tekmar 406 Installation

Installation & Operation Manual

tekmarNet®2 House Control 406

Introduction

The tN2 House Control 406 is designed to operate the equipment in a 2-pipe, single tank, hydronic heating and cooling system. It operates two heat pump stages (waterto-water or air-to-water) with a backup heat source (boiler or electric resistance). The heat pump provides either hot or chilled water to a storage tank loop and optional mixed temperature loop. For radiant heating, the water temperature is calculated using outdoor temperature reset. For radiant cooling, the chilled water temperature is maintained at an adjustable setpoint, or is adjusted using dew-point reset with a humidity sensor. A backup boiler can provide an outdoor reset water temperature as well as domestic hot water and setpoint water temperatures. The 406 operates 4 on-board heating and cooling zones and is expandable up to 52 zones total on the boiler, tank, and mix water temperatures.

406_D

11/12

Alternative

Energy

Features

•

One or two-stage heat pump control

•

Equal runtime rotation for two heat pumps

•

On/off or modulating boiler control

•

Tank, mix and boiler outdoor reset temperatures

•

Domestic hot water operation

•

Setpoint operation

•

Mixing with variable speed pump

•

For use with tekmarNet Four 24 V (ac) built in powered zone valve outputs

• Expand to 24 zones on t wo water temperatures using

• tekmarNet®4 expansion ports

CSA C US Certified for use in USA and Canada

•

2 Thermostats

Replaces: 12/11

Item

House Control 406

Beneﬁ ts

•

Energy efficiency through Outdoor Temperature Reset with Indoor Temperature Feedback

•

Indoor Temperature Feedback minimizes the water temperature (increasing energy savings), and the efficiency of your mechanical equipment through integrated tekmarNet

•

Zone Synchronization reduces equipment cycling

•

Auto Differential - Reduces boiler cycling Compact enclosure for flexible installation

• Simple zone expansion using Wiring Centers

•

Thermostats

Note

For hydronic cooling with a fancoil, use tekmarNet®2

• Thermostat 530 or tekmarNet®4 Thermostat 540 with a date code of December 2011 or newer.

For floor cooling, use tekmarNet®2 Thermostats 527, 528,

• 529, 530 or tekmarNet®4 Thermostats 537, 538, and 540 with a date code of December 2011 or newer.

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 .............................................8

Testing the Control Wiring ............................................. 9

Max Heat ..................................................................... 10

Applic ations ..................................................................... 11

User Interface ..................................................................21

Display ......................................................................... 21

Symbols ....................................................................... 21

Navigating The Display ...............................................21

Access Levels and Thermostat Lock ..........................22

Programming and Settings ..........................................22

View Menu .................................................................. 22

Adjust Menu ................................................................ 24

Monitor Menu ..............................................................29

Toolbox Menu ............................................................. 31

Sequence of Operation ...................................................32

tekmarNet

System Setup ..............................................................32

Heat Cool Operation .................................................... 34

Hydronic Operation .....................................................35

Heat Pump Operation ..................................................36

DHW Operation ...........................................................37

Boiler Operation ..........................................................39

Setpoint Operation ...................................................... 41

Mixing Operation ......................................................... 42

Pump Operation ..........................................................42

Troub leshooting ............................................................... 43

Error Messages ..........................................................43

Frequently Asked Questions .......................................46

Job Record .................................................................. 47

Technical Data .................................................................48

Limited Warranty and Product Return Procedure ...........48

System .....................................................32

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 instruc-

tion 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

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

Preparation

Tools Requi r e d

tekmar or jeweller screwdriver

• Phillips head screwdriver

•

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safety limits must be placed into 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.

the control off and on, the user is encouraged to try 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.

Needle-nose Pliers

• Wire Stripper

•

Materials Required

(2) #10 x 1” Wood Screws

• (5) Wire Nuts

• 18 AWG LVT Solid Wire (Low Voltage Connections)

• 14 AWG Solid Wire (Line Voltage Connections)

•

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tekmar 009K (24 V (ac) transformer with 4” x 4” junction box)

• 4” x 4” Extension Ring for Electrical Junction Box

• Cable or Conduit Connectors

•

Power Required

----------------------------------------------------------------------------------------

------------------------------------------------------------------------------------

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• Power disconnect (optional)•

115 V (ac), 1-phase, 15 A service from circuit breaker panel

----------------------------------------------------------------------------------------

(potentially up to two circuits)

Physical Dimensions

Front View Side View

1/2” Knock-out (x 4)

5–1/2”

(140 mm)

(22 mm)

7/8”

Mix/DHW

No Power

Tank ComBoil HPRt OutCom

Sensors - No Power

Setpoint DHW

Call Call

H8009B

VlvC VlvC VlvC

1–1/8” (30 mm)

tN2 tN2 tN2 tN2 tN2 tN2 tN2 tN2

Zone 1

Zone 2 Zone 3 Zone 4

Item

House Control 406

Zone 3Zone 1 Zone 2 Zone 4

Input Power

VlvC

5–1/2”

(140 mm)

Rc1 Y1 O/B

tN4 tN4CC

Mod dc/mA Boil / Mix Tank

Backup

Rc2 Y2

2–1/4”

(57 mm)

4–1/2” (114 mm)

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.

Locate the control near pumps and/or zone valves if possible.

•

Control designed to mount on 4” x 4” electrical box (not included). For systems that require 2 power sources of 115 V (ac), a box extension ring is required to increase box fill capacity.

1/2” x 5/8”

(12 mm x 16 mm)

Knock-out (x 4)

•

Provide easy access for wiring, viewing and adjusting the

Back View

Ø 1/8”

(3 mm)

7/8” x 1/2” (23 mm x 12 mm)

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.

•

Install the extension ring onto the electrical junction box. Total box volume must be 38 cubic inches (623 cm greater to comply with National Electrical Code (NEC) or Canadian Electrical Code (CEC).

Knock-out (x 4)

) or

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.

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).

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

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Pull a three conductor 14 AWG cable for the following equipment:

•

Circuit Breaker or Power Disconnect

•

Variable Speed Pump (if applicable) HP Loop Pump

• Boiler System Pump (if applicable)

• Tank System Pump (if applicable)

• Mix System Pump (if applicable)

• DHW Pump (if applicable)

• Transfer (Xfr) Pump (if applicable)

•

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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.

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Pull two conductor 18 AWG LVT cable, up to 500 feet (150 m) for the following equipment:

tekmarNet®2 Thermostats

• Heat Pump Compressor Stage 1

• Heat Pump Compressor Stage 2 (if applicable)

• Heat Pump Reversing Valve (O or B)

• Modulating Boiler 0-10 V (dc) or 4-20 mA (if applicable)

• On/Off Boiler or Backup Heat Source (if applicable)

•

Sizing the Transformer

Outdoor Temperature Sensor

• HP Return Temperature Sensor

• Tank Supply Temperature Sensor

• Boiler Supply Temperature Sensor (if applicable)

• Mix Supply Temperature Sensor (if applicable)

• DHW Tank Temperature Sensor (if applicable)

• DHW Tank Aquastat (if applicable)

• Setpoint Device (if applicable)

•

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

• Each zone valve must be sized for peak load. This can be

•

2 Thermostats draw approximately 2 VA each.

This chart is provided to

simplify transformer sizing:

Zone Thermostat Load Zone Valve Load

Total Zone Load

1234

obtained by multiplying the peak current draw (in Amps) by 24 V (ac).

•

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.

+++

Control Wiring

Line Voltage Wiring

CAUTION: TURN ALL POWER OFF BEFORE PERFORMING ANY WIRING.

Ensure Junction Box Extension Ring is Installed

•

An extension ring must be installed on the 4” x 4” junction box when 6 or more powered outputs for the pumps are used on the rear of the control.

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

•

If the combined pump power load is less than 12 A, then a only a single 15 A circuit is required.

•

If the combined pump power load exceeds 12 A, then two separate 15 A circuits are required.

Each power circuit requires it’s own neutral wire.

• Connect the Neutral (N) wires from each pump and wire to

•

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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 and Figure 3.

Wire the Pump Power (L)

If the combined pump power load is less than 12 A, then a

• only a single 15 A circuit is required.

If the combined pump power load exceeds 12 A, then two

• separate 15 A circuits are required.

•

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 4.

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 5 and 6.

Control

Load (VA)

Transformer

must exceed:

Figure 1 - Connect Ground Wires Figure 2 - Connect Neutral Wires

Tank System Pump

for Power Source 1

Boil System Pump

HP Loop Pump

Variable

Speed Pump

Power

Source 1

Power

Source 2

Mix System

DHW Pump

Transfer Pum

Boil System

Pump

HP Loop

Pump

Variable

Speed Pump

Tank System Pump

Power

Source 1

Figure 3 - Connect Neutral Wires

----------------------------

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for Power Source 2

Power

Source 2

Mix System Pump

DHW Pump

Transfer Pump

Figure 5 - System Pumps (Left)

Tank System Pump

Boil System

Pump

HP Loop

Pump

Variable

Speed Pump

Figure 4 - Line Voltage

Power

Source 1

Power

Source 2

Rear Line Voltage Wiring Diagram

Tank Sy s

Boil Sys

HP Sys

(black)

(red)

Figure 6 - System Pumps (Right)

Mix Syste Pump

DHW Pump

Transfer Pump

----------------------------------------------------------------------

Back of House Control 406

Boil Sys Pump

HP Loop Pump

Pump Power (L)

Mix Sys PumpTank Sys Pump

DHW Pump

Transfer Pump

Pump Power (L)

(black)

(red)

Mix Sys

DHW

Transfer

(blue)

Variable

Speed

to pump grounds

N1L1 G

115 V (ac)

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, securely

• fasten it to the junction box extension ring with 2 #10 screws

----------------------------

Variable Speed Pump

to pump grounds

N2GL2

115 V (ac)

Figure 7

as shown in Figure 7.

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Front Low Voltage Wiring Diagram

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tekmarNet

2 Thermostats

Mix Supply / DHW

Universal

Sensor

Tank S u p p l y

Universal Sensor

Boiler Supply

Universal Sensor

HP Return

Universal Sensor

Outdoor Sensor

Setpoint Call

DHW Call

from DHW

Tank A q u a s t at

(optional)

Mix/DHW

tN2 tN2 tN2 tN2 tN2 tN2 tN2 tN2

No Power

Zone 1

Tank ComBoil HPRt OutCom

Call Call

H8009B

Sensors - No Power

Setpoint DHW

VlvC VlvC VlvC

Zone 2 Zone 3 Zone 4

Item

House Control 406

Zone 3Zone 1 Zone 2 Zone 4

24 V (ac) Zone Valves

VlvC

Input Power

tN2tN2tN2tN2tN2tN2tN2tN2

Rc1 Y1 O/B

tN4 tN4CC

Mod dc/mA Boil / Mix Tank

Backup

Rc2 Y2

tekmarNet

4 Expansion to

Wiring Centers, Timers, or

User Switch

CtN4

tN4 Tank

Expansion

CtN4

tN4 Boil/Mix

Expansion

—+

Modulating

Boiler

One Stage

Boiler T-T

One or Two Stage

Heat Pump

L N

Low Voltage Wiring

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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 406.

tekmarNet®2 Thermostats (tN2)

The 406 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 cor-

• responding tN2 terminals for each zone on the 406.

Zone Valves

Wire the zone valves to the C and Vlv terminals on the 406.

• End switches on zone valves are not required when using

• the 406.

tN4 Expansion Terminals

The 406 uses the Expansion tN4 and C terminals to communicate with additional thermostats, setpoint controls, and other tekmarNet® devices. Connect to either the Tank or the Boil / Mix tN4 and C terminals on the 406.

24 V (ac) Transformer 009

Tank

To add additional Tank water temperature zones to the system, install a tekmarNet® Wiring Center.

Connect the Tank terminals, tN4 and C, on the 406 to the

• corresponding tN4 and C Expansion terminals on the external Wiring Center.

Boil / Mix

To add additional Boil or Mix water temperature zones to the

system, install a tekmarNet

•

Connect the Boil/Mix terminals, tN4 and C, on the 406 to

Wiring Center.

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 switch to the DHW call terminals.

•

To create a Setpoint call, wire a dry contact switch to the Setpoint call terminals.

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Wiring the Heat Pump

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The 406 can operate a single heat pump with a two-stage compressor in heating or cooling mode.

Connect the Rc1 and Y1 terminals on the 406 to the R and

• Y1 terminals on the heat pump.

Connect the Rc2 and Y2 terminals on the 406 to the R and

• Y2 terminals on the heat pump.

•

Connect the Rc1 and O/B terminal on the 406 to the R and O or B terminal on the heat pump.

Wiring the Auxiliary Backup

The 406 can operate an auxiliary backup other than a boiler.

Use the Backup terminals on the 406 to switch on the aux-

• iliary backup (ie electric element).

Sensor Wiring

On/Off Boiler

Connect the Backup terminals on the 406 to the T-T (or R-

• W) terminals on the boiler.

Modulating Boiler

Wire the Mod (dc/mA) positive (+) and negative (-) terminals

• on the 406 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 Backup terminals on the 406 to the T-T (or RW) terminals on the boiler.

Mounting the Outdoor Sensor

--------------------------------------------------------------------------

Note: The temperature sensor (thermistor) is built into the sensor enclosure.

•

Remove the screw and pull the front cover off the sensor enclosure.

•

The outdoor sensor can either be mounted directly onto a wall or a 2” x 4” electrical box. When the outdoor sensor is wall mounted, the wiring should enter through the back or bottom of the enclosure. Do not mount the outdoor sensor with the conduit knockout facing upwards as rain could enter the enclosure and damage the sensor.

Sensor with rear entry wiring

•

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 outdoor sensor should not be exposed to heat sources such as ventilation or window openings.

•

The outdoor sensor should be installed at an elevation above the ground that will prevent accidental damage or tampering.

Sensor with bottom entry wiring

Sensor mounted onto 2" x 4" electrical box

Wiring the Outdoor Sensor

•

Connect 18 AWG or similar wire to the two terminals provided in the enclosure and run the wires from the outdoor 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

-----------------------------------------------------------------------------

Wires from outdoor

sensor to control

(Com Sen - Out Sen)

terminals

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.

•

Sensor is built into

the enclosure

Mounting the Universal Sensor

-------------------------------------------------------------------------

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.

Retaining

Clip

Universal

Sensor

Sensor Well

Universal

Sensor

Bottom of

Enclosure 080

Cable Tie

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 control while the test is performed. Using the chart below, estimate

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 28 0, 279 35 2 29,99 6 105 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 -26 139,403 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 2,75 4 205 9 6 763 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 62,4 65 80 27 9,29 9 150 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

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.

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 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 i

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.

----------------------------------------

-------------------------------

------------------------

V (dc) for 20 seconds, then there is an

s correct.

User Test Sequence

Step 1 Step 2 Step 3 Step 4 Step 5

Step 6

Step 7 Step 8 Step 9 Step 10

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 1 device ramps up to 100% over 30 seconds

or according to the motor speed setting. The Mix 1 device ramps down to 0% over 30 seconds

or according to the motor speed setting. The mix system pump turns on for 10 seconds. The tank system pump turns on for 10 seconds. The O/B contacts are closed for 10 seconds. The HP loop pump turns on for 10 seconds.

Step 11

Step 12

Step 13

Step 14

Step 15

Step 16

Step 17

Step 18

•

Step 19

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 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 Variable Speed Pump

Activate the User Test sequence and pause at Step 5 or Step 15 by pressing the Item button once the variable speed 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 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).

Testing the Tank System Pump

Activate the User Test sequence and pause at Step 8 by pressing the Item button once the tank system pump turns on. Using an electrical meter, measure the voltage between the tank system pump and a neutral. The voltage should measure between 103.5 V (ac) and 126.5 V (ac).

Testing the O/B Contact

Activate the User Test sequence and pause at Step 9 by pressing the Item button once the O/B contact turns on. Using an electrical meter, measure for continuity between the O/B and Rc1 terminals.

The HP loop pump turns on and the Y1 contacts are closed for 10 seconds

The HP loop pump turns on and the Y2 contacts are closed for 10 seconds if HP TYPE = ROT.

The HP loop pump turns on and the Y1 and Y2 contacts are closed for 10 seconds if HP TYPE = 2STG.

The Backup contacts are closed for 10 seconds if BACKUP = AUX.

The transfer pump turns on for 10 seconds if BACKUP = XFER.

The variable speed pump turns on for 10 seconds if BACKUP = VAR.

The DHW pump turns on for 10 seconds if WATERTEMP = T+B or T+MB and DHW Mode ≠ OFF.

The boil system pump turns on for 10 seconds if WATERTEMP = T+B or T+MB.

If WATERTEMP = T+B or T+MB The boil system pump turns on, and the tN2 zones, transfer pump, variable speed pump (20%), and tank pump turn on if necessary.

If the Boil Type is 1 Stage, the backup relay is closed for 10 seconds and then opened.

If Boiler Type is modulating 0-10 or 4-20, the backup relay is closed for 10 seconds and the modulating output operates at 50 % [5 V (dc) or 12 mA].

Control returns to normal operation.

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Testing the HP Loop Pump

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---------------------

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-----------------

------------

----------------------------

------------------------

Activate the User Test sequence and pause at Step 10 by pressing the Item button once the HP Loop pump turns on. Using an electrical meter, measure the voltage between the HP Loop pump and a neutral. The voltage should measure between 103.5 V (ac) and 126.5 V (ac).

Testing the Heat Pump Stage 1 Contact

Activate the User Test sequence and pause at Step 11 by pressing the Item button once the Y1 contact turns on. Using an electrical meter, measure for continuity between the Y1 and Rc1 terminals.

Testing the Heat Pump Stage 2 Contact

Activate the User Test sequence and pause at Step 12 by pressing the Item button once the Y2 contact turns on. Using an electrical meter, measure for continuity between the Y2 and Rc2 terminals.

Testing the Backup Contact

Activate the User Test sequence and pause at Step 13 or Step 18 by pressing the Item button once the boiler stage 1 turns on. Using an electrical meter, measure for continuity over the Backup terminals.

Testing the Transfer Pump

Activate the User Test sequence and pause at Step 14 by pressing the Item button once the Transfer pump turns on. Using an electrical meter, measure the voltage between the Transfer pump and a neutral. The voltage should measure between 103.5 V (ac) and 126.5 V (ac).

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Testi ng the DHW Pump

Activate the User Test sequence and pause at Step 16 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 17 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 Modulating Output

This test applies for modulating boilers only. Active the User Test sequence and pause at Step 18 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.

Testi ng the DHW C all

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

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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.

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 heat pump and

• backup will run to maintain the target at the Design temperature. (One can purge the system using this test and leave the heat pump and backup 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 are disabled during Max Heat

• mode.

Cooling 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’.

Applications

Mechanical A406-1

Description: The House Control 406 operates a two stage air source heat pump in heating or cooling mode to supply an

outdoor reset water temperature to 4 on board tank temperature zones. Additional zones can be added using the Tank tN4 and C Expansion terminals. Domestic Hot Water pre-heat is achieved by maintaining the DHW sensor S5 in the preheat storage tank at an adjustable temperature, 90°F (32°C) default, using the DHW pump P6. The heat pump will target a water temperature 20°F (11°C) higher than the preheat tank target at the return sensor S2, and is limited by the HP RETURN MAX setting in the Adjust Menu. An electric element in the system storage tank is switched on through an isolation relay with the backup relay on the 406 to provide backup heat to maintain the Tank Sensor S4 at its target temperature.

Tank zones can have fan-coils, air handling units, chilled beams, or chilled panels as their terminal units depending on the type of tekmarNet® thermostat selected.

Legend

P2 HP Loop Pump

P4 Tank System Pump

P6 DHW Pump

S1 Outdoor Sensor

S2 HP Return Sensor

S4 Tank Sensor

S5 DHW Sensor

Preheat

Storage Tank

Application Settings

WATER TEMP T (tank)

BACKUP AUX (auxiliary)

HP LOOP INT (intermittent)

HP TYPE 2STG (2-stage)

DHW MODE 5 (DHW preheat)

406

tekmarNet

DHW Out

2 Thermostats

Cold In

Coaxial

Heat Exchanger

Two S tag e Air to Water Heat Pump

Freeze

Protection

Device

Electric

Elem

Bac

ent

kup

Electric

Wat

Heater

Expansion

Ta nk

Z1 Z2 Z3 Z4

Electrical A406-1

tekmarNet®2 Thermostats

DHW Sensor (S5)

Tank S ens o r (S 4)

Heat Pump

Return Sensor (S2)

Outdoor

Sensor

(S1)

Tank ComBoil HPRt OutCom

Call Call

H8009B

tN2 tN2 tN2 tN2 tN2 tN2 tN2 tN2

Mix/DHW

No Power

Zone 1

Sensors - No Power

Setpoint DHW

VlvC VlvC VlvC

Zone 2 Zone 3 Zone 4

Item

House Control 406

Zone 3Zone 1 Zone 2 Zone 4

VlvC

Input Power

tN2tN2tN2tN2tN2tN2tN2tN2

Rc1 Y1 O/B

tN4 tN4CC

Boil / Mix Tank

Mod dc/mA

Backup

Rc2 Y2

240 V (ac)

Electric Element

Stor. Tank

Element

003 Relay

Y2 OY1R

A1 A2

Two S tag e

Air to Water

Heat Pump

5 4

NLG

115 V (ac)

(P4)

(P2)

(Z1) (Z2) (Z3) (Z4)

Tank S y s

(black)

HP Sys

(black)

to pump grounds

(red)

(blue)

Back of House Control 406

Mix Sys PumpTank Sys Pump

Boil Sys Pump

HP Loop Pmp

Pump Power (L)

Variable Speed Pump

DHW Pump

Transfer Pump

Pump Power (L)

24 V (ac)

Tran s for m e r 00 9

(black)

(red)

to pump grounds

DHW

(P6)

NGL

115 V (ac)

Mechanical A406-2

Description: The House Control 406 operates two air source heat pumps in heating or cooling mode to supply an outdoor reset

water temperature to 4 on board mix temperature zones and 4 tank zones connected to the Tank expansion terminals with a Wiring Center 314. An electric boiler supplies backup heat using the Backup relay and the Transfer Pump P7.

By setting HP LOOP to ON, the HP Loop Pump P2 will operate whenever there is a call on the tank or mix bus, or when the transfer pump is on to ensure flow through the storage tank while heating or cooling.

Mixing is useful to separate the hot and cold water temperatures required for fancoils from the warm and cool temperatures required for radiant floor heating and cooling. The Variable Speed Pump P1 is able to mix the water temperature down for heating or mix the water temperature up above the dewpoint for floor cooling.

Legend

P1 Variable Speed Pump

P2 HP Loop Pump

P5 Mix System Pump

P7 Transfer Pump

S1 Outdoor Sensor

S2 HP Return Sensor

S3 Boiler Sensor

S4 Tank Sensor

S5 Mix Sensor

Application Settings

WATER TEMP T+MB (tank + mix + boiler)

ZONES 1-4 MIX

BACKUP XFER (transfer pump)

BOIL TYPE 1STG (1 stage)

HP LOOP ON

HP TYPE ROT (rotate)

DHW MODE OFF

314

406

tekmarNet®2 ThermostatstekmarNet®2 Thermostats

Backup:

Electric Boiler

Z5 Z6 Z7 Z8

Coaxial

2 Air to Water

Heat Pumps

Heat Exchanger

Freeze

Protection

Device

2-Port

Storage tank

Expansion

Tan k

Z1 Z2 Z 3 Z4

S5S4

Electrical A406-2

Two

Air to Water

tekmarNet

2 Thermostats

Heat Pumps

Mix Sensor (S5)

Tank S ens o r (S 4)

Boiler Sensor (S4)

Heat Pump Return

Sensor (S2)

Outdoor

Sensor

(S1)

tN2 tN2 tN2 tN2 tN2 tN2 tN2 tN2

Mix/DHW

No Power

Zone 1

Tank ComBoil HPRt OutCom

Call Call

H8009B

Sensors - No Power

Setpoint DHW

VlvC VlvC VlvC

Zone 2 Zone 3 Zone 4

Item

House Control 406

Zone 3Zone 1 Zone 2 Zone 4

(Z1) (Z2) (Z3) (Z4)

Back of House Control 406

VlvC

Input Power

tN2tN2tN2tN2tN2tN2tN2tN2

Rc1 Y1 O/B

tN4 tN4CC

Boil / Mix Tank

Mod dc/mA

Backup

Rc2 Y2

Tran s for m er 00 9

24 V (ac)

OCYR

CtN4

tN4 Tank

Expansion

Electric Boiler

Backup

OCYR

8 1

003 Relay

5 4

314

Mix Sys PumpTank Sys Pump

DHW Pump

Transfer Pump

Pump Power (L)

(P2)

HP Sys

(black)

(red)

Boil Sys Pump

HP Loop Pmp

Pump Power (L)

(blue)

(P1)

Variable

Speed

to pump grounds

Variable Speed Pump

N1L1 G

115 V (ac)

(black)

Mix Sys

(black)

Transfer

(red)

to pump grounds

(P5)

(P7)

N2GL2

115 V (ac)

Mechanical A406-3

Description: The House Control 406 operates a water source heat pump in heating or cooling mode to supply an outdoor reset

water temperature to 4 on board tank temperature zones. The 406 also operates a modulating condensing boiler to supply an outdoor reset water temperature to 4 boiler zones connected to the Boil expansion terminals with a Wiring Center 313. The boiler supplies backup heat to the tank loop using the transfer pump P7.

To allow the heat pump to operate for some amount of time before the transfer pump starts adding heat to the storage tank, use the backup delay setting in the adjust menu. This ensures the heat pump is being used to its full potential before backup is allowed. Placing the Transfer Pump P7 on the upstream side of the storage tank allows for hot water temperatures from the boiler loop to be buffered by the storage tank to prevent sending hot water out to the tank temperature zones.

Tank zones can have fan-coils, air handling units, chilled beams, or chilled panels as their terminal units depending on the type of tekmarNet® thermostat selected.

Legend

Application Settings

P2 HP Loop Pump

P3 Boiler System Pump

P4 Tank System Pump

P6 DHW Pump

P7 Transfer Pump

S1 Outdoor Sensor

S2 HP Return Sensor

S3 Boiler Sensor

S4 Tank Sensor

S5 DHW Sensor

tekmarNet®2 Thermostats

DHW

Backup: Mod-Con Boiler

Setpoint

313

Z5 Z6 Z7 Z8

WATER TEMP T+B (tank + boiler)

ZONES 1-4 TANK

BACKUP XFER (transfer pump)

BOIL TYPE 0-10

HP LOOP INT

HP TYPE 1STG

DHW MODE 2

406

tekmarNet®2 Thermostats

Z1 Z2 Z3 Z4

Water-to Water

Heat Pump

Geo Field

Expansion

Tan k

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