Tyco Raychem HWAT-ECO User manual

HWAT®-ECO
Installation and Operation
Manual
Electronic controller for hot water
temperature maintenance systems

A
F
B
C
D
E
Item Qty Description
A 1 HWAT-ECO controller
B 1 Water heater sensor with 13 ft (4 m) cable
C 2 Mounting screws
D 2 Mounting washers
E 1 Aluminum tape
F 1 Manual
HWAT ®-ECO
Installation and Operation
Manual
Electronic controller for hotwater
temperature maintenance systems
Figure 1: Kit contents
ii

Table of Contents
1. General Information
1.1 Use of the Manual ....................................................................1
1.2 Features....................................................................................1
1.3 Technical Data .......................................................................... 2
1.4 Care and Maintenance .............................................................. 5
1.5 HWAT Heating Cables...............................................................5
1.5.1 Maintain temperature.....................................................5
1.5.2 Installing the heating cables ..........................................5
1.5.3 Ground-fault protection ................................................. 6
1.5.4 Pre-Installation testing...................................................6
2. Installation
2.1 Installing the Controller ............................................................ 7
2.1.1 Opening the controller ...................................................7
2.1.2 Wall mounting the controller .........................................8
2.2 Wiring the Controller .............................................................. 10
2.2.1 Water heater sensor.....................................................13
2.2.2 Alarm wiring ................................................................ 15
2.2.3 Network .......................................................................16
2.2.4 Building Management System (BMS).......................... 18
2.2.5 Closing the controller...................................................20
3. Programming the Controller
3.1 Programming Overview..........................................................22
3.2 Initializing the Controller.........................................................23
3.2.1 Time and Date.............................................................. 24
3.2.2 Cable type .................................................................... 24
3.2.3 Voltage.........................................................................24
3.2.4 Units ............................................................................24
3.2.5 Ambient temperature ................................................... 24
3.2.6 Maintain temperature................................................... 25
3.2.7 Economy temperature.................................................. 26
3.2.8 Default programs......................................................... 26
3.2.9 Water heater sensor.....................................................26
3.3 Advanced Programming.......................................................... 28
3.3.1 Time and Date.............................................................. 30
iii

3.3.2 Setup ...........................................................................30
3.3.3 Timer ...........................................................................33
3.3.4 Holiday.........................................................................35
3.3.5 Info ..............................................................................35
4. Troubleshooting Guide................................................. 36
5. Pre-Defined Programs................................................................... 38
Heat-Up Cycle Graphs...................................................................40
Cool-Down Graph..........................................................................42
Power supply (green LED)
Power to heating cable (green LED)
Heat-up cycle (green LED) - increased risk of scalding
Water heater alarm (requires installed sensor) that lowers maintain
temperature if water heater temperature is too low (green LED)
Alarm (red LED)
Escape, backspace; NO; or display maintain temperature setpoint
Arrow keys: to change menu selection or position the cursor
Confirm selection, new value or YES
6.5"
(165 mm)
2 ea - 1/2" conduit
entries To water heater sensor
To HWAT-ECO network/alarm
entries
3.4"
(85 mm)
A
B
C
D
E
F
G
H
A
B
C
D
E
F
G
H
Figure 2: HWAT-ECO controller
iv

1.1 Use of the Manual
This manual covers the installation and operation of the
HWAT-ECO controller and must be used with the following
additional documents:
• HWAT System Product and Selection Design Guide
(H57538)
• HWAT System Installation and Operation Manual
(H57548)
Important: For the Tyco Thermal Controls warranty and
agency approvals to apply, the instructions included in this
manual and product packages must be followed.
1.2 Features
The Raychem HWAT-ECO controller is designed for
operation with HWAT-Y2 and HWAT-R2 self-regulating
heating cables. The HWAT-ECO controller provides the
following features:
• Flexibletemperaturecontrolofhotwatertemperature
maintenance systems.
• Integratedfunctionthatlowersthemaintaintemperature
during low use hours to save energy.
• Heat-Upcyclefunctionthatincreasesthewatertemperature
in a stagnant pipe.
• BuildingManagementSystem(BMS)interfacethat
receives a DC voltage to set the maintain temperature.
• Alarmrelaytosignalpower,temperature,or
communication problems.
1
General Information
1

• Waterheatersensorfunctionthatalarmsandlowersthe
maintain temperature if the water heater temperature is
too low.
• Master/slavefunctionthatallowsoneHWAT-ECOto
control up to eight additional HWAT-ECO controllers.
• 9pre-definedprogramsthatcanbecustomizedbytheuser.
1.3 Technical Data
Use Only for HWAT-Y2 and
HWAT-R2 heating cables
Maintain temperature 105˚F (40˚C) to 140˚F (60˚C)
setpoint
Controller ambient 40˚F (5˚C) to 105˚F (40˚C)
temperature ambient
Switchingcapacity 24A208/240Vacmax.
SPST
Operating voltage 208/240 (±10%), 60 Hz
Internal power consumption 2.5 W
Circuitprotection Max.30Awith30mA
ground-fault protection
Power terminal block 16 – 10 AWG (1.5 – 4 mm2)
Use copper conductors only
Internal temperature alarm 185˚F (85˚C)
BMS control voltage 0 – 10 Vdc
Alarmcontacts Max.24Vdcor24Vac,1A,
SPST, voltage free, NO / NC
General Information
2
1

Alarm events Loss of power
Controller reinitialized
Internal controller
temperature too high
Water heater temperature
too high
Water heater temperature
too low
Master/slave error
Power correction factor To increase or decrease
your actual pipe maintain
temperature or adjust for
plastic pipe.
Water heater sensor Thermistor with 13 ft (4 m)
lead provided. A PT100 RTD
may be optionally used
Electromagnetic Complies to EN 50081-1/2
Compatibility (EMC) for emission and EN 50082-1/2
for immunity
Real time clock Leap year correction
Clock accuracy ±10 minutes per year
Enclosure rating NEMA 12 (IP54) – indoor
use only
Enclosure material ABS
Mounting Wall mount with two screws
or optional DIN rail
Conduit entries 2 ea – 1/2 in conduit entries
3
General Information
1

Cable gland 3-hole grommet
Maximumcablesize:
•2-wire:20AWG(0.5mm2)
•4-wire:24AWG(0.2mm2)
Default programs 9 pre-defined programs that
can be customized by user
Program settings 48 1/2-hour time blocks
of the following program
settings: Off, Economy,
Maintain and Heat-Up cycle
Password 4-digit password protection
Master/slave Master is selectable in the
controller, up to 8 slaves
can be connected
Master/slave cable 2-wire, min. 24 AWG
(0.2 mm2) twisted pair and
insulation of 300 V
Parameters in memory All parameters are stored in
non-volatilememory,except
time and date
Clock backup time Minimum 1 year with lithium
battery model 2025.
Approvals
80BJ
Type 12
Energy Management Equipment
Weight 2 lbs (1 kg)
Size 6.5inx3.4inx2.8in
(165mmx85mmx71mm)
General Information
4
1

1.4 Care and Maintenance
To clean the HWAT-ECO use a damp cloth. Do not use
solvents. Do not pour water directly on the device. Do not
use a water hose or high pressure cleaner.
In case of questions or product failure, please
contact your Tyco Thermal Controls representative,
or call Tyco Thermal Controls at [phone].
1.5 HWAT Heating Cables
1.5.1 Maintain temperature
Depending on the ambient temperature and voltage,
HWAT-Y2 is designed to maintain temperatures up to
125˚F (52˚C), and HWAT-R2 is designed to maintain
temperatures up to 140˚F (60˚C).
1.5.2 Installing the heating cables
Install the HWAT heating cable system as instructed in
the HWAT System Installation and Operation Manual
(H57548). The controller must be installed by a profes-
sional electrical installer familiar with electrical safety
codes and practices.
Verify that the heating cable circuit length does not
exceedthevaluesshowninTable1:
5
General Information
1

Table 1: Maximum circuit length in feet (meters)
30 Amp 800 (240) 500 (150)
20 Amp 500 (150) 330 (100)
15 Amp 350 (105) 250 (75)
Breaker HWAT-Y2 HWAT-R2
Size @208/240-volt @208/240-volt
1.5.3 Ground-fault protection
WARNING: To minimize the danger of fire from
sustained electrical arcing if the heating cable is damaged
or improperly installed, and to comply with the require-
ments of approvals agencies, Tyco Thermal Controls and
national and local electrical codes, you must use 30-mA
ground-fault equipment protection on each heating cable
branch circuit. Arcing may not be stopped by conventional
circuit protection. The HWAT-ECO does not include
ground-fault protection.
1.5.4 Pre-Installation testing
Prior to installing the HWAT-ECO controller, do an insulation
resistance (Megger) test on the heating cable as detailed
in the HWAT System Installation and Operation Manual
(H57548).
General Information
6
1

2.1 Installing the Controller
Install the controller in an indoor, dry, clean, accessible loca-
tion. If using a water heater sensor, make sure you install the
controller within 328 ft (100 m) of the water heater.
2.1.1 Opening the controller
WARNING: To prevent shock, always switch off the
power supply (circuit breaker) before opening the
controller.
The HWAT-ECO has a removable front cover. Both the cover
andtheboxhaveelectronicpartsandareconnectedto
each other by a 14-pin connector. First unscrew the four
screws in the cover. Carefully pull the cover straight out,
not sideways! Inside the controller an ABS separation
sheet will help to guide the connector when disconnecting.
Figure 3: Opening the controller
7
Installation
2

2.1.2 Wall mounting the controller
Mount the controller using either of the options below:
1.You can mount the controller to the wall using the two
supplied screws and sealing rings in the two holes
located inside the bottom part of the controller.
5.9" (148 mm)
1.7"
(43 mm)
TEMP BMS
B A
Figure 4: Hole locations for mounting with screws
Installation
8
2

2.Optionally you can mount the controller using DIN 35
Rail mounting.
Optional Din Rail Mount
(Rail not provided)
Mounting
Removing
Press tab to remove box
Figure 5: Mounting with DIN 35 Rail
9
Installation
2

2.2 Wiring the Controller
The diagram below shows the arrangement of the
terminal blocks for power, alarm, water heater sensor,
BMS and network.
Ground
HWAT-ECO
General Arrangement
Power
terminal block
Sensor, BMS,
and network
terminal block
Alarm
terminal block
Ø1Ø2
HWAT Line
Ø1Ø2
TEMP BMS
B A
Figure 6: General arrangement for terminal blocks
Installation
10
2

The diagram below shows the connection of a single
controller (without optional water heater sensor, BMS,
network and alarm connections).
Note: Put the terminal screws in place and
tighten to 6 inch-lbs. (0.68 N-m)
ØØ
G
1/2"
Conduits
HWAT
heating
cable
RayClic-PC
Max. 30A
ground fault
circuit breaker
208-240 Vac
Ground
Incoming power
208/240 Vac Max
Wiring diagram
for HWAT-ECO
To
HWAT
heating
cable
TEMP BMS
B A
Figure 7: Connecting a single controller
(w/o sensor, BMS, network and alarm connections)
11
Installation
2

For controlling multiple HWAT circuits with the same pro-
gramming parameters (i.e. voltage, maintain temperature,
ambient temperature, economy temperature), connect the
heatingcableoutputrelaytoanexternalcontactorcoil(s).
N
ø1
Panel energized light
Contactor coil
(208 or 240V)
CNC
HWAT-ECO internal switch
ø3 ø2
HWAT
heating
cable
HWAT
heating
cable
Braid/pipe
Two-pole
with 30-mA
ground-fault trip
(208/240 Vac)
Two-pole
with 30-mA
ground-fault trip
(208/240 Vac)
Three-pole
main circuit
breaker
Power
connection
Heating cable
End seal
Three-pole
main
contactor
Line voltage
208V or 240V
Ground
HWAT-ECO Controller
Contact your Tyco Thermal Controls
representative for more information
on how to integrate the HWAT-ECO
with a Tyco Thermal Controls power
distribution panel.
TEMP BMS
B A
Figure 8: Multiple HWAT circuits connection
Installation
12
2

2.2.1 Water heater sensor (optional usage)
Installation of the water heater sensor is optional. If installed,
the water heater sensor ensures that the HWAT-ECO maintain
temperaturedoesnotexceedthewaterheatertemperature.
The temperature sensor should be connected to a single or
master controller only. Connect both wires of the tempera-
ture sensor to the TEMP terminal in the controller (PL4). The
sensor wires do not have a special polarity. To connect a
wire, use a screwdriver to push down the orange tab on the
side of the terminal. Put the wire into the hole and release
the orange tab.
PL4PL3 PL5
Standard temperature sensor
PT100 sensor (2 wire)
short
for
PT100
TEMP BMS
B A
PL4PL3 PL5
TEMP BMS
B A
Alarm,
Sensor,
and BMS
terminals PL6
Alarm contact
TEMP BMS
B A
Figure 9: TEMP terminal location and sensor wiring
Optionally, PT100 RTD’s from the water heater can be used.
To install a PT100 sensor first connect a jumper between the
terminals indicated in Figure 9, then connect the two wires
from the RTD. If you are using a three wire sensor, remove
the compensation lead and only connect the two mea-
surement wires.
13
Installation
2

Ifyoursystemdoesnotincludeamixingvalve,position
thewaterheatersensorapproximately8in(20cm)from
the water heater shown as Ain Figure 10.
Ifyoursystemincludesamixingvalve,positionthewater
heater sensor as close as possible to, but downstream
from,themixingvalveshownasBin Figure 10.
Fold the metal tabs that are located on the sensor around the
hot water output pipe. Use the aluminum tape (included) to
attach the water heater sensor to the pipe. Cover the sensor
and at least 8 in (20 cm) of the sensor cable with insulation.
Always keep the heating cable at least 8 in (20 cm) away
from the water heater sensor as shown in Figure 10.
The water heater sensor cable is 13 ft 3 in (4 m) in length,
howevertheusercanextendthecableupto328ft(100m).
The wire used to connect the temperature sensor to the
HWAT-ECO should have a basic insulation of 300 V and a
solid core of at least 18 AWG (0.75 mm2).
Min. 8"
(200 mm)
Min. 8"
(200 mm)
insulation
Cold water in
mixing
valve
Tempered water out
Hot water out
Hot water in
HWAT-Y2
HWAT-R2
Water
heater
AB
Figure 10: Positioning water heater sensor
Installation
14
2

2.2.2 Alarm wiring (optional)
The alarm contact (24 Vac, 24 Vdc, 1A) inside the controller
canbeusedtoswitchanexternaldevice.Thecontact
is closed during operation and open during an alarm or
during loss of power. In a network, all alarm contacts
should be connected in series.
The alarm terminal (PL6) is
located in the upper right cor-
ner of the controller and has
thetext“alarmcontact”next
to it. To connect a wire, use a
screwdriver to push down the
orange tab on the side of the
terminal. Put the wire into the
hole and release the orange
tab. The wires used for the
alarm contact should be rated
for300V.See“Chapter4,
TroubleshootingGuide”for
more information
about alarm conditions. Figure 11: Connecting
the alarm contact
The alarm contact is designed as a fail safe mode and
can be wired for normally open (NO) or normally closed
(NC) operation. The following table summarizes the relay
positions in the different controller states:
Position NC NO
Power Off Open Closed
Power On Closed Open
Alarm Mode Open Closed
Alarm,
Sensor,
and BMS
terminals PL6
Alarm contact
TEMP BMS
B A
NC O NO
15
Installation
2

2.2.3 Network
The Master/slave function allows one HWAT-ECO to control
up to eight additional HWAT-ECO controllers. Connect all
HWAT-ECO controllers to each other in parallel using the
A and B inputs on terminal (PL3). This means that several
controllers will have two wires in one hole. The wire should
beatwistedpairandberatedfor300V.Thetotalmaxi-
mum length of this cable between all controllers is 328 ft
(100m).BecarefulnottomixAandBconnections.To
connect a wire, use a screwdriver to push down the orange
tab on the side of the terminal. Put the wire into the hole
and release the orange tab.
MASTER
TEMP BMS
B A
TEMP BMS
B A
SLAVE 1
OPTIONAL BMS
WATER HEATER SENSOR
NETWORK WIRE
TO SLAVE 2
Figure 12: Networking controllers together
Installation
16
2