tekmar 704 User Manual

- Data Brochure

Mixing Station 704

WARNING SYMBOL: THIS SYMBOL INDICATES THE PRESENCE OF HAZARDS WHICH CAN CAUSE SEVERE PERSONAL INJURY, SUBSTANTIAL PROPERTY DAMAGE OR EVEN DEATH IF IGNORED.

D 704

04/05

General

The Mixing Station 704 represents a breakthrough in the design, control and installation of radiant systems. The patent pending design combines a variable speed injection mixing control (RMC), injection circulator, system circulator, and air elimination into a single unit. Extremely versatile, the Mixing Station 704 can be set up to operate as an outdoor reset control, a setpoint control or a delta T limiting control.

Mixing Station 704

RADIANT MIXING CONTROL (RMC)

MIXING STATION 704 (RMB)

Table of Contents

TYPICAL PIPING ------------------------------------------------- 2 GETTING READY ------------------------------------------------ 3 APPLICATION ---------------------------------------------------- 3 DESIGN PROCEDURE -----------------------------------------3 INSTALLATION OF MIXING STATION 704 --------------- 4 OUTDOOR RESET MODE ------------------------------------ 5 OUTDOOR RESET SETTINGS ------------------------------ 5 SETPOINT AND DELTA T MODE --------------------------- 6 SETPOINT AND DELTA T SETTINGS --------------------- 7 BOILER OPERATION MODE ---------------------------------7

SET UP OF RADIANT MIXING CONTROL --------------- 8 DISPLAY OPERATION ---------------------------------------- 11 TROUBLE SHOOTING ---------------------------------------- 13 ERROR MESSAGES ------------------------------------------- 14 REPLACING CARTRIDGE ASSEMBLY ----------------- 14 REPLACING THE CHECK VALVE ------------------------ 15 TECHNICAL DATA ---------------------------------------------- 15 CLEANING -------------------------------------------------------- 16 LIMITED WARRANTY STATEMENT ----------------------- 16

Typical Piping

Outdoor Sensor

Boiler

Sensor

Supply Sensor

Mixing Station 704 Mixing Station 704

Outdoor Sensor

Boiler

Sensor

Supply Sensor

Mixing Station 704, Multiple Zone Circulators

Outdoor Sensor

Radiant Manifold - Return

Outdoor Sensor

Supply Sensor

Radiant Manifold - Supply

Supply Sensor

Boiler Sensor

Boiler

Sensor

Mixing Station 704, Multiple Zone Valves

Outdoor Sensor

Boiler

Sensor

Outdoor Sensor

Supply Sensor

Outdoor Sensor

Radiant Manifold - Return

Radiant Manifold - Supply

Boiler

Sensor

Supply Sensor

Mixing Station 704, Multiple Temperature System

Outdoor Sensor

Boiler

Sensor

Supply Sensor

Mixing Station 704, Multiple Temperature System

Boiler

Sensor

Outdoor Sensor

Radiant Manifold - Return

Supply Sensor

Radiant Manifold - Supply

Outdoor Sensor

Radiant Manifold - Return

Boiler

Sensor

Supply Sensor

Radiant Manifold - Supply

Multiple Mixing Station 704s,

Multiple Temperature System

Boiler

Sensor

Multiple Mixing Station 704s,

Multiple Temperature System

Supply Sensor

Radiant Manifold - Supply

Radiant Manifold - Return

Getting Ready

Check the contents of this package. If any of the contents listed are missing or damaged, please contact your wholesaler or tekmar sales representative for assistance.

Contents should include the following:

• One Mixing Station 704, unit consisting of the following parts: (One Radiant Mixing Control, One Blue Enclosure, One Casing with two circulators attached, One Backplate, One Power Cord (6 feet, attached to backplate))

• One 070 Outdoor Sensor

• One Universal Sensor 071

• One Universal Sensor 082

• Data Brochure D 704

Application

The Mixing Station 704 is a complete injection mixing system. Integral to the unit is a variable speed injection circulator, constant speed system circulator, air elimination, and the electronics to drive it all. With only four piping connections needed, the RMB greatly reduces the time and space required for installation. The RMB can be set up to operate as an outdoor reset control, a setpoint control or a delta T limiting control, creating ﬂ exibility never seen before in a single unit.

Design Procedure

1. Using the pump curve located below, ensure that the System Pump of the Mixing Station 704 will provide adequate ﬂ ow for the system in which it is to be installed.

2. Using the table or equation below, determine the required ﬂ ow rate for the Injection Pump.

3. Using the pump curve located below, ensure that the Injection Pump of the Mixing Station 704 will provide adequate ﬂ ow for the system in which it is to be installed.

SYSTEM PUMP CURVE

5.5

4.8

4.2

3.6

3.0

2.4

HEAD (m)

1.8

1.2

0.6

18 16 14 12 10

HEAD (ft)

6 4 2

051015

0 1.14 2.27 3.41

FLOW (gpm)

FLOW (m

/h)

REQUIRED INJECTION PUMP FLOW RATE

Tb = Boiler Supply Temperature Ts = Radiant Supply Temperature

Injection Flow Rate (GPM) = BTU’s (Tb - Ts) x 500

INJECTION PUMP CURVE

5.5

4.8

4.2

3.6

3.0

2.4

HEAD (m)

1.8

1.2

0.6

18 16 14 12 10

HEAD (ft)

6 4 2

051015

0 1.14 2.27 3.41

FLOW (gpm)

FLOW (m

/h)

Required Injection Flow Rate (GPM)

BTU’s x 1,000 Tb - Ts 20 40 60 80 100 120 100 0.4 0.8 1.2 1.6 2.0 2.4 80 0.5 1.0 1.5 2.0 2.5 3.0 60 0.7 1.3 2.0 2.7 3.3 4.0 40 1.0 2.0 3.0 4.0 5.0 20 2.0 4.0

Installation of the Mixing Station 704

STEP ONE MOUNTING

1. Mounting position – The Mixing Station 704 must be mounted in the vertical position with the automatic air vent located at the top of the Mixing Station 704.

2. To mount the Mixing Station 704 begin by removing the Radiant Mixing Control from the front of the Mixing Station 704. Remove the screw and pull the Radiant Mixing Control straight forward. Ensure that the Radiant Mixing Control is stored in a safe place until it is ready to be remounted.

3. Remove the three screws holding the blue plastic cover to the Mixing Station 704.

4. Select a suitable location to mount the Mixing Station 704 that allows sufﬁ cient space for easy pipe connections.

5. Attach the sheet metal base to the wall with screws (not included) through the small mounting holes. See technical data for hole location and spacing.

6. Using four suitable screws (not included), fasten the Mixing Station 704 to the selected location. Ensure that at least two of the mounting screws are attached to a wall stud or similar surface.

STEP TWO PIPING CONNECTIONS

1. Using proper piping practices, connect the supply to the radiant heating system to the Radiant Supply (bottom right hand connection) as indicated on the plastic cover of the Mixing Station 704. Ensure that a proper isolation valve is installed.

2. Using proper piping practices, connect the return from the radiant heating system to the Radiant Return (top right hand connection) as indicated on the plastic cover of the Mixing Station 704. Ensure that a proper isolation valve is installed.

3. Using proper piping practices, connect the supply from the boiler loop to the Boiler Supply (top left hand connection) as indicated on the plastic cover of the Mixing Station 704. Ensure that a proper isolation valve is installed.

4. Using proper piping practices, connect the return to the boiler loop to the Boiler Return (bottom left hand connection) as indicated on the plastic cover of the Mixing Station 704. Ensure that a proper isolation valve is installed.

5. Connect the Boiler Supply and Boiler Return lines to the boiler loop using standard Primary Secondary piping practices.

STEP THREE FILLING

1. Fill system with tap water – The system must be ﬁ lled before operating the circulator. The bearings are water lubricated and should not be allowed to operate dry. Filling the system will result in immediate lubrication of the bearings. It is always good practice to ﬂ ush a new system of foreign matter before starting the circulator.

2. Circulator operation – Operate the circulators for 5 minutes immediately after ﬁ lling system to purge remaining air from the bearing chamber. This is especially important when installing the circulator during the off-season.

STEP FOUR REPLACING THE FRONT COVER

1. Place the blue plastic cover over the Mixing Station 704.

2. Using the original three screws, fasten the blue plastic cover to the Mixing Station 704.

3. Reinstall the Radiant Mixing Control and fasten it in place with the remaining original screw. RMC wiring starts on page 9.

STEP FIVE ELECTRICAL CONNECTIONS

1. Electrical connections – Observe all applicable codes when connecting to power supply. The motors are impedance protected, and do not require overload protection. The pumps cannot run backwards.

WARNING:

Do not use in swimming pool or spa areas; pump has not been investigated for this application.

WARNING:

In the event the retaining screws have been pulled out of the housing, DO NOT replace them. Use of any other screw may short out the stator windings, creating a risk of electrical shock.

CAUTION:

1. The addition of petroleum based ﬂ uids or certain chemical additives to systems utilizing TACO equipment voids the warranty.

2. Use supply wires suitable for 194°F (90°C) – ATTENTION: Employer des ﬁ ls d´alimentation adequats pour 194°F (90°C).

WARNING:

To avoid electrical shock, disconnect the power supply to the circulator and the main electrical unit.

Outdoor Reset Mode of Operation

In order to properly control a hot water heating system, the amount of heat supplied to the building must equal the amount of heat lost by the building. The amount of heat delivered into a building depends on the temperature of the water in the heating unit and the surface area of the heating unit. Heating units with a small surface area, such as baseboard radiators, require a higher water temperature than heating units with a larger surface area such as radiant ﬂ oors. The amount of heat lost from a building depends on the outdoor temperature. As the outdoor temperature becomes colder, the amount of heat a building loses increases. The operation of a hot water heating system can generally be improved by adjusting the supply water temperature to the system as the outdoor temperature changes. Using this approach, the heat input to the building can be matched to the heat lost from the building. This method of controlling the supply water temperature to a heating system greatly improves the comfort of the system and is known as Outdoor Reset.

When an Outdoor Sensor is connected to the Radiant Mixing Control (RMC), the RMC provides outdoor reset. When operating in the outdoor reset mode of operation, the installer must set the Outdoor Design Temperature and the Design Supply Temperature in order to establish the relationship between the outdoor temperature and the supply water temperature. This is known as setting the Heating Curve.

SEQUENCE OF OPERATION

When the RMC receives a Demand and it is not in a WWSD, the RMC turns on the system pump and calculates a Mixing Target temperature. The variable speed injection pump is then operated to maintain the Mixing Target temperature at the mixing supply sensor.

The boiler contact operates as described in the Boiler Operation section. The RMC also provides boiler protection as described in the Boiler Operation section.

DEMAND

The RMC requires a demand signal before it will begin operation. The RMC can use either a powered or an unpowered demand signal. Once a demand signal is received, the RMC displays the demand pointer in the display and operates as described above.

Powered Demand

The RMC recognizes a Powered Demand Signal when 24 V (ac) is applied across the Com and Heat Dem terminals.

Unpowered Demand

The RMC recognizes an Unpowered Demand signal when a switch is closed between the Com and Heat Dem terminals.

SYSTEM PUMP OPERATION

The RMC has an internal system pump contact. This contact turns on when the RMC has a mixing demand and is not in a WWSD. The integrated system pump as well as an external boiler pump may be controlled by this relay. By providing proper ﬂ ow in the boiler loop, the boiler temperature can be accurately controlled based on the mixing load.

Powered

Demand

24 V (ac)

Unpowered

Demand

Boil Out

Switch

Boil Out

Switch

Com Heat

Dem

Com Heat

Dem

Outdoor Reset Settings

HEATING CURVE SETTINGS

In order to establish the heating curve, the RMC must be given two points to work with. The ﬁ rst point is the Outdoor Reset Starting Point and the second point is the Design Condition.

Outdoor Reset Starting Point

The Outdoor Reset Starting Point for the RMC is ﬁ xed at 72°F (22°C). This means that when the outdoor temperature is 72°F (22°C), the RMC calculates a required supply water temperature (Mix Target) of 72°F (22°C).

Design Conditions

The design conditions represent the supply water temperature required to satisfy the heating system on the typical coldest day of the year. These are the conditions that are used when calculating the size of the heating equipment needed to heat the building. The Design Conditions are made up of an outdoor temperature (Outdoor Design) and a supply water temperature (Design Supply).

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