tekmar 422 User Manual

- Data Brochure

•

Universal Reset Module 422

D 422

08/07

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Introduction

The Universal Reset Module 422 provides outdoor reset to a hydronic heating system in order to maximize comfort and efficiency. The 422 can operate a single on / off boiler or a single modulating boiler. The 422 can override the outdoor reset water temperature to provide Domestic Hot Water or Setpoint operations. The 422 can operate two outdoor reset water temperatures, either one boiler water temperature and a single mix water temperature, or two mix water temperatures. To operate two mixing devices, a Mixing Expansion Module must be connected to the 422. The single mix output can operate a floating action mixing valve or a variable speed injection pump.

Features:

• tN4 Compatible

• Two Outdoor Reset Temperatures

• Single On-Off or Modulating Boiler

• Powered Pump Outputs

• DHW Operation

• Variable Speed Injection Pump

• Floating Action Valve

• Includes Sensors

Boiler DHW Setpoint C C2 tN4 C Com Boil Mix Com Out+Opn Cls

H7008B

Var. Pump Fuse

Demand Demand 24 V (ac) Boil/Mix2 R R Mod (dc)

52 53 54 55 56 57 58 59 60 61 62 63 64 65

tN4 Boiler / Mix 2 Boil Sens Sup / Ret Boiler On-Oﬀ / Mod Oﬀ / tekmar Stager Oﬀ / Flushing

Meets Class B: Canadian ICES & FCC Part 15 Made in Canada

Test

T2.5 A 250 V

71 72 73 74

DHW Variable Speed

Pump Pump

Item

2.5 A

Floating Output:

24 V (ac) 8 VA

Powered OutputOutput 1 VA

Universal Reset Module 422

–

66 67 68 69 70

Do not apply power

tektra 991-03

Var. Pump: 115 V (ac) 2.5 A Demands: 20 - 260 V (ac) Relay Rating: 115 V (ac) 5 A

75 76 77 78

Primary Mix Sys P1

Pump NPump

tN4

10 A max.

Table of Contents

•

tN4 Boiler / Mix 2 Boil Sens Sup / Ret Boiler On-Oﬀ / Mod Oﬀ / tekmar Stager Oﬀ / Flushing

Table of Contents ...........................................................2

Display and DIP Switches ..............................................2

Dip Switch Settings ................................................2

Access Level ...........................................................3

Display and Symbols Description............................4

User Interface ........................................................5

Display Menus ................................................................6

View Menu ..............................................................6

Adjust Menu ............................................................8

Miscellaneous Menu .............................................13

Testing the Control ....................................................... 14

Sequence of Operation ................................................. 16

tekmarNet

4 Communication ...............................16

Outdoor Reset ...................................................... 16

Boiler Temperature Control .................................. 19

tekmar Stager Operation ......................................21

Boil Enable ............................................................22

Direct Fired - DHW Tank as a Heat Source .........22

Zone Load Shedding ............................................22

Mixing Operation ..................................................22

Domestic Hot Water Temperature Operation .......23

DHW with Low Temperature Boilers .....................25

Setpoint Temperature Operation ...........................25

Pump Operation ....................................................27

Pump Exercising ................................................... 27

Error Messages ............................................................28

Troubleshooting ............................................................ 31

Warranty .......................................................................32

Display and DIP Switches

Dip Switch Settings

Set the DIP switch settings prior to making adjustments to the control through the user interface. Setting the DIP switches determines which menu items are displayed in the user interface.

If you change a DIP switch setting while the control is powered up, the LCD display returns to the View menu.

Lock / Unlock

Use the Lock / Unlock DIP switch to lock and unlock the Access Level of the 422 and all connected tN4 devices, including tN4 thermostats. For details, see “Access Levels”

• Once locked, the access level in all devices cannot be viewed or changed.

• To determine if the control is currently locked a small segment representing a padlock is viewed in the bottom right hand corner of the display.

• To unlock the Access Level, set the DIP switch to Unlock.

• To lock the Access Level, set the DIP switch to Lock.

Boiler DHW Setpoint C C2 tN4 C Com Boil Mix Com Out+Opn Cls

Demand Demand 24 V (ac) Boil/Mix2 R R Mod (dc)

52 53 54 55 56 57 58 59 60 61 62 63 64 65

H7008B

tN4 Boiler / Mix 2 Boil Sens Sup / Ret Boiler On-Oﬀ / Mod Oﬀ / tekmar Stager Oﬀ / Flushing

Meets Class B: Canadian ICES & FCC Part 15 Made in Canada

Test

Var. Pump Fuse

T2.5 A 250 V

Item

71 72 73 74

DHW Variable Speed

Pump Pump

Floating Output:

24 V (ac) 8 VA

Universal Reset Module 422

2.5 A

Powered OutputOutput 1 VA

–

66 67 68 69 70

Do not apply power

tektra 991-03

Var. Pump: 115 V (ac) 2.5 A Demands: 20 - 260 V (ac) Relay Rating: 115 V (ac) 5 A

75 76 77 78

Primary Mix Sys P1

Pump NPump

tN4

10 A max.

tN4 Boiler / Mix 2

•

Off / Flushing

Use the tN4 Boiler / Mix 2 DIP switch to select whether the second tN4 bus (terminals 59-60) is to operate as a boiler water temperature or as a second mixing water temperature.

• If set to Boiler, this creates a system with one boiler and one mix water temperature.

• If set to Mix 2, this creates a system with two mix water temperatures. If Mix 2 is selected, a mixing expansion module must be connected to the Boiler / Mix 2 bus.

Boiler Sup / Ret

Use the Boiler Sensor Supply / Return DIP switch to select the location of the boiler sensor.

• If the boiler sensor is located on the supply, this DIP switch should be set to Sup. The 422 is the control that determines the boiler water temperature. Set the boiler’s aquastat at least 20°F (11.0°C) higher than the Boiler Maximum setting.

• If the 422 provides a heat demand to an external boiler control, this DIP switch must be set to Ret. Install the boiler sensor on the return side of the boiler loop. The boiler’s operating temperature is controlled by its aquastat, or an external boiler reset control.

The Off / Flushing DIP switch selects whether the control operates a Flushing feature. Heating systems that use potable water require periodic flushing to prevent the water from stagnating.

The flushing operation occurs if any zone has not operated for 7 days. All zones, mixing device(s), and applicable system pumps are turned on for 4 minutes.

• To activate the Flushing feature, set to Flushing.

• To deactivate the Flushing feature, set to Off.

tekmar Stager / Off

Use the tekmar Stager / Off DIP switch when a tekmar staging control is be connected to the 422 in order to operate multiple boilers. A tekmar stager may include Boiler Controls 264, 265, and 268.

• If a tekmar Stager is installed, set to tekmar Stager. The 422 will then provide the stager with a target temperature via a 0-10 V (dc) signal. When the tekmar Stager / Off DIP switch is set to tekmar Stager, the Boiler Sensor DIP switch must be set to Sup.

• If a tekmar Stager is not installed, set to Off.

Boil On-Off / Mod

The Boil On-Off / Mod DIP switch selects whether the control operates an On-Off boiler or the firing rate of a Modulating boiler.

• If set to Boil On-Off, the control operates an On-Off boiler.

• If set to Mod, the control operates a Modulating boiler.

Access Level

The Access Level restricts the number of Menus, Items, and Adjustments that can be accessed by the user. The Access Level setting is found in the Miscellaneous (MISC) menu. Select the appropriate access level for the people who work with the control on a regular basis.

There are two Access Level settings:

• Installer (InS): This is the factory default setting. This access level is sufficient for the normal set up of the control.

• Advanced (Ad): All of the control settings are available to the user.

In the following menu tables, the access level the item is visible in is shown in the access column.

Display

Symbols Description S

Menu Field

Displays the

current menu

Status Field

Displays the current

status of the control’s

inputs, outputs and

operation. Most symbols

in the status field are only visible when the

VIEW Menu is selected

Symbols Description

PUMP

Displays when the primary or mixing pump is in operation.

Item Field

Displays an abbreviated name of the selected item

Number Field

Displays the current value of the selected item

BOILER DEMAND

Displays when a boiler demand is present.

BURNER

Displays when the burner contact is closed.

LOCK

Displays when the access levels are locked.

WARNING

Displays when an error exists.

COMMUNICATION BUS

Displays when tN4 thermostats are connected.

DHW PUMP

Displays when the DHW Pump is in operation.

°F, °C, %, HOURS, MINUTES

Units of measurement.

MIX 1 DEMAND

Displays when a mix 1 demand is present.

MIX 2 DEMAND

Displays when a mix 2 demand is present.

DHW DEMAND

Displays when a DHW demand is present.

SETPOINT DEMAND

Displays when a Setpoint demand is present.

DEVICE OUTPUT SCALE

Displays output of the modulating boiler, injection pump, or mixing valve.

OPEN / CLOSE

Displays whether the actuator is opening or closing the mixing valve.

User Interface

•

Use the User Interface available on the Liquid Crystal Display (LCD) to setup and monitor the operation of the system. Use the four push buttons to the left of the LCD (Menu, Item, Up, Down) to select settings. As you enter settings, record the settings in the Job Record J 422.

The menus display in the Menu Field at the top left side of the LCD. Three menus are available: View, Adjust, and Miscellaneous.

• To select a menu, press and release the Menu button.

Item

In each menu, a group of items can be selected. The abbreviated name of the selected item displays in the Item field of the LCD display.

• To view the next available item, press and release the Item button.

• To view the previous item, hold down the Item button. and press and release the Up button.

Adjusting a Setting

To adjust a setting:

1. Select the appropriate menu using the Menu button.

2. Select the item using the Item button.

3. Use the Up or Down button to make the adjustment.

Default Item

• To set the default item in the View menu, display the

item for more than five seconds.

After navigating menus, the display reverts back to the default item after 60 seconds of button inactivity.

Back to View Menu

Continue to next Item

Display Menus

View Menu (1 of 2)

Item Field Range Access Description

The View menu items display the current operating temperatures and status information of the system.

VIEW MENU

-76 to 149°F

(-60.0 to 65.0°C)

-22 to 266°F

(-30.0 to 130.0°C)

– – –, 35 to 230°F

(– – –, 1.5 to 110.0°C)

-22 to 266°F

(-30.0 to 130.0°C)

– – –, 35 to 230°F

(– – –, 1.5 to 110.0°C)

InS

OUTDOOR SECTION B

Current outdoor air temperature as measured by the outdoor sensor.

MIX 1 SUPPLY SECTION B

Current Mix 1 supply water temperature as measured by the Mix 1 supply sensor.

MIX 1 TARGET SECTION C

The Mix 1 target is the temperature the control is currently trying to maintain at the Mix 1 supply sensor. “– – –” is displayed when no heat is required for Mix 1 zones.

MIX 2 SUPPLY SECTION B

Current Mix 2 supply water temperature as measured by the Mix 2 supply sensor.

Note: This item is only available when the tN4 DIP switch is set to Mix 2.

MIX 2 TARGET SECTION C

The mix 2 target is the temperature the control is currently trying to maintain at the Mix 2 supply sensor. “– – –” is displayed when no heat is required for mix 2 zones.

Note: This item is only available when the tN4 DIP switch is set to Mix 2.

-22 to 266°F

(-30.0 to 130.0°C)

Continued on next page.

InS

BOILER SUPPLY SECTION C

Current boiler supply water temperature as measured by the boiler sensor.

Note: This item is only available when the Boiler Sensor Sup / Ret DIP switch is set to Sup.

View Menu (2 of 2)

Item Field Range Access Description

VIEW MENU

– – –, 35 to 230°F

(– – –, 1.5 to 110.0°C)

-22 to 266°F

(-30.0 to 130.0°C)

0-100% Ad

0 to 9999 hr

InS

BOILER TARGET

The boiler target is the temperature the control is currently trying to maintain at the boiler supply sensor. “– – –” is displayed when no heat is required for boiler zones.

Note: This item is only available when the Boiler Sensor Sup / Ret DIP switch is set to Sup.

BOILER RETURN SECTION G

Current boiler return water temperature as measured by the boiler sensor.

Note: This item is only available when the Boiler Sensor Sup / Ret DIP switch is set to Ret.

BOILER MODULATION SECTION C

Current percent modulation of the boiler’s burner. Note: This item is only available when the Boiler

On-Off / Mod DIP switch is set to Mod, and the Boiler Sensor Sup / Ret DIP switch is set to Sup.

BOILER

The total running time of the boiler since this item was last cleared. To clear this item, press the Up and Down buttons simultaneously while viewing this item.

Note: This item is only available when the Boiler Sensor Sup / Ret DIP switch is set to Sup.

SECTION C

After the last item, the control returns to the first item in the menu.

Adjust Menu (1 of 5)

The Adjust Menu items are the programmable settings used to operate the mechanical equipment.

Item Field

Range

-60 to 45°F

(-51.0 to 7.0°C)

Default = 10°F

(-12.0°C)

VAr, FLt

Default = VAr

1 HRF1 2 HRF2 3 Fancoil 4 Fin-tube Convector 5 Radiator 6 Baseboard

Default = 1

40 to 100°F

(4.5 to 38.0°C)

Default = 70°F (21.0°C)

Access Description

OUTDOOR DESIGN

InS

The design outdoor air temperature used in the heat loss calculations for the heating system. Typically set to the temperature of the coldest day of the year.

MIX 1 MODE SECTION G

Select the type of mixing device to be used for Mix 1. Options are variable speed injection pump (VAr) or floating action (FLt).

MIX 1 TERMINAL SECTION B

The type of heating terminal units that are being used in Mix 1 zones.

MIX 1 INDOOR SECTION B

The design indoor air temperature used in the heat loss calculation for Mix 1 zones. Typically set to 70°F (21.0°C).

SECTION B

ADJUST MENU

70 to 220°F

(21.0 to 104.5°C)

Default = 120°F

(49.0°C)

OFF, 40 to 150°F

(OFF, 4.5 to 65.5°C)

Default = OFF

80 to 220°F, OFF

(26.5 to 104.5°C, OFF)

Default = 140°F

(60.0°C)

Continued on next page.

InS

MIX 1 DESIGN SECTION B

The supply water temperature required for the Mix 1 zones on the typical coldest day of the year.

MIX 1 MINIMUM SECTION G

The minimum allowed Mix 1 target temperature.

MIX 1 MAXIMUM SECTION G

The maximum allowed Mix 1 target temperature.

Adjust Menu (2 of 5)

Item Field

Range

30 to 230 seconds

Default = 105

1 HRF1 2 HRF2 3 Fancoil 4 Fin-tube Convector 5 Radiator 6 Baseboard

Default = 1

40 to 100°F

(4.5 to 38.0°C)

Default = 70°F (21.0°C)

70 to 220°F

(21.0 to 104.5°C)

Default = 120°F

(49.0°C)

Access Description

MIX 1 MOTOR SECTION G

The time that the Mix 1 actuating motor requires to

InS

operate from fully closed to fully open. Note: This item is only available when the Mix 1

Mode setting is set to floating action (FLt).

MIX 2 TERMINAL SECTION B

The type of heating terminal units that are being used in mix 2 zones.

Note: This item is only available when the tN4 DIP switch is set to Mix 2.

MIX 2 INDOOR SECTION B

The design indoor air temperature used in the heat loss calculation for mix 2 zones. Typically set to 70°F (21.0°C).

Note: This item is only available when the tN4 DIP switch is set to Mix 2.

MIX 2 DESIGN SECTION B

The supply water temperature required for the mix 2 zones on the typical coldest day of the year.

Note: This item is only available when the tN4 DIP switch is set to Mix 2.

ADJUST MENU

OFF, 40 to 150°F

(OFF, 4.5 to 65.5°C)

Default = OFF

80 to 220°F

(26.5 to 104.5°C)

Default = 140°F

(60.0°C)

30 to 230 seconds

Default = 105

1 HRF1 2 HRF2 3 Fancoil 4 Fin-tube Convector 5 Radiator 6 Baseboard

Default = 4

InS

MIX 2 MINIMUM SECTION G

The minimum allowed mix 2 target temperature. Note: This item is only available when the tN4 DIP

switch is set to Mix 2.

MIX 2 MAXIMUM SECTION G

The maximum allowed mix 2 target temperature. Note: This item is only available when the tN4 DIP

switch is set to Mix 2.

MIX 2 MOTOR SECTION G

The time that the mix 2 actuating motor requires to operate from fully closed to fully open.

Note: This item is only available when the tN4 DIP switch is set to Mix 2. Availability also depends on the type of mixing module being used.

BOILER TERMINAL SECTION B

The type of heating terminal units that are being used in boiler zones.

Note: This item is only available when the Boiler Sensor Sup / Ret DIP switch is set to Sup and the tN4 DIP switch is set to Boiler.

Continued on next page.

Adjust Menu (3 of 5)

Item Field

Range

40 to 100°F

(4.5 to 38.0°C)

Default = 70°F

(21.0°C)

70 to 220°F

(21.0 to 104.5°C)

Default = 180°F

(82.0°C)

OFF, 80 to 180°F

(OFF, 26.5 to 82.0°C)

Default = 140°F

(60.0°C)

120 to 225°F, OFF

(49.0 to 107.0°C, OFF)

Default = 200°F

(93.5°C)

Access Description

BOILER INDOOR

The design indoor air temperature used in the heat loss calculation for the boiler zones. Typically set to

InS

70°F (21.0°C). Note: This item is only available when the Boiler

Sensor Sup / Ret DIP switch is set to Sup and the tN4 DIP switch is set to Boiler.

BOILER DESIGN SECTION B

The supply water temperature required for boiler zones on the typical coldest day of the year.

Note: This item is only available when the Boiler Sensor Sup / Ret DIP switch is set to Sup and the tN4 DIP switch is set to Boiler.

BOILER MINIMUM SECTION C

The minimum allowed boiler target temperature and boiler return protection temperature. Check the boiler manufacturer’s manual for recommend supply water temperatures.

BOILER MAXIMUM SECTION C

The maximum allowed boiler target temperature. Note: This item is only available when the Boiler

Sensor Sup / Ret DIP switch is set to Sup and the tekmar stager DIP switch is set to OFF.

SECTION B

ADJUST MENU

0:00 to 3:00 min

Default = 0:10 min

Au, 2 to 42°F

(Au, 1 to 23.5°C)

Default = Au

10 to 230 seconds

Default = 30 seconds

FIRE DELAY SECTION C

The time delay the control can expect between the time that the relay contact closes to fire the boiler and when the burner actually fires.

Note: This item is only available when the Boiler Sensor Sup / Ret DIP switch is set to Sup and the tekmar stager DIP switch is set to OFF.

BOILER DIFFERENTIAL SECTION C

The temperature differential that the control is to use when it is operating the boiler.

Note: This item is only available when the Boiler Sensor Sup / Ret DIP switch is set to Sup and the tekmar stager DIP switch is set to OFF.

BOILER MOTOR SECTION C

The amount of time required for the modulating actuating motor to fully open the gas valve or operate the fan speed from a stopped position to full speed on a modulating boiler.

Note: This item is only available when the Boiler Sensor Sup / Ret DIP switch is set to Sup, the Boiler On-Off / Mod DIP switch is set to Mod and the tekmar stager DIP switch is set to OFF.

Continued on next page.

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