Rheem Raypak TempTracker MOD+ HYBRID Owner's manual

E󰀨ective: 03-25-22
Replaces: 02-24-12
P/N 241382 Rev. 5
INSTALLATION AND OPERATION INSTRUCTION
CONDENSING and NON-CONDENSING HYBRID CONTROL
IMPORTANT SAFETY INSTRUCTIONS. READ AND FOLLOW
ALL INSTRUCTION. SAVE THESE INSTRUCTIONS.
AWARNING: The TempTracker mod+ Hybrid 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+
Hybrid is installed.
This control must be installed by a licensed electrician.
This manual should be maintained in legible condition and kept adjacent to the unit or in a safe place for future
use.
F
H
J
Power
CAUTION:
Risk of Electric Shock.
More than one disconnect switch may be required
to de-energize the equipment before servicing.
PWR
L N
1 2
E
3 4
F
5 6
G
7 8
H
9 10
I
11 12
EXTENSION
MODULE
RS-485
Ext A
INPUT RATINGS:
115VAC 60Hz, 12VA MAX
Use Copper Conductors Only.
OUTPUT RATINGS:
120VAC, 6A RESISTIVE
1A PILOT DUTY, 15A TOTAL
FOR ALL CIRCUITS
E
G
I
Comm
Ext B
K
M
O
L
N
P
1514
VLTmA
CUR / VLT
181716
VLTmAGND
CUR / VLT
212019
VLTmAGND
CUR / VLT
242322
VLTmAGND
CUR / VLT
J
11 12
K M OL N P
E F G H
K ML N
13
GND
16
GND
19
GND
22
GND
2726
VLTmA
CUR / VLT
302916
VLTmAGND
CUR / VLT
25
GND
28
GND
I J
O P
ENCLOSED
ENERGY
MANAGEMENT
EQUIPMENT
99RA
HYBRID
SYSTEM
A
B
C
D
12
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
LN
-+
+
TT
OORS-485
mA
GND VLT
SYS ABCD
PWR
CUR / VLT
A
-+
+
mA
GND VLT
-+
+
mA
GND VLT
+
+
mA
22
-
GND VLT
+
mA
TEMP
OUTDOOR
OO
TEMP
SYSTEM
EXTENSION
MODULE
CUR / VLT
B
CUR / VLT
C
CUR / VLT
D
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
HYBRID
Now with Optional
BACnet MS/TP
This product can be used with the following systems:
• Hi Delta Hydronic Boilers, Models 302C-902C
• Hi Delta SS Hydronic Boilers, Models HD101-HD401
• MVB Modulating Vertical Hydronic Boilers 503A-2003A
• MVB Modulating Vertical Hydronic Boilers 504A-2004A
• MVB Modulating Vertical Water Heater 2503-4003
• MVB Modulating Vertical Water Heaters 503A-2003A

2
Revision 5 reects the following changes:
Reformatted and reorganized. Additional metric data added. Final paragraph added to Staging Logic Overview on page 4. Final
sentence added to Wiring the Voltage Modulating or Staging Boilers on page 16. First bullet point added to Lead Boiler Rotation on
page 33.

3
TABLE OF CONTENTS
1. WARNINGS ............................................................ 4
Pay Attention to these Terms ..................................4
2. HYBRID LOGIC OVERVIEW................................. 5
3. MODULATING LOGIC OVERVIEW...................... 6
4. STAGING LOGIC OVERVIEW .............................. 6
5. OUTDOOR RESET CONCEPT ............................. 6
6. TEMPTRACKER MOD+ HYBRID LAYOUT ........ 8
7. TEMPTRACKER MOD+ EXTENSION LAYOUT. 9
8. FEATURES ............................................................ 10
Make Sure You Have the Right Control ................ 11
9. INSTALLATION..................................................... 11
Mounting the Enclosure ........................................ 11
Install the Sensors................................................. 12
Wiring .................................................................... 13
10. STARTUP SETTINGS .......................................... 18
11. HYBRID STARTUP MENU .................................. 20
12. MODULATING & STAGING STARTUP MENU . 21
HYBRID Startup Settings ...................................... 22
HYBRID Modulating Boiler Settings ...................... 23
HYBRID Staging Boiler Settings ........................... 24
Modulating Boiler Settings ....................................24
Staging Boiler Settings .......................................... 25
Setting the Control to Factory Defaults ................. 27
13. HYBRID OPERATING MENU.............................. 28
14. MODULATING AND STAGING OPERATING
MENU ..................................................................... 29
15. OPERATING SETTINGS ..................................... 30
System Settings .................................................... 32
Modulating Boiler Operating Settings.................... 34
Staging Boiler Operating Settings ......................... 35
Day / Night Schedule ............................................36
Maintenance.......................................................... 37
Display ..................................................................38
Display Messages ................................................. 39
16. BOILER STAGE MENU........................................ 40
Boiler Status .......................................................... 40
Boiler Stage Settings............................................. 41
17. TROUBLESHOOTING ......................................... 43
18. BACNET MSTP STARTUP MENU...................... 45
19. BACNET PICS STATEMENT .............................. 46
20. HYBRID - OUTDOOR RESET - BACNET
VARIABLE LIST.................................................... 47
21. MODULATION - OUTDOOR RESET - BACNET
VARIABLE LIST.................................................... 49
22. STAGING - OUTDOOR RESET - BACNET
VARIABLE LIST.................................................... 51
23. MODULATION - SETPOINT - BACNET
VARIABLE LIST.................................................... 53
24. STAGING - SETPOINT - BACNET VARIABLE
LIST ........................................................................ 55
25. PIPING AND WIRING DIAGRAMS..................... 57
Hybrid Piping Diagram .......................................... 57
Hybrid Wiring Diagram .......................................... 58
Modulating Piping Diagram ................................... 59
Modulating Wiring Diagram ................................... 60
Staging Piping Diagram ........................................61
Staging Wiring Diagram ........................................ 62
26. SPECIFICATIONS ................................................ 63

4
1. WARNINGS
Pay Attention to these Terms
ADANGER Indicates the presence of immediate hazards which will cause severe personal injury, death or substantial
property damage if ignored.
AWARNING Indicates the presence of hazards or unsafe practices which could cause severe personal injury, death or
substantial property damage if ignored.
ACAUTION Indicates the presence of hazards or unsafe practices which could cause minor personal injury or product
or property damage if ignored.
CAUTION CAUTION used without the warning alert symbol indicates a potentially hazardous condition which could
cause minor personal injury or product or property damage if ignored.
NOTE Indicates special instructions on installation, operation, or maintenance which are important but not related
to personal injury hazards.

5
2. HYBRID LOGIC OVERVIEW
In response to new advancements in condensing boiler
design and size, many applications utilize both multiple
condensing boilers and multiple non-condensing boilers.
That triggered Raypak's patented design of the TempTracker
mod+ Hybrid ("Hybrid Controller"). It is intended to manage
the two groups of boilers to maximize system e󰀩ciency
at the lowest operating cost while maintaining the desired
setpoint. When Hybrid is selected as the Boiler Type, the
TempTracker mod+ Hybrid will operate each group based
on the Target temperature switching setpoint. See "Boiler
Type" on page 19.
Each of the condensing and non-condensing groups of
boilers can be either modulating or staging. Modulating
boilers can be driven by either a 4-20mA modulating signal
or a 0-10V modulating signal. Staging boilers must be
driven by a 0-10V signal.
Depending on the actual System Temperature, the
TempTracker mod+ Hybrid will determine which group
of boilers will be the lead and which group will be the lag
group. The Condensing group of boilers will be the Lead
group when the System temperature is below the System
Target Switching Setpoint. However, when the System
temperature rises above the Switching Setpoint, the Non-
Condensing boiler group will be the lead group and the
Condensing Group will be the lag group.
The TempTracker mod+ Hybrid will control the condensing
group of boilers as the lead group so long as the sensed
water temperature is below the Switching Setpoint. See
"Switch Setpoint" on page 22. During that period, if
additional boilers are needed than are available in the
condensing group, the TempTracker mod+ Hybrid will
energize the Non-Condensing boilers as needed to meet
the load. See "Heavy Load Sequence 2nd Group" on page
23. When less output is required the TempTracker mod+
Hybrid will de-energize the Non-Condensing boilers prior
to de-energizing the Condensing boilers.
To eliminate any short-cycling due to rapid changes in
the Target Temperature used in the switching, a user-
adjustable Switching Delay has been incorporated. See
"Switch Delay" on page 22.
For Hybrid settings, See "Boiler Type" on page 19. See
"HYBRID Startup Settings" on page 22.
To set the Condensing and Non-Condensing boiler types,
see "HYBRID Modulating Boiler Settings" on page 23
and "HYBRID Staging Boiler Settings" on page 24.
Target Switch
Set Point = 120°F (49°C)
120°F
140°F
100°F
CONDCOND
NON-
COND
NON-
COND
NON-
COND
NON-
COND
CONDCOND
SYSTEM
A
B
C
D
12
RUNPROGRAM DO NOTAPPLY ANY VOLTAGE
TOINPUTTERMINALS
34567 8 910 1112 13 15
14 17
16 18 22
20
19 21 24
23 29
25 27
26 28 32
30 31
LN
-+
+
TT
OORS-485
mA
GNDVLT
SYS ABCD
PWR
CUR/VLT
A
-+
+
mA
GNDVLT
-+
+
mA
GND VLT
-+
+
mA
GND VLT
+
mA
TEMP
OUTDOOR
OO
TEMP
SYSTEM
EXTENSION
MODULE
CUR/VLT
B
CUR/VLT
C
CUR/VLT
D
PROVE
/DHW
SHUTDOWN
/TSTAT
/SETBACK
OD=25oF SYS= 145 oF
<<A>> B
100% 52%
System
Temp SYSTEM
A
B
C
D
12
RUNPROGRAM DO NOTAPPLY ANY VOLTAGE
TOINPUTTERMINALS
34567 8 910 1112 13 15
14 17
16 18 22
20
19 21 24
23 29 25 27
26 28 32
30 31
LN
-+
+
TT
OORS-485
mAGNDVLT
SYS ABCD
PWR
CUR/VLT
A
-+
+
mA
GND VLT
-+
+
mA
GND VLT
-+
+
mA
GNDVLT
+
mA
TEMP
OUTDOOR
OO
TEMP
SYSTEM
EXTENSION
MODULE
CUR/VLT
B
CUR/VLT
C
CUR/VLT
D
PROVE
/DHW
SHUTDOWN
/TSTAT
/SETBACK
OD=25oF SYS= 145 oF
<<A>> B
100% 52%
Above the Switch Set Point
Non-Condensing are the Lead Group
Condensing are the Lag Group
Below the Switch Set Point
Condensing are the Lead Group
Non-Condensing are the Lag Group
Figure 1. Hybrid Logic Overview

6
3. MODULATING LOGIC
OVERVIEW
The Modulation PID logic provides the capability of
controlling multiple modulating-current or modulating-
voltage boilers. When heat is required, the control PID
will activate the lead boiler and start its purge. See "Purge
Delay" on page 33. This will be followed by the initiation of
its modulation at the Ignition %. See "Figure 91. Ignition %"
on page 42. After the Purge period and when additional
heat is needed, the control shall start to increase the lead
boiler modulation until the Modulation Start % has been
reached. See "Modulation Start Point %" on page 63.
That shall be followed by the lag boiler purge initiation.
The lead boiler shall resume its modulation while the lag
boiler is in purge until the lead boiler reaches full re (100%
modulation). Any additional heat requirements will trigger
the control to increase the lag boiler modulation.
When the Temp Tracker mod+ Hybrid PID requires
reduced output, it will reduce the modulation of the lag
boiler until it reaches its Ignition %. That shall be followed
by the reduction of modulation of the lead boiler until it
reaches 40% percent of the Modulation Start %. This shall
trigger the control to turn o󰀨 the lag boiler. The control will
keep reducing the lead boiler modulation until it reaches
its Ignition %. If the Last Stage Hold was activated, the
control will hold the lead boiler at the Ignition % until the
System Temperature exceeds the Target Setpoint by the
Last Stage hold setting. "Last Stage Hold" on page 34.
For Modulating boilers, See "Boiler Type" on page 19.
Also, See "Modulating Boiler Settings" on page 24.
4. STAGING LOGIC
OVERVIEW
The Staging PID control logic is primarily used with multi-
stage boilers. The logic will utilize two primary settings to
add or subtract stages. The Reaction Time is used to turn
on/energize stages. See "Reaction Time" on page 35.
The Minimum Runtime is used to turn o󰀨/de-energize
stages. See "Minimum Runtime" on page 36. A call
for heat, by either closing the TSTAT input or opening
the SHUTDOWN input while the outdoor temperature is
below the Outdoor Cuto󰀨, will trigger the Temp Tracker
mod+ Hybrid to turn on/energize the lowest ring stage of
the Lead Boiler to start its Purge. See "Purge Delay" on
page 33. After the elapse of the purge period, the Temp
Tracker mod+ Hybrid will start calculating the Reaction
Period. If after a full Reaction Time the control logic
foresees the need for additional stages, the TempTracker
mod+ Hybrid will energize the following stage. If that stage
was another boiler, that boiler has to go through a full
Purge Delay before starting to calculate the Reaction Time
for that stage. Otherwise, if the next stage was the higher
ring stage on the same boiler, the Reaction Time will start
from the moment the higher ring stage relay is energized.
When the Temp Tracker mod+ Hybrid PID logic foresees
that the system will overshoot, regardless of the current
system and target values, it will make sure that the last
stage turned on/energized has elapsed a full Minimum
Runtime before it is turned o󰀨/ de-energized. Except for
the lead stage, no additional stages will be turned o󰀨/de-
energized until another full Minimum Runtime is elapsed.
On the other hand, if the last stage is a lead stage, it will
remain energized until the system reading exceeds the
target setpoint by the Last Stage Hold value in addition to
satisfying the Minimum Runtime condition. That is, if the
Setpoint was 150°F and the Last Stage Hold was set to
10°F, the lead stage will remain energized until the system
reaches 160°F and a full Minimum Runtime elapses. This
is useful in protecting the lead stages from short cycling.
In order for the TempTracker mod+ Hybrid controller to
properly drive 2-stage or 4-stage boilers (Raypak ring
modes H3 and H9, respectively), it will be necessary to
install a stage interface card (sales option B-60) on each
unit to translate the modulating signal to stage closure.
5. OUTDOOR RESET
CONCEPT
The TempTracker mod+ Hybrid has multiple operating
modes that satisfy most hydronic systems. It changes the
System Setpoint based on outdoor temperature (Outdoor
Reset). The TempTracker mod+ Hybrid varies the
temperature of the circulating heating water in response
to changes in the outdoor temperature. The heating
water temperature is controlled through the modulation or
sequencing of the stages.
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
1:4
OUTDOOR TEMPERATURE (IN °F)
RESET RATIO IS PRESENTED AS
OUTDOOR TEMP.: WATER TEMP. RATIO
RESET RATIO CURVES
WATER TEMPERATURE (IN °F)
Figure 2. Outdoor Reset Concept
The TempTracker mod+ Hybrid also controls the system
circulating pump with an adjustable Outdoor Cuto󰀨. When
the outdoor temperature is above the Outdoor Cuto󰀨, the
pump is o󰀨 and no heating water is circulated through
the system. When the outdoor temperature drops below
the Outdoor Cuto󰀨, the system pump relay is activated
and the heating water circulates through the system.
The temperature of the heating water is controlled by the

7
Reset Ratio, Water O󰀨set, 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 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
(21°C) Outdoor Temperature and 100°F (38°C) Water
Temperature. For example with a 1.00 (OD):1.00 (SYS)
ratio, if the outdoor temperature is 50°F (10°C), this
means the temperature has fallen 20°F (11°C) from the
starting point of 70°F (21°C). Therefore, the heating water
temperature will increase 20°F (11°C) to 120°F (49°C).
Each building has di󰀨erent 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°F (1°C) to increase the
water temperature 1°F (0.6°C). On the other hand, a poorly
insulated building with insu󰀩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+ Hybrid 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 the type of radiation will improve heat comfort.
The following are suggested initial settings for di󰀨erent
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.
70 405060
130
120
110
100
70 405060
110
100
90
80
70 405060
150
140
130
120
1:4
1:4
1:4 1:1
1:1
1:1
4:1
4:1
4:1
90
100
+20 Offset
-20 Offset
WITH A 0°F OFFSET,
THE RESET CURVES
BEGIN AT 100°F
WATER TEMPERA-
TURE.
W
ITH A -20°F OFFSET,
THE
RESET CURVES
B
EGIN AT 80°F WATER
T
EMPERATURE.
W
ITH A +20°F OFFSET,
THE
RESET CURVES
B
EGIN AT 120°F WATER
T
EMPERATURE.
WATER TEMPERATURE °FWATER TEMPERATURE °FWATER TEMPERATURE °F
OUTDOOR TEMPERATURE °F
OUTDOOR TEMPERATURE °F
OUTDOOR TEMPERATURE °F
Figure 3. Reset Ratio/Outdoor Reset
Type of Radiation in
Building Reset Ratio O󰀨set
Radiators (Steel & Cast Iron)
1.00 (OD) : 1.00 (SYS) 0˚F
Baseboard (Finned copper
tube & Cast Iron)
Radiant (High Mass/
Concrete) 4.00 (OD) : 1.00 (SYS) -10˚F
(-5.6˚C)
Radiant (Low Mass/Joists) 2.00 (OD) : 1.00 (SYS)
Fan Coils & Air Handlers 1.00 (OD) : 1.00 (SYS) 20˚F
(11.1˚C)
Table A. Suggested Initial Settings

8
6. TEMPTRACKER MOD+ HYBRID LAYOUT
SYSTEM
A
B
C
D
12
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
LN
-+
+
TT
OORS-485
mA
GND VLT
SYS ABCD
PWR
CUR / VLT
A
-+
+
mA
GND VLT
-+
+
mA
GND VLT
+
+
mA
22
-
GND VLT
+
mA
TEMP
OUTDOOR
OO
TEMP
SYSTEM
EXTENSION
MODULE
CUR / VLT
B
CUR / VLT
C
CUR / VLT
D
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
HYBRID
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/staging outputs can be
4-20mA or Voltage. Go to Startup Menu
to determine the type of output for each stage.
When connecting the control Outdoor Air
Sensor (#013398F) and System Sensor (#012187F), no
Polarity is observed. Prove terminals must be connected
for TempTracker mod+ Hybrid to operate boilers.
Connect Extension panels to add
additional stages using a RJ11 cable(cable
provided with Extension) and RJ45-RJ11
Adaptor (Supplied with control) only or add
BACnet Interface Module using RJ45
(cable provided with BACnet
Interface Module)
Figure 4. Complete TempTracker mod+ Hybrid Part Number 011922

9
7. TEMPTRACKER MOD+ EXTENSION LAYOUT
F
H
J
Power
CAUTION: Risk of Electric Shock.
More than one disconnect switch may be required
to de-energize the equipment before servicing.
PWR
L N
1 2
E
3 4
F
5 6
G
7 8
H
9 10
I
11 12
EXTENSION
MODULE
RS-485
Ext A
INPUT RATINGS:
115VAC 60Hz, 12VA MAX
Use Copper Conductors Only.
OUTPUT RATINGS:
120VAC, 6A RESISTIVE
1A PILOT DUTY, 15A TOTAL
FOR ALL CIRCUITS
E
G
I
Comm
Ext B
K
M
O
L
N
P
1514
VLTmA
CUR / VLT
181716
VLTmAGND
CUR / VLT
212019
VLTmAGND
CUR / VLT
242322
VLTmAGND
CUR / VLT
J
11 12
K M OL N P
E F G H
K ML N
13
GND
16
GND
19
GND
22
GND
2726
VLTmA
CUR / VLT
302916
VLTmAGND
CUR / VLT
25
GND
28
GND
I J
O P
ENCLOSED
ENERGY
MANAGEMENT
EQUIPMENT
99RA
120VAC Power
Six N.O. Boiler startup relay
outputs. Each is wired in series
with the boiler's limit circuit.
Six modulating outputs can be 4-20mA or voltage.
Go to TempTracker mod+ Hybrid Startup Menu to
determine the type of output for each stage.
LED indicates the
associated relay status.
Connect to any TempTracker mod+ or Hybrid
and additional Extension panels to add
additional stages using a RJ11 cable only
(cable provided with TempTracker mod+ Ext).
Extension Selection Switch to determine
Stage letters and LED colors.
Ext-A Stages E - J and all LEDs are Green
Ext-B Stages K - P and all LEDs are Red
This switch is covered with the Wiring Enclosure.
HYBRID
Figure 5. Complete TempTracker mod+ Extension Part Number 013179F

10
8. FEATURES
The TempTracker mod+ Hybrid has been designed with
Hydronic building heating, using both condensing and
non-condensing boilers, as the primary purpose. As well,
it is capable of controlling modulating or staging boilers.
With this in mind, many of the TempTracker mod+ Hybrid
features can be utilized to ease, enhance, and improve
your system performance.
Condensing and Non-Condensing Boilers Can be
Modulating or Multi-Stage.
The TempTracker mod+ Hybrid can operate both
modulating and staging boilers. Just specify each of the
Condensing and Non-Condensing boiler group type and
the TempTracker mod+ Hybrid will activate the groups
based on an adjustable set of criteria.
PID Type Logic
The TempTracker mod+ Hybrid'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+
Hybrid will react quickly to adjust the modulating stages’
output. If the system temperature changes slowly, the
TempTracker mod+ Hybrid will make slow and gradual
output adjustments. Therefore, the TempTracker mod+
Hybrid adapts to specic system requirements and
minimizes uctuations around the setpoint.
Controls 0-10 V or 4-20 mA modulating Burners
Whenever any of the Condensing or Non-Condensing
group type is set to Modulating, the TempTracker mod+
Hybrid will accurately control the output from 0 to 100%
of modulation for each of these di󰀨erent types of motors.
Moreover, a single TempTracker mod+ Hybrid can
control multiple modulating burners each with a di󰀨erent
modulating signal.
Controls On/O󰀨, 2-Stage, 3-Stage, or 4-Stage
Burners
Whenever one of the Condensing or Non-Condensing
group Type is set to Staging, the TempTracker mod+
Hybrid will accurately sequence the stages using a PID
logic. The sequencing group will have a set of adjustable
parameters to help achieve better operation.
Digital Display of all System Settings
The TempTracker mod+ Hybrid’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 lead stage of each group promotes even
wear. The TempTracker mod+ Hybrid 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+ Hybrid has a hydronic outdoor
temperature reset function. This allows the TempTracker
mod+ Hybrid to change the setpoint based on outdoor
temperature. Furthermore, additional settings have been
added to ne tune this operation, like O󰀨set, Minimum, and
Maximum Water Temperature and night setback schedule.
System Output
This output can be used to activate a system pump,
combustion air damper, or perform any other function
that is required when any stage is active. It will energize
whenever the outdoor temperature is below the Outdoor
Cuto󰀨 setting. A System Prove input checks the status of
components activated by the System output before stages
can be activated.
Normal or Parallel Modulation
The TempTracker mod+ Hybrid can stage modulating
boilers as needed. In Normal Modulation, it will allow the
modulation to increase on the lead boiler until it reaches its
modulation start point adjustment. Then, the TempTracker
mod+ Hybrid will start the next boiler and so on. Moreover,
the TempTracker mod+ Hybrid allows for a parallel mode
that can modulate several boilers together as a one large
boiler. This mode is useful when used with condensing
boilers as they run more e󰀩cient at lower modulation.
Thus, it is better to run several boilers at lower modulation
than to run a single boiler at full re.
Add up to 16 Boiler Stages (Optional)
As a stand-alone, the TempTracker mod+ Hybrid is
designed to control four stages. However, it has the
capability of expanding its control to two extension panels
each with six boiler stages. Thus, the TempTracker mod+
Hybrid can control a total of up to 16 boiler stages.
Setback or Day/Night Scheduling
Two Setback modes are available for the TempTracker
mod+ Hybrid:
• The Day/Night Scheduling provides an adjustable
time-based schedule for the Setback (only available
when Shutdown or Tstat is selected as the Setback/
Shutdown Startup option). See "Shutdown/Tstat/
Setback Mode" on page 26.
• The Setback mode uses an external signal to switch
the operation of the TempTracker mod+ Hybrid in and
out of setback mode (only available when Setback is
selected as the Setback/Shutdown Startup option).
Remote Setpoint (EMS 4-20mA)
By connecting the control to the optional 4-20mA EMS
Interface, the control shall be capable of accepting a
remote setpoint.

11
BACnet MS/TP Communication
An optional BACnet Interface Module (#651735) can be
used to connect the control to a BACnet MSTP network for
remote access.
Make Sure You Have the
Right Control
If you need the TempTracker mod+ Hybrid to do additional
tasks that either are not listed or do not know how to
congure them, contact your local Raypak representative.
Setting an Initial Program will ease the conguration of the
TempTracker mod+ Hybrid and will give the opportunity
to utilize many of the energy saving features while giving
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.
See "Installation" on page 11.
• Setting the System Startup. See "Startup Settings"
on page 18.
• Setting the System Operating Settings. See
"Operating Settings" on page 30.
• Setting the Stages. See "Modulating Boiler Operating
Settings" on page 34 and also see "Staging Boiler
Operating Settings" on page 35.
• Adjusting Reset Ratio and Water Offset (In Reset
Mode Only). See "Reset Ratio" on page 30.
• If using BACnet MSTP communication, then connect
the BACnet Interface Module to the TempTracker
mod+ Hybrid. Then connect the BACnet Interface
Module to the BMS system. Configure the control's
BACnet settings. See "BACnet MSTP Startup Menu"
on page 45.
9. INSTALLATION
Each of the TempTracker mod+ Hybrid or Extension
consists of three primary enclosure components.
• The Enclosure Display Module: contains the control
electronic board, display, buttons, LEDs and electric
wiring terminals. It has two screws to hold it to the
base. A program configuration switch, used to adjust
the control 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 flat 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
ease 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 flat and sufficiently wide and
strong to hold the TempTracker mod+ Hybrid or the
Extension.
• Keep the control away from extreme heat, cold, or
ENCLOSURE DISPLAY MODULE
ENCLOSURE WIRING COVER ENCLOSURE BASE
HOLE FOR OPTIONAL LOCK
(NOT SUPPLIED)
MOUNTING HOLES
DISPLAY MOUNTING SCREWS
WIRING COVER
MOUNTING SCREWS
Figure 6. Enclosure Features

12
Install the Sensors
System Sensor Installation
AWARNING: Use only the System and Outdoor Air
sensors included with the control. Do not use boiler
sensors as it will cause operational problems.
• Only use the System sensor (#012187F) provided
with the unit.
SHIELD
IMMERSION WELL
3/8" ID 1/2" NPT COMMON SUPPLY PIPE
HEATING SYSTEM
SENSOR SENSOR PROBE
Figure 7. Immersion Heating System Sensor
NOTE: If the HSS can not sense the correct water
temperature, the TempTracker mod+ Hybrid will not
provide comfortable heat levels.
• The sensor wires can be extended up to 500' (152 m)
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.
• If installing the system sensor on the supply, insert
the sensor in a well with heat paste approximately 5'
feet past the boiler loop outlet 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+
Hybrid will not sequence the boilers correctly.
• The sensor can also be installed on the return to the
boilers after all major returns and before any boiler.
However, when setting the reset ratio and the offset,
the user must consider the temperature drop across
the building loop.
Outdoor Sensor Installation
• Only use the Raypak Outdoor Air Sensor group
included with the unit (#013398F).
SEAL AROUND
SENSOR AND WALL
MOUNTING
SCREW
LOCATION
OUTDOOR
DRIP-HOLE
OUTDOOR
SENSOR SNAP-IN
LOCATION
SHIELD NOT
CONNECTED
OUTDOOR LABEL
ON BACK OF
SENSOR
CONDUIT
Figure 8. Outdoor Sensor
• 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 ft
(3 m) 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 affix 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' (152
m) 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”.
humidity. Ambient operating temperature is from
20°F to 120°F (-7°C to 49°C).
• Remove the Enclosure Wiring Cover from the control
enclosure by removing the two bottom screws.
• Remove the Enclosure Display Module by removing
the enclosure 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 enclosure middle screws.
• Do not replace the enclosure wiring cover until all
wiring is done.
• When purchasing a padlock for the enclosure, the
maximum shank diameter should not exceed ¼" (6.4
cm).

13
• Do not run sensor wires in conduit with line voltage
wiring.
NOTE: Determining the proper location of the Outdoor
Sensor is very important. The TempTracker mod+ Hybrid
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 di󰀨erent from the
actual Outdoor temperature (OD).
Wiring
• All wiring must enter the enclosure through the bottom
knockouts.
• Class 1 voltage wiring must utilize a di󰀨erent knockout
and conduit from any Class 2 voltage wiring.
Wiring the Power
(Terminals 1, 2)
• Bring the 120VAC 60Hz power wires through the
bottom left knockout of the enclosure.
• 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+
Hybrid.
12
LN
120VAC
POWER SOURCE
LINE
NEUTRAL
Figure 9. Wiring the Power
AWARNING: Class 1 voltages must enter the
enclosure through a di󰀨erent opening from any Class 2
voltage wiring. Raypak recommends installing a surge
suppressor on the power source to the TempTracker
mod+ Hybrid.
Wiring the Sensors
AWARNING: Connect the shield at the control
terminal end and cut the shield wire at the sensor end.
To avoid operational problems, use only the System and
Outdoor Air sensors included with the control.
System Sensor Wiring (Terminals 27, 28)
• A TempTracker mod+ Hybrid must be connected to
a System temperature sensor (#012187F) located in
the common header. The sensor must be inserted in
a 3/8" ID well using heat paste.
• Temperature sensor wires can be extended up to
500’ by splicing its wires with a shielded 2-conductor
cable (Belden #8760 or equivalent (#18/2)).
• Temperature sensors have no polarity. Connect the
two wires from the sensor to the TempTracker mod+
Hybrid terminals marked SYSTEM TEMP 27, 28.
• Connect the sensor shield to the circled terminal 28
with one of the sensor wires.
25 27
26 28
TT
OO
TEMP
OUTDOOR
TEMP
SYSTEM
rosneSroodtuO
dleihSrosneS
Figure 10. System Sensor Wiring
Outdoor Sensor Wiring (Terminals 25, 26)
• The TempTracker mod+ Hybrid will vary the system
Setpoint based on outdoor temperature. In addition,
the Outdoor Air Sensor group (#013398F) is used as
an Outdoor Cutoff. The TempTracker mod+ Hybrid
will disable all boilers when the outdoor temperature
is above the adjustable Outdoor Cutoff temperature.
• For an outdoor sensor use the outdoor sensor
provided.
• The sensor wires can be extended up to 500’
using shielded 2-conductor cable (Belden #8760 or
equivalent (#18/2)).
• Temperature sensors have no polarity. Connect the
wires from the outdoor sensor to the TempTracker
mod+ Hybrid terminals marked OUTDOOR TEMP -
25, 26.
• Connect the shield to the circled terminal 26 with one
of the sensor wires.
29
27
26
28 30
31
T
O
O
TEMP
OUTDOOR
O
TEMP
SYSTEM PROVE
/DHW
SHUTDOWN
/SETBACK
rosneSmetsyS
dleihSrosneS
Figure 11. Outdoor Sensor Wiring
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 "Shutdown/Tstat/Setback Mode" on page
26. This will provide the user with an adjustable
Day/Night Schedule. See "Day / Night Schedule" on
page 36.
• The Shutdown feature can be used whenever it is

14
desirable to turn off the TempTracker mod+ Hybrid
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, offer the capability of
controlling the operation of the TempTracker mod+
Hybrid based on a thermostat input. This will provide
the user with a adjustable Day/Night Schedule.
• The thermostat will send the TempTracker mod+
Hybrid 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 modulating boilers
will immediately modulate down to low for the Soft-
Off period, then turn off. All staging boilers will turn
off immediately.
• The System Output relay will remain active until the
System Run-On Delay expires and then it will turn off.
• When Setback is selected in the Startup, a BMS/EMS
or external clock can provide a Setback signal using
these input terminals. See "Shutdown/Tstat/Setback
Mode" on page 26. No Day/Night Schedule will
be available when Setback is selected from the
Shutdown/Tstat/Setback mode in the Startup menu.
• Bring the two wires from the dry contact to the
terminals marked SHUTDOWN/TSTAT/SETBACK-
31,32.
• The signal must be a dry contact only. No voltage
can be placed across the SHUTDOWN/TSTAT/
SETBACK terminals.
29
32
30
31
OO
PROVE SHUTDOWN
/SETBACK
/TSTAT
SHUTDOWN,
T-STAT, OR
SETBACK SIGNAL
Figure 12. Wiring the Shutdown, Tstat, or Setback
Wiring the Prove
(Terminals 29, 30)
• The Prove feature is provided to check system
component operation and must be selected in the
Startup Menu from the Prove/DHW Sharing menu.
See "Prove/Indirect Domestic Hot Water (DHW)
Priority" on page 26.
• A typical use of this feature is to check for pump flow
or combustion air damper status before firing any
boiler.
• If the PROVE input is open on a call for heat, the
TempTracker mod+ Hybrid will enable only the
System Output. All boiler outputs will be off when the
PROVE input is open.
• A factory-installed jumper provides the System Prove
signal. Do not remove the jumper unless it will be
replaced by a System Prove signal or these terminals
are to be used for DHW call input.
• Bring the two wires from the dry contact to the
terminals marked PROVE - 29, 30.
• Prove Input terminals can accept a dry-contact
signal only. No voltage can be placed across these
terminals.
29
28
32
30 31
O
OO
TEMP
SYSTEM
PROVE
/DHW
SHUTDOWN
/SETBACK
/TSTAT
PROVE SIGNAL
Figure 13. Wiring the Prove
AWARNING: The PROVE input cannot 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.
Wiring the Indirect Domestic Hot Water
(DHW) Call
(Terminals 29, 30)
• DHW can be used to raise system Setpoint to the
DHW Setpoint as well as manage the System Pump
according to the DHW Priority setting. One of the
DHW options must be selected from the Prove/DHW
Sharing Startup menu. See "Prove/Indirect Domestic
Hot Water (DHW) Priority" on page 26.
• Wire an aquastat or a control to provide dry-contact
closure on the DHW Call - 29, 30 terminals.
• Remove the jumper on the DHW terminals for proper
operation.
• DHW Call terminals can accept dry contact signals
only. No voltage can be placed across these terminals.
29
28
32
30 31
O
OO
PROVE
/DHW
SHUTDOWN
/SETBACK
/TSTAT
INDIRECT
DHW SIGNAL
Figure 14. Wiring DHW Call

15
Wiring the System Output
(Terminals 3, 4)
• The SYS output relay will energize and remain
constantly energized whenever the outdoor
temperature is below the Outdoor Cutoff.
• When the outdoor temperature rises 2°F (1°C) above
the Outdoor Cutoff, the SYS output will remain
energized for the period set by the System Run-On
then de-energize. See "System Run-On" on page
33.
• In addition, the System output will energize during
summer DHW calls when DHW No Priority is
selected. See "Prove/Indirect Domestic Hot Water
(DHW) Priority" on page 26.
• The SYS output has one Normally Open (N.O.) relay
contact rated for (1/8 HP).
• 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.
3456
7
SYS A
SYSTEM PUMP
OR PUMP STARTER
L
N
Figure 15. Wiring the System Output
Wiring the Boilers
• When wiring Condensing and Non-Condensing
boilers make sure that Condensing boilers utilize the
first stages and Non-Condensing boilers will utilize
the following stages. That is, if the installation had
two Condensing Modulating boilers and two Non-
Condensing Staging On/Off boilers, Stage A and B
will be used by the Condensing boilers while C and D
will be used by the Non-Condensing boilers.
Wiring Boiler Activation or On/O󰀨 Staging
Boilers
(A Terminals 5, 6), (B Terminals 7, 8), ...
• Each boiler output has a Normally Open (N.O.) dry-
contact relay. They do not source any power.
• Wire the N.O. relay contacts in series with the unit’s
limit circuit.
• When connecting to On/Off boilers, each stage relay
output will be connected to a single boiler.
• Class 1 voltages must enter the enclosure through
a different opening from any Class 2 voltage wiring.
345678
SYS AB
BOILER ENABLE
OUTPUT
Boiler
Figure 16. Wiring Boiler Activation or On/O󰀨 Staging
Boilers
•
NOTE: Some modulating boilers may not require the
use of these outputs.
Wiring Multi-Stage Boilers
(For Staging Boiler Types Only) See page 19
• Each multi-stage boiler must use only one of the
N.O. relays and the voltage output for that stage. The
TempTracker mod+ Hybrid will sequence the boiler
stages using the 0-10V output signal.
• Note that on the display of the TempTracker mod+
Hybrid each staging boiler will consist of a single
letter.
• Each stage output has one Normally Open (N.O.)
relay contact that does not source any power.
• Class 1 voltages must enter the enclosure through
a different opening from any Class 2 voltage wiring.
11
10
9
8
12 14 17 19
+
VLT
CD
+
BOILER 4
STAGING
NON-CONDENSING
GROUP (BOILER 3 & 4)
{
18 20
19 21 24
23
+-+
+
mA
GND VLT
+
+
mA
22
-
GND VLT
+
CUR / VLT
LT
C
CUR / VLT
D
BOILER 3 BOILER 4
STAGING V
OLTAGE
SIGNAL OUTPUTS
mA
Figure 17. Wiring Multi-Stage Boilers
OD=55oF SYS=142oF
<<A>> B
HI LOW
STAGE ◄►MENU
MULTI-STAGE BOILER
EACH BOILER "A" OR "B" HAS MULTIPLE STAGES
Figure 18. Wiring Multi-Stage Boiler Display

16
Wiring to Modulating Boilers
AWARNING: The Modulating Output Type must be set
to match the boiler modulating signal prior to wiring the
boiler signal to avoid control or equipment damage.
The TempTracker mod+ Hybrid can modulate any
combination of current or voltage boiler signals. The
Modulating Output Type must be set to match the boiler
modulating signal before connecting any output wires to
avoid damaging components. See "Modulating Output
Type" on page 25. Some modulating boilers may
require the use of the stage output relay in addition to the
modulating output.
MODULATING BOILER
(MODULATING BOILER TYPE)
OD=55oF SYS=142oF
<A> B
80% 50%
STAGE ◄►MENU
Figure 19. Wiring to Modulating Boilers
Wiring the 4-20mA Modulating Boilers
(A Terminals 13, 14), (B Terminals 16, 17),...
• The TempTracker mod+ Hybrid can operate up to
four 4-20 mA modulating motors.
• The Extension can operate up to six 4-20 mA
modulating motors.
• The TempTracker mod+ Hybrid and the Extension
sources excitation voltage for the 4-20mA signal.
• Wire the (-) from the boiler modulating motor to the
(GND) terminal on the TempTracker mod+ Hybrid.
That is for boiler A, the modulating (GND) terminal
will be 13.
• Wire the (+) from the boiler modulating motor to the
(mA+) terminal on the TempTracker mod+ Hybrid.
That is for boiler A, the modulating (mA+) terminal
will be 14.
13 15
14 16
17
-+
+
mA
GND VLT
CUR / VLT
A
-
GND
CUR / VLT
B
BOILER 4-20MA
MODULATION OUTPUT
4-20mA
Burner
Motor
-+
Figure 20. Wiring the 4-20mA Modulating Boilers
Wiring the Voltage Modulating or Staging
Boilers
(A Terminals 13, 15), (B Terminals 16, 18),...
• The TempTracker mod+ Hybrid can operate up to
four 0-10V modulating motors.
• The Extension can operate up to six 0-10V modulating
motors.
• Wire the (GND) from the boiler modulating motor
to the (GND) terminal on the TempTracker mod+
Hybrid. That is for boiler D, the modulating (GND)
terminal will be 22.
• Wire the (VLT+) from the boiler modulating motor
to the (VLT+) terminal on the TempTracker mod+
Hybrid. That is for boiler D, the modulating (VLT+)
terminal will be 23.
On staged boilers, the modulating signal must connect
to a stage interface card (sales option B-60), which will
translate the signal to stage closure on the boiler.
20
19
21 24
23
-
+
+
mA
GND
VLT
+
+
mA
22
-
GND VLT
+
mA
CUR / V
LT
C
CUR / VLT
D
BOILER VOLTAGE
MODULATION OUTPUT
VOLTAGE
BURNER
MOTOR
GND V+
Figure 21. Wiring Voltage Modulating or Staging Boilers
Connecting to the Extensions and 4-20mA
EMS Interface
• The TempTracker mod+ Hybrid is equipped with a
RJ45 socket and a RJ45 to RJ11 Adaptor to connect
to extension panels (#013179F) and 4-20mA EMS
Interfaces (#012019). The Extension is equipped
with two RJ11 sockets and a RJ11 cable to connect
to TempTracker mod+ Hybrid and an additional
Extension. Use the RJ45 to RJ11 Adaptor on the
TempTracker mod+ Hybrid.
• The order in which the control, the extensions, and
the interface are wired is not observed.
• Set each Extension to a different letter (EXT-A or
EXT-B). The TempTracker mod+ Hybrid will assign
the stage letters based on the extension letter
selected.
• Extension A will operate stages (E - J) and all the
LEDs will be Green. However, Extension B will
operate stages (K - P) and all the LEDs will be Red.
• Configure the Modulating and Sequencing Output
Types after connecting the Extension panels to be
able to configure their outputs. See "Boiler Type" on
page 19.

17
• Only the 6-wire RJ11 cable supplied with the
extension must be used for proper operation.
• RJ11 cables must be of a 6-wire with 6-pin terminals.
NOTE: To set the Extension to a specic letter, remove
the wiring cover and switch the Ext A/Ext B to the desired
letter. DO NOT set both extensions to the same letter to
avoid errors.
Ext A Ext B
TempTracker mod+ Hybrid
connected to Two Extension Panels
and 4-20mA EMS Interface
TempTracker mod+ Extension ATempTracker mod+ Hybrid
TempTracker mod+ Extension B
Each Extension Panel or 4-20mA EMS
Interface comes with Connection Cable.
RJ11
RJ45
RJ45 to RJ11
Adaptor
RJ11
RJ11
4-20 mA EMS
4-20mA INPUT
+Signal GND
123
RS485
EXTENSION
CONNECTORS
SYSTEM
A
B
C
D
12
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
LN
-+
+
TT
OORS-485
mA
GND VLT
SYS ABCD
PWR
CUR / VLT
A
-+
+
mA
GND VLT
-+
+
mA
GND VLT
+
+
mA
22
-
GND VLT
+
mA
TEMP
OUTDOOR
OO
TEMP
SYSTEM
EXTENSION
MODULE
CUR / VLT
B
CUR / VLT
C
CUR / VLT
D
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
F
H
J
Power
CAUTION: Risk of Electric Shock.
More than one disconnect switch may be required
to de-energize the equipment before servicing.
PWR
L N
1 2
E
3 4
F
5 6
G
7 8
H
9 10
I
11 12
EXTENSION
MODULE
RS-485
Ext A
INPUT RATINGS:
115VAC 60Hz, 12VA MAX
Use Copper Conductors Only.
OUTPUT RATINGS:
120VAC, 6A RESISTIVE
1A PILOT DUTY, 15A TOTAL
FOR ALL CIRCUITS
E
G
I
Comm
Ext B
K
M
O
L
N
P
1514
VLTmA
CUR / VLT
181716
VLTmAGND
CUR / VLT
212019
VLTmAGND
CUR / VLT
242322
VLTmAGND
CUR / VLT
J
11 12
K M OL N P
E F G H
K ML N
13
GND
16
GND
19
GND
22
GND
2726
VLTmA
CUR / VLT
302916
VLTmAGND
CUR / VLT
25
GND
28
GND
I J
O P
ENCLOSED
ENERGY
MANAGEMENT
EQUIPMENT
99RA
F
H
J
Power
CAUTION: Risk of Electric Shock.
More than one disconnect switch may be required
to de-energize the equipment before servicing.
PWR
L N
1 2
E
3 4
F
5 6
G
7 8
H
9 10
I
11 12
EXTENSION
MODULE
RS-485
Ext A
INPUT RATINGS:
115VAC 60Hz, 12VA MAX
Use Copper Conductors Only.
OUTPUT RATINGS:
120VAC, 6A RESISTIVE
1A PILOT DUTY, 15A TOTAL
FOR ALL CIRCUITS
E
G
I
Comm
Ext B
K
M
O
L
N
P
1514
VLTmA
CUR / VLT
181716
VLTmAGND
CUR / VLT
212019
VLTmAGND
CUR / VLT
242322
VLTmAGND
CUR / VLT
J
11 12
K M OL N P
E F G H
K ML N
13
GND
16
GND
19
GND
22
GND
2726
VLTmA
CUR / VLT
302916
VLTmAGND
CUR / VLT
25
GND
28
GND
I J
O P
ENCLOSED
ENERGY
MANAGEMENT
EQUIPMENT
99RA
Figure 22. Connecting to the Extensions and 4-20mA EMS Interface

18
Connecting to BACnet Interface Module
• The TempTracker mod+ Hybrid can communicate
to BACnet MSTP networks when used the BACnet
Interface Module (#651735). The module must be
purchased separately.
• The BACnet Interface Module comes with an RJ45
cable.
• Both the TempTracker mod+ Hybrid and the BACnet
Interface Module (#651735) are equipped with a
RJ45 socket (RS485) to connect to communicate to
each other.
• The Interface BACnet Module must be wired to the
BACnet MSTP network using the RS485 terminals A,
GND, and B.
• If both an extension panel and the BACnet Interface
Module are to be used, connect the RJ11 socket on
the BACnet Interface Module to the extension.
• Set the BACnet parameters. See "BACnet MSTP
Startup Menu" on page 45.
BACnet Interface Module
MSTP
1 2 3
A GND B PRODUCT
COMM RS485
SYSTEM
A
B
C
D
12
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
LN
-+
+
TT
OORS-485
mA
GND VLT
SYS ABCD
PWR
CUR / VLT
A
-+
+
mA
GND VLT
-+
+
mA
GND VLT
+
+
mA
22
-
GND VLT
+
mA
TEMP
OUTDOOR
OO
TEMP
SYSTEM
EXTENSION
MODULE
CUR / VLT
B
CUR / VLT
C
CUR / VLT
D
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
HYBRID
RJ45 Communication Cable
RJ45 Cable
Extension
RJ11 Extension Cable
F
H
J
Power
CAUTION: Risk of Electric Shock.
More than one disconnect switch may be required
to de-energize the equipment before servicing.
PWR
L N
1 2
E
3 4
F
5 6
G
7 8
H
9 10
I
11 12
EXTENSION
MODULE
RS-485
Ext A
INPUT RATINGS:
115VAC 60Hz, 12VA MAX
Use Copper Conductors Only.
OUTPUT RATINGS:
120VAC, 6A RESISTIVE
1A PILOT DUTY, 15A TOTAL
FOR ALL CIRCUITS
E
G
I
Comm
Ext B
K
M
O
L
N
P
1514
VLTmA
CUR / VLT
181716
VLTmAGND
CUR / VLT
212019
VLTmAGND
CUR / VLT
242322
VLTmAGND
CUR / VLT
J
11 12
K M OL N P
E F G H
K ML N
13
GND
16
GND
19
GND
22
GND
2726
VLTmA
CUR / VLT
302916
VLTmAGND
CUR / VLT
25
GND
28
GND
I J
O P
ENCLOSED
ENERGY
MANAGEMENT
EQUIPMENT
99RA
RJ45
RJ11
RJ45 RJ11
A (+)
Ground
B (-)
To BACnet
MSTP
Figure 23. Connecting to BACnet Interface Module
10. STARTUP SETTINGS
Program Change Switch Setting
To be able to change the TempTracker mod+ Hybrid
settings the Program/Run Switch must be set to Program.
The switch is located under the Enclosure Wiring Cover
for security.
RUNPROGRAM
Figure 24. Program Change Switch Setting
Startup Sequence
Button: MENU/<System Startup>
• When powered, the TempTracker mod+ Hybrid
performs a self diagnostics-test.

19
• On the first power up, the System Startup screen will
appear after the initialization is complete. If it doesn’t,
the TempTracker mod+ Hybrid has already been
configured.
• The System Startup menu sets the main parameters
that relate to the heating application. These settings
must be set by the installer.
-------- SETTINGS ----
Season Winter
System Target 140oF
<System Settings>
<Maintenance>
<Histories>
<System Startup>
BACK ▲▼SELECT
Figure 25. Startup Sequence
Boiler Type
Modulation, Staging, Hybrid (Default: Modulation)
Button: MENU/<System Startup>/..../Boiler Type
• The same Raypak control can operate modulating
boilers, staging boilers, or a combination of both
types.
• The Modulation option will operate a variety of
modulating boilers.
• The Staging option will operate a variety of On/Off or
multi-stage boilers.
• The Hybrid option will sequence two groups of boilers,
condensing and non-condensing. Each group could
be of a different boiler type (Modulation or Staging).
See "HYBRID Startup Settings" on page 22. Each
Multi-Stage boiler will use a single output relay. The
staging will take place using the voltage output signal.
• If BACnet is to be used, each of the Boiler Type
modes will have a different set of BACnet variables.
See "Hybrid - Outdoor Reset - BACnet Variable List"
on page 47.
--- BOILER TYPE ---
Modulation
Staging
Hybrid
BACK ▲▼SAVE
Figure 26. Boiler Type
Sensor Type
Reset °F, Reset °C, Setpoint °F, Setpoint °C, 4-20mA
EMS (Default: Reset °F)
(Setpoint Options Not Available with Hybrid Boiler
Type)
Button: MENU/<System Startup>/..../Sensor Type
• If Reset °F is selected, all temperatures and settings
will be displayed in degrees Fahrenheit and the
control will use Reset Ratios to adjust the system
setpoint.
• If Reset °C is selected, all temperatures and settings
will be displayed in degrees Celsius and the control
will use Reset Ratios to adjust the system setpoint.
• If Setpoint °F is selected, all temperatures and
settings will be displayed in degrees Fahrenheit and
the control will have an adjustable system setpoint.
• If Setpoint °F is selected, all temperatures and
settings will be displayed in degrees Celsius and the
control will have an adjustable system setpoint.
• The 4-20mA EMS option is only available to the
Hybrid Boiler Type option. To use 4-20mA EMS with
Staging and Modulating Boiler Types, select one of
the Setpoint options and the EMS Input Mode menu
will follow to offer the 4-20mA EMS option.
• The use of the 4-20mA EMS option requires the
purchase of the 4-20mA EMS Interface (#012019).
It gives the TempTracker mod+ Hybrid the capability
of accepting a remote 4-20mA signal from a BMS or
EMS system as the target setpoint.
• If BACnet is to be used, each of the Sensor Type
modes will have a different set of BACnet variables.
See "Hybrid - Outdoor Reset - BACnet Variable List"
on page 47.
-- SENSOR TYPE --
Reset oF
Reset oC
Set Point oF
Set Point oC
BACK ▲▼SAVE
--- SENSOR TYPE ---
Reset oF
Reset oC
4-20mA EMS
BACK
▲
▼
SAVE
Figure 27. Sensor Type
EMS Input Mode
Disable, Enable (Default: Disable)
(Available after Setpoint with Staging or Modulation
Boiler Types)
Button: MENU/<System Startup>/..../Boiler Type/
Sensor Type / EMS Input Mode
• It allows the TempTracker mod+ Hybrid to utilize the
4-20mA EMS Interface (#012019) to accept a remote
4-20mA signal from a BMS or EMS system as the
target setpoint.
- EMS INPUT MODE -
Disable
Enable
BACK ▲▼SAVE
Figure 28. EMS Input Mode

20
11. HYBRID STARTUP MENU
-------- SETTINGS ----
Season Winter
System Target 140oF
<System Settings>
<Maintenance>
<System Startup>
BACK ▲▼SELECT
-- ARE YOU SURE? --
No
Yes
BACK ▲▼SAVE
--- SENSOR TYPE ---
Reset oF
Reset oC
4-20mA EMS
BACK ▲▼SAVE
- SWITCH SETPOINT -
150oF
[ ]
BACK ▲▼SAVE
--- SWITCH DIFF ---
10 oF
[ ]
BACK ▲▼SAVE
--- SWITCH DELAY ---
0.5Hour
[ ]
BACK ▲▼SAVE
HEAVY LOAD
-SEQUENCE #2 GROUP-
No
Yes
BACK ▲▼SAVE
CONDENSING
---- BOILER TYPE ----
Modulating
Staging
BACK ▲▼SAVE
CONDENSING
-- BOILER NUMBER --
2
[ ]
BACK ▲▼SAVE
CONDENSING
- MODULATING MODE -
Normal
Parallel
BACK ▲▼SAVE
NON-CONDENSING
---- BOILER TYPE ----
Modulating
Staging
BACK ▲▼SAVE
PROVE/DHW SHARING
Prove
DHW Priority
DHW No Priority
No Priority (Summer)
BACK ▲▼SAVE
- DHW SETPOINT -
180 oF
[]
BACK ▲▼SAVE
- SETBCK/SHUTDOWN -
Shutdown/Disable
Tstat/Enable
Setback
BACK ▲▼SAVE
Modulating
Modulating
Shutdown
or Tstat
Setback
CONDENSING
-- OUTPUT A TYPE --
4-20mA
0-10volt
1-10v Custom
BACK ▲▼SAVE
--- BOILER TYPE ---
Modulation
Staging
Hybrid
BACK ▲▼SAVE
-EMS 4ma SETPOINT -
70 oF
[]
BACK ▲▼SAVE
-EMS 20ma SETPOINT-
220 oF
[ ]
BACK ▲▼SAVE
4-20mA EMS
Reset
--- BOOST MODE ---
30 Minutes
Disable
BACK ▲▼SAVE
--- SENSOR FAULT ---
All Off
All On
BACK ▲▼SAVE
NON-CONDENSING
-- BOILER NUMBER --
1
[
]
BACK ▲▼SAVE
CONDENSING
-- OUTPUT B TYPE --
4-20mA
0-10volt
1-10v Custom
BACK ▲▼SAVE
NON-CONDENSING
-- OUTPUT C TYPE --
4-20mA
0-10volt
1-10v Custom
BACK ▲▼SAVE
NON-CONDENSING
- MODULATING MODE -
Normal
Parallel
BACK ▲▼SAVE
Yes
All DHW Options
--- BACNET MODE ---
Disable
Enable
BACK ▲▼SAVE
page 22
page 22
page 19
page 19
page 22
page 23
page 23
page 23
page 24
page 45
page 22
page 23
page 23
page 26
page 27
page 27
page 23
page 25
page 23
page 26
page 26
Figure 29. HYBRID Startup Menu