tekmar 270 User Manual

- Data Brochure

Boiler Control 270

D 270

08/10

The tekmar Boiler Control 270 can control the supply water temperature from a single modulating boiler based on outdoor temperature or domestic hot water requirements. A large easy to read display provides current system temperatures and operating status.

Additional functions include:

• Outdoor Reset

• Installer and Advanced access levels

• Primary pump output

• Pump exercising

• Pump purging

• DHW demand for domestic hot water loads

• Optional indoor sensor for room air temperature control

• Test sequence to ensure proper component operation

• Setback input for energy savings

• CSA C US certified

• Boiler demand for space heating loads

Input

Boiler

Demand

Menu Item

Boiler Control 270

One Modulating Boiler & DHW

4 5NL6

DHW Dem

Prim

Boil

Com

Dem

Boiler Demand

DHW Demand

Modulation

DHW Priority Override

7 8 9 10 11

DHW

Power

Pmp/Vlv

Boiler

Pmp P2

Advanced Oﬀ

Installer Exercise

Test

oﬀ not testing red red

For maximum heat press & hold Test button for 3 second

Made in Canada by tekmar Control Systems Ltd. tektra 969-03

Power 115 V ±10% 50/60 Hz 600 VA Relays 230 V (ac) 5 A 1/3 hp, pilot duty 240 VA Demands 20 to 260 V (ac) 2 VA

Signal wiring must be rated at least 300 V.

Do not apply power

12 13 14 15 16 17 18

Mod V(dc) Out Com Indr

UnO Boil

Com

+--

testing testing paused

Meets Class B: Canadian ICES FCC Part 15

Date Code

H2039A

Input

Indoor Sensor

Optional

Input

DHW

Demand

Input

Outdoor Sensor

Included

Output

Primary

Pump

Input

115 V (ac)

Power Supply

Output

DHW Pump or

DHW Valve

Output

Pump

Output

Boiler

Input

tekmar

Timer

Input

Universal Sensor

Included

How To Use The Data Brochure

This brochure is organized into four main sections. They are: 1) Sequence of Operation, 2) Installation, 3) Control Settings, and

4) Testing and Troubleshooting. The Sequence of Operation section has six sub-sections. We recommend reading Section A: General of the Sequence of Operation, as this contains important information on the overall operation of the control. Then read the sub sections that apply to your installation.

The Control Settings section (starting at DIP Switch Settings) of this brochure describes the various items that are adjusted and displayed by the control. The control functions of each adjustable item are described in the Sequence of Operation.

Table of Contents

User Interface ..................................................Pg 2

Display ............................................................. Pg 3

Sequence of Operation ..................................Pg 4

Section A: General Operation .............. Pg 4

Section B: Boiler Operation.................. Pg 5

Section C: Pump Operation .................. Pg 8

Section D: Boiler Reset Operation ......Pg 8

Section E: DHW Operation ...................Pg 10

DIP Switch Settings ........................................Pg 17

Control Settings ..............................................Pg 18

View Menu ..............................................Pg 18

Adjust Menu ...........................................Pg 19

Testing the Control ......................................... Pg 21

Error Messages ...............................................Pg 23

Technical Data .................................................Pg 24

Limited Warranty ............................................Pg 24

Installa tion ....................................................... Pg 13

User Interface

The control uses a Liquid Crystal Display (LCD) as the method of supplying information. You use the LCD in order to setup and monitor the operation of your system. The control has four push buttons (Menu, Item, , ) for selecting and adjusting settings. As you program your control, record your settings in the ADJUST menu table, which is found in the second half of this brochure.

All of the items displayed by the control are organized into two menus (View and Adjust). These menus are listed on the top left hand side of the display (Menu Field). To select a menu, use the Menu button. By pressing and releasing the Menu button, the display sequences between the two menus. Once a menu is selected, there will be a group of items that can be viewed within the menu.

Item

The abbreviated name of the selected item will be displayed in the item field of the display. To view the next available item, press and release the Item button. Once you have reached the last available item in a menu, pressing and releasing the Item button will return the display to the first item in the selected menu.

The items can be quickly scrolled through by holding the Item button and then pressing

button. To rapidly scroll through the items in the reverse order, hold the Item

the button and press the button.

Adjust

To make an adjustment to a setting in the control, begin by selecting the ADJUST menu using the Menu button. Then select the desired item using the Item button. Finally, use the , and / or button to make the adjustment.

Additional information can be gained by observing the Status field of the LCD. The status field will indicate which of the control’s outputs are currently active. Most symbols in the status field are only visible when the VIEW menu is selected.

Display

Menu Field

Displays the current menu

Item Field

Displays an abbreviated name of the selected item

Status Field

Displays the current status of the control's inputs, outputs and operation

Number Field

Displays the current value of the selected item

Boiler Demand DHW Demand Modulation DHW Priority Override

Buttons

Selects Menus, Items and adjust settings

Symbol Description

Burner

Displays when Relay 1 is turned on.

Pump

Displays when the primary or boiler pump is operating.

DHW

Displays when the DHW pump is on.

Occupied Schedule

Displays when the control is in occupied mode.

UnOccupied Schedule

Displays when the control is in unoccupied mode.

Warning

Displays when an error exists or when a limit has been reached.

Lock / Unlock

Displays when the Advanced / Installer DIP switch is set to Installer.

°F, °C, min, hr, %

Units of measurement.

Pointer

Displays the control operation as indicated by the text.

Modulating Output Scale

Displays the total modulation output level of the boiler.

Definitions

The following defined terms and symbols are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important information concerning the life of the product.

- Warning Symbol: Indicates presence of hazards which can cause severe personal injury, death or substantial property damage if ignored.

INSTALLATION

CATEGORY II

- Double insulated

- Local level, appliances

Sequence of Operation

Section A

General

Operation

Page 4 - 5

Section B

Boiler Operation Page 5 - 7

Section C

Pump

Operation

Page 8

Section D

Boiler Reset

Operation

Page 8 - 10

Section E

DHW

Operation

Page 10 - 13

Section A: General Operation

POWERING UP THE CONTROL

When the control is powered up, all segments in the LCD are turned on for 2 seconds. Next, the control displays the control type number in the LCD for 2 seconds. Next, the software version is displayed for 2 seconds. Finally, the control enters into the normal operating mode.

OPERATION

The control stages or modulates the boiler to control supply water temperature to a hydronic system. The supply water temperature is based on outdoor reset or a fixed temperature for DHW.

Outdoor Reset

When a boiler demand signal from the heating system is present, the control operates the boiler(s) to maintain the supply temperature based on the outdoor air temperature and the Characterized Heating Curve settings. Refer to section D.

DHW

When a DHW demand is present, the control operates the boiler to maintain the supply water temperature at least as hot as the DHW exchange setting or high enough to satisfy tank temperature. Refer to section E.

SETBACK (Occ and UnOcc)

To provide greater energy savings, the control has a setback feature. With setback, the supply water temperature in the system is reduced when the building is unoccupied. By reducing the supply water temperature, the air temperature in the space may be reduced even when thermostat(s) are not turned down. Any time the UnO Sw (18) and the Com (17) are shorted together, the control operates in the unoccupied mode.

When in the unoccupied mode, the UNOCC segment is displayed in the LCD. The control adjusts the supply water temperature based on the UNOCC settings made in the control.

UnO

Com

UnOccupied

Switch

EXERCISING

The control has a built-in exercising feature that is selected through the Exercise / Off DIP switch. To enable the exercising feature set the Exercise / Off DIP switch to Exercise. If exercising is enabled, the control ensures that each pump is operated at least once every 3 days. If a pump has not been operated at least once every 3 days, the control turns on the output for 10 seconds. This minimizes the possibility of the pump seizing during a long period of inactivity. While the control is exercising, the Test LED flashes quickly.

Note: The exercising function does not work if power to the control or pumps is disconnected.

RUNNING TIMES

The control displays the accumulated running time of the boiler in the VIEW menu.

Resetting the Running Time

To reset the running time for the boiler, select the running time in the VIEW menu. Next press the and buttons simultaneously until CLR is displayed.

FACTORY D EFAULTS

The control comes preset with several factory defaults. These are based on the terminal unit selection. To fine-tune building requirements, these defaults may be changed.

To reload the factory default, power down the control and wait for 10 seconds. Power up the control while simultaneously holding the Menu and buttons. An E01 error occurs forcing the installer to go through the ADJUST menu to ensure the settings are correct.

Section B: Boiler Operation

BOILER TARGET TEMPERATURE

The boiler target temperature is determined by the type of demand received by the control. A boiler demand calculates a boiler target based on the characterized heating curve settings and the outdoor air temperature. A DHW demand has a temperature setting to which the boiler is operated to meet.

The control displays the temperature that it is currently trying to maintain as the boiler supply temperature. If the control does not presently have a requirement for heat, it does not show a boiler target temperature. Instead, “– – –” is displayed in the LCD.

BOILER MINIMUM

The boiler minimum is the lowest temperature that the control is allowed to use as a boiler target temperature. During mild conditions, if the control calculates a boiler target temperature that is below the Boiler Minimum setting, the boiler target temperature is adjusted to at least the Boiler Minimum setting. During this condition, if the boiler is operating, the minimum segment is turned on in the display when viewing either the boiler supply temperature or the boiler target temperature. Set the Boiler Minimum setting to the boiler manufacturer’s recommended temperature.

BOILER MAXIMUM

The boiler maximum is the highest temperature that the control is allowed to use as a boiler target temperature. If the control does target the Boiler Maximum setting, and the boiler temperature is near the boiler maximum temperature, the maximum segment will be displayed in the LCD while either the boiler target temperature or the boiler temperature is being viewed. At no time does the control operate the boiler above 248°F (120°C).

MIN Segment On

MAX Segment

Boiler Contact Closes

Boiler Fires

MAX Segment

FIRE DELAY

The Fire Delay is the time delay that occurs between the time that the control closes a stage contact to fire a stage and the burner fires for that stage.

Fire

Delay

Time

MODULATION

The Boiler Control 270 provides a modulating output signal to operate a single modulating boiler. The control first closes the boiler contact on to ignite the ignition sequence. The boiler is then modulated from the minimum modulation using Proportional, Integral and Derivative (PID) logic in order to satisfy the boiler target temperature.

MOTOR SPEED

The Motor Speed is the amount of time the boiler requires to go from 0% modulation to 100% modulation.

Gas valve actuating motors have a design time from fully closed to fully open which can be found in the manufacturer’s manual. The Motor Speed should be set to this time.

The Motor Speed setting for a Variable Frequency Drive (VFD) is the amount of time required to go from a stopped position to 100% fan speed. Since a VFD has a very quick response rate, it may be necessary to increase the Motor Speed setting in order to increase the stability of the boiler modulation.

MODULATION RANGE (0 to 10 V (dc), 2 to 10 V (dc), 0 to 20 mA, 4 to 20 mA)

The modulation output can be adjusted from a 0 to 10 V (dc) or to a 2 to 10 V (dc) output range using the Boil Modulation setting. If a 0 to 20 mA range is required, set the Boil Modulation item to 0 to 10 V (dc) and cut the jumper wire located next to the modulation

output. If a 4 to 20 mA range is required, set the Boil Modulation item to 2 to 10 V (dc) and cut the jumper wired located next to the

modulation output.

MINIMUM MODULATION

The minimum modulation defines the minimum output signal from the control to the boiler burner. It is based on a percentage of the control’s output signal range.

The Minimum Modulation setting for boilers with power burners is typically set to 0%.

For boilers with electronic operators, the boiler’s input signal range may not match the output signal range of the 270 control. The Minimum Modulation setting limits the control output range in order to match the boiler’s input range.

To calculate the Minimum Modulation, use the following formula:

For 0 to 10 V (dc):

Minimum Modulation =

0 V (dc) – Boiler’s Minimum Input Signal

0 – 10 V (dc)

x 100%

For 2 to 10 V (dc):

Minimum Modulation =

2 V (dc) – Boiler’s Minimum Input Signal

2 – 10 V (dc)

x 100%

MINIMUM MODULATION

Control's

Output Signal Range

Minimum Modulation

100%10 V (dc) 10 V (dc)

Boiler's Input Signal Range

18%

0%0 V (dc)

1.8 V (dc)

Boiler's Minimum

Input Signal

Example:

A boiler requires a 1.8 V (dc) signal to fire the boiler at low fire. The boiler can be modulated to 10 V (dc) where it reaches high fire. This means the boiler’s input signal range is 1.8 to 10 V (dc). The 270 control has an output signal range of 0 to 20 mA.

To make the two signal ranges the same, the Minimum Modulation required is:

0 V – 1.8 V

Minimum Modulation

0 V – 10 V

x 100% = 18%

MAXIMUM MODULATION

The maximum modulation defines the maximum output signal from the control to the boiler burner. It is based on a percentage of the control’s output signal range.

The Maximum Modulation setting for boilers with power burners is typically set to 100%.

For boilers with electronic operators, the boiler’s input signal range may not match the output signal range of the 270 control. The Maximum Modulation setting limits the control output range in order to match the boiler’s input range.

Maximum

Modulation

MAXIMUM MODULATION

Control's

Output

Signal

Range

100%10 V (dc)

88%

9 V (dc)

Boiler's Input Signal Range

0%2 V (dc)

2 V (dc)

Boiler's

Maximum

Input Signal

To calculate the Maximum Modulation, use the following formula:

For 0 to 10 V (dc): Maximum Modulation =

0 V (dc) – Boiler’s Maximum Input Signal

0 – 10 V (dc)

x 100%

For 2 to 10 V (dc):

Maximum Modulation =

2 V (dc) – Boiler’s Maximum Input Signal

2 – 10 V (dc)

x 100%

Example:

A boiler’s input signal range is 2 to 9 V (dc). The 270 control has an output signal range of 2 to 10 V (dc).

To make the two signal ranges the same, the Maximum Modulation required is:

Maximum Modulation =

2 V – 9 V

2 V – 10 V

x 100% = 88%

BOILER MASS

The Boiler Mass setting allows the installer to adjust the control to the thermal mass of the type of heat sources used in the application. The modulation of the boiler can become unstable if the incorrect Boiler Mass setting is chosen. A key sign of the boiler modulation being unstable is the flame will continue to increase and then decrease in short periods of time. By choosing a lower Boiler Mass setting, the boiler response will become more stable.

Lo (1)

The Lo setting is selected if the boiler that is used has a low thermal mass. This means that the boiler has a very small water content and has very little metal in the heat exchanger. A boiler that has a low thermal mass comes up to temperature quite rapidly when fired. This is typical of many copper fin-tube boilers. The Lo Mass setting provides a fast response to the heating system.

Med (2)

The Med setting is selected if the boiler that is used has a medium thermal mass. This means that the boiler either has a large water content and a low metal content or a low water content and a high metal content. This is typical of many modern residential cast iron boilers or steel tube boilers. The Med Mass setting provides a moderate response to the heating system.

Hi (3)

The Hi setting is selected if the boiler that is used has a high thermal mass. This means that the boiler has both a large water content and a large metal content. A boiler that has a high thermal mass is relatively slow in coming up to temperature. This is typical of many commercial cast iron and steel tube boilers. The Hi Mass setting provides a slow response to the heating system.

DIFFERENTIAL

A modulating boiler must be operated with a differential while operating in low fire. The boiler differential is divided around the boiler target temperature. The boiler burner ignites at low fire when the supply water temperature is ½ of the Boiler Differential setting below the boiler target temperature. The boiler is shut off in low fire as the supply temperature reaches at least ½ of the differential above the boiler target temperature. With the control, either a fixed or an auto differential may be selected.

When the boiler is modulating above low fire, the differential does not apply. Instead, the modulation output signal is determined using Proportional, Integral and Derivative (PID) logic in order to satisfy the boiler target temperature.

Desired temperature

Fixed Differential

If the user desires to have a fixed differential, this is set using the Boiler Differential setting in the ADJUST menu.

160°F (71°C)

Boiler Oﬀ

Boiler On

165°F (74°C)

155°F (68°C)

Diﬀerential 10°F (6°C)

Time

Auto Differential

If the Auto Differential is selected, the control automatically determines the best differential as the load changes. This reduces potential short cycling during light load conditions.

Oﬀ

Diﬀerential

Increasing Load

Time

Section C: Pump Operation

•

PRIMARY PUMP OPERATION

The primary pump operates under the following conditions:

• A boiler demand is present and the control is not in Warm Weather Shut Down (WWSD).

• A DHW demand is present and DHW MODE is set to 3 or 4.

Primary

Primary Pump Purge

Pump

After a demand is removed, the control continues to operate the primary pump for a period of time. The maximum length of time that the primary pump continues to run is adjustable using the Primary Pump Purge setting. The primary pump continues to run until either the purging time has elapsed or the boiler supply temperature drops more than a differential below the Boiler Minimum setting.

BOILER PUMP OPERATION

The boiler pump turns on prior to the boiler firing (pre-purge) and continues to run after the boiler is turned off (post-purge). The boiler pump pre-purge time is determined by the Boiler Mass setting. As the Boiler Mass setting is increased, the boiler pump pre- purge time of the boiler also increases.

Boiler Pump Purge

The amount of time that the boiler pump continues to run after the boiler turns off is adjustable using the Boiler Pump Purge setting.

DHW

Pump

Boiler

Sensor

Boiler Pump

Section D: Boiler Reset Operation

BOILER DEMAND

A boiler demand is required in order for the control to provide heat to the heating system. A boiler demand is generated by applying a voltage between 24 and 230 V (ac) across the Boiler Demand terminals (1 and

2). Once voltage is applied, the Boiler Demand pointer is displayed in the LCD. If the control is not in Warm Weather Shut Down (WWSD), the control closes the primary pump contact. The control calculates a boiler target supply temperature based on the outdoor air temperature and the characterized heating curve settings. The control then fires the boiler, if

24 to 230 V (ac)

required, to maintain the target supply temperature.

OUTDOOR DESIGN TEMPERATURE

The outdoor design temperature is the outdoor air temperature that is the typical coldest temperature of the year where the building is located. This temperature is used when doing the heat loss calculations for the building. If a cold outdoor design temperature is selected, the boiler supply temperature rises gradually as the outdoor temperature drops. If a warm outdoor design temperature is selected, the boiler supply temperature rises rapidly as the outdoor temperature drops.

Boil

Dem

Com

Dem

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