tekmar 422 User Manual

- Data Brochure

D422

Universal Reset Module 422

08/07

1

Information

2

Application

3

Rough-in

4

Wiring

5

Data

6

Job

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Wiring

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Record

Choose controls

Design your

Rough-in

Wiring and

Control settings

Record settings &

to match

mechanical

wiring

installation of

and sequence of

wiring details for

application

applications

instructions

specific control

operation

future reference

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	•	DHW Operation
• Two Outdoor Reset Temperatures		• Variable Speed Injection Pump
• Single On-Off or Modulating Boiler		•	Floating Action Valve
•	Powered Pump Outputs	•	Includes Sensors

Boiler

DHW

Setpoint

Demand Demand

51 52 53 54 55 56

H7008B

/

tN4 Boiler / Mix 2

Boil Sens Sup / Ret

Boiler On-O / Mod

O / tekmar Stager

O / Flushing

Meets Class B: Canadian

ICES & FCC Part 15

Made in Canada

C

R

C2

tN4

C

Opn

Cls

+

–

Com Boil

Mix

Com Out

24 V (ac)			Boil/Mix2			Floating Output:	R		R	Mod (dc)
57		58	59		60	24 V (ac) 8 VA	61 62		63	64		65	66	67 68 69 70
Output 1 VA							Powered Output					Do not apply power
						Universal Reset Module 422								tN4

Menu

Item

tektra 991-03

Var. Pump: 115 V (ac) 2.5 A

Demands: 20 - 260 V (ac)

Relay Rating: 115 V (ac) 5 A

Test

2.5 A

10 A

71

72

73

74

75

76

77

78

max.

DHW

Variable Speed

Primary

Mix Sys P1

Pump

N

Pump

N

Pump

N

Pump

N

Var. Pump Fuse

T2.5 A 250 V

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Table of Contents

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.

/
tN4 Boiler / Mix 2
Boil Sens Sup / Ret
Boiler On-O / Mod
O / tekmar Stager	Setpoint	C	R	C2	tN4
O / Flushing	56	57	58	59	60
	Demand	24 V (ac)		Boil/Mix2
		Output 1 VA
H7008B		Menu
		Item
tN4 Boiler / Mix 2
/
Boil Sens Sup / Ret
Boiler On-O / Mod
O / tekmar Stager
O / Flushing
Meets Class B: Canadian
ICES & FCC Part 15
Made in Canada
Test	71	72	73	74	2.5 A
	DHW		Variable Speed
	Pump	N	Pump	N

Var. Pump Fuse

T2.5 A 250 V

	C	Opn	Cls		+	–	Com Boil		Mix Com		Out
Floating Output:		R		R	Mod (dc)
24 V (ac) 8 VA 61		62	63		64	65	66 67 68 69 70
Powered Output						Do not apply power
Universal Reset Module 422									tN4
						tektra 991-03
						Var. Pump: 115 V (ac) 2.5 A
						Demands: 20 - 260 V (ac)
						Relay Rating: 115 V (ac) 5 A
											10 A
					75	76	77		78		max.
					Primary			Mix Sys P1
				Pump		N		Pump	N

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tN4 Boiler / Mix 2

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.

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.

Off / Flushing

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.

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.

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SymbolsDisplay 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

Item Field

Displays an

abbreviated name

of the selected item

Number Field

Displays the

current value of

the selected item

Symbols Description

PUMP

Displays when the primary or mixing pump is in operation.

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.

BOILER DEMAND

Displays when a boiler demand is present.

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.

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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.

Menu

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.

Back to View Menu

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.

Continue to next Item

Continue to next Item

Continue to next Item

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Display Menus

View Menu (1 of 2)

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

VIEW MENU

			Item Field		Range	Access		Description
					-76 to 149°F	InS	OUTDOOR	SECTION B
							Current outdoor air temperature as measured by the
					(-60.0 to 65.0°C)	Ad
							outdoor sensor.
					-22 to 266°F	InS	MIX 1 SUPPLY	SECTION B
							Current Mix 1 supply water temperature as measured
					(-30.0 to 130.0°C)	Ad
							by the Mix 1 supply sensor.
							MIX 1 TARGET	SECTION C
					– – –, 35 to 230°F	Ad	The Mix 1 target is the temperature the control
							is currently trying to maintain at the Mix 1 supply
					(– – –, 1.5 to 110.0°C)
							sensor. “– – –” is displayed when no heat is required
							for Mix 1 zones.
							MIX 2 SUPPLY	SECTION B
					-22 to 266°F	InS	Current Mix 2 supply water temperature as measured
							by the Mix 2 supply sensor.
					(-30.0 to 130.0°C)	Ad
							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
					– – –, 35 to 230°F		is currently trying to maintain at the Mix 2 supply
						Ad	sensor. “– – –” is displayed when no heat is required
					(– – –, 1.5 to 110.0°C)
							for mix 2 zones.
							Note: This item is only available when the tN4 DIP
							switch is set to Mix 2.
							BOILER SUPPLY	SECTION C
					-22 to 266°F	InS	Current boiler supply water temperature as measured
							by the boiler sensor.
					(-30.0 to 130.0°C)	Ad
							Note: This item is only available when the Boiler
							Sensor Sup / Ret DIP switch is set to Sup.

Continued on next page.

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View Menu (2 of 2)

Item Field

MENUVIEW

	Range	Access	Description
			BOILER TARGET	SECTION C
			The boiler target is the temperature the control is currently
	– – –, 35 to 230°F	Ad	trying to maintain at the boiler supply sensor. “– – –” is
	(– – –, 1.5 to 110.0°C)		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
	-22 to 266°F	InS	Current boiler return water temperature as measured
			by the boiler sensor.
	(-30.0 to 130.0°C)	Ad
			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.
	0-100%	Ad	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
		InS	was last cleared. To clear this item, press the Up
	0 to 9999 hr		and Down buttons simultaneously while viewing
		Ad
			this item.
			Note: This item is only available when the Boiler
			Sensor Sup / Ret DIP switch is set to Sup.

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

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Adjust Menu (1 of 5)

ADJUST MENU

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

			Item Field		Range	Access	Description
					-60 to 45°F		OUTDOOR DESIGN	SECTION B
					(-51.0 to 7.0°C)	InS	The design outdoor air temperature used in the heat
					Default = 10°F	Ad	loss calculations for the heating system. Typically set
					(-12.0°C)		to the temperature of the coldest day of the year.
					VAr, FLt	InS	MIX 1 MODE	SECTION G
							Select the type of mixing device to be used for Mix 1.
					Default = VAr	Ad	Options are variable speed injection pump (VAr) or
							floating action (FLt).
					1 HRF1
					2 HRF2		MIX 1 TERMINAL	SECTION B
					3 Fancoil	InS
					4 Fin-tube Convector		The type of heating terminal units that are being
						Ad
					5 Radiator
							used in Mix 1 zones.
					6 Baseboard
					Default = 1
					40 to 100°F		MIX 1 INDOOR	SECTION B
							The design indoor air temperature used in the heat
					(4.5 to 38.0°C)	Ad
					Default = 70°F (21.0°C)		loss calculation for Mix 1 zones. Typically set to
							70°F (21.0°C).
					70 to 220°F		MIX 1 DESIGN	SECTION B
					(21.0 to 104.5°C)	InS
							The supply water temperature required for the Mix 1
					Default = 120°F	Ad
							zones on the typical coldest day of the year.
					(49.0°C)
					OFF, 40 to 150°F		MIX 1 MINIMUM	SECTION G
					(OFF, 4.5 to 65.5°C)	Ad
							The minimum allowed Mix 1 target temperature.
					Default = OFF
					80 to 220°F, OFF
					(26.5 to 104.5°C, OFF)	Ad	MIX 1 MAXIMUM	SECTION G
					Default = 140°F		The maximum allowed Mix 1 target temperature.
					(60.0°C)

Continued on next page.

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Adjust Menu (2 of 5)

Item Field

Range

Access

Description

MIX 1 MOTOR

SECTION G

30 to 230 seconds

The time that the Mix 1 actuating motor requires to

Ad

operate from fully closed to fully open.

Default = 105

Note: This item is only available when the Mix 1

Mode setting is set to floating action (FLt).

1 HRF1

MIX 2 TERMINAL

SECTION B

2 HRF2

The type of heating terminal units that are being

3 Fancoil

InS

4 Fin-tube Convector

used in mix 2 zones.

Ad

5 Radiator

Note: This item is only available when the tN4 DIP

6 Baseboard

switch is set to Mix 2.

Default = 1

MIX 2 INDOOR

SECTION B

40 to 100°F

The design indoor air temperature used in the heat

loss calculation for mix 2 zones. Typically set to

(4.5 to 38.0°C)

Ad

70°F (21.0°C).

Default = 70°F (21.0°C)

Note: This item is only available when the tN4 DIP

switch is set to Mix 2.

MENU

70 to 220°F

MIX 2 DESIGN

SECTION B

The supply water temperature required for the mix 2

(21.0 to 104.5°C)

InS

zones on the typical coldest day of the year.

Default = 120°F

Ad

Note: This item is only available when the tN4 DIP

(49.0°C)

ADJUST

switch is set to Mix 2.

OFF, 40 to 150°F

MIX 2 MINIMUM

SECTION G

The minimum allowed mix 2 target temperature.

(OFF, 4.5 to 65.5°C)

Ad

Note: This item is only available when the tN4 DIP

Default = OFF

switch is set to Mix 2.

80 to 220°F

MIX 2 MAXIMUM

SECTION G

(26.5 to 104.5°C)

Ad

The maximum allowed mix 2 target temperature.

Default = 140°F

Note: This item is only available when the tN4 DIP

(60.0°C)

switch is set to Mix 2.

MIX 2 MOTOR

SECTION G

30 to 230 seconds

The time that the mix 2 actuating motor requires to

Ad

operate from fully closed to fully open.

Default = 105

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.

1 HRF1

BOILER TERMINAL

SECTION B

2 HRF2

The type of heating terminal units that are being

3 Fancoil

InS

used in boiler zones.

4 Fin-tube Convector

Ad

Note: This item is only available when the Boiler

5 Radiator

6 Baseboard

Sensor Sup / Ret DIP switch is set to Sup and the

Default = 4

tN4 DIP switch is set to Boiler.

Continued on next page.

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Adjust Menu (3 of 5)

					Item Field		Range	Access	Description
									BOILER INDOOR	SECTION B
							40 to 100°F		The design indoor air temperature used in the heat
									loss calculation for the boiler zones. Typically set to
							(4.5 to 38.0°C)
								Ad	70°F (21.0°C).
							Default = 70°F
									Note: This item is only available when the Boiler
							(21.0°C)
									Sensor Sup / Ret DIP switch is set to Sup and the
									tN4 DIP switch is set to Boiler.
							70 to 220°F		BOILER DESIGN	SECTION B
									The supply water temperature required for boiler
							(21.0 to 104.5°C)	InS	zones on the typical coldest day of the year.
							Default = 180°F	Ad	Note: This item is only available when the Boiler
							(82.0°C)		Sensor Sup / Ret DIP switch is set to Sup and the
									tN4 DIP switch is set to Boiler.
							OFF, 80 to 180°F		BOILER MINIMUM	SECTION C
									The minimum allowed boiler target temperature and
							(OFF, 26.5 to 82.0°C)	InS
							Default = 140°F	Ad	boiler return protection temperature. Check the boiler
									manufacturer’s manual for recommend supply water
							(60.0°C)
	MENU								temperatures.
							120 to 225°F, OFF		BOILER MAXIMUM	SECTION C
									The maximum allowed boiler target temperature.
							(49.0 to 107.0°C, OFF)
								Ad	Note: This item is only available when the Boiler
							Default = 200°F
	ADJUST						(93.5°C)		Sensor Sup / Ret DIP switch is set to Sup and the
							0:00 to 3:00 min		time that the relay contact closes to fire the boiler
									tekmar stager DIP switch is set to OFF.
									FIRE DELAY	SECTION C
									The time delay the control can expect between the
							Default = 0:10 min	Ad	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
							Au, 2 to 42°F		The temperature differential that the control is to use
									when it is operating the boiler.
							(Au, 1 to 23.5°C)	Ad
									Note: This item is only available when the Boiler
							Default = Au
									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
							10 to 230 seconds	Ad	the fan speed from a stopped position to full speed
									on a modulating boiler.
							Default = 30 seconds
									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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