiled

25 27

26 28 32

30 31

TEMP

OUTDOOR

TEMP

SYSTEM

System Sensor

Sensor Shiled

Shutdown,

T-Stat, or

Setback Signal

345678910 11 12

SYS ABCD

System Pump

or Pump Starter

Boiler Enable

Output

Boiler

Boiler 4-20mA

Modulation Output

4-20mA

Burner

Motor

Boiler Voltage

Modulation Output

Voltage

Burner

Motor

GND V+

PROVE

/DHW

SHUTDOWN

/SETBACK

PROVE

/DHW

25 27

26 28 32

30 31

TEMP

OUTDOOR

TEMP

SYSTEM

Prove Signal

PROVE

/DHW

25 27

28 32

30 31

TEMP

OUTDOOR

TEMP

SYSTEM

DHW Signal

PROVE

/DHW

FOR ALL CIRCUITS

120VAC, 6A RESISTIVE

OUTPUT RATINGS:

1A PILOT DUTY, 15A TOTAL

115VAC 60Hz , 30VA MAX

INPUT RATINGS:

USE COPPER WIRE,

CLASS 1 WIRE ONLY.

ENCLOSED

ENERGY

MANAGEMENT

EQUIPMENT

LISTED

99RA

CAUTION: RISK OF ELECTRIC SHOCK

More than one disconnect switch may be required

to de-energize the equipment before servicing.

/TSTAT

SHUTDOWN

/SETBACK

/TSTAT

SHUTDOWN

/SETBACK

/TSTAT

SHUTDOWN

/SETBACK

/TSTAT

WIRING FOR DOMESTIC HOT WATER PRIORITY (TERMINALS 29, 30)

• DHW can be used to raise system Set Point to the DHW Set Point. Any of the DHW Priority options must be

selected from the Startup menu. See page 15.

• DHW Call terminals are dry contact N.O. terminals.

• Wire an aquastat or other controls to provide closure on the DHW Call terminals.

• Remove the jumper on the DHW terminals for proper operation.

WIRING THE SYSTEM OUTPUT (TERMINALS 3, 4)

• The SYS output relay will energize whenever the outdoor temperature is below the Outdoor Cutoff.

• The SYS will remain constantly energized while the outdoor temperature is below the Outdoor Cutoff.

• When the outdoor temperature rises 2°F above the Outdoor Cutoff, the SYS output will remain energized for the

period set by the System Run-On.

• The SYS output has one Normally Open (N.O.) relay contact.

• The N.O. contacts are dry contacts only. They do not source any voltage.

• Class 1 voltages must enter the enclosure through a different opening from any Class 2 voltage wiring.

• Each N.O. contact is capable of switching 6A resistive at 120VAC.

Mini-MOD

SYSTEM

Full Modulation Sequencing Control

RUNPROGRAM DO NOT APPLY ANY VOLTAGE

TO INPUT TERMINALS

345678910 11 12 13 15

14 17

16 18 22

19 21 24

23 29

25 27

26 28 32

30 31

OORS-485

GND VLT

SYS ABCD

PWR

CUR / VLT

GND VLT

TEMP

OUTDOOR

TEMP

SYSTEM

EXTENSION

MODULE

CUR / VLT

------

Line

Neutral

120VAC

Power Source

Outdoor Sensor

Sensor Shiled

25 27

26 28 32

30 31

TEMP

OUTDOOR

TEMP

SYSTEM

System Sensor

Sensor Shiled

Shutdown,

T-Stat, or

Setback Signal

345

678910 11 12

SYS

ABCD

System Pump

or Pump Starter

Boiler Enable

Output

Boiler

Boiler 4-20mA

Modulation Output

4-20mA

Burner

Motor

Boiler Voltage

Modulation Output

Voltage

Burner

Motor

GND V+

PROVE

/DHW

SHUTDOWN

/SETBACK

PROVE

/DHW

25 27

26 28 32

30 31

TEMP

OUTDOOR

TEMP

SYSTEM

Prove Signal

PROVE

/DHW

25 27

26 28 32

30 31

TEMP

OUTDOOR

TEMP

SYSTEM

DHW Signal

PROVE

/DHW

FOR ALL CIRCUITS

120VAC, 6A RESISTIVE

OUTPUT RATINGS:

1A PILOT DUTY, 15A TOTAL

115VAC 60Hz , 30VA MAX

INPUT RATINGS:

USE COPPER WIRE,

CLASS 1 WIRE ONLY.

ENCLOSED

ENERGY

MANAGEMENT

EQUIPMENT

LISTED

99RA

CAUTION: RISK OF ELECTRIC SHOCK

More than one disconnect switch may be required

to de-energize the equipment before servicing.

/TSTAT

SHUTDOWN

/SETBACK

/TSTAT

SHUTDOWN

/SETBACK

/TSTAT SHUTDOWN

/SETBACK

/TSTAT

WIRING THE BOILERS

WIRING THE BOILER OUTPUTS (A TERMINALS 5,6), (B TERMINALS 7,8), (C TERMINALS 9,10), ...

• Each Boiler output (A through D) has one Normally Open (N.O.) relay contact.

• The N.O. contacts are dry contacts only. They do not source any voltage.

• Each N.O. contact is capable of switching 6A resistive at 120VAC.

• Total output of all Boilers, including the SYS, must not exceed 15A.

• Wire the N.O. relay contacts to the Enable/Disable connection at the associated unit.

• Class 1 voltages must enter the enclosure through a different opening from any Class 2 voltage wiring.

Mini-MOD

SYSTEM

Full Modulation Sequencing Control

RUNPROGRAM DO NOT APPLY ANY VOLTAGE

TO INPUT TERMINALS

5678910

11 12 13 15

14 17

16 18 22

19 21 24

23 29

25 27

26 28 32

30 31

OORS-485

GND VLT

SYS

ABC

PWR

CUR / VLT

GND VLT

TEMP

OUTDOOR

TEMP

SYSTEM

EXTENSION

MODULE

CUR / VLT

------

Line

Neutral

120VAC

Power Source

Outdoor Sensor

Sensor Shiled

25 27

26 28 32

30 31

TEMP

OUTDOOR

TEMP

SYSTEM

System Sensor

Sensor Shiled

Shutdown,

T-Stat, or

Setback Signal

345678910 11 12

SYS ABCD

System Pump

or Pump Starter

Boiler Enable

Output

Boiler

Boiler 4-20mA

Modulation Output

4-20mA

Burner

Motor

Boiler Voltage

Modulation Output

Voltage

Burner

Motor

GND V+

PROVE

/DHW

SHUTDOWN

/SETBACK

PROVE

/DHW

25 27

26 28 32

30 31

TEMP

OUTDOOR

TEMP

SYSTEM

Prove Signal

PROVE

/DHW

25 27

26 28 32

30 31

TEMP

OUTDOOR

TEMP

SYSTEM

DHW Signal

PROVE

/DHW

FOR ALL CIRCUITS

120VAC, 6A RESISTIVE

OUTPUT RATINGS:

1A PILOT DUTY, 15A TOTAL

115VAC 60Hz , 30VA MAX

INPUT RATINGS:

USE COPPER WIRE,

CLASS 1 WIRE ONLY.

ENCLOSED

ENERGY

MANAGEMENT

EQUIPMENT

LISTED

99RA

CAUTION: RISK OF ELECTRIC SHOCK

More than one disconnect switch may be required

to de-energize the equipment before servicing.

/TSTAT

SHUTDOWN

/SETBACK

/TSTAT

SHUTDOWN

/SETBACK

/TSTAT SHUTDOWN

/SETBACK

/TSTAT

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