tekmar 365 User Manual

Page 1
- Data Brochure
R
D 365
Mixing Control 365
WWSD
Power
Heat
UnOcc.
Demand
Switch
Max. or
Min.
Setpoint
105 (41)
Pump
is on
Return
Boiler
Pump
90
70
of full
50
output
%
30
10
R
R
LR 58233
E150539
70°F
70°F
(21°C)
(21°C)
35
35
105
(2
(2
(41)
)
)
Occupied
Unoccupied
Mixing Control 365
Variable Speed and 4-20 mA
Control is
maintaining
Minimum Return
System
Unoccupied
temperature
setting
Occupied
temperature
setting
Variable Speed
and 4-20 mA
operating level
Terminal Plugs:
Power and out-
put connections
The tekmar Mixing Control 365 is a microprocessor-based control with a 120 Vac output for operating a variable speed injection pump. A 4-20mA output is available for operating devices such as a 4­20mA actuating motor, modulating gas valve, a mixing valve combination, or for operating a 4-20mA motor drive for larger variable speed pumps. The variable speed pump or mixing valve regulates the supply water temperature to a heating system based on the outdoor air temperature, and optionally, the indoor air temperature. The system is shut down when there is no Heat Demand signal or when the outdoor temperature is warm enough so that the system no longer requires heat (WWSD).
Outdoor Reset Strategy. . pg. 2 Variable Speed Pump . . . pg. 3 Sequence of Operation . . pg. 5
Installation . . . . . . . . . . . . pg. 7
Settings . . . . . . . . . . . . . . . pg. 11
Heating
is required
35 (2)
Occupied
Mixing Control 365
Variable Speed and 4-20 mA
Use Nº 20 AWG or larger copper conductors rated for at least 75°C and 300V.
12 3456
Heat
Dem Pmp
70°F
(21°C)
105 (41)
120Vac power
supply is on
70°F
(21°C)
35
105
(2)
(41)
Unoccupied
Power
System
N
L
Pmp
System is in
Warm Weather
Shut Down
7
Var. Pmp
Power
Heat Demand
Min. Return
Pump
LR 58223
89
Boiler
90
70
50
30
10
R
switched to
Unoccupied
WWSD
UnOcc. Switch
Max. or Setpoint
Boiler
of full
output
%
Listed
5T62
R
E150539
Testing . . . . . . . . . . . . pg. 13
Error Messages . . . . . pg. 15
Technical Data . . . . . . pg. 16
Limited Warranty . . . . pg. 16
System is
Setpoint
123 4
Reset
60
Test
Manufactured in Canada by
Power: 120V 50/60Hz 300VA System pump: 120Vac 12A 1/3 hp, pilot duty 480VA 4A Var pump: 120V 50/60Hz 2.2A 1/6 hp, internally fused Relay: 120Vac 10A 1/4 hp, pilot duty 240VA 2A Enclosed Energy Management Equipment
1000 max
Do not apply power here
13 14
12 15
10 11
Ret
UnO
4-20
Com
+
Sen
Control is
maintaining
Maximum Supply
Boiler on when 25% open External Heat Demand Zone Control
Indoor Sensor Permanent Heat Demand Boiler on when 10% open
2.0
0.4
3.6
Heating Curve
100°F
150
Minimum
Boiler Return
16 17
2K10K
Com Com
SenSw
Sen
RTU
Sen
150°F
100 200
Max./Setpoint
130 sec.
30 230Off
Motor Speed /
Pump Response
2093 1234567
18 19
Sup Out Sen
Sen
Date
R
06/00
Boiler is on
Operating Mode selector switches
Heating Curve
Maximum
/Setpoint
Supply
Minimum Boiler Return
Motor Speed
Test button and LED to test main
S/N
control functions
Terminal Plug: Sensor and timer input
H1073
Input: Heat Demand signal.
Optional
120Vac Power Supply
Output: Turn on
system pump
Output: Control
variable speed pump
Output:
Turn on boiler
OR
Output:
4-20mA device
M
Input: Return
Sensor 071.
Optional
Input:
Unoccupied
signal (030
Timer)
Optional
Input: Indoor
Sensor 074
Optional
Copyright © D 365 - 06/001 of 16
Input: Outdoor
Sensor 070
Included
Input: Supply Universal
Sensor 071.
Included
OR
Input: 2k RTU
Optional
Page 2
Outdoor Reset Strategy
Correct setting and shifting of the Heating Curve... the key to More Comfort and Energy Savings.
Heating Curve
As outdoor temperatures get colder, heat losses from a building increase, requiring the addition of more heat to prevent the indoor air temperature from also getting colder. This tekmar reset control measures the outdoor temperature and as the outdoor temperature gets colder, it balances the heat loss by making the heating supply water hotter. The Heating Curve is used to calculate how hot to make the supply water at different outdoor temperatures. It is the number of degrees the supply water temperature is raised for each degree that the outdoor temperature falls.
Setting the Heating Curve
Two examples of how the Heating Curve works are given in the following illustration. With a 2.4 Curve, the supply water temperature is raised 2.4 degrees for every degree of outdoor temperature drop.
If WWSD point = 70°F and Outdoor temperature = 30°F, then Supply temperature = 166°F
With a 0.6 Curve, the supply water temperature is raised 0.6 degrees for every degree of outdoor temperature drop.
If WWSD point = 70°F and Outdoor temperature = 30°F, then Supply temperature = 94°F
If the Heating Curve selected is too low;
able to raise the supply temperature high enough to keep the room temperature warm during colder weather.
If the Heating Curve selected is too high;
the building will overheat during colder weather.
Warm Weather Shut Down (WWSD)
At warm outdoor temperatures, the indoor space of a building gains heat from the outdoors; additional heat is not required, and if the heating system is running (even on standby), enough excess heat can be produced to overheat the building, causing discomfort and wasting valuable energy.
This control turns off the system pump and injection pump (or closes a mixing valve), when the outdoor temperature is above the WWSD point.
As outdoor temperatures get colder, there comes a point where the heat gain turns into heat loss; the heat loss causes the indoor temperature to fall below the comfort level, and the heating system must be turned on to start delivering heat.
To provide heat to the building, this control turns on the system pump and starts the injection pump (or opens the mixing valve), delivering heat at the low output required by the Heating Curve near the WWSD point. If the outdoor temperature rises above the WWSD point, the control shuts the system off again, and because the system was operating at a low heat output level, overheating and temperature swings in mild weather are avoided.
When the system is operating near the WWSD point and the building is too cold; When the system is operating near the WWSD point and the building is too warm;
3.0
WWSD
Point
will
shift
up and
down
with
shift of
Heating
Curve
(32)
3.6
Heating
Curve
Parallel Shift of Heating Curve
UP
DOWN
UP
90
70
(21)
50
(10)
Outdoor air temperature
2.4 2.0
DOWN
30
(-1)10(-12)
A very cool room temperature can shift the curve far enough up to bring the control out of WWSD at warm outdoor temperatures. A very warm room temperature can shift the curve far enough down to put the control into WWSD at cool outdoor temperatures.
the heating system will not be
too much heat is delivered and
Shifting the Heating Curve
(a) Manually, at the control:
The Occupied and Unoccupied dials on this control can shift the WWSD point up or down from 35 to 105°F (2 to 41°C).
(b) Automatically, using room temperature feedback:
In addition to a Supply Sensor and an Outdoor Sensor, this control can use a tekmar 2k RTU, 10k Zone Control or 10k Indoor Sensor to provide room temperature feedback for added comfort and system flexibility.
The control still calculates a desired supply temperature based on the
Supply water temperature
Heating Curve setting and the outdoor temperature.
If the air temperature in the room is too cold, the control will shift the Heating Curve (and WWSD point) room warms up again.
If the air temperature in the room is too warm, the control will shift the Heating Curve (and WWSD point)
1.6
1.2
1.0
0.8
0.6
0.4
-10°F
(-23)°C
210 (99)
190 (88)
170 (77)
150 (65)
130 (54)
11 0 (43)
90
(32)
70
(21)
50°F
(10)°C
ture until the room cools down.
3.0
90
(32)
WWSD
Point
Heating
Curve
70
(21)
3.6
50
(10)
Outdoor air temperature
2.4 2.0
30
(-1)10(-12)
the WWSD point should be raised.
the WWSD point should be lowered.
up,
which raises the supply temperature until the
down,
which lowers the supply tempera-
1.6
1.2
1.0
0.8
0.6
0.4
-10°F
(-23)°C
210 (99)
190 (88)
170 (77)
150 (65)
130 (54)
11 0 (43)
Supply water temperature
90
(32)
70
(21)
50°F
(10)°C
Refer to the tekmar Essays E 001 and E 002 for more detailed information regarding control strategy and integration of control functions.
Copyright © D 365 - 06/00 2 of 16
Page 3
The tekmar Variable Speed Pump Output
Variable Speed Pump
When using a variable speed pump, the injection of high tempera­ture water into the lower temperature heating system loop should be continuous and the volume of water injected should be varied by speeding up (more heat) or slowing down (less heat) the pump rotation speed. This is a flexible and inexpensive method of mixing reset/setpoint control and can be used for a number of applications on systems with a wide variety of flow rates.
Ideally, the variable speed pump should operate near 100 % output during system design temperature conditions (when run­ning in mixing reset mode). Injection rates will vary with changing high temperature loop water temperatures, and correct sizing of the injection pump must take this factor into account. Plumbing arrangements and pump sizing calculations are covered in more detail in the Essay E 021.
Operation
The Mixing Control 365 has a 120Vac 50/60Hz output which has been designed to directly power an injection pump at variable speeds to control the rate at which hot water is added to the heating system loop. The maximum drive capacity for this circuit is 1/6 hp,
2.2 Amp, 120Vac. There are a number of manufacturers produc­ing small circulators that can be operated by this 120Vac output. A permanent capacitor, impedance protected pump motor (no start switch) under 1/6 hp is required. Most small "wet rotor" circulators have proven to be acceptable. Consult the accompa­nying Addendum for a list of the specific pumps tested and approved by their manufacturers. As these companies test and approve new products for use with the tekmar variable speed output, the Addendum will be updated.
Larger pumps require that a compatible 4–20 mA motor drive be used as an interface between the control and the pump motor. Contact the pump manufacturer regarding compatible equipment for specific pumps.
The variable speed ( the same time. If the 120Vac output is used and remote monitoring is important, a remote read out via the 4–20 mA could be connected. The 4–20 mA is proportional to the level of the variable speed output.
Var Pmp
) and the 4–20 mA output operate at
Supply To Low
Temperature Loop
Return from Low
Temperature Loop
Supply To Low
Temperature Loop
Return from Low
Temperature Loop
Mixing Point
Crossover
Flow
Variable Speed Injection Pump
Crossover
Flow
Variable Speed
Injection Mixing
Low Output
Mixing Point
Crossover
Flow
Variable Speed
Injection Pump
Crossover
Flow
Variable Speed
Injection Mixing
High Output
Supply From High Temperature Loop
Return to High
Temperature Loop
Supply From High Temperature Loop
Return to High
Temperature Loop
Variable Speed Pump Start Up
The control gives an initial 100% power output to the motor for 1/5 second to get it started up from a dead stop. This full power output is required to get the pump motor turning. After the 1/5 second starting pulse, the control adjusts the pump speed to meet the heating requirements.
The maximum
rate
at which the motor can change its speed from 0% output to 100% or from 100% output back to 0% output is set by the "Motor Speed/Pump Response" dial. This dial should be set according to system response times and will typically be set somewhere between 30 and 50 seconds. Refer to the "Settings" section, page 12, for more information.
% of Full Output
The control's variable speed output has been designed to provide a linear GPM flow rate over the full operating range of the pump. For example, when the "10 % of full output " LED is on, the control will be running the pump to deliver 10% of its GPM output rather than 10% of its rated rotational speed. As the above illustration indicates, the % output of flow from the pump is directly propor­tional (within 10%) to the "% of full output" scale of the control.
Variable Speed & 4-20 mA Output Operation
100%
80%
60%
40%
Rated GPM of Pump
20%
90
70
50
30
10
20%
% of Full Output Display (Pump GPM output in %)
90
70
50
90
70
50
30
90
70
50
30
90
70
50
30
10
40% 60% 80% 100%
10
Note: Refer to Pump
Manufacturers' Specifications
10
for G.P.M. Output
30
10
Within 10%
(typical)
Copyright © D 365 - 06/003 of 16
Page 4
Plumbing Arrangements
T
T
F
F
T
F
F
T
T
T
F
F
T
F
F
T
tekmar has developed two significantly different ways of piping variable speed injection pumps for small commercial and residential hydronic heating systems. Each method has its advantages and disadvantages, and designers should read the tekmar essay E 021 thoroughly in order to correctly choose the best arrangement for their particular application.
Reverse Injection
Reverse injection requires that the water from the boiler loop is injected into the low temperature loop upstream of the return to the boiler loop. Mixing occurs directly after the point of injection. Since some of the mixed water is then returned back to the boiler loop, higher injection flow rates are required than in direct injection systems.
Pump Sizing
Reverse Injection
To calculate the required size of the injection pump:
F1 = System Supply flow rate in US GPM T1 = Hot Loop (Boiler) supply temperature available T2 = Low Temperature (System) Supply temperature Ts = Low Temperature (System) temperature drop (T2 – Tr)
Note: All values are to be given at design conditions.
Maximum Variable Flow
(Fv) =
F1 x Ts T1 - T2
Sample Calculation
Values at
Design
Conditions
Are:
T1 = Boiler Supply = 180°F T2 = System Supply = 130°F
Ts = System T = 25°F
F1 = System Flow = 10 GPM
r
1
T
s
Supply To Low
Temperature Loop
1 x Ts 10 x 25 250
F
Fv = = = = 5 GPM
T1 - T2 180 - 130 50
"REVERSE" INJECTION
2
1
Variable
Speed
Injection
Pump
V
V
Supply From High
Temperature Loop
1
Direct Injection
Direct injection requires the water from the hot loop to be injected into the low temperature loop so that the heat rise and the mixing occur directly after the point of injection, down­stream of the return to the hot loop.
Pump Sizing
Direct Injection
To calculate the required size of the injection pump:
F1 = System Supply flow rate in US GPM T1 = Hot Loop (Boiler) supply temperature available T2 = Low Temperature (System) Supply temperature Tr = Low Temperature (System) Return temperature Ts = Low Temperature (System) temperature drop (T2 – Tr)
Note: All values are to be given at design conditions.
Maximum Variable Flow
(Fv) =
F1 x Ts T1 - Tr
Sample Calculation
Values at
Design
Conditions
Are:
T1 = Boiler Supply = 200°F T2 = System Supply = 120°F
Ts = System T = 20°F
F1 = System Flow = 60 GPM Tr = System Return = T2 – Ts = 100°F
Fv = = = = 12 GPM
This example illustrates an important point to consider when designing variable speed systems. The hotter the maximum boiler supply temperature is designed for, or the cooler the maximum system supply temperature is designed for, the less injection flow is required. Quite large systems can be designed with relatively small injection pumps when this is kept in mind.
Supply To Low
Temperature Loop
2
1
T
s
F
1 x Ts 60 x 20 1200
"DIRECT" INJECTION
1
r
Variable
Speed
Injection
Pump
V
V
T1 - Tr 200 - 100 100
Supply From High Temperature Loop
1
For more details on variable speed pumping, refer to tekmar essay E 021
The variable speed injection pump should be sized for full load heat transfer at design conditions. Calculations reveal that in most typical residential and small commercial applications the smallest circulators are of sufficient size and in many cases exceed the maximum required GPM rating. If an appropriate pump size is not available, a larger pump may be used provided a balancing valve is included to reduce flow through the transfer loop.
Copyright © D 365 - 06/00 4 of 16
Page 5
Sequence of Operation
Zone Control
Boiler on when 25% open
External Heat Demand
Setpoint
123 4
When the Mixing Control 365 is powered-up, the "Power" light will come on and the control will turn on all LEDs for five seconds. If no errors are detected, the control enters the operating mode.
Once in operating mode, the control determines whether to operate in Reset or Setpoint mode based on the setting of the Reset/Setpoint DIP switch.
If the control is configured for Setpoint it will monitor:
a Universal Sensor 071 to continually monitor the system supply water temperature.
Optionally,
a Universal Sensor 071 to continually monitor the boiler return water temperature.
If the control is configured for Reset it will monitor:
an Outdoor Sensor 070 to continually monitor the outdoor temperature.
a Universal Sensor 071 to continually monitor the system supply water temperature.
Optionally,
Optionally,
a Universal Sensor 071 to continually monitor the boiler return water temperature.
the indoor temperature can be monitored through the use of: (a) - a tekmar 2K RTU or 10K Indoor Sensor 074 (DIP switch in "Indoor Sensor" position) or; (b) - a tekmar 10K Zone Control (DIP switch in "Zone Control" position)
While monitoring all of these temperatures, the control recognizes the following temperature conditions and inputs and will respond as described. During operation, the lights of the control will indicate operational status as illustrated.
Heating Operation (Reset Mode)
Selector Switch = Reset
When the control is in the reset mode, its main function is to reset the supply water temperature based on the changing outdoor temperature.
External Heat Demand signal
Selector Switch = External Heat Demand
A heat demand signal is caused by either 24 or 120Vac applied to terminals
Heat Dem Heat Dem
(1 and 2).
AND/OR
An active (calling for heat) 10 K Zone Control connected to terminals
Com Sen 10K Sen
(14 and 15).
Setpoint
123 4
Boiler on when 25% open External Heat Demand
Zone Control
4-20
+
1110
Com –Ret
Reset
12 13
Sen
UnO
Sw
123 4
14
Com
Sen
?
Power
Heat Demand
Min. Return
Pump
90
70
50
30
10
Setpoint
Reset
Indoor Sensor Permanent Heat Demand Boiler on when 10% open
15
16
10K
2K
Sen
RTU
%
17
Com
Sen
WWSD
UnOcc. Switch
Max. or Setpoint
Boiler
of full
output
123 4
12
Heat
Dem Dem
18 19
Sup
Sen
Test
Out
Sen
Permanent Heat Demand signal
Selector Switch = Permanent Heat Demand
A heat demand signal is continuously present unless a10K Zone Control is connected to terminals
Com Sen 10K Sen
(14 and 15).
(If a10K Zone Control is connected, there will only be a heat demand
present when it calls for heat)
Occupied/Unoccupied dial function
With no indoor air temperature feedback, the control will monitor the outdoor and supply temperatures. The Occupied and Unoccupied dial settings become the WWSD points. When in Occupied mode and the outdoor temperature is warmer than the setting of the Occupied dial, the control enters WWSD. When switched into Unoccupied mode – (short circuit) terminals
UnO Sw Com Sen
(13 and 14) together by a switch or isolated timer
Connect
relay contacts (tekmar Timer 030) – the "UnOcc. Switch" light will come on, the Occupied dial will become inactive and the Unoccupied dial will become active
as the control starts to
operate at the temperature of the Unoccupied dial setting.
Indoor Sensor 074 function
Selector switch = Indoor Sensor
The control will monitor the indoor, outdoor and supply temperatures, and shift the Heating Curve (and the WWSD point) up or down to fine adjust the system supply water temperature whenever the room temperature is different than the setting of the Occupied dial. When switched into Unoccupied mode, the "UnOcc. Switch
" light will come on, and the control will operate at the
temperature of the Unoccupied dial setting.
2K RTU function
Selector switch = Indoor Sensor
The control will monitor the indoor, outdoor and supply temperatures, and shift the Heating Curve (and the WWSD point) up or down to fine adjust the system supply water temperature whenever the room temperature is different than the setting of the RTU dial. The Occupied and Unoccupied dials are not functional. A Setback RTU 308 must be used if Unoccupied schedules are desired.
tekmar Zone Control function
Selector switch = Zone Control
The control accepts a zone input signal from a tekmar 10K Zone Control which monitors the indoor temperature of all zones – as well as the outdoor and supply temperatures – and shifts the Heating Curve (and the WWSD point) up or down to fine adjust the system supply water temperature for whichever zone requires the hottest supply water. The Occupied and Unoccu­pied dials are only functional if an external heat demand is given and the dial setting is higher than the zone control desired temperature.
4-20
+
12
1110
Com –Ret
Sen
Reset
Reset
Setpoint
Reset
13 14
UnO SwCom
123 4
123 4
123 4
Copyright © D 365 - 06/005 of 16
123 4
Sen
Indoor Sensor
Permanent Heat Demand
Boiler on when 10% open
15
16
10K
2K
Sen
RTU
Indoor Sensor
Permanent Heat Demand Boiler on when 10% open
Indoor Sensor
Permanent Heat Demand Boiler on when 10% open
Boiler on when 25% open External Heat Demand
Zone Control
17
Com
Sen
18
Sup
Sen
19
Out
Sen
Page 6
WWSD function
When WWSD occurs, the "WWSD" light will come on, the 4-20 mA will go to 4 mA, the variable speed pump will be off, and the boiler and system pump will shut down. The control will continue to monitor the outdoor and supply temperatures. Whenever 3 days pass with the control in uninterrupted WWSD, the system pump will be cycled on for 10 seconds, the 4 to 20 mA mixing valve (if used) will be run open and then closed to help prevent seizing, and the variable speed pump (if used) will be turned fully on and then ramped off again. If a tekmar zone control is connected to this control, the system pump will only be turned off when the zone control does not require heat or the valve/injection pump is being exercised.
Outdoor temperature cold enough to require heating
Occupied/Unoccupied dial:
With no Heat Demand signal
When the outdoor temperature is colder than the WWSD point, the control will leave WWSD. Whenever the control leaves WWSD, the "WWSD" light will go out and the control will continue to monitor the outdoor and supply temperatures, but no further control action will take place unless there is a heat demand signal.
With Heat Demand signal
The "Heat Demand" light will come on, the control will switch on the system pump and boiler, and calculate the desired supply temperature based on the requirements of the Heating Curve.
The control will operate the 4-20 mA output and the variable speed pump to deliver the correct supply temperature. The 4-20 mA and variable speed pump output levels are displayed on the "% of full output" LEDs.
When controlling the 4-20 mA / variable speed pump, the control acts as follows:
(a) - To increase the supply temperature. The 4-20 mA drive and variable speed pump output
levels will increase at a rate determined by the control. The maximum rate is set at the Motor Speed/Pump Response dial.
(b) - To decrease the supply temperature. The 4-20 mA drive and variable speed pump output
levels will decrease at a rate determined by the control. The maximum rate is set at the Motor Speed/Pump Response dial.
(c) - To maintain a steady supply temperature. The 4-20 mA drive and the variable speed pump
output levels will remain relatively constant provided the heating load and boiler tempera­ture does not change significantly.
Maximum Supply temperature operation
To provide a measure of protection to system components that may be damaged by excessive heat, (e.g.. some types of plastic pipe) this control has a setting for Maximum Supply temperature.
When the supply temperature is close to the setting on the Max./Setpoint dial, the control will reduce the "% of output" in order to keep the supply water temperature below the maximum setting. At this time the "Max. or Setpoint" light will come on.
The control may operate for a long time at the Maximum temperature if:
(a) - it is coming out of a deep setback or just starting up from a cold start; (b) - an RTU (or Occupied dial when Indoor Sensor 074 is used) is turned up suddenly; or (c) - the maximum setting is too low for system design conditions.
Minimum Boiler Return temperature operation
To provide a measure of protection to boilers that may have minimum return water temperature requirements, this control has a setting for Minimum Boiler Return temperature.
When the boiler return temperature is close to the setting on the Minimum Boiler Return dial, the control will decrease the "% of output" in order to increase the boiler return temperature and prevent undershoot. The "Min. Return" light will come on and the control will continue to decrease the output in order to maintain the temperature slightly above the Minimum Boiler Return temperature setting. The "Boiler" light will be on as the control continues to fire the boiler (even below the 10%/25% open settings) in order to raise the return temperature.
The control may operate for a long time at the Minimum temperature if:
(a) - it is coming out of a deep setback or just starting up from a cold start; (b) - an RTU (or Occupied dial when Indoor Sensor 074 is used) is turned up suddenly; (c) - the Minimum setting is too high for system design conditions; or (d) - the boiler aquastat is set lower than the "Minimum Boiler Return" dial setting.
WWSD
Power
Heat
UnOcc.
Demand
Switch
Max. or
Min.
Setpoint
UnOcc.
Switch
light may
also be on
Pump
light may
also be on
Any or all "% of Full Output" LEDs may also be on
Any or all "% of Full Output" LEDs may also be on
Return
Boiler
Pump
90
70
50
30
10
Power
Heat Demand
Min. Return
Pump
90
70
50
30
10
UnOcc. Switch
light may also be on
Boiler light may also be on
UnOcc. Switch light may also be on
Power
Heat Demand
Min. Return
Pump
90
70
50
30
10
Power
Heat Demand
Min. Return
Pump
Power
Heat Demand
Min. Return
Pump
OR
of full
output
%
WWSD
UnOcc. Switch
Max. or Setpoint
Boiler
OR
of full
output
%
WWSD
UnOcc. Switch
Max. or Setpoint
Boiler
of full
output
%
WWSD
UnOcc. Switch
Max. or Setpoint
Boiler
90
70
of full
50
output
%
30
10
WWSD
UnOcc. Switch
Max. or Setpoint
Boiler
90
70
of full
50
output
%
30
10
UnOcc. Switch light may also be on
Power
Heat Demand
Min. Return
Pump
Power
Heat Demand
Min. Return
Pump
WWSD
UnOcc. Switch
Max. or Setpoint
Boiler
90
70
of full
50
output
%
30
10
WWSD
UnOcc. Switch
Max. or Setpoint
Boiler
90
70
of full
50
output
%
30
10
Copyright © D 365 - 06/00 6 of 16
Page 7
Notes on operation of Minimum Return and Maximum Supply functions
At times, the control may be trying to control both the Maximum Supply and Minimum Return temperatures (e.g.. when leaving a deep setback). When this occurs, the control is programmed to give priority to the Minimum Boiler Return function, and only the "Min. Return" light will be displayed.
When the control is in WWSD, the "Min. Return" and "Max. Supply" lights will not be displayed. When using a Return Sensor for Minimum Return protection, it is essential that there always be water flow past the return sensor
whenever there is a heat demand.
See Brochure A 365.
Caution:
The tekmar Mixing Control 365 is an operating control and not certified or intended for use as a primary safety device. Under normal operating conditions, the control will provide excellent protection against excessive supply temperatures and low boiler return temperatures; However, if fail-safe protection against either of these conditions is essential then separate certified safety limit devices should be employed.
Setpoint Operation
Selector Switch = Setpoint
When the control is in the Setpoint mode, it will control the supply water temperature based on the setting of the Max./Setpoint dial. The Outdoor Sensor need not be installed and the Occupied, and Heating Curve dials are inactive. If the control receives an Unoccupied signal, the supply temperature will be controlled at the setting of the Unoccupied dial. When an optional Boiler Return Sensor 071 is installed, the Minimum
Setpoint
1
2
3
4
Boiler on when 25% open External Heat Demand Zone Control
Boiler Return function is activated based on the setting of the "Min. Return" dial.
External Heat Demand signal
A heat demand signal is caused by either 24 or 120Vac applied to terminals Heat Dem Heat Dem (1 and 2). This signal will activate the control, allowing it to operate the system to deliver the selected setpoint temperature.
Selector Switch = External Heat Demand
Setpoint
123 4
Boiler on when 25% open
External Heat Demand
Zone Control
+
12
Heat
Dem Dem
AND/OR
An active (calling for heat) 10 K Zone Control connected to terminals
Permanent Heat Demand signal
Com Sen 10K Sen
(14 and 15).
Selector Switch = Permanent Heat Demand
Setpoint
123 4
Boiler on when 25% open External Heat Demand
Zone Control
4-20
A heat demand signal is continuously present and the control will continuously operate the system to deliver the selected setpoint temperature.
+
12 13
1110
Com –Ret
Sen
UnO
Sw
14
Com
Sen
Reset
15
10K
Sen
123 4
16
17
2K
Com
RTU
Sen
Indoor Sensor
Permanent Heat Demand
Boiler on when 10% open
18 19
Sup
Sen
Out
Sen
Installation
Caution
Improper installation and operation of this control could result in damage to equipment and possibly even personal injury. It is your responsibility to ensure that this control is safely installed according to all applicable codes and standards.
Step One Getting ready
Check the contents of this package. If any of the contents listed are missing or damaged, please refer to the Limited Warranty and Product Return Procedure on the back of this brochure and contact your wholesaler or tekmar sales agent for assistance.
Type 365 includes:
Other information available:
Read Brochure A 365 and E 021 and select the correct Application for your job.
Note:
Carefully read the details of the Application, and the Sequence of Operation sections in all applicable brochures to ensure that you have chosen the proper control and understand its functions within the operational requirements of your system. Some applications feature boiler return protection and require an additional Universal Sensor 071 to be ordered.
Step Two
The control should be removed from its base by pressing down on the release clip in the wiring chamber and sliding upwards on the control. The base is then mounted in accordance with the instructions in the Data Brochure D 001.
Step Three
All electrical wiring terminates in the control base wiring chamber. It has standard 7/8" (22mm) knock-outs that will accept common wiring hardware and conduit fittings. Before breaking out the knock-outs, check the wiring diagram and select those sections of the chamber with common voltages, since the safety dividers will later prevent wiring from crossing between sections.
Power should not be applied to any of the wires during this rough-in wiring stage.
Install the Outdoor Sensor 070, and the Universal Sensor 071 according to the instructions in the Data Brochure D 001 and run the wiring back to the control.
One Control 365 One Outdoor Sensor 070 One Universal Sensor 071
One Data Brochure D 365 One Data Brochure D 001 One Application Brochure A 365
One Essay E 021
Essay E 001 Essay E 002
Mounting of the base
Rough-in Wiring
Copyright © D 365 - 06/007 of 16
Page 8
Rough-in wiring (continued)
Option:
A Universal Sensor 071 can be installed to provide Minimum Boiler Return protection. See Brochure A 365.
Option:
A 10K Indoor Sensor 074, 2K RTU or 10K Zone control can also be connected. See the instructions with these products.
Install the wiring from the other system components (Boiler, System Pump, Actuating Motor, Heat Demand circuit) to the base.
Install 120Vac to the power terminals on the control.
Use a clean 120 Vac power source to ensure proper operation.
Step Four Electrical connections to the control
Power and output connections
The installer should test to confirm that no voltage is present at any of the wires.
Install the control into the base, sliding it down until it snaps into place.
All electrical connections are made directly to the plug terminals.
Connect the 120Vac power supply to terminals
Power N Power L
System Pump
(3 and 4).
Power
N
43
L
System
Pmp Pmp
756
Var.
Pmp
Connect the System Pump circuit to terminals These terminals lead to a dry relay contact which closes when the control requires System Pump operation.
System Pmp System Pmp
(5 and 6).
Power
N
43
L
Pmp Pmp
56
System
7
Var
Pmp
Boiler
Connect the boiler circuit to terminals relay contact which closes when the control requires boiler operation. Boilers with a 24Vac to 120Vac control circuit can be switched directly through the control.
Boiler
(8 and 9). These terminals lead to a dry
89
Boiler
120Vac Variable Speed Pump
Connect one of the variable speed pump leads to the 120Vac neutral terminal "Power N" (terminal 3).
Connect the other variable speed pump lead to terminal "Var Pmp" (terminal 7).
456
Power
L
N
System
Pmp Pmp
73
Var
Pmp
Caution:
The maximum variable speed pump load is 1/6 hp, 120Vac. Pumps must be permanent capacitor, impedance protected, with locked rotor current not ex­ceeding 2.2 amps.
Output To Variable Speed Pump
(Maximum 1/6 hp)
The Mixing Control 365 has an internal, slow blow 2.5 Amp fuse for the variable speed pump output. If the maximum load is exceeded – causing this fuse to blow – the control must be returned to tekmar where it will be examined for damage, repaired if necessary, and the fuse replaced. This procedure will not be covered as a warranty claim.
4- 20 mA Connections
The 4-20 mA output can be used to operate a variety of actuating motors for mixing valves and motor drives for larger pumps. Consult the manufacturers' installation instructions for these devices for more details on these connections.
1110
4-20
+
Com
1
R S
4-20
+
1110
Com
1
R S
500 resistor 4-20 mA converted to 2-10 Vdc output
10
4-20
+
11
4-20
66.5 resistor
OR
250 resistor
+
4 - 20 mA
Actuating Motor
Connection to Operate
a 4 - 20 mA Device
Copyright © D 365 - 06/00 8 of 16
Converting the 4 - 20 mA Output to
Operate a 1 - 5 Vdc or 2 - 10 Vdc Device
+
1-5 or 2-10 Vdc
Actuating Motor
4-20 mA converted to 1-5 Vdc output
B
W
0 - 135 "Slidewire"
Actuating Motor
Converting the 4 - 20 mA Output to Operate a 0 - 135 Actuating Motor
237 resistor
R
Page 9
Powered input connections
12 13
10K
Sen
2K
RTU
16
Out
Sen
19
Com –Ret
Sen
1110
+
4-20
14 15
UnO SwCom
Sen
Sup
Sen
18
Com
Sen
17
If a 24Vac to 120Vac external heat demand signal is used, (zone valve end switches, etc.) connect the wiring from the Heat Demand circuit to terminals
Heat Dem Heat Dem
(1 and 2). When 24Vac
to 120Vac is applied to these terminals, the control will respond to a call for heat from the system.
Sensor and unpowered input connections
Power should never be applied to these terminals. Damage to the control will result.
Connect the two wires from the Outdoor Sensor 070 to terminals
Com Sen Out Sen
(17 and 19).
4-20
+
Do not apply power here!
12 13
1110
Com –Ret
Sen
UnO SwCom
Sen
Connect the two wires from the Universal Sensor 071 – which should be mounted on the system supply pipe – to the terminals
Com Sen Sup Sen
(17 and 18).
Option: Boiler Return temperature sensor
(Must be ordered separately)
Connect the two wires from the Universal Sensor 071 to terminals
Com – Ret Sen
(11 and 12).
4-20
+
11
Com –Ret
12
Sen
13
UnO SwCom
Option: Indoor temperature feedback sensor
(Select one option only)
(1) Connect the two wires from the Indoor Sensor 074 or a
tekmar 10K Zone Control to terminals
Com Sen 10K Sen
(14 and 15).
4-20
+
12 13
1110
Com –Ret
Sen
UnO
Sw
Com
OR
(2) Connect the two wires from the tekmar 2K RTU or the tekmar
2K
Zone Control type 240 to terminals
2K RTU – Com Sen
(16 and 17).
10
4-20
+
11
12
Com –Ret
Sen
13
UnO
Sw
Com
Option: Occupied/Unoccupied switch input
Connect the two wires from the Occupied/Unoccupied dry contact switch, (tekmar Timer 030) to terminals
UnO Sen Com Sen
(13 and 14).
4-20
+
12
1110
Com –Ret
Sen
13 14
UnO SwCom
14 15
10K
Sen
14 15
10K
Sen
Sen
14
15
10K
Sen
Sen
OR
14 15
10K
Sen
Sen
15
10K
Sen
Sen
16
2K
RTU
16 2K
RTU
16
2K
RTU
16
2K
RTU
16
2K
RTU
12
Heat
Dem Dem
17
18
Sup
Com
Sen
Sen
17
18 1910
Com
Sup
Sen
Sen
17
18 19
Sup
Com
Sen
Sen
17
18 19
Sup
Com
Sen
Sen
17
18
Com
Sup
Sen
Sen
19
Out
Sen
Out
Sen
Out
Sen
Out
Sen
19
Out
Sen
Electrical connections to the terminal plugs of the type 365 control. Control relays are shown in "power down" condition.
type 365
Maximum 120 Vac
12 A
10 A
2.2 A
12
Heat
Dem Dem
Power Supply
120 Vac +/- 10%,
Heat Demand
Apply 24 or 120 Vac
signal when heat is
required from system
4563
Power
N
L Pmp Pmp
50/60Hz. Required
System
Pmp
Variable
Speed Pump
Output
System Pump
Relay
closes to turn
on System Pump
7
Var
89
Boiler
Boiler Relay
closes to turn
on boiler
10
4-20
+
4 to 20 mA
Output
12 13 14 15
11
Ret
Com
Sen
Return
Sensor
071
(Optional)
Unoccupied
Switch (optional)
to switch control to
Unoccupied mode
Note: This is not a wiring Diagram
For a detailed wiring schematic of your specific application, refer to the Application Brochure A 365.
Do not apply
power here!
UnO SwCom
Sen
16
10K
2K
Sen
RTU
2K RTU
10K Indoor
Sensor or
Zone Control
(optional)
17
Com
Sen
OR
19
18
Sup
Out
Sen
Sen
Outdoor
Sensor
Copyright © D 365 - 06/009 of 16
070
Supply Sensor
071
Page 10
Step Five Testing the wiring
Caution
Before applying power to the control for testing, each terminal plug must be unplugged from its header on the control. Pull straight down to unplug.
These tests are to be performed using standard electrical testing practices and procedures and should only be carried out by properly trained and experi-
10
4-20
+
11
Com
Ret
Sen
14
13
12
Com
Uno
Sen
Sw
Sen
enced persons.
A good quality electrical test meter, capable of reading from at least 0 200 Volts AC, and at least 0 1,000,000 Ohms, is essential to properly test this control.
Test the sensors
These test must be made
before
turning on the power supply, and with the terminals unplugged. The sensors are to be tested according to the instructions in brochure D 001. If a tekmar RTU or Zone Control is used, check the applicable data brochure for the product used.
Terminal plug disconnected
from its header on the control
Test the power supply
Make sure exposed wiring or bare terminals are not in contact with any other wires or grounded surfaces. Turn on the 120 Vac power and use an AC voltmeter to measure the voltage between terminals
N L
(3 and 4). Between 110 and 130 Vac should be
measured at these terminals.
10
4-20
+
11
Com
12
Ret
Sen
13
Uno Sw
14
Com Sen
15
10K
Sen
RTU
Test the powered inputs
If an external Heat Demand signal is used, power up the Heat Demand circuit and supply a Heat Demand signal to the control. Use an AC voltmeter to measure the voltage between terminals
Heat Dem Heat Dem
should be measured at these terminals.
(1 and 2). From 22 to 130 Volts AC
Terminal plug pushed into
its header on the control
Test the outputs
If a System Pump circuit is connected to the
Sys Pmp Sys Pmp
(5 and 6) terminals; make sure power to the circuit is off and install a jumper in the terminal plug between terminals 5 and 6. When the system Pump circuit is powered-up, the pump should operate. If it does not come on, check the circuit wiring for errors and ensure that it is powered up and the voltage is correct. Check the devices in the circuit (pump, switching relay, etc.) for faults.
If the pump operates properly when the circuit is powered up
disconnect the power, remove the jumper and proceed to the next step.
Note: When a Return Sensor 071 is used, the boiler loop pump must operate with the system pump. See Brochure A 365.
If you are using the control to operate the boiler; make sure power to the boiler circuit is off and install a jumper in the terminal plug between the
Boiler
(8 and 9) terminals. When the boiler circuit is powered-up, the boiler should operate. If it does not come on, check the circuit wiring for errors and ensure that it is powered up and the voltage is correct. Check the devices in the circuit (limits, flow switches, etc.) for faults.
If the boiler operates properly when the circuit is powered up, disconnect the power, remove the jumper
and proceed to the next step.
If a Variable Speed Pump is connected to the install a jumper in the terminal plug between speed pump should operate. and proceed to the next step.
If the pump operates properly when the circuit is powered up, disconnect the power, remove the jumper
During operation, this output from the control can be measured with a standard voltmeter. Push the
test button, and monitor the voltage at terminals 3 & 7.
Power N Var Pmp
L Var Pmp
(4 and 7) terminals. When 120 Vac supply is powered up, the variable
At 100% output
(3 and 7) terminals; make sure power to the circuit is off and
the voltage should read between 90 and 130Vac.
Connect the control
Turn the power off and make sure all test jumpers have been removed from the plugs.
Connect the plugs to the control by carefully aligning them with their respective headers and
pushing them upwards into the headers. The plugs should snap firmly into place.
4-20
+
1110
Com
1
R
S
Install the supplied safety divider(s) between low voltage and high voltage wiring chambers.
The control is now ready for set-up and operation.
Testing the 4-20 mA output
The 4-20 mA output terminals (10 and 11) cannot be tested without power being applied to the control. If you are going to be using this output, connect an ammeter to the 4-20 mA output terminals (10 and 11) and observe the current reading during operation. Refer to the Sequence of Operation section of this brochure for details on 4-20 mA output levels.
Caution
Measuring
the 4-20 mA
Output
The tekmar Mixing Reset Control 365 is an operating control and is not certified or intended for use as a safety device. Under no circumstances should safety limit devices be left disconnected after installation of this control. The installer shall check all applicable code requirements and obtain necessary inspections to ensure that the installation is in compliance with those requirements.
17
16
15
Com
2K
10K
Sen
RTU
18
17
16
Sup
Com
2K
Sen
Sen
Test the output using a milliamp meter 1000 mA = 1 amp
6.4 mA
Milli Amp
18
Sup
Sen
19
Out
Sen
19
Out
Sen
Copyright © D 365 - 06/00 10 of 16
Page 11
Settings
Step Six Essential control settings
To obtain the best operation from a reset control, it is important to measure the system supply temperature as accurately as possible. Whenever the control receives a heat demand signal, the system pump must be operated to maintain continuous water flow across the supply temperature sensor. Whenever the control uses a boiler return sensor, the boiler pump must also be operated to maintain continuous water flow across the boiler return sensor.
For specific application details refer to Brochure A 365. A more detailed technical description of the effect of control settings on overall system operation is described in the tekmar Essay, E 002.
Heating Curve
As outdoor temperatures drop, heat losses from a space become greater and the heating system supply water temperature must be raised to maintain a constant room temperature. The heating curve value describes how many degrees the supply water temperature is raised for a one degree drop in outdoor temperature. The supply temperature starts to increase when the outdoor temperature falls below the WWSD point. To calculate the correct setting for the heating curve, use the following formula.
Heating Curve =
For example: Design outdoor temperature = 5
Heating curve = = = 1.4
For more information regarding the Heating Curve, refer to page 2 of this
design supply temperature – room temperature
room temperature – design outdoor temperature
°F (-15°C)
Room temperature = 70
Design supply temperature = 160
160°F - 70°F
70°F - 5°F
90°F 65°F
°F (21°C)
°F (71°C)
WWSD
Point
Heating
Curve
3.6
3.0
brochure. If the design supply water temperature for a system is unknown, a trial setting can be calculated using these typical supply temperatures:
Fan coils 180° to 210°F (82° to 99°C)
Baseboard convectors 160° to 190°F (71° to 88° C)
Hydronic radiant floors 100° to 130°F (38° to 54°C).
90
(32)
70
(10)30(-1)10(-12)
(21)
Outdoor air temperature
50
Occupied temperature
When there is no room temperature feedback to the control, the Occupied dial setting determines the starting point of the Heating Curve. This starting point becomes a fixed WWSD point. When an Indoor Sensor 074 is connected to the control, the Occupied dial setting becomes the actual controlled temperature of the room. This allows the control to compensate for unexpected internal heat gains or losses. If the room temperature is too high or too low, the indoor sensor shifts the Heating Curve up or down accordingly. Except when there is an external heat demand, when a Zone Control or RTU (Room Temperature Unit) is connected, the RTU dial(s) set the desired room temperature and the Occupied dial becomes inactive.
2.0
0.4
Heating Curve
2.4 2.0
35 (2)
3.6
1.6
1.2
1.0
0.8
0.6
0.4
-10°F
(-23)°C
70°F
(21°C)
Occupied
105 (41)
210 (99)
190 (88)
170 (77)
150 (65)
130 (54)
11 0 (43)
Supply water temperature
90
(32)
70
(21)
50°F
(10)°C
Unoccupied temperature
The Unoccupied dial operates in the same way as the Occupied dial, but at a different temperature. When the terminals
UnO Sw — Com Sen
(13 and 14) are shorted together, the control switches from operating at the Occupied dial setting to operating at the Unoccupied dial setting. When a tekmar Zone Control or RTU (Room Temperature Unit) is connected to the control, the RTU setting(s) becomes the controlled temperature and the Occupied/Unoccupied dials become inactive. Unoccupied temperatures must be controlled at the zones.
Indoor Sensor/Zone Control switch
Set this selector switch to the "Indoor Sensor" position when a tekmar Indoor Sensor 074 or a tekmar RTU is connected. The control will receive room temperature feedback from the room that has the
Reset
Sensor or RTU. Set the switch to the "Zone Control" position when a tekmar Zone control is connected, the control
receives information from the Zone Control that allows the Heating Curve to be shifted so the supply
Setpoint
water temperature is hot enough to satisfy the requirements of the zone with the highest heat demand.
Setpoint/Reset switch
When this selector switch is in the "Setpoint" position, the control will operate the system to maintain
Setpoint
the supply water temperature at the setting of the "Max./Setpoint" dial.
Reset
When the switch is in the "Reset" position, the Heating Curve is active, and the "Max./Setpoint" dial becomes an override to the Heating Curve, limiting the maximum allowable water temperature.
70°F
(21°C)
123 4
123 4
123 4
35 (2)
Unoccupied
105 (41)
Indoor Sensor
Permanent Heat Demand Boiler on when 10% open
Boiler on when 25% open External Heat Demand
Zone Control
Boiler on when 25% open External Heat Demand Zone Control
150°F
100 200
Max./Setpoint
Copyright © D 365 - 06/0011 of 16
Page 12
Heat Demand switch
When the heating system uses zone valve end switches or some other means of delivering an external heat demand signal to terminals
Heat Dem Heat Dem
(1 and 2), set this switch to "External Heat Demand" and the control will only operate the system pump, boiler and mixing device when it receives a 24/120 Vac signal from the heat demand circuit. If a 10K Zone control (tekmar
366) is connected
Setpoint
123 4
Boiler on when 25% open
External Heat Demand
Zone Control
to terminals 10K Sen Com Sen (14 and 15), the zone control may also call for heat. If an external heat demand signal is not used, set the switch to "Permanent" and the control will be
enabled all the time unless a 10K zone control is connected.
Reset
123 4
Indoor Sensor
Permanent Heat Demand
Boiler on when 10% open
Maximum Supply temperature
This setting determines the maximum allowable supply temperature to be delivered to the system. When the supply temperature becomes too hot, the variable speed pump slows down – or the mixing
150°F
valve closes – until the temperature is stabilized at the maximum. To get the fastest system heat up times, this setting should be set as high as allowable. Refer to page 6 for more details on maximum supply operation and requirements.
100 200
Max./Setpoint
Minimum Boiler Return temperature
When a Boiler Return Sensor 071 is connected to the control, and the dial is turned up from "Off", this setting determines the minimum allowable boiler return temperature. When the boiler return temperature becomes too cold, the variable speed pump slows down – or the mixing valve is closed – until the temperature is stabilized at the minimum. To minimize standby losses and get the fastest system heat up times, this setting should be set as low as allowable. Refer to page 6 for more details on minimum boiler return operation and requirements.
100°F
60
Off
Minimum
Boiler Return
150
Boiler Enable switch
The position of this switch determines at which pump/valve position the control will fire the boiler under normal conditions. If there is a Return Sensor 071 installed and the return temperature is too cold, the control will immediately turn on the boiler in order to raise the water temperature more quickly.
At the "10% open" position, the control will not fire the boiler until the pump/valve has opened at least 10%, and will turn the boiler off when the pump/valve closes to 5% open. This setting would normally
Reset
123 4
Indoor Sensor Permanent Heat Demand
Boiler on when 10% open
be chosen for high mass boilers (cast iron, steel fire tube, etc.), or systems with a large thermal mass in the loop between the boiler and the mixing pump/valve.
At the "25% open" position, the control will not fire the boiler until the valve has opened at least 25%,
Setpoint
123 4
Boiler on when 25% open
External Heat Demand Zone Control
and will turn the boiler off when the valve closes to 15% open. This setting would normally be chosen for low mass boilers (copper fin tube, etc.), and systems with low thermal mass in the loop between the boiler and the mixing pump/valve.
Note:
Some heating systems combine high input, low mass boilers with very little thermal mass in the loop between the boiler and mixing pump/valve. In some extreme cases, erratic boiler action (short cycling and tripping of high limits) may result from this type of system even at the "25% open" position. To prevent this type of operation it may be necessary to add thermal mass to the system by installing a storage tank or making the loop larger.
Motor Speed/
Pump Response
The type of device being controlled, and the length of time required for the system to respond to a control action will determine the setting for this dial.
Motor Speed (4-20 mA valve output)
130 sec.
When operating a valve, the control uses the information from this setting to synchronize the firing of the boiler to the valve position. Set this adjustment to match the time required for the actuating motor to drive from the fully closed to the fully open position.
30 230
Motor Speed /
Pump Response
If you are unsure of the opening time, complete the following procedure: (1) Make sure the actuating motor/mixing valve is in the fully closed position.
(2) Set the "Motor Speed/Pump Response" dial to the longest (fully clockwise) position. (3) Power up the control and push the Test Button. (4) Observe the motor as it is driven open by the test routine. When the motor reaches its fully open position by stopping against
its end switch, turn the dial down just until the control cycles through to the next step in the test routine.
(5) The "Motor Speed/Pump Response" dial is now set to the operating speed of the actuating motor. Let the control cycle through
to the end of the test routine.
Motor Speed/ Pump Response (variable speed pump)
When using a variable speed system pump, this dial adjusts the amount of time required for the injection pump to go from 0% to 100% flow when maximum output is required, and from 100% back to 0% when no output is required. The output response of the variable speed pump depends on the magnitude of the controlling error (calculated from the readings the control is receiving from the sensors). Experimentation may be necessary in some systems to avoid instability (pump continually ramping up to 100% output and back down), but most standard heating installations work best with settings in the 30 to 50 second range.
Copyright © D 365 - 06/00 12 of 16
Page 13
Testing the Control Functions
Indicator lights
There are fourteen LEDs on the front of the control that will aid in testing and troubleshooting. During normal operation, these lights indicate the following functions:
Power light on
Heat Demand light on
WWSD light on
Unoccupied light on
Min. Return light on
Max. or Setpoint light on
Boiler light on
Pump light on
% of full output lights on
Test light on
Step Seven Operational test of control functions - Test button
the 120 Vac power supply has been connected and the control is energized.
the control is receiving a 24 or 120 Vac external heat demand signal at terminals
Heat Dem Heat Dem
(1 and 2) or from a 10K Zone Control or the heat demand selector switch is in the "Permanent Heat Demand " position.
the control has calculated that the outdoor temperature is warm enough to not require heat.
the terminals
Uno Sw Com Sen
(13 and 14) are shorted together, switching the control into the
Unoccupied (setback) mode.
the control is operating the mixing valve (4-20 mA) or variable speed pump (Var Pmp) to satisfy the minimum boiler return temperature requirement.
the control is operating the mixing valve (4-20 mA) or variable speed pump (Var Pmp) to prevent maximum supply temperature overshoot, or the control is operating in the setpoint mode.
the boiler relay is on, closing the contacts between the
the system pump relay is on, closing the contacts between the
Boiler
(8 and 9) terminals.
System Pmp
(5 and 6) terminals.
the control is displaying the output level of both the 4-20 mA output (from terminals 10 and 11) and the Variable Speed Pump output (from terminals 3 and 7) in incremental % levels.
the control is going through the programmed test routine.
Test button
When the settings are made and the terminal plugs firmly seated, power up the control. For approximately 5 seconds, all the red LED status lights and the yellow "% of full output" lights are turned on. If a fault in a sensor exists, the LED lights will flash an error message until the fault is located and corrected. The error messages are listed on page 15.
If there are no flashing error messages, the control will enter the operating mode. To initiate the test routine, press the Test button.
Power
Heat Demand
Min. Return
Pump
WWSD
WWSD
WWSD
UnOcc. Switch
Max. or Setpoint
Boiler
90
70
of full
50
output
%
30
10
Test
Power
Heat
UnOcc.
Demand
Switch
Max. or
Min.
Setpoint
Return
Boiler
Pump
90
70
of full
50
output
%
30
10
Test
Push Test Button
All lights on (except Pump, Boiler) Test StartsPower-up for 5 seconds
Power
Heat Demand
Min. Return
Pump
UnOcc. Switch
Max. or Setpoint
Boiler
90
70
of full
50
output
%
30
10
Test
Power
Heat Demand
Min. Return
Pump
WWSD
UnOcc. Switch
Max. or Setpoint
Boiler
90
70
of full
50
output
%
30
10
Power light on Test light on Increasing "% of full output" lights on
The control ramps the variable speed pump and the 4-20 mA output up to 100% together, in the time set by the "Motor Speed/ Pump Response" dial.
If the Test Button is pushed once during this step, the "Test" light will flash and the control will be held in a pause mode for 5 minutes, after which time it will automatically exit the test routine and return to normal operating mode. Pushing the Test button during the 5 minute pause will allow the control to resume the test routine at the next step.
Power
Heat Demand
Min. Return
Pump
WWSD
UnOcc. Switch
Max. or Setpoint
Boiler
90
70
of full
50
output
%
30
10
Test
Power
Heat Demand
Min. Return
Pump
WWSD
UnOcc. Switch
Max. or Setpoint
Boiler
90
70
of full
50
output
%
30
10
Test
Power
Heat Demand
Min. Return
Pump
WWSD
UnOcc. Switch
Max. or Setpoint
Boiler
90
70
50
%
30
10
Power light on Test light on all "% of full output" lights on System pump on
WWSD
Once 100% output on the 4-20 mA and variable speed injection pump has been reached, the control will then begin to ramp down the output and turn the system pump on.
During this 10 second step,
if there is a heat demand signal
, and the Test button is pressed once, the test routine will be halted and the system pump will remain on. The "Test" light will flash, and the control will be held in a pause mode for 5 minutes, after which time it will automatically exit the test routine and cycle into normal operating mode. Pushing the Test button during the 5 minute pause will allow the control to resume the test routine at the next step.
Power
Heat Demand
Min. Return
Pump
WWSD
UnOcc. Switch
Max. or Setpoint
Boiler
90
70
of full
50
output
%
30
10
Test
Power
Heat Demand
Min. Return
Pump
UnOcc. Switch
Max. or Setpoint
Boiler
90
70
50
%
30
10
output
of full
output
Test
of full
Test
Test
Copyright © D 365 - 06/0013 of 16
Page 14
Power light on Test light on Decreasing "% of full output" lights on System Pump light on Boiler light on
After 10 seconds of the system pump running the control leaves the system pump on and turns on the boiler relay for 10 seconds.
During this 10 second step,
if there is a heat demand signal
, and the Test button is pressed, the test routine will be halted and the system pump and boiler will remain on. The "Test" light will flash, and the control will be held in a pause mode for 5 minutes, after which time it will automatically exit the test routine and cycle into normal operating mode. Pushing the Test button during the 5 minute pause will allow the control to resume the
Power
Heat Demand
Min. Return
Pump
WWSD
UnOcc. Switch
Max. or Setpoint
Boiler
90
70
of full
50
output
%
30
10
Test
Power
Heat Demand
Min. Return
Pump
90
70
50
30
10
test routine at the next step.
Power light on Test light on Decreasing "% of full output" lights on
Power
Heat
The control turns off the boiler and system pump and continues to ramp down the 4-20 mA / Variable speed pump outputs.
If the Test button is pushed once during this step, the "Test" light will flash, and the control will be held in a pause mode for 5 minutes, after which time it will automatically exit the test routine and cycle into normal operating mode. Pushing the Test button during the 5 minute pause will allow the control to exit the test routine.
Demand
Min. Return
Pump
90
70
50
%
30
10
Power light on Test light off
The control has exited the test routine, entered operating mode and will function according to the sequence of operation described on pages 5, 6 & 7.
One or more of the indicator lights may be on.
Refer
to pages 5, 6 & 7 for a description of the possible indicator light combinations under operating conditions.
Power
Heat Demand
Min. Return
Pump
90
70
50
%
30
10
Step Eight Troubleshooting
As in any troubleshooting procedure, it is important to isolate a problem as much as possible before proceeding. The Error Messages and Test button greatly simplify troubleshooting of the Mixing Control 365. When the control is flashing an Error Message, identify the fault from the look-up table on the next page and then follow standard testing procedures to confirm the problem. If you suspect a wiring fault, return to steps four and five and carefully check all external wiring and wiring connections.
Notes:
When a fault occurs in Reset Mode
If the Outdoor Sensor develops either a short circuit or an open circuit, the control is programmed to calculate the outdoor temperature at 32°F (0°C), and control the supply temperature accordingly, subject to the limit of the supply maximum setting. An error message will then be displayed (see error messages).
If the Supply Sensor develops either a short circuit or an open circuit, the control is programmed to fully close the mixing valve and turn off the variable speed pump and boiler. An error message will then be displayed (see error messages).
If a 2k RTU or a 10k Indoor Sensor or Zone Control is connected and an open circuit develops, the control will operate at the setting of the Occupied and Unoccupied dials. No error message will be generated.
• If a short circuit develops at either the 2k RTU – Com Sen or 10k Sen – Com Sen terminals, the control will operate at the setting of the Occupied and Unoccupied dials. An error message will then be displayed (see error messages).
If a Boiler Return Sensor is connected and an open circuit develops, or if no sensor is installed but the "Minimum Boiler Return" dial is set up from the off position. An error message will then be displayed (see error messages).
If a short circuit develops at the boiler return sensor terminals, the Boiler Return function will become inactive. An error message will then be displayed (see error messages).
If the enclosure overheats, the control will shut down its outputs and display an error message (see error messages) until it cools off again. Check to ensure that the ambient temperature is less than 104°F(40°C).
When a fault occurs in Setpoint Mode
A short circuit or an open circuit at the Outdoor Sensor terminals will not affect the operation of the control. In the case of a short circuit, an error message will be displayed (see error messages). An open circuit will not cause an error message to be generated.
If the Supply Sensor develops either a short circuit or an open circuit, the control is programmed to fully close the mixing valve and turn off the variable speed pump and boiler. An error message will then be displayed (see error messages).
A short circuit or an open circuit at the 2k RTU or a 10k Indoor Sensor or Zone Control terminals will not affect the operation of the control if these terminals are not being used. In the case of a short circuit, an error message will be displayed (see error messages). An open circuit will not cause an error message to be generated.
• If a short circuit develops at either the 2k RTU – Com Sen or 10k Sen – Com Sen terminals, the control will operate at the setting of the Occupied and Unoccupied dials. An error message will then be displayed (see error messages).
If the enclosure overheats, the control will shut down its outputs and display an error message (see error messages) until it cools off again. Check to ensure that the ambient temperature is less than 104°F(40°C).
WWSD
UnOcc. Switch
Max. or Setpoint
Boiler
of full
output
WWSD
UnOcc. Switch
Max. or Setpoint
Boiler
of full
output
%
WWSD
UnOcc. Switch
Max. or Setpoint
Boiler
of full
output
Test
Test
Copyright © D 365 - 06/00 14 of 16
Page 15
If a Boiler Return Sensor is connected and an open circuit develops, or if no sensor is installed but the "Minimum Boiler Return"
dial is set up from the off position. An error message will then be displayed (see error messages).
If a short circuit develops at the boiler return sensor terminals, the Boiler Return function will become inactive. An error message
will then be displayed (see error messages).
After any repair has been completed, press the Test button to confirm that correct operation has been restored.
Error Messages
Whenever a fault is detected in any of the sensors, the indicator lights will flash in specific ways, indicating the location of the problem.
The following look-up table describes each error condition and shows the flashing light sequence that results. After repairing the problem, press the Test button to cycle the control through the test routine. This will confirm that the fault has been repaired and that correct control action has been restored. For detailed sensor testing instructions see Data Brochure D 001.
Outdoor Sensor short circuit (see trouble­shooting notes)
Outdoor Sensor open circuit (see trouble­shooting notes)
Power
Heat Demand
Min. Return
Pump
90
70
50
30
10
Power
Heat Demand
Min. Return
Pump
90
70
50
30
10
%
%
WWSD
UnOcc. Switch
Max. or Setpoint
Boiler
of full
output
WWSD
UnOcc. Switch
Max. or Setpoint
Boiler
of full
output
Test
Test
Supply Sensor short circuit (see trouble­shooting notes)
Supply Sensor open circuit (see trouble­shooting notes)
Power
Heat Demand
Min. Return
Pump
Power
Heat Demand
Min. Return
Pump
WWSD
UnOcc. Switch
Max. or Setpoint
Boiler
Boiler Return Sensor short circuit
90
70
50
30
10
%
of full output
WWSD
UnOcc. Switch
Max. or Setpoint
Boiler
Test
(see trouble­shooting notes)
Boiler Return Sensor open circuit
90
70
50
30
10
%
of full output
Test
(see trouble­shooting notes)
Light on continuously
Light flashing
Light off
Power
Heat Demand
Min. Return
Pump
Power
Heat Demand
Min. Return
Pump
WWSD
UnOcc. Switch
Max. or Setpoint
Boiler
90
70
50
30
10
90
70
50
30
10
%
%
of full
output
WWSD
UnOcc. Switch
Max. or Setpoint
Boiler
of full
output
Test
Test
RTU short circuit (see trouble­shooting notes)
Power
Heat Demand
Min. Return
Pump
90
70
50
30
10
%
WWSD
UnOcc. Switch
Max. or Setpoint
Boiler
of full
output
Test
10K Indoor sensor short circuit (see trouble­shooting notes)
Power
Heat Demand
Min. Return
Pump
WWSD
UnOcc. Switch
Max. or Setpoint
Boiler
Enclosure Over­heated
Power
Heat Demand
Min. Return
Pump
(see
90
70
50
30
10
%
of full
output
Test
trouble­shooting notes)
90
70
50
30
10
Step Nine Before you leave
Install the wiring cover over the wiring chamber and secure it to the base with the two screws provided. Place the front cover on the control to cover the setting dials and snap it into place. Install a lock if security is required.
Place this brochure, and all other brochures relating to the installation, in the protective plastic bag supplied with the control. Place the bag in a conspicuous location near the control for future reference.
It is important to explain the operation and maintenance of this control and of the system to the end user and anyone else who may be operating the system.
Copyright © D 365 - 06/0015 of 16
%
WWSD
UnOcc. Switch
Max. or Setpoint
Boiler
of full
output
Test
Page 16
Specifications
Mixing Control 365
Literature Control — Microprocessor PID control; This is not a safety (limit) control. Packaged weight 3.3 lb. (1500 g), Enclosure A, blue PVC plastic
Variable Speed / 4 - 20 mA
D 365, A 365's, D 001, D 070, E 021.
Setpoint & UnOcc Min. Boiler Return Motor Speed
35 to 200°F (2 to 93°C)Off, 60 to 150°F (Off, 16 to 66°C)30 to 230 seconds
Dimensions — 6-5/8” H x 7-9/16” W x 2-13/16” D (170 x 193 x 72 mm) Approvals — CSA, UL listed, meets ICES & FCC regulations for EMI/RFI. Ambient conditions Indoor use only, 30 to 105°F (0 to 40°C), < 90% RH non-
condensing. Power — 120 V (ac) ±10% 50/60 Hz 300 VA System Pump 120 V (ac) 12 A 1/3 hp, pilot duty 480 VA 4 A Var. Pump 120 V (ac) 50/60 Hz 2.2 A 1/6 hp, internally fused Boiler Relay 120 V (ac) 10 A 1/4 hp, pilot duty 240 VA 2 A Demands — 24 to 120 V (ac) 2 VA Sensors included NTC thermistor, 10 k@ 77°F (25°C ±0.2°C) ß=3892
Outdoor Sensor 070 and Universal Sensor 071. Optional devices tekmar type #: 031, 071, 072, 073, 076, 077, 367, 368, 369.
Occupied Unoccupied Heating Curve Maximum Supply
35 to 105°F (2 to 41°C)35 to 105°F (2 to 41°C)0.4 to 3.6100 to 190°F, Off (38 to 88°C, Off)
70°F
(21°C)
35 (2)
Occupied
Mixing Control 365
Variable Speed and 4-20 mA
Use Nº 20 AWG or larger copper conductors rated for at least 75°C and 300V.
12 34 56
Heat
Dem
Dem Pmp
70°F
(21°C)
105
35
105
(2)
Unoccupied
Power N
L
Pmp
System
(41)
89
7
Var.
Pmp
Boiler
(41)
Power
Heat Demand
Min. Return
Pump
C US
158033
Setpoint
WWSD
UnOcc.
Reset
Switch
Max. or Setpoint
Boiler
90
70
of full
50
output
%
30
10
R
Test
Made in Canada by tekmar Control Systems Ltd.
Power: 120 V (ac) ±10% 50/60Hz 300VA
Listed
System pump: 120 V (ac) 12A 1/3 hp, pilot duty 480VA 4A
5T62
R
Var pump: 120 V 50/60 Hz 2.2A 1/6 hp, internally fused Relay: 120 V (ac) 10A 1/4 hp, pilot duty 240VA 2A
E150539
Enclosed Energy Management Equipment
1000 max
10 11
4-20
Com
+
2.0
0.4
Heating Curve
100°F
60
Minimum
Boiler Return
Do not apply power here
13 14
12 15
Ret
Com Com
UnO
Sen
Sen
Sen
Boiler on when 25% open External Heat Demand Zone Control
Indoor Sensor Permanent Heat Demand Boiler on when 10% open
150°F
3.6
100 200
Max./Setpoint
130 sec.
30 230Off
150
Motor Speed /
Pump Response
16 17
18 19
2K10K
Sup Out
SenSw
Sen
RTU
Sen
The installer must ensure that this control and its wiring are isolated and/or shielded from strong sources of electromagnetic noise. Conversely, this Class B digital apparatus complies with Part 15 of the FCC Rules and meets all requirements of the Canadian Interference-Causing Equipment Regulations. However, if this control does cause harmful interference to radio or television reception, which is determined by turning the control off and on, the user is encouraged to try to correct the interference by reorienting or relocating the receiving antenna, relocating the receiver with respect to this control, and/or connecting the control to a different circuit from that to which the receiver is connected.
Cet appareil numérique de la classe B respecte toutes les exigences du Règlement sur le matériel brouilleur du Canada.
Caution The nonmetallic enclosure does not provide grounding between conduit connections. Use grounding type bushings and jumper wires.
Attention Un boîtier nonmétallique nassure pas la continuité électrique des conduits. Utiliser des manchons ou des fils de accord spécialement conçus pour la mise á la terre.
H1073 2
Limited Warranty and Product Return Procedure
Limited Warranty The liability of tekmar Control Systems Ltd. and tekmar Control Systems, Inc. (“tekmar”) under this warranty is limited. The purchaser, by taking receipt of the tekmar product (“product”), acknowledges receipt of the terms of the warranty and acknowledges that it has read and understands same.
tekmar warrants each tekmar product against defects in workmanship and materi­als, if the product is installed and used in compliance with tekmar's instructions. The warranty period is for a period of twenty-four (24) months from the production date if the product is not installed during that period, or twelve (12) months from the documented date of installation if installed within twenty-four (24) months from the production date.
The liability of tekmar under this warranty shall be limited to, at tekmar's sole dis­cretion: the cost of parts and labor provided by tekmar to repair defects in materials and/or workmanship of the defective product; or to the exchange of the defective product for a replacement product; or to the granting of credit limited to the original cost of the defective product, and such repair, exchange or credit shall be the sole remedy available from tekmar, and, without limiting the foregoing in any way, tekmar is not responsible, in contract, tort or strict product liability, for any other losses, costs, expenses, inconveniences, or damages, whether direct, indi­rect, special, secondary, incidental or consequential, arising from ownership or use of the product, or from defects in workmanship or materials, including any liability for fundamental breach of contract.
This warranty applies only to those products returned to tekmar during the warranty period. This warranty does not cover the cost of the parts or labor to remove or transport the defective product, or to reinstall the repaired or
tekmar Control Systems Ltd., Canada
Control Systems
Product design, software and literature are Copyright © 2000 by: tekmar Control Systems Ltd. and tekmar Control Systems, Inc.
tekmar Control Systems, Inc., U.S.A.
Head Office: 5100 Silver Star Road Vernon, B.C. Canada V1B 3K4 Tel. (250) 545-7749 Fax. (250) 545-0650 Web Site: www.tekmarcontrols.com
16 of 16
replacement product. Returned products that are not defective are not cov­ered by this warranty.
This warranty does not apply if the product has been damaged by negligence by persons other than tekmar, accident, fire, Act of God, abuse or misuse; or has been damaged by modifications, alterations or attachments made sub­sequent to purchase which have not been authorized by tekmar; or if the product was not installed in compliance with tekmars instructions and the local codes and ordinances; or if due to defective installation of the product; or if the product was not used in compliance with tekmars instructions.
This warranty is in lieu of all other warranties, express or implied, which the Governing Law (being the law of British Columbia) allows parties to contrac­tually exclude, including, without limitation, warranties of merchantability, fitness for a particular purpose, durability or description of the product, its non-infringement of any relevant patents or trademarks, and its compliance with or non-violation of any applicable environmental, health or safety legis­lation; the term of any other warranty not hereby contractually excluded is limited such that it shall not extend beyond twenty-four (24) months from the production date, to the extent that such limitation is allowed by the Govern­ing Law.
Product Return Procedure Products that are believed to have defects in work-
manship or materials must be returned, together with a written description of the defect, to the tekmar representative for that territory. If the address of the repre­sentative is not known, please request it from tekmar at the telephone number listed below
.
All specifications are subject to change without notice.
Printed in Canada. D 365 - 06/00.
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