heat-timer DHW Energy Saver User manual

Installation and Operation Manual DHW

Energy Saver
Domestic Hot Water Boiler or Direct or
Indirect Water Heater and Recirculating
Pump Control with Setback Schedule
WARNING
This Heat-Timer control is strictly an operating control; it should
never be used as a primary limit or safety control. All equipment
must have its own certified limit and safety controls required by local
codes. The installer must verify proper operation and correct any
safety problems prior to the installation of this Heat-Timer control.
DHW Energy Saver
Boiler Pump
6 7 8 9
COM
3 4 5
A GND B
16VAC
1 2
~ ~



2DHW Energy Saver Installation and Conguration Manual

Contents
OVERVIEW                                                         
INSTALLATION                                                      
WIRING                                                           
Power Wiring                                                      
Communication Wiring                                                
Boiler or Direct/Indirect Water Heater Wiring                                     
Domestic Hot Water Circulating Pump Wiring                                    
Temperature Sensor Wiring                                              
 
                                             
PLATINUM CONTROL MENU SETTINGS                                        
ICMS WEB MENU SETTINGS                                              
Using the Supply or Return Sensor 
Supply or Return Set Point                                              
Supply or Return Peak and Light Differential                                    
Demand Schedule                                                    
Copy Schedule                                                     
INTERNET ALARMS THROUGH ICMS                                          
Sensor Fault                                                       
Communication Error                                                  
TROUBLESHOOTING AND LEDS                                            
PIPING/WIRING TO WATER HEATER                                          
PIPING/WIRING TO BOILER AND INDIRECT WATER HEATER                            
PIPING/WIRING TO BOILER AND A TEMPERING VALVE                              
SPECIFICATION                                                     

DHW Energy Saver Installation and Conguration Manual 3

Overview
TheDHW(DomesticHotWater)EnergySaverconnectstoaHeat-TimerRINetPlatinumseriescontrol(allMPC,
MPCQ,HWR,HWRQ,SRCRINetPlatinumcontrolswithsoftwareversion7.05orhigher)tooperateaboilerordirect/
indirectwaterheaterandaDHWcirculatingpumpbasedontwosetpoints.Onesetpointisfortheboilerandtheother
isforthepump.TwosensorsconnectedtothePlatinumRINet(Internetcommunicationcapablecontrol)areused.
AuxTemp0sensormeasuresthedomestichotboilersupplytemperature.AuxTemp1sensormeasuresthedomestic
recirculatinglinereturntemperature.
AlltheDHWEnergySaversettingscanbeviewedandadjustedthroughthePlatinumcontrolmenusorthePlatinum
controlpagesonICMSwebsite(http://www.htcontrols.com).Eachofthesupplyandreturntemperatureshaveasetpoint
andapeakdemandandlightloadconditiondifferentials.Thisoffersbetteroperationandsavingsthanonedifferential.
Asthegoalistoreduceboiler/waterheaterandpumpoperationduringlightperiods.Thatcanbeachievedbyhaving
slightlylongerboiler/waterheaterrunperiodsandlongeroffperiodsusingalargerdifferential.Whenthesupply
temperaturedropsbelowtheSupplySetPointanddifferential,theControlwillenergizetheboileroutput.Theboiler
outputwillremainenergizeduntilthesupplytemperaturereachestheSupplySetPoint.Whenthereturntemperature
dropsbelowtheReturnSetPointlessthedifferential,theControlwillenergizethecirculatingpumpoutput.Thepump
outputwillremainenergizeduntilthereturntemperaturereachestheReturnSetPoint.
WARNING
• Make sure Recirculating Pump control does not adversely affect other equipment. I.e. tempering valve.
• Make sure the boiler/water heater can operate properly at the lowest desired differential adjustment.
ThePlatinumcontrolhasaseparateDHWEnergySaverweeklyDay/NightschedulethatcanbesetusingtheInternet
ICMSwebsiteorthroughthePlatinumcontrolmenu.Itoffers4peakand4lightloadperiodsforeachdayoftheweek.
Wheninthepeakperiod,thePlatinumcontrolwillusethePeakDifferentialsetting.Wheninthelightusageperiod,the
PlatinumcontrolwillusetheLightDifferentialsetting.TheLightDifferentialmustbegreaterthanthePeakDifferential
toprovidelongerboilerorpumpruntimeandlongeroffperiods.
DHW Energy Saver
Boiler Pump
6 7 8 9
COM
3 4 5
A GND B
16VAC
1 2
~ ~












4DHW Energy Saver Installation and Conguration Manual

Installation
TheDHWEnergySavercommunicateswiththeHeat-TimerPlatinumcontrolusingRS485(3-wireconnection).Thus,it
needstobeinstalledincloseproximitytothePlatinumcontroltoreducelongcommunicationwireruns.
• MounttheDHWEnergySaveronaatsurfacenexttothePlatinumcontrol.
• TheModulecanbemountedhorizontallyorvertically.
• Keepthecontrolawayfromextremeheat,cold,orhumidity.
• Screwthemoduletotheatsurfaceusingthetwosidetabswithholes.
• NoneedtoremovetheDHWEnergySavercover.
Wiring
• WhenwiringtheDHWEnergySaver,makesurethatthecoverwiththe
terminallabelsisavailable.
• Allmoduleterminalsareoftheremovaltype.Thatfacilitateseasy
wiring.Justunscrewtheterminalblocksidescrewstoremovethefull
terminalblock.
DHW Energy Saver
Boiler Pump
6 7 8 9
COM
3 4 5
A GND B
16VAC
1 2
~ ~




Power Wiring
• TheDHWEnergySaverispoweredusing16VACtransformer.
Transformermustbeaminimumof10VAandisincludedwithcontrol.
• ConnectthetransformeroutputstotheDHWEnergySaver’sleftmost
terminals.Powerpolarityisnotobserved.
WARNING
DO NOT share the DHW Energy Saver transformer with other
devices. This may cause problem in the control operation or
permanent damage to the equipment.
Communication Wiring
• TheDHWEnergySavercommunicatesallofitsinformationtothe
PlatinumcontrolusingRS485(3-wireconnection).
• TheDHWEnergySaverRS485terminalsarewiredtothePlatinum
mainboard’sRS485(underthePCBboard).
• Followthewiringasperthegraphontheright.
ALERT
DO NOT connect the DHW Energy Saver to the RS485 on the
Platinum RI board. Instead, connect the DHW Energy Saver
RS485 to the Platinum main board.
• Maximumwiringlengthshouldnotexceed100Feet.Use18
gauge2-conductorshieldedwire(#18).Connecttheshieldtothe
middleterminalsonbothoftheRS485connections.Toeliminate
communicationerrors,DONOTsplicethecommunicationcablewires.
• WhenconnectingtheDHWEnergySaverandaPlatinumExtension
tothesameconnector,makesuretosplicethecablesexternallybefore
bringingthemtotheRS485PlugConnectoronthemainPlatinum
Board.
DHW Energy Saver
Boiler Pump
6 7 8 9
COM
3 4 5
A GND B
16VAC
1 2
~ ~







DHW Energy Saver Installation and Conguration Manual 5

Boiler or Direct/Indirect Water Heater Wiring
• TheDHWEnergySavercancontrolasingleboiler.Itturnsonthe
boiler/waterheaterwheneverthesupplytemperaturedropsbelowthe
SupplySetPointlessthedifferential.
• Justwireterminal6and7totheboilerTTterminals.
• Heat-Timerrecommendstheinstallationofabypassswitchfor
maintenanceandmanualoperationoftheboiler/waterheater.
• MakesuretosettheboilerlimitshigherthantheDHWEnergySaver
SupplySetPoint.
DHW Energy Saver
Boiler Pump
6 7 8 9
COM
3
4 5
A GND B
16VAC
1 2
~ ~






Domestic Hot Water Circulating Pump Wiring
• WhentheDHWReturnisactivated,theDHWEnergySaverwill
energizetheDHWcirculatingpumprelaywheneverthereturn
temperaturedropsbelowtheReturnSetPointlessthedifferential
• TheDHWEnergySaverisequippedwithacirculatingpumprelay
output.Therelaycanoperateupto⅛HPpumpat120VAC.
• ThePumpoutputrelaydoesnotsourceanypower.Aseparatepower
sourceisrequiredforthepump.
• Heat-Timerrecommendstheinstallationofabypassswitchfor
maintenanceandmanualoperationofthepump.
DHW Energy Saver
Boiler Pump
6 7 8 9
COM
3 4 5
A GND B
16VAC
1 2
~ ~






Temperature Sensor Wiring
• OnlyuseaStandardBrassTubesensorprovided(HT#904250-00).
• Thesensorwirescanbeextendedto500Ftbysplicingitto
2-conductorshieldedcable(#18/2Shielded)(HT#703001-01).
• ConnecttheshieldatthePlatinumcontrolcircledterminal.Theshield
MUSTbecutatthesensorend.
• Thesensorsmustbeinsertedin⅜”IDNPTwell(HT#904011-00or
equivalent).
AUX
TEMP 0
AUX
TEMP 1












AUX
TEMP 2






NETWORK
PROVE
SHUTDOWN
OUT
TEMP




PRESS
4-20 mA







Platinum Control
Supply Temperature Sensor
• TheSupplyTemperatureSensorisrequiredtobeconnectedtothe
PlatinumAuxTemp0inputterminalsfortheDHWEnergySaverto
controltheboiler/waterheaterrelay.
• TheSupplysensormustbeinstalledinanyoftheboilerorwater
heateraquastatttingsornomorethan10Ftpasttheoutletofthe
boiler/waterheater,beforeanytakeoffs.
Return Temperature Sensor
• ThereturnTemperatureSensorisincludedbutoptional.Itshouldbe
connectedtothePlatinumAuxTemp1inputterminalsfortheDHW
EnergySavertocontrolthePumprelay.
• TheReturnsensorshouldbeinstalledlessthan3feetfromthereturn
circulatoronthereturnline.

6DHW Energy Saver Installation and Conguration Manual

Platinum Control Menu Settings
------ SETTINGS ------
Shift
<System Settings>
<Schedules>
<Maintenance>
<System Startup>
- MAINTENANCE MENU-
System Trim +0 F
Outdoor Trim +0 F
Password
<DHW Settings>
--- DHW SETTINGS ----
<Supply Settings>
<Return Settings>
Demand Schedule
Copy Schedule
DHW Settings
DHW SUPPLY SETTINGS
Use Sensor? Yes
Setpoint 140 F
Peak Diff 20 F
Light Diff 40 F
DHW RETURN SETTINGS
Use Sensor? Yes
Setpoint 120 F
Peak Diff 20 F
Light Diff 40 F
- DHW DEMAND SCHED -
MON#1
Peak Time 6:00Am
Light Time 10:00Pm
ICMS Web Menu Settings
DHW Mode = Peak
Supp 165 F Ret OPEN
DISABLED
Press the BACK button twice
from the Main Display to show
DHW Status

DHW Energy Saver Installation and Conguration Manual 7

Using the Supply or Return Sensor
Yes, No Default: No
SELECTMaintenance/DHW Settings/Supply Settings/Use Sensor Supply Sensor
SELECTMaintenance/DHW Settings/Return Settings/Use Sensor Return Sensor
• ByactivatingtheSupplySensorfeature,thePlatinumcontrolwillutilizeAuxTemp0input
astheSupplySensor.
• ByactivatingtheReturnSensorfeature,thePlatinumcontrolwillutilizeAuxTemp1input
astheReturnSensor.
• AnyofthetwofeaturescanbeenabledeitherusingthePlatinumcontrolmenusorthe
PlatinumcontrolICMSwebpageat(http://www.htcontrols.com).
USE SUPPLY SENSOR
No
Yes
USE RETURN SENSOR
No
Yes
Supply or Return Set Point
Boiler is adjustable from 60°F/16°C to 200F°/93°C Boiler Default: 140°F/60°C
Pump is adjustable from 60°F/16°C to 200F°/93°C Pump Default: 120°F/49°C
SELECTMaintenance/DHW Settings/Supply Settings/Setpoint Supply Sensor
SELECTMaintenance/DHW Settings/Return Settings/Setpoint Return Sensor
• TheSupplySetPointdeterminesthemaximumtemperatureatwhichtheboiler/water
heaterrelaywillde-energize.ItisthemaximumDHWtargettemperaturetheDHWEnergy
Saverwilltrytoachieve.Therelaywillenergizewheneverthesupplytemperaturedrops
belowthissetpointlessthedifferential.Seenextsetting.
• TheReturnSetPointdeterminesthemaximumtemperatureatwhichtheDHWpumprelay
willde-energize.Thecirculatingpumprelaywillenergizewheneverthereturntemperature
dropsbelowthissetpointlessthedifferential.Seenextsetting.
DHW SUPPLY SETPOINT
140 F
[ ]
DHW RETURN SETPOINT
120 F
[ ]
Supply or Return Peak and Light Differential
Peak is adjustable from 5F°/3C° to 100F°/56C° Peak Default: 10F°/6C°
Light is adjustable from 5F°/3C° to 100F°/56C° Light Default: 20F°/11C°
SELECTMaintenance/DHW Settings/Supply Settings/Peak Diff or Light Diff Supply Sensor
SELECTMaintenance/DHW Settings/Return Settings/Peak Diff or Light Diff Return Sensor
• Anyofthedifferentialsissubtractedfromthesetpointtodeterminethetemperatureat
whichtheboiler/waterheaterorpumprelaywillenergize.
• TheDHWEnergySaverhastwoindependentdifferentialsforeachofthesupplyandreturn.
ThePeakDifferentialisusedtokeepatightcontrolovertheDHWtemperatureduring
heavyusage.ThisdifferentialisusedwhentheDHWScheduleisinthePeakperiod.Its
valuemustbelessthanorequaltotheLightDifferentialforthesamesensor.
• TheLightDifferentialisusedduringthenight,lowDHWusage,orwhenatightcontrolof
thetemperatureisnotrequired.Itallowstheboilerorpumprelaytoturnonforaslightly
longerperiod.However,duetothereducedusage,therelaywillremainoffforamuch
longerperiod.ThistypeofdifferentialisusedwhentheDHWScheduleisintheLight
period.ItsvaluemustbegreaterthanorequaltothePeakDifferentialforthesamesensor.
DHW SUPPLY PEAK DIFF
20 F
[ ]
DHW SUPPLY LIGHT DIFF
40 F
[ ]
DHW RETURN PEAK DIFF
20 F
[ ]
DHW RETURN LIGHT DIFF
40 F
[ ]

8DHW Energy Saver Installation and Conguration Manual

Demand Schedule
SELECTMaintenance/DHW Settings/Demand Schedule
• ThePeakandLightDemandScheduleactivatestherespectivedifferential.Eachdayofthe
weekhas4PeakTimesand4LightTimesthatcanbesetdifferently.
• WhenintheDHWSchedule,pressingtheNEXTbuttononthePlatinumcontroldisplays
thenextScheduleentry.
• PressingtheDAYbuttononthePlatinumcontroldisplaysthenextweekdayentry.
• DomestichotwaterDemandSchedulecanbeaccessedontheICMSwebsitebyselecting
SchedulesfromthePlatinumcontrolLiveSessionthenselectingtheDHWDemand.
- DHW DEMAND SCHED -
MON#1
Peak Time 6:00Am
Light Time 10:00Pm
Copy Schedule
SELECTMaintenance/DHW Settings/Copy Schedule
• AftersettingtheMondaySchedule,theusercancopyitssettingstotherestofthedaysof
theweek.Thisreducessetuptime.
- DHW DEMAND SCHED -
Copy Mon Schedule
to all other days
(SELECT to Execute)
Internet Alarms Through ICMS
Sensor Fault
• IfanyofthesensorsfailedorweredisconnectedfromthePlatinumControl,thecontrolwill
energizetherespectiverelay.Makesurethattheboiler/waterheaterhasitsoperatingand
limitcontrolsinstalledandabletocontroltheboiler/waterheatertemperatureduringsensor
failuretoavoidhazardoussituations.
• Tosetupanalarmdeliveryforasensorfaultsituation,selectthesensorontheICMSweb
site.SelectAlarmDeliverySetupandthenAddDeliveryfortheSensorFault.
WARNING
The boiler/water heater must have its operating and limit controls installed and wired in
a way so that the Supply sensor fault or DHW Energy Saver communication Error will
not cause a hazardous situation. It is the responsibility of the installer to make sure of
the system operation and users safety during sensor fault or communication error.
Heat-Timer recommends the installation of a precision tempering valve, ETV, or TMC to
help protect the output from excessive temperatures.
Communication Error
• IftheDHWEnergySaverlostitscommunicationtothePlatinumcontrolformorethan1
minute,itwillenergizebothoutputrelays.Makesurethattheboiler/waterheaterhasits
operatingandlimitcontrolsinstalledandabletocontroltheboiler/waterheatertemperature
duringCommunicationErrorstoavoidhazardoussituations.
Troubleshooting and LEDs
WhentheDHWEnergySavercoverisremoved,severalLEDswillbeavailableforviewing.TheseLEDsareusedfordiagnosing
andtroubleshootingmanycommunicationandrelayoperation.
• ApowerRedLEDindicatesthattheunithasthepropervoltagetooperate.
• AGreenLEDblinkseverysecondtoindicatethereiscommunicationbetweentheDHWEnergySaverandthePlatinumcontrol.
Ifthatcommunicationfails,thisLEDwillkeepblinkingfor15secondsthenitwillturnoff.Afteranadditional45seconds,the
controlwillenergizebothoutputrelays.
• EachoftheoutputrelayshasaRedLEDthatisturnedonwheneverthatrelayisenergized.

DHW Energy Saver Installation and Conguration Manual 9

DHW Energy Saver
Boiler Pump
6 7 8 9
COM
3 4 5
B A GND
16VAC
1 2
~ ~


HWR
Platinum







OUT
TEMP
DHW
CAL
AUX
TEMP 0
AUX
TEMP 1

 
 
 
 
 

 
  

 



MON 12/28/04 10:43Am













AUX
TEMP 2








NETWORK
PROVE
SHUTDOWN
SYSTEM
TEMP









MOTORIZED
VALVE
 







TGT= 126oF
Cut= 55oF Day
OD= 31oF SYS= 125oF



 
MOTORIZED
VALVE
  









               

















OUT
TEMP
DHW
CAL
AUX
TEMP 0
AUX
TEMP 1


 







AUX
TEMP 2







MOTORIZED
VALVE
 







TGT= 126oF
Cut= 55oF Day
OD= 31oF SYS= 125oF


 
MOTORIZED
VALVE
  






            




Recirculating
Pump
Return
Sensor
Supply
Sensor
Water
Heater
Cold
Suggested Settings:








Piping/Wiring to Water Heater
Control Valve
Check Valve
Sensor Shield (Connect to O)

10 DHW Energy Saver Installation and Conguration Manual

10
Piping/Wiring to Boiler and Indirect Water Heater
Suggested Settings:










DHW Energy Saver
Boiler Pump
6 7 8 9
COM
3 4 5
B A GND
16VAC
1 2
~ ~


HWR
Platinum







OUT
TEMP
DHW
CAL
AUX
TEMP 0
AUX
TEMP 1

 
 
 
 
 

 
  

 



MON 12/28/04 10:43Am













AUX
TEMP 2








NETWORK
PROVE
SHUTDOWN
SYSTEM
TEMP









MOTORIZED
VALVE
 







TGT= 126oF
Cut= 55oF Day
OD= 31oF SYS= 125oF



 
MOTORIZED
VALVE
  









               

















OUT
TEMP
DHW
CAL
AUX
TEMP 0
AUX
TEMP 1


 







AUX
TEMP 2







MOTORIZED
VALVE
 







TGT= 126oF
Cut= 55oF Day
OD= 31oF SYS= 125oF


 
MOTORIZED
VALVE
  






            




DHW
Pump
Boiler
Recirculating
Pump
Return
Sensor
Supply
Sensor
Cold
Indirect
Control Valve
Check Valve
Sensor Shield (Connect to O)

DHW Energy Saver Installation and Conguration Manual 11

11
DHW Energy Saver
Boiler Pump
6 7 8 9
COM
3 4 5
B A GND
16VAC
1 2
~ ~


HWR
Platinum







OUT
TEMP
DHW
CAL
AUX
TEMP 0
AUX
TEMP 1

 
 
 
 
 

 
  

 



MON 12/28/04 10:43Am













AUX
TEMP 2








NETWORK
PROVE
SHUTDOWN
SYSTEM
TEMP









MOTORIZED
VALVE
 







TGT= 126oF
Cut= 55oF Day
OD= 31oF SYS= 125oF



 
MOTORIZED
VALVE
  









               

















OUT
TEMP
DHW
CAL
AUX
TEMP 0
AUX
TEMP 1


 







AUX
TEMP 2







MOTORIZED
VALVE
 







TGT= 126oF
Cut= 55oF Day
OD= 31oF SYS= 125oF


 
MOTORIZED
VALVE
  






            




Recirculating
Pump
Boiler
Boiler Heat
Exchanger
Return
Sensor
Supply
Sensor
Tempering
Valve
Cold
Control Valve
Check Valve
Sensor Shield (Connect to O)
Piping/Wiring to Boiler and a Tempering Valve
Suggested Settings:









Control Valve
Check Valve
Sensor Shield (Connect to O)


   
http://www.heat-timer.com

Specication
VoltageInput. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  16VAC(transformerprovidedminimum10VA)
OutputRelays . . . . . . . 2N.O.(SPST).Eachamaximum⅛HPpumpor6Ampresistiveloadat120VAC/60Hz
Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  DHWboiler/waterheaterandDHWpump
Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS485(3-wireA,Ground,andB)
LEDs . . . . . . . . . . . . . . . . . . . . . . . 4(1Power(Red),2RelayOutputs(Red),1communication(Green))
Dimension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-¾”x3-⅝”x1”
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Pound