PVI Industries TEMPTRAC User manual

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WATER HEATER
ELECTRONIC CONTROLLER
USER MANUAL
PVI Industries, LLC • 3209 Galvez Dr • Fort Worth, Texas 76111 • 800-784-8326
UPPER LED READOUT
LOWER LED READOUT
LED ICONS

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1. DISPLAY AND INTERFACE
1.1 KEYBOARD BUTTONS
SET
-Displays and modifies the temperature set points.
-In programming mode, it selects a parameter or confirms an operation.
UP
-Displays and modifies the energy saving (Night Time setback) settings.
-In programming mode, it browses the parameter codes or increases a displayed value.
DOWN
-Displays the working hours of the load relays.
-In programming mode, it browses the parameter codes or decreases a displayed value.
CLOCK
-Changes the lower display from the Probe temperature to current time and vice versa.
-To set the current time and day.
EXT
-Changes upper display between Probe 1, 2 and 3 temperatures, modulation % or the
temperature difference between Probe 1 and 2.
-In programming mode it sets the 4-20mA output (Passkey is required (321)).
ON/OFF -Switches the control ON or OFF.
1.2 KEY COMBINATIONS
+ To lock and unlock the keyboard.
+
To enter the programming mode.
+ To exit the programming mode.
1.3 LED ICON LEGEND
LED MODE Function
ON Temperatures are displayed in degrees Fahrenheit
ON Temperatures are displayed in degrees Celsius
Flashing Call for heat time delay or remote enable/disable is in standby (disabled)
ON Call for heat is on
Flashing Second stage time delay (On 2-stage units only)
ON Second stage on or the AL2 alarm output is enabled.
Flashing Output 3 time delay
ON Output 3 relay on
ON Modulation output signal is in manual control mode or forced to the i1S setting
by digital input 1
ON Modulation output signal is automatically controlled by temperature probe 1
Flashing Modulation output time delay is activated.
Ext
ON Probe 3 is displayed
FLASHING Digital input 2 (alarm) is activated
FLASHING Digital input 3 (alarm) is activated
ON Lower display is displaying the time
FLASHING Alarm signal
FLASHING Programmed working hours limit is exceeded
ON Working hours are displayed in Lower LED readout
ES ON The energy saving function is running

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1.4 UPPER LED READOUT
The default display of this readout is the temperature sensed at Probe 2. Probe 2 may display the tank stored water
temperature, outlet water temperature, flue gas temperature, ambient temperature, remote tank or blended water
temperature, etc., depending on the product and application. Refer to your specific water heaters Installation and
Maintenance Manual and the supplied wiring drawing. The upper LED readout can also be switched to display
Probe 1 or 3 (if used) or the modulation % or the temperature difference between Probe 1 and 2. If Probe 2 is not
utilized, the display will show “nu”.
By pressing and releasing the button once, the Upper LED will display the actual temperature sensed at
Probe 3. Probe 3 (if used) may display the flue gas temperature or outside ambient temperature, etc.,
depending on the product and application.
By pressing and releasing the button again, the Upper LED will display the modulation % (indicated by 0 to
100%). If the product is a non-modulating product, the displayed value should not be considered.
By pressing and releasing the button a third time, the Upper LED will display the difference between the
temperature sensed at Probe 2 (if used) and the temperature sensed at Probe 1.
To return to the default in the Upper LED readout, press the button to cycle back to the Probe 2
temperature.
All of the display information described above is available for monitoring through the optional MODBUS RTU
interface.
1.5 LOWER LED READOUT
The default display of this readout is the temperature sensed at Probe 1. Probe 1 will be inserted into the
appropriate area of the storage tank to provide effective temperature response for the heat source (this may not
be at the top of the tank). Refer to your specific water heaters Installation and Maintenance Manual and the
supplied wiring drawing. The lower LED readout can also be switched to display Probe 2 or 3 (if used) or the
modulation % or the Time of Day.
By pressing and releasing the button once, the Lower LED display will show the Time of Day. Press again
to return to default display.
1.6 TO SET THE CURRENT TIME AND DAY (MILITARY TIME)
1. Push and hold the button for more than 3 seconds. The LED icon starts flashing and the “Hur”(hour)
parameter name is displayed in the Upper LED readout, its value is displayed in the Lower LED readout.
2. Pushing the or button alternates the LED readouts between the following:
“Hur” (hour) in the Upper readout and its value in the lower readout
“Min” (minute) in the Upper readout, its value in the Lower readout
“dAY” (day) in the Upper readout, its value in the Lower readout
3. To adjust a value, press the button and the value in the Lower LED will start flashing. Change the value by
pressing the or buttons. When correct, press .
4. To exit push + or wait 15 seconds without pressing any buttons.
Note: This device recognizes Sunday as the first day of the week and Saturday as the last.

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1.7 TO SET THE ENERGY SAVING TIME (NIGHTIME SETBACK)
1. Push and hold the button for more than 3 seconds and the first parameter of the energy saving will be
displayed.
2. Use the or buttons to browse them.
3. To change a value, push the button followed by or and then the button again.
4. To exit from the menu, press and or wait for 30 seconds.
1.8 TO SET MODULATION PARAMETERS
1. Push and hold the button for more than 3 seconds and the LED will switch ON and a passkey will
be required to view and manually change the modulation % value. Passkey is “321”.
2. Upon entering the password, the modulation % value will be displayed in the lower display.
3. To manually adjust this value, push the button; the value will start flashing. Adjust it by using the
or buttons and then the button again.
4. To exit from the menu, press and together or wait for 30 seconds.
2. PROGRAMMING
2.1 SETPOINT DESCRIPTIONS AND PROGRAMMING
Setpoints are those temperature or operating parameters that the user can adjust.
St 1 - This setpoint temperature should be considered the °F or °C temperature threshold to activate the energy
source. The setpoint corresponds directly to the temperature sensed by probe 1. The St 1 setpoint is programmed as
an absolute temperature; for example 120°F.
St 2 - This setpoint corresponds to either the threshold for second-stage burner operation or an ancillary devise such
as a pump. The St 2 setpoint is either programmed as the number of degrees below St 1 (setpoint 1) when the second
stage will activate; for instance, - 8°F OR as an independent; for instance 115°F. The St 2 setpoint is only applicable
on products that have stage-fired/modulating burners or ancillary components such as circulation pumps.
St 3 - This setpoint represents the temperature threshold for activation of freeze protection or flue gas temperature
protection, depending on the product or application. The St 3 setpoint is programmed as an absolute temperature; for
example 40°F or 150°F. The St 3 setpoint is only applicable on products that have freeze protection or require flue gas
temperature protection.

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To program different set points proceed as described below:
1. Press the button, the Upper LED readout will display the “St1” parameter name, while the Lower LED
readout will show the corresponding value.
2. Use the or buttons to cycle the Upper LED readout through the St1, St2 and St3 parameter names.
On some products St2 and St3 will be located in the PR2 menu and require password access.
3. Press the button to modify a parameter value. The value starts flashing in the Lower LED readout.
4. To change it, press the or buttons.
5. Press the button to confirm the value and pass to the setting of next set point.
6. Repeat the operations described at point 3, 4, 5.
7. To exit, push + or wait 15 seconds without pressing any button.
NOTE: each point has a time out of 15 seconds. If no key is pushed within 15 seconds, the controller exits the set
points programming procedure. The set value is stored even when the procedure exits due to the 15 second
expiration.
2.2 HOW TO LOCK THE KEYBOARD
1. Push and hold the + keys for more than 3 seconds.
2. The “POF” message will be displayed and the keyboard is locked. At this point it is only possible to
view the set point.
3. Repeat step 1 to unlock the keyboard.
2.3 HOT KEY PROGRAMMING (FOR FACTORY SUPPORTED FIELD REPROGRAMMING)
To upload a program from a control to a HOT KEY:
To download a program from a HOT KEY to a control:
+
Insert HOT KEY into the TTL connection on the back of the control. Press and hold
+ keys momentarily then press the key. The “Upl” message will
appear while uploading is occurring and the “End” message will appear when
finished. Push any key to return to normal operation.
ON/OFF
Press the key to turn off the control. Insert the HOT KEY into the TTL connection on the
back of the control. Press the key again and downloading will begin. The “don” message will
appear while downloading is occurring and the “End” message will appear when finished. Push
any key to return to normal operation.

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2.4 ASSIGNING TEMPTRAC ADDRESS FOR MODBUS-RTU
The first step to interfacing a BAS (Building Automation Control) with a water heater or group of water heaters will be the
assignment of the address number for each heater.
1. Enter the Programming mode by pressing the Set and DOWN key for 3s.
(lead with the SET key)
2. Press the DOWN key.
3. Select “Pr2” – “PAS” parameter and press the “SET” key.
4. The value “0 - -” with a flashing zero is displayed.
5. Use UP or DOWN keys to input the Passkey in the flashing digit; confirm the figure by
pressing “SET”. The Passkey is “321“.
6. Once you have entered the Pr2 menu press the DOWN key three times and the
parameter Adr will appear on the screen as follows:
7. Now press the SET key once and the number will begin to blink. Use the arrow key to
set the address. Each TempTrac on a RS-485 network must have a different address
8. Each water heater should be assigned a different address in order for proper
communication to occur.
Note: The default for each TempTrac is Address #1. You can assign them to any number in the range of 1-247, this is the
limitations of the MODBUS RTU standard.
3. ALARMS
Alarm messages are displayed in the upper LED readout and alternate with the default display.
An alarm LED icon is also illuminated.
Message Cause Results of alarm condition
“P1” Probe 1 failure Call for heat and burner second stage interrupted; modulation output % will be the PP4 parameter
(generally low fire)
“P2” Probe 2 failure Output 3 is open
“P3” Probe 3 failure Dynamic reset of Set1 disabled. Outdoor reset is disabled (if used) or Flue gas
temperature protection is disabled (if used)
“HA” High-temperature limit set point exceeded Audible alarm sounds, operation continues
“LA” Low-temperature alarm Audible alarm sounds, operation continues
“AL2” Digital Input 2 is activated for one or more of
the conditions listed in section 3.1
Unit de-energized after time delay. Audible alarm
sounds. On some products, the alarm contacts may
close for remote indication of alarm. Internal alarm
register will communicate an alarm condition through
the Modbus RTU communication link (if equipped)
“AL3” Digital Input 3 is activated for one or more of
the conditions listed in section 3.1 Unit de-energized after time delay.
“Mn1” Maintenance alert for call-for-heat Audible alarm sounds, operation continues
“Mn2” Maintenance alert for second stage Audible alarm sounds, operation continues
“Mn3” Maintenance alert for freeze protection Audible alarm sounds, operation continues
“rtc” The real time clock has lost the setting Energy saving functions disabled
“rtF” Real time clock failure Energy saving functions disabled
“AL1” Digital Input 1 Alarm Output 1 open.
Adr
1

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3.1 AUDIBLE ALARM
The TempTrac audible alarm is activated each time a connected alarm condition occurs. The following are
representative alarm conditions that may be connected to and activate the TempTrac audible alarm (some alarms may
be connected to and operate separately from the TempTrac on some products).
High/low water temperature alarm
Probe failures
External thermostat limit failure
Flame Failure
High and low gas pressure
Low water
The audible alarm is silenced by pressing any button (alarm condition still present)
3.2 ALARM RECOVERY
1. Probe failure alarm automatically ends after normal operation is re-established. Check connections before
replacing the probe.
2. Temperature alarms “HA” and “LA” automatically stop as soon as probe 1 senses temperatures within normal
operating parameters.
3. Digital input 2 & 3 alarms recover when condition(s) listed above are normalized and any button is pressed (if
used). Resetting the alarm condition may require resetting individual safety devices or cycling main power switch.
4. RTC alarm stops after programming the real time clock.
5. RTF alarm requires the replacement of the real time clock.
For additional information, contact the PVI Industries Customer Service Dept at 800-784-8326.