Taco X Pump Block Instruction Sheet
Instruction Sheet
A
X – Pump Block (XPB)
102-202
SUPERSEDES: July 1, 2010
EFFECTIVE: October 1, 2010
Plant ID#: 001-3883
WARNING SYMBOL: THIS SYMBOL INDICATES THE PRESENCE OF HAZARDS WHICH
CAN CAUSE SEVERE PERSONAL INJURY, SUBSTANTIAL PROPERTY DAMAGE OR
EVEN DEATH IF IGNORED.
General
The Taco X – Pump Block (XPB) represents a breakthrough in the design, control and installation of heating systems. The patent
pending design combines a variable speed mixing control (VSMC), heat source circulator, system circulator, and heat exchanger into a
single unit. This combination delivers complete isolation between the heat creation source side of the system (boiler, water heater, etc.)
and the heat delivery side of the system (radiant tubing, glycol based snowmelt, baseboard, etc.). Extremely versatile, the
X – Pump Block can be set up to operate in outdoor reset, setpoint or delta T limiting mode.
VIEW
MIX SUP
%
1
F
DEM
X – PUMP BLOCK (XPB) VARIABLE SPEED MIXING CONTROL (VSMC)
Table of Contents
TYPICAL PIPING ------------------------------------------------ 2
GETTING READY ----------------------------------------------- 3
APPLICATION ---------------------------------------------------- 3
DESIGN PROCEDURE ----------------------------------------- 3
INSTALLATION OF X – PUMP BLOCK ------------------- 4
OUTDOOR RESET MODE ------------------------------------ 5
OUTDOOR RESET SETTINGS ------------------------------ 5
SETPOINT AND DELTA T MODE --------------------------- 6
SETPOINT AND DELTA T SETTINGS --------------------- 7
MENU
PATENT PENDING
ITEM
X - PUMP BLOCK
U
C
TM
XPB-1
L
R
US
HEAT SOURCE OPERATION MODE ---------------------- 7
SET UP OF VARIABLE SPEED MIXING CONTROL -- 8
DISPLAY OPERATION ---------------------------------------- 11
TROUBLE SHOOTING ---------------------------------------- 13
ERROR MESSAGES ------------------------------------------ 14
REPLACING CARTRIDGE ASSEMBLY ------------------ 14
TECHNICAL DATA --------------------------------------------- 15
CLEANING ------------------------------------------------------- 16
LIMITED WARRANTY STATEMENT ---------------------- 16
Taco resource – saving product
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Typical Piping
Warning! Must Install a Pressure Relief Valve and Expansion Tank on Secondary Side
in addition to Units Installed on Primary Side of System.
Outdoor
Sensor
Pressure
Relief
Exp
Tank
Output to
System
Supply
Sensor
HEAT
SOURCE
Return
Sensor
Input from
Heat Source
Outdoor
Sensor
Pressure
Relief
Exp
Tank
Output to
System
Supply
Sensor
Return
Sensor
Input from
Heat Source
Radiant Manifold - Return
Radiant Manifold - Supply
X - Pump Block (XPB)
Outdoor
Sensor
HEAT
SOURCE
Return
Sensor
Input from
Heat Source
Pressure
Relief
Exp
Tank
Output to
System
Supply
Sensor
X - Pump Block (XPB), Multiple Zones - Circulators
Outdoor
Sensor
Pressure
Relief
Exp
Tank
Return
Sensor
Input from
Heat Source
Output to
System
Supply
Sensor
X - Pump Block (XPB), Multiple Temperature System – Circulators
Outdoor
Sensor
M
Return
Sensor
Input from
Heat Source
Pressure
Relief
Exp
Tank
Output to
System
Supply
Sensor
Relief
Exp
Tan k
System
System
Supply
Sensor
System
Return
Sensor
X - Pump Block (XPB), Primary / Secondary Piping
Pressure
Return
Sensor
Input from
Heat Source
Output to
X - Pump Block (XPB), Setpoint Temp with delta T
System
Supply
Sensor
System
Return
Sensor
Return
Sensor
HEAT
SOURCE
Input from
Heat Source
Pressure
Relief
Exp
Tan k
Output to
System
X - Pump Block (XPB), delta T Snow Melt System
Outdoor
Sensor
HEAT
SOURCE
Return
Sensor
Input from
Heat Source
Pressure
Relief
Exp
Tank
Output to
System
Supply
Sensor
M
Radiant Manifold - Return
Radiant Manifold - Supply
M
M
X - Pump Block (XPB), Multiple Temperature System – Circulators and Zone Valves
Typical Installation
Tempering
Valve
Domestic
Hot
Supply
MIX
Hot
C
H
WATER
HEATER
Cold
Cold
Supply
Check
Valve
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X-PUMP
BLOCK
X - Pump Block (XPB), Multiple Zones - Zone Valves
Relief
Air
Separator
Valve
Return
Exp.
Tank
RADIANT
SYSTEM
Supply
Getting Ready
Ensure that the contents of this package are complete. If any of the contents are missing or damaged, please contact your local Taco
sales representative for assistance.
Contents should include the following:
• One X – Pump Block, preassembled
unit consists of the following parts:
- One Variable Speed Mixing Control (VSMC)
• One Taco Outdoor Sensor
• Two Taco Strap-on Sensors
• One Instruction Sheet
- One Green Enclosure
- Two Casings with Circulators Attached
- One Heat Exchanger
- One Power Cord (6 feet)
Application
The Taco X – Pump Block (XPB) is a complete mixing system with an attached heat exchanger for system isolation. Integral to the unit
is a variable speed heat source circulator, constant speed system circulator, heat exchanger, and the electronics to drive it all. With
only four piping connections needed, the XPB greatly reduces the time and space required for installation. The heat exchanger
provides complete isolation between fluid on the heat source side and the fluid on the system side. The XPB can be set up to operate
as an outdoor reset control, a setpoint control or a delta T limiting control, creating flexibility never seen before in a single unit.
Design Procedure
1. Verify BTU capacity of X-Pump Block using charts below.
BTU/H Capacity @ 10 degree Delta T Across System
X-Pump BTU Capacities*
System
Temp.
120/100 130/110 140/120 150/130 160/140 170/150 180/160
70/80 29,900 29,900 29,900 29,900 29,900 29,900 29,900
80/90 29,800 29,800 29,800 29,800 29,800 29,800 29,800
190/100 29,800 29,800 29,800 29,800 29,800 29,800 29,800
100/110 4,500 29,700 29,700 29,700 29,700 29,700 29,700
110/120 5,500 29,600 29,600 29,600 29,600 29,600
120/130 6,000 29,600 29,600 29,600 29,600
130/140 6,500 29,500 29,500 29,500
140/150 7,000 29,400 29,400
150/160 7,500 29,300
* Assuming 6 gpm Flow on Radiant Side of XPB
Heat Source Temperature Range
BTU/H Capacity @ 20 degree Delta T Across System
X-Pump BTU Capacities*
System
Temp.
120/100 130/110 140/120 150/130 160/140 170/150 180/160
60/80 59,900 59,900 59,900 59,900 59,900 59,900 59,900
70/90 59,800 59,800 59,800 59,800 59,800 59,800 59,800
180/100 27,000 59,800 59,800 59,800 59,800 59,800 59,800
190/110 4,500 29,000 59,700 59,700 59,700 59,700 59,700
100/120 5,500 31,500 59,600 59,600 59,600 59,600
110/130 6,000 33,500 59,600 59,600 59,600
120/140 6,500 35,500 59,500 59,500
130/150 7,000 37,600 59,400
140/160 7,500 39,700
Heat Source Temperature Range
2. Using the pump curve located below, ensure that the System Pump of the X – Pump Block will provide adequate head and flow for
the system in which it is to be installed. If flow rate is unknown, then use Equation No. 1 below to determine required flow.
3. Using the pump curve located below, ensure that the Heat Source Pump of the X – Pump Block will provide adequate head and flow
for the system in which it is to be installed. If flow rate is unknown, then use Equation No. 1 below to determine required flow.
4. Use Equation No. 1 to verify flow rates. Example: 25000 BTU
radiant load with supply temperature of 100° and return
temperature of 90°.
EQUATION NO. 1:
Flow Rate (GPM) =
BTU's
500 x delta T
EXAMPLE:
25,000
500 (100 - 90)
= 5 GPM
20
18
16
14
12
10
HEAD (ft)
8
6
4
2
0
024681012
PUMP CURVES
1
SYSTEM SIDE
2
HEAT SOURCE SIDE
1
2
FLOW (gpm)
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Installation of the X – Pump Block
STEP ONE MOUNTING
1. Mounting position – The X – Pump Block must be mounted in the vertical position with the Variable Speed Mixing Control (VSMC)
located at the top of the X – Pump Block.
2. Mount the X – Pump Block, using the attached brackets, to a solid surface capable of supporting 23.5 pounds.
3. Using four suitable screws or bolts (1⁄4”), fasten the X – Pump Block to the selected location. Ensure that at least two of the mounting
screws are attached to a wall stud or similar surface.
STEP TWO PIPING CONNECTIONS
Warning! Must Install a pressure relief valve and expansion tank on secondary side in addition to units
installed on primary side of system. Note! Heat should never be applied to X – Pump Block connections
or damage to housing and/or electronics may result.
1. Using proper piping practices, connect the supply to the radiant heating system to the Radiant Supply (bottom right hand connection) as indicated on the plastic cover of the X – Pump Block. Ensure that a proper isolation valve is installed.
2. Using proper piping practices, connect the return from the radiant heating system to the Radiant Return (top right hand connection)
as indicated on the plastic cover of the X – Pump Block. Ensure that a proper isolation valve is installed.
3. Using proper piping practices, connect the supply from the heat source to the Heat Source Supply (bottom left hand connection) as
indicated on the plastic cover of the X – Pump Block. Ensure that a proper isolation valve is installed.
4. Using proper piping practices, connect the return to the heat source to the Heat Source Return (top left hand connection) as
indicated on the plastic cover of the X – Pump Block. Ensure that a proper isolation valve is installed.
5. When using a non-condensing heat source as heat source, connect the Heat Source Supply and Heat Source Return lines of the
X – Pump Block to the heat source loop using standard Primary Secondary piping practices.
Pressure
Relief
Exp
Tank
Heat Source
Return
Variable
Flow
Heat Source
Supply
Radiant
Return
Constant
Flow
Radiant
Supply
Pressure
Relief
Exp
Tank
Heat Source
Return
Constant
Heat Source
Supply
Flow
Snow
Melt
Return
Variable
Flow
Snow Melt
Supply
Refer to Page 2 for More Piping Diagrams
When using the X - Pump Block on snow melting systems, it is recommended to switch the system pump motor with the variable
speed pump motor to protect the brazed plate heat exchanger from freezing up.
Follow the instructions for cartridge replacement (page 14) to disassemble the X – Pump.
Unbolt the fixed speed system pump motor (lower) and switch it with the heat source variable speed pump motor (upper).
This now insures constant flow on the heat source side of heat exchanger by the fixed speed pump to minimize the chance of freeze
up. The snow melt system pump is now variable speed and both the System Supply Sensor and System Return Sensor must be
installed and in Setpoint with delta T max mode.
STEP THREE FILLING
1. Fill both system and heat source with tap water – The system must be filled before operating the circulator. The bearings are water
lubricated and should not be allowed to operate dry. Filling the system will result in immediate lubrication of the bearings. It is always
good practice to flush a new system of foreign matter before starting the circulator.
2. Circulator operation – Operate the circulators for 5 minutes immediately after filling system to purge remaining air from the bearing
chamber. This is especially important when installing the circulator during the off-season.
STEP FOUR ELECTRICAL CONNECTIONS
1. Observe all applicable codes when connecting to power supply. The motors are impedance protected, and do not require overload
protection. The pumps cannot run backwards.
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Outdoor Reset Mode of Operation
In order to properly control a hot water heating system, the amount of heat
supplied to the building must equal the amount of heat lost by the building.
The amount of heat delivered into a building depends on the temperature of
the water in the heating unit and the surface area of the heating unit. Heating units with a small surface area, such as baseboard radiators, require a
higher water temperature than heating units with a larger surface area such
as radiant floors.
The amount of heat lost from a building depends on the outdoor temperature. As the outdoor temperature becomes colder, the amount of heat a
building loses increases.
The operation of a hot water heating system can generally be improved by
adjusting the supply water temperature to the system as the outdoor temperature changes. Using this approach, the heat input to the building can be
matched to the heat lost from the building. This method of controlling the
supply water temperature to a heating system greatly improves the comfort
of the system and is known as Outdoor Reset.
When a Taco Outdoor Sensor is connected to the Variable Speed Mixing Control (VSMC), the VSMC provides outdoor reset. When
operating in the outdoor reset mode of operation, the installer must set the Outdoor Design Temperature and the Design Supply Temperature in order to establish the relationship between the outdoor temperature and the supply water temperature. This is known as
setting the Heating Curve.
SEQUENCE OF OPERATION
When the VSMC receives a Demand and it is not in warm weather shut down (WWSD), the VSMC turns on the system pump and
calculates a Mixing Target temperature. The variable speed heat source side pump is then operated to maintain the Mixing Target
temperature at the mixing supply sensor.
The heat source contact operates as described in the Heat Source Operation section. The VSMC also provides heat source protection
as described in the Heat Source Operation section.
DEMAND
The VSMC requires a demand signal before it will begin operation. The VSMC can use
either a powered or an unpowered demand signal. Once a demand signal is received, the
VSMC displays the demand icon in the display and operates as described above.
Powered Demand
The VSMC recognizes a Powered Demand Signal when 24 V (ac) is applied across the
Com and Heat Dem terminals.
Unpowered Demand
The VSMC recognizes an Unpowered Demand signal when a switch is closed between
the Com and Heat Dem terminals (relay type thermostat or end switch on zone control).
SYSTEM PUMP OPERATION
The VSMC has an internal system pump contact. This contact turns on when the VSMC
has a mixing demand and is not in a WWSD. The integrated system pump as well as an
external heat source pump may be controlled by this relay. By providing proper flow in the
heat source loop, the heat source temperature can be accurately controlled based on the
mixing load.
Powered
Demand
C
24 V (ac)
R
Unpowered
Demand
Boil Out
Switch
Boil Out
Switch
Com Heat
Com Heat
Outdoor Reset Settings
HEATING CURVE SETTINGS
In order to establish the heating curve, the VSMC must be given two points to work with. The first point is the Outdoor Reset Starting
Point and the second point is the Design Condition.
Outdoor Reset Starting Point
The Outdoor Reset Starting Point for the VSMC is fixed at 72°F. This means that when the outdoor temperature is 72°F, the VSMC
calculates a required supply water temperature (Mix Target) of 72°F.
Dem
Dem
Design Conditions
The design conditions represent the supply water temperature required to satisfy the heating system on the typical coldest day of
the year. These are the conditions that are used when calculating the size of the heating equipment needed to heat the building.
The Design Conditions are made up of an outdoor temperature (Outdoor Design) and a supply water temperature (Design Supply).
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