SunStat Relay 500680 Thermostat
Your new SunStat Nonprogrammable thermostat is designed to control the voltage to either a 120VAC or 240VAC resistive floor warming system. Please follow this manual for complete installation and operation instructions. If you have any questions or comments, try calling Technical Support at 1-800-276-2419.
CAUTION: Make sure you are qualified and are familiar with house wiring. This is a line voltage device that could cause serious injury or damage if improperly installed.
Preparation
- Unpack your thermostat and make sure everything is in good condition: • Thermostat • Floor sensor • Small screwdriver • Mounting screws • Wire nuts for wiring connections
- If any parts are missing or damaged, contact the store where you purchased this thermostat. Do not install a damaged part.
- Gather the following tools and supplies:
- Phillips screwdriver, hole saw
- Wire strippers, “fish tape”, other electrical tools
- Electrical box for thermostat:
- If you are connecting to power leads from only 1 or 2 floor warming systems, you may use a single-gang, 31⁄2 inch deep box.
- If you are connecting to power leads from 3 floor warming systems, use a 4x4x21⁄8 inch or deeper box (not a 2-gang box) when your wall studs are still exposed. Install a single-gang “mud-ring” cover on the box before installing drywall materials.
- For more than 3 floor warming systems or other layouts, you may need to install a junction box to connect the power leads together. Then use house wire to connect between the junction box and the thermostat electrical box. See the installation instructions for your floor warming system for more information.
Installation
Remove the Thermostat Face
- Remove the thermostat Front Module from the Power Module by opening the door and loosening the screw.
- Pull outward near the bottom on the Front Module and lift off. Be careful not to bend or damage the 14-pin electrical connector on the back of the Front Module.
Prepare the Wiring
- Find a location for your thermostat. It is suitable for indoor use only, on insulated or uninsulated walls. Locate it about 41⁄2 feet to 5 feet above the floor on an inside wall. Make sure it is well-ventilated and not located in a confined space such as a small closet or cabinet. Avoid placing it near other heat sources such as hot-water piping, heat duct, wall-mount lighting, and direct sunlight to help prevent adversely affecting the thermostat.
- Turn off the power to the floor warming system at the main circuit panel before doing any electrical work.
- A qualified electrician should run a dedicated circuit from the main circuit panel to the thermostat location.
- If a dedicated circuit is not possible, you may tap from another circuit in the room. Make sure there is enough load capacity (amps) to handle the addition of your floor warming system, and that it is NOT wired in series with any other device, including other GFCIs.
- The circuit breaker in the main circuit panel should be 15 amps maximum for a floor warming system totaling 12 amps or less. For larger systems up to 15 amps, use a 20 amp maximum circuit breaker. Never exceed 15 amps on this thermostat. You may consider using an arc-fault (AFCI) type circuit breaker for additional protection.
- Pull the power supply wiring into this box, leaving about 6 inches of wire.
- Pull the floor sensor wire and the power lead wires from your floor warming system up the wall, into this box. Refer to your floor warming system installation instructions for placement of the floor sensor tip into the floor area.
- Note: The sensor wires should not be run in the same conduit as line voltage wires to avoid possible interference. If the sensor lead wires are not long enough, they may be extended an additional 15 feet (4.5 m) using a minimum 20-gage 2-conductor wire or up to 50 feet (15 m) using shielded wire.
- Mount the electrical box.
Connect Wires
- Match and connect the two wires marked “LINE1” and “LINE2” to the power supply wires using the wire nuts provided.
- Gently tug on the wires to make sure they are secure, otherwise a wire could loosen and cause failure.
- Overwrap the wire nuts with electrical tape to better secure them to the wires.
- Match and connect the two wires marked “LOAD1” and “LOAD2” to the floor warming system lead wires and secure these wires the same way.
- Connect the house ground wire to the green or bare lead wire(s) of your floor warming system.
- Insert the ends of the floor sensor wire into the “SENSOR” terminals (1 and 2) and tighten the screws. There is no polarity, so it does not matter which wire end goes into which terminal
Connect Signal Wires From Thermostat
- Pull 2-conductor wire, size 18- to 24-gage, through the wall from the SunStat thermostat into this electrical box.
- This wire may be up to 100 feet (30 m) in length from the thermostat to the last SunStat Relay installed. If the signal wire between the main SunStat and the Relay is more than 20 feet in length, 18- to 20-gage wire is recommended.
- Connect the wire ends into the “RELIN” terminals(2 and 5) and tighten the screws (observe polarity). See diagram below.
Connect Signal Wires to Other SunStat Relays
- You may drive up to 10 SunStat Relays with one master SunStat thermostat.
- Connect 2-conductor wire, size 18- to 24-gage, into the “RELOUT” terminals(3 and 4) of the first Relay.
- Pull this wire through the wall to the next Relay and connect to its “RELIN” terminals(2 and 5)(observe polarity) See diagram below.
- Repeat this process for additional SunStat Relays.
Mount the Relay
- Carefully fold and press the wires back into the electrical box. Do not use the control to push them in, as this may cause connections to loosen and possible failure.
- Secure the Power Module into the box with the mounting screws provided.
- Carefully snap the Front Module onto the Power Module. Be careful not to bend or damage the 14-pin electrical connector on the back of the Front Module.
- Tighten the screw.
- Switch on the power at the main circuit panel.
- NOTE to contractors: After installing the thermostat, be sure to:
- Switch on the relay(s)
- Do a Quick Setup of the master thermostat (see instructions for your SunStat thermostat)
- Temporarily override the thermostat setpoint temperature, making sure it signals this Relay to begin heating for a few minutes
- Test the GFCI (section 3)
Operation
On/Off Switch
- Your SunStat Relay should be turned off when it is first installed.
- Slide the on/off switch to the upper position, turning the control on. A green light will show on the front if power is applied. If the light is amber, it indicates power is applied to the floor warming system.
- To turn the control off anytime, slide the on/ off switch to the lower position. No heating will occur.
Test the GFCI
There is a GFCI (Ground Fault Circuit Interrupter) inside the SunStat Relay. It is designed to help protect people from possible electrical shock if the floor warming system has been damaged.
To make sure the GFCI is operating, test it after it is installed and once each month:
- Make sure the Relay is heating, showing the amber light on the front. You may need to increase the setpoint temporarily on the master thermostat.
- Press the GFCI Test button on the side of the control. A red light should show next to the GFCI Test button. You should also hear a click, indicating power has been removed from the floor warming system. If any of these indicators fail, turn off the Relay and replace it. Do not continue to use.
- To reset the GFCI, slide the On/Off switch off and back on. If the GFCI does not reset, turn the control off and go to section “4 Troubleshooting” for help.
Troubleshooting
| Problem | Solution |
|
Relay works (has green light) but no heat from the system. |
1. Check signal wire connections at Relay and master thermostat.
2. Check power wiring connections. 3. If GFCI is tripped, reset Relay. 4. Check resistances on floor warming system. See manual for system. |
|
No lights showing. |
1. Check power wiring connections.
2. Check circuit breaker or other protection “upstream” of thermostat. 3. Check the 14-pin connection on the back of the Front Module. Sometimes the pins can become misaligned when connecting the Front Module to the Power Module. |
|
GFCI is tripped. |
1. Check wiring connections.
2. Reset Relay by switching off/on. 3. Check resistances on floor warming system. See manual for system. |
|
Red light blinking on front of relay |
> 0.5s on / 0.5s off : Signal problem. Check signal wire connections including polarity. Or faulty Relay or master thermostat. Or signal wire too long. Or too many relays.
> 0.1s on / 0.1s off : “End-of-life” indication. GFCI will no longer function correctly or safely. Reset the circuit breaker or replace Relay. |
Specifications
- Power Supply 120/240 VAC, 50/60 Hz
- Maximum Load 15 amps, resistive
- Maximum Power 1800 watts at 120 VAC
- 3600 watts at 240 VAC
- GFCI Class A (5 milliamp trip)
- Storage Temp 0 °F to 120 °F (0 °C to 49 °C)
- ETL Listing Control No. 3037530
- Conforms to UL 873, UL 943, CSA C22.2 No.
- 24, and CAN/CSA C22.2 No. 144
Warranty
Limited Warranty
Watts Radiant, Inc. warrants this control (the product) to be free from defects in material and workmanship for a period of (2) years from the date of original purchase from authorized dealers. During this period, Watts Radiant, Inc. will replace the product or refund the original cost of the product at Watts Radiant’s option, without charge, if the product is proven defective in normal use. Please return the control to your distributor to begin the warranty process. This limited warranty does not cover shipping costs. Nor does it cover a product subjected to misuse or accidental damage. This warranty does not cover the cost of installation, diagnosis, removal or reinstallation, or any material costs or loss of use. This limited warranty is in lieu of all other warranties, obligations, or liabilities expressed or implied by the company. In no event shall Watts Radiant, Inc. be liable for consequential or incidental damages resulting from installation of this product. Some states or provinces do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental or consequential damages, so the above exclusions or limitations may not apply to you. This warranty gives you specific legal rights and you may also have other rights that vary from state to state.
REFERENCE
DOWNLOAD MANUAL
SunStat Relay 500680 Thermostat Owners Guide
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