Pentair Raychem HWAT System, Installation And Operation Manual

Page 1: ...HWAT System INSTALLATION AND OPERATION MANUAL FOR HOT WATER TEMPERATURE MAINTENANCE SYSTEMS FOR THERMALLY INSULATED PIPES THERMAL MANAGEMENT SOLUTIONS WWW THERMAL PENTAIR COM...

Page 2: ...not sub stitute parts or use vinyl electrical tape Bus wires will short if they contact each other Keep bus wires separated Connection kits and heating cable ends must be kept dry before and during in...

Page 3: ...Pre Installation Checks 8 3 3 Installation 8 4 Heating Cable Components 14 4 1 General Connection Kit Information 14 5 Control and Monitoring 16 5 1 HWAT ECO and ACCS 30 Controllers 16 6 Thermal Insu...

Page 4: ...iv Raychem IM H57548 HWATsystem EN 16 08 10 Test Procedures 34 11 Troubleshooting Guide 38...

Page 5: ...uide H57538 HWAT ECO Data Sheet H57339 ACS 30 Mulitpoint Commercial heat tracing Control System Data Sheet H58261 HWAT Heating Cable Data Sheet H57512 RayClic Connection System Data Sheet H57545 HWAT...

Page 6: ...rtant Follow them carefully to minimize these risks and to ensure that the HWAT System performs reliably Pay special attention to the following Instructions marked Important Warnings marked WARNING 1...

Page 7: ...Codes Section 427 of the National Electrical Code NEC and Part 1 Section 62 of the Canadian Electrical Code CEC in particular govern the installation of electrical heat tracing systems used on hot wat...

Page 8: ...coordination between trades is a critical aspect of all HWAT System Installations The instal lation of the heating cable and connections must be properly scheduled along with the scheduling of the ris...

Page 9: ...work All heat traced pipes and equipment must be ther mally insulated Insulation is an important part of the HWAT System For an effective system the fiberglass insulation must be a specific thickness...

Page 10: ...d For installing cable and connection kits Utility knife Diagonal cutters Cable cutters Tape measure Screwdriver Heat gun or propane torch For testing the heating cable Megohmmeter 2500 Vdc Multimeter...

Page 11: ...CO or ACS 30 controllers Figure 2 shows the construction of the heating cable Nickel plated copper bus wires Self regulating conductive core Polymer coated aluminum wrap Tinned copper braid Modified p...

Page 12: ...age avail able is correct Inspect the heating cable and connection kits to ensure there is no in transit damage Verify that the heating cable jackets are not dam aged by conducting the insulation resi...

Page 13: ...netrations and pipe hangers are particular areas of concern Figure 3 Protecting the heating cable in floor penetrations Run insulation through the pipe hanger ensuring that the pipe is not resting on...

Page 14: ...the floor penetration Run the heating cable over the outside of the pipe support Do not clamp the heating cable to the pipe with the pipe support In high rise construction it may be necessary to inst...

Page 15: ...sive pulling force or jerking Kinking and crushing Walking on it or running over it with equipment WARNING Fire and shock hazard Do not install damaged cable Connection kits and cable ends must be kep...

Page 16: ...the heating cable on the pipe do not bend tighter than 1 2 radius The heating cable does not bend easily in the flat plane Do not force such a bend as the heating cable will be damaged 1 2 Figure 8 Be...

Page 17: ...n plastic pipes as shown in Figure 10 WARNING Do not use metal attachments such as pipe straps or tie wire Do not use vinyl based electrical or duct tape Use only Pentair Thermal Management approved t...

Page 18: ...he labels provided in the kits RayClic PT powered tee RayClic PC powered connection RayClic S splice RayClic X cross tee RayClic T tee RayClic PS powered splice RayClic LE lighted end seal RayClic E e...

Page 19: ...ion Service loop All power connection kits must be installed in accessible locations Access to splices tee kits and end seals is recommended for future modifi cation or maintenance but is not required...

Page 20: ...tallation and operation instructions of the controller Figure 12 HWAT ECO controller The ACS 30 Control System is also approved for use with HWAT R2 heating cable Refer to the ACS 30 Programming Guide...

Page 21: ...eter with one run of heating cable or 1 3 the pipe diameter with two runs of heating cable 6 2 Insulation Installation Before insulating the pipe visually inspect the heating cable and connection kit...

Page 22: ...ge the HWAT heating cable Figure 14 Sealing the insulation seam When installing splice tee and end seal kits under neath the thermal insulation mark the location of splices tees and end seals on the o...

Page 23: ...w insulation Make sure that all heat traced piping fittings wall penetrations and branch piping are insulated Correct temperature maintenance requires proper ly installed and dry thermal insulation Un...

Page 24: ...ection or provide equivalent levels of ground fault protection Ground fault protection is integrat ed into the ACS 30 control system so no additional protection is required Table 3 MAXIMUM CIRCUIT LEN...

Page 25: ...fault protection of equipment and a ground ed metallic covering on all heating cables All HWAT heating cables meet the metallic covering require ments Ground fault protection must be provided by the...

Page 26: ...l damage Check that no moisture is present electrical con nections are tight and grounded insulation is dry and sealed and control and monitoring systems are operational and properly set Damaged heati...

Page 27: ...testing is used to verify the integrity of the heating cable inner and outer jackets IR testing is analogous to pressure testing a pipe and detects if a hole exists in the jacket Power check The powe...

Page 28: ...ts refer to Section 10 for trouble shooting assistance Make the necessary repairs and replace any damaged cable immediately De energize all cir cuits that may be affected by maintenance Protect the he...

Page 29: ...m them Record the results in the Installation and Inspection Record in Section 11 1 Visual inspection test Check inside all power splice and tee kits for proper installation overheating corrosion mois...

Page 30: ...t allow test leads to touch junction box which can cause inaccurate readings Important System tests and regular maintenance procedures require that insulation resistance testing be performed Test dire...

Page 31: ...y particular circuit should not vary more than 25 percent as a function of measuring voltage Greater variances may indicate a problem with your heat tracing system confirm proper installation and or c...

Page 32: ...short Record the insulation resistance value in the Inspection Record 8 Repeat Steps 4 7 at 1000 and 2500 Vdc 9 Turn off the megohmmeter 10 If the megohmmeter does not self discharge discharge phase...

Page 33: ...WAT R2 heating cable This will ensure the system is at a uniform pipe tempera ture Dot not power the system when the pipe temper ature is below 50F 10C 1 Power the heating cable and allow it to stabil...

Page 34: ...he point of use closest to the water heater and progress out Testing should be done after a minimum of 4 hours of no water usage This will ensure that the tem peratures indicated are not due to flow c...

Page 35: ...hm meter this method can also be used to find a fault from a bus wire to the ground braid This type of short would trip a GFPD and show a failed reading Measure the bus to bus heating cable resistance...

Page 36: ...2 Conductance method The conductance method uses the core resistance of the heating cable to approximate the location of a fault when the heating cable has been severed and the bus wires have not bee...

Page 37: ...connected Record the capacitance reading from one end of the heating cable The capacitance reading should be measured between both bus wires twisted together positive lead and the braid negative lead...

Page 38: ...re 24 and resistance can be tested at the other end as each additional component is added to the system Procedure 1 De energize the circuit 2 Disconnect cable bus wires and ground wire 3 Temporarily c...

Page 39: ...braid to A and braid to B are within 20 of each other the cable continuity is intact Continue with system installation 9 Repeat test procedures for all branch lines to verify entire heat tracing circ...

Page 40: ...the design Refer to the HWAT or ACS 30 Program Verify that the plum See Circuit breake Symptom Probable Causes Corrective Actio Low or no power output Low or no input voltage applied The circuit is sh...

Page 41: ...re operating properly See Circuit breaker trips section of this Troubleshooting Guide Corrective Action e applied han the design or tees not being ing cable having connection nce connection set wrong...

Page 42: ...output of the heating Clear the test leads f Symptom Probable Causes Corrective Action Circuit breaker trips Circuit breaker is undersized Connections and or splices are shorting out Physical damage...

Page 43: ...m junction box and restart Corrective Action rsized ices are shorting out ating cable is causing at the end ating cable or power present or moisture mA used instead of Recheck the design for startup t...

Page 44: ...s in the RayClic and HWAT ECO are tight and wires secure Visual inspection inside connection boxes for overheating corrosion moisture loose connections and other problems Proper electrical connection...

Page 45: ...48 HWATsystem EN 16 08 llation and Inspection Record Test Date _________ Circuit Number nction HWAT ECO are tight ating corrosion nsulated over eference Table 2 hot water piping system n insulation sw...

Page 46: ...42 Raychem IM H57548 HWATsystem EN 16 08...

Page 47: ...43 Raychem IM H57548 HWATsystem EN 16 08...

Page 48: ...21 2412 1688 Fax 86 21 5426 2917 cn thermal info pentair com LATIN AMERICA Tel 1 713 868 4800 Fax 1 713 868 2333 thermal info pentair com Pentair RayClic and HWAT are owned by Pentair or its global a...

Page 49: ...HWAT ECO INSTALLATION AND OPERATION MANUAL FOR HOT WATER TEMPERATURE MAINTENANCE SYSTEM ELECTRONIC CONTROLLER THERMAL MANAGEMENT SOLUTIONS WWW THERMAL PENTAIR COM...

Page 50: ...y Do not substitute parts or use vinyl electrical tape Bus wires will short if they contact each other Keep bus wires separated Connection kits and heating cable ends must be kept dry before and durin...

Page 51: ...e and Maintenance 7 1 5 HWAT Heating Cables 7 2 Installation 9 2 1 Installing the Controller 9 2 2 Wiring the Controller 13 3 Programming the Controller 26 3 1 Programming Overview 26 3 2 Initializing...

Page 52: ...er B 1 Temperature sensor with 13 ft 4 m cable C 2 Mounting screws D 2 Mounting washers E 1 Aluminum tape F 1 Manual HWAT ECO INSTALLATION AND OPERATION MANUAL FOR HOT WATER TEMPERATURE MAINTENANCE SY...

Page 53: ...arm requires installed sensor green LED Alarm red LED Escape backspace NO or display maintain temperature setpoint Arrow keys to change menu selection or position the cursor Confirm selection new valu...

Page 54: ...vi EN RaychemHWATECOcontroller IM H57340 03 13...

Page 55: ...l Management warranty and agency approvals to apply the instruc tions included in this manual and product packages must be followed 1 2 Features The Raychem HWAT ECO controller is designed for operati...

Page 56: ...to set the maintain temperature Alarm relay to signal power temperature or communication problems Pipe temperature monitoring low temperature alarm and high temperature cut out Master slave function t...

Page 57: ...C Controller ambient temperature 40 F 5 C to 105 F 40 C ambient Switching capacity 24 A 208 240 Vac max Operating voltage 208 240 10 60 Hz Internal power consumption 2 5 W Circuit protection not prov...

Page 58: ...er temperature too high Lost date and time settings Internal failure Pipe temperature too high optional Pipe heater tempera ture too low optional Network error Power correction factor To increase or d...

Page 59: ...sure rating NEMA 12 IP54 indoor use only Enclosure material ABS Mounting Wall mount with two screws or optional DIN rail Conduit entries 2 ea 1 2 in conduit entries Cable gland 3 hole grommet Maximum...

Page 60: ...d pair and insulation of 300 V Max length cable is 100 m Parameters in memory All parameters are stored in nonvolatile memory except time and date Clock backup time Rechargable Lithium bat tery Batter...

Page 61: ...ntative or call Pentair Thermal Management at 800 545 6258 1 5 HWAT Heating Cables Maintain temperature Depending on the ambient temperature and voltage HWAT Y2 is designed to maintain temperatures up...

Page 62: ...anagement and national electrical codes ground fault equipment protection must be used on each heating cable branch circuit Arcing may not be stopped by conventional circuit protection The HWAT ECO do...

Page 63: ...r within 328 ft 100 m of where you want to monitor the pipe temperature Opening the controller WARNING To prevent shock always switch off the power supply circuit breaker before opening the controller...

Page 64: ...e 3 Opening the controller Wall mounting the controller Mount the controller using either of the options below 1 You can mount the controller to the wall using the two supplied screws and sealing ring...

Page 65: ...2 Installation 11 EN RaychemHWATECOcontroller IM H57340 03 13 5 9 148 mm 1 7 43 mm TEMP BMS B A Figure 4 Hole locations for mounting with screws...

Page 66: ...hemHWATECOcontroller IM H57340 03 13 2 Optionally you can mount the controller using DIN 35 Rail mounting Optional Din Rail Mount Rail not provided Mounting Removing Press tab to remove box Figure 5 M...

Page 67: ...elow shows the arrangement of the terminal blocks for power alarm pipe temperature sensor BMS and network Ground HWAT ECO General Arrangement Power terminal block Sensor BMS and network terminal block...

Page 68: ...work and alarm connections Important Tighten the terminal screws to 6 inch lbs 0 68 N m G 1 2 Conduits HWAT heating cable RayClic PC Max 30 A ground fault circuit breaker 208 240 Vac Ground Incoming p...

Page 69: ...mA ground fault trip 208 240 Vac Three pole main CB HWAT ECO internal relay Power connection Panel energized light Contactor coil 208 or 240 V Heating cable End seal Three pole main contactor Ground...

Page 70: ...PL4 PL3 PL5 Standard temperature sensor PT100 sensor 2 wire short for PT100 TEMP BMS B A PL4 PL3 PL5 TEMP BMS B A Alarm Sensor and BMS terminals PL6 Alarm contact TEMP BMS B A Figure 9 TEMP terminal...

Page 71: ...measure the pipe temperature The temperature sensor cable is 13 ft 3 in 4 m in length however the user can extend the cable up to 328 ft 100 m by splicing a length of 300 volt 18 AWG 0 75 mm2 cable Co...

Page 72: ...ntacts should be connected in series Alarm Sensor and BMS terminals PL6 Alarm contact TEMP BMS B A NC O NO Figure 11 Connecting the alarm contact The alarm terminal PL6 is located in the upper right c...

Page 73: ...en Closed Network The Master slave function allows one HWAT ECO to control up to eight additional HWAT ECO controllers Connect all HWAT ECO controllers to each other in parallel using the A and B inpu...

Page 74: ...H57340 03 13 MASTER TEMP BMS B A TEMP BMS B A SLAVE 1 OPTIONAL BMS WATER HEATER SENSOR NETWORK WIRE TO SLAVE 2 Figure 12 Networking controllers together The diagram below shows the connection of multi...

Page 75: ...ollers with RS 485 When multiple controllers are networked and you are using BMS and Alarm functions you must use a 4 wire conductor max 20 AWG 0 5 mm2 max 24 AWG 0 2 mm2 Figure 14 Combine alarm and B...

Page 76: ...Vdc input If the controller is programmed to have a BMS connection the BMS controls the temperature set point Using 300 V rated cable connect the BMS sig nal wire to terminal PL5 Connect the ground wi...

Page 77: ...40 03 13 Figure 16 shows the connection of a single controller with optional sensor BMS and alarm connections Master HWAT heating cable Sensor BMS Alarm L L 208 240V RayClic PC Figure 16 Single contro...

Page 78: ...ver in front of the wall mounted box The separation sheet inside the controller will help guide the cover and the connector Push the cover onto the box Note that the connector pins will offer some res...

Page 79: ...increased risk of scalding Pipe temperature alarm requires installed sensor green LED Alarm red LED Escape backspace NO or display maintain temperature setpoint Arrow keys to change menu selection or...

Page 80: ...lowing text on start up The HWAT ECO has six buttons Up Down Left Right arrows Escape ESC button Enter button You can program the HWAT ECO by simply executing the Quickstart program which is suitable...

Page 81: ...ry Table 1 QUICKSTART MENU Time and date Year Month Day Hour Minutes Select Year Select Month Select Day Select Hour Select Minutes Cable type HWAT R2 Press Enter for this cable type HWAT Y2 Press Ent...

Page 82: ...SC button to go back to a previous menu On startup the dis play will show the following text Quickstart Any key to start Press a key to start and the following menus appear Time and Date Use the up do...

Page 83: ...er Ambient temperature The ambient temperature is the air temperature surrounding the hot water piping where the heating cable is installed Use the up down arrow keys to select from 60 F 15 C to 80 F...

Page 84: ...ERATURE 208 VOLT Ambient temperature Heating cable 60 F 15 C 70 F 20 C 80 F 25 C HWAT Y2 120 F 49 C 125 F 52 C 125 F 52 C HWAT R2 140 F 60 C 140 F 60 C 140 F 60 C Table 3 MAXIMUM MAINTAIN TEMPERATURE...

Page 85: ...ernal memory During this time a row of dots will show in the display Pipe temperature This function also ensures that the delivered water temperature is not lower than the desired maintain temperature...

Page 86: ...and a star to indi cate that the controller is unlocked 02 11 2013 Maintain 09 13 While in operating mode press ESC to view a bar graph that shows the maintain temperature setpoint To enter the progra...

Page 87: ...Programming Advanced programming options are also available Table 4 and the remainder of this section outline the advanced programming options that include modify ing initial settings setting addition...

Page 88: ...point 3 Ambient Temp Enter ambient temp 4 Power Correction Selectable 5 Lock Lock unlock Setup and Timer menus 6 BMS Select Yes No 7 Network Master Select Yes No 8 Reinitialize Select Yes No 9 Short h...

Page 89: ...esc home 2 Edit program Monday Tuesday Wednesday Thursday Friday Saturday Sunday Edit timer for Monday Edit timer for Tuesday Edit timer for Wednesday Edit timer for Thursday Edit timer for Friday Edi...

Page 90: ...ini mum temperature is 105 F 40 C or the economy temperature whichever is higher The maximum temperature depends on cable type pipe diameter insulation thickness and ambient temperature 2 Economy temp...

Page 91: ...l pipe maintain tem perature or to adjust for using HWAT heating cables on rigid plastic pipes The power correction factor can be adjusted from 0 6 to 1 40 increasing or decreasing the percent time th...

Page 92: ...k On again 6 Building Management System BMS You can activate the Building Management System option using this menu When set to Yes the control ler responds only to the voltage applied to the BMS termi...

Page 93: ...elect one controller as the Master This con troller should be fully programmed and all slave controllers will use the Master settings The master controller sends commands to all slave controllers to s...

Page 94: ...5 cables and repeat this procedure 8 Reinitialize To Reinitialize all settings back to the factory set tings except time and date set the Reinitialize menu to Yes 9 Short Heater This feature allows yo...

Page 95: ...t Out When the optional pipe temperature sensor option is installed the HWAT ECO controller monitors the temperature of the hot water distribution pipes where the sensor is installed and a high temper...

Page 96: ...ted you will need to enter the password to unlock the controller After you enter the password the controller remains unlocked until five minutes of key inactivity or the Lock On is selected again Sele...

Page 97: ...ected number of hours When hot water is not being used and the pipes are stagnant the HWAT ECO can raise the temperature of the water in the stagnant pipes To determine the amount of time that is requ...

Page 98: ...ed off or to resume your timer program On The controller uses the normal operation the timer program Off The controller will not power the system until you select Use timer xx Days off You can select...

Page 99: ...ool and then re energize The controller will lock out after three occur rences If this does not restore the controller replace the HWAT ECO Error 2 Pipe Sensor failure Only when tempera ture alarm ena...

Page 100: ...controlling a contactor ensure that the Short Heater Alarm is enabled Error 6 Configuration Error Refer to Short Heater menu If heating cable is longer that 15 ft 4 5 m then Short heater No If heating...

Page 101: ...put time again will be asked by the unit when a button is pressed Error 9 Pipe temperature is too low Only when temperature alarm yes selected Pipe temperature too low Correct boiler mixing valve temp...

Page 102: ...lue of ambient temperature is too high Insulation thickness is different than stan dard thickness Check boiler tem perature and timer program Mixing valves and janitor sinks may be allowing cold water...

Page 103: ...stan dard thickness Entered value of ambient temperature is too low Change heater type in HWAT ECO can only be done in quick install Setup on page 36 Reinitialize Adjust power correc tion factor if p...

Page 104: ...I I 00 06 12 18 24 02 04 16 14 10 08 20 22 00 06 12 18 24 02 04 16 14 10 08 20 22 00 06 12 18 24 02 04 16 14 10 08 20 22 Heat up Economy Maintain Heat up Economy Maintain Heat up Economy Maintain 00 0...

Page 105: ...day 00 06 12 18 24 02 04 16 14 10 08 20 22 00 06 12 18 24 02 04 16 14 10 08 20 22 00 06 12 18 24 02 04 16 14 10 08 20 22 4 4 4 4 4 re Maintain temperature Heat up cycle Economy temperature Off Heat up...

Page 106: ...t Up HWAT Y2 125 52 120 49 115 46 110 43 Time hours Pipe Temperature F C 105 41 0 2 4 6 8 10 12 14 16 18 22 24 20 70 F 21 C ambient 1 2 inch pipe 1 inch pipe 2 inch pipe 208V 0 2 4 6 8 10 12 14 16 18...

Page 107: ...2 24 20 Time hours 150 66 140 60 130 54 120 49 110 43 Pipe Temperature F C 105 41 240V 1 2 inch pipe 1 inch pipe 2 inch pipe 70 F 21 C ambient 150 66 140 60 130 54 120 49 110 43 105 41 Time hours Pipe...

Page 108: ...hese cool down curves represent when the heating cable is turned off 0 1 2 3 4 5 6 7 8 9 11 12 10 Time hours Cool Down 150 66 140 60 130 54 120 49 110 43 145 63 135 57 125 52 115 46 105 40 Pipe Temper...

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Page 110: ...Tel 86 21 2412 1688 Fax 86 21 5426 2917 cn thermal info pentair com LATIN AMERICA Tel 1 713 868 4800 Fax 1 713 868 2333 thermal info pentair com Pentair and HWAT are owned by Pentair or its global af...