tekmar 402 Installation
Installation & Operation Manual
tekmarNet®2 House Control 402
Introduction
The House Control 402 is designed to operate as part of a
complete hydronic heating system with tekmarNet®2 (tN2)
thermostats. It can provide operation of two outdoor reset
water temperatures such as radiant floor heating on the first
temperature and baseboard or fan coil heating on the second
temperature. In addition the control has 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 402
HVAC Systems
Features
•
Single on-off, two-stage or modulating boiler
•
Boiler outdoor reset temperature
•
Mixing outdoor reset temperature
•
Domestic Hot Water tank operation
•
Setpoint operation
•
Mix with variable speed injection, floating action,
or proportional 0-10 V (dc), proportional 4-20 mA
•
For use with tekmarNet
Four 24 V (ac) powered zone valve outputs
•
Expand to 24 zones per temperature using
•
tekmarNet®4 expansion ports
CSA C US Certified for use in USA and Canada
•
®
2 Thermostats
Replaces: 01/10
09/10
VIEW
Calls
Pumps
Boil Exp Boil System
Menu
Item
House Control 402
Zones
1 2 3 4
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
Zone Synchronization reduces equipment cycling
•
Auto Differential - Reduces boiler cycling
•
Compact enclosure for flexible installation
•
Simple zone expansion using Wiring Centers
•
1 of 32 © 2010 D 402 - 09/10
Table of Contents
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Installation ...................................................................... 2
Preparation ................................................................ 2
Physical Dimensions ................................................. 3
Installation Location .................................................. 3
Rough-In Wiring ........................................................ 3
Sizing the Transformer .............................................. 4
Control Wiring ........................................................... 4
Sensor Wiring ............................................................ 7
Testing the Sensor Wiring ......................................... 9
Testing the Control Wiring ......................................... 9
Max Heat ..................................................................10
Applic ations .................................................................. 11
User Interface ............................................................... 13
Display......................................................................13
Symbols ...................................................................13
Navigating The Display ............................................14
Access Levels and Thermostat Lock ........................14
Programming and Settings .......................................14
View Menu ...............................................................15
Adjust Menu ........................................................16-18
Monitor Menu ...........................................................19
Toolbox Menu .......................................................... 20
Sequence of Operation ................................................21
tekmarNet
Mix Temperature Reset Operation ...........................21
Boiler Temperature Reset Operation ....................... 22
Domestic Hot Water Tank Operation ....................... 23
Setpoint Operation .................................................. 25
Boiler Operation ...................................................... 25
Domestic Hot Water Heat Source ............................27
Pump Operation .......................................................27
Energy Saving Features .......................................... 28
Trouble shooting ............................................................ 28
Error Messages .................................................. 28-30
Frequently Asked Questions .............................. 30-31
Job Record ...............................................................31
Technical Data ..............................................................32
Limited Warranty and Product Return Procedure ........32
®
System ..................................................21
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.
Tools Required
tekmar or jeweller screwdriver
•
Phillips head screwdriver
•
© 2010 D 402 - 09/10 2 of 32
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Needle-nose Pliers
•
Wire Stripper
•
Materials Required
-----------------------------------------------------------------------------------
--------------------------------------------------------------------------------------
-----------------------------------------------------------------------------------
(2) #10 x 1” Wood Screws
•
(3) Wire Nuts
•
18 AWG LVT Solid Wire (Low Voltage Connections)
•
-----------------------------------------------------------------------------------
14 AWG Solid Wire (Line Voltage Connections)
•
tekmar 009K (24 V (ac) transformer with 4” x 4” junction box)
•
Cable or Conduit Connectors
•
Power Required
120 V (ac), 1-phase, 15 A service from circuit breaker
• Power disconnect (optional)•
--------------------------------------------------------------------------------------
panel
Physical Dimensions
Side ViewCover Off Front View Back View
1/2” Knock-out (x 4)
Contro l designed to mo unt on 4” x 4”
elect rical box (not include d).
Electr ical box shown comes wit h 009K
tN2 C
ClsOpn
Floating Action
Boil Exp. Mix Exp.
tN4 tN4C C
+
Mod dc/mA
Stage 2Stage 1
Input Power
Use at least 167°F
(75°C) conductors
VlvC
RC
2–1/4”
(57 mm)
2–1/4”
(57 mm)
5–1/2”
(140 mm)
7/8”
(22 mm)
CL
Made in Canada
Mix ComBoil Out DHW
Com
Sensors - No Power
Setpoint DHW
Call Call
H8007B
1–1/8”
(30 mm)
tN2 tN2 tN2 tN2 tN2 tN2 tN2
Zone 1
Zone 2 Zone 3 Zone 4
Menu
Item
House Control 402
Zone 3Zone 1 Zone 2 Zone 4
VlvC VlvC VlvC
5–1/2”
(140 mm)
1/2” x 5/8”
(12 mm x 16 mm)
Knock-out (x 4)
Pump Power L
Speed Pump
∅1/ 8”
(3 mm)
Boil System Pump
DHW Pump
Variable
Mix System Pump
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.
-----------------------------------------------------------------------------------
Locate the control near pumps and/or zone valves if
•
possible.
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:
Circuit Breaker or Power Disconnect
•
Mix System Pump
•
Boiler System Pump
•
DHW Tank Pump (if applicable)
•
Variable Speed Injection Pump (if applicable)
•
3 of 32 © 2010 D 402 - 09/10
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Low Voltage Wiring
-----------------------------------------------------------------------------------
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
•
Zone Valves
•
Mixing Valve Actuator Proportional 0-10 V (dc)
•
Boiler Stage 1 T-T
•
-----------------------------------------------------------------------------------
Sizing the Transformer
The control requires an external transformer. A tekmar
Transformer 009 (or 009K which includes a 4”x 4” electrical
box) can supply up to 40 VA, and includes an in-line fuse
to protect the transformer and control.
In order to correctly size the external transformer, all loads
connected to the control must be taken into account.
When adding up the loads, consider the following:
tekmarNet®2 Thermostats draw approximately 2 VA each.
•
Each zone valve must be sized for peak load. This can
•
be obtained by multiplying the peak current draw (in
Amps) by 24 V (ac).
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
•
Mix Supply Temperature Sensor
•
DHW Tank Temperature Sensor (if applicable)
•
DHW Tank Aquastat (if applicable)
•
Setpoint Devices (if applicable)
•
Pull three conductor 18 AWG LVT cable for the following
equipment:
Mixing Valve Actuator Floating Action
•
tekmarNet®4 Accessories (User Switch, Timer)
•
If using a Floating Action mixing valve, add the VA
•
draw for the actuating motor. A tekmar Actuating Motor
741 draws 1.5 VA during normal operation.
The total power capacity of the power supply should be
larger than the total load of all the devices connected
to the control. This total load must not exceed 100 VA.
Multiple tekmar Transformer 009’s can be wired together
to increase total VA capacity.
The following chart is provided to simplify transformer
sizing:
Zone
Thermostat Load
Zone Valve Load
Total Zone Load
1234
Floating
Action (VA)
+ +++ +
Control
Load (VA)
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.
-----------------------------------------------------------------------------------
Wire the Pump Power (L)
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.
Transformer
must exceed:
2
VA
© 2010 D 402 - 09/10 4 of 32
Figure 1 - Connect
-------------------------------------------------------------------
Ground Wires
Variable Speed Pump
Figure 2 - Connect
Neutral Wires
Variable Speed Pump
Pump
Pump
DHW Pump
Pump
Boil System Pump
Figure 3 - Connect
Line Voltage (Hot)
V. S. Pump
DHW Pump
Boil Sys Pump
Mix System
Pump
Mix System
Pump
Power
Source
(L,N)
Pump
Power Source
(L,N)
402
Mix System Pump
Boil System Pump
DHW Pump
Strip wires
Variable
1/2 inch (13 mm).
Speed Pump
Installed wires are
not remov
able.
Pum
p Power L
12-18
AWG
Pump
DHW Pump
Boil System Pump
Figure 4 - Connect
Pump Line (Hot)
V. S. Pump
DHW Pump
Boil Sys Pump
Mix System
Pump
Pump
Pump
Power
Source
(L,N)
Mix System
Pump
Pump
402
Mix System Pump
Boil System Pump
DHW Pump
Variab le
Speed Pump
Pump Power L
Power Source
(L,N)
Strip wires
1/2 inch (13 mm).
Installed wires are
not removable.
12-18 AWG
Rear Line Voltage Wiring Diagram
N
G
L
N
115 V (ac)
-------------------------------------------------------------------
Back of House Control 402
Mix
(black)
Mix System Pump
Boil
(black)
Boil System Pump
DHW
(black)
DHW Pump
(red)
Pump Power L
L
Variable
Speed
to pump grounds
(blue)
Variable
Speed Pump
Strip wires
1/2 inch (13 mm).
Installed wires are
not removable.
12-18 AWG
5 of 32 © 2010 D 402 - 09/10
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Install The Enclosure
---------------------------------------------------------------------------------
Ensure that the pump wires are neatly tucked inside
•
---------------------------------------------------------------------------------
the electrical box.
Using 2 of the 4 holes in the back of the enclosure, se-
•
curely fasten it to the electrical junction box with 2 #10
screws as shown in Figure 5.
Figure 5
Low Voltage Wiring
-----------------------------------------------------------------------------------
External Power Supply
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 402.
tN2 Thermostats
The 402 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 402.
Zone Valves
Wire the zone valves to the C and Vlv terminals on the
•
402.
End switches on zone valves are not required when
•
using the 402.
tN4 Expansion Terminals
The 402 uses the Expansion tN4 and C terminals to
communicate with additional thermostats, setpoint controls,
and other tekmarNet® devices. There are two sets of tN4
and C terminals on the 402.
Boil Exp.
To add additional boiler water temperature zones (typically
baseboard or fan coil zones) to the system, install a
tekmarNet® Wiring Center.
Connect the tN4 and C Boil Exp. terminals on the 402
•
to the corresponding tN4 and C Expansion terminals
on the external Wiring Center.
Mix Exp.
The 402 has the capacity to expand the number of mixing
zones in the system beyond the four on board zones. To
add additional mix water temperature zones (typically
radiant floor zones) to the system, install a tekmarNet
Wiring Center.
Connect the tN4 and C Mix Exp. terminals on the 402
•
to the corresponding tN4 and C Expansion terminals
on the external Wiring Center.
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 402 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 402 to the
•
T-T (or R-W) terminals on the boiler.
If required, connect the Boiler Stage 2 terminals on the
•
402 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 402 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
402 to the T-T (or R-W) terminals on the boiler.
Floating Action Terminals
Applications that use a floating action mixing valve actuator
(tekmar type 741) will use the Floating Action Opn, Cls, and
C terminals. This is a powered output (24 V (ac)).
Wire the Opn, Cls, and C terminals on the 402 to the
•
open, close, and C terminals on the floating action
actuator.
Proportional Mixing (0-10 V (dc) or 4-20 mA)
®
Applications that use a proportional mixing valve actuator
will use the Mod (dc/mA) terminals. Proportional mixing can
only be used when a modulating boiler is not installed.
Wire the Mod positive (+) on the 402 to the positive (+)
•
terminal on the actuator.
Wire the Mod negative (-) on the 402 to the negative (-)
•
or common terminal on the actuator.
© 2010 D 402 - 09/10 6 of 32
R
C
L
N
Com
Open
Close
Expansion
tN4 Boil
CtN4
Modulating
Boiler
—+
Expansion
tN4 Mix
CtN4
2
1
WC
WC
Menu
House Control 402
Item
+
Mix ComBoil Out DHW
VlvC VlvC VlvC
Zone 3Zone 1 Zone 2 Zone 4
Made in Canada
VlvC
Com
Zone 1
H8007B
Zone 2 Zone 3 Zone 4
tN2 tN2 tN2 tN2 tN2 tN2 tN2 tN2
C
Floating Action
ClsOpn
Sensors - No Power
Call Call
tN4 tN4CC
Mod dc/mA Boil Exp. Mix Exp.
Setpoint DHW
Use at least 167°F
(75°C) conductors
RC
Input Power
Stage 2Stage 1
Front Low Voltage Wiring Diagram
-------------------------------------------------------------------
--------------------------------------------------------------------
tekmarNet
Mix Supply
Sensor 082
Outdoor
Sensor
070
Boiler Supply
Sensor 082
DHW Tank
Sensor 082
Setpoint Call
-------------------------------------------------------------------
®
2 Thermostats
24 V (ac) Floating
Action Actuator
tekmarNet®4
Expansion to
Wiring Centers,
Timers, or
User Switch
One or Two Stage
Boiler T-T
DHW Call
from DHW
Tank Aquastat
(optional)
Zone Valves
Sensor Wiring
Mounting the Outdoor Sensor 070
Note: The temperature sensor (thermistor) is built into the
070 enclosure.
Remove the screw and pull the front cover off the
•
sensor enclosure.
The 070 can either be mounted directly onto a wall or
•
a 2” x 4” electrical box. When the 070 is wall mounted,
the wiring should enter through the back or bottom of
the enclosure. Do not mount the 070 with the conduit
knockout facing upwards as rain could enter the enclosure and damage the sensor.
--------------------------------------------------------------------
24 V (ac) Transformer 009
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 070 should be mounted on a wall which best rep-
•
resents 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 070
should not be exposed to heat sources such as ventilation or window openings.
The 070 should be installed at an elevation above
•
the ground that will prevent accidental damage or
tampering.
Sensor with rear
entry wiring
Sensor with bottom
entry wiring
7 of 32 © 2010 D 402 - 09/10
Sensor mounted
onto 2" x 4"
electrical box
Wiring the Outdoor Sensor 070
-----------------------------------------------------------------------
-------------------------------------------------------------
Connect 18 AWG or similar wire to the two terminals
•
-----------------------------------------------------------------------
provided in the enclosure and run the wires from the
070 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
•
and connect the wires to the control.
Replace the front cover of the sensor enclosure.
•
Wires from outdoor
sensor to control
terminals
(Com Sen - Out Sen)
Sensor is built into
the enclosure
Mounting the Boiler and Mix Sensor 082
-------------------------------------------------------------
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 082 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 082 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.
Retaining Clip
Universal
Sensor 082
Universal
Sensor 082
Sensor Well
Bottom of
Enclosure 080
Cable Tie
© 2010 D 402 - 09/10 8 of 32
Testing the Sensor Wiring
------------------------------
-----------------------
--------------------------------------
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,
TemperatureResistanceTemperatureResistanceTemperatureResistanceTemperatureResistance
°F °C
-50 -46 490,813 20 -7 46,218 90 32 7,334 160 71 1,689
-45 -43 405,710 25 -4 39,913 95 35 6,532 165 74 1,538
-40 -40 336,606 30 -1 34,558 100 38 5,828 170 77 1,403
-35 -37 280,279 35 2 29,996 105 41 5,210 175 79 1,281
-30 -34 234,196 40 4 26,099 110 43 4,665 180 82 1,172
-25 -32 196,358 45 7 22,763 115 46 4,184 185 85 1,073
-20 -29 165,180 50 10 19,900 120 49 3,760 190 88 983
-15 -26 139,402 55 13 17,436 125 52 3,383 195 91 903
-10 -23 118,018 60 16 15,311 130 54 3,050 200 93 829
-5 -21 100,221 65 18 13,474 135 57 2,754 205 96 763
0 -18 85,362 70 21 11,883 140 60 2,490 210 99 703
5-15 72,918 7524 10,501 14563 2,255 215102 648
10 -12 62,465 80 27 9,299 150 66 2,045 220 104 598
15 -9 53,658 85 29 8,250 155 68 1,857 225 107 553
°F °C °F °C °F °C
Testing the Control Wiring
Testing the Power
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
The Mix 1 device ramps up to 100% over 30 seconds
or according to the motor speed setting.
Step 2
The Mix 1 device ramps down to 0% over 30 seconds
or according to the motor speed setting.
Step 3
Step 4
Step 5
Step 6
Step 7
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 mix system pump turns on for 10 seconds.
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Step 8
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Step 9
Step 10
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Step 11
Testing the Variable Speed Injection Pump
Activate the User Test sequence and pause at Step 1
by pressing the Item button once the injection pump is
operating at 100%. Using an electrical meter, measure the
voltage between the variable speed pump and a neutral.
The voltage should measure between 103.5 V (ac) and
126.5 V (ac).
Testing the Zone Output
Activate the User Test sequence and pause at Step 3 by
pressing the Item button once Zone 1 turns on. Using an
electrical meter, measure the voltage between the zone
valve and the common (C) terminals. The voltage should
measure between 21.6 V (ac) and 26.4 V (ac). Repeat for
Zones 2, 3, and 4.
Testing the Mix System Pump
Activate the User Test sequence and pause at Step 7 by
pressing the Item button once the mix system pump turns
on. Using an electrical meter, measure the voltage between
the mix system pump and a neutral. The voltage should
measure between 103.5 V (ac) and 126.5 V (ac).
The DHW pump turns on for 10 seconds.
The boiler system pump turns on for 10
seconds.
During the boiler test step, zone relays 1 through 4
turn on, the mix system pump turns on, and the boil
system pump turns on. The mixing device operates
up to 20%. This ensures there is a location for heat
to move when the boiler is turned on.
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).
Control returns to normal operation.
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Testing the DHW Pump
Activate the User Test sequence and pause at Step 8 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).
Testing the Boiler System Pump
Activate the User Test sequence and pause at Step 9 by
pressing the Item button once the boiler system pump turns
on. Using an electrical meter, measure the voltage between
the boiler system pump and a neutral. The voltage should
measure between 103.5 V (ac) and 126.5 V (ac).
Testing the Boiler Stage 1 Contact
Activate the User Test sequence and pause at Step 10 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.
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 10 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 10 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.
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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, purging air from the piping.
This feature 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
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run to maintain a target of Boil Design + 10°F (+ 6°C).
(One can purge the system using this test and leave
© 2010 D 402 - 09/10 10 of 32
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
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boiler will operate at the DHW exchange or Setpoint
temperature settings.
WWSD and DHW Priority is disabled during Max Heat
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mode.
When Max Heat is on the display will show ‘Max Heat
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Test ’.
Max Heat will automatically turn off after 24 hours.
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To Cancel Max Heat, go to Max Heat in the Toolbox menu
and use the down arrow to select ‘Off’.
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