The House Control 401 is designed to operate as part of a
complete hydronic heating system with tekmarNet®2 (tN2)
thermostats. It can provide operation of a single outdoor
reset water temperature, Domestic Hot Water and Setpoint
capabilities. It is easy to add more zones, add schedules
or other convenient accessories through the use of the
tekmarNet®4 (tN4) Expansion terminals.
D 401
07/11
HVAC Systems
Features
•
Single on-off, two-stage or modulating boiler
•
Boiler outdoor reset temperature
•
Domestic Hot Water tank operation
•
Setpoint operation
•
For use with tekmarNet
Four 115 V (ac) powered zone pump outputs
•
Expand to 24 zones using tekmarNet®4 expansion
•
ports
CSA C US Certified for use in USA and Canada
•
®
2 Thermostats
Replaces: 09/10
VIEW
Calls
Boil
Menu
Pumps
Zones
1 2 3 4
Item
House Control 401
Benefi ts
Energy efficiency through Outdoor Temperature
•
Reset with Indoor Feedback
Indoor Feedback minimizes the water temperature
•
(increasing energy savings), and the efficiency of
your mechanical equipment through integrated
tekmarNet® Thermostats
Job Record ...............................................................27
Technical Data ..............................................................28
Limited Warranty and Product Return Procedure ........28
®
System ..................................................19
Getting Started
®
Congratulations on the purchase of your new tekmarNet
This manual covers the complete installation, programming and sequence of operation for this control. You will also find
instruction on testing, commissioning, and troubleshooting the control and system that it operates.
House Control!
Installation
Caution
Improper installation and operation of this control could
result in damage to the equipment and possibly even
personal injury or death. It is your responsibility to ensure
that this control is safely installed according to all applicable
codes and standards. This electronic control is not intended
for use as a primary limit control. Other controls that are
intended and certified as safety limits must be placed into
Radio Frequency Interference
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
Preparation
the control circuit. Do not attempt to service the control.
Refer to qualified personnel for servicing. There are no
user serviceable parts. Attempting to do so voids warranty
and could result in damage to the equipment and possibly
even personal injury or death.
to correct the interference by re-orientating 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.
Contro l designed to mo unt on 4” x 4” electr ical
box (not included). Electrical box shown
comes with tekm ar 009K
1/2” x 5/8”
(12 mm x 16 mm)
Knock-out (x 4)
Ø 1/8” (3 mm)
wires are not removable.
Strip wires 1/2 inch
(13 mm). Installed
12-18 AWG
401
DHW Pump
Zone 4
Pump Power
Zone 3
Zone 2
Zone 1
7/8” x 1/2” (23 mm x 12 mm)
Knock-out (x 4)
Installation Location
When choosing the location for the control, consider the
•
following:
Keep dry. Avoid potential leakage onto the control.
•
RH 90% to 104°F (40°C).
Non-condensing environment.
Do not expose to operating temperatures beyond 32-
•
104°F (0-40°C)
Provide adequate ventilation.
•
Keep away from equipment, appliances or other
•
sources of electrical interference.
Rough-In Wiring
Line Voltage Wiring
The control operates a number of pumps through wiring
on the back of the control. The control must be mounted
to a 4” x 4” electrical junction box so that these electrical
connections are safely contained.
For ease of service, the circuit breaker or power disconnect
should be located in reasonably close proximity to the
equipment.
All line voltage wire connections are recommended to
be pulled inside a flexible or solid conduit. Always follow
proper wiring practices, building and electrical codes for
your jurisdiction.
•
Provide easy access for wiring, viewing and adjusting
•
the control.
Mount approximately 5 ft. (1.5 m) off the finished floor.
•
Install the electrical junction box to a wall using #10
•
x 1” wood screws. Wall anchors are recommended
when mounting to sheet rock wallboard or masonry.
Each cable must be pulled from the equipment to the
electrical junction box. It is recommended to label each
cable for easy identification. All line voltage wires should
be stripped to a length of 1/2” (13 mm).
Pull a three conductor 14 AWG cable for the following
equipment:
Each cable must be pulled from the equipment to the
control’s plastic enclosure. All low voltage wiring connections
enter the enclosure through conduit knockouts on the
sides, or through the square knockouts on the rear. It is
recommended to label each cable for easy identification.
All low voltage wires are to be stripped to a length of 3/8”
(9 mm) to ensure proper connection to the control.
Pull two conductor 18 AWG LVT cable, up to 500 feet
(150 m) for the following equipment:
tekmarNet®2 Thermostats
•
Boiler Stage 1 T-T
•
Sizing the Transformer
Boiler Stage 2 T-T (if applicable)
•
Modulating Boiler 0-10 V (dc) or 4-20 mA (if applicable)
•
Outdoor Temperature Sensor
•
Boiler Supply Temperature Sensor
•
DHW Tank Temperature Sensor (if applicable)
•
DHW Tank Aquastat (if applicable)
•
Setpoint Device (if applicable)
•
Pull three conductor 18 AWG LVT cable for the following
equipment:
tekmarNet®4 Accessories (User Switch, Timer)
•
The control requires an external transformer with 20 VA
capacity or greater. A tekmar Transformer 009 (or 009K
VA, and includes an in-line fuse to protect the transformer
and control.
which includes a 4” x 4” electrical box) can supply up to 40
Control Wiring
Line Voltage Wiring
CAUTION: TURN ALL POWER OFF BEFORE PERFORMING ANY WIRING.
Ground the Pumps
Connect the pump grounds to the power supply
•
ground as shown in Figure 1. The ground wire must
also be grounded to the electrical box.
Wire the Pump Neutrals
Connect the Neutral (N) wires from each pump and wire
•
to the 115 V (ac) Neutral (N) wire. If the transformer has
been mounted to this electrical box, connect its neutral
wire with this group. This is shown in Figure 2.
Connect the 115 V (ac) line voltage (L) wire to the red
•
Pump Power (L) wire on the back of the House Control
and to the 115 V (ac) side of the transformer. Use a
wire nut or approved connector. See Figure 3.
Wire the Pumps
Wire each remaining line voltage pump wire into the
•
push-in wire connector of the corresponding pump
lead on the back of the House Control. This is shown
in Figure 4.
It is strongly recommended that a transformer with an in-line
fuse be used in order to protect the transformer from high
currents. The tekmar Transformer 009 includes a fuse.
Connect the 24 V (ac) leads from the transformer to the
•
C and R terminals marked “Input Power” on the 401.
tN2 Thermostats
The 401 is designed to operate with tekmarNet®2 Thermostats.
They provide the heating and cooling control for each zone,
and communicate with any other tekmarNet® device on
the system.
•
Connect the tN2 terminals from each thermostat to the
corresponding tN2 terminals for each zone on the 401.
tN4 Boiler Expansion Terminals
The 401 uses the Expansion tN4 and C terminals to
communicate with additional thermostats, setpoint controls,
wiring centers, and other tekmarNet® devices.
Connect the tN4 and C Boil Exp. terminals on the 401
•
to the corresponding tN4 and C Expansion terminals
of the additional external device.
Domestic Hot Water (DHW) or Setpoint Call
When the control receives a DHW Call or Setpoint Call for
heat it will override Outdoor Reset and Indoor Feedback
and operate the boiler to heat the DHW tank or the Setpoint
equipment.
To create a DHW call, wire a dry contact OR apply 24
•
V (ac) to the DHW call terminals.
To create a Setpoint call, wire a dry contact OR apply
•
24 V (ac) to the Setpoint call terminals.
Wiring the Boiler
The 401 can operate a single modulating boiler, single
on-off, or a single two-stage on-off boiler.
On/Off Boiler
Connect the Boiler Stage 1 terminals on the 401 to the
•
T-T (or R-W) terminals on the boiler.
If required, connect the Boiler Stage 2 terminals on the
•
401 to the second stage T-T (or R-W) terminals on the
boiler.
Modulating Boiler
Wire the Mod (dc/mA) positive (+) and negative (-) ter-
•
minals on the 401 to the input signal terminals on the
boiler. Correct polarity of the wires is important.
In some cases, the modulating boiler also requires
•
contact closure on the T-T terminals to fire the boiler. If
required, connect the Boiler Stage 1 terminals on the
401 to the T-T (or R-W) terminals on the boiler.
Note: The temperature sensor (thermistor) is built into the
sensor enclosure.
Remove the screw and pull the front cover off the
•
enclosure.
The sensor can either be mounted directly onto a
•
wall or a 2” x 4” electrical box. When the senor is wall
mounted, the wiring should enter through the back
or bottom of the enclosure. Do not mount the sensor
with the conduit knockout facing upwards as rain could
enter the enclosure and damage the sensor.
In order to prevent heat transmitted through the wall
•
from affecting the sensor reading, it may be necessary
to install an insulating barrier behind the enclosure.
The Outdoor Sensor should be mounted on a wall
•
which best represents the heat load on the building (a
northern wall for most buildings and a southern facing
wall for buildings with large south facing glass areas).
The sensor should not be exposed to heat sources
such as ventilation or window openings.
The sensor should be installed at an elevation above
•
the ground that will prevent accidental damage or
tampering.
provided in the enclosure and run the wires from the
sensor to the control. Do not run the wires parallel to
telephone or power cables. If the sensor wires are located in an area with strong sources of electromagnetic interference (EMI), shielded cable or twisted pair
should be used or the wires can be run in a grounded
metal conduit. If using shielded cable, the shield wire
should be connected to the Com or Com Sen terminal
on the control and not to earth ground.
Follow the sensor testing instructions in this brochure
Note: These sensors are designed to mount on a pipe or
in a temperature immersion well.
The Universal Sensor should be placed downstream of a
pump or after an elbow or similar fitting. This is especially
important if large diameter pipes are used as the thermal
stratification within the pipe can result in erroneous sensor
readings. Proper sensor location requires that the fluid
is thoroughly mixed within the pipe before it reaches the
sensor.
Strapped to Pipe
The Universal Sensor can be strapped directly to the pipe
using the cable tie provided. Insulation should be placed
around the sensor to reduce the effect of air currents on
the sensor measurement.
Immersion Well
If a Universal Sensor is mounted onto 1” (25 mm) diameter
L type copper pipe, there is approximately an 8 second
delay between a sudden change in water temperature and
the time the sensor measures the temperature change.
This delay increases considerably when mild steel (black
iron) pipe is used. In general, it is recommended that
a temperature well be used for steel pipe of diameter
greater than 1-1/4” (32 mm). Temperature wells are also
recommended when large diameter pipes are used and
fluid stratification is present.
Conduit Connection
The Universal Sensor and Universal Sensor Enclosure
080 (sold separately) are specifically designed to mount
onto a 3/8” (10 mm) ID temperature well that is supplied
with an end groove. To install the well, plumb a ‘T’ into the
pipe and fix the well into the ‘T’. The 080 enclosure has
a 7/8” (22 mm) back knockout that must be removed and
fitted over the temperature well. The Universal Sensor is
then inserted into the well and the retaining clip supplied
with the enclosure is snapped onto the well end groove.
If the well has a threaded end, the installer must supply a
standard threaded conduit retaining ring. The two wires from
the sensor are connected to the terminal block provided in
the enclosure. The other side of the terminal block is used
to connect wires from the control.
A good quality test meter capable of measuring up to 5,000
kΩ (1 kΩ = 1000 Ω) is required to measure the sensor
resistance. In addition to this, the actual temperature must
be measured with either a good quality digital thermometer,
or if a thermometer is not available, a second sensor can
be placed alongside the one to be tested and the readings
compared.
First measure the temperature using the thermometer and
then measure the resistance of the sensor at the control.
The wires from the sensor must not be connected to the
estimate the temperature measured by the sensor. The
sensor and thermometer readings should be close. If the
test meter reads a very high resistance, there may be a
broken wire, a poor wiring connection or a defective sensor.
If the resistance is very low, the wiring may be shorted,
there may be moisture in the sensor or the sensor may
be defective. To test for a defective sensor, measure the
resistance directly at the sensor location.
Do not apply voltage to a sensor at any time as damage
to the sensor may result.
control while the test is performed. Using the chart below,
If the control display does not turn on, check the Input
Power wiring terminals using an electrical multimeter.
The voltage should measure between 21.6 to 26.4 V
(ac). If the voltage is below this range, measure the
line voltage side of the transformer. The voltage should
measure between 103.5 to 126.5 V (ac).
Testing the Thermostats
If the thermostat display turns on, this indicates that
the thermostat is operating correctly and there are no
electrical issues. In the event that the display is off, or
the display is cycling on and off, follow this procedure.
1. Remove the tN2 wires from the thermostat.
2. Use an electrical meter to measure DC voltage between
the tN2 terminals.
If the DC voltage is 0 V (dc) for 20 seconds, then there is
an open or short circuit in the tN2 wires. If the DC voltage
is 0 V (dc) for 10 seconds and then is 23 to 24 V (dc) for 5
seconds, this indicates the wiring is correct.
3. Connect the thermostat to the tN2 wires from a zone
on a House Control, Wiring Center, or Zone Manager.
4. If the thermostat display is off, or is cycling on and off,
move the thermostat to the next available zone on the
House Control, Wiring Center, or Zone Manager.
If the thermostat display remains permanently on, there
may be a fault with the previously tried zone on the House
Control, Wiring Center, or Zone Manager.
------------------------------
-----------------------
If the thermostat display continues to be off, or is cycling
on and off, there may be a fault on the thermostat.
If a fault is suspected, contact your tekmar sales
representative for assistance.
User Test
--------------------------------------
The User Test is found in the Toolbox menu of the control.
Press the Menu button to access the Toolbox Menu. Press
the Item button to locate the User Test.
Start the test sequence by going to the User Test item and
pressing the ‘Up’ arrow button.
Pause the test sequence by pressing the Item button. To
advance to the next step, press the Item button again.
If the test sequence is paused for more than five minutes,
the control exits the entire test routine and returns to normal
operation.
To advance to a particular step, repeatedly press and
release the Item button to display the appropriate device.
User Test Sequence
Step 1
Step 2
Step 3
Step 4
Step 5
Step 6
Zone 1 turns on for 10 seconds.
Zone 2 turns on for 10 seconds.
Zone 3 turns on for 10 seconds.
Zone 4 turns on for 10 seconds.
The DHW pump turns on for 10 seconds.
During the boiler test step, zone relays 1 through
If the Boil Type is 1 Stage, the boiler stage 1 relay is
----------------------
-----------------------
-------------
-------------
----------
--------------------------
----------------------
•
closed for 10 seconds and then opened.
If the Boil Type is 2 Stage, the boiler stage 1 relay is
•
closed for 10 seconds, then the boiler stage 2 relay is
closed for 10 seconds and then both relays are opened.
If Boiler Type is modulating 0 - 10, the boiler stage
•
1 relay is closed for 10 seconds and the modulating
output operates at 50 % [5 V (dc)].
If Boiler Type is modulating 4 - 20, the boiler stage
•
1 relay is closed for 10 seconds and the modulating
output operates at 50 % (12 mA).
Step 7
Testing the Zone Output
Activate the User Test sequence and pause at Step 1 by
pressing the Item button once Zone 1 turns on. Using an
electrical meter, measure the voltage between the zone
1 pump and terminals. The voltage should measure
between 103.5 V (ac) and 126.5 V (ac). Repeat for Zones
2, 3, and 4.
Testing the DHW Pump
Activate the User Test sequence and pause at Step 5 by
pressing the Item button once the DHW pump turns on.
Using an electrical meter, measure the voltage between
the DHW pump and a neutral. The voltage should measure
between 103.5 V (ac) and 126.5 V (ac).
Control returns to normal operation.
----------------------
-----------------------
Testing the Boiler Stage 2 Contact
This test applies for 2 stage on-off boilers only.
Activate the User Test sequence and pause at Step 6 by
pressing the Item button once the boiler stage 2 turns on.
Using an electrical meter, measure for continuity over the
boiler stage 2 terminals.
Testing the Boiler Modulating Output
This test applies for modulating boilers only.
Active the User Test sequence and pause at Step 6 by
pressing the Item button once the boiler stage 1 turns on.
Using an electrical meter, measure for either a 5 V (dc) or
12 mA signal. The Boil Type setting selects whether the
signal is V (dc) or mA.
Testing the DHW Call
Remove all wires from the DHW Call terminals. The control
display should show no DHW Call. Reconnect wires. Then
apply either a short circuit or 24 V (ac) over the DHW Call
terminals. The control should now show a DHW Call.
Testing the Setpoint Call
Remove all wires from the Setpoint Call terminals. The
control display should show no Setpoint Call. Reconnect
wires. Then apply either a short circuit or 24 V (ac) over
the Setpoint Call terminals. The control should now show
a Setpoint Call.
--------------------------
----------------------
-------------
----------
Testing the Boiler Stage 1 Contact
Activate the User Test sequence and pause at Step 6 by
pressing the Item button once the boiler stage 1 turns on.
Using an electrical meter, measure for continuity over the
boiler stage 1 terminals.
-------------
Max Heat
The control has a function called Max Heat. In this mode,
the control turns on and operates the system up to the
maximum set temperatures as long as there is a call for
heat. Use this mode to run the circulators during system
start-up and commissioning, and purging air from the piping.
This function is useful when drying sheet rock and paint
in the building.
To enable Max Heat, enter the Toolbox Menu and find Max
Heat. Use the up arrow to select ‘On’.
When a space heating call is present, the boiler will
•
run to maintain a target of Boil Design + 10°F (+ 6°C).
(One can purge the system using this test and leave
the boiler un-powered. This will prevent heat from entering the system during the purge.)
When a DHW Call or Setpoint Call is present, the
•
boiler will operate at the DHW exchange or Setpoint
temperature settings.
WWSD and DHW Priority is disabled during Max Heat
•
mode.
When Max Heat is on the display will show ‘Max Heat
•
Test ’.
Max Heat will automatically turn off after 24 hours.
•
To Cancel Max Heat, go to Max Heat in the Toolbox menu
and use the down arrow to select ‘Off’.